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Gradall G440 Operator's Manual

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OPERATOR'S MANUAL
G440
8343-1026
July 2002
Original Issue 1976
Revised Issue 3/80
Form #7555
GRADALL
406 Mill Avenue S.W.
New Philadelphia, OH, 44663, USA
Telephone: (330) 339-2211
Fax: (330) 339-3579

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  • Page 1 OPERATOR’S MANUAL G440 8343-1026 July 2002 Original Issue 1976 Revised Issue 3/80 Form #7555 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...

  • Page 4: Important Safety Notice

    Safe operation depends on reliable equipment and the use of proper operating pro- cedures. Performing the checks and services described in this manual will help to keep your Gradall in reliable condition and use of the recommended operating pro- cedures can help you avoid unsafe practices. Because some procedures may be new to even the experienced operator we recommend that this manual be read, under- stood and followed by all who operate the Gradall.
  • Page 5 A FEW WORDS TO THE OPERATOR This manual provides important information to familiarize you with safe operating and maintenance procedures for the Gradall. Even though you may be familiar with similar equpiment you MUST read and understand this manual before oper- ating the unit.
  • Page 7 SAFETY Read and understand this manual and separate CIMA safety manual before operating. Serious injury or death can result from unsafe operating practices. Inspect your machine daily. At the beginning of each CHECKS AFTER STARTING ENGINE and shift, perform all the CHECKS AND SERVICES BEFORE DIGGING.
  • Page 8 SAFETY (Cont.) Keep swing area free of tools, buckets and blocking. To prevent slipping, keep deck and cab area free of oil and trash. Always use caution when working near people. Never pass the boom or bucket over people. Never operate the machine with someone stand- except in the ing anywhere on the upperstructure cab.
  • Page 9 for upper- Be sure you have enough clearance structure tail swing, especially if there are cars or peo- ple in the area. Always have a flagman to direct traffic. On truck-mounted Gradalls, watch out for the car- rier cab when swinging the boom. Keep the boom high, and if possible, do not swing close to the cab.
  • Page 10 SAFETY (Cont.) Before disconnecting any hydraulic components place the boom on the ground or testing equipment, or in the boom rest and shut off the engine. Move the control levers and pedals to relieve pressures within the cylinders. Anchor boom using heavy timber or chain.
  • Page 11 17. Swing Left Pedal 18. Swing Right Pedal 19. Emergency Brake Control 20. Air Pressure Gage WARNING 21. Pull To Stop 22. Emergency Stop Handle Know and understand controls and instru- 23. Throttle Control Lever ments before operating the Gradall.
  • Page 12 (To be performed at beginning of each work shift) WARNING Use extreme caution when checking items beyond your normal reach. WARNING Any defects or deficiencies noted must be corrected before the Gradall is placed in service. Check oil level in engine crankcase and fill as neces- sary using specified grade of oil.
  • Page 13 Be sure in upper- EMERGENCY BRAKE BUTTON Check air cleaner condition indicator. Replace ele- structure is in position (pulled up). (Furnished ment when orange band rises to top of indicator win- only on units equipped for remote control). dow. Reset band position by pushing button up. Check lubricant level in swing transmission and fill...
  • Page 14 CHECKS AND SERVICES (Cont.) Check condition and mounting of If a is required by law or jobsite con- bucket teeth. spark arrester Replace teeth showing excessive wear. ditions, make sure that one is attached and that it is in good working condition.
  • Page 15 Once engine has reached operating temperature run at Be alert for unusual noises or vibration. When an full throttle for efficient Gradall operation. unusual condition is noticed, stop machine in a safe position and shut off engine. Determine cause and cor- rect problem before continuing.
  • Page 16 UPPER ENGINE OPERATION (Cont.) Stopping the Engine Operate the engine at idle speed for a few minutes before turning it off. This provides an opportunity for CAUTION engine coolant and lubricating oil to carry excessive Use “EMERGENCY ONLY” handle only in heat away from critical engine areas.

