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Summary of Contents for Gradall G660C
- Page 1 OPERATION & LUBRICATION MANUAL G660C 83914001 July 2002 Starting Lot 240 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
- Page 3 G-660C ® Hydraulic Excavators UPPERSTRUCTURE OPERATION & LUBRICATION MANUAL Covers upperstructures starting Lot 240 IMPORTANT Read and understand this manual, the G-660C Carrier Operator’s Manual, Truck Safety Manual, and the CIMA Hydraulic Excavator User’s Safety Manual before starting, operating or performing maintenance procedures on this machine.
- 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...
- Page 5 A kit the operator’s seat. containing all decals for the G-660C is available from your Gradall Distributor. He can also furnish In relation to the carrier, front, rear, right and left additional manuals for your machine.
- Page 6 SAFETY HIGHLIGHTS Read and understand this manual, G-660C Carrier Operator’s Manual, CIMA Excavator User’s Safety Manual, CIMA Off-Highway Truck Safety Manual and all instructional decals and plates before starting, operating or performing maintenance procedures on this equipment. Keep this manual in cab. Watch for these symbols;...
- Page 7 SAFETY HIGHLIGHTS Learn to recognize ‘PINCH POINTS’ Counterweight & Another Object Boom Cradle Boom Holes Boom 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 8 Never carry a water can, equipment, or other in this manual. If it differs, or if you aren’t sure, worker ’s tools or personal items on the contact your Gradall distributor before you run machine. Such items can cause other workers to your unit.
- Page 9 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 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 10 3. Center boom over rear of chassis and rest boom 6. If one or more wheels indicate brake failure, or bucket on the ground. DO NOT DRIVE THE GRADALL HYDRAULIC 4. Apply down pressure with boom (but not EXCAVATOR. Investigate and correct. For enough to remove weight from wheels) and push assistance, contact your Gradall Distributor.
- Page 11 SAFETY HIGHLIGHTS GRADALL LIFTING CAPACITIES RATED LIFT CAPACITY Always check Lift Capacity Chart and plan lift (pages 28 & 29) to be sure lift can be performed safely. Watch out for carrier cab when swinging. Position unit so that it won’t be necessary to swing close to cab.
- Page 12 SAFETY HIGHLIGHTS Do not operate with bystanders or other Always be sure bucket is resting firmly in boom workers near machine. rest or on ground and that engine is stopped before performing lubrication or maintenance procedures inside boom. WARNING Avoid injury! Always relieve pressure trapped in circuits before removing or Installing plugs or gages.
- Page 13 OPERATOR’S CAB Heater Seat Adjustment Units equipped with Detroit Diesel engine The operator’s seat and pedestal combination have a heater behind the operator’s seat. The include adjustments for height, seat angle and fore heater fan is controlled by a switch on overhead and aft positioning.
- Page 14 CONTROL AND INSTRUMENT IDENTIFICATION (Common to all units unless noted) Joystick Switch Defroster Switch Boom Hoist & Bucket Joystick Heater Switch Horn Button Engine Hourmeter Throttle Lever (also Engine Stop Lever for Water Temperature Gage (Detroit Diesel only) Detroit Diesel) Oil Pressure Gage Travel/ Steering Joystick Voltmeter...
- Page 15 CONTROL AND INSTRUMENT VARIATIONS UNITS EQUIPPED WITH DEUTZ ENGINE FAN BELT WARNING LIGHT & BUZZER OIL TEMPERATURE GAGE ENGINE STOP HANDLE SELF-PROPELLED UNITS DIGGING BRAKE TOGGLE BRAKE PEDAL TRANSMISSION SHIFT LEVER...
- Page 16 CHECKS AND 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 of o-rings, seals, packings and bearings. When adding fluids or changing filter elements, Use extreme caution when checking items refer to the lubrication section of this manual to beyond your normal reach.
- Page 17 Check fuel level and replenish as necessary. It is recommended that the unit be refueled at the end of the work shift to minimize condensation. Engine should be turned off while refuel- Check for presence of fully charged fire extin- ing.
- Page 18 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 13 and 14). Turning ignition switch to START position while engine flywheel is rotating can cause serious damage to engine and/or starting motor. It is recommended that engine be started with clutch engaged.
- Page 19 Cold Weather Starting Aids Diesel engine ignition is accomplished by heat specific instructions for their use in this manual. generated when fuel/air mixture is compressed Carefully follow instructions furnished with your within the cylinders. Because this heat may be starting aid. insufficient to start a cold engine in cold weather, the use of starting aids has become common practice.
- Page 20 EMERGENCY STOP (furnished with Detroit seconds after attempting to stop the engine in the Diesel engines only): In the event your Detroit normal manner, pull the “EMERGENCY STOP” Diesel engine continues to run for more than 15 handle. Turn ignition switch off. Use “EMERGENCY STOP”...
- Page 21 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 22 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 Apply parking brake. Start carrier engine and develop full brake system pressure in front and rear portions of Be sure to keep feet clear of clutch pedal svstem (125 psi/862 kPa.).
- Page 23 Precautions for Remote Control Operation Never tow load using remote control drive. Be sure of clear visibility in direction of travel; use a signalman to compensate for blind spots. Always give audible signal before moving unit. Be sure upperstructure swing brake functions Never permit bucket to drag while moving unit.
