JLG G6-42A Operator Manual

®

OWNER/OPERATOR MANUAL

®

G6-42A

®

Form #20036

CORPORATE OFFICE

JLG INDUSTRIES, INC. 1 JLG DRIVE McConnellsburg, PA 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417

9147-4003

June 2003

Starting Serial No.

0190001 thru 0190457

& 0160000022 thru Current

Original Issue 3/01 Revised Issue 6/03

GRADALL DIVISION

JLG INDUSTRIES, INC. 406 Mill Avenue S.W. New Philadelphia, OH 44663 USA Telephone: (330) 339-2211 Fax: (330) 339-8458

G6-42A MATERIAL HANDLER

OWNER/OPERATOR MANUAL

COVERING OPERATION & PERIODIC MAINTENANCE

material handler

IMPORTANT!

Read and understand this Manual and the Gradall Material

Handler Safety Manual before starting, operating or

performing maintenance procedures on this machine.

KEEP OPERATOR AND SAFETY MANUALS IN CAB

A Company

Form No. 20036

®

COVERS MATERIAL HANDLER G6-42A

STARTING SERIAL NUMBER

0190001 thru 0190457 & 0160000022 thru Current

Part No. 9147-4003

Revised 6-13-03

®

4

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IMPORTANT SAFETY NOTICE

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Safe operation depends on reliable equipment and proper operating procedures. Performing the checks and services described in this Manual will help keep your GRADALL Material Handler in reliable condition. Following recommended operating procedures can help you avoid accidents. Because some procedures may be new to even the experienced operator, we require that this Manual be read, understood and complied with by all who operate this machine.

Strict attention to and compliance with instructions provided in this Manual, the GRADALL Material Handler Safety Manual, as well as instructional decals and plates affixed to the machine will help prevent injuries to personnel and damage to the equipment. The information provided herein is not intended to cover all situations; it is impossible to anticipate and evaluate all possible applications and methods of operation for this equipment.

This Manual covers recommended operating procedures and basic maintenance checks and services for the Material Handler. Detailed maintenance information is available in the appropriate Service Manual.

Any procedure not specifically recommended by GRADALL must be thoroughly evaluated from the standpoint of safety before it is placed in practice. If you are not sure, contact your GRADALL Material Handler Distributor before operating.

Use only GRADALL authorized parts. The use of counterfeit parts may cause premature failure which could lead to injuries and/or machine damage.

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Do not modify this machine without written

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permission from GRADALL. Use only genuine

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GRADALL replacement parts.

OTHER NOTICES

GRADALL retains all proprietary rights to the information contained in this Manual.

GRADALL reserves the right to change specifications without notice.

Gradall is a registered trademark for Hydraulic Excavators, Hydraulic Material Handlers and Attachments manufactured by The Gradall Company.

REVISIONS

This page is provided so you may determine that this Manual is complete and current with respect to Gradall Engineering Specifications.

Page Date Revision

17.1 7-22-02 Added an additional lubrication notice.

Cover 6-13-03 Revised Notes & Serial Numbers.

Intro Revised Operator Qualification section.

2.0 Revised all.

2.1 Revised all.

2.2 Replaced 9140-3525 Decal with 9150-3102 Decal.

2.3 Replaced 9147-3123 Decal with 9147-3217 Decal; added 9141-3061 Decal &

P/N’s to Angus Palm Decal.

2.4 Revised locations on 9108-3492, 9114-3288, 9114-3284, 9114-3281 &

9114-3285 Decals.

2.5 Revised location on 9114-3282 Decal.

3.0 Revised Operator’s Cab section & Figure 3-1.

3.1 Revised Warning.

3.2 Revised Service Brake description.

6.0 Revised Cold-Weather Starting Aid section.

7.0 Revised Service Brake section.

8.0 Revised Precaution & Parking Procedure sections.

12.2 Revised Load Center section; Removed Figure.

12.3 Changed Figure 12-5 to 12-4.

12.4 Changed Figure 12-6 to 12-5.

13.1 Revised Attachment Operation section.

13.8 Revised Personnel Work Platform section.

14.0 Revised Step 4; Added Figure 14-1.

16.0 Revised Moving Short Distances section.

16.1 Added Carraro Axle to title; changed all chock references to block.

16.2 Added Page for Dana Axle.

17.0 Added Figure 17-1.

17.1 Revised Art.

17.3 Changed Carraro Axle Values & Added Dana Axle Values.

Form No. 20036 • G6-42A Owner/Operator Manual

Operators of the material handler must be in good physical and mental condition, have normal reflexes and reaction time, good vision and depth perception and normal hearing. He must not be using medication which could impair abilities nor be under the influence of alcohol or any other intoxicant during the work shift.

The operator should possess a valid, applicable driver’s license and must have completed a training course for this type of material handling equipment.

In addition, the operator must read/view, understand and comply with instructions contained in the following material furnished with the material handler:

• This Owner/Operator Manual

• GRADALL Material Handler Safety Manual

• All instructional decals and plates

• Any optional equipment instructions furnished

INTRODUCTION

NOTE!

“Material handler” and handler are used interchangeably throughout this Manual.

NOTE!

Though no offense or discrimination is intended, only the masculine pronouns will be used throughout the remainder of this Manual.

