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Summary of Contents for Gradall XL5100
- Page 1 OPERATOR’S MANUAL XL5100 XL5200 2460-4068 XL5100 Starting S/N 0511000 XL5200 Starting S/N 0521000 Form #29114 Original Issue 7/92 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
- Page 4 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 Excavator in reliable condition and use of the recommended operating procedures can help you avoid accidents. Because...
- Page 6 G r a d a l l H y d r a u l i c E x c a v a t o r. XL5100 6 x 4 & 6 x 6 Carrier Operator’s Manual Gradall Hydraulic Excavator Safety Manual...
- Page 7 SAFETY HIGHLIGHTS Read and understand this manual, XL5100 6 x 4 & 6 x 6 Carrier Operator’s Manual, CIMA Excavator User’s Safety Manual, CIMA DUMPER Safety Manual, Gradall Hydraulic Excavator Safety Manual and all instructional decals and plates before starting, operating or erforming maintenance procedures on this equipment.
- Page 8 SAFETY HIGHLIGHTS Learn to recognize ‘PINCH POINTS’ Counterweight & Another Object Boom Cradle Boom Holes Boom Upperstructure & Carrier Bucket & Linkage Learn to recognize “PINCH POINTS” and stay clear of them. Getting caught in a pinch point can cause serious injury or death.
- Page 9 Some owners alter their machines. Check to be sure your machine fits the pictures and description in this manual. If it differs, or if you aren’t sure, Never carry a water can, equipment, or other contact your Gradall distributor before you run worker’s tools personal items your unit.
- Page 10 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 Transmission in proper range...
- Page 11 SAFETY HIGHLIGHTS Travel on off-highway grades is re- commended 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 LL1 gear range Use boom tie-down device to secure boom in...
- Page 12 SAFETY HIGHLIGHTS GRADALL LIFTING CAPACITIES RATED LIFT CAPACITY Always check Lift Capacity Chart and plan lift (pages 33 & 34) to be sure lift can be performed safely. 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 Always be sure bucket is resting firmly in boom workers near machine. rest or on ground and that engine is stopped before performing lubrication maintenance p r o c e d u r e s i n s i d e b o o m . Avoid injury ! Always relieve pressure trap- ped in circuits before disconnecting , re- moving or installing hydraulic components.
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Page 14: Decals Inside Cab
Decals Inside Cab GRADALL CRAWLER GRADALL OPERATING CONTROLS HYDRAULIC REMOTE SOUND HORN OPERATING CONTROLS SOUND HORN SOUND HORN JOYSTICK ON/OFF LEVER JOYSTICK ON/OFF LEVER ARM REST UP = OFF ARM REST UP = OFF ARM REST DOWN = ON ARM REST DOWN = ON... - Page 15 Decals Inside Cab (cont.) F O R S A F E O P E R AT I O N O F FOR SAFE OPERATION OF M A C H I N E A N D T O M I N I M I Z E MACHINE AND TO MINIMIZE R I S K O F S E R I O U S I N J U R Y: RISK OF SERIOUS INJURY:...
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Page 16: Decals Outside Cab
Decals Inside Cab (cont.) TO OPERATE CARRIER FROM UPPERSTRUCTURE FORWARD-REVERSE CONTROL PEDAL MUST BE IN NORMAL (NEUTRAL) POSITION. S TA RT U P P E R S T R U C T U R E P O W E R U N I T. W H E N A I R G A U G E S H O W S O P E R AT I N G P R E S S U R E ( 1 2 5 P S I ) , R E L E A S E EMERGENCY BRAKE. -
Page 17: Diesel Fuel
Decals Outside Cab TO PREVENT INJURY, STAY CLEAR OF MOVING PARTS, FASTEN COVERS OR INJURY MAY RESULT FROM DEATH BEFORE STARTING CONTACTING ELECTRICAL LINES. ENGINE . READ SERVICE TO PLACE ANY PART OF THIS MANUAL BEFORE MACHINE OR LOAD WITHIN 10 ADJUSTING OR UNLAWFUL SERVICING. -
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 ATTACHMENTS FOR TRANSPORT PREPARATION MAX LIFT CAPACITY 2000 LBS. -
Page 19: Seat Adjustment
O P E R ATO R ’ S C A B 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. - Page 20 conditions require more frequent element Heater 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/ control console.
