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Summary of Contents for Gradall G-440
- Page 1 OPERATOR’S MANUAL G-440 8368-3062 J u l y 2 0 0 2 S t a r t i n g S / N 974001 Original Issue 1/80 Form #7910 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211...
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Page 4: Important Safety Notice
Any procedure not specifically recommended by Warner & Swasey must be thoroughly evaluated from the standpoint of safety before it is placed in practice. If you aren’t sure, contact your Gradall Distributor before operating. WARNING BEFORE WELDING ON THIS MACHINE: DISCONNECT BATTERY CABLES AND TURN OFF IGNITION BEFORE WELDING TO PREVENT DAMAGE. - Page 6 Gradall Hydraulic Wheeled Excavator undercarriage. Truck type carriers for the G-440 and G-660 Gradall Hydraulic Excavators are furnished with the Because two operators are sometimes assigned to...
- Page 7 SAFETY HIGHLIGHTS Read and understand this manual and “CIMA Off-Highway Truck Safety Manual” before starting, operating or performing maintenance procedures on this carrier. Do not permit this carrier to be driven by an operator who cannot read English unless these manuals have been read and explained to him and his full under- standing is determined.
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Page 8: Instruction Decals
SAFETY HIGHLIGHTS Check to be sure all WARNING, CAUTION Know overall height of your unit before traveling. INSTRUCTION DECALS are in place and can be Approach unknown clearances slowly. read. Clean or replace decals as required. Some owners alter their machines. Check to be sure your machine fits the pictures and description in this manual. - Page 9 SAFETY HIGHLIGHTS Remember, getting too close to unstable ground or or move the unit until all Do not carry passengers the edge of an excavation can cause the machine other persons have gotten off and are clear of the to tip. machine.
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Page 10: Instruments And Indicators
INSTRUMENTS AND INDICATORS 1. Left Turn Signal Indicator Light 11. Digging Brake Indicator Light (flashes to indicate digging brake is applied) 2. Fuel Gage *12. Wheel Lock Control Indicator Light (glows to 3. Oil Pressure Gage indicate failure of front axle portion of wheel lock control system) 4. - Page 11 CONTROLS 1. Windshield Washer Switch 13. Choke Control Knob (gasoline engine only) 2. Head, Tail & Clearance Light Switch 14. Engine Stop Handle (diesel engine only) 3. Windshield Wiper Switch 15. Headlight Hi/Lo Beam Switch 4. Heat Vent Control Knob (down for defrost) 16.
- Page 12 CHECKS AND SERVICES BEFORE STARTING ENGINE Complete all required maintenance before driving the carrier WARNING Use extreme caution when checking items beyond your normal reach. Use an approved safety ladder. Check fluid level in windshield washer reservoir on rear wall in carrier cab. Add windshield washer solvent as necessary.
- Page 13 as indicated on lubrication chart. and replenish as necessary. Refuel Lubricate unit Check fuel level at the end of the work shift to minimize con- densation. WARNING Engine should be turned off while refueling. Be sure area is free of open flame, sparks or any condition which could cause fuel to ignite.
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Page 14: Engine Operation
ENGINE OPERATION NOTE: If engine is being started at beginning of work shift be sure to perform all “CHECKS AND SERVICES BEFORE STARTING ENGINE” Starting International Harvester Engine 1. Be sure main transmission is in neutral and park- seconds, release key and allow starting motor to ing brake is applied. -
Page 15: Cold Weather Starting Aids
Cold weather starting aids Diesel engine ignition is accomplished by heat instructions for their use in this manual. Carefully generated when fuel/air mixture is compressed follow instructions furnished with your starting aid. within the cylinders. Because this heat may be insufficient to start a cold engine in cold weather, the If you use a starting aid employing ether or a use of starting aids has become common practice. -
Page 16: Checks After Starting Engine
CHECKS AFTER STARTING ENGINE (To be performed at beginning of each work shift) Complete all required maintenance before driving. 1. Check operation of 6. Observe Proper oper- windshield washer and water temperature gage. ating temperature is approximately 160/180°F. wiper. (71/82°C). 2. -
Page 17: Brake System
BRAKE SYSTEM The air brake system includes a service brake, an emergency brake, a parking brake and a digging brake. The system may also include an optional wheel lock control system to minimize skidding. WARNING WARNING Wear safety belt to avoid being thrown from driver’s seat during emergency braking. -
Page 18: Emergency Brake
that the bulbs and the related circuitry are in good EMERGENCY BRAKE APPLICATION working order. In the event of a defect in the wheel (pressure lost in rear) lock control system, one or more lights will glow continuously to call attention to the condition. WARNING When WHEEL LOCK CONTROL light continues to glow, the wheel lock control system is... -
Page 19: Parking Brake
pressure remaining, it may be possible to drive the DIGGING BRAKE APPLICATION unit a short distance to remove it from a hazardous position (use first gear and low range only). If carrier cannot be moved, direct traffic around carrier until warning flags, flares or lights can be displayed. - Page 20 Remote control braking element to thaw ice which may form in cold weather. A control screw located on the bottom of the valve can be set in three positions, AUTOMATIC, The digging brake is applied by the control toggle in MANUAL DRAIN and SHUT OFF.
