Gradall XL3100III Operators Safety Manual
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Gradall XL3100III Operators Safety Manual

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Operator & Safety
Keep this manual with machine at all times.
XL3100III - XL4100III - XL5100III
(4x2) S/N 3120000116 & After; including 3120000103
(6x4) S/N 4100000224 & After; including 4100000188
(4x4) S/N 3140000231 & After
(6x6) S/N 4160000026 & After
S/N 5100000540 & After
80854002
Revised
February 23rd, 2021
Manual

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Summary of Contents for Gradall XL3100III

  • Page 1 Operator & Safety Manual Keep this manual with machine at all times. XL3100III - XL4100III - XL5100III (4x2) S/N 3120000116 & After; including 3120000103 (4x4) S/N 3140000231 & After (6x4) S/N 4100000224 & After; including 4100000188 (6x6) S/N 4160000026 & After S/N 5100000540 &...
  • 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 maintenance machines, attachments and other components manufactured and marketed by Gradall Industries, Inc.
  • Page 3 Revision Log Revision Log REVISION LOG July 23rd, 2010 - A - Original Issue of Manual November 20th, 2013 - B - Added Battery Spec to Section 7 October 25th, 2017 - C - 80854002_Revisions_RevC December 7th, 2018 - D - Op Manual Revision Log.xlsx February 23rd, 2021 - E - Op Manual Revision Log.xlsx 80854002...

  • 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: 80854002...

  • 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 Joystick Controls ..............2-30 Operator Seat Adjustments............2-34 Ignition..................2-35 Intermittent Wiper/Washer ............2-36 Park Brake Switch..............2-37 Section 3 - Operation Travel Mode Engine Operation............. 3-1 Starting Engine from Undercarriage Cab ........3-1 Normal Engine Operation............3-1 Cold Weather Starting Aids............
  • 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 - XL3100III ..5-10 Monthly (125 Hour Maximum) Lubrication Schedule - XL4100III & XL5100III...........5-12 Semi-Annual (750 Hour Maximum) Lubrication Schedule - XL3100III...............5-14...
  • Page 10 Table of Contents 10 Hours................... 5-21 50 Hours................... 5-30 125 Hours................. 5-34 750/1500 Hours................ 5-36 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 ........

  • 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. 80854002...

  • 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. 80854002...

  • 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 80854002...

  • 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 13 14 OAC0380 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. Air Tanks - Check for damage/leaks; open petcocks to eliminate condensation. See page 5-30 for instructions. 5. Worklights- Clean, undamaged and aligned properly. 6. Upperstructure Cab - • General appearance; no visible damage; Operator & Safety manual located in manual drawer.
  • Page 28 Section 2 - Pre-Operation and Controls 18. 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 (XL3100III) 80703003 (XL4100III) 80509008 (XL5100III) 80509010 80509019 80509009 80509017 80509012...
  • Page 30 Section 2 - Pre-Operation and Controls 80509013 80509015 80509012 80509016 80509013 80373077 NO STEP 91143288 80509015 OAC0990 80854002...

  • Page 31: Undercarriage Decal Locations

    Section 2 - Pre-Operation and Controls Undercarriage Decal Locations 80483160 80509012 77383675 80213104 OAC1400 NOTE: MODEL XL3100III ILLUSTRATED 80854002...
  • Page 32 REAR OF CAB 80509014 80509006 80509029 80509016 CONTACT GRADALL BEFORE WELDING ON MACHINE. WELDING COULD DAMAGE WIRES, ELECTRONIC PROCESSORS, HOSES, AND TUBES. PRIOR TO WELDING, TURN OFF IGNITION, UNPLUG ALL ELECTRONIC PROCESSORS AND DISCONNECT POSITIVE (+) AND NEGATIVE (-) BATTERY CABLES FROM BATTERY POSTS ONLY.
  • Page 33 Section 2 - Pre-Operation and Controls NOTES: 80854002...

  • Page 34: Undercarriage Cab Components

    Section 2 - Pre-Operation and Controls UNDERCARRIAGE CAB COMPONENTS OAC0420 2-10 80854002...
  • Page 35 Section 2 - Pre-Operation and Controls 1. Turn Signal/High Beam/Hazards Lever: See page 2-18 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: Undercarriage Cab Controls & Indicators

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

  • Page 37: Right Hand Dash Panel

    Section 2 - Pre-Operation and Controls Right Hand Dash Panel CHASSIS UPPER STOP STOP FRONT INTER AXLE AXLE AXLE DIFF DRIVE DRIVE TRAVEL MAIN LEFT RIGHT REMOTE OAC0440 1. Information Display Area: See page 2-15 for details. 2. Ignition: Key Activated. See page 2-17 for details. 3.

