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Summary of Contents for Gradall XL4100
- Page 1 OPERATOR'S MANUAL XL4100 CARRIER 24604133 July 2002 Starting S/N Undercarriage - G04391 Form #29612 Original Issue 8/96 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
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Page 4: Important Safety Notice
Performing the checks and services described in this manual ® will help to keep your Gradall Excavator Carrier in reliable condition and use of the recommended operating procedures can help you avoid accidents. Because some procedures may be new to even the experienced operator we recommend that this manual be read, understood and followed by all who operate the unit. - Page 6 When used to indicate direction or location, the terms front, rear, left and right relate to the orientation of a If you have any questions regarding the Gradall Carrier person sitting in the driver’s seat. or the Upperstructure, contact your Gradall Distributor;...
- Page 7 Keep these manuals in cab. If driver will operate upperstructure, he must also read and understand Gradall Upperstructure Operation & Lubrication Manual and Gradall Hydraulic Excavators Safety Manual. Watch for these symbols; they are used to call your attention to safety notices.
- Page 8 SAFETY HIGHLIGHTS Learn to recognize ‘PINCH POINTS’ Boom Holes Boom Cradle Stay clea of PINCH POINTS. Getng caught in a pinch point can cause serious indjry or death. Boom Acces Covers Bucket & Linkage Counteweight & Another Object Upperstructure & Carrier...
- Page 9 Never carry a water can, equipment, or other in this manual. If it differs, or if you aren’t sure, worker ’s tools or personal items on the contact your Gradall distributor before you run machine. Such items can cause other workers to your unit.
- Page 10 SAFETY HIGHLIGHTS Be particularly careful if this is not the machine you usually operate. Read the manuals listed on page 2 and then operate the unit in a safe, open Learn and follow your employer’s safety rules. area to become familiar with the controls. WARNING Travel off-highway...
- Page 11 SAFETY HIGHLIGHTS Check to be sure windows and mirrors are clean and that mirrors are properly adjusted for your driving position and machine configuration. Ensure adequate visibility for safe travel. DANGER Whenever rotating equipment (such as a mower or mixer) is installed on machine, Use boom tie-down device to secure boom in adequate shielding must be installed to rack when traveling between jobsites.
- Page 12 SAFETY HIGHLIGHTS If required, secure attachment as shown to prevent drift while traveling. Remember, getting too close to unstable ground or the edge of an excavation can cause the machine to tip. Always apply digging brake to prevent carrier movement while operating upperstructure. Check for proper slack adjuster operation in accordance with Lubrication &...
- Page 13 Decals Inside Cab TO PREVENT INJURY, STAY CLEAR OF MOVING PARTS. FASTEN COVERS OR INJURY MAY RESULT FROM BEFORE STARTING DEATH CONTACTING ELECTRICAL LINES ENGINE. READ SERVICE MANUAL BEFORE TO PLACE ANY PART OF THIS UNLAWFUL MACHINE OR LOAD WITHIN 10 ADJUSTING OR FEET OF HIGH VOLTAGE LINES SERVICING.
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Page 14: Diesel Fuel
Decals Outside Cab USE TWO KEEP CLEAR OF MACHINE SWING AREA. HANDS WHEN Located on back of cab CLIMBING ON Part No. 8360-1018 MACHINE. 7702-3003 Located at right of cab door PRESSURIZED Part No. 7702-3003 COOLING SYSTEM REMOVE CAP SLOWLY NYLON BRAKE 9104-3210 LINES MAY BE... -
Page 15: Instruments And Indicators
INSTRUMENTS AND INDICATORS Alternator Indicator Light Voltmeter Speedometer/Odometer Hi/Lo Beam Indicator Light Tachometer (optional) Air Pressure Gage (front) Low Air Indicator Light Fuel Gage Differential Lock Indicator Light Digging Brake Indicator Light Oil Pressure Gage Coolant Temperature Gage Hourmeter Turn Signal/Hazzard Indicator Light Air Pressure Gage (rear) WARNING Do not move carrier while low air light is... - Page 16 CONTROLS Heat Control Knob Front Wheel Drive Toggle (6x6 only) Interaxle Differential Toggle Heater Fan Switch Dome Light Switch Defroster Fan Switch Differential Lock Toggle High/Low Beam Switch Digging Brake Toggle Clutch Pedal Brake Valve Pedal Parking Brake Knob Light Switch Accelerator Pedal Ignition Switch Range Preselection Lever...
- Page 17 CHECKS AND SERVICES BEFORE STARTING ENGINE Complete all required maintenance before driving the carrier WARNING Use extreme caution when checking items beyond your normal reach. Use an approved safety ladder. Check fluid level in windshield washer reservoir on rear wall in carrier cab. Add windshield washer solvent as necessary.
- Page 18 Lubricate unit as indicated on lubrication chart. Check oil level in engine crankcase and replenish as necessary. DO NOT OVERFILL. Check engine coolant level and replenish as necessary. Be sure anti-freeze solution is adequate for expected temperatures. Be sure radiator fins are clean.
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Page 19: Engine Operation
ENGINE OPERATION NOTE: If engine is being started at beginning of work shift be sure to perform all “CHECKS AND SERVICES BEFORE STARTING ENGINE” Starting Diesel Engine (Cummins) NOTES: Your unit may be equipped with standard Position throttle at low idle. 6BTA5.9, 200 HP engine or optional 6CTA8.3, 245 HP engine. - Page 20 Normal engine operation (Cummins) Observe volt meter water temperature and oil RPM - 22 00 RPM). The governor has no control over pressure gages trequently to be sure all engine engine speed when engine is being “pushed” by systems are functioning properly. carrier load.
