Page 1 EXCAVATOR TECHNICAL MANUAL VOLUME 1 XL4000 Starting S/N 0411200 thru 0414225 S/N 0424200 thru 0427225 XL5000 Starting S/N 0511100 thru 0517110 S/N 0522100 thru 0525110 2460-4122 July, 2002 GRADALL 406 Mill Avenue, S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211...
Page 4 It is impossible to anticipate and evaluate all possible applications and methods of apparition for this equipment. Any procedure not specifically recommended by The Gradall Company must be thoroughly evaluated from the standpoint of safety before it is placed in practice.
Page 6 Reservoir The hydraulic reservoir is located at the rear of the frame, behind the boom. Within the hydraulic system, the reservoir performs these important functions: Provides storage for a sufficient volume of oil that allows cylinders to extend and reserves a sufficient volume of oil to prevent pump starvation.
Page 7 FIGURE 1 RESERVOIR AND FILTRATION SECTION Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 8 Filtration XL Series machines use a number of filters to condition and cleanse hydraulic oil. These filters ore located in the reservoir area and the engine compartment. See Figure 2. This is done using: Return oil from the valves which is filtered before entering the reservoir. A suction screen that prevents foreign objects from entering the pump inlet.
Page 9 Hydraulic Reservoir Return Filter - 10-micron filter mounted in reservoir (see reservoir section of this manual for details about two different filters used). With both types, oil returning From the control valves must pass through the hydraulic reservoir return filter before entering the reservoir. Due to the pump used on XL Series machines, return oil from the control valves flows only when a valve is actually shifted.
Page 10 XL Series machines use a bent-axis, variable-displacement main pump to provide oil to all hydraulic functions (except swing and pilot). The main pump assembly contains a pump housing, pump end cover, pump splitter box, two pump assemblies, pump stroking controls and on auxiliary drive PTO for other hydraulic pumps. Both pump groups are connected to a single set of pump stroking controls that vary pump displacement in response to system pressure.
Page 11 FIGURE 3 MAIN PUMP ASSEMBLY (TOP CROSS SECTION) FIGURE 4 START-UP PROCEDURE: XL SERIES EXCAVATORS Start the engine at idle speed (800 RPM) for 15 With boom level actuate boom out 2" then Before starting the engine make sure all assem- seconds (all valves in neutral).
Page 12 FIGURE 5 PUMP STROKING SYSTEM FIGURE 6 LOAD SENSING CIRCUIT Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 13 FIGURE 7 MAIN PUMP Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 14 This variable displacement pump/fixed displacement motor provides independent swing function. Separate from the main hydraulic pump, the swing pump is an inline overcenter, variable-displacement piston pump. It is attached to the main pump case at the PTO drive (which drives the input shah of the swing pump). The input shaft of the swing pump drives the pump rotary group and swing charge pump and has a thru-drive for auxiliary drive at the rear of the swing pump.
Page 15 FIGURE 9 SWING PUMP (TOP VIEW) This small tandem gear pump is mounted at the rear of the swing pump. It is driven by the thru-drive from the swing pump. The input shaft drives the gear of both pump sections. See Figures 10 and 11. Oil is supplied to both pump sections via a common feed tube from the reservoir using a separate outlet in each section.
Page 16 FIGURE 10 FIGURE 11 Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 17 Pilot oil flow/pressure serves joystick operation, boom tilt, remote travel functions and auxiliary hydraulic functions (optional). Pilot oil is supplied from a 6.6 gpm pilot pump. The rear section of the tandem gear pump, or pilot pump, is driven at engine speed by the thru-drive of the swing pump. Oil from the pilot pump flows through an inline pilot filter in the engine compartment.
Page 18 Gradall uses two types of hydraulic controllers for at the valve end caps. See Figure 14B. As he Gradall uses the same pedal valves for travel in the pilot functions. Two joysticks are used for the progressively strokes the hand lever, the pressure the crawlers as well as the truck mounts.
Page 19: Foot Pedal
FIGURE 14A FIGURE 14B JOYSTICK PORTS JOYSTICK FIGURE 15 FOOT PEDAL Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 20 XL Series machines use independent closed loop swing hydraulics for the swing circuit. This circuit consists of an inline overcenter, variable-displacement piston pump, circuit lines and a bent axis fixed-displacement piston motor. See Figure 16. There is no control valve within the circuit. Stroking of the pump is controlled by a valve mounted on the pump.
Page 21: Swing Motor
FIGURE 16 SWING MOTOR FIGURE 17 SWING CIRCUIT Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 22 FIGURE 18 SWING BRAKE RELEASE VALVE SWING BRAKE RELEASE VALVE signal on the opposite pilot line. This pilot signal The swing brake release valve releases the swing exhausting too rapidly from the swing parking pressurizes the top of the sequence valve. It takes brake when the machine is swinging.
Page 23 FIGURE 19 SWING TORQUE VALVE (PILOT PRESSURE SECTION) Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 24 FIGURE 20 SWING TOROUE VALVE (HIGH PRESSURE SECTION) Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 25 This high pressure signal also shifts the cushioning spool to direct more charge oil into the stroking piston. The result is a 14-to-1 high pressure to pilot pressure ratio. Whenever the two pressures are out of balance, the torque control spool Ships, bringing the pump on stroke to generate enough oil flow so resistant to flow pressure will balance the pilot signal.
Page 26 FIGURE 22 CUSHIONING VALVE Form No. 29410 XL 4100/XL 5100 Hydraulicc System Operation Manual...
Page 27 Two control valve banks are provided. See Figure 23. A large control valve bank with diverter, bucket, hoist and tilt valves is located behind the operator’s cab. See Figure 24. A smaller control valve bank with travel and boom valves is located behind the large bank. See Figure 25.
