Gradall XL2300 Operator's Manual
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Gradall XL2300 Operator's Manual

Hydraulic excavator
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OPERATOR'S MANUAL
XL2300
2300-4003
December 2003
Starting S/N 0235400
Form #20141
Original Issue 7/03
GRADALL
406 Mill Avenue S.W.
New Philadelphia, OH, 44663, USA
Telephone: (330) 339-2211
Fax: (330) 339-3579

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  • Page 1 OPERATOR’S MANUAL XL2300 2300-4003 December 2003 Starting S/N 0235400 Form #20141 Original Issue 7/03 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
  • Page 3 XL 2300 EXCAVATOR OWNER/OPERATOR MANUAL COVERING OPERATION & PERIODIC MAINTENANCE IMPORTANT Read and understand this manual and the Gradall and EMI Hydraulic Excavator Safety Manuals before starting, operating or performing maintenance procedures on this machine. KEEP THESE MANUALS IN CAB Si vous ne lisez pas l’Anglais, demandez a votre surveillant de...

  • Page 4: Important Safety Notices

    Strict attention to, and compliance with, instructions provided in this 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 5: List Of Effective Pages

    LIST OF EFFECTIVE PAGES This page is provided to enable reader to determine PAGE DATE DESCRIPTION that this manual is complete and current with respect to the latest printed publication issued. Revised material within this manual will be indicated by a vertical bar to the left of added, changed or deleted material.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS IMPORTANT SAFETY NOTICES ..................inside of front cover LIST OF EFFECTIVE PAGES ..........................1 TABLE OF CONTENTS ............................2 INTRODUCTION ..............................3 General ................................. 3 Related Manuals & Decals ......................... 3 Operator Qualifications ..........................3 Orientation ..............................3 PIN Plate Location ............................

  • Page 7: Introduction

    • EMI Hydraulic Excavator Safety Manual familiarize you with required maintenance by operator • All Instructional decals and plates and with safe operating procedures for the Gradall • Any optional equipment instructions furnished Hydraulic Excavator. The upperstructure includes an operator’s station for Orientation control of all excavator and travel functions.
  • Page 8 Nomenclature...

  • Page 9: Tool Kits

    TOOL KIT XL 2300 Tool Kit (Kit can be ordered under part number 8020-5008) PART NO. DESCRIPTION 8504-1300 Grease Gun Apply grease to fittings 8504-1301 Hose and Coupling Adapt grease gun to fittings 8504-1302 Grease Cartridges Initial supply for grease gun 8504-1356 Box Wrench (1-7/8”) Install and remove attachment...
  • Page 10 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 11 SAFETY HIGHLIGHTS “Pinch Points” points! Save lives & prevent injuries: Learn to recognize & avoid pinch It must remain the to be certain is aware of RESPONSIBILITY OF OWNER OPERATOR and the dangers involved. The dangers include “PINCH POINTS” SERIOUS INJURY OR DEATH.
  • Page 12 SAFETY HIGHLIGHTS Pinch Points (continued) ACCESS COVERS BOOM CRADLE & DECK Be certain access cover is securely latched in Rest boom or attachment on ground and stop open position before performing any engine before permitting anyone to work procedure inside cover’s compartment. beneath boom cradle.
  • Page 13 Such items can cause other workers to in this manual. If it differs, or if you aren’t sure, approach the machine without your knowledge and contact your Gradall distributor before you run result in serious injury or death. your unit.
  • Page 14 SAFETY HIGHLIGHTS Be particularly careful if this is not the machine you usually operate. Read the manuals listed on Learn and follow your employer’s safety rules. page 3 and then operate the unit in a safe, open area to become familiar with the controls. •...
  • Page 15 SAFETY HIGHLIGHTS DANGER WARNING TRAVEL ON OFF-HIGHWAY GRADES Whenever rotating equipment (such as IS RECOMMENDED ONLY UNDER THE a mower or mixer) is installed on FOLLOWING CONDITIONS: machine, adequate shielding must be installed to deflect flying debris Boom is fully retracted and positioned for maximum visibility and adequate Never operate such equipment with clearances.
  • Page 16 SAFETY HIGHLIGHTS WARNING Avoid injury! Always relieve pressure trapped in circuits before disconnecting, removing or installing hydraulic components. Do not operate with bystanders or other workers near machine. 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 17: Safety Highlights

    SAFETY HIGHLIGHTS The XL 2300 excavator is designed as a one- Lock front axle oscillation cylinders to increase man machine. There is no safe place for another stability when digging or maneuvering a load. Unlock oscillation cylinders when traveling to person on the unit other than the operator.

