Gradall G6-42P Owner's/Operator's Manual
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Gradall G6-42P Owner's/Operator's Manual

Material handler
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G6-42P M
H
ATERIAL
ANDLER
O
/O
M
WNER
PERATOR
ANUAL
COVERING OPERATION & PERIODIC MAINTENANCE
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
COVERS MATERIAL HANDLER MODEL G6-42P
®
STARTING SERIAL NUMBERS
®
0189001 THRU 0189345,
Form No. #20027
Part No. 9140-4003
& 0160000230 THRU 0160004017
Revised 11-25-08
Courtesy of Crane.Market

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Summary of Contents for Gradall G6-42P

  • Page 1 WNER PERATOR ANUAL COVERING OPERATION & PERIODIC MAINTENANCE 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 Company COVERS MATERIAL HANDLER MODEL G6-42P ®...

  • Page 2: Important Safety Notice

    1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 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.
  • Page 3 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 11.0 9/24/01 Revised section on checking and adjusting boom. 16.0 7/22/02 Added an additional lubrication notice.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS IMPORTANT SAFETY NOTICE ............. inside front cover TABLE OF CONTENTS INTRODUCTION General Operator Qualifications Orientation Related Manuals & Decals Serial Number Location NOMENCLATURE SAFETY ................. 1.0 thru 1.2 DECALS ................. 2.0 thru 2.4 Decals Inside Cab Decals Outside Cab OPERATORS CAB ..............

  • Page 5: Introduction

    GRADALL Material Handler Distributor. Models Covered This Manual covers the G6-42P Material Handler. This unit is equipped with a three-section boom and four-wheel drive. Optional equipment available for use with this unit is described in appropriate sections of the Manual. Be certain to refer to proper information for your unit and the operational equipment furnished ®...

  • Page 6: Nomenclature

    NOMENCLATURE ENGINE & VALVE ENGINE HYDRAULIC HYDROSTATIC COMPARTMENT FILTERS TRANSMISSION CONTROL IMPLEMENT MIRROR BATTERY CLEANER VALVES PUMP STEERING SWAY CYLINDER CYLINDER TIE-DOWN LUGS TIE DOWN LUGS FRONT DRIVE STEERING AXLE CYLINDER OPERATOR’S STEERING AXLE BOOM OPERATOR’S HYDRAULIC RESERVOIR BOOM SECTION 1 BREATHER SECTION 2 BOOM...

  • Page 7: Safety

    WARNING operation. This symbol indicates a hazard which GRADALL Material Handlers are equipped with a right-side rearview mirror. This could result in death or serious mirror is intended as an operator’s aid and does not replace the requirement for injury if proper precautions are not line-of-sight.
  • Page 8 Keep all windows and mirror(s) clean. Adjust mirror(s) as required for maximum visibility, before and during operation. Contact The Gradall Company prior to welding on machine. Never permit diesel engine to run out of fuel. Doing so can cause severe damage.
  • Page 9 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. Boom Rear Steering Axle Boom Holes Attachment Tilt Cylinder Carriage Forks Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...

  • Page 10: Decals

    WITHOUT LOAD WHEN EXTENDED INTO "NO OPERATION" ZONE AS NOTED P/N 9140-3529 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. 9140-3618 9140-3618 BACK FRONT Located on dashboard...
  • Page 11 AND TO MINIMIZE TURBOCHARGER DAMAGE, IDLE ENGINE AT LEAST 3-5 MINUTES AFTER START-UP AND BEFORE SHUTDOWN. 9134-3016 Located on dashboard Located on dash w/ turbo option Starting S/N 0160001286 P/N 9134-3016 P/N 9141-3061 Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...
  • Page 12 OUTSIDE THE CAB Located on frame below engine cover P/N 9108-3492 Genuine Parts HYDRAULIC SYSTEM FILL WITH TRACTOR HYDRAULIC FLUID or equivalent. For Mobil Product Information, Call 1-800-662-4525. 9114-3288 Located on frame below engine cover Located on hydraulic fill cap P/N 9114-3288 P/N 9140-3573 JUMP STARTING INSTRUCTIONS...
  • Page 13 ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH. 9114-3282 Located on right and left rear frame, engine cover and boom head P/N 9114-3282 Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...
  • Page 14 P/N 9015-3001 READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL. PINCH POINT WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM. DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM. KEEP OUT WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN CAB WITH PERSONNEL IN DIRECT LINE OF SIGHT.

