Gradall D152 Instruction Manual

Operator & Safety
Manual
Keep this manual with machine at all times.
D152/D154
S/N D152000001 & After
S/N D154000001 & After
82104002
Revised
February 10th, 2020
This manual, and all manuals for the Gradall Hydraulic
Excavator product line, can be viewed or downloaded, free-of-charge, at
www.mygradall.com

IMPORTANT! - If printed, or downloaded in electronic format, this is an
uncontrolled copy of the manual. The current version can be viewed/down-
loaded at www.mygradall.com
Gradall is a registered trademark for hydraulic excavators, industrial
maintenance machines, attachments and other components
manufactured and marketed by Gradall Industries, Inc.

Revision Log
a82104002
Revision Log REVISION LOG
August 31st, 2015 - A - Original Issue of Manual
November 5th, 2015 - B - Added Section 5; Swing Brake Spec to Section 7
March 8th, 2016 - C - Revised torque specs on page 5-5; added torque spec for
D154. Revised D152 specs on page 7-2; added specs for D154.Added s/n range for
PTO indicator on page 2-13.
October 12th, 2016 - D - Revised control scheme on pages 2-18, 2-19, 2-20 & 3-10.
Revised dig brake application parameters on page 3-4. Revised remote driving
procedure on pages 3-6 thru 3-8.
February 10th, 2020 - E- Op Manual Revision Log

Read This First
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Read This First
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and
lessees with the precautions and operating procedures essential for the safe and
proper machine operation for its intended purpose.
Due to continuous product improvements, Gradall Industries, Inc. reserves the right
to make specification changes without prior notification. Contact Gradall Industries,
Inc. for updated information.
Operator Qualifications
The operator of the machine must not operate or drive the machine until this manual
has been read, training is accomplished and operation of the machine has been
completed under the supervision of an experienced and qualified instructor.
Operators of this equipment must possess a valid, applicable driver’s license, be in
good physical and mental condition. Operator must not be using medication which
could impair abilities nor be under the influence of alcohol or any other intoxicant
during the work shift.
In addition, the operator must read, understand and comply with instructions
contained in the following material furnished with the hydraulic excavator:
• This Operator & Safety Manual
• AEM Off-Highway Dump Truck Manual
• EMI Hydraulic Excavator Safety Manual
• All instructional decals and plates
• Any optional equipment instructions furnished
• OEM Chassis Manual
The operator must also read, understand and comply with all applicable Employer,
Industry and Governmental rules, standards and regulations.
If any manual is missing or illegible, get a replacement from your employer,
distributor, or from Gradall Industries.
Modifications
Any modification to Gradall products must be approved by Gradall.

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This product must comply with all safety related bulletins. Contact Gradall Industries,
Inc. or the local authorized Gradall representative for information regarding safety-
related bulletins which may have been issued for this product.
Gradall Industries, Inc. sends safety related bulletins to the owner of record of this
machine. Contact Gradall Industries, Inc. to ensure that the current owner records
are updated and accurate.
Gradall Industries, Inc. must be notified immediately in all instances where Gradall
products have been involved in an accident involving bodily injury or death of
personnel or when damage has occurred to personal property or the Gradall
product.
FOR:
• Accident Reporting and Product Safety Publications
• Current Owner Updates
• Questions Regarding Product Applications and Safety
• Standards and Regulations Compliance Information
• Questions Regarding Product Modifications
CONTACT:
Product Safety and Reliability Department
Gradall Industries, Inc.
406 Mill Avenue
New Philadelphia, OH 44663
Phone: [phone]
Toll-Free: 1-800-445-4752
Other Publications Available
Illustrated Parts Manual.................................................82104001
Service Supplement......................................................82104003

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NOTES:

