Gradall 544D Service Manual

SERVICE MANUAL

544D-10

CORPORATE OFFICE

JLG INDUSTRIES, INC. 1 JLG DRIVE McConnellsburg, PA 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417

9136-4003

April 30, 2007

Starting Serial No.

0355001 thru 0455362

GRADALL DIVISION

JLG INDUSTRIES, INC. 406 Mill Avenue S.W. New Philadelphia, OH 44663 USA Telephone: (330) 339-2211 Fax: (330) 339-8458

544D MATERIAL HANDLER

OWNER/OPERATOR MANUAL

COVERING OPERATION & PERIODIC MAINTENANCE

IMPORTANT!

material handler

Read and understand this Manual and the Gradall Material

Handler Safety Manual before starting, operating or

performing maintenance procedures on this machine.

KEEP OPERATOR AND SAFETY MANUALS IN CAB

A Company

Form No. 20220

COVERS MATERIAL HANDLER MODEL 544D-10

STARTING SERIAL NUMBER

0355001 thru 0455632 & 0160000192

thru 0160003968 excluding 0160003856

Part No. 9136-4142

Revised 01-11-07

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IMPORTANT SAFETY NOTICE

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Safe operation depends on reliable equipment and proper operating procedures. Performing the checks and services described in this Manual will help keep your GRADALL Material Handler in reliable condition. Following recommended operating procedures can help you avoid accidents. Because some procedures may be new to even the experienced operator, we require that this Manual be read, understood and complied with by all who operate this machine.

Strict attention to and compliance with instructions provided in this Manual, the GRADALL Material Handler Safety Manual, as well as instructional decals and plates affixed to the machine will help prevent injuries to personnel and damage to the equipment. The information provided herein is not intended to cover all situations; it is impossible to anticipate and evaluate all possible applications and methods of operation for this equipment.

This Manual covers recommended operating procedures and basic maintenance checks and services for the Material Handler. Detailed maintenance information is available in the appropriate Service Manual.

Any procedure not specifically recommended by GRADALL must be thoroughly evaluated from the standpoint of safety before it is placed in practice. If you are not sure, contact your GRADALL Material Handler Distributor before operating.

Use only GRADALL authorized parts. The use of counterfeit parts may cause premature failure which could lead to injuries and/or machine damage.

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Do not modify this machine without written

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permission from GRADALL. Use only genuine

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GRADALL replacement parts.

OTHER NOTICES

GRADALL retains all proprietary rights to the information contained in this Manual.

GRADALL 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.

REVISIONS

This page is provided so you may determine that this Manual is complete and current with respect to Gradall Engineering Specifications.

Page Date Revision

6/03 Original Issue, replaces Owner/Op Manual 9136-4024 (Form #20047).

Cover 01/07 Revised ending serial number.

Form No. 20220

544D-10 Owner/Operator Manual

TABLE OF CONTENTS

IMPORTANT SAFETY NOTICE ..................................................... inside front cover

TABLE OF CONTENTS INTRODUCTION

General Operator Qualifications Orientation Related Manuals & Decals

Serial Number Location NOMENCLATURE

SAFETY HIGHLIGHTS ............................................................... 1.0

DECALS ................................................................................. 2.0

Decals Inside Cab

Decals Outside Cab

OPERATORS CAB ..................................................................... 3.0

Cab

Control & Instrument Identification

CHECKS & SERVICES BEFORE STARTING ENGINE ....................... 4.0

WARM-UP & OPERATIONAL CHECKS .......................................... 5.0

ENGINE OPERATION ................................................................ 6.0

Starting the Engine

Cold-Weather Starting Aids

Battery-Boosted Starting

Normal Engine Operation

Stopping the Engine

John Deere Engine Shut-Down Protection Feature

BRAKE SYSTEM ....................................................................... 7.0

General

Inching Travel

Service Brakes

Parking Brakes

PARKING THE HANDLER........................................................... 8.0

STEERING SYSTEM .................................................................. 9.0

DRIVE TRAIN .......................................................................... 10.0

LEVELING THE HANDLER ......................................................... 11.0

OPERATING PROCEDURE & TECHNIQUES ................................... 12.0

Hydraulic Controls

Rated Capacity Chart

ATTACHMENTS ........................................................................ 13.0

Approved Attachments

Non-Approved Attachments

Carriage/Fork Capacities

Other Attachment Capacities

Attachment Installation

Attachment Operation

OBTAINING HYDRAULIC OIL SAMPLE FOR ANALYSIS ................... 14.0

LOADING & SECURING FOR TRANSPORT .................................... 15.0

MOVING HANDLER IN EMERGENCY............................................ 16.0

Moving Short Distances

Moving Longer Distances

To Activate Tow Bypass

To Release Parking Brake

To Restore Parking Brake

MAINTENANCE SECTION .......................................................... 17.0

Nomenclature

Lubrication and Maintenance

Lubrication Chart

Torque Chart

Boom

Stabilizer

INSPECTION AND MAINTENANCE LOG ....................................... 18.0

HAND SIGNALS ....................................................................... inside back cover

INTRODUCTION

General

This Manual provides important information regarding safe operating and maintenance requirements for GRADALL Material Handlers.

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 must not be using medication which could impair abilities nor be under the influence of alcohol or any other intoxicant during the work shift.

The operator should possess a valid, applicable driver’s license and must have completed a training course in the safe operation of this type of material handling equipment.

In addition, the operator must read/view, understand and comply with instructions contained in the following material furnished with the material handler:

• This Owner/Operator Manual

• GRADALL Material Handler Safety Manual

• All warning and instructional decals and plates

• Any optional equipment instructions furnished

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

NOTE!

“Material handler” and handler are used interchangeably throughout this Manual.

NOTE!

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

FRONT

RIGHT

LEFT

Orientation

When used to describe the 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. (See Figure I-1)

Related Manuals & Decals

Separate publications are furnished with the material handler to provide information concerning safety, replacement parts, maintenance procedures, theory of operation and vendor components. Replacement manuals, decals and instruction plates can be ordered from your GRADALL Material Handler Distributor.

Models Covered

This Manual covers basic information for Gradall Material Handlers. Detailed information for each particular machine is in the maintenance section in the back of this manual. Be certain to refer to proper information for your unit and the operational equipment furnished on your machine.

Serial Number Location

Specify Model Number and Serial Number when ordering parts and when discussing specific applications and procedures with your Distributor. The model/ serial number plate is located inside the operator’s cab, right wall.

(See Figure I-2)

REAR

Figure I-1

GRADALL IS A REGISTERED TRADEMARK

FOR HYDRAULIC EQUIPMENT BUILT BY THE JLG COMPANY

1 JLG DRIVE, McCONNELLSBURG, PA.

U.S.A.