  • Page 18: Decals Inside Cab

    Decals Inside Cab Located on switch console Part No. 8026-3118 Located on right cab wall Part No. 8091-3074 MANUALS Located on manual holder Part No. 8321-1037 Located inside cab door Located on right cab wall Part No. 8060-3036 Part No. 8026-3129...
  • Page 19 Located on right cab wall Located on right cab wall Part No. 8026-3126 Part No. 8026-3125 (for S.A.E. control congifuration) (for Gradall control congifuration) Located on electronic monitor Part No. 8026-3132 Located on right cab wall Part No. 8026-3127 (for J.D. control congifuration)

  • Page 20: Decals

    Decals Outside Cab Located above battery Located outside cab door Part No. 7736-3358 Part No. 8060-3036 Located on both sides of extension boom Part No. 8090-3017 Located beside sight gages Part No. 8697-1197 Indicating lift point Part No. 8021-3050 Located on each wheel rim Surrounding lift point Part No.
  • Page 21 Decals Outside Cab Located on each side of boom Part No. 8060-3037 Located on hyd. reservoir & valve compartment Part No. 8021-3070 Located inside & outside engine compartment door Part No. 8060-3038 Located beside transport lock pin hole Part No. 8020-3013 DEATH UNLAWFUL Located on each side of frame at rear...
  • Page 22 Decals Outside Cab Located inside valve compartment door Part No. 9108-3492 Located at front center of upperstructure Part No. 7733-3047 Located outside right cab wall Located beside pressure fill port Part No. 8029-3030 Part No. 9114-3288 Located on front middle of upper frame Part No.

  • Page 23: Serial No. Plates

    SERIAL NO. PLATES See page 4 for help in finding locations Machine P.I.N. Plate Swing Motor Located on Front Upperstructure Frame Located on Swing Transmission Engine Swing Transmission Located Beneath Boom Cradle Located in Engine Compartment Drive & Steer Axles Drive Motor (under) Located on undercarriage Located on Drive Axle...

  • Page 24: Operator's Cab

    OPERATOR’S CAB Ventilation Heater The cab is equipped with a heater located beneath WARNING operator’s seat. Engine coolant supplied to heater is controlled by a valve at rear of engine cylinder head and a push/pull knob located on right arm rest. Raise Always be certain to position boom or attachment on ground and stop engine before knob fully for maximum heat or depress knob fully...

  • Page 25: Seat Adjustment

    Seat Adjustment WARNING Perform all seat adjustments with engine stopped. Accidental actuation of controls can cause serious accidents. It may become necessary to revise some adjustments to find the most comfortable operating position. Be sure to stop engine first. NOTE: Raise control to unlock control pod and armrest assembly.

  • Page 26: Control & Instrument Identification

    Test your controls before operating. The joystick control pattern shown is the SEE OPPOSITE PAGE FOR OTHER standard Gradall pattern. If controls have CONTROLS & INDICATORS. been modified to another pattern, be sure you are familiar with functions and ensure...
  • Page 27 Control & Instrument Identification (con’t) CONTROL FOR HAZARD WARNING LIGHTS CONTROL FOR TRAVEL ALARM (REFER TO DRIVE TRAIN SECTION) ELECTRONIC MONITOR (SEE NEXT PAGE FOR DETAILS) CONTROL FOR OPTIONAL LIGHT PACKAGE CONTROL FOR OPTIONAL LIGHT PACKAGE SELECTS FIRST OR SECOND GEAR RANGE (NEVER SHIFT WHEN TRAVELING) (TRAVEL SPEEDS ON OPPOSITE PAGE) NOTE: AN HOURMETER IS LOCATED ON...

  • Page 28: Electronic Monitor

    Electric Monitor WARNING An electronic monitor caution signal indicates a condition which could cause FUEL LEVEL serious damage to your unit. Correct cause ENGINE ENGINE COOLANT of signal before continuing operation. COOLANT TEMPERATURE LEVEL U.S./METRIC ENGINE OIL SELECTION PRESSURE CAUTION SYMBOLS & ALARM SWITCH HYDRAULIC OIL BATTERY...

  • Page 29: Blank

    THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 30: Checks & Services Before Starting Engine

    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 major hydraulic WARNING components Use extreme caution when checking items When adding fluids or lubricants, refer to lubrication beyond your normal reach.
  • Page 31 WARNING 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 fuel level symbol on electronic monitor Check for the presence of a fully charged fire and replenish as necessary.

  • Page 32: 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”. Starting Engine CAUTION NOTES: This procedure assumes that engine Turning ignition key to START position and hydraulic systems are cold and engine is when flywheel is rotating can cause being started at beginning of work shift.

