Gradall 544B Operation Manual

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IMPORT ANT SAFETY NOTICE

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Safe operation depends upon reliable equipment and proper operating procdures. Performing the checks and services described in this manual will help to keep your Gradall® Material Handler 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 unit.

Strict attention to, and compliance with instructions provided in this manual, the EMI Rough Terrain Forklift Safety Manual, the Gradall Material Handler Safety Manual, as well as instructional decals and plates affixed to the machine, will help you avoid personal injury and damage to the equipment. The information provided is not intended to cover all situations; 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 Material Handler Distributor before operating.

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Do not modify this machine without written

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permission from The Gradall Company. Use

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only genuine Gradall replacement parts.

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OTHER NOTICES

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The Gradall company retains all proprietary rights to the information contained in this manual.

The Company also reserves the right to change specifications without notice.

Gradall is a registered trademark for hydraulic excavators, hydraulic material handlers and attachments manufactured by The Gradall Company.

The Gradall Company

406 Mill Avenue, S.W ., New Philadelphia, Ohio 44663

Form No. 29027 - Revised 1/95

INTRODUCTION

General

The manual provides important information to familiarize you with safe operating procedures and operator maintenance requirements for the Gradall/ 544B Material Handler.

If you have any questions regarding the material handler, contact your Gradall Material Handler Distributor.

Operator Qualifications

Operators of the material handler must be in good physical and mental condition, have normal reflexes and reaction time, good vision and depth perception and normal hearing. He/she* must not be using medications which could impair his abilities nor be under the influence of alcohol or any other drug during the work shift.

The operator should also possess a valid, applicable driver’s license and must have completed a course of training in the safe operation of this type of material handling equipment. In addition, the operator must read, understand and comply with instructions contained in the following material furnished with the material handler:

This Operator’s Manual FIEI Rough T errain Forklift Safety Manual Gradall Material Handler Safety Manual All instruction decals and plates Any optional equipment instructions furnished

Related Manuals & Decals

Separate publications are furnished with the material handler to provide information concerning safety, replacement parte, maintenance components. Replacement manuals, decals and instruction plates can be ordered from your Gradall Material Handler Distributor.

Serial Number Location

Specify Model and Serial Numbers when ordering parts and when discussing specific applications and procedures with your distributor. The model/serial number plate is located on the right cab wall.

The operator must also read, understand and comply with all applicable Employer, Industry and Governmental rules standards and regulations.

Regardless of previous experience operating similar equipment, the operator must be given sufficient opportunity to practice with the 544B Material Handler in a safe, open area (not hazardous to people or property) to develop the skills and “feel” required for safe, efficient operation

*Though no offense or discrimination is intended, only the masculine pronouns will be used throughout the remainder of this manual.

Orientation

When used to describe location of components in the material handler, the directions front, rear, right and left relate to the orientation of a person sitting in the operator’s seat.

Nomenclature

The illustrations on page 3 include nomenclature applied to major components of the material handler. The term “handler” will be used throughout the balance of this manual in place of the words “material handler”.

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NOMENCLATURE

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SAFETY HIGHLIGHTS

Read and understand this manual, the Gradall Material Handler Safety Manual and all instructional decals and plates before starting, operating or performing maintenance procedures on this equipment.

Most safety notes included in this manual involve characteristics of the Model 544B Material Handler. Refer to the FIEI Rough Terrain Forklift Safety Manual and the Gradall Material Handler Safety Manual for safety precautions relating to general material handling procedures and practices.

Watch for these symbols; they are used

to call your attention to safety notices.

Operators of this equipment must have successfully completed a training program in the safe operation of this type of material handling equipment.

Regardless of previous experience operating similar equipment, the operator must be given sufficient opportunity to practice with the 544B Material Handler in a safe open area (not hazardous to people or property) to develop the skills and “feel” required for safe, efficient operation.

This symbol indicates an extreme hazard which would result in high probability of death or serious in|injury if proper precautions are not taken.

This symbol indicates a hazard which could result in death or serious injury it proper precautions are not taken.

This symbol Indicates a hazard which could result in injury or damage to equipment or property it proper precautions are not taken.

