operator & safety manual - gradall excavator...

Operator & SafetyManual

Keep this manual with machine at all times

XL3300III - XL4300III - XL5300IIIXL3310III - XL4310III - XL5310IIIXL3320III - XL4320III - XL5320III

S/N 3300000679 & After

S/N 4300000043 & After

S/N 5300000001 & After

S/N 3310000001 & After

S/N 4310000002 & After

S/N 5310000001 & After

S/N 3320000001 & After

S/N 4320000001 & After

S/N 5320000001 & After

80644002

RevisedNovember 20th, 2013

Gradall is a registered trademark for hydraulic excavators, industrial maintenance machines, attachments and other components

manufactured and marketed by Gradall Industries, Inc.

CALIFORNIA PROPOSITION 65

BATTERY WARNINGBattery posts,

terminals and relatedaccessories contain

lead and lead compounds,chemical known to the

State of Californiato cause cancer andreproductive harm.

WASH HANDSAFTER HANDLING!

CALIFORNIA PROPOSITION 65

EXHAUST WARNINGDiesel Engine exhaust and some of its constituents are known to the State of

California to cause cancer, birth defects and other

reproductive harm.

Revision Log

Revision Log REVISION LOGFebruary 4th, 2011 - A - Original Issue of ManualJuly 20th, 2012 - B - Revised ManualNovember 20th, 2013 - C - Revised Manual

a80644002

Read This First

Read This FirstThis 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, andlessees with the precautions and operating procedures essential for the safe andproper machine operation for its intended purpose.

Due to continuous product improvements, Gradall Industries, Inc. reserves the rightto 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 manualhas been read, training is accomplished and operation of the machine has beencompleted under the supervision of an experienced and qualified instructor.

Operators of this equipment must possess a valid, applicable driver’s license, be ingood physical and mental condition. Operator must not be using medication whichcould impair abilities nor be under the influence of alcohol or any other intoxicantduring the work shift.

In addition, the operator must read, understand and comply with instructionscontained 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.

b 80644002

Read This First

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 thismachine. Contact Gradall Industries, Inc. to ensure that the current owner recordsare updated and accurate.

Gradall Industries, Inc. must be notified immediately in all instances where Gradallproducts have been involved in an accident involving bodily injury or death ofpersonnel or when damage has occurred to personal property or the Gradallproduct.

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 DepartmentGradall Industries, Inc.406 Mill AvenueNew Philadelphia, OH 44663Phone: 330-339-2211Toll-Free: 1-800-445-4752

Other Publications Available

Service Manual .............................................................80644003

Illustrated Parts Manual.................................................80644001

c80644002

Read This First

NOTES:

d 80644002

Table of ContentsTable of Contents

TABLE OF CONTENTSRevision Log

Read This FirstOperator Qualifications ......................................................bModifications ......................................................................bOther Publications Available .............................................. c

Table of Contents

Section 1 - General Safety Practices1.1 Hazard Classification System ..............................................1-1

Safety Alert System and Safety Signal Words................1-11.2 General Precautions ............................................................1-11.3 Operation Safety..................................................................1-2

Electrical Hazards ...........................................................1-2Swing Hazards................................................................1-3Slip and Fall Hazard........................................................1-5Crush Hazards ................................................................1-6Travel Hazards................................................................1-8Tip Over Hazard..............................................................1-9Chemical Hazards.........................................................1-10Dust Hazard ..................................................................1-12

1.4 Personal Protection Equipment .........................................1-13

Section 2 - Pre-Operation and Controls2.1 Pre-Operation Checks & Inspection.....................................2-12.2 Walk-Around Inspection.......................................................2-22.3 Safety Decals - XL3300III, XL4300III & XL5300III ...............2-4

Decal Locations ..............................................................2-42.4 Safety Decals - XL3300III, XL4300III & XL5300III (CE).......2-6

Decal Locations ..............................................................2-62.5 Safety Decals - XL3310III, XL4310III, XL5310III,

XL3320III, 4320III & XL5320III2-8Decal Locations ..............................................................2-8

2.6 Safety Decals - XL3310III, XL4310III, XL5310IIIXL3320III, XL4320III & XL5320III (CE)2-10

Decal Locations ............................................................2-102.7 Cab Components...............................................................2-122.8 Cab Controls & Indicators..................................................2-14

Electronic Monitoring Unit .............................................2-14Electronic Monitoring Unit Digital Display .....................2-16Right Hand Arm Pod .....................................................2-22Left Hand Arm Pod .......................................................2-24Joystick Control Pattern Selection ................................2-26

i80644002

Table of Contents

Joystick Controls .......................................................... 2-27Operator Seat Adjustments .......................................... 2-31Ignition .......................................................................... 2-32Intermittent Wiper/Washer............................................ 2-33Park Brake Switch ........................................................ 2-34

Section 3 - Operation3.1 Engine Operation ................................................................ 3-1

Starting Engine............................................................... 3-1Normal Engine Operation ............................................... 3-1Cold Weather Starting Aids ............................................ 3-2

3.2 Checks Before Operation .................................................... 3-33.3 Brake System...................................................................... 3-43.4 Travel Modes....................................................................... 3-6

Moving Machine Less than 4.6m (5 yds)........................ 3-6Performing Grading Operations...................................... 3-7Moving Machine to a Different Worksite......................... 3-7Over-the-Road Travel..................................................... 3-8

3.5 Typical Dig Cycle............................................................... 3-10Standard SAE Boom and Attachment Functions.......... 3-10

3.6 Lifting & Placing a Load - XL3300III, XL4300III & XL5300III....3-16

Precautions................................................................... 3-16General......................................................................... 3-17Positioning Machine For A Lift...................................... 3-17Planning A Lift .............................................................. 3-18Carrying a Load............................................................ 3-19Delivering a Load.......................................................... 3-19

3.7 Lift Capacity - XL3300III, XL4300III & XL5300III............... 3-203.8 Engine Shutdown .............................................................. 3-223.9 Parking the Excavator ....................................................... 3-23

Precaution .................................................................... 3-23Parking Procedure........................................................ 3-23

3.10 Preservation & Storage ..................................................... 3-24Maintenance................................................................. 3-24

3.11 Rail Gear Operation (Optional).......................................... 3-25

Section 4 - Attachments4.1 Approved Attachments ........................................................ 4-14.2 Unapproved Attachments.................................................... 4-14.3 Attachment Operation ......................................................... 4-1

Excavating Buckets ........................................................ 4-2Ditching Buckets............................................................. 4-2Trenching Buckets.......................................................... 4-3Pavement Removal Bucket ............................................ 4-3

ii 80644002

Table of Contents

Dredging Bucket .............................................................4-4Grading Blade .................................................................4-4

4.4 Adapter Attachment Installation...........................................4-5

Section 5 - Lubrication & Maintenance5.1 Introduction ..........................................................................5-1

Clothing and Safety Gear................................................5-15.2 General Maintenance Instructions .......................................5-2

Tire Service.....................................................................5-25.3 Service & Maintenance Schedules ......................................5-3

10 Hour Maintenance Schedule......................................5-350 Hour Maintenance Schedule......................................5-4100 Hour Maintenance Schedule....................................5-51st 30 Days (250 hrs Max) & 250 Hour Maintenance Sched-ule ...................................................................................5-6600 Hour Maintenance Schedule....................................5-7750 Hour Maintenance Schedule....................................5-81500 Hour Maintenance Schedule..................................5-9

5.4 Lubrication Schedules .......................................................5-1010 Hour Lubrication Schedule.......................................5-1050 Hour Lubrication Schedule.......................................5-11100 Hour Lubrication Schedule.....................................5-12

Section 6 - Emergency Procedures6.1 Loss Of Power .....................................................................6-16.2 If You Get Stuck...................................................................6-16.3 Towing the machine.............................................................6-3

Section 7 - Specifications7.1 Product Specifications .........................................................7-1

Lubrication & Fluid Capacities ........................................7-1Tires ................................................................................7-2Battery.............................................................................7-3Weight.............................................................................7-3Dimensions .....................................................................7-4

7.2 Torque Chart........................................................................7-67.3 Fuses ...................................................................................7-8

Index

iii80644002

Table of Contents

iv 80644002

Section 1 - General Safety Practices

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, willresult in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, couldresult in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, mayresult in minor or moderate injury.

1.2 GENERAL PRECAUTIONSBefore operation, read & understand this manual.Failure to comply with the information in this manualcould result in machine damage, property damage,personal injury or death.

DANGEROW0010

WARNINGOW0021

CAUTIONOW0031

WARNINGOW0021

1-180644002


1.3 OPERATION SAFETY

Electrical Hazards

• This machine is not insulated and does not provide protection from contact orbeing near electrical current.

• NEVER operate the excavator in an area where overhead power lines, overheador underground cables, or other power sources may exist without ensuring theappropriate 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 theOne-Call referral number (888-258-0808 in USA and Canada) to have undergroundutilities located before digging.

OAC0330

10 FT(3 M)

OAC1290

811

1-2 80644002


Swing Hazards

• Keep others away from machine while in operation. Ensure others are clear ofthe swing radius prior to swinging upperstructure.

• Never carry a water can, equipment, or other worker’s tools or personal items onthe machine.

• Never permit anyone close enough to machine to become trapped betweenchassis and upperstructure.

• Position machine to prevent possibility of a person being crushed betweencounterweight and another object.

• Do not allow anyone inside the cab (other than the operator) while in operation.

• Always be careful when using mirrors; distances are distorted and field of view islimited, especially when swinging. Always use a signal person when working intight quarters.

OAC0340

1-380644002


• The circle of safety is a circle around the excavator with the boom at fullextension.

• Establish and inform others of the circle of safety. Keep others from entering intothe circle of safety.

OAC1240

1-4 80644002


Slip and Fall Hazard

• Always maintain 3-point contact using proper hand holds and steps providedwhen mounting or dismounting. Never grab control levers or steering wheel whenmounting or dismounting machine.

• Repair or replace damaged steps and grab handles.

• Keep grab handles, steps, and walkways free of mud, oil, grease and otherforeign material. Replace non-skid surface material as required.

• Do not get off machine until shutdown procedure has been performed.

• Align upperstructure with chassis before dismounting.

• Keep others off machine while in operation.

• Do not lift personnel with this machine.

OAC0350

OAC0360

1-580644002


Crush Hazards

• Do not lean on boom or reach into boom holes, bucket linkage or boom rollersuntil 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 anyprocedures inside compartments.

• Prior to raising or lowering outriggers/blade, sound horn and check mirrors toassure the areas are clear of personnel.

• Stay clear of moving parts while engine is running.

OAC1250

OAC0570

1-6 80644002


• Never permit anyone under boom, attachment or load. Rest boom or attachmenton ground and stop engine before permitting anyone to work beneath boom orbehind cradle.

OAC1020

1-780644002


Travel Hazards

• Look out for and avoid other personnel, machinery and vehicles in the area. Usea spotter if you do not have a clear view.

• Before moving be sure of a clear path for chassis, boom and counterweight andsound horn.

• Always look in the direction of travel.

• Before travel, check to be sure you are aware of orientation ofupperstructure with regard to chassis. Confusion could cause travel in theopposite 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 after digging.

• When driving, ensure boom and attachment are properly secured andpositioned for maximum visibility and adequate clearances. Know the overallheight 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.

��

OH20911OH2291

1-8 80644002


Tip Over Hazard

• Understand how to properly use the capacity chart located in cab. Do notexceed 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 ratingsare 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 themachine.

• Tether suspended loads to restrict movement.

• Never pass load line over open bucket. Relief valves in bucket circuit could causeunexpected, dangerous movement of the load. Bucket linkage could also bedamaged.

• Be sure the surface excavator is on is firm enough to support unit and allows foradequate traction.

• 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.

OAC0670

1-980644002


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 forthat purpose by Gradall and site owner. Sparks from the electrical system andthe engine exhaust can cause an explosion.

• If spark arrestors are required, be sure they are in place and in good workingorder.

Flammable Fuel

• DO NOT fill the fuel tank or service the fuel system near an open flame, sparksor smoking materials. Engine fuel is flammable and can cause a fire and/orexplosion.

OW0300

1-10 80644002


Hydraulic Fluid

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paperto search for leaks. Wear appropriate equipment to protect yourself from sprayingfluid. If fluid is injected into the skin seek medical attention immediately.

• Stop engine and relieve trapped pressure before loosening any hydraulic fitting.Hydraulic oil is under enough pressure that it can penetrate the skin.

• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while theengine is running or when the hydraulic system is pressurized.

• Relieve pressure from the hydraulic reservoir using the vent valve near thereservoir breather before loosening the filter lid or cover.

OAC1260

OAC0960

1-1180644002


Battery

• Keep sparks, flames and lighted material away from batteries. Explosive gasescould cause death or serious injury.

Dust Hazard

• Repeated or substantial breathing of hazardous dusts, including crystalline silica,could cause fatal or serious respiratory disease including silicosis. Concrete,masonry, many types of rock, and various other materials contain silica sand.California lists respirable crystalline silica as a substance known to cause cancer.Operation of this equipment under certain conditions may generate airborne dustparticles that could contain crystalline silica. In those conditions personalprotective equipment including an appropriate respirator must be used. Ifexcessive dust is generated, a dust collection or suppression system should alsobe used during operation.

OAC1270

OAC0660

1-12 80644002


1.4 PERSONAL PROTECTION EQUIPMENTWear all the protective clothing and personal safety devices issues to you or calledfor by job conditions. You may need:

• Hard hat

• Safety shoes

• Safety glasses, goggles or face shield

• Heavy gloves

• Hearing protection

• Reflective clothing

• Wet weather gear

• Respirator or filter mask

Wear adequate clothing for the job conditions.

Always know where to get assistance in the case of an emergency. Know where tofind and how to use a first aid kit and fire extinguisher/fire suppression system.

1-1380644002


NOTES:

1-14 80644002

Section 2 - Pre-Operation and Controls

SECTION 2 - PRE-OPERATION AND CONTROLS

2.1 PRE-OPERATION CHECKS & INSPECTION

Note: Complete all required maintenance before operating unit.

