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Gradall XL3200III Operators Safety Manual

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Operator & Safety
Keep this manual with machine at all times
XL3200III - XL4200III - XL5200III
XL3210III - XL4210III - XL5210III
XL3220III
S/N 3200000552 & After
S/N 4200000018 & After
S/N 5200000743 & After
S/N 3210000009 & After
S/N 4210000020 & After
S/N 5210000855 & After
S/N 3220000001 & After
80744002
Revised
November 3rd, 2017
Manual

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Summary of Contents for Gradall XL3200III

  • Page 1 Operator & Safety Manual Keep this manual with machine at all times XL3200III - XL4200III - XL5200III XL3210III - XL4210III - XL5210III XL3220III S/N 3200000552 & After S/N 4200000018 & After S/N 5200000743 & After S/N 3210000009 & After S/N 4210000020 & After S/N 5210000855 &...

  • 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 November 1st, 2010 - A - Original Issue of Manual November 20th, 2013 - B - Revised Manual November , 2017 - C - 80744002_Revisions_RevC 80744002...

  • 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: 80744002...

  • Page 7: Table Of Contents

    2.2 Walk-Around Inspection ..............2-2 2.3 Safety Decals - XL3200III, XL4200III & XL5200III ......2-4 Decal Locations ..............2-4 2.4 Safety Decals - XL3200III, XL4200III & XL5200III (CE) ....2-6 Decal Locations ..............2-6 2.5 Safety Decals - XL3210III, XL4210III & XL5210III ......2-8 Decal Locations ..............2-8 2.6 Safety Decals - XL3210III, XL4210III &...
  • Page 8 Crawler Operation..............3-6 3.4 Typical Dig Cycle ................ 3-7 Standard SAE Boom and Attachment Functions ....3-7 3.5 Lifting & Placing a Load - XL3200III, XL4200III & XL5200III ..3-13 Precautions ................. 3-13 General ................3-14 Positioning Machine For A Lift ..........3-14 Planning A Lift..............
  • Page 9 Table of Contents 5.2 General Maintenance Instructions..........5-2 5.3 Service & Maintenance Schedules..........5-3 10 Hour Maintenance Schedule ..........5-3 50 Hour Maintenance Schedule ..........5-4 100 Hour Maintenance Schedule ..........5-5 1st 30 Days (250 hrs Max) & 250 Hour Maintenance Schedule. 400 Hour Maintenance Schedule ..........5-7 750 Hour Maintenance Schedule ..........5-8 1500 Hour Maintenance Schedule ........5-9 5.4 Lubrication Schedules ...............5-10...
  • Page 10 Table of Contents 80744002...

  • Page 11: 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 12: 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 13: 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 14 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. 80744002...

  • Page 15: 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 16: 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 17 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. 80744002...

  • Page 18: 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 19: 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 20: 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 21 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 22: 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 23: 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 24 Section 1 - General Safety Practices NOTES: 1-14 80744002...

  • Page 25: 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 26: 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. The boom and attachment must be resting on the ground and securely blocked. Begin your walk-around inspection at item 1, as noted below.
  • Page 27 Section 2 - Pre-Operation and Controls 5. Hydraulic Reservoir - Recommended fluid level on sight gauge; filler/breather cap secure and working; oil is clear. 6. Main Control Valve and Cover - See Inspection Note. Replace damaged latch and weak access cover support strut immediately. 7.

  • Page 28: Safety Decals - Xl3200Iii, Xl4200Iii & Xl5200Iii

    Section 2 - Pre-Operation and Controls SAFETY DECALS - XL3200III, XL4200III & XL5200III Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required. Decal Locations 80813002 (XL3200III) 80713002 (XL4200III)
  • Page 29 Section 2 - Pre-Operation and Controls 80509013 80509016 NO STEP 80509015 80373077 OAE0020 80509004 80509013 80509015 80509018 80509012 80509016 80509015 OAE0031 80744002...

