Gradall XL3100IV Operators Safety Manual
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Gradall XL3100IV Operators Safety Manual

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XL3100IV - XL4100IV - XL5100IV
This manual, and all manuals for the Gradall Hydraulic
Excavator product line, can be viewed or downloaded, free-of-
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Operator & Safety
Keep this manual with machine at all times.
(4x2) S/N 3120000244 & After
(4x4) S/N 3140000313 & After
(6x4) S/N 4100000461 & After
(6x6) S/N 4160000050 & After
S/N 5100000586 & After
December 10th, 2018
80804002
Revised
Manual

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Summary of Contents for Gradall XL3100IV

  • Page 1 (6x4) S/N 4100000461 & After (6x6) S/N 4160000050 & After S/N 5100000586 & After 80804002 Revised December 10th, 2018 This manual, and all manuals for the Gradall Hydraulic Excavator product line, can be viewed or downloaded, free-of- charge, at www.myexcavatormanuals.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/downloaded at www.mygradall.com Gradall is a registered trademark for hydraulic excavators, industrial mainte- nance machines, attachments and other components manufactured and marketed by Gradall Industries, Inc.
  • Page 3 Revision Log Revision Log REVISION LOG August 1, 2011 - A - Original Issue of Manual September 19, 2013 - B - Revised 10 and 50 hour Maintenance Schedules November 20, 2013 - C - Added Battery Spec to Section 7 May 1st, 2014 - D - Revised 1500 hour Maintenance Schedule and Transfer Case Spec.

  • 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: 80804002...

  • 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 Turn Signal/High Beam/Hazards Lever........2-28 Upperstructure Cab Components ..........2-30 Upperstructure Cab Controls & Indicators ........2-32 Electronic Monitoring Unit ............2-32 Right Hand Arm Pod ..............2-34 Left Hand Arm Pod..............2-36 Joystick Control Pattern Selection ........... 2-38 Joystick Controls ..............
  • Page 9 400 Hour Maintenance Schedule ..........5-7 Semi-Annual (750 Hour Maximum) Maintenance Schedule..5-8 Annual (1500 Hour Maximum) Maintenance Schedule ....5-9 Undercarriage Lubrication Schedules .........5-10 Monthly (125 Hour Maximum) Lubrication Schedule - XL3100IV..5-10 Monthly (125 Hour Maximum) Lubrication Schedule - XL4100IV & XL5100IV ..........5-12...
  • Page 10 Table of Contents XL3100IV..............5-14 Semi-Annual (750 Hour Maximum) Lubrication Schedule - XL4100IV & XL5100IV..........5-16 Upperstructure Lubrication Schedules........5-18 Daily or Shift (10 Hour Maximum) Lubrication Schedule ..5-18 Weekly (50 Hour Maximum) Lubrication Schedule ....5-19 Annual (1500 Hour Maximum) Lubrication Schedule....5-20 Operator Maintenance Instructions..........

  • 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. 80804002...

  • 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. 80804002...

  • 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 80804002...

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

    Section 2 - Pre-Operation and Controls SECTION 2 - PRE-OPERATION AND CONTROLS PRE-OPERATION CHECKS & INSPECTION Note: Complete all required maintenance before operating unit. FALL HAZARD. Use extreme caution when checking WARNING items beyond your normal reach. Use an approved ladder.

  • Page 26: Walk-Around Inspection

    Section 2 - Pre-Operation and Controls WALK-AROUND INSPECTION 16 17 19 20 OAC1890 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. Hydraulic Reservoir - Recommended fluid level on sight gauge (see page 5-22 for instructions); filler/breather cap secure and working; oil is clear. 5. Air Tanks - Check for damage/leaks; open petcocks to eliminate condensation. See page 5-30 for instructions.
  • Page 28 Section 2 - Pre-Operation and Controls 19. Engine Compartment - • Engine crankcase, check oil level & refill as required. See page 5-29 for instructions. Do not overfill. • Check engine coolant level at overflow bottle and refill as required. See page 5-28 for instructions.

  • Page 29: Safety Decals

    Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required. Upperstructure Decal Locations 80509018 80509015 80509007 80509015 80509018 80803001 (XL3100IV) 80703003 (XL4100IV) 80509008 (XL5100IV) 80509010 80509019 80503006 80509017 80509012...
  • Page 30 Section 2 - Pre-Operation and Controls 80509013 80509015 80509012 80509016 80509013 80373077 NO STEP 91143288 OAC0990 80509015 80804002...

  • Page 31: Undercarriage Decal Locations

    Section 2 - Pre-Operation and Controls Undercarriage Decal Locations 80503005 91143288 80509016 80509015 80509004 80509012 80783208 77383675 OAC1590 80804002...
  • Page 32 Section 2 - Pre-Operation and Controls 80509012 80483160 (ON FAN SHROUD) 80509014 AdBlue ONLY Diesel 80784165 80509015 80213104 OAC1601 80804002...
  • Page 33 Section 2 - Pre-Operation and Controls NOTES: 80804002...

  • Page 34: Undercarriage Cab Components

    Section 2 - Pre-Operation and Controls UNDERCARRIAGE CAB COMPONENTS OAC1610 2-10 80804002...
  • Page 35 Section 2 - Pre-Operation and Controls 1. Turn Signal/High Beam/Hazards Lever: See page 2-28 for details. 2. Steering Wheel: Turn steering wheel to left or right to steer the machine in the corresponding direction. 3. Horn Button: Depress button to sound horn. 4.

