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OPERATOR’S MANUAL XL3210 R/C 80324069 August 2007 S/N 3210000003 & After GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
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Strict attention to, and compliance with, instructions provided in this manual as well as the EMI & Gradall Hydraulic Excavator Safety Manuals and all instructional decals and plates affixed to the machine, will help you avoid personal injury and damage to the equipment.
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LIST OF EFFECTIVE PAGES This page is provided to enable reader to determine PAGE DATE DESCRIPTION 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.
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TABLE OF CONTENTS IMPORTANT SAFETY NOTICES ....................inside front cover LIST OF EFFECTIVE PAGES ..........................1 TABLE OF CONTENTS ............................2 INTRODUCTION ..............................3 General ................................. 3 Related Manuals & Decals ......................... 3 Operator Qualifications ..........................3 Orientation ..............................3 PIN Plate Location ............................
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All decals for In relation to the crawler, track drive sprockets are your machine are available from your Gradall at the rear of undercarriage. Distributor. The Distributor can also furnish additional manuals for your machine.
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NOMENCLATURE VALVE COMPARTMENT FUEL TANK FUEL TANK FILL HYDRAULIC RESERVOIR HYDRAULIC FILTER HYDRAULIC RESERVOIR PRESSURE RELEASE VALVE MAIN BOOM TELESCOPING BOOM HOIST CYLINDER SWING TRANSMISSION ENGINE / PUMP COMPARTMENT TILT TRANSMISSION AIR CLEANER TILT BEARING HOIST CYLINDER TOOL CYLINDER TELESCOPING CYLINDER ENGINE BOOM ROLLERS RADIO...
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TOOL KIT XL 3210 Tool Kit (Kit can be ordered under part number 8031-5004) PART NO. DESCRIPTION 1440-4645 12oz. can of Boeshield (not shown) Cylinder Rod Protectant 8345-1128 Female Coupling Pressure fill hydraulic reservoir 8362-3027 Dust Plug Protect female coupling Adapt grease gun to adjust tracks 8381-3109 Button Hd Coupling...
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SAFETY HIGHLIGHTS Read and understand this manual, the Gradall Hydraulic Excavator Safety Manual, the EMI Hydraulic Excavator Safety Manual and all instructional decals and plates before starting, operating or performing maintenance procedures on this machine. Keeps these manuals in cab.
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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”...
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SAFETY HIGHLIGHTS “PINCH POINTS” BOOM & ATTACHMENT BUCKET & LINKAGE Never permit anyone under boom, attachment Be certain that attachment is resting firmly on or load when machine is in operation. An the ground or adequately supported and engine unexpected movement of machine or load could is stopped before performing any procedure on injure or kill someone.
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If it differs, or if you aren’t sure, contact Such items can cause other workers to approach your Gradall distributor before you run your unit. the machine without your knowledge and result in serious injury or death.
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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:...
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SAFETY HIGHLIGHTS DANGER WARNING TRAVEL ON OFF-HIGHWAY GRADES Whenever rotating equipment (such as IS RECOMMENDED ONLY UNDER THE a mower or mixer) is installed on FOLLOWING CONDITIONS: machine, adequate shielding must be installed to deflect flying debris Boom is fully retracted and parallel with tracks.
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SAFETY HIGHLIGHTS WARNING Avoid injury! Always relieve pressure trapped circuits before disconnecting, removing or installing hydraulic components. Do not operate with bystanders or other workers near 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”...
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SAFETY HIGHLIGHTS Additional Precautions • The excavator is equipped with a travel alarm to warn others in area of machine travel, either forward or reverse. If alarm fails to sound when traveling, STOP. Contact maintenance personnel to have condition repaired before traveling. “Call before you dig”.
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Decals FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF SERIOUS INJURY: 1.BEFORE OPERATING,READ OPERATOR AND SAFETY ATTENTION: F1 SP-1 (OPT) MANUALS, UNDERSTAND ALL CONTROLS IN CAB F2 SWING BRAKE RELAY USE FUSE SIZES AS DESIGNATED. AND CLEAR LOOSE OBJECTS OFF MACHINE, F3 SWING BRAKE PRESSURE SW.