Page 28 FIGURE 24 BUCKET/HOIST VALVE BANK (ALL MODELS, TYPIAL) FIGURE 25 BOOM/PROPEL VALVE BANK (XL 4100 AND XL 5100) Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 29 FIGURE 26 LOAD SENSING CIRCUIT FIGURE 27 VALVE SECTION (TYPICAL) XL 4100/XL 5100 Hydraulic System Operation Manual Form No. 29410...
Page 30 An auxiliary valve section may be added to the front valve bank to power auxiliary hydraulics. Installation kits are available from Gradall. Due to the load sensing circuit in the valves, use of aftermarket auxiliary valves is not possible. Use only genuine Gradall parts when adding auxiliary hydraulics to a machine.
Page 31 FIGURE 28 COMPENSATOR SPOOL OPERATION (VENT POSITION) FIGURE 29 COMPENSATOR SPOOL OPERATION (LOAD CHECK POSITION) Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 32 FIGURE 30 COMPENSATOR SPOOL OPERATION (FLOW POSITION) Inlet Pressure Compensated Pressure Port Pressure Tank Pressure FIGURE 31 CONTROL VALVE LOAD SENSE SHUTTLES (CROSS SECTION) Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 33 FIGURE 32 VALVE BANK INLET COVER (TYPICAL) TORQUE 50 FT/LBS. TOROUE 50 FT/LBS. FIGURE 33 PORT RELIEF VALVE (TYPICAL) Form No. 29410 30XL 4100/X1 5100 Hydraulic System Operation Manual...
Page 34 FIGURE 34 COMPENSATOR REGULATOR FIGURE 35 CONTROL VALVE - TORQUE VALUES (TYPICAL) Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 35 The diverter valve is a special valve assembly located in the front valve bank. The assembly consists of a dummy spool, retainer plates (to prevent spool movement), special compensator with integral shuttle assembly, cap on the “A” port, reservoir plug for the “A” port option, and a dummy relief plug (8093-4350) for the “B” port option. See Figures 36 and 37.
Page 36 FIGURE 37 DIVERTER VALVE (CURRENT PRODUCTION) FIGURE 38 DIVERTER VALVE CIRCUIT HOIST/BUCKET VALVE BANK ASSEMBLY BOOM VALVE BANK ASSEMBLY Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 37 FIGURE 39 DIVERTER VALVE (FLOW POSITION) The bucket valve consists of two port reliefs, o section compensator and compensator regulator. See Figure 40. Oil flows from the front port when the ,Front end cop is pressurized. When the joystick is actuated, the pilot signal shift the valve spool and the compensator meters oil to the spool.
Page 38 FIGURE 40 BUCKET VALVE SECTION The hoist valve consists of two port reliefs, a section compensator and compensator regulator. See Figure 41. Oil flows from the front port when the front end cap is pressurized. When the joystick is actuated, the pilot signal shifts the valve spool and the compensator meters oil to the spool.
Page 39 FIGURE 41 HOIST VALVE SECTION (EARLY XL 5000 SERIES ONLY) FIGURE 42 HOIST VALVE SECTION (ALL XL 4000s AND CURRENT XL 5000s) Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 40 The tilt valve consists of two port reliefs and a section compensator. See Figure 43. The spool shift using electrically triggered end caps. Proportional solenoids on each end cap receive pilot oil from the pilot feed line. Pilot oil then flows end cover of the control valve assembly.
Page 41 FIGURE 44 TILT MOTOR XL 4100/XL 5100 Hydraulic System Operation Manual Form No. 29410...
Page 42 The boom cylinder is attached to the boom cradle and telescoping boom to provide boom crowd action. As in other Gradall models, oil is routed to the boom cylinder through the boom rod. A gland on the back of the rod allows for rod tilt and provides ports into the rod.
Page 43 FIGURE 45 BOOM VALVE SECTION (EARLY REMOTE MACHINES AND ALL STD. CRAWLERS) FIGURE 46 BOOM VALVE SECTION (REMOTE MACHINES, CURRENT) Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 44 The propel valve consists of two port reliefs and a section compensator. See Figure 47. Oil flows from the front port when the front end cap is pressurized. When the foot pedal is actuated, the pilot signal shifts the valve spool and the compensator meters oil to the spool.
Page 45 Oil from the recirculating pump supplies the priority flow regulator in the pilot manifold. See Figure 48. This priori- ty flow regulator controls the amount of oil diverted from the recirculating pump to the chassis steering valve. The maximum flow to the chassis steering valve is 4 gpm. The steering circuit in the pilot manifold is protected by a 2,100 psi relief.
Page 46 FIGURE 49 STEERING PEDAL VALVE Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 47 Return oil from the remote steering valve keeps the stabilizer cylinders filled with oil. An air signal from the remote brakes controls the release of the stabilizer cylinders. This release occurs when moving in remote; the cylinders lock when they are not moving in remote. They float freely during travel. See Figure 50. FIGURE 50 FRONT AXLE STABILIZERS Form No.
Page 48 The auxiliary hydraulic circuit can be factory or dealer installed. The XL Series machines’ load sense hydraulic system makes it is necessary to use a Gradall hydraulic kit. Use of aftermarket kits will prevent the proper operation of the pump load sense system, resulting in poor/no hydraulic function. For additional kit information, contact Gradall Parts Marketing.
Page 49 FIGURE 51 AUXILLIARY VALVE SECTION Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 50 HOIST VALVE SECTION (SPECIAL) (XL 5110, XL 5210 AND XL 6210) Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 51 BOOM VALVE SECTION (SPECIAL (XL 5110, XL 5210, AND XL 6210) Form No. 29410 XL 4100/XL 5100 Hydraulic System Operation Manual...
