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Gradall G6-42P User Manual

Gradall G6-42P
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material handler
G6-42P MATERIAL HANDLER
OWNER/OPERATOR MANUAL
COVERING OPERATION & PERIODIC MAINTENANCE
KEEP OPERATOR AND SAFETY MANUALS IN CAB
Part No. 9140-4003
Revised 11-25-08
Form No. #20027
COVERS MATERIAL HANDLER MODEL G6-42P
STARTING SERIAL NUMBERS
0189001 THRU 0189345,
& 0160000230 THRU 0160004017
IMPORTANT!
Read and understand this Manual and the Gradall Material
Handler Safety Manual before starting, operating or
performing maintenance procedures on this machine.
Courtesy of Crane.Market
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Gradall G6-42P Specifications

General IconGeneral
BrandGradall
ModelG6-42P
CategoryForklifts
LanguageEnglish

Summary

INTRODUCTION TO GRADALL G6-42P

General Information

Provides an overview of safe operating procedures and maintenance requirements for the G6-42P handler.

Operator Qualifications and Orientation

Details physical/mental requirements, training, and directional terms for operators.

Related Manuals, Decals, and Models

Information on other manuals, decals, and specific models covered by this manual.

SAFETY GUIDELINES AND WARNINGS

General Safety Precautions

Covers decal checks, surface stability, travel awareness, and control cleanliness for safe operation.

Understanding Safety Symbols

Explains DANGER, WARNING, and CAUTION symbols to identify hazards and necessary precautions.

OPERATIONAL SAFETY PROCEDURES

Essential Safety Practices

Covers visibility, fuel, avoiding modifications, body parts inside, and power line clearance.

Standard Shut-Down Procedure

Step-by-step instructions for safely shutting down the handler.

MACHINE DECALS AND IDENTIFICATION

Inside the Cab Decals

Details decals inside the operator's cab, including capacity charts and warnings.

CAB DECALS AND LABELS

Model, Serial Number, and Warning Labels

Location of model/serial plates and descriptions of ROPS, turbocharger, and operational warning decals.

EXTERNAL DECALS AND WARNINGS

High-Pressure Oil and Battery Safety

Warnings for high-pressure oil leaks, hydraulic fluid, and lead-acid batteries with safety precautions.

EXTERNAL SAFETY DECALS

High Voltage and Refueling Safety

Critical warning for high voltage lines and safety during refueling operations.

Rider and Pinch Point Warnings

Warnings against unauthorized riders and awareness of pinch point hazards.

OPERATOR'S CAB AND CONTROLS

Operator's Cab Features

Describes cab features, seat, visibility, and ROPS/FOPS structure for operator protection.

Control and Instrument Identification

Identifies the location and function of all major controls and instruments within the cab.

CONTROL DESCRIPTIONS

Accelerator, Attachment, and Boom Controls

Explains accelerator, attachment tilt, auxiliary, and boom control joystick operations.

Engine Gauges and Other Controls

Details engine oil pressure, coolant temperature, fuel gauges, and other operator controls.

ADDITIONAL CONTROLS AND GAUGES

Steering, Drive Train, and Brake Controls

Covers seat lock release, steering wheel, traction-lock pedal, and 4x2/4x4 switch.

Optional Heater Controls

Describes the controls for the optional heater, including defroster fan and temperature adjustment.

PRE-OPERATION CHECKS AND SERVICES

Daily Pre-Operation Checks

Outlines essential daily checks for spark arrestors, windows, mirrors, and fluid ports.

Maintenance and Leak Inspection

Emphasizes required maintenance completion and inspection for structural damage and leaks.

WARM-UP AND OPERATIONAL CHECKS

Pre-Cab Entry Checks

Checks to perform before entering the cab, such as the Air Filter Restriction Indicator.

Post-Warm-up Operational Checks

Details checks for brakes, travel, steering, boom, and hydraulic filter condition.

ENGINE OPERATION AND STARTING

Engine Starting Procedure

Step-by-step guide for safely starting the engine, including oil pressure checks.

Cold-Weather and Battery-Boost Starting

Information on using starting aids and procedures for jump-starting the handler.

ENGINE OPERATION AND SHUTDOWN

Normal Engine Operation Monitoring

Focuses on monitoring gauges, identifying unusual noises, and avoiding prolonged idling.

Engine Shutdown Procedure

Correct procedure for shutting down the engine, including a warm-up period.

BRAKE SYSTEM OPERATION

Brake System Overview and Inching

Explains service/parking brakes and how the inching travel pedal functions.

Parking Brake Control

Details the parking brake switch operation and its effect on four-wheel drive.

PARKING THE HANDLER

Parking Precautions and Procedures

Lists precautions for parking and the step-by-step procedure to park safely.

STEERING SYSTEM OPERATION

Steering Familiarization and Warnings

Emphasizes practicing steering and warns about power assist failure effects.

DRIVE TRAIN OPERATION

Hydrostatic Drive and Travel Modes

Explains hydrostatic drive, normal travel, inching, and four-wheel drive engagement.

Traction-Lock Function

Details the operation and precautions for using the traction-lock switch.