(WITHOUT ATTACHMENTS)

AS RELEASED FROM FACTORY THIS TRUCK MEETS THE DESIGN SPECIFICATIONS ESTABLISHED IN AMERICAN NATIONAL STANDARDS FOR POWERED INDUSTRIAL TRUCKS PART ASME B56.6b-1998

III

CAPACITY WITH STANDARD

48", 66", & 72" CARRIAGE

CAP#

10 8

X1000

34 39

24 24

SAMPLE ONLY - USE CHART IN CAB

24 24

-.8

SHIPPED

ATTACHMENT

WITH

48" CARRIAGE P/N 9045-5051

66" CARRIAGE P/N 9045-5052

72" CARRIAGE P/N 9055-5008

3/4 YD BUCKET P/N 9045-5049

1 1/4 YD BUCKET P/N 9055-5020

WORK PLATFORM P/N 9055-5024

TRUSS BOOM P/N 9045-5011

TRUSS BOOM W/WINCH P/N 9045-5012

6' SWING MAST P/N 9045-5047

6' MAST W/48" CARR P/N 9045-5035

6' MAST W/66" CARR P/N 9045-5037

72" 100° SWING CARR P/N 9045-5044

48" SLOPE PILER P/N 9108-5058

66" SLOPE PILER P/N 9130-5016

72" 180° SWING CARR P/N 9055-3024

*WEIGHTS ARE BASED ON USING 2 X 6 X 48" FORKS (APPROX. 408# PER PAIR) **BUCKET DIMENSIONS (A & D) REFER TO BUCKET LIP HEIGHT. ***TRUSS BOOM, WINCH & QUICK HOOK DIMENSIONS (A & D) REFER TO HOOK CENTER.

****WEIGHT IS BASED ON SP'L SWING MAST FORKS (APPROX. 190# PER PAIR)

*****PLATFORM DIMENSIONS (A & D) REFER TO CENTER OF FLOOR.

FORKS RATED LESS THAN THE ATTACHMENT CAPACITY SHOWN ABOVE DECREASE CAPACITY OF ATTACHMENT TO THAT OF FORKS. FORKS RATED MORE THAN ATTACHMENT CAPACITY DO NOT

6.5

CAP# 1000

10 33,570

****

***

1.6 33,520

***

4 35,350

****

6 34,530

6 34,610

INCREASE ATTACHMENT CAPACITY.

TRUCK &

ATTACHMENT

33,670

33,68010

33,140

33,310

33,420

33,280

34,310

33,780

33,900

34,890

WEIGHT

32,670 LBS

IN IN

34 24 24

24 24

55 --- ---

--- ---

---

65 --- ---

IN IN

24 24

IN IN

24 24

IN IN

24 24

IN IN

24 24

IN IN

24 24

IN IN

24 24

IN IN

24 24

---

9136-3011 (REV E)

DCBA

-.8

8.9

9.4

3.2

7.4

8.7

1.3

-2

-.4

-2

Form No. 20220

544D-10 Owner/Operator Manual

Figure I-2

1.0

SAFETY HIGHLIGHTS

Read and understand all manuals and instructional material listed on cover, inside front cover and introduction page of this Manual before starting, operating or performing maintenance procedures on this equipment.

Operators of this equipment must have successfully completed a training course 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 handler in a safe, open area (not hazardous to people or property) to gain operating skills and the proper “feel” for controls and operating clearances required for safe, efficient operation.

GRADALL Material Handlers are equipped with a right-side rearview mirror. This mirror is intended as an operator’s aid and does not replace the requirement for line-of-sight. Certain job site and machine conditions may require use of a signal person to help the operator when picking, placing or transporting a load. Never operate the handler until you know pick-up point, line of travel and landing point are clear. Always be aware that objects in mirror are closer than they appear.

Safety Precautions

Make sure all DANGER, WARNING, CAUTION and INSTRUCTIONAL DECALS are in place and can be read. Clean or replace decals as required.

Ensure handler is on a firm, level surface before lifting or placing load. Have surface leveled if necessary. Unit can tip over if load is raised with handler

on a soft or uneven surface.

Always look in the direction of travel. Reduce speed and be especially careful when traveling in reverse and/or turning. Be aware of tail swing due to rear-pivot steering.

WATCH FOR THESE SYMBOLS ; THEY CALL YOUR ATTENTION TO SAFETY NOTICES.

DANGER

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

WARNING

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

CAUTION

This symbol indicates a hazard which may result in injury or damage to equipment or property if proper precautions are not taken.

If load or conditions obstruct view, use a signal person when lifting, carrying or placing a load.

Loose clothing can get caught in moving machinery and can also cause accidental actuation of controls. Dress properly for the job.

Be alert to any unusual response to controls. If unusual response is noticed, position handler in a safe area, lower forks to ground, apply parking brake, stop engine and remove key from ignition switch. Tag steering wheel to forbid operation and notify maintenance personnel.

Keep hands, gloves, shoes, control knobs and pedals clean. Slippery controls

can cause accidents. Keep a firm grip on the steering wheel when traveling.

Load capacities are based on load center being within 24 inches (610mm) from front vertical face of forks.

Never service the handler with the engine running.

Release trapped pressure before disconnecting, opening or removing any

hydraulic component.

WARNING

Operator must be seated with seat belt fastened, forward reverse lever in “Neutral” position, parking brake applied and all hydraulic controls in “Neutral” before starting engine.

1.1

Keep all windows and mirror(s) clean. Adjust mirror(s) as visibility, before and during opera

tion.

required for maximum

Never permit diesel engine to run out of fuel. Doing so can cause severe engine damage.

DO NOT burn or drill holes in forks. Modifying any part of machine or attachment may affect machine capacity and/or stability.

Keep head, arms, hands, legs and all other body parts inside the operator’s cab at all times.

DO NOT approach power lines, overhead or underground cables or other power sources with any part of your material handler or load unless all local, state/ provincial and federal regulations have been met and the appropriate utility company has been contacted to de-energize the lines.

Whenever leaving the cab, perform standard shut-down procedure:

Standard Shut-Down Procedure

Position the handler in a safe location, apply parking brake, lower forks to ground, move all controls to minutes.

Stop engine and remove ignition key. Block wheels.

“Neutral”, allow engine to run at low idle for 3 to 5

Pinch Points

Stay clear of pinch points and rotating parts on the material handler. Getting caught in a pinch point or a moving part can cause serious injury or death. Before performing any maintenance on machine, follow the “STANDARD SHUT-DOWN PROCEDURE”.

WARNING

Contact The Gradall Company prior to welding on machine.

Form No. 20220

Rear Steering Axle Boom

Boom Holes Attachment Tilt

Carriage Forks Stabilizers

544D-10 Owner/Operator Manual

2.0

DECALS

INSIDE THE CAB

Located on dashboard

P/N 9116-3184

9116-3184 REV. A

USE CAPACITY CHART FOR SPECIFIC ATTACHMENT ON MACHINE.

FOR OTHER ATTACHMENTS CONSULT A GRADALL DEALER FOR LOAD RATINGS NOT LISTED.

SAMPLE ONLY - USE CHART IN CAB

USE LARGEST NUMBER VISIBLE FROM THE CAB TO DETERMINE BOOM EXTENSION.

MATCH WITH BOOM ANGLE TO DETERMINE ALLOWABLE LOAD.

FIGURES SHOWN ARE STACKING CAPACITY TRUCK LEVEL.

RATED LIFTING CAPACITIES SHOWN ARE WITH MACHINE ON A FIRM, LEVEL SURFACE WITH UNDAMAGED, PROPERLY INFLATED, HYDROFILLED (CALCIUM CHLORIDE AND WATER) TIRES.

MACHINE SPECIFICATIONS AND STABILITY ARE BASED ON RATED LIFT CAPACITIES AT SPECIFIC BOOM ANGLES AND BOOM LENGTHS.

IF SPECIFICATIONS ARE CRITICAL, THE PROPOSED APPLICATION SHOULD BE DISCUSSED WITH YOUR DEALER.

DO NOT EXCEED RATED LIFT CAPACITY LOADS, AS UNSTABLE AND DANGEROUS MACHINE CONDITIONS WILL RESULT.

