Gradall XL5100 Operator's Manual

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OPERATOR'S MANUAL

XL5100 UPPER

XL5200

24604140

July 2002

Remote Control Units S/N's 0516121 thru 0512152,

0510526 thru 0510539

& 0210017490 thru 0210017933

Crawler Units S/N's 0529121 thru 0522150,

0520726 thru 0520735,

0210017451 thru 0210017943

& 5200000736 & After

Form #29619

Original Issue 8/96

GRADALL

406 Mill Avenue S.W.

New Philadelphia, OH, 44663, USA

Telephone: (330) 339-2211

Fax: (330) 339-3579

Table of Contents

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Summary of Contents for Gradall XL5100

Page 1 OPERATOR'S MANUAL XL5100 UPPER XL5200 24604140 July 2002 Remote Control Units S/N's 0516121 thru 0512152, 0510526 thru 0510539 & 0210017490 thru 0210017933 Crawler Units S/N's 0529121 thru 0522150, 0520726 thru 0520735, 0210017451 thru 0210017943 & 5200000736 & After Form #29619...
Page 4: Important Safety Notice
Strict attention to, and compliance with, instructions provided in this manual, the XL5100 6x4 & 6x6 Carrier Operation & Lubrication Manual, as well as the EMI & Gradall Hydraulic Excavator Safety Manuals and all instructional decals and plates affixed to the machine, will help you avoid personal injury and damage to the equipment.
Page 6 If operator will also drive carrier: The upperstructure includes a separate operator’s station XL5100 & XL5200 6x4 & 6x6 Carrier Operation for control of excavator functions and is equipped with & Lubrication Manual a separate engine to power the upperstructure.
Page 7 SAFETY HIGHLIGHTS Read and understand this manual, XL5100 6x4 & 6X6 Carrier Operator’s Manual, the Gradall and EMI Hydraulic Excavator Safety Manuals 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 Cradle Boom Holes Stay clear of PINCH POINTS. Getting caught in a pinch point can cause serious injury or death. Boom Access Covers Bucket & Linkage Counterweight & Another Object Upperstructure & Carrier...
Page 9 If it differs, or if you aren’t sure, worker’s tools personal items contact your Gradall distributor before machine. Such items can cause other workers to your unit. approach the machine without your knowledge and 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...
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 LO LO gear range Whenever rotating equipment (such as a...
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 carrier when swinging. Position unit so that it won’t be necessary to swing close to cab.
Page 13 SAFETY HIGHLIGHTS operate with bystanders 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 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 GRADALL GRADALL CRAWLER HYDRAULIC REMOTE GRADALL CRAWLER HYDRAULIC REMOTE OPERATING CONTROLS OPERATING CONTROLS OPERATING CONTROLS OPERATING CONTROLS SOUND HORN SOUND HORN ATTACHMENT ON JOYSTICK ON/OFF LEVER JOYSTICK ON/OFF LEVER ATTACHMENT ON JOYSTICK ON/OFF LEVER ARM REST UP = OFF...
Page 15 Decals Inside Cab 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 OPEERATING, 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 LOOSE OBJECTS OFF MACHINE, SOUND...
Page 16 Located on left window (remote units only) Part No. 8364-3035 Located on control console Part No. 8091-3020 Located on control console Part No. 8091-3016 Decal Outside Cab GRADALL ® HYDRAULIC SYSTEM HYDRAULIC SYSTEM IS FILL WITH TRACTOR HYDRAULIC FLUID PRESSURIZED Mobifluid BEFORE OPENING THE HYDRAULIC SYSTEM.
Page 17: Diesel Fuel
Decals Outside Cab TO PREVENT INJURY, STAY CLEAR OF MOVING DEATH OR INJURY MAY RESULT FROM PARTS. FASTEN COVERS CONTACTING ELECTRICAL LINES. BEFORE STARTING ENGINE. READ SERVICE TO PLACE ANY PART OF THIS UNLAWFUL MACHINE OR LOAD WITHIN 10 MANUAL BEFORE FEET OF HIGH VOLTAGE LINES ADJUSTING OR OF UP TO 50,000 VOLTS...
Page 18: Hydraulic Oil
GRADALL THE GRADALL COMPANY 4 0 6 M i l l A v e . , S . W . N e w P h i l a d e l p h i a , O h i o Located at front center of frame Part No.
Page 19: 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 fine the most comfortable operating position. Be sure to stop engine first. Armrest Release Backrest Release Seat Height/ Slope Releases...
Page 20 c o n d i t i o n s m a y r e q u i r e m o r e f r e q u e n t e l e m e n t Heater washing/replacement.
Page 21 Test your controls before operating. The control pattern illustrated is the standard Gradall controll pattern. If your machine controls have been modified to any other pattern, be certain you are familiar with thier functions before operating and ensure that control diagram in cab is changed to show thw actual pattern.
Page 22: Electronic Monitor
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 SYMBOL & ALARM Battery Charge: Symbol glows (red) in response to low battery charge (below 11.6 VDC). Engine Coolant Level: Symbol glows (red) and...
Page 23: Before Starting Engine
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 changing filter elements, Use extreme caution when checking items...
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 m i n i m i z e c o n d e n s a t i o n . Check for presence of fully charged fire extin- Engine should be turned off while refuel- quisher on wall behind seat in cab.
Page 25: Cold Weather Starting Aids
E N G I N E O P E R AT I O N N O T E : I f e n g i n e i s b e i n g s t a r t e d a t b e g i n n i n g o f w o r k s h i f t b e s u r e t o p e r f o r m a l l “ C H E C K S A N D S E RV I C E S B E F O R E S TA RT I N G E N G I N E ”...
Page 26 N o r m a l E n g i n e O p e r a t i o n 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 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 .
Page 27 WARM UP & OPERATIONAL CHECKS (To be performed at beginning of each work shift) C o m p l e t e a l l r e q u i r e d m a i n t e n a n c e b e f o r e o p e r a t i n g u n i t . safety, efficiency service...
Page 28 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
REMOTE CONTROL NOTE: Remote control is to be used for positioning unit at job site, not for over-the road travel. P r e p a r i n g C a r r i e r f o r R e m o t e C o n t r o l O p e r a t i o n With carrier on level surface, apply parking brake.
Page 30 Precautions for Remote Control Operation Always give audible signal before moving unit. Be sure to clear visibility in direction to travel; use a signalman to compensate for blind spots. Never permit buckle to drag while moving unit. Be sure all Warm-Up and Operational Checks have been performed.
Page 31 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. Never park crawler units on a steep incline or on the side of a hill.
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 stop engine before repositioning Always operate with engine at full throttle to door and windows.
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 right (H) to swing right to digging site.
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 c l o c k w i s e .
Page 36 A TYPICAL GRADALL DIGGING CYCLE M o v e l e f t j o y s t i c k t o l e f t ( C ) t o e m p t y t h e M o v e r i g h t j o y s t i c k t o r i g h t ( H ) t o s w i n g r i g h t o r t o l e t ( G ) t o s w i n g l e f t t o d u m p s i t .
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 a r e n o t d e s i g n e d f o r p i c k a n d c a r r y l i f t s . hydraulic lift capacity, not stability.
Page 38 P e r f o r m a n u n l o a d e d t r i a l r u n o f t h e l i f t t o Measure boom height/depth from bucket adapter d e t e r m i n e m a x i m u m l o a d r a d i u s r e q u i r e d a n d pivot shaft to ground level (same plane as bottom of m a x i m u m b o o m h e i g h t a n d d e p t h r e q u i r e d t o...
Page 39 SECURING BOOM & ATTACHMENT FOR TRAVEL I F Y O U G E T S T U C K 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...
Page 40 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 41 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.
Page 44: Lubrication And Maintenance
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/ *** Capacities are approximate - check level to be sure.

This manual is also suitable for:

Xl5200