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Gradall G3WD Operator's Manual

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OPERATOR'S MANUAL
Form #8487
G3WD
7733-1003
July 2002
Upperstructure Starting
Lot 200 thru 228
Undercarriage
Starting S/N 84D001
thru 84D023
GRADALL
406 Mill Avenue S.W.
New Philadelphia, OH, 44663, USA
Telephone: (330) 339-2211
Fax: (330) 339-3579
Original Issue 1984

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  • Page 1 OPERATOR’S MANUAL G3WD 7733-1003 July 2002 Upperstructure Starting Lot 200 thru 228 Undercarriage Starting S/N 84D001 thru 84D023 Form #8487 Original Issue 1984 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
  • Page 4 Safe operation depends upon reliable equipment and proper operating procedures. Performing the checks and services described in this manual will help to keep your Gradall Excavator Carrier in reliable condition and use of the recommended operating procedures can help you avoid accidents. Because...
  • Page 6 Gradall to provide information concerning safety, replacement parts, service manual with vendor components and literature. You must read and understand the Gradall Opera- tion Manual and Safety Manuals before operating the machine. If you have any questions regarding the Gradall Excavator, contact your Gradall Distributor;...
  • Page 7 SAFETY HIGHLIGHTS Read and understand this manual, The Gradall Excavator Safety Manual, CIMA Safety Manuals and all instructional decals and plates before starting, operating or performing maintenance procedures on this equipment. KEEP THIS MANUAL IN THE CAB. Watch for these symbols; they are used to call your attention to safety notices.
  • Page 8 CARRIER CAB CONTROLS INSTRUMENTS AND INDICATORS While in lower cab, the four wheel drive Do not move carrier while low air light is can be engaged at any time in the lower glowing or while any auxiliary device is signal- range.
  • Page 9 UPPERSTRUCTURE CAB CONTROLS AND INSTRUMENTS Throttle Lever Malfunction Light & Buzzer Boom In/Out & Swing Joystick Engine Start Button Joystick On/Off Switch Wiper Washer Button (optional) Boom Hoist & Bucket Joystick Windshield Wiper Control Horn Button Tilt Pedal Gear Shift Toggle Switch Air Pressure Gage Travel/Steering Joystick Parking Brake Knob...
  • Page 10 CARRIER CAB DISPLAY LIGHT PANEL Left turn signal (A) flashes when lever on steering If air pressure drops below 60 psi, (F) will light. post is activated to indicate a left hand turn. (RED). Check gauge. (GREEN) If engine temperature reaches 210ø F, (G) will light. Remote Control Indicator (B) is lit when the (RED).
  • Page 11 SHIFT SOLENOIDS. A combination of these lights tell which gear ratio has been selected. The position of the gear selector lever on the dash should match. The following will show the light combinations while in the travel mode with high air and the key turned on and engine running: C1 is lit to show the travel mode.
  • Page 12 C2-T4. The following lights are lit when the remote control switch is depressed to show the gear ratio being used: The shift lever in the carrier cab will not move. With engine running, and in remote, lights C-2, T4 and Neut Start will be lit. C2 is always lit.
  • Page 13 NEUTRAL. Any time the shift lever in the carrier cab is in the neutral position, the Neutral light will be lit. The travel shifter must be in neutral before engine can be started, or switched from Travel to Remote and vice versa. If in Travel, the C1 light will also be lit.
  • Page 14 MALFUNCTION INDICATOR. Indicates a wire shorting between the Controller Monitor and the transmission shift solenoids. It can also indicate that the Controller Box is defective and should be re- placed. LOW AIR. If the system air pressure drops below 60 psi, T1 will light. ENGINE OFF.
  • Page 15 CHECKS AND SERVICES BEFORE STARTING ENGINE (To be performed at beginning of each work shift) Complete all required maintenance before operating unit. Inspect visually for damage, leaks, vandalism & needed maintenance. Test lights, turn signals, horn, & gages. Inspect battery fluid level. Make sure fire extinguisher is present.
  • Page 16 Cold weather starting aids Start In travel mode (pump not operating). Diesel engine ignition is accomplished by heat it would be impractical to attempt to provide generated when fuel/air mixture is compressed specific instructions for their use in this manual. within the cylinders.
  • Page 17 CHECKS AFTER STARTING ENGINE (To be performed at beginning of each work shift) Complete all required maintenance before driving Observe water temperature gage. Proper op- Check operation of windshield washer and erating temperature is approximately 160/ wiper. 210° F. (71/104° C). Check all lights and turn signals for proper Observe tachometer response to changes in operation.
  • Page 18 AIR CONTROLS shifts the cylinders at the pump and motor to cause Air pressure is used to control the engine RPM the jaw clutches to close and engage the pump and while driving the chassis or while operating the up- motor.
  • Page 19 AIR THROTTLE CONTROL CIRCUIT It is possible to control the engine RPM from the carrier cab or the upperstructure cab. Remote Control Driving Mode: Conventional Driving Mode: When driving the carrier from the upperstructure in When driving the carrier, the floorboard acceler- the remote control mode a hand controlled air valve ator is used to control the engine speeds from idle to is used (8).
