Operator & Safety

Manual
Keep this manual with machine at all times.

Model
F/A-50
F/A-70

S/N FA00000001 & After

S/N FA70000001 & After

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.

Gradall is a registered trademark for hydraulic excavators, industrial

maintenance machines, attachments and other components manufactured
and marketed by Gradall Industries, Inc.

Revision Log
Revision Log

REVISION LOG

July 17, 2006 - A - Original Issue of Manual

September 6, 2006 - B - Revised page 2-4
May 31, 2011 - C - Revised Sections 2 and 5.
November 9th, 2015 - D - Added FA-70 designation.

83304192

Read This First

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, 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

Read This First

This product must comply with all safety related bulletins. Contact the chassis
manufacturer or the local authorized Gradall dealer for information regarding safetyrelated bulletins which may have been issued for this product.
Gradall Industries, Inc. sends safety related bulletins to the chassis manufacturer
and authorized dealers. Contact the chassis manufacturer to ensure that the current
owner records are updated and accurate.
Gradall Industries, Inc. must be notified immediately in all instances where Gradall
products have been involved in an accident involving bodily injury or death of
personnel or when damage has occurred to personal property or the Gradall
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
Gradall Industries, Inc.
406 Mill Avenue
New Philadelphia, OH 44663
Phone: 330-339-2211
Toll-Free: 1-800-445-4752

Other Publications Available

Parts/Service Combined Manual - FA50 .......................83304001

83304192

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This Page Intentionally Left Blank

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 2 - Pre-Operation and Controls

2.1
2.2
2.3
2.4
2.5

Pre-Operation Checks & Inspection.....................................2-1

Walk-Around Inspection.......................................................2-2
Safety Decals.......................................................................2-4
Chassis Cab Controls ..........................................................2-6
Remote Control System.......................................................2-7
Remote Control Transmitter/Receiver Locations ............2-7
Remote Control Transmitter............................................2-8
Joystick Detail ...............................................................2-10
Remote Control Transmitter Battery .............................2-12
2.6 Manual Operation Procedures ...........................................2-14
Boom Hand Control Levers...........................................2-14
Outrigger Hand Control Levers .....................................2-16
Outrigger Override Control Box ....................................2-17

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
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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 5 - Emergency Procedures

5.1 Emergency Operations Overview........................................ 5-1
5.2 Emergency Operations........................................................ 5-2
Emergency Operation due to Electrical Failure .............. 5-2
Emergency Operation due to Mechanical Failure .......... 5-2
5.3 Emergency Operator Stations ............................................. 5-3
Boom Hand Control Levers ............................................ 5-3
Outrigger Hand Control Levers....................................... 5-5

Section 6 - Lubrication & Maintenance

6.1 Introduction.......................................................................... 6-1
Clothing and Safety Gear ............................................... 6-1
6.2 Service & Maintenance Schedule ....................................... 6-2
10 & 40 Hour Maintenance Schedule............................. 6-2
500 Hour Maintenance Schedule ................................... 6-2
6.3 Lubrication Schedule........................................................... 6-3
40 Hour Lubrication Schedule ........................................ 6-3
40 Hour Lubrication Schedule, (contd) .......................... 6-4
6.4 Operator Maintenance Instructions ..................................... 6-5
Hydraulic Oil ................................................................... 6-5

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

HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER

OW0010

DANGER indicates an imminently hazardous situation which, if not avoided, will

result in death or serious injury.

WARNING

OW0020

WARNING indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION

OW0030

CAUTION indicates a potentiality hazardous situation which, if not avoided, may

result in minor or moderate injury.

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

Keep others clear of outriggers.

1-2

83304192

Section 1-Safety

OAK0030

Keep clear of boom holes and rollers.

Do not stand under elevated boom. or suspended load
Keep fingers and hands clear of outriggers.

Fall Hazards

OAK0040

The Emergency Operator Station (EOS) is to be used for emergency operation

only. No riders are permitted on this station.
Do not use boom or attachments for lifting personnel.