Page 54 It is impossible to anticipate and evaluate all possible applications and methods of operation for this equipment. Any procedure not specifically recommended by The Gradall Company must be thoroughly evaluated from the standpoint of safety before it is placed in practice.
Page 56 I. Reservoir and Filtration System Reservoir The hydraulic reservoir is located at the rear of the frame, behind the boom. Within the hydraulic system, the reservoir performs these important functions: Provides storage for a sufficient volume of oil that allows cylinders to extend and reserves a sufficient volume of oil to prevent pump starvation.
Page 57 I. Reservoir and Filtration Systems (continued) FIGURE 1 RESERVOIR AND FILTRATION SECTION Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 58 I. Reservoir and Filtration Systems (continued) Filtration XL Series machines use a number of filters to condition and cleanse hydraulic oil. These filters are located in the reservoir area and the engine compartment. See Figure 2. This is done using: Return oil from the valves which is filtered before entering the reservoir.
Page 59 I. Reservoir and Filtration Systems (continued) Hydraulic Reservoir Return Filter - 10-micron filter mounted in reservoir (see Reservoir section of this manual for details about two different filters used). With both types, oil returning from control valves must pass through the hydraulic reservoir return filter before entering the reservoir.
Page 60 II. Main Hydraulic Pump XL Series machines use a bent-axis, variable-displacement main pump to provide oil to all hydraulic functions (except swing and pilot). The main pump assembly contains a pump housing, pump end cover, pump splitter box, two pump assemblies, pump stroking controls and an auxiliary drive PTO for other hydraulic pumps.
Page 61 II. Main Hydraulic Pump (continued) FIGURE 3 MAIN PUMP ASSEMBLY (TOP CROSS SECTION) FIGURE 4 START-UP PROCEDURE: XL SERIES EXCAVATORS Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 62 II. Main Hydraulic Pump (continued) FIGURE 5 PUMP STROKING SYSTEM FIGURE 6 LOAD SENSING CIRCUIT Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 63 II. Main Hydraulic Pump (continued) FIGURE 7 MAIN PUMP Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 64 III. Swing Pump This variable displacement pump/fixed displacement motor provides independent swing function. Separate from the main hydraulic pump, the swing pump is a variable displacement, overcenter, inline piston pump. It is attached to the main pump case at the PTO drive (which drives the input shaft of the swing pump). The input shaft of the swing pump drives the pump rotary group and swing charge pump and has a thru-drive for auxiliary drive at the rear of the swing pump.
Page 65 III. Swing Pump (continued) FIGURE 9 SWING PUMP (TOP VIEW) IV. Gear Pump This small tandem gear pump is mounted at the rear of the swing pump. It is driven by the thru-drive from the swing pump. The input shaft drives the gear of both pump sections. See Figures 10 and 11. Oil is supplied to both pump sections via a common feed tube from the reservoir using a separate outlet in each section.
Page 66 IV. Gear Pump (continued) FIGURE 10 FIGURE 11 Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 67: Pilot System
V. Pilot System Pilot oil flow/pressure serves joystick operation, boom tilt, crawler travel functions and auxiliary hydraulic functions (optional). Pilot oil is supplied from a 6.6 gpm pilot pump. The rear section of the tandem gear pump, or pilot pump, is driven at engine speed by the thru-drive of the swing pump. Oil from the pilot pump flows through an inline pilot filter in the engine compartment.
Page 68 V. Pilot System (continued) FIGURE 13 JOYSTICK CONTROL PATTERNS FIGURE 14 JOYSTICKS AND FOOT PEDALS Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 69 V. Pilot System (continued) FIGURE 14B FIGURE 14A JOYSTICK JOYSTICK PORTS FIGURE 15 FOOT PEDAL Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 70 VI. Swing Circuit XL Series machines use independent closed loop swing hydraulics for the swing circuit. This circuit consists of an inline overcenter, variable-displacement piston pump, circuit lines and a bent axis fixed-displacement piston motor. See Figure 16. There is no control valve within the circuit. Stroking of the pump is controlled by a valve mounted on the pump.
Page 71 VI. Swing Circuit (continued) FIGURE 16 SWING MOTOR FIGURE 17 SWING CIRCUIT Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 72 VI. Swing Circuit (continued) FIGURE 18 SWING BRAKE RELEASE VALVE FIGURE 18A SWING BRAKE RELEASE VALVE Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 73 VI. Swing Circuit (continued) FIGURE 19 SWING TORQUE CONTROL VALVE (PILOT PRESSURE SECTION) Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 74 VI. Swing Circuit (continued) FIGURE 20 SWING TORQUE VALVE (HIGH PRESSURE SECTION) Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 75 VI. Swing Circuit (continued) This high pressure signal also shifts the cushioning spool to direct more charge oil into the stroking piston. The result is a 14-to-1 high pressure to pilot pressure ratio. Whenever the two pressures are out of balance, the torque control spool shifts, bringing the pump on stroke to generate enough oil flow so resistance to flow pressure will balance the pilot signal.
Page 76 VI. Swing Circuit (continued) FIGURE 22 CUSHIONING VALVE Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 77: Control Valve
VII. Control Valve Two control valve banks are provided. See Figure 23. Large control valve bank with diverter, bucket, hoist and tilt valves is located behind the operator’s cab. See Figure 24. Smaller control valve bank with travel and boom valves is located behind the large bank. See Figure 25.
Page 78: Control Valves
VII. Control Valves (continued) FIGURE 24 BUCKET/HOIST VALVE BANK (ALL MODELS, TYPICAL) FIGURE 25 BOOM/PROPEL VALVE BANK (XL 4200 AND XL 5200) Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 79 VII. Control Valve (continued) FIGURE 26 LOAD SENSING CIRCUIT FIGURE 27 VALVE SECTION (TYPICAL) Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 80 An auxiliary valve section may be added to the front valve bank to power auxiliary hydraulics. Installation kits are available from Gradall. Due to the load sensing circuit in the valves, use of after market auxiliary valves is not possible. Use only genuine Gradall parts when adding auxiliary hydraulics to a machine.
