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Summary of Contents for Gradall XL5100
- Page 1 OPERATOR’S MANUAL XL5100 2460-4069 July 2002 Starting S/N G051001 Form #29115 Original Issue 7/92 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
- Page 4 Any procedure not specifically recommended by The Gradall Company must be thoroughly evaluated from the standpoint of safety before it is placed in practice. If you aren’t sure, contact your Gradall Distributor before operating. Do not modify this machine without written permission from the Gradall Company.
- Page 6 , r e a r , l e f t a n d r i g h t r e l a t e t o t h e Gradall Hydraulic Excavators Safety Manual and the o r i e n t a t i o n o f a m a n s i t t i n g i n t h e d r i v e r ’s s e a t .
- Page 7 If driver will operate upperstructure, he must also read and understand Gradall Upperstructure Operation & Lubrication Manual, Gradall Hydraulic E x c a v a t o r s S a f e t y M a n u a l a n d C I M A H y d r a u l i c E x c a v a t o r U s e r ’ s S a f e t y Manual.
- Page 8 SAFETY HIGHLIGHTS Learn to recognize ‘PINCH POINTS’ Boom Cradle Counterweight & Another Object Boom Boom Holes Bucket & Linkage Upperstructure & Carrier Lear n t o re co g ni ze “PIN CH P O I N TS ” an d s tay clea r o f the m. G e ttin g c au gh t i n a p i n c h p o i n t c a n c a u s e s e r i o u s i n j u r y o r d e a t h .
- Page 9 SAFETY HIGHLIGHTS C h e c k t o b e s u r e a l l D A N G E R , WA R N I N G , C A U T I O N a n d I N S T R U C T I O N D E C A L S a r e i n place and can be read.
- Page 10 SAFETY HIGHLIGHTS 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 Learn and follow your employer’s safety rules. area to become familiar with the controls. Tr a v e l o f f - h i g h w a y g r a d e s...
- Page 11 SAFETY HIGHLIGHTS Check to be sure windows and mirrors are clean a n d t h a t m i r r o r s a r e p r o p e r l y a d j u s t e d f o r y o u r Use boom tie-down device to secure boom in driving position.
- Page 12 SAFETY HIGHLIGHTS If required, secure attachment as shown to prevent drift while traveling. Remember, getting too close to unstable ground o r t h e e d g e o f a n e x c a v a t i o n c a n c a u s e t h e machine to tip.
- Page 13 Decals Inside Cab TO PREVENT INJURY, STAY CLEAR OF MOVING OR INJURY MAY RESULT FROM DEATH PARTS. FASTEN COVERS CONTRACTING ELECTRICAL LINES. BEFORE STARTING ENGINE. READ SERVICE TO PLACE ANY PART OF THIS MANUAL BEFORE MACHINE OR LOAD WITHIN 10 UNLAWFUL FEET OF HIGH VOLTAGE LINES ADJUSTING OR...
- Page 14 Decals Outside Cab USE TWO KEEP CLEAR OF HANDS WHEN MACHINE SWING AREA. Located on back of cab CLIMBING ON Part No. 8360-1018 MACHINE 7702-3003 Located at right of cab door Part No. 7702-3003 PRESSURIZED COOLING SYSTEM REMOVE CAP SLOWLY 9104-3210 Located on fan shroud NYLON BRAKE...
- Page 15 INSTRUMENTS AND INDICATORS Alternator Indicator Light Voltmeter Speedometer/Odometer Hi/Lo Beam Indicator Light Tachometer (optional) Air Pressure Gage (front) Low Air Indicator Light Fuel Gage Digging Brake Indicator Light Oil Pressure Gage Coolant Temperature Gage Turn Signal/Hazzard Indicator Light Air Pressure Gage (Rear) Do not move carrier while low air light is glowing or while any auxiliary device is signal ing a dangerous condition.
