Gradall XL3100V Operators Safety Manual Download | Manualshive

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Section 2 - Pre-Operation and Controls

2-21

80884013

OAC1880

P2714
P2715
P2718
P2720
P2721
P2723
P2724
P2727
P2729
P2730
P2736
P2738
P2739
P2740
P2742
P2743
P2761
P2763
P2764
P278A
P2789
P2793
P2808
P2809
P2812
P2814
P2815
U0001

U0010
U0100
U0103

U0115
U0291

U0304

U0333

U0404

U0592

PRESSURE CONTROL SOLENOID 4, STUCK OFF
PRESSURE CONTROL SOLENOID 4, STUCK ON
PRESSURE CONTROL SOLENOID 4, STUCK OPEN
PRESSURE CONTROL SOLENOID 4 CONTROL, LOW
PRESSURE CONTROL SOLENOID 4 CONTROL, HIGH
PRESSURE CONTROL SOLENOID 1, STUCK OFF
PRESSURE CONTROL SOLENOID 1, STUCK ON
PRESSURE CONTROL SOLENOID 1 CONTROL, OPEN
PRESSURE CONTROL SOLENOID 1 CONTROL, LOW
PRESSURE CONTROL SOLENOID 1 CONTROL, HIGH
PRESSURE CONTROL SOLENOID 5 CONTROL, OPEN
PRESSURE CONTROL SOLENOID 5 CONTROL, LOW
PRESSURE CONTROL SOLENOID 5 CONTROL, HIGH
RETARDER OIL TEMPERATURE, HOT
RETARDER OIL TEMPERATURE SENSOR, LOW
RETARDER OIL TEMPERATURE SENSOR, HIGH
TCC PCS CONTROL, OPEN
TCC PCS CONTROL, HIGH
TCC PCS CONTROL, LOW
KICKDOWN INPUT, FAILED ON
CLUTCH ADAPTIVE LEARNING AT LIMIT
GEAR SHIFT DIRECTION
PRESSURE CONTROL SOLENOID 6, STUCK OFF
PRESSURE CONTROL SOLENOID 6, STUCK ON
PRESSURE CONTROL SOLENOID 6 CONTROL, OPEN
PRESSURE CONTROL SOLENOID 6 CONTROL, LOW
PRESSURE CONTROL SOLENOID 6 CONTROL, HIGH
HIGH SPEED CAN BUS RESET COUNTER OVERRUN
(IESCAN)
CAN BUS RESET COUNTER OVERRUN
LOST COMMUNICATION WITH ECM/PCM (J1587)
LOST COMMUNICATION WITH GEAR SHIFT MODULE
(SHIFT SELECTOR) 1
LOST COMMUNICATION WITH ECM
LOST COMMUNICATION WITH GEAR SHIFT MODULE
(SHIFT SELECTOR) 2
INCOMPATIBLE GEAR SHIFT MODULE 1 (SHIFT
SELECTOR ID)
INCOMPATIBLE GEAR SHIFT MODULE 2 (SHIFT
SELECTOR ID)
INVALID DATA RECIEVED FROM GEAR SHIFT MODULE
(SHIFT SELECTOR) 1
INVALID DATA RECIEVED FROM GEAR SHIFT MODULE
(SHIFT SELECTOR) 2

https://tractormanualz.com/

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Summary of Contents for XL3100V

Page 1: ...N 4140000100 After Railgear S N 4140R00100 After Railgear S N 4130R00100 After 6x6 S N 4160000088 After 6x4 S N 5140000100 After 6x6 S N 5160000100 After 80884013 Revised December 7th 2018 This manual...

Page 2: ...y of the manual The current version can be viewed downloaded at www mygradall com Gradall is a registered trademark for hydraulic excavators industrial maintenance machines attachments and other compo...

Page 3: ...Issue of Manual April 14th 2016 B Added battery shutdown warning January 6th 2017 C Added description to chassis lube points in Section 5 Revised Upper Cab Heater Spec Added XL4100V XL5100V Weight Dim...

Page 4: ...on of an experienced and qualified instructor Operators of this equipment must possess a valid applicable driver s license be in good physical and mental condition Operator must not be using medicatio...

Page 5: ...ediately in all instances where Gradall products have been involved in an accident involving bodily injury or death of personnel or when damage has occurred to personal property or the Gradall product...

