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Gradall D152 Operators Safety Manual

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Operator & Safety
Manual
Keep this manual with machine at all times.
D152/D154
S/N D152000001 & After
S/N D154000001 & After
82104002
Revised
February 10th, 2020
This manual, and all manuals for the Gradall Hydraulic
Excavator product line, can be viewed or downloaded, free-of-charge, at
www.mygradall.com

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  • Page 1 Keep this manual with machine at all times. D152/D154 S/N D152000001 & After S/N D154000001 & After 82104002 Revised February 10th, 2020 This manual, and all manuals for the Gradall Hydraulic Excavator product line, can be viewed or downloaded, free-of-charge, at www.mygradall.com...
  • Page 2 IMPORTANT! - If printed, or downloaded in electronic format, this is an uncontrolled copy of the manual. The current version can be viewed/down- loaded at www.mygradall.com Gradall is a registered trademark for hydraulic excavators, industrial maintenance machines, attachments and other components manufactured and marketed by Gradall Industries, Inc.
  • Page 3 November 5th, 2015 - B - Added Section 5; Swing Brake Spec to Section 7 March 8th, 2016 - C - Revised torque specs on page 5-5; added torque spec for D154. Revised D152 specs on page 7-2; added specs for D154. Added s/n range for PTO indicator on page 2-13.

  • Page 4: Read This First

    Due to continuous product improvements, Gradall Industries, Inc. reserves the right to make specification changes without prior notification. Contact Gradall Industries, Inc.

  • Page 5: Other Publications Available

    Inc. or the local authorized Gradall representative for information regarding safety- related bulletins which may have been issued for this product. Gradall Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact Gradall Industries, Inc. to ensure that the current owner records are updated and accurate.
  • Page 6 Read This First NOTES: 82104002...

  • Page 7: Table Of Contents

    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 - General Safety Practices Hazard Classification System............1-1 Safety Alert System and Safety Signal Words......1-1 General Precautions ..............1-1 Operation Safety ................1-2 Electrical Hazards...............1-2...
  • Page 8 Table of Contents Normal Engine Operation............3-3 Remote Mode Brake System............3-4 Remote Control Braking............. 3-4 Digging Brake................3-4 Remote Mode Power Train............3-6 Driving Undercarriage from Upperstructure Cab......3-6 Steering the Undercarriage from Upperstructure Cab ....3-9 Typical Dig Cycle ................ 3-10 Standard SAE Boom and Attachment Functions .....
  • Page 9 Table of Contents 1500 Hour Maintenance Schedule ..........5-5 Upperstructure Lubrication Schedule ..........5-6 Undercarriage Lubrication Schedule ..........5-7 Section 6 - Emergency Procedures Loss Of Power................6-1 Stowing the boom without engine power ........6-1 To extend the boom without engine power.........6-1 To raise the boom without engine power........6-1 Towing ..................6-2 If You Get Stuck .................6-2 Section 7 - Specifications...
  • Page 10 Table of Contents 82104002...

  • Page 11: Section 1 - General Safety Practices

    Section 1 - General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES 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 OW0021 WARNING indicates a potentially hazardous situation which, if not avoided, could...

  • Page 12: Operation Safety

    Section 1 - General Safety Practices OPERATION SAFETY Electrical Hazards 10 FT (3 M) OAC0330 • This machine is not insulated and does not provide protection from contact or being near electrical current. • NEVER operate the excavator in an area where overhead power lines, overhead or underground cables, or other power sources may exist without ensuring the appropriate power or utility company de-energizes the lines.

  • Page 13: Swing Hazards

    Section 1 - General Safety Practices Swing Hazards OAC0340 • Keep others away from machine while in operation. Ensure others are clear of the swing radius prior to swinging upperstructure. • Never carry a water can, equipment, or other worker’s tools or personal items on the machine.
  • Page 14 Section 1 - General Safety Practices OAC1240 • The circle of safety is a circle around the excavator with the boom at full extension. • Establish and inform others of the circle of safety. Keep others from entering into the circle of safety. 82104002...

  • Page 15: Slip And Fall Hazard

    Section 1 - General Safety Practices Slip and Fall Hazard OAC0350 • Always maintain 3-point contact using proper hand holds and steps provided when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting machine. • Repair or replace damaged steps and grab handles. •...

