Subscribe to Our Youtube Channel
Related Manuals for Gradall XL4100
Summary of Contents for Gradall XL4100
- Page 1 OPERATION & LUBRICATION MANUAL XL4100 XL4200 2460-4092 July 2002 Starting S/N 0411200 & 0421200 Also Covers S/N’s 0411000, 0412000 & 0423000 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
-
Page 4: Important Safety Notice
Strict attention to, and compliance with instructions provided in this manual, the XL4100 Carrier Operation Manual, the EMI Safety Manual, the Gradall Safety Manual, as well as instructional decals and plates affixed to the machine, will help you avoid personal injury and damage to the equipment. - Page 6 A kit con- taining all decals for the XL4100 and XL4200 is In relation to the carrier, front, rear, right and left available from your Gradall Distributor. He can also are determined by the orientation of a man sitting in furnish additional manuals for your machine.
- Page 7 SAFETY HIGHLIGHTS Read and understand 1his manual, XL4100 6x4 & 6x6 Carrier Operator’s Manual, EMI Safety Manual, Gradall Hydraulic Excavator Safety Manual and all instructional decals and plates before starting, operating or performing maintenance procedures on this equipment. Keep these manuals in cab.
- Page 8 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. Boom Access Covers Bucket & Linkage Upperstructure & Carrier Counterweight & Another Object...
- Page 9 ’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 10 SAFETY HIGHLIGHTS Learn and follow your emmployer’s safety rules. Be particularly careful if this is not the machine 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: Transmission in proper range Signal persons positioned to observe and...
- Page 11 SAFETY HIGHLIGHTS Travel on off-highway grades is recom- mended only under the following conditions: Boom secured in rest tires properly inflated Surface is firm enough to support unit Surface provides adequate traction to prevent slipping Surface is not rough enough or steep enough to cause tipping Transmission is in LL 1 gear range Whenever rotating equipment (such as a...
- Page 12 GRADALL LIFTING CAPACITIES SAFETY HIGHLIGHTS RATED LIFT CAPACITY Always check Lift Capacity Chart and plan lift (pages 33 & 34) to he sure lift can be performed safety. Watch out for carrier cab when swinging. Position unit so that it won’t be necessary to swing close to cab.
- Page 13 SAFETY HIGHLIGHTS Do not operate with bystanders or other workers near machine. Always be sure bucket is resting firmly in boom rest or on ground and that engine is stopped before performing lubrication or maintenance procedures inside boom. Avoid injury! Always relieve pressure trap- ped in circuits before disconnecting, re- moving or installing hydraulic components.
-
Page 14: Decals Inside Cab
Decals Inside Cab GRADALL CRAWLER GRADALL CRAWLER GRADALL GRADALL OPERATING CONTROLS OPERATION CONTROLS HYDRAULIC REMOTE HYDRAULIC REMOTE OPERATING CONTROLS OPERATING CONTROLS 1. SOUND HORN 1. ATTACHMENT ON 2. JOYSTICK ON/OFF LEVER 1. SOUND HORN 2. JOYSTICK ON/OFF LEVER 1. ATTACHMENT ON ARM REST UP = OFF 2. - Page 15 Decals Inside Cab (cont.) FOR SAFE OPERATION OF FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE MACHINE AND TO MINIMIZE RISK OF SERIOUS INJURY: RISK OF SERIOUS INJURY: BEFORE OPERATING. READ OPERATOR BEFORE OPERATING, READ OPERATOR AND SAFETY MANUALS. UNDERSTAND AND SAFETY MANUALS, UNDERSTAND ALL CONTROLS IN CAB AND CLEAR ALL CONTROLS IN CAB AND CLEAR...
-
Page 16: Decals Outside Cab
Decals Inside Cab (cont.) TO OPERATE CARRIER FROM UPPERSTRUCTURE (A) FORWARD-REVERSE CONTROL PEDAL MUST BE IN NORMAL (NEUTRAL) POSITION. (B) START UPPERSTRUCTURE POWER UNIT. (C) WHEN AIR GAUGE SHOWS OPERATING PRESSURE (125 PSI), RELEASE EMERGENCY BRAKE. (D) CONTROL AND DIRECTION OF CARRIER TRAVEL IS NOW DETERMINED BY POSITION OF FORWARD-REVERSE CONTROL PEDAL. -
Page 17: Diesel Fuel
Decals Outside Cab OR INJURY MAY RESULT FROM DEATH CONTACTING ELECTRICAL LINES. TO PLACE ANY PART OF THIS MACHINE OR LOAD WITHIN 10 UNLAWFUL FEET OF HIGH VOLTAGE LINES OF UP T 50,000 VOLTS. 7702-3004 Located on engine compartment & inside valve cover Part No. -
Page 18: Hydraulic Oil
Decals Outside Cab (cont.) THE GRADALL COMPANY 406 Mill Ave.,S.W.,New Philadelphia,Ohio Located at front center of frame Part No. 7733-3047 ARRANGE CHAIN ONLY AS SHOWN TO LIFT ATACHMENT FOR TRANSPORT TO PREPARATION M A X L I F T C A PA C I T Y 2 0 0 L B S . -
Page 19: Seat Adjustment
Seat Adjustment OPERATOR’S CAB 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. Raise lever to unlock and raise or lower front Raise lever to unlock and adjust angle of Raise lever to unlock and raise armrest for... -
Page 20: Air Conditioner (Optional)
Heater conditions may require more frequent element washing/replacement. A noticeable reduction of air The cab is equipped with a heater located behind flow from deflector vents indicates a need to service operator’s seat. Engine coolant supply to heater is filter elements. controlled by a valve on engine block and a push/pull knob located on instrument/control console. - Page 21 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 22 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: Symbols 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 23 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 24 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- guisher on wall behind seat in cab.
