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Gradall 660E Operation Manual

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OPERATION & LUBRICATION
MANUAL
G660E
8395-1003
July 2002
Starting S/N 0161400
thru 0164470
GRADALL
406 Mill Avenue S.W.
New Philadelphia, OH, 44663, USA
Telephone: (330) 339-2211
Fax: (330) 339-3579

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Summary of Contents for Gradall 660E

  • Page 1 OPERATION & LUBRICATION MANUAL G660E 8395-1003 July 2002 Starting S/N 0161400 thru 0164470 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 proper operating procedures. Performing the checks and services described in this manual will help to keep your Gradall R Excavator in reliable condition and use of the recommended operating procedures can help you avoid accidents. Because...
  • Page 6 Gradall Hydraulic Excavator. CIMA DUMPER Safety Manual If you have any questions regarding the excavator, G-660E 6 x 4 & 6 x 6 Carrier Operator’s Manual contact your Gradall Distributor. He is familiar Gradall Hydraulic Excavator Safety Manual with the unit and will be happy to help you.
  • Page 7 SAFETY HIGHLIGHTS Read and understand this manual, G-660E 6 x 4 & 6 x 6 Carrier Operator’s Manual, CIMA Excavator User’s Safety Manual, CIMA DUMPER Safety Manual, Gradall Hydraulic Excavator Safety Manual and all instructional decals and plates before starting, operating or performing maintenance procedures on this equipment.
  • Page 8 SAFETY HIGHLIGHTS ‘PINCH POINTS’ Learn to recognize Boom Cradle Counterweight & Another Object Boom Boom Holes Upperatructure & Carrier Bucket & Linkage Learn to recognize “PINCH POINTS” and stay clear of them. Getting caught in a pinch point can cause serious injury or death.
  • Page 9 ’s tools or personal items on the in this manual. If it differs, or if you aren’t sure, machine. Such items can cause other workers to contact your Gradall distributor before you run approach the machine without your knowledge and your unit.
  • Page 10 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 2 and then operate the unit in a safe, open area to become familiar with the controls. REPOSITION FOR EXCAVATOR OPERATION ONLY UNDER FOLLOWING CONDITIONS: Signal persons positioned to observe and Transmisslon in proper range...
  • Page 11 Center boom fully over rear of chassis and rest If one or more wheels indicate brake failure, boom or bucket on the ground. DO NOT DRIVE THE GRADALL HYDRAULIC EXCAVATOR. Investigate and correct. For Apply down pressure with boom (but not assistance, contact your Gradall Distributor.
  • Page 12 GRADALL LIFTING CAPACITIES SAFETY HIGHLIGHTS RATED LIFT CAPACITY Always check Lift Capacity Chart and plan lift (pages 28 & 29) to be sure lift can be performed safely. Watch out for carrier cab when swinging. Position unit so that it won’t be necessary to swing close to cab.
  • Page 13 SAFETY HIGHLIGHTS Do not operate with bystanders or other Always be sure bucket is resting firmly in boom workers near machine. rest or on ground and that engine is stopped before performing lubrication or maintenance procedures inside boom. Avoid injury! Always relieve pressure trap- ped in circuits before disconnecting, re- moving or installing hydraulic components.
  • Page 14 SAFETY HIGHLIGHTS MAX LIFT CAPACITY 2000 LBS. (907 KG.) Position attachment for transport only as shown. Be sure to secure attachment to deck before traveling. If required, secure attachment as shown to prevent drift while traveling...
  • Page 15 Decals Inside Cab Located on left cab wall (crawler units only) Located on left cab wall Part No. 8364-3033 Part No. 8364-3034 Located on joystick pedal Part No. 7733-3026 MANUALS Located on joystick column Part No. 8364-3041 Located on manual holder Part No.
  • Page 16 OUT WHILE TRAVELING, OTHER- WISE UNEXPECTED BOOM MOVE- MENT MAY OCCUR WITH SERIOUS INJURY RESULTING. GRADALL PART NO 8360 1023 Located on selection valve cover Located on left cab wall (crawler units only) Part No. 8697-3006 Part No. 8360 - 1023...
  • Page 17 Decals Inside Cab (cont.) TO OPERATE CARRIER FROM UPPERSTRUCTURE FORWARD-REVERSE CONTROL PEDAL MUST BE IN NORMAL (NEUTRAL) POSTION. START UPPERSTRUCTURE POWER UNIT. WHEN AIR GAUGE SHOWS OPERATING PRESSURE (125 PSI), RELEASE EMERGENCY BRAKE. CONTROL AND DIRECTION OF CARRIER TRAVEL IS NOW DETERMINED BY POSITION OF FORWARD-REVERSE CONTROL PEDAL.