  • Page 16: Crush Hazards

    Section 1 - General Safety Practices Crush Hazards OAC1250 • Do not lean on boom or reach into boom holes, bucket linkage or boom rollers until the attachment or boom is resting on the ground and the engine is stopped. •...
  • Page 17 Section 1 - General Safety Practices OAC1020 • Never permit anyone under boom, attachment or load. Rest boom or attachment on ground and stop engine before permitting anyone to work beneath boom or behind cradle. 82104002...

  • Page 18: Travel Hazards - Remote And Driving

    Section 1 - General Safety Practices Travel Hazards - Remote and Driving OAC0710 • Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you do not have a clear view. • Before moving be sure of a clear path for undercarriage, boom and counterweight and sound horn.

  • Page 19: Tip Over Hazard

    Section 1 - General Safety Practices Tip Over Hazard • Understand how to properly use the capacity chart located in cab. Do not exceed rated lift capacity. Plan the lift to be sure it can be performed safely. • Maintain proper tire pressure at all times. •...

  • Page 20: Chemical Hazards

    • DO NOT operate machine in an enclosed area without proper ventilation. • DO NOT operate the machine in hazardous environments unless approved for that purpose by Gradall and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion.
  • Page 21 Section 1 - General Safety Practices Hydraulic Fluid OAC1260 • 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. •...

  • Page 22: Dust Hazard

    Section 1 - General Safety Practices Battery OAC1270 • Keep sparks, flames and lighted material away from batteries. Explosive gases could cause death or serious injury. Dust Hazard OAC0660 • Repeated or substantial breathing of hazardous dusts, including crystalline silica, could cause fatal or serious respiratory disease including silicosis.

  • Page 23: Personal Protection Equipment

    Section 1 - General Safety Practices PERSONAL PROTECTION EQUIPMENT Wear all the protective clothing and personal safety devices issues to you or called for by job conditions. You may need: • Hard hat • Safety shoes • Safety glasses, goggles or face shield •...
  • Page 24 Section 1 - General Safety Practices NOTES: 1-14 82104002...

  • Page 25: Section 2 - Pre-Operation And Controls

    Section 2 - Pre-Operation and Controls SECTION 2 - PRE-OPERATION AND CONTROLS PRE-OPERATION CHECKS & INSPECTION Complete all required maintenance before operating unit. FALL HAZARD. Use extreme caution when checking WARNING items beyond your normal reach. Use an approved ladder. Failure to comply could result in death or OW0021 serious injury.

  • Page 26: Walk-Around Inspection

    Section 2 - Pre-Operation and Controls WALK-AROUND INSPECTION 19 20 21 Begin your walk-around inspection at item 1, as noted below. Continue to your right, checking each item in sequence. INSPECTION NOTE: In addition to any other criteria mentioned, on all components: •...
  • Page 27 Section 2 - Pre-Operation and Controls 4. Fuel Tank - Check fuel level, refill as required; filler cap securely fastened. 5. DEF (Diesel Exhaust Fluid) Tank - Check DEF level, refill as required. 6. Battery Box - Battery cables tight, no visible damage or corrosion. Battery box cover properly latched.
  • Page 28 Section 2 - Pre-Operation and Controls 19. Engine Compartment - • Engine crankcase, check oil level & refill as required. Do not overfill. • Check engine coolant level at overflow bottle and refill as required.Do not remove the radiator cap. Be sure antifreeze solution is adequate for expected temperatures.

  • Page 29: Safety Decals

    Section 2 - Pre-Operation and Controls SAFETY DECALS Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required. Decal Locations 80509018 80509015 80509013 80509015 80373077 80509016 82104002...
  • Page 30 Section 2 - Pre-Operation and Controls 80509019 80509017 80509016 80373077 80509012 80509018 80509015 80509013 80509015 82104002...
  • Page 31 Section 2 - Pre-Operation and Controls 80509015 80509016 80509015 80509015 80509012 80783208 80509004 82104002...

