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- Page 1 OPERATOR'S MANUAL XL2210SI 22104003 March 2000 Starting S/N Upperstructure - 0224417 Form #20002 Original Issue 3/00 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
- Page 2 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. 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5...
- Page 3 LIST OF EFFECTIVE PAGES This page is provided to enable reader to PAGE DATE DESCRIPTION determine 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 4 TABLE OF CONTENTS IMPORTANT SAFETY NOTICES ................... inside front cover LIST OF EFFECTIVE PAGES (revision info) ..................1 TABLE OF CONTENTS ........................... 2 INTRODUCTION ............................. 3 General ............................3 Related Manuals & Decals ......................3 Operator Qualifications ........................ 3 Orientation ............................ 3 Serial Number Plate Location .......................
- Page 5 All decals for Specify Serial Number (S/N) when ordering parts your machine are available from your Gradall and when discussing specific applications and Distributor. He can also furnish additional manuals procedures with your distributor.
- Page 6 NOMENCLATURE SHIPPING PIN STORAGE LOCATION HYDRAULIC RESERVOIR HYDRAULIC HYDRAULIC VALVE PRESSURE RELEASE FILTER RESERVOIR COMPARTMENT FUEL TANK TELESCOPING BOOM MAIN BOOM SWING TRANSMISSION BATTERY BOOM ROLLERS ATTACHMENT WRENCH STORAGE LOCATION ENGINE COMPARTMENT PUMP COMPARTMENT (service light connector location) LIFTING BAIL TILT BEARING AIR CLEANER TELESCOPING...
- Page 7 Seal threaded open holes 8022-1287 Boom Roller Gauge Boom roller adjustment 8345-1128 Female Coupling Hydraulic oil fill system 8362-3027 Dust Cap, (female) Female quick disconnect coupling XL 2210 Tool Box W/Lock Gradall P/N 8021-3108 (Hand held - store in appropriate location)
- Page 8 SAFETY HIGHLIGHTS Read and understand this manual and all instructional decals and plates before starting, operating or performing maintenance procedures on this machine. Keep these manuals with machine. Watch for these symbols; they are used to call your attention to safety notices. This symbol indicates an extreme hazard which would result in high probability of death or DANGER...
- Page 9 SAFETY HIGHLIGHTS “PINCH POINTS” Save lives & prevent injuries: Learn to recognize & avoid pinch points! Stop engine and remove keys before performing any service or maintenance to your machine. It must remain the RESPONSIBILITY OF OWNER to be certain OPERATOR is aware of “PINCH POINTS”...
- Page 10 SAFETY HIGHLIGHTS “PINCH POINTS” BOOM & ATTACHMENT ATTACHMENT & LINKAGE Never permit anyone under boom or attachment Be certain that attachment is resting firmly on when machine is in operation. An unexpected the ground or adequately supported and engine movement of machine or attachment could injure is stopped before performing any procedure on or kill someone.
- Page 11 Never carry a water can, equipment, or other or alter this machine without written permission worker’s tools or personal items on the machine. from The Gradall Company. Such items can cause other workers to approach the machine without your knowledge and result in serious injury or death.
- Page 12 SAFETY HIGHLIGHTS WARNING TRAVEL ON OFF-HIGHWAY GRADES IS RECOMMENDED ONLY UNDER THE FOLLOWING CONDITIONS: Boom is fully retracted and parallel with tracks. Tracks are properly adjusted. Surface is firm enough to support unit. Surface provides adequate traction to prevent slipping. Surface is not rough enough or steep enough to cause tipping.
- Page 13 SAFETY HIGHLIGHTS WARNING Avoid injury! Always relieve pressure trapped in circuits before disconnect- ing, removing or installing hydraulic components. Do not operate with bystanders or other workers near or on 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 14 SAFETY HIGHLIGHTS Be particularly careful if this is not the machine Learn and follow your employer's safety rules. you usually operate. Read the manuals listed on page 3 and then operate the unit in a safe, open area to become familiar with the controls. OPERATE ON ROADWAY ONLY UNDER THE FOLLOWING CONDITIONS:...
- Page 15 SAFETY HIGHLIGHTS Do not allow anyone inside the swing radius of the boom while the machine is in operation. Failure to keep all people clear could cause an accident resulting in serious injury or death. Additional Precautions • Before traveling, adjust boom elevation and attachment tilt to ensure clear view.
- Page 16 Decals 8021-3101 8021-3096 Part No. 8021-3096 Part No. 8021-3101 Located on upper right corner of Radio Located on right hand front side of Valve Control Housing Door Cover Open valve cover door and maintain three point Read the Owner/Operator Manual for proper operating procedures, failure to do so may result in contact when climbing on or off machine.
