® ® OWNER/OPERATOR MANUAL ® TF6-42 9150-4003 March 2003 Starting Serial No. 0192001 thru 0192007 & 0160000052 thru Current Form #20136 Original Issue 03/03 CORPORATE OFFICE GRADALL DIVISION JLG INDUSTRIES, INC. 1 JLG DRIVE McConnellsburg, PA 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417 JLG INDUSTRIES, INC. 406 Mill Avenue S.W.
TF6-42 MATERIAL HANDLER “TRANSFORMER SERIES” OWNER/OPERATOR MANUAL m a t e r i a l h a n d l e r 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 Work Platform Safety Manual before starting, operating or performing maintenance procedures on this machine.
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REVISIONS This page is provided so you may determine that this Manual is complete and current with respect to JLG/ Gradall Engineering Specifications. Page Form No.
TABLE OF CONTENTS MATERIAL HANDLER IMPORTANT SAFETY NOTICE ..................................................... TABLE OF CONTENTS INTRODUCTION inside front cover SAFETY HIGHLIGHTS ............................................................... DECALS ................................................................................. OPERATORS CAB ..................................................................... CHECKS & SERVICES BEFORE STARTING ENGINE .......................
INTRODUCTION General This Manual provides important information regarding safe operating and maintenance requirements for JLG/GRADALL Material Handlers. Refer to front cover for specific model and serial number range. If you have any questions regarding the material handler, contact your JLG/ GRADALL Distributor. NOTE! “Material handler” and handler are used interchangeably throughout this Manual.
SAFETY HIGHLIGHTS Read and understand all manuals and instructional material listed on cover, inside front cover and introduction page of this Manual before starting, operating or performing maintenance procedures on this equipment.
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. ! WARNING Contact The JLG/Gradall Company prior to welding on machine. Release trapped pressure before disconnecting, opening or removing any hydraulic component. Keep all windows and mirror(s) clean.
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 Boom Holes Attachment Tilt Cylinder R Carriage Forks 1.
SAFETY HIGHLIGHTS Fork Pin Area on Carriages Form No.
DECAL LOCATIONS 914 0 - 3 5 7 3 18 2 PRODUCE FLAMABLE AND BATTERIES BATTERIES , USING BATTERIES: ACID GASSES BATTERIES: BATTERIES BATTERIES LEAD TESTING, , TESTING CHARGING NEAR BATTERIES BATTERIES EXPLOSIVE Y OR MATERIALS CHECKING CHECKING, FROM MATERIALS YTE BATTERY BATTER WHEN AWAY ELECTROL SPARKS BOOSTER USE SMOKING AND ELECTROLYTE AND SPARKS NOT * DO FLAMES GLASSES FROZEN COULD * KEEP SAFETY Y IS NOT CELL TO THE BATTERY IN EACHINSTRUCTIONS BATTER * WEAR LEVEL THESE DAMAGE * ASSURE Y OR PROPER IN
DECAL LOCATIONS 24 B A B 22 21 23 20 25 A 24 B-B A-A 26 27 24 28 29 30 31 22 20 21 22 23 24 25 9150-3128 9147-3132 9114-3282 9100-3031 9151-3210 9150-3096 Form No. 20136 TF6-42 Decal Gradall Decal Warning Decal, pinch point Boom Angle Decal Warning Decal, moving parts Warning Decal, lifting personnel 3/03 • TF6-42 Owner/Operator Manual 26 27 28 29 30 31 9100-3016 9100-3018 9112-3042 9100-3020 9112-3044 9116-3077 “1” Decal “2” Decal “3” Decal “4” Decal “5” Decal “6” Decal 2.
DECALS Instructions Instructions R SA MP TWO METHODS OF USING THE CAPACITY CHART. Method 1 LE 1. The operator must determine: ON 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. LY 3. The number in the load zone where these two cross is the maximum capacity for this lift.
DECALS GRADALL IS A REGISTERED TRADEMARK FOR HYDRAULIC EQUIPMENT BUILT BY THE JLG COMPANY 1 JLG DRIVE, McCONNELLSBURG, PA. U.S.A. R TF6-42 Box 61 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. C CAPACITY WITH STANDARD 48" & 72" CARRIAGE. CAP# X1000 SA A B C D MP LE 6.6 1.2 42' 4.6' 24" 24" 24" 2.0' 26.