  • Page 32: Upperstructure Cab Controls & Indicators

    Section 2 - Pre-Operation and Controls UPPERSTRUCTURE CAB CONTROLS & INDICATORS LCD Display STOP n/min 1700 Allison 155oF 120oF AUTO n/min n/min OAC2111 The LCD display is a collection of controls and indicators. The following pages provide detail of how to understand and function this unit, starting at the top of the display to the bottom.
  • Page 33 Selection button (3) to confirm selection. If a new pattern is selected, controls will not change until the next power cycle. Available control patterns are Gradall (3-a), SAE (3-b) and John Deere (3-c). See “Joystick Controls” on page 2-19 for control details.
  • Page 34 Section 2 - Pre-Operation and Controls STOP OAC2130 1. Parking Brake Indicator: See “Park Brake Switch” on page 2-26. 2. Low Air Indicator: Illuminates red to indicate air system pressure is below minimum operating pressure. An audible alarm is also activated. Upperstructure cab controls will be inoperative if indicator is red.
  • Page 35 Section 2 - Pre-Operation and Controls n/min 1700 Allison 155oF 120oF OAC2210 1. Engine Speed (RPM) Indicator 2. Fuel Level Indicator 3. Diesel Exhaust Fluid (DEF) Level Indicator 4. Transmission Gear Indicator: See “Driving Undercarriage from Upperstructure Cab” on page 3-6. 5.
  • Page 36 Section 2 - Pre-Operation and Controls AUTO n/min n/min n/min OAC2220 2-12 82104002...
  • Page 37 Section 2 - Pre-Operation and Controls 1. Remote Mode/Travel Mode Indicator: Travel mode indicator (image of chassis cab) will illuminate yellow until air pressure reaches 70psi. Upperstructure cab controls will not be active. Remote Mode Indicator (image of upper cab) will appear and illuminate green once required air pressure is met, and upperstructure cab controls will be active.

  • Page 38: Auxiliary Hydraulics Control (Optional)

    Section 2 - Pre-Operation and Controls Auxiliary Hydraulics Control (optional) Will not change until Will not change until next power cycle. next power cycle. Will not change until Will not change until next power cycle. next power cycle. OAC2710 1. Auxiliary Hydraulics Control Selection: Press this button to view available Auxiliary Hydraulic Control options.
  • Page 39 Section 2 - Pre-Operation and Controls This Page Intentionally Left Blank 82104002 2-15...

  • Page 40: Left Hand Arm Pod

    Section 2 - Pre-Operation and Controls Left Hand Arm Pod OAC2150 1. Boom Tilt Speed Switch: Rotary switch. Rotate switch clockwise to decrease boom tilt speed; rotate counterclockwise to increase boom tilt speed. 2. Park Brake Switch: See page 2-26 for details. 3.

  • Page 41: Right Hand Arm Pod

    Section 2 - Pre-Operation and Controls Right Hand Arm Pod OAC2140 1. Fan Speed: Rotary switch for heater and air conditioner fan. 2. Boom Lights Switch (optional): On/Off switch. 3. Work Lights Switch (optional): On/Off switch. 4. Intermittent Wiper/Washer Switch: See “Intermittent Wiper/Washer” on page 2-25.
  • Page 42 Section 2 - Pre-Operation and Controls NOTES: 2-18 82104002...

  • Page 43: Joystick Controls

    Section 2 - Pre-Operation and Controls Joystick Controls Activating the Joysticks The joysticks will remain locked/inactive until the control cut out lever (1) located on the left hand arm pod (2) is moved to the unlocked/active position. INACTIVE ACTIVE OAC0920 Joystick Control Patterns Before operating, refer to the selected joystick control pattern located on the LCD display to verify control pattern setting.
  • Page 44 Section 2 - Pre-Operation and Controls SAE Joystick Controls OAC2640 Left Hand Joystick Functions • Move the joystick back to retract boom; move joystick forward to extend boom. Move joystick right to swing boom right; move joystick left to swing boom left. •...
  • Page 45 Section 2 - Pre-Operation and Controls GRADALL Joystick Controls OAC2650 Left Hand Joystick Functions • Move the joystick back to raise boom; move joystick forward to lower boom. Move joystick right to close tool; move joystick left to open tool.
  • Page 46 Section 2 - Pre-Operation and Controls JOHN DEERE Joystick Controls OAC2660 Left Hand Joystick Functions • Move the joystick back to raise boom; move joystick forward to lower boom. Move joystick right to swing boom right; move joystick left to swing boom left. •...