- Page 21 C O N T R O L A N D I N S T R U M E N T I D E N T I F I C AT I O N (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...
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Page 22: Electronic Monitor
Electronic Monitor Battery Charge: Symbol glows (red) in response to l o w b a t t e r y c h a r g e . 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. When adding fluids or changing filter elements, Use extreme caution when checking items b e y o n d y o u r n o r m a l r e a c h .
- Page 24 heck 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.
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Page 25: Engine Operation
ENGINE OPERATION NOTE: If engine is being started at beginning of work shift be sure to perform all “CHECKS AND S E R V I C E S B E F O R E S T A R T I N G E N G I N E ” ( p a g e s 1 9 a n d 2 0 ) . Turning ignition switch to START position while engine flywheel is rotating can cause serious damage to engine and/or starting motor. -
Page 26: 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 a n d c o r r e c t p r o b l e m b e f o r e c o n t i n u i n g . 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 Check to be sure reservoir breather and hoses are firmly attached. excavator will increased...
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Page 28: At Ta C H M E N T I N S Ta L L At I O N
AT TA C H M E N T I N S TA L L AT I O N 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 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. Be sure to keep feet clear or clutch pedal Start carrier engine...
- 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 R o t a t i o n o f s t e e r i n g w h e e l w i l l o c c u r d u r i n g have been performed.
- Page 31 Mud, frozen mud and debris can prevent rollers Crawler undercarriages furnished enable from turning and cause flat spots. Clean track the Gradall to travel over rough terrain and reach components as often as necessary. work sites which would not be accessible to the ordinary wheeled-carrier mounted Gradall.
- 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 directon 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. t h r o t t l e l e v e r t o f u l l t h r o t t l e p o s i t i o n .
- Page 34 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 r i g h t ( H ) t o s w i n g r i g h t t o d i g g i n g s i t e .
- Page 35 A TYPICAL GRADALL DIGGING CYCLE While pushing forward on left joystick (B) to If required, press left side of tilt switch (I) to tilt 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 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 pushing right j o y s t i c k f o r w a r d ( F ) .
- Page 37 LIFTING AND POSITIONING A LOAD Precautions Do not depend on machine tipping as a warning Do not travel with a suspended load. Excavators 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 Hydraulic relief valve settings must be correct movement of the load and tip the machine.
- Page 38 Measure boom height/depth from bucket adapter Perform an unloaded trial run of the lift to pivot shaft to ground level (same plane as bottom of determine maximum load radius required and tires). Be sure to allow for length of sling and height maximum boom height and depth required to of load.
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Page 39: Torque Chart
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 Hydrauic Fluid Specifications: ** Specific hydraulic fluid specifications are shown. Tractor Hydraulic Fluid *** Capacities are approximate - check level to be sure. - Page 40 LUBRICATION & MAINTENANCE DIAGRAM SYMBOLS = Fitting = Other Service LUBRICANT SYMBOLS CG - Grease, Extreme Pressure GO - Multi-Purpose Lubricant EO - Engine Oil MC - Molycote GL - Open Gear Lube FUEL FILTER NOTE HF - Hydraulic Fluid 1997 EPA engines have fuel filter mounted on right side of engine rather than on left side as on prior...
- Page 41 Item Lube No. of CAUTION At End of First 30 Days Con’t Symbol Points Service intervals are based on machine usage of 1500 hours annually. Use of your unit Planetary Gear Drain Plug (drain and fill to level with plugs in position shown - may vary significantly and you must adjust service frequency for your usage to obtain item 61 is fill and level plug) maximum service life.
- Page 42 EXCAVATOR HAND SIGNALS Standard Signal - 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 43 THIS FAR TO GO - With hands raised and open CLOSE BUCKET - Hold one hand closed and MOVE SLOWLY - Place one hand motionless in inward, move hands laterally, indicating distance to stationary. Rotate other hand in small vertical circle front of hand giving motion signal.
- Page 44 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. b o o m t o h e l p f r e e i t . While actuating travel pedal in appropriate direction, Position carrier and upperstructure controls for extend or retract boom as required to help push or...
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