Related Manuals for Gradall G3WD Series
Summary of Contents for Gradall G3WD Series
- Page 1 OPERATOR’S MANUAL G3WD 2460-4079 July 2002 Upperstructure Starting S/N 013428 Undercarriage Starting S/N 01D567 Form #29122 Original Issue 11/91 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
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Page 4: Important Safety Notice
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 M a n u a l a n d S a f e t y M a n u a l s b e f o r e o p e r a t i n g frame. the machine. If you have any questions regarding the Gradall Excavator, contact...
- Page 7 SAFETY HIGHLIGHTS Read and understand this manual, The Gradall Excavator Safety Manual, CIMA Safety Manuals and all instructional decals and plates before starting, operating or performing maintenance procedures on this equipment. KEEP THIS MANUAL IN THE CAB. Watch for these symbols; they are used to call your attention to safety notices.
- Page 8 SAFETY HIGHLIGHTS Learn to recognize ‘PINCH POINTS’ Boom Cardle Counterweight & Another Object 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 Items 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. result in serious injury or death.
- 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 T r a n s m i s s i o n i n p r o p e r r a n g e...
- Page 11 Conduct test with controls set for remote operation (page 28). If one or more wheels indicate brake failure, DO NOT DRIVE THE GRADALL HYDRAULIC Center boom fully over rear of chassis and rest EXCAVATOR. Investigate and correct. For boom or bucket on the ground.
- Page 12 SAFETY HIGHLIGHTS Do not operate with bystanders or other workers near machine. Watch out for carrier cab when swinging. Position unit so that it won’t be necessary to swing close to cab. Attach load only as shown. Lift Capacity Chart values are based on load hanging vertically from tool eye as shown.
- Page 13 SAFETY HIGHLIGHTS Avoid injury! Always relieve pressure trap- GRADALL LIFTING CAPACITIES ped in circuits before disconnecting, re- RATED LIFT CAPACITY moving or installing hydraulic components. Pressure can be maintained in hydraulic circuits long after the engine has been shut down. This pressure can cause oil (or items such as pipe plugs) to “shoot out”...
- Page 14 Decals Inside Carrier Cab USE TWO HANDS WHEN CLIMBING ON MACHINE. 7702-3003 Located on cab wall Part No. 7702-3003 Located on dashboard Part No. 7738-3422 REMOTE CONTROL ENGAGEMENT PROCEDURE STOP THE MACHINE PLACE THE TRANSMISSION SHIFTER IN NEUTRAL SET THE PARKING BRAKES TURN THE ENGINE OFF AFTER AIR PRESSURE EXCEEDS 100 PSI AFTER ENGINE STOPS COMPLETELY TURN THE KEY...
- Page 15 Decals Inside Carrier Cab CAUTION ALLOW INCREASED STOPPING DISTANCE WITH NEW BRAKES. BRAKE CAPABILITY WILL IMPROVE AFTER SEVERAL STOPS. Located inside cab PART NO. 8688-1755 Part No. 8688-1305 Located inside cab Part No. 8688 1755 Located on dashboard Part No. 7738-3252 TO PREVENT ENGINE RING GEAR DAMAGE, WAIT 10 SECONDS AFTER ENGINE ROTATION STOPS BEFORE ATTEMPTING...
- Page 16 Decals Outside Carrier Cab PRESS POPPET TO NYLON BRAKE RELIEVE PRESSURE BEFORE REMOVING LINES MAY BE FILLER CAP DAMAGED BY 7700-1001 HEAT. AVOID Located on hydraulic reservoir WELDING ON Part No. 7700-1001 OR AROUND CARRIER FRAME UNLESS LINES ARE PROTECTED FROM HEAT.
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Page 17: Diesel Fuel
Decals Outside Carrier Cab (cont.) KEEP CLEAR OF MACHINE SWING AREA. Located on each side of frame at rear, on each side of boom & on counterweight Part No. 8360-1018 Located on hydraulic reservoir Part No. 8697-1197 TO PREVENT ENGINE RING GEAR DAMAGE, WAIT 10 SECONDS AFTER ENGINE DIESEL FUEL ROTATION STOPS BEFORE ATTEMPTING... - Page 18 7733-3004 Located on right cab wall Part No. 7733-3004 GRADALL G-3WD HYDRAULIC REMOTE OPERATING CONTROLS (GRADALL TRADITIONAL CONTROL PATTERN) 1. BUCKET OPEN 2. BUCKET CLOSE 3. RAISE BOOM 4. LOWER BOOM 5. SWING LEFT 6. SWING RIGHT 7. RETRACT BOOM 8.
- Page 19 Decals Inside Upperstructure Cab (cont.) ALWAYS OPERATE ENGINE AT FULL THROTTLE TO KEEP CYLINDERS FULL OF OIL TO PREVENT UNEXPECTED MACHINE MOVEMENTS. 7733-3026 Located on joystick column Part No. 7733-3026 Located on joystick column Part No. 7733-3029 Located on right cab will (4 x 4 units only) Part No.
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Page 20: Hot Exhaust
Decals Outside Upperstructure Cab TO PREVENT INJURY, KEEP OUT OF BOOM HOLES. 7702-3009 Located on each side of boom Part No. 7702-3009 Located on each side of boom CLAMP BOLT Part No. 8360-1011 TORQUE 200 ft.lb. Located on both side of boom clamps Part No. - Page 21 CARRIER CAB CONTROLS, INSTRUMENTS & INDICATORS REMOTE display glows red to indicate Remote/Travel switch is positioned for remote control * ENGINE TEMP . display glows red to indicate engine coolant temperature has reached 210 F . operation. * CONV. TEMP . display glows red to indicate torque converter temperature has reached * OIL PRESS.
- Page 22 UPPERSTRUCTURE CAB CONTROLS AND INSTRUMENTS 1. Throttle Lever Defroster Switch 2. Boom In/Out & Swing Joystick Accessory Switch 3. Boom Tilt Switch Accessory Switch 4. Transmission Shift Up/Down Switch Emergency Brake Knob 5. Horn Switch Air Pressure Gage 6. Boom Hoist & Bucket Joystick Forward/Reverse Travel Pedal 7.
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Page 23: Engine Operation
ENGINE OPERATION Checks & Services Before Starting Engine (To be performed at beginning of each work shift) Complete all required maintenance before operating unit. Inspect visually for damage, leaks, vandalism & Make sure remote switch is in travel position. needed maintenance. Check coolant level. -
Page 24: Normal Engine Operation
Normal engine operation overspeeding engine (exceeding governed Observe voltmeter, water temperature RPM). governor control over engine pressure gages frequently sure engine speed when engine is being “pushed” by carrier load. systems are functioning properly. Select appropriate gear ratio service Be alert for unusual noises or vibration. When brake to assist in slowing travel down steep grades. -
Page 25: Checks After Starting Engine
CHECKS AFTER STARTING ENGINE (To be performed at beginning of each work shift) Complete all required maintenance before driving Observe water temperature gage. Proper op- Check operation of windshield washer and erating temperature approximately 160/ wiper. 210 °F. (71/104 °C). Check all lights and turn signals for proper tachometer Observe... -
Page 26: Brake System
BRAKE SYSTEM The air brake system includes a service brake, an emergency brake, parking brake digging brake. Wear seat belt being thrown from carrier driver’s seat during braking LOW AIR INDICATOR emergency. DUAL AIR GAGE Service Brake Do not operate carrier or upperstructure SERVICE BRAKE while low air indicator is glowing . -
Page 27: Parking Brake
BRAKE SYSTEM (Con’t.) EMERGENCY BRAKE pressure gages indicate some system APPLICATION pressure remaining, it may be possible to drive the (pressure lost in rear) unit a short distance to remove it from a hazardous position (use first gear only). carrier cannot moved, direct... - Page 28 Digging brake (Con’t.) Remote control braking The digging brake is applied by the remote switch DIGGING BRAKE APPLICATION carrier cab. digging brake will released reapplied automatically travel p e d a l i n u p p e r s t r u c t u r e i s a c t u a t e d a n d r e l e a s e d . Do not activate remote switch while trav- eling .
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Page 29: Steering System
STEERING SYSTEM Conventional steering Remote control steering Your unit is equipped with a travel/steering pedal power steering system provides effort upperstructure cab. engine must steering under normal conditions greater running provide power remote control control in the event of a blowout or soft ground. steering. -
Page 30: Power Train
POWER TRAIN The power train furnished on 4 x 2 carriers (units both front and rear driving axles) includes the engine, having one driving axle at rear) includes the engine, torque converter, power shift transmission and the torque converter, power shift transmission and the front rear driving... -
Page 31: Differential Lock
Though it is permissible to use the braking power of speed when the engine is being pushed by the carrier the engine when traveling downhill, take care to load. Select an appropriate gear ratio and use your avoid overspeeding the engine (exceeding governed brakes to assist in slowing the carrier. - Page 32 R E M O T E C O N T R O L 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 After reaching job site, perform following procedure REMOTE display light will glow t o p r e p a r e c a r r i e r f o r r e m o t e c o n t r o l t r a v e l .
- Page 33 Precautions for Remote Control Operation counterweight before starting to move. Be especially watchful for overhead wires and traffic. Always return machine to TRAVEL mode after leaving upper cab unless REMOTE Never tow load using remote control drive. operation will be continued within a few Always give audible signal before moving unit.
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Page 34: In Case Of Trouble
TRAVEL portion Remote/Travel switch. This returns carrier to conventional travel mode. PARKING THE GRADALL Precautions: Avoid parking on slopes or near an excavation. chine with boom in air. Avoid parking on roads or highways. If it can- Park on level ground and block wheels. - Page 35 Practice with joystick 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 36 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 right to digging site.
- Page 37 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 lower boom and force bucket into ground, pull tilt clockwise.
- Page 38 A TYPICAL GRADALL DIGGING CYCLE Move right joystick to right (H) to swing right Move left joystick to left (C) to empty the bucket. or to left (G) to swing left to dump site. If necessary, extend boom pushing right joystick forward (F).
- Page 39 LlFTING AND POSITIONING A LOAD Precautions Do not travel with a suspended load. Excava- Do not depend on machine tipping as a warning of tors are not designed for pick and carry lifts. overload. Some load ratings are based on hydraulic lift capacity, not stability.
- Page 40 General Planning A Lift The excavator can lift and position loads safely Determine the weight of the load. Weight of O N LY I F Y O U P L A N T H E L I F T P R O P E R LY. slings, chains and auxiliary lifting devices must be added as part of the load.
- Page 41 SLIDE-A-BOOM EXTENSION & RETRACTION The Slide-A-Boom feature enables the operator to quickly reposition the boom on the cradle to gain an additional four feet of reach. Failure to apply proper torque to cap screws in steps 9 and 10 can cause structural dam- Extending Slide-A-Boom age.
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Page 42: 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 45: Lubrication And Maintenance
LUBRICATION & MAINTENANCE Lubrication Notes See recommended lubricants & capacities (pg. 39) Lubrication Notes Intervals shown are for normal (8 hour day) usage and conditions. Check lubricant levels when lubricant is cool. Adjust intervals for abnormal usage and conditions. Clean filter and air cleaner housing and reusable elements using Lubricate points indicated by dotted leaders on both sides of unit. - Page 46 TORQUE CHECK DIAGRAM CARRIER CARRIER...
- Page 47 TORQUE CHECK SCHEDULE *Torque may be increased to maximum of 2000 ft.-lbs. (2720 Newton-Metres) to align lock. Precautions Check fastener torques for all items listed using an A p p l i c a t i o n o f l e s s t h a n p r o p e r t o r q u e c a n a l s o c a u s e accurate torque wrench.
- Page 48 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 u nles s si gnal s are clearl y un der stoo d b y bo th signalman and operator.
- Page 49 THIS FAR TO GO - With hands raised and open C LO S E B U C K ET - Ho l d o ne h a n d clo sed an d M O V E S L O W LY - P l a c e o n e h a n d m o t i o n l e s s i n inward, move hands laterally, indicating distance to stationary.
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Page 50: Hydraulic Equipment
Hydraulic Equipment 406 Mill Avenue, S.W. New Philadelphia, Ohio 44663 PHONE: (330) 339-2211 FAX: (330) 339-8468 WEB SITE: www.gradall.com CALIFORNIA CALIFORNIA Proposition 65 Warning Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead Diesel engine exhaust and some of its...
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