- Page 24 Crawler undercarriages are furnished to enable 6. Mud and debris can prevent rollers from turn- the Gradall to travel over rough terrain and reach ing and cause flat spots. Clean track com- work sites which would not be accessible to the ponents as often as necessary.
- Page 25 HOW TO OPERATE THE CRAWLER Practice with travel joystick in a safe, open area. FRONT CRAWLER FRONT FRONT CRAWLER CRAWLER STRAIGHT FORWARD TURN TURN RIGHT LEFT FRONT FRONT CRAWLER CRAWLER COUNTER— COUNTER— ROTATE ROTATE FRONT FRONT LEFT RIGHT CRAWLER CRAWLER FRONT CRAWLER REVERSE...
- Page 26 Always give audible signal before traveling. properly before moving unit. Be sure of clear path for carrier, boom and coun- Never tow load with self-propelled Gradall. terweight before starting to move. Avoid confusion! Before actuating travel/steering joystick, think about the direction you are facing with respect to the direction the carrier is facing.
- Page 27 A TYPICAL GRADALL DIGGING CYCLE 1. Position unit for efficient digging cycle and apply digging brake. Always operate with engine at full throttle to keep cylinders full of oil to prevent un- expected machine movements. Avoid accidental actuation of the controls.
- Page 28 A TYPICAL GRADALL DIGGING CYCLE 5. Pull back on left joystick (A) to raise boom from 6. 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 29 A TYPICAL GRADALL DIGGING CYCLE 9. If required, press left side of tilt pedal (I) to tilt 10. While pushing forward on left joystick (B) to counterclockwise of right side of pedal (J) to lower boom and force bucket into ground, pull back on right joystick (E) to retract boom and tilt clockwise.
- Page 30 A TYPICAL GRADALL DIGGING CYCLE 13. Move right joystick to right (H) to swing right 14. Move left joystick to left (C) to empty the or to left (G) to swing left to dump site. If bucket. necessary, extend boom by pushing right joystick forward (F).
- Page 31 LIFTING AND POSITIONING A LOAD Precautions Do not depend on machine tipping as a warning of Do not travel with a suspended load. Excavators are not designed for pick and carry lifts. overload. Some load ratings are based on hydraulic lift capacity, not stability.
- Page 32 3. Perform an unloaded trial run of the lift to Measure boom height/depth from bucket adapter determine maximum load radius required and pivot shaft to ground level (same plane as bottom of maximum boom height and depth required to tires). Be sure to allow for length of sling and height complete the lift.
- Page 33 LUBRICATION & MAINTENANCE DIAGRAM SYMBOLS • = Fitting = Other Service LUBRICANT SYMBOLS CG - Grease, Extreme Pressure GO - Multi-Purpose Lubricant For service, extend boom fully over rear and EO - Engine Oil Location varies depending MC - Molycote on engine furnished.
- Page 34 Lube No. of Lube No. of Symbol Points Symbol Item Points Item Weekly Lubrication & Maintenance Daily Lubrication & Maintenance (includes all daily services) Tool Link Pin (at adapter) Tilt Pedal Pivot Adapter Pivot Pin Battery (check electrolyte level and refill as req’d) Connecting Link Pin (at tool link) Hydraulic Reservoir Breather (check condition and clean as req’d) Pump Drive Gear Box (check level at lower plug &...
- Page 35 LUBRICATION AND MAINTENANCE DIAGRAM 6x4 SELF-PROPELLED UNITS No. of Lube No. of Lube Item Symbol Points Symbol Item Points Monthly Lubrication & Maintenance Semi-Annual Lubrication & Maintenance King Pin Bearings (includes all monthly services) Universal Joints Drive Shaft Splines Wheel Bearings (remove, clean, pack and install) Drop Box Trunnion Support Transmission Drain Plug (drain and refill) Differential Fill and Level Plug (check and fill to level)
- Page 36 LUBRICATION AND MAINTENANCE DIAGRAM 6x6 SELF-PROPELLED UNITS See pages 30 and 31 for Lubrication Notes. Lube No. of Lube No. of Item Item Symbol Points Symbol Points Monthly Lubrications & Maintenance Semi-Annual Lubrication & Maintenance Steering Knuckle (includes all monthly services) Tie Rods Wheel Bearings (remove, clean, pack and install) Universal Joints...
- Page 37 Recommended Lubricants & Capacities *Refer to manufacturer’s service literature for this information. **Specific hydraulic fluid specifications are shown below. ***Capacities are approximate - check level to be sure. Hydraulic Fluid Specifications: Carbon Residue, Rams, wt% Grade, ASTM Viscosity: Zinc, wt% SUS at 100 F 0.08 Grade, AGMA...
- Page 38 SECURING BOOM/BUCKET FOR TRAVEL Position for buckets narrower than boom rest Position for buckets with same Position for buckets wider width as boom rest than boom rest IF YOU GET STUCK rear to prevent tipping) and imbed bucket in ground. If unit becomes stuck in soft ground you can use the boom to help free it.
- Page 39 EXCAVATOR HAND SIGNALS Standard Signals - When excavator work condition 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.
- Page 40 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 hand.
- Page 42 Gradall Industries, Inc. 406 Mill Ave SW New Philadelphia OH. 44663 Phone: (330) 339-2211 Customer Support Toll Free: (800) 445-4752 Fax: (330) 339-3579...
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