operation & lubrication manual - Gradall Hydraulic Excavators Service
Contents
1. 30 PARKING THESIBADSd s uius icai i era citur BNR ACURA TEST MGR NR eol 31 PIED ca ook fme HO inii ness ate dau aer dic ned bacc 31 Parking cisco sae aeri med ieee mis veis 4003 SNR NUN QE Bd cix adu voor rama a 31 INCASE OF TROUBLE gt gt ec qun adn ENS FUR AMET ipa cont amd race namin diu d 31 TOWNE ans sory cern a RES BEE eae QUEE WR Res Quia Mente xcti ware ba sing Vig xm 31 LUBRICATION 4 vococpru tdas Wa d ULS Des anos was coun Hine Barca eve Xv dis 32 6 x 4 Carrier Lubrication and Maintenance Diagram 32 6 x 6 Carrier Lubrication and Maintenance Diagram 34 Recommended Lubricants amp Capacities 36 Torg Chati tdi om vage wan dir VERS dita ete 36 Securing Boom Bucket for Travel esu was cei Ebr ens iaa cioe ere inside back cover If You Get Sines aden de sax B58 Lae pura sits as2. Rage WEA tS V DEHA Ves 854 Aud aeu oxen 1 INTRODUCTION nee aceros wales Qus pee URT WOE poemas debut alid tomis 2 General roere 1494 354 845 LE ERG aod nots mary nd aieiai Comme miele qum 2 3053 drinks tk serons mismes aire ewe iui 2 Operator Qualifications didici nia sns ssi anardinds Ht dara iil am diera Me Union 2 Orientation Kop AA M a ii aps wien 4 WES ERE ROS VOX UA REN way Moo COLE Qus UA IUS baton 2 Senak Number Location san 2x0 Ways FEET WHS RIBS GEG ara Leo es eo 2 SAFETY HIGHLIGHTS t siti WAG gt BAS CORE nce vidis 3 INSTRUMENTS AND INDICATORS 2252 vctus rte ena mms tenta suem acie Wold ps 11 CONTROLS c ces 1923 8 QN TEX ee timete dene wri inv ees Gin aad Game Huse DES 12 CHECKS AND SERVICES BEFORE STARTING ENGINE 0 cccecccccuucccccuuecccecens 13 qa qai anseis Ga iow wid sean muon adodk oss Bh a eter es
3. inside back cover INTRODUCTION General This manual provides important information to familiarize you with required operator maintenance and with safe operating procedures for the Gradall wheeled excavator undercarriage Because two operators are sometimes assigned to the unit operator information for the upper structure and for the undercarriage is provided in separate manuals The undercarriage includes a separate operator s station for control of undercarriage functions and is equipped with a separate engine to propel the unit Throughout this manual the term carrier will be used to designate the excavator undercarriage Related Manuals Separate publications are furnished with the Gradall to provide information concerning safety replacement parts detailed maintenance proce dures vendor components and operation of the upperstructure You must read and understand the Gradall Upper structure Operation amp Lubrication Manual the Gradall Hydraulic Excavators Safety Manual and the CIMA Hydraulic Excavator User s Safety Manual before operating the upperstructure If you have any questions regarding the Gradall Carrier or the Upperstructure contact your Gradall Distributor he is thoroughly familiar with the unit and will be happy to help you Operator Qualifications The operator must hold a valid applicable driver s license which requires acceptable age vision hearing manual dexterity a
4. imum torque may cause failure of fastener THREAD TORQUE lubricated POUND FEET NEWTON METRES Spring U Bolt Nuts 34 16 Steering Gear Box 78 14 8 Wheel Lug Nuts spoke wheel 6 x 4 Front 6 x 4 Rear 6 x 6 Front 6 x 6 Rear Wheel Lub Nuts disc wheel 36 SECURING BOOM 8 ATTACHMENT FOR TRAVEL 4 If unit becomes stuck in soft ground you can use the boom to help free it Position carrier and upperstructure controls for remote control operation Position boom over rear of carrier centered over 37 rear to prevent tipping and imbed bucket in ground While actuating travel pedal in appropriate direction extend or retract boom as required to help push or pull unit to solid ground Raise or lower boom as necessary to keep rear wheels in proper contact with ground CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm GRADALL 406 Mill Ave SW New Philadelphia Ohio 44663 Phone 330 339 2211 FAX 330 339 8468 hitp www gradall com Printed in USA
5. reason it is extremely important that you NEVER TURN ENGINE WHILE TRAVELING In the event power steering fails stop as soon as possible Do not drive unit until problem has been corrected 21 POWER TRAIN The power train furnished on 6x4 carriers units having two driving axles at rear includes the engine clutch transmission rear tandem axles and the necessary propeller shafts to transfer torque power between these units The major variations found on 6x6 carriers units having two driving axles at rear and a third driving axle in front are the substitution of a front driving axle in place of a non driving front axle and the addition of a transfer case to drive front axle Clutch The clutch is located within a housing between the engine and transmission and functions to control the transfer of torque from engine to transmission Depressing the clutch pedal disengages the clutch and prevents a transfer of torque from the engine to the transmission Releasing the clutch pedal engages the clutch and causes a transfer of torque from the engine to the transmission Clutch Brake The clutch brake slows rotation of transmission input gearing Its only purpose is to ease the shift from neutral to lst or reverse gear while the carrier is stopped The clutch brake is controlled by the clutch brake button mounted on the rear side of the gear shift lever Depress button to apply brake and release button to r
6. drain and refill to level on dipstick item 18 is oil filter cap 41 Fuel Filter Water Drain drain water from filter Pao maximum Check torque of all items listed in torque chart page 36 At End of First 30 Days Annual Lubrication amp Maintenance Check torque of all items listed in torque chart page 36 z 2 includes all daily weekly monthly amp semi annual services 12 Steering system drain amp refill to level EQ 1 Monthly Lubrication amp Maintenance 19 Coolant Filter replace element 1 includes all daily and weekly services 20 Fuel Filter replace element E 1 1 Steering Cylinder Pivots CG 2 23 Fuel Strainer clean or replace element 1 2 Battery check electrolyte level and replenish as req d 2 31 Air Drier refer to page 20 of this manual 1 3 Slack Adjuster 6 36 Differential Drain Plug drain and refill GO 2 5 King Pin Bearings CG 6 43 amp 44 Transmission Front and Rear Drain Plug drain front amp rear sections amp replace drain 7 Tie Rod Ends 2 plugs items 27 amp 28 are level plugs Fill each section to its own level GO 2 9 Spring Anchor Pin CG 2 10 Shift Tower Shaft CG 2 11 Shift Linkage Universal Joint CG 1 12 Power Steering Reservoir check level amp refill as req d EQ 1 14 Steering Universal Joints CG 2 15 Steering Shaft Splines CG 1 24 Clutch Throwout Bearing lubricate sparingly CG 1 LUBRICATION Clean lubrication fittings
7. 31 Air Drier refer to page 20 of this manual 1 14 ply 1W psi Rear Tire 10 W x 20 14 ply 90 psi 9 00 x 20 12 ply 85 psi 32 Differential Fill and Level Plug check and fill to level GO 2 10 00 x 20 14 ply 90 psi 10 34 Walking Beam Pivot CG 2 37 Drag Link Ball Joints Cg 2 40 Engine Crankcase Dipstick check level amp refill as req d EO 1 Orig pee 99 38 Clutch Pedal Pivot Shaft 2 At End of First 20 Hours 42 Clutch Trowout Shaft Bearing CG 2 17 Engine Oil Filter replace 1 Semi Annual Lubrication amp Maintenance 39 Engine Crankcase Drain Plug drain amp refill EO 1 includes all daily weekly amp monthly services 4 Brake Camshaft lubricate sparingly CG 6 43 amp 44 Transmission Front amp Rear Drain Plugs drain front amp rear sections amp replace drain 6 Wheel Beari front axle remove clean pack and install plugs items 27 amp 28 are level plugs Fill each section to its own level GO 2 garnas iront axie T p CG 2 16 Engine Drive Belt check condition and tension replace or adjust as req d 1 Weekly Lubrication amp Maintenance 17 Engine Oil Filter replace elements at each oil change 250 hours maximum 2 includes daily services 26 Transmission Breather remove clean and install 1 35 Differential Breather remove clean and install 2 9T Automatic Reservoir Drain Nalves Aller TO 53 mann E f 39 Crankcase Drain Plug