-
Page 25: 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 26: Normal Engine Operation
Normal Engine Operation Be alert for unusual noises or vibration. When an unusual condition is notice, 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 27 WARM UP & OPERATIONAL CHECKS (To be performed at beginning of each work shift) Complete all required maintenance before operating unit. The safety efficiency and service life of your NOTE: Step 4 requires that hydraulic oil be at least excavator will be increased by performing the 60°F.
-
Page 28: Attachment 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 29: Remote Control
REMOTE CONTROL NOTE: Remote control is to be used for positioning unit at job site, not for over-the-road travel. Preparing Carrier for Remote Control Operation With carrier on level surface, apply parking brake. Start carrier engine and develop full brake Be sure to keep clear of clutch pedal system pressure in front and rear portions of when moving DIGGING BRAKE toggle to... - Page 30 Precautions for Remote Control Operation Always give audible signal before moving unit. Be sure of clear visibility in direction of travel; use a signalman to compensate for blind spots. Never permit bucket to drag while moving unit. Be sure all Warm-Up and Operational Checks Rotation of steering wheel will occur during have been performed.
- Page 31 Crawler undercarriages are furnished to enable Mud, frozen mud and debris can prevent rollers the Gradall to travel over rough terrain and reach from turning and cause flat spots. Clean track work sites which would not be accessible to the components as often as necessary.
- Page 32 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 33 A TYPICAL GRADALL DIGGING CYCLE Position unit for efficient digging cycle and apply Warm up engine and hydraulic oil and then move digging brake. throttle lever to full throttle position. Avoid accidental actuation of the controls. Always operate with engine at full throttle to Always stop engine before repositioning prevent stalling under heavy load.
- Page 34 A TYPICAL GRADALL DIGGING CYCLE Move right joystick to left (G) to swing left or to Pull back on left joysticks(A) to raise boom from right (H) to swing right to digging site. boom rest.Be sure to raise boom far enough to clear all obstructions.
- Page 35 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 36 A TYPICAL GRADALL DIGGING CYCLE Move left joystick to left (C) to empty the Move right joystick to right (H) to swing right bucket. or to left (G) to swing left to dump site. If necessary, extend boom by pushing right joystick forward (F).
- Page 37 LIFTING AND POSITIONING A LOAD Precautions Do not travel with a suspended load. Excavators Do not depend on machine tipping as a warning 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 38 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 39 SECURING BOOM & ATTACHMENT FOR TRAVEL IF YOU GET STUCK If unit becomes stuck in soft ground you can use the rear to prevent tipping) and imbed bucket in ground. boom to help tree it. While actuating travel pedal in appropriate direction, Position carrier and upperstructure controls for extend or retract boom as required to help push or remote control operation.
- Page 40 EXCAVATOR HAND SIGNALS Standard Signal - When excavator work conditions require hand signals, they shall be provided or posted conspicuously for the use of both signal man and operator No excavator motions shall be made unless signals are clearly understood by both signalman and operator.
- Page 41 MOVE SLOWLY - Place one hand motionless in CLOSE BUCKET - Hold one hand closed and THIS FAR TO GO - With hands raised and open front of hand giving motion signal. (Raise load stationary. Rotate other hand in small vertical circle inward, move hands laterally, indicating distance to slowly is shown.) with forefinger pointing horizontally at closed hand.
- Page 42 LUBRICATION & MAINTENANCE DIAGRAM SYMBOLS = Fitting → → → → → =Other Service LUBRICANT SYMBOLS AF - Anti-Freeze CG - Grease, Extreme Pressure GO - Multi-Purpose Lubricant EO - Engine Oil MC - Molycote GL - Open Gear Lube HF - Hydraulic Fluid Lubrication Notes Drain engine and gear cases only after operation...
- Page 44 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 Hydraulic Fluid Specifications: ** Specific hydraulic fluid specifications are shown. ISO Grade 46, Pour Point, °F.
Need help?
Do you have a question about the XL4100 and is the answer not in the manual?
Questions and answers