  • Page 47: Operator Seat Adjustments

    Section 2 - Pre-Operation and Controls Operator Seat Adjustments OAC2190 Prior to starting engine adjust seat for position and comfort. 1. Height Adjustment Control 2. Upper Seat Fore and Aft Adjustment Control 3. Weight Control Adjustment 4. Lower Seat Fore and Aft Adjustment Control 5.

  • Page 48: Ignition

    Section 2 - Pre-Operation and Controls Ignition STOP OAC0820 1. ACC: Voltage is available for all electrical functions. 2. OFF: Engine off. 3. RUN: Prohibits rotating key switch to position 4 in the event the engine does not start. Rotate the key to position 2 then back to position 4 to re-engage the starter.

  • Page 49: Intermittent Wiper/Washer

    Section 2 - Pre-Operation and Controls Intermittent Wiper/Washer OAC0930 1. OFF 2. DELAY: Rotating knob clockwise decreases delay. 3. LOW: Low wiper speed. No delay. 4. HIGH: High wiper speed. No delay. 5. WASHER: Press and hold switch to activate washer. 82104002 2-25...

  • Page 50: Park Brake Switch

    Section 2 - Pre-Operation and Controls Park Brake Switch OAC0940 • Park Brake Switch: This switch controls the application and release of the park brake. Indicator light on the LCD display illuminates red to indicate brake is applied. View of indicator when park brake View of indicator when is on.

  • Page 51: Section 3 - Operation

    Section 3 - Operation SECTION 3 - OPERATION REMOTE CONTROL PREPARATION Preparing Undercarriage for Remote Control Operation Remote travel is to be used for positioning unit at job site, not for over-the-road driving. After reaching job site, perform the following steps to prepare undercarriage for remote control operation: 1.

  • Page 52: Preparing Upperstructure For Remote Control Operation

    Section 3 - Operation Preparing Upperstructure for Remote Control Operation All instructions on undercarriage cab remote control decal must be followed before starting machine in remote operation. 1. Place control cut out lever in locked/inactive position (refer to page 2-19). 2.

  • Page 53: Checks Before Remote Control Operation

    Section 3 - Operation CHECKS BEFORE REMOTE CONTROL OPERATION This section outlines the checks to be performed at the beginning of each work shift or at each change of operator. Repair any deficiencies before driving or operating the equipment. During warm-up period, check the following: •...

  • Page 54: Remote Mode Brake System

    Section 3 - Operation REMOTE MODE BRAKE SYSTEM Remote Control Braking REMOTE CONTROL BRAKING. Allow sufficient time WARNING for full brake system pressure to develop before operating unit in remote control. Low air light indicator OW0021 will turn off when pressure reaches 70 psi. Always apply upperstructure parking brake before leaving upperstructure cab.
  • Page 55 Section 3 - Operation This Page Intentionally Left Blank 82104002...

  • Page 56: Remote Mode Power Train

    Section 3 - Operation REMOTE MODE POWER TRAIN Driving Undercarriage from Upperstructure Cab Note: Never tow a load using remote control drive. Operate the engine at full throttle. Undercarriage speed is controlled by the amount of travel pedal actuation. OAC2680 1.
  • Page 57 Section 3 - Operation With boom positioned over front of machine: • Forward Travel - Press and hold the forward travel joystick button (4). Fully depress brake pedal (2). Transmission Gear Indicator on LCD display will display a “1” on the left hand side of icon, indicating request for 1st gear engagement has been made: Allison Transmission Gear Indicator will then display a “1”...
  • Page 58 Section 3 - Operation With boom positioned over front of machine: • Reverse Travel - Press and hold the reverse travel joystick button (5). Fully depress brake pedal (2). Transmission Gear Indicator on LCD display will display an “R” on the left hand side of icon, indicating request for reverse gear engagement has been made: Allison Transmission Gear Indicator will then display an “R”...

