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Summary of Contents for Gradall G-550C
- Page 3 OPERATION & MAINTENANCE INTRODUCTION This portion of the service manual is supplied to show the portion of the Gradall excavator that relates to the crawler undercarriage. For information regarding the Gradall upperstructure functions, refer to the manual portions covering it, but disregard the sections related to the remote control carrier.
- Page 4 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE PILOT MANIFOLD - Crawler Units PILOT MANIFOLD - Crawler Units On the crawler units, a pilot manifold is used to receive oil from the 6 gpm pump which is mounted on the power unit. This oil is used to supply the joysticks, the two speed selector valve and the sequence valve for the swing brakes.
- Page 5 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE PILOT PUMP FEED CIRCUITS PILOT PUMP FEED CIRCUITS PILOT PUMP CIRCUIT: Oil from the pilot pump (1) feeds the pilot manifold (2) where the flow is directed to several functions. Oil is routed to the...
- Page 6 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE OPERATOR’S CAB The operator’s cab contains all of the controls needed for the operation of the Gradall upper- structure movements, plus controls for the crawler undercarriage. SIDE VIEW A. Adjustable Operator’s Seat B.
- Page 7 JOYSTICK CONTROLS Joysticks are provided to control the movements of Operation of the joystick valve is based on the the Gradall upper and undercarriage. The joystick pressure reducing concept, and will, from a fixed handgrips and foot pedal activates control valve...
- Page 8 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE JOYSTICK OPERATION Levers can be moved in any direction to obtain dual The following actions take place as the controls are actions. Example: By moving the boom lever moved. These are in relation to the operator forward and to the right at the same time, the boom position.
- Page 9 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE OPERATOR’S INSTRUCTIONS To further assist the Gradall operator, we have provided detailed instructions for the use of all the cab controls and levers. GRADALL G660C & G880C CRAWLER OPERATING CONTROLS Bucket Open...
- Page 10 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE MAIN CONTROL VALVES The two main control valves are of the stack type, where combinations of inlet, circuit, mid-inlet and outlet sections are bolted together. Where needed, the main relief valves are located in the inlet sections or the mid-inlet section.
- Page 11 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE MAIN CONTROL VALVE BANKS (Neutral Position Oil Flow) SWING, TILT & TOOL VALVE BANK Oil from the swing, tilt, tool pump enters the inlet section and is mace available to any of the three control valves.
- Page 12 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE CRAWLER TRAVEL PILOT CIRCUITS The function of the crawler travel circuit is to propel the machine forward and backward and to steer right or left as necessary. For clarity the drive sprocket end is the rear and the idler end is the front of the machine.
- Page 13 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE CRAWLER TRAVEL CIRCUITS Oil for the crawler drive circuit is supplied from the main hoist and boom pumps (6) to the inlet ports of the hoist, boom and travel valve bank (7)for the left &...
- Page 14 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE 2 SPEED CRAWLER DRIVE The Gradall operator has an option of either speed or power when using the crawler drive. Two foot buttons are located on the cab floor to the left of the seat area.
- Page 15 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE CENTER PIN The center pin (swivel joint) is used to transfer hydraulic oil for the crawler travel and brake system from the upperstructure to the crawler. Oil enters the inlet section on top and passes to the outlet section through internal ports machined in the pin.
- Page 16 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE TABLE OF HYDRAULIC DATA FOR TESTING For test procedures, see G-660C & G-880C Testing & AdJusting Manual Sections.
- Page 17 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE CRAWLER COMPONENT NOMENCLATURE Hydraulic Centerpin Sequence Valve (Lockout) (2) Carbody and Side Frame Assembly Drive Motors (2) Planetary Reduction Gear Boxes Drive Sprockets (2) Idlers (2) Chains (2) Tracks (2) Roller, Top Brackets (2)
- Page 18 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE GRADALL CRAWLER COMPONENTS The following illustrates and discusses all of the major components which make up the crawler undercar- riage portion of the Gradall. This shows the basic carbody-frame assembly and it’s features which are;...
- Page 19 Each track can be tightened using a grease gun and common lube grease. A button type adapter is furn- nished in the Gradall tool kit so that the common grease gun can be used. If it becomes necessary to loosen the tracks, the grease can be expelled from the cylinder by backing off on the adjusting fitting.