Page 6: ...Read This First d 80884013 NOTES https tractormanualz com...

Page 7: ...Dust Hazard 1 12 1 4 Personal Protection Equipment 1 13 Section 2 Pre Operation and Controls 2 1 Pre Operation Checks Inspection 2 1 2 2 Walk Around Inspection 2 2 2 3 Safety Decals 2 5 Upperstructur...

Page 8: ...Brake System 3 4 Service Brake 3 5 Emergency Brake 3 6 Parking Brake 3 8 3 4 Travel Mode Power Train 3 10 Shifting Gears 3 10 3 5 Travel Mode Engine Shutdown 3 14 3 6 Remote Control Preparation 3 15 P...

Page 9: ...ing Blade 4 4 4 4 Adapter Attachment Installation 4 5 Section 5 Lubrication Maintenance 5 1 Introduction 5 1 Clothing and Safety Gear 5 1 5 2 General Maintenance Instructions 5 2 Tire Service 5 2 5 3...

Page 10: ...s 5 20 50 Hours 5 25 100 Hours 5 27 750 Hours 5 29 Section 6 Emergency Procedures 6 1 Loss Of Power 6 1 Stowing the boom without engine power 6 1 To extend the boom without engine power 6 1 To raise t...

Page 11: ...s a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderat...

Page 12: ...ead power lines overhead or underground cables or other power sources may exist without ensuring the appropriate power or utility company de energizes the lines Always check for power lines before rai...

Page 13: ...achine to prevent possibility of a person being crushed between counterweight and another object Do not allow anyone inside the cab s other than the operator while in operation Always be careful when...

Page 14: ...1 4 80884013 The circle of safety is a circle around the excavator with the boom at full extension Establish and inform others of the circle of safety Keep others from entering into the circle of safe...

Page 15: ...ng machine Repair or replace damaged steps and grab handles Keep grab handles steps and walkways free of mud oil grease and other foreign material Replace non skid surface material as required Do not...

Page 16: ...he ground and the engine is stopped Be sure all access covers are in the fully open position before performing any procedures inside compartments Stay clear of moving parts while engine is running Rot...

Page 17: ...ty Practices 1 7 80884013 Never permit anyone under boom attachment or load Rest boom or attachment on ground and stop engine before permitting anyone to work beneath boom or behind cradle OAC1020 htt...

Page 18: ...ou may expect Always wear seat belt Keep head arms and other body parts inside cab at all times Maintain proper tire pressure at all times Inspect brakes before driving undercarriage after digging See...

Page 19: ...ent Never pass load line over open bucket Relief valves in bucket circuit could cause unexpected dangerous movement of the load Bucket linkage could also be damaged Be sure the surface excavator is on...

Page 20: ...micals including gasoline diesel fuel lubricants petroleum products engine exhaust carbon monoxide and phthalates which are known to the State of California to cause cancer and birth defects or other...

Page 21: ...on 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...

Page 22: ...te 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 cert...

Page 23: ...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 c...

Page 24: ...Section 1 General Safety Practices 1 14 80884013 NOTES https tractormanualz com...

Page 25: ...und inspection must be performed at beginning of each work shift or at each change of operator Ensure all Safety decals are legible and in place Clean or replace as required Refer to pages 2 5 through...

Page 26: ...awer Grab handles and steps secure and clean Window glass and mirrors clean and unobstructed Adjust mirrors for maximum visibility before and during operation Be sure windows and doors are securely la...

Page 27: ...belt if frayed or cut webbing damaged buckles or loose mounting hardware 9 Center Pin See Inspection Note 10 Wheel Tire Assemblies No loose or missing lug nuts proper inflation see page 5 26 for deta...

Page 28: ...lution is adequate for expected temperatures Be sure radiator and oil cooler fins are clean Drive belt check condition replace as required Engine cover properly latched and secured Power steering flui...

Page 29: ...nstructional decals and proper capacity charts are legible and in place Clean and replace as required Upperstructure Decal Locations OAC0980 80509018 80509018 80509015 80509015 80509007 80509010 80803...

Page 30: ...Section 2 Pre Operation and Controls 2 6 80884013 NO STEP OAC2600 80509013 80373077 80509015 91143288 80509013 80509016 80509012 80509015 https tractormanualz com...