8. APPLICATION ff Release parking brake by depressing parking brake control knob system must be pressurized to release parking brake Digging brake Digging brakes are furnished on units equipped only for conventional control as well as on units equipped for both conventional and remote control When activated the digging brake is applied to all wheels to hold the carrier stationary while the excavator is digging Air pressure requirements for digging brake application are not the same as those for the service brake 60 to 85 p s i 414 to 586 kPa If pressure is lost after the digging brake has been applied emergency brakes will be applied automatically DIGGING BRAKE APPLICATION DIGGING BRAKE TOGGLE ON DASH Move digging brake control toggle to ON position only when carrier is stopped Maximum braking is applied to wheels when toggle is moved to ON Moving toggle to ON while traveling would also cause disengagement of clutch and engagement of remote drive power take off Apply digging brake by moving control toggle to ON position and release by moving toggle to OFF position amp D BRANE The DIGGING BRAKE indicator light will flash on and off when digging brake is applied and ignition switch is turned on Remote control braking The digging brake is applied by the control toggle in the carrier cab After moving digging brake control toggle to ON the digging brake will be released and reappli
9. ENGINE pages 11 amp 12 CHECKS AFTER STARTING THE ENGINE page 17 and CHECKS BEFORE DRIVING page 17 before driving the carrier Complete all required maintenance before driving the carrier SAFETY HIGHLIGHTS Learn to recognize PINCH POINTS Upperstructure amp Carrier Bucket amp Linkage Learn to recognize PINCH POINTS and stay clear of them Getting caught ina pinch point can cause serious injury or death 4 Check to be sure aff DANGER WARNING CAUTION and INSTRUCTION DECALS are in place and can be read Clean or replace decals as required Some owners alter their machines Check to be sure your machine fits the pictures and description in this manual If it differs or if you aren t sure contact your Gradall distributor before you run your unit Always sound horn to warn others of unexpected machine movements horn button is located at top of left joystick The unit is also equipped with an automatic back up alarm to warn others of reverse travel SAFETY HIGHLIGHTS Keep steps and deck areas free of mud oil grease and other foreign material Replace non skid surface material as required Never carry a water can equipment or other worker s tools or personal items on the machine Such items can cause other workers to approach the machine without your knowledge and result in serious injury or death Stay clear of moving tan belts pulleys meshing gears d
10. amp install Check torque of all items listed torque chart page 36 i Annual Lubrication amp Maintenance includes all daily weekly monthly amp semi annual services 8 Differential Drain Plug drain amp refill item 3 is fill amp level plug GO 16 Wheel Bearings front axle remove clean pack and install CG 17 Wedge Brakes lube per Rockwell Lubrication Manual SG 19 Air Drier service or replace cartridge refer to page 20 of this manual 25 Coolant Filter replace element 26 Fuel Filter replace element 29 Steering System drain amp refill to level ATE 30 Fuel Strainer clean or replace element 41 Differential Drain Plug drain and refill GO 49 amp 50 Transmission Front amp Rear Drain Plugs drain front amp rear sections amp replace drain plugs items 34 amp 35 are fill amp level plugs each section to its own level GO 52 Transfer Case Drain Plug drain and refill to level item 53 is fill amp level plug GO Refer to vendor component literature in service manual for additional lubrication and maintenance requirements Clean lubrication fittings before lubricating Intervals shown are for normal 8 hour day usage and conditions Ad just intervals for abnormal usage and conditions See recommended lubricants Page 36 Lubricate points indicated by dotted leaders on both side of unit Drain engine and gear cases only after operation when lubricant is hot C
11. before lubricating Lubricate points indicated leaders on Clean filter and air cleaner housing and reusable both side of unit elements using cleaning solvent or diesel fuel Dry NOTE Intervals shown are for normal 8 hour day usage and conditions Adjust intervals for abnormal usage Drain engine and gear cases only after operation components Vorougnby using sit ree and conditions when lubricant is hot Apply a light coating of engine oil to all linkage pivot Check lubricant levels when lubricant is cool points See recommended lubricants Page 36 re 21 6X6 CARRIER LUBRICATION amp MAINTENANCE DIAGRAM 10 11 SYMBOLS e Fitting Other Service 22 23 24 25 25 27 28 GO EO 3 32 33 34 35 36 36 37 36 8 344 Grease Extreme Pressure Multi Purpose Lubricant Engine Oil 29 74 P Refer to vendor component literature in service manual LUBRICANT SYMBOLS for additional lubrication and maintenance requirements SG Special Grease 30 36 37 42 36 39 40 41 S 9 20 27 38 45 23 46 Item Lube Daily Lubrication amp Maintenance Fuel Tank fill at end of work shift to minimize condensation Radiator Filler Cap check coolant level and replenish as req d Symbol Air Cleaner Condition Indicator observe indicator amp clean or replace air cleaner element as req d item 28 is air cleaner Tires check for damage amp pressure Front
12. brake 2 Shift transmission to neutral 3 Move DIGGING BRAKE toggle to OFF position 4 If condition permit move inter axle differential toggle to UNLOCK position 5 Shift transfer case to engage or disengage front drive axle as appropriate for driving conditions if so equipped PARKING THE GRADALL Precautions Avoid parking on banks or near an excavation chine with boom air Avoid parking on roads or highways If It can Park on level ground and block wheels not be avoided be sure to display warning flags during day and flares or flashing lights at night If parking on a slope cannot be avoided posi tion unit at right angle to slope and block Position boom In boom rest never leave ma wheels Parking Procedure 5 Block carrier wheels as extra precaution against l Using service brake stop unit in appropriate rolling parking area 6 Fill fuel tank to minimize condensation 2 Set PARKING BRAKE to ON 7 Lock carrier and upperstructure cabs and install 3 Allow engine to cool at idle speed for a few protective window covers if available minutes and then turn off 8 Disconnect batteries if unit is in an area where 4 Shifttransmission to first gear tampering seems possible IN CASE OF TROUBLE Park unit in a safe area apply parking brake and block wheels Display warning flags flares or flashing lights as necessary 2 Contact supervisor and advise Nature of problem Location of unit Whe
13. controlled by a toggle lever mounted at the lower right portion of the dashboard With toggle in UNLOCK position the front and rear tandem axles are permitted to rotate at different speeds to compensate for worn tires on one of the axles Keep toggle in UNLOCK position when driving on good tractive conditions With toggle in LOCK position there is positive drive to the front and rear tandem axles and either axle will drive up to its maximum tractive ability without regard to the other axle Keep toggle in LOCK position when driving over poor tractive conditions mud ice snow or off road travel Also use lock position for remote control travel The inter axle differential may be locked when traveling BUT NEVER when wheels have lost traction and are spinning CAUTION Serious damage will occur if inter axle differential is shifted while wheels are spinning If shifting inter axle differential while traveling release accelerator first to provide an interruption in torque to the axles KEEP CARRIER IN GEAR WHILE DRIVING COASTING IS DANGEROUS AND MAY CAUSE SERIOUS DAMAGE TO TRANSMISSION 28 REMOTE CONTROL NOTE Remote control is to be used for positioning unit at job site not for over the road travel Preparing Carrier for Remote Control Operation With carrier on level surface apply parking brake Start carrier engine and develop full brake system pressure in front and rear portions of system 125