DO NOT TIP THE MACHINE FORWARD TO DETERMINE ALLOWABLE LOAD.

CERTAIN CARRIAGE/FORK COMBINATIONS MAY CAUSE HANDLER TO TIP WITHOUT LOAD WHEN EXTENDED INTO "NO OPERATION" ZONE AS NOTED ON CAPACITY CHART.

CAPACITY LIMITS FOR THIS UNIT ARE BASED IN ACCORDANCE WITH STANDARDS LISTED ON SERIAL NUMBER PLATE.

LEVEL GRADALL HANDLER BEFORE LIFTING ABOVE 4 FT.

9136-3012 REV. A

Located on dashboard

P/N 9136-3012

60'

STABILIZERS UP

56'

52'

48'

44'

SAMPLE ONLY - USE CHART IN CAB

40'

36'

32'

28'

24'

20°

20'

16'

12'

10°

0°

-4'

RATED CAPACITY 2 FT LOAD CENTER

50°

40°

30°

2000 LBS

1500 LBS

1000 LBS

500 LBS

NO LIFT

-4°

USE WITH: 9045-5051 48" CARRIAGE 9045-5052 66" CARRIAGE 9055-5008 72" CARRIAGE 9116-5011 WINCH (4000 LB MAX CAP.)

60°

4000 LBS

3000 LBS

71°

8000 LBS

6000 LBS

10000 LBS

0'4'8'12'16'20'24'28'32'36'40'44'

MODEL 544D-10

9136-3013 REV. A

Located on dashboard

P/N 9136-3013

ACC

RUN

START

MACHINE MUST BE

IN NEUTRAL AND

PARK BRAKE ON TO START

Located on dashboard

P/N 9114-3120

OFF

Located on dashboard

P/N 9114-3182

9114-3182

9102-3006

Located on seat pedestal

P/N 9102-3006

SAMPLE ONLY - USE CHART IN CAB

2.1

INSIDE THE CAB

TRACTION LOCK SWITCH

SWITCH LOCATED

ON FLOOR. SWITCH

HYDRAULICALLY

LOCKS FRONT AND

REAR WHEELS

SURFACES. MACHINE

TOGETHER FOR

INCREASED TRACTION.

Located on dashboard

P/N 9108-3314

STARTING AID INSTRUCTIONS

1. HOLD SWITCH ON FOR 3 SECONDS TO FILL VALVE.

2. RELEASE SWITCH TO DISCHARGE ETHER WHILE CRANKING ENGINE.

3. AS ENGINE STARTS, USE ADDITIONAL ETHER AS REQUIRED TO KEEP ENGINE RUNNING.

Located on dashboard

(Cummins Engines Only)

P/N 9114-3202

9114-3202

DO NOT ENGAGE

WHEN WHEELS ARE

IN MOTION OR ON IMPROVED

MUST BE IN 4

WHEEL DRIVE.

9108-3314

Located on lever knob

TURBOCHARGER DAMAGE CAN RESULT

FROM QUICK START-UP & SHUTDOWN.

FOR LONGER TURBOCHARGER LIFE

AND TO MINIMIZE TURBOCHARGER

DAMAGE, IDLE ENGINE AT LEAST

3-5 MINUTES AFTER START-UP

AND BEFORE SHUTDOWN.

9134-3016

Located on dashboard

P/N 9134-3016

P/N 9108-3318

Located on forward/reverse lever

P/N 9116-3028

CERTAIN FORK/CARRIAGE COMBINATIONS MAY CAUSE

HANDLER TO TIP WHEN EXTENDED INTO "NO

OPERATION" ZONE AS NOTED ON CAPACITY CHART

WITH STABILIZERS UP CAUSING SERIOUS INJURY

OR DEATH. NEVER OPERATE MACHINE WITHOUT

CONSULTING PROPER CAPACITY CHART FOR THE

CARRIAGE/FORK COMBINATION BEING USED.

Located on dashboard

P/N 9116-3212

Form No. 20220

544D-10 Owner/Operator Manual

9116-3212

9130-3047

Located on joystick pedestal

P/N 9130-3047

Located on lever knob

P/N 9108-3317

7733-3027

Located on left cab wall

P/N 7733-3027

2.2

INSIDE THE CAB

NO RIDERS PERMITTED ON HANDLER.

OPERATOR ONLY IN MACHINE

RIDERS COULD FALL OFF MACHINE

CAUSING SERIOUS INJURY OR DEATH.

WHILE RUNNING.

9114-3283

SAMPLE ONLY

Box 61 SD 57201

GRADALL MATER 06 / 9 / 10 MAX WEIGHT : 2150 MEETS SAE : J1040 MA MEETS ISO : 3471 (94) / 3 MEETS ANSI : B56.6 - 8.16 / P GRADALL : SERIAL :

Located on left cab wall

P/N 9114-3283

GRADALL IS A REGISTERED TRADEMARK

FOR HYDRAULIC EQUIPMENT BUILT BY THE JLG COMPANY

1 JLG DRIVE, McCONNELLSBURG, PA.

U.S.A.

(WITHOUT ATTACHMENTS)

AS RELEASED FROM FACTORY THIS TRUCK MEETS THE DESIGN SPECIFICATIONS ESTABLISHED IN AMERICAN NATIONAL STANDARDS FOR POWERED INDUSTRIAL TRUCKS PART ASME B56.6b-1998

III

CAPACITY WITH STANDARD

48", 66", & 72" CARRIAGE

CAP# X1000

34 39

24 24

SAMPLE ONLY - USE CHART IN CAB

24 24

-.8

SHIPPED

ATTACHMENT

WITH

48" CARRIAGE P/N 9045-5051

66" CARRIAGE P/N 9045-5052

72" CARRIAGE P/N 9055-5008

3/4 YD BUCKET P/N 9045-5049

1 1/4 YD BUCKET P/N 9055-5020

WORK PLATFORM P/N 9055-5024

TRUSS BOOM P/N 9045-5011

TRUSS BOOM W/WINCH P/N 9045-5012

6' SWING MAST P/N 9045-5047

6' MAST W/48" CARR P/N 9045-5035

6' MAST W/66" CARR P/N 9045-5037

72" 100° SWING CARR P/N 9045-5044

48" SLOPE PILER P/N 9108-5058

66" SLOPE PILER P/N 9130-5016

72" 180° SWING CARR P/N 9055-3024

*WEIGHTS ARE BASED ON USING 2 X 6 X 48" FORKS (APPROX. 408# PER PAIR) **BUCKET DIMENSIONS (A & D) REFER TO BUCKET LIP HEIGHT.

***TRUSS BOOM, WINCH & QUICK HOOK DIMENSIONS (A & D) REFER TO HOOK CENTER. ****WEIGHT IS BASED ON SP'L SWING MAST FORKS (APPROX. 190# PER PAIR) *****PLATFORM DIMENSIONS (A & D) REFER TO CENTER OF FLOOR.

FORKS RATED LESS THAN THE ATTACHMENT CAPACITY SHOWN ABOVE DECREASE CAPACITY OF

ATTACHMENT TO THAT OF FORKS. FORKS RATED MORE THAN ATTACHMENT CAPACITY DO NOT

10 8

6.5

CAP# 1000

10 33,570

****

***

1.6 33,520

***

****

INCREASE ATTACHMENT CAPACITY.

