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Gradall XL6210 Operators Safety Manual

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Operator & Safety
Manual
Keep this manual with machine at all times
Model
XL6210
S/N 6210000003 & After
62104005
Original Issue
May 6th, 2008

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Summary of Contents for Gradall XL6210

  • Page 1 Operator & Safety Manual Keep this manual with machine at all times Model XL6210 S/N 6210000003 & After 62104005 Original Issue May 6th, 2008...
  • Page 2 State of California to cause cancer, birth defects and other reproductive harm. Gradall is a registered trademark for hydraulic excavators, industrial maintenance machines, attachments and other components manufactured and marketed by Gradall Industries, Inc.
  • Page 3 Revision Log Revision Log REVISION LOG May 6th, 2008 - A - Original Issue of Manual 62104005...
  • Page 4 Due to continuous product improvements, Gradall Industries, Inc. reserves the right to make specification changes without prior notification. Contact Gradall Industries, Inc.
  • Page 5 Inc. or the local authorized Gradall representative for information regarding safety- related bulletins which may have been issued for this product. Gradall Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact Gradall Industries, Inc. to ensure that the current owner records are updated and accurate.
  • Page 6 Read This First NOTES: 62104005...
  • Page 7 Table of Contents Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications ............b Modifications ..............b Other Publications Available ..........c Table of Contents Section 1 - General Safety Practices 1.1 Hazard Classification System ..........1-1 Safety Alert System and Safety Signal Words ....1-1 1.2 General Precautions ............1-1 1.3 Operation Safety ..............1-2...
  • Page 8 Table of Contents Proper Crawler Usage ............ 3-5 Crawler Operation ............3-6 3.4 Typical Dig Cycle..............3-7 Standard SAE Boom and Attachment Functions.... 3-7 3.5 Engine Shutdown .............. 3-13 3.6 Parking the Excavator ............3-14 Precaution ..............3-14 Parking Procedure............3-14 3.7 Preservation &...
  • Page 9 Section 1 - General Safety Practices SECTION 1 - GENERAL SAFETY PRACTICES HAZARD CLASSIFICATION SYSTEM Safety Alert System and Safety Signal Words DANGER OW0010 DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING OW0021 WARNING indicates a potentially hazardous situation which, if not avoided, could...
  • Page 10 Section 1 - General Safety Practices OPERATION SAFETY Electrical Hazards 10 FT (3 M) OAC0330 • This machine is not insulated and does not provide protection from contact or being near electrical current. • NEVER operate the excavator in an area where overhead power lines, overhead or underground cables, or other power sources may exist without ensuring the appropriate power or utility company de-energizes the lines.
  • Page 11 Section 1 - General Safety Practices Swing Hazards OAC0340 • Keep others away from machine while in operation. Ensure others are clear of the swing radius prior to swinging upperstructure. • Never carry a water can, equipment, or other worker’s tools or personal items on the machine.
  • Page 12 Section 1 - General Safety Practices OAC1240 • The circle of safety is a circle around the excavator with the boom at full extension. • Establish and inform others of the circle of safety. Keep others from entering into the circle of safety. 62104005...
  • Page 13 Section 1 - General Safety Practices Slip and Fall Hazard OAC0350 • Always maintain 3-point contact using proper hand holds and steps provided when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting machine. • Repair or replace damaged steps and grab handles. •...
  • Page 14 Section 1 - General Safety Practices Crush Hazards OAC1250 • Do not lean on boom or reach into boom holes, bucket linkage or boom rollers until the attachment or boom is resting on the ground and the engine is stopped. •...
  • Page 15 Section 1 - General Safety Practices OAC1020 • Never permit anyone under boom, attachment or load. Rest boom or attachment on ground and stop engine before permitting anyone to work beneath boom or behind cradle. 62104005...
  • Page 16 Section 1 - General Safety Practices Travel Hazards OAC0710 • Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you do not have a clear view. • Before moving be sure of a clear path for chassis, boom and counterweight and sound horn.