  • Page 18: Diesel Fuel

    Decals Outside Cab OR INJURY MAY RESULT FROM DEATH CONTACTING ELECTRICAL LINES. TO PLACE ANY PART OF THIS MACHINE OR LOAD WITHIN 10 UNLAWFUL 7702-3004 FEET OF HIGH VOLTAGE LINES Located on tilt gear box, left side of valve compartment & OF UP TO 50,000 VOLTS.

  • Page 19: Hydraulic Oil

    Decals Outside Cab (cont.) ® THE GRADALL COMPANY 406 Mill Ave., S.W. New Philadelphia, Ohio Located at front center of frame Part No. 7733-3047 ARRANGE CHAIN ONLY AS SHOWN TO LIFT ATTACHMENTS FOR TRANSPORT PREPARTAION MAX LIFT CAPACITY 2000 LBS.

  • Page 20: Operator's Cab

    OPERATOR’S CAB Seat Adjustment Defroster The operator’s seat and pedestal combination A defroster fan is mounted near the front window include adjustments for height, seat angle and fore and is controlled by a switch on the overhead and aft positioning. instrument/control panel.
  • Page 21 THIS PANEL FURNISHED ON UNITS STARTING S/N 0163407 Test your controls before operating. The control pattern illustrated is the standard Gradall control pattern. If your machine controls have been modified to any other pattern, be certain you are familiar with their functions before operating and ensure that control diagram in cab is changed to show the actual pattern.
  • Page 22 CONTROL AND INSTRUMENT VARIATIONS CRAWLER UNITS CRAWLER OPERATING CONTROLS SOUND HORN JOYSTICK ON/OFF SWITCH RIGHT TRACK REVERSE RIGHT TRACK FORWARD LEFT TRACK REVERSE LEFT TRACK FORWARD THROTTLE INCREASE THROTTLE DECREASE TRAVEL LOW SPEED TRAVEL HIGH SPEED...
  • Page 23 CHECKS AND SERVICES BEFORE STARTING ENGINE (To be performed at beginning of each work shift) Complete all required maintenance before operating unit. enter these ports it can shorten the life of o-rings, seals, packings and bearings. When adding fluids or changing filter elements, Use extreme caution when checking items refer to the lubrication section of this manual to beyond your normal reach.
  • Page 24 Check fuel level and replenish as necessary. It is recommended that the unit be refueled at the end of the work shift to minimize condensation. Check for presence of fully charged fire extin- Engine should be turned off while refuel- quisher on wall behind seat in cab.

  • Page 25: 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” (pages 19 and 20). Turning ignition switch to START position while engine flywheel is rotating can cause serious damage to engine and/or starting motor. It is recommended that engine be started with clutch engaged (if so equipped).
  • Page 26 Normal Engine Operation Be alert for unusual noises or vibration. When an unusual condition is noticed, stop machine in a safe position and shut off engine. Determine cause Always operate with engine at full throttle and correct problem before continuing. to keep cylinders full of oil to prevent un- expected machine movements.
  • Page 27 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 Emergency braking (from upperstructure - attempt excavator will be increased by performing the to travel with brake applied).