TRUCK &

ATTACHMENT

WEIGHT

33,670

33,68010

33,140

33,310

33,420

33,280

4 35,350

6 34,530

6 34,610

34,310

33,780

33,900

34,890

32,670 LBS

IN IN

34 24 24

24 24

55 --- ---

--- ---

---

65 --- ---

IN IN

24 24

IN IN

24 24

IN IN

24 24

IN IN

24 24

IN IN

24 24

IN IN

24 24

IN IN

24 24

---

9136-3011 (REV E)

DCBA

-.8

8.9

9.4

3.2

7.4

8.7

1.3

-2

-.4

-2

Located on right cab wall

P/N 9136-3011

Located on left side, front cab plate

P/N 9116-4097 (enclosed cab)

P/N 9116-4093 (open cab)

THE PROTECTION OFFERED BY THIS ROPS WILL BE IMPAIRED IF IT HAS BEEN SUBJECTED TO ANY MODIFICATION, STRUCTURAL DAMAGE, OR HAS BEEN INVOLVED IN AN OVERTURN INCIDENT. THIS ROPS MUST BE REPLACED AFTER A ROLL-OVER. SEAT BELTS MUST BE WORN WHILE OPERATING VEHICLE.

000850

Located on left side, front cab plate

P/N 9116-4094

ENGINE OIL

LEVEL

Located on right cab wall

(Cummins Engines Only)

P/N 9114-3292

9114-3292

FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF

1. ONLY TRAINED AND AUTHORIZED PERSONNEL MAY OPERATE THIS MACHINE.

2. BEFORE OPERATING, READ AND UNDERSTAND ALL CAPACITY CHARTS, OPERATOR MANUALS AND SAFETY MANUALS. IF MANUALS ARE NOT AVAILABLE, CONSULT AN AUTHORIZED GRADALL DEALER. UNDERSTAND ALL CONTROLS IN CAB AND CHECK FOR PROPER OPERATION. CLEAR LOOSE OBJECTS OFF MACHINE AND SOUND HORN BEFORE STARTING ENGINE.

3. OPERATOR MUST BE SEATED WITH SEAT BELT FASTENED. ASSURE FORWARD/REVERSE LEVER IS IN NEUTRAL,PARK BRAKE APPLIED AND ALL HYDRAULIC CONTROLS ARE IN NEUTRAL BEFORE IGNITION SWITCH IS TURNED ON.

4. DO NOT OPERATE MACHINE WITHOUT PROPER CAPACITY CHART IN PLACE.

5. BEFORE MOVING, BE SURE OF A CLEAR PATH AND SOUND HORN. WATCH FOR PEDESTRIANS AND OBSTRUCTIONS. CHECK OVERHEAD AND SIDE CLEARANCES. ALWAYS LOOK IN DIRECTION OF TRAVEL.

6. START, TURN, AND BRAKE SMOOTHLY. REDUCE TRAVEL SPEEDS FOR TURNS, SLIPPERY, OR UNEVEN SURFACES. AVOID RUNNING OVER LOOSE OBJECTS OR HOLES IN THE ROADWAY SURFACE.

SERIOUS INJURY, READ AND OBSERVE THE FOLLOWING:

7. WHEN TRAVELING WITH LOAD, FULLY RETRACT BOOM AND PLACE FORKS IN CARRY POSITION. TILT CARRIAGE BACK SLIGHTLY TO CRADLE LOAD. USE EXTREME CAUTION WHEN TURNING.

8. ON INCLINES, TRAVEL WITH LOAD UP-GRADE.

9. DO NOT USE BOOM AS WALKWAY.

10. USE TWO HANDS WHEN CLIMBING ON MACHINE.

11. USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM FOR LIFTING PERSONNEL. NO RIDERS ON MACHINE, FORKS, LOAD, OR OTHER LIFTING ATTACHMENTS AT ANY TIME. DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL HANDLER/PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN THE CAB. DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.

12. KEEP OTHERS AWAY FROM MACHINE WHILE OPERATING.

DO NOT STAND UNDER BOOM OR LOAD.

13. USE EXTREME CARE WHEN HANDLING LONG, HIGH, OR WIDE LOADS. DO NOT HANDLE UNSTABLE OR LOOSELY STACKED LOADS.

14. FORKS TO BE CENTERED UNDER LOAD AND SPACED APART AS FAR AS POSSIBLE.

Located on right cab wall

P/N 9055-3028

15. BEFORE ADJUSTING OR SERVICING, PLACE FORWARD/REVERSE LEVER IN NEUTRAL, REST BOOM ON GROUND OR SUPPORT, SET PARKING BRAKE, SHUT OFF ENGINE AND CHOCK WHEELS.

16. BEFORE LEAVING MACHINE UNATTENDED, PLACE FORWARD/REVERSE LEVER IN NEUTRAL, LOWER BOOM, SET PARKING BRAKE,AND SHUT-OFF ENGINE. CHOCK WHEELS IF MACHINE MUST PARK ON AN INCLINE.

17. LEVEL MACHINE BEFORE LIFTING ANY LOAD ABOVE 4 FEET. (IF EQUIPPED WITH FRAME LEVELING).

18. OPERATOR PROTECTION (SUCH AS HARD HATS, SAFETY GLASSES, AND/OR HEARING PROTECTION) SHOULD BE WORN WHEN JOB CONDITIONS WARRANT. ALWAYS USE SEAT BELT.

19. IMPROPER USE OF MACHINE COULD RESULT IN MACHINE TIPPING OVER. IF MACHINE STARTS TO TIP OVER, DO NOT LEAVE OPERATORS SEAT. LEAN AWAY FROM TIP & BRACE YOURSELF.

20. KEEP MIRROR(S) CLEAN AND PROPERLY ADJUSTED. OBJECTS IN MIRROR ARE CLOSER THAN THEY APPEAR.

9055-3028 REV. A

2.3

ADD

CHECK OIL LEVEL WITH HANDLER LEVEL AND ALL CYLINDERS RETRACTED.

1 GALLON BETWEEN

ADD AND FULL MARKS

FULL

HYDRAULIC OIL LEVEL

9116-3130

OUTSIDE THE CAB

HYDRAULIC SYSTEM

FILL WITH TRACTOR HYDRAULIC FLUID

For Mobil Product Information, Call 1-800-662-4525.

Located on hydraulic reservoir

P/N 9114-3288

Genuine Parts

Located on valve access cover in cab

Located on hydraulic reservoir

P/N 9108-3492

or equivalent.

9114-3288

WHEN REPLACING COOLANT OR IN

CASE OF COOLANT LOSS PURGE AIR

BY OPENING DE-AERATION PETCOCK

WHILE ENGINE IS RUNNING.

Located on engine

(Cummins Engines Only)

P/N 9116-3256

Form No. 20220

STAY CLEAR OF MOVING PARTS

WHILE ENGINE IS RUNNING.

MOVING PARTS CAN CAUSE

SERIOUS INJURY.

Located on sheet metal cover of

hydraulic reservoir and fuel tank

P/N 9114-3281

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

Located on right and left rear frame,

hydraulic reservoir & boom head

P/N 9114-3282

544D-10 Owner/Operator Manual

9114-3281

9114-3282

Located on hydraulic reservoir

P/N 9116-3130

9114-3162

Located on hydraulic filter bracket

P/N 9114-3162

2.4

OUTSIDE THE CAB

KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.

EXHAUST SYSTEMS CAN BE HOT.

HOT EXHAUST COMPONENTS CAN CAUSE

SEVERE BURNS.