- Page 20 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE Motor, planetary & brake assembly to drive the sprockets. Piston type motor. It is connected to the two-speed control in the cab to shift from high speed to low speed by changing the swash plate angle. Motors also include drain line cooling circuits for additional cooling action.
- Page 21 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE Lockout valve (sequence valve) used in circuit between the centerpin and each drive motor. When the crawler is not actuated the valve plunger is in neutral, locking all oil in the drive motor circuit.
- Page 22 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE HOW UNDERCARRIAGE WORKS AND WEARS Undercarriage parts are a close working team. The sprocket pulls the bushings. Bushings pull the pins inserted inside them. Pins pull the links into which they are pressed. The moving links pick up and lay down the track shoes bolted onto them.
- Page 23 OPERATION & MAINTENANCE HOW TO GET MORE LIFE OUT OF YOUR UNDERCARRIAGE As a crawler mounted Gradall Hydraulic Excavator works, the parts are wearing. We hope that the information which we provide regarding operation and preventive maintenance will be followed and that long and trouble-free crawler life will result.
- Page 24 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE Remember, although the design is called tractor type the Gradall Excavators are not tractors. However, wear does occur to the track components, when not traveling. A machine working hard in one position will often require more maintenance and lubrication than one making frequent moves.
- Page 25 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE HOW TO GET LONG LIFE FROM YOUR UNDERCARRIAGE Regular checking is necessary to keep the undercar- riage in a shape that will give best productivity. In order to help you obtain maximum satisfaction, we are outlining some of the maintenance procedures which if followed, will give maximum use of the crawler.
- Page 26 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE TRACK TIGHTNESS The tracks should be kept tight enough so that there is only a limited amount of sag between the drive sprocket and the top center roller. Using a straight edge, measure the sag. It should be maintained to no more than 1.187"...
- Page 27 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE Allowing pins and bushings to be run to destruction will result in accelerated wear to all the track components. The space resulting from internal pin and bushing wear permits the bushings to cock relative to the pies, allowing the track to wander from side to side.
- Page 28 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE Since wear takes place on only one side of the pin and since wear takes place on only the sprocket side of the bushing, it is common practice to rotate the pins and bushings one time before replacing them. Therefore, let’s take a set of tracks that would normally be good for 2000 hours.
- Page 29 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE There are three basic guides to determine when pins and bushings should be turned. They are: When the (current) wear line on the drive side of the sprocket teeth approaches 1/4" of the tips (if this is...
- Page 30 As the crawler is inspected and lubricated, inspect all for dirt and clean out the dirt as needed. A feature of the Gradall is it’s ability to use down-pressure of the boom to lift one track clear of the ground. With the track lifted clear of the ground, the track can be rotated to help it clean itself.
- Page 31 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE A drive sprocket always has an uneven number of teeth. In this way the teeth and links always seek a different notch, therefore giving more even wear. As the chain links, bushings, and pins wear, there will be a longer distance between bushings.
- Page 32 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE Wear to the track rollers on your machine will vary depending on the ground conditions and the operator’s work habits. Periodic examination of the individual rollers will tell you the amount of wear on each.
- Page 33 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE WHEN TO REPLACE TRACK PARTS To assure good and long life for your crawler under- carriage, we are providing wear limits. For normal operation, 100% is the time at which the part should be replaced to repaired.
- Page 34 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE TRACK ROLLERS MODEL 75% 100% G-660C 6.11" 6.08" 6.05" 5.9" 5.86" G-880C 6.06" 6.05" 6.0" 5.9" 5.83" FRONT IDLERS MODEL 75% 100% G-660C .75" .78" .84" .89" .98" G-880C .78" .83" .89"...
- Page 35 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE CRAWLER LUBRICATION Parts like the idlers and rollers are sealed units which There are only four (4) pressure grease fittings on the have been filled with SAE 30 or 40 oil at assembly. If crawler undercarriage.
- Page 36 G-660C & G-880C GRADALL (Crawler) OPERATION & MAINTENANCE G-880C HEAT EXCHANGER; An extra heat exchanger is provided on the G-880CC crawler excavator. Oil is taken from the return line to the reservoir and circulated thru a cooler mounted on the left hand deck. A DC electric motor turns a fan to force air thru the radiator.
- Page 37 G-660C & G-880C GRADALL (Crawler) NOTES OPERATION & MAINTENANCE...
- Page 38 G-660C & G-880C GRADALL (Crawler) NOTES OPERATION & MAINTENANCE...
- Page 39 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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