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Gradall XL4210III Operators Safety Manual

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Operator & Safety
Manual
Keep this manual with machine at all times
XL4210III
(Skimmer Boom)
S/N 4210000056
80724002
Original Issue
October 30th, 2015
This manual, and all manuals for the Gradall Hydraulic Excavator product
line, can be viewed or downloaded, free-of-charge, at www.mygradall.com

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Summary of Contents for Gradall XL4210III

  • Page 1 Manual Keep this manual with machine at all times XL4210III (Skimmer Boom) S/N 4210000056 80724002 Original Issue October 30th, 2015 This manual, and all manuals for the Gradall Hydraulic Excavator product line, can be viewed or downloaded, free-of-charge, at www.mygradall.com...

  • Page 2: Battery Warning

    State of California to cause cancer, birth defects and other reproductive harm. Gradall is a registered trademark for hydraulic excavators, industrial mainte- nance machines, attachments and other components manufactured and marketed by Gradall Industries, Inc.

  • Page 3: Revision Log

    Revision Log Revision Log REVISION LOG October 30th, 2015 - A - Original Issue of Manual 80724002...

  • 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: 80724002...

  • 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 1.1 Hazard Classification System............1-1 Safety Alert System and Safety Signal Words ......1-1 1.2 General Precautions..............1-1 1.3 Operation Safety .................1-2 Electrical Hazards..............1-2...
  • Page 8 Table of Contents 3.2 Checks Before Operation ............3-3 3.3 Crawler Chassis................3-4 Track Drive Pedals/Levers............ 3-4 Proper Crawler Usage ............3-5 Crawler Operation..............3-6 3.4 Engine Shutdown................ 3-7 3.5 Parking the Excavator..............3-8 Precaution................3-8 Parking Procedure ..............3-8 3.6 Preservation &...

  • Page 9: 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 10: 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 11: 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 12 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. 80724002...

  • Page 13: 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 14: 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 15 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. 80724002...

  • Page 16: Travel Hazards

    Section 1 - General Safety Practices Travel Hazards 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 chassis, boom and counterweight and sound horn.

  • Page 17: 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 18: 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 19 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 20: 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 21: 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 22 Section 1 - General Safety Practices NOTES: 1-14 80724002...

  • Page 23: 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 24: Walk-Around Inspection

    Section 2 - Pre-Operation and Controls WALK-AROUND INSPECTION Before conducting the walk around inspection, make sure the engine is off and the transmission is in neutral with the park brake engaged. Begin your walk-around inspection at item 1, as noted below. Continue to your right, checking each item in sequence.
  • Page 25 Section 2 - Pre-Operation and Controls 6. Main Control Valve and Cover - See Inspection Note. Replace damaged latch and weak access cover support strut immediately. 7. Center Pin - See Inspection Note. 8. Worklights - Clean, undamaged and aligned properly. 9.

  • Page 26: Safety Decals

    Section 2 - Pre-Operation and Controls SAFETY DECALS Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required. Decal Locations 80509013 80509017 80509015 80509012 80509018 80509015 80509019 ATTENTION OAE0410 TOP OFF COOLING SYSTEM AT EXPANSION TANK 80509014...
  • Page 27 Section 2 - Pre-Operation and Controls 80373077 80509016 NO STEP 80509015 OAE0420 80509004 80213104 80509015 80509012 OAE0430 80509016 80509013 80724002...

  • Page 28: Cab Components

    Section 2 - Pre-Operation and Controls CAB COMPONENTS OAE0040 80724002...
  • Page 29 Section 2 - Pre-Operation and Controls 1. Air Diffuser Vents 2. Electronic Monitoring Unit: See page 2-8 for details. 3. 12-Volt Accessory Outlet: A cigarette lighter is provided. The receptacle can be used to power an auxiliary 12 VDC device equipped with the appropriate adapter.

  • Page 30: Cab Controls & Indicators

    Section 2 - Pre-Operation and Controls CAB CONTROLS & INDICATORS Electronic Monitoring Unit OAD0260 1. Digital Display: See “Electronic Monitoring Unit Digital Display” on page 2-10 2. Ignition: Key Activated. See page 2-22 for details. 3. Joystick Control Pattern Selection Switch: (This switch is inactive for this machine).
  • Page 31 Section 2 - Pre-Operation and Controls This Page Intentionally Left Blank 80724002...