Page 31: ...Section 2 Pre Operation and Controls 2 7 80884013 Undercarriage Decal Locations OAC1590 80503005 91143288 80509016 80509015 80509004 80509012 80783208 77383675 https tractormanualz com...

Page 32: ...Section 2 Pre Operation and Controls 2 8 80884013 80509014 80509012 80509015 80213104 77373048 https tractormanualz com...

Page 33: ...Section 2 Pre Operation and Controls 2 9 80884013 NOTES https tractormanualz com...

Page 34: ...Section 2 Pre Operation and Controls 2 10 80884013 2 4 UNDERCARRIAGE CAB COMPONENTS OAC1610 9 8 6 7 5 6 13 11 10 1 2 3 4 12 https tractormanualz com...

Page 35: ...ts 5 Defroster Vents 6 Air Vents 7 Right Hand Dash Panel See page 2 23 for details 8 Transmission Shift Selector See Shifting Gears on page 3 10 for detailed operating instructions 9 Accelerator Pedal...

Page 36: ...used to access navigate prognostics diagnostics 4 Down Arrow Pushbutton downshifts transmission when pressed Also used to access navigate prognostics diagnostics 5 Drive Pushbutton shifts transmission...

Page 37: ...ns solid for two minutes after Drive is selected Filter Life Monitor When the filter s is due for a change the wrench icon 1 flashes on and off for two minutes after Drive is selected Transmission Hea...

Page 38: ...he Up and Down arrows 1 two times oM appears followed by a number from 99 to 0 which represents the percentage of oil life remaining before a fluid change is required Filter Life Monitor Simultaneousl...

Page 39: ...and hold Mode button 1 for approximately 10 seconds while in Filter Life Monitor mode Or Perform the following shift sequence with the ignition on but the engine off Do not stop the sequence for more...

Page 40: ...rical countdown Engine is at idle The fluid temperature is between 60 C 140 F and 104 C 220 F Transmission is in N Neutral The vehicle has been stationary for approximately two minutes to allow the fl...

Page 41: ...l display The numerical display is a fault code and indicates conditions are not proper to recieve the fluid level information or there is a system malfunction The fault codes that may be encountered...

Page 42: ...ed followed by the Diagnostic Trouble Code DTC P 07 22 Each item is displayed for about one second The display cycles continuously until the next code list position is accessed by pressing the MODE bu...

Page 43: ...NT TEMP INPUT NOT PRESENT ACTUATOR SUPPLY VOLTAGE1 HSD1 LOW ACTUATOR SUPPLY VOLTAGE1 HSD1 HIGH TRANSMISSION CONTROL SYSTEM PERFORMANCE TRANSMISSION CONTROL SYSTEM ELECTRICAL TRANSID BRAKE SWITCH CIRCU...

Page 44: ...SSURE CONTROL SOLENOID MAIN MOD CONTROL OPEN PRESSURE CONTROL SOLENOID MAIN MOD CONTROL LOW PRESSURE CONTROL SOLENOID MAIN MOD CONTROL HIGH PRESSURE CONTROL SOLENOID 2 CONTROL OPEN PRESSURE CONTROL SO...

Page 45: ...ENOID 5 CONTROL HIGH RETARDER OIL TEMPERATURE HOT RETARDER OIL TEMPERATURE SENSOR LOW RETARDER OIL TEMPERATURE SENSOR HIGH TCC PCS CONTROL OPEN TCC PCS CONTROL HIGH TCC PCS CONTROL LOW KICKDOWN INPUT...

Page 46: ...Tachometer w Engine Hourmeter Tachometer indicates engine speed in revolutions per minute rpm Hourmeter indicates total time of engine operation in hours and tenths of hours 8 Engine Coolant Temperatu...

Page 47: ...ivate headlights depress bottom of switch to activate marker lights Middle position is OFF 7 Engine Brake Switch if equipped 3 position rocker switch Depress top of switch to activate compression brak...

Page 48: ...either remote control mode or travel mode 3 Pump PTO Indicator Illuminates green to indicate main PTO pump is engaged PTO pump must be off to start engine in travel mode PTO pump must be engaged to st...

