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Summary of Contents for Gradall XL5210
- Page 1 OPERATOR'S MANUAL XL5210 24604103 July 2002 Covers S/N's 0526105 thru 0525152, 0521826 thru 0521830, 0210017507 thru 0210018076 & 05210000831 & After Form #29312 Original Issue 12/93 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
- Page 2 Safe operation depends on reliable equipment and proper operating procedures. Performing the checks and services described In this manual will help to keep your Gradall R Excavator In reliable condition and use of the recommended operating procedures can help you avoid accidents. Because...
- Page 4 A kit containing all decals for the XL5210 can be obtained from your Gradall PIN Location Distributor. He Can also furnish additional manuals (Product Identification No.) for your machine.
- Page 5 SAFETY HIGHLIGHTS Read and understand this manual, the Gradall Hydraulic Excavator Safety Manual, the EMI Hydraulic Excavator Safety Manual and all instructional decals and plates before starting, operating or performing maintenance procedures on this machine. Keep these manuals in cab.
- Page 6 SAFETY HIGHLIGHTS Learn to recognize ‘PINCH POINTS’ Boom Holes Boom Cradle Stay clear of PINCH POINTS. Getting caught in a pinch point can cause serious injury or death. Access Covers Boom Bucket & Linkage Counterweight & Another Object Upperstructure & Carrier...
- Page 7 ’s tools or personal items on the in this manual. If it differs, or if you aren’t sure, machine. Such items can cause other workers to contact your Gradall distributor before you run approach the machine without your knowledge and your unit.
- Page 8 SAFETY HIGHLIGHTS Be particularly careful if this is not the machine Learn and follow your employer’s safety rules. you usually operate. Read the manuals listed on page 2 and then operate the unit in a safe, open area to become familiar with the controls. REPOSITION UNIT FOR EXCAVATOR OPERATION ONLY UNDER FOLLOWING CONDITIONS: Signal persons positioned to observe and Appropriate travel speed selected...
- Page 9 SAFETY HIGHLIGHTS Travel on grades is recommended only under following conditions: Boom fully retracted Tracks properly adjusted Surface is firm enough to support unit Surface provides adequate traction to prevent slipping Surface is not rough enough or steep enough Use boom tie-down device to secure boom to cause tipping before transporting the excavator.
- Page 10 SAFETY HIGHLIGHTS Will load attached as shown, boom must be level Do not operate with bystanders or other from side-to-side and bucket adapter must be workers near machine. closed against stops. Always sound horn to warn others of unexpected machine movements (horn button is located at top of left joystick).
- Page 11 SAFETY HIGHLIGHTS Do not operate with bystanders or other workers near machine. Avoid injury! Always relieve pressure trap- ped in circuits before disconnecting, re- moving or installing hydraulic components. Pressure can be maintained in hydraulic circuits long after the engine has been shut down. This Always be sure attachment is resting firmly on pressure can cause oil (or items such as pipe plugs) ground and that engine is stopped before...
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Page 12: Decals Inside Cab
Decals Inside Cab Optional GRADALL CRAWLER Located on right arm rest OPERATING CONTROLS Part No. 9103 - 3089 SOUND HORN JOYSTICK ON/OFF LEVER ARM-REST UP - OFF ARM REST SOWN = ON RIGHT TRACK REVERSE RIGHT TRACK FORWARD LEFT TRACK REVERSE... - Page 13 Decals Inside Cab (cont.) FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF SERIOUS INJURY: BEFORE OPERATING. READ OPERATOR AND SAFETY MANUALS. UNDERSTAND ALL CONTROL IN CAB AND CLEAR LOOSE OBJECTS OFF MACHINE. SOUND HORN BEFORE STARTING ENGINE. STABILITY IS DECREASED DURING TRAVEL.