NOTE!

In the U.S.A., the operator must have completed a training course meeting the OSHA Powered Industrial Truck Operator Training Requirements (CFR 1910.178)

FRONT

The operator must also read, understand and comply with all applicable Employer, Industry and Governmental rules, standards and regulations.

Orientation

When used to describe the location of components in the material handler, the directions “front’”, “rear”, “right” and “left” relate to the orientation of a person sitting in the operator’s seat. (See figure I-1)

Related Manuals & Decals

Separate publications are furnished with the material handler to provide information concerning safety, replacement parts, maintenance procedures, theory of operation and vendor components. Replacement manuals, decals and instruction plates can be ordered from your GRADALL Material Handler Distributor.

Models Covered

This Manual covers basic information for Gradall Material Handlers. Detailed information for each particular machine is in the maintenance section in the back of this manual. Be certain to refer to proper information for your unit and the optional equipment furnished on your machine.

Serial Number Location

Specify Model Number and Serial Number when ordering parts and when discussing specific applications and procedures with your Distributor. The model/ serial number plate is located inside the operator’s cab, right wall.

(See figure I-2)

LEFT

REAR

Figure I-1

GRADALL IS A REGISTERED TRADEMARK FOR HYDRAULIC EQUIPMENT BUILT BY THE

(WITHOUT ATTACHMENTS)

48" & 72" CARRIAGE.

6.6

42'

24"

2.0' 26.9'

GRADALL CO. MANUFACTURED IN THE U.S.A.

19430 LBS

C

B

1.0

4.6'

D

24"

A

24"

TRUCK &

CAP#

ATTACHMENT

1000

WEIGHT

6.6

20,180

42' 24" 24"

6.6

20,290

42' 24"

20,460

20,650

42' 24" 24"

24"

24"24"42'

6.6

406 MILL AVE. S.W., NEW PHILADELPHIA, OHIO 44663

AS RELEASED FROM FACTORY THIS TRUCK MEETS THE DESIGN SPECIFICATIONS ESTABLISHED IN AMERICAN NATIONAL STANDARDS FOR POWERED INDUSTRIAL TRUCKS PART III ASME B56.6b-1998.

CAPACITY WITH STANDARD

CAP# X1000

A

B

C

SAMPLE ONLY

D

SHIPPED

ATTACHMENT

WITH

48" CARRIAGE P/N 9140-5073 *

72" CARRIAGE P/N 9140-5074 *

48" SLOPE PILER P/N 9140-5101 *

72" SLOPE PILER P/N 9140-5079 *

RIGHT

DCBA

2.0'

2.7'

Form No. 20036 • G6-42A Owner/Operator Manual

*WEIGHTS ARE BASED ON USING 2 X 4 X 48" FORKS (APPROX. 268# PER PAIR) **BUCKET DIMENSIONS (A & D) REFER TO BUCKET LIP HEIGHT. ***TRUSS BOOM & WINCH DIMENSIONS (A & D) REFER TO HOOK CENTER. ****WEIGHT IS BASED ON SP'L SWING MAST FORKS (APPROX. 230# PER PAIR) *****PLATFORM DIMENSIONS (A & D) REFER TO CENTER OF FLOOR.

FORKS RATED LESS THAN THE ATTACHMENT CAPACITY SHOWN ABOVE DECREASE CAPACITY OF ATTACHMENT TO THAT OF FORKS. FORKS RATED MORE THAN ATTACHMENT CAPACITY DO NOT INCREASE ATTACHMENT CAPACITY.

Figure I-2

9147-3131 (B)

SAFETY HIGHLIGHTS

Read and understand all manuals and instructional material listed on cover, inside front cover and introduction page of this Manual before starting, operating or performing maintenance procedures on this equipment.

Regardless of previous experience operating similar equipment, the operator must be given sufficient opportunity to practice with the handler in a safe, open area (not hazardous to people or property) to gain operating skills and the proper “feel” for controls and operating clearances required for safe, efficient operation.

GRADALL Material Handlers are equipped with a right-side rearview mirror. This mirror is intended as an operator’s aid and does not replace the requirement for line-of-sight. Certain job site and machine conditions may require use of a signal person to help the operator when picking, placing or transporting a load. Never operate the handler until you know pick-up point, line of travel and landing point are clear. Always be aware that objects in mirror are closer than they appear.

Safety Precautions

Make sure all DANGER, WARNING, CAUTION and INSTRUCTIONAL DECALS are in place and can be read. Clean or replace decals as required.

Ensure handler is on a firm, level surface before lifting or placing load. Have surface leveled if necessary. Unit can tip over if load is raised with handler

on a soft or uneven surface.

When traveling at high rates of speed, use two wheel front steer mode and

slow the machine prior to turning.

WATCH FOR THESE SYMBOLS ; THEY CALL YOUR ATTENTION TO SAFETY NOTICES.

DANGER

!

This symbol indicates an extreme hazard which will result in high probability of death or serious injury if proper precautions are not taken.

WARNING

!

This symbol indicates a hazard which could result in death or serious injury if proper precautions are not taken.

CAUTION

!

This symbol indicates a hazard which may result in injury or damage to equipment or property if proper precautions are not taken.