FALL HAZARD. Use extreme caution when checking items beyond your normal reach. Use an approved ladder. Failure to comply could result in death or serious injury.

Walk around inspection must be performed at beginning of each work shift or ateach change of operator.

Ensure all Safety decals are legible and in place. Clean or replace as required. Referto pages 2-4 through 2-5.

Before removing filler caps or fill plugs, wipe all dirt and grease away from the ports.If dirt enters these ports, it can severely reduce component life.

When adding fluids, refer to “Product Specifications” on page 7-1 to determineproper fluid type, and“Service & Maintenance Schedules” on page 5-3 for intervals.

WARNINGOW0021

2-180644002


2.2 WALK-AROUND INSPECTION

Before conducting the walk around inspection, make sure the engine is off and thetransmission is in neutral with the park brake engaged. The boom and attachmentmust be resting on the ground and securely blocked.

Begin your walk-around inspection at item 1, as noted below. Continue to your right,checking each item in sequence.

INSPECTION NOTE: In addition to any other criteria mentioned, on all components:

• Ensure there are no loose or missing parts and that all parts are securelyfastened.

• Check for visible leaks and excessive wear.

• Inspect all structural members including attachment for cracks, excessivecorrosion and other damage.

1. Cab -

• General appearance; no visible damage; Operator & Safety manual located inmanual drawer.

• Grab handles and steps secure and clean.

• Window glass and mirrors clean and unobstructed. Adjust mirrors formaximum visibility, before and during operation. Be sure windows and doorsare securely latched in open or closed position when operating. Replacedamaged latches immediately.

• Check seat belt for working condition and damage, replace belt if frayed or cutwebbing, damaged buckles or loose mounting hardware.

2. Front Axle - Steer cylinder and oscillation lock cylinders undamaged, not leaking; hydraulic hoses undamaged, not leaking.

3. Wheel/Tire Assembly - No loose or missing lug nuts; proper inflation (See page page 7-2 for details). No damage to rims or tires; axle bolts torqued.

4. Engine Compartment -

• Engine crankcase, check oil level & refill as required. Do not overfill.

• Check engine coolant level at overflow bottle and refill as required. Do notremove the radiator cap. Be sure antifreeze solution is adequate for expectedtemperatures. Be sure radiator and oil cooler fins are clean.

• Drive belt; check condition & replace as required.

• Engine cover properly latched and secured.

• Battery cables tight, no visible damage or corrosion. Battery box coverproperly latched.

• Transmission - no leaks.

2-2 80644002


5. Air Cleaner - Air cleaner element condition indicator, check for clogged condition. Replace element as required.

6. Rear Axle - See Inspection Note.

7. Wheel/Tire Assembly - No loose or missing lug nuts; proper inflation (See page page 7-2 for details). No damage to rims or tires; axle bolts torqued.

8. Fuel Tank - Check fuel level, refill as required; filler cap securely fastened.

9. Hydraulic Reservoir - Recommended fluid level on sight gauge; filler/breather cap secure and working; oil is clear.

10. Main Control Valve and Cover - See Inspection Note. Replace damaged latch and weak access cover support strut immediately.

11. Center Pin - See Inspection Note.

12. Tilt Gear - Properly lubricated.

13. Worklights - Clean, undamaged and aligned properly.

14. Boom - Rollers properly adjusted; no visible damage to boom hoses.

15. Attachment - Properly installed.

2-380644002


2.3 SAFETY DECALS - XL3300III, XL4300III & XL5300IIIEnsure all DANGER, WARNING, CAUTION and instructional decals and propercapacity charts are legible and in place. Clean and replace as required.

Decal Locations

FOR INITIAL FILL OF COOLING SYSTEM:

ATTENTIONTOP OFF COOLING SYSTEM AT EXPANSION TANK

1. FILL COOLING SYSTEM THROUGHDEAERATION TANK.

2. FILL EXPANSION TANK TO MARK 80 48-31 60

OAD0031

GRADALL XL3300III Lift Capacity - lb. (kg.)

The above l oa ds are in c om pl ian c e wit h t he SA E s t a nda rdJ 10 97 D EC2 0 0 5. The y do not e x c ee d 8 7% of hydra ul icl ift i ng ca pac i t y or 7 5% of t ipping c apac it y .

Loa ds s how n in s hade d are as in dic at e th e load i sl im it ed by t ip pi ng ra the r tha n hy drauli c lif t c apa ci ty .

The ra t ed li ft c apac it y is ba s ed o n t he ma chi ne be in ge qui ppe d w it h 6 ,0 00 lb (2 72 4 kg ) counte rw e ight, st a ndardboo m, s ta nda rd ti re s , n o a ux il ia ry hydrau l ics , a nd n o buc k et .

A dj us t the li s t ed ra te d ca pac it ie s by subt ra ct ing t he v al uel ist ed for buc k et /a tt ac hm ent use d:

8 06 5- 6 00 7 60 ” ( 1. 5 m)8 06 5- 6 00 6 66 ” ( 1. 7 m)8 06 5- 6 118 7 2 ” ( 1.6 m)8 04 5- 6 02 0 24 ” ( 61 0 mm )8 04 5- 6 02 1 30 ” ( 76 2 mm )8 04 5- 6 02 2 36 ” ( 91 4 mm )8 04 5- 6 02 3 42 ” ( 1. 1 m)8 06 5- 6 117 4 8 ” ( 1.5 m)8 06 5- 6 01 3 72 ” ( 1. 8 m)8 06 5- 6 10 2 40 ” ( 1. 0 m)8 06 5- 6 02 4 8’ (2 .4 m)8 06 5- 6 00 9 S ingle Toot h Ripper -

Di tc hin g -Di tc hin g -Di tc hin g -Ex ca va t ing -Ex ca va t ing -Ex ca va t ing -Ex ca va t ing -Ex ca va t ing -Dre dgi ng -Pa ve m e nt -Bl ade -

80 7 l bs . (3 6 6 k g)89 2 l bs . (4 0 5 k g)11 4 8 lbs . (5 2 1 k g)60 3 l bs . (2 7 4 k g)66 0 l bs . (3 0 0 k g)74 1 l bs . (3 3 6 k g)84 1 l bs . (3 8 2 k g)95 9 l bs . (4 3 5 k g)11 1 4 lbs . ( 50 5 kg)12 6 2 l bs . (5 7 3 k g)63 0 l bs . (2 8 5 k g)55 7 l bs . (2 5 3 k g)

The l oa d point is lo ca te d on t he buck e t piv ot po int ,inc ludi ng loads lis t ed f or ma x imum ra di us.

Do not at te mpt to l ift or hold any loa d gre a te r th a n the serat ed v a lu es a t s pe c if ie d load ra dii a nd heights . The w eig htof sli ngs a nd any a ux ili ary d ev ice s mu st be ded uct ed f ro mthe rat e d load t o de t ermi ne t he ne t loa d t hat ma y be li ft ed .

ATTENTIO N: All rat ed l oa ds are bas ed on t he m a c hi ne being s ta ti ona ry a nd le ve l o n a f irm s upportin g s urf a ce . The us e r mus t m ak e a ll ow a nc e for p art ic ul ar j ob c ondi t ions suc h as s oft or un e ve n ground, out o f l ev el co ndit ions, si de loads , h a za rdous conditi on s , e xpe rie nc e of pe rs onne l, et c. The ope ra tor a nd ot her pe r sonne l m us t rea d a nd under s ta nd the ope rat or ma nua l be fore ope rat in g this ma chi ne . R u les for s af e ope rat ion of e quip ment mus t be adhe re d t o at a ll ti mes .

8 08 93 00 3N ote : Buck e t a djust m ent v al ue s are 87 % of the a ct ual buc k e t we ight s .

LO A D POI NT HEI GH T

ABO V EGRO U N D

LEVE L

B ELO WGRO U N D

LEVE L

LO AD RA D IUS

AT G RO UN D L EVEL

OVEREND

OVERSIDE

10’ ( 3.0m)

OVEREND

OVERSIDE

15’ ( 4.6m)

OVEREND

OVERSIDE

20 ’ (6.1 m)MAXIMUMRADI US OV ER

EN DO VERSIDE

1 5’ (4 .6 m)

1 0 ’ (3.0 m)

8 ’ 6” ( 2.6 m)

5 ’ ( 1.5 m)

BO OM LEVEL

1 0’ (3 .0 m)

5 ’ (1 .5 m)

385 5(175 0)

38 55(17 50)

787 0(357 0)

78 70(35 70)

556 5(252 5)

409 5(185 5)

55 65(25 25)

40 95(18 55)

50 50(22 90)51 60(23 40)52 45(23 80)4 920(2 230)

4 230(1 920)

4 455(2 020)

5 050(2 290)5 160(2 340)5 245(2 380)

4230( 1920 )

4455( 2020 )

4 920(2 230)

2 2’ 7”( 6.9 m)

24’ 0”(7.3 m)2 4’ 2”( 7.4 m)

2 4’ 2”( 7.4 m)23’ 4 ”(7.1 m)21’ 2”

( 6.4 m)

17’ 1 ”( 5.2 m)

36 90(16 75)

37 05(16 80)37 25(16 90)37 75(17 10)

3 6 90(1 6 75)

3 7 05(1 6 80)3 7 25(1 6 90)3 7 75(1 7 10)

38 75(17 60)3 950(1 790)

3 8 75(1 7 60)3 9 50(1 7 90)

3 850(1 745)

3 8 50(1 7 45)

628 5(285 0)

62 85(28 50)

663 0(300 5)

66 30(30 05)

809 5(367 0)

80 95(36 70)

815 0(369 5)

81 50(36 95)

714 0(324 0)

71 40(32 40)

80509017 80509019

80509014

80483160

80509012

80893003

80763023

2-4 80644002


��

��

��

80509018

80509015

80509013

80509016

80373077

8050901580509004

80509015

80509012

80509013

80509018

80509015

80509016

80213104

2-580644002


2.4 SAFETY DECALS - XL3300III, XL4300III & XL5300III (CE)Ensure all DANGER, WARNING, CAUTION and instructional decals and propercapacity charts are legible and in place. Clean and replace as required.

Decal Locations

FOR INITIAL FILL OF COOLING SYSTEM:



2. FILL EXPANSION TANK TO MARK 80 48-31 60

OAD0490

GRADALL XL3300III Lift Capacity - lb. (kg.)

The above l oa ds are in c om pl ian c e wit h t he SA E s t a nda rdJ 10 97 D EC2 0 0 5. The y do not e x c ee d 8 7% of hydra ul icl ift i ng ca pac i t y or 7 5% of t ipping c apac it y .

Loa ds s how n in s hade d are as in dic at e th e load i sl im it ed by t ip pi ng ra the r tha n hy drauli c lif t c apa ci ty .

The ra t ed li ft c apac it y is ba s ed o n t he ma chi ne be in ge qui ppe d w it h 6 ,0 00 lb (2 72 4 kg ) counte rw e ight, st a ndardboo m, s ta nda rd ti re s , n o a ux il ia ry hydrau l ics , a nd n o buc k et .

A dj us t the li s t ed ra te d ca pac it ie s by subt ra ct ing t he v al uel ist ed for buc k et /a tt ac hm ent use d:

8 06 5- 6 00 7 60 ” ( 1. 5 m)8 06 5- 6 00 6 66 ” ( 1. 7 m)8 06 5- 6 118 7 2 ” ( 1.6 m)8 04 5- 6 02 0 24 ” ( 61 0 mm )8 04 5- 6 02 1 30 ” ( 76 2 mm )8 04 5- 6 02 2 36 ” ( 91 4 mm )8 04 5- 6 02 3 42 ” ( 1. 1 m)8 06 5- 6 117 4 8 ” ( 1.5 m)8 06 5- 6 01 3 72 ” ( 1. 8 m)8 06 5- 6 10 2 40 ” ( 1. 0 m)8 06 5- 6 02 4 8’ (2 .4 m)8 06 5- 6 00 9 S ingle Toot h Ripper -

Di tc hin g -Di tc hin g -Di tc hin g -Ex ca va t ing -Ex ca va t ing -Ex ca va t ing -Ex ca va t ing -Ex ca va t ing -Dre dgi ng -Pa ve m e nt -Bl ade -

80 7 l bs . (3 6 6 k g)89 2 l bs . (4 0 5 k g)11 4 8 lbs . (5 2 1 k g)60 3 l bs . (2 7 4 k g)66 0 l bs . (3 0 0 k g)74 1 l bs . (3 3 6 k g)84 1 l bs . (3 8 2 k g)95 9 l bs . (4 3 5 k g)11 1 4 lbs . ( 50 5 kg)12 6 2 l bs . (5 7 3 k g)63 0 l bs . (2 8 5 k g)55 7 l bs . (2 5 3 k g)

The l oa d point is lo ca te d on t he buck e t piv ot po int ,inc ludi ng loads lis t ed f or ma x imum ra di us.

Do not at te mpt to l ift or hold any loa d gre a te r th a n the serat ed v a lu es a t s pe c if ie d load ra dii a nd heights . The w eig htof sli ngs a nd any a ux ili ary d ev ice s mu st be ded uct ed f ro mthe rat e d load t o de t ermi ne t he ne t loa d t hat ma y be li ft ed .

ATTENTIO N: All rat ed l oa ds are bas ed on t he m a c hi ne being s ta ti ona ry a nd le ve l o n a f irm s upportin g s urf a ce . The us e r mus t m ak e a ll ow a nc e for p art ic ul ar j ob c ondi t ions suc h as s oft or un e ve n ground, out o f l ev el co ndit ions, si de loads , h a za rdous conditi on s , e xpe rie nc e of pe rs onne l, et c. The ope ra tor a nd ot her pe r sonne l m us t rea d a nd under s ta nd the ope rat or ma nua l be fore ope rat in g this ma chi ne . R u les for s af e ope rat ion of e quip ment mus t be adhe re d t o at a ll ti mes .

8 08 93 00 3N ote : Buck e t a djust m ent v al ue s are 87 % of the a ct ual buc k e t we ight s .