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Page 14: Decals Outside Cab
Decals Inside Cab (Cont.) Located on control console Part No. 8091-3020 8091-3016 Located on control console Part No. 8091-3016 Decals Outside Cab DO NOT GO NEAR LEAKS • High pressure oil easily punctures skin causing serious injury, gangrene or death. •... -
Page 15: Diesel Fuel
Decals Outside Cab TO PREVENT INJURY, STAY CLEAR OF MOVING PARS. FASTEN COVERS OR INJURY MAY RSULT FROM DEATH BEFORE STARTING CONTACTING ELECTRICAL LINES. ENGINE. READ SERVICE MANUAL BAFORE TO PLACE ANY PART OF THIS MACHINE OR LOAD WIHIN 10 ADJUSTING OR UNLAWFUL FEET OF HIGH VOLTAGE LINES... -
Page 16: Hydraulic Oil
Decals (continued) ® GRADALL THE GRADALL COMPANY 406 Mill Ave., S.W., New Philadelpia, Ohio Located at front center of frame Part No. 7733-3047 COLD Located on hydraulic resrvoir WARNING Part No. 8697-1197 HIGH HYDRAULIC OIL PRESSURE CYLINDER 7702-3006 APPLY LUBRICANT THROUGH FITTING ONLY TO TIGHTEN TRACK. -
Page 17: Seat Adjustment
OPERATOR’S CAB Seat Adjustment Perform all seat adjustments with engine stopped. Accidental actuation of controls can cause serious accidents. It may become necessary to revise some adjustments to find the most comfortable operating position. Be sure to stop engine first. Backrest Release Seat Height/Slope Releases Armrest Release... - Page 18 Heater conditions may require more frequent element washing/replacement. A noticeable reduction of air flow from deflector vents indicates a need to service The cab is equipped with a heater located behind filter elements. operator’s seat. Engine coolant supply to heater is controlled by a push/pull knob located on instrument/ Ventilation control console.
- Page 19 CONTROL AND INSTRUMENT IDENTIFICATION (Common to all units unless noted) Test your controls before operating. The control pattern illustrated is the standard Gradall control pattern. If your machine controls have been modified to any other pattern, be certain you are...
- Page 20 Electronic Monitor An electronic monitor caution signal indi- cates a condition which could cause serious damage to your unit. Correct cause of signal before continuing operation. CAUTION SYMBOLS & ALARM Battery Charge: Symbol glows (red) in response to low battery charge (below 11.6 VDC) Engine Coolant Level: Symbol glows (red) and alarm sounds if coolant level falls below acceptable operating level.
- Page 21 CHECKS AND SERVICES BEFORE STARTING ENGINE (To be performed at beginning of each work shift) Complete all required maintenance before operating unit. enter these ports, it can shorten the life of o-rings, seals, packings and bearings. Use extreme caution when checking items When adding fluids or changing filter elements, beyond your normal reach.
- Page 22 Check fuel level symbols on electronic monitor and replenish as necessary. It is recommended that the unit be refueled at the end of the work shift to minimize condensation. Check for presence of fully charged fire extin- Engine should be turned off while refuel- quisher on wall behind seat in cab.
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Page 23: 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 19 and 20). Turning ignition switch to START position while engine flywheel is rotating can cause serious damage to engine and/or starting motor. Starting Cummins Engine After engine starts, reduce speed to low idle and Insert ignition key and turn clockwise to RUN... -
Page 24: Normal Engine Operation
Normal Engine Operation Be alert for unusual noises or vibration. When an unusual condition is noticed, stop machine in a safe position and shut off engine. Determine cause Always operate with engine at full throttle to and correct problem before continuing. prevent possibility of stalling under heavy load. - Page 25 WARM UP & OPERATIONAL CHECKS (To be performed at beginning of each work shift) Complete all required maintenance before operating unit. Check to be sure reservoir breather and hoses are The safety, efficiency and service life of your firmly attached. excavator will be increased by performing the following operational checks while the engine and hydraulic oil are warming to operating temperature.