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

Section 2 - Pre-Operation and Controls

SECTION 2 - PRE-OPERATION AND CONTROLS

2.1

PRE-OPERATION CHECKS & INSPECTION

Note: 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.
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

Section 2 - Pre-Operation and Controls

2.2

WALK-AROUND INSPECTION
4

6
2

5
4

*CHASSIS PANELS REMOVED FOR CLARITY

OAK0050

Begin your walk-around inspection at item 1, as noted below.

INSPECTION NOTE: In addition to any other criteria mentioned, on all components:
Ensure there are no loose or missing parts and that all parts are securely
fastened.
Check for visible leaks and excessive wear.
Inspect all structural members, including attachment, for cracks, excessive
corrosion and other damage.
1. Hydraulic Oil Reservoir - Check fluid level.
2. Boom - Inspect for signs of damage or wear, hydraulic leaks, loose fittings,
clamps and attaching hardware.

2-2

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Section 2 - Pre-Operation and Controls

3. Waterway - Inspect for signs of leaks, damage or wear.
4. Hydraulic Cylinders - Inspect for signs of damage or wear, hydraulic leaks, loose
fittings and attaching hardware.
5. Outriggers, Jack Stands and Foot Pads - Inspect for signs of damage or wear,
loose fittings, clamps and attaching hardware.
6. Piercing Head and Adapter- Inspect for signs of damage or wear, hydraulic
leaks, loose fittings, clamps and attaching hardware. Ensure pins are present
and undamaged.
7. Remote Control Transmitter - Check that battery is charged before use.

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Section 2 - Pre-Operation and Controls

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

FILL WITH FIRE RESISTANT HYDRAULIC FLUID

8093-3301

80933301

8330-3219

83303219

83303216
(IN REAR
COMPARTMENT)

OAK0061

83303216

*CHASSIS PANELS REMOVED FOR CLARITY

2-4

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Section 2 - Pre-Operation and Controls

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

*CHASSIS PANELS AND BOOM REMOVED FOR CLARITY

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Section 2 - Pre-Operation and Controls

2.4

CHASSIS CAB CONTROLS

The following switches are located on the dash in the chassis cab.

IAL

AER

T
FAS
IDLE

PTO

3
OAK0080

1. Aerial Switch: Transfers power to activite remote control receiver.

2. PTO Switch: Activates hydraulic pump.
3. High Idle Switch: Engages high idle.

2-6

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Section 2 - Pre-Operation and Controls

2.5

REMOTE CONTROL SYSTEM

Remote Control Transmitter/Receiver Locations

The major components of the wireless remote control system are the remote control
transmitter worn by the operator and the remote control receiver.

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.

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Section 2 - Pre-Operation and Controls

Remote Control Transmitter
2

16

16

15

STOP

14

6
7

10

11

12

13
OAK0090

1. Boom Control Joystick: See page 2-10 for details.

2. Emergency Stop Button: Pressing button disables the transmitter. Rotate button
clockwise to release.
3. Battery LED: Flashing green indicates charged battery. Flashing red indicates
low battery.
4. Boom Control Joystick: See page 2-10 for details.
5. Control Panel Lights Switch: Switch activates control panel lights.
6. Outrigger Enable Switch: Switch must be on to activate outrigger controls.
7. Left Front Outrigger Switch: Switch must be on to operate left front outrigger.
Outriggers operate simultaneously if all switches are activated at the same time.
8. Left Rear Outrigger Switch: Switch must be on to operate left rear outrigger.
Outriggers operate simultaneously if all switches are activated at the same time.
9. Outrigger Control Joystick: See page 2-11 for details.
10. Transmitter Belt/Harness: Properly secure transmitter belt/harness prior to
turning transmitter on.

2-8

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Section 2 - Pre-Operation and Controls

11. Right Rear Outrigger Switch: Switch must be on to operate right rear outrigger.
Outriggers operate simultaneously if all switches are activated at the same time.
12. Right Front Outrigger Switch: Switch must be on to operate right front outrigger.
Outriggers operate simultaneously if all switches are activated at the same time.
13. Boom Lights Switch: Activates work lights located on boom and at each
outrigger station.
14. On/Off Switch: On/Off switch located on right side of transmitter. Switch must be
in 1 position to activate transmitter and 0 postition to deactivate transmitter.
15. Horn Button: Horn button located on right side of transmitter.
16. Control Panel Lights: Can be turned on and off with the Control Panel Lights
Switch.