LO A D POI NT HEI GH T

ABO V EGRO U N D

LEVE L

B ELO WGRO U N D

LEVE L

LO AD RA D IUS

AT G RO UN D L EVEL

OVEREND

OVERSIDE

10’ ( 3.0m)

OVEREND

OVERSIDE

15’ ( 4.6m)

OVEREND

OVERSIDE

20 ’ (6.1 m)MAXIMUMRADI US OV ER

EN DO VERSIDE

1 5’ (4 .6 m)

1 0 ’ (3.0 m)

8 ’ 6” ( 2.6 m)

5 ’ ( 1.5 m)

BO OM LEVEL

1 0’ (3 .0 m)

5 ’ (1 .5 m)

385 5(175 0)

38 55(17 50)

787 0(357 0)

78 70(35 70)

556 5(252 5)

409 5(185 5)

55 65(25 25)

40 95(18 55)

50 50(22 90)51 60(23 40)52 45(23 80)4 920(2 230)

4 230(1 920)

4 455(2 020)

5 050(2 290)5 160(2 340)5 245(2 380)

4230( 1920 )

4455( 2020 )

4 920(2 230)

2 2’ 7”( 6.9 m)

24’ 0”(7.3 m)2 4’ 2”( 7.4 m)

2 4’ 2”( 7.4 m)23’ 4 ”(7.1 m)21’ 2”

( 6.4 m)

17’ 1 ”( 5.2 m)

36 90(16 75)

37 05(16 80)37 25(16 90)37 75(17 10)

3 6 90(1 6 75)

3 7 05(1 6 80)3 7 25(1 6 90)3 7 75(1 7 10)

38 75(17 60)3 950(1 790)

3 8 75(1 7 60)3 9 50(1 7 90)

3 850(1 745)

3 8 50(1 7 45)

628 5(285 0)

62 85(28 50)

663 0(300 5)

66 30(30 05)

809 5(367 0)

80 95(36 70)

815 0(369 5)

81 50(36 95)

714 0(324 0)

71 40(32 40)

8 089- 30 20-A

80 89-3016-A

8 08 9 -3 0 14 - A

80 21 -3 101

80213101

80893020

80893016

80483160

80893014

80893003

80763023

2-6 80644002


��

��

��

��

��

��

��

��

��

��

��

��

��

��

80893019

80893017

80893015

80893018

80893012

8089301780893013

80893017

80893014

80893015

80893019

80893017

80893018

80213104

2-780644002


2.5 SAFETY DECALS - XL3310III, XL4310III, XL5310III,XL3320III, 4320III & XL5320III

Ensure all DANGER, WARNING, CAUTION and instructional decals are legible andin place. Clean and replace as required.

Decal Locations

OAD0410FOR INITIAL FILL OF COOLING SYSTEM:



2. FILL EXPANSION TANK TO MARK8048-316 0

80509017

8050901480483160

80509012

80509013

80509019

80509015 80509018

80509015 80509018

2-8 80644002


OAD0390

NO STEP

OAD040080509013

80509016

80373077

80509015

80509004

80509015

80509012

80509016

80213104

2-980644002


2.6 SAFETY DECALS - XL3310III, XL4310III, XL5310IIIXL3320III, XL4320III & XL5320III (CE)

Ensure all DANGER, WARNING, CAUTION and instructional decals are legible andin place. Clean and replace as required.

Decal Locations

OAD0420FOR INITIAL FILL OF COOLING SYSTEM:



2. FILL EXPANSION TANK TO MARK80 48-31 60

80 3 1 - 30 4 3

80213101

8089301680483160

80893014

80893015

80893020

80893017 80893019

80893017 80893019

2-10 80644002


OAD0430

OAD044080893015

80893018

80893012

80893017

80893013

80893017

80893014

80893018

80213104

2-1180644002


2.7 CAB COMPONENTS

OAD0041

1

3

4

5

6

78

9

210

11

12

13

14

15

16

2-12 80644002


1. Air Diffuser Vents

2. Manual Drawer (under operator seat): Keep Operator & Safety Manual with machine at all times.

3. Steering Wheel: Turn steering wheel to left or right to steer the machine in the corresponding direction.

4. Lights/Turn Signal Switch

5. Electronic Monitoring Unit: See page 2-14 for details.

6. 12-Volt Accessory Outlet: A cigarette lighter is provided. The receptacle can be used to power an auxiliary 12 VDC device equipped with the appropriate adapter.

7. Right Hand Joystick: See “Joystick Controls” on page 2-27.

8. Right Hand Arm Pod: See page 2-16 for details.

9. Circuit Board and Fuse Box: See “Fuses” on page 7-8.

10. Operator Seat: See “Operator Seat Adjustments” on page 2-31.

11. Left Hand Arm Pod: See page 2-24 for details.

12. Control Cut Out Lever: See “Activating the Joysticks” on page 2-27.

13. Foot Pedals: Travel pedal is located to the right of the steering column. Brake pedal is located to the left of the steering column.

14. Left Hand Joystick: See “Joystick Controls” on page 2-27.

15. Steering Wheel Adjustment Lever

16. Travel Direction/Gear Select Switch: Press switch forward for forward travel. Pull switch back for reverse travel. Rotate end of switch to select first or second gear.

2-1380644002


2.8 CAB CONTROLS & INDICATORS

Electronic Monitoring Unit

1. Digital Display: See “Electronic Monitoring Unit Digital Display” on page 2-16

2. Ignition: Key Activated. See page 2-32 for details.

3. Joystick Control Pattern Selection Switch: See “Joystick Control Pattern Selection” on page 2-26.

OAD0260

1

23

2-14 80644002


This Page Intentionally Left Blank

2-1580644002


Electronic Monitoring Unit Digital Display

User Interface - Work Mode

1. Visual Display (Work Mode): See page 2-17 for details.

2. Green Visual Indicator: Illuminated when no alarms are present.

3. Orange Visual Indicator: Illuminated when CAN fault is detected. See pages 2-18 & 2-19 for details.

4. Yellow Visual Indicator: Illuminated when a non-critical alarm is recognized by the operator but the condition that activated the alarm is still present. See pages 2-18 & 2-19 for details.

5. Red Visual Indicator: Illuminated upon reception of an alarm. It will remain activated for critical alarms if the condition is still present. It will turn off if the alarm is non-critical and is recognized by the operator. See pages 2-18 & 2-19 for details.

6. Keypad Input “1”: Selects operator mode. See page 2-17 for details.

7. Keypad Input “2”: Scrolls left display variable. See page 2-17 for details.

8. Keypad Input “3”: Scrolls right display variable. See page 2-17 for details.

9. Keypad Input “4”: Silences non-critical alarm(s). See page 2-18 for details.

1

54

7 8

9

32

6

OAD0320

2-16 80644002


Visual Display (Work Mode)

After a “welcome” screen, the visual display is shown as illustrated below.

1. Machine Hours

2. Fuel Gauge

3. Operator Mode: The display can be alternated between two saved operator modes by pressing Keypad Input “1”. Selection can only be made for a short period of time after start up. Machine hours per selected operator is also displayed.

4. Right Display Variable: Variable is changed by pressing the Keypad Input “3”.

5. System Status Bar: See page 2-18 for details.

6. Left Display Variable: Variable is changed by pressing the Keypad Input “2”.

Changing Display Variables

The display variables can be changed using the Keypad Input “2” for the left displayvariable and Keypad Input “3” for the right display variable. The order of the variabledisplays are as follows:

OAD0330

1

HOURS99999.9

OPER A999.9

FUEL

WATER TEMP HYD TEMPSYSTEM OK

105 100°C °C

23

6 4

5

OAD0340

Order Keypad“2”

Keypad“3”

LeftVariable

RightVariable

12

3

4

Oil Pressure

Battery Voltage

HydraulicTemperature

Engine SpeedWater Temp

Pilot Pressure(Aux 1 4-20)

Pump Pressure(Aux2 4-20)

2-1780644002


System Status

The System Status bar is used to display machine system status. When themachine system is functioning normally, “SYSTEM OK” is displayed.

When the machine system has an alarm or fault present, it will display along withother alarms of the same level. Levels are separated as “Critical” or “Warning”. Thesystem status bar will display the alarm text and then the alarm level. For example:

Scenario 1 - Low fuel level warning: System status bar will display “LOW FUELLEVEL” then “CRITICAL ALARM” and cycle those messages until no alarm ispresent.

If more than one alarm is present, the system status bar will display them one byone, then display the level of that group of alarms. For example:

Scenario 2 - Low fuel level and battery charge warning: System status bar willdisplay “LOW FUEL LEVEL”, then “LOW BATTERY CHARGE” followed by“CRITICAL ALARM” and cycle those messages until no alarm is present.

When a new alarm or fault condition is detected, the message bar will add the alarmto the list and will be cycled in the system status bar. Sound and visual feedback willalso indicate alarm condition until the alarm is recognized by the operator.Recognition of the alarm is performed by pressing Keypad Input “4”. Recognition of“critical” alarms will change their status to “warning”. There are a few alarms whichcan only be recognized or silenced for a specific amount of time. See page 2-19 fordetails.

The system status bar will only display one group of alarms. “Critical” alarms willhave display priority. For example, in Scenario 2, we if both alarms are silenced andthe system status bar would change to “LOW FUEL LEVEL” “LOW BATTERYCHARGE” “WARNING ALARM”. If the operator only silenced one of those alarms,the other will remain as “critical” and will be the only one in the display cycle.

In case both alarms are silenced (status changed to “warning” level) and a newcritical alarm is detected, the new alarm will be displayed instead of the two silencedones. For example, if high water temperature is detected, the system status bar willdisplay “HIGH WATER TEMP 200F”, then “CRITICAL ALARM” and cycle them untilprevious alarms expire and join the “critical” alarm cycle, or if the critical alarmcondition is cleared. If the critical alarm is cleared to a “warning” level, all threepresent warning alarms will cycle in the system status bar (if they are still present).

2-18 80644002


System Status Alarms

Messages to be displayed on the system status bar and the visual and audibleactions are described as follows:

The “Buzzer” column indicates the behavior of the audible alarm.

The “Reset Freq” column indicates the length of time an alarm can be silencedbefore the audible alarm returns if condition is still present.

The “Quiet” column indicates whether an alarm can be silenced upon operatorrecognition.

The “Lamp” column indicates the status of the warning lamp depending oncondition.

Activating Menu Mode

Menu Mode allows the operator to set preferences to what and how basicinformation on the electronic monitoring unit is displayed.

To enter Menu Mode, press and hold Keypad Input “1” and “2” until display menuchanges (approx. 3 seconds). Release Keyapd Input “1” and “2” once displaychanges. All lamps will be flashing and audible alarms will be silent while in MenuMode.

OAD0350

MessageDisplayed Buzzer Reset

Freq Quiet Lamp

HIGH WATERTEMPERATURE

LOW FUELLEVEL

LOW BATTERY

HYDTEMPERATURE

OIL PRESSURE

HYD OIL LEVEL

Constant

Chirp

N/A

1Hour

1Hour

1Hour

N/A

N/A

NO

YES

YES

NO

NO

NO

RED WHILECONDITION EXISTSRED ON DETECTIONYELLOW AFTERRECOGNITION

Constant

Constant

Constant

Constant

RED ON DETECTIONYELLOW AFTERRECOGNITIONRED ON DETECTIONYELLOW AFTERRECOGNITIONRED WHILECONDITION EXISTSRED WHILECONDITION EXISTS

CAN FAILURE N/A NOConstant RED WHILECONDITION EXISTS

2-1980644002


User Interface - Menu Mode

1. Visual Display (Menu Mode): See page 2-21 for details.

2. Keypad Input “1”: Scroll up through menu options.

3. Keypad Input “2”: Scroll down through menu options.

4. Keypad Input “3”: Changes parameter of highlighted option.

5. Keypad Input “4”: Saves preferences and returns to work mode.

1

5

43

2

OAD0360

2-20 80644002


Visual Display (Menu Mode)

To select a parameter, press the Keypad Input “1” or “2” buttons to scroll to desiredselection. Press the Keypad Input “3” to cycle through selected parameter value.When desired parameters are selected, press and hold the Keypad Input “4” to saveand return to work mode.

The following chart displays Menu Mode options:

OAD0370

MENU: PREFERENCES

1 (UP) 2(DOWN)3(SET) 4(ESC)

UNITSLANGUAGEAUDIBLE ALARMCONTRAST

METRICENGLISHON53

OAD0380

ParameterAUDIBLE ALARM Silences the audible alarm

Sets intensity or contrastlevel

Changes units of measure

Changes language

Values Comment

DISPLAY LEVEL

UNITS

LANGUAGE

ON/OFF

47 to 60

METRIC/US

English/Spanish

2-2180644002


Right Hand Arm Pod

1. Engine Speed: Rotary switch. Rotate switch clockwise to increase engine rpm; rotate counterclockwise to decrease engine rpm.

2. Mode Select Switch: Depress front of switch (I) for fine grade mode. Depress back of switch (II) for dig mode.

3. Fan Speed: Rotary switch for heater and air conditioner fan.

4. Air Conditioning Switch: On/Off switch.

5. Travel Speed Switch: Depress front of switch to allow full speed in first and second gear. Depress back of switch to limit first and second gear to approximately 35% of normal speed.

Note: If travel speed is switched while unit is in motion, the machine will not shift to selected travel speed until the travel pedal is released and digging brake is set.

6. Boom Lights Switch: On/Off switch.

7. Work Lights Switch: On/Off switch.

8. Intermittent Wiper/Washer Switch: See “Intermittent Wiper/Washer” on page 2-33.

9. Temperature Control: Adjustable rotary switch.

1

2

3

4

5

67

8

9

10

OAC0840

2-22 80644002


10. Auto Idle Override Switch: Depress front of switch (I) to activate auto idle. Depress back of switch (II) to deactivate auto idle.

• With auto idle activated, engine speed will return to low idle after 7 seconds ofhydraulic control inactivity. Once controls are activated, engine resumesspeed set by the operator.

• With auto idle deactivated, engine speed remains as set by the operator.