Page 81 VIII. Control Valves (continued) FIGURE 28 COMPENSATOR SPOOL OPERATION (VENT POSITION) FIGURE 29 COMPENSATOR SPOOL OPERATION (LOAD CHECK POSITION) Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 82 VII. Control Valves (continued) FIGURE 30 COMPENSATOR SPOOL OPERATION (FLOW POSITION) FIGURE 31 CONTROL VALVE LOAD SENSE SHUTTLES (CROSS SECTION) Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 83 VII. Control Valves (continued) FIGURE 32 VALVE BANK INLET COVER (TYPICAL) FIGURE 33 PORT RELIEF VALVE (TYPICAL) Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 84 VII. Control Valves (continued) FIGURE 34 COMPENSATOR REGULATOR FIGURE 35 CONTROL VALVE - TORQUE VALUES (TYPICAL) Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 85 VIII. Diverter Valve/Circuit The diverter valve is a special valve assembly located in the front valve bank. The assembly consists of a dummy spool, retainer plates (to prevent spool movement), a special compensator with integral shuttle assembly, a cap on “A” port, reservoir plug for the “A” port option, and a dummy relief plug (8093-4350) for the “B” port option. See Figures 36 and 37 .
Page 86 VIII. Diverter Valve/Circuit (continued) FIGURE 37 DIVERTER VALVE (CURRENT PRODUCTION) FIGURE 38 DIVERTER VALVE CIRCUIT Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 87 VIII. Diverter Valve/Circuit (continued) FIGURE 39 DIVERTER VALVE (FLOW POSITION) IX. Bucket Valve/Circuit The bucket valve consists of two port reliefs, a section compensator and compensator regulator. See Figure 40. Oil flows from the front port when the front end cap is pressurized. When the joystick is actuated, the pilot signal shifts the valve spool and the compensator meters oil to the spool.
Page 88 IX. Bucket Valve/Circuit (continued) FIGURE 40 BUCKET VALVE SECTION X. Hoist Valve/Circuit The hoist valve consists of two port reliefs, a section compensator and compensator regulator. See Figure 41. Oil flows from the front port when the front end cap is pressurized. When the joystick is actuated, the pilot signal shifts the valve spool and the compensator meters oil to the spool.
Page 89 X. Hoist Valve/Circuit (continued) FIGURE 41 HOIST VALVE SECTION (EARLY XL 5000 SERIES ONLY) FIGURE 42 HOIST VALVE SECTION (ALL XL 4000s AND CURRENT XL 5000s) Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 90 XI. Tilt Valve/Circuit The tilt valve consists of two port reliefs and a section compensator. See Figure 43. The spool shifts using electrically triggered end caps. Proportional solenoids on each end cap receive pilot oil from the pilot feed line. Pilot oil then flows to the end cover of the control valve assembly.
Page 91 XI. Tilt Valve/Circuit (continued) FIGURE 44 TILT MOTOR Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 92 The boom cylinder is attached to the boom cradle and telescoping boom to provide boom crowd action. As in other Gradall models, oil is routed to the boom cylinder through the boom rod. A gland on the back of the rod allows for rod tilt and provides ports into the rod.
Page 93 XII. Boom Valve/Circuit (continued) FIGURE 45 BOOM VALVE SECTION (EARLY REMOTE MACHINES AND ALL STD. CRAWLERS) XIII. Propel Valve/Circuit Each crawler valve has two port reliefs and a section compensator. See Figure 46. Oil flows from the front port when the front end cap is pressurized. When the foot pedal is actuated, the pilot signal shifts the valve spool and the compensator meters oil to spool.
Page 94 XIII. Propel Valve/Circuit (continued) Crawler oil is routed through the center pin to the travel motors mounted on the side frame of the undercarriage. Each motor connects with two circuit lines, a tank line nod a shift line. Circuit oil from the valve not only drives the motor, but also releases the travel brakes, which are part of the final drive.
Page 95 XIV. Crawler Motor and Final Drive The hydraulic crawler motor and final drive are specifically designed to be an excavator drive assembly. See figure 47: This assembly consists of a spring-applied parking brake, a double counterbalance valve, a two-speed valve, crossover relief valves, an inline piston motor and a three-stage planetary reduction unit.
Page 96 XIV. Crawler Motor and Final Drive (continued) The counterbalance valve hydraulically locks the motor when the circuit is not actuated. When the circuit is actuated, the counterbalance valve prevents the motor from overrunning while descending a grade. When the control valve is shifted, circuit oil is routed to the counterbalance valve which won’t shift until oil from the control valve over- comes oil trapped between the counterbalance valve and the motor.
Page 97 The auxiliary hydraulic circuit can be factory or dealer installed. The XL Series machines’ load sense hydraulic system makes it is necessary to use a Gradall hydraulic kit. Use of after-market kits will prevent the proper operation of the pump load sense system, resulting in poor/no hydraulic function. For additional kit information, contact Gradall Parts Marketing.
Page 98 XV. Auxiliary Valve/Circuit (Optional) (continued) FIGURE 48 AUXILIARY VALVE SECTION Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 99 XVI. Appendix A HOIST VALVE SECTION (SPECIAL) (XL 5110, XL 5210, AND XL 6210) Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 100 XVII. APPENDIX B BOOM VALVE SECTION (SPECIAL) (XL 5110, XL 5210, AND XL 6210) Form No. 29411 XL 4200/XL 5200 Hydraulic System Operation Manual...
Page 104 It is impossible to anticipate and evaluate all possible applications and methods of operation for this equipment. Any procedure not specifically recommended by The Gradall Company must be thoroughly evaluated from the standpoint of safety before it is placed in practice.