Page 49: ...manifold to proper starting temperature 4 Undercarriage Key Indicator Illuminates green to indicate undercarriage ignition key is in the RUN position see page 2 27 for details 5 Upperstructure Key Ind...

Page 50: ...engaged XL3100V Illuminates green to indicate front rear tandem axle differential lock is engaged XL4100V XL5100V 12 Engine Brake Indicator if equipped Illuminates green if engine brake is activated 1...

Page 51: ...ble 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 en...

Page 52: ...am function for the headlights Turn Signal Hazards Push the lever forward 2 to activate the right turn signal Pull the lever back 3 to activate the left turn signal Pull hazard switch 5 to activate ha...

Page 53: ...Section 2 Pre Operation and Controls 2 29 80884013 NOTES https tractormanualz com...

Page 54: ...Section 2 Pre Operation and Controls 2 30 80884013 2 7 UPPERSTRUCTURE CAB COMPONENTS OAC0470 1 2 3 4 5 6 8 9 10 11 12 7 https tractormanualz com...

Page 55: ...t Keep Operator Safety manual with machine at all times 6 Electronic Monitoring Unit See page 2 32 for details 7 Circuit Board and Fuse Box See Fuses on page 7 9 8 Right Hand Joystick See Joystick Con...

Page 56: ...kout condition 3 Hydraulic Oil Level Indicator Illuminates red if oil level falls below acceptable operating level 4 Hydraulic Filter Indicator Illuminates red to indicate hydraulic reservoir filter n...

Page 57: ...tes red and a pulsing alarm is activated to indicate excessive engine temperature or low engine oil pressure Stop engine immediately and repair before continued use 14 Low Air Indicator Illuminates re...

Page 58: ...ditioning Switch On Off switch 5 Travel Speed Switch Depress front of switch for high travel speed Depress back of switch for low creeper travel speed Note If travel speed is switched while unit is in...

Page 59: ...e Depress back of switch II to deactivate auto idle With auto idle activated engine speed will return to low idle after 7 seconds of hydraulic control inactivity Once controls are activated engine res...

Page 60: ...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 Park Brake Switch See page 2 46 for detai...

Page 61: ...Section 2 Pre Operation and Controls 2 37 80884013 NOTES https tractormanualz com...

Page 62: ...the engine 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 be displayed in the cab GRADALL Control Pa...

Page 63: ...ed on the 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 on the electronic...

Page 64: ...the left will extend and swing the boom left simultaneously Right Hand Joystick Functions Move the joystick back to raise boom move joystick forward to lower boom Move joystick right to open tool move...

Page 65: ...will lower boom and open tool simultaneously Right Hand Joystick Functions Move the joystick back to retract boom move joystick forward to extend boom Move joystick right to swing boom right move joys...

Page 66: ...to the left will lower and swing boom left simultaneously Right Hand Joystick Functions Move the joystick back to retract boom move joystick forward to extend boom Move joystick right to open tool mo...

Page 67: ...t 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 Co...

Page 68: ...ble 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 en...

Page 69: ...884013 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...

Page 70: ...the park brake Indicator light on electronic monitoring unit illuminates to indicate brake is applied With the engine running and the park brake switch in OFF position 1 park brakes are disengaged Wi...

Page 71: ...tice The engine must not start or crank with the transmission in gear Release key immediately when engine starts If engine does not start after three attempts check fuel supply system 7 After engine s...

Page 72: ...id may be used with this engine only if it does not have the optional grid heater ENGINE EXPLOSION If your excavator is equipped with a cold start aid do not spray additional ether into air cleaner If...

Page 73: ...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 oi...

Page 74: ...iver s seat during braking emergency Do not fan the brake valve pedal A long series of rapid brake applications could reduce system pressure to a point where effective service braking will be lost unt...

Page 75: ...ich supplies the rear axle brakes If pressure in either portion of the system falls below safe operating range the low air indicator light will illuminate and an audible alarm will sound 20 100 250 20...

Page 76: ...rear axle There will be no braking of the wheels of the front axle If air pressure is lost from the rear portion of the dual brake system normal actuation of the brake pedal will apply service brakes...

Page 77: ...psi 414 kpa and there will be a complete application when pressure decreases to 40 psi 276 kpa Air pressure is required to release the spring brakes therefore they will remain ON until pressure can b...