  • Page 33: Normal Engine Operation

    Normal Engine Operation WARNING Battery charge indication of alternator output: Approximately 14 volts with engine running at When using excavator or travel functions, 2000 RPM operate engine at full throttle to prevent Be alert for unusual noises or vibration. When possibility of stalling under heavy load.

  • Page 34: Warm Up & Operational Checks

    WARM UP & OPERATIONAL CHECKS (To be performed at beginning of each work shift) Complete all required maintenance before operating unit. NOTE: There is very light flow from main hydraulic The safety, efficiency and service life of your excavator will be increased by performing the pump until there is demand from circuits served following operational checks while the engine and by the pump (all boom functions and travel).

  • Page 35: Adapter Attachment Installation

    ADAPTER ATTACHMENT INSTALLATION WARNING Keep boom in fully extended position while installing bucket. Stay clear until bucket adapter has been fitted to bucket as shown in step 3. CAUTION Digging with a loose or improperly fitted bucket can cause excessive wear, shear adapter bolts or cause loss of bucket.
  • Page 36 (on left control console). AUTO Excavator IS NOT similar to previous System will not permit gear shift to occur unless Gradall travel systems. Even experienced these conditions are met. Gradall operators must study and understand TRAVEL section completely 2. Select other gear by moving the TRAVEL SPEED before practicing in a safe, open area.
  • Page 37 1. Align upperstructure with carrier with cab facing WARNING direction of travel. Be certain of orientation of upper on carrier (see previous under WARNING Do not attempt to perform excavator and heading). DIRECTION OF TRAVEL travel functions at the same time. While possible under some conditions, this 2.
  • Page 38 . However, it is not MACHINE A FEW YARDS necessarily the same. Gradall cannot predict worksite conditions and cannot provide an exact procedure for unknown conditions. Inspect travel path to new worksite to discover all conditions which could cause problems.
  • Page 39 NOTE: If machine is being prepared for transport on But first, perform preliminary steps below: another vehicle, position boom in horizontal position • Inspect pick (lift) site, travel path and delivery and align cradle bore with frame TRANSPORT site. . Secure alignment using (SHIPPING) PIN BORE and lock using hitch and TRANSPORT (SHIPPING) PIN...

  • Page 40: Travel

    Carry (travel) function: 7. With machine in planned position at delivery point, 1. With load aligned according to plan, have helpers move switch to either DIG BRAKE AUTO attach tag lines to load. Helpers must keep load in position. Disengage if necessary.

  • Page 41: Steering System

    This operator option is provided to modes. Indicator lights are provided to show which silence alarm for over-the-road travel. mode has been selected. This control governs Gradall cannot anticipate all operating situations. The hydraulic flow to drive motor. operator and/or supervisor, company, and owner •...

  • Page 42: Lubrication & Maintenance Diagram

    LUBRICATION & MAINTENANCE DIAGRAM SYMBOLS = Lube Fitting = Other Service = Service Both Sides For service, extend boom half way and rest bottom of bucket flat on ground. LUBRICATION NOTES Lubricant Symbols • Clean lubrication fittings before lubricating. AF - ANTI-FREEZE (permanent) •...
  • Page 43 60. Transfer Case Drain Plug (drain & refill) 63. Planetary Wheel Ends (drain & refill) 63. Planetary Wheel Ends (drain & refill) • Check torque of all items listed in torque table. FAILURE TO USE GRADALL HYDRAULIC FILTER ELEMENTS COULD VOID WARRANTY...

  • Page 44: Recommended Lubricants & Capacities

    To check GRADALL torque values, set the torque wrench at 95% of rated torque value 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 45: Emergency Towing

    4. If transfer case is not accessible, an attempt may Procedures: Because Gradall cannot predict the be made to tow unit very slowly. The leakage path exact cause of any failure, the following procedures in hydraulic motor is very small. If wheels do not must be used when appropriate.

  • Page 46: Lifting Machine

    LOADING & SECURING FOR TRANSPORT Lifting Machine Weight with 60 inch ditching bucket is 29,300 pounds. (optional blade kit: add 1,550 pounds) 1. Retract horizontal boom fully, install shipping 4. Pad chains as necessary to prevent damage to pin in transport position and secure hitch pins. Pins components and paint.

  • Page 47: Preservation & Storage

    Because Gradall cannot anticipate all storage • Apply Boeshield* T9 (Gradall Part No. 1440-4645) situations, we do not provide a step-by-step procedure to exposed cylinder rods. for short term storage. However, we do require that...

  • Page 48: Excavator Hand Signals

    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. Special Signals - When signals for auxiliary equipment functions or conditions not covered are required, they shall be agreed upon in advance by...
  • Page 49 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 disctance with forefinger pointing horizontally at closed hand.

  • 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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