  • Page 30: Safety Decals - Xl3200Iii, Xl4200Iii & Xl5200Iii (Ce)

    Section 2 - Pre-Operation and Controls SAFETY DECALS - XL3200III, XL4200III & XL5200III (CE) Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required. Decal Locations 80813002 (XL3200III)
  • Page 31 Section 2 - Pre-Operation and Controls 80893015 8089-3015-A 80893018 8089-3018-A 80893017 80893012 OAE0540 8089-3017-A 80893013 80893015 8089-3013-A 80893017 80893019 8089-3015-A 8089-3017-A 8089-3019-A 8089-3014-A 80893014 80893018 80893017 OAE0550 8089-3018-A 8089-3017-A 80744002...

  • Page 32: Safety Decals - Xl3210Iii, Xl4210Iii & Xl5210Iii

    Section 2 - Pre-Operation and Controls SAFETY DECALS - XL3210III, XL4210III & XL5210III 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...
  • Page 33 Section 2 - Pre-Operation and Controls 80373077 80509016 NO STEP 80509015 OAE0420 80509004 80213104 80509015 80509012 OAE0430 80509016 80509013 80744002...

  • Page 34: Safety Decals - Xl3210Iii, Xl4210Iii & Xl5210Iii (Ce)

    Section 2 - Pre-Operation and Controls SAFETY DECALS - XL3210III, XL4210III & XL5210III (CE) Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required. Decal Locations 80893015 8 08 9 - 3 0 15-A 80213101 802 1-31 01 80893014...
  • Page 35 Section 2 - Pre-Operation and Controls 80893012 80893018 8089-3018-A 80893017 OAE0570 8 08 9- 301 7- A 80893013 80213104 80893017 80 89-30 17 -A 8089-3013-A 8089-3 014-A 80893014 OAE0430 8089-3018-A 80893018 8 089 -3015-A 80893015 80744002 2-11...

  • Page 36: Cab Components

    Section 2 - Pre-Operation and Controls CAB COMPONENTS OAE0040 2-12 80744002...
  • Page 37 Section 2 - Pre-Operation and Controls 1. Air Diffuser Vents 2. Electronic Monitoring Unit: See page 2-14 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 38: 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 2-16 2. Ignition: Key Activated. See page 2-31 for details. 3. Joystick Control Pattern Selection Switch: See “Joystick Control Pattern Selection”...
  • Page 39 Section 2 - Pre-Operation and Controls This Page Intentionally Left Blank 80744002 2-15...

  • Page 40: 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 2-17 for details. 2. Green Visual Indicator: Illuminated when no alarms are present. 3. Orange Visual Indicator: Illuminated when CAN fault is detected. See pages 2-18 &...

  • Page 41: 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 42 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 43: 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 44 Section 2 - Pre-Operation and Controls User Interface - Menu Mode OAD0360 1. Visual Display (Menu Mode): See page 2-21 for details. 2. Keypad Input “1”: Scroll up through menu options. 3. Keypad Input “2”: Scroll down through menu options. 4.
  • Page 45 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 46: 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: Depress front of switch (I) for fine grade mode. Depress back of switch (II) for dig mode.
  • Page 47 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 48: 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 2-24 80744002...

  • Page 49: Joystick Control Pattern Selection

    The control pattern selection switch allows the operator to select from three joystick control patterns; GRADALL, SAE and JOHN DEERE. The pattern must be selected with the ignition key in the “OFF” position. If a new pattern is selected while the engine is running, it will not change until the engine is turned off then restarted.

  • Page 50: 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 51 Section 2 - Pre-Operation and Controls SAE Joystick Controls OAC0890 Left Hand Joystick Functions • Move the joystick back to retract boom; move joystick forward to extend boom. Move joystick right to swing boom right; move joystick left to swing boom left. •...
  • Page 52 Section 2 - Pre-Operation and Controls GRADALL Joystick Controls OAC0900 Left Hand Joystick Functions • Move the joystick back to raise boom; move joystick forward to lower boom. Move joystick right to close tool; move joystick left to open tool.
  • Page 53 Section 2 - Pre-Operation and Controls JOHN DEERE Joystick Controls OAC0910 Left Hand Joystick Functions • Move the joystick back to raise boom; move joystick forward to lower boom. Move joystick right to swing boom right; move joystick left to swing boom left. •...

  • Page 54: Operator Seat Adjustments

    Section 2 - Pre-Operation and Controls Operator Seat Adjustments OAE0090 Prior to starting engine adjust seat for position and comfort. 1. Upper Seat Fore and Aft Adjustment Control 2. Weight Adjustment Control 3. Lower Seat Fore and Aft Adjustment Control 4.