  • Page 38: Travel/Remote Display Area

    Section 2 - Pre-Operation and Controls Travel/Remote Display Area TRAVEL RIGHT MAIN LEFT REMOTE OAC0450 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.

  • Page 39: Information Display Area

    9. Axle Differential Lock Indicator: Illuminates green to indicate rear axle differential lock is engaged (XL3100III). Illuminates green to indicate front rear tandem axle differential lock is engaged (XL4100III & XL5100III). 10. Engine Brake Indicator (if equipped): Illuminates green if engine brake is activated.
  • Page 40 Section 2 - Pre-Operation and Controls 11. Rotating Beacon Indicator (if equipped): Illuminates green if beacon is activated. 12. Low Air Indicator: Illuminates red to indicate air system pressure is below minimum operating pressure. An audible alarm is also activated. Do not move undercarriage while illuminated.

  • Page 41: 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 42: 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 43 Section 2 - Pre-Operation and Controls NOTES: 80854002 2-19...

  • Page 44: Upperstructure Cab Components

    Section 2 - Pre-Operation and Controls UPPERSTRUCTURE CAB COMPONENTS OAC0470 2-20 80854002...
  • Page 45 Section 2 - Pre-Operation and Controls 1. Operator Seat: See “Operator Seat Adjustments” on page 2-34. 2. Left Hand Arm Pod: See page 2-26 for details. 3. Foot Pedals: See “Driving Undercarriage from Upperstructure Cab” on page 3-22. 4. Left Hand Joystick: See “Joystick Controls” on page 2-30. 5.

  • Page 46: Upperstructure Cab Controls & Indicators

    Section 2 - Pre-Operation and Controls UPPERSTRUCTURE CAB CONTROLS & INDICATORS Electronic Monitoring Unit OAC0490 Note: When key is turned to the “RUN” position (see page 2-35 for details), the engine stop, check engine, and optional engine preheat displays illuminate for approximately two seconds and then go off.
  • Page 47 Section 2 - Pre-Operation and Controls 10. Engine Stop Indicator: Illuminates red and a pulsing alarm is activated to indicate excessive engine temperature or low engine oil pressure. Stop engine immediately and repair before continued use. 11. Low Air Indicator: Illuminates red to indicate air system pressure is below minimum operating pressure.

  • Page 48: 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 49 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 50: 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 2-37 for details. 3.
  • Page 51 Section 2 - Pre-Operation and Controls NOTES: 80854002 2-27...

  • Page 52: 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 53 Section 2 - Pre-Operation and Controls Joystick Control Pattern Selection (XL3100III - 4X2 s/n 3120000135 & After; 4X4 s/n 3140000240 & After) (XL4100III - 6X4 s/n 4100000270 & After; 6X6 s/n 4160000029 & After) (XL5100III - s/n 5100000560 & After) The control pattern selection switch allows the operator to select from three joystick control patterns;...

  • Page 54: 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 55 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 56 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 57 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 58: 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 59: 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 60: 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. 2-36 80854002...

  • Page 61: 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 brake is released.
  • Page 62 Section 2 - Pre-Operation and Controls NOTES: 2-38 80854002...

  • Page 63: 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 64: 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 65: 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 3-37 for procedure to check brakes after remote control operation and digging. Repair any deficiencies before driving or operating the equipment.

  • Page 66: 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 67: 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 FUEL 0 0 0 0 0 0...

  • Page 68: 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 XL3100III EMERGENCY BRAKE APPLICATION EMERGENCY BRAKE APPLICATION (pressure lost in front) (pressure lost in rear) BRAKE PEDAL BRAKE PEDAL...
  • Page 69 Section 3 - Operation XL3100III EMERGENCY BRAKE APPLICATION (pressure lost in front & rear) Automatic XL4100III & XL5100III 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 70: 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 on when in remote mode.
  • Page 71 Section 3 - Operation NOTES: 80854002...