Page 78: ...ure cab is inoperative when in travel mode Undercarriage park brake must remain applied when in remote mode Apply parking brake in undercarriage cab by raising parking brake control knob Knob will rai...

Page 79: ...Section 3 Operation 3 9 80884013 NOTES https tractormanualz com...

Page 80: ...ission upshifts automatically through each range As the vehicle speed decreases the transmission automatically downshifts to the correct range You may also manually select a lower forward gear below t...

Page 81: ...avel The interaxle differential may be locked when traveling but NEVER when the wheels have lost traction and are spinning If shifting interaxle differential while traveling release accelerator first...

Page 82: ...e When differential is locked the turning radius will increase Unlock the differential when need for maximum traction has passed or when traveling on good surface Do not lock differential when the veh...

Page 83: ...on Notice Engaging front axle drive while undercarriage is moving will damage transfer case Stop undercarriage before engaging front axle drive To Disengage Stop machine Move toggle lever on dash to t...

Page 84: ...tor park in a safe location on flat level ground and away from other equipment and or traffic lanes From Undercarriage Cab 1 Apply the park brake 2 Shift transmission to neutral 3 Operate engine at lo...

Page 85: ...ure cab Preparing Upperstructure for Remote Control Operation All instructions on undercarriage cab remote control decal must be followed before starting machine in remote operation 1 Place control cu...

Page 86: ...and horn function properly Both must be audible from the cab with engine running Check to ensure control pattern decal matches joystick controls Make sure all boom and attachment functions operate sm...

Page 87: ...fore leaving upperstructure cab With the travel remote switch in remote position the digging brake will set and release as travel pedal in upperstructure is actuated and released Under certain circums...

Page 88: ...ging brake is applied to all wheels to hold the undercarriage stationary while the excavator is digging Apply digging brake by moving travel remote switch to remote position and turning on upperstruct...

Page 89: ...the transmission Never tow a load using remote control drive Operate the engine at full throttle Undercarriage speed is controlled by travel speed switch position and amount of travel pedal actuation...

Page 90: ...avel alarms and back up lights will activate when steer pedal is depressed NOTE Due to varying conditions of front axle load and ground conditions steering may be restricted until unit is in motion 3...

Page 91: ...steering wheel or remote steering pedal in full turn position will cause system to overheat This may cause steering pump to fail POWER STEERING FAILURE In the event power steering fails stop as soon...

Page 92: ...on Remove boom tie down chain from boom 3 Perform checks before remote control operation located on page 3 16 Set engine to full throttle position 4 Be certain control cut out lever is in down positio...

Page 93: ...or conditions 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 b...

Page 94: ...t 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...

Page 95: ...on 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...

Page 96: ...ucket 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...

Page 97: ...Section 3 Operation 3 27 80884013 11 Move left joystick to left G or right H to align boom for next cut Repeat steps 3 through 11 https tractormanualz com...

Page 98: ...on the lift capacity chart If it becomes necessary to shut the engine off while positioning a load place load on the ground prior to shutting off engine Be thoroughly familiar with excavator hand sig...

Page 99: ...ot the best The worst condition can only be determined by performing an UNLOADED TEST AND DELIVERY of the load Loads shown on chart in cab are hydraulic lift capacities with those in shaded area indic...

Page 100: ...ht 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 v...

Page 101: ...ty The rated lift capacity is based on the machine being equipped with 15 500 lb 7030 kg counterweight standard boom standard tires no auxiliary hydraulics and no bucket Adjust the listed rated capaci...

Page 102: ...eing 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...

Page 103: ...ing the machine to align upperstructure with undercarriage 3 Lower attachment boom to ground or stow boom in boom rest See Boom Stow Procedure on page 3 35 4 Operate engine at low idle for 3 to 5 minu...

Page 104: ...e shown on page 5 30 3 Position boom over rear of undercarriage and embed bucket in ground or against a solid object 4 Apply down pressure with boom and pull and push with boom while a helper watches...

Page 105: ...ive to and from job site only under the following conditions Position boom in boom rest and secure boom as shown above Mirrors are clean and properly adjusted for visibility Doors and upperstructure w...

Page 106: ...ning flags flares or flashing lights Parking Procedure 1 Perform Travel Mode Engine Shutdown on page 3 14 or Remote Mode Engine Shutdown on page 3 33 2 Fill fuel tank to minimize condensation ATTENTIO...

