Gradall G880E Operation Manual

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OPERATION & LUBRICATION

MANUAL

G880E

24604054

July 2002

Starting S/N G018042

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 OPERATION & LUBRICATION MANUAL G880E 24604054 July 2002 Starting S/N G018042 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 Carrier in reliable condition and use of the recommended operating procedures can help you avoid accidents.
Page 6 This manual provides important information to familiarize you with required operator maintenance This Operation & Lubrication Manual and with safe operating procedures for the Gradall CIMA DUMPER Safety Manual wheeled excavator undercarriage. All Instructional decals and plates...
Page 7 Keep these manuals in cab. If driver will operate upperstructure, he must also read and understand Gradall Upperstructure Operation & Lubrication Manual, Gradall Hydraulic Excavators Safety Manual and CIMA Hydraulic Excavator User ’s Safety Manual.
Page 8 SAFETY HIGHLIGHTS Learn to recognize ‘PINCH POINTS’ Counterweight & Another Object Boom Cradle Boom Holes Boom Bucket & Linkage Upperstructure & Carrier Learn to recognize “PINCH POINTS” and stay clear of them. Getting caught in a pinch point can cause serious injury or death.
Page 9 If it differs, or if you aren’t sure, Such items can cause other workers to machine. contact your Gradall distributor before you run approach the machine without your knowledge and your unit. result in serious injury or death.
Page 10 SAFETY HIGHLIGHTS if this is not the machine Be particularly careful you usually operate. Read the manuals listed on page 2 and then operate the unit in a safe, open Learn and follow your employer ’s safety rules. to become familiar with the controls. area Travel off-highway...
Page 11 Center boom over rear of chassis and rest boom If one or more wheels indicate brake failure, 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 SAFETY HIGHLIGHTS Know overall height of your unit before traveling. Approach unknown clearances slowly. Remember, getting too close to unstable ground or the edge of an excavation can cause the machine to tip. Always apply digging brake to prevent carrier movement while operating upperstructure.
Page 13 Decals Inside Cab Located inside cab door & above engine compartment Part No. 7702-3004 Located inside cab door Part No. 8360-1011 Located on right cab window Part No. 8688-1755 Located inside cab door Part No. 8368-3576 Located on right cab window Located on right cab window Part No.
Page 14 Decals Outside Cab Located on back of cab Part No. 8360-1018 Located at right of cab door Part No. 7702-3003 Located on fan shroud Part No. 9104-3210 Located on air reservoir Located on right frame rail Part No. 77202-3002 Part No. 7702-3029 Located inside battery box cover Located above fuel tank Part No.
Page 15: Instruments And Indicators
INSTRUMENTS AND INDICATORS Alternator Indicator Light Voltmeter Speedometer/Odometer Hi/Lo Beam Indicator Light Tachometer (optional) Air Pressure Gage (front) Low Air Indicator Light Fuel Gage Digging Brake Indicator Light Oil Pressure Gage Coolant Temperature Gage Turn Signal/Hazzard Indicator Light Air Pressure Gage (Rear) Do not move carrier while low air light is glowing or while any auxiliary device is signal- ing a dangerous condition.
Page 16 CONTROLS Heat Control Knob. Interaxle Differential Toggle Windshield Wiper Valve Heater Fan Switch Dome Light Switch Defroster Fan Switch Front Wheel Drive Toggle (6x6 only) High/Low Beam Switch Clutch Pedal Digging Brake Toggle Brake Valve Pedal Parking Brake Knob Light Switch Accelerator Pedal Range Preselection Lever Ignition Switch...
Page 17 CHECKS AND SERVICES BEFORE STARTING ENGINE Complete all required maintenance before driving the carrier 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 18 Lubricate unit as indicated on lubrication chart. Check fuel level and replenish as necessary. Refuel at the end of the work shift to minimize condensation. Engine should turned while refueling. Be sure area is tree of open flame, sparks or any condition which could cause fuel to ignite.
Page 19: 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 Diesel Engine (Cummins) Turn ignition switch fully clockwise to engage Be sure transmission is in neutral and parking starting motor.
Page 20 Normal engine operation (Cummins) RPM-2200 RPM). The governor has no control over Observe voltmeter, water temperature and oil engine speed when engine is being “pushed” by pressure gages frequently to be sure all engine carrier load. systems are functioning properly. When Select an appropriate gear ratio and use service Be alert for unusual noises or vibration.
Page 21: Checks After Starting Engine
CHECKS AFTER STARTING ENGINE (To be performed at beginning of each work shift) Complete all required maintenance before driving Check operation of windshield washer and Observe Proper water temperature gage. wiper. operating temperature is approximately 140/200 F. (60/93°C). Check all for proper lights and turn signals operation.
Page 22: Brake System
BRAKE SYSTEM Do not drive while low air indicator is The air brake system includes a service brake, an flashing. If light comes on while carrier is emergency brake, a parking brake and a digging moving, stop carrier in a safe area as soon brake.
Page 23 treadle valve will apply service brakes to the wheel If the air pressure gages indicate some system of the forward and rear tandem axles. There will be pressure remaining, it may be possible to drive the no braking on the wheels of the front axle. unit a short distance to remove it from a hazardous position (hold parking brake knob in depressed EMERGENCY BRAKE...