Do not change steer mode while the machine is traveling. Change the steer mode only when machine is stopped.

Always look in the direction of travel. Reduce speed and be especially careful when traveling in reverse and/or turning. Bring the machine to a complete stop before changing the direction of travel.

Travel in reverse only at slow rates of speed.

When turning, the forks on the four wheel steer machine sweep through an arc beyond the turn radius of the tires. Maintain adequate clearance between

the forks/load and other objects.

If load or conditions obstruct view, use a signal person when lifting, carrying or placing a load.

Loose clothing can get caught in moving machinery and can also cause accidental actuation of controls. Dress properly for the job.

Be alert to any unusual response to controls. If unusual response is noticed, position handler in a safe area, lower forks to ground, apply parking brake, stop engine and remove key from ignition switch. Tag steering wheel to forbid operation and notify maintenance personnel.

Keep hands, gloves, shoes, control knobs and pedals clean. Slippery controls can cause accidents. Keep a firm grip on the steering wheel when traveling.

WARNING

!

Operator must be seated with seat belt fastened, transmission control lever in “Neutral” position, parking brake applied and all hydraulic controls in “Neutral” before starting engine.

Load capacities are based on load center being within .6m (24 inches) from front vertical face of forks.

1.0

Release trapped pressure before disconnecting, opening or removing any

hydraulic component.

WARNING

!

Keep all windows and mirror(s) clean. Adjust mirror(s) as visibility, before and during opera

Do not increase engine speed with the transmission in forward or reverse and the service brake pedal depressed in an attempt to get quicker hydraulic

performance. This could cause unexpected machine movement.

After bringing the material handler to a stop using the service brake, place the directional control lever in neutral, and set the park brake prior to lifting a load.

Allow the handler to slow down, or use the service brakes prior to down-shifting.

Do not downshift more than one gear at a time.

When traveling on downhill slopes, downshift to a lower gear and use the service brake as necessary to maintain a slow speed. Do not shift into neutral and

coast downhill.

Never permit diesel engine to run out of fuel. Doing so can cause severe

engine damage.

DO NOT burn or drill holes in forks. Modifying any part of machine or attachment affects it’s capacity and/or stability of machine.

Keep head, arms, hands, legs and all other body parts inside the operator’s cab at all times.

tion.

required for maximum

Contact The Gradall Company prior to welding on machine.

DO NOT approach power lines, overhead or underground cables or other power sources with any part of your material handler or load unless all local, state/provincial and federal regulations have been met and the appropriate utility company’s hotline has been contacted to de-energize the lines.

Whenever leaving the cab, perform standard shut-down procedure:

Standard Shut-Down Procedure

Position the handler in a safe location, lower forks to ground, apply park brake, move all controls to minutes.

Stop engine and remove ignition key. Chock wheels.

“Neutral”, allow engine to run at low idle for 3 to 5

Form No. 20036 • G6-42A Owner/Operator Manual

1.1

Pinch Points

Stay clear of pinch points and rotating parts on the material handler. Getting caught in a pinch point or a moving part can cause serious injury or death. Before performing any maintenance on machine, follow the “STANDARD SHUT-DOWN PROCEDURE” on page 1.1.

Front & Rear Steering Axles

Boom Holes Attachment Tilt Cylinder

Boom

1.2

Carriage Forks

THIS PAGE INTENTIONALLY LEFT BLANK.

Form No. 20036 • G6-42A Owner/Operator Manual

DECAL LOCATIONS

Figure 2-1

5

1

2

STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

9114-3282

EXHAUST SYSTEMS CAN BE HOT.

KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.

HOT EXHAUST COMPONENTS CAN CAUSE

SEVERE BURNS.

9114-3280

3

FULL

ADD

HYDRAULIC OIL LEVEL

CHECK OIL LEVEL WITH HANDLER LEVEL AND ALL CYLINDERS RETRACTED.

2.5 GALLON BETWEEN ADD AND FULL MARKS

Genuine Parts

HYDRAULIC SYSTEM

4

9140-3569

1

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

9114-3282

6

7

NEVER OPERATE MACHINE WITHOUT

CONSULTING PROPER CAPACITY CHART FOR THE

CARRIAGE/FORK COMBINATION BEING USED.

9132-3030

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM.

DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.

WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN CAB WITH PERSONNEL

IN DIRECT LINE OF SIGHT.

OPERATE CONTROLS LIGHTLY AND CAUTIOUSLY WHEN LIFTING PERSONNEL.

READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL BEFORE LIFTING PERSONNEL.

DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL

HANDLER/PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN CAB.

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

AVOID HIGH VOLTAGE LINES.

IT IS UNLAWFUL TO PLACE

ANY PART OF THIS MACHINE

OR LOAD WITHIN 10 FEET

OF HIGH VOLTAGE LINES

UP TO 50,000 VOLTS.

DEATH OR INJURY MAY

RESULT FROM CONTACTING

ELECTRIC LINES.

8060-3022

9055-3027 REV. A

VIEW B-B

* High pressure oil easily punctures skin causing serious injury, gangrene or death.

* If injured, seek emergency medical help. Immediate surgery is required to remove oil.

* Do not use finger or skin to check for leaks.

