JLG Telehandler Personnel Work Platform Operator Manual

®

OWNER/OPERATOR MANUAL

®

TF6-42

®

Form #20136

CORPORATE OFFICE

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

9150-4003

March 2003

Starting Serial No.

0192001 thru 0192007

& 0160000052 thru Current

Original Issue 03/03

GRADALL DIVISION

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

TF6-42 MATERIAL HANDLER

“TRANSFORMER SERIES”

OWNER/OPERATOR MANUAL

COVERING OPERATION & PERIODIC MAINTENANCE

IMPORTANT!

Read and understand this Manual, the Transformer Series Work Platform Owner/Operator Manual, the Gradall Material Handler Safety Manual, the ANSI A92.5 Responsibilities Manual, and the EMI Aerial

material handler

Work Platform Safety Manual before starting, operating or performing maintenance procedures on this machine.

KEEP OPERATOR AND SAFETY MANUALS IN CAB

A Company

Form No. 20136

®

COVERS MATERIAL HANDLER TF6-42

STARTING SERIAL NUMBER 0192001 THRU 0192007

AND SERIAL NUMBER 0160000052 THRU CURRENT

Part No. 9150-4003

®

4

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6

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6

1

6

1

6

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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 JLG/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 Transformer Series Work Platform Owner/Operator Manual, the GRADALL Material Handler Safety Manual, the ANSI A92.5 Responsibilities Manual, the EMI Aerial Work Platform Safety Manual, as well as instructional decals and plates affixed to the machine and attachments 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 JLG/GRADALL must be thoroughly evaluated from the standpoint of safety before it is placed in practice. If you are not sure, contact your JLG/GRADALL Material Handler Distributor before operating.

Use only JLG/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 JLG/GRADALL. Use only

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genuine JLG/GRADALL replacement parts.

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OTHER NOTICES

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

JLG/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 JLG/Gradall Company.

REVISIONS

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

Page Date Revision

Form No. 20136 3/03 • TF6-42 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 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

• The Transformer Series Work Platform Owner/Operator Manual

• ANSI Responsibilities Manual

• EMI Aerial Work Platform Safety 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

LEFT

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 JLG/GRADALL Distributor.

Models Covered

This Manual covers basic information for JLG/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.

REAR

Figure I-1

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)

CAPACITY WITH STANDARD

ATTACHMENT

48" & 72" CARRIAGE.

6.6

42'

24"

2.0' 26.9'

19430 LBS

C

B

1.0

4.6'

D

24"

A

24"

TRUCK &

CAP#

ATTACHMENT

DCBA

1000

WEIGHT

6.6

2.0'

20,180

42' 24" 24"

6.6

2.0'

20,290

42' 24"

24"

6.6

2.7'

20,460

42' 24" 24"

6.6

2.7'

20,650

24"24"42'

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.

CAP# X1000

A

B

C

SAMPLE ONLY

D

SHIPPED WIT

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 *

Serial Number Location (See figure I-2)

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.

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This machine has been equipped with a serial number specific Transformer Series

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Personnel Work Platform. Do not exchange transformer platforms between

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machines. Doing so will require calibration changes to the controller that must be

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performed by a qualified service technician. This platform assembly is designed

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soley for use with the

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Transformer Model Machines only.

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

Important Notice !

*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)

RIGHT

SAFETY HIGHLIGHTS

DANGER

!

WARNING

!

CAUTION

!

WARNING

!

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.

JLG/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.

Be aware that when rotating the platform within indicated area on capacity charts, it can swing into tires. Be sure to allow clearance to avoid damage to tires.

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

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

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

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

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

slow the machine prior to turning.

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.

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.

1.0

SAFETY HIGHLIGHTS

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

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

Release trapped pressure before disconnecting, opening or removing any

hydraulic component.

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.

tion.

required for maximum

WARNING

!

Contact The JLG/Gradall Company prior to welding on machine.

WARNING

!

Do not operate the “transformer series” platform without proper installation, including electrical and hydraulic connections in place.

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.

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/attachment to ground, apply park brake, move all controls to minutes. emergency stop button in run mode. Chock wheels.

Rotate control station selector switch to “off”, remove key and place

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

WARNING

!

Do not allow personnel to tamper with or operate the machine from the cab with personnel in the platform equipped with controls, except in an emergency.

Do not allow others to occupy cab while platform controls are in use.

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

1.1

SAFETY HIGHLIGHTS

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

R

Platform & Tires

Fork Pin Area on Carriages

SAFETY HIGHLIGHTS

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

DECAL LOCATIONS

9

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14-3283

NO RIDERS PERMITTED ON HANDLER.

IN MACHINE

RIDERS COULD F

OFF MACHINE

CAUSING SERIOUS INJUR

7733-3027

** unknown ** ** unknown **

CHECK OIL

LEVEL

WITH

HANDLER LEVEL

AND

CYLINDERS RETRACTED.

2.5 GALLON BETWEEN AND FULL

LEVEL

14-3282

1

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12

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

9114-3282

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.

BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

9114-3282

14

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

** unknown ** ** unknown ** 2 NO

13

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

9114-3282

13

A

R

** unknown ** ** unknown ** 2 NO

1

7733-3027

NO RIDERS PERMITTED ON HANDLER. OPERATOR ONLY IN MACHINE

RIDERS COULD F

ALL OFF MACHINE

CAUSING SERIOUS INJUR

Y OR DEATH.

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

9114-3282

9114-3283

13

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

9114-3282

A

16

1 9150-3097 Warning Decal, moving parts 2 9150-3099 Warning Decal, battery 3 9151-3207 Load Chart Cover 4 9150-3083 Carriage Chart - TF6-42 5 9150-3084 Swing Carriage - TF6-42

9150-3085 Swing Mast - TF6-42 9150-3086 Truss Boom - TF6-42

9150-3087 Platform Chart - TF6-42 6 9150-3096 Warning Decal, lifting personnel 7 9150-3110 Danger Decal, high voltage 8 9150-3098 Warning Decal, operation

2.0

9 9150-3088 Serial No. & Attaching Plate 10 9150-3112 Aux. Hyd. De-Press Decal 11 9150-3102 Boom Operation Decal 12 9150-3101 Inspection Decal 13 9150-3108 Warning Decal, pinch point 14 9150-3107 Oil Level Decal 15 7733-3027 Made in USA Decal 16 9150-3109 Warning Decal, no riders 17 9150-3113 Service Instruction Plate 18 1701529 Decal 19 7702-3008 Fuel Decal

DECAL LOCATIONS

24

22

A

A-A

25

23

26

27

24

28

29

30

21

31

20

B

24

B-B

22

20 9150-3128 TF6-42 Decal 21 9147-3132 Gradall Decal 22 9114-3282 Warning Decal, pinch point 23 9100-3031 Boom Angle Decal 24 9151-3210 Warning Decal, moving parts 25 9150-3096 Warning Decal, lifting personnel

26 9100-3016 “1” Decal 27 9100-3018 “2” Decal 28 9112-3042 “3” Decal 29 9100-3020 “4” Decal 30 9112-3044 “5” Decal 31 9116-3077 “6” Decal

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

2.1

DECALS

R

Instructions

TWO METHODS OF USING THE CAPACITY CHART.