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9100-3039

Located on Dashboard Part No.9100-3039

Decals

9103-3089

Located on Dashboard

Part No. 9103-3089

9100-3040

Located on Dashboard

Part No. 9100-3040

Located on Boom Lever Knob

Part No. 9100-3400

Located on Right Cab Wall

Part No. 9104-3184

5

Located on Dashboard

Part No. 9103-3341

Decals (cont.)

FOR LONGER TURBOCHARGER LIFE, IDLE ENGINE AT LEAST 1 MINUTE AFTER START-UP AND BEFORE SHUT DOWN.

TO PREVENT ENGINE RING GEAR DAMAGE, WAIT 10 SECONDS AFTER ENGINE STOPS BEFORE ATTEMPTING TO RESTART.

FOR OPTIMUM CONTROL AND BRAKE LIFE. USE LOW GEAR WHEN DESCENDING STEEP GRADES.

Located on Dashboard

Part No. 9103-3443

Located on Left Cab Wall

Part No. 9103-3396

WHEN TRA VELING AT HIGH SPEEDS

FOR OVER 2 MILES, DISENGAGE

REAR HUBS BY REVERSING SMALL

COVER PLA TE AT HUB CENTER.

Located on Dashboard

9103-3418

Located on Mudguard

Part No. 9103-3395

6

Decals (cont.)

IMPORTANT

To prevent damage to the electrical system when using booster battery or charger, always connect

( + ) POSITIVE TO POSITIVE

( - ) NEGA TIVE TO NEGA TIVE

Located on Battery Cover

Part No. 7702-3007

HOT EXHAUST

Located on Engine Cover

Part No.7734-3018

HYDRAULIC OIL

Located on Hydraulic T ank

Park No. 7702-3006

Located on Side of Boom

Part No. 9100-3031

DEATH

UNLAWFUL

PARK BRAKE

PULL TO SET

PUSH TO RELEASE

OR INJURY MAY RESULT FROM CONTACTING ELECTRICAL LINES.

TO PLACE ANY PART OF THIS MACHINE OR LOAD WITHIN 10 FEET OF HIGH VOLTAGE LINES OF UP TO 50,000 VOLTS.

Located on Mud Guard

Part No. 8360-1011

FUEL-DIESEL

EXTINGUISH ALL OPEN FLAME AND SMOKING MA TERIALS WHEN REFUELING

Located on Fuel T ank

Part No. 9100-3052

Located on Seat Pedestal

Part No. 9104-3129

Located Inside Cab

Part No. 9106-3047

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DO NOT INSERT HAND IN OPENING WHILE ENGINE IS RUNNING

Located on Engine Cover

Part No. 9103-3011

DO NOT USE OXYGENDO NOT USE OXYGEN

DO NOT USE OXYGEN

DO NOT USE OXYGENDO NOT USE OXYGEN

USE “OIL PUMPED OR DRY NITROGEN.”USE “OIL PUMPED OR DRY NITROGEN.”

USE “OIL PUMPED OR DRY NITROGEN.”

USE “OIL PUMPED OR DRY NITROGEN.”USE “OIL PUMPED OR DRY NITROGEN.” CONSULT DEALER BEFORE CHARGING ACCUMULATORCONSULT DEALER BEFORE CHARGING ACCUMULATOR

CONSULT DEALER BEFORE CHARGING ACCUMULATOR

CONSULT DEALER BEFORE CHARGING ACCUMULATORCONSULT DEALER BEFORE CHARGING ACCUMULATOR

9104-3206

Decals (cont.)

9103-3011

PRESSURIZED-PRESSURIZED-

PRESSURIZED-

PRESSURIZED-PRESSURIZED-

COOLING SYSTEMCOOLING SYSTEM

COOLING SYSTEM

COOLING SYSTEMCOOLING SYSTEM

REMOVE CAPREMOVE CAP

REMOVE CAP

REMOVE CAPREMOVE CAP

SLOWLYSLOWLY

SLOWLY

SLOWLYSLOWLY

9104-3210

Located on Engine Cover

Part No. 9104-3210

NO RIDERS

Located on Accumulator

Part No. 9104-3206

PINCH POINT AREAPINCH POINT AREA

PINCH POINT AREA

PINCH POINT AREAPINCH POINT AREA

TO PREVENT INJURY, KEEPTO PREVENT INJURY, KEEP

TO PREVENT INJURY, KEEP

TO PREVENT INJURY, KEEPTO PREVENT INJURY, KEEP CLEAR ANYTIME MACHINECLEAR ANYTIME MACHINE

CLEAR ANYTIME MACHINE

CLEAR ANYTIME MACHINECLEAR ANYTIME MACHINE IS RUNNING.IS RUNNING.

