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Manual
Keep this manual with machine at all times.
Model
F/A-50
F/A-70
P/N 83304192
Revised
November 9th, 2015
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
Revision Log
REVISION LOG
83304192
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, Gradall Industries, Inc. reserves the right
to make specification changes without prior notification. Contact Gradall 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.
Operators of this equipment must possess a valid, applicable drivers 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 machine:
This Operator & Safety Manual
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 Gradall.
83304192
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
Gradall Industries, Inc.
406 Mill Avenue
New Philadelphia, OH 44663
Phone: 330-339-2211
Toll-Free: 1-800-445-4752
83304192
83304192
Table of Contents
Table of Contents
TABLE OF CONTENTS
Revision Log
Read This First
Operator Qualifications ...................................................... b
Modifications ...................................................................... b
Other Publications Available .............................................. c
Table of Contents
Section 1-Safety
1.1 General Precautions ............................................................1-1
1.2 Hazard Classification System ..............................................1-1
Safety Alert System and Safety Signal Words ................1-1
1.3 Operation Safety ..................................................................1-2
Electrical Hazards ...........................................................1-2
Crush Hazards ................................................................1-2
Fall Hazards....................................................................1-3
Travel Hazards................................................................1-3
Tip Over Hazards............................................................1-4
Chemical Hazards...........................................................1-4
Section 3 - Operation
3.1 Preparation and Setup .........................................................3-1
Preparing Chassis for Remote Operation .......................3-1
Remote Control Transmitter Activation Procedure .........3-3
Outrigger Operation ........................................................3-4
3.2 Return to Travel Mode .........................................................3-7
Stowing the Boom ...........................................................3-7
Retracting the Outriggers................................................3-7
Preparing Chassis for Travel Mode ................................3-9
83304192
Table of Contents
3.3 Lifting & Placing a Load - FA50......................................... 3-10
Precautions................................................................... 3-10
General......................................................................... 3-10
Lift Points...................................................................... 3-11
Planning A Lift .............................................................. 3-11
Positioning Machine For A Lift...................................... 3-12
Rated Lift Capacity Chart - FA50.................................. 3-12
Section 4 - Attachments
4.1 Water Flow and Nozzle Operations - FA50......................... 4-1
Section 7 - Specifications
7.1 Product Specifications......................................................... 7-1
Fluid & Lubrication Capacities - FA50 ............................ 7-1
Index
ii
83304192
Section 1-Safety
SECTION 1-SAFETY
1.1
GENERAL PRECAUTIONS
WARNING
Before operation, read & understand this manual. Failure to comply with the
safety precautions listed in this manual could result in machine damage, property
damage, personal injury or death.
1.2
DANGER
OW0010
WARNING
OW0020
CAUTION
OW0030
83304192
1-1
Section 1-Safety
1.3
OPERATION SAFETY
Electrical Hazards
10 FT
(3 M)
OAK0010
The F/A-50 is not insulated and does not provide protection from contact or being
near electrical current.
Before operating, check location of all electric, phone and cable lines. Stay clear
of all utility lines.
Do not spray water, foam or any other substance toward or through electric lines.
Crush Hazards
OAK0020
1-2
83304192
Section 1-Safety
OAK0030
Fall Hazards
OAK0040
Travel Hazards
DO NOT drive unit unless boom is completely stowed.
Store F/A-50 boom/attachment after use.
Do not drive the unit if the drive warning indicator in the chassis is flashing.
83304192
1-3
Section 1-Safety
Tip Over Hazards
The ground must be level and able to support the machine.
Carry load as low as possible. Tether suspended loads to restrict movement.
Operate slowly to prevent load from swinging.
Do not suspend loads in high winds. Wind can cause a suspended load to swing
and cause dangerous side loads - even with tag lines.
Keep heavy part of load closest to attachment.
Never drag the load; lift vertically.
Chemical Hazards
Hydraulic Fluid
OW0950
DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to
search for leaks. Wear appropriate equipment to protect yourself from spraying
fluid. If fluid is injected into the skin seek medical attention immediately.