SAMPLE ONLY - USE CHART IN CAB

Method 1

1. The operator must determine:

BOOM EXTENSION NUMBER where the load is to be placed.

BOOM ANGLE where the load is to be placed.

2. On the capacity chart, find the arc for the boom extension number, and follow it down to the boom angle.

3. The number in the load zone where these two cross is the maximum capacity for this lift. If the two cross at a division between zones, the smaller number must be used.

Method 2

1. The operator must determine:

HEIGHT where the load is to be placed.

DISTANCE from the front of the machine where the load is to be placed.

2. On the capacity chart, find the line for the height and follow it over to the distance.

3. The number in the load zone where the two cross is the maximum capacity for this lift. If the two cross at a division between zones, the smaller number must be used.

For each method, the number in the load zone must be equal to or greater than the weight of the load to be lifted. Determine the limits of the load zone on the capacity chart by boom angle AND boom extension number. Keep the load within theses limits.

9151-3207 REV.-

TIPOVER HAZARD. Failure to comply with instructions could result in death or serious injury.

The operator MUST:

1. Make sure the handler is on a firm, level surface before lifting or placing a load.

2. Make sure that the capacity charts are for the appropriate Gradall model.

3. Make sure that the Part Numver shown on the attachment's Serial Number Plate matches the Part Number shown on the capacity chart.

4. Be sure of the WEIGHT of the load to be lifted.

BACK

Located on dashboard

P/N 9151-3207

MODEL TF6-42

48'

RATED CAPACITY @ 2 FT LOAD CENTER

44'

40'

36'

32'

48" & 72"

SLOPE PILER

28'

24'

20'

16'

12'

10°

8'

4'

0°

0'

-9°

-4'

-8'

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

50°

40°

30°

20°

800 LBS

70°

60°

6

SAMPLE ONLY - USE CHART IN CAB

5

4

3

2

1

5000 LBS

6600 LBS

4000 LBS

3000 LBS

2000 LBS

12'16'20'24'28'32'

0'4'8'

9150-3083 (-)

USE WITH: 9140-5073 48" CARRIAGE 9140-5074 72" CARRIAGE 9140-5077 72" DRYWALL CARR. (4,000 LB MAX. CAPACITY) 9140-5054 60" 3/4 YD. BUCKET (4,500 LB MAX. CAPACITY) 9140-5055 74" 1 1/4 YD. BUCKET (4,500 LB MAX. CAPACITY) 9140-5071 102" 1 1/4 YD. BUCKET (4,500 LB MAX. CAPACITY)

BACK

2

1

6

5

4

3

0' 4' 8'

RATED CAPACITY @ 2 FT LOAD CENTER

70°

60°

6000 LBS

5000 LBS

4000 LBS

6600 LBS

12' 16' 20' 24' 28' 32'

Located on dashboard

P/N 9150-3083

FRONT

MODEL

TF6-42

50°

40°

3000 LBS

2000 LBS

FRONT

9151-3207 REV.-

30°

1200 LBS

20°

10°

0°

-9°

9150-3083 (-)

48'

44'

40'

36'

32'

28'

24'

20'

16'

12'

8'

4'

0'

-4'

-8'

Instructions

48" & 72"

CARRIAGES

2.2

For safe operation of machine, and to minimize risk of

serious injury, READ AND OBSERVE the following:

1. Only trained and authorized personnel may operate this machine.

2. Before operating, read and understand all capacity charts, operator manual and safety manuals.

3. Operator must be seated with seat belt fastened. Assure all controls are in neutral before ignition switch is turned on.

4. Do not travel with boom raised. When traveling, fully retract boom and place forks in carry position, which is approximately 4 feet (1.2 m) above ground. Tilt carriage back slightly to cradle load. Use extreme caution when turning.

5. On inclines, travel with load up-grade.

Located on right cab wall

6. Keep others away from machine when operating. Do not allow others to stand under boom or load. Always look in direction of travel.

7. Use extreme care when handling long, high or wide loads. Do not handle unstable or loosely stacked loads.

8. Forks must be centered under load, and spaced apart as far as possible.

9. Level machine before lifting any load above 4 feet (1.2m).

10. Improper use of machine could result in machine tipping over. If machine starts to tip over, do not leave operator's seat. Lean away from tip, and brace yourself.

11. Keep mirror(s) clean and properly adjusted. Objects in mirror(s) are closer than they appear.

P/N 9150-3098

9150-3098 REV. A

000850

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.

R

GRADALL IS A REGISTERED TRADEMARK

FOR HYDRAULIC EQUIPMENT BUILT BY THE JLG COMPANY

1 JLG DRIVE, McCONNELLSBURG, PA.

U.S.A.

TF6-42

(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'

A

24"

B

24"

C

2.0'

D

ATTACHMENT

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 *

60" 3/4 YD BUCKET P/N 9140-5054 **

74" 1 1/4 YD BUCKET P/N 9140-5055 **

102" 1 1/4 YD BUCKET P/N 9140-5071 **

10FT TRUSS BOOM P/N 9140-5083 ***

10FT TRUSS BOOM W/WINCH P/N 9140-5081 ***

15FT TRUSS BOOM P/N 9140-5082 ***

15FT TRUSS BOOM W/WINCH P/N 9140-5080 ***

6FT MAST W/48" CARR. P/N 9140-5060 *

6FT MAST W/72" CARR. P/N 9140-5061 *

6FT SWING MAST P/N 9140-5070 ****

72" 100° SWING CARR. P/N 9140-5075 *

WORK PLATFORM P/N 9141-5025 *****

4.6'

26.9'

1.2

24"

CAP# 1000

6.6

4.5

2.0

6.0

4.0

6.0

1.8

X1000

SAMPLE ONLY - USE CHART IN CAB

SHIPPED WITH

*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 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

21,030

21,140

21,310

21,500

20,780

20,960

21,000

20,830

21,010

20,950

21,140

22,000

22,100

22,880

21,800

21,040

20280 LBS

C

D

42' 24" 24"

42' 24"

42' 24" 24"

42' --- ---

52' --- ---

57' --- ---

39' 24" 24"

48' 24" 24"

31' 24" 24"

42' --- ---

DCBA

2.0'

24"

2.0'

2.7'

24"24"42'

2.7'

4.3'

4.9'

4.3'

3.8'

4.3'

1.9'

4.2'

4.4'

4.7'

9150-3088 (A)

DECALS

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 N/A (enclosed cab)

P/N N/A (open cab)

Located on right cab wall

P/N 9150-3088

LUBRICATION AND MAINTENANCE

SERVICE INTERVALS

DAILY

EVERY 5

WEEKLY

WKS OR

MATERIAL HANDLER

Diesel Engine

Air Cleaner Element

Fuel Filter

Engine Oil Filter

Engine Oil

Coolant

Diesel Fuel

Transmission

Lubricant

Filter

Transfer Case

SAMPLE ONLY - USE CHART IN CAB

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.)

