Gradall XL3100III Instruction Manual

Operator & Safety
Manual
Keep this manual with machine at all times.
XL3100III - XL4100III - XL5100III
(4x2) S/N 3120000116 & After; including 3120000103
(4x4) S/N 3140000231 & After
(6x4) S/N 4100000224 & After; including 4100000188
(6x6) S/N 4160000026 & After
S/N 5100000540 & After
80854002
Revised
February 23rd, 2021

IMPORTANT! - If printed, or downloaded in electronic format, this is an
uncontrolled copy of the manual.
The current version can be viewed/downloaded 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
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Revision Log REVISION LOG
July 23rd, 2010 - A - Original Issue of Manual
November 20th, 2013 - B - Added Battery Spec to Section 7
October 25th, 2017 - C - 80854002_Revisions_RevC
December 7th, 2018 - D - Op Manual Revision Log.xlsx
February 23rd, 2021 - E - Op Manual Revision Log.xlsx

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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
• AEM Hydraulic Excavator Safety Manual
• All instructional decals and plates
• Any optional equipment instructions furnished
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
Service Manual..............................................................80854003
Illustrated Parts Manual.................................................80854001

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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
Upperstructure Decal Locations .................................................2-5
Undercarriage Decal Locations ..................................................2-7
2.4 Undercarriage Cab Components ................................................2-10
2.5 Undercarriage Cab Controls & Indicators....................................2-12
Dash Panel ..............................................................................2-12
Right Hand Dash Panel............................................................2-13
Travel/Remote Display Area.....................................................2-14
Information Display Area ..........................................................2-15
Ignition......................................................................................2-17
Turn Signal/High Beam/Hazards Lever....................................2-18
2.6 Upperstructure Cab Components ...............................................2-20
2.7 Upperstructure Cab Controls & Indicators...................................2-22
Electronic Monitoring Unit.........................................................2-22
Right Hand Arm Pod.................................................................2-24
Left Hand Arm Pod...................................................................2-26
Joystick Control Pattern Selection............................................2-28
Table of Contents

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Joystick Controls...................................................................... 2-30
Operator Seat Adjustments...................................................... 2-34
Ignition......................................................................................2-35
Intermittent Wiper/Washer .......................................................2-36
Park Brake Switch.................................................................... 2-37
Section 3 - Operation
3.1 Travel Mode Engine Operation..................................................... 3-1
Starting Engine from Undercarriage Cab................................... 3-1
Normal Engine Operation........................................................... 3-1
Cold Weather Starting Aids........................................................ 3-2
3.2 Checks Before Undercarriage Operation...................................... 3-3
3.3 Travel Mode Brake System .......................................................... 3-4
Service Brake............................................................................. 3-5
Emergency Brake....................................................................... 3-6
Parking Brake............................................................................. 3-8
3.4 Travel Mode Power Train ........................................................... 3-10
Shifting Gears .......................................................................... 3-10
3.5 Travel Mode Engine Shutdown................................................... 3-17
3.6 Remote Control Preparation....................................................... 3-18
Preparing Undercarriage for Remote Control Operation..........3-18
Preparing Upperstructure for Remote Control Operation......... 3-18
3.7 Checks Before Remote Control Operation.................................3-19
3.8 Remote Mode Brake System......................................................3-20
Remote Control Braking...........................................................3-20
Digging Brake........................................................................... 3-21
3.9 Remote Mode Power Train.........................................................3-22
Driving Undercarriage from Upperstructure Cab...................... 3-22
Shifting Gears While in Remote Control ..................................3-23
3.10 Steering System .........................................................................3-24
3.11 Typical Dig Cycle........................................................................ 3-25
Standard SAE Boom and Attachment Functions ..................... 3-25
3.12 Lifting & Placing a Load..............................................................3-31
Precautions.............................................................................. 3-31
General .................................................................................... 3-32
Positioning Machine For A Lift ................................................. 3-32
Planning A Lift.......................................................................... 3-33
3.13 Lift Capacity................................................................................ 3-34
3.14 Remote Mode Engine Shutdown................................................ 3-36
3.15 Return to Travel Mode................................................................3-37
Preparing Upperstructure for Undercarriage Operation........... 3-37
Preparing Undercarriage for Conventional Operation..............3-37
Boom Stow Procedure............................................................. 3-38
Securing Unit for Driving.......................................................... 3-38

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3.16 Parking the Excavator.................................................................3-39
Precaution ................................................................................3-39
Parking Procedure....................................................................3-39
3.17 Preservation & Storage...............................................................3-40
Maintenance.............................................................................3-40
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
Trenching Buckets......................................................................4-3
Pavement Removal Bucket ........................................................4-3
Dredging Bucket.........................................................................4-4
Grading Blade.............................................................................4-4
4.4 Adapter Attachment Installation ....................................................4-5
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
Daily or Shift (10 Hour Maximum) Maintenance Schedule.........5-3
Weekly (50 Hour Maximum) Maintenance Schedule..................5-4
Monthly (125 Hour Maximum) Maintenance Schedule...............5-5
1st 30 Days (250 hrs Max) & 250 Hour Maintenance Schedule.5-6
400 Hour Maintenance Schedule ...............................................5-7
Semi-Annual (750 Hour Maximum) Maintenance Schedule.......5-8
Annual (1500 Hour Maximum) Maintenance Schedule..............5-9
5.4 Undercarriage Lubrication Schedules.........................................5-10
Monthly (125 Hour Maximum) Lubrication Schedule - XL3100III....
5-10
Monthly (125 Hour Maximum) Lubrication Schedule -
XL4100III & XL5100III...................................................5-12
Semi-Annual (750 Hour Maximum) Lubrication Schedule -
XL3100III.......................................................................5-14
Semi-Annual (750 Hour Maximum) Lubrication Schedule -
XL4100III & XL5100III...................................................5-16
5.5 Upperstructure Lubrication Schedules........................................5-18
Daily or Shift (10 Hour Maximum) Lubrication Schedule..........5-18
Weekly (50 Hour Maximum) Lubrication Schedule...................5-19
Annual (1500 Hour Maximum) Lubrication Schedule...............5-20
5.6 Operator Maintenance Instructions.............................................5-21

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10 Hours...................................................................................5-21
50 Hours...................................................................................5-30
125 Hours.................................................................................5-34
750/1500 Hours........................................................................5-36
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
Tires........................................................................................... 7-3
Battery........................................................................................ 7-3
Weight........................................................................................ 7-4
Dimensions ................................................................................ 7-5
7.2 Torque Chart.................................................................................7-6
7.3 Fuses............................................................................................7-9
Upperstructure ........................................................................... 7-9
Undercarriage ............................................................................ 7-9
Index