  • Page 36: Transmission Shift Selector

    Section 2 - Pre-Operation and Controls TRANSMISSION SHIFT SELECTOR MODE OAC1700 1. Digital Display 2. Mode Button: Pushbutton used to access/navigate prognostics/diagnostics. 3. Up Arrow: Pushbutton upshifts transmission when pressed. Also used to access/navigate prognostics/diagnostics. 4. Down Arrow: Pushbutton downshifts transmission when pressed. Also used to access/navigate prognostics/diagnostics.

  • Page 37: Prognostic Features

    Section 2 - Pre-Operation and Controls Prognostic Features If the wrench icon (1) illuminates briefly in the digital display (2) after ignition is turned to the “RUN” position, then prognostics are enabled. OAC1700 Oil Life Monitor When fluid is due for a change, the wrench icon (1) is illuminated and remains solid for two minutes after “Drive”...

  • Page 38: Accessing Prognostics

    Section 2 - Pre-Operation and Controls Accessing Prognostics When you are alerted via the wrench icon on the transmission shift selector that service is due, you can check the status by toggling through the shift selector display as follows. Be sure to park the vehicle on a level surface, shift to N (Neutral) and apply park brake before accessing prognostics through the shift selector Oil Life Monitor Simultaneously press the Up and Down arrows (1) two times.

  • Page 39: Resetting Prognostics

    Section 2 - Pre-Operation and Controls Resetting Prognostics Oil Life Monitor Press and hold Mode button (1) for approximately 10 seconds while in Oil Life Monitor mode. -Or- Perform the following shift sequence with the ignition on but the engine off. Do not stop the sequence for more than three seconds once you have started: N-D-N-D-N-R-N.

  • Page 40: Checking Fluid Levels

    Section 2 - Pre-Operation and Controls Checking Fluid Levels Use the following procedure to display oil level information. To enter the oil level function: 1. Park vehicle on a level surface, shift to N (Neutral) and apply the parking brake. 2.
  • Page 41 Section 2 - Pre-Operation and Controls • Low Fluid Level - “oL” is displayed (“oL” represents “Fluid (Oil) Level Check”) followed by “Lo” (“Lo” represents “Low Oil Level”) and the number of quarts the transmission fluid is low. OAC1810 Example: “oL Lo 02” indicates that 2 additional quarts of fluid will bring the fluid level within the middle of the “oK”...

  • Page 42: Diagnostic Codes

    Section 2 - Pre-Operation and Controls Diagnostic Codes To enter the diagnostic code function: 1. Bring the vehicle to a complete stop and apply the parking brake. 2. Simultaneously press the Up and Down arrows (1) five times. OAC1790 To read diagnostic codes in the digital display: Diagnostic codes will appear two characters at a time.

  • Page 43: Diagnostic Transmission Codes

    Section 2 - Pre-Operation and Controls Diagnostic Transmission Codes DIAGNOSTIC CODE CODE DESCRIPTION C1312 RETARDER REQUEST SENSOR, FAILED LOW C1313 RETARDER REQUEST SENSOR, FAILED HIGH P0122 PEDAL POSITION SENSOR, LOW VOLTAGE P0123 PEDAL POSITION SENSOR, HIGH VOLTAGE P0218 TRANSMISSION FLUID OVER TEMPERATURE P0602 TCM NOT PROGRAMMED P0610...
  • Page 44 Section 2 - Pre-Operation and Controls Diagnostic Transmission Codes, (cont’d) P0741 TORQUE CONVERTER CLUTCH SYSTEM, STUCK OFF P0776 PRESSURE CONTROL SOLENOID 2, STUCK OFF P0777 PRESSURE CONTROL SOLENOID 2, STUCK ON P0796 PRESSURE CONTROL SOLENOID 3, STUCK OFF P0797 PRESSURE CONTROL SOLENOID 3, STUCK ON P0842 TRANSMISSION PRESSURE SWITCH 1, LOW P0843...
  • Page 45 Section 2 - Pre-Operation and Controls P2714 PRESSURE CONTROL SOLENOID 4, STUCK OFF P2715 PRESSURE CONTROL SOLENOID 4, STUCK ON P2718 PRESSURE CONTROL SOLENOID 4, STUCK OPEN P2720 PRESSURE CONTROL SOLENOID 4 CONTROL, LOW P2721 PRESSURE CONTROL SOLENOID 4 CONTROL, HIGH P2723 PRESSURE CONTROL SOLENOID 1, STUCK OFF P2724...

  • Page 46: Undercarriage Cab Controls & Indicators

    Section 2 - Pre-Operation and Controls UNDERCARRIAGE CAB CONTROLS & INDICATORS Dash Panel RPM/X1000 p si 10 0 INTERAXLE 0 0 0 0 0 0 FUEL DIFFERENTIAL 1000 WATER °F HOURS 1/10 FRONT AXLE DRIVE BATTERY AXLE DIFFERENTIAL O IL P.S.I WIPER WASHER...

  • Page 47: Right Hand Dash Panel

    Section 2 - Pre-Operation and Controls Right Hand Dash Panel OAC1630 1. Information Display Area: See page 2-25 for details. 2. Ignition: Key Activated. See page 2-27 for details. 3. Travel/Remote Switch: See “Travel/Remote Display Area” on page 2-24. 4. Fan Speed: Rotary switch for heater and air conditioner (if equipped). 5.

  • Page 48: Travel/Remote Display Area

    Section 2 - Pre-Operation and Controls Travel/Remote Display Area OAC1640 1. Parking Brake Indicator: Illuminates red to indicate parking brake is activated (See page 3-8). Parking brake must be applied to start engine while in remote control mode. 2. Neutral Gear Indicator: Illuminates green to indicate unit is in neutral gear. Transmission must be in neutral gear to start engine in either remote control mode or travel mode.