Table of Contents
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TABLE OF CONTENTS
Revision Log
Read This First
Operator Qualifications..............................................................................b
Modifications .............................................................................................b
Other Publications Available .....................................................................c
Table of Contents
Section 1 - General Safety Practices
1.1 Hazard Classification System........................................................1-1
Safety Alert System and Safety Signal Words............................1-1
1.2 General Precautions .....................................................................1-1
1.3 Operation Safety ...........................................................................1-2
Electrical Hazards.......................................................................1-2
Swing Hazards ...........................................................................1-3
Slip and Fall Hazard ...................................................................1-5
Crush Hazards............................................................................1-6
Travel Hazards - Remote and Driving ........................................1-8
Tip Over Hazard .........................................................................1-9
Chemical Hazards ....................................................................1-10
Dust Hazard..............................................................................1-12
1.4 Personal Protection Equipment...................................................1-13
Section 2 - Pre-Operation and Controls
2.1 Pre-Operation Checks & Inspection..............................................2-1
2.2 Walk-Around Inspection................................................................2-2
2.3 Safety Decals................................................................................2-5
Decal Locations..........................................................................2-5
2.4 Upperstructure Cab Controls & Indicators.....................................2-8
LCD Display................................................................................2-8
Auxiliary Hydraulics Control (optional)......................................2-14
Left Hand Arm Pod...................................................................2-16
Right Hand Arm Pod.................................................................2-17
Joystick Controls.......................................................................2-19
Operator Seat Adjustments ......................................................2-23
Ignition......................................................................................2-24
Intermittent Wiper/Washer........................................................2-25
Park Brake Switch ....................................................................2-26
Section 3 - Operation
3.1 Remote Control Preparation .........................................................3-1
Preparing Undercarriage for Remote Control Operation............3-1
Preparing Upperstructure for Remote Control Operation...........3-2
3.2 Checks Before Remote Control Operation....................................3-3
Table of Contents

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ii 82104002
Normal Engine Operation........................................................... 3-3
3.3 Remote Mode Brake System........................................................3-4
Remote Control Braking............................................................. 3-4
Digging Brake............................................................................. 3-4
3.4 Remote Mode Power Train........................................................... 3-6
Driving Undercarriage from Upperstructure Cab........................ 3-6
Steering the Undercarriage from Upperstructure Cab ............... 3-9
3.5 Typical Dig Cycle........................................................................ 3-10
Standard SAE Boom and Attachment Functions ..................... 3-10
3.6 Lifting & Placing a Load..............................................................3-16
Precautions.............................................................................. 3-16
General .................................................................................... 3-17
Positioning Machine For A Lift ................................................. 3-17
Planning A Lift.......................................................................... 3-18
3.7 Lift Capacity................................................................................3-19
3.8 Remote Mode Engine Shutdown................................................3-21
3.9 Return to Travel Mode................................................................3-22
Preparing Upperstructure for Undercarriage Operation...........3-22
Boom Stow Procedure............................................................. 3-23
Securing Unit for Driving.......................................................... 3-23
3.10 Parking the Excavator................................................................. 3-24
Precaution................................................................................3-24
Parking Procedure ................................................................... 3-24
3.11 Preservation & Storage...............................................................3-25
Maintenance.............................................................................3-25
Section 4 - Attachments
4.1 Approved Attachments .................................................................4-1
4.2 Unapproved Attachments............................................................. 4-1
4.3 Attachment Operation...................................................................4-1
Excavating Buckets....................................................................4-2
Ditching Buckets ........................................................................ 4-2
Section 5 - Lubrication & Maintenance
5.1 Introduction................................................................................... 5-1
Clothing and Safety Gear........................................................... 5-1
5.2 General Maintenance Instructions................................................5-2
Tire Service................................................................................ 5-2
5.3 Service & Maintenance Schedules............................................... 5-3
10 Hour Maintenance Schedule................................................. 5-3
50 Hour Maintenance Schedule................................................. 5-3
100 Hour Maintenance Schedule............................................... 5-4
1st 30 Days (250 hrs Max) & 250 Hour Maintenance Schedule -
(Upperstructure) ............................................................. 5-4
750 Hour Maintenance Schedule............................................... 5-5