Stop engine and relieve trapped pressure. Hydraulic oil is under enough
pressure that it can penetrate the skin.
DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the
engine is running or when the hydraulic system is pressurized.
1-4
83304192
WARNING
FALL HAZARD. Use extreme caution when checking items beyond your normal
reach. Use an approved ladder. Failure to comply could result in death or serious
injury.
Walk around inspection must be performed on a regularly scheduled interval.
Ensure all safety decals are legible and in place. Clean or replace as required. Refer
to page 2-4 for decal locations.
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.
When adding fluids, refer to Section 6 - Lubrication & Maintenance and Section 7 Specifications to determine proper type and intervals.
83304192
2-1
WALK-AROUND INSPECTION
4
6
2
5
4
OAK0050
2-2
83304192
83304192
2-3
SAFETY DECALS
Observe and follow all safety decals and placards on unit. Clean and replace as
required.
83303215
(IN TRANSMITTER
COMPARTMENT)
83303218
(BOTH SIDES OF
BOOM)
8330-3215
83303209
8330-3218
8330-3209
83303214
(IN REAR
COMPARTMENT)
8330-3214
HYDRAULIC SYSTEM
8093-3301
80933301
8330-3219
83303219
83303216
(IN REAR
COMPARTMENT)
OAK0061
83303216
2-4
83304192
83303217
8330-3217
83303217
83303217
83303217
8330-3217
8330-3217
8330-3217
8330-3217
83303217
8330-3217
83303217
8330-3217
83303217
8330-3217
OAK0070
83303217
83304192
2-5
The following switches are located on the dash in the chassis cab.
IAL
AER
T
FAS
IDLE
PTO
3
OAK0080
2-6
83304192
The remote control transmitter is stored in a compartment on the drivers side behind
the cab.
The remote control receiver is located in a compartment above the right rear tire.
83304192
2-7
16
16
15
STOP
14
6
7
10
11
12
13
OAK0090
2-8
83304192
The effective range of the remote control transmitter is approximately 300 yds. (274
meters). The lights on the outriggers will flash when transmitter and receiver are
functioning properly. If the signal is disrupted, the lights will not flash. When out of
range, transmitter will automatically revert to a secure state with controls no
longer activated.
During operation, there is continuous communication between the remote control
transmitter and receiver. These communications are coded to ensure that no foreign
communication can affect F/A-50 operation.
Any foreign signal will be rejected and cause system to revert to a secure state.
Low transmitter battery charge will cause system to revert to a secure state. The
flashing green indicator light on the transmitter will change to flashing red to alert
operator before system reverts to secure state.
WARNING
Failure of operator to respond immediately to alarm and/or warning light
signal could cause equipment damage. When signal is noticed, stop
operation and determine cause. Do not operate until repaired.
83304192
2-9
OAK0100
OAK0110
2-10
83304192
OAK0120
83304192
2-11
Changing Battery
Note: For purposes of this procedure it is assumed the remote control receiver and
transmitter are activated. The procedure could be performed with system
deactivated but battery LED would not respond.
OAK0130
1. Turn 0/1 switch (1) to the 0 position to deactivate remote control transmitter.
Transmitter LED (2) should go out.
2. Remove battery from underside of transmitter.
3. Remove charged battery from charger (green LED on charger indicates fully
charged battery).
4. Install battery in charger (yellow LED on charger indicates battery is charging,
red LED indicates battery has failed). It will take approximately 4-6 hours to
recharge battery.
5. Install charged battery in underside of transmitter.
2-12
83304192
OAK0140
6. Turn 0/1 switch (1) to the 1 position to activate remote control transmitter.
Battery LED (2) should flash green to indicate battery is charged and properly
installed and the transmitter is functional.
OAK0150
7. Turn 0/1 switch (1) to the 0 position to deactivate remote control transmitter
until you are ready to operate. The battery is continually discharging when the
transmitter is on.