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Page 26: Installation
ATTACHMENT INSTALLATION Keep boom in fully extended position while installing bucket. Stay clear until bucket adapter has been fitted to bucket as shown in step 2. Digging wIth a loose or an improperly fitted bucket can shear adapter bolts and cause excessive wear. - Page 27 Crawler undercarriages are furnished to enable the Rough operation and operation on uneven ground can cause unnecessary wear and damage to track Gradall to travel over rough terrain and reach work sites which would not be accessible to the ordinary wheeled- components, Reasonable operation and regular carrier mounted Gradall.
- Page 28 HOW TO OPERATE THE CRAWLER Practice with travel controls in a safe, open area. Avoid confusion! Before actuating track drive pedals, think about the direction you are facing with respect to the direction the crawler is facing. (Drive sprockets are at rear of crawler). Confusion could cause you to travel in the direction opposite that expected.
- Page 29 Practice with controls in a safe, open area. Test your controls before operating. The control pattern illustrated is the standard Gradall control pattern. If your machine controls have been modified to any other pattern, be certain you are...
- Page 30 A TYPICAL GRADALL DIGGING CYCLE Pull back on left joystick (A) to raise boom from Move right joystick to left (G) to swing left or to boom rest. Be sure to raise boom far enough to right (H) to swing ring to digging site.
- Page 31 A TYPICAL GRADALL DIGGING CYCLE If required, press left side of tilt switch (I) to tilt While pushing forward on left joystick (B) to counterclockwise or right side of switch (J) to tilt lower boom and force bucket into ground, pull clockwise.
- Page 32 A TYPICAL GRADALL DlGGlNG CYCLE Move right joystick to right (H) to swing right Move left joystick to left (C) to empty the or to left (G) to swing left to dump site. If bucket. necessary, extend boom by pushing right joystick forward (F).
- Page 33 LIFTING AND POSITIONING A LOAD Precautions Do not depend on machine tipping as a warning Do not travel with a suspended load. Excavators of overload. Some load ratings are based on are not designed for pick and carry lifts. hydraulic lift capacity, not stability. Sudden swing braking can cause unexpected movement of the load and tip the machine.
- Page 34 Perform an unloaded trial run of the lift to Measure boom height/depth from bucket adapter determine maximum load radius required and pivot shaft to ground level (same plane as bottom of maximum boom height and depth required to tires). Be sure to allow for length of sling and height complete the lift.
- Page 35 LUBRICATION & MAINTENANCE TORQUE CHART Check torque using an accurate torque wrench to apply maximum torque value shown. DO NOT EXCEED MAXIMUM TORQUE. Exceeding maximum torque may cause failure of fastener. Recommended Lubricants & Capacities ** Specific hydraulic fluid specifications are shown. Hydraulic Fluid Specifications: *** Capacities are approximate - check level to be sure.
- Page 36 LUBRICATION & MAINTENANCE DIAGRAM SYMBOLS • = Fitting = Other Service LUBRICANT SYMBOLS CG - Grease. Extreme Pressure GO - Multi-Purpose Lubricant EO - Engine Oil MC - Molycote FUEL FILTER NOTE GL - Open Gear Lube 1997 APA engines have fuel filter HF - Hydraulic Fluid mounted on right side of engine rather than on left side as on prior...
- Page 38 EXCAVATOR HAND SIGNALS Standard Signals - When excavator work conditions require hand signals, they shall be provided or posted conspicuously for the use of both signalman and operator. No excavator motions shall be made unless signals are clearly understood by both signalman and operator.
- Page 39 CLOSE BUCKET - Hold one hand closed and MOVE SLOWLY - Place one hand motionless in THIS FAR TO GO - With hands raised and open stationary. Rotate other hand in small vertical circle front of hand giving motion signal. (Raise load inward move hands laterally, indicating distance to with forefinger pointing horizontally at closed hand.
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