Page 107: ...xposed cylinder rods Maintenance Take a sample of hydraulic fluid for analysis Note Not all analysis methods are compatible with all hydraulic fluids e g laser particle counters do not record accurate...

Page 108: ...Section 3 Operation 3 38 80884013 This Page Intentionally Left Blank https tractormanualz com...

Page 109: ...ved 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 excavato...

Page 110: ...g on page 4 4 Ditching Buckets Installation Procedure Refer to Adapter Attachment Installation beginning on page 4 4 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...

Page 111: ...stallation beginning on page 4 4 Pavement Removal Bucket Installation Procedure Refer to Adapter Attachment Installation beginning on page 4 4 Size Cu Yd m3 15 381mm 1 5 15 21 533mm 1 4 19 Size Cu Yd...

Page 112: ...dure Refer to Adapter Attachment Installation beginning on page 4 4 Grading Blade Installation Procedure Refer to Adapter Attachment Installation beginning on page 4 4 Size Cu Yd m3 72 1 83m 1 1 8 87...

Page 113: ...apter 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 sect...

Page 114: ...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...

Page 115: ...ed for service replace them before operating machine Do not step or stand on engine cover or upperstructure heater cover when performing checks and services in the area of the main boom and cradle Bef...

Page 116: ...ngine 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 welding on mach...

Page 117: ...AINTENANCE SCHEDULES Daily or Shift 10 Hour Maximum Maintenance Schedule Drain air tanks daily To prevent possible damage to emission controls components wait a minimum of 10 minutes after shutting of...

Page 118: ...sure Inspect Air Filter Vacuator Valve for damage Drain Fuel Water Separator Check Brake System Air Drier Check Power Steering Fluid Level 50 EVERY Check Swing Transmission Oil Level Follow Lubricatio...

Page 119: ...xle Oil Level Check Front Axle Wheel End Oil Levels 4X2 6X4 Machines Only Check Transfer Case Oil Level Check Fan Belt Check Battery Check Transmission Oil Level Inspect and Clean Cooler Cores Follow...

Page 120: ...r Filter Follow Lubrication Schedule Check Hydraulic Cab Heater Oil Reservoir 250 Torque all Items Listed in Torque Chart 1st 30 DAYS Drain and Refill Swing Transmission Oil Drain and Refill Tilt Tran...

Page 121: ...Section 5 Lubrication Maintenance 5 7 80884013 500 Hour Maintenance Schedule OAC2451 500 Change Engine Oil and Filter EVERY https tractormanualz com...

Page 122: ...ic fluid analyzed to determine condition Use test port mini check in pump line to obtain sample Drain flush and replenish system if required Check Brake System Slack Adjusters Follow Lubrication Sched...

Page 123: ...Hydraulic Fluid Filters Drain and Refill Steering System Reservoir Unless hydraulic fluid is analyzed semi annually to determine level of contamination system must drained flushed and replenished on a...

Page 124: ...Lube Points Additional Lube Points for 4x4 OAC2501 125 EVERY Grease extreme pressure 2 4x2 FRONT STEER AXLE 4x4 FRONT DRIVE AXLE Universal Joints Drive Shaft Splines Wheel End King Pin Pivot King Pin...

Page 125: ...be Points for 4x4 OAC2561 125 EVERY Grease extreme pressure 2 C S P R 4x4 TRANSFER CASE AND DRIVE SHAFT 4x2 DRIVE SHAFT Slack Adjusters Universal Joints Universal Joints Universal Joints Universal Joi...

Page 126: ...for 6x6 OAC2511 125 EVERY Grease extreme pressure 2 6x4 FRONT STEER AXLE 6x6 FRONT DRIVE AXLE 6x6 FRONT DRIVE AXLE Universal Joints Universal Joints Drive Shaft Splines Wheel End King Pin Pivot King...

Page 127: ...RY Grease extreme pressure 2 6x6 TRANSFER CASE AND DRIVE SHAFT 6x4 DRIVE SHAFT Slack Adjusters Universal Joints Universal Joints Universal Joints Walking Beam Pivot Universal Joints Universal Joints U...