DECALS Batteries produce EXPLOSIVE GASES. EXPLOSION could result in serious injury. Keep sparks, flames and lighted materials away from batteries. 9150-3099 REV - Located in engine compartment P/N 9150-3099 MOVING PARTS can cut or entangle. Keep clear while engine is running. 9150-3097 REV. - Located in engine compartment P/N 9150-3097 10 FT. (3 M) 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.
DECALS R 7733-3027 Located on left outside cab wall P/N 7733-3027 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 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.
DECALS FIRST DELIVERY 1 YEAR 2 YEARS Located on Frame P/N 1701529 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. 5 YEARS 6 YEARS 7 YEARS 3 YEARS STAMP FRAME WITH MONTH/DAY/YEAR NEXT TO ARROW AFTER EACH INSPECTION RETAIN RECORDS IN ACCORDANCE WITH ANSI. 8 YEARS 4 YEARS NOTIFY GRADALL IMMEDIATELY OF ANY CHANGES OF OWNERSHIP.
OPERATOR’S CAB 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.
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.
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.
CHECKS & SERVICES BEFORE STARTING ENGINE 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.
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.
ENGINE OPERATION Starting the Engine 1. Make sure all controls are in “Neutral” and all electrical components (lights, heater, defroster, etc.) are turned off. Set parking brake. 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.
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.
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 axle housing. Service Brakes ! WARNING 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.
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.
STEERING SYSTEM • 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.
DRIVE TRAIN 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.
LEVELING THE HANDLER “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.
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.
UNDERSTANDING RATED CAPACITY CHARTS Rated Capacity Chart NOTE! The rated capacity chart, located on dashboard, indicates maximum load capacities for handlers equipped with GRADALL-furnished carriage/fork or other attachment combinations. These capacities apply to standard carriage/fork and other attachment combinations except as stated on the capacity chart. See page 13-2 for instructions on how to read capacity charts.
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.
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.
UNDERSTANDING RATED CAPACITY CHARTS Figure 12-6: NOTE! Description of items on a Capacity Chart This is a sample Capacity Chart ONLY ! Do not use this chart, use the one located in your cab. MODEL TF6-42 This Capacity Chart may be used with this model ONLY 48' RATED CAPACITY @ 2 FT LOAD CENTER 44' 70° 60° 40' 36' 6 5 50° 4 32' 3 40° 28' Boom Extension Numbers 2 24' 1 30° 20' Boom Angle 20° 16' 12' 10° 8' 4' 0° 0' -4' -9° -8' 32' These numbers should match the Part No.
ATTACHMENT INSTALLATION PROCEDURES INSTALLATION PROCEDURE FOR MOST ATTACHMENTS (items 1 thru 6): ! WARNING 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. 2. Align boom head pivot with recess in attachment.
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. 8.
ATTACHMENTS Approved Attachments Several JLG/GRADALL-approved attachments are available for use with your material handler. Contact your JLG/GRADALL Distributor or JLG/Gradall for information on approved attachments designed to solve special material handling problems. The serial number plate lists attachments approved for use with your Transformer Series Material Handler. However, there may be additional approved attachments available. Contact your JLG/GRADALL Distributor for further information.
ATTACHMENTS Other Attachment Capacities A serial number/capacity plate is attached to all JLG/GRADALL-furnished attachments. Do not assume that any JLG/GRADALL attachment may be used on any JLG/GRADALL Material Handler. First, check the listing of approved attachments on handler serial number plate. If the attachment in question is not included in the list, contact your local JLG/GRADALL Distributor to check whether or not the attachment is approved.
ATTACHMENTS Fork Positioner Capacity: Maximum load capacity for fork positioner carriage is the same as standard carriage without fork positioner. Refer to Attachment Capacity Chart. Capacity varies with boom extension and elevation positions. Controls: Figure 13-1 OPEN FORKS AUXILIARY CONTROL LEVER The auxiliary control lever is used to adjust fork position. Pull lever back to close forks, push lever forward to open forks. CLOSE FORKS Installation Procedure: 1.
ATTACHMENTS Operation: • Raise or lower boom to appropriate height for loading material from stockpile. • Align handler with face of stockpile and drive slowly and smoothly into pile to load bucket. Do not corner-load bucket. • Tilt bucket up far enough to retain load and back away from pile. • Lower bucket to carry position 1.2m (4 feet) or less above ground and travel carefully to unloading point. Turn bucket down to dump load. Mast (1.8m [6'] with 1.2m [4’] or 1.