  • Page 17 Section 1 - General Safety Practices Tip Over Hazard • Understand how to properly use the capacity chart located in cab. Do not exceed rated lift capacity. Plan the lift to be sure it can be performed safely. • Maintain proper tire pressure at all times. •...
  • Page 18 • DO NOT operate machine in an enclosed area without proper ventilation. • DO NOT operate the machine in hazardous environments unless approved for that purpose by Gradall and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion.
  • Page 19 Section 1 - General Safety Practices Hydraulic Fluid OAC1260 • DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear appropriate equipment to protect yourself from spraying fluid. If fluid is injected into the skin seek medical attention immediately. •...
  • Page 20 Section 1 - General Safety Practices Battery OAC1270 • Keep sparks, flames and lighted material away from batteries. Explosive gases could cause death or serious injury. Dust Hazard OAC0660 • Repeated or substantial breathing of hazardous dusts, including crystalline silica, could cause fatal or serious respiratory disease including silicosis.
  • Page 21 Section 1 - General Safety Practices PERSONAL PROTECTION EQUIPMENT Wear all the protective clothing and personal safety devices issues to you or called for by job conditions. You may need: • Hard hat • Safety shoes • Safety glasses, goggles or face shield •...
  • Page 22 Section 1 - General Safety Practices NOTES: 1-14 62104005...
  • Page 23 Section 2 - Pre-Operation and Controls SECTION 2 - PRE-OPERATION AND CONTROLS PRE-OPERATION CHECKS & INSPECTION Note: Complete all required maintenance before operating unit. FALL HAZARD. Use extreme caution when checking WARNING items beyond your normal reach. Use an approved ladder.
  • Page 24 Section 2 - Pre-Operation and Controls WALK-AROUND INSPECTION Before conducting the walk around inspection, make sure the engine is off and the transmission is in neutral with the park brake engaged. The boom and attachment must be resting on the ground and securely blocked. Begin your walk-around inspection at item 1, as noted below.
  • Page 25 Section 2 - Pre-Operation and Controls 5. Hydraulic Reservoir - Recommended fluid level on sight gauge; filler/breather cap secure and working; oil is clear. 6. Main Control Valve and Cover - See Inspection Note. Replace damaged latch and weak access cover support strut immediately. 7.
  • Page 26 Section 2 - Pre-Operation and Controls SAFETY DECALS Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required. Decal Locations 80413018 80213098 80213097 80313047 80413017 80413017 80413019 80313038 80363204 80993177 80213103...
  • Page 27 Section 2 - Pre-Operation and Controls 80973103 80973102 80213095 80213095 80213097 80313038 80213103 80413017 80313047 80413018 80413017 OAE0240 80613016 80213098 62104005...
  • Page 28 Section 2 - Pre-Operation and Controls CAB CONTROLS & INDICATORS Cab Console 1. Air Diffuser Vents 2. Air Restriction Indicator 3. Hourmeter 4. Distribution Box: See “Distribution Box” on page 2-7. 5. Heater Control Knob 6. Guage Panel Assembly: See “Gauge Panel Assembly” on page 2-8. 7.
  • Page 29 Section 2 - Pre-Operation and Controls Distribution Box TILT SPEED START IGNITION OAE0310 1. Ignition: See “Ignition” on page 2-13. 2. Blower Fan Switch: Rotary switch for blower fan. 3. Boom Tilt Speed Switch: Rotary switch. Rotate switch clockwise to decrease boom tilt speed;...
  • Page 30 Section 2 - Pre-Operation and Controls Gauge Panel Assembly 1. Tachometer: Indicates engine rpm. 2. Oil Pressure Gauge: Indicates engine oil pressure. 3. Water Temperature Gauge: Indicates water temperature 4. Fuel Gauge: Shows fuel supply level. 5. Oil Temperature Gauge: Indicates oil temperature. 6.