14. next lower gear or serious damage to engine may result Use service brake to slow carrier to proper speed for downshift it necessary aviv Y LUIN As conditions permit use upshift double clutching method to shift thru 7th 8th and 9th gears to 10th gear MAXIMUM CARRIER SPEED IN EACH GEAR GEAR MI HR KM HR NOTE Gears in the main transmission are not synchronized and double clutching procedure must be used when shifting 26 1 Using downshift double clutching method shift thru 9th 8th and 7th gears to 6th gear Ri If it is necessary to shift to deep reduction move deep reduction button forward to LO LO position i Transmissions 6 Immediately shift to LL3 using downshift double clutching method While still in 6th gear push range preselection lever down to LO range position Using downshift double clutching method im mediately shift to 5th gear Transmission will shift to LO range as shift lever passes thru neutral 7 Continue to use downshift double clutching method to shift to LL2 and LL1 Continue downshifting thru 4th 3rd and 2nd gears to 1st gear using downshifting double clutching method H 27 INTER AXLE DIFFERENTIAL An inter axle differential is provided at the rear of the front tandem axle This unit divides input torque equally between the front and rear tandem axles e Ad DIFFERENTIAL UNLOCK The inter axle is
15. psi 862 kPa With engine running depress clutch and shift transmission to LL1 LL2 or LL3 gear range LL4 may be used only on hard level surface When sure of complete engagement stop engine and release clutch A WARNING Be sure to keep feet clear of clutch pedal when moving DIGGING BRAKE toggle to ON position step 4 4 Move DIGGING BRAKE toggle to ON position This applies digging brake disengages carrier engine clutch and engages remote drive power take off 5 Release parking brake Move inter axle differential toggle to LOCK position for off road conditions Preparing Upperstructure for Remote Control Operation 1 2 REMOTE CONTROLS IN UPPERSTRUCTURE 4 lt iom THROTTLE KNOB P r i 1 1 1 NM E EMERGENCY BRAKE TOGGLE Q ama AN TRAVEL 2 PEDAL STEERING PEDAL Be sure controls in carrier cab have been properly set for remote control operation above Be sure joystick and foot pedal controls are in neutral position 29 NOTE Disengage engine clutch for easier starting in cola weather if so equipped After starting engage clutch with engine stopped to reduce shock load on hydraulic pump shaft 3 Start upperstructure engine and develop full brake system pressure 125 psi 862 kPa 4 Be sure engine clutch is engaged 5 With emergency brake applied perform following procedure to be sure power take off is fully engaged a Adjust upp
16. shift lever in neutral while vehicle is moving ANGE PRESELECTION 1 With parking brake applied depress clutch and move gear shift lever to neutral un 5 If conditions require starting in LO LO range 2 Start engine and wait till carrier air system a Move deep reduction button forward to select reaches 125 psi 862 kPa deep reduction range zx Transmissions 3 Release parking brake and hold carrier in eO position using service brake 24 b Depress clutch pedal depress clutch brake button and move shift lever to LL1 gear position ZS I R I 24 7 Neutral pa c Release clutch brake button d Release clutch pedal evenly while depressing accelerator pedal smoothly Carrier will move forward in LL1 gear e Use upshift double clutching method to shift thru LL2 gear to LL3 gear f When ready to shift to next higher gear 1st gear move deep reduction button to rear to LO Range position DEEP REDUCTION BUTTON g Using upshift double clutch method shift to lst gear position BUT do not release clutch to engage Ist gear see note 25 OR If conditions permit starting in LO range A Move deep reduction button to rear to select LO range DEEP REDUCTION 1 BUTTON B Depress clutch pedal depress clutch brake button and move shift lever to 1st gear position RI NE C Release clutch brake button BUT
17. while low air warning light is still glowing Observe air pressure gages Proper brake system pressure is 60 125 psi 414 862 kPa CHECKS BEFORE DRIVING To be performed at beginning of each work shift Complete all required maintenance before driving 1 Check operation of brakes by performing the following procedure a Position unit on level surface and apply digging brake b Position boom over rear of chassis and imbed bucket in ground or against a solid object c Apply down pressure with boom and pull and push with boom while helper watches for rotation of each wheel d Rotation of any wheel during step c indicates brake failure on that wheel Have any failure corrected before driving the unit 2 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 Check operation of horn and travel and back upalarm and any other signal devices PLAN YOUR TRIP 1 Plan safe route to your destination 2 Ask your supervisor about permit requirements Check on load amp clearance limits along your route 3 Dimensions for your unit are shown below Height varies depending on attachment measure unit to be sur Width tid 8 2 44 m Ground 10 254 Weight varies depending on options weigh uni
18. 15 Diesel ENIM a aia M viam du es cita eos em e vase 15 Cold Weather Staring Aids Lassen sige eqs LAS PEK HAM Lidia nex exl muc ndr nam 15 Normal Engine Operation x css vua x qnos ET xs VULSHUT Essa wake som ewes wan soma Data 16 Stopping the Engine vacuus coos ney a3 ska ies sis rita sin capu ena aus enc aoe adhe ig un 16 CHECKS AFTER STARTING ENGINE 4 view Rich cmn acce em bacon cha p paa Uh t 17 CHECKS BEFORE DRIVING etica sie ea oaa ee DEPT IG pas x 17 FLAN YOUR TRIP nens Dapusbtsue NU Hie vnd abst canton veu VEL 2 ache 17 dati dye Fang DER TIU QS Enti GALE HOD Bde 18 SEVICE BEBE usa ease nos oi Aou DD VER ES ERR UES distr ence spain Fora piti 18 Emergency Brake ss aces oin exa iust COR EVE Eb ORAE Ene van wows 18 Parkings Beg kenmore CREER Rd dia pied x Rm p X qo duis Pini Heme Fito 19 Digging sace cau QUE Vaso sed sida Leni virion eoi aai MINI Ud veu Od FOU RUPE QU KISS VAS acis 19 Remote Control Braking saa vius mo epic xti en
19. 15 00 x 22 5 16 pl 100 psi or 16 x 20 14 ply 099 pet Rear 10 00 x 20 14 ply 90 dst 9 p e Engine Crankcase Dipstick check level amp refill as req d item 24 is filler cap EO At End of First 20 Hours Engine Oil Filter replace Engine Crankcase Drain Plug drain amp refill EO 49 amp 50 Transmission Front amp Rear Drain Plugs drain front amp rear sections amp re 52 47 DOW dc 12 13 14 15 19 21 22 29 31 LUBRICATION NOTES S placesg drain plugs items 34 amp 35 are level plugs fill each section to its own level Transfer Case Drain Plug drain amp refill to level item 53 is level plug GO Weekly Lubrication amp Maintenance includes all daily services Fuel Filter Water Drain drain water from filter At End of First 30 Days Check torque of all items listed in torque chart page 36 Monthly Lubrication amp Maintenance includes all daily and weekly service Steering Cylinder Pivots Battery check electrolyte level and replenish as req d Differential Level Plug check level amp refill as req d Universal Joint turn wheels to extreme right amp left to uncover fittings Front Axle Drive Spline Wheel Pivot Trunnions Tie Rod Ends Slack Adjuster Drag Link Ball Joints Spring Anchor Pin Shift Tower Shaft Shift Linkage Universal Joint 9899888888 Air Drier check for excessive moisture refer to pg 20 of this manua
