Gradall XL3100V Instruction Manual

Operator & Safety
Manual
Keep this manual with machine at all times.
XL3100V - XL4100V - XL5100V
XL4130V
(4x2) S/N 3120000375 & After
(4x4) S/N 3140000378 & After
(6x4) S/N 4140000100 & After
(Railgear) S/N 4140R00100 & After
(Railgear) S/N 4130R00100 & After
(6x6) S/N 4160000088 & After
(6x4) S/N 5140000100 & After
(6x6) S/N 5160000100 & After
80884013
Revised
December 7th, 2018
This manual, and all manuals for the Gradall Hydraulic
Excavator product line, can be viewed or downloaded, free-of-charge, at
www.mygradall.com
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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.
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Revision Log
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Revision Log
REVISION LOG
February 12th, 2016 - A - Original Issue of Manual
April 14th, 2016 - B - Added battery shutdown warning
January 6th, 2017 - C - Added description to chassis lube points in Section 5.
Revised Upper Cab Heater Spec. Added XL4100V & XL5100V Weight & Dimension
Specs.
December 7th, 2018 - D - Op Manual Revision Log
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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, or access the most recent version of this manual at
www.mygradall.com.
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
Illustrated Parts Manual.................................................80884012
Service Manual .............................................................80884014
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Read This First
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NOTES:
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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 Transmission Shift Selector ........................................................2-12
Prognostic Features .................................................................2-13
Accessing Prognostics..............................................................2-14
Resetting Prognostics...............................................................2-15
Checking Fluid Levels...............................................................2-16
Diagnostic Codes .....................................................................2-18
Diagnostic Transmission Codes...............................................2-19
2.6 Undercarriage Cab Controls & Indicators....................................2-22
Dash Panel ..............................................................................2-22
Right Hand Dash Panel............................................................2-23
Travel/Remote Display Area.....................................................2-24
Information Display Area ..........................................................2-25
Ignition......................................................................................2-27
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Turn Signal/High Beam/Hazards Lever....................................2-28
2.7 Upperstructure Cab Components............................................... 2-30
2.8 Upperstructure Cab Controls & Indicators.................................. 2-32
Electronic Monitoring Unit........................................................ 2-32
Right Hand Arm Pod ................................................................ 2-34
Left Hand Arm Pod...................................................................2-36
Joystick Control Pattern Selection ........................................... 2-38
Joystick Controls...................................................................... 2-39
Operator Seat Adjustments......................................................2-43
Ignition......................................................................................2-44
Intermittent Wiper/Washer ....................................................... 2-45
Park Brake Switch....................................................................2-46
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...................................................3-14
3.6 Remote Control Preparation....................................................... 3-15
Preparing Undercarriage for Remote Control Operation..........3-15
Preparing Upperstructure for Remote Control Operation.........3-15
3.7 Checks Before Remote Control Operation................................. 3-16
3.8 Remote Mode Brake System......................................................3-17
Remote Control Braking........................................................... 3-17
Digging Brake........................................................................... 3-18
3.9 Remote Mode Power Train.........................................................3-19
Driving Undercarriage from Upperstructure Cab...................... 3-19
Shifting Gears While in Remote Control .................................. 3-20
3.10 Steering System .........................................................................3-21
3.11 Typical Dig Cycle........................................................................3-22
Standard SAE Boom and Attachment Functions .....................3-22
3.12 Lifting & Placing a Load..............................................................3-28
Precautions .............................................................................. 3-28
General .................................................................................... 3-29
Positioning Machine For A Lift ................................................. 3-29
Planning A Lift..........................................................................3-30
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3.13 Lift Capacity ................................................................................3-31
3.14 Remote Mode Engine Shutdown ................................................3-33
3.15 Return to Travel Mode ................................................................3-34
Preparing Upperstructure for Undercarriage Operation............3-34
Preparing Undercarriage for Conventional Operation ..............3-34
Boom Stow Procedure..............................................................3-35
Securing Unit for Driving...........................................................3-35
3.16 Parking the Excavator.................................................................3-36
Precaution ................................................................................3-36
Parking Procedure....................................................................3-36
3.17 Preservation & Storage...............................................................3-37
Maintenance.............................................................................3-37
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
500 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 - XL3100V.....
5-10
Monthly (125 Hour Maximum) Lubrication Schedule -
XL4100V & XL5100V....................................................5-12
Semi-Annual (750 Hour Maximum) Lubrication Schedule -
XL3100V .......................................................................5-14
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Semi-Annual (750 Hour Maximum) Lubrication Schedule -
XL4100V & XL5100V....................................................5-16
5.5 Upperstructure Lubrication Schedules........................................ 5-18
Daily or Shift (10 Hour Maximum) Lubrication Schedule .........5-18
Annual (1500 Hour Maximum) Lubrication Schedule...............5-19
5.6 Operator Maintenance Instructions............................................. 5-20
10 Hours...................................................................................5-20
50 Hours...................................................................................5-25
100 Hours.................................................................................5-27
750 Hours.................................................................................5-29
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 ................................................................................ 7-4
7.2 Torque Chart................................................................................. 7-6
7.3 Fuses............................................................................................ 7-9
Upperstructure ........................................................................... 7-9
Undercarriage ............................................................................ 7-9
Index
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Section 1 - General Safety Practices
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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
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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
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Section 1 - General Safety Practices
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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
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Section 1 - General Safety Practices
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• 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
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Section 1 - General Safety Practices
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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
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Section 1 - General Safety Practices
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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
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• 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
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Section 1 - General Safety Practices
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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.
•Maintain proper tire pressure at all times.
• Inspect brakes before driving undercarriage after digging. See page 3-34 for
details.
• 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
OH2291