  • Page 59: Steering The Undercarriage From Upperstructure Cab

    Section 3 - Operation Steering the Undercarriage from Upperstructure Cab OAC2280 On Left Hand Joystick, left-click steer control button to turn front wheels left. Right- click steer control button to turn front wheels right. UNEXPECTED DIRECTION OF TRAVEL. Before WARNING remote travel, check to be sure you are aware of orientation upperstructure...

  • Page 60: Typical Dig Cycle

    Section 3 - Operation TYPICAL DIG CYCLE Standard SAE Boom and Attachment Functions Prepare for boom and attachment function: 1. Position unit for efficient attachment usage. Notice!: While digging, pay close attention to boom position in relation to undercarriage components. In certain instances it is possible for the boom to come into contact with the undercarriage.
  • Page 61 Section 3 - Operation OAC2670 Standard SAE control pattern shown in illustration above. Note: Practice with controls in a safe, open area. Joysticks and pedals return to neutral position when released. 1. Pull back on right joystick (A) to raise boom far enough to clear all obstructions.
  • Page 62 Section 3 - Operation 2. Move left joystick to left (G) to swing left or to right (H) to swing right. 3. While pushing left joystick forward (F) to extend boom, push right joystick forward (B) to lower boom into position for start of cut. 4.
  • Page 63 Section 3 - Operation 5. If required, press left side of tilt switch (I) to tilt counterclockwise or right side of switch (J) to tilt clockwise. 6. While pushing forward on right joystick (B) to lower boom and force bucket into ground, pull back on left joystick (E) to retract boom and fill bucket.
  • Page 64 Section 3 - Operation 8. When bucket is full, or when boom is fully retracted, move right joystick to left (D) to close bucket. At same time pull right joystick back (A) to raise boom far enough to clear obstructions. 9.
  • Page 65 Section 3 - Operation 11. Move left joystick to left (G) or right (H) to align boom for next cut. Repeat steps 3 through 11. 82104002 3-15...

  • Page 66: Lifting & Placing A Load

    Section 3 - Operation LIFTING & PLACING A LOAD LIFTING & POSITIONING LOADS. Failure to plan a WARNING lift properly could result in death or serious injury. The automatic boom tilt brake will not prevent boom OW0021 from tilting in response to an external load. Load must be centered under bucket adapter with boom level from side to side.

  • Page 67: General

    Section 3 - Operation General There is a lift capacity difference between the excavator’s 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, both hydraulic and stability tipping limits, are not exceeded.

  • Page 68: Planning A Lift

    Section 3 - Operation Planning A Lift Note: Lift capacities are based on machine being on a firm, level surface and also no load being suspended beneath bucket adapter. 1. Determine the weight of the load including weight of slings, chains, bucket/ attachment (tool), and auxiliary lifting devices.

  • Page 69: Lift Capacity

    Section 3 - Operation LIFT CAPACITY LOAD RADIUS 10’ (3.0m) 15’ (4.6m) 20’ (6.1m) 25’ (7.6m) LOAD POINT HEIGHT MAXIMUM OVER OVER OVER OVER OVER OVER OVER OVER OVER OVER RADIUS SIDE SIDE SIDE SIDE SIDE 5715 5715 27’ 4” 5070 5070 20’...
  • Page 70 -698lbs. (317kg) Note: Bucket adjustment values are 87% of the actual bucket weights. Any weight adjustment for Gradall buckets not shown can be calculated by multiplying actual bucket weight by .87. • The load point is located on the bucket pivot point, including load listed for maximum radius.

  • Page 71: Remote Mode Engine Shutdown

    Section 3 - Operation REMOTE MODE ENGINE SHUTDOWN To shutdown the excavator, park in a safe location on flat level ground and away from other equipment and/or traffic lanes. From Upperstructure Cab: 1. Stop machine by releasing travel pedal to neutral position to engage digging brake.

  • Page 72: Return To Travel Mode

    Section 3 - Operation RETURN TO TRAVEL MODE Preparing Upperstructure for Undercarriage Operation 1. Position unit on level surface and release travel pedal to neutral position to engage digging brake. 2. Position boom in rest, allowing clearance for attachment. See “Boom Stow Procedure”...

  • Page 73: Boom Stow Procedure

    Section 3 - Operation Boom Stow Procedure 1. With teleboom extended, stow boom in boom rest. 2. Retract telescope boom until the boom position decal is visible in the bottom smaller hole in the main boom, as illustrated: OAC2690 Securing Unit for Driving Drive to and from job site only under the following conditions: •...

