JLG Gradall Telehandlers G6-42P ANSI Service Repair Workshop Manual (P/N:9140-4002)

G6-42P 9140-4002 November 2008 Starting Serial No. 0189001 thru 0189345 & 0160000230 thru Current ® SERVICE MANUAL CORPORATE OFFICE JLG INDUSTRIES, INC. 1 JLG DRIVE McConnellsburg, PA 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417

Operation & Safety Manual Keep this manual with machine at all times.  Model G6-42P S/N 0160004018 & After 31200148 Original November 25, 2008

CALIFORNIA PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of California to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING! CALIFORNIA PROPOSITION 65 EXHAUST 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.

Revision Log a 31200148 Revision Log REVISION LOG November 25, 2008 - A - Original Issue of Manual

Read This First b 31200148 Read This First This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information. Operator Qualifications The operator of the machine must not operate the machine until this manual has been read, training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator. Operation within the U.S.A. requires training per OSHA 1910.178. Operators of this equipment must possess a valid, applicable driver’s license, be in good physical and mental condition, have normal reflexes and reaction time, good vision and depth perception and normal hearing. Operator must not be using medication which could impair abilities nor be under the influence of alcohol or any other intoxicant during the work shift. In addition, the operator must read, understand and comply with instructions contained in the following material furnished with the material handler: • This Operation & Safety Manual • Telehandler Safety Manual (as required) • All instructional decals and plates • Any optional equipment instructions furnished The operator must also read, understand and comply with all applicable Employer, Industry and Governmental rules, standards and regulations. Modifications Any modification to this machine must be approved by JLG.

Read This First c 31200148 This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local authorized JLG representative for information regarding safety- related bulletins which may have been issued for this product. JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate. JLG Industries, Inc. must be notified immediately in all instances where JLG products have been involved in an accident involving bodily injury or death of personnel or when damage has occurred to personal property or the JLG product. FOR: • Accident Reporting and Product Safety Publications • Current Owner Updates • Questions Regarding Product Applications and Safety • Standards and Regulations Compliance Information • Questions Regarding Product Modifications CONTACT: Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 USA or Your Local JLG Office (Addresses on back cover) In USA: Toll Free: 1-877-JLG-SAFE (877-554-7233) Outside USA: Phone: +1-717-485-5161 E-mail: ProductSafety@JLG.com Other Publications Available Service Manual ............................................................. 91404002 Illustrated Parts Manual................................................. 91404001

Read This First d 31200148 This Page Intentionally Left Blank

Table of Contents i 31200148 TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ...................................................... b Modifications ...................................................................... b Other Publications Available .............................................. c Table of Contents Section 1 - General Safety Practices 1.1 Hazard Classification system............................................... 1-1 Safety Alert System and Safety Signal Words ................ 1-1 1.2 General Precautions ............................................................ 1-1 1.3 Operation Safety .................................................................. 1-2 Electrical Hazards ........................................................... 1-2 Tip Over Hazard.............................................................. 1-3 Travel Hazard ................................................................. 1-6 Load Falling Hazard ........................................................ 1-7 Lifting Personnel ............................................................. 1-8 Driving Hazards on Slopes ............................................. 1-9 Pinch Points and Crush Hazards .................................. 1-10 Fall Hazard.................................................................... 1-12 Chemical Hazards......................................................... 1-13 Section 2 - Pre-Operation and Inspection 2.1 Pre-Operation Check and Inspection................................... 2-1 2.2 Safety Decals....................................................................... 2-3 2.3 Walk-Around Inspection....................................................... 2-6 2.4 Warm-Up and Operational Checks ...................................... 2-8 Warm-Up Check ............................................................. 2-8 Operational Check .......................................................... 2-8 2.5 Operator Cab ....................................................................... 2-9 2.6 Windows ............................................................................ 2-10 Cab Door Window (if equipped) .................................... 2-10 Section 3 - Controls and Indicators 3.1 General ................................................................................ 3-1 3.2 Controls ............................................................................... 3-2 Transmission Control Lever ............................................ 3-3 Ignition Switch ................................................................. 3-4 Boom Joystick ................................................................. 3-5 Attachment Tilt and Frame Sway Lever .......................... 3-6 Auxiliary Control Joystick (if equipped) ........................... 3-7 Dash Controls and Indicators.......................................... 3-8 Park Brake Switch........................................................... 3-9 Table of Contents

Table of Contents ii 31200148 Parking Procedure .......................................................... 3-9 Heater ........................................................................... 3-10 3.3 Operator Seat .................................................................... 3-11 Seat Adjustments ......................................................... 3-11 Seat Belt ....................................................................... 3-13 3.4 Boom Angle and Extension Indicators .............................. 3-14 3.5 Mirror ................................................................................. 3-14 Section 4 - Operation 4.1 Engine ................................................................................. 4-1 Starting the Engine ......................................................... 4-1 Cold Weather Starting Aids ............................................ 4-2 Battery Boosted Starting................................................. 4-3 Normal Engine Operation ............................................... 4-4 Shut-Down Procedure .................................................... 4-4 4.2 Operating with a Load ......................................................... 4-5 Lift Load Safely ............................................................... 4-5 Picking Up a Load .......................................................... 4-5 Transporting the Load .................................................... 4-6 Leveling Procedure......................................................... 4-6 Placing the Load ............................................................. 4-7 Disengaging the Load..................................................... 4-7 4.3 Operating with a Suspended Load ...................................... 4-8 Lift Load Safely ............................................................... 4-8 Picking Up a Suspended Load ....................................... 4-8 Transporting a Suspended Load .................................... 4-9 Leveling Procedure......................................................... 4-9 Placing a Suspended Load........................................... 4-10 Disengaging a Suspended Load .................................. 4-10 4.4 Loading and Securing for Transport .................................. 4-11 Tiedown ........................................................................ 4-11 Lifting ............................................................................ 4-12 Section 5 - Attachments 5.1 Approved Attachments ........................................................ 5-1 5.2 Unapproved Attachments .................................................... 5-2 5.3 Telehandler/Attachment/Fork Capacity ............................... 5-3 5.4 Use of the Capacity Chart ................................................... 5-4 Capacity Indicator Locations .......................................... 5-4 Sample Capacity Chart................................................... 5-5 Example.......................................................................... 5-6 5.5 Attachment Installation ........................................................ 5-7 5.6 Adjusting/Moving Forks ....................................................... 5-9 5.7 Attachment Operation ....................................................... 5-10 Carriage w/Forks .......................................................... 5-11

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JLG Gradall Telehandlers G6-42P ANSI Service Repair Workshop Manual (P/N:9140-4002)

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