9114-3280

Located on engine compartment

P/N 9114-3280

JUMP STARTING INSTRUCTIONS

WHEN JUMP STARTING MATERIAL HANDLER * NEVER ALLOW VEHICLES TO TOUCH * CONNECT THE POSITIVE (+) JUMPER CABLE TO

POSITIVE (+) POST OF DISCHARGED BATTERY

* CONNECT OPPOSITE END OF POSITIVE (+) JUMPER

CABLE TO POSITIVE (+) POST OF BOOSTER BATTERY

* CONNECT THE NEGATIVE (-) JUMPER CABLE TO

NEGATIVE (-) POST ON BOOSTER BATTERY

* CONNECT OPPOSITE END OF NEGATIVE (-) JUMPER

CABLE TO GROUND POINT ON MACHINE AWAY FROM

DISCHARGED BATTERY * FOLLOW STANDARD STARTING PROCEDURES * REMOVE CABLES IN REVERSE ORDER AFTER MACHINE

HAS STARTED

Located beside battery

P/N 9114-3285

9114-3285

COOLING SYSTEM

IS PRESSURIZED.

REMOVE CAP SLOWLY.

HOT FLUID CAN CAUSE BURNS.

Located on engine cover

P/N 8060-3026

LEAD ACID BATTERIES PRODUCE FLAMABLE AND

BOOSTER BATTERY OR CHARGING BATTERIES: * DO NOT USE SMOKING MATERIALS NEAR BATTERIES * KEEP FLAMES AND SPARKS AWAY FROM BATTERIES * WEAR SAFETY GLASSES * ASSURE BATTERY IS NOT FROZEN AND ELECTROLYTE

IS AT PROPER LEVEL IN EACH CELL

FAILURE TO FOLLOW THESE INSTRUCTIONS COULD

RESULT IN SERIOUS INJURY OR DAMAGE TO THE

EXPLOSIVE GASSES

WHEN CHECKING, TESTING, USING

ELECTRICAL SYSTEM

Located beside battery

P/N 9114-3284

8060-3026

9114-3284

AVOID HIGH VOLTAGE LINES.

IT IS UNLAWFUL TO PLACE

ANY PART OF THIS MACHINE

OR LOAD WITHIN 10 FEET

OF HIGH VOLTAGE LINES

UP TO 50,000 VOLTS.

DEATH OR INJURY MAY

RESULT FROM CONTACTING

ELECTRIC LINES.

Located on mud guard

P/N 8060-3022

8060-3022

PINCH POINT

KEEP OUT

REACHING INTO BOOM

HOLES AND OTHER PINCH

POINTS CAN CAUSE

SERIOUS INJURY

Located on boom

P/N 8060-3037

DIESEL FUEL IS FLAMMABLE

EXTINGUISH ALL OPEN FLAME AND

SMOKING MATERIALS WHEN REFUELING

INJURY OR DEATH COULD RESULT

FROM FIRE.

Located on fuel tank

P/N 9114-3286

OR DEATH.

8060-3037-A

9114-3286

2.5

ATTACH LANYARD HERE

9055-3032

OUTSIDE THE CAB

GRADALL HANDLER SERVICE INSTRUCTIONS FOR: 544D-10

DIESEL ENGINE AIR CLEANER ELEMENTS FUEL FILTERS OIL FILTER OIL (12 QT.) DIESEL FUEL (40 GAL.) HYDRAULIC SYSTEM OIL (50 GAL.) FILTERS

HYD.TANK BREATHER/FILTER CAP

SAMPLE ONLY - USE CHART IN CAB

FRONT AXLE (5 GAL)

REAR AXLE WHEEL END LUBE(4 PT.)

WHEEL NUT TORQUE-350/400 FT-LBS

BATTERY & TERMINALS

RADIATOR 3 GAL WATER 3 GAL ANTI-FREEZE

TIRES: 14.00x24(12 PLY) 65 PSI

TIRES: RADIAL 70 PSI

CYLINDER FITTINGS EACH END

REAR AXLE (12) FITTINGS FRONT AXLE PIVOT (2) FITTINGS

ALL BEARINGS PADS

FRONT BOTTOM BEARING PADS

BOOM PIVOT (2) FITTINGS

HEAD PIN (2) FITTINGS

BOOM SHEAVES (5) FITTINGS

QUICK SWITCH (1) FITTING

RETRACT & EXTEND CHAIN TENSION SEE MANUAL FOR PROCEDURE

EXTEND CHAIN LUBE

THIS CHART MUST BE USED IN CONJUNCTION WITH SERVICE MANUAL AND RECOMMENDED PROCEDURE.

* *******

IT IS RECOMMENDED THAT FILTER ELEMENTS AND FRONT AXLE LUBRICANT BE CHANGED AFTER FIRST 50 HRS ON NEW OR REBUILT UNITS.

---------------**---------------------------------

--------------------------------------- ------------

----------------------------------- -------------------

---------------------- ------ -------------------

--------------- --------------------------------

-----------------------------------------------------

--------------------- ------------ ------

-------------------------------------------------------

CHECK INDICATOR ON HYDRAULIC FILTER. CHANGE FILTER IF NEEDLE IS IN YELLOW AT FULL THROTTLE & AT OPERATING TEMPERATURE.

CHECK AIR CLEANER RESTRICTION INDICATOR. CLEAN OR CHANGE PRIMARY FILTER IF NECESSARY. SAFETY ELEMENT TO BE CHANGED EVERY 3RD CHANGE OF PRIMARY FILTER ELEMENT.

CONSULT DEALER FOR RECOMMENDATIONS AT EXTREME TEMPERATURES.

DAILY SERVICE MAY BE REQUIRED FOR OPTIMUM LIFE DEPENDING UPON APPLICATION SEVERITY.

------------------- ------ ------

-----------------------------

--------------------

-------------------- -------------------------

----------------------- -------------------------

----------------

---------------

-------------------

--------------

----------------------------

--------------

-------------------

---------------------

----------------

------------------

-----------------------

SERVICE INTERVALS

DAILY

WEEKLY

10 HRS

50 HRS

CHECK

FILL

CHECK

GREASE

****

GREASE

****

GREASE

****

GREASE

****

GREASE

****

GREASE

ANNUALLY

EVERY

5WKS OR

250 HRS

CHANGE CHANGE

CHECK

-------------------------

GREASE

CHECK

-------------------------

6 MO.

3 MO.

500 HRS

CHANGE

INSPECT

------ ------

TORQUE

-------------------

CHECK

1500 HRS

1000 HRS

CHANGE CHANGE

CHANGE

------------------------------------

-------------

-----------------------------------------------

LUBE

TYPE OR

EQUIVALENT

SAE 15W-40-CD *** DIESEL FUEL #2

MOBIL 424

ETHYLENE GLYCOL ANTI-FREEZE

623# LIQUID FILLED

MYSTIK TETRIMOLY

SCHAFFER 200S SILVER STREAK

9136-3142 REV -

Located on boom head

P/N 9114-3290

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED

ALL PERSONNEL IN PLATFORM MUST WEAR A FULL BODY HARNESS WITH

LANYARD ATTACHED TO A DESIGNATED ANCHORAGE POINT.

READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

PERSONNEL WORK PLATFORM.

BEFORE OCCUPYING PERSONNEL WORK PLATFORM.

9055-3026 REV. A

Located on mudguard

P/N 9136-3142

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM.

READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL BEFORE LIFTING PERSONNEL.

DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.

WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN CAB WITH PERSONNEL

OPERATE CONTROLS LIGHTLY AND CAUTIOUSLY WHEN LIFTING PERSONNEL.

DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL

HANDLER/PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN CAB.

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

IN DIRECT LINE OF SIGHT.

9055-3027 REV. A

Located on mudguard

P/N 9055-3027

Located on left side of boom

P/N 9100-3031

406 MILL AVE. S.W. NEW PHILADELPHIA, OHIO MADE IN U. S. A.

ATTACHMENT

SERIAL NUMBER

WEIGHT

CAPACITY

HYD. PRESSURE

THE CAPACITY OF FORKLIFT, ATTACHMENT AND FORK

COMBINATION MAY BE LESS THAN THE CAPACITY SHOWN

ON ATTACHMENT - CONSULT FORKLIFT NAMEPLATE

AND ALSO INSURE FORKS ARE OF PROPER SIZE.

9015-3001

Located on boom head

P/N 9055-3026

Located on Personnel Work Platform

P/N 9055-3032

MAXIMUM OCCUPANCY THREE (3) PEOPLE.

DO NOT USE PERSONNEL WORK PLATFORM

WITHOUT THE PROPER GRADALL MATERIAL

HANDLER/PERSONNEL WORK PLATFORM

CAPACITY CHART DISPLAYED IN CAB.

FAILURE TO COMPLY COULD RESULT IN

SERIOUS INJURY OR DEATH.

9055-3031 REV. A

Located on Personnel Work Platform

P/N 9055-3031

406 MILL AVE. S.W. NEW PHILADELPHIA, OHIO MADE IN U. S. A.

ATTACHMENT

SERIAL NUMBER

WEIGHT

CAPACITY

HYD. PRESSURE

DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE

PROPER GRADALL MATERIAL HANDLER/PERSONNEL WORK

PLATFORM CAPACITY CHART DISPLAYED IN CAB.

9055-3033

Located on attachment

P/N 9015-3001

Form No. 20220

544D-10 Owner/Operator Manual

Located on Personnel Work Platform

P/N 9055-3033

3.0

OPERATOR’S CAB

The standard cab permits vision from all sides and includes an overhead guard to provide protection from falling objects.

WARNING

A fully-enclosed cab with windows and a lockable door is available as an option. The top half of the cab door must be secured in the fully-opened or closed position. The bottom half of the cab door can be secured in the closed position only. 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 variations in operator size. The adjustment release/lock is located beneath front edge of seat. Wear seat belt when

operating machine.

An optional windshield wiper/washer is available for use with enclosed cabs. A control switch is located on the instrument panel.

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.

A heater fan is available for use with units equipped with a heater. An “On/Off” switch is located on the dashboard. Hot water to the heater can be controlled by a valve at the engine.

The operator’s cab is an S.A.E. “FOPS/ROPS” structure. Do not make any modification to this structure. If damaged, the cab cannot be repaired. It must be replaced.

CONTROL AND INSTRUMENT IDENTIFICATION

Figure 3-1

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

WARNING

Any modification to this machine must be approved by GRADALL to assure compliance with FOPS/ ROPS certification for the cab/ machine configuration.

NOTE!

Relevant S.A.E. Recommended Practices: S.A.E. J1040 for ROPS S.A.E. J231 for FOPS

3.1

Accelerator Pedal: Depress pedal to increase speed and release pedal to

decrease speed.

WARNING

Alternator Indicator Light: Glows (red) to indicate alternator is not charging.

Attachment Tilt Lever: This lever controls tilt of the fork carriage. Speed is

proportional to lever actuation and engine RPM. Push lever forward to tilt down; pull lever back to tilt up.

Attachment Tilt Switch (optional): Depress front of switch

to tilt down; depress

rear of switch to tilt up.

Auxiliary Control Lever (optional): This lever is used to control optional hydraulic attachments. Follow decal instructions for lever/handler movements.

Auxiliary Light Switch (optional):

This switch turns auxiliar

y lights on and

off.

Boom Control Joystick: Pull joystick back to raise boom;

This joystick controls boom elevation

push joystick

forward to lower boom. Move

and extension.

joystick to right to extend boom; move to left to retract boom. Speed of boom movement is proportional to joystick actuation and engine RPM.

Check Engine Light (Deere Engines Only): Glows (red) for 30 seconds before engine shuts down when a “Shutdown” fault is detected.

Engine Coolant Temperature Gauge: This gauge displays engine coolant temperature.

Engine Oil Pressure Gauge: This gauge displays engine oil pressure.

A brief description of controls and instruments is provided here as a convenience for the operator. These descriptions DO NOT provide complete operation instructions. Read & understand this Manual and the GRADALL Material Handler Safety Manual.

Forward/Reverse Lever: This lever engages forward or reverse travel. Lift & push lever fully forward for forward travel; Lift & pull lever fully backward for reverse travel. Move lever to centered position for “Neutral”.

Fuel Gauge: This gauge displays level of fuel in fuel tank.

Heater Fan Switch (optional): This switch turns heater fan on and off.

Horn Button: Depress button to sound horn.

Hourmeter: This meter indicates total time of engine operation in hours and

tenths of hours.

Ignition Switch: This switch is actuated by a key. In “ACC” or “RUN” position, voltage is available for all electrical functions. Full clockwise rotation to “START” engages starter motor. re

moves voltage from all electrical functions.

Counter-clockwise rotation to “OFF” stops engine and

Level Indicator: This bubble level indicator enables the operator to determine the left to right level condition of the handler.

Lights Switch (optional): This switch controls optional lighting which may be provided with the handler.

Machine Level Lever: This lever controls the relationship of the handler frame to the front axle. Push the lever forward to tilt frame to left, pull lever back to tilt frame to right.

Parking Brake Switch: This switch controls the application and release of the parking brake.

Form No. 20220

544D-10 Owner/Operator Manual

3.2

Parking Brake Indicator Light: Glows (red) to indicate brake is applied.

Rotating Beacon Switch (optional): This switch controls operation of rotating

beacon.

Seat Lock Release Lever: This lever unlocks and locks seat position adjustment.

Service Brake/Inching Travel Pedal: This pedal operates the service brakes on the front axle. It also permits slow travel speed while engine speed is kept high for other handler functions. The further the pedal is depressed, the slower the travel speed. Full depression of pedal causes full service brake application.

Shutdown Override Switch (Deere Engines Only): The operator may delay a shutdown for 30 seconds by pushing the “Shutdown Override” switch. The switch resets the shutdown timer to 30 seconds and may be used repeatedly. However, continuously holding the “Shutdown Override” switch will not reset the 30 second timer.

Stabilizer Control Levers: Left lever controls left stabilizer; right lever controls right stabilizer. Push levers forward to lower stabilizers; pull levers back to raise stabilizers.

Starting Aid Switch (optional on Cummins Engines): This switch engages and disengages the cold-weather starting aid.

Steering Wheel: The steering wheel controls the angle of rear wheels. Turning the steering wheel to the right causes a right turn by angling rear wheels to left. A left turn is caused by angling rear wheels to right.

Traction-Lock Pedal: This pedal operates traction-lock valve which functions to restore traction when a wheel spins in four-wheel drive.

Voltmeter: This gauge indicates alternator output and battery condition.

4x2/4x4 Switch: This switch engages and disengages rear-wheel

Rear drive motors are engaged for four-wheel drive.

4x4 Indicator Light: Glows (amber) to indicate four-wheel drive is engaged When park brake is applied, this light will not glow.

drive motors.

4.0

CHECKS & SERVICES BEFORE STARTING ENGINE

To be performed at the beginning of each work shift.

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

order.