2-2380644002


Left Hand Arm Pod

1. Boom Tilt Speed Switch: Rotary switch. Rotate switch clockwise to decrease boom tilt speed; rotate counterclockwise to increase boom tilt speed.

2. Steering Flow Interruption Warning Light (CE machines only)

3. Travel Mode Indicator (CE machines only): Illuminates when Joystick Lock Switch is activated.

4. Right Front Outrigger Enable Switch: Depress front of switch (I) to activate Right Front Outrigger control. Depress back of switch (0) to deactivate Right Front Outrigger control.

• With outrigger control switch activated, use the right hand joystick foroutrigger operation. See page 2-27 for details.

5. Right Rear Outrigger Enable Switch: Depress front of switch (I) to activate Right Rear Outrigger Control. Depress back of switch (0) to deactivate Right Rear Outrigger Control.

• With outrigger control switch activated, use the right hand joystick foroutrigger operation. See page 2-27 for details.

6. Park Brake Switch: See page 2-34 for details.

1

OAD0050

2

3

4

5

6

7

8

9

10

11

12

13

14

2-24 80644002


7. Swing Lock Switch: Depress front of switch to extend swing lock pin. Slowly align upperstructure with chassis until swing lock pin engages in reciever. Depress back of switch to retract swing lock pin.

8. AM/FM Radio

9. Travel/Work Mode Alarm Switch:

• Depress front of switch for travel mode alarm setting. Alarm will sound for 3seconds each time travel pedal is depressed then remain silent. Setting to beused for over-road-travel only.

• Depress back of switch for work mode alarm setting. Alarm will beepcontinually during machine movement.

10. Dig Brake Mode Select Switch: 3-position switch.

• Depress front of switch to turn dig brake off.

• Center position turns dig brake on.

• Depress back of switch for dig brake auto mode.

11. Joystick Lock Switch: Depress front of switch to disable joystick functions. Depress back of switch to enable joystick functions.

12. Axle Oscillation Lock Switch: 3 position switch. Axle Oscillation will ALWAYS unlock no matter position of switch while traveling in second gear.

• Depress front of switch to unlock axle oscillation.

• Center position locks axle oscillation.

• Depress back of switch for axle oscillation auto mode.

13. Rear Blade/Left Rear Outrigger/Rear Rail Gear (optional) Enable Switch: Depress front of switch (I) to activate Rear Blade/Left Rear Outrigger/Rear Rail Gear control. Depress back of switch (0) to deactivate Rear Blade/Left Rear Outrigger/Rear Rail Gear control.

• With outrigger/blade/rail gear control switch activated, use the right handjoystick for outrigger/blade/rail gear operation. See page 2-27 for details.

14. Front Blade/Left Front Outrigger/Front Rail Gear (optional) Enable Switch: Depress front of switch (I) to activate Front Blade/Left Front Outrigger/Front Rail Gear control. Depress back of switch (0) to deactivate Front Blade/Left Front Outrigger/Front Rail Gear control.

• With outrigger/blade/rail gear control switch activated, use the right handjoystick for outrigger/blade/rail gear operation. See page 2-27 for details.

2-2580644002


Joystick Control Pattern Selection

The control pattern selection switch allows the operator to select from three joystickcontrol patterns; GRADALL, SAE and JOHN DEERE. The pattern must be selectedwith the ignition key in the “OFF” position. If a new pattern is selected while theengine is running, it will not change until the engine is turned off then restarted.

When a control pattern is changed, the corresponding control decal must bedisplayed in the cab.

GRADALL Control Pattern

SAE Control Pattern

JOHN DEERE Control Pattern

OAD0270

AUX

8089-3005-A

CONTROLS

GRADALL CONTROL DECAL OVERLAY

80893005

OAD0280

AUX

8089-3004-AAUTO

SAE CONTROL DECAL80893004

OAD0290

AUX

8089-3006-A

DEERE CONTROLS

JOHN DEERE CONTROL DECAL OVERLAY

80893006

2-26 80644002


Joystick Controls

Activating the Joysticks

The joysticks will remain locked/inactive until the control cut out lever (1) located onthe left hand arm pod (2) is moved to the unlocked/active position.

Joystick Control Patterns

Before operating, refer to the position of the joystick control pattern switch located onthe electronic monitoring unit to verify control pattern setting. Ensure the joystickdecal matches the machine controls before operating.

1

OAC0920

2

INACTIVE

ACTIVE

2-2780644002


SAE Joystick Controls

Left Hand Joystick Functions

• Move the joystick back to retract boom; move joystick forward to extend boom.Move joystick right to swing boom right; move joystick left to swing boom left.

• Attachment shake button (1) allows excess dirt or debris to be removed from theboom attachment.

• For two simultaneous boom functions, move the joystick between quadrants. Forexample, moving the joystick forward and to the left will extend and swing theboom left simultaneously.

Right Hand Joystick Functions

• Move the joystick back to raise boom; move joystick forward to lower boom. Movejoystick right to open tool; move joystick left to close tool.

• Left-click boom tilt button (2) to tilt boom counterclockwise; right-click boom tiltbutton (2) to tilt boom clockwise.

• Use fast tilt button (3) simultaneously with boom tilt button (2) to momentarilyincrease boom tilt speed.

• For two simultaneous boom functions, move the joystick between quadrants. Forexample, moving the joystick forward and to the left will lower the boom and closethe tool simultaneously.

• When outrigger(s)/blade/rail gear functions are activated on the Left Hand ArmPod, move joystick back to raise outrigger(s)/blade/rail gear; move joystickforward to lower outrigger(s)/blade/rail gear.

OAD0520

AUX

1

2

3

2-28 80644002


GRADALL Joystick Controls


• Move the joystick back to raise boom; move joystick forward to lower boom. Movejoystick right to close tool; move joystick left to open tool.


• For two simultaneous boom functions, move the joystick between quadrants. Forexample, moving the joystick forward and to the left will lower boom and opentool simultaneously.


• Move the joystick back to retract boom; move joystick forward to extend boom.Move joystick right to swing boom right; move joystick left to swing boom left.



• For two simultaneous boom functions, move the joystick between quadrants. Forexample, moving the joystick forward and to the left will extend and swing theboom left simultaneously.


OAD0530

AUX

1

2

3

2-2980644002


JOHN DEERE Joystick Controls


• Move the joystick back to raise boom; move joystick forward to lower boom. Movejoystick right to swing boom right; move joystick left to swing boom left.


• For two simultaneous boom functions, move the joystick between quadrants. Forexample, moving the joystick forward and to the left will lower and swing boomleft simultaneously.


• Move the joystick back to retract boom; move joystick forward to extend boom.Move joystick right to open tool; move joystick left to close tool.



• For two simultaneous boom functions, move the joystick between quadrants. Forexample, moving the joystick forward and to the left will extend boom and closethe tool simultaneously.


OAD0540

AUX

1

2

3

2-30 80644002


Operator Seat Adjustments

Prior to starting engine adjust seat for position and comfort.

1. Upper Seat Fore and Aft Adjustment Control

2. Weight Adjustment Control

3. Lower Seat Fore and Aft Adjustment Control

4. Height Adjustment Control

5. Lumbar Adjustment Control

6. Seat Back Adjustment

OAD0100

1

46

2

3

5

2-3180644002


Ignition

1. ACC: Voltage is available for all electrical functions.

2. OFF: Engine off.

3. RUN: Prohibits rotating key switch to position 4 in the event the engine does not start. Rotate the key to position 2 then back to position 4 to re-engage the starter.

4. START: Engine start.

OAC0820

STOP1

2

3

4

2-32 80644002


Intermittent Wiper/Washer

1. OFF

2. DELAY: Rotating knob clockwise decreases delay.

3. LOW: Low wiper speed. No delay.

4. HIGH: High wiper speed. No delay.

5. WASHER: Press and hold switch to activate washer.

1

2

3

4OAC0930

5

2-3380644002


Park Brake Switch

• Park Brake Switch: This switch controls the application and release of the parkbrake.

• With the engine running and the park brake switch in “OFF” position (1), parkbrakes are disengaged. With switch in “ON” position (2), park brake is engagedand transmission will not engage forward or reverse and joystick functions will beinactive.

OAD0110

2

1

2-34 80644002

Section 3 - Operation

SECTION 3 - OPERATION

3.1 ENGINE OPERATION

Starting Engine

1. Perform walk-around inspection on page 2-2

2. Apply the parking brake.

3. With travel pedal in idle position, turn ignition to “START” position. Release key immediately when engine starts. If engine does not start after three attempts, check fuel supply system.

4. Observe Digital Display on Electronic Monitoring Unit to ensure machine is functioning properly.

5. Operate engine at idle speed for three to five minutes before operating with a load. Increase engine speed slowly.

Normal Engine Operation

• Observe digital display frequently to ensure all engine systems are functioningproperly.

• Be alert for unusual noises or vibration. When an unusual condition isnoticed, park machine in a safe position and perform shut-down procedure. See“Engine Shutdown” on page 3-22. Report condition to your supervisor ormaintenance personnel.

• Avoid prolonged idling. If the engine is not being used, turn it off.

3-180644002


Cold Weather Starting Aids

• It is the owners responsibility to determine proper use of starting aid withregard to engine and starting aid manufacturer’s instruction.

• An ether starting aid may be used with this engine only if it does not have theoptional grid heater.

ENGINE EXPLOSION. If your excavator is equippedwith a cold start aid, do not spray additional ether intoair cleaner. If machine is not equipped with cold startaid, follow instructions listed in the engine manualsupplied with the excavator. Failure to comply mayresult in death or serious injury.

CAUTIONOW0031

3-2 80644002


3.2 CHECKS BEFORE OPERATION

This section outlines the checks to be performed at the beginning of each work shiftor at each change of operator. Repair any deficiencies before driving or operatingthe equipment.

1. Check all lights and turn signals, defroster, windshield wiper and washer for proper operation.

2. Check park brake and service brakes to ensure they are working properly.

3. Check operation of steering while moving slowly in first gear. Be alert for any increase in effort needed to turn wheels and any unusual steering response to normal steering effort.

4. Check operation of horn, back-up alarm, and any other signal devices. Must be audible from inside operator’s cab with the engine running.

5. Observe Digital Display on Electronic Monitoring Unit to ensure machine is functioning properly.

3-380644002


3.3 BRAKE SYSTEMThe brake system includes service brakes, parking brakes and digging brakes.

NEW BRAKES. New brakes need increased stopping distance. Brake capability will improve after several stops. Failure to stop may result in death or serious injury.

BRAKING HAZARDS. Always wear seat belt to avoidbeing thrown from driver’s seat during brakingemergency.

Do not “fan” the brake valve pedal. A long series ofrapid brake applications could reduce system pressureto a point where effective service braking will be lostuntil brake pressure is restored.

CAUTIONOW0031

WARNINGOW0021

3-4 80644002



3-580644002


3.4 TRAVEL MODESThere are at least five modes of travel which should be considered separately:

• Moving machine less than 4.6m (5 yds)

• Performing grading operations

• Moving machine to a different area of worksite

• Over-the-road travel

• Lifting & Placing a Load, (see page 3-16 for details)

These five travel modes do not cover all possible travel conditions, but a thoroughunderstanding of these travel modes will enable the operator to select proper controloptions for other conditions.

Regardless of the operation being performed:

• ALWAYS fasten seat belt when seated in the cab.

• Unless immediate travel will be on a flat and level surface, always move axleoscillation lock switch to “unlock” or “auto” position. Traveling with oscillationcylinders locked could cause an unstable condition.

Moving Machine Less than 4.6m (5 yds)

Note: It is assumed the machine is performing a ditching or similar operation.

1. Switch travel alarm to “work mode”, place machine in first gear and ensure dig brake is switched to “Auto”.

Note: If unit is working from a roadway, be sure all required traffic control devices/persons are in position.

2. Align upperstructure and chassis with cab facing direction of travel.

3. If lowered, raise outriggers and blade (if equipped). Select appropriate direction of travel with the Travel Direction/Gear Select Switch.

4. Ensure adequate clearance along travel path. Pay attention to how unit must be steered to avoid obstacles. Pay attention to orientation of upperstructure with chassis to avoid steering and travel in the wrong direction.

5. Sound horn to warn others of intention to travel.

6. Depress travel pedal to move unit to new position. Dig brake will release when travel pedal is depressed and engage when travel pedal is released.

3-6 80644002


Performing Grading Operations

If machine is equipped with optional blade, light to medium grading operations canbe performed. “Medium” grading is defined as moving loose or previously brokenmaterial. Material must not spill over top of blade. If material spills over top of blade,grading will be distorted. There is no provision to tilt the blade. Use excavatingfunctions to create a roughly “level” condition before grading.

The machine equipped with a blade is not to be used for “bulldozing”. Use of themachine in this manner will shorten component life.

1. Position machine on surface parallel (side-to-side) to desired grade. Axle Osclillation Lock Switch should be in “unlocked” position. Switch travel alarm to “work mode”.

2. Select forward travel and first gear with the Travel Direction/Gear Select Switch.

3. Using Front Blade/Left Front Outrigger Enable Switch, enable the blade and adjust height using the right hand joystick.

4. Place Dig Brake Switch to “Auto” or “Off” (as condition requires). If “Off” is selected, Service Brake Pedal must be used to slow or stop machine.

5. Depress Travel Pedal to obtain appropriate travel speed and adjust blade height as needed for grading operation.

Moving Machine to a Different Worksite

Follow the procedure for Moving Machine Less than 4.6m (5 yds) on page 3-6, butuse the following information to adjust travel procedure.

Worksite conditions are unpredictable and do not allow for exact procedure formoving the machine. Inspect the intended travel path for hazardous conditions andplan move accordingly. Consider the following conditions to select the safestpossible move:

Is travel path on-road or off-road, or both?

• If both, determine point at which you must stop and adjust machine controlsfor new conditions.

Consider travel speed.

• If travel path terrain is rough, select lower gear. This makes operational speedeasier to control.

• If travel path terrain is smooth and grade is not too steep, high gear can beselected.

Consider terrain.