Page 128: ...r Maximum Lubrication Schedule XL3100V 4x2 FRONT STEERING AXLE FRONT Number of Lube Points Additional Lube Points for 4x4 OAC2521 750 EVERY Grease extreme pressure 2 4x4 FRONT DRIVE AXLE Brake Camshaf...

Page 129: ...Section 5 Lubrication Maintenance 5 15 80884013 REAR Number of Lube Points Additional Lube Points for 4x4 OAC2531 750 EVERY Grease extreme pressure 2 Brake Camshafts https tractormanualz com...

Page 130: ...ximum Lubrication Schedule XL4100V XL5100V 6x4 FRONT STEERING AXLE FRONT Number of Lube Points Additional Lube Points for 6x6 OAC2541 750 EVERY Grease extreme pressure 2 6x6 FRONT DRIVE AXLE Brake Cam...

Page 131: ...Section 5 Lubrication Maintenance 5 17 80884013 REAR Number of Lube Points Additional Lube Points for 6x6 OAC2551 750 EVERY Grease extreme pressure 2 Brake Camshafts https tractormanualz com...

Page 132: ...Y Number of Lube Points Grease extreme pressure OAC2480 Hoist Cylinder Barrel Pivot Swing Bearing Hoist Cylinder Rod Pivot Main Boom Rollers Tool Cylinder Rod Pivot Straight Link Pivots Bucket Adapter...

Page 133: ...Section 5 Lubrication Maintenance 5 19 80884013 Annual 1500 Hour Maximum Lubrication Schedule 1500 EVERY Number of Lube Points Grease extreme pressure OAC2490 Swing Bull Gear https tractormanualz com...

Page 134: ...wn procedure on page 3 14 or page 3 33 and proceed to fuel tank 3 3 Turn fuel tank cap 2 and remove from fuel tank 3 Add diesel fuel as needed Replace fuel tank cap Replenish diesel fuel at end of eac...

Page 135: ...ocedure on page 3 14 or page 3 33 3 Check level of hydraulic oil at the sight gauge 1 on the hydraulic tank 2 The oil level should be visible in the upper gauge window 4 If hydraulic oil is low locate...

Page 136: ...t cap from pressure fill port 5 Locate female coupling from tool kit and attach to pressure fill port Add hydraulic fluid to level where oil is visible in upper gauge window 6 Remove female coupling f...

Page 137: ...hange as filter indicator light indicates 1 Perform shutdown procedure on page 3 14 or page 3 33 2 Locate reservoir breather 1 mounted on hydraulic tank 2 3 Depress breather plunger 3 to relieve all h...

Page 138: ...5 24 80884013 4 Remove bolts 4 on return filter to allow removal of filter cover 5 5 Remove old filter element 6 and replace with new element 6 Replace filter cover 5 and bolts 4 Torque bolts to 200 2...

Page 139: ...1 Perform shutdown procedure on page 3 14 or page 3 33 2 Locate air tanks 1 3 Loosen drain cocks 2 to drain any moisture from air tanks If significant moisture is found check operation of air drier 4...

Page 140: ...orm shutdown procedure on page 3 14 or page 3 33 2 Remove valve stem cap 3 Check tire pressure using a good quality gauge 4 Add air if required inflate tires to air pressure located on sidewall of equ...

Page 141: ...14 or page 3 33 2 Locate reservoir breather 1 mounted on hydraulic tank 2 3 Depress breather plunger 3 to relieve hydraulic reservoir pressure 4 Spin reservoir breather counter clockwise to remove fr...

Page 142: ...page 3 14 or page 3 33 2 Open the battery box cover 3 Wearing eye protection visually inspect the batteries 1 Check terminals for corrosion Replace battery if it has a cracked melted or damaged case 4...

Page 143: ...ug 3 Drain oil into a suitable container 4 Unscrew bowl 4 and remove filter element from element location spigot in the filter head 5 Replace the filter element Verify that the designation corresponds...

Page 144: ...fy maintenance personnel for adjustment or repair 1 Position unit in a safe level area 2 With brake system fully charged 125 psi apply digging brake stop engine and remove key 3 Install wheel chocks 4...

Page 145: ...the boom circuit 2 Direct the rod side oil into a waste container as the boom is SLOWLY pulled out 3 Once the boom is at the proper extension secure the telescoping boom to the main boom using a chain...