  • Page 15: Operators Cab

    PARK BRAKE ON TO START HORN BUTTON ATTACHMENT TILT/ MACHINE LEVEL (STANDARD) CAPACITY CHARTS AUX CONTROL LEVER (OPTIONAL) IGNITION SWITCH 4x2/4x4 SWITCH ACCELERATOR PEDAL SERVICE BRAKE/ INCHING TRAVEL PEDAL TRACTION LOCK SWITCH Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...
  • Page 16 Auxiliary Control Lever (optional): This lever is used to control optional GRADALL Material Handler Safety hydraulic attachments. Follow decal instructions for lever/handler movements. Manual and view the GRADALL/EMI Operator Orientation Video. Auxiliary Light Switch (optional): This switch turns auxiliary lights on and off.
  • Page 17 (amber) to indicate four-wheel drive is engaged. When park brake is applied, light will not glow. OPTIONAL HEATER CONTROLS Figure 3-2 AIR VENT DEFROSTER FAN AIR VENT TEMPERATURE CONTROL BLOWER CONTROL ACCESS COVER/ HEATER VENT HEATER Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...

  • Page 18: Checks & Services Before Starting Engine

    CHECKS & SERVICES BEFORE STARTING ENGINE To be performed at the beginning of each work shift. WARNING • If spark arrestors are required, be sure they are in place and in good working order. Use extreme caution when checking items beyond your •...

  • Page 19: Warm-Up & Operational Checks

    Filter element must be changed before reaching bypass condition (change before indicator reaches red area). Complete all required maintenance before operating unit. Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...

  • Page 20: Engine Operation

    Optional Cold-Weather Starting Aids In cold weather situations, a supplemental starting aid may be required. CAUTION Gradall-approved starting aids employ ether. If your handler is equipped with an optional ether starting aid, the following applies: If you use a starting aid employing •...

  • Page 21: Normal Engine Operation

    • Do not “gun” engine before shut down: This practice causes incompletely burned fuel to remove oil film from cylinder walls and dilute lubricant in crankcase. Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...

  • Page 22: Brake System

    BRAKE SYSTEM 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 WARNING axle housing. Practice inching/braking in a safe, Because service braking and “inching” (slow travel) functions overlap, some open area until you are thoroughly features of inching will be discussed here.

  • Page 23: Parking The Handler

    NEVER TURN ENGINE OFF WHILE TRAVELING. If power steering fails, stop as soon as possible. Do not drive handler until problem has been corrected. Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...

  • Page 24: Drive Train

    10.0 DRIVE TRAIN General The Material Handler covered by this Manual is equipped with hydrostatic drive. From the operator’s standpoint, operation is similar to driving a vehicle equipped with an automatic transmission. Operation Normal Travel. Direction of travel is selected by moving forward/reverse lever forward for forward travel, backward for reverse travel.

  • Page 25: Boom

    Pads must not directly contact shims, thus a spacer must be inserted between pad and shims. • Use Loctite 242 (Gradall P/N 1440-3364) on screws when adding or removing shims. Boom Chain Check boom chain adjustment. With boom horizontal, extend boom 1.2m to 1.5m (4 to 5 feet), then fully retract boom.

  • Page 26: Leveling The Handler

    12.0 LEVELING THE HANDLER “Leveling” means positioning the handler so that it is level from side to side WARNING (left to right). Raising the boom (loaded or A level indicator is located in upper right corner of front window frame to permit unloaded) when handler is leaning operator to determine whether the handler frame is level.
  • Page 27 Have surface leveled. 4. Lift or place load as appropriate. 5. Retract and lower boom to carry position. 6. Realign frame to position noted in step 2. Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...

  • Page 28: Operating Procedure & Techniques

    13.0 OPERATING PROCEDURE & TECHNIQUES Hydraulic Controls NOTE! All boom and attachment movements are governed by hydraulic controls. Rapid, Much of the material in this jerky operation of hydraulic controls will cause rapid, jerky movement of the section may be new to even the load.

  • Page 29: Rated Capacity Chart

    Rated Capacity Chart The rated capacity chart, located on dashboard, indicates maximum load WARNING capacities for handlers equipped with GRADALL-furnished carriage/fork or other attachment combinations. These capacities apply to standard carriage/fork and All loads shown on rated capacity other attachment combinations except as stated on the capacity chart.

  • Page 30: Attachments

    • GRADALL cannot assure the ability of a non-approved attachment to perform its intended function safely. • Non-approved attachments may cause structural or other damage to the handler.