• Check to be certain that windows and mirror(s) are clean and undamaged. Also make certain that mirror(s) are properly adjusted for operator’s view.

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

• When adding fluids, refer to lubrication section of Manual to determine proper type.

Complete all required maintenance before operating unit.

Service the unit in accordance with the “Lubrication and Routine

Maintenance” schedule.

WARNING

Use extreme caution when checking items beyond your normal reach. Use an approved safety ladder.

WARNING

Before operating handler, complete all required maintenance. Replace or repair all damaged, worn or missing components before starting or operating handler. Failure to properly maintain handler could cause serious injury or death.

Form No. 20220

544D-10 Owner/Operator Manual

Inspect all structural members, including attachment, for signs of damage.

Inspect unit for obvious damage, vandalism and necessary maintenance. Check for signs of fuel, lubricant, coolant and hydraulic leaks. Open all access doors and look for loose fittings, clamps, components and attaching hardware. Replace hydraulic lines that are cracked, brittle, cut or which show signs of leakage or abrasion.

WARNING

Use a piece of cardboard or paper to search for leaks. DO NOT use bare hands. If anyone is injured by hydraulic fluid, including penetration into the skin, obtain medical help immediately!

5.0

To be performed at beginning of each work shift.

The safety, efficiency and service life of your handler will be increased by performing the operational checks listed below. If any of the items in the following checks are not operating properly, have them repaired prior to the machine being placed into service. Items preceded by an asterisk (*) are optional and may not be furnished on a standard machine.

Before entering the operator’s cab, check:

1. Air Filter Restriction Indicator. If needle is in red area, filter is clogged

During warm-up period, check:

* 2. Heater, defroster and windshield wiper.

* 3. Operating lights and rotating beacon.

4. Voltmeter - should show 13.5 to 14 volts.

When engine warms to operating range, check:

5. Service brake and parking brake.

WARM-UP & OPERATIONAL CHECKS

and element must be changed.

6. Forward and reverse travel.

7. Steering (stop to stop in both directions) with engine at low idle.

8. “Inching” travel-should be smooth through full pedal travel.

9. Horn and back-up alarm.

10. All boom and attachment functions - operate fully and correctly.

11. Hydraulic level sight gauge, level handler, retract all cylinders and check sight gauge for hydraulic fluid level - refill as required.

12. Hydraulic Filter Condition Indicator - observe engine coolant temperature gauge after starting normal operation. When needle has been in operating range for an hour or so, stop handler in a safe area, apply parking brake, lower attachment fully, shift forward/reverse lever to “Neutral” position and block wheels. With engine running at full throttle, have an assistant check the Hydraulic Filter Condition Indicator. When needle is in red area, filter is clogged and hydraulic oil is bypassing filter. Filter element must be changed before needle reaches red area.

Complete all required maintenance before operating unit.

CAUTION

Continued operation with hydraulic fluid bypassing the filter may cause severe damage to hydraulic system components.

6.0

ENGINE OPERATION

Starting the Engine

1. Make sure all controls are in “Neutral” and all electrical heater, defroster, etc.) are turned off. Set

2. Depress accelerator pedal approximately 1/4 to 1/3 of travel from top.

3. Turn ignition switch to “START” to engage starting motor. Release key immediately when engine starts. If engine fails to start within 20 seconds, release key and allow starting motor to cool for a few minutes before trying again.

4. After engine starts, observe oil pressure gauge. If gauge remains on zero for more than ten seconds, stop engine and determine cause. Correct malfunction before restarting engine. Minimum pressure at operating temperature:

Low idle: 10 PSI (69kPa)

5. Warm up engine at approximately 1/2 throttle until engine coolant temperature reaches operating range.

parking brake.

components (lights,

Cold-Weather Starting Aids

In cold approved starting aids employ ether. If your handler is equipped with an ether starting aid, the following applies:

weather situations, a supplemental starting aid may be required.

Gradall-

WARNING

Operator must be seated with seat belt fastened, forward/reverse lever in “Neutral” position, parking brake applied and all hydraulic controls in “Neutral” before starting engine.

CAUTION

Turning ignition switch to “START” position while engine flywheel is rotating may cause serious damage to engine and/or starting motor.

NOTE!

Engine will not start unless forward/ reverse lever is in “Neutral” and parking brake switch is applied.

Cummins Engine

• Hold switch on for 3 seconds to fill valve.

• Release switch to discharge ether while cranking engine.

• As engine starts, use additional ether as required to keep engine running.

Deere Engine

• Ether application is triggered by temperature gauge located on engine.

• At start-up, temperature gauge on engine will detect if ether is needed. Follow normal start-up procedure, shown above.

• Ether is employed and additional will be released if needed, to keep engine running.

• A second battery is added for additional cold-cranking capacity.

Battery-Boosted Starting

If you ever have to battery-boost start (jump-start) your handler, proceed as follows:

• Never allow vehicles to touch

• Connect the positive (+) jumper cable to positive (+) post of discharged battery

• Connect opposite end of positive (+) jumper cable to positive (+) post of booster battery

• Connect the negative (-) jumper cable to negative (-) post on booster battery

• Connect opposite end of negative (-) jumper cable to ground point on machine away from discharged battery

• Follow standard starting procedures

• Remove cables in reverse order after machine has started

CAUTION

If you use a starting aid employing ether or a similar substance, pay particular attention to manufacturer’s warnings. Excessive ether may cause severe engine damage.

Form No. 20220

544D-10 Owner/Operator Manual

6.1

Normal Engine Operation

Observe gauges frequently to be sure all engine systems are functioning properly.

The voltmeter shows the “charge/discharge” state of the battery charging system. With the engine running, meter should indicate 13.5 to 14 volts. With engine stopped, meter indicates battery charge (12 volts). The alternator indicator light glows (red) to indicate alternator is not charging.

Be alert for unusual noises or vibration. When an unusual condition is noticed, park machine in safe position and perform standard shut-down procedure. See Page 1.1. Report condition to your supervisor or maintenance personnel.

Avoid prolonged idling. Idling causes engine temperature 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.

Stopping the Engine

• To stop engine, perform standard shut-down procedure.

• Operate engine at low idle for 3 to 5 minutes before turning it off. This allows engine coolant and lubricating oil to carry excessive heat away from critical engine areas, including turbocharger.

• Do not “gun” engine before shut down: This practice causes incompletelyburned fuel to remove oil film from cylinder walls and dilute lubricant in crankcase.

CAUTION

Always keep engine cover closed while engine is running.

John Deere Engine Shut-Down Protection Feature

The feature monitors coolant temperature, oil pressure and charge-air temperature. If any of the listed items cause a fault in the system the check

engine light will illuminate and the engine will shut down after 30 seconds. Within that 30 second period, lower the boom and apply parking brake. Report condition to your supervisor or maintenance personnel.

NOTE!

In the event of needing to delay a shutdown, See “Shutdown

Override Switch,” Page 3.2.

NOTE!

In the event of engine or hydraulic failure, parking brakes can be released for towing. See “To

Release Parking Brake,” Page

16.1.

7.0

BRAKE SYSTEM

General

The brake system includes a service brake and a parking brake. Service and parking brakes are applied through wet disc brake packs located within axle housing.

WARNING

Because service braking and “inching” (slow travel) functions overlap, some features of inching will be discussed here. See “Drive Train” Section, Page

10.0, for additional information on inching travel. (See Figure 3-1 for layout of controls)

Inching Travel

Overlap between braking and inching occurs because the same pedal controls both functions; also because both functions control travel speed. However, the methods of controlling travel speed are quite different. Service braking involves a controlled stopping force applied to the front wheels. Inching involves a controlled driving force applied to the driving wheels.