ATTACHMENTS Attachment Tilt Controls: Figure 13-4 SWING LEFT AUXILIARY CONTROL LEVER SWING RIGHT The carriage tilt cylinder is used to tilt the swing forks up and down and the carriage tilt lever controls fork tilt. The auxiliary control lever is used to swing the forks to the left and right. Pull lever back to swing forks right; push lever forward to swing forks left. Installation Procedure: 1. Remove carriage/fork combination or other attachment from boom head. See page 14.1. 2.
ATTACHMENTS • Tilt carriage to left or right to align forks with load and engage load. • Raise load slightly and then level carriage. • Travel with load lowered to travel position 1.2m (4 feet) or less above ground. Truss Boom & Truss Boom with Winch Capacity: Maximum capacity for the truss boom (with or without winch) is shown on attachment serial number plate. However, maximum lift capacity applies only to certain areas within boom extension/elevation pattern of handler/truss boom combination.
ATTACHMENTS Truss Boom & Truss Boom with Winch (cont.) Operation continued: • Position truss boom/winch hook as close as possible to balance point of load and secure load to boom using short slings or other rigging. Be sure rigging will not allow load to slip in any direction. • Open clamps at heel of truss boom far enough to clear load and tilt truss boom up until truss/bundle contacts heel of truss boom. • Close clamps to hold load lightly and secure clamps.
ATTACHMENTS Operation: • Always lower carriage fully in mast and position forks straight ahead before engaging load. • To travel with a load, keep forks straight ahead and lower load to travel position 1.2m (4 feet) or less above ground. • Inspect supporting surface at delivery point and have it leveled if necessary. • Level handler before raising load. ! WARNING Observe all precautions and load capacity limits when handling loads.
ATTACHMENTS “Transformer Series” Personnel Work Platform (with controls on Platform) For proper operation of the “Transformer Series” Platform, refer to the appropriate Owner/Operator manual P/N 9150-4004 located at the back of this manual and included with the attachment prior to using the platform. Capacity: Refer to capacity decal on platform and capacity indicator located on control console. The load includes personnel, materials, tools, etc.
OBTAINING HYDRAULIC OIL SAMPLE 1. Operate unit until hydraulic oil reaches normal operating temperature. 2. Apply parking brake, lower boom to rest and shift Forward/Reverse lever to “Neutral” Observe Hydraulic Filter Bypass Indicator with engine running at full throttle. Replace filter elements if necessary. 3. Obtain a container to receive waste oil and a CLEAN container to receive oil sample.
LOADING & SECURING FOR TRANSPORT Loading & Securing Handler For Transport 1. Level the material handler prior to loading. 2. Using a spotter, load the handler with boom as low as possible to keep a low center of gravity. 3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck. Move all controls to “Neutral”, stop engine and remove the control station selector key. 4. Secure machine to deck by passing chains through four tie-down lugs on front and rear of machine.
MOVING HANDLER IN EMERGENCY The following information assumes the handler cannot be moved under its own power. Before moving the handler, read all of the following information to understand options available. Then select the appropriate method. The steering system permits manual steering if engine or power assist feature fails. Remember: • Although manual steering is possible without power assist, steering will be slow and will require much greater force.
MOVING HANDLER IN EMERGENCY CARRARO AXLE: TO RELEASE PARKING BRAKE 1. If possible position unit on level ground, lower attachment to approximately .3m (one foot) from ground, move forward/reverse lever to “Neutral”, apply parking brake and stop engine. 2. Chock all wheels to prevent inadvertent movement. Figure 16-1 RELEASE SCREW (12 o’clock position) ! WARNING If you release the park brake without first chocking the wheels, the material handler could roll. Chock all wheels before releasing park brake.
MOVING HANDLER IN EMERGENCY DANA AXLE: AXLE MANUAL RELEASE (steps 1-3) Chock wheels before performing this procedure. ! WARNING The front axle service brakes will not operate when the park brakes are manually disengaged. The rear brakes may only provide half of the machine’s normal braking capability. Always reset the brake release screws before allowing machine back in to regular service. ADJUSTMENTS AFTER MANUAL RELEASE (steps 4-6) 1.