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.

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Section 2 - Pre-Operation and Controls

Joystick Detail

OAK0100

Boom Control Joystick (item 1):

Pull joystick backward to raise boom. Push joystick forward to lower boom.
Move joystick left to move nozzle in. Move joystick right to move nozzle out.
Rotate joystick grip clockwise to move stick out. Rotate joystick grip
counterclockwise to move stick in.

OAK0110

Boom Control Joystick (item 4):

Pull joystick backward to retract boom. Push joystick forward to extend boom.
Move joystick left to swing left and right to swing right.
Rotate joystick grip clockwise to tilt clockwise and counterclockwise to tilt
counterclockwise.

2-10

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Section 2 - Pre-Operation and Controls

OAK0120

Outrigger Control Joystick (item 9):

Pull joystick backward to raise outrigger(s). Push joystick forward to lower
outrigger(s).
Move joystick left to retract outrigger(s). Move joystick right to extend
outrigger(s).
When outrigger(s) move in any direction, an audible alarm will sound.

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Section 2 - Pre-Operation and Controls

Remote Control Transmitter Battery
Battery Charger
A fully charged battery will function for approximately 8 hours of use. Install fully
charged battery at the beginning of each work shift. The battery will not charge if the
main power switch located in the chassis is in the Off position.

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

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Section 2 - Pre-Operation and Controls

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.

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Section 2 - Pre-Operation and Controls

2.6

MANUAL OPERATION PROCEDURES

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.

Boom Hand Control Levers

1

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

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Section 2 - Pre-Operation and Controls

7. Swing Clockwise/Counterclockwise - Push lever forward to swing boom
clockwise; pull lever backward to swing boom counterclockwise.
8. Hoist Down/Up - Push lever forward to raise boom; pull lever backward to lower
boom.
Detailed view of swing and hoist functions:

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

b. To operate the swing clockwise/counterclockwise function, press down and

hold the swing lock button (3) while simultaneously engaging the swing
clockwise/counterclockwise lever (4). Release the swing lock button to
return to swing lock mode.

83304192

2-15

Section 2 - Pre-Operation and Controls

Outrigger Hand Control Levers

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

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Section 2 - Pre-Operation and Controls

Outrigger Override Control Box
The indicator lights on the outrigger override control box will illuminate only when the
outrigger(s) is fully extended and lowered and is supporting a portion of the machine
weight.

STRONG ARM OUTRIGGER STATUS

LEFT FRONT
OUTRIGGER

RIGHT FRONT
OUTRIGGER

LEFT REAR
OUTRIGGER
ON

OUTRIGGER SET OVERRIDES

OFF
LEFT SIDE
OVERRIDE
ON

RIGHT REAR
OUTRIGGER

ON

OFF
RIGHT SIDE
OVERRIDE

EMERGENCY
HYDRAULIC POWER
DIRECTIONS

HOLD SWITCH IN ON POSITION TO SUPPLY

HYDRAULIC POWER IN CASE OF MAIN PUMP
MALFUNCTION. IGNITION AND AERIAL MASTER
SWITCH MUST BE IN THE ON POSITION

OFF

OAK0160

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Section 2 - Pre-Operation and Controls

This Page Intentionally Left Blank

2-18

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Section 3 - Operation

SECTION 3 - OPERATION
3.1

PREPARATION AND SETUP

Preparing Chassis for Remote Operation

Note: For purposes of this procedure it is assumed that the chassis engine is
running.
1. Position chassis unit in best possible location.
2. Engage park brake.
3. Apply gear selection switch to neutral.

IAL
AER

T
FAS
IDLE

PTO

OAK0180

4. Engage aerial switch (1).

IAL
AER

T
FAS
IDLE

PTO

2
OAK0170

5. Engage PTO switch (2) to activate hydraulic pump.

6. Follow instructions in chassis to engage water pump.

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

1. Turn transmitter On/Off switch (1) to 0 position to deactivate transmitter.

2. Check fit of transmitter belt/harness for comfortable access to controls. Adjust if
necessary.
3. Check all lever-type controls to ensure they are in neutral position. Ensure all
switches are in Off position.
4. Ensure Emergency Stop button is fully raised. Transmitter cannot be activated
with button depressed.