Page 106 Gradall XL 4100 machines use pressures that are unique for the particular model. Use this procedure to set pressures on these machines. Gradall Test Kit (PN 7713-4197) contains all gauges, hoses and adapters required to test machine functions. In addition to normal mechanics hand tools, metric wrenches (box, open end, and allen) are required.
Page 107 Build air pressure up in the upperstructure for remote operation. Shut engine off. At reservoir breather located next to the engine, push release plunger to expel all air pressure in the hydraulic tank. See Figure 1. Observe reservoir pressure gauge as pressure builds up. Reservoir pressure should be 6 - 8 psi. If pressure is too high or low, adjust regulator, dump tank pressure and recheck (regulator and gauge are attached to filter bracket on engine above air compressor).
Page 108 Put gauge (1,000 psi) on pilot manifold on pilot test port (pilot manifold is above heat exchanger valve; test port is lower rear). See Figure 2. Run engine at full RPM. Pressure should be 480 - 500 psi. Adjust relief as needed. See Figure 2. Put gauge on upper (1,000 psi) test port on pilot charge valve assembly (on bellhousing in front of swing pump).
Page 109 Form No. 29412...
Page 110 Assemble two Gradall gauge hoses from test kit together with connector. Route across machine so that gauge is in cab and hose will reach swing pump test ports. Put gauge (10,000 psi) on outside test port on top of swing pump. Place boom firmly on ground, run engine at full RPM and stall the swing to the right.
Page 111 Put gauge (1,000 psi) on test port of pump supply line to bucket, hoist and tilt valve bank (large valve bank). See Figure 7. Leave right hand armrest up, run engine at full RPM. Pressure should read 300 - 350 psi. Adjust as required at load sense valve on main pump (load sense valve is located at control block on main pump, facing the reservoir).
Page 112 Put gauge (10,000 psi) on front tilt test port. Set tilt speed to maximum speed. Run engine at full RPM, tilt boom counterclockwise and stall tilt. Pressure should be 2,800 - 2,850 psi. Adjust front port relief as required. See Figure 9. Put gauge on rear tilt test port and repeat for clockwise boom tilt.
Page 113 Move gauge (10,000 psi) to front hoist test port. Run engine at full RPM, lower boom to ground and stall hoist. Pressure should be 2,200 - 2,300 psi. Adjust front port relief as required. See Figure 10. Move gauge to rear test port. Rotate section regulator adjusting screw clockwise one and one-half turns. Raise hoist fully up, use procedure for “cracking”...
Page 114 Put gauge (10,000 psi) on rear boom test port. Rotate section regulator adjusting screw clockwise one and one-half turns. Fully retract boom, use procedure for “cracking” pressure. Pressure should be 3,400 - 3,450 psi. Adjust port relief as required. See Figure 11. Leave gauge on test port, turn section regulator adjusting screw back to original position.
Page 115 Place carrier transmission in LL4. Place carrier into remote operation. Set carrier brakes in upper cab to locked position. Put gauge (10,000 psi) on front test port of remote travel valve. Run engine at full RPM and depress travel pedal for forward travel. Gauge should read 3,000 - 3,100 psi. Adjust front port relief as required. See Figure 12. Place gauge (10,000 psi) on rear test port and repeat for reverse travel.
Page 116 Place gauge (10,000 psi) on pilot manifold on upper front test port. Use two gauge hoses and connector to allow gauge to be in cab. See Figure 13. Run engine at full RPM and steer chassis fully in one direction with foot pedal. Pressure should be 2,100 psi. Adjust as required by removing cap from steering relief.
Page 117 Function Pressure (psi) Reservoir Air Pressure Pilot Pressure 480-500 Swing Circuit Swing Charge Pressure 380-420 320-350 Swing Makeup Pressure Swing Torque Pressure 5,450-5,750 (Maximum swing pressure) Swing Cushioning 3,300-3,500 Main Pump Main Pump Standby Pressure 300-350 Main Pump Cutoff Pressure 4,925-5,075 Valve Bank Clipper Reliefs 5,050-5,150...
Page 120 It is impossible to anticipate and evaluate all possible applications and methods of preparation for this equipment. Any procedure not specifically recommended by The Gradall Company must be thoroughly evaluated from the standpoint of safety before it is placed in practice.
Page 122 I. Testing and Adjusting Gradall XL 4200 machines use pressures that are unique for the particular model. Use this procedure to set pressures on these machines. Gradall Test Kit (P/N 7713-4197) contains all gauges, hoses and adapters required to test machine functions. In addition to normal mechanics hand tools, metric wrenches (box, open end, and allen) are required.
Page 123 II. Reservoir Air Pressure NOTE: This step requires that the compressor relay be bypassed to set the air pressure regulator. Remove cover from the electrical panel and place o jumper across the large terminals of the compressor relay. Remove jumper after the regulator is adjusted. At reservoir breather located next to the engine, push release plunger to expel all air pressure in the hydraulic tank.
Page 124 III. Joystick Pilot Pressure Put LP gauge (1,000 psi) on pilot manifold on pilot test port (pilot manifold is above heat exchanger valve). Run engine at full RPM. Pressure should be 480 - 500 psi. Adjust relief as needed. See Figure 2. FIGURE 2 IV.
Page 125 IV. Swing Charge and Pilot Charge Pressure (continued) FIGURE 5 FIGURE 3 FIGURE 4 Form No. 29413...
Page 126 V. Swing Circuit Pressure Adjustments Assemble two Gradall gauge hoses from test kit together with connector. Route across machine so that gauge is in cab and hose will reach swing pump test ports. Put HP gauge (10,000 psi) on outside test port on top of swing pump. Place boom firmly on ground, run engine at full RPM and stall the swing to the right.