MAINTENANCE NOMENCLATURE 8 6 7 11 10 9 1. 2. 3. 4. 13 12 14 5 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 15 4 16 3 17 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 2 18 1 19 20 26 24 25 32 30 29 23 22 21 33 31 28 34 27 35 36. 37. 38. 39. 40. 41. 42. 43. 42 36 DO NOT GO NEAR LEAKS C * High pressure oil easily punctures skin causing serious injury, gangrene or death. * If injured, seek emergency medical help.
MAINTENANCE NOMENCLATURE 46 45 44 47 47 47 47 44. 45. 46. 47. 48. 49. 47 50. 51. 53 54 52. 53. 47 52 51 Form No. 20136 50 49 3/03 • TF6-42 Owner/Operator Manual 45 48 44 54. ENTRY/EXIT GATE LATCH ELECTRONIC CONTROL PANEL LANYARD ANCHORAGE POINT MANUAL STORAGE BOX PLATFORM SUPPORT WELDMENT ROTATING CYLINDER QUICKSWITCH WELDMENT DOUBLE PILOT CHECK VALVE VALVE MOUNTING PLATE ELECTRICAL CONNECTOR STORAGE 19.
LUBRICATION & ROUTINE MAINTENANCE 1 1 2 1 DF EO HF HM 5 5 5 1 5 • 4 - = Lube Fitting = Other Service 14 = Service Both Sides 6 2 4 2 2 2 2 19 20 16 21 22 24 17 23 18 6 15 11 3 Lubrication Symbols DIESEL FUEL ENGINE FUEL HYDRAULIC FLUID MOLY LUBE (extreme pressure) FAILURE TO USE GRADALL HYDRAULIC FILTER ELEMENTS COULD VOID WARRANTY SYMBOLS 2 10 13 10 7 8 7 8 9 6 6 27 36 27 IMPORTANT NOTICE Be certain to check extend chain adjustment every 5 weeks or 250 hours and adjust
PERFORM PRE-START & FUNCTION CHECK ON PAGE P6.1 AND THE “WALK-AROUND INSPECTION” AS DESCRIBED ON PAGES P6.2 & P6.3 IN THE TRANSFORMER SERIES WORK PLATFORM MANUAL SECTION LOCATED IN THE BACK OF THIS MANUAL. THIS INSPECTION IS A DAILY REQUIREMENT BEFORE OPERATING THIS MACHINE. Lube No. of Symbol Points ! CAUTION Service intervals are based on machine usage of 1500 hours annually. Use of your unit may vary significantly and you must adjust service frequency for your usage to obtain maximum service life.
RECOMMENDED LUBRICANTS & CAPACITIES ! CAUTION When replacing foam filled tires, replace the complete tire and rim assembly. APPLICATION Boom Chain Boom Bearing Paths SYMBOL WHEN USED GRADE SPECIFICATION CL (chain lube) All Year - P/N 1440-4751 - - All Year NLGI #2 P/N 1440-4595 - - HM (extreme pres. lube) CAPACITY* Coolant Additive (refer to engine man.) (SCA supplemental coolant additive) All Year - - 0.5 qts 0.48 L Transfer Case HF (hydraulic fluid) All Year ** ** 0.
BOOM Checking & Adjusting Boom Boom Bearing Pads Boom bearing pads are to be adjusted for all boom sections. This should be done at boom assembly, however, some adjustments may be required after assembly. • Add shims as required so that front and sides of boom have no more than 1.5mm (.06 inch) clearance. • Add shims as required so that rear of boom has no more than 1.5mm (.06 inch) total clearance.
INSPECTION AND MAINTENANCE LOG Date 22.
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.
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. Wash hands after handling. Hydraulic Equipment 406 Mill Ave.
® ® OPERATION & SAFETY MANUAL ® WORK PLATFORM 9150-4004 March 2003 Starting Serial No. 0190001 thru 0190457 & 0160000022 thru Current Form #20140 Original Issue 3/03 CORPORATE OFFICE GRADALL DIVISION JLG INDUSTRIES, INC. 1 JLG DRIVE McConnellsburg, PA 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417 JLG INDUSTRIES, INC. 406 Mill Avenue S.W.
Transformer Series PERSONNEL WORK PLATFORM MANUAL w o r k p l a t f o r m COVERING OPERATION & SAFETY IMPORTANT! p e r s o n n e l Read and understand this Manual, the TF6-42 Owner/ Operator Manual, the Gradall Material Handler Safety Manual, the ANSI A92.5 Responsibilities Manual, and the EMI Aerial Work Platform Safety Manual before starting, operating or performing maintenance procedures on this machine.