Page 146: ...ack to travel mode Towing When transporting the vehicle with one or all axles on the road it is possible to damage the axles if the wrong procedure is used before transporting begins Before towing the...

Page 147: ...ated oil Cooling System System Capacity 11 gallons 41 6 liters Type of Coolant OAT Coolant p n 80533046 Hydraulic System System Capacity XL3100V 65 gallons 246 liters System Capacity XL4100V XL4130 XL...

Page 148: ...ty 34 pints 16 liters Type of Fluid 80w90 8053 3027 Rear Tandem Axle rear XL4100V XL5100V Capacity 31 pints 14 7 liters Type of Fluid 80w90 8053 3027 Front Axle XL3100V 4x4 Capacity 27 pints 12 8 lite...

Page 149: ...uired 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...

Page 150: ...kg Note Refer to detailed specification sheet for additional machine weight information Specification sheets can be viewed downloaded at www gradall com Dimensions XL3100V Wheelbase 13 4 ft 4 1 m Gro...

Page 151: ...ucket 25 6 ft 7 8 m Transport Height without bucket 6x4 11 2 ft 3 4 m Transport Height without bucket 6x6 11 5 ft 3 5 m Transport Width 8 6 ft 2 6 m Note Refer to detailed specification sheet for addi...

Page 152: ...r Quantity 6 Thread Size grade 5 8 11 8 Torque lubricated 200 215 lb ft 272 292 Nm Swing Bearing Quantity 72 Thread Size grade 5 8 11 8 Torque lubricated 200 215 lb ft 272 292 Nm Swing Motor Quantity...

Page 153: ...ated 200 215 lb ft 272 292 Nm Wheel Lug Nuts Quantity ALL Thread Size grade 3 4 10 8 Torque lubricated 450 500 lb ft 610 678 Nm Front Axle U Bolt Nuts Quantity ALL Thread Size grade 3 4 10 8 Torque 30...

Page 154: ...7 8 14 8 Torque bolts in a 4 stage criss cross pattern Torque Stage 1 150 185 lb ft 203 251 Nm Torque Stage 2 280 315 lb ft 380 427 Nm Torque Stage 3 470 505 lb ft 637 685 Nm Torque Stage 4 560 595 l...

Page 155: ...POWER F23 SPARE ACCY B POWER F24 POWER OUTLET 2 F25 WIPER POWER F26 D C CONVERTER POWER F27 SPARE ACCY A POWER F28 SWITCH POWER F29 POWER OUTLET 1 F30 HEATER POWER F31 SP 1 SPARE 1 OAC1910 OAC1920 AT...

Page 156: ...Section 7 Specifications 7 10 80884013 This Page Intentionally Left Blank https tractormanualz com...

Page 157: ...torque no damage or cracks Grab Handles and Steps secure and clean Tires proper inflation no damage adequate tread Horn clean and undamaged Air tanks open petcocks to drain water no damage hoses in g...

Page 158: ...tes properly Upperstructure Lights Indicators and Gages function properly Dash Lights Indicators and Gages function properly Control Cut Out Lever controls do not operate while in the raised position...

Page 159: ...torque no damage or cracks Grab Handles and Steps secure and clean Tires proper inflation no damage adequate tread Horn clean and undamaged Air tanks open petcocks to drain water no damage hoses in g...

Page 160: ...tes properly Upperstructure Lights Indicators and Gages function properly Dash Lights Indicators and Gages function properly Control Cut Out Lever controls do not operate while in the raised position...

Page 161: ...se Panel 7 9 G Grading Blade 4 4 H Hazards Lever 2 28 High Beam Lever 2 28 Hydraulic Oil Level 5 21 Hydraulic Reservoir Breather 5 27 Hydraulic Return Filter Element 5 23 Hydraulic System 7 1 I Igniti...

Page 162: ...our 5 6 500 Hour 5 7 Annual 1500 Hour Max 5 9 Daily Shift 10 Hour Max 5 3 Monthly 125 Hour Max 5 5 Semi Annual 750 Hour Max 5 8 Weekly 50 Hour Max 5 4 Shifting Gears 3 10 Slack Adjuster Check 5 30 Sli...

Page 163: ...ace 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 inwar...

Page 164: ...hone 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 Hyvink Finland Tel 358 0 20 759 0400 Fax 358 0 19...

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