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Gradall XL4100 User Manual

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July 2002
Starting S/N
Undercarriage - G04391
OPERATOR'S MANUAL
GRADALL
406 Mill Avenue S.W.
New Philadelphia, OH, 44663, USA
Telephone: (330) 339-2211
Fax: (330) 339-3579
XL4100 CARRIER
24604133
Form #29612 Original Issue 8/96
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Gradall XL4100 Specifications

General IconGeneral
BrandGradall
ModelXL4100
CategoryExcavators
LanguageEnglish

Summary

IMPORTANT SAFETY NOTICE

OTHER NOTICES

INTRODUCTION

General

Introduces the manual's purpose for Gradall wheeled excavator undercarriage operation and maintenance.

Related Manuals

Lists other essential manuals required for safe operation and maintenance.

Operator Qualifications

Details the requirements and responsibilities for operating the Gradall excavator.

Orientation

Defines directional terms (front, rear, left, right) relative to the driver's seat.

Serial Number Location

Explains where to find the carrier's serial number for identification and ordering.

SAFETY HIGHLIGHTS

General Safety Precautions

Emphasizes three-point contact for climbing and performing pre-driving checks.

SAFETY HIGHLIGHTS

Pinch Point Awareness

Identifies common pinch points on the machine to avoid serious injury or death.

SAFETY HIGHLIGHTS

Machine Checks and Operation Safety

Advises verifying decals, keeping areas clean, using alarms, and avoiding carrying items.

SAFETY HIGHLIGHTS

Travel Safety Conditions

Outlines requirements for safe off-highway and jobsite travel.

SAFETY HIGHLIGHTS

Travel Preparations and Checks

Covers boom securing, brake inspection, and window/door latch checks.

SAFETY HIGHLIGHTS

Operational Safety Considerations

Advises knowing unit height, securing attachments, and avoiding passengers.

Decals Inside Cab

Key Cab Decal Information

Highlights DANGER, WARNING, CAUTION, and operational procedure decals found inside the cab.

Decals Outside Cab

Key Exterior Decal Information

Highlights WARNING, CAUTION, and IMPORTANT decals found outside the cab.

INSTRUMENTS AND INDICATORS

Instrument Panel Overview

Details all gauges and indicator lights on the dashboard, including their purpose and normal readings.

CONTROLS

Operator Cab Controls

Lists and describes the purpose of all controls within the operator's cab.

CHECKS AND SERVICES BEFORE STARTING ENGINE

Pre-Start Engine Checks

Covers checks for washer fluid, lights, heater, and engine gauges like oil, voltage, and air pressure.

CHECKS BEFORE DRIVING

Pre-Driving Operational Checks

Verifies brake, steering, horn, alarms, and seat belt functions before driving.

PLAN YOUR TRIP

ENGINE OPERATION

Starting Diesel Engine (Cummins)

Step-by-step guide for starting the Cummins diesel engine, including checks and warm-up.

Cold Weather Starting Aids

Discusses the use of starting aids for diesel engines in cold weather conditions.

ENGINE OPERATION

Normal Engine Operation (Cummins)

Guidelines for monitoring engine gauges, responding to unusual conditions, and managing loads.

Stopping the Engine (Cummins)

Procedures for properly shutting down the Cummins engine, including warm-up.

CHECKS AFTER STARTING ENGINE

Post-Start Engine Checks

Covers checks for washer fluid, lights, heater, and engine gauges like oil, voltage, and air pressure.

CHECKS BEFORE DRIVING

Pre-Drive System Checks

Verifies brake, steering, horn, alarms, and seat belt functions before driving.

BRAKE SYSTEM

Service and Emergency Brakes

Details the operation of the service and emergency brakes and their pressure requirements.

BRAKE SYSTEM

Parking and Digging Brakes

Explains how to apply and release parking and digging brakes and their system requirements.

BRAKE SYSTEM

Remote Braking and Air Drier

Covers remote control braking and the function of the air drier system.

STEERING SYSTEM

Conventional and Remote Steering

Explains the operation and precautions for conventional power steering and remote pedal steering.

POWER TRAIN

Clutch, Transfer Case, and Transmission

Describes the clutch, transfer case (6x6), and the 8-speed transmission operation.

Countershaft Brake

Explains the purpose and operation of the countershaft brake for easing gear shifts.

SHIFTING GEARS

Shifting Procedures and Timing

Guides on optimal timing for shifting and the importance of double-clutching.

SHIFTING GEARS

Double-Clutching for Downshift and Upshift

Details double-clutching for downshifting and the steps for upshifting.

Shifting Precautions

Important safety and operational guidelines for gear shifting, especially with range selection.

SHIFTING GEARS

Shifting Procedures for Lo Lo and Lo Ranges

Step-by-step guides for selecting and engaging Lo Lo and Lo gear ranges under various conditions.

SHIFTING GEARS

Downshifting and Maximum Speeds

Explains downshifting procedures and provides a chart of maximum carrier speeds per gear.

SHIFTING GEARS

Downshifting Steps

Detailed steps for performing downshifts using the double-clutching method.

INTER-AXLE DIFFERENTIAL

Differential Lock Operation

Details how to engage and disengage the differential lock for improved traction, with precautions.

REMOTE CONTROL

Preparing for Remote Operation

Steps to prepare both the carrier and upperstructure for remote control operation.

REMOTE CONTROL

Remote Operation Precautions and Driving

Key safety guidelines, driving instructions, and preparation for conventional control.

PARKING THE GRADALL

Parking Precautions and Procedure

Guidelines for safe parking locations, boom positioning, and the step-by-step parking process.

IN CASE OF TROUBLE

IF YOU GET STUCK

6X4 CARRIER LUBRICATION & MAINTENANCE DIAGRAM

Lubrication & Maintenance Schedule

Daily/Shift Maintenance

Routine checks and lubrication performed daily or per shift.

Initial Service (30/40 Hours)

Initial service tasks to be performed after the first 30 or 40 hours of operation.

Weekly Maintenance

Maintenance tasks to be completed weekly or every 50 operating hours.

Monthly Maintenance

Maintenance schedule for monthly or 125-hour intervals.

Annual Maintenance

Annual or 1500-hour service requirements for the carrier.

6 X G CARRIER LUBRICATION & MAINTENANCE DIAGRAM

Lubrication & Maintenance Schedule

Daily/Shift Maintenance

Routine checks and lubrication performed daily or per shift.

Initial Service (40 Hours)

Initial service tasks to be performed after the first 40 hours of operation.

Weekly Maintenance

Maintenance tasks to be completed weekly or every 50 operating hours.

Monthly Maintenance

Maintenance schedule for monthly or 125-hour intervals.

Annual Maintenance

Annual or 1500-hour service requirements for the carrier.

Recommended Lubricants & Capacities

Torque Chart

CHECKING AUTOMATIC SLACK ADJUSTERS

Automatic Slack Adjuster Procedure

Step-by-step guide for checking the automatic slack adjuster system.

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