  • Page 49: Information Display Area

    Section 2 - Pre-Operation and Controls Information Display Area UPPER CHASSIS STOP FRONT INTER AXLE AXLE AXLE DIFF DRIVE DIFF OAC1650 Note: When ignition is turned to the “RUN” position (see page 2-27 for details), the engine stop, check engine, and optional engine preheat displays illuminate for approximately two seconds and then go off.
  • Page 50 11. Axle Differential Lock Indicator: Illuminates green to indicate rear axle differential lock is engaged (XL3100IV). Illuminates green to indicate front rear tandem axle differential lock is engaged (XL4100IV & XL5100IV).

  • Page 51: 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 52: Turn Signal/High Beam/Hazards Lever

    Section 2 - Pre-Operation and Controls Turn Signal/High Beam/Hazards Lever The turn signal/high beam/hazards lever (1) operates the turn signals, hazards and low beam/high beam function for the headlights. OAC0830 Turn Signal/Hazards • Push the lever forward (2) to activate the right turn signal. •...
  • Page 53 Section 2 - Pre-Operation and Controls NOTES: 80804002 2-29...

  • Page 54: Upperstructure Cab Components

    Section 2 - Pre-Operation and Controls UPPERSTRUCTURE CAB COMPONENTS OAC0470 2-30 80804002...
  • Page 55 Section 2 - Pre-Operation and Controls 1. Operator Seat: See “Operator Seat Adjustments” on page 2-43. 2. Left Hand Arm Pod: See page 2-36 for details. 3. Foot Pedals: See “Driving Undercarriage from Upperstructure Cab” on page 3-19. 4. Left Hand Joystick: See “Joystick Controls” on page 2-39. 5.

  • Page 56: Upperstructure Cab Controls & Indicators

    Section 2 - Pre-Operation and Controls UPPERSTRUCTURE CAB CONTROLS & INDICATORS Electronic Monitoring Unit OAC1660 Note: When key is turned to the “RUN” position (see page 2-44 for details), the engine stop, check engine, and optional engine preheat displays illuminate for approximately two seconds and then go off.
  • Page 57 Section 2 - Pre-Operation and Controls 9. Check Engine Indicator: Illuminates yellow to indicate a malfunction. Stop engine and repair before continued use. 10. Joystick Control Pattern Selection Switch: See “Joystick Control Pattern Selection” on page 2-38. 11. Ignition: Key Activated. See page 2-44 for details. 12.

  • Page 58: Right Hand Arm Pod

    Section 2 - Pre-Operation and Controls Right Hand Arm Pod OAC0840 1. Engine Speed: Rotary switch. Rotate switch clockwise to increase engine rpm; rotate counterclockwise to decrease engine rpm. 2. Mode Select Switch: Depress front of switch (I) for fine grade mode. Depress back of switch (II) for dig mode.
  • Page 59 Section 2 - Pre-Operation and Controls 10. Auto Idle Override Switch: Depress front of switch (I) to activate auto idle. Depress back of switch (II) to deactivate auto idle. • With auto idle activated, engine speed will return to low idle after 7 seconds of hydraulic control inactivity.

  • Page 60: Left Hand Arm Pod

    Section 2 - Pre-Operation and Controls Left Hand Arm Pod OAC0850 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 2-46 for details. 3.
  • Page 61 Section 2 - Pre-Operation and Controls NOTES: 80804002 2-37...

  • Page 62: Joystick Control Pattern Selection

    The control pattern selection switch allows the operator to select from three joystick control patterns; GRADALL, SAE and JOHN DEERE. The pattern must be selected with the ignition key in the “OFF” position. If a new pattern is selected while the engine is running, it will not change until the engine is turned off then restarted.

  • Page 63: 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 position of the joystick control pattern switch located on the electronic monitoring unit to verify control pattern setting.
  • Page 64 Section 2 - Pre-Operation and Controls SAE Joystick Controls OAC0890 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 65 Section 2 - Pre-Operation and Controls GRADALL Joystick Controls OAC0900 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 66 Section 2 - Pre-Operation and Controls JOHN DEERE Joystick Controls OAC0910 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 67: Operator Seat Adjustments

    Section 2 - Pre-Operation and Controls Operator Seat Adjustments TILT SPE ED READ OPERATORS MANUAL OAC0510 Prior to starting engine adjust seat for position and comfort. 1. Weight Control Adjustment 2. Upper Seat Fore and Aft Adjustment Control 3. Lower Seat Fore and Aft Adjustment Control 4.

  • Page 68: 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 69: 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. 80804002 2-45...

  • Page 70: 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 electronic monitoring unit illuminates to indicate brake is applied. • With the engine running and the park brake switch in “OFF” position (1), park brakes are disengaged.

  • Page 71: Section 3 - Operation

    Section 3 - Operation SECTION 3 - OPERATION TRAVEL MODE ENGINE OPERATION Starting Engine from Undercarriage Cab 1. Perform walk-around inspection on page 2-2 2. Apply the parking brake. Put transmission in neutral. Using the travel/remote switch, select the travel position. 3.

  • Page 72: Cold Weather Starting Aids

    Section 3 - Operation Cold Weather Starting Aids • It is the owners responsibility to determine proper use of starting aid with regard to engine and starting aid manufacturer’s instruction. • An ether starting aid may be used with this engine only if it does not have the optional grid heater.