• If travel path includes rough terrain, place Axle Oscillation Lock Switch to“unlock” position. Engage Swing Lock for over-the-road travel.

3-780644002


Consider brake mode.

• If traveling at a low speed and in low gear, Dig Brake Mode Select Switch canbe set to “Auto” for stopping the machine when travel pedal is released.

• If traveling at high speed and in high gear, Dig Brake Mode Select Switchshould be “Off” and service brake pedal should be used for slowing andstopping the machine.

Over-the-Road Travel

Over-the-road travel is permitted when it is in compliance with federal, state/provincial and local laws and traffic regulations. Special conditions such as slowmoving vehicle signs, permits, clearances, escort cars, etc. may be needed. Do notoperate machine on the road until all conditions are known and met.

Perform the following procedure in preparation for over-the-road travel:

1. Align upperstructure and chassis with cab facing front. Engage swing lock. See page 2-24 for details.

2. Postion boom for travel.

3. Engage joystick lock. See page 2-24 for details.

4. Switch Axle Oscillation Lock Switch to “unlocked” position.

5. Be sure mirrors and lights are functional, cleaned and properly adjusted.

6. Select appropriate gear range.

7. With service brake pedal engaged, place Dig Brake Mode Select Switch to “Off” position. In this condition, the service brake pedal must be used to slow or stop machine. Continue to engage service brake pedal to hold machine in position.

8. Turn on hazard lights.

9. Release service brake pedal and depress travel pedal to obtain appropriate travel speed.

10. Prior to operation at a new work site, perform Walk-Around Inspection on page 2-2 and reset controls accordingly.

3-8 80644002



3-980644002


3.5 TYPICAL DIG CYCLE

Standard SAE Boom and Attachment Functions

Prepare for boom and attachment function:

1. Position unit for efficient attachment usage. Notice!: While digging, pay close attention to boom position in relation to chassis components. In certain instances it is possible for the boom to come into contact with the chassis.

2. Stop engine and secure door and windows in desired position for ventilation. Remove boom tie down chain from boom.

3. Start engine, let hydraulic oil warm and set to full throttle position.

4. Be certain control cut out lever is in down position to energize joysticks and foot pedals.

UNEXPECTED MOVEMENT. Test your controls beforeoperating. If controls have been changed to anotherpattern, be sure you are familiar with the functions andensure that the diagram in the cab shows the actualpattern in use. Alternate patterns are located in theoperator cab in the manual compartment. If you do nothave the proper control decal, do not change thecontrol pattern.

WARNINGOW0021

3-10 80644002


Joystick controls standard SAE control pattern. If tilt speed has been reduced forconditions, speed can be temporarily increased by depressing fast tilt button (1).

Note: Practice with controls in a safe, open area. Joysticks and pedals return to neutral position when released.

1. Pull back on right joystick (A) to raise boom far enough to clear all obstructions.

OAD0300

1AUX

3-1180644002


2. Move left joystick to left (G) to swing left or to right (H) to swing right.

3. While pushing left joystick forward (F) to extend boom, push right joystick forward (B) to lower boom into position for start of cut.

4. Move right joystick to right (C) to open bucket or to left (D) to close bucket for correct penetration. Teeth should angle downward slightly (about 5 degrees). Angle may be greater for soft digging.

3-12 80644002


5. If required, press left side of tilt switch (I) to tilt counterclockwise or right side of switch (J) to tilt clockwise. If necessary, use fast tilt button to return to fast tilt.

6. While pushing forward on right joystick (B) to lower boom and force bucket into ground, pull back on left joystick (E) to retract boom and fill bucket.

7. As bucket is filling, jog right joystick forward (B) to lower boom and maintain depth of cut. At same time jog right joystick to right (C) to open bucket and maintain proper bucket angle.

3-1380644002


8. When bucket is full, or when boom is fully retracted, move right joystick to left (D) to close bucket. At same time pull right joystick back (A) to raise boom far enough to clear obstructions.

9. Move left joystick to right (H) to swing right or to left (G) to swing left to dump site. If necessary, extend boom by pushing left joystick forward (F).

10. Move right joystick to right (C) to open bucket and dump load.

3-14 80644002


11. Move left joystick to left (G) or right (H) to align boom for next cut. Repeat steps 3 thru 11.

3-1580644002


3.6 LIFTING & PLACING A LOAD - XL3300III, XL4300III & XL5300III

LIFTING & POSITIONING LOADS. Failure to plan alift properly could result in death or serious injury.

The automatic boom tilt brake will not prevent boomfrom tilting in response to an external load. Load mustbe centered under bucket adapter with boom levelfrom side to side.

Precautions

• Use the lift capacity chart to calculate maximum load. Keep in mind, theattachment weight and rigging must be added to the load, then compared to thevalue on the lift capacity chart.

• If it becomes necessary to shut the engine off while positioning a load, place loadon the ground prior to shutting off engine.

• Be thoroughly familiar with excavator hand signals shown at the end of themanual.

• Operate machine at full throttle and do not shut off engine with suspended load.

• Do not travel with suspended load positioned over the side of the machine.

• Suspend loads only as shown above. Passing load line over open bucket cancause uncontrolled movement of load.

• To lift loads, level boom from side to side and close adapter fully against stops.Pass thru adapter as shown and be certain chain is locked on itself.

WARNINGOW0021

OAC0670

3-16 80644002


General

There is a lift capacity difference between the excavator’s best and worst liftpositions. Just because it can lift a load from one point does not mean it can safelydeliver the load to any other point.

Prior to lifting and placing a load, map out the lift, swing, and lower path to ensurethat capacity, both hydraulic and stability tipping limits, are not exceeded. The bestlifting position is over the rear with the excavator level and the boom fully retracted.

You must plan the lift based on the worst condition of the lift and delivery, not thebest. The worst condition can only be determined by performing an UNLOADEDTEST AND DELIVERY of the load.

Loads shown on chart in cab are hydraulic lift capacities with those in shaded areaindicating tipping limits. Exceeding these capacities can cause a relief valve to openallowing the load to fall or in some cases, the machine to tip over.

Positioning Machine For A Lift

The machine must be on a firm, level surface when making a lift.

The shorter the load radius, the greater the lift capacity. Position the unit to minimizeboom extension and swing while keeping adequate distance from obstructions andexcavations.

Position machine to gain maximum visibility of load and delivery point. If conditionsdo not permit a clear view, use a signal person.

3-1780644002


Planning A Lift

Note: Lift capacities are based on machine being on a firm, level surface and also no load being suspended beneath bucket adapter. Do not travel with suspended load positioned over the side of the machine.

1. Determine the weight of the load including weight of slings, chains, bucket/attachment (tool), and auxiliary lifting devices. Refer to lift capacity chart for weight adjustment required for bucket.

2. Move the machine to the best position for making the lift.

3. Perform an unloaded trial run of lift to determine maximum boom height/depth and load radius required to complete the lift.

4. Measure boom height/depth from hole in adapter to ground level (same level as bottom of tire). Be sure to allow for length of chain and height of load.

5. Measure load radius from inner corner of frame at front of cab to vertical load line (as shown above) and add distance to center of rotation (63 inches).

6. Refer to lift capacity chart column for required load radius. If required radius is between columns, use column for next larger radius.

7. Check the appropriate capacities for required boom height/depth. The smaller of these capacities is the maximum load permitted for lift conditions.

Note: To determine working load limits the operator must also consider wind, hazardous conditions, experience of personnel and proper load handling.

8. Lower outriggers (and blade, if equipped) to increase stability.

9. Place Axle Oscillation Lock Switch to “Lock” position to increase stability. This provides a rigid support betwen the front axle and upperstructure.

OAC0680

��

3-18 80644002


Carrying a Load

With load picked and boom in desired position:

1. Raise outriggers and blade (if equipped).

2. Move Joystick Lock switch to “Lock” position to prevent accidental control actuation.

3. Attach tag lines to the load. Additional personnel must keep load in proper alignment during carry function using tag lines.

4. Move Axle Lock Oscillation Switch to “unlocked” position.

CARRYING LOADS. Never carry load with axleoscillation lock switch in “locked” or “auto” position.This could cause a loss of traction and an unstablesituation resulting in a serious accident.

5. Select travel speed based on terrain and/or walking speed of those holding tag lines.

6. With service brake pedal engaged, move Dig Brake Mode Select Switch to “Off” position. Always use service brake pedal when carrying a load to slow or stop machine.

7. Observe personnel guiding load with tag lines and clearance point between load and ground while traveling to the delivery point.

Delivering a Load

With machine at delivery point location:

1. With service brake pedal engaged, move Dig Brake Mode Select Switch to “Auto” or “On” position.

2. Move Joystick Lock Switch to “unlocked” position.

3. Lower outriggers and blade (if equipped) to increase stability.

4. Move Axle Oscillation Lock Switch to “lock” position to increase stability.

5. With tag lines attended as needed, position load at delivery point.

WARNINGOW0021

3-1980644002


3.7 LIFT CAPACITY - XL3300III, XL4300III & XL5300III

Note: This is a sample capacity chart only! DO NOT use this chart, use the one located in your operator cab.

OAC0690

LOAD POINT HEIGHT

ABOVEGROUND

LEVEL

BELOWGROUND

LEVEL

LOAD RADIUS

AT GROUND LEVEL

OVEREND

OVERSIDE

10’ (3.0m)

OVEREND

OVERSIDE

15’ (4.6m)

OVEREND

OVERSIDE

20’ (6.1m)

OVEREND

OVERSIDE

25’ (7.6m)MAXIMUMRADIUS OVER

ENDOVERSIDE

20’ (6.1m)

15’ (4.6m)

10’ (3.0m)

8’ 7” (2.4m)

5’ (1.5m)

BOOM LEVEL

20’ (6.1m)

15’ (4.6m)

10’ (3.0m)

5’ (1.5m)

8500(3855)5840

(2650)

8500(3855)5840

(2650)

12425(5635)

12425(5635)

11090(5030)8630

(3915)

6640(3010)

11090(5030)8630

(3915)

6640(3010)

8795(3990)

9880(4480)10080(4570)

10290(4665)

9815(4450)

8705(3950)

7365(3340)

6075(2755)

8795(3990)

9880(4480)10080(4570)

8705(3950)

7365(3340)

6075(2755)

10030(4550)

9800(4445)

5715(2590)

6515(2955)

7140(3240)7255

(3290)

7415(3365)

7265(3295)

6745(3060)6010

(2725)

5715(2590)

6515(2955)

7140(3240)7255

(3290)

6745(3060)6010

(2725)

7175(3255)7035

(3190)

27’ 4”(8.3m)

29’ 5”(9m)

30’ 6”(9.3m)

30’ 7”(9.3m)

30’ 7”(9.3m)29’ 11”(9.1m)

28’ 3”(8.6m)25’ 5”(7.7m)20’ 11”(6.4m)

12’ 10”(3.9m)

5070(2300)

5120(2320)

5230(2370)

5265(2390)

5070(2300)

5120(2320)

5230(2370)

5265(2390)

5375(2440)

5550(2515)

5740(2605)

5195(2355)

5310(2410)

5725(2595)

5910(2680)

5930(2690)4875

(2210)

5910(2680)

5930(2690)4875

(2210)

The above loads are in compliance with the SAE standardJ1097 DEC2005. They do not exceed 87% of hydrauliclifting capacity or 75% of tipping capacity.

Loads shown in shaded areas indicate the load islimited by tipping rather than hydraulic lift capacity.

The rated lift capacity is based on the machine beingequipped with 15,500 lb (7030 kg) counterweight, standardboom, standard tires, no auxiliary hydraulics, and no bucket.

Adjust the listed rated capacities by subtracting the valuelisted for bucket/attachment used:

8065-6007 60” (1.5 m)8065-6006 66” (1.7 m)8065-6002 72” (1.8 m)8045-6020 24” (610 mm)8045-6021 30” (762 mm)8045-6022 36” (914 mm)8045-6023 42” (1.1 m)8045-6024 48” (1.2 m)8065-6013 72” (1.8 m)8065-6102 40” (1.0 m)8065-6024 8’ (2.4 m)8065-6009 Single Tooth Ripper -

Ditching -Ditching -Ditching -Excavating -Excavating -Excavating -Excavating -Excavating -Dredging -Pavement -Blade -

807 lbs. (366 kg)892 lbs. (405 kg)944 lbs. (428 kg)603 lbs. (274 kg)660 lbs. (300 kg)741 lbs. (336 kg)841 lbs. (382 kg)957 lbs. (434 kg)1114 lbs. (505 kg)1262 lbs. (573 kg)630 lbs. (285 kg)557 lbs. (253 kg)

The load point is located on the bucket pivot point,including loads listed for maximum radius.

Do not attempt to lift or hold any load greater than theserated values at specified load radii and heights. The weightof slings and any auxiliary devices must be deducted fromthe rated load to determine the net load that may be lifted.

ATTENTION: All rated loads are based on the machine being stationary and level on a firm supporting surface. The user must make allowance for particular job conditions such as soft or uneven ground, out of level conditions, side loads, hazardous conditions, experience of personnel, etc. The operator and other personnel must read and understand the operator manual before operating this machine. Rules for safe operation of equipment must be adhered to at all times.

Note: Bucket adjustment values are 87% of the actual bucket weights.

3-20 80644002


The rated lift capacity is based on the machine being on flat, level ground andequipped with standard boom and no bucket. Adjust the listed rated capacities oncapacity chart located in operator cab according to each bucket as shown:

Note: Bucket adjustment values are 87% of the actual bucket weights. Any weight adjustment for Gradall buckets not shown can be calculated by multiplying actual bucket weight by .87.

• The load point is located on the bucket pivot point, including load listed formaximum radius.

• Do not attempt to lift or hold any load greater than the rated values at specifiedload radii and heights. The weight of slings and any auxiliary devices must bededucted from the rated load to determine the net load that may be lifted.

ATTENTION: All rated loads are based on the machine being stationary and level ona firm supporting surface. The user must make allowance for particular jobconditions such as soft or uneven ground, out of level conditions, side loads,hazardous conditions, experience of personnel, etc. The operator and otherpersonnel must be fully trained and understand this Operator Manual and SafetyManuals furnished by the manufacturer before operating this machine. Rules for safeoperation of equipment must be adhered to at all times.