20. AKE START CARRIER ENGINE AND FULLY CHARGE AIR SYSTEM 125 5 1 SHIFT TRANSMISSION TO LL st LL2nd LL3rd OR LL4th TURN ENGINE OFF DONOT OPERATE CARRIER ENGINE KEEPING FEET CLEAR OF CLUTCH PEDAL MOVE DIGGING BRAKE LEVER TO ON POSITION RELEASE PARKING BRAKE WARNING ROTATION OF STEERING WHEEL OCCURS DURING REMOTE OPERATION 8368 3576 Located inside cab door Part No 8369 3576 Fuller Roadranger RTO 6613 DEEP REDUCTION BR PRE SELECT ALL RANGE SHIFTS MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER PROGRESSIVE SHIFTING SEQUENCES Neutral L1 LL2 LL3 1 2 3 4 5 6 7 B 9 1 tr n us LLA LL5 3 4 5 6 7 8 9 10 UPSHIFTIN ABT wi RANGE SELECTOR DOWN 12445 RAISE RANGE SELECTOR Suet 6 7 9 10 DOWNSHIELE NG 109 2 MOVE RANGE SELECTOR DOWN m He CHANGE RANGE WHILE MOVING IN REVERSE Located on right cab window Part No 8368 3911 STAY CLEAR OF MOVING PARTS FASTEN COVERS BEFORE STARTING ENGINE READ SERVICE MANUAL BEFORE ADJUSTING OR SERVICING 7702 3004 Located inside cab door amp above engine compartment Part No 7702 3004 CAUTION ALLOW INCREASED STOPPING DISTANCE WITH NEW BRAKES BRAKE CAPABILITY WILL IMPROVE AFTER SEVERAL STOPS PART NO 8688 1755 Located on right cab window Part No 8688 1755 Fuller CLUTCH BRAKE VALVE PUSH BRAKE VALVE WHILE SHIFTING INTO FORWARD OR REVERSE s onents Locate
21. GRADALL OPERATION amp LUBRICATION MANUAL G660E 8368 1834 July 2002 Starting S N G016301 GRADALL 406 Mill Avenue S W New Philadelphia OH 44663 USA Telephone 330 339 2211 Fax 330 339 3579 28804 660E 6x4 amp 6x6 CARRIER OPERATION amp LUBRICATION MANUAL Read and understand this manual the 660E Upperstructure Operation Manual the Gradall Safety Manual the CIMA Safety Manuals and all of the Gradall Service Manual Sections before starting operating or performing maintenance procedures on this machine KEEP THESE MANUALS IN CAB AVERTISSEMENT ATENCION VORSICHT Si vous ne lisez pas Si no lee ingles pre Wen Sie kein Englisch l anglais demandez a guntele a su supervisor lesen bitten Sie ihren votre surveillant de vous para las instrucciones Vorgesetzten um die donner les instructions de seguridad Sicherheitsvorschriften de securite COVERS CARRIERS STARTING S N G016301 Part No 8368 1834 IMPORTANT SAFETY NOTICE Safe operation depends on reliable equipment and proper operating procedures Performing the checks and services described in this manual will help to keep your Gradall Carrier in reliable condition and use of the recommended operating procedures can help you avoid accidents Because some procedures may be new to even the experienced operator we recommend that this manual be read understood and followed by all who operate the carrier Dang
22. MBER PLATE SERIAL NO ie FRONT TIRES MIN REAR TIRES ENGINE SERIAL NO CYLINDERS BORE SAFETY HIGHLIGHTS Read and understand this manual and CIMA DUMPER Safety Manual before starting operating or performing maintenance procedures on this carrier Do not permit this carrier to be driven by an operator who cannot read English unless these manuals have been read and explained to him and his full understanding is determined Keep these manualls in cab If driver will operate upperstructure he must also read and understand Gradall Upperstructure Operation amp Lubrication Manual Gradall Hydraulic Excavators Safety Manual and CIMA Hydraulic Excavator User s Safety Manual Watch for these symbols they are used to call your attention to safety notices Maintain three point contact with grab handles and steps when climbing on and off the machine Never jump from the machine Repair or replace damaged steps and grab handles This symbol indicates an extreme hazard which would result in high probability of death or serious injury if proper precautions are not taken This symbol indicates a hazard which could result in death or serious injury if proper precautions are not taken This symbol indicates a hazard which could result in injury or damage to equipment or property if proper precautions are not taken Perform all CHECKS amp SERVICES BEFORE STARTING
23. ROLS 1 Heat Control Knob 13 Interaxle Differential Toggle 2 Heater Fan Switch 14 Windshield Wiper Valve 3 Defroster Fan Switch 15 Dome Light Switch 4 Front Wheel Drive Toggle 6x6 only 16 High Low Beam Switch 5 Digging Brake Toggle 17 Clutch Pedal 6 Parking Brake Knob 18 Brake Valve Pedal 7 Light Switch 19 Accelerator Pedal 8 Ignition Switch 20 Range Preselection Lever 9 Turn Signal Lever 21 Gear Shift Lever 10 Hazard Flasher Switch 22 Deep Reduction Button 11 Horn Button 23 Clutch Brake Button 12 Windshield Washer Button 12 CHECKS AND SERVICES BEFORE STARTING ENGINE Complete all required maintenance before driving the carrier A WARNING Use extreme caution when checking items beyond your normal reach Use an approved safety ladder Inspect carrier for obvious damage vandalism and needed maintenance Check for signs of fuel lubricant coolant and hydraulic leaks Open access doors and look for loose fittings clamps com ponents and attaching hardware Check brake and steering systems for obvious damage Check operation of all lights and repair as necessary before operating Broken windows must be replaced before operating If spark arrestors are used be sure they are in place and in good working order Check for fully charged fire extinguisher on rear wall in carrier cab Be sure to read and understand instructions on extinguisher Replace extinguisher as necessary Check flui
24. TEERING SYSTEM Conventional steering Remote control steering The power steering system provides low effort steering under normal conditions and greater control in the event of a blowout or soft ground Road feel is similar to that of a conventional manual steering system Your unit is equipped with a steering pedal in the upperstructure cab Upperstructure engine must be running to provide power for remote control steering Regardless of upperstructure position on carrier moving pedal to left turns wheels to left moving joystick to right turns wheels to right A CAUTION When not held in a left or right steering position the Use of power steering while carrier is steering pedal will return automatically to its neutral stopped causes unnecessary stress on non steering position Be sure upperstructure cab is system components and can cause kept free of equipment and foreign material which serious damage to system could jam steering pedal in a steering position Holding steering wheel in full left turn or Rotation of steering wheel will occur during remote full right turn position will cause system to operation KEEP CLEAR overheat This can cause steering pump to fail WARNING Be alert for any increase in effort needed to steer If any difference is noted notify maintenance personnel immediately for correction If power assist feature should fail for any reason IT WOULD BECOME VERY DIFFICULT TO STEER For this
25. d for each successive upshift until reaching desired cruising speed Unless starting from a standstill on an uphill grade or in off road use it is unnecessary to use LO LO range When load conditions cause a continuing loss of engine speed downshift to the next lower gear In general operate in a gear that will permit acceleration Though it is permissible to use the braking power of the engine when traveling downhill take care to avoid overspeeding the engine exceeding governed RPM The governor has no control over engine speed when the engine is being pushed by the carrier load Select an appropriate gear ratio and use your brakes to assist in slowing the carrier Use LL1 LL2 LL3 for off road conditions First gear may be used off road only if surface is hard and level 23 A WARNING Stop carrier and select appropriate gear range before driving down steep grade under off highway conditions Attempting to downshift under these conditions can be dangerous Double Clutching Gears in the main transmission are not synchronized and double clutching procedure must be used when shifting Double clutching is a procedure for adjusting the speed of one transmission gear shaft driven by the engine to a second transmission gear shaft driven by carrier drive wheels to prevent clashing when gears on these shafts mesh This is accomplished by using the engine to increase or decrease the speed of the engine