Page 24 DIGGING BRAKE APPLICATION Allow sufficient time for full brake system pressure (125 p.s.i.-862 kPa) to be devel- oped in upperstructure before operating unit in remote control. Move digging brake control toggle to ON position only when carrier is stopped. Maximum braking is applied to wheels when toggle is moved to ON.
Page 25: Steering System
STEERING SYSTEM Remote control steering Conventional steering Your unit is equipped with a travel/steering joystick The power steering system provides low effort in the upperstructure cab. Upperstructure engine steering under normal conditions and greater must be running to provide power for remote control control in the event of a blowout or soft ground.
Page 26: Power Train
POWER TRAIN Transfer Case The power train furnished on 6x4 carriers (units (for 6x6 units only) having two driving axles at rear) includes the engine, clutch, transmission, rear tandem axles and the The transfer case is a gearbox located between the necessary propeller shafts to transfer torque (power) transmission and rear tandem axles.
Page 27: Shifting Gears
SHIFTING GEARS Smooth, efficient gear shifting depends on coordin- Stop carrier and select appropriate gear ated use of accelerator pedal, clutch pedal, range range before driving down steep grade preselection lever, deep reduction button and shift under “off highway” conditions. Attempting to downshift under these lever.
Page 28 Double-Clutching for Downshift Depress accelerator pedal to increase engine speed to high idle, depress clutch and shift to next lower NOTE: Downshifting is used to aid in reducing gear. If shift timing has been correct, gears will carrier speed or to increase carrier power. mesh smoothly with no clash.
Page 29 Depress clutch pedal, depress clutch brake button and move shift lever to LL1 gear position. If conditions permit starting in LO range: Move deep reduction button to rear to select Lo range. Depress clutch pedal, depress clutch brake button and move shift lever to 1st gear position. Release clutch brake button.
Page 30 When ready, move range preselection lever up As conditions permit, use upshift - double- to HI position. clutching method to shift thru 7th, 8th and 9th gears to 10th gear. Using upshift - double-clutching method, im- mediately shift from 5th gear position to 6th gear position.
Page 31 Using downshift - double-clucthing mehod, shift If it is necessary to shift to deep reduction, move thru 9th, 8th and 7th gears to 6th gear. deep reduction button forward to LO-LO position. Immediately shift to LL3 using downshift - double- clutching method.
Page 32 INTER-AXLE DIFFERENTIAL With toggle in LOCK position, there is positive drive to the front and rear tandem axles and either axle will drive up to its maximum tractive ability without regard to the other axle. Keep toggle in LOCK An inter-axle differential is provided at the rear of the position when driving over poor tractive conditions front tandem axle.
Page 33: 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 With carrier on level surface, apply parking brake. Be sure to keep feet clear of clutch pedal Start carrier engine and develop full brake when moving DIGGING BRAKE toggle to system pressure in front and rear portions of...
Page 34 Precautions for Remote Control Operation Be sure of clear visibility in direction ot 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 all Warm-Up and Operational Checks have been performed.
Page 35: In Case Of Trouble
PARKING THE GRADALL Precautions: chine with boom in air. Avoid parking on banks or near an excavation. Park on level ground and block wheels. Avoid parking on roads or highways. If It can- not be avoided be sure to display warning flags If parking on a slope cannot be avoided, posi- during day and flares or flashing lights at night.
Page 36 6X4 CARRIER LUBRICATION & MAINTENANCE DIAGRAM SYMBOLS LUBRICANT SYMBOLS Refer to vendor component literature in service manual = Fitting CG – Grease, High Temp for additional lubrication and maintenance requirements. = Other Service GO – Gear Oil EO – Engine Oil...
Page 37 Refer to vendor component literature in service manual for additional lubrication and maintenance requirements. Item Monthly Lubrication & Maintenance (continued) Shift Linkage (at transmission) Transmission Front Fill & Level Plug (check level & refill as req’d) Transmission Rear Fill & Level Plug (check level & refill as req’d) Universal Joints Drive Shaft Splines Air Drier (refer to page 20 of this manual...
Page 38 6 X 4 CARRIER LUBRICATION & MAINTENANCE DIAGRAM SYMBOLS =Fitting =Other Services LUBRICANT SYMBOLS SG - Special Grease Refer to vendor component literature in service manual CG - Grease, Extreme Pressure GO - Multi-Purpose Lubricant for additionl lubrication and maintenance requirements. EO - Multi-Purpose Lubricant EO - Engine Oil...
Page 39 Item Lube No. of Item Lube No. of Symbol Points Symbol Points Daily Lubrication & Maintenance Monthly Lubrication & Maintenance (continued) Fuel Tank (fill at end of work shift to minimize condensation) - 1 Shift Linkage (et transmission) Radiator Filler Cap (check coolant level and replenish as req’d) - 1 Transmission Front Fill &...
Page 40: Torque Chart
Recommended Lubricants & Capacities * Refer to manufacturer’s service literatura for this information ** Capacities are approxi mate - check level to be sure. TORQUE CHART Check torque using an accurate torque wrench to apply maximum torque value shown. DO NOT EXCEED MAXIMUM TORQUE. Exceeding max- imum torque may cause failure of fastener.
Page 41 SECURING BOOM & ATTACHMENT FOR TRAVEL IF YOU GET STUCK If unit becomes stuck in soft ground you can use the rear to prevent tipping) and imbed bucket in ground. boom to help free it. While actuating travel joystick in appropriate direc- Position carrier and upperstructure controls for tion, extend or retract boom as required to help push remote control operation.
Page 42 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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