  • Page 17: Checks After Starting Engine

    (see page 14). release swing pedal. Note effectiveness of auto- matic swing brake. Notify maintenance personnel 5. Operate the Gradall slowly through a few com- immediately if swing brake action is weak. Have plete digging cycles to warm the hydraulic oil brake system adjusted as necessary.

  • Page 18: Bucket Installation

    BUCKET INSTALLATION WARNING Keep boom in fully extended position while installing bucket. Stay clear of bucket and boom until bucket adapter has been fitted to bucket as shown in step 3. Position adapter above bucket tube with adapter in Lower boom until bucket tube seats firmly within “Bucket Open”...

  • Page 19: 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 When moving DIGGING BRAKE toggle to ON pressure in front and rear portions of system position (step 4), clutch pedal is pulled to floor (125 psi).
  • Page 20 IF YOUR CARRIER GETS STUCK CAUTION Perform procedure with boom extended over rear only. 1. Shift carrier transmissions (main & auxiliary) to 3. Engage travel lever until you hear brakes release. low range. 4. As brakes release (Step 3) engage boom lever in 2.
  • Page 21 TO MAKE A TYPICAL GRADALL CUT IMPORTANT Your Gradall has sufficient power to permit a fast efficient digging cycle. The procedure on the following pages describes a typical cycle in separate steps; as you gain experience, combine control functions for a smooth cycle with no lost time.
  • Page 22 TO MAKE A TYPICAL GRADALL CUT (Cont.) Press outer right pedal to swing the boom right Push right lever forward to extend boom and at the (J), inner right pedal to swing left out over the pro- same time push left lever forward to lower boom...
  • Page 23 Position bucket open or closed for correct pen- Pull center lever back to tilt boom clockwise etration while boom is being lowered. Push forward push center lever forward to tilt boom counterclock- on left lever to force boom down for penetration wise if necessary.
  • Page 24 TO MAKE A TYPICAL GRADALL CUT (Cont.) Pull right lever back to retract boom and at the The bucket cutting edge raises as the boom retracts. (E), same time push left lever forward to apply down pres- Slight adjustment of bucket open pedal...
  • Page 25 Pull left lever back and as the boom rises, press When bucket is raised high enough to clear obstruc- inner left pedal to close the bucket and prevent tions, swing boom left or right to dump location, excess spillage. Do not raise the boom higher than is and if required, extend boom by pushing right lever necessary.
  • Page 26 TO MAKE A TYPICAL GRADALL CUT (Cont.) Press outer left pedal to open bucket and release Swing boom left or right to align boom for next dirt. cut and repeat steps 4 through 11.

  • Page 27: Operating Tips

    2. When ditch cleaning from the road on a truck-mounted Gradall, travel with traffic toward the unclean end of the ditch, for a clear view of the cleaned ditch, the road shoulder, and the truck hauling the spoil.
  • Page 28 ABOUT YOUR GRADALL Tools Standard tools that are common in tool boxes are not furnished with your Gradall. Tools especially designed for use with your machine are shipped with the unit. You should be familiar with these tools, and know where they are kept.

  • Page 29: In Case Of Trouble

    Parking Procedures NOTE: Parking procedure for conventional 6x4 and 2. Fill fuel tank to minimize condensation. 6x6 carriers is fully explained in the “G-440 GRADALL 6x4 and 6x6 CARRIERS OPERATOR’S 3. Lock cab and install protective window covers if MANUAL”. available.
  • Page 35 8341-1037 J u l y 2 0 0 2 S t a r t i n g Lot 10 Original Issue 1977 Form #7723 GRADALL 406 Mill Avenue S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
  • Page 37 All Safety Rules found in other Publications, noted above, apply to the operation and maintenance of this unit. If you have any questions regarding your Gradall, contact your Gradall dis- tributor. He is familiar with the entire unit and will be happy to help you.
  • Page 38 Do not operate your Gradall until it is crawler. The idler is located at the front of the properly adjusted.
  • Page 39 USE YOUR CRAWLER PROPERLY Travel in FORWARD position whenever possi- not neglect service because of infrequent travel- ble (with track drive motors at rear). Traveling ing. in reverse increases wear on sprockets. Operation on rough or uneven ground can cause unnecessary wear and damage to track compo- Use extreme caution on steep slopes to avoid nents.