83304192
2-13
Note: Manual operation procedures and operator stations are to be used only to
stow the boom and outriggers. Do not use these procedures and controls for other
operations.
OAK0300
Note: The Manual Operator Station is to be used for manual operation only when
the boom can not be operated from the remote control transmitter. No riders are
permitted on this station.
1. Swing Lock - Press and hold button to disengage swing lock; release button to
engage swing lock.
2. Hoist Lock - Press and hold button to disengage hoist lock; release button to
engage hoist lock.
3. Tilt Clockwise/Counterclockwise - Push lever forward to tilt boom
counterclockwise; pull lever backward to tilt boom clockwise.
4. Nozzle In/Out - Push lever forward to move nozzle out; pull lever backward to
move nozzle in.
5. Stick In/Out - Push lever forward to move stick in; pull lever backward to move
stick out.
6. Boom In/Out - Push lever forward to extend boom; pull lever backward to retract
boom.
2-14
83304192
OAK0320
a. To operate the hoist down/up function, press down and hold the hoist lock
button (1) while simultaneously engaging the hoist up/down lever (2).
Release the hoist lock button to return to hoist lock mode.
OAK0330
83304192
2-15
4
6
1
3
5
7
OAK0310
1. Right Front Outrigger Raise/Lower - Push lever forward to raise outrigger; pull
lever backward to lower outrigger.
2. Right Front Outrigger Extend/Retract - Push lever forward to extend outrigger;
pull lever backward to retract outrigger.
3. Right Rear Outrigger Raise/Lower - Push lever forward to raise outrigger; pull
lever backward to lower outrigger.
4. Right Rear Outrigger Extend/Retract - Push lever forward to extend outrigger;
pull lever backward to retract outrigger.
5. Left Rear Outrigger Raise/Lower - Push lever forward to raise outrigger; pull
lever backward to lower outrigger.
6. Left Rear Outrigger Extend/Retract - Push lever forward to extend outrigger; pull
lever backward to retract outrigger.
7. Left Front Outrigger Raise/Lower - Push lever forward to raise outrigger; pull
lever backward to lower outrigger.
8. Left Front Outrigger Extend/Retract - Push lever forward to extend outrigger;
pull lever backward to retract outrigger.
2-16
83304192
LEFT FRONT
OUTRIGGER
RIGHT FRONT
OUTRIGGER
LEFT REAR
OUTRIGGER
ON
OFF
LEFT SIDE
OVERRIDE
ON
RIGHT REAR
OUTRIGGER
ON
OFF
RIGHT SIDE
OVERRIDE
EMERGENCY
HYDRAULIC POWER
DIRECTIONS
OFF
OAK0160
83304192
2-17
2-18
83304192
Section 3 - Operation
SECTION 3 - OPERATION
3.1
IAL
AER
T
FAS
IDLE
PTO
OAK0180
IAL
AER
T
FAS
IDLE
PTO
2
OAK0170
83304192
3-1
Section 3 - Operation
IAL
AER
PTO
T
FAS
IDLE
OAK0190
7. If water is not being pumped through the water pump on the truck, engage fast
idle switch (3) to increase engine RPM. If water is being pumped through the
water pump on the truck, determine engine RPM requirements when pump is in
use.
8. Exit chassis cab.
9. Remove remote control transmitter from storage location showed on page 2-7
and proceed to Remote Control Transmitter Activation Procedure on
page 3-3.
3-2
83304192
Section 3 - Operation
Remote Control Transmitter Activation Procedure
Note: Do not open, tamper with or modify transmitter. Perform the following
prior to activating transmitter.
OAK0150
OAK0200
WARNING
Test your controls before operating. Practice with controls in a safe, open
area. Perform all checks and services on Pre-Operation Checks &
Inspection on page 2-1 prior to operation.