  • Page 73: Checks Before Undercarriage Operation

    Section 3 - Operation CHECKS BEFORE UNDERCARRIAGE OPERATION This section outlines the checks to be performed at the beginning of each work shift or at each change of operator. Refer to page 3-34 for procedure to check brakes after remote control operation and digging. Repair any deficiencies before driving or operating the equipment.

  • Page 74: Travel Mode Brake System

    Section 3 - Operation TRAVEL MODE BRAKE SYSTEM The air brake system includes service brakes, emergency brakes, parking brakes and digging brakes. NEW BRAKES. New brakes need increased stopping CAUTION distance. Brake capability will improve after several stops. Failure to stop may result in death or serious OW0031 injury.

  • Page 75: Service Brake

    Section 3 - Operation Service Brake • The operating pressure range for service brakes is 60-125 psi (414/862 kpa). • A dual air pressure gauge (1) is furnished to indicate pressure in front and rear portions of the system. RPM/X1000 INTERAXLE 0 0 0 0 0 0 FUEL...

  • Page 76: Emergency Brake

    The emergency brake functions only when air pressure has been lost from the brake system. EMERGENCY BRAKE. Emergency brake will not stop WARNING undercarriage in as short a distance as the service brakes. OW0021 XL3100IV EMERGENCY BRAKE APPLICATION EMERGENCY BRAKE APPLICATION (pressure lost in front) (pressure lost in rear) BRAKE PEDAL BRAKE PEDAL...
  • Page 77 Section 3 - Operation XL3100IV EMERGENCY BRAKE APPLICATION (pressure lost in front & rear) Automatic XL4100IV & XL5100IV EMERGENCY BRAKE APPLICATION (pressure lost in front & rear) Automatic • In the event air pressure is lost from the system, the spring brakes will begin to apply as pressure drops to 60 psi (414 kpa) and there will be a complete application when pressure decreases to 40 psi (276 kpa).

  • Page 78: Parking Brake

    Section 3 - Operation Parking Brake OAC0550 • Two parking brake controls are provided; one on undercarriage dashboard (1) and another on left hand pod panel in the upperstructure (2). The switch in the upperstructure cab is inoperative when in travel mode. Undercarriage park brake must remain applied when in remote mode.
  • Page 79 Section 3 - Operation NOTES: 80804002...

  • Page 80: Travel Mode Power Train

    Section 3 - Operation TRAVEL MODE POWER TRAIN Shifting Gears The transmission is automatically shifted with 6 forward speeds plus reverse. Ranges are selected by pressing and releasing the button for the desired range on the Transmission Shift Selector. For example, press and release the “N” button to select Neutral, the “D”...
  • Page 81 Section 3 - Operation RPM/X1000 INTERAXLE 0 0 0 0 0 0 FUEL DIFFERENTIAL 1000 WATE R HOURS 1/10 ° F FRONT AXLE DRIVE BATTERY AXLE DIFFERENTIAL P.S.I WIPER WASHER PULL TO APPLY PARKING BRAKE PUSH TO RELEASE OAC0620 1. Interaxle Differential Lock Switch (XL4100IV & XL5100IV only): The interaxle differential is controlled by a toggle lever mounted on the dashboard in the undercarriage cab.
  • Page 82 Section 3 - Operation Differential Lock Normally, differential lock will engage and disengage immediately in response to lock/unlock toggle; however, differential “wind-up”, or misalignment can delay engagement/disengagement. In this event, reversing direction of travel and/or operation of steering while traveling may relieve differential “wind-up”. Indicator light shows actual state of lock engagement/disengagement.
  • Page 83 Section 3 - Operation 3. Front Axle Drive Switch (if equipped): To Engage: • Stop machine. • Move toggle lever on dash to the “I” position. Notice!: Engaging front axle drive while undercarriage is moving will damage transfer case. Stop undercarriage before engaging front axle drive. To Disengage: •...

  • Page 84: Travel Mode Engine Shutdown

    Section 3 - Operation TRAVEL MODE ENGINE SHUTDOWN MACHINE ROLL-AWAY HAZARD. Always move park WARNING brake switch to "ON" position and stop engine before leaving cab. OW0021 When parking the excavator, park in a safe location on flat level ground and away from other equipment and/or traffic lanes.

  • Page 85: Remote Control Preparation

    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 to prepare undercarriage for remote control operation: 1.

  • Page 86: 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 87: 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 125 psi (862 kpa) to develop before operating unit in remote control. Low OW0021 air light indicator will turn off when pressure reaches 60 psi.

  • Page 88: Digging Brake

    Section 3 - Operation Digging Brake When in remote mode, the digging brakes are automatically applied upon releasing the travel pedal. • When activated, the digging brake is applied to all wheels to hold the undercarriage stationary while the excavator is digging. •...

  • Page 89: Remote Mode Power Train

    Section 3 - Operation REMOTE MODE POWER TRAIN Driving Undercarriage from Upperstructure Cab Remote travel is possible at all times except when indicated by an audible alarm and the travel lockout symbol being illuminated on the monitor. When this condition exists, the directional travel pedal must be slowly and carefully activated in both directions until the light and alarm turn off.

  • Page 90: Shifting Gears While In Remote Control

    Section 3 - Operation UNEXPECTED DIRECTION OF TRAVEL. Before WARNING remote travel, check to be sure you are aware of orientation upperstructure with regard OW0021 undercarriage. Confusion could cause travel in the opposite direction you are expecting. Note: Engage park brake to stop undercarriage if automatic digging brake fails. 2.