  • Page 28: Attachment Installation

    ATTACHMENT INSTALLATION Keep boom in fully extended position while instalilng bucket. Stay clear until bucket adapter has been fitted to bucket as shown in step 2. Digging with a loose or an improperly fitted bucket can shear adapter bolts and cause excessive wear.

  • Page 29: 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 Romote Control Operation With carrier on level surface, apply parking brake. Start carrier engine and develop full brake Be sure to keep feet clear of clutch pedal system pressure in front and rear portions of when moving DIGGING BRAKE toggle to...
  • Page 30 Precautions for Remote Control Operation Always give audible signal before moving unit. Be sure of clear visibility in direction of travel; use a signalman to compensate for blind spots. Never permit bucket to drag while moving unit. Be sure all Warm-Up and Operational Checks Rotation of steering wheel will occur during have been performed.
  • Page 31 Crawler undercarriages are furnished to enable Mud and debris can prevent rollers from turning the Gradall to travel over rough terrain and reach and cause flat spots. Clean track components as work sites which would not be accessible to the often as necessary.
  • Page 32 HOW TO OPERATE THE CRAWLER Practice with travel controls in a safe, open area. 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). Confusion could cause you to travel in the direction opposite that expected.
  • Page 33 Practice with joystick controls in a safe, open area. Test your controls before operating. The control pattern illustrated is the standard Gradall control pattern. If your machine controls have been modified to any other pattern, be certain you are...
  • Page 34 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 35 A TYPICAL GRADALL DIGGING CYCLE If required, press left side of tilt switch (I) to tilt While pushing forward on left joystick (B) to counterclockwise or right side of switch (J) to tilt lower boom and force bucket into ground, pull clockwise.
  • Page 36 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 37 LIFTING AND POSITIONING A LOAD Precautions Do not depend on machine tipping as a warning Do not travel with a suspended load. Excavators of overload. Some load ratings are based on are not designed for pick and carry lifts. hydraulic lift capacity, not stability. Sudden swing braking can cause unexpected Hydraulic relief settings must be correct when movement of the load and tip the machine.
  • Page 38 Perform an unloaded trial run of the lift to Measure boom height/depth from bucket adapter determine maximum load radius required and pivot shaft to ground level (same plane as bottom of maximum boom height and depth required to tires). Be sure to allow for length of sling and height complete the lift.
  • Page 39 Recommended Lubricants & Capacities Hydraulic Fluid Specifications: *Refer to manufacturer’s service literature for this information, ISO Grade 46, Pour Point, F. -20 to -40 **Specific hydraulic fluid specifications are shown. SSU @ 100 F., 200-240 ***Capacities are approximate - check level to be sure. Flash Point, COC, F.
  • Page 40 LUBRICATION & MAINTENANCE DIAGRAM SYMBOLS For Units Starting S/N 0169449 = Fitting Also used on S/N 0163449 & S/N 0164449 = Other Service WEEKLY LUBRICANT SYMBOLS A. Swing Trans. Fill & Level Plug (Check level & refill as req’d) - GO CG - Grease, Extreme Pressure C.
  • Page 41 • • • • • • • • •...
  • Page 42 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 43 MOVE SLOWLY - Place one hand motionless in CLOSE BUCKET - Hold one hand closed and THIS FAR TO GO - With hands raised and open front of hand giving motion signal. (Raise load stationary. Rotate other hand in small vertical circle inward, move hands laterally, indicating distance to slowly is shown.) with forefinger pointing horizontally at closed hand.
  • Page 44 SECURING BOOM & ATTACHMENT FOR TRAVEL IF YOU GET STUCK rear to prevent tipping) and imbed bucket in ground. If unit becomes stuck in soft ground you can use the boom to help free it. While actuating travel pedal in appropriate direction, Position carrier and upperstructure controls for pull unit to solid ground.

This manual is also suitable for:

G660e