Part Number Size Description Weight Adjustment

80656007 60" (1.5m) Ditching -807lbs. (366kg)

80656006 66" (1.7m) Ditching -892lbs. (405kg)

80656002 72" (1.8m) Ditching -943lbs. (428kg)

80456020 24" (610mm) Excavating -560lbs. (255kg)



80456023 42" (1.1m) Excavating -841lbs. (382kg)

80456024 48" (1.2m) Excavating -957lbs. (434kg)

80656013 72" (1.8m) Dredging -1114lbs. (505kg)

80656102 40" (1.0m) Pavement -1262lbs. (573kg)

80656024 8’ (2.4m) Blade -630lbs. (285kg)

80656009 24" Single Tooth Ripper -557lbs. (253kg)

3-2180644002


3.8 ENGINE SHUTDOWN

To shutdown the excavator, park in a safe location on flat level ground and away fromother equipment and/or traffic lanes.

1. Stop machine by engaging service brake pedal.

2. Swing the machine to align upperstructure with chassis

3. Lower attachment/boom to ground.

4. Engage park brake.

5. Operate engine at low idle for 3 to 5 minutes. DO NOT rev engine.

6. Turn key to “OFF” position and remove key.

7. Exit excavator maintaining 3-point contact.

8. Chock wheels (if necessary).

MACHINE ROLL-AWAY HAZARD. Lower boom toground or boom rest and stop engine before leavingcab.

WARNINGOW0021

3-22 80644002


3.9 PARKING THE EXCAVATOR

Precaution

Avoid parking on roads or highways. If it cannot be avoided, or in case of emergency,display warning flags, flares or flashing lights.

Parking Procedure

1. Perform “Engine Shutdown” on page 3-22.

2. Fill fuel tank to minimize condensation.

3. Disconnect battery.

4. Lock all doors and covers and install protective window covers if available.

3-2380644002


3.10 PRESERVATION & STORAGE• Park the machine following the procedure on page 3-23.

• If it is impractical to activate functions regularly, and if freezing temperatures areexpected, remove batteries and store in a warm location.

• Tape a note inside cab window indicating the person to be called in anemergency.

• If machine is on an unpaved surface, be sure tires are resting on sturdy boards toprevent them from being frozen in soft ground.

• Periodically cycle hydraulic functions until normal operating temperature isreached, then apply Boeshield *T9 (part number 1440-4645) to exposed cylinderrods.

Maintenance

• Take a sample of hydraulic fluid for analysis. Note: Not all analysis methods arecompatible with all hydraulic fluids (e.g., laser particle counters do not recordaccurate cleanliness levels in Mobil 424 due to some of the oil additives beinginterpreted as contaminants). Consult with your analysis lab as to oil type andtest method.

• Thoroughly clean all mud and debris from the machine to help protect surfacesfrom corrosion.

• Lubricate all grease fittings until fresh lube is expelled from the lube point.

• Check the hourmeter and the lubrication and maintenance schedule. If you areclose to any lubricant change period, make the change before storage.

• Check level of anti-freeze protection, drain and refill if necessary to obtain properprotection.

3-24 80644002


3.11 RAIL GEAR OPERATION (OPTIONAL)Deploying Rail Gear

Note: Ensure boom is in stowed position before proceeding.

1. Position machine on crossing, aligning with rail.

2. Rotate Upperstructure to allow operator view of rear rail gear.

3. Activate Rear Rail Gear Switch. (See “Left Hand Arm Pod” on page 2-24.)

4. Lower rail gear using right hand joystick (see “Joystick Controls” on page 2-26.) until rail gear is in firm contact with rail(s). Ensure that rear axle is not lifted clear of rail.

5. Deactiviate Rear Rail Gear Switch.

6. Rotate Upperstructure to allow operator view of front rail gear.

7. Activate Front Rail Gear Switch. (See “Left Hand Arm Pod” on page 2-24.)

8. Lower rail gear using right hand joystick (see “Joystick Controls” on page 2-26.) until rail gear is in firm contact with rail(s). Ensure that front axle is not lifted clear of rail.

9. Deactiviate Front Rail Gear Switch.

10. Engage axle oscillation lock. (See “Left Hand Arm Pod” on page 2-24.)

11. Orient Upperstructre Cab over steering axle.

Stowing Rail Gear

Note: Both front and rear rail gear can be stowed simultaneously.

1. Position machine on crossing, aligning with rail.

2. Activate Rear Rail Gear Switch. (See “Left Hand Arm Pod” on page 2-24.)

3. Raise rail gear using right hand joystick (see “Joystick Controls” on page 2-26.) until rail gear comes to a stop.

4. Deactiviate Rear Rail Gear Switch.

5. Activate Front Rail Gear Switch. (See “Left Hand Arm Pod” on page 2-24.)

6. Raise rail gear using right hand joystick (see “Joystick Controls” on page 2-26.) until rail gear comes to a stop.

7. Deactiviate Front Rail Gear Switch.

3-2580644002


The rail gear can lift the Gradall clear of the rail. Thisallows the unit to be towed on rail and roll throughtighter curves. It is important to ensure appropriatetraction before operation. If traction is not set, the unitcould roll on a grade or not have sufficient traction forbraking or drive. If track conditions change, tractionshould be tested in a safe position.

Operation on Rail

• Obey all railroad rules.

• Do Not exceed 25mph.

• Slow for curves, switches, crossings and other track features.

• Test and verify traction when conditions change.

• Exercise additional caution on wet rail.

CAUTIONOW0031

3-26 80644002

Section 4 - Attachments

SECTION 4 - ATTACHMENTS

4.1 APPROVED ATTACHMENTSTo determine if an attachment is approved for use on the hydraulic excavator you areusing, perform the following prior to installation.

• Use only Gradall approved attachments.

• Before selecting specific attachments for specific models, consult the load charton the model literature and consult either an authorized Gradall distributor orGradall.

If any of the above conditions are not met, do not use the attachment.

4.2 UNAPPROVED ATTACHMENTSUse only approved attachments. Attachments which have not been approved for use with your excavator could cause machine damage or an accident resulting in death or serious injury.

Do not use unapproved attachments for the following reasons:

• Gradall cannot establish range and capacity limitations for “will fit,” homemade,altered, or other non-approved attachments.

• An overextended or overloaded excavator can tip over with little or no warningand cause death or serious injury to the operator and/or those working nearby.

• Gradall cannot assure the ability of a non-approved attachment to perform itsintended function safely.

4.3 ATTACHMENT OPERATION• Capacities and range limits for the excavator change depending on the

attachment being used.

• Separate attachment instructions (if applicable) must be kept in Manual Holder incab with this Operator & Safety Manual. An additional copy must be kept with theattachment if it is equipped with a manual holder.

• Window guards must be in place when using powered attachments such ashammers, augers or mowers capable of producing flying debris.

WARNINGOW0021

4-180644002


Excavating Buckets

Installation Procedure

• Refer to "Adapter Attachment Installation" beginning on page 4-4.

Ditching Buckets



Size Cu. Yd. m3

24" (610mm) 3/8 .31

30" (762mm) 1/2 .41

36" (914mm) 5/8 .54

42" (1.07m) 3/4 .64

48" (1.22m) 1 .76

Size Cu. Yd. m3

30" (.80m) 1/4 .20

60" (1.52m) 7/8 .73

66" (1.68m) 1 .76

72" (1.83m) 1-1/8 .87

OAC0590

OAC0600

4-2 80644002


Trenching Buckets



Pavement Removal Bucket



Size Cu. Yd. m3

15" (381mm) 1/5 .15

Size Cu. Yd. m3

18" (.50m) N/A N/A

24" (.60m) N/A N/A

28" (.70m) N/A N/A

40" (1.02m) N/A N/A

OAC0720

OAC0730

4-380644002


Dredging Bucket



Grading Blade



Size Cu. Yd. m3

72" (1.83m) 1-1/8 .87

Size Cu. Yd. m3

8’ (2.4m) N/A N/A

OAC0740

OAC0750

4-4 80644002


4.4 ADAPTER ATTACHMENT INSTALLATION

1. Wedge Bolts

2. Bucket Adapter

3. Bucket Bars

Installation Procedure:

1. Be sure wedge bolts (1) are secured in storage position (toward rear) and position bucket adapter (2) above bucket bar (3) as shown.

2. Lower boom until concave section of adapter contacts bucket bar.

1

2

3

OAC0760

1

2

3

OAC0770

OAC0780

4-580644002


3. Move adapter toward "bucket close" position until outer end of adapter contacts bucket. Ensure proper alignment and continue to close until adapter contacts stops (1).

4. Only use the nuts to move wedge bolts forward to position wedge between adapter and bucket bar. Do not use fingers to slide wedges forward or to keep wedges from turning when tightening nuts. Be certain wedge surfaces are flush between adapter and bar and tighten fully. Jog tool control a few times and re-tighten. Check often to be sure bolts remain tight.

CRUSH HAZARD. Keep boom in fully extendedposition while installing bucket. Stay clear until bucketadapter has been fitted to bucket as shown in step 3.

Digging with a loose or improperly fitted bucket may cause excessive wear, shearadapter bolts or cause loss of bucket.

OAC0790

1

OAC0800

WARNINGOW0021

4-6 80644002

Section 5 - Lubrication & Maintenance

SECTION 5 - LUBRICATION & MAINTENANCE

5.1 INTRODUCTIONService the product in accordance with the maintenance schedule on the followingpages. Complete all required maintenance before operating unit.

Service intervals are based on machine usage of 1500 hours annually. Use of yourproduct may vary significantly and you must adjust service frequency for your usageto obtain maximum service life.

Always check hourmeter and date at beginning of shift to be certain services areperformed at proper intervals. Perform service at whichever interval comes first.

Note: Failure To Use Gradall Hydraulic Filter Elements Could Void Warranty.

FALL HAZARD. Use extreme caution when checking items beyond your normal reach. Use an approved ladder. Failure to comply could result in death or serious injury.

If guards are removed for service, replace them before operating machine.

Do not step or stand on engine cover or upper heater cover when performing checksand services in the area of the main boom and cradle.

Before removing filler caps or fill plugs, wipe all dirt and grease away from the ports.If dirt is allowed to enter ports, it can shorten the life of major hydraulic componentsalong with o-rings, seals, packing and bearings.

ELECTRICAL COMPONENT DAMAGE. Do notpressure wash or steam clean under the valve coveron the upperstructure.

When adding fluids, refer to “Product Specifications” on page 7-1 to determineproper fluid type, and“Service & Maintenance Schedules” on page 5-3 for intervals.

Clothing and Safety Gear

Wear all the protective clothing and personal safety devices issued to you or calledfor by job conditions. DO NOT wear loose clothing or jewelry that can get caught oncontrols or moving parts. Refer to page 1-13 for more detail.

WARNINGOW0021

CAUTIONOW0031

5-180644002


5.2 GENERAL MAINTENANCE INSTRUCTIONSPrior to performing any service or maintenance on the excavator, follow theshutdown procedure on page 3-22 unless otherwise instructed and place “DoNot Operate” tag on steering wheel in associated cab.

CUT/CRUSH/BURN HAZARD. Do not perform serviceor maintenance on the machine with the enginerunning. Failure to comply could cause death orserious injury.

• Ensure excavator is level for proper fluid readings.

• For boom service, extend boom, close bucket and lower onto flat ground.

• Clean lubrication fittings before lubricating.

• After greasing excavator, cycle all functions several times to distribute lubricants.

• Apply a light coating of engine oil to all linkage pivot points.

• Drain engine and gear cases after operating when oil is hot.

• Check all lubricant and coolant levels when cool.

MACHINE DAMAGE. Contact Gradall before weldingon machine. Welding could damage wires, electronicprocessors, hoses, and tubes. Prior to welding, turn offignition, unplug all electronic processors anddisconnect positive (+) and negative (-) battery cablesfrom battery posts only. Do not disconnect cable leadsfrom studs on battery box panel. Connect positive (+)and negative (-) cables together. Remove oradequately shield all components, hoses, tubes, andwires in the area. Component damage could cause anaccident resulting in death or serious injury.

Tire Service

Tire service must be performed by a qualified tire service center or an authorizedperson that is properly trained in procedures and use of safety equipment designedfor tire service.

WARNINGOW0021

WARNINGOW0021

5-2 80644002


5.3 SERVICE & MAINTENANCE SCHEDULES

10 Hour Maintenance Schedule

OAD0160

10EVERY

Windshield/WasherFluid Bottle

(clean cab glass)

Mirrors(clean and adjust

for proper visibility)

Check FuelLevel

Air FilterRestrictionIndicator

Check HydraulicOil Level

Check HydraulicReturn Filter

Indicator

Check EngineOil Level

Check EngineCoolant Level

Follow LubricationSchedule

5-380644002



OAD0170

50EVERY

Check TirePressure

Drain Fuel/Water

Separator

50EVERY

Check SwingTransmission

Oil Level

Inspectand Clean

Oil Cooler Assy.


Air FilterVacuator

Valve

5-4 80644002



100EVERY

Air FilterVacuator

Valve

CheckFan Belt

CheckBattery

Inspectand Clean

Cooler Cores


OAD0181

100EVERY

CheckTransmission

Oil Level

Check AxleOil Level


Check WheelEnd Oil Level

5-580644002


1st 30 Days (250 hrs Max) & 250 Hour Maintenance Schedule

OAD0191

250

Drain and Refill Swing Transmission

Oil

Apply OpenGear Lube to

Tilt Gear Teeth


250EVERY

Inspect, Cleanor Replace

Heater Air Filter


250

Torque all ItemsListed in

Torque Chart

1st 30 DAYS



Torque Chart

1st 30 DAYS

5-6 80644002



OAD0200

600

Change EngineOil andFilter

EVERY

5-780644002



OAD0211

750EVERY

ChangeDifferential

Oil

*- Have hydraulic fluid analyzed to determine condition. Use test port mini-check in pump line to obtain sample. Drain, flush and replenish system if required.