* Lower load or relieve hydraulic pressure before loosening fittings.

1

5

12 13

B

STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

9114-3282

B

DO NOT GO NEAR LEAKS

10814B

14

10

A

1

STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

9114-3282

A

8

DIESEL FUEL IS FLAMMABLE

EXTINGUISH ALL OPEN FLAME AND SMOKING MATERIALS WHEN REFUELING INJURY OR DEATH COULD RESULT

FROM FIRE.

NO RIDERS PERMITTED ON HANDLER.

RIDERS COULD FALL OFF MACHINE CAUSING SERIOUS INJURY OR DEATH.

9114-3286

OPERATOR ONLY IN MACHINE

WHILE RUNNING.

9114-3283

9

11

15

1 9114-3282 Warning Decal, Pinch P oint 2 9114-3280 Warning Decal, Exhaust System 3 9140-3569 Oil Level Decal 4 9114-3288 Hydraulic Oil Decal 5 9132-3030 Warning Decal, Capacity Chart 6 9055-3027 Warning Decal, Lifting P ersonnel 7 8060-3022 Danger Decal, High V oltage 8 7733-3027 Made in USA Decal 9 9114-3283 Warning Decal, No Riders

10 9114-3286 Warning Decal, Diesel Fuel

2.0

VIEW A-A

16 17

48" & 72" CARRAIGE

18

WORK PLATFORM

CARRIAGE 100° SWING

6 FT. MAST

9140-3618

19

11 9108-3492 Oil Warning Decal 12 9055-3028 Warning Decal, Safe Operation 13 9147-3131 Serial No. & Attaching Plate 14 9150-3102 Boom Operation Decal 15 9147-3217 Service Instruction Plate 16 9140-3618 Load Chart Cover 17 9147-3139 Carriage Chart 18 9147-3162 G6-42A Capacity Chart 19 9141-3061 Ignition Decal,

(S/N 0160001283 thru Current)

Figure 2-2

23

24

D

29

D

20

6 2

.

0 3

Y

0

L

6

.

80

S

W

N D M

N

A

O E E

L

R C

Z

T I

S

U

S

D

R

I

B P Y U

U A S

E

S

L C

S

F G

U

E E

T

N I

A

V R

O L

C

P

O

H O

M S I O

E C

R

S

T R A P

G N I

V

.

O

G

M

N I

F

N

O

N

R

U

A

R E L

E S I

S

C

E

U

Y

N

A

I

C

T

G

S

1

N

8 2

E

A

3

4 1

C

1

E

9

L

S

I

T

H

R

.

W

A

Y

P

R U

G

J

N I

V

S

O

U

M

O

I R E S

21

22

C

25

27

28

26

1

33

31

32

29

34

35

36

C

30

VIEW C-C

20 8060-3026 Caution Decal, Cooling System 21 9114-3281 Warning Decal, Moving Parts 22 9114-3284 Warning Decal, Battery 23 9114-3285 Instruction Decal, Jump Start 24 9140-3573 Hydraulic Fluid Decal 25 9147-3133 G6-42A Decal 26 9147-3132 Gradall Decal 27 9114-3290 Warning Decal, Attachment 28 9100-3031 Boom Angle Decal

Form No. 20036 • G6-42A Owner/Operator Manual

29

VIEW D-D

29 8060-3037 Warning Decal, Pinch Point 30 9055-3026 Warning Decal, Lifting P ersonnel 31 9100-3016 “1” Decal 32 9100-3018 “2” Decal 33 9112-3042 “3” Decal 34 9100-3020 “4” Decal 35 9112-3044 “5” Decal 36 9116-3077 “6” Decal

2.1

DECALS

NOTES

USE CAPACITY CHART FOR SPECIFIC ATTACHMENT ON MACHINE.

GENERAL

SAMPLE ONLY - USE CHART IN CAB

FOR OTHER ATTACHMENTS CONSULT A GRADALL DEALER FOR LOAD RATINGS NOT LISTED.

USE LARGEST NUMBER VISIBLE FROM THE CAB TO DETERMINE BOOM EXTENSION.

MATCH WITH BOOM ANGLE TO DETERMINE ALLOWABLE LOAD.

FIGURES SHOWN ARE STACKING CAPACITY TRUCK LEVEL.

RATED LIFTING CAPACITIES SHOWN ARE WITH MACHINE ON A FIRM, LEVEL SURFACE WITH UNDAMAGED, PROPERLY INFLATED TIRES.

MACHINE SPECIFICATIONS AND STABILITY ARE BASED ON RATED LIFT CAPACITIES AT SPECIFIC BOOM ANGLES AND BOOM LENGTHS.

IF SPECIFICATIONS ARE CRITICAL, THE PROPOSED APPLICATION SHOULD BE DISCUSSED WITH YOUR DEALER.

DO NOT EXCEED RATED LIFT CAPACITY LOADS, AS UNSTABLE AND DANGEROUS MACHINE CONDITIONS WILL RESULT.

DO NOT TIP THE MACHINE FORWARD TO DETERMINE ALLOWABLE LOAD.

CERTAIN CARRIAGE/FORK COMBINATIONS MAY CAUSE HANDLER TO TIP WITHOUT LOAD WHEN EXTENDED INTO "NO OPERATION" ZONE AS NOTED ON CAPACITY CHART.