  • Page 31 Section 2 - Pre-Operation and Controls Suction Filter Warning Illuminates yellow to indicate in response to a condition. Use the following steps to troubleshoot. This procedure requires hydraulic oil to be at least 60° F (15.6° C). OAE0330 1. If suction filter warning light is still illuminated and hydraulic oil temperature is not above 60°...
  • Page 32 Section 2 - Pre-Operation and Controls Joystick Controls Activating the Joysticks The joysticks will remain locked/inactive until the control cut out lever (1) located on the left hand arm pod (2) is moved to the unlocked/active position. INACTIVE ACTIVE OAC0250 2-10 62104005...
  • Page 33 Section 2 - Pre-Operation and Controls SAE Joystick Controls OAE0260 Left Hand Joystick Functions • Move the joystick back to retract boom; move joystick forward to extend boom. Move joystick right to swing boom right; move joystick left to swing boom left. •...
  • Page 34 Section 2 - Pre-Operation and Controls Operator Seat Adjustments OAE0270 Prior to starting engine adjust seat for position and comfort. 1. Seat Back Adjustment 2. Lower Seat Fore and Aft Adjustment Control 3. Weight Adjustment Control 4. Height Adjustment Control 2-12 62104005...
  • Page 35 Section 2 - Pre-Operation and Controls Ignition START IGNITION OAE0290 1. ACC: Voltage is available for all electrical functions. 2. OFF: Engine off. 3. RUN: Prohibits rotating key switch to position 4 in the event the engine does not start. Rotate the key to position 2 then back to position 4 to re-engage the starter.
  • Page 36 Section 2 - Pre-Operation and Controls This Page Intentionally Left Blank 2-14 62104005...
  • Page 37 Section 3 - Operation SECTION 3 - OPERATION ENGINE OPERATION Starting Engine 1. Perform walk-around inspection on page 2-2 2. Turn ignition to “START” position. Release key immediately when engine starts. If engine does not start after three attempts, check fuel supply system. 3.
  • Page 38 Section 3 - Operation Cold Weather Starting Aids • It is the owners responsibility to determine proper use of starting aid with regard to engine and starting aid manufacturer’s instruction. • An ether starting aid may be used with this engine only if it does not have the optional grid heater.
  • Page 39 Section 3 - Operation CHECKS BEFORE OPERATION This section outlines the checks to be performed at the beginning of each work shift or at each change of operator. Repair any deficiencies before driving or operating the equipment. 1. Check all lights, heater and fan blower for proper operation. 2.
  • Page 40 Section 3 - Operation CRAWLER CHASSIS Track Drive Pedals/Levers OAE0220 1. Left Hand Track Pedal/Lever: Press lever/pedal forward to engage left track forward. Pull lever/pedal back to engage left track reverse. Note: Lever and pedal move as one. 2. Right Hand Track Pedal/Lever: Press lever/pedal forward to engage right track forward.
  • Page 41 Section 3 - Operation Proper Crawler Usage Keep the following in mind when operating to extend the life of the crawler: • Travel in forward direction whenever possible (with track drive motors at rear). Traveling in reverse increases wear on sprockets and rollers. •...
  • Page 42 Section 3 - Operation Crawler Operation ORIENTATION CONFUSION. Before actuating track WARNING drive pedals, think about the direction you are facing with respect to the direction the crawler is facing. OW0021 (Drive sprockets are at the rear of crawler). Confusion could cause you to travel in the direction opposite of what is expected.
  • Page 43 Section 3 - Operation TYPICAL DIG CYCLE Standard SAE Boom and Attachment Functions Prepare for boom and attachment function: 1. Position unit for efficient attachment usage. Notice!: While digging, pay close attention to boom position in relation to chassis. In certain instances it is possible for the boom to come into contact with the chassis.
  • Page 44 Section 3 - Operation OAE0340 Joystick controls standard SAE control pattern. If tilt speed has been reduced for conditions, speed can be temporarily increased by depressing fast tilt button (1). Note: Practice with controls in a safe, open area. Joysticks and pedals return to neutral position when released.