  • Page 31: Attachment Installation

    Attachment Operation Operation of the handler equipped with carriage/fork combination is covered in the GRADALL Material Handler Safety Manual and this Manual. Operation of the handler when equipped with other approved attachments is covered in this section or in separate instructions furnished with the attachment.
  • Page 32 14.2 Fork Positioner WARNING Capacity: PRECAUTIONS Maximum load capacity for fork positioner carriage is the same as standard • Always adjust fork position carriage without fork positioner. Refer to Attachment Capacity Chart. before engaging load. Capacity varies with boom extension and elevation positions. •...
  • Page 33 The auxiliary control lever is used to swing RIGHT the forks to the left and right. Pull lever back to swing forks right; push lever forward to swing forks left. Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...
  • Page 34 14.4 Swing Forks Installation Procedure: WARNING 1. Remove carriage/fork combination or other attachment from boom head. See Page 14.1 Do not handle a load with Swing Forks attachment until you study 2. Install swing forks attachment on boom head. & understand the “Swing Forks Capacity Chart”.
  • Page 35 Study and understand this chart before attempting to handle lowered to travel position a load with truss boom. (load approximately one foot above ground). • Always lower load to rest before leaving handler. Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...
  • Page 36 14.6 Truss Boom & Truss Boom with Winch WARNING WARNING Do not handle a load with Truss Boom & Truss Boom with Winch A side load or a swinging load could cause the handler to tip over and/ attachment until you study & or damage the boom.
  • Page 37 Capacity: WARNING The Gradall personnel work platform is designed to carry a maximum of 3 occupants. The load includes personnel, materials, tools, etc. The maximum Do not use the Personnel Work capacity of your work platform is based on specific model material handler/ Platform until you study &...
  • Page 38 Courtesy of Crane.Market...

  • Page 39: Loading & Securing For Transport

    (See Figures 15-1 & 15-2) serious injury or death. 5. Do not tie down front of boom. Figure 15-1 (front view) Figure 15 -2 (rear view) Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...
  • Page 40 16.0 LUBRICATION & ROUTINE MAINTENANCE Lubrication Symbols AF - ANTI-FREEZE CC - COOLANT CONDITIONER DF - DIESEL FUEL EO - ENGINE FUEL HF - HYDRAULIC FLUID HM - MOLY LUBE (extreme pressure) IMPORTANT NOTICE SYMBOLS Be certain to check extend chain AILURE RADALL = Lube Fitting...

  • Page 41: Lubrication & Maintenance

    35. Hydraulic Suction Filter (replace filter element) Lubrication & Maintenance • Check torque of all items listed in Torque Chart (pg 18.0) DETAILED SERVICE INSTRUCTIONS ARE CONTAINED IN THE GRADALL SERVICE MANUAL FOR YOUR PARTICULAR MATERIAL HANDLER Form No. 20027 • G6-42P Owner/Operator Manual...

  • Page 42: Recommended Lubricants & Capacities

    * Capacities are approximate - check level to be sure. * * Fill to level using Mobilfluid ® 424 (GRADALL P/N 1440-4535) * * * Fill to level using Mobilfluid ® 424 -OR- Citgo Tractor Hydraulic Fluid (product code 33310)

  • Page 43: Torque Chart

    18.0 TORQUE CHART To check GRADALL torque values, set the torque wrench at 95% of rated torque value and check fastener. If the torque wrench releases before the fastener moves, assume fastener torque is correct. When setting GRADALL torque values, use the values given on the following chart. Do not exceed allowances.
  • Page 44 9. Stop engine and check oil level in reservoir and replenish as required. The filtration system is designed to maintain a minimum ISO 10. Contact your GRADALL Distributor for information concerning oil analysis. cleanliness level of 18/15. Oil sample containers are available from several sources: •...

  • Page 45: Moving Handler In Emergency

    2. Repeat step 1 for forward relief valve. Front axle drive is now bypassed. below reverse relief valve. 3. Before returning machine to service, be certain to return relief valve cartridges to original position. Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...

  • Page 46: To Release Parking Brake

    20.1 TO RELEASE PARKING BRAKE MERITOR AXLE 1. Position unit on level ground, lower attachment to approximately one foot from ground, move forward/reverse lever to “Neutral,” apply parking brake and stop engine. 2. Block all wheels to prevent inadvertent movement. Figure 20-2 RELEASE SCREW...
  • Page 47 Then screw the bolts back in 1/4 turn. 3. Install plugs over each release screw. 4. Repeat procedure on other side of differential. Parking brake should be restored to operation. Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...
  • Page 48 Courtesy of Crane.Market...

  • Page 49: Inspection And Maintenance Log

    This page is provided so you may record all inspections and maintenance on your machine. Record the date, hourmeter reading and a detailed description of the procedure in the comment area. Record all information in the Owner/Operator Manual, stored in the operator’s cab. Date Hourmeter Comments Reading Form No. 20027 • G6-42P Owner/Operator Manual Courtesy of Crane.Market...
  • Page 50 INSPECTION AND MAINTENANCE LOG Date Hourmeter Comments Reading Courtesy of Crane.Market...

  • Page 51: Hand Signals

    HAND SIGNALS Standard Signals - When handler work conditions require hand signals, they shall be provided or posted conspicuously for the use of both signalman and operator. No handler motions shall be made unless signals are clearly understood by both signalman and operator. Special Signals - When signals for auxiliary equipment functions or conditions not covered are required, they shall be agreed upon in advance by the operator and signalman.
  • Page 52 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. CALIFORNIA Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

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