Gradall XL4000 User manual

July, 2002
EXCAVATOR TECHNICAL
MANUAL
GRADALL
406 Mill Avenue, S.W.
New Philadelphia, OH, 44663, USA
Telephone: [phone]
Fax: [phone]
VOLUME 2
2460-4144
XL4000 Starting
S/N 0415225/0428225
XL5000 Starting
S/N 0518110/0526110

HYDRAULIC EXCAVATORS
GRADGRAD
GRADGRAD
GRADALLALL
ALLALL
ALL
®
Form No. 29703
Issued 8/98

The following symbols are used to call your attention to softly notices:
This symbol indicates an extreme hazard which would result in high probability of death or serious injury
if proper precautions are not taken.
This symbol indicates a hazard which could result in death or serious injury if proper precautions are not taken.
This symbol indicates a hazard which could result in injury or damage to equipment or property if proper
precautions are not taken.
I. Introduction
Read and understand this Manual, along with the appropriate Upperstructure and Carrier Owner /Operator Manual, EMI Excavator 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. Keep operator and safety manuals in cab.
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!DANGER
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!WARNING
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!CAUTION
Read and understand all manuals listed above. Be sure you are familiar with machine response to controls.
Read and understand all material relating to the circuit to be checked. Be sure you understand circuit to be checked.
Always relieve trapped pressure before opening or disconnecting any portion of a hydraulic circuit. Oil at operating temperature can
cause serious burns. Oil released at operating temperature, as well as trapped pressure, can cause serious injury or death.
If you are working with a helper, be sure they understand the procedure. Be certain each of you knows what to expect from the other
and when to expect it. Make sure each of you knows where the other is at all times.
Be sure you understand all steps of the procedure before testing and/or adjusting any circuit. Follow the procedure carefully.
Always wear safety glasses when performing testing and adjusting procedures.
Clean up oil spills immediately. Slippery surfaces can cause serious accidents.
Always make sure engine RPM is correct before performing testing and adjusting procedures.
Always make sure hydraulic oil level in reservoir is correct and that oil is at normal operating temperature before testing
and adjusting circuits.
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Safe operation depends on reliable equipment and proper operating procedures. Performing the checks and services described in this Manual will keepyour
GRADALL XL 4100/XL 5100 Excavator in reliable condition. Use of the recommended operating procedures can help you avoid accidents.Because some procedures may
be new to even the experienced technician, we recommend that this manual be read, understood and followed by all who service this unit. ! DANGER, ! WARNING
and ! CAUTION notes in this Manual will help you avoid injury and damage to the equipment. These notes are not intended to cover all eventualities. It is
impossible to anticipate and evaluate all possible applications and methods of operation for this equipment. Any procedure not specifically recommended by
GRADALL must be thoroughly evaluated from the standpoint of safety before it is placed in practice. If you are not sure, contact your GRADALL Distributor before
operating. Do not modify this machine without written permission from GRADALL.
Testing & Adjusting Precautions
Form No. 29703
Important Safety Notice

Hydraulic System:
The XL 4100 and XL 5100 Remote Control Gradall Hydraulic System is designed for efficient operation with a
minimum amount of wear to related system components. Air from an electric compressor and from the engine
intake manifold pressurizes the hydraulic system to 6-8 PSI. A 120 PSI backpressure valve is located in the main
control valve banks return line. These features ensure fluid is always present to components when required.
DO NOT OPEN the hydraulic reservoir without relieving air pressure. Serious injury could result from being
sprayed with hot hydraulic fluid. Hydraulic fluid temperature is controlled by a cooler circuit which maintains the
fluid temperature approximately 100° above ambient temperature. Individual hydraulic components and circuitry
will be explained in this Manual.
The primary circuits of the GRADALL XL Series Crawler -Mounted Excavator are as follows:
Main pump: Work circuits whose fluid is supplied by the main hydraulic pumps
Pilot Pump: Control circuits whose fluid is supplied by the pilot pump
Recirculating Pump: Cooling circuit directing a constant flow of fluid through the cooler
Swing Pump: Closed loop circuit separate from the main pump circuit
Hydraulic fluid: Use only specified hydraulic fluid in the Gradall. Use of fluids other than those which meet
specifications will seriously damage the hydraulic components, resulting in expensive failure or machine
downtime. Approved fluids are: Hydraulic Oil: M
bilfluid®424 or Citgo Tractor Hyd. Fluid #33310.
Fire-Resistant Fluid: Quaker Chemical Quintolubric 822-300. Do Not use any other fluid without first
receiving approval from your GRADALL Distributor or the GRADALL factory. Fluid specifications are listed in the
lubrication chart on your machine and the decal on the fluid reservoir of the upperstructure.
Add additional fluid through the main reservoir return filter when topping up the system. If the reservoir has
been drained, follow START-UP PROCEDURE. See Section VII, Main Hydraulic Pump.
Hydraulic System logic is determined by the following: Load Sense Control which regulates standby pressure.
High Pressure Cutoff which senses pressure above 5000 PSI then reduces pressure by destroking the pump.
Horsepower Control which does not let the engine draw down below 1900 RPM when all circuits are activated
at the same time.
If repairs or adjustments to the hydraulic system become necessary, we recommend you contact your GRADALL
Distributor to have this work done by a qualified GRADALL technician.
See Appendix B & Appendix C for circuit operating times.
II. Hydraulic System - General
3XL 4100/XL 5100 HYDRAULIC SYTEM OPERATIONS MANUALForm No. 29703