CAPACITY LIMITS FOR THIS UNIT ARE BASED IN ACCORDANCE WITH STANDARDS LISTED ON SERIAL NUMBER PLATE.

LEVEL GRADALL HANDLER BEFORE LIFTING ABOVE 4 FT.

BACK

9140-3618

Located on dashboard

P/N 9140-3618

FRONT

R

9150-3102 REV. -

9140-3618

Located on right cab wall

P/N 9150-3102

DEDUCT 350 LBS FROM ALL CAPACITIES

WHEN MACHINE IS EQUIPPED WITH WINCH

48'

44'

40'

36'

32'

48" & 72"

SLOPE PILER

28'

24'

20'

20°

16'

12'

10°

8'

4'

0°

0'

-4'

-8'

MODEL

G6-42A

RATED CAPACITY 2 FT. LOAD CENTER

40°

30°

600 LBS

-9°

20'24'28'32'

USE WITH: 9140-5101 48" 9140-5079 72" SLOPE PILER CARRIAGE

70°

60°

3000 LBS

4000 LBS

5000 LBS

8'12'

6

6600 LBS

4'

5

4

3

2

1

0'

9147-3139 (-)

SAMPLE ONLY - USE CHART IN CAB

50°

2000 LBS

16'

MODEL

G6-42A

4

3

2

1

USE WITH: 9140-5073 48" CARRIAGE 9140-5074 72" CARRIAGE 9140-5024 WINCH (4,000 LB MAX. CAPACITY)

0'4'8' 12'

BACK

Located on dashboard

P/N 9147-3139

FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF

1. ONLY TRAINED AND AUTHORIZED PERSONNEL MAY OPERATE THIS MACHINE.

2. BEFORE OPERATING, READ AND UNDERSTAND ALL CAPACITY CHARTS, OPERATOR MANUALS AND SAFETY MANUALS. IF MANUALS ARE NOT AVAILABLE, CONSULT AN AUTHORIZED GRADALL DEALER. UNDERSTAND ALL CONTROLS IN CAB AND CHECK FOR PROPER OPERATION. CLEAR LOOSE OBJECTS OFF MACHINE AND SOUND HORN BEFORE STARTING ENGINE.

3. OPERATOR MUST BE SEATED WITH SEAT BELT FASTENED. ASSURE FORWARD/REVERSE LEVER IS IN NEUTRAL,PARK BRAKE APPLIED AND ALL HYDRAULIC CONTROLS ARE IN NEUTRAL BEFORE IGNITION SWITCH IS TURNED ON.

4. DO NOT OPERATE MACHINE WITHOUT PROPER CAPACITY CHART IN PLACE.

5. BEFORE MOVING, BE SURE OF A CLEAR PATH AND SOUND HORN. WATCH FOR PEDESTRIANS AND OBSTRUCTIONS. CHECK OVERHEAD AND SIDE CLEARANCES. ALWAYS LOOK IN DIRECTION OF TRAVEL.

6. START, TURN, AND BRAKE SMOOTHLY. REDUCE TRAVEL SPEEDS FOR TURNS, SLIPPERY, OR UNEVEN SURFACES. AVOID RUNNING OVER LOOSE OBJECTS OR HOLES IN THE ROADWAY SURFACE.

SERIOUS INJURY, READ AND OBSERVE THE FOLLOWING:

DEDUCT 350 LBS FROM ALL CAPACITIES WHEN MACHINE IS

EQUIPPED WITH WINCH

40°

2000 LBS

9147-3139 (-)

30°

20°

1000 LBS

-9°

48'

44'

40'

36'

32'

48" & 72"

CARRIAGES

28'

24'

20'

16'

12'

10°

8'

4'

0°

0'

-4'

-8'

RATED CAPACITY 2 FT. LOAD CENTER

70°

60°

6

5

6000 LBS

6600 LBS

4000 LBS

5000 LBS

50°

3000 LBS

20' 24' 28' 32'

16'

FRONT

7. WHEN TRAVELING WITH LOAD, FULLY RETRACT BOOM AND PLACE FORKS IN CARRY POSITION (APPROX.12" ABOVE GROUND). TILT CARRIAGE BACK SLIGHTLY TO CRADLE LOAD. USE EXTREME CAUTION WHEN TURNING.

8. ON INCLINES, TRAVEL WITH LOAD UP-GRADE.

9. DO NOT USE BOOM AS WALKWAY.

10. USE TWO HANDS WHEN CLIMBING ON MACHINE.

11. USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM FOR LIFTING PERSONNEL. NO RIDERS ON MACHINE, FORKS, LOAD, OR OTHER LIFTING ATTACHMENTS AT ANY TIME. DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL HANDLER/PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN THE CAB. DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.

12. KEEP OTHERS AWAY FROM MACHINE WHILE OPERATING. DO NOT STAND UNDER BOOM OR LOAD.

13. USE EXTREME CARE WHEN HANDLING LONG, HIGH, OR WIDE LOADS. DO NOT HANDLE UNSTABLE OR LOOSELY STACKED LOADS.

14. FORKS TO BE CENTERED UNDER LOAD AND SPACED APART AS FAR AS POSSIBLE.

NEVER OPERATE MACHINE WITHOUT

CONSULTING PROPER CAPACITY CHART FOR THE

CARRIAGE/FORK COMBINATION BEING USED.