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Decals HIGH LEAD ACID BATTERIES PRODUCE FLAMMABLE AND EXPLOSIVE GASSES WEAR SAFETY GLASSES WHEN WORKING AROUND BATTERIES PRESSURE DO NOT USE SMOKING MATERIALS NEAR BATTERIES KEEP FLAMES AND SPARKS AWAY FROM BATTERIES CYLINDER ASSURE BATTERY IS NOT FROZEN AND ELECTROLYTE IS AT PROPER LEVEL IN EACH CELL DISCONNECT BATTERY BEFORE WELDING OR CUTTING ANYWHERE ON THE MACHINE...
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Decals PINCH POINT KEEP OUT REACHING INTO BOOM HYDRAULIC SYSTEM IS HOLES AND OTHER PINCH POINTS COULD CAUSE PRESSURIZED AND HOT SERIOUS INJURY OR DEATH. BEFORE OPENING THE HYDRAULIC SYSTEM, RELEASE AIR PRESSURE BY VENTING AIR WITH THE VALVE 8060-3037-B PROVIDED NEAR HYDRAULIC SYSTEM BREATHER HOT OIL UNDER PRESSURE COULD CAUSE SERIOUS BURNS READ MACHINE SERVICE MANUAL FOR INSTRUCTIONS...
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Serial Number Plates Machine P.I.N. Plate Located on Front Upperstructure Frame Track Drive Motors Located Under Cover at Rear of Tracks Engine Located in Engine Compartment Main Hydraulic Pump Located in Pump Compartment Swing Motor Tilt Motor Located on Swing Transmission Located within Boom Cradle Tilt Transmission Swing Transmission...
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FUSE COMPARTMENT IGNITION HOURMETER CONTROL COMPARTMENT The remote control receiver is to be opened only by technicians 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.
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A fully charged battery will function for approximately Turn transmitter Off until you are ready to operate 8 hours with transmitter turned on. It is recommended machine. There is a continuous drain on battery as that a fully charged battery be installed at beginning of long as transmitter is turned on.
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Remote Control Transmitter (continued) General: Engine cannot be started unless Start/Horn button is passed first. With remote control system switched on (RUN posi- tion - see Control Console heading on page 21) the The engine should have been stopped at low idle remote control receiver is ON, and is in contact with speed at end of previous shift.
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Control & Instrument Identification Electric Monitor WARNING An electronic monitor caution signal indicates a condition which could cause serious damage to your unit. Correct cause of signal before continuing operation. FUEL LEVEL ENGINE CAUTION SYMBOLS & ALARM COOLANT ENGINE COOLANT LEVEL TEMPERATURE U.S./METRIC...
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CHECKS & SERVICES BEFORE STARTING ENGINE (To be performed at beginning of each work shift.) Complete all required maintenance before operating unit. Before removing filler caps or fill plugs, wipe all WARNING dirt and grease away from the ports. If dirt is allowed to enter these ports, it can shorten the life of major hydraulic components along with o-rings, seals, Use extreme caution when checking items...
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CHECKS & SERVICES BEFORE STARTING ENGINE (To be performed at beginning of each work shift.) Complete all required maintenance before operating unit. 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.
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ENGINE OPERATION NOTE: If engine is being started at beginning of work shift be sure to perform all CHECKS & SERVICES BEFORE STARTING ENGINE (pages 24 & 25). Raise Emergency Stop button, press Start/Horn Starting Engine button briefly and then press Engine Start Button to Follow instructions under REMOTE CONTROLS engage starter motor.
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ENGINE OPERATION Normal Engine Operation CAUTION Always keep engine covers closed while engine is running. John Deere Engine Be alert for unusual noises or vibration. When an unusual condition is noticed, stop machine in a Engine Oil Pressure: safe position and shut off engine. Determine cause Low Idle - 15psi (105 kPa) and correct problem before continuing.
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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 excavator will be increased by performing the symbol.
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ADAPTER ATTACHMENT INSTALLATION WARNING Keep boom in fully extended position while installing bucket. Stay clear until bucket adapter has been fitted to bucket as shown in step two. STOP CAUTION Digging with a loose or improperly fitted bucket can cause excessive wear, shear adapter bolts or cause loss of bucket.