  • Page 74: 3.10 Parking The Excavator

    Section 3 - Operation 3.10 PARKING THE EXCAVATOR Precaution If the machine is in remote and must be shut down for an extended period of time, return the machine to conventional undercarriage operation. Avoid parking on roads or highways. If it cannot be avoided, or in case of emergency, display warning flags, flares or flashing lights.

  • Page 75: 3.11 Preservation & Storage

    Section 3 - Operation 3.11 PRESERVATION & STORAGE • Park the machine following the procedure on page 3-24. • Tape a note inside cab window indicating the person to be called in an emergency. • If machine is on an unpaved surface, be sure tires are resting on sturdy boards to prevent them from being frozen in soft ground.
  • Page 76 Section 3 - Operation This Page Intentionally Left Blank 3-26 82104002...

  • Page 77: Section 4 - Attachments

    • An overextended or overloaded excavator can tip over with little or no warning and cause death or serious injury to the operator and/or those working nearby. • Gradall cannot assure the ability of a non-approved attachment to perform its intended function safely.

  • Page 78: Excavating Buckets

    Section 4 - Attachments Excavating Buckets Size 36" (914mm) OAC0230 Ditching Buckets Size 60" (1.52m) OAC2240 82104002...

  • Page 79: Section 5 - Lubrication & Maintenance

    Always check hourmeter and date at beginning of shift to be certain services are performed at proper intervals. Perform service at whichever interval comes first. Note: Failure To Use Gradall Hydraulic Filter Elements Could Void Warranty. FALL HAZARD. Use extreme caution when checking WARNING items beyond your normal reach.

  • Page 80: General Maintenance Instructions

    • Apply a light coating of engine oil to all linkage pivot points. • Drain engine and gear cases after operating when oil is hot. • Check all lubricant and coolant levels when cool. MACHINE DAMAGE. Contact Gradall before welding WARNING on machine. Welding could damage wires, electronic processors, hoses, and tubes.

  • Page 81: Service & Maintenance Schedules

    Section 5 - Lubrication & Maintenance SERVICE & MAINTENANCE SCHEDULES 10 Hour Maintenance Schedule EVERY Follow Lubrication Windshield/Washer Mirrors Schedule Fluid Bottle (clean and adjust for proper visibility) (clean cab glass) OAC2350 50 Hour Maintenance Schedule EVERY Inspect Check Swing Follow Lubrication and Clean Transmission...

  • Page 82: 100 Hour Maintenance Schedule

    Section 5 - Lubrication & Maintenance 100 Hour Maintenance Schedule EVERY Check Boom Roller Alignment OAC2370 1st 30 Days (250 hrs Max) & 250 Hour Maintenance Schedule - (Upperstructure) 1st 30 DAYS Drain and Refill Follow Lubrication Apply Open Torque all Items Swing Transmission Schedule Listed in...

  • Page 83: 750 Hour Maintenance Schedule

    Section 5 - Lubrication & Maintenance 750 Hour Maintenance Schedule EVERY Remove, Clean Follow Lubrication Check Tilt Torque all Items and Replace Schedule Transmission Level Listed in Swing Transmission Torque Chart Breather OAC2390 1500 Hour Maintenance Schedule EVERY 1500 Drain and Refill Drain, Change Filter, Follow Lubrication Swing Transmission...

  • Page 84: Upperstructure Lubrication Schedule

    Section 5 - Lubrication & Maintenance UPPERSTRUCTURE LUBRICATION SCHEDULE Tilt Bearing 10 Hr Boom Cradle Pivot Pins Weekly Telescoping Boom Rollers (3 places) Boom Rollers (5 places) Hoist Cylinder Barrel Pins & Swing Bearing Hoist Cylinder Rod Ends Tool Cylinder Barrel Pin & Boom Cylinder Spherical Bearing Curved &...

