Related Manuals for Gradall G3WD
Summary of Contents for Gradall G3WD
- Page 1 OPERATOR'S MANUAL G3WD 24604084 July 2002 Starting S/N Upperstructure - 0136307 Undercarriage - 01D686 Form #29215 Original Issue 11/92 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
- Page 4 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...
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Page 6: Related Manuals
The PIN plate is components literature. located on front center portion of upperstructure You must read and understand the Gradall Opera- frame. tion Manual and Safety Manuals before operating the machine. - 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 Cradle Counterweight & Another Object Boom Boom Holes 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 ’s tools or personal items on the 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.
- Page 10 SAFETY HIGHLIGHTS Learn and follow your employer’s safety rules. Be particularly careful if this is not the machine 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 Transmission in proper range...
- Page 11 Center boom fully over rear of chassis and rest If one or more wheels indicate brake failure, boom or bucket on the ground. DO NOT DRIVE THE GRADALL HYDRAULIC EXCAVATOR. Investigate and correct. For Apply down pressure with boom (but not assistance, contact your Gradall Distributor.
- 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. PULL TO APPLY PARKING BRAKE PUSH TO RELEASE Attach load only as shown.
- Page 13 SAFETY HIGHLIGHTS GRADALL LIFTING CAPACITIES Avoid injury! Always relieve pressure trap- RATED LIFT CAPACITY ped in circuits before disconnecting, re- 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 FRONT DRIVE AXLE MUST NOT BE EN- GAGED WHEN DRIVING OR INJURY MAY RESULT FROM ON PAVED ROADS DEATH CONTACTING ELECTRICAL LINES OR FOR PROLONGED TO PLACE ANY PART OF THIS MACHINE OR LOAD WITHIN 10 UNLAWFUL FEET OF HIGH VOLTAGE LINES PERIODS ON ANY...
- Page 15 Decals Inside Carrier Cab CAUTION WARNING READ BEFORE PERFORMING ANY WELDING OPERATIONS ON THIS MACHINE. ALLOW INCREASED STOPPING DISCONNECT BATTERY CABLES AND TURN OFF IGNITION BEFORE WELDING TO PREVENT DAMAGE. DISTANCE WITH NEW BRAKES . BRAKE THIS MACHINE IS EQUIPPED WITH NYLON HOSE ADEQUATELY IN THE IMMEDIATE AREA PRIOR TO CAPABILITY WILL IMPROVE AFTER WELDING.
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Page 16: Hydraulic Oil
Decals Outside Carrier Cab PRESS POPPET TO NYLON BRAKE RELIEF PRESSURE BEFORE REMOVING LINES MAY BE FILLER CAP 7700 1001 DAMAGED BY Located on hydraulic reservoir HEAT. AVOID Part No. 7700-1001 WELDING ON OR AROUND CARRIER FRAME UNLESS LINES ARE PROTECTED FROM HEAT. -
Page 17: Diesel Fuel
Decals Outside Carrier Cab (cont.) COLD Located on right frame rail Located on hydraulic reservoir Part No. 7702-3029 Part No. 8697- 1197 DIESEL FUEL TO PREVENT ENGINE RING GEAR DAMAGE, 7702-3008 WAIT 10 SECONDS AFTER ENGINE ROTATION STOPS BEFORE ATTEMPTING Located near fuel filler cover TO RESTART. - Page 18 Decals Inside Upperstructure Cab FOR SAFE OPERATION OF USE TWO MACHINE ANF TO MINIMIZE RISK OF SERIOUS INJURY: HANDS WHEN BEFORE OPERATING, READ OPERATOR AND SAFETY MANUALS,UNDERSTAND ALL CONTROLS IN CAB AND CLEAR CLIMBIN1G ON LOOSE OBJECTS OFF MACHINE. SOUND HORN BEFORE STARTING ENGINE.
- 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 OR INJURY MAY RESULT FROM DEATH CONTACTING ELECTRICAL LINES.
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Page 20: Hot Exhaust
Decals Outside Upperstructure Cab TO PREVENT INJURY ,KEEP OR INJURY MAY RESULT FROM DEATH OUT OF BOOM CONTACTING ELECTRICAL LINES. HOLES TO PLACE ANY PART OF THIS 7702-3009 UNLAWFUL MACHINE OR LOAD WITHIN 10 Located on each side of boom at front & rear FEET OF HIGH VOLTAGE LINES OF UP TO 50,000 VOLTS. - Page 21 CARRIER CAB CONTROLS, INSTRUMENTS & INDICATORS LEFT TURN SIGNAL RIGHT TURN SIGNAL REMOTE display glows red to indicate Remote/Travel switch is positoned for remote control *ENGINE TEMP. display glows red to indicate engine coolant temperature has reached operation. 210 F. *CONV.
- Page 22 UPPERSTRUCTURE CAB CONTROLS AND INSTRUMENTS 9. Defroster Switch 1. Throttle Lever 10. Accessory Switch 2. Boom In/Out & Swing Joystick 11. Accessory Switch 3. Boom Tilt Switch 12. Ignition Switch 4. Transmission Shift Switch 13. Parking Brake Knob 5. Horn Switch 14.