- Page 16 CONTROLS Heat Control Knob Front Wheel Drive Toggle (6x6 only) Heater Fan Switch Interaxle Differential Toggle Defroster Fan Switch Dome Light Switch Differential Lock Toggle High/Low Beam Switch Digging Brake Toggle Clutch Pedal Parking Brake Knob Brake Valve Pedal Accelerator Pedal Light Switch Ignition Switch Range Preselection Lever...
- Page 17 CHECKS AND SERVICES BEFORE STARTING ENGINE C o m p l e t e a l l r e q u i r e d m a i n t e n a n c e b e f o r e d r i v i n g t h e c a r r i e r U s e e x t r e m e c a u t i o n w h e n c h e c k i n g i t e m s b e y o n d y o u r n o r m a l r e a c h .
- Page 18 Lub ric ate unit a s i n d i c a t e d o n l u b r i c a t i o n c h a r t . Check fuel level and replenish as necessary. Refuel a t t h e e n d o f t h e w o r k s h i f t t o m i n i m i z e c o n d e n s a t i o n .
- Page 19 ENGINE OPERATION NOTE: If engine is being started at beginning of work shift be sure to perform all “CHECKS AND SERVICES BEFORE STARTING ENGINE” Starting Diesel Engine (Cummins) Be sure transmission is in neutral and parking Turn ignition switch fully clockwise to engage brake is applied.
- Page 20 Normal engine operation (Cummins) Observe voltmeter, water temperature RPM -2200 RPM). The governor has no control over pressure gages frequently to be sure all engine engine speed when engine is being “pushed” by systems are functioning properly. carrier load. Be alert for unusual noises or vibration. When Select an appropriate gear ratio and use service an unusual condition is noticed, stop in a safe area brake to assist in slowing travel down steep grades.
- Page 21 CHECKS AFTER STARTING ENGINE (To be performed at beginning of each work shift) Complete all required maintenance before driving Observe water temperature gage. Proper Check operation windshield washer wiper. operating temperature is approximately 140/200°F. ( 6 0 / 9 3 ° C ) . Check all lights and turn signals for proper Observe tachometer response to changes in operation.
- Page 22 BRAKE SYSTEM The air brake system includes a service brake, an emergency brake, a parking brake and a digging brake. Do not drive while low air indicator is flashing. If light comes on while carrier is moving, stop carrier in a safe area as soon as possible.
- Page 23 treadle valve will apply service brakes to the wheels If the air pressure gages indicate some system of the forward and rear tandem axles. There will be pressure remaining, it may be possible to drive the no braking on the wheels of the front axle. unit a short distance to remove it from a hazardous position (hold parking brake knob in depressed p o s i t i o n a n d u s e L L 1 g e a r r a n g e ) .
- Page 24 DIGGING BRAKE APPLICATION Allow sufficient time for full brake system pressure (125 p.s.i.- 862 kPa) to be devel- oped in upperstructure before operating unit in remote control. Move digging brake control toggle to ON position only when carrier is stopped. Maximum braking is applied to wheels when toggle is moved to ON.
- Page 25 Conventional steering STEERING SYSTEM The power steering system provides low effort Remote control steering steering under normal conditions greater control in the event of a blowout or soft ground. Your unit is equipped with a steering pedal in the “Road feel” is similar to that of a conventional upperstucture cab.
- Page 26 POWER TRAIN The power train furnished on 6x4 carriers (units Transfer Case having two driving axles at rear) includes the engine, (for 6x6 units only) clutch, transmission, rear tandem axles and the necessary propeller shafts to transfer torque (power) The transfer case is a gearbox located between the between these units.
- Page 27 SHIFTING GEARS Smooth, efficient gear shifting depends on coordin- ated use of accelerator pedal, clutch pedal, range preselection lever, deep reduction button and shift Stop carrier and select appropriate gear lever. It is also important that shifting occur at the range before driving down steep grade proper time with respect to carrier power require- under...
- Page 28 Double-Clutching for Downshift NOTE: Downshifting is used to aid in reducing Depress accelerator pedal to increase engine speed ca r ri e r s p e e d or t o i n c r e a se ca r r i er p o w e r. to high idle, depress clutch and shift to next lower gear.