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REVISIONS This page is provided so you may determine that this Manual is complete and current with respect to Gradall Engineering Specifications. Page Date Form No.
TABLE OF CONTENTS TRANSFORMER SERIES WORK PLATFORM IMPORTANT SAFETY NOTICE ..................................................... TABLE OF CONTENTS INTRODUCTION inside front cover SAFETY ................................................................................. DECAL LOCATIONS .................................................................. DECALS ................................................................................. NOMENCLATURE .........................................................
INTRODUCTION General NOTE! This manual provides important information regarding safe operating procedures for JLG/Gradall Transformer Series work platform. If you have any questions regarding the JLG/Gradall personnel platform contact your JLG/Gradall Material Handler Distributor. The terms “Gradall personnel work platform,” “Transformer Series work platform,” “work platform,” and “platform” are used interchangeably throughout this Manual.
SAFETY Read and understand all manuals and instructional material listed on cover, inside front cover and introduction page of this Manual before putting the Transformer Series personnel work platform into service.
SAFETY If a platform occupant performs welding, electrically connected electrode holders shall be protected from contact with metal components of the platform. Do not make modifications to the platform, by welding or any other means. Do not ground through any part of machine. Platform occupants shall not place any portion of their body between the boom and the platform. Keep the gate closed at all times unless entering or exiting the platform.
SAFETY Trip and Fall Hazards Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach or height. Never use the boom assembly to gain access to or leave the platform. Use extreme caution when entering or leaving platform. Ensure that the platform is fully lowered.
DECAL LOCATIONS 8 7 1 4 5 3 2 1 5 5 6 7 1 2 3 4 5 6 7 8 9 Form No. 20140, Issued 3/03 z 7 9150-4060 9150-4061 9150-4062 9150-4063 9150-4064 9150-4065 9150-4066 9150-3111 1705684 Rail Caution Decal Manual Decal Function Decal Safety Precaution Decal Lanyard Attachment Decal JLG/Gradall Decal Capacity Warning Decal Serial Number Plate Wheel Load Decal (not illustrated) Transformer Series Work Platform Manual P2.
DECALS JLG/GRADALL PART NUMBER FOR MODEL SERIAL NUMBER MODEL YEAR MAXIMUM HYDRAULIC PRESSURE PSI BAR LBS KG MAX ATTACHMENT WEIGHT UNRESTRICTED RATED CAPACITY WITH PLATFORM INSTALLED MAXIMUM (RESTRICTED) RATED CAPACITY Refer to capacity indicator lights located in platform for capacity. 12420 lbs 5640 kg Refer to capacity chart for maximum reach and height. Platform to be used with same serial number Gradall material handler.
DECALS ! CAUTION NO HANDS OR LANYARD PLACING HAND HERE MAY RESULT IN MINOR OR MODERATE INJURY. 1702868 P/N 9150-4063 1704277 B P/N 9150-4060 1701509 P/N 9150-4064 (6) Locations Form No. 20140, Issued 3/03 z Transformer Series Work Platform Manual P/N 9150-4061 P3.
NOMENCLATURE 2 3 1 4 4 4 4 1. 2. 3. 4. 5. 6. 4 10 7. 8. 11 9. 4 9 8 P4.0 7 6 1 5 2 10. 11.
WORK PLATFORM INSTALLATION Approved Attachments The Transformer Series Work Platform With Controls has been approved for use with JLG/Gradall Transformer Series Material Handlers. Several other JLG/GRADALL-approved attachments are available for use with your material handler. Contact your JLG/GRADALL Material Handler Distributor for information on approved attachments designed for special material handling situations. The machine serial number plate lists attachments approved for use with your handler.
WORK PLATFORM INSTALLATION ! WARNING 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. 2. Align boom head pivot with recess in attachment. Raise boom slightly to engage boom head pivot in recess.
WORK PLATFORM INSTALLATION 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. 8. Press the decompression valve located in cab, this takes the pressure out of the auxiliary hydraulic lines located on boom head. 9.
CHECKS BEFORE OPERATING Be sure to service the Material Handler in accordance with the “Lubrication and Routine Maintenance” schedule, located in the TF642 Owner/Operator Manual. These checks and services are to be performed in addition to those specified in the Owner/Operator Manual for the material handler. Prior to using the material handler with the JLG/Gradall personnel work platform attached, perform the following checks: P6.