Page 127 VI. Main Pump Standby Pressure Put LP gauge (1,000 psi) on test port of pump supply fine to bucket, hoist and tilt valve bank (large valve bank). See Figure 7. Leave right hand armrest up, run engine at full RPM. Pressure should read 300 - 350 psi. Adjust as required at load sense valve on main pump (load sense valve is located at control block on main pump, facing the reservoir).
Page 128 VII. Tilt Valve Adjustments Put HP gauge (10,000 psi) on front tilt test port. Set tilt speed to maximum speed. Run engine at full RPM, tilt boom counterclockwise and stall tilt. Pressure should be 2,800 - 2,900 psi. Adjust front port relief as required. See Figure 9.
Page 129 IX. Hoist Valve Adjustments Move HP gauge (10,000 psi) to front hoist test port. Run engine at full RPM, lower boom to ground and stall hoist. Pressure should be 2,200 - 2,300 psi. Adjust front port relief as required. See Figure 10. Move HP gauge (10,000 psi) to rear test port.
Page 130 X. Boom Valve Adjustments Put HP gauge (10,000 psi) on rear boom test port. Rotate section regulator adjusting screw clockwise one and one-half turns. Fully retract boom, use procedure for “cracking” pressure. Pressure should be 3,400 - 3,450 psi. Adjust port relief as required. See Figure 11. Leave HP gauge (10,000 psi) on test port, turn section regulator adjusting screw back to original position.
Page 131 XI. Crawler Drive Pressure Place HP gauge (10,000 psi) on front tube of left hand crawler valve. Switch crawler travel speed to high speed. See Figure 12. Run engine at full RPM. Depress left hand travel pedal for forward travel. Stall the track, pressure should be 4,300 - 4,400 psi.
Page 132 XII. Hydraulic System Pressures Function Pressure (psi) 6 - 8 Reservoir Air Pressure 480 - 500 Pilot Pressure Swing Circuit 380 - 420 Swing Charge Pressure Swing Makeup Pressure 320- 350 5,450 - 5,750 Swing Torque Pressure (Maximum swing pressure) 3,300- 3,500 Swing Cushioning 300 - 350...
Page 136: Important Safety Notice
It is impossible to anticipate and evaluate all possible applications and methods of operation for this equipment. Any procedure not specifically recommended by The Gradall Company must be thoroughly evaluated from the standpoint of safety before it is placed in practice.
Page 138: Testing And Adjusting
I. Testing and Adjusting Gradall Xl 5100 machines use pressures that are appropriate for the application. Use this procedure to set pressures on these machines. Gradall Test Kit (P/N 7713-4197) contains all gauges, hoses and adapters required to test machine functions. In addition to normal mechanics hand tools, metric wrenches (box, open end, and allen) are required.
Page 139 II. Reservoir Air Pressure Build air pressure up in the upperstructure for remote operation. Shut engine off. At reservoir breather located next to the engine, push release plunger to expel all air pressure in the hydraulic tank. See Figure 1. Observe reservoir pressure gauge as pressure builds up.
Page 140 III. Joystick Pilot Pressure Put LP gauge (1,000 psi) on pilot manifold on pilot test port (pilot manifold is above heat exchanger valve; test port is lower rear). See Figure 2. Run engine at full RPM. Pressure should be 480 - 500 psi. Adjust relief as needed. See Figure 2. FIGURE 2 IV.
Page 141 IV. Swing Charge and Pilot Charge Pressure (continued) FIGURE 3 FIGURE 5 FIGURE 4 Form No. 29414...
Page 142 V. Swing Circuit Pressure Adjustments Assemble two Gradall gauge hoses from test kit together with connector. Route across machine so that gauge is in cab and hose will reach swing pump test ports. Put HP gauge (10,000 psi) on outside test port on top of swing pump. Place boom firmly on ground, run engine at full RPM and stall the swing to the right.
Page 143 VI. Main Pump Standby Pressure Put LP gauge (1,000 psi) on test port of pump supply fine to bucket, hoist and tilt valve bank (large valve bank). See Figure 7. Leave right hand armrest up, run engine at full RPM. Pressure should read 300 - 350 psi. Adjust as required at load sense valve on main pump (load sense valve is located at control block on main pump, facing the reservoir).
Page 144 VII. Tilt Valve Adjustments Put HP gauge (10,000 psi) on front bucket test port. Set tilt speed to maximum speed. Run engine at full RPM, tilt boom clockwise and stall tilt. Pressure should be 3,000 - 3,050 psi. Adjust front port relief as required. See Figure 9.
Page 145 IX. Hoist Valve Adjustments Move HP gauge (10,000 psi) to front hoist test port. Run engine at full RPM, lower boom to ground and stall hoist. Pressure should be 3,000 - 3,100 psi. Adjust front port relief as required. See Figure 10. Move HP gauge (10,000 psi) to rear test port.
Page 146 X. Boom Valve Adjustments Put HP gauge (10,000 psi) on rear boom test port. Rotate section regulator adjusting screw clockwise one and one-half turns. Fully retract boom, use procedure for “cracking” pressure. Pressure should be 3,650 - 3,700 psi. Adjust port relief as required. See Figure 11. Leave HP gauge (10,000 psi) on test port, turn section regulator adjusting screw back to original position.
Page 147 XI. Remote Travel Pressures Place carrier transmission in LL4. Place carrier into remote operation. Set carrier brakes in upper cab to locked position. Put HP gauge (10,000 psi) on front test port of remote travel valve. Run engine at full RPM and depress travel pedal for forward travel.