- Page 17 Decals 8021-3093 8021-3102 Part No. 8021-3093 Part No. 8021-3102 Located on track adjustment plate Located on each side of main boom Stay clear of electric lines, contact may result in High pressure cylinder, do not remove any parts until all pressure has been relieved. Apply lubricant death or injury.
- Page 18 Decals 8021-3104 8021-3098 Part No. 8021-3098 Part No. 8021-3104 Located on lower left side of rear engine cover Located on center outside top of fuel tank To prevent injury, stay clear of moving parts. Fasten Diesel fuel decal. covers before starting engine. Refer to Service Manual before adjusting or servicing.
- Page 19 Decals 12,700 kg 8021-3090 8021-3107 Part No. 8021-3107 Part No. 8021-3090 Located on outside lower center of fuel tank Located on lower right side of fuel tank and lower right side of engine cover Lift Instruction diagram. Refer to Owner/Operator Noise level decal, sound pressure level 108 dB(A) Manual for proper procedures according to ISO 6393...
- Page 20 Decals F1- POWER TO LIGHT SWITCHES F15- HORN - FRONT F2- NOT USED F16- HORN - REAR F3- NOT USED F17- NOT USED F4- SWING LIGHT FLASHER F18- NOT USED F5- HYDRAULIC FLUID LEVEL F19- NOT USED F6- AIR DRYER F20- FUEL SOLENOID F7- THROTTLE POWER F21- MONITOR &...
- Page 21 Serial Number Plates See page 4 for help in finding locations THE GRADALL COMPANY 406 MILL AVENUE S.W. NEW PHILIDELPHIA, OHIO U.S.A. MODEL NO. SERIAL NO. YEAR ENGINE POWER WEIGHT 8021-3105-A THIS PRODUCT MAY EMBODY FEATURES OF ONE OR MORE...
- Page 22 CHECKS & SERVICES BEFORE STARTING ENGINE (To be performed at beginning of each work shift.) Complete all required maintenance before operating unit. of major hydraulic components along with o-rings, WARNING seals, packing and bearings. Use extreme caution when checking When adding fluids or lubricants, refer to items beyond your normal reach.
- Page 23 CHECKS & SERVICES BEFORE STARTING ENGINE (To be performed at beginning of each work shift.) 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 for the presence of a fully charged fire extinguisher inside control compartment.
- Page 24 KG/CM N/MIN VOLTS CONTROL COMPARTMENT The remote control receiver is to be opened only by tehnicians authorized by the Gradall Company. General Unauthorized tampering in this area can void machine warranty. The control compartment is located at front left corner of upperstructure.
- Page 25 7. Turn transmitter Off until you are ready to operate A fully charged battery will function for approximately machine. There is a continuous drain on battery 8 hours with transmitter turned on. It is as long as transmitter is turned on. recommended that a fully charged battery be installed at beginning of each work shift.
- Page 26 Remote Control Transmitter (continued) General: The engine should have been stopped at low With remote control system switched on (RUN idle speed at end of previous shift. If you aren’t position - see Control Console heading on page 21) sure of throttle position, hold Throttle switch in the remote control receiver is ON, and is in contact decrease position for several seconds.
- Page 27 Electronic Monitor CAUTION An electronic monitor caution signal indicates a condition which could cause serious damage to your unit. Correct cause of signal before continuing FUEL LEVEL operation. ENGINE COOLANT ENGINE COOLANT LEVEL TEMPERATURE CAUTION SYMBOLS & ALARM U.S./METRIC ENGINE OIL SELECT SWITCH PRESSURE (on rear of panel)
- Page 28 ENGINE OPERATION NOTE: If engine is being started at beginning of work shift be sure to perform all CHECKS AND SERVICES BEFORE STARTING ENGINE (pages 18 and 19). Starting Engine Raise Emergency Stop button, press Start/Horn button briefly and then press Engine Start button Follow instructions under...
- Page 29 Normal Engine Operation CAUTION Be alert for unusual noises or vibration. When WARNING an unusual condition is noticed, stop machine in a safe position and shut off engine. Determine cause Always keep all engine covers and and correct problem before continuing. compartment doors closed while engine is running.
- Page 30 WARM UP & OPERATIONAL CHECKS (To be performed at beginning of each work shift) Complete all required maintenance before operating unit. The safety, efficiency and service life of your Observe hydraulic oil return filter caution equipment will be increased by performing the symbol.
- Page 31 ADAPTER & SCALING HOOK INSTALLATION Scaling Hook 8025-5010 Weight - 367 kg. WARNING Keep boom in fully extended position while installing atachment. Stay clear until adapter has been fitted to attachment as shown in step four. STOP CAUTION Operation with a loose or improperly fitted attachment can cause excessive wear, shear adapter bolts or cause loss of Move adapter toward “close”...