  • Page 20 HYDRAULIC PUMP & MOTOR DISCONNECT When driving the Gradall from the carrier cab, the REMOTE OPERATION: When the remote switch hydraulic pump and the hydraulic remote drive (5) is activated the air solenoid (6) routes pilot air to motor is not engaged to the transmission.
  • Page 21 BRAKE SYSTEM The air brake system includes a service brake, an emergency brake, a parking brake and a digging brake. DUAL AIR GAGE Wear safety belt to avoid being thrown from carrier driver’s seat during braking emergency. WARNING Do not operate carrier while low air indicator is glowing, If light comes on while carrier is Service Brake moving, stop carrier in a safe area as soon as...
  • Page 22 BRAKE SYSTEM (Con’t.) If the air pressure gages indicate some system EMERGENCY BRAKE pressure remaining, it may be possible to drive the APPLICATION unit a short distance to remove it from a hazardous (pressure lost in rear) position (use first gear only). If carrier cannot be moved, direct traffic around carrier until warning flags, flares or lights can be displayed.
  • Page 23 Digging brake (Con’t.) Remote control braking The digging brake is applied by the remote switch DIGGING BRAKE APPLICATION in the carrier cab. The digging brake will be re- leased and reapplied automatically as travel joy- stick in upperstructure is actuated and released. Do not activate remote switch while traveling.
  • Page 24 STEERING SYSTEM Remote control steering Conventional steering Your unit is equipped with a travel/steering joy- The power steering system provides low effort stick in the upperstructure cab. The engine must steering under normal conditions and greater be running to provide power for remote control control in the event of a blowout or soft ground.
  • Page 25 POWER TRAIN The power train furnished on 4 x 2 carriers (units The power train on the 4 x 4 carriers (units having having one driving axle at rear) include the engine, both front and rear driving axles) include the torque converter, power shift transmission and the engine, torque converter, power shift transmission rear axle.
  • Page 26 Downshifting During normal driving there are times when it is necessary to downshift (shift from one gear or range to the next lower gear or range) to decrease carrier Never downshift when carrier speed will speed or increase carrier power. The procedure for cause engine to overspeed in next lower downshifting is described below gear or serious damage to engine may...
  • Page 27 Preparing Carrier for Remote Control Operation Actuate the remote control switch. When the driver wants to stop the Gradall on the job A remote indicator will go on. and operate the upperstructure, he switches to re- The controller lights will show air is OK.
  • Page 28 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 29 Move the remote switch to the travel position. This releases the remote brakes, disengages the Apply parking brake. hydraulic pump and the drive motor. PARKING THE GRADALL Precautions: Avoid parking on slopes or near an excavation. chine with boom in air.
  • Page 30 FRONT AXLE LOCK OUT CIRCUIT The G3WD is equipped with an automatic front (D) is mounted to the chassis frame on the right front axle lock out system. It provides a positive lock be- side. It functions automatically to keep the oil...
  • Page 31 A TYPICAL GRADALL DIGGING CYCLE Position unit for efficient digging cycle. Start and warm up engine and hydraulic oil and then move throttle lever to full throttle position. Stop engine and secure door and windows in Move JOYSTICK rocker switch to ON position.
  • Page 32 A TYPICAL GRADALL DIGGING CYCLE Pull back on left joystick (A) to raise boom from 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 33 A TYPICAL GRADALL DIGGING CYCLE While pushing forward on left joystick (B) to If required, press left side of tilt pedal (I) to tilt lower boom and force bucket into ground, pull counterclockwise or right side of pedal (J) to tilt clockwise.
  • Page 34 A TYPICAL GRADALL DIGGING CYCLE Move right joystick to right (H) to swing right 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 35 LIFTING AND POSITIONING A LOAD Precautions Do not depend on machine tipping as a warning of Do not travel with a suspended load. Excava- overload. Some load ratings are based on hydraulic tors are not designed for pick and carry lifts. lift capacity, not stability.
  • Page 36 General Planning A Lift The excavator can lift and position loads safely Determine the weight of the load. Weight of ONLY IF YOU PLAN THE LIFT PROPERLY. slings, chains and auxiliary lifting devices must be added as part of the load. Refer to lift capacity chart for weight adjustment required for bucket.
  • Page 37 HOW TO EXTEND THE SLIDE-A-BOOM Start engine. Position the upperstructure with Place the four 1” cap screws removed from the the boom over the right or left side of the front stop blocks into the rear stop blocks. carrier. Extend the telescopic boom four feet and Tighten these cap screws.
  • Page 38 ATTACHMENT INSTALLATION Keep boom in fully extended position Digging with a loose or an improperly while installing bucket. Stay clear until fitted bucket can shear adapter bolts and bucket adapter has been fitted to bucket as cause excessive wear. shown In step 2. Position bucket adapter above bucket tube as Move adapter toward “Bucket Close”...
  • Page 39 EXCAVATOR HAND SIGNALS Standard Signals - When excavator work conditions 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 41 G3WD GRADALL...