Stabilizer Cylinder (3 Pts.)

Boom

Front Bottom Bearing Pads

All Other Bearing Pads

Extend/Retract Chains

Options And Attachments

Work Platform Pins Attachment Pivots And Pins

Tires

13.00-33.5 12 PLY LSW G-2

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

Grease Grease

Check

250 HRS

Change

Check

Grease

Check

3 MO.

OR

500 HRS

Change

Torque

6 MO.

OR

1000 HRS

Change Change

Change

YEARLY

OR

1500 HRS

Change

LUBRICANT TYPE

OR

SPECIFICATION

SAE 15W-40 CE Oil

Etheylene Glycol

No. 2 Diesel Fuel

Mobil 424

Mystik Tetrimoly

See Manual

Mystik Tetrimoly Mystik Tetrimoly

65 PSI (448 kPa)

350-400 Lb-Ft (39-45 Nm)

9150-3113 REV -

9150-3102 REV. -

Located on right cab wall

P/N 9150-3102

Located inside engine cover

P/N 9150-3113

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

Located on left side, front cab plate

P/N 9116-4094

2.3

DECALS

Batteries produce EXPLOSIVE GASES. EXPLOSION could result in serious injury.

Keep sparks, flames and lighted materials away from batteries.

Located in engine compartment

P/N 9150-3099

CONTACTING ELECTRIC POWER LINES will result in death or serious injury.

Do not place machine or load within 10 feet (3m) of electric

power lines.

Located on right cab wall

P/N 9150-3110

9150-3099 REV -

10 FT.

(3 M)

9150-3110 REV - A

MOVING PARTS can cut or entangle. Keep clear while engine is running.

9150-3097 REV. -

Located in engine compartment

P/N 9150-3097

2.4

MOVING PARTS COULD CRUSH,

CAUSING DEATH OR SERIOUS INJURY.

KEEP CLEAR OF WHEELS AND MOVING PARTS

WHILE ENGINE IS RUNNING.

Located on right and left frame,

front & rear

P/N 9150-3108

9150-3108 REV -

9150-3107

Located on hydraulic reservoir

P/N 9150-3107

NO RIDERS. Riders could FALL OFF

machine causing death or serious injury.

9150-3109 REV -

Located on left cab outside wall

P/N 9150-3109

DECALS

R

7733-3027

Located on left outside cab wall

P/N 7733-3027

Located on left side of boom

P/N 9100-3031

When lifting personnel, USE ONLY a Gradall manufactured personnel work platform.

READ AND UNDERSTAND personnel work platform Owner/Operator manual before lifting personnel.

DO NOT DRIVE machine from cab when personnel are on platform.

All personnel on platform must WEAR A FULL BODY HARNESS, with lanyard attached to a designated anchorage point.

OPERATE CONTROLS CAUTIOUSLY and lightly when lifting or positioning personnel.

IN ADDITION, when using a personnel work platform WITHOUT CONTROLS:

Do not use personnel work platform without proper CAPACITY CHART DISPLAYED in cab.

When personnel are on platform, the OPERATOR MUST REMAIN SEATED in cab with personnel in direct line of sight.

Failure to comply could result in death or serious injury.

Located on boom head,

and inside right cab wall

P/N 9150-3096

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

9150-3096 REV A

MOVING PARTS could cut or crush causing death or serious injury. Keep clear of moving parts while engine is running.

Located on boom

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

Located on attachment

P/N 9015-3001

9151-3210 REV -

P/N 9151-3210

2.5

DECALS

Located on Frame

P/N 1701529

DIESEL FUEL

FIRST DELIVERY

1 YEAR

2 YEARS

3 YEARS

4 YEARS

ANSI REQUIRES AN ANNUAL INSPECTION BE PERFORMED BY QUALIFIED PERSONNEL IN ACCORDANCE WITH MANUFACTURER'S SPECIFICATIONS.

USE GRADALL APPROVED MANUALS, PARTS AND PROCEDURES. CONTACT GRADALL REGARDING STRUCTURAL REPAIRS.

STAMP FRAME WITH MONTH/DAY/YEAR NEXT TO ARROW AFTER EACH INSPECTION RETAIN RECORDS IN ACCORDANCE WITH ANSI.

NOTIFY GRADALL IMMEDIATELY OF ANY CHANGES OF OWNERSHIP.

REPLACE IF DEFACED

9150-3101 REV -

Located on Boom Pivot Frame

P/N 9150-3101

5 YEARS

6 YEARS

7 YEARS

8 YEARS

9 YEARS

10 YEARS

Located on outside of Cab

P/N 7702-3008

2.6

OPERATOR’S CAB

The cab permits vision from all sides and includes an overhead guard to provide protection from falling objects.

A fully-enclosed cab with windows and a lockable door is available as an option. The top half of the cab door must be secured in either the fully-opened or closed position. The bottom half of the cab door must be secured in the closed position only. Be sure the door is fully secured when operating the handler.

The operator’s seat is equipped with a seat belt and includes fore and aft adjustment to compensate for variations in operator size. The adjustment release/lock is located on the side

machine.

An optional windshield wiper/washer is available for use with enclosed cabs. A control switch is located on the instrument panel.

of seat. Wear seat belt when operating

OPERATOR’S CAB

WARNING

!

Never operate the handler unless the overhead guard is in good condition.

A variable-speed defroster fan is available for use with enclosed cabs. An “On/ Off” control switch and speed control are located on the base of the fan.

The heater fan speed is controlled by a knob on the panel to the right of the operator’s seat. Hot water to the heater can be controlled by a knob on the same panel or a valve in the engine compartment.

The operator’s cab is an S.A.E. “FOPS/ROPS” structure. Do not make any modification to this structure. If damaged, the cab cannot be repaired. It must be replaced.