5. Make certain all personnel are clear of machine.

OAK0200

6. Turn transmitter On/Off switch (1) to 1 position to activate transmitter.

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.

STRONG ARM OUTRIGGER STATUS

3
ON

LF
SET

RF
SET

LR
SET

RR
SET

OUTRIGGER SET OVERRIDES

OFF
LEFT SIDE
OVERRIDE
ON

ON

OFF
RIGHT SIDE
OVERRIDE

EMERGENCY
HYDRAULIC POWER
DIRECTIONS

HOLD SWITCH IN ON POSITION TO SUPPLY

HYDRAULIC POWER IN CASE OF MAIN PUMP
MALFUNCTION. IGNITION AND AERIAL MASTER
SWITCH MUST BE IN THE ON POSITION

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

RETURN TO TRAVEL MODE

Stowing the Boom

If the F/A-50 was used in water flow operations, drain as follows:
1. Disconnect water supply from apparatus and raise the boom.
2. Open water way drain at the rear of the apparatus and allow piping to drain.
3. While the boom is raised, retract boom completely and move nozzle assembly
to open position.
4. Move jib to fully closed position and position boom directly over apparatus cab.
5. Rotate the arm nozzle, jib and nozzle assembly to three oclock stored position.
6. Stow the boom in the boom rest.

Retracting the Outriggers

2
OAK0210

Note: Boom must be stowed before performing the following procedure.

1. Turn on outrigger enable switch (1) and all four outrigger power switches (2).
2. Locate and remove the four safety pins from the outrigger legs. If the pins can
not be removed, extend the outrigger leg to release pressure and remove the
pin.
3. Fully raise and retract outriggers either individually or simultaneously.
4. Store outrigger ground pads.

83304192

3-7

Section 3 - Operation

2
OAK0230

5. Turn off outrigger enable switch (1) and all four outrigger power switches (2)

OAK0240

6. Turn transmitter On/Off switch (3) to 0 position to deactivate transmitter. Store

transmitter in location shown on page 2-7.

3-8

83304192

Section 3 - Operation
Preparing Chassis for Travel Mode

PTO

IAL
AER

T
FAS
IDLE

OAK0250

1. Disengage Fast Idle switch (1) located in chassis cab.

IAL
AER

T
FAS
IDLE

PTO

OAK0260

2. Disengage PTO switch (2) located in chassis cab.

IAL
AER

PTO

T
FAS
IDLE

OAK0270

3. Disengage Aerial switch (3) located in chassis cab.

4. Check to assure interior cab warning light is not flashing after the park brake is
released. A flashing warning light indicates the boom and/or outriggers are not
stowed.

83304192

3-9

Section 3 - Operation
3.3

LIFTING & PLACING A LOAD - FA50

Note: This section applies to the FA50 model only.

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

Suspend loads only from locations shown in illustration above.

1. Piercing Adapter Lift Eye
2. Telescope Boom Lift Eye - Both sides of telescope boom.
3. Nozzle Lift Eye (Optional)
To lift loads, level boom from side to side and be certain chain is locked on itself.

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.

Rated Lift Capacity Chart - FA50

BOOM CONFIGURATION

NOZZLE
LIFT EYE

PIERCING ADAPTER TELESCOPE BOOM

LIFT EYE
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)

TELESCOPE BOOM FULLY

RETRACTED
BOOM AT ANY ANGLE
STICK AND ADAPTER IN ANY
CONFIGURATION
TELESCOPE BOOM FULLY
RETRACTED
BOOM AT ANY ANGLE
STICK AT 90 DEGREES TO
TELESCOPE BOOM
ADAPTER FULLY CLOSED
(cylinder fully extended)
OAK0290