BOOM MAINTENANCE AND ADJUSTMENT

Boom Bearing Pad Adjustment

Procedures for adjusting boom bearing pads for proper clearance.

Boom Chain Adjustment

Steps to check and adjust the boom chain for optimal performance.

HANDLER LEVELING PROCEDURES

Understanding Handler Leveling

Explains leveling concepts, essential considerations for load handling, and potential hazards.

Leveling Methods and Frame System

Discusses surface leveling vs. frame system use and the frame leveling capabilities.

OPERATING PROCEDURES AND TECHNIQUES

Hydraulic Controls and Feathering

Details hydraulic control operation and the feathering technique for smooth movements.

Boom Control Joystick and Carriage Tilt

Explains the boom control joystick and carriage tilt control operations.

RATED CAPACITY CHARTS AND LOAD LIMITS

Using Rated Capacity Charts

Guides on reading and interpreting capacity charts for safe load handling.

Load Center and Limit Factors

Defines load center and factors affecting load limits, crucial for preventing tip-overs.

ATTACHMENTS AND ACCESSORIES

Approved Attachments and Capacities

Information on approved attachments, their capacities, and considerations for non-approved types.

ATTACHMENT INSTALLATION AND OPERATION

Attachment Installation and Securing

Steps for securely installing attachments and general operational advice.

SPECIFIC ATTACHMENT TYPES

Fork Positioner and Light Material Bucket

Details on capacity and operation for fork positioners and light material buckets.

MAST AND SWING FORKS ATTACHMENTS

Mast Attachment Operation and Precautions

Information on mast attachment capacity, operation, and safety considerations.

Swing Forks Attachment Operation

Details on swing forks capacity, operation, and handling loads.

SWING FORKS AND SLOPE PILER CARRIAGE

Swing Forks and Slope Piler Operation

Guidelines for operating swing forks and slope piler carriage attachments.

BOOM HEAD WINCH AND TRUSS BOOM

Boom Head Winch and Truss Boom Operation

Information on boom head winch and truss boom capacity and operational procedures.

TRUSS BOOM WINCH AND SWING MAST

Truss Boom Winch and Swing Mast Operation

Details on truss boom winch and swing mast operation, including safety precautions.

SWING MAST AND PERSONNEL PLATFORM

Swing Mast Controls and Personnel Platform Safety

Covers swing mast operation and critical safety for personnel platforms.

LOADING AND SECURING FOR TRANSPORT

Transport Loading and Securing Procedure

Step-by-step guide for safely loading and securing the handler for transport.

LUBRICATION AND ROUTINE MAINTENANCE

Lubrication Symbols and Maintenance Notices

Explains lubrication symbols and important notices regarding chain adjustment and maintenance.

MAINTENANCE SCHEDULE AND INTERVALS

Daily, Weekly, and 5-Week Maintenance

Covers lubrication and maintenance tasks for daily, weekly, and 5-week intervals.

Periodic and Initial Maintenance Intervals

Details maintenance for 250, 500, 1000, and 1500-hour intervals, plus initial service.

RECOMMENDED LUBRICANTS AND CAPACITIES

Lubricant Specifications and Usage

Lists recommended lubricants, grades, specifications, and usage for various machine applications.

Fluid Capacities for Maintenance

Provides approximate capacities for engine oil, fuel, hydraulic fluid, and coolant needed for maintenance.

TORQUE CHART SPECIFICATIONS

Fastener Torque Values

Lists torque values for various fasteners with thread sizes, grades, and frequencies for proper tightening.

HYDRAULIC OIL SAMPLING AND ANALYSIS

Hydraulic Oil Sampling Procedure

Step-by-step guide on collecting hydraulic oil samples for analysis to monitor system health.

Importance of Oil Cleanliness

Highlights the critical role of oil cleanliness and the filtration system's design for optimal performance.

EMERGENCY HANDLING AND TOWING

Moving Handler Short Distances

Procedures for moving the handler over short distances without using its own power.

Towing Longer Distances and Tow Bypass

Guidelines for longer distance towing and activating the tow bypass feature for hydraulic drive.

PARKING BRAKE RELEASE AND RESTORATION

Release Parking Brake (Meritor Axle)

Detailed steps for releasing the parking brake on Meritor axles for towing purposes.

Restore Parking Brake (Meritor Axle)

Instructions on how to restore the parking brake function after it has been released.

CARRARO AXLE BRAKE PROCEDURES

Release Parking Brake (Carraro Axle)

Detailed steps for releasing the parking brake on Carraro axles for towing.

Restore Parking Brake (Carraro Axle)

Instructions on how to restore the parking brake function on Carraro axles.

INSPECTION AND MAINTENANCE LOG

Recording Inspections and Maintenance

Instructions for documenting machine inspections, maintenance performed, and hourmeter readings.

HAND SIGNALS FOR OPERATION

Standard Hand Signals

Illustrates and describes standard hand signals for controlling handler movements, ensuring clear communication.

Special Signals and Communication Instructions

Covers special signals for auxiliary functions and general instructions for effective operator-signalman communication.

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