  • Page 91: 3.10 Steering System

    Section 3 - Operation 3.10 STEERING SYSTEM Notice!: Use of power steering while undercarriage is stopped causes unnecessary stress on system components and may cause serious damage to system. Holding steering wheel or remote steering pedal in full turn position will cause system to overheat.

  • Page 92: 3.11 Typical Dig Cycle

    Section 3 - Operation 3.11 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 93 Section 3 - Operation OAC0560 Joystick controls standard SAE control pattern. If tilt speed has been reduced for conditions, speed can be temporarily increased by depressing fast tilt button (1). Note: Practice with controls in a safe, open area. Joysticks and pedals return to neutral position when released.
  • Page 94 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 95 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. If necessary, use fast tilt button to return to fast tilt. 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 96 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 97 Section 3 - Operation 11. Move left joystick to left (G) or right (H) to align boom for next cut. Repeat steps 3 through 11. 80804002 3-27...

  • Page 98: 3.12 Lifting & Placing A Load

    Section 3 - Operation 3.12 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 99: 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 100: 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 101: 3.13 Lift Capacity

    Section 3 - Operation 3.13 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 102 -557lbs. (253kg) 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 103: 3.14 Remote Mode Engine Shutdown

    Section 3 - Operation 3.14 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 removing pressure from foot pedals. 2.

  • Page 104: 3.15 Return To Travel Mode

    Section 3 - Operation 3.15 RETURN TO TRAVEL MODE Preparing Upperstructure for Undercarriage Operation 1. Check operation of brakes after remote operation and digging. 2. Position unit on level surface, apply digging brake and stop engine. Check the following for damage; brake actuator chambers and rods, brake actuator brackets, and slack adjusters.

  • Page 105: 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: OAC0640 •...

  • Page 106: 3.16 Parking The Excavator

    Section 3 - Operation 3.16 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 107: 3.17 Preservation & Storage

    Section 3 - Operation 3.17 PRESERVATION & STORAGE • Park the machine following the procedure on page 3-36. • If it is impractical to activate functions regularly, and if freezing temperatures are expected, remove batteries and store in a warm location. •...
  • Page 108 Section 3 - Operation This Page Intentionally Left Blank 3-38 80804002...

  • Page 109: 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 110: Excavating Buckets

    Section 4 - Attachments Excavating Buckets Size Cu. Yd. 24" (610mm) 30" (762mm) 36" (914mm) 42" (1.07m) 48" (1.22m) OAC0590 Installation Procedure • Refer to "Adapter Attachment Installation" beginning on page 4-4. Ditching Buckets Size Cu. Yd. 30" (.80m) 60" (1.52m) 66"...

  • Page 111: Trenching Buckets

    Section 4 - Attachments Trenching Buckets Size Cu. Yd. 15" (381mm) 21" (533mm) OAC0720 Installation Procedure • Refer to "Adapter Attachment Installation" beginning on page 4-4. Pavement Removal Bucket Size Cu. Yd. 18" (.50m) 24" (.60m) OAC0730 28" (.70m) 40" (1.02m) Installation Procedure •...

  • Page 112: Dredging Bucket

    Section 4 - Attachments Dredging Bucket Size Cu. Yd. 72" (1.83m) 1-1/8 OAC0740 Installation Procedure • Refer to "Adapter Attachment Installation" beginning on page 4-4. Grading Blade Size Cu. Yd. 8’ (2.4m) OAC0750 Installation Procedure • Refer to "Adapter Attachment Installation" beginning on page 4-4. 80804002...

  • Page 113: Adapter Attachment Installation

    Section 4 - Attachments ADAPTER ATTACHMENT INSTALLATION OAC0760 1. Wedge Bolts 2. Bucket Adapter 3. Bucket Bars Installation Procedure: 1. Be sure wedge bolts (1) are secured in storage position (toward rear) and position bucket adapter (2) above bucket bar (3) as shown. OAC0770 2.
  • Page 114 Section 4 - Attachments 3. Move adapter toward "bucket close" position until outer end of adapter contacts bucket. Ensure proper alignment and continue to close until adapter contacts stops (1). OAC0790 4. Only use the nuts to move wedge bolts forward to position wedge between adapter and bucket bar.

  • Page 115: 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 116: 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 117: Service & Maintenance Schedules

    Section 5 - Lubrication & Maintenance SERVICE & MAINTENANCE SCHEDULES Daily or Shift (10 Hour) Maximum Maintenance Schedule * Drain air tanks daily. To prevent possible damage to emission controls components, wait a minimum of 10 minutes after shutting off engine before draining air tanks.

  • Page 118: Weekly (50 Hour Maximum) Maintenance Schedule

    Section 5 - Lubrication & Maintenance Weekly (50 Hour Maximum) Maintenance Schedule EVERY Check Tilt Check Tilt Check Swing Follow Lubrication Transmission Level Transmission Level Schedule Transmission Oil Level EVERY Check Power Inspect Air Filter Check Brake Drain Expansion Check Tire Steering Fluid Vacuator System Air...

  • Page 119: Monthly (125 Hour Maximum) Maintenance Schedule

    Section 5 - Lubrication & Maintenance Monthly (125 Hour Maximum) Maintenance Schedule EVERY Check Boom Roller Alignment EVERY Check Check Clean Hydraulic Check Axle Battery Reservoir Breather Oil Level Fan Belt Follow Lubrication Check Transfer Inspect Check Schedule and Clean Transmission Case Oil Level Cooler Cores...