CONTROL AND INSTRUMENT IDENTIFICATION

Figure 3-1

LEVEL

INDICATOR

HOURMETER

STEERING

EMERGENCY STOP SWITCH

TRANSMISSION CONTROL LEVER

(FORWARD/REVERSE/GEAR

CHANGE LEVER)

AUX CONTROL LEVER

(OPTIONAL)

CONTROL STATION

TRANS TEMP WARNING LIGHT

SELECTOR SWITCH

QUARTZ

000000

WHEEL

PARK BRAKE

SWITCH

R

F

80

FUEL

OIL

E

0

240

16

TEMP

VOLTS

-+

10

100

START

IGNITION

MACHINE MUST BE IN NEUTRAL AND PARK BRAKE ON TO START

48" & 72"

CARRAIGE

48" & 72"

CARRAIGE

48" & 72"

CARRAIGE

OIL PRESSURE/

COOLANT TEMP/

VOLTMETER/

FUEL GAUGE

BOOM CONTROL

JOYSTICK

HORN BUTTON

CAPACITY CHARTS

START/AUX. POWER

SWITCH

STEER SELECT SWITCH

WARNING

!

Any modification to this machine must be approved by JLG/GRADALL to assure compliance with FOPS/ ROPS certification for this cab/ machine configuration.

NOTE!

Relevant S.A.E. Recommended Practices: S.A.E. J1040 for ROPS S.A.E. J231 for FOPS

BRAKE PEDAL

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

MICROPROCESSOR

CONTROLLER

ACCELERATOR PEDAL

3.0

WARNING

!

OPERATOR’S CAB

Accelerator Pedal: Depress pedal to increase speed and release pedal to

decrease speed.

Attachment Tilt Lever: This lever controls tilt of the fork carriage. Speed is proportional to lever actuation and engine RPM. Push lever forward to tilt down; pull lever back to tilt up.

Attachment Tilt Switch (optional): Depress left side of switch to tilt down; depress right side of switch to tilt up.

Auxiliary Control Lever (optional): This lever is used to control optional hydraulic attachments. Follow decal instructions for lever/handler movements.

Auxiliary Light Switch (optional): This switch turns auxiliary lights on and off.

Boom Control Joystick: This joystick controls boom elevation and extension. Pull joystick back to raise boom; push joystick forward to lower boom. Move joystick to right to extend boom; move to left to retract boom. Speed of boom movement is proportional to joystick actuation and engine RPM.

Control Station Selector Switch: Rotate key activated switch to “Platform” to transfer power to platform controls. Rotate key activated switch to “Cab” to transfer power to cab controls. When not in use, turn the selector switch to “Off”. If the switch is not positioned in the “Off” position during shutdown and emergency stop button is in run mode, the battery will drain.

Decompression Valve: Used only for connecting/disconnecting Auxiliary Hydraulics. Located in cab, left side of seat pedestal.

A brief description of controls and instruments is provided here as a convenience for the operator. These descriptions DO NOT provide complete operation instructions. Read & understand this Manual, the Transformer Series Work Platform Manual, the ANSI A92.5 Responsibilities Manual, the EMI Aerial Work Platform Safety Manual, and the GRADALL Material Handler Safety Manual.

Emergency Stop Button: Pushing the button stops engine operation.

Engine Coolant Temperature Gauge: This gauge displays engine coolant

temperature.

Engine Oil Pressure Gauge: This gauge displays engine oil pressure.

Fuel Gauge: This gauge displays level of fuel in fuel tank.

Heater Fan Switch (optional): This switch turns heater fan on and off.

DEFROSTER FAN

AIR VENT

ACCESS COVER/

HEATER VENT

AIR VENT

TEMPERATURE CONTROL

HEATER FAN SWITCH

3.1

HEATER

Horn Button: Depress button to sound horn.

OPERATOR’S CAB

Hourmeter: This meter indicates total time of engine operation in hours

and tenths of hours.

Start/Aux. Switch: The control selector switch must be in cab position for start/ aux. switch to be operational. Momentarily push switch up to start engine. With engine off, simultaneously push switch down and activate controls to activate auxiliary power.

Level Indicator: This bubble level indicator enables the operator to determine the left to right level condition of the handler.

Lights Switch (optional): This switch controls optional lighting which may be provided with the handler.

Machine Level Lever: This lever controls the relationship of the handler frame to the front axle. Move the lever left to tilt frame to left, move the lever right to tilt frame to right.

Microprocessor Controller: This unit processes information for the transmission.

Neutral Lock Lever: The transmission control lever is equipped with a switch that locks the transmission control lever in neutral when activated.

4-Wheel Circle Steer

Parking Brake Switch: This switch controls the application and release of

the parking brake. Indicator light on switch glows (red) to indicate brake is applied.

Seat lock Release Lever: This lever unlocks and locks seat position adjustment.

Service Brake: This pedal operates the service brakes. The further the pedal is depressed, the slower the travel speed. Full depression of pedal causes full service brake application.

Steer Select Switch: This switch has three positions to allow selection of 4-wheel circle steer, 4-wheel crab steer and 2-wheel steer. 4-wheel circle steer allows the front and rear wheels to steer in opposite directions for tight turns. 4-wheel crab steering turns the front and rear tires in the same direction for moving the machine to the side. 2-wheel steer allows only the front wheels to steer.

Steering Wheel: The steering wheel controls the angle of wheels. Turning the steering wheel to the right causes a right turn. Turning the steering wheel to the left causes a left turn.

Transmission Control: This lever engages forward or reverse travel. Push lever fully forward for forward travel; pull lever fully backward for reverse travel. Move lever to centered position for “Neutral.” Twist hand grip to select gear.

Transmission Temperature Light:

procedure for a bulb check. If transmission temperature exceeds 250° light will glow indicating the need for service.

This light will illuminate during starting

4-Wheel Crab Steer

2-Wheel Front Steer

CAUTION

!

If transmission temperature light glows, move material handler to a safe location and shut down.

CAUTION

!

When traveling at higher speeds use 2-wheel front steering.

Voltmeter: This gauge indicates alternator output and battery condition.

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

3.2

CHECKS & SERVICES BEFORE STARTING ENGINE

WARNING

!

WARNING

!

WARNING

!

To be performed at the beginning of each work shift.

PERFORM “WALK-AROUND INSPECTION” AS DESCRIBED ON PAGES P6.2 & P6.3 IN THE TRANSFORMER SERIES WORK PLATFORM MANUAL LOCATED IN THE BACK OF THIS MANUAL. THIS INSPECTION IS A DAILY REQUIREMENT BEFORE OPERATING THIS MACHINE.

• Check to be sure the material handler is equipped with the proper load/ capacity chart and that it is legible before operating.

• If spark arrestors are required, be sure they are in place and in good working order.

• Check to be certain that windows and mirror(s) are clean and undamaged. Also make certain that mirror(s) are properly adjusted for operator’s view.