  • Page 55: 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 56: 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. 2-32 80744002...

  • Page 57: 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 58: 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 59: 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 60: 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 61: 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 62: 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 63: Typical Dig Cycle

    Section 3 - Operation TYPICAL DIG CYCLE Standard SAE Boom and Attachment Functions Prepare for boom and attachment function: 1. Position unit for efficient attachment usage. Notice!: While digging, pay close attention to boom position in relation to chassis. In certain instances it is possible for the boom to come into contact with the chassis.
  • Page 64 Section 3 - Operation OAC0560 Joystick controls standard SAE control pattern. If tilt speed has been reduced for conditions, speed can be temporarily increased by depressing fast tilt button (1). Note: Practice with controls in a safe, open area. Joysticks and pedals return to neutral position when released.
  • Page 65 Section 3 - Operation 2. Move left joystick to left (G) to swing left or to right (H) to swing right. 3. While pushing left joystick forward (F) to extend boom, push right joystick forward (B) to lower boom into position for start of cut. 4.
  • Page 66 Section 3 - Operation 5. If required, press left side of tilt switch (I) to tilt counterclockwise or right side of switch (J) to tilt clockwise. If necessary, use fast tilt button to return to fast tilt. 6. While pushing forward on right joystick (B) to lower boom and force bucket into ground, pull back on left joystick (E) to retract boom and fill bucket.
  • Page 67 Section 3 - Operation 8. When bucket is full, or when boom is fully retracted, move right joystick to left (D) to close bucket. At same time pull right joystick back (A) to raise boom far enough to clear obstructions. 9.
  • Page 68 Section 3 - Operation 11. Move left joystick to left (G) or right (H) to align boom for next cut. Repeat steps 3 thru 11. 3-12 80744002...

  • Page 69: Lifting & Placing A Load - Xl3200Iii, Xl4200Iii & Xl5200Iii

    Section 3 - Operation LIFTING & PLACING A LOAD - XL3200III, XL4200III & XL5200III LIFTING & POSITIONING LOADS. Failure to plan a WARNING lift properly could result in death or serious injury. The automatic boom tilt brake will not prevent boom OW0021 from tilting in response to an external load.

  • Page 70: General

    Section 3 - Operation General There is a lift capacity difference between the excavator’s best and worst lift positions. Just because it can lift a load from one point does not mean it can safely deliver the load to any other point. Prior to lifting and placing a load, map out the lift, swing, and lower path to ensure that capacity, both hydraulic and stability tipping limits, are not exceeded.

  • Page 71: Planning A Lift

    Section 3 - Operation Planning A Lift Note: Lift capacities are based on machine being on a firm, level surface and also no load being suspended beneath bucket adapter. Do not travel with suspended load positioned over the side of the machine. 1.

  • Page 72: Carrying A Load

    Section 3 - Operation Carrying a Load With load picked and boom in desired position: 1. Attach tag lines to the load. Additional personnel must keep load in proper alignment during carry function using tag lines. 2. Select travel speed based on terrain and/or walking speed of those holding tag lines.

  • Page 73: Lift Capacity - Xl3200Iii, Xl4200Iii & Xl5200Iii

    Section 3 - Operation LIFT CAPACITY - XL3200III, XL4200III & XL5200III LOAD RADIUS 10’ (3.0m) 15’ (4.6m) 20’ (6.1m) 25’ (7.6m) LOAD POINT HEIGHT MAXIMUM OVER OVER OVER OVER OVER OVER OVER OVER OVER OVER RADIUS SIDE SIDE SIDE SIDE...
  • Page 74 -557lbs. (253kg) Note: Bucket adjustment values are 87% of the actual bucket weights. Any weight adjustment for Gradall buckets not shown can be calculated by multiplying actual bucket weight by .87. • The load point is located on the bucket pivot point, including load listed for maximum radius.

  • Page 75: 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 76: 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 3-19. 2.

  • Page 77: 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 78 Section 3 - Operation This Page Intentionally Left Blank 3-22 80744002...

  • Page 79: Section 4 - Attachments

    • An overextended or overloaded excavator can tip over with little or no warning and cause death or serious injury to the operator and/or those working nearby. • Gradall cannot assure the ability of a non-approved attachment to perform its intended function safely.