26. d level in windshield washer reservoir on rear wall in carrier cab Add windshield washrsolvent as necessary Check position of DIGGING BRAKE toggle Toggle should be in OFF position for operation from carrier cab Be sure parking brake is applied before moving toggle to OFF position Check for secure stowage of boom and any auxiliary equipment or material Lubricate unit as indicated on lubrication chart Check engine coolant level and replenish as necessary Be sure anti freeze solution is adequate for expected temperatures Be sure radiator fins are clean A WARNING If it is necessary to check the coolant level in a hot radiator shut off the engine and relieve pressure before removing the radiator cap Relieve pressure by holding the cap with rags and turning to the left till pressure begins to escape Wait a few minutes till sound of escaping pressure stops and remove cap cautiously 14 Check fuel level and replenish as necessary Refuel at the end of the work shift to minimize condensation A WARNING Engine should be turned off while refueling Be sure area is free of open flame sparks or any condition which could cause fuel to ignite Check oil level in engine crankcase and replenish as necessary DO NOT OVERFILL ENGINE OPERATION NOTE If engine is being started at beginning of work shift be sure to perform all CHECKS AND SERVICES BEFORE STARTING ENGINE Starting Diese
27. d on right cab window Part No 8395 3002 Decals outside Cab USE TWO KEEP CLEAR OF HANDS WHEN MACHINE SWING AREA CLIMBING ON Located on back of cab MAC H N ES 7702 3003 Part No 8360 1018 Located at right of cab door Part No 7702 3003 A CAUTION PRESSURIZED COOLINGSYSTEM REMOVE CAP SLOWLY 9104 3210 NYLON BRAKE LINES MAY BE Located on fan shroud DAMAGED BY Part No 9104 3210 HEAT AVOID WELDING ON OR AROUND CARRIER FRAME UNLESS LINES ARE PROTECTED FROM HEAT MODEL REAR TIRE Located on air reservoir Part No 7702 3002 Located on right frame rail IMPORTANT Part No 7702 3029 To prevent damage to the electrical system when using booster battery or charger always connect POSITIVE TO POSITIVE D L NEGATIVE TO NEGATIVE Located inside battery box cover Located above fuel tank Part No 7702 3007 Part No 7702 3008 10 INSTRUMENTS AND INDICATORS 1 Alternator Indicator Light 2 Voltmeter 3 Speedometer Odometer 4 Hi Lo Beam Indicator Light 5 Tachometer optional 6 Air Pressure Gage front 7 Low Air Indicator Light 8 Fuel Gage 9 Digging Brake Indicator Light 10 Oil Pressure Gage 11 Coolant Temperature Gage 12 Turn Signal Hazard Indicator Light 13 Air Pressure Gage Rear A WARNING Do not move carrier while low air light is glowing or while any auxiliary device is signal ing a dangerous condition 11 CONT
28. do not release clutch to engage Ist gear see note NOTE If starting in LO LO range a thru g of step 5 carrier will be moving If starting in LO range A thru C of step 5 carrier will not be moving Otherwise transmission and clutch will be in same condition ready to release clutch to engage 1st gear Proceed with step 6 6 Immediately release clutch evenly while de pressing accelerator smoothly to engage 1st gear 7 Using upshift double clutching method shift from 1st gear thru 2nd 3rd and 4th gears to 5th gear When ready move range preselection lever up to HI position RANGE PRESELECTION 4 LEVER Using upshift double clutching method im mediately shift from 5th gear position to 6th gear position Downshifting During normal driving there are times when it is necessary to downshift shift from one gear or range to the next lower gear or range to decrease carrier speed or increase carrier power NOTE The following procedure assumes that carrier is traveling in 10th gear However this procedure will apply to downshifting from lower gears Follow procedure from appropriate gear This procedure covers downshifting from 10th gear to LL1 Unless traveling a very steep upgrade it shouldn t be necessary to downshift thru the entire range of gears use that portion of procedure which applies to your conditions A CAUTION Never downshift when carrier speed will cause engine to overspeed in
29. driven gear shaft Two double clutching procedures are given one for upshifting and one for downshifting Be sure to use each at the proper time Using the wrong procedure will cause gears to clash NOTES The following double clutching procedures apply to shifts within a gear range LO LO LO or HI Additional steps are required when shifting from one range to another These steps will be explained under Upshifting and Downshifting headings Although double clutching procedures are broken down into separate steps the actual performance of these steps should be rapid and smooth Double Clutching for Upshift 1 Release accelerator pedal and depress clutch pedal 2 Move gear shift lever to neutral and release clutch pedal 3 When engine speed nears low idle depress clutch and shift to next higher gear If shift timing has been correct gears will mesh smoothly with no clash 4 Release clutch evenly while depressing accelerator to apply power smoothly Double Clutching for Downshift 3 Depress accelerator pedal to increase engine speed to high idle depress clutch and shift to next lower NOTE Downshifting is used to aid in reducing gear If shift timing has been correct gears will carrier speed or to increase carrier power mesh smoothly with no clash 1 Release accelerator pedal and depress clutch pedal 4 Release clutch evenly and depress accelerator as 2 Move gear shift lever to neutral and release clutch appropriate f
30. ed automatically as travel pedal in upper structure is actuated and released 20 WARNING Allow sufficient time for full brake system pressure 125 p s i 862 kPa to be devel oped in upperstructure before operating unit in remote control Units equipped for remote control have an emergency brake control located in the upper structure cab This control is to be used in case of failure of the automatic digging brake If digging brake fails to apply when travel pedal is released move emergency brake toggle to apply emergency brake Notify maintenance personnel immediately for repair of digging brakes Apply upperstructure emergency brake when leaving upperstructure cab See pages 29 and 30 for detailed instructions on remote control operation Air Drier An air drier is furnished to remove moisture and contaminants from air as it is delivered from com pressor to first air reservoir The drier includes a heating element to prevent freezing During compressor unloading moisture and contam inants are purged from drier to atmosphere Under certain temperature conditions condensation may cause a small amount of water to accumulate in system Check air reservoirs monthly for moisture accumulation The air drier desiccant cartridge should be serviced or replaced annually unless experience indicates a shorter or longer interval Refer to brake section of service manual for air drier maintenance instructions S
31. elease brake DO NOT use clutch brake when downshifting 22 Transfer Case for 6x6 units only The transfer case is a gearbox located between the transmission and rear tandem axles It functions with the transmission to transmit torque power to the front and rear driving axles Front axle drive is controlled by the front wheel drive toggle located on the dashboard CAUTION Do not engage front axle drive while carrier is moving Stop carrier before shifting A Transmission The transmission is a gearbox which transmits torque from the engine as it is delivered to move the carrier The transmission in your carrier provides 13 forward speeds and 3 reverse speeds The lowest transmission gear range LL 1 provides the greatest carrier power and the lowest carrier speed The highest transmission gear range tenth gear provides the greatest carrier speed with the least carrier power Gear selections between these gear ranges provide power speed combinations between these extremes Reverse gears provide approximately the same power speed ratios as LL1 1st gear and 6th gear NOTE Study the shift pattern decal and you will see that it would be possible to shift to fifteen forward speeds rather than the stated thirteen speeds However LL4 provides the same reduction as 1st gear and 11 5 provides the same reduction as 2nd gear Using either of the suggested progressive shift sequences on the decal provides thirteen fo