- Page 32 HAMMER INSTALLATION This installation procedure is to be performed ONLY by experienced field maintenance personnel. Installation: 1. Extend boom approximately half way and tilt boom 180 degrees as shown above. NOTE: The following conditions are assumed: • Hammer bracket has been installed on hammer. BRACKET BAR •...
- Page 33 HAMMER INSTALLATION (Continued) 4. Move adapter toward “close” position until outer end of adapter contacts hammer bracket. 6. Raise and tilt boom 180 degrees. Move hammer to vertical position. 7. Check to be sure transmitter Attachment switch is in off position. Lower hammer to force hammer point against hammer piston.
- Page 34 USE YOUR CRAWLER PROPERLY Travel in forward direction whenever Mud, frozen mud and debris can prevent rollers possible (with track drive motors at rear). from turning and cause flat spots. Clean track Traveling in reverse increases wear on components as often as necessary. sprockets and rollers.
- Page 35 HOW TO OPERATE THE CRAWLER Practice with travel controls in a safe, open area. CAUTION WARNING Avoid confusion! Before actuating track drive levers, think about the direction you are facing with respect to the direction the crawler is facing (drive sprockets are at rear of crawler).
- Page 36 BOOM & TOOL FUNCTIONS Practice with controls in a safe, open area. Activate Remote Control System as instructed WARNING on pages 22, 23 & 24. Perform all Checks & Services before starting When operating, run engine at high idle (full engine (pages 20 &...
- Page 37 BOOM & TOOL FUNCTIONS Pull back on right joystick (A) to raise boom far Move left joystick to left (G) to swing left or to enough to clear all obstructions. right (H) to swing right. While pushing left joystick forward (F) to extend Move right joystick to right (C) to tool open or to boom, push right joystick forward (B) to lower left (D) to tool close.
- Page 38 BOOM & TOOL CONTROL FUNCTIONS If required, move tilt lever to left (I) to tilt counter- While pushing forward on right joystick (B) to clockwise or to right (J) to tilt clockwise. Turn tilt lower boom to ground, pull back on left joystick speed knob as required to increase or decrease (E) to retract boom to position tool for operation.
- Page 39 BOOM & TOOL CONTROL FUNCTIONS Move left joystick to right (H) to right or to left Move right joystick to right (C) to open tool. (G) to swing left to work site. If necessary, ex- tend boom by pushing left joystick forward (F). When equipped with hammer, push button (K) Move left joystick to left (G) or right (H) to align to fire (attachment toggle switch must be on to...
- Page 40 Always check hourmeter and date at beginning of shift to be certain services are performed at proper interval. Perform service at whichever interval occurs first. FAILURE TO USE GRADALL HYDRAULIC FILTER ELEMENTS COULD VOID WARRANTY Lube No. of Lube No.
- Page 41 LUBRICATION & MAINTENANCE DIAGRAM 1 2 3 7 8 9 10 11 12 13 14 For service, extend boom half way and extend tool cylinder half way. 15 16 17 20 21 22 23 21 26 27 28 29 30 31 32 41 42 SYMBOLS...
- Page 42 An over-torqued bolt in most cases will fail as rapidly as an under- torqued one. 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.
- Page 43 SECURING BOOM LOWER BOOM MANUALLY Hitch Pin 8021-3096 8021-3096 Shipping Pin Always install shipping pin and secure with hitch pins when preparing machine for transport. Shipping pin is stored in valve compartment. TOWING View from rear of machine of area between engine compartment and hydraulic &...
- Page 44 LOADING & SECURING FOR TRANSPORT Position machine and secure to transport using four cross chains as shown. TRANSPORT LOCK PIN (ON RIGHT SIDE OF BOOM CRADLE) Weights Machine 12,333 kg (27,190 lb) Scaling Hook (8025-6028) 367 kg (809 lb) Hammer (8025-3023) 688 kg (1,517 lb) Adapter (8025-6022)
- Page 45 • Apply Boeshield *T9 (Gradall Part No. 1440- Because Gradall cannot anticipate all storage 4645) to exposed cylinder rods. situations, we do not provide step-by-step procedures for short term storage.
- Page 46 HAND SIGNALS Standard Signals - When equipment work conditions require hand signals, they shall be provided or posted conspicuously for the use of both signalman and operator. No equipment motions shall be made unless signals are clearly understood by both signalman and operator.
- Page 47 CLOSE BUCKET - Hold one hand closed THIS FAR TO GO - With hands raised and MOVE SLOWLY - Place one hand motionless and stationary. Rotate other hand in small open inward, move hands laterally, indicating in front of hand giving motion signal. (Raise vertical circle with forefinger pointing distance to go.
- Page 48 Hydraulic Equipment 406 Mill Avenue, S.W. New Philadelphia, Ohio USA 44663 PHONE: (330) 339-2211 FAX: (330) 339-8468 WEB SITE: www.gradall.com PRINTED in U.S.A.
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