Located on right cab wall

and cab fender

P/N 9132-3030

15. BEFORE ADJUSTING OR SERVICING, PLACE FORWARD/REVERSE LEVER IN NEUTRAL, REST BOOM ON GROUND OR SUPPORT, SET PARKING BRAKE, SHUT OFF ENGINE AND CHOCK WHEELS.

16. BEFORE LEAVING MACHINE UNATTENDED, PLACE FORWARD/REVERSE LEVER IN NEUTRAL, LOWER BOOM, SET PARKING BRAKE,AND SHUT-OFF ENGINE. CHOCK WHEELS IF MACHINE MUST PARK ON AN INCLINE.

17. LEVEL MACHINE BEFORE LIFTING ANY LOAD ABOVE 4 FEET. (IF EQUIPPED WITH FRAME LEVELING).

18. OPERATOR PROTECTION (SUCH AS HARD HATS, SAFETY GLASSES, AND/OR HEARING PROTECTION) SHOULD BE WORN WHEN JOB CONDITIONS WARRANT. ALWAYS USE SEAT BELT.

19. IMPROPER USE OF MACHINE COULD RESULT IN MACHINE TIPPING OVER. IF MACHINE STARTS TO TIP OVER, DO NOT LEAVE OPERATORS SEAT. LEAN AWAY FROM TIP & BRACE YOURSELF.

20. KEEP MIRROR(S) CLEAN AND PROPERLY ADJUSTED. OBJECTS IN MIRROR ARE CLOSER THAN THEY APPEAR.

9055-3028 REV. A

9132-3030

2.2

Located on right cab wall

P/N 9055-3028

GRADALL IS A REGISTERED TRADEMARK FOR HYDRAULIC EQUIPMENT BUILT BY THE GRADALL CO. MANUFACTURED IN THE U.S.A.

406 MILL AVE. S.W., NEW PHILADELPHIA, OHIO 44663

(WITHOUT ATTACHMENTS)

AS RELEASED FROM FACTORY THIS TRUCK MEETS THE DESIGN SPECIFICATIONS ESTABLISHED IN AMERICAN NATIONAL STANDARDS FOR POWERED INDUSTRIAL TRUCKS PART III ASME B56.6b-1998.

CAPACITY WITH STANDARD

48" & 72" CARRIAGE.

CAP#

6.6

42'

24"

2.0' 26.9'

ATTACHMENT

1.0

4.6'

24"

CAP# 1000

6.6

X1000

A

B

SAMPLE ONLY - USE CHART IN CAB

C

D

SHIPPED

WITH

48" CARRIAGE P/N 9140-5073 *

72" CARRIAGE P/N 9140-5074 *

48" SLOPE PILER P/N 9140-5101 *

72" SLOPE PILER P/N 9140-5079 *

*WEIGHTS ARE BASED ON USING 2 X 4 X 48" FORKS (APPROX. 268# PER PAIR)

**BUCKET DIMENSIONS (A & D) REFER TO BUCKET LIP HEIGHT.

***TRUSS BOOM & WINCH DIMENSIONS (A & D) REFER TO HOOK CENTER.

****WEIGHT IS BASED ON SP'L SWING MAST FORKS (APPROX. 230# PER PAIR)

*****PLATFORM DIMENSIONS (A & D) REFER TO CENTER OF FLOOR.

FORKS RATED LESS THAN THE ATTACHMENT CAPACITY SHOWN ABOVE DECREASE CAPACITY OF ATTACHMENT TO THAT OF FORKS. FORKS RATED MORE THAN ATTACHMENT CAPACITY DO NOT INCREASE ATTACHMENT CAPACITY.

B

A

TRUCK & ATTACHMENT WEIGHT

20,180

20,290

20,460

20,650

19430 LBS

C

D

42' 24" 24"

42' 24"

42' 24" 24"

DCBA

2.0'

24"

2.7'

24"24"42'

9147-3131 (B)

SAMPLE ONLY

Box 61 SD 57201

GRADALL MATER 06 / 9 / 10 MAX WEIGHT : 2150 MEETS SAE : J1040 MA MEETS ISO : 3471 (94) / 3 MEETS ANSI : B56.6 - 8.16 / P GRADALL : 9114-3261 SERIAL : 8

Located on back wall, behind

operator’s seat

P/N 9147-4483 (enclosed cab)

P/N 9147-4471 (open cab)

THE PROTECTION OFFERED BY THIS ROPS WILL BE IMPAIRED IF IT HAS BEEN SUBJECTED TO ANY MODIFICATION, STRUCTURAL DAMAGE, OR HAS BEEN INVOLVED IN AN OVERTURN INCIDENT. THIS ROPS MUST BE REPLACED AFTER A ROLL-OVER. SEAT BELTS MUST BE WORN WHILE OPERATING VEHICLE.