Figure 7-1

LOWEST INCHING TRAVEL SPEED

SERVICE BRAKING

Most of the inching travel pedal stroke controls the speed of inching travel. As the pedal nears the bottom of its stroke, service brakes are engaged.

SERVICE BRAKE/INCHING

TRAVEL PEDAL

HIGHEST INCHING TRAVEL SPEED

Practice inching/braking in a safe, open area until you are thoroughly familiar with handler response.

WARNING

If power-assist feature should fail for any reason, it would require greater effort to apply service brake. It is extremely important

that you never stop the engine while traveling. If power assist

fails, stop as soon as possible. Do not drive the handler until problem has been corrected.

Service Brakes

epressing service brake/inching travel pedal to braking

portion of pedal travel causes controlled hydraulic pressure to be applied to service brakes. The greater the pedal travel, the greater the braking force.

If power-assist fails, it will require much greater force on pedal to apply brake, and stopping distance will be greater.

Parking Brakes

The parking brakes are spring-applied and hydraulically-released.

Hydraulic power to release parking brakes is provided by the hydraulic system and is controlled by the parking brake switch located on the dashboard.

With the engine running and the parking brake switch “Off,” parking brakes are disengaged. Moving the switch to “On” releases hydraulic pressure to apply the parking brakes. With switch in “ON” position, four-wheel drive is disabled.

WARNING

Always move parking brake switch to “On” position before leaving cab.

Never stop engine while traveling. Parking brake will be fully-applied and unit may stop abruptly. A sudden stop could cause load loss.

NOTE!

In the event of engine or hydraulic failure, parking brakes can be released for towing. See “To

Release Parking Brake,” Page

16.1.

Form No. 20220

544D-10 Owner/Operator Manual

8.0

PARKING THE HANDLER

Precautions

• Avoid parking on slopes or near an excavation.

• Park on level ground and chock wheels.

• Avoid parking on roads or highways. If it cannot be avoided,be sure to display warning flags during day and flares or flashing lights at night.

• Position boom-head or attachment on ground; never leave machine with boom in air.

• If parking on a slope cannot be avoided, position the handler at a right angle across the slope, straighten rear wheels and chock all wheels.

Parking procedure

1. Using service brake, stop the handler in an appropriate parking area.

2. Move parking brake switch to “On.”

3. Shift forward/reverse lever to “Neutral.”

4. Position attachment on ground.

5. Allow engine to cool at idle speed for 3 to 5 minutes, stop engine and remove ignition key.

6. Chock wheels as an extra precaution against rolling.

7. Fill fuel tank to minimize condensation.

8. Lock cab and install protective covers, if so-equipped.

9. Disconnect batteries if unit is in an area where tampering is a risk.

9.0

• Rear-wheel power steering is provided to reduce operator fatigue and to permit high maneuverability in close quarters.

• It is imperative that the operator practice maneuvering the handler in a safe, open area to become thoroughly familiar with steering response and clearance required for tail swing and load when turning.

STEERING SYSTEM

WARNING

Be alert for any increase in effort needed to steer. If any difference is noted, notify maintenance personnel immediately. If power assist feature should fail for any reason, IT WOULD BECOME VERY DIFFICULT TO STEER. For this reason it is extremely important that you NEVER TURN ENGINE OFF WHILE TRAVELING.

In the event power steering fails, stop as soon as possible. Do not drive handler until problem has been corrected.

10.0

DRIVE TRAIN

General

The Material Handler covered by this Manual is equipped with hydrostatic drive. From the operator’s standpoint, operation is similar to driving a vehicle equipped with an automatic transmission.

Major components of the system include a front drive axle with a differential and planetaries. The differential receives torque from a variable-displacement piston pump and a motor.

This combination of components eliminates the need for a conventional mechanical transmission and also provides inching travel.

These handlers also have piston motors to provide torque to rear-wheel drive hubs, as well as an electrically-controlled valve which functions to restore tractive effort if conditions cause a wheel to spin.

Operation

Normal Travel. Direction of travel is selected by moving forward/reverse lever

forward for forward travel, backward for reverse travel. Move lever to center position for “Neutral”. (See Figure 3-1 for layout of controls)

WARNING

If hydrostatic drive system senses increased travel load, the system will compensate automatically by reducing travel speed to match load and engine RPM.

Inching Travel: Inching travel is provided to permit slow travel speed while maintaining high engine speed for other handler functions.

The service brake/inching travel pedal controls inching travel.

The upper portion of pedal travel actuates a valve which controls travel pump output. The greater the pedal travel, the less the pump flow; the slower the travel.

The lower portion of pedal travel actuates the service brake. The greater the pedal travel, the stronger the brake application. Travel flow is further reduced when brakes begin to apply. (See Figure 7-1)

Four-Wheel Drive: When required by travel conditions, rear-wheel (fourwheel) drive can be engaged by moving switch to “4x4” position. Return unit to two-wheel drive by moving switch to “4x2” position.

Four-wheel drive can be engaged and disengaged while traveling.

When parking brake is applied, four-wheel drive is disabled.

Traction-Lock Switch: This switch (pedal) controls the traction-lock valve which functions to restore tractive effort when a wheel spins in four-wheel drive.

Bring handler to a complete stop before shifting forward/reverse lever when carrying a load. A sudden change in direction of travel could reduce stability and/or cause load to shift or fall.

WARNING

Practice inching/braking in a safe, open area until you are thoroughly familiar with response of machine to pedal travel.

When switch pedal is depressed and held, traction-lock valve functions to cause delivery of full drive pressure to wheels of other axle, regardless of low pressure at spinning wheel.

DO NOT engage traction-lock function on improved surfaces. Unit must be in four-wheel drive to engage the traction-lock function.

DO NOT engage traction-lock function while wheels are turning. Return engine to idle, engage traction-lock and increase RPM. Disengage after traction resumes while in motion.

Form No. 20220

544D-10 Owner/Operator Manual

CAUTION

Never disengage rear hubs except when activating towbypass procedure.

11.0

LEVELING THE HANDLER

“Leveling” means positioning the handler so that it is level from side to side (left to right).

A level indicator is located in the upper right corner of front window frame to permit operator to determine whether handler frame level. (See Figure 3-1)

There are four very important things to remember about handler leveling:

1. Never engage a load or lift a load more than four feet (1.2m) above

ground unless handler is level.

2. A handler with the boom raised and/or an attachment installed is a partially-

loaded handler.

3. Once the handler frame is level and the handler has raised a load more

than four feet (1.2m) above ground, it must not be moved from this position if such movement could change the level condition. Do not use sway to level handler with load more than four feet (1.2m) above ground.

4. The combination of side tilt and load can cause the handler to tip over.

Two ways to level the handler with stabilizers up :

The surface which will support the handler can be leveled. This method must be chosen if it will be necessary to move the handler from its position after the load has been raised over four feet (1.2m) from ground AND such movement could change the level condition.

WARNING

Raising the boom (loaded or unloaded) when handler is leaning to one side could cause machine to tip over with little or no warning and cause serious injury or death.

Remember: The supporting surface must be large enough, smooth enough and firm enough to keep the handler level when it is moved from its position.

The handler may be leveled by means of the frame-leveling system. This method may be chosen when it will not be necessary to move the handler from its position after the load has been raised above four feet (1.