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Page 21: Checks After Starting Engine
CHECKS AFTER STARTING ENGINE (To be performed at beginning of each work shift) Complete all required maintenance before driving Observe water temperature gage. Proper Check operation of windshield washer and wiper. operating temperature is approximately 140/200°F. (60/93 C.). Check all lights and turn signals for proper Observe tachometer response to changes in operation. -
Page 22: Brake System
BRAKE SYSTEM W A R N I N G The air brake system includes a service brake, an Do not drive while low air indicator is emergency brake, a parking brake and a digging flashing. If light comes on while carrier is brake. - Page 23 treadle valve will apply service brakes to the wheels If the air pressure gages indicate some system of the forward and rear tandem axles. There will be pressure remaining, it may be possible to drive the no braking on the wheels of the front axle. unit a short distance to remove it from a hazardous position (hold parking brake knob in depressed Emergency Brake...
- Page 24 DIGGING BRAKE APPLICATION Allow sufficient time for full brake system pressure (125 p.s.i. – 862 kPa) to be devel- oped in upperstructure before operating unit in remote control. W A R N I N G Move digging brake control toggle to ON position only when carrier is stopped.
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Page 25: Steering System
STEERING SYSTEM Conventional steering Remote control steering The power steering system provides low effort steering under normal conditions and greater Your unit is equipped with a steering pedal in the control in the event of a blowout or soft ground. upperstructure cab. -
Page 26: Power Train
POWER TRAIN The power train furnished on 6x4 carriers (units Transfer Case having two driving axles at rear) includes the engine, (for 6x6 units only) clutch, transmission, rear tandem axles and the necessary propeller shafts to transfer torque (power) The transfer case is a gearbox located between the between these units. - Page 27 SHIFTING GEARS W A R N I N G Smooth, efficient gear shifting depends on coordin- Stop carrier and select appropriate gear ated use of accelerator pedal, clutch pedal, range range before traveling a steep grade preselection lever, deep reduction button and shift under off-highway conditions.
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Page 28: Important Notes
Double-Clutching for Downshift Depress accelerator pedal to increase engine speed to high idle depress clutch and shift to next lower NOTE: Downshifting is used to aid in reducing gear. If shift timing has been correct, gears will carrier speed or to increase carrier power. mesh smoothly with no clash. - Page 29 For all conditions: Release accelerator pedal immediately and fully depress clutch pedal. Release clutch pedal. Trans- mission will shift from Lo Lo to Lo when gears are With parking brake applied, depress clutch and synchronized. Accelerate to appropriate travel speed/ move gear shift lever to neutral.
- Page 30 When ready, move range preselection lever up to high range position. As conditions permit, still using upshift, double- clutching method, shift from 5th gear to 6th, 7th and 8th gear. Using upshift, double-clutching method, immedi- ately shift from 4th to 5th gear position. Downshifting MAXIMUM CARIER SPEED IN EACH GEAR...
- Page 31 Using downshift, double-clutching method, shift Continue to downshift using double-clutching from 8th gear to 7th, 6th and 5th gears as method from 4th to 3rd, 2nd, 1st and Lo gears as appropriate. appropriate. If it is absolutely necessary to downshift to Lo Lo range while moving, perform steps 6 and 7.
- Page 32 With toggle in LOCK position, there is positive drive to the INTER-AXLE DIFFERENTIAL front and rear tandem axles and either axle will drive up to its maximum tractive ability without regard to the other An inter- axle differential is provided at the rear of the front axle.
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Page 33: Remote Control
REMOTE CONTROL NOTE: Remote control is to be used lor positioning unit at job site, not for over-the-road travel. Preparing Carrier for Remote Control Operation With carrier on level surface, apply parking brake. W A R N I N G Be sure to keep feet clear of clutch pedal Start carrier engine and develop full brake when moving DIGGING BRAKE toggle to... - Page 34 Precautions for Remote Control Operation Be sure of clear visibility in direction of travel; Always give audible signal before moving unit. use a signalman to compensate for blind spots. Never permit bucket to drag while moving unit. Be sure all Warm-Up and Operational Checks have been performed.
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Page 35: In Case Of Trouble
PARKING THE GRADALL Precautions: Never leave machine with boom in air. Avoid parking on banks or near an excavation. Avoid parking on roads or highways. If it can- Park on level ground, apply parking brake and not be avoided, be sure to display warning chock wheels. - Page 36 6X4 CARRIER LUBRICATION & MAINTENANCE DIAGRAM LUBRICANT SYMBOLS Antifreeze SYMBOLS Auto. Trans. Fluid • Grease. High Temp. Refer to vendor component literature in = Fitting Gear Oil service manual for additional lubrication = Other Service Engine Oil and service requirements. Special Grease...
- Page 38 6 X G CARRIER LUBRICATION & MAINTENANCE DIAGRAM Refer to vendor component literature in service manual for additional lubrication and service requirements. LUBRICANT SYMBOLS Antifreeze SYMBOLS Auto. Trans. Fluid = Fitting Grease. High Temp. = Other Service Diesel Fuel Gear Oil Engine Oil Special Grease...
- Page 40 **Refer to manufacture’s literature for this information. NOTE: Lubricants described in this table are used in standard machines when they are shipped from Gradall. Acceptable alternative lubricants (for varying conditions) are listed in component manufacture’s literature included in your service manual.
- Page 41 CHECKING AUTOMATIC SLACK ADJUSTERS Procedure IMPORTANT NOTES Position unit in a safe, level area. Brake actuator chambers on your unit provide visual indication that automatic slack adjusters are, With brake system fully charged (125 psi), apply or are not, working properly. These indications must digging brake and stop engine.
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