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1500 Hour Maintenance Schedule .............................................5-5
5.4 Upperstructure Lubrication Schedule............................................5-6
5.5 Undercarriage Lubrication Schedule.............................................5-7
Section 6 - Emergency Procedures
6.1 Loss Of Power...............................................................................6-1
Stowing the boom without engine power....................................6-1
To extend the boom without engine power.................................6-1
To raise the boom without engine power....................................6-1
Towing........................................................................................6-2
If You Get Stuck .........................................................................6-2
Section 7 - Specifications
7.1 Product Specifications...................................................................7-1
Lubrication & Fluid Capacities....................................................7-1
Weight ........................................................................................7-2
Dimensions.................................................................................7-2
7.2 Torque Chart.................................................................................7-3
7.3 Fuses ............................................................................................7-6
Upperstructure............................................................................7-6
Undercarriage.............................................................................7-6
Index

Table of Contents
iv 82104002

Section 1 - General Safety Practices
1-182104002
SECTION 1 - GENERAL SAFETY PRACTICES
1.1 HAZARD CLASSIFICATION SYSTEM
Safety Alert System and Safety Signal Words
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury.
1.2 GENERAL PRECAUTIONS
Before operation, read & understand this manual.
Failure to comply with the information in this manual
could result in machine damage, property damage,
personal injury or death.
DANGER
OW0010
WARNING
OW0021
CAUTION
OW0031
WARNING
OW0021

Section 1 - General Safety Practices
1-2 82104002
1.3 OPERATION SAFETY
Electrical Hazards
• This machine is not insulated and does not provide protection from contact or
being near electrical current.
•NEVER operate the excavator in an area where overhead power lines, overhead
or underground cables, or other power sources may exist without ensuring the
appropriate power or utility company de-energizes the lines.
• Always check for power lines before raising boom.
Always “Call Before You Dig”.Contact your local One-Call (811 in USA) or the
One-Call referral number (888-258-0808 in USA and Canada) to have underground
utilities located before digging.
OAC0330
10 FT
(3 M)
OAC1290
811

Section 1 - General Safety Practices
1-382104002
Swing Hazards
• Keep others away from machine while in operation. Ensure others are clear of
the swing radius prior to swinging upperstructure.
• Never carry a water can, equipment, or other worker’s tools or personal items on
the machine.
• Never permit anyone close enough to machine to become trapped between
undercarriage and upperstructure.
• Position machine to prevent possibility of a person being crushed between
counterweight and another object.
• Do not allow anyone inside the cab(s) (other than the operator) while in
operation.
• Always be careful when using mirrors; distances are distorted and field of view is
limited, especially when swinging. Always use a signal person when working in
tight quarters.
• Be aware of undercarriage cab, if equipped, and undercarriage components
when swinging upperstructure or digging. Position unit so that it won’t be
necessary to swing boom close to cab or undercarriage components.
OAC0340

Section 1 - General Safety Practices
1-4 82104002
• The circle of safety is a circle around the excavator with the boom at full
extension.
• Establish and inform others of the circle of safety. Keep others from entering into
the circle of safety.
OAC1240

Section 1 - General Safety Practices
1-582104002
Slip and Fall Hazard
• Always maintain 3-point contact using proper hand holds and steps provided
when mounting or dismounting. Never grab control levers or steering wheel
when mounting or dismounting machine.
• Repair or replace damaged steps and grab handles.
• Keep grab handles, steps, and walkways free of mud, oil, grease and other
foreign material. Replace non-skid surface material as required.
• Do not get off machine until shutdown procedure has been performed.
• Align upperstructure with undercarriage before dismounting.
•Keep others off machine while in operation.
• Do not lift personnel with this machine.
OAC0350
OAC0360