000850

Located on right cab wall

P/N 9147-3131

LUBRICATION AND MAINTENANCE

SERVICE INTERVALS

EVERY 5

DAILY

WEEKLY

WKS OR

MATERIAL HANDLER

Diesel Engine

Air Cleaner Element

Fuel Filter

Engine Oil Filter

Engine Oil

Coolant

Diesel Fuel

Transmission

Lubricant

Filter

SAMPLE ONLY - USE CHART IN CAB

Transfer Case

Lubricant

Axle Lubricant

Center Section

Planetary Hubs

Hydraulic System

Lubricant

Filter

Breather/Filter

Grease Fittings

Axles (6 Pts. Ea.)

Boom Head Pivot (2 Pts.)

Boom Pivot (2 Pts.)

Cylinder Pins(13 Pts.)

Drive Shafts (1 Pt. Ea.)

Extend Chain Sheave (1 Pt.)

Quick Switch Pin (1 Pt.)

Retract Chain Sheave (1 Pt.)

Boom

Front Bottom Bearing Pads

All Other Bearing Pads

Extend/Retract Chains

Options And Attachments

Stabilizer Cylinder (3 Pts.)

Attachment Pivots And Pins

Tires

13.00-24 12 Ply

13.00R24 Radial

15.5-25 12 Ply

Lug Nut Torque

Use this chart in conjunction with the "Lubrication & Maintenance" and "Recommended Lubricants & Capacities" sections of the Owner/Operator Manual.

Service intervals may need to be more frequent than those shown depending upon application severity. Consult your Gradall dealer for recommendations.

It is recommended that engine oil and filter, transmission lubricant and filter, transfer case lubricant and axle lubricant be changed after first 100 hours on new, or rebuilt units.

OR

10 HRS

Check

Fill

Check

OR

50 HRS

Check

Grease

Check

250 HRS

Change

Check

Grease

Check

Grease

Check

500 HRS

3 MO.

OR

Change

Torque

6 MO.

OR

1000 HRS

Change

YEARLY

OR

1500 HRS

Change

Located on right cab wall

P/N 9147-3217

Form No. 20036 • G6-42A Owner/Operator Manual

LUBRICANT TYPE

OR

SPECIFICATION

SAE 15W-40 CH/CI Oil

Ethylene Glycol

No. 2 Diesel Fuel

Mobil 424

Mystik Tetrimoly

See Manual

Mystik Tetrimoly

65 PSI (448 kPa)

70 PSI (483 kPa)

58 PSI (400 kPa)

350-400 Lb-Ft (475-540 Nm)

9147-3217 REV(-)

Located on left side, front cab plate

P/N 9116-4094

ATTACHMENT MUST BE SECURED TO MACHINE.

CHECK TO ASSURE QUICK SWITCH PLUNGER

PIN IS FULLY ENGAGED AND LOCKED AFTER

AND LOCKED ATTACHMENT MAY FALL OFF

ATTACHMENT CHANGE.

IF PLUNGER PIN IS NOT FULLY ENGAGED

CAUSING SERIOUS INJURY OR DEATH.

9114-3290

Located on boom head

P/N 9114-3290

Located on dash

Starting S/N 0160001283

P/N 9141-3061

2.3

DECALS

Located on frame beside main control valve

Genuine Parts

HYDRAULIC SYSTEM

FILL WITH TRACTOR HYDRAULIC FLUID

For Mobil Product Information, Call 1-800-662-4525.

R

or equivalent.

P/N 9108-3492

9114-3288

3

7

5

3

-

0

4

1

9

Located on hydraulic reservoir

P/N 9114-3288

LEAD ACID BATTERIES PRODUCE FLAMABLE AND

BOOSTER BATTERY OR CHARGING BATTERIES: * DO NOT USE SMOKING MATERIALS NEAR BATTERIES * KEEP FLAMES AND SPARKS AWAY FROM BATTERIES * WEAR SAFETY GLASSES * ASSURE BATTERY IS NOT FROZEN AND ELECTROLYTE

IS AT PROPER LEVEL IN EACH CELL

FAILURE TO FOLLOW THESE INSTRUCTIONS COULD

RESULT IN SERIOUS INJURY OR DAMAGE TO THE

EXPLOSIVE GASSES

WHEN CHECKING, TESTING, USING

ELECTRICAL SYSTEM

9114-3284

Located on frame below engine cover

P/N 9114-3284

STAY CLEAR OF MOVING PARTS

WHILE ENGINE IS RUNNING.

MOVING PARTS CAN CAUSE

SERIOUS INJURY.

9114-3281

Located on hydraulic fill cap

P/N 9140-3573

JUMP STARTING INSTRUCTIONS

WHEN JUMP STARTING MATERIAL HANDLER * NEVER ALLOW VEHICLES TO TOUCH * CONNECT THE POSITIVE (+) JUMPER CABLE TO

POSITIVE (+) POST OF DISCHARGED BATTERY

* CONNECT OPPOSITE END OF POSITIVE (+) JUMPER

CABLE TO POSITIVE (+) POST OF BOOSTER BATTERY

* CONNECT THE NEGATIVE (-) JUMPER CABLE TO

NEGATIVE (-) POST ON BOOSTER BATTERY

* CONNECT OPPOSITE END OF NEGATIVE (-) JUMPER

CABLE TO GROUND POINT ON MACHINE AWAY FROM

DISCHARGED BATTERY * FOLLOW STANDARD STARTING PROCEDURES * REMOVE CABLES IN REVERSE ORDER AFTER MACHINE

HAS STARTED

9114-3285

Located on frame below engine cover

P/N 9114-3285

COOLING SYSTEM

IS PRESSURIZED.