  • Page 40: Recommended Lubricants

    LUBRICATION LUBRICANT SYMBOLS SYMBOLS CG - Grease, High Temp = Fitting GO - Gear Oil = See Note * ITEM “ A ” WARNING Do not Grease - High Pressure Cylinder These fittings, two for each track, are used for track adjustments only.
  • Page 41 G-440 STARTING LOT 1 What is Scheduled Maintenance for GRADALL? It is the day-by-day care of small details on your machine — all according to a regular plan. Scheduled Maintenance keeps your GRADALL in steady production. It extends the life of your machine over more productive years, and helps keep your machine in efficient condition.
  • Page 42 GRADALL PRE-OPERATIONAL SCHEDULED MAINTENANCE Check These Points Before Operating the Gradall Upperstructure! 1. Fill engine radiator with water or 2. Inspect air cleaner indicator. 3. Check oil level. If low, add to full anti-freeze as applicable. Replace if filter is dirty.
  • Page 43 GRADALL CHART SCHEDULED MAINTENANCE Here is a Typical Gradall Maintenance Program The above schedule is a guide to good scheduled maintenance. However, frequency of checking and lubricating may have to be increased under certain conditions. Also, additional points may need attention.
  • Page 44 GRADALL RECOMMENDATIONS SCHEDULED MAINTENANCE...
  • Page 45 GRADALL RECOMMENDATIONS SCHEDULED MAINTENANCE...

  • Page 46: Hydraulic Fluid

    HYDRAULIC FLUID The wrong hydraulic oil will cause serious trouble. Hydraulic oil quality and cleanliness directly influence the overall efficiency of the Gradall. The oil flowing through the highly sensitive elements of the hydraulic system must be absolutely clean. Here are some instances where action is required to prevent serious trouble: 1.
  • Page 47 GRADALL TORQUE CHART SCHEDULED MAINTENANCE...
  • Page 48 GRADALL KEEP MACHINE CLEAN SCHEDULED MAINTENANCE...
  • Page 55 GRADALL CO. These pages have been reproduced from a booklet pro- vided by the Denison Division of the Abex Corporation. Graphic Symbols for Fluid Power Diagrams INTRODUCTION Fluid power systems are those that trans- mit and control power through the use of a pressurized fluid (liquid or gas) within an enclosed circuit.
  • Page 56 Rotary Devices 8. contiued Form No. 0002...
  • Page 57 Form No. 0002...
  • Page 59 120° F. As a pump works, the pump output will also be reduced depending upon the degree of internal wear. Gradall is a registered trademark for hydraulic excavators, hydraulic material handlers, and attachments built by The Gradall Company.

  • Page 60: Control Levers And Pedals

    GRADALL G-440 TESTING HYDRAULIC SYSTEM PUMPS CONTROL LEVERS AND PEDALS The excavator is operated and tested by movement of hand control levers and foot pedals to actuate the respective control valves. Testing pumps with Flow Meter. OIL FLOW TO CIRCUITS...
  • Page 61 GRADALL G-440 TESTING HYDRAULIC SYSTEM CONTROL VALVES AND MANIFOLD For your convenience, the hose adapters are fitted with test gage ports. These permit easy access with your pressure gages.
  • Page 62 GRADALL G-440 TESTING HYDRAULIC SYSTEM TESTING PUMP RELIEF VALVES HOW TO TEST PUMP RELIEF VALVES 4. Position machine as shown for test to be performed. WARNING 5. Start engine, engage clutch (if so equipped) and run Always relieve trapped pressure from circuits at proper R.P.M.
  • Page 63 GRADALL G-440 TESTING HYDRAULIC SYSTEM TESTING PUMP RELIEF VALVES (Continued)
  • Page 64 GRADALL G-440 TESTING HYDRAULIC SYSTEM TESTING HOSE RELIEF VALVES HOSE RELIEF VALVES WARNING For protection of hoses and other components, and Always relieve trapped pressure from circuits (steps as a safety device, hose relief valves are installed 1 & 2 below) before installing or removing pressure between the control valves and the cylinders and motors.
  • Page 65 7. Actuate control to pressurize first one motor 13. If this test indicates acceptable motor effi- working line and then the other. Observe and ciency and circuit performance is unaccept- record gage readings. able, contact your Gradall distributor.