  • Page 80: Excavating Buckets

    Section 4 - Attachments Excavating Buckets Size Cu. Yd. 24" (610mm) 30" (762mm) 36" (914mm) 42" (1.07m) 48" (1.22m) OAC0590 Installation Procedure • Refer to "Adapter Attachment Installation" beginning on page 4-4. Ditching Buckets Size Cu. Yd. 30" (.80m) 60" (1.52m) 66"...

  • Page 81: Trenching Buckets

    Section 4 - Attachments Trenching Buckets Size Cu. Yd. 15" (381mm) OAC0720 Installation Procedure • Refer to "Adapter Attachment Installation" beginning on page 4-4. Pavement Removal Bucket Size Cu. Yd. 18" (.46m) 24" (.60m) OAC0730 28" (.71m) 40" (1.02m) Installation Procedure •...

  • Page 82: Dredging Bucket

    Section 4 - Attachments Dredging Bucket Size Cu. Yd. 72" (1.83m) 1-1/8 OAC0740 Installation Procedure • Refer to "Adapter Attachment Installation" beginning on page 4-4. Grading Blade Size Cu. Yd. 8’ (2.4m) OAC0750 Installation Procedure • Refer to "Adapter Attachment Installation" beginning on page 4-4. 80744002...

  • Page 83: Adapter Attachment Installation

    Section 4 - Attachments ADAPTER ATTACHMENT INSTALLATION OAC0760 1. Wedge Bolts 2. Bucket Adapter 3. Bucket Bars Installation Procedure: 1. Be sure wedge bolts (1) are secured in storage position (toward rear) and position bucket adapter (2) above bucket bar (3) as shown. OAC0770 2.
  • Page 84 Section 4 - Attachments 3. Move adapter toward "bucket close" position until outer end of adapter contacts bucket. Ensure proper alignment and continue to close until adapter contacts stops (1). OAC0790 4. Only use the nuts to move wedge bolts forward to position wedge between adapter and bucket bar.

  • Page 85: Section 5 - 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 86: 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 87: Service & Maintenance Schedules

    Section 5 - 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 88 Section 5 - 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 89: 100 Hour Maintenance Schedule

    Section 5 - 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 90: 1St 30 Days (250 Hrs Max) & 250 Hour Maintenance Schedule

    Section 5 - 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 91: 400 Hour Maintenance Schedule

    Section 5 - Lubrication & Maintenance 400 Hour Maintenance Schedule EVERY Clean Fuel Replace Fuel/ Change Engine Strainer Water Oil and Separator Element Filter OAE0131-SIII 80744002...

  • Page 92: 750 Hour Maintenance Schedule

    Section 5 - 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 93: 1500 Hour Maintenance Schedule

    Section 5 - 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 94: Lubrication Schedules

    Section 5 - Lubrication & Maintenance LUBRICATION SCHEDULES 10 Hour Lubrication Schedule Grease (extreme pressure #2) EVERY **** **** ***** * - Number of Lube Points OAE0160 5-10 80744002...
  • Page 95 Section 5 - Lubrication & Maintenance 50 Hour Lubrication Schedule Grease (extreme pressure #2) EVERY * - Number of Lube Points OAE0170 80744002 5-11...

  • Page 96: 100 Hour Lubrication Schedule

    Section 5 - Lubrication & Maintenance 100 Hour Lubrication Schedule Grease (extreme pressure #2) EVERY * - Number of Lube Points OAE0180 5-12 80744002...

  • Page 97: Section 6 - Emergency Procedures

    Section 6 - Emergency Procedures SECTION 6 - EMERGENCY PROCEDURES LOSS OF POWER The engine will de-rate if a problem develops. If this occurs, lower boom and attachment to the ground as soon as possible. Make all necessary repairs before continued operation.
  • Page 98 Section 6 - Emergency Procedures This Page Intentionally Left Blank 80744002...

  • Page 99: Section 7 - Specifications

    Capacity ..................55 gallons (208 liters) ® Type of Oil ........Mobilfluid 424 Tractor Hydraulic Fluid (ISO 46)** Fuel Tank (XL3200III, XL4200III & XL5200III) Capacity ..................99 gallons (375 liters) Type of Fuel....................#2 Diesel Fuel Tank (XL3210III, XL4210III & XL5210III) Capacity ..................82 gallons (310 liters) Type of Fuel....................