  • Page 72: Travel Mode Power Train

    Section 3 - Operation TRAVEL MODE POWER TRAIN Shifting Gears The transmission is a manually shifted, non-synchronized gearbox with 8 forward speeds plus Lo and reverse. In lower gears, use only enough engine speed to get the undercarriage rolling easily. Use more engine speed for each successive upshift until reaching desired cruising speed.
  • Page 73 Section 3 - Operation OAC0610 1. Gear Shift Lever 2. Accelerator Pedal 3. Brake Pedal 4. Clutch Pedal Double-Clutching Although double-clutching procedures are broken down into separate steps, performing these steps should be rapid and smooth. The following double-clutching procedures apply to shifts within a gear range (LO through 4th gears and 5th through 8th gears).
  • Page 74 Section 3 - Operation Precautions: • For a smooth start, select a starting gear that will provide sufficient reduction for the load and terrain. • Always use normal double-clutching procedures when making shifts. • Never slam or jerk the shift lever to complete gear engagement. •...
  • Page 75 Section 3 - Operation Downshifting: The following procedure covers downshifting from 8th gear to LO gear. This procedure can be applied to downshifts from other gears. ENGINE DAMAGE. Never downshift when CAUTION undercarriage speed will cause engine to over-rev in next lower gear or serious damage to engine may OW0031 result.
  • Page 76 Section 3 - Operation RPM/X1000 INTERAXLE FUEL 0 0 0 0 0 0 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 (XL4100III & XL5100III only): The interaxle differential is controlled by a toggle lever mounted on the dashboard in the undercarriage cab.
  • Page 77 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 78 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 79: 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 80: 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 81: 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 82: 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 83: 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 84: 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 85: 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 86: 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 87: 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 88 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 89 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 90 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 91 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 92 Section 3 - Operation 11. Move left joystick to left (G) or right (H) to align boom for next cut. Repeat steps 3 through 11. 3-30 80854002...

  • Page 93: 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 94: 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 95: 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 96: 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 97 -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 98: 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 99: 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 100: 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 101: 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 102: 3.17 Preservation & Storage

    Section 3 - Operation 3.17 PRESERVATION & STORAGE • Park the machine following the procedure on page 3-39. • If it is impractical to activate functions regularly, and if freezing temperatures are expected, remove batteries and store in a warm location. •...

  • Page 103: 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 104: 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 105: Trenching Buckets

    Section 4 - Attachments Trenching Buckets Size Cu. Yd. 15" (381mm) 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 106: 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. 80854002...

  • Page 107: 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 108 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 109: 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 110: 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 111: Service & Maintenance Schedules

    Section 5 - Lubrication & Maintenance SERVICE & MAINTENANCE SCHEDULES Daily or Shift (10 Hour Maximum) Maintenance Schedule EVERY Mirrors Follow Lubrication Windshield/Washer (clean and adjust Schedule Fluid Bottle for proper visibility) (clean cab glass) EVERY Air Filter Check Engine Check Engine Check Hydraulic Check Hydraulic...

  • Page 112: Weekly (50 Hour Maximum) Maintenance Schedule

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

  • Page 113: Monthly (125 Hour Maximum) Maintenance Schedule

    Reservoir Level Schedule and Clean Transmission Cooler Cores Oil Level Check Wheel Check Transfer End Oil Levels Case Oil Level (XL4100III & XL5100III 6 x 6 Only) (XL3100III 4 x 4 Only) (XL4100III & XL5100III6 x 6 Only) OAC1541 80854002...

  • Page 114: 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 115: 400 Hour Maintenance Schedule

    Section 5 - Lubrication & Maintenance 400 Hour Maintenance Schedule EVERY Change Engine Oil and Filter OAC0131 80854002...

  • Page 116: 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 Change Fuel Clean Fuel Hydraulic Differential Differential Filter Strainer Fluid &...

  • Page 117: Annual (1500 Hour Maximum) Maintenance Schedule

    Change Change Differential Differential Transfer Case Oil In-Line High Pressure (XL3100III 4 x 4 Only) Filter Pilot Filter (XL4100III & XL5100III 6 x 6 Only) OAC1550 - Unless hydraulic fluid is analyzed semi-annually to determine level of contamination, system must drained, flushed and replenished on an annual basis.

  • Page 118: Undercarriage Lubrication Schedules

    Section 5 - Lubrication & Maintenance UNDERCARRIAGE LUBRICATION SCHEDULES Monthly (125 Hour Maximum) Lubrication Schedule - XL3100III 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 119 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 120: Monthly (125 Hour Maximum) Lubrication Schedule

    Section 5 - Lubrication & Maintenance Monthly (125 Hour Maximum) Lubrication Schedule - XL4100III & XL5100III 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 121 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 122: Semi-Annual (750 Hour Maximum) Lubrication Schedule

    Section 5 - Lubrication & Maintenance Semi-Annual (750 Hour Maximum) Lubrication Schedule - XL3100III 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 123 Section 5 - Lubrication & Maintenance Grease (extreme pressure #2) EVERY Brake Camshafts Rear * - Number of Lube Points - Added Number of Lube Points if 4x4 OAC1431 80854002 5-15...