32. er Warning and Caution notes in this manual will help you avoid injury and damage to the equipment These notes are not intended to cover all eventualities it would be impossible to anticipate and evaluate all possible applications and methods of operation for this equipment Any procedure not specifically recommended by The Gradall Company must be thoroughly evaluated from the standpoint of safety before it is placed in practice If you aren t sure contact your Gradall Distributor before operating Do not modify this machine without written permission from the Gradall Company WARNING BEFORE WELDING ON THIS MACHINE DISCONNECT BATTERY CABLES AND TURN OFF IGNITION BEFORE WELDING TO PREVENT DAMAGE THIS MACHINE IS EQUIPPED WITH NYLON AIR BRAKE HOSE REMOVE AND OR SHIELD THE NYLON HOSE ADEQUATELY IN THE IMMEDIATE AREA PRIOR TO WELDING NOTICE The Gradall Company retains all proprietary rights to the information contained in this manual The Company also reserves the right to change specifications with out notice The Gradall Company 406 Mill Avenue S W New Philadelphia Ohio 44663 Gradall is a registered trademark for hydraulic excavators hydraulic material handlers and attachments built by the Gradall Company The Gradall Company Form 28804 TABLE OF CONTENTS IMPORTANT SAFETY NOTICE Lu stents Feu Wake Wetton kt amm Kees Bes cus inside front cover TABLE OP CONTENTS a sess
33. erstructure engine speed to idle and move variable flow control lever to high full flow if so equipped b Very gently engage travel pedal to cause a slight rotation of power take off gear If step b caused gears to clash power take off was not engaged Repeat step b If step b caused engine to reduce speed power take off 15 fully engaged Move variable flow control lever to desired mode and increase engine speed to full throttle foupperstructure operation 6 Move EMERGENCY BRAKE NORMAL position control to Precautions for Remote Control Operation Be sure of clear visibility in direction of travel use a Signalman to compensate for blind spots Always give audible signal before moving unit Never permit bucket to drag while moving unit Be sure all Warm Up and Operational Checks have been performed Rotation of steering wheel will occur during remote operation KEEP CLEAR Be sure of clear path for carrier boom and counterweight before starting to move Be especially watchful for people overhead wires and traffic Be sure travel alarm function properly Over the side stability is reduced during remot travel because front axle lock cylinders auto Never tow load using remote control drive matically unlock when traveling Driving carrier from upperstructure cab A WARNING Avoid confusion Before actuating remote control steering and travel pedals think about the direction you are facing with respec
34. f the system falls below safe operating range the low air indicator light will flash A WARNING Do not drive while low air indicator is flashing If light comes on while carrier is moving stop carrier in a safe area as soon as possible If carrier will not maintain proper brake pressure notify maintenance personnel immediately for repair of condition LOW AIR FRONT SYSTEM PRESSURE REAR SYSTEM PRESSURE Emergency brake The emergency brake functions only when air pressure has been lost from some portion of the dual brake system Emergency brakes are applied by normal foot pressure on the brake treadle Emergency brakes will not stop carrier in as short a distance as the service brakes EMERGENCY BRAKE APPLICATION If air pressure is lost from the front portion of the dual brake system normal actuation of the brake treadle valve will apply service brakes to the wheels of the forward and rear tandem axles There will be no braking on the wheels of the front axle EMERGENCY BRAKE APPLICATION pressure lost in rear BRAKE TREADLE ON FLOQI If air pressure is lost from the rear portion of the dual brake system normal actuation of the brake treadle will apply service brakes to the wheels of the front axle and cause a controlled application of spring brakes to the wheels of the forward and rear tandem axles After pressure is lost from one portion of the dual brake system there may only be en
35. heck lubricant levels when lubricant is cool points No of Points an O p po HR CO a a Pp Pp a Clean filter and air cleaner housing and reusable elements using cleaning solvent or diesel fuel Dry components thoroughly using a lint free cloth Apply a light coating of engine oil to all linkage pivot Recommended Lubricants amp Capacities icati Specifications Application Symbol When Used Grade English Liters Engine Crankcase Cummins EO engine oil 23 7 quarts 22 4 Cooling System 6CT 8 3 6CTA 8 3 27 quarts 28 quarts 26 pints initial 16 pints refill P T O amp Transmission Combination Transfer Case 6 6 only GO gear lubricant EN Tandem Axle forward GO gear lubricant EIN Tandem Axle rear GO gear lubricant 9 GO gear lubricant 10 quarts Front Drive 6x6 only GO gear lubricant 23 pints Grease Fittings CG ext essure lube All Y Wheel Bearings extreme pr ear MIL G 24139 Dexron Steering Reservoir ATF auto trans fluid All Year Wedge Brakes 6x6 only SG special grease All Year Refer to manufacturer s service literature for this information Capacities are approximate check level to be sure TORQUE CHART Check torque using an accurate torque wrench to apply maximum torque value shown DO NOT EXCEED MAXIMUM TORQUE Exceeding max
36. ing aid employing ether or a similar substance pay particular attention to manufacturer s warnings WARNING DO NOT use ether starting aid if air system is equipped with an alcohol moisture evap orator 15 Normal engine operation Cummins Observe voltmeter water temperature and oil pressure gages frequently to be sure all engine systems are functioning properly Be alert for unusual noises or vibration When an unusual condition is noticed stop in a safe area and shut off engine Determine cause and correct before continuing Early recognition and correction of unusual con ditions can often prevent a major breakdown Apply load to engine gradually shock loads are hard on all drive line components When using engine breaking power downshifting or releasing accelerator and permitting carrier to push engine to slow travel take care to avoid overspeeding the engine exceeding governed Stopping the engine Cummins Operate engine at idle speed for a few minutes before turning it off This allows engine coolant and lubricating oil to carry excessive heat away from critical engine areas This is especially important for turbo charged engines 16 RPM 2200 RPM The governor has no control over engine speed when engine is being pushed by carrier load Select an appropriate gear ratio and use service brake to assist in slowing travel down steep grades Permitting the engine to labor under too great a
37. l Steering Universal Joints Steering Shaft Splines Power Steering Reservoir check level amp refill as req d ATF Clutch Throwout Bearing lubricate sparingly CG No of Points 1 1 1 10 N NA NA NH 1 1 Lube Monthly Lubrication amp Maintenance continued Symbol 32 Shift Linkage f at transmission CG 34 Transmission Front Fill amp Level Plug check level amp refill as req d GO 35 Transmission Rear Fill amp Level Plug check level amp refill as req d GO 36 Universal Joints 37 Drive Shaft Splines CG 39 Differential Fill and Level Plug check and fill to level GO 42 Walking Beam Pivot CG 44 Clutch Pedal Pivot Shaft CG 48 Clutch Throwout Shaft Bearing CG 53 Transfer Case Fill amp Level Plug check level amp refill as req d GO Semi Annual Lubrication amp Maintenance includes all daily weekly amp monthly services 11 Brake Camshaft lubricate sparingly CG 18 Differential Breather remove clean amp install 5 23 Engine Oil Filter replace element at each oil change 250 hours maximum 33 Transmission Breather remove clean and install 40 Differential Breather remove clean and install 43 Engine Drive Belt check condition and tension replace or adjust as req d 46 Crankcase Drain Plug drain and refill to level on dipstick item 24 is oil filler 250 hours maximum EO 51 Transfer Case Breather remove clean