REMOVE CAP SLOWLY.

HOT FLUID CAN

CAUSE BURNS.

8060-3026

2.4

Located in engine compartment

P/N 9114-3281

Located on radiator

P/N 8060-3026

AVOID HIGH VOLTAGE LINES.

IT IS UNLAWFUL TO PLACE

ANY PART OF THIS MACHINE

OR LOAD WITHIN 10 FEET

OF HIGH VOLTAGE LINES

UP TO 50,000 VOLTS.

DEATH OR INJURY MAY

RESULT FROM CONTACTING

ELECTRIC LINES.

Located on cab fender

P/N 8060-3022

8060-3022

NO RIDERS PERMITTED ON HANDLER.

OPERATOR ONLY IN MACHINE

WHILE RUNNING.

RIDERS COULD FALL OFF MACHINE

CAUSING SERIOUS INJURY OR DEATH.

9114-3283

Located on left cab wall

P/N 9114-3283

R

FULL

ADD

HYDRAULIC

OIL LEVEL

CHECK OIL LEVEL WITH HANDLER LEVEL AND ALL CYLINDERS RETRACTED.

2.5 GALLON BETWEEN ADD AND FULL MARKS

9140-3569

Located on hydraulic reservoir

P/N 9140-3569

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

9114-3282

7733-3027

Located on left cab wall

P/N 7733-3027

DIESEL FUEL IS FLAMMABLE

EXTINGUISH ALL OPEN FLAME AND

SMOKING MATERIALS WHEN REFUELING

INJURY OR DEATH COULD RESULT

FROM FIRE.

9114-3286

Located on left cab wall

P/N 9114-3286

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM.

READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL BEFORE LIFTING PERSONNEL.

DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.

WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN CAB WITH PERSONNEL

OPERATE CONTROLS LIGHTLY AND CAUTIOUSLY WHEN LIFTING PERSONNEL.

DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL

HANDLER/PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN CAB.

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

IN DIRECT LINE OF SIGHT.

9055-3027 REV. A

Located on both sides of frame

near axles and boom head

P/N 9114-3282

Form No. 20036 • G6-42A Owner/Operator Manual

Located on mud guard

P/N 9055-3027

2.5

DECALS

KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.

HOT EXHAUST COMPONENTS CAN CAUSE

Located on right rear frame

Located on left side of boom

EXHAUST SYSTEMS CAN BE HOT.

SEVERE BURNS.

P/N 9114-3280

P/N 9100-3031

9114-3280

PINCH POINT

KEEP OUT

REACHING INTO BOOM

HOLES AND OTHER PINCH

POINTS CAN CAUSE

SERIOUS INJURY

OR DEATH.

Located on boom

P/N 8060-3037

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED

ALL PERSONNEL IN PLATFORM MUST WEAR A FULL BODY HARNESS WITH

LANYARD ATTACHED TO A DESIGNATED ANCHORAGE POINT.

READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

PERSONNEL WORK PLATFORM.

BEFORE OCCUPYING PERSONNEL WORK PLATFORM.

8060-3037-A

9055-3026 REV. A

MAXIMUM OCCUPANCY THREE (3) PEOPLE.

DO NOT USE PERSONNEL WORK PLATFORM

WITHOUT THE PROPER GRADALL MATERIAL

HANDLER/PERSONNEL WORK PLATFORM

CAPACITY CHART DISPLAYED IN CAB.

FAILURE TO COMPLY COULD RESULT IN

SERIOUS INJURY OR DEATH.

9055-3031 REV. A

Located on Personnel

work platform

P/N 9055-3031

406 MILL AVE. S.W. NEW PHILADELPHIA, OHIO MADE IN U. S. A.

ATTACHMENT

SERIAL NUMBER

WEIGHT

CAPACITY

HYD. PRESSURE

DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE

PROPER GRADALL MATERIAL HANDLER/PERSONNEL WORK

PLATFORM CAPACITY CHART DISPLAYED IN CAB.

9055-3033

Located on boom head & personnel

work platform

P/N 9055-3026

ATTACH LANYARD HERE

Located on work platform

P/N 9055-3032

406 MILL AVE. S.W. NEW PHILADELPHIA, OHIO MADE IN U. S. A.

ATTACHMENT

SERIAL NUMBER

WEIGHT

CAPACITY

HYD. PRESSURE

THE CAPACITY OF FORKLIFT, ATTACHMENT AND FORK

COMBINATION MAY BE LESS THAN THE CAPACITY SHOWN

ON ATTACHMENT - CONSULT FORKLIFT NAMEPLATE

AND ALSO INSURE FORKS ARE OF PROPER SIZE.

9015-3001

9055-3032

2.6

Located on Personnel Work Platform

P/N 9055-3033

Located on attachment

P/N 9015-3001

JLG G6-42A Operator Manual

IMPORTANT SAFETY NOTICE

REVISIONS

TABLE OF CONTENTS

INTRODUCTION

SAFETY HIGHLIGHTS