  • Page 124: Semi-Annual (750 Hour Maximum) Lubrication Schedule

    Section 5 - Lubrication & Maintenance Semi-Annual (750 Hour Maximum) Lubrication Schedule - XL4100III & XL5100III 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 80854002...
  • Page 125 Section 5 - Lubrication & Maintenance Grease (extreme pressure #2) EVERY Brake Camshafts Rear * - Number of Lube Points - Added Number of Lube Points if 6x6 OAC0041 80854002 5-17...

  • Page 126: 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 80854002...

  • Page 127: 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 80854002 5-19...

  • Page 128: 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 80854002...

  • Page 129: Operator Maintenance Instructions

    Section 5 - Lubrication & Maintenance OPERATOR MAINTENANCE INSTRUCTIONS 10 Hours Fuel Level Check OAC1030 OW0990 FUEL 0 0 0 0 0 0 10 00 FRONT AXLE DRIVE BATTERY OAC1040 1. Check fuel gauge (1) located on dash panel in undercarriage cab. 2.
  • Page 130 Section 5 - Lubrication & Maintenance Hydraulic Oil Level Check OAC1030 OW1030 OAC1110 1. Be sure machine is level, boom is level and retracted and bucket is open. 2. Perform shutdown procedure on page 3-17 or page 3-36. 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 131 Section 5 - Lubrication & Maintenance 5. Remove dust cap from pressure fill port (6) . 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 132 Section 5 - Lubrication & Maintenance Hydraulic Tank Element Change (as filter indicator indicates) NO ELEMENT CLEAN REPLACE BYPASS OAC1230 1. Perform shutdown procedure on page 3-17 or page 3-36. 2. Locate reservoir breather (1) mounted on boom rest (2) . 3.
  • Page 133 Section 5 - Lubrication & Maintenance 4. Loosen 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 tighten bolts (4) . (Torque bolts to 200-225 lb-in). 7.
  • Page 134 Section 5 - Lubrication & Maintenance Air Filter Restriction Indicator Check OAC1030 OW1010 OAC1080 1. Perform shutdown procedure on page 3-17 or page 3-36. 2. Locate air cleaner (1) and check restriction indicator (2) . If red band is visible, filter(s) must be replaced.
  • Page 135 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 136 Section 5 - Lubrication & Maintenance Engine Coolant Level Check OAC1030 OAC1160 TOP VIEW OF POWER UNIT SHOWN HOT LEVEL COLD LEVEL OAC1210 1. Perform shutdown procedure on page 3-17 or page 3-36. 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 137 Section 5 - Lubrication & Maintenance Engine Oil Level Check OAC1030 OW1020 OAC1060 1. Perform shutdown procedure on page 3-17 or page 3-36. 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 138: 50 Hours

    Section 5 - Lubrication & Maintenance 50 Hours Check & Drain Air Tanks OAC1070 OAC1150 OAC1190 1. Perform shutdown procedure on page 3-17 or page 3-36. 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 139 Section 5 - Lubrication & Maintenance Drain Fuel/Water Separator OW0980 OW1000 OAC1050 1. Perform shutdown procedure on page 3-17 or page 3-36. 2. Locate fuel/water separator on boom rest (4) . 3. Loosen drain cock (6) on underside of fuel filter (5) and allow all water to drain into a glass until clear fuel is visible.
  • Page 140 Section 5 - Lubrication & Maintenance Power Steering Fluid Check OAC1070 OAC1170 TOP VIEW OF POWER UNIT SHOWN OAC1200 1. Perform shutdown procedure on page 3-17 or page 3-36. 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 141 Section 5 - Lubrication & Maintenance Tire Air Pressure Check OAC1070 OW1040 1. Perform shutdown procedure on page 3-17 or page 3-36. 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 142: 125 Hours

    Section 5 - Lubrication & Maintenance 125 Hours Replace Hydraulic Reservoir Breather OAC1130 OW1030 OAC1180 1. Perform shutdown procedure on page 3-17 or page 3-36. 2. Locate reservoir breather (1) mounted on boom rest (2) . 3. Depress breather plunger (3) to relieve hydraulic reservoir pressure. 4.
  • Page 143 Section 5 - Lubrication & Maintenance Battery Check OAC1130 OW1080 OAC1120 1. Perform shutdown procedure on page 3-17 or page 3-36. 2. Open the battery box cover. 3. Wearing eye protection, visually inspect the batteries (1) . Check terminals for corrosion.