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USE YOUR CRAWLER PROPERLY Travel in forward direction whenever possible Mud, frozen mud and debris can prevent rollers (with track drive motors at rear). Traveling in from turning and cause flat spots. Clean track reverse increases wear on sprockets and components as often as necessary.
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HOW TO OPERATE THE CRAWLER Practice with travel controls in a safe, open area. CAUTION WARNING Avoid confusion! Before actuating track drive pedals, think about the direction you are facing with respect to the direction the crawler is facing. (Drive sprockets are at rear of crawler).
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When operating, run engine at high idle control pattern shown is the standard (full throttle) for maximum efficiency. Gradall pattern. If controls have been When excavator/travel functions will not modified to another pattern, be sure you Be used for a period exceeding five are familiar with altered pattern, and minutes, reduce engine speed to low idle.
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Move right joystick to left (G) to swing left or to Pull back on left joystick (A) to raise boom far right (H) to swing right to digging site. enough to clear all obstructions. While pushing right joystick forward (F) to extend Move left joystick to left (C) to open bucket or to boom, push left joystick forward (B) to lower right (D) to close bucket for correct penetration.
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If required, move tilt lever to left (I) to tilt counter While pushing forward on left joystick (B) to clockwise or to right (J) to tilt clockwise. Turn Tilt lower boom and force bucket into ground, pull back Speed knob as required to increase or decrease on right joystick (E) to retract boom and fill bucket.
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Move right joystick to right (H) to swing right or Move left joystick to left (C) to open bucket and to left (G) to swing left to dump site. If necessary, dump load. extend boom by pushing right joystick forward (F). Move right joystick to left (G) or right (H) to align boom for next cut.
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HAMMER INSTALLATION This installation procedure is to be performed ONLY by experienced field maintenance personnel. Installation: Extend boom approximately half way and tilt boom 180 degrees as shown below. NOTE: The following conditions are assumed: With engine operating at low idle, align telescoping boom with hammer bracket as shown.
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Secure pin weldment using retaining rod and 1/4-20 screws and nuts. Lubricate tool cylinder rod eye and hammer bracket pivot pin (3 fittings). Raise boom and tilt boom 180 degrees. Move ham- mer to a vertical position. Check to be sure transmitter Attachment switch is in Off position.
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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.
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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 At End of First 30 Days (250 Hours Maximum) Lube No.
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LUBRICATION & MAINTENANCE DIAGRAM 9 10 11 12 13 SYMBOLS = Lube Fitting = Other Service 1 2 3 4 = Service Both Sides Lubricant Symbols AF - ANTI-FREEZE (permanent) CC- COOLANT CONDITIONER CG - GREASE (extreme pressure) DF - DIESEL FUEL EO - ENGINE OIL GO - MULTI-PURPOSE LUBE HF - HYDRAULIC FLUID...
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SECURING BOOM Transport Tie Down Chain WARNING Do not use transport tie down chain for lifting loads. Transport tie down chain was developed specifically for transport purpose only. Always install transport tie down chain and secure when preparing machine for transport. Transport tie down chain is stored in engine compartment.
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LOADING & SECURING FOR TRANSPORT LIFT EYE For Transporting: For Lifting (in addition to transport step 1): Attach four legged chain as shown. Using crane Retract horizontal boom fully, install transport of adequate capacity, take most of slack from chain and secure with hitch pins. Chains are chains.
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• Apply Boeshield *T9 (Gradall Part No. 1440- procedures for short term storage. However, we do 4645) to exposed cylinder rods. require that you review the following points and...
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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.
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EXCAVATOR HAND SIGNALS CLOSE BUCKET - Hold one hand closed and stationary. Rotate other hand in small MOVE SLOWLY - Place one hand motionless THIS FAR TO GO - With hands raised and open inward, move hands laterally, indicating vertical circle with forefinger pointing in front of hand giving motion signal.
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Hydraulic Equipment 406 Mill Avenue, S.W. New Philadelphia, Ohio 44663 PHONE: (330) 339-2211 FAX: (330) 339-8468 WEB SITE: www.gradall.com CALIFORNIA CALIFORNIA Proposition 65 Warning Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead Diesel engine exhaust and some of its...
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