38. l Engine Cummins 1 Be sure transmission is in neutral and parking brake is applied 2 Turn ignition switch to ON position 3 Depress accelator pedal fully and then release pedal A CAUTION Do not engage starting motor while fly wheel or starting motor is rotating Serious damage could result Cold weather starting aids Diesel engine ignition is accomplished by heat generated when fuel air mixture is compressed within the cylinders Because this heat may be insufficient to start a cold engine in cold weather the use of starting aids has become common practice Because of the wide variety of starting aids available 4 Turn ignition switch fully clockwise to engage starting motor Release key immediately when engine starts If engine fails to start within fifteen seconds release key and allow starting motor tocool for a few minutes before trying again NOTE It may be necessary to use a cold weather starting aid in temperatures below freezing 5 After engine starts observe oil pressure gage If gage remains on zero for more than 15 seconds stop engine and determine cause Correct before restarting engine 6 Warm up engine at approximately 1000 RPM until coolant temperature reaches operating range approximately 140 F 60 C it would be impractical to attempt to provide specific instructions for their use in this manual Carefully follow instructions furnished with your starting aid If you use a start
39. load for the gear ratio being used lugging the engine will shorten engine life Shift to the proper gear ratio for conditions Avoid prolonged idling Idling causes engine tem perature to drop and this permits formation of heavy carbon deposits and dilution of lubricating oil by incompletely burned fuel If the engine is not being used turn it off Do not gun engine before shut down this practice causes raw fuel to remove oil film from cylinder walls and dilute lubricant in crankcase Stop engine by turning ignition switch to OFF position CHECKS AFTER STARTING ENGINE To be performed at beginning of each work shift Complete all required maintenance before driving Check operation of windshield washer and wiper Check all lights and turn signals for proper operation Check operation of heater and defroster Observe oil pressure gage with engine running at operating temperature and speed Minimum oil pressure is 10 to 30 psi 69 to 207 kPa Observe voltmeter indication of alternator out put Proper output is approximately 14 V with engine running at 2000 RPM 6 Observe water temperature gage Proper Operating temperature is approximately 140 200 F 60 93 C Observe tachometer response to changes in engine speed Observe low air warning light Light should continue to glow until brake system pressure reaches approximately 60 psi 414 kPa Do not release parking brake or move carrier
40. nd response He must also be in acceptable physical and mental condition not undergoing medical treatment or using drugs or alcohol which would violate traffic laws Before driving the unit on the highway or operating the excavator at a worksite the operator must familiarize himself with the machine by practicing in a safe open area not hazardous to people or property The operator must read understand and comply with instructions contained in the following material furnished with the excavator This Operation amp Lubrication Manual CIMA DUMPER Safety Manual All Instructional decals and plates If driver will also operate upperstructure G 660E Upperstructure Operation amp Lubrication Manual Gradall Hydraulic Excavators Safety Manual CIMA Hydraulic Excavator User s Safety Manual Models Covered Wheeled carriers for the G 660E Gradall Hydraulic Excavators are furnished with the following basic carrier variations to suit job application and con tractor preference Orientation When used to indicate direction or location the terms front rear left and right relate to the orientation of a man sitting in the driver s seat Serial Number Location The carrier nameplate is located on the right side of the carrier frame Be sure to specify the serial number on nameplate when ordering parts and when discussing procedures and applications with your distributor THIS IS NOT A PIN PRODUCT IDENTIFICATION NU
41. or conditions pedal Upshifting GEAR SHIFT LEVER Fuller Roadranger RTO 6613 t Es REDUCTION MER T DEEP SELECTOR 5 UCTION Far io BUTTON PRE SELECT ALL RANGE SHIFTS MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER PROGRESSIVE SHIFTING SEQUENCES LL1 LL2 LL3 1 2 3 4 5 6 7 8 9 10 RANGE LL1 LL2 LL3 LL4 LL5 3 4 5 6 7 8 9 10 PRESELECTION UPSHIFTING START WITH RANGE SELECTOR DOWN SHIFT 1 2 3 4 5 RAISE RANGE SELECTOR SHIFT 6 7 8 9 10 NG 10 9 8 7 6 MOVE RANGE SELECTOR DOWN Shi FT 4 3 2 1 DO NOT CHANGE RANGE WHILE MOVING IN REVERSE CLUTCH BRAKE BUTTON Precautions CAUTION NEVER move range preselection lever of deep reduction button while carrier is moving For a smooth start select a starting gear that will provide sufficient reduction for the load and terrain Always use normal double clutching pro cedures when making lever shifts and transmission is in neutral When carrier is moving these controls MUST be moved to desired position while carrier is in gear BEFORE disengaging clutch and shifting to neutral for next shift Never slam or jerk the shift lever to com plete gear engagement Never coast with the gear shift lever in neutral Never make a range shift when in reverse Never downshift at too high of a road 4 Move range preselection lever down to LO speed range position Never move the Deep Reduction Button or the Range Preselection Lever with the gear
42. ough pressure in the other portion for one or two emergency brake applications When the available pressure has been used the spring brakes will apply automatically EMERGENCY BRAKE APPLICATION pressure lost in front and rear AUTOMATIC In the event air pressure is lost from both front and rear portions of the system there will be an automatic application of the spring brakes They will begin to apply as pressure drops to 60 p s i 414 kPa and there will be a complete application when pressure decreases to 40 p s i 276 kPa Because air pressure is required to release spring brakes an automatic application will remain ON until air pressure can be restored 19 If the air pressure gages indicate some system pressure remaining it may be possible to drive the unit a short distance to remove it from a hazardous position hold parking brake knob in depressed position and use 11 1 gear range If carrier cannot be moved direct traffic around carrier until warning flags flares or lights can be displayed Notify proper authorities and maintenance personnel as soon as possible Parking brake Apply parking brake by raising parking brake control knob This causes air pressure to be vented from spring chambers allowing springs to apply brakes to wheels of forward and rear tandem axles Knob will raise automatically if air pressure is lost from front and rear portions of system PARKING BRAKE BUTTON ON DASH PARKING BRAKE
43. re you can be reached by phone Towing Should it become necessary to tow carrier have maintenance personnel remove propeller shafts between axles and transmission or transfer case if so equipped Store propeller shafts in a safe location 31 6X4 CARRIER LUBRICATION amp MAINTENANCE DIAGRAM LUBRICANT SYMBOLS SYMBOLS CG Grease High Temp Refer to vendor component literature in service manual for additional lubrication and maintenance requirements Fitting GO Gear Oil gt Other Service Refer to vendor component literature in service manual for additional lubrication and maintenance requirements Item Item RS Lube No of Lube Lube Daily Lubrication amp Maintenance Symbol Points Monthly Lubrication amp Maintenance continued Symbol Symbol 8 Fuel Tank till at end of work shift to minimize condensation 1 25 Shift Linkage at transmission CG 3 13 Radiator Filler Cap check coolant level and replenish as req d 4 27 Transmission Front Fill amp Level Plug check level amp refill as req d GO 1 28 Transmission Rear Fill amp Level Plug check level amp refill as req d GO 1 21 Air Cleaner Condition Indicator observe indicator amp clean or replace 29 Universal Joints CG 4 air cleaner element as req d item 22 is air cleaner 5 1 30 Drive Shaft Splines CG 2 33 Tires check for damage amp pressure Front Tires 15 00 x 22 5 14 ply 85 psi 10 00x 20