*

HydraulicFluid & Filters**

Change FuelFilter

Clean FuelStrainer

Replace Fuel/Water

Separator Element

750EVERY


Torque Chart

Remove, Cleanand Replace

Swing TransmissionBreather


Torque Chart

ChangeHydraulic Tank

Breather



5-8 80644002



��

��

��

��

��

�� !"�#� !��!��$��%!�� &'��&��%!��(��'#�"'�&�%!��&!'�)��&�%�% �&��!��)�#� ��*��!��'�� +��!�,

�

-��.��.!��-''��&

/�� !"0� !��1�0!�&��

�� !"��#�$��#%��!��

�� !"��#�$��#%��!��

5-980644002


5.4 LUBRICATION SCHEDULES

10 Hour Lubrication Schedule

10EVERY

*- Number of Lube Points

Grease (extreme pressure #2)

OAD0230

**

**

**

*****

**

*******

****

5-10 80644002



50EVERY



OAD0240

**

****

****

**

****

****

5-1180644002



100EVERY



OAD0250

**

5-12 80644002

Section 6 - Emergency Procedures

SECTION 6 - EMERGENCY PROCEDURES

6.1 LOSS OF POWERThe engine will de-rate if a problem develops. If this occurs, lower boom andattachment to the ground as soon as possible. Make all necessary repairs beforecontinued operation.

6.2 IF YOU GET STUCKIf unit becomes stuck, you can use the boom to help free it.

• Position boom over rear of chassis (centered over rear to prevent tipping) andimbed bucket or attachment in ground.

• While actuating travel pedal in appropriate direction, extend or retract boom asrequired to help push or pull unit to solid ground. Keep wheels in contact withground.

6-180644002



6-2 80644002


6.3 TOWING THE MACHINETo be performed ONLY by qualified field maintenance personnel.

Activate the Emergency Actuation

1. Shut down engine.

2. Block machine with wheel chocks and attach machine to tow vehicle using a rigid tow bar.

3. Disengage transmission by pumping grease into grease fitting (2) until fresh grease discharges from relief valve (3).

TRANSMISSION/AXLE DAMAGE. Do not tow above6.2MPH (10kmh), or further than .3m (5km). Doing soWILL cause transmission/axle failure.

Deactivate the Emergency Actuation

1. After towing the machine, block machine with wheel chocks before removing tow bar.

2. To deactivate the emergency actuation, open the bleed screw (1). Start the engine and shift into second gear (apply a control pressure of 30-35 bar at the connection of the brake). Tighten the bleed screw when finished.

TRANSMISSION DAMAGE. If the emergencyactuation device is deactivated incorrectly, thetransmission WILL be damaged during operation.

CAUTIONOW0031

CAUTIONOW0031

6-380644002


1

2

OAD0151

3

6-4 80644002

Section 7 - Specifications

SECTION 7 - SPECIFICATIONS

7.1 PRODUCT SPECIFICATIONS

Lubrication & Fluid Capacities

Note: Lubricants described in this table are used in standard machines when they are shipped from Gradall Industries, Inc.

Engine Crankcase Oil

Capacity with Filter Change .........................................................17 quarts (16 liters)

Type of Oil .............................................................................. 15W-40 (MIL-L-2104E)

Cooling System

System Capacity .....................................................................5.6 gallons (21,2 liters)

Type of Coolant ............................................................ 50/50 ethylene glycol & water

Hydraulic System

Capacity ....................................................................................65 gallons (246 liters)

Type of Oil ..................................... Mobilfluid® 424 Tractor Hydraulic Fluid (ISO 46)**

Transmission

Capacity ........................................................................................3 quarts (2,9 liters)

Type of Fuel............................................................................ 15W-40 (MIL-L-2104E)

Rear Axle Differential

Capacity ......................................................................................... 32 pints (15 liters)


Front Axle Differential

Capacity ........................................................................................ 20 pints (9,6 liters)


Wheel Ends

Capacity .......................................................................................... 5 pints (2,5 liters)


7-180644002


Fuel Tank (XL3300III, XL4300III & XL5300III)

Capacity.................................................................................... 99 gallons (375 liters)

Type of Fuel ..................................................................................................#2 Diesel

Fuel Tank (XL3310III, XL4310III & XL5310III)

Capacity.................................................................................... 82 gallons (310 liters)

Type of Fuel ..................................................................................................#2 Diesel

Note: Either fuel tank listed above can be used on the XL3320, XL4320 & XL5320.

Swing Transmission

Capacity....................................................................................4.75 quarts (4,5 liters)

Type of Fluid ..............................................................................EP 90 (MIL-L-2105E)

Swing Bull Gear

Capacity.....................................................................................................as required

Type of Fluid .....................................................................Extreme Pressure Lube #2

Tilt Transmission

Capacity..........................................................................32-35 ounces (0,9-1,0 liters)

Type of Fluid .................................................................................80w90 (8053-3027)

Tilt Bull Gear


Type of Fluid ................................................................ Open Gear Lube (8664-1304)

Grease Fittings


Type of Lube .....................................................................Extreme Pressure Lube #2

* Capacities are approximate - Check level to be sure** Hydraulic Fluid Specifications; Pour Point -46°F., SSU @ 100° F. 275;

Flash Point 442° F. Approved Supplier & Type: Mobil Mobilfluid 424

Tires

Air Pressure

All Tires.................................................................................. 95-105 psi (6.6-7.2 bar)

7-2 80644002


Battery

TROJAN C31BCI Group 31Maintenance Free CLAC/CALC w/handles1000 Cold Cranking AMPS @ 0°F (-17°C)200 Minutes Minimum Reserve Capacity @ 25 AMPSTop Studs: 3/8-16Trojan Type C31-1000SDimensions (LxWxH):12.970” x 8.685” x 6.750” (329.4 mm x 220.59 mm x 171.45 mm)

Weight

XL3300III

Operating Weight ...................................................................... 39,294 lb (17,823 kg)

Outriggers ..................................................................................... 2,720 lb (1,234 kg)

Blade ................................................................................................ 1,054 lb (479 kg)

XL4300III


Outriggers ..................................................................................... 2,720 lb (1,234 kg)

Blade ................................................................................................ 1,529 lb (694 kg)

XL5300III


Outriggers ..................................................................................... 2,720 lb (1,234 kg)

Blade ................................................................................................ 1,529 lb (694 kg)

XL3310III/XL3320III


Outriggers ..................................................................................... 2,720 lb (1,234 kg)

Blade ................................................................................................ 1,480 lb (671 kg)

XL4310III/XL4320III


Outriggers ..................................................................................... 2,720 lb (1,234 kg)

Blade ................................................................................................ 1,529 lb (694 kg)

7-380644002


XL5310III/XL5320III

Operating Weight.......................................................................51,216 lb (23,231 kg)

Outriggers......................................................................................2,720 lb (1,234 kg)

Blade ................................................................................................1,529 lb (694 kg)

Dimensions

XL3300III

Wheelbase.............................................................................................. 8.9 ft (2,7 m)

Ground Clearance ...............................................................................11 in (279 mm)

Transport Length (without bucket) ...................................................... 20.11 ft (6,4 m)

Transport Height (without bucket) ....................................................... 11.10 ft (3,4 m)

Transport Width ...................................................................................... 8.6 ft (2,6 m)

XL4300III

Wheelbase.............................................................................................. 8.9 ft (2,7 m)



Transport Height (without bucket) ....................................................... 11.10 ft (3,4 m)


XL5300III

Wheelbase.............................................................................................. 8.9 ft (2,7 m)



Transport Height (without bucket) ......................................................... 12.0 ft (3,7 m)


7-4 80644002


XL3310III/XL3320III

Wheelbase ..............................................................................................8.9 ft (2,7 m)


Transport Length (without bucket) .......................................................21.10 ft (6,7 m)

Transport Height (without bucket)..........................................................11.2 ft (3,4 m)

Transport Width .......................................................................................9.0 ft (2,7 m)

XL4310III/XL4320III

Wheelbase ..............................................................................................8.9 ft (2,7 m)





XL5310III/XL5320III

Wheelbase ..............................................................................................8.9 ft (2,7 m)





7-580644002


7.2 TORQUE CHARTTo check Gradall torque values, set the torque wrench at 95% of the rated torquevalues and check fastener. If the torque wrench releases before the fastener moves,assume fastener torque is correct. When setting Gradall torque values, use thevalues given on the following chart. DO NOT EXCEED allowances.

Boom Cylinder Rod Retainer

Quantity .....................................................................................................................6

Thread Size (grade)..................................................................................... 5/8-11 (8)

Torque (lubricated).......................................................... 200-215 lb-ft (272-292 N·m)

Swing Bearing

Quantity ...................................................................................................................72



Swing Motor

Quantity .....................................................................................................................4


Torque (lubricated)................................................................ 68-78 lb-ft (92-105 N·m)

Swing Transmission

Quantity ...................................................................................................................10



Tilt Bearing

Quantity ...................................................................................................................63



Tilt Motor

Quantity .....................................................................................................................2


Torque (lubricated)................................................................ 68-78 lb-ft (92-105 N·m)

7-6 80644002


Tilt Transmission

Quantity .....................................................................................................................8

Thread Size (grade) .................................................................................... 5/8-11 (8)

Torque (lubricated) ..........................................................200-215 lb-ft (272-292 N·m)

Wheel Lug Nuts

Quantity .................................................................................................................ALL

Thread Size (grade) ............................................................................. M22X1.5 (8.8)

Torque (lubricated) ..........................................................450-500 lb-ft (610-678 N·m)

7-780644002


7.3 FUSESFuse location and size designations are identified with the decal shown below.

FI MONITOR POWERF2 SPARE IGNITION POWERF3 RC POWER - 1F4 SENSOR POWERF5 RC POWER - 3F6 RC POWER - 2F7 SP-3F8 SP-2F9 SP-1F10 JOYSTICK POWERF11 HYD PILOT POWERF12 MR IGN POWERF13 ADM IGN POWERF14 DIAG IGN POWERF15 SPARE ACC RLY POOWERF16 KEY POWERF17 FLASHER POWERF18 SPARE ACCY - A POWERF19 SPARE ACCY - B POWERF20 12V POWER PORTF21 POWER OUTLET #1F22 COLUMN POWERF23 BATTERY POWERF24 SPARE BATTERY POWERF25 DIAG BAT POWERF26 HORN POWERF27 WIPER POWERF28 HEATER POWERF29 TILT/AUXILIARY POWERF30 BLADE O.R. SWITCH POWERF31 POWER OUTLET #2F32 SWITCH POWERF33 WASHER POWERF34 A/C CLUTCHCB1 HEAD LIGHT POWER

IGNITION ACCESSORY

BATTERY

F1

F2

F3

F4

F5

F6

F7

F8

F9

F10

F11

F12

F13

F14

CB1

F15

F16

F17

F23

F24

F25

F26

F18

F19

F20

F21

F22

F27

F28

F29

F30

F31

F32

F33

F34

10A

10A

3A

5A

15A

15A

10A

10A

10A

3A

3A

10A

10A

10A

10A

10A

25A

20A

10A

10A

10A

10A

15A

10A

10A

10A

15A

25A

25A

10A

15A

10A

10A

10A

10A

ATTENTION:USE FUSE SIZES AS DESIGNATED.USING THE WRONG FUSE SIZE CANCAUSE DAMAGE TO ELECTRICALSYSTEM.

8076-3006 - A

OAD0310

7-8 80644002

Gra

dall

Whe

eled

Exc

avat

or P

re-O

pera

tion

Insp

ectio

n Ch

eckl

ist

ID

/Ser

ial N

umbe

r:

Shift

:

Dat

e:

B

efor

e co

nduc

ting

the

wal

k ar

ound

insp

ectio

n, m

ake

sure

the

engi

ne is

off

and

the

tran

smis

sion

is in

neu

tral

with

the

park

bra

ke e

ngag

ed.

The

boo

m a

nd a

ttac

hmen

t mus

t be

rest

ing

on th

e gr

ound

and

secu

rely

blo

cked

.

Item

√

Com

men

ts if

no

t O.K

. It

em

√C

omm

ents

if

not O

.K.

Ope

rato

r an

d Sa

fety

Man

uals

– lo

cate

d in

cab

Tra

nsm

issi

on –

no

leak

s, un

dam

aged

W

arni

ng D

ecal

s – in

pla

ce a

nd le

gibl

e

Bra

kes –

no

dam

age;

in g

ood

cond

ition

G

rab

Han

dles

and

Ste

ps –

secu

re a

nd c

lean

C

ab W

indo

ws a

nd D

oor

– no

t bro

ken

and

clea

n, d

oor

latc

hes i

n op

en a

nd c

lose

d po

sitio

n

Hor

n –

clea

n an

d un

dam

aged

Se

at B

elt –

und

amag

ed; w

orki

ng c

ondi

tion

M

irro

rs –

goo

d co

nditi

on, c

lean

, and

pro

perly

adj

uste

d

Fr

ont A

xle

– st

eerin

g lin

kage

- go

od c

ondi

tion;

no

cylin

der

or h

ose

leak

s, no

axl

e le

aks

H

eadl

ight

s, M

arke

r L

ight

s, an

d T

urn

Sign

als –

cle

an

and

unda

mag

ed

Whe

els –

che

ck lu

g nu

t tor

que;

no

dam

age

or c

rack

s

Boo

m –

rolle

rs a

djus

ted,

no

dam

age

Tir

es –

pro

per i

nfla

tion;

no

dam

age;

ade

quat

e tre

ad

B

oom

Att

achm

ent –

secu

rely

inst

alle

d

W

ork

light

s – C

lean

and

und

amag

ed

Hyd

raul

ic H

oses

and

Cyl

inde

rs –

no

leak

s or d

amag

e

Fu

el T

ank

– no

leak

s; fi

ller c

ap se

cure

ly fa

sten

ed

Fu

el L

evel

– a

dequ

ate

Rea

r A

xle

– no

axl

e le

aks

W

inds

hiel

d W

ashe

r Fl

uid

– le

vel a

dequ

ate

in c

ab

Hyd

raul

ic O

il R

eser

voir

– o

il is

cle

ar a

nd a

t pro

per l

evel

B

oom

Tilt

Bea

ring

– p

rope

rly lu

bric

ated

, und

amag

ed

M

ain

cont

rol v

alve

and

cov

er –

no

dam

age

or le

aks;

co

ver s

uppo

rt ga

s stru

t and

latc

h w

orki

ng p

rope

rly

Bat

tery

– c

able

s tig

ht

Mai

nten

ance

– u

p to

dat

e w

ith sc

hedu

le in

man

ual

Eng

ine

– oi

l and

coo

lant

at p

rope

r lev

el.