Page 148 XII. Remote Steering Pressure Place HP gauge (10,000 psi) on pilot manifold on upper front test port. Use two gauge hoses and connector to allow gauge to be in cab. See Figure 13. Run engine at full RPM, and steer chassis fully in one direction with foot pedal. Pressure should be 2,100 psi. Adjust as required by removing cap from steering relief.
Page 149 XIII. Hydraulic System Pressure Function Pressure (psi) 6 - 8 Reservoir Air Pressure Pilot Pressure 480 - 500 Swing Circuit 380 - 420 Swing Charge Pressure Swing Makeup Pressure 320 - 350 5,450 - 5,750 Swing Torque Pressure (Maximum swing pressure) 3,300 - 3,500 Swing Cushioning Main Pump...
Page 152 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 XL Series Excavator in reliable condition. Use of the recommended operating procedures can help you avoid accidents. Because same procedures may be new to even the experienced technician, we recommend that this manual be read, understood, and followed by all who service this unit.
Page 154 Gradall XL 5200 machines use pressures that are appropriate for the application. Use this procedure to set pressures on these machines. Gradall Test Kit (P/N 7713-4197) contains all gauges, hoses and adopters required to test machine functions. In addition to normal mechanics hand tools, metric wrenches (box, open end, and allen) are required.
Page 155 NOTE: This step requires that the compressor relay be bypassed to set the air pressure regulator. Remove cover from the electrical panel, and place a jumper across the large terminals of the compressor relay. Remove jumper after the regulator is adjusted. At reservoir breather located next to the engine, push release plunger to expel all pressure in the hydraulic tank See Figure 1.
Page 156 Put LP gauge (1,000 psi) on pilot manifold on pilot test port (pilot manifold is above heat exchanger valve). Run engine at full RPM. Pressure should be 480 - 500 psi. Adjust relief as needed. See Figure 2. FIGURE 2 Put LP gauge (1,000 psi) on upper test port on pilot charge valve assembly (on bellhousing in front of swing pump).
Page 157 FIGURE 3 FIGURE 5 FIGURE 4 Form No. 29415...
Page 158 Assemble two Gradall gauge hoses from test kit together with connector. Route across machine so that gauge is in cab and hose will reach swing pump test ports. Put HP gauge (10,000 psi) on outside test port on top of swing pump. Place boom firmly on ground, run engine at full RPM and stall the swing to the right.
Page 159 Put LP gauge (1,000 psi) on test port of pump supply line to bucket, hoist and tilt valve bank (large valve bank). See Figure 7. Leave right hand armrest up, run engine at full RPM. Pressure should read 275 - 325 psi. Adjust as required at load sense valve on main pump (load sense valve is located at control block on main pump, facing the reservoir).
Page 160 VI Main Pump Standby Pressure Put HP gauge (10,000 psi) on front tilt test port. Set tilt speed to maximum speed. Run engine at full RPM, tilt boom clockwise and stall tilt. Pressure should be 3,000 - 3,050 psi. Adjust front port relief as required. See Figure 9. Put HP gauge (10,000 psi) on rear tilt test port and repeat for counterclockwise boom tilt.
Page 161 Move HP gauge (10,000 psi) to front hoist test port. Run engine at full RPM, lower boom to ground and stall hoist. Pressure should be 3,000 - 3,100 psi. Adjust front port relief as required. See Figure 10. Move HP gauge (10,000 psi) to rear test port. Rotate section regulator adjusting screw clockwise one and one-half turns.
Page 162 Put HP gauge (10,000 psi) on rear boom test port. Rotate section regulator adjusting screw clockwise one and one-half turns. Fully retract boom, use procedure for “cracking” pressure. Pressure should be 3,650 - 3,700 psi. Adjust port relief as required. See Figure 11. Leave HP gauge (10,000 psi) on test port, turn section regulator adjusting screw back to original position.
Page 163 Place HP gauge (10,000 psi) on front tube of left hand crawler valve. Switch crawler travel speed to high speed. See Figure 12. Run engine at full RPM. Depress left hand travel pedal for forward travel. Stall the track, pressure should be 4,500-4,600 psi.
Page 164 FUNCTION PRESSURE(psi) 6 - 8 Reservoir Air Pressure 480 - 500 Pilot Pressure 380 - 420 Swing Circuit 320 - 350 Swing Charge Pressure 5,450 - 5,750 Swing Makeup Pressure Swing Torque Pressure 3,300 - 3,500 (Maximum swing pressure) Swing Cushioning Main Pump 300 - 350 Main Pump Standby Pressure...
Page 185 XL 4000/5000 C ENTER EBUILD Form No. 20026 Part No. 2460-4164...
Page 186 EVISIONS u may determine that this Manual is complete and current with respect to Gradall This page is provided so yo Engineering Specifications. Page Date Revision Part No. 2460-4164...
Page 187 XL 4000/5000 ENTER EBUILD ABLE OF ONTENTS ECTION Introduction Safety Nomenclature Preparing the Machine Identifying the Machine: Hydraulic Hose Machines Hydraulic Tubing Machines Removing the Clamps (Tube Machines Only) Center Pin Removal Center Pin Disassembly Installing the Seals: Top Gland Lower Gland Center Pin Reassembly Center Pin Installation...
Page 188 NTRODUCTION This Manual details Center Pin removal, rebuild and reinstallation pro- cedures for all Gradall XL 4000 and XL 5000 Series Hydraulic Excava- tors. Components are referenced in full in the appropriate Gradall Parts Manual. Pressure Settings are referenced in the Gradall Hydraulic Ex- cavator Technical Manual.
Page 189 NTRODUCTION Remove only the guards/covers on the area being serviced. Replace all guards/covers immediately upon completion of the task. If the Excavator has special optional equipment, make sure that the appropriate maintenance and operational require- ments are understood by everyone who operates and services the machine.