  • Page 45 Section 3 - Operation 2. Move left joystick to left (G) to swing left or to right (H) to swing right. 3. While pushing left joystick forward (F) to extend boom, push right joystick forward (B) to lower boom into position for start of cut. 4.
  • Page 46 Section 3 - Operation 5. If required, press left side of tilt switch (I) to tilt counterclockwise or right side of switch (J) to tilt clockwise. If necessary, use fast tilt button to return to fast tilt. 6. While pushing forward on right joystick (B) to lower boom and force bucket into ground, pull back on left joystick (E) to retract boom and fill bucket.
  • Page 47 Section 3 - Operation 8. When bucket is full, or when boom is fully retracted, move right joystick to left (D) to close bucket. At same time pull right joystick back (A) to raise boom far enough to clear obstructions. 9.
  • Page 48 Section 3 - Operation 11. Move left joystick to left (G) or right (H) to align boom for next cut. Repeat steps 3 thru 11. 3-12 62104005...
  • Page 49 Section 3 - Operation ENGINE SHUTDOWN To shutdown the excavator, park in a safe location on flat level ground and away from other equipment and/or traffic lanes. 1. Bring machine to a stop by releasing Track Drive Levers/Pedals. 2. Swing the machine to align upperstructure with chassis 3.
  • Page 50 Section 3 - Operation PARKING THE EXCAVATOR Precaution Avoid parking on roads or highways. If it cannot be avoided, or in case of emergency, display warning flags, flares or flashing lights. Parking Procedure 1. Perform “Engine Shutdown” on page 3-13. 2.
  • Page 51 Section 3 - Operation PRESERVATION & STORAGE Because Gradall Industries cannot anticipate all storage situations, we do not provide step-by-step procedures for short-term storage. However, we do require that you review the following points and implement those appropriate to your situation.
  • Page 52 Section 3 - Operation This Page Intentionally Left Blank 3-16 62104005...
  • Page 53 • An overextended or overloaded excavator can tip over with little or no warning and cause death or serious injury to the operator and/or those working nearby. • Gradall cannot assure the ability of a non-approved attachment to perform its intended function safely.
  • Page 54 Section 4 - Attachments This Page Intentionally Left Blank 62104005...
  • Page 55 Always check hourmeter and date at beginning of shift to be certain services are performed at proper intervals. Perform service at whichever interval comes first. Note: Failure To Use Gradall Hydraulic Filter Elements Could Void Warranty. FALL HAZARD. Use extreme caution when checking WARNING items beyond your normal reach.
  • Page 56 • Apply a light coating of engine oil to all linkage pivot points. • Drain engine and gear cases after operating when oil is hot. • Check all lubricant and coolant levels when cool. MACHINE DAMAGE. Contact Gradall before welding WARNING on machine. Welding could damage wires, electronic processors, hoses, and tubes.
  • Page 57 Section 5 - Lubrication & Maintenance SERVICE & MAINTENANCE SCHEDULE 62104005...
  • Page 58 Section 5 - Lubrication & Maintenance 62104005...
  • Page 59 Section 5 - Lubrication & Maintenance LUBRICANT SYMBOLS • CG - Grease, Extreme Pressure • GO - Multi-Purpose Lubricant • EO - Engine Oil • MC - Molycote • GL - Open Gear Lubricant • HF - Hydraulic Fluid Daily or Shift (10 Hour Maximum) Lube # of Item/Location...
  • Page 60 Section 5 - Lubrication & Maintenance Daily or Shift (10 Hour Maximum) Lube # of Item/Location Symbol points 50. Engine Crankcase Dipstick, (check level & refill as req’d. Item 52 is filler cap) Weekly (50 Hour Maximum) Lube # of Item/Location Symbol points...