  • Page 120: 1St 30 Days (250 Hrs Max) & 250 Hour Maintenance Schedule.5-6

    Section 5 - Lubrication & Maintenance 1st 30 Days (250 hrs Max) & 250 Hour Maintenance Schedule 1st 30 DAYS Drain and Refill Drain and Refill Apply Open Follow Lubrication Torque all Items Swing Transmission Tilt Transmission Gear Lube to Schedule Listed in Tilt Gear Teeth...

  • Page 121: 400 Hour Maintenance Schedule

    Section 5 - Lubrication & Maintenance 400 Hour Maintenance Schedule EVERY Change Engine Replace DEF Oil and Injector Unit Filter Filter OAC2031 80804002...

  • Page 122: Semi-Annual (750 Hour Maximum) Maintenance Schedule

    Section 5 - Lubrication & Maintenance Semi-Annual (750 Hour Maximum) Maintenance Schedule EVERY Remove, Clean Follow Lubrication Torque all Items and Replace Schedule Listed in Swing Transmission Torque Chart Breather EVERY Clean Change Fuel Check Clean Fuel Hydraulic Differential Differential Filter Strainer Fluid &...

  • Page 123: Annual (1500 Hour Maximum) Maintenance Schedule

    Section 5 - Lubrication & Maintenance Annual (1500 Hour Maximum) Maintenance Schedule EVERY 1500 Drain and Refill Drain, Change Filter, Follow Lubrication Swing Transmission and Refill Hydraulic Schedule Cab Heater Oil Reservoir EVERY 1500 Change Drain and Refill Change Hydraulic Engine Coolant Steering System Transmission...

  • Page 124: Undercarriage Lubrication Schedules

    Section 5 - Lubrication & Maintenance UNDERCARRIAGE LUBRICATION SCHEDULES Monthly (125 Hour Maximum) Lubrication Schedule - XL3100IV Grease (extreme pressure #2) EVERY Drive Shaft Splines Universal Joints King Pin Pivot Tie Rod Pivot Slack Adjuster 4 x 2 King Pin Pivot...
  • Page 125 Section 5 - Lubrication & Maintenance Grease (extreme pressure #2) EVERY Slack Adjusters Rear 4 x 2 DRIVE SHAFT Universal Joints Drive Shaft Splines Universal Joints 4 x 4 TRANSFER CASE AND DRIVE SHAFT Drive Shaft Drive Shaft Universal Joints Universal Splines Splines...

  • Page 126: Monthly (125 Hour Maximum) Lubrication Schedule - Xl4100Iv & Xl5100Iv

    Section 5 - Lubrication & Maintenance Monthly (125 Hour Maximum) Lubrication Schedule - XL4100IV & XL5100IV Grease (extreme pressure #2) EVERY Drive Shaft Splines Universal Joints Slack Adjuster Wheel End King Pin Pivot Slack Adjuster Front Steering Column Tie Rod Pivot King Pin Pivot U-Joints Tie Rod Pivot...
  • Page 127 Section 5 - Lubrication & Maintenance Grease (extreme pressure #2) EVERY Slack Adjusters Universal Joints Rear Universal Joints Universal Joints Drive Shaft Drive Shaft Universal Splines Splines Joints Universal Joints Drive Shaft Drive Shaft Universal Joints Splines Walking Beam Pivot Splines * - Number of Lube Points - Added Number of Lube Points if 6x6...

  • Page 128: Semi-Annual (750 Hour Maximum) Lubrication Schedule

    Section 5 - Lubrication & Maintenance Semi-Annual (750 Hour Maximum) Lubrication Schedule - XL3100IV Grease (extreme pressure #2) EVERY Brake Camshafts Brake 4 x 2 Camshafts FRONT Front STEERING AXLE 4 x 4 FRONT DRIVE AXLE Steering Gear Dirt Seal...
  • Page 129 Section 5 - Lubrication & Maintenance Grease (extreme pressure #2) EVERY Brake Camshafts Rear * - Number of Lube Points - Added Number of Lube Points if 4x4 OAC1431 80804002 5-15...

  • Page 130: Semi-Annual (750 Hour Maximum) Lubrication Schedule

    Section 5 - Lubrication & Maintenance Semi-Annual (750 Hour Maximum) Lubrication Schedule - XL4100IV & XL5100IV Grease (extreme pressure #2) EVERY Brake Brake Camshafts Camshafts Front Steering Gear Dirt Seal * - Number of Lube Points - Added Number of Lube Points if 6x6 OAC0031 5-16 80804002...
  • Page 131 Section 5 - Lubrication & Maintenance Grease (extreme pressure #2) EVERY Brake Camshafts Rear * - Number of Lube Points - Added Number of Lube Points if 6x6 OAC0041 80804002 5-17...

  • Page 132: Upperstructure Lubrication Schedules

    Section 5 - Lubrication & Maintenance UPPERSTRUCTURE LUBRICATION SCHEDULES Daily or Shift (10 Hour Maximum) Lubrication Schedule Grease (extreme pressure) EVERY * - Number of Lube Points OAC0051 5-18 80804002...

  • Page 133: Weekly (50 Hour Maximum) Lubrication Schedule

    Section 5 - Lubrication & Maintenance Weekly (50 Hour Maximum) Lubrication Schedule Grease (extreme pressure) EVERY * - Number of Lube Points OAC0061 80804002 5-19...

  • Page 134: Annual (1500 Hour Maximum) Lubrication Schedule

    Section 5 - Lubrication & Maintenance Annual (1500 Hour Maximum) Lubrication Schedule Grease (extreme pressure) EVERY 1500 * - Number of Lube Points OAC0081 5-20 80804002...

