Gradall G660 Operator's Manual
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Gradall G660 Operator's Manual

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CHASSIS OPERATOR'S
MANUAL
G660
Form #7345
July 2002
GRADALL
406 Mill Avenue S.W.
New Philadelphia, OH, 44663, USA
Telephone: (330) 339-2211
Fax: (330) 339-3579

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  • Page 1 CHASSIS OPERATOR’S MANUAL G660 Form #7345 July 2002 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
  • Page 4 Safe operation depends of reliable equiptment and the use of proper operating proce- dures. Performing the checks and services described in this manual will help to keep your Gradall Carrier in reliable condition and use of the recommended operating procedures can help you avoid unsafe practices. Because some procedures may be new to even the experienced operator we recommend that this manual be read, understood and followed by all who operate the carrier.
  • Page 5 A WORD TO THE OPERATOR This manual provides important information to familiarize you with safe operating and maintenance procedures for the Gradall carrier. Even though you may be familiar with similar equipment you MUST read and understand this manual before operating the unit.
  • Page 7 SAFETY Inspect your machine daily before operating and before engine startup. Check for loose, worn, or damaged parts. Report or correct any unsafe conditions immediately. Replace all missing or broken guards and panels. They are there to protect you. Check sheet metal screws and bolts for looseness, and keep them tight.
  • Page 8 Always fasten your seat belt when driving the carrier; Do not coast with clutch disengaged or transmission in it could save your life. neutral. When traveling on highway keep your lights on. Have warning flags and safety stripe your machine to pre- scribed regulations.
  • Page 9 MODELS Truck mounted G-660 Gradalls are available with three basic carrier variations to suit job application and contractor preference. Your unit may include: 1. A Chrysler gasoline engine or a Detroit or Caterpillar diesel engine 2. Driving axles at rear only (6x4) or driving axles at both front and rear (6x6) 3.

  • Page 10: Instruments And Indicators

    INSTRUMENTS AND INDICATORS 1. Brake Warning Light — glows to indicate parking 7. High Beam Indicator Light brake is applied. 8. Flasher and Turn Signal Indicator Light 2. Oil Pressure Gage 9. Tachometer — indicates engine speed Hourmeter 3. Voltmeter — indicates alternator output. —...
  • Page 11 CONTROLS 1. Light Switch — controls carrier headlights, tail- lights and clearance lights. 2. Cab Controlled Brakes Toggle — (only on units equipped for remote control). 14. Windshield Wiper Switch 3. Ignition and Starter Switch 15. Transmission Shift Lever 4. Turn Signal Switch 16.
  • Page 12 CHECKS AND SERVICES BEFORE STARTING ENGINE (To be performed at beginning of each work shift) WARNING: Any defects or deficiencies noted must be corrected before the carrier is placed in service. 1. Check all air reservoir drain cocks and close any found open.
  • Page 13 6. Check for secure stowage of boom and any auxil- iary equipment or material. 7. Check for adequate fuel supply and refill as nec- essary using specified fuel. Tank should be kept filled to minimize condensation. 8. Check oil level in engine crankcase and fill as nec- essary using specified grade of oil.
  • Page 14 CHECKS AND SERVICES (Continued) 12. Check hydraulic fluid level in steering pump reservoir and refill as necessary. 13. Check condition and tension of all engine drive belts and adjust or replace as necessary. WARNING Do not check belts with engine running. 14.
  • Page 15 17. Check fluid level in windshield washer reservoir on wall in front of seat in carrier cab. Add wind- shield washer solvent as necessary. 18. Check position of steering selector valve knob (only on units equipped for remote control). Knob should be down for operation from carrier cab.

  • Page 16: Engine Operation

    ENGINE OPERATION NOTE: If engine is being started at beginning of work shift be sure to perform all “CHECKS AND SERVICES BEFORE STARTING ENGINE” (pages 8 through 11). WARNING If carrier is on a slope and transmission has been left in gear by previous driver, block wheels securely before attempting to start engine.

  • Page 17: Cold Weather Starting Aids

    4. After engine starts, observe oil pressure gage. If 5. Warm up diesel engines at approximately one third gage remains on zero for more than ten seconds, of governed speed until water temperature reaches stop engine and determine cause. Correct cause of operating range (approximately 160°F.).

  • Page 18: Stopping The Engine

    ENGINE OPERATION (Continued) Permitting the engine to labor under too great a load Avoid prolonged idling. Idling causes engine for the gear ratio being used (lugging the engine) will temperature to drop and this permits formation of shorten engine life. Shift to the proper gear ratio for heavy carbon deposits and dilution of lubricating conditions.

  • Page 19: Checks After Starting Engine

    CHECKS AFTER STARTING ENGINE (To be performed at beginning of each work shift) WARNING Any defects or deficiencies noted must be corrected by qualified personnel before carrier is placed in service. Proper output is approximately 14 V. with engine 1. Check operation of windshield washer and wiper. running at 2000 RPM.

  • Page 20: Checks Before Driving

    CHECKS BEFORE DRIVING (To be performed at beginning of each work shift following performance of “CHECKS AFTER STARTING ENGINE.”) CAUTION WARNING Unblock carrier wheels before moving Any defects or deficiencies noted must carrier. Be sure air pressure is at be corrected by qualified personnel required operating level and parking before carrier is placed in service.
  • Page 21 c. Stop engine and then release clutch. d. Open drain cock on No. 1 air reservoir to relieve all pressure from that reservoir only (located behind cab, next to frame). e. Depress clutch, start engine and then drive carrier forward at low speed in first gear. Check emergency brake by depressing brake treadle.

  • Page 22: Brake System

    BRAKE SYSTEM The air brake system furnished on Gradall carriers the wheels of the forward rear axle. In effect, there is includes a service brake, an emergency brake and a three axle braking for service brakes and single axle parking brake. Three separate reservoirs, all isolated braking for emergency and parking brakes.