  • Page 32: Electronic Monitoring Unit Digital Display

    Section 2 - Pre-Operation and Controls Electronic Monitoring Unit Digital Display User Interface - Work Mode OAD0320 1. Visual Display (Work Mode): See page 2-11 for details. 2. Green Visual Indicator: Illuminated when no alarms are present. 3. Orange Visual Indicator: Illuminated when CAN fault is detected. See pages 2-12 &...

  • Page 33: Water Temp

    Section 2 - Pre-Operation and Controls Visual Display (Work Mode) After a “welcome” screen, the visual display is shown as illustrated below. HOURS FUEL OPER A 99999.9 999.9 °C °C WATER TEMP HYD TEMP SYSTEM OK OAD0330 1. Machine Hours 2.
  • Page 34 Section 2 - Pre-Operation and Controls System Status The System Status bar is used to display machine system status. When the machine system is functioning normally, “SYSTEM OK” is displayed. When the machine system has an alarm or fault present, it will display along with other alarms of the same level.

  • Page 35: Message Displayed

    Section 2 - Pre-Operation and Controls System Status Alarms Messages to be displayed on the system status bar and the visual and audible actions are described as follows: The “Buzzer” column indicates the behavior of the audible alarm. The “Reset Freq” column indicates the length of time an alarm can be silenced before the audible alarm returns if condition is still present.
  • Page 36 Section 2 - Pre-Operation and Controls User Interface - Menu Mode OAD0360 1. Visual Display (Menu Mode): See page 2-15 for details. 2. Keypad Input “1”: Scroll up through menu options. 3. Keypad Input “2”: Scroll down through menu options. 4.
  • Page 37 Section 2 - Pre-Operation and Controls Visual Display (Menu Mode) MENU: PREFERENCES UNITS METRIC LANGUAGE ENGLISH AUDIBLE ALARM CONTRAST 1 (UP) 2(DOWN) 3(SET) 4(ESC) OAD0370 To select a parameter, press the Keypad Input “1” or “2” buttons to scroll to desired selection.

  • Page 38: 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: (This switch is inactive for this machine). 3.
  • Page 39 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 40: Left Hand Arm Pod

    Section 2 - Pre-Operation and Controls Left Hand Arm Pod OAE0050 1. Boom Tilt Speed Switch: Rotary switch. Rotate switch clockwise to decrease boom tilt speed; rotate counterclockwise to increase boom tilt speed. 2. AM/FM Radio 2-18 80724002...

  • Page 41: 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 42 Section 2 - Pre-Operation and Controls Joystick Controls OAC0880 Left Hand Joystick Functions • Move the joystick back to retract rear boom hoist cylinder; move joystick forward to extend rear boom hoist cylinder. Move joystick right to swing boom right; move joystick left to swing boom left.

  • Page 43: Operator Seat Adjustments

    Section 2 - Pre-Operation and Controls Operator Seat Adjustments OAC2190 Prior to starting engine adjust seat for position and comfort. 1. Height Adjustment Control 2. Upper Seat Fore and Aft Adjustment Control 3. Weight Adjustment Control 4. Lower Seat Fore and Aft Adjustment Control 5.

  • Page 44: 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 45: 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. 80724002 2-23...
  • Page 46 Section 2 - Pre-Operation and Controls This Page Intentionally Left Blank 2-24 80724002...

  • Page 47: Section 3 - Operation

    Section 3 - Operation SECTION 3 - OPERATION ENGINE OPERATION Starting Engine 1. Perform walk-around inspection on page 2-2 2. Turn ignition to “START” position. Release key immediately when engine starts. If engine does not start after three attempts, check fuel supply system. 3.

  • Page 48: 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 49: Checks Before Operation

    Section 3 - Operation CHECKS BEFORE 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. 1. Check all lights, defroster, windshield wiper and washer for proper operation. 2.

  • Page 50: Crawler Chassis

    Section 3 - Operation CRAWLER CHASSIS Track Drive Pedals/Levers OAE0220 1. Left Hand Track Pedal/Lever: Press lever/pedal forward to engage left track forward. Pull lever/pedal back to engage left track reverse. Note: Lever and pedal move as one. 2. Right Hand Track Pedal/Lever: Press lever/pedal forward to engage right track forward.