  • Page 144: 750/1500 Hours

    Section 5 - Lubrication & Maintenance 750/1500 Hours Replace In-Line Pilot Filters 1500 OW1180 OAC1580 OAC1570 In-Line Pilot Filter Element (750 Hours) 1. Perform shutdown procedure on page 3-17 or page 3-36. 2. Remove oil drain plug (1) . Drain oil into a suitable container. 3.
  • Page 145 Section 5 - Lubrication & Maintenance In-Line High Pressure Filter (1500 hours) 1. Perform shutdown procedure on page 3-17 or page 3-36. 2. Remove in-line high pressure filter (3) and replace with new filter. (Note: Filter will flow in any direction mounted). 80854002 5-37...
  • Page 146 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 147: 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 148: 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 149: Section 7 - Specifications

    Transmission (includes pump PTO) Capacity ..................17 Quarts (16 liters) Type of Fluid.............. Mobil 50 Synthetic (1440-4967) Transfer Case (XL3100III 4x4; XL4100III 6x6 & XL5100III 6x6) Capacity ..................3 pints (1,4 liters) Type of Fluid.............. Mobil 50 Synthetic (1440-4967) 80854002...
  • Page 150 Front Axle (XL3100III 4x4) Capacity..................27 pints (12,8 liters) Type of Fluid .................80w90 (1440-3126) Front Axle Wheel Ends (XL3100III 4x2; XL4100III 6x4 & XL5100III 6x4) Capacity..................4 ounces (0,1 liters) Type of Fluid .................80w90 (1440-3126) Front Axle (XL4100III 6x6 & XL5100III 6x6) Capacity..................

  • Page 151: Tires

    Section 7 - Specifications 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 ....................as required Type of Lube..............Extreme Pressure Lube #2 * Capacities are approximate - Check level to be sure ** Hydraulic Fluid Specifications;...

  • Page 152: Weight

    Operating Weight (6x6) .............56,868 lb (25,795 kg) Gross Vehicle Axle Rating (6x4) ..........66,000 lb (29,937 kg) Gross Vehicle Axle Rating (6x6) ..........69,000 lb (31,928 kg) Note: Refer to detailed specification sheet for additional machine weight information. Specification sheets can be viewed/downloaded at www.gradall.com 80854002...

  • Page 153: Dimensions

    Transport Length (without bucket)............25.6 ft (7,8 m) Transport Height (without bucket) ............11 ft (3,4 m) Transport Width (without bucket) ............8.5 ft (2,6 m) Note: Refer to detailed specification sheet for additional machine dimension information. Specification sheets can be viewed/downloaded at www.gradall.com 80854002...

  • Page 154: 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 155 Section 7 - Specifications Tilt Transmission Mounting Hardware Quantity ........................8 Thread Size (grade) ..................5/8-11 (8) Torque (lubricated) ............200-215 lb-ft (272-292 Nm) Wheel Lug Nuts Quantity .........................ALL Thread Size (grade) .................M22x1.5 (8) Torque (lubricated) ............450-500 lb-ft (610-678 Nm) Undercarriage Cab Steering Wheel Retaining Nut Quantity ........................
  • Page 156 Section 7 - Specifications Rear Axle Mounting Bolts (XL3100III) Quantity ........................8 Thread Size (grade)..................7/8-14 (8) (VIEW FROM REAR OF MACHINE) TORQUE SEQUENCE OAC1560 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 157: Fuses

    Section 7 - Specifications FUSES Fuse location and size designations are identified with the decals shown below. Upperstructure SPARE BATTERY POWER 1706769 REV. A F2 SPARE BAT POWER #1 F3 SPARE BAT POWER #2 ATTENTION: F4 AC FAN POWER USE FUSE SIZES AS DESIGNATED. BOOM LIGHT POWER USING THE WRONG FUSE SIZE CAN F6 OPTION #1 POWER...
  • Page 158 Section 7 - Specifications This Page Intentionally Left Blank 7-10 80854002...

  • Page 163: 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 164 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..... 3-18 Transfer Case ........7-1 Operation, Travel Mode....3-1 Transmission........7-1 Operator Maintenance Instructions 5-21 Travel Hazard........1-8 Operator Seat .........
  • Page 165 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 166 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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