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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. Make sure remote switch is in travel position. Inspect visually for damage, leaks, vandalism & Check coolant level. needed maintenance. -
Page 24: Normal Engine Operation
Normal engine operation overspeeding the engine (exceeding governed Observe voltmeter, water temperature and oil pressure gages frequently to be sure all engine RPM). The governor has no control over engine systems are functioning properly. speed when engine is being “pushed” by carrier load. Be alert for unusual noises or vibration. -
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 is approximately 160/ wiper. 210 F. (71/104 C). Check all lights and turn signals for proper Observe tachometer response to changes in operation. -
Page 26: Brake System
BRAKE SYSTEM The air brake system includes a service brake, an emergency brake, a parking brake and a digging brake. Wear seat belt to avoid being thrown from carrier driver ’s seat during braking emergency Service brake Do not operate carrier or upperstructure while low air indicator is glowing. - Page 27 BRAKE SYSTEM (Con’t.) If the air pressure gages indicate some system pressure remaining, it may be possible to drive the unit a short distance to remove it from a hazardous position (use first gear only). If carrier cannot be moved, direct traffic around carrier until warning flags, flares or lights can be displayed.
- Page 28 Digging brake (Con’t.) Remote control braking The digging brake is applied when operating in remote mode. The digging brake will be released and DIGGING BRAKE APPLICATION reapplied automatically as travel pedal in upper- structure is actuated and released. A parking brake control knob is located in the Do not activate remote switch while trav- upperstructure cab.
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Page 29: Steering System
STEERING SYSTEM Conventional steering Remote control steering Your unit is equipped with a travel/steering pedal The power steering system provides low effort in the upperstructure cab. The engine must be steering under normal conditions and greater running to provide power for remote control control in the event of a blowout or soft ground. -
Page 30: Power Train
POWER TRAIN The power train furnished on 4 x 2 carriers (units Notify maintenance personnel of malfunction as having one driving axle at rear) includes the engine, soon as possible. torque converter, power shift transmission and the Four-Wheel-Drive Default(4x4 units only):Four- rear axle. -
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: Remote Control
REMOTE CONTROL 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 Move transmission shift lever to NEUTRAL After reaching job site, perform following procedure position. Remote drive gear is selected from to prepare carrier for remote control travel. - Page 33 Precautions for Remote Control Operation counterweight before starting to move. Be especially watchful for overhead wires and traffic. Always apply parking brake and stop Never tow load using remote control drive. engine before leaving upper cab. Always give audible signal before moving unit. Never permit bucket to drag while moving unit.
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Page 34: In Case Of Trouble
Depress TRAVEL portion of Remote/Travel Disengage differential lock and four-wheel drive switch. (refer to page 27 for procedure). 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 While pushing forward on left joystick (B) to If required, press left side of tilt switch (I) to tilt lower boom and force bucket into ground, pull counterclockwise or right side of switch (J) to back on right joystick (E) to retract boom and tilt clockwise.
- Page 38 A TYPICAL GRADALL DIGGING CYCLE 14. Move left joystick to left (C) to empty the Move right joystick to right (H) to swing right bucket. or to left (G) to swing left to dump site. If bucket. necessary, extend boom by pushing right joystick forward (F).
- Page 39 LIFTING AND POSITIONING A LOAD Precautions Do not depend on machine tipping as a warning of Do not travel with a suspended load. Excava- 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 Determine the weight of the load. Weight of The excavator can lift and position loads safely slings, chains and auxiliary lifting devices must ONLY IF YOU PLAN THE LIFT PROPERLY. be added as part of the load. Refer to lift capacity chart for weight adjustment required for bucket.
- 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 Extending Slide-A-Boom in steps 9 and 10 can cause structural dam- age.
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Page 42: Attachment Installation
ATTACHMENT INSTALLATION 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 43 Recommended Lubricants & Capacities *Refer to manufacturer’s literature for this information. **Specific hydraulic specifications are shown below. ***Capacities are approximate - check level to be sure. **Hydraulic fluid specifications: ISO Grade 46, Pour Point, °F-20 to -40 SSU @ 100° F, 200-240 Flash Point, COC, °F 280 min.
- Page 44 LUBRICATION & MAINTENANCE DIAGRAM SYMBOLS ATF - Automatic Transmission Fluid CG - Grease - Extreme Pressure GO - Multi-Purpose Lubricant DF - Diesel Fuel EO - Engine Oil GL - Open Gear Lube HF - Hydraulic Fluid HTF - Hydraulic Transmission Fluid - Grease Fitting →...
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Page 45: Lubrication And Maintenance
LUBRICATION & MAINTENANCE No. of No. of Points Points Lube Item Lube Item Symbol Symbol Monthly Lubrication and Maintenance Cont. Daily Lubrication & Maintenance Oil Cooler (inspect fins & clean as req’d) Tool Link Pin Engine Drive Belts (check condition & Tool Cylinder Pivot Pins tension - adjust or replace as req’d) Adapter Pivot Pin... - Page 46 TORQUE CHECK SCHEDULE *Torque nut hand tight and turn to next castellation to align with nut retainer. Precautions Check fastener torques for all items listed using an Application of less than proper torque can also cause accurate torque wrench. Check torques manually; do fasteners to fail.
- Page 47 CHECKING BRAKE ADJUSTMENT NOTE: This procedure applies to all axles excep front drive axle on 6 x 6 units. 6 x 6 front drive BRAKES RELEASED axles are equipped with wedge brakes which are self-adjusting. Position unit in a safe level area. With brake system fully charged (125 psi and controls set for conventional travel), apply parking brake and stop engine.
- Page 48 EXCAVATOR HAND SIGNALS Standard Signal - When excavator work conditions require hand signals, they shall be provided or posted conspicuously for the use of both signal man and operator No excavator motions shall be made unless signals are clearly understood by both signalman and operator.
- 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 distance to with forefinger pointing horizontally at closed slowly is shown.)
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