• Before removing filler caps or fill plugs, wipe all dirt and grease away from the ports. If dirt enters these ports, it can severely reduce component life.

Use extreme caution when checking items beyond your normal reach. Use an approved safety ladder.

• When adding fluids, refer to lubrication section of Manual to determine proper type.

Complete all required maintenance before operating unit.

Service the unit in accordance with the “Lubrication and Routine

Maintenance” schedule, pages

19.2 and 19.3.

Inspect all structural members, including attachment, for signs of damage.

Before operating handler, complete all required maintenance. Replace or repair all damaged, worn or missing components before starting or operating. Failure to properly maintain handler could cause serious injury or death.

4.0

(Optional Turbo Charged Engine Shown)

Inspect unit for obvious damage, vandalism and necessary maintenance. Check for signs of fuel, lubricant, coolant and hydraulic leaks. Open all access doors and look for loose fittings, clamps, components and attaching hardware. Replace hydraulic lines that are cracked, brittle, cut or which show signs of leakage or abrasion.

Use a piece of cardboard or paper to search for leaks. DO NOT use bare hands. If anyone is injured by hydraulic fluid, including penetration of the skin, obtain medical help immediately!

PRE-START & FUNCTION CHECKS

To be performed at beginning of each work shift. PERFORM “WALK-AROUND INSPECTION” AS DESCRIBED ON PAGES P6.2 & P6.3 IN THE TRANSFORMER SERIES WORK PLATFORM MANUAL LOCATED IN THE BACK OF THIS MANUAL. THIS INSPECTION IS A DAILY REQUIREMENT BEFORE OPERATING THIS MACHINE.

The safety, efficiency and service life of your handler will be increased by performing the operational checks listed below. Items preceded by an asterisk (*) are optional and may not be furnished on your machine.

Before entering the operator’s cab, check:

1. Engine oil level.

2. Hydraulic oil level.

3. Air Filter Restriction Indicator. If needle is in red area, filter is clogged and element must be cleaned or changed.

During warm-up period, check:

* 4. Heater, defroster and windshield wiper.

WARNING

!

Check all tires and rims periodically for damage due to impact. Replace before use if damage is detected.

* 5. Operating lights and rotating beacon.

6. Voltmeter-should show 13.5 to 14 volts.

When engine warms to operating range, check:

7. Transmission fluid level.

8. Service brake and parking brake.

9. Forward and reverse travel.

10. Each of the gear ranges.

11. Steering (in both directions) with engine at low idle. Check in each steering mode.

12. Horn and back-up alarm. Must be audible from inside operators cab with engine running.

13. All boom and attachment functions - operate smoothly and correctly.

14. Hydraulic Filter Condition Indicator - observe engine coolant temperature gauge after starting normal operation. When needle has been in operating range for an hour or so, stop handler in a safe area, apply parking brake, lower forks fully, shift forward/reverse lever to “Neutral” position and chock wheels. With engine running at full throttle, have an assistant check the Hydraulic Filter Condition Indicator. When bar gauge is in red area, filter is clogged and hydraulic oil is bypassing filter. Filter element must be changed before reaching bypass condition (change before needle reaches red area).

CAUTION

!

Keep engine cover closed while engine is running except when checking Transmission Oil Level and hydraulic filter condition indicator.

CAUTION

!

Continued operation with hydraulic fluid bypassing the filter may cause severe damage to hydraulic system components.

Complete all required maintenance before operating unit.

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

5.0

ENGINE OPERATION

WARNING

!

CAUTION

!

Starting the Engine

1. Make sure all controls are in “Neutral” and all electrical heater, defroster, etc.) are turned off. Set

2. Depress accelerator pedal approximately 1/4 to 1/3 of travel from top.

3. Turn control station selector switch to cab, pull up emergency stop, and push up on start/aux. switch to engage starting motor. If engine fails to start within 20 seconds, release start/aux. switch and allow starting motor to cool for a few minutes before trying again.

4. After engine starts, observe oil pressure gauge. If gauge remains on zero for more than ten seconds, stop engine and determine cause. Correct malfunction before restarting engine. Minimum pressure at operating temperature:

Low idle: 10 PSI (69kPa)

5. Warm up engine at approximately 1/2 throttle until engine coolant temperature reaches operating range.

parking brake.

components (lights,

Cold-Weather Starting Aids

In cold approved starting aids employ ether. If your handler is equipped with an ether starting aid, the following applies:

• All employed ether is triggered by temperature gauge located on engine.

• At start-up, temperature gauge on engine will detect if ether is needed. Follow

• Ether is employed and additional will be released if needed, to keep engine

• A second battery is added for additional cold-cranking capacity.

weather situations, a supplemental starting aid may be required.

normal start-up procedure, shown above.

running.

Gradall-

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.

NOTE!

Engine will not start unless transmission control lever is in “Neutral” and parking brake switch is applied.

If your machine is equipped with a cold start aid, do not spray additional ether into air cleaner.

If machine is not equipped with cold start aid, follow instructions listed in the engine manual supplied with machine.

6.0

Battery-Boosted Starting

If you ever have to battery-boost start (jump-start) your handler, proceed as follows:

• 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

ENGINE OPERATION

Normal Engine Operation

Observe gauges frequently to be sure all engine systems are functioning properly.

The voltmeter shows the “charge/discharge” state of the battery charging system. With the engine running, meter should indicate 13.5 to 14 volts. With engine stopped, meter indicates battery charge (12 volts).

Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe position and perform standard shut-down procedure. (See

Page 1.1) Report condition to your supervisor or maintenance personnel.

Avoid prolonged idling. Idling causes engine temperature to drop and this

permits formation of heavy carbon deposits and dilution of lubricating oil by incompletely-burned fuel. If the engine is not being used, turn it off.

Stopping the Engine

• To stop engine, perform standard shut-down procedure shown on page 1.1.

• Operate engine at low idle for 3 to 5 minutes before turning it off. This allows engine coolant and lubricating oil to carry excessive heat away from critical engine areas, including turbocharger.

• Do not “gun” engine before shut down: This practice causes incompletelyburned fuel to remove oil film from cylinder walls and dilute lubricant in crankcase.

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

6.1

BRAKE SYSTEM

WARNING

!

WARNING

!

WARNING

!

General

The brake system includes a service brake and a parking brake. Service and parking brakes are applied through wet disc brake packs located within axle housing.

Service Brakes

D

epressing the service brake pedal applied to service brakes. The greater the pedal travel, the greater the braking force.

If power-assist fails, it will require much greater force on pedal to apply brake and stopping distance will be greater.

Parking Brakes

The parking brakes are spring-applied and hydraulically-released.