- Page 29 Depress clutch pedal, depress clutch brake button and move shift lever to LL1 gear position. If conditions permit starting in LO range: Move deep reduction button to rear to select L O r a n g e . Depress clutch pedal, depress clutch brake R e l e a s e c l u t c h b r a k e b u t t o n .
- Page 30 When ready, move range preselection lever up As conditions permit, use upshift - double- to HI position. clutching method to shift thru 7th, 8th and 9th gears to 10th gear. Using upshift - double-clutching method, im- mediately shift from 5th gear position to 6th gear position.
- Page 31 Using downshift - double-clutching method, shift If it is necessary to shift to deep reduction, move thru 9th, 8th and 7th gears to 6th gear. deep reduction button forward to LO-LO position. Immediately shift to LL3 using downshift - double- clutching method.
- Page 32 INTER-AXLE DIFFERENTIAL With toggle in LOCK position, there is positive drive to the An inter-axle differential is provided at the rear of the front front and rear tandem axles and either axle will drive up to tandem axle. This unit divides input torque equally its maximum tractive ability without regard to the other between the front and rear tandem axles.
- Page 33 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 With carrier on level surface, apply parking brake. Start carrier engine develop full brake Be sure to keep feet clear of clutch pedal system pressure in front and rear portions of when moving DIGGING BRAKE toggle to system (125 psi/862 kPa.).
- Page 34 Precautions for Remote Control Operation Always give audible signal before moving unit. Be sure of clear visibility in direction of travel; use a signalman to compensate for blind spots. Never permit bucket to drag while moving unit. Be sure all Warm-Up and Operational Checks Rotation of steering wheel will occur during have been performed.
- Page 35 PARKING THE GRADALL Precautions: chine with boom in air. Avoid parking on banks or near an excavation. Park on level ground and block wheels. Avoid parking on roads or highways. If It can- not be avoided be sure to display warning flags If parking on a slope cannot be avoided, posi- during day and flares or flashing lights at night.
- Page 36 6X4 CARRIER LUBRICATION & MAINTENANCE DIAGRAM LUBRICATION SYMBOLS AF - Antifreeze ATF - Auto. Trans. Fluid SYMBOLS Refer to vendor component literature in service manual CG - Grease, High Temp = Fitting for additional lubrication and maintenance requirements. → → → → → GO - Gear Oil = Other Service EO - Engine Oil...
- Page 37 item Lube No. of CAUTION Monthly Lubrication & Maintenance Cont. Symbol Points Service intervals are based on carrier usage of 250 hours annually. Use of your unit may vary significantly and your must adjust service frequency for your usage to obtain Clutch Throwout Shaft Bearing maximum service life.
- Page 38 SYMBOLS LUBRICANT SYMBOLS AF - Antifreeze = Fitting ATF - Auto. Trans. Fluid = Other Service CG - Grease, High Temp GO - Gear Oil Refer to vendor component literature in service manual EO - Engine Oil for additional lubrication and maintenance requirements. SG - Special Grease...
- Page 39 CAUTION Item Service intervals are based on machine usage of 1500 hours annually. Use of your unit Monthly Lubrication & Maintenance Cont. may vary significantly and you must adjust service frequency for your usage to obtain Clutch Throwout Shaft Bearing maximum service life.
- Page 40 LUBRICATION & MAINTENANCE Recommended Lubricants & Capacities Lubricants described in this sable are used in standard machines when they are shipped from Gradall. Acceptable alternative lubricants (for varying conditions) are listed in component manufacturer’s literature included in your service manual.
- Page 41 CHECKING BRAKE ADJUSTMENT NOTE: This procedure applies to all axles except BRAKES RELEASED front drive axle on 6 x 6 units. 6 x 6 front drive axles are equipped with wedge brakes which are self-adjusting. Position unit in a safe level area. With brake system fully charged (125 psi), apply digging brake and stop engine.
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