  • Page 100: Battery

    Section 7 - Specifications Tilt Transmission Capacity................32-35 ounces (0,9-1,0 liters) Type of Fluid .................80w90 (8053-3027) Tilt Bull Gear Capacity.....................as required Type of Fluid ..............Open Gear Lube (8664-1304) Crawler Planetary Capacity..................6.3 quarts (6 liters) Type of Fluid ................EP80/90 (MIL-L-2105D) Track Idler Capacity..................

  • Page 101: Weight

    Section 7 - Specifications Weight XL3200III Operating Weight (600mm Tracks)..........39,240 lb (17,799 kg) XL4200III Operating Weight (600mm Tracks)..........45,746 lb (20,750 kg) Operating Weight (800mm Tracks)..........46,862 lb (21,256 kg) XL5200III Operating Weight (600mm Tracks)..........53,336 lb (24,193 kg) Operating Weight (800mm Tracks)..........

  • Page 102: Dimensions

    Section 7 - Specifications Dimensions XL3200III Crawler Width ..................8.6 ft (2,6 m) Upperstructure Width ................8.6 ft (2,6 m) Ground Clearance ................18 in (454 mm) Transport Length (without attachment) ..........21.3 ft (6,5 m) Transport Height (without attachment) ..........10.1 ft (3,1 m) XL4200III Crawler Width ..................
  • Page 103 Section 7 - Specifications XL4210III Crawler Width..................10.6 ft (3,2 m) Upperstructure Width ................9.0 ft (2,7 m) Ground Clearance ................18 in (454 mm) Transport Length (without attachment)..........23.10 ft (7,3 m) Transport Height (without attachment) ..........10.5 ft (3,2 m) XL5210III Crawler Width..................10.6 ft (3,2 m) Upperstructure Width ................9.0 ft (2,7 m) Ground Clearance ................18 in (454 mm) Transport Length (without attachment)..........26.3 ft (8,0 m)

  • Page 104: Torque Chart

    Section 7 - 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 105 Section 7 - Specifications Tilt Transmission Mounting Hardware Quantity ........................8 Thread Size (grade) ..................5/8-11 (8) Torque (lubricated) ............200-215 lb-ft (272-292 Nm) Center Pin Mounting Hardware Quantity ........................4 Thread Size (grade) ..................1/2-13 (5) Torque (lubricated) ..............68-78 lb-ft (92-105 Nm) Counterweight Mounting Hardware Quantity ........................
  • Page 106 Section 7 - Specifications Track Roller Quantity ........................48 Thread Size (grade)..................5/8-11 (8) Torque (lubricated)............200-215 lb-ft (272-292 Nm) Carrier Roller Quantity ........................8 Thread Size (grade)..................5/8-11 (8) Torque (lubricated)............200-215 lb-ft (272-292 Nm) Crawler Drive Mounting Hardware Quantity ........................52 Thread Size (grade)..................

  • Page 107: Fuses

    Section 7 - 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 108 Section 7 - Specifications This Page Intentionally Left Blank 7-10 80744002...

  • Page 113: Index

    Index Index Adapter Attachment Installation 4-5–4-6 Fuse Panel........7-9 Approved Attachments ..... 4-1 Attachment Operation ...... 4-1 Grading Blade ........4-4 Attachments ........4-1 Ignition ..........2-31 Battery ..........7-2 Intermittent Wiper/Washer ....2-32 Cab Components ......2-12 Joystick Control Pattern Selection ..2-25 Cab Controls & Indicators ....2-14 Joystick Controls......2-26 Capacities.........
  • Page 114 Index Safety Signal Words ......1-1 Service & Maintenance Schedule..5-3 10 Hour ........5-3 100 Hour ........5-5 1500 Hour ........5-9 1st 30 Days ......... 5-6 250 Hour ........5-6 400 Hour ........5-7 50 Hour ........5-4 750 Hour ........

  • Page 115: 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 116 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...

This manual is also suitable for:

Xl4200iiiXl5200iiiXl3210iiiXl4210iiiXl5210iiiXl3220iii