Pressure to release parking brakes is provided by the hydraulic system and is controlled by the parking brake switch located on the dashboard.

causes controlled hydraulic pressure to be

If power-assist feature should fail for any reason, it would require greater effort to apply service brake. If power assist fails, stop as soon as possible. Do not drive the handler until problem has been corrected.

Always move parking brake switch to “On” position before leaving cab. Never stop engine while traveling. Parking brake will be fully-applied and unit could stop abruptly. A sudden stop could cause load loss.

With the engine running and the parking brake switch “Off”, parking brakes are disengaged. Moving the switch to “On” releases hydraulic pressure to apply the parking brakes. With switch in “On” position, the transmission will not engage forward or reverse.

Always ensure that transmission control lever is in neutral before releasing park brake. Releasing park brake in either forward or reverse could cause the machine to move abruptly.

7.0

PARKING THE HANDLER

Precautions

• Avoid parking on slopes or near an excavation.

• Park on level ground and chock wheels.

• Avoid parking on roads or highways. If it cannot be avoided, be sure to display warning flags during day and flares or flashing lights at night.

• Position boom-head or attachment on ground; never leave machine with boom in air.

• If parking on a slope cannot be avoided, position the handler at a right angle across the slope, straighten and chock all wheels.

Parking procedure

1. Using service brake, stop the handler in an appropriate parking area.

2. Move parking brake switch to “On”.

3. Shift transmission control lever to “Neutral”.

4. Position attachment on ground.

5. Allow engine to cool at idle speed for 3 to 5 minutes, stop engine. Rotate control station selector switch to “off”, remove key and place emergency stop button in run mode.

6. Chock wheels as an extra precaution against rolling.

7. Fill fuel tank to minimize condensation.

8. Lock cab and install protective covers, if so-equipped.

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

8.0

WARNING

!

STEERING SYSTEM

WARNING

!

• Three modes of steering are provided as standard equipment. A three position switch on the dashboard allows the operator to select the steering mode.

• 4-wheel circle steer allows for tight turns and better maneuverability in close quarters.

• 4-wheel crab steering allows the machine to move sideways at an angle.

• 2-wheel front steer is used for high speed travel.

• It is imperative that the operator practice maneuvering the handler in a safe, open area to become thoroughly familiar with steering response and clearance required for fork swing and load when turning.

Be alert for any increase in effort needed to steer. If any difference is noted, notify maintenance personnel immediately. If power assist feature should fail for any reason, IT WOULD BECOME VERY DIFFICULT TO STEER. For this reason it is extremely important that you NEVER TURN ENGINE OFF WHILE TRAVELING. In the event power steering fails, stop as soon as possible. Do not drive handler until problem has been corrected.

Use only 2-wheel steer when traveling at high speeds. Never use 4-wheel circle steer at high speeds, sharp turns could cause machine roll-over.

9.0

General

This model material handler is equipped with a powershift transmission. With this type of transmission, the operator simply selects a gear, selects the direction of travel, releases brakes and depresses the accelerator pedal to move the handler.

Operation

Gear Selection: Gear selection is accomplished by rotating the twist grip

handle on the transmission control lever. It is best to begin travel in a lower gear, however the machine will move away from rest in any gear. Upshifts are most smoothly accomplished by lifting off the throttle pedal when shifting. Caution should be taken of downshifting to ensure that the ground speed of the material handler has slowed sufficiently so as not to over-speed the engine.

DRIVE TRAIN

Select the appropriate gear for the task being performed. Use a lower gear when transporting a load. Use a higher gear only when traveling longer distances without a load. When traveling through deep mud, or up slopes, use a lower gear. Downshift a gear when traveling down a long hill. Use the service brakes, if necessary, to prevent over-speeding the engine.

Direction of Travel: Direction of travel is selected by moving the transmission control lever towards the front of the machine for forward travel, and towards the rear of the machine for reverse travel. Neutral is selected by moving the transmission control lever to the center position. If neutral is selected while the machine is moving, the machine will continue rolling in the direction of travel.

Always bring the machine to a complete stop before changing direction of travel. This will prevent damage to the transmission or torque converter.

Forward or reverse travel can be selected while in any gear.

WARNING

!

Bring handler to a complete stop before shifting transmission control lever. A sudden change in direction of travel could reduce stability and/or cause load to shift or fall.

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

10.0

WARNING

!

LEVELING THE HANDLER

WARNING

!

WARNING

!

“Leveling” means positioning the handler so that it is level from side to side (left to right). A level indicator is located in upper right corner of front window frame to permit operator to determine whether the handler frame is level.

There are four very important things to remember about handler leveling:

1. Never engage a load or lift a load more than 1.2m (four feet) above

ground unless handler is level.

2. A handler with the boom raised and/or an attachment installed is a partially-loaded handler.

3. Once the handler frame is level and the operator has raised a load more than 1.2m (four feet) above ground, it must not be moved from this position if such movement could change the level condition. Do not use sway to level handler with load more than 1.2m (four feet) above ground.

4. The combination of side tilt and load could cause the handler to tip over.

Level the handler:

The surface which will support the handler can be leveled. This method must be chosen if it will be necessary to move the handler from its position after the load has been raised over 1.2m (four feet) from ground AND such movement could change the level condition.

Raising the boom (loaded or unloaded) when handler is leaning to one side could cause machine to tip over with little or no warning and cause serious injury or death.

Remember: The supporting surface must be large enough, smooth enough and firm enough to keep the handler level when it is moved from its position.

The handler may be leveled by means of the frame-leveling system. This method may be chosen when it will not be necessary to move the handler from its position after the load has been raised above 1.2m (four feet) from ground - OR - when such movement will not change the level condition of the handler.

Always determine best position for handler to raise load from its present location and also to position load at its destination. THEN determine which method of leveling will be required at each location.

FINALLY, consider terrain between present location of load and its destination. Never attempt to transport a load across terrain which could cause handler to tip over.

Leveling Handler Frame:

The handler is designed to permit tilting main frame 10° to left or right to compensate for uneven ground conditions.

Leveling Procedure:

Position machine in best location to lift or place load, position forward/ reverse lever in neutral and apply parking brake. Observe level indicator to determine whether machine must be leveled and level machine with the machine level lever.

Always move boom to carry position (horizontal or below) before leveling frame. Attempting to level machine with boom raised could cause it to tip over.

If handler cannot be leveled using leveling system, do not attempt to raise or place load. Have surface leveled.

11.0

OPERATING PROCEDURE & TECHNIQUES

Hydraulic Controls

All boom and attachment movements are governed by hydraulic controls. Rapid, jerky operation of hydraulic controls will cause rapid, jerky movement of the load. Such movements can cause the load to shift or fall or may cause the machine to tip over.