  • Page 23: Service Brake

    Service brake Foot pressure on the dual brake valve treadle activates the service brake. Just as in an auto, the greater the foot pres- sure, the harder the brakes are applied. WARNING Do not “fan” the brake valve treadle. A long series of rapid brake applications can reduce system pressure to a point where effective service braking will be lost until...

  • Page 24: Steering System

    STEERING SYSTEM The power steering system furnished on Gradall carriers provides accurate steer- ing under normal conditions and greater control in the event of a blowout or soft ground. “Road feel” is similar to that of a conventional manual steering system.

  • Page 25: Power Train

    POWER TRAIN The power train furnished on 6x4 carriers (units having The major variations found on 6x6 carrier (units hav- two driving axles at rear) includes the engine, clutch, ing two driving axles at rear and a third driving axle in transmission, auxiliary transmission, rear tandem axles front) are the substitution of a front driving axle in and the necessary propeller shafts to transfer torque...
  • Page 26 POWER TRAIN (Continued) 4. Depress clutch pedal and shift main transmission to first gear and auxiliary transmission to desired range. Continue to hold clutch in depressed position. 5. Release clutch a short distance to cause a slight rotation of transmission gears and check to be sure auxiliary transmission is fully engaged.
  • Page 27 Transmissions in Gradall carriers speed. provide five forward speeds and one reverse speed.

  • Page 28: Shifting Gears

    Shifting gears As indicated above, efficient gear shifting involves physical coordination and a good sense of tim- ing. The following procedure will tell you how and when. Practice on level ground till you gain confidence. 1. With transmission in neutral start carrier engine and wait till brake system is fully pressurized (125 psi).
  • Page 29 6. With carrier moving forward smoothly, release accelerator pedal while depressing clutch and move transmission shift lever out of first gear position. With shift lever in neutral, release clutch. 7. Depress clutch again and move shift lever to second gear position. Release clutch smoothly while depressing accelerator pedal as in step 5.
  • Page 30 Downshifting The procedure described above is used to take the carrier from a standstill to a desired road speed. During normal driving there are times when it is necessary to downshift (shift from one gear to the next lower gear) to decrease carrier speed or increase carrier power.
  • Page 31 When to shift gears Smooth, timely shifting not only increases carrier serv- governed engine speed. Reserve full governed RPM ice life, it provides greater driving safety. for conditions requiring full power. When load conditions cause a continuing loss of Use of the proper gear for existing driving conditions engine speed, downshift to the next lower gear.
  • Page 32 PREPARING CARRIER FOR REMOTE CONTROL OPERATION (after conventional carrier operation) 1. Start carrier engine and develop full brake system pressure (125 psi). Pull PARKING BRAKE control up to PARK posi- tion (ON). 2. Set CAB CONTROLLED BRAKES toggle to LOCKED position. (for 6x4 units only) 3.
  • Page 33 PREPARING UPPERSTRUCTURE FOR REMOTE OPERATION (after conventional carrier operation) 1. Be sure controls in carrier cab have been properly set for remote control operation (page 28). 2. Be sure BRAKES toggle in upperstructure is in ON position. WARNING Never move BRAKES toggle to OFF position until ready to engage travel lever.
  • Page 34 PREPARING UPPERSTRUCTURE FOR REMOTE OPERATION (Continued) 4. Start upperstructure engine and develop full brake system pressure (125 psi). 5. Be sure engine clutch is engaged. NOTE: Disengage engine clutch for easier starting in cold weather. After starting, engage clutch with engine at idle speed. 6.
  • Page 35 PRECAUTIONS FOR REMOTE CONTROL Be sure of unobstructed visibility in direction counterweight before starting to move. Be of travel; use a signalman to compensate for especially watchful for overhead wires and blind spots. traffic. Never permit bucket to drag while moving Be sure upperstructure swing brake functions unit.
  • Page 36 PREPARING UPPERSTRUCTURE FOR CONVENTIONAL CARRIER OPERATION (after remote control operation) 1. Retract boom and store in boom rest as necessary using hold down toggle. 2. Be sure BRAKES toggle in upperstructure is in ON position. 3. If upperstructure engine is to be turned off, allow to cool by running at idle speed for a few minutes before stopping.
  • Page 37 PREPARING CARRIER FOR CONVENTIONAL OPERATION (after remote control operation) 1. Push steering selector valve knob down to lower position. 2. Shift main transmission to neutral. 3. Set REMOTE DRIVE toggle to OUT position. 4. Start carrier engine and develop full brake system pressure (125 psi).

  • Page 38: Parking Procedure

    PARKING THE GRADALL Position boom in boom rest; never leave PRECAUTIONS: machine with boom in air. Avoid parking on banks or near an excavation. Park on level ground and block wheels. Avoid parking on roads or highways. If it can-...
  • Page 39 LUBRICATION RECOMMENDED LUBRICANTS CAPACITIES (Capacities are approximate — check level) REPLACEMENT FILTER ELEMENTS W&S Part No. Oil Filter (Chyrsler engine) ......8307-2558 (Detroit Diesel engine) .
  • Page 44 CHRYSLER ENGINE LUBRICATION DIAGRAM DETROIT DIESEL ENGINE LUBRICATION DIAGRAM CATERPILLAR ENGINE LUBRICATION DIAGRAM...
  • Page 45 CHRYSLER LUBE SYMBOL INTERVAL 1. Crankcase Dipstick (checl level) Daily 2. Crankcase Fill (fill to level on dipstick as required) As Req’d 3. Crankcase Drain (drain and refill) (initial change for new or rebuilt engines shoul be made at 25 hours of operation) 50 Hours 4.

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