  • Page 135: Operator Maintenance Instructions

    Section 5 - Lubrication & Maintenance OPERATOR MAINTENANCE INSTRUCTIONS 10 Hours Fuel Level Check OAC1030 OW0990 0 0 0 0 0 0 FUEL 10 00 FRONT AXLE DRIVE BATTERY OAC1040 1. Check fuel gauge (1) located on dash panel in undercarriage cab. 2.
  • Page 136 Section 5 - Lubrication & Maintenance Hydraulic Oil Level Check OAC1030 OW1030 OAC1930 1. Be sure machine is level, boom is level and retracted and bucket is open. 2. Perform shutdown procedure on page 3-14 or page 3-33. 3. Check level of hydraulic oil at the sight gauge (1) on the hydraulic tank (2). The oil level should be visible in the upper gauge window.
  • Page 137 Section 5 - Lubrication & Maintenance 5. Remove dust cap from pressure fill port (5). Locate female coupling from tool kit and attach to pressure fill port. Add hydraulic fluid to level where oil is visible in upper gauge window. 6.
  • Page 138 Section 5 - Lubrication & Maintenance Hydraulic Tank Element Change (as filter indicator light indicates) OAC1940 1. Perform shutdown procedure on page 3-14 or page 3-33. 2. Locate reservoir breather (1) mounted on hydraulic tank (2). 3. Depress breather plunger (3) to relieve all hydraulic reservoir pressure. 5-24 80804002...
  • Page 139 Section 5 - Lubrication & Maintenance 4. Remove bolts (4) on return filter to allow removal of filter cover (5). 5. Remove old filter element (6) and replace with new element. 6. Replace filter cover (5) and bolts (4). (Torque bolts to 200-225 lb-in). 80804002 5-25...
  • Page 140 Section 5 - Lubrication & Maintenance Air Filter Restriction Indicator Check OAC1030 OW1010 OAC1080 1. Perform shutdown procedure on page 3-14 or page 3-33. 2. Locate air cleaner (1) and check restriction indicator (2). If red band is visible, filter(s) must be replaced. 3.
  • Page 141 Section 5 - Lubrication & Maintenance Air Filter Element Change (as restriction indicator indicates) 1. Unlock air cleaner cover (4), turn counterclockwise and remove from air cleaner body (5). 2. Remove outer primary element (6) and inspect for damage. Damaged elements must not be reused.
  • Page 142 Section 5 - Lubrication & Maintenance Engine Coolant Level Check OAC1030 OAC1160 TOP VIEW OF POWER UNIT SHOWN HOT LEVEL COLD LEVEL OAC1950 1. Perform shutdown procedure on page 3-14 or page 3-33. 2. Open the engine cover. 3. Check coolant level in overflow bottle (1). When coolant is hot, level should be at the “HOT LEVEL”...
  • Page 143 Section 5 - Lubrication & Maintenance Engine Oil Level Check OAC1030 OW1020 OAC1060 1. Perform shutdown procedure on page 3-14 or page 3-33. 2. Open the engine cover. 3. Remove dipstick (1) and check oil mark. The oil should be between the full (2) and add (3) marks within the crosshatched area of the dipstick.

  • Page 144: 50 Hours

    Section 5 - Lubrication & Maintenance 50 Hours Check & Drain Air Tanks OAC1070 OAC1150 OAC1190 1. Perform shutdown procedure on page 3-14 or page 3-33. 2. Locate air tanks (1). 3. Loosen drain cocks (2) to drain any moisture from air tanks. If significant moisture is found, check operation of air drier.
  • Page 145 Section 5 - Lubrication & Maintenance Drain Fuel/Water Separator OW0980 OW1000 OAC1960 1. Perform shutdown procedure on page 3-14 or page 3-33. 2. Locate fuel/water separator on front fuel tank mount (1). 3. Loosen drain cock (3) on underside of fuel filter (2) and allow all water to drain into a glass until clear fuel is visible.
  • Page 146 Section 5 - Lubrication & Maintenance Power Steering Fluid Check OAC1070 OAC1170 TOP VIEW OF POWER UNIT SHOWN OAC1200 1. Perform shutdown procedure on page 3-14 or page 3-33. 2. Open the engine cover. 3. Locate power steering reservoir (1). Remove dipstick (2) and check fluid mark. The fluid should be between the full (3) and add (4) marks within the crosshatched area of the dipstick.
  • Page 147 Section 5 - Lubrication & Maintenance Tire Air Pressure Check OAC1070 OW1040 1. Perform shutdown procedure on page 3-14 or page 3-33. 2. Remove valve stem cap. 3. Check tire pressure using a good quality gauge. 4. Add air if required (inflate tires to air pressure located on sidewall of equipped tire).

  • Page 148: 100 Hours

    Section 5 - Lubrication & Maintenance 100 Hours Replace Hydraulic Reservoir Breather OAC2050 OW1030 OAC1970 1. Perform shutdown procedure on page 3-14 or page 3-33. 2. Locate reservoir breather (1) mounted on hydraulic tank (2). 3. Depress breather plunger (3) to relieve hydraulic reservoir pressure. 4.
  • Page 149 Section 5 - Lubrication & Maintenance Battery Check OAC2050 OW1080 OAC1120 1. Perform shutdown procedure on page 3-14 or page 3-33. 2. Open the battery box cover. 3. Wearing eye protection, visually inspect the batteries (1). Check terminals for corrosion. Replace battery if it has a cracked, melted or damaged case. 4.

