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Gradall XL2210 Operator's Manual
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Gradall XL2210 Operator's Manual

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OPERATOR'S MANUAL
XL2210
24604150
July 2002
Covers S/N's 0225402 thru 0227422,
0221332 thru 0221335,
0210017437 thru 0210018042
& 2210000336 & 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

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Summary of Contents for Gradall XL2210

  • Page 1 OPERATOR'S MANUAL XL2210 24604150 July 2002 Covers S/N's 0225402 thru 0227422, 0221332 thru 0221335, 0210017437 thru 0210018042 & 2210000336 & 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...

  • Page 2: Important Safety Notice

    Safe operation depends upon 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 recommend operating procedures can help you avoid accidents.

  • Page 3: List Of Effective Pages

    LIST OF EFFECTIVE PAGES This page is provided to enable reader to determine that PAGE DATE DESCRIPTION this manual is complete and current with respect to the latest revision issued. Revised material will be indicated by a vertical bar to the left of added.
  • Page 4 EMI Hydraulic Excavator Safety Manual major components and areas of the excavator. NOTICE The XL2210 Special Industrial unit is an excavator based machine. Although it is referred to through- out this manual as an excavator, its intended ap- plication is performing industrial functions.
  • Page 5 Nomenclature...
  • Page 6 TOOL KITS TOOL KIT (Kit can be ordered under part number 8021-5004)
  • Page 7 SAFETY HIGHLIGHTS Read and understand this manual, the Gradall Hydraulic Excavator Safety Manual, the EMI Hydraulic Excavator Safety Manual and all instructional decals and plates before starting, operating or performing maintenance procedures on this machine. Keep these manuals in cab.
  • Page 8 SAFETY HIGHLIGHTS Learn to recognize ‘PlNCH POINTS’...
  • Page 9 Never carry a water can, equipment, or other in this manual. If it differs, or if you aren’t sure, worker ’s tools or personal items on the contact your Gradall distributor before you run machine. Such items can cause other workers to 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 3 and then operate the unit in a safe, open area to become familiar with the controls. OPERATE ON ROADWAY ONLY UNDER swinging.
  • Page 11 SAFETY HIGHLIGHTS TRAVEL ON OFF-HIGHWAY GRADES IS RECOMMENDED ONLY UNDER THE Whenever rotating equipment (such as a FOLLOWING CONDITIONS: mower or mixer) is installed on machine, Boom is fully retracted and parallel with adequate shielding must be installed to tracks. deflect flying debris.
  • Page 12 SAFETY HIGHLIGHTS Do not operate with bystanders or other workers near machine. Be certain boom or attachment is resting on ground and that engine is stopped before performing lubrication or maintenance procedures inside boom. Always be sure of adequate visibility in area of operation.
  • Page 13 Decals FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE USE TWO RISK OF SERIOUS INJURY: HANDS WHEN BEFORE OPERATIONS. READ OPERATOR AND SAFETY MANUALS. UNDERSTAND ALL CONTROLS AND CLEAR OFF LOOSE OBJECTS OFF MACHINE, SOUND HORN CLIMBING ON BEFORE STARTING ENDGINE. STABILTY IS DECREASED DURING TRAVEL.
  • Page 14 (8 HOUR MAXIMUM OPERATING TIME) REURN THROTTLE TO IDLE BEFORE SHUTTING DOWN Located on transmitter Part No. 8029-3017 Located on control compartment door Part No. 8029-3016 (Gradall control pattern) Part No. 8029-3024 (SAE control pattern) Part No. 8029-3025 (J D control pattern)
  • Page 15 Decals WARNING HIGH PRESSURE CYLINDER APPLY LUBRICANT THROUGH FITTING ONLY TO TIGHTEN TRACK. TOP TRACK SAG TO BE SET AT 13/16” (20 MM). WHEN TRACK IS TOO TIGHT RELIEVE PRESSURE BY OPENING FILL FITTING 1 TO 2 TURNS ALLOWING GREASE TO ESCAPE. DO NOT REMOVE ANY PARTS UNTIL ALL PRESSURE HAS BEEN RELIEVED.
  • Page 16 Decals T O P R E V E N T I N J U R Y, S TAY C L E A R O F M O V I N G PA R T S . FA S T E N C O V E R S OR INJURY MAY RESULT FROM DEATH B E F O R E S TA R T I N G...
  • Page 17 Decals DO NOT GO NEAR LEAKS High pressure oil easily punctures skin causing serious injury, gangrene or death. If injured, seek emergency medical help. Immediate surgery is required to remove oil. Do not use finger or skin to check for leaks. Lower load or relieve hydraulic pressure before loosening fittings.
  • Page 18 SERIAL NO. PLATES See page 4 for help in finding locations. Machine P.l.N. Plate Located on Front Upperstructure Frame Engine Main Hydraulic Pump Located in Engine Compartment Located in Pump Compartment Swing Transmission Implement Pump Located in Pump Compartment Located Beneath Boom Cradle Swing Motor Track Drive Motors Located on Swing Transmission...
  • Page 19 CHECKS & 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, packing and bearings. When adding fluids or lubricants, refer to lubrication Use extreme caution when checking section of this manual to determine proper type, items beyond your normal reach.
  • Page 20 Always stop engine when refueling. Be sure area is free of open flame, sparks or any condition which could cause fuel or fuel vapor to ignite. Check for the presence of a fully charged fire Check fuel level symbol on electronic monitor extinguisher inside control compartment.