Page 190 Any procedure not specifically recommended by Gradall must be thoroughly evaluated from the standpoint of safety before it is placed in practice. If you are not sure, contact your Authorized Gradall Distributor.
Page 191 SING ANUAL This Manual is a guide for maintenance technicians for removing, rebuilding and/or reinstalling a center pin on an XL 4000 or XL 5000 Series Excavator. In every instance, there are certain basic precautions and steps you should take before commencing the procedure. These precautions are outlined in the “Introduction”...
Page 192 1.0 N OMENCLATURE Stabilizer (current design - front mount) Note! A-1 Stabilizer (old style - side mount) See the appropriate Gradall Top Cap Parts Manual for more Top Gland detailed information on all Lower Gland these components. Center Pin Mounting Plate...
Page 193: Preparing The Machine
REPARING ACHINE Before starting any center pin procedure, perform the following opera- tions: Correct positioning of the upperstructure is a vital part of machine preparation. If you are working on a wheeled excava- tor, lift the boom out of the rack, close the bucket, retract the telescope boom fully and position the boom with the bucket on the ground at the right front of the carrier.
Page 194: Identifying The Machine
3.0 I DENTIFYING ACHINE YDRAULIC ACHINES XL4100: Serial Number 0411200 through 0414225 XL4200: Serial Number 0421200 through 0427225 XL5100: Serial Number 0511100 through 0517110 XL5200: Serial Number 0522100 through 0525110 Before starting any center pin procedure, you need to determine whether the machine you are working on has hydraulic hoses or tubes.
Page 195 EMOVING LAMPS (T ACHINES To remove all hydraulic and air lines, you will first need to remove all the relevant clamps. Note! Remember to cap or plug all hydraulic fittings, hoses and tubes upon disassembly to reduce the possibility of hydraulic system contami- nation due to dirt and dust.
Page 196 5.0 C ENTER EMOVAL Remove the top cap, allowing the stabilizer bar to be removed. At this point, a lifting device capable of lifting 300 lbs. may be attached to the top of the center pin assembly. There is a threaded hole in the middle of the pin post which accepts a lifting eye.
Page 197 ENTER ISASSEMBLY When breaking down the center pin assembly, make sure you mark the gland assemblies in relation to the center pin post. This will make re- assembly and re-installation much easier. To properly perform this operation, you will need a small flat-blade screwdriver and an O-ring pick.
Page 198 7.0 I NSTALLING EALS After you have taken the center pin assembly apart, clean and inspect everything. Installing the seals is the first part of the center pin rebuild process. Lay everything out on a clean, neat workbench. Make sure all the correct parts are there.
Page 199 NSTALLING EALS OWERGLAND Carefully inspect the lower gland. Use a wire buffing wheel to Note! clean out all the areas which house the seals. Blow off the gland When using a wire buffer wheel with low-pressure air, making sure it is absolutely clean. and/or air hose to clean compo- nents, always wear eye protec- Install the high pressure seals (“L, M, N”) into the housing of the...
Page 200 8.0 C ENTER EASSEMBLY First, make sure your work area is as clean as possible. You will be handling all components of the center pin and they must be kept as free of contaminants as possible. Once you open the seals and install them into the glands, make every effort to get the glands onto the post as soon as possible.
Page 201 ENTER NSTALLATION TAGE Install a lifting eye on top of the center pin assembly. Secure lifting tackle of sufficient capacity to lift 300 lbs. and bring the center pin assembly back to the machine. Once the center pin assembly is in place, secure the mounting Note! See comments in Section 9, “Hy- plate to the frame of the machine.
Page 202 9.1 C ENTER NSTALLATION (continued) Operate the machine in a clear, open area until the hydraulic oil reaches operating temperature. When you have verified that the machine is operating correctly and that all the hydraulic circuits are properly connected with- out leaks, the center pin assembly installation is complete.
Page 203: Hydraulic Plumbing
10.0 YDRAULIC LUMBING HEELED XCAVATORS The lower ports of the center pin deliver hydraulic oil to the remote drive motor and the remote steering valve. Ports “1” and “2” are used for remote drive routings. Ports “3” and “4” are used for remote steering routings. This oil supplies the remote steering valve, located behind the right front wheel.
Page 204 PPENDIX ASTENER ORQUE HARTS UBRICATED NGLISH OLTS GRADE 8 BOLTS GRADE 5 BOLTS Torque Tolerance Clamp Torque Tolerance Clamp + or - Load + or - Load BOLT SIZE (ft-lb) (ft-lb) (lb) (ft-lb) (ft-lb) (lb) +3-0 2,700 +3-0 3,000 1/4 - 20 +3-0 3,300 +3-0...
Page 205 5870.59 4329.93 6886.66 5079.34 Note! Use 50% of listed values for aluminum fasteners. Note! To check Gradall torque values, set the torque wrench at 95% of rated torque value and check the fastener. If the torque wrench releases before fastener moves, assume that fastener torque is correct.
Page 206 PPENDIX ITTING ORQUE HARTS CODE 61 4-BOLT SPLIT FLANGE BOLT TORQUE SAE FITTINGS; STRAIGHT & ADJUSTABLE FLANGE BOLT BOLT THREAD PORT SIDE DASH SIZE SIZE TORQUE DASH SIZE ASSEMBLY SIZE ft-lb SIZE TORQUE ft-lb 3/8-16 25+/-4.5 3/8-16 31+/-4.5 5/16-24 7.5+/-.5* 1 1/4 7/16-14 41+/-5...
Page 207 Specifications are correct at time of publication. However, Gradall reserves the right to make any necessary changes without prior notice. Gradall is a registered trademark for Hydraulic Excavators, Material Handlers, Industrial Maintenance Machines, Attachments and other Components manufactured and marketed by The Gradall Company.

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