Feathering

Feathering is a control operation technique used for smooth operation. To feather controls, move control lever very slowly until function begins to move, then gradually move lever further until function is moving at desired speed. Gradually move lever toward “Neutral” as load approaches destination. Continue to reduce load speed to bring load to a smooth stop. Feathering effect can be increased by reducing engine speed at beginning and near end of load movement.

Boom Control Joystick

The boom control joystick can be positioned to activate individual boom movements or combinations of boom movements as illustrated:

Figure 12-1

LOWER &

RETRACT

BOOM

RETRACT

BOOM

LOWER

BOOM LOWER &

EXTEND

BOOM

EXTEND

BOOM

FRONT OF

MACHINE

NOTE!

Much of the material in this section may be new to even the experienced operator.

WARNING

!

Do not permit lift cylinders to hit the end of their stroke. The jolt could topple loads, causing a hazard to personnel and equipment nearby.

RAISE &

RETRACT

BOOM

RAISE

BOOM

RAISE &

EXTEND

BOOM

With boom raised above horizontal, forks can be inserted under a load by moving boom control joystick forward and to the right until forks move forward horizontally.

With boom raised above horizontal, forks can be removed from a load by moving boom control joystick back and to the left until forks move rearward horizontally.

With boom lowered below horizontal, forks can be inserted under

a load by moving boom control joystick back and to the right until forks move forward horizontally.

With boom lowered below horizontal, forks can be removed from a load by moving boom control joystick forward and to the left until forks move rearward horizontally.

The closer the boom is to horizontal, the less boom raise/lower movement required for inserting and removing forks.

Carriage Tilt Controls

Figure 12-2

TILT FORKS DOWN

TILT

FORKS

UP

TILT

FORKS

UP

RIGHT HAND

(standard)

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

OPTIONAL

12.0

WARNING

!

UNDERSTANDING RATED CAPACITY CHARTS

Rated Capacity Chart

The rated capacity chart, located on dashboard, indicates maximum load capacities for handlers equipped with G attachment combinations. These capacities other attachment combinations except as stated on the capacity chart.

Figure 12-3

Instructions

TWO METHODS OF USING THE CAPACITY CHART.

SAMPLE ONLY - USE CHART IN CAB

Method 1

1. The operator must determine:

BOOM EXTENSION NUMBER where the load is to be placed.

BOOM ANGLE where the load is to be placed.

2. On the capacity chart, find the arc for the boom extension number, and follow it down to the boom angle.

3. The number in the load zone where these two cross is the maximum capacity for this lift. If the two cross at a division between zones, the smaller number must be used.

Method 2

1. The operator must determine:

HEIGHT where the load is to be placed.

DISTANCE from the front of the machine where the load is to be placed.

2. On the capacity chart, find the line for the height and follow it over to the distance.

3. The number in the load zone where the two cross is the maximum capacity for this lift. If the two cross at a division between zones, the smaller number must be used.

For each method, the number in the load zone must be equal to or greater than the weight of the load to be lifted. Determine the limits of the load zone on the capacity chart by boom angle AND boom extension number. Keep the load within theses limits.

BACK

9151-3207 REV.-

TIPOVER HAZARD. Failure to comply with instructions could result in death or serious injury.

The operator MUST:

1. Make sure the handler is on a firm, level surface before lifting or placing a load.

2. Make sure that the capacity charts are for the appropriate Gradall model.

3. Make sure that the Part Numver shown on the attachment's Serial Number Plate matches the Part Number shown on the capacity chart.

4. Be sure of the WEIGHT of the load to be lifted.

RADALL-furnished carriage/fork or other

apply to standard carriage/fork and

R

Instructions

MODEL

TF6-42

70°

60°

6

SAMPLE ONLY - USE CHART IN CAB

5

4

5000 LBS

6600 LBS

4000 LBS

3000 LBS

12'16'20'24'28'32'

0'4'8'

BACK

FRONT

9151-3207 REV.-

48'

RATED CAPACITY @ 2 FT LOAD CENTER

44'

40'

36'

32'

48" & 72"

SLOPE PILER

28'

24'

20'

16'

12'

8'

4'

0'

-4'

-8'

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

50°

40°

30°

20°

800 LBS

10°

0°

-9°

2000 LBS

NOTE!

See page 13-2 for instructions on how to read capacity charts.

All loads shown on rated capacity chart are based on machine being on firm, level ground; the forks being positioned evenly on carriage; the load being centered on forks; proper size tires being properly inflated; and the handler being in good operating condition.

RATED CAPACITY @ 2 FT LOAD CENTER

70°

60°

6

5

3

2

1

USE WITH: 9140-5073 48" CARRIAGE 9140-5074 72" CARRIAGE 9140-5077 72" DRYWALL CARR. (4,000 LB MAX. CAPACITY) 9140-5054 60" 3/4 YD. BUCKET (4,500 LB MAX. CAPACITY) 9140-5055 74" 1 1/4 YD. BUCKET (4,500 LB MAX. CAPACITY)

9150-3083 (-)

9140-5071 102" 1 1/4 YD. BUCKET (4,500 LB MAX. CAPACITY)

2

1

4

3

0' 4' 8'

6600 LBS

6000 LBS

5000 LBS

MODEL

TF6-42

50°

40°

4000 LBS

30°

3000 LBS

2000 LBS

1200 LBS

20°

12' 16' 20' 24' 28' 32'

FRONT

10°

0°

-9°

9150-3083 (-)

48'

44'

40'

36'

32'

48" & 72"

CARRIAGES

28'

24'

20'

16'

12'

8'

4'

0'

-4'

-8'

Elevation

Numbers at left side of sample chart represent elevation to top of horizontal fork as measured from level ground (in feet). Elevation relates to dimension “A” shown on serial number plate inside operator’s cab.

Boom Extension

Numbers across bottom of sample chart and numbers parallel to boom represent boom reach as measured from front of front tires to extended position.

Number decals on boom relate directly to boom extension. The largest number which can be read from operator’s seat indicates total boom extension and must be matched with boom angle to determine load capacity.

Boom extension relates to dimension “D” shown on serial number plate.

Boom Angle

Numbers shown at ends of angled lines represent angle of boom to horizontal as measured from horizontal. Maximum angles are -9° below horizontal with boom fully lowered to 70° above horizontal with boom fully raised.

A boom angle indicator is located on left side of boom-section 1 to show boom angle. Be sure machine is level from front to rear or indicator will provide

incorrect reading.

13.0

UNDERSTANDING RATED CAPACITY CHARTS

Load Center

Loads shown on rated capacity chart are based on the load center being 610mm (two feet) above and 610mm (two feet) forward of surfaces of horizontal forks.