Lub

rica

tion

– re

fere

nce

lubr

icat

ion

char

t in

man

ual

Air

Cle

aner

– c

heck

ele

men

t con

ditio

n in

dica

tor

Rad

iato

r –

free

of d

ebris

, no

leak

s

Ove

rall

Mac

hine

Con

ditio

n –

no c

rack

s on

boom

, up

pers

truct

ure

fram

e, c

hass

is fr

ame,

or f

iber

glas

s

Com

men

ts:

DO

NO

T O

PER

AT

E U

NSA

FE E

QU

IPM

EN

T

Rep

air

any

defic

ienc

ies b

efor

e dr

ivin

g or

ope

ratin

g th

e eq

uipm

ent

O

pera

tors

Sig

natu

re:

D

ate:

Gradall W

heeled Excavator Pre-Operation Inspection Checklist

ID

/Serial Num

ber:

Shift:

Date:

B

efore conducting the operational check of the excavator perform a w

alk around inspection. Do not operate the

excavator until any discrepancies noted during the walk around inspection have been repaired. M

ake sure others are clear of the m

achine before starting the engine and during operation.

Item

√

Com

ments if

not O.K

. Item

√C

omm

ents if not O

.K.

Control C

ut Out L

ever – engine only starts with lever

raised; controls do not operate with lever raised.

T

ravel Alarm

(Work and T

ravel Modes) – function

properly

Park Brake – functions properly

H

orn – functions properly

H

ead Lights, M

arker Lights, T

urn Signals – clean and function properly

B

oom Functions (B

oom - U

p, Dow

n, In, Out, T

ilt Left

& R

ight, Bucket O

pen & C

losed) – function properly

Engine – operates properly

Lights, Indicators, and G

ages – function properly

Swing Function – sw

ing left, right, and swing brake

functions properly

Windshield W

iper – functions properly

Swing L

ights – function properly

C

ontrol Pattern Decal – m

atches control pattern

Swing L

ock – functions properly

Steering – functions properly

Service Brakes – functions properly

O

utriggers (if equipped) Up and D

own – function

properly

Dig B

rakes (On, O

ff, Auto M

ode) – function properly

Blade (if equipped) U

p and Dow

n – functions properly

Joystick L

ockout – functions properly

T

ransmission – travel forw

ard and rearward

A

xle Oscillation L

ock (On, O

ff, Auto M

ode) – function properly.

Com

ments:

DO

NO

T O

PER

AT

E U

NSA

FE E

QU

IPME

NT

R

epair any deficiencies before driving or operating the equipment

O

perators Signature:

Date:

Gra

dall

Whe

eled

Exc

avat

or P

re-O

pera

tion

Insp

ectio

n Ch

eckl

ist

ID

/Ser

ial N

umbe

r:

Shift

:

Dat

e:

B

efor

e co

nduc

ting

the

wal

k ar

ound

insp

ectio

n, m

ake

sure

the

engi

ne is

off

and

the

tran

smis

sion

is in

neu

tral

with

the

park

bra

ke e

ngag

ed.

The

boo

m a

nd a

ttac

hmen

t mus

t be

rest

ing

on th

e gr

ound

and

secu

rely

blo

cked

.

Item

√

Com

men

ts if

no

t O.K

. It

em

√C

omm

ents

if

not O

.K.

Ope

rato

r an

d Sa

fety

Man

uals

– lo

cate

d in

cab

Tra

nsm

issi

on –

no

leak

s, un

dam

aged

W

arni

ng D

ecal

s – in

pla

ce a

nd le

gibl

e

Bra

kes –

no

dam

age;

in g

ood

cond

ition

G

rab

Han

dles

and

Ste

ps –

secu

re a

nd c

lean

C

ab W

indo

ws a

nd D

oor

– no

t bro

ken

and

clea

n, d

oor

latc

hes i

n op

en a

nd c

lose

d po

sitio

n

Hor

n –

clea

n an

d un

dam

aged

Se

at B

elt –

und

amag

ed; w

orki

ng c

ondi

tion

M

irro

rs –

goo

d co

nditi

on, c

lean

, and

pro

perly

adj

uste

d

Fr

ont A

xle

– st

eerin

g lin

kage

- go

od c

ondi

tion;

no

cylin

der

or h

ose

leak

s, no

axl

e le

aks

H

eadl

ight

s, M

arke

r L

ight

s, an

d T

urn

Sign

als –

cle

an

and

unda

mag

ed

Whe

els –

che

ck lu

g nu

t tor

que;

no

dam

age

or c

rack

s

Boo

m –

rolle

rs a

djus

ted,

no

dam

age

Tir

es –

pro

per i

nfla

tion;

no

dam

age;

ade

quat

e tre

ad

B

oom

Att

achm

ent –

secu

rely

inst

alle

d

W

ork

light

s – C

lean

and

und

amag

ed

Hyd

raul

ic H

oses

and

Cyl

inde

rs –

no

leak

s or d

amag

e

Fu

el T

ank

– no

leak

s; fi

ller c

ap se

cure

ly fa

sten

ed

Fu

el L

evel

– a

dequ

ate

Rea

r A

xle

– no

axl

e le

aks

W

inds

hiel

d W

ashe

r Fl

uid

– le

vel a

dequ

ate

in c

ab

Hyd

raul

ic O

il R

eser

voir

– o

il is

cle

ar a

nd a

t pro

per l

evel

B

oom

Tilt

Bea

ring

– p

rope

rly lu

bric

ated

, und

amag

ed

M

ain

cont

rol v

alve

and

cov

er –

no

dam

age

or le

aks;

co

ver s

uppo

rt ga

s stru

t and

latc

h w

orki

ng p

rope

rly

Bat

tery

– c

able

s tig

ht

Mai

nten

ance

– u

p to

dat

e w

ith sc

hedu

le in

man

ual

Eng

ine

– oi

l and

coo

lant

at p

rope

r lev

el.

Lub

rica

tion

– re

fere

nce

lubr

icat

ion

char

t in

man

ual

Air

Cle

aner

– c

heck

ele

men

t con

ditio

n in

dica

tor

Rad

iato

r –

free

of d

ebris

, no

leak

s

Ove

rall

Mac

hine

Con

ditio

n –

no c

rack

s on

boom

, up

pers

truct

ure

fram

e, c

hass

is fr

ame,

or f

iber

glas

s

Com

men

ts:

DO

NO

T O

PER

AT

E U

NSA

FE E

QU

IPM

EN

T

Rep

air

any

defic

ienc

ies b

efor

e dr

ivin

g or

ope

ratin

g th

e eq

uipm

ent

O

pera

tors

Sig

natu

re:

D

ate:

Gradall W

heeled Excavator Pre-Operation Inspection Checklist

ID

/Serial Num

ber:

Shift:

Date:

B

efore conducting the operational check of the excavator perform a w

alk around inspection. Do not operate the

excavator until any discrepancies noted during the walk around inspection have been repaired. M

ake sure others are clear of the m

achine before starting the engine and during operation.

Item

√

Com

ments if

not O.K

. Item

√C

omm

ents if not O

.K.

Control C

ut Out L

ever – engine only starts with lever

raised; controls do not operate with lever raised.

T

ravel Alarm

(Work and T

ravel Modes) – function

properly

Park Brake – functions properly

H

orn – functions properly

H

ead Lights, M

arker Lights, T

urn Signals – clean and function properly

B

oom Functions (B

oom - U

p, Dow

n, In, Out, T

ilt Left

& R

ight, Bucket O

pen & C

losed) – function properly

Engine – operates properly

Lights, Indicators, and G

ages – function properly

Swing Function – sw

ing left, right, and swing brake

functions properly

Windshield W

iper – functions properly

Swing L

ights – function properly

C

ontrol Pattern Decal – m

atches control pattern

Swing L

ock – functions properly

Steering – functions properly

Service Brakes – functions properly

O

utriggers (if equipped) Up and D

own – function

properly

Dig B

rakes (On, O

ff, Auto M

ode) – function properly

Blade (if equipped) U

p and Dow

n – functions properly

Joystick L

ockout – functions properly

T

ransmission – travel forw

ard and rearward

A

xle Oscillation L

ock (On, O

ff, Auto M

ode) – function properly.

Com

ments:

DO

NO

T O

PER

AT

E U

NSA

FE E

QU

IPME

NT

R

epair any deficiencies before driving or operating the equipment

O

perators Signature:

Date:

IndexIndex

AAdapter Attachment Installation 4-5–4-6

Approved Attachments ..................... 4-1

Attachment Operation ...................... 4-1

Attachments ..................................... 4-1

BBattery .............................................. 7-3

Brake System................................... 3-4

CCab Components ........................... 2-12

Cab Controls & Indicators .............. 2-14

Capacities......................................... 7-1

Chemical Hazards .......................... 1-10

Crush Hazards ................................. 1-6

DDecals .......................2-5, 2-7, 2-9, 2-11

Dig Cycle........................................ 3-10

Ditching Buckets............................... 4-2

Dredging Bucket............................... 4-4

Dust Hazard ................................... 1-12

EElectrical Hazards ............................ 1-2

Electronic Monitoring Unit .............. 2-14

Electronic Monitoring Unit Digital Display2-16

Activating Menu Mode .............. 2-19Changing Display Variables...... 2-17System Status........................... 2-18System Status Alarms............... 2-19User Interface - Menu Mode ..... 2-20User Interface - Work Mode...... 2-16Visual Display (Menu Mode)..... 2-21Visual Display (Work Mode)...... 2-17

Emergency Procedures.................... 6-1

Engine Operation ............................. 3-1

Engine Shutdown ........................... 3-22

Excavating Buckets .......................... 4-2

FFuse Panel........................................7-8

GGrading Blade ...................................4-4

IIgnition ............................................2-32

Intermittent Wiper/Washer ..............2-33

JJoystick Control Pattern Selection ..2-26

Joystick Controls.............................2-27

LLeft Hand Arm Pod .........................2-24

Lift Capacity ....................................3-20

Lifting a Load ..................................3-16

Lubrication & Maintenance ...............5-1

Lubrication Schedule ......................5-1010 Hour......................................5-10100 Hour....................................5-1250 Hour......................................5-11

OOperator Seat .................................2-31

PPark Brake Switch...........................2-34

Parking Procedure ..........................3-23

Pavement Removal Bucket...............4-3

Personal Protection Equipment ......1-13

Placing a Load ................................3-16

Pre-Operation and Controls ..............2-1

Pre-Operation Checks ......................2-1

Preservation & Storage...................3-24

RRail Gear Operation ........................3-25

Right Hand Arm Pod .......................2-22

180644002

Index

SSafety Practices................................ 1-1

Safety Signal Words......................... 1-1

Service & Maintenance Schedule..... 5-310 Hour ....................................... 5-3100 Hour ..................................... 5-51500 Hour ................................... 5-91st 30 Days ................................. 5-6250 Hour ..................................... 5-650 Hour ....................................... 5-4600 Hour ..................................... 5-7750 Hour ..................................... 5-8

Slip and Fall Hazard ......................... 1-5

Specifications ................................... 7-1

Swing Hazards ................................. 1-3

TTip Over Hazard ............................... 1-9

Tire Pressure.................................... 7-2

Tires.................................................. 7-2

Travel Hazard................................... 1-8

Travel Modes.................................... 3-6Moving Machine Less than 4.6m

(5yds) ................................. 3-6Moving Machine to a Different Work

Area.................................... 3-7Over-the-Road Travel ................. 3-8Performing Grading Operations .. 3-7

Trenching Buckets............................ 4-3

WWheel Lug Nut.................................. 7-7

2 80644002

Hand Signals

Special Signals - When signals for auxiliary equipment functions or conditions not covered are required, they shall be agreed upon in advance by the operator and signalman.

EMERGENCY STOP - With both arms extended laterally, hands open downward, move arms back and forth.

STOP - With either arm extended laterally, hand open downward, move arm back and forth.

STOP ENGINE - Draw thumb or forefinger across throat.

RAISE BOOM - With either arm extended horizontally, fingers closed, point thumb upward.

LOWER BOOM - With either arm extended horizontally, fingers closed, point thumb downward.

MOVE SLOWLY - Place one hand motionless in front of hand giving motion signal. (Raise load slowly shown)

EXTEND BOOM - With both hands clenched, point thumbs outward.

RETRACT BOOM - With both hands clenched, point thumbs inward.

THIS FAR TO GO - With hands raised and open inward, move hands laterally, indicating distance to go.

SWING- With either arm extended horizontally, point with forefinger to direction of swing rotation.

OPEN BUCKET- Hold one hand open and stationary. Rotate other hand in small vertical circle with forefinger pointing horizontally at open hand.

CLOSE BUCKET- Hold one hand closed and stationary. Rotate other hand in small vertical circle with forefinger pointing horizontally at closed hand.

OY1090 OY1100 OY1110

OY1120 OY1130 OY1140

OY1150 OY1160 OY1170

OAC0300

OAC0310 OAC0310

Gradall Industries, Inc.

406 Mill Ave SW

New Philadelphia OH. 44663

USA

Phone: (330) 339-2211

Customer Support Toll Free: (800) 445-4752

Fax: (330) 339-3579

www.gradall.com

Gradall Europe

Division of Tieluiska

Harkkokatu 6

FI-05800 Hyvinkää, Finland

Tel. +358 (0)20 759 0400

Fax. +358 (0)19 485 278

VAT:FI05973039

www.gradalleurope.com

operator & safety manual - gradall excavator...

Documents