  • Page 85: Undercarriage Lubrication Schedule

    Section 5 - Lubrication & Maintenance UNDERCARRIAGE LUBRICATION SCHEDULE 10 Hr Weekly Rear U-Joint Tie Rod End (Both Sides) Slip Joint & Middle U-Joint R.H. King Pin - Top & Bottom Steer Cylinder (Barrel End) L.H. King Pin - Top & Bottom Tie Rod at Steer Arm Steer Cylinder Rod End OAD0730...
  • Page 86 Section 5 - Lubrication & Maintenance 10 Hr Weekly Idler Arm Slack Adjusters & Drag Link Brake Cam Shafts Front U-Joint OAD0740 82104002...

  • Page 87: Section 6 - Emergency Procedures

    Section 6 - Emergency Procedures SECTION 6 - EMERGENCY PROCEDURES LOSS OF POWER The engine will de-rate if a problem develops. If this occurs, place the boom in the boom rest as soon as possible. Make all necessary repairs before continued operation.

  • Page 88: Towing

    Section 6 - Emergency Procedures 8. Once the boom is raised high enough to clear the cab and boom rest, swing into position over the boom rest. 9. While still supporting the boom with another machine, remove the test hose from the hoist up side of the circuit.

  • Page 89: Section 7 - Specifications

    SECTION 7 - SPECIFICATIONS PRODUCT SPECIFICATIONS Lubrication & Fluid Capacities Note: Lubricants described in this table are used in standard machines when they are shipped from Gradall Industries, Inc. Hydraulic System System Capacity ...............62 gallons (235 liters) ® Type of Oil ... Mobilfluid...

  • Page 90: Weight

    Operating Weight...............34,500 lb (15,689 kg) Gross Vehicle Axle Rating ............36,200 lb (16,420 kg) Note: Refer to detailed specification sheet for additional machine weight information. Specification sheets can be viewed/downloaded at www.gradall.com Dimensions D152 & D154 Wheelbase.................... 15.1 ft (4,8 m) Ground Clearance ................10 in (254 mm)

  • Page 91: Torque Chart

    Section 7 - Specifications TORQUE CHART To check Gradall torque values, set the torque wrench at 95% of the rated torque values and check fastener. If the torque wrench releases before the fastener moves, assume fastener torque is correct. When setting Gradall torque values, use the values given on the following chart.
  • Page 92 Section 7 - Specifications Front Axle Torque Check D152 • Ensure front axle u-bolt nuts are torqued to 370-395 lb-ft (8 nuts) D154 • Ensure front axle u-bolt nuts are torqued to 560-595 lb-ft (8 nuts) (BOTH SIDES OF FRONT AXLE) If replacement or torquing of nut(s) is required: •...
  • Page 93 Section 7 - Specifications Rear Axle Torque Check • Ensure rear axle cap screws are torqued to 560-595 lb-ft (8 screws) (BOTH SIDES OF REAR AXLE) OAC2410 If replacement or torquing of cap screw(s) is required, follow the pattern illustrated: Torque bolts in a 4-stage, criss- cross pattern: Stage 1 - 150-185 lb-ft...

  • Page 94: Fuses

    Section 7 - Specifications FUSES Fuse location and size designations are identified with the decals shown below. Upperstructure OAD0680 Undercarriage OAD0690 82104002...

  • Page 95: Index

    Index Index Left Hand Arm Pod ......2-16 Lift Capacity ........3-19 Approved Attachments ..... 4-1 Lifting a Load ........3-16 Attachment Operation ...... 4-1 Load Falling Hazard......1-9 Attachments ........4-1 Lubrication & Maintenance ....5-1 Lubrication Schedule, Undercarriage5-7 Boom Stow Procedure ....3-23 Lubrication Schedule, Upperstructure..
  • Page 96 Index Travel Hazard ........1-8 Upperstructure Cab Controls & Indica- tors ..........2-8 82104002...
  • Page 97 Hand Signals OY1090 OY1100 OY1110 EMERGENCY STOP - With both STOP - With either arm extended STOP ENGINE - Draw thumb or arms extended laterally, hands laterally, hand open downward, forefinger across throat. open downward, move arms back move arm back and forth. and forth.
  • Page 98 Gradall Industries, Inc. 406 Mill Ave SW New Philadelphia OH. 44663 Phone: (330) 339-2211 Customer Support Toll Free: (800) 445-4752 Fax: (330) 339-3579 www.gradall.com...

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D154

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