IS RUNNING.

IS RUNNING.IS RUNNING.

Located on Rear of Frame

Part No. 9104-3209

9104-3209

9104-3211

Located at Cab Entrance &

on Engine Cover

Part No. 914-3211

DO NOT USE THIS MACHINE FOR LIFTING PERSONEL.

9104-3215

Located on Mudgaurd

Part No. 9104-3215

TT

O PREVENTO PREVENT

T

O PREVENT

TT

O PREVENTO PREVENT

INJURINJUR

INJUR

INJURINJUR

OUT OF BOOMOUT OF BOOM

OUT OF BOOM

OUT OF BOOMOUT OF BOOM

HOLES.HOLES.

HOLES.

HOLES.HOLES.

Located on each side of boom

Part No. 7702-3009

YY

,,

KEEP KEEP

Y

,

KEEP

YY

,,

KEEP KEEP

7702-3009

INSURE FORKS ARE LEVEL AND LOAD IS SECURE BEFORE ROTATING LOAD WHEN EQUIPPED WITH SWING FORKS. BOOM SHOULD BE PROPERLY SHIMMED TO MINIMIZE TWIST. LOSS OF LOAD WILL RESULT FROM MISUSE OF SWING FORKS.

Located on left cab wall

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Part No. 9104-3173

9104-3173

Optional Equipment Decals

9103-3417

Located on Instrument Console

Part No. 9103-3417

9103-3394

Located on Instrument Console

Part No. 9103-3394

Located on Attachment

Part No. 9015-3001

9102-3006

Located on Dashboard

Part No. 9108-3363

Located on Seat Pedestal

Part No. 9102-3006

CHECK TO ASSURE QUICK SWITCHCHECK TO ASSURE QUICK SWITCH

CHECK TO ASSURE QUICK SWITCH

CHECK TO ASSURE QUICK SWITCHCHECK TO ASSURE QUICK SWITCH PIN IS FULLY ENGAGED AND LOCKEDPIN IS FULLY ENGAGED AND LOCKED

PIN IS FULLY ENGAGED AND LOCKED

PIN IS FULLY ENGAGED AND LOCKEDPIN IS FULLY ENGAGED AND LOCKED AFTER ATTACHMENT CHANGE.AFTER ATTACHMENT CHANGE.

AFTER ATTACHMENT CHANGE.

AFTER ATTACHMENT CHANGE.AFTER ATTACHMENT CHANGE.

2-9103-3023

Located on Boom Head

Part No. 9103-3023

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OPERA TOR’S CAB

The standard cate is open on three sides and includes an overhead guard to provide protection from falling objects.

Never operate the handler unless the overhead guard is in place and in good condition.

A fully enclosed cate with windows and a lockable door is available as an option. The cab door can be secured in the fully opened or closed position. Be sure the door is fully secured when operating the handler.

The operator’s seat is equipped with a seat belt and includes fore and aft adjustment to compensate for

CONTROL AND INSTRUMENT IDENTIFICATION

variations in operator size. The adjustment release/lock lever is located beneath front edge of seat. Wear set belt at all times.

An optional windshield wiper is available for use with enclosed cabs. An ON/OFF control switch is Located on the wiper motor.

A variable speed defroster fan is available for use with enclosed cabs. An ON/OFF control switch and speed control are located on the base of the fan.

An optional variable speed heater fan is available for use with units equipped with a heater. An ON/OFF/ SPEED CONTROL knob is located on the dashboard. Hot water to the heater can be controlled by a valve at the engine.

*Items preceded by an asterisk are optional and may not be furnished on your handler

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Gradall 544B Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

IMPORT ANT SAFETY NOTICE

INTRODUCTION

NOMENCLATURE

SAFETY HIGHLIGHTS

Decals

CONTROL AND INSTRUMENT IDENTIFICATION