PRE-START & FUNCTION CHECKS To be performed at beginning of each work shift or at each change of operator. The safety, efficiency and service life of your handler will be increased by performing the operational checks listed below. Before entering the platform, be sure to complete all necessary warmup and operational checks outlined in the Operators Manual supplied with the TF6-42. Also, complete the following pre-start inspection and function checks before use or each time the operator changes.
WALK-AROUND INSPECTION To be performed at beginning of each work shift or at each change of operator. Begin your walk-around inspection at item 1, as noted below. Continue to your right (counterclockwise when viewed from top) checking each item in sequence for the conditions listed in the following checklist. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Work Platform Assembly - No loose or missing parts; no visible damage.
WALK-AROUND INSPECTION 14 13 15 16 17 12 11 10 9 8 18 7 6 19 5 4 3 20 2 3 ! 21 1 Form No. 20140, Issued 3/03 z Transformer Series Work Platform Manual P6.
DAILY REAR AXLE LOCK-OUT TEST PROCEDURE TESTING REAR AXLE LOCKING SYSTEM (perform daily test) The TF6-42 is equipped with a rear axle locking system for use while in work platform mode. In this mode, when the boom is raised above 50 degrees, a cylinder at the rear will lock, preventing oscillation of the rear axle. With the boom below this angle the cylinder will allow the rear axle to oscillate freely.
DAILY REAR AXLE LOCK-OUT TEST PROCEDURE Checking the rear axle locking system in material handler mode Perform the following check from the cab. Disconnect the electrical cables and remove the work platform. Do not engage a load before performing this check. This test will require the use of an assistant. 1.) Position Control Station selector Key switch to Cab (see page 3.0 in the TF6-42 Operator Manual). 2.) Start the machine from the cab.
PLATFORM CONTROLS AND INDICATORS Controls and Indicators This machine is equipped with a work platform. The intended purpose is to position personnel with their tools and supplies at positions above ground level, and can be used to reach work areas located above machinery or equipment. The platform has an operator Control Station. From this control station, the operator can drive and steer the machine in both forward and reverse directions.
PLATFORM CONTROLS AND INDICATORS Boom Control Joystick: An infinitely proportional dual axis joystick is provided for lifting, lowering, boom extend, and boom retract. Lift detent ring up and push forward to lift, lift detent ring up and pull backward to lower. Lift detent ring up and move joystick left to extend boom, lift detent ring up and move joystick right to retract boom. Capacity Indicator: Three lights are used to indicate the maximum platform capacity for the position of the platform.
PLATFORM CONTROLS AND INDICATORS Engine Start/Auxiliary Power: Engine Start Push “UP” on Engine Start/Auxiliary Power switch to start engine. If engine fails to start within 20 seconds, release Engine Start/Auxiliary Power switch and allow starting motor to cool for a few minutes before trying again. For engine starting, the footswitch must be in the released (up) position.
PLATFORM CONTROLS AND INDICATORS Low Fuel Indicator: When illuminated the fuel tank is 1/8 full or less. When the light first turns on, there are approximately four usable gallons of fuel remaining. Platform Leveling Override: The PLATFORM LEVEL control switch allows the operator to adjust the level of the platform by positioning the switch to UP or DOWN.
PLATFORM OPERATION Control Station Selector Switch The Control Station Selector switch functions to direct power to the desired control station when the POWER/EMERGENCY STOP switch is pulled out (on). With the switch rotated to the CAB position power is supplied to the cab control station. When the switch is rotated to the PLATFORM position, power is supplied to the platform control station. NOTE! Footswitch must be depressed prior to activating any function, otherwise function will not operate.
PLATFORM OPERATION Steering Depress footswitch, position thumb switch on Drive/Steer controller to right for steering right, or to left for steering left. Traveling (driving) 1. If machine is shut down, pull out Emergency Stop at Cab Controls and place Control Station Selector switch to Platform. 2. At Platform Controls, pull out Emergency Stop switch and start engine. 3. Position Drive controller to Forward or Reverse as desired. Angle of controller will determine travel speed.
EMERGENCY PROCEDURES 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. Auxiliary Power A toggle type auxiliary power control switch is located on the platform control station and another is located in the operators cab. Operation of either switch turns on the electrically driven auxiliary hydraulic pump. This should be used in case of failure of the main power plant.
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.
406 Mill Ave. SW, New Philadelphia, Ohio USA 44663 Phone (330) 339-2211 Fax (330) 339-8468 http://www.gradall.