  • Page 150: 750 Hours

    Section 5 - Lubrication & Maintenance 750 Hours Replace In-Line Pilot Filter OAC1090 OW1180 OAC1980 In-Line Pilot Filter Element 1. Perform shutdown procedure on page 3-14 or page 3-33. 2. Locate in-line pilot filter (1) located on hydraulic tank (2). 3.
  • Page 151 Section 5 - Lubrication & Maintenance Automatic Slack Adjuster Check OAC1090 OAC1100 Note: Brake actuator chamber is shown with digging brake applied and with brake worn to a point just before automatic adjustment. If orange band is visible, notify maintenance personnel for adjustment or repair. 1.
  • Page 152 Section 5 - Lubrication & Maintenance NOTES: 5-38 80804002...

  • Page 153: 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 154: 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 155: 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. Engine Crankcase Oil Capacity with Filter Change ............29.6 quarts (28 liters) Type of Oil: See approved oils on Sheets 228.3 &...
  • Page 156 Front Axle (XL3100IV 4x4) Capacity..................27 pints (12,8 liters) Type of Fluid .................80w90 (1440-3126) Front Axle Wheel Ends (XL3100IV 4x2; XL4100IV 6x4 & XL5100IV 6x4) Capacity..................4 ounces (0,1 liters) Type of Fluid .................80w90 (1440-3126) Front Axle (XL4100IV 6x6 & XL5100IV 6x6) Capacity..................

  • Page 157: Tires

    Section 7 - Specifications Swing Bull Gear Capacity ....................as required Type of Fluid ..............Extreme Pressure Lube #2 Tilt Transmission Capacity ................. 32-35 ounces (0,9-1,0 liters) Type of Fluid .................80w90 (1440-3126) Tilt Bull Gear Capacity ....................as required Type of Fluid ..............Open Gear Lube (8664-1304) Grease Fittings Capacity ....................

  • Page 158: Weight

    Section 7 - Specifications Weight XL3100IV Operating Weight (4x2) .............40,930 lb (18,566 kg) Operating Weight (4x4) .............41,720 lb (18,924 kg) Gross Vehicle Axle Rating (4x2)..........41,250 lb (18,711 kg) Gross Vehicle Axle Rating (4x4)..........44,250 lb (20,071 kg) XL4100IV Operating Weight (6x4) .............49,684 lb (22,536 kg) Operating Weight (6x6) .............50,925 lb (23,099 kg)

  • Page 159: Dimensions

    Section 7 - Specifications Dimensions XL3100IV Wheelbase ....................13.4 ft (4,1 m) Ground Clearance ................10 in (254 mm) Transport Length (without bucket) ............23.3 ft (7,1 m) Transport Height (without bucket)............11.1 ft (3,4 m) Transport Width (without bucket) .............8.6 ft (2,6 m) XL4100IV Wheelbase ....................14.2 ft (4,3 m)

  • Page 160: 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 161 Section 7 - Specifications Tilt Transmission Quantity ..................31 pints (14,7 liters) Thread Size (grade) ..............80w90 (1440-3126) Torque (lubricated) ............200-215 lb-ft (272-292 Nm) Wheel Lug Nuts Quantity .........................ALL Thread Size (grade) ..................3/4-10 (8) Torque (lubricated) ............450-500 lb-ft (610-678 Nm) Front Axle U-Bolt Nuts Quantity .........................ALL Thread Size (grade) ..................
  • Page 162 Section 7 - Specifications Rear Axle Mounting Bolts (XL3100IV) Quantity ........................8 Thread Size (grade)..................7/8-14 (8) (VIEW FROM REAR OF MACHINE) TORQUE OAC1560 SEQUENCE Torque bolts in a 4 stage, criss-cross pattern: Torque (Stage 1).............. 150-185 lb-ft (203-251 Nm) Torque (Stage 2).............. 280-315 lb-ft (380-427 Nm) Torque (Stage 3)..............

  • Page 163: Fuses

    Section 7 - Specifications FUSES Fuse location and size designations are identified with the decals shown below. Upperstructure SPARE BATTERY POWER 80763098 REV. - SPARE BAT POWER #1 SPARE BAT POWER #2 ATTENTION: USE FUSE SIZES AS DESIGNATED. AC FAN POWER USING THE WRONG FUSE SIZE CAN BOOM LIGHT POWER CAUSE DAMAGE TO ELECTRICAL...
  • Page 164 Section 7 - Specifications This Page Intentionally Left Blank 7-10 80804002...

  • Page 169: Index

    Index Index Adapter Attachment Installation 4-5–4-6 Fuel Level ........5-21 Air Filter Element......5-27 Fuel Tank ..........7-2 Air Filter Restriction Indicator ..5-26 Fuel/Water Separator......5-31 Air Tanks ........5-30 Fuse Panel........7-9 Approved Attachments ..... 4-1 Attachment Operation ...... 4-1 Grading Blade ........4-4 Attachments ........
  • Page 170 Index Daily/Shift (10 Hour Max) ..5-18 Weekly (50 Hour Max) ....5-19 Tip Over Hazard........1-9 Tire Pressure......5-33, 7-3 Tires ..........7-3 Operation, Remote Control..... 3-15 Transfer Case ........7-1 Operation, Travel Mode....3-1 Transmission........7-1 Operator Maintenance Instructions 5-21 Travel Hazard........1-8 Operator Seat .........
  • Page 171 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 172 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 Gradall Europe Division of Tieluiska Harkkokatu 6 FI-05800 Hyvinkää, Finland Tel. +358 (0)20 759 0400 Fax. +358 (0)19 485 278 VAT:FI05973039 www.gradalleurope.com...

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