44. rive shafts and other moving parts Do not operate without covers and guards in place SAFETY HIGHLIGHTS Be particularly careful if this is not the machine you usually operate Read the manuals listed on page 2 and then operate the unit in a safe open area to become familiar with the controls Travel on off highway grades is recommended only under the following conditions Boom secured in rest Tires properly inflated Surface is firm enough to support unit Surface provides adequate traction to prevent slipping Surface is firm enough to support unit enough to cause tipping Transmission is in LL1 LL2 or LL3 gear TRAVEL TO AND FROM JOBSITE ONLY UNDER FOLLOWING CONDITIONS No load attached to any part of machine Boom secured in rest Mirrors clean and properly adjusted Seat belt buckled snugly across lap Door secured in closed position Plan your route Bucket secured to boom Joystick switch in off position Travel in accordance with local requirements Tires inflated to proper pressure Upperstructure engine stopped SAFETY HIGHLIGHTS Check to be sure windows and mirrors are clean and that mirrors are properly adjusted for your driving position Use boom tie down device to secure boom in rack when traveling between jobsites Test brakes before driving carrier after digging TO TEST FOR BRAKE FAILURE and pull with boom while helper watches each 1 Park machine on a level surface rear wheel for ro
45. rward speeds Fuller RTO 6613 15 MOVE RANGE SELECTOR BEFORE MOviNG 5 VE SHIFTING SEQUENCES REDUCTION x 10 SELECTOR IN RANGE HI R 7 7 SELECTOR OUT PRE SELECT Ait RANGE SHIF Neutral SELECTOR DOWN RAISE HANGE SELECTO SHIFTING GEARS Smooth efficient gear shifting depends on coordin ated use of accelerator pedal clutch pedal range preselection lever deep reduction button and shift lever It is also important that shifting occur at the proper time with respect to carrier power require ments and engine speed For those unfamiliar with a manual transmission it may seem that gear shifting is a complicated procedure A practice period with the carrier parked and the engine turned off will help develop the necessary coordination and confidence There should be little difficulty if shifting procedures are followed step by step When practicing with the engine turned off there will be areas in the shift pattern where you will be unable to make a complete engagement Don t use excessive force just learn the pattern When to shift gears Smooth timely shifting not only increases carrier service life it provides greater driving safety In lower gears use only enough engine speed to get the carrier rolling easily High engine speeds under light load conditions waste fuel and cause excessive and unnecessary noise Use a little more engine spee
46. t to be sure 17 BRAKE SYSTEM The air brake system includes a service brake an emergency brake a parking brake and a digging brake A WARNING Wear safety belt to avoid being thrown from driver s seat during braking emergency NOTE Lines in following simplified brake system diagrams show pressure and exhaust air flow under various system conditions Service brake SERVICE BRAKE TAN APPLICATION Q AS M NC BRAKE TREADLE ON FLOOR The basic system includes two reservoirs to store and furnish air pressure for service brake operation One reservoir supplies pressure to apply brakes to the wheels of the front axle and the other supplies pressure to apply brakes to the wheels of the forward and rear tandem axles Depressing the brake treadle causes air pressure to be applied to brake actuators of all wheels simultaneously WARNING Do not fan the brake valve treadle A longseries of rapid brake applications can reduce system pressure to a point where effective service braking will be lost until air compressor can restore pressure The operating pressure range for service brakes is 60 to 125 psi 414 862 kPa Two pressure gages are furnished to indicate pressure in front and rear portions of the system The gage on top indicates pressure available for front axle brakes and the gage on the bottom indicates pressure available for tandem axle brakes If pressure in either portion o
47. t to the direction the carrier is facing Confusion could cause you to travel in the direction opposite that expected 1 Be sure controls in carrier and upperstructure cabs have been properly set for remote control Operation see previous page 2 Be sure engine is running at full throttle Carrier speed is controlled by gear selection and amount of pedal actuation 3 Travel pedal controls forward and reverse travel Depressing front of pedal releases digging brake and causes forward travel Depressing rear of pedal releases digging brake and causes reverse travel Gear range selection engine speed and extent of pedal depression determine travel speed Digging brake is applied automatically when travel pedal is released 4 Steering pedal right side of pedal causes right turn and depressing left side of pedal causes left turn 5 Use EMERGENCY BRAKE to stop carrier if automatic digging brake fails Move emergency Preparing Upperstructure for Conventional Carrier Operation 1 Test brakes refer to page 7 2 With bucket opened fully retract boom watch bucket clearance and position in boom rest as shown on page 7 Secure boom and bucket using hold down devices as necessary 3 Allow engine to cool by running at idle speed for a few minutes Stop engine 4 Be sure travel and steering pedals are in neutral position and emergency brake is released Preparing Carrier for Conventional Operation 1 Apply parking
48. tation 2 Apply digging brake 5 Rotation of any wheel during step 4 indicates brake failure on that wheel 3 Center boom over rear of chassis and rest boom or bucket on the ground 6 If one or more wheels indicate brake failure DO NOT DRIVE THE GRADALL HYDRAULIC 4 Apply down pressure with boom but not EXCAVATOR Investigate and correct For enough to remove weight from wheels and push assistance contact your Gradall Distributor SAFETY HIGHLIGHTS If required secure attachment as shown to prevent Remember getting too close to unstable ground drift while traveling or the edge of an excavation can cause the machine to tip Always apply digging brake to prevent carrier movement while operating upperstructure Do not carry passengers or move the unit until all Know overall height of your unit before travelnig other persons have gotten off and are clear of the Approach unknown clearances slowly machine Decals Inside Cab AX WARNING TO PREVENT INJURY OR INJURY MAY RESULT FROM DEATH CONTACTING ELECTRICAL LINES TO PLACE ANY PART OF THIS MACHINES OR LOAD WITHIN 10 UNLAWFUL FEET OF HIGH VOLTAGE LINES OF UP TO 50 000 VOLTS FOR MINIMUM CLEARANCES NIGH VOLTAGE LINES IN EXCESS OF 50 000 VOLTS SEE YOUR LOCAL STATE AND FEDERAL REGULATIONS DO DEF ACE OR REMOVE THIS SIGN FROM THIS MACHINE Located inside cab door Part No 8360 1011 REMOTE CONTROL ENGAGEMENT PROCEDURE APPLY PARKING BR
49. ted ded ximus qi Bund dava Bus a mt ds a 20 STEERINGSYSTEM ca aai qus seit Mae dns MON RU ance M gets s E i e 21 ALTON ua cea Suet vig DIL sca rd d 21 Remote Contral Siring x ecco nod ves Pass dete vut sts CES GER exor ides saree acie ema ater 21 POWER TRAIN is hes waives suy gen Hes 9 RAYS bo eva quei dens xxi Cau ind O A 22 Shifting DENIS coa ct HESS DU DERE IWS Pace wad sated Atq mowed owe ists cix VETUS Six uae 24 Inter Axle Differential aoi duh QE mex cnn enin dato montos qas cit mc em vare Ex WHET GREK GEN DES s 28 REMOTE CONTROL qi mei Bs engein tatur eme socis Hin qua mui BBS Cun ERAT queo 29 Preparing Carrier for Remote Control Operation 29 Preparing Upperstructure for Remote Control 29 Precautions for Remote Control 30 Driving Carrier from Upperstructure Cab ini sued kan eet von hme cima ca as A PUE Y 30 Preparing Upperstructure for Conventional Carrier 30 Preparing Carrier for Conventional
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