  • Page 61 Section 5 - Lubrication & Maintenance End of First 30 Days (250 Hours Maximum) Lube # of Item/Location Symbol points 46. Swing Transmission Drain Plug (drain & refill) 61. Final Drive Drain Plugs (drain & refill) (CHECK ALL TORQUE VALUES) Monthly (125 Hour Maximum) Lube # of...
  • Page 62 Section 5 - Lubrication & Maintenance Semi-Annual (750 Hours Maximum) Lube # of Item/Location Symbol points 22. Hydraulic Return Filter (replace element if it has not been replaced in previous six months - also clean magnet) 23. Hydraulic Return Filter Indicator (this indicator is not for operator use;...
  • Page 63 Lube # of Item/Location Symbol points 49. Hydraulic Reservoir Breather (replace element) Note: For all maintenance related to the crawler chassis, refer to the “Caterpillar Operation & Maintenance Manual” located in your Gradall XL6210 Service Manual, part number 62104006. 62104005...
  • Page 64 Section 5 - Lubrication & Maintenance This Page Intentionally Left Blank 5-10 62104005...
  • Page 65 Section 6 - Emergency & Transport Procedures SECTION 6 - EMERGENCY & TRANSPORT PROCEDURES LOSS OF POWER The engine will de-rate if a problem develops. If this occurs, lower boom and attachment to the ground as soon as possible. Make all necessary repairs before continued operation.
  • Page 66 Section 6 - Emergency & Transport Procedures LIFTING THE MACHINE (LIFTING SLING) OAE0350 1. Fully Retract telescopic boom. 2. Move boom to level position. 3. Turn off engine. 4. Install the hold down chains (1) as shown. 5. Use four lifting points (2) to lift machine. 6.
  • Page 67 PRODUCT SPECIFICATIONS Lubrication & Fluid Capacities Note: Lubricants described in this table are used in standard machines when they are shipped from Gradall Industries, Inc. Engine Crankcase Oil Capacity with Filter Change ............29.6 quarts (28 liters) Type of Fuel................15W-40 (MIL-L-2104E) Cooling System System Capacity ..............9.8 gallons (37,1 liters)
  • Page 68 Flash Point 442° F. Approved Supplier & Type: Mobil Mobilfluid 424 Note: For all lubrication & fluid capacities related to the crawler chassis, refer to the “Caterpillar Operation & Maintenance Manual” located in your Gradall XL6210 Service Manual, part number 62104006.
  • Page 69 Section 7 - Specifications TORQUE CHART To check Gradall torque values, set the torque wrench at 95% of the rated torque values and check fastener. If the torque wrench releases before the fastener moves, assume fastener torque is correct. When setting Gradall torque values, use the values given on the following chart.
  • Page 70 Quantity ........................4 Thread Size (grade)..................M10X1.5 Torque (lubricated)..............38-43 lb-ft (52-58 N·m) Note: For all torque values related to the crawler chassis, refer to the “Caterpillar Operation & Maintenance Manual” located in your Gradall XL6210 Service Manual, part number 62104006. 62104005...
  • Page 71 Section 7 - Specifications FUSES Fuse location and size designations are identified with the decal shown below. OAE0360 62104005...
  • Page 72 Section 7 - Specifications This Page Intentionally Left Blank 62104005...
  • Page 73 Index Index Approved Attachments ..... 4-1 Operator Seat .........2-12 Attachment Operation ...... 4-1 Attachments ........4-1 Parking Procedure ......3-14 Personal Protection Equipment ..1-13 Cab Console........2-6 Pre-Operation and Controls ....2-1 Cab Controls & Indicators ....2-6 Pre-Operation Checks ......2-1 Capacities......... 7-1 Preservation &...
  • Page 74 Index 62104005...
  • Page 75 Hand Signals OY1090 OY1100 OY1110 EMERGENCY STOP - With both STOP - With either arm extended STOP ENGINE - Draw thumb or arms extended laterally, hands laterally, hand open downward, forefinger across throat. open downward, move arms back move arm back and forth. and forth.
  • Page 76 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...