  • Page 51: Proper Crawler Usage

    Section 3 - Operation Proper Crawler Usage Keep the following in mind when operating to extend the life of the crawler: • Travel in forward direction whenever possible (with track drive motors at rear). Traveling in reverse increases wear on sprockets and rollers. •...

  • Page 52: Crawler Operation

    Section 3 - Operation Crawler Operation ORIENTATION CONFUSION. Before actuating track WARNING drive pedals, think about the direction you are facing with respect to the direction the crawler is facing. OW0021 (Drive sprockets are at the rear of crawler). Confusion could cause you to travel in the direction opposite of what is expected.

  • Page 53: Engine Shutdown

    Section 3 - Operation ENGINE SHUTDOWN To shutdown the excavator, park in a safe location on flat level ground and away from other equipment and/or traffic lanes. 1. Bring machine to a stop by releasing Track Drive Levers/Pedals. 2. Swing the machine to align upperstructure with chassis 3.

  • Page 54: Parking The Excavator

    Section 3 - Operation PARKING THE EXCAVATOR Precaution Avoid parking on roads or highways. If it cannot be avoided, or in case of emergency, display warning flags, flares or flashing lights. Parking Procedure 1. Perform “Engine Shutdown” on page 3-7. 2.

  • Page 55: Preservation & Storage

    Section 3 - Operation PRESERVATION & STORAGE Because Gradall Industries cannot anticipate all storage situations, we do not provide step-by-step procedures for short-term storage. However, we do require that you review the following points and implement those appropriate to your situation.
  • Page 56 Section 3 - Operation This Page Intentionally Left Blank 3-10 80724002...

  • Page 57: Section 4 - 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 58: 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 59: Service & Maintenance Schedules

    Section 4 - Lubrication & Maintenance SERVICE & MAINTENANCE SCHEDULES 10 Hour Maintenance Schedule EVERY Check Engine Follow Lubrication Check Engine Windshield/Washer Mirrors Oil Level Schedule Coolant Level Fluid Bottle (clean and adjust for proper visibility) (clean cab glass) Air Filter Check Hydraulic Check Hydraulic Check Fuel...
  • Page 60 Section 4 - Lubrication & Maintenance 50 Hour Maintenance Schedule EVERY Inspect Check Swing Follow Lubrication Air Filter Drain Fuel/ and Clean Schedule Water Transmission Vacuator Oil Cooler Assy. Oil Level Valve Separator EVERY Check Track Check Track Check Planetary Idlers Rollers Gear Oil Level...

  • Page 61: 100 Hour Maintenance Schedule

    Section 4 - Lubrication & Maintenance 100 Hour Maintenance Schedule EVERY Apply Open Check Follow Lubrication Gear Lube to Schedule Fan Belt Tilt Gear Teeth EVERY Follow Lubrication Check Schedule Track Fitting** - Adjustment must be made by qualified personnel only. OAE0110 There should be 1-3/8”...

  • Page 62: 1St 30 Days (250 Hrs Max) & 250 Hour Maintenance Schedule

    Section 4 - Lubrication & Maintenance 1st 30 Days (250 hrs Max) & 250 Hour Maintenance Schedule 1st 30 DAYS Drain and Refill Follow Lubrication Torque all Items Swing Transmission Schedule Listed in Torque Chart 1st 30 DAYS Follow Lubrication Drain and Refill Torque all Items Schedule...

  • Page 63: 600 Hour Maintenance Schedule

    Section 4 - Lubrication & Maintenance 600 Hour Maintenance Schedule EVERY Clean Fuel Replace Fuel/ Change Engine Strainer Water Oil and Separator Element Filter OAE0130 80724002...

  • Page 64: 750 Hour Maintenance Schedule

    Section 4 - Lubrication & Maintenance 750 Hour Maintenance Schedule EVERY Hydraulic Remove, Clean Torque all Items Follow Lubrication Change Fuel Fluid & Filters** and Replace Schedule Listed in Filter Swing Transmission Torque Chart Breather Check Battery - Have hydraulic fluid analyzed to determine condition. Use test port mini-check in pump line to obtain sample.