Section 1 - General Safety Practices
1-6 82104002
Crush Hazards
• Do not lean on boom or reach into boom holes, bucket linkage or boom rollers
until the attachment or boom is resting on the ground and the engine is stopped.
• Be sure all access covers are in the fully open position before performing any
procedures inside compartments.
• Stay clear of moving parts while engine is running.
• Rotation of undercarriage cab steering wheel will occur during remote steering
operation. Do not occupy undercarriage cab during remote operation.
OAC1250
OAC0570

Section 1 - General Safety Practices
1-782104002
• Never permit anyone under boom, attachment or load. Rest boom or attachment
on ground and stop engine before permitting anyone to work beneath boom or
behind cradle.
OAC1020

Section 1 - General Safety Practices
1-8 82104002
Travel Hazards - Remote and Driving
• Look out for and avoid other personnel, machinery and vehicles in the area. Use
a spotter if you do not have a clear view.
•Before moving be sure of a clear path for undercarriage, boom and
counterweight and sound horn.
•Always look in the direction of travel.
•Before remote travel, check to be sure you are aware of orientation of
upperstructure with regard to undercarriage. Confusion could cause travel in
the opposite direction you may expect.
• Always wear seat belt.
• Keep head, arms and other body parts inside cab at all times.
• When machine is operating or driving on public roadways, comply with all
local, state and federal restrictions.
•When driving, ensure boom and attachment are properly secured and
positioned for maximum visibility and adequate clearances. Know the overall
height of the machine.
•Always check overhead and side boom clearances carefully before driving.
Position attachment/load to clear obstacles.
• Never drag boom or attachment while moving unit.
OAC0710
OH20911

Section 1 - General Safety Practices
1-982104002
Tip Over Hazard
• Understand how to properly use the capacity chart located in cab. Do not
exceed rated lift capacity. Plan the lift to be sure it can be performed safely.
• Maintain proper tire pressure at all times.
• Do not depend on machine tipping as a warning of overload. Some load ratings
are based on hydraulic lift capacity, not stability.
• Do not increase hydraulic relief settings to lift a load.
• Sudden swing braking can cause unexpected movement of the load and tip the
machine.
• Tether suspended loads to restrict movement.
• Never pass load line over open bucket. Relief valves in bucket circuit could
cause unexpected, dangerous movement of the load. Bucket linkage could also
be damaged.
• Be sure the surface excavator is on is firm enough to support unit and allows for
adequate traction.
• Select low travel speed for off-highway grade travel. See “LCD Display” on
page 2-8.
• Do not travel over excessively steep slopes or excessively rough terrain.
• No load in bucket, attached to boom or any other part of machine during off-
highway grade travel.
• Front axle lock cylinders automatically unlock during travel. Do not travel with
load over side.
• Shutting off engine will cause front axle lock cylinders to unlock. Place load on
ground before shutting off engine.
OAC0670

Section 1 - General Safety Practices
1-10 82104002
Chemical Hazards
Exhaust Fumes
•DO NOT operate machine in an enclosed area without proper ventilation.
•DO NOT operate the machine in hazardous environments unless approved for
that purpose by Gradall and site owner. Sparks from the electrical system and
the engine exhaust can cause an explosion.
• If spark arrestors are required, be sure they are in place and in good working
order.
Flammable Fuel
•DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or
smoking materials. Engine fuel is flammable and can cause a fire and/or
explosion.
Operating, servicing and maintaining this equipment
can expose you to chemicals including gasoline, diesel
fuel, lubricants, petroleum products, engine exhaust,
carbon monoxide, and phthalates, which are known to
the State of California to cause cancer and birth
defects or other reproductive harm. To minimize exposure, avoid breathing exhaust,
do not idle the engine except as necessary, service your vehicle in a well-ventilated
area and wear gloves or wash your hands frequently when servicing your vehicle.
Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the state of California to cause cancer, birth defects or other
reproductive harm. For more information go to www.P65Warnings.ca.gov. This
website, operated by California's Office of Environmental Health Hazard
Assessment, provides information about these chemicals and how individuals may
be exposed to them.
OW0300
WARNING
OW0021