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Page 21: Steering System
STEERING SYSTEM Conventional steering Remote control steering The power steering system provides accurate Your unit is equipped with a steering lever in the steering under normal conditions and greater control upperstructure cab. Upperstructure engine must be in the event of a blowout or soft ground. “Road feel” running to provide power for remote control steering. -
Page 22: Power Train
POWER TRAIN The power train furnished on 6x4 carriers (units The major variations found on 6x6 carriers (units having two driving axles at rear) includes the engine, having two driving axles at rear and a third driving clutch, transmission, auxiliary transmission, rear axle in front) are the substitution of a front driving axle tandem axles and the necessary propeller shafts to in place of a non-driving front axle and the substitution... - Page 23 Four speed auxiliary “ ” is a high range which permits maximum speed and fuel economy but at reduced power. transmission “ ” is recommended only for light engine load (furnished with diesel engine) conditions and should never be used for starting carrier from a standstill.
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Page 24: Main Transmission
Main Transmission The transmission is a gearbox which transmits torque from the engine as it is delivered to move the carrier. The transmission in your carrier provides five forward speeds and one reverse speed. The lowest transmission gear range (first gear) provides the greatest carrier power and the lowest carrier speed. - Page 25 4. With clutch pedal still depressed shift auxiliary 2. Depress clutch again and carefully shift auxiliary transmission or transfer case to desired power/ transmission from “N” to “OD”. If shift timing speed range and engage or disengage front wheel has been correct, gears will engage smoothly with drive as required (if so equipped).
- Page 26 Shifting main and auxiliary Avoid continuous operation at full governed engine RPM. Cruising at governed RPM reduces engine transmissions service life and provides no reserve power for varying conditions. It is good practice to select a gear offering desired carrier speed at approximately When shifting both the main and auxiliary trans- 85 percent of governed engine speed.
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Page 27: Remote Control
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 1. Apply parking brake. WARNING 2. Start carrier engine and develop full brake system Be sure to keep feet clear of clutch pedal when pressure in front and rear portions of system moving DIGGING BRAKE toggle to ON position (125 psi/862 kPa). - Page 28 Precautions for remote control operation Be sure of clear visibility in direction of travel; Never tow load using remote control drive. use a signalman to compensate for blind spots. Always give audible signal before moving unit. Be sure upperstructure swing brake functions properly before moving carrier in remote control.
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Page 29: Parking Procedure
PARKING THE GRADALL Precautions: Park on level ground and block wheels. Avoid parking on banks or near an excavation. Avoid parking on roads or highways. If it cannot If parking on a slope cannot be avoided, position be avoided be sure to display warning flags unit at right angle to slope and block wheels. - Page 34 INTERNATIONAL HARVESTER ENGINE LUBRICATION & MAINTENANCE DIAGRAM DETROIT DIESEL ENGINE LUBRICATION & MAINTENANCE DIGRAM Power Steering Reservoir - Filled auto,atically from main hydraulic system. SEE LUBRICATION NOTES AND SYMBOLS ON CARRIER LUBRICATION PROGRAM...
- Page 35 G-660 & G-440 Diesel Tandem Axle (forward)........
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Page 36: Scheduled Maintenance
SCHEDULED MAINTENANCE Check automatic reservoir drain valves monthly....... Refer to page 16 Check battery monthly . -
Page 37: Bucket Position
BUCKET POSITION Position for buckets narrower than boom rest Position for buckets with width Position for buckets wider same as boom rest than boom rest...
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