  • Page 65: 1500 Hour Maintenance Schedule

    Section 4 - Lubrication & Maintenance 1500 Hour Maintenance Schedule EVERY 1500 Change Hydraulic Drain and Refill Follow Lubrication Engine Coolant Fluid & Filters** Swing Transmission Schedule - Unless hydraulic fluid is analyzed semi-annually to determine level of contamination, system must drained, flushed and replenished on an annual basis.

  • Page 66: Lubrication Schedules

    Section 4 - Lubrication & Maintenance LUBRICATION SCHEDULES Boom Sheaves • Lube Frequency - Every Shift (BOTH SIDES OF BOOM) (BOTH SIDES OF BOOM) OAE0890 4-10 80724002...

  • Page 67: Boom Rollers

    Section 4 - Lubrication & Maintenance Boom Rollers • Lube Frequency - Every Shift FRONT OF BOOM (8 rollers) (8 rollers) (4 rollers) REAR OF SECOND BOOM (5 rollers) REAR OF THIRD BOOM OAE0910 80724002 4-11...

  • Page 68: Hoist Cylinders & Swing Bearing

    Section 4 - Lubrication & Maintenance Hoist Cylinders & Swing Bearing • Lube Frequency - Weekly Rear Hoist Cylinders - Top Swing Bearing - Bottom OAE0900 4-12 80724002...

  • Page 69: Section 5 - Specifications

    PRODUCT SPECIFICATIONS Lubrication & Fluid Capacities Note: Lubricants described in this table are used in standard machines when they are shipped from Gradall Industries, Inc. Engine Crankcase Oil Capacity with Filter Change ............17 quarts (16 liters) Type of Oil ................15W-40 (MIL-L-2104E) Cooling System System Capacity ..............5.6 gallons (21,2 liters)

  • Page 70: Battery

    Section 5 - Specifications Track Idler Capacity..................0.71 pints (.34 liters) Type of Fluid ..............SAE 30/40 (MIL-L-2104E) Track Idler Capacity..................1.1 pints (.52 liters) Type of Fluid ..............SAE 30/40 (MIL-L-2104E) Grease Fittings Capacity.....................as required Type of Lube ..............Extreme Pressure Lube #2 * Capacities are approximate - Check level to be sure Battery TROJAN C31...

  • Page 71: Torque Chart

    Section 5 - 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 72 Section 5 - Specifications Flywheel Mounting Hardware Quantity ........................12 Thread Size (grade)..................M8-1.25 Torque (lubricated)..............16-20 lb-ft (22-27 Nm) Gear Pump Mounting Hardware Quantity ........................2 Thread Size (grade)..................M10X30 Torque (lubricated)..............32-36 lb-ft (43-48 Nm) Track Roller Quantity ........................48 Thread Size (grade)..................5/8-11 (8) Torque (lubricated)............

  • Page 73: Fuses

    Section 5 - Specifications FUSES Fuse location and size designations are identified with the decal shown below. MONITOR POWER SPARE IGNITION POWER RC POWER - 1 ATTENTION: SENSOR POWER USE FUSE SIZES AS DESIGNATED. RC POWER - 3 USING THE WRONG FUSE SIZE CAN RC POWER - 2 CAUSE DAMAGE TO ELECTRICAL SP-3...
  • Page 74 Section 5 - Specifications This Page Intentionally Left Blank 80724002...

  • Page 75: Index

    Index Index Lubrication & Maintenance ....4-1 Lubrication Schedule ......4-10 Battery ..........5-2 Operator Seat .........2-21 Cab Components ......2-6 Cab Controls & Indicators ....2-8 Capacities......... 5-1 Parking Procedure ......3-8 Chemical Hazards ......1-10 Personal Protection Equipment ..1-13 Crawler Chassis ....... 3-4 Pre-Operation and Controls ....2-1 Crawler Operation ......
  • Page 76 Index 80724002...

  • Page 77: Hand Signals

    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 78 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 Gradall Europe Division of Tieluiska Harkkokatu 6 FI-05800 Hyvinkää, Finland Tel. +358 (0)20 759 0400 Fax. +358 (0)19 485 278 VAT:FI05973039 www.gradalleurope.com...

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4210000056