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

WATER FLOW AND NOZZLE OPERATIONS - FA50

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

This Page Intentionally Left Blank

4-2

83304192

Section 5 - Emergency Procedures

SECTION 5 - EMERGENCY PROCEDURES

5.1

EMERGENCY OPERATIONS OVERVIEW

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

OUTRIGGER SET OVERRIDES

OFF
LEFT SIDE
OVERRIDE

EPU SWITCH

ON

ON

OFF
RIGHT SIDE
OVERRIDE

EMERGENCY
HYDRAULIC POWER
DIRECTIONS

HOLD SWITCH IN ON POSITION TO SUPPLY

HYDRAULIC POWER IN CASE OF MAIN PUMP
MALFUNCTION. IGNITION AND AERIAL MASTER
SWITCH MUST BE IN THE ON POSITION

OFF

OAK0341

Performing Emergency Operations

It is recommended that during emergency operation, two operators are to be used.
One operator to control the EPU switch functions, and the other operator to control
hydraulic functions from either the remote control transmitter or emergency operator
stations.
Note: Functions will be slower than normal when powered by the emergency
hydraulic pump.

CAUTION
OW0031

83304192

COMPONENT DAMAGE. The electric motor that

operates the emergency hydraulic pump can not be
engaged continually. Disengage EPU switch for 15
minutes after 10 minutes of use to allow electric
motor to cool. Repeat cool down period for every 10
minutes of use thereafter.

5-1

Section 5 - Emergency Procedures

5.2

EMERGENCY OPERATIONS

Emergency Operation due to Electrical Failure

In the event of an electrical failure, the remote control transmitter will not be
functional. Functions will need to be controlled by the Boom hand control levers and
the Outrigger hand control levers.
Note: This procedure requires two operators.
1. Turn off Remote Control Transmitter by pressing the emergency stop button.
See Remote Control Transmitter on page 2-8.
2. Activate emergency hydraulics by engaging the EPU switch. The switch must
be held in the on position by operator to remain activated. The second operator
should then proceed to boom hand control levers.
3. Operate boom hand control levers as required to stow boom. See Boom Hand
Control Levers on page 5-3 for control details.
4. Remove and stow outrigger pins.
5. Move to ground level at the rear of the vehicle. Open the rear compartment
housing the outrigger control valve.
6. Operate outrigger hand control levers to raise and retract all outriggers to the
fully stowed position. SeeOutrigger Hand Control Levers on page 5-5 for
control details.

Emergency Operation due to Mechanical Failure

In the event of a mechanical failure (Engine, Transmission, PTO, Main Hydraulic
Pump), the Boom hand control levers and the Outrigger hand control levers can be
used for emergency operation as shown above. Functions can also be controlled by
the Remote Control Transmitter, as shown below.
Note: This procedure requires two operators.
1. Activate emergency hydraulics by engaging the EPU switch. The switch must
be held in the on position by operator to remain activated.
2. The second operator can perform all functions using the remote control
transmitter.
3. Operate remote control transmitter as required to stow boom. See Remote
Control Transmitter on page 2-8 for control details.
4. Remove and stow outrigger pins.
5. Operate remote control transmitter to raise and retract all outriggers to the fully
stowed position. SeeRemote Control Transmitter on page 2-8 for control
details.

5-2

83304192

Section 5 - Emergency Procedures

5.3

EMERGENCY OPERATOR STATIONS

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.

Boom Hand Control Levers

1

OAK0300

Note: The Emergency Operator Station (EOS) is to be used for emergency

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.

83304192

5-3

Section 5 - Emergency Procedures

7. Swing Clockwise/Counterclockwise - Push lever forward to swing boom
clockwise; pull lever backward to swing boom counterclockwise.
8. Hoist Down/Up - Push lever forward to raise boom; pull lever backward to lower
boom.
Detailed view of swing and hoist functions:

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

b. To operate the swing clockwise/counterclockwise function, press down and

hold the swing lock button (3) while simultaneously engaging the swing
clockwise/counterclockwise lever (4). Release the swing lock button to
return to swing lock mode.

5-4

83304192

Section 5 - Emergency Procedures

Outrigger Hand Control Levers

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

Section 5 - Emergency Procedures

This Page Intentionally Left Blank

5-6

83304192

Section 6 - Lubrication & Maintenance

SECTION 6 - LUBRICATION & MAINTENANCE

6.1

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.

Clothing and Safety Gear

Wear all the protective clothing and personal safety devices issued to you or
called for by job conditions.
DO NOT wear loose clothing or jewelry that can get caught on controls or moving
parts.