The load center of a load is the center of gravity of the load. For regularlyshaped loads of the same material, such as a pallet of blocks, the center of gravity can be located by measuring the load to find its center. For irregular loads, or loads of dissimilar materials, keep the heaviest part of the load as close to the heel of the forks as possible.

In all cases, the load center must be centered between the forks.

Load Limits

Some capacities shown on the rated capacity chart are based on machine stability

and some are based on hydraulic lift capacity.

Items needed to Use a Capacity Chart

There are five items you must know and/or have in order to properly use a Capacity Chart:

1. The weight of the load to be lifted

2. The angle of the boom

3. How much boom extension will be needed

4. The proper Capacity Chart

5. A Gradall-approved Attachment

Every Gradall attachment comes with its own Identification Plate. This Plate has the Attachment Serial Number, Part Number, Attachment Capacity and Attachment Weight stamped on it. Make sure that the Capacity Chart you are using matches the attachment exactly. This may be done by matching the attachment part number on the Capacity Chart to the part number stamped on the Identification Plate. The Machine Serial Number Plate is mounted inside the cab and lists all standard attachments that may be used with the machine by part number, at the time it was shipped from the factory. Be aware that a specific Capacity Chart must not only match the attachment, but also the machine model.

WARNING

!

Exceeding load limits can cause damage, or, in some cases, cause the machine to tip over.

NOTE!

Some attachments may not be approved for use with certain machine models.

The boom angle can be determined by looking at the angle indicator mounted on the side of the boom (see figure 12-5).

The boom extension can be determined by looking at the second boom section. As the second boom section slides out of the main boom, numbers are revealed starting with 1. Each number represents approximately 5’ of total boom extension (see figure 12-5). It is important to remember that these

numbers are designed to be read from the operator’s seat only!

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

13.1

** unknown ** ** unknown **

UNDERSTANDING RATED CAPACITY CHARTS

How to read a Capacity Chart

When reading the capacity chart you must check to be sure the correct model number is listed (see figure 12-6). The next thing to look for is that the part number of your attachment is listed under the “Use With” section. Identify and find the amount of boom extension required, along with the angle of the boom. Trace the boom extension arc down until it intersects with the appropriate boom angle. If the intersection of the boom extension arc and the boom angle line occur within a weight region, the value within that region is the maximum capacity for that particular lift. If the intersection occurs on a bold line separating capacity regions, the smaller of the two values must be used. The regions are clearly marked with heavier outlines as shown on page 12.4. If you do not have the correct capacity chart for your machine and/or attachment, contact your Distributor or Gradall to order one.

Example (this is for instructional purpose only - use capacity chart located in your cab):

A contractor has purchased a TF6-42 with the 48” Slope Piler Carriage Attachment (see figure 12-6). He knows his attachment may be used with this model since the attachment part number, 9140-5101, matches the attachment part number stamped on the machine Serial Number Plate. He also knows that the Capacity Chart is correct since it is clearly marked for use with a TF6-42 and that the attachment he is using is listed at the bottom by part number. He has determined the weight of the load to be lifted is 400 lbs. and that he needs to place the load at a boom extension of 6 at a boom angle of 20°. By tracing the boom extension arc down to where the 20° line intersects it, the contractor can see that the maximum weight he can lift is 800 lbs. In this case, he may lift the load.

Figure 12-5: Where to look on the machine

BOOM

EXTENSION

NUMBER

FORK WEIGHT

STAMP

ATTACHMENT

IDENTIFICATION PLATE

BOOM ANGLE

INDICATOR

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

9114-3282

MACHINE SERIAL

NUMBER PLATE

(RIGHT WALL)

R

DIESEL FUEL IS FLAMMABLE EXTINGUISH ALL OPEN FLAME AND SMOKING MATERIALS WHEN REFUELING INJURY OR DEATH COULD RESULT

FROM FIRE.

** unknown ** ** unknown ** 2 NO

9114-3286

1

7733-3027

NO RIDERS PERMITTED ON HANDLER. OPERATOR ONLY IN MACHINE

WHILE RUNNING.

RIDERS COULD FALL OFF MACHINE

CAUSING SERIOUS INJURY OR DEATH.

9114-3283

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

9114-3282

DO NOT GO NEAR LEAKS

* 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.

C

10814B

13.2

UNDERSTANDING RATED CAPACITY CHARTS

Figure 12-6: Description of items on a Capacity Chart

48'

RATED CAPACITY @ 2 FT LOAD CENTER

44'

40'

36'

32'

28'

60°

50°

40°

70°

NOTE!

This is a sample Capacity Chart ONLY ! Do not use this chart, use the one located in your cab.

MODEL

TF6-42

6

5

4

3

2

This Capacity Chart

may be used with

this model ONLY

Boom Extension Numbers

Boom Angle

These numbers

should match

the Part No. stamped on

the attachment

ID Plate

24'

20'

16'

12'

8'

4'

0'

-4'

-8'

30°

20°

10°

0°

-9°

12'16'20'24'28'32'

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

1

0'4'8'

Regions indicate the maximum weight that may be safely lifted

9150-3083 (-)

Form No. 20136 3/03 • TF6-42 Owner/Operator Manual

Capacity Chart Part number

13.3

WARNING

!

WARNING

!

ATTACHMENT INSTALLATION PROCEDURES

INSTALLATION PROCEDURE FOR MOST ATTACHMENTS (items 1 thru 6):

This installation procedure is designed for one-man operation. If a helper is involved, shut off the engine before proceeding to steps 4, 5, and 6.

1. Retract Quick Switch™ (attachment tilt lever forward) to provide clearance. Check to be sure lock pin is secured in out position with retainer pin.

3. Engage Quick Switch™ (attachment tilt lever backward).

2. Align boom head pivot with recess in attachment. Raise boom slightly to engage boom head pivot in recess.

Always be certain that carriage or other attachment is properly positioned on boom head and is secured by lock pin and retainer pin. Failure to ensure proper installation could permit attachment to disengage and cause serious injury or death.

4. Remove retainer pin and slide lock pin in fully.

14.0

5. Secure lock pin in locked position using retainer pin.

6. Swing saddles down and pin in place.

4

ATTACHMENT INSTALLATION PROCEDURES

ADDITIONAL STEPS TO INSTALL TRANSFORMER SERIES PLATFORM (items 7 thru 10):

NOTE!

When hooking up the Transformer Series platform, the hydraulic hoses are run through the Quick Switch™. Pull these hoses and electrical cables back to prevent pinching when attaching and hooking up hydraulic hoses to the front of the boom.

7. Always turn off the machine before performing the next several steps.

9. Attach the electric harness lines as shown to the front of boom.

8. Press the decompression valve located in cab, this takes the pressure out of the auxiliary hydraulic lines located on boom head.

10. Attach the hydraulic lines to the side of boom as shown.