  • Page 66: Hydraulic Cylinders

    GRADALL G-440 TESTING HYDRAULIC SYSTEM HYDRAULIC CYLINDERS HYDRAULIC CYLINDERS HOW TO TEST CYLINDER EFFICIENCY (By-Pass Test) One of the easiest tests is to observe the amount of oil being forced past the piston rings inside the cylinder. The amount of oil which flows indicates the condition of the cylinder (shown at A).
  • Page 67 GRADALL G-440 TESTING HYDRAULIC SYSTEM HYDRAULIC CYLINDERS TILT/TOOL CYLINDER 1. Close bucket fully and rest it on the ground. 2. Disconnect the hose at the rod end of the cylin- der. Plug or cap this hose. 3. Actuate control to close bucket.

  • Page 68: Hydraulic Pressures

    GRADALL G-440 TESTING HYDRAULIC SYSTEM HYDRAULIC PRESSURES Engine R.P.M. (Full Load) ..2500 (With two pump sections under full load-hoist up and boom in) Hydraulic Pressures** ALL RELIEF VALVES ARE STAMPED TO SHOW FACTORY RECOMMENDED SETTINGS.
  • Page 69 2. Loosen Valve Retainer Cap (A) carefully. pressure or volume the pump should be rebuilt. Consult 3. Turn Adjusting Screw (B) clockwise or counter- your Gradall distributor, who is qualified to overhaul your clockwise. pump. Read pages at the rear in this section.
  • Page 70 GRADALL G-440 HYDRAULIC ADJUSTMENTS RELIEF VALVES AND HYDRAULIC CYLINDERS HOW TO ADJUST HOSE RELIEF VALVES HYDRAULIC CYLINDERS If these valves open at lower than desired pressure, new The hydraulic cylinders, under normal conditions, springs should be installed. should be repacked once every year for every 1800 or 2000 hours, whichever comes first.
  • Page 71 5. Inspect inside of cylinder barrel. Make sure it is 11. Use common sense safety precautions. perfectly clean and smooth. In repacking the hydraulic cylinders of the Gradall we 6. Clean all parts thoroughly. Lubricate and install recommend that it be done in the following order: new parts that are subject to periodic replace- First, the Tool Cylinder (remove from machine).
  • Page 72 GRADALL G-440 HYDRAULIC ADJUSTMENTS HOIST AND BOOM CYLINDERS HOW TO REMOVE THE HOIST CYLINDERS Locate the machine in a safe working area where the boom can be lowered to give best clearance above the cylinders and make cylinder removal easier. Repack only one cylinder at a time.
  • Page 73 GRADALL G-440 HYDRAULIC ADJUSTMENTS TILT CYLINDERS HOW TO REPACK THE TILT CYLINDER 10. On one end install cylinder head. Torqueing bolts to spec chart. 1. Remove seal cap from each end of cylinder. 11. Slide o’ring over rod and push into cylinder 2.
  • Page 74 GRADALL G-440 HYDRAULIC ADJUSTMENTS BOOM CYLINDER BOOM CYLINDER REPACKING 3. Secure the two booms together with both come- CAUTION alongs. WORK SAFELY 4. Place wooded wedges under front of cylinder barrel and under exposed cylinder rod. Use ALWAYS SECURE THE TWO BOOMS wedges to help center the parts.
  • Page 75 GRADALL G-440 HYDRAULIC ADJUSTMENTS BOOM CYLINDER REPLACING O’RINGS & SEALS IN REAR BOOM GLAND 1. Place bucket on ground with boom ran 1/2 way out. Block and lock boom in position (come-along). 2. Remove swing pinion cap (7). 3. Remove cotter pin (1) and nut (2) from rod end.