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

Section 6 - Lubrication & Maintenance

6.2

SERVICE & MAINTENANCE SCHEDULE

10 & 40 Hour Maintenance Schedule

EVERY

10

Check Hydraulic
Oil Level

EVERY

40

Lubrication
Schedule
OAK0350

500 Hour Maintenance Schedule

Swing Bearing Mounting Bolt torque inspection
Check torque of bolts that mount the swing bearing to the chassis. If torquing is
necessary, remove bolt, clear threads of existing loctite. Apply loctite (blue 242) to
replacement bolts (per loctite manufacturer directions) and use the appropriate
torque value, as listed below:
FA50:
240-255 lb-ft
FA70:
500 lb-ft

6-2

83304192

Section 6 - Lubrication & Maintenance

6.3

LUBRICATION SCHEDULE

40 Hour Lubrication Schedule

No. 2 Grade Extreme Pressure Grease

EVERY

40

OAK0360

83304192

6-3

Section 6 - Lubrication & Maintenance

40 Hour Lubrication Schedule, (contd)

No. 2 Grade Extreme Pressure Grease

EVERY

40

(EXTEND BOOM TO ACCESS

CYLINDER SPIDER
LUBE FITTING)

OAK0370

6-4

83304192

Section 6 - Lubrication & Maintenance

6.4

OPERATOR MAINTENANCE INSTRUCTIONS

Hydraulic Oil

10

A. Hydraulic Oil Level Check

2
3

OAK0380

1. Be sure all cylinders are fully retracted and machine is level.

2. Turn off engine.
3. Check level of hydraulic oil in tank at the sight gauge (3) on the hydraulic
tank (1). The oil level should fill the gauge window.
4. If hydraulic oil is low, remove oil fill cap (2) from filler neck. Add Quintolubric
888-68 fire-resistant hydraulic fluid until gauge window is filled.
5. Replace hydraulic oil fill cap.

83304192

6-5

Section 6 - Lubrication & Maintenance

This Page Intentionally Left Blank

6-6

83304192

Section 7 - Specifications

SECTION 7 - SPECIFICATIONS
7.1

PRODUCT SPECIFICATIONS

Fluid & Lubrication Capacities - FA50

Hydraulic System
System Capacity .......................................................................90 gallons (341 liters)
Reservoir Capacity to Full Mark ................................................55 gallons (208 liters)
Type of Oil .................................. Quintolubric 888-68 Fire Resistant Hydraulic Fluid

83304192

7-1

Section 7 - Specifications

This Page Intentionally Left Blank

7-2

83304192

Index

Index
A
Attachments ..................................... 4-1

Lubrication Schedule ........................6-3

40 Hour........................................6-3

Battery Charger .............................. 2-12

Manual Operation Procedures ........2-14

Battery Replacement...................... 2-12

C
Capacities - FA50............................. 7-1

Outrigger Operation ..........................3-4

Long-Jack Setup..........................3-4
Retracting Outriggers ..................3-7
Short-Jack Setup .........................3-5

Chemical Hazards ............................ 1-4

Outrigger Override Control Box ......2-17

Cab Controls .................................... 2-6

Crush Hazards ................................. 1-2

Placing A Load - FA50 ....................3-10

Decals .............................................. 2-4

Pre-Operation Checks & Inspection..2-1

Electrical Hazards ............................ 1-2

Remote Control Transmitter..............2-8

Emergency Operation
Electrical Failure ......................... 5-2
Mechanical Failure...................... 5-2

Emergency Operator Stations .......... 5-3

Boom Hand Control Levers 2-14, 5-3
Outrigger Hand Control Levers 2-16,
5-5
Emergency Procedures.................... 5-1

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

Joystick Controllers ........................ 2-10

L
Lift Capacity Chart - FA50 .............. 3-12
Lift Points........................................ 3-11
Lifting A Load - FA50...................... 3-10
Lubrication & Maintenance............... 6-1

83304192

Index

83304192

Gradall Industries, Inc.

406 Mill Ave SW
New Philadelphia, OH 44663
USA
Phone: (330) 339-2211
Customer Support Toll Free: (800) 445-4752
Fax: (330) 339-3579