83304192
3-3
Section 3 - Operation
Outrigger Operation
The outriggers can be set in a long-jack or short-jack position. A long-jack outrigger
condition occurs when the outriggers are fully extended and lowered. A short-jack
outrigger condition occurs when an outrigger or outriggers can not be fully extended.
Use the long-jack position when possible.
Long-Jack Outrigger Setup
2
OAK0210
1. Turn on outrigger enable switch (1) and the outrigger power switches (2) for
those outriggers being set. All four outrigger power switches (2) can be
activated simultaneously.
2. Extend the outriggers to their maximum allowable extension and lower outrigger
pads. It is recommended that cribbing blocks or pads be used under the
outrigger pads.
3. In each outrigger leg, install one outrigger pin in the highest possible location.
4. Check apparatus level indicator at both sides and rear of machine to ensure the
machine is as near level as possible.
3
ON
LF
SET
RF
SET
LR
SET
RR
SET
OFF
LEFT SIDE
OVERRIDE
ON
ON
OFF
RIGHT SIDE
OVERRIDE
EMERGENCY
HYDRAULIC POWER
DIRECTIONS
OFF
OAK0220
3-4
83304192
Section 3 - Operation
5. All four outrigger indicator lights must (3) be illuminated on the outrigger status
panel (4) to raise the boom out of boom rest. When all lights are illuminated,
turn off all outrigger switches on remote control transmitter.
Short-Jack Outrigger Setup
WARNING
TIP-OVER HAZARD: When working over the short-jacked side of the machine,
the weight of the boom may cause the truck to tip, depending on the position of
the short-jacked outrigger(s). This condition should be avoided, if possible, and
only experienced operators should attempt to work over a short-jacked condition.
Note: This procedure requires two operators.
1. Position the unit so that outriggers can be extended the furthest on the side the
boom will be used.
2
OAK0210
2. Turn on outrigger enable switch (1) and the outrigger power switches (2) for
those outriggers being set. All four outrigger power switches (2) can be
activated simultaneously.
3. Extend the outriggers to their maximum allowable extension and lower outrigger
pads. It is recommended that cribbing blocks or pads be used under the
outrigger pads.
4. In each outrigger leg, install one outrigger pin in the highest possible location.
5. Check the apparatus level indicator at both sides and rear of machine to ensure
the machine is as near level as possible.
6. The second operator must check the outrigger status panel to determine which
outriggers are short jacked. If an outrigger is short jacked, the light on the status
panel next to outrigger will not be illuminated.
7. To raise the boom out of the boom rest, the second operator must activate the
outrigger override switch for the side where a short jack situation is indicated. If
both sides indicate a short jack condition, both switches must be activated. The
83304192
3-5
Section 3 - Operation
switch or switches must be held in the on position until the boom is raised
using the remote control transmitter.
8. Normal boom operation is possible over the long-jacked side of the truck.
9. The boom will only swing 5 degrees to the short-jacked side of the truck. If the
boom must be swung beyond 5 degrees, the corresponding override switch
must be held in the on position for the entire time the boom is beyond the 5
degrees in order for the swing to function.
3-6
83304192
Section 3 - Operation
3.2
2
OAK0210
83304192
3-7
Section 3 - Operation
2
OAK0230
5. Turn off outrigger enable switch (1) and all four outrigger power switches (2)
OAK0240
3-8
83304192
Section 3 - Operation
Preparing Chassis for Travel Mode
PTO
IAL
AER
T
FAS
IDLE
OAK0250
IAL
AER
T
FAS
IDLE
PTO
OAK0260
IAL
AER
PTO
T
FAS
IDLE
OAK0270
83304192
3-9
Section 3 - Operation
3.3
WARNING
LIFTING & POSITIONING LOADS. Failure to plan a lift properly could result in
death or serious injury.
The automatic boom tilt brake will not prevent boom from tilting in response to an
external load. Load must be centered under the boom with boom level from side
to side.
Precautions
Use the rated lift capacity chart on page 3-12 to determine maximum load. The
rigging weight must be added to the load, then compared to the value on the lift
capacity chart. The information shown is with the outriggers fully deployed. Do not
lift loads if the outriggers are in a short jacked position.
If it becomes necessary to shut the engine off while positioning a load, place load on
the ground prior to shutting off engine.
Operate machine at full throttle.
General
There is a lift capacity difference between the best and worst lift positions. Just
because it can lift a load from one point does not mean it can safely deliver the load
to any other point.
Prior to lifting and placing a load, map out the lift, swing, and lower path to ensure
that capacity is not exceeded.
You must plan the lift based on the worst condition of the lift and delivery, not the
best. The worst condition can only be determined by performing an UNLOADED
TEST AND DELIVERY of the load.
Loads shown on chart on page 3-12 are hydraulic lift limits. Exceeding these limits
can cause a relief valve to open allowing the load to fall or in some cases, the
machine to tip over.
3-10
83304192
Section 3 - Operation
Lift Points
3
OAK0280
Planning A Lift
Note: Lift capacities are based on machine being on a firm, level surface and also
no load being suspended beneath lift eye.
1. Determine the weight of the load including weight of chains.
2. Move the machine to the best position for making the lift. See Positioning
Machine For A Lift on page 3-12 for more details.
3. Perform an unloaded trial run of lift to determine maximum boom height and
load radius required to complete the lift.
4. Refer to rated lift capacity chart on page 3-12 to ensure lift limits are not
exceeded. To determine working load limits the operator must also consider
wind, hazardous conditions, experience of personnel and proper load handling.
83304192
3-11
Section 3 - Operation
Positioning Machine For A Lift
The machine must be on a firm, level surface with outriggers completely extended
and lowered when making a lift.
The shorter the load radius, the greater the lift capacity. Position the unit to minimize
boom extension and swing while keeping adequate distance from obstructions.
BOOM CONFIGURATION
NOZZLE
LIFT EYE
BOOM AT ANY
ANGLE/CONFIGURATION
730 lbs
(331 kg)
820 lbs
(372 kg)
1490 lbs
(676 kg)
1838 lbs
(834 kg)
2225 lbs
(1009 kg)
5400 lbs
(2449 kg)
2750 lbs
(1247 kg)
2750 lbs
(1247 kg)
6100 lbs
(2767 kg)
Note: Values in lift chart above are with the outriggers in long-jack configuration.
The values are not valid for lifting with outriggers in short-jack configuration.
3-12
83304192
Section 4 - Attachments
SECTION 4 - ATTACHMENTS
4.1
A 16 inch (41 cm) nozzle head is referred to as the "Fifth Man Nozzle". This
nozzle has the ability to deliver a 25 foot (7,6 m) water curtain with the
appropriate water supply operated at 150 psi. The nozzle head will flow class "A"
and class "B" foam.
A water cannon is supplied with one 2-1/2 inch (6,4 cm) national hose connection
for expanded defensive fire capability.
Industry standard thread connections are available for other types of water flow
appliances.
83304192
4-1
Section 4 - Attachments
4-2
83304192
Each machine is equipped with an Emergency Power Unit (EPU) that is to be used
to supply limited hydraulic power to the boom and outriggers in the event of an
electrical or mechanical failure.
In an event where failure has occured, boom should be cradled and outriggers
stowed before moving the chassis.
Location of EPU
Location of the EPU switch is determined by chassis manufacturer, and is often
located near the water pump controls. Operation of the EPU switch is controlled by
either holding a monitary switch in place or engaging a positive lock switch that must
be manually disengaged. (Note: Chassis ignition switch must be on to engage EPU
power.) Once the switch has been engaged, the EPU will start producing limited
hydraulic flow. Below is an illustration showing a common EPU switch location,
controlled by holding the switch in place.
ON
OFF
LEFT SIDE
OVERRIDE
EPU SWITCH
ON
ON
OFF
RIGHT SIDE
OVERRIDE
EMERGENCY
HYDRAULIC POWER
DIRECTIONS
OFF
OAK0341
CAUTION
OW0031
83304192
5-1
EMERGENCY OPERATIONS
5-2
83304192
Note: Emergency operation procedures and operator stations are to be used only
to stow the boom and outriggers. Do not use these procedures and controls for other
operations.
OAK0300
83304192
5-3
OAK0320
a. To operate the hoist down/up function, press down and hold the hoist lock
button (1) while simultaneously engaging the hoist up/down lever (2).
Release the hoist lock button to return to hoist lock mode.
OAK0330
5-4
83304192
4
6
1
3
5
7
OAK0310
1. Right Front Outrigger Raise/Lower - Push lever forward to raise outrigger; pull
lever backward to lower outrigger.
2. Right Front Outrigger Extend/Retract - Push lever forward to extend outrigger;
pull lever backward to retract outrigger.
3. Right Rear Outrigger Raise/Lower - Push lever forward to raise outrigger; pull
lever backward to lower outrigger.
4. Right Rear Outrigger Extend/Retract - Push lever forward to extend outrigger;
pull lever backward to retract outrigger.
5. Left Rear Outrigger Raise/Lower - Push lever forward to raise outrigger; pull
lever backward to lower outrigger.
6. Left Rear Outrigger Extend/Retract - Push lever forward to extend outrigger; pull
lever backward to retract outrigger.
7. Left Front Outrigger Raise/Lower - Push lever forward to raise outrigger; pull
lever backward to lower outrigger.
8. Left Front Outrigger Extend/Retract - Push lever forward to extend outrigger;
pull lever backward to retract outrigger.
83304192
5-5
5-6
83304192
INTRODUCTION
Service the product in accordance with the maintenance schedule on the following
pages. Complete all required maintenance before operating unit.
WARNING
FALL HAZARD. Use extreme caution when checking items beyond your normal
reach. Use an approved ladder. Failure to comply could result in death or serious
injury.
Before removing filler caps or fill plugs, wipe all dirt and grease away from the ports.
If dirt is allowed to enter ports, it can shorten the life of the hydraulic components.
When adding fluids or lubricants, refer to Section 7 - Specifications of this manual to
determine proper type, specification and grade to be used.
WARNING
CUT/CRUSH/BURN HAZARD. Do not perform service or maintenance on the
machine with the engine running. Failure to comply could cause death or serious
injury.
83304192
6-1
EVERY
10
Check Hydraulic
Oil Level
EVERY
40
Lubrication
Schedule
OAK0350
6-2
83304192
LUBRICATION SCHEDULE
EVERY
40
OAK0360
83304192
6-3
EVERY
40
OAK0370
6-4
83304192
Hydraulic Oil
10
2
3
OAK0380
83304192
6-5
6-6
83304192
Section 7 - Specifications
SECTION 7 - SPECIFICATIONS
7.1
PRODUCT SPECIFICATIONS
83304192
7-1
Section 7 - Specifications
7-2
83304192
Index
Index
A
Attachments ..................................... 4-1
C
Capacities - FA50............................. 7-1
Emergency Operation
Electrical Failure ......................... 5-2
Mechanical Failure...................... 5-2
F
Fall Hazards ..................................... 1-3
H
Hazard Classification System........... 1-1
Hydraulic Oil Level ........................... 6-5
Hydraulic System ............................. 7-1
Safety Decals....................................2-4
Safety Signal Words .........................1-1
Service & Maintenance Schedule .....6-2
10 Hour........................................6-2
40 Hour........................................6-2
500 Hour......................................6-2
Specifications....................................7-1
Stowing The Boom............................3-7
T
Tip Over Hazards..............................1-4
Travel Hazards..................................1-3
W
Water Flow Operations - FA50 .........4-1
L
Lift Capacity Chart - FA50 .............. 3-12
Lift Points........................................ 3-11
Lifting A Load - FA50...................... 3-10
Lubrication & Maintenance............... 6-1
83304192
Index
83304192