  • Page 21: Remote Controls

    The major components of the radio remote control to revert to a secure state. However, machine horn system provided on the XL2210 industrial machine are will sound intermittently for at least 15 minutes to alert the remote control receiver and the control operator before system reverts to secure state.

  • Page 22: Remote Control Transmitter

    A fully charged battery will function for approximately Turn transmitter Off until you are ready to operate 8 hours with transmitter turned on. It is recommended machine. There is a continuous drain on battery as that a fully charged battery be installed at beginning of long as transmitter is turned on.
  • Page 23 Remote Control Transmitter (continued) General: Engine cannot be started unless Start/Horn button is passed first. With remote control system switched on (RUN posi- tion - see Control Console heading on page 21) the The engine should have been stopped at low idle remote control receiver is ON, and is in contact with speed at end of previous shift.

  • Page 24: 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 SYMBOLS & ALARM Battery Charge: Symbol 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 25: Engine Operation

    ENGINE OPERATION NOTE: If engine is being started at beginning of work shift be sure to perform all CHECKS & SERVICES BEFORE STARTING ENGINE (pages 18 & 19). Raise Emergency Stop button, press Start/Horn Starting Engine button briefly and then press Engine Start Button to Follow instructions under REMOTE CONTROLS engage starter motor.

  • Page 26: Normal Engine Operation

    Normal Engine Operation Engine Operating Temperature: Cummins - 160 to 200°F. (71 to 93° C.) Battery charge indication of alternator output: Approximately 14 volts with engine running at 2000 RPM When using excavator or travel functions, operate engine at full throttle to prevent Be alert for unusual noises or vibration.
  • Page 27 WA R M U P & O P E R AT I O N A L C H E C K S (To be performed at beginning of each work shift) Complete all required maintenance before operating unit. The safety, efficiency and service life of your excavator Observe hydraulic oil return filter caution will be increased by performing the following symbol.
  • Page 28 ADAPTER ATTACHMENT INSTALLATION Keep boom in fully extended position while installing bucket. Stay clear until bucket adapter has been filled to buckets as shown in step 4. Digging with a loose or improperly fitted bucket can cause excessive wear, shear adapter bolts or cause loss of bucket.
  • Page 29 USE YOUR CRAWLER PROPERLY Travel in forward direction whenever Never park crawler unit on a steep incline or on the possible (with track drive motors at rear). side of a hill. This can distort roller seals and cause a loss of lubricant which could ruin Traveling in reverse increases wear on sprockets rollers.
  • Page 30 HOW TO OPERATE THE CRAWLER Practice with travel controls in a safe, open area. Avoid confusion! Before actuating track drive levers, 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 machine to travel in the direction opposite of that expected.
  • Page 31 When operating, run engine at high idle control pattern shown is the standard (full throttle) for maximum efficiency. Gradall pattern. If controls have been When excavator/travel functions will not modified to another pattern, be sure you Be used for a period exceeding five are familiar with altered pattern, and minutes, reduce engine speed to low idle.
  • Page 32 A TYPICAL GRADALL DIGGING CYCLE Pull back on left joystick (A) to raise boom far Move right joystick to left (G) to swing left or to right (H) to swing right to digging site. enough to clear all obstructions. Move left joystick to left (C) to open bucket or to While pushing right joystick forward (F) to extend right (D) to close bucket for correct penetration.
  • Page 33 A TYPICAL GRADALL DIGGING CYCLE If required, move tilt lever to left (I) to tilt counter While pushing forward on left joystick (B) to clockwise or to right (J) to tilt clockwise. Turn Tilt lower boom and force bucket into ground, pull back on right joystick (E) to retract boom and fill bucket.
  • Page 34 A TYPICAL GRADALL DIGGING CYCLE Move right joystick to right (H) to swing right or Move left joystick to left (C) to open bucket and to left (G) to swing left to dump site. If necessary, dump load. extend boom by pushing right joystick forward (F).

  • Page 35: Installation

    HAMMER INSTALLATION This installation procedure is to be performed ONLY by experienced field maintenance personnel. Installation: Extend boom approximately half way and tilt boom 180 degrees as shown below. NOTE: The following conditions are assumed: With engine operating at low idle, align telescoping boom with hammer bracket as shown.
  • Page 36 Secure pin weldment using retaining rod and 1/4-20 screws and nuts. Lubricate tool cylinder rod eye and hammer bracket pivot pin (3 fittings). Raise boom and tilt boom 180 degrees. Move ham- Check to be sure transmitter Attachment switch mer to a vertical position. is in Off position.
  • Page 37 LUBRICATION & MAINTENANCE DIAGRAM SYMBOLS =Lube Fitting =Other Service -------- =Service Both Sides Lubricant Symbols ANTI-FREEZE (permanent) GREASE (extreme pre ure) DIESEL FUEL ENGINE OIL OPEN GEAR LUBRICANT MULTI-PURPOSE LUBE HYDRAULIC FLUID LUBRICATION. NOTES Clean lubrication fittings before lubricating. Intervals shown are for normal (8 hour day) usage and conditions.
  • Page 38 Planetary Gear Drain Plug (drain & fill to level with plugs in position shown) Planetary Gear Drain Plug (drain & refill) Check torque of all items listed in torque table. SEE MANUFACTURERS COMPONENT LITERATURE FOR ADDITIONAL LUBRICATION AND MAINTENANCE INFORMATION. FAILURE TO USE GRADALL HYDRAULIC FlLTER ELEMENTS COULD VOID WARRANTY.
  • Page 39 Recommended Lubricants & Capacities *Capacities are approximate; check level to be sure . **May vary; check vendor literature in service manual for ambient temperature limits. ***Hydraulic Fluid Specifications: Pour Point -46° F.; SSU 100° F. 275; Flash point 442° F. Approved Supplier &...
  • Page 40 SECURING BOOM Always install shipping pin and secure with hitch pins when preparing machine for transport. Shipping pin is stored in valve compartment. TOWING REFER TO SERVICE MANUAL FOR INSTRUCTIONS FOR TOWING CRAWLER. IF YOU GET STUCK While actuating travel lever controls in appropriate If unit becomes stuck in soft ground you can use the boom lo help free it.
  • Page 41 LOADING & SECURING FOR TRANSPORT Approximate weight with 1700 lb (770 KG) attachment is 28,000 Ibs (12,700 KG). Retract horizontal boom fully, install transport lock Pad chains as necessary to prevent damage to components and paint. Be certain right rear chain is pin and secure with hitch pies.

  • Page 42: Site Conditions

    Obviously, some storage sites will require greater storage precautions than others. Choosing the best Apply Boeshield* T9 (Gradall Part No. 1440-464) storage site available is one of the most important steps to exposed cylinder rods.
  • Page 45 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 46 CLOSE BUCKET - Hold one hand closed and MOVE SLOWLY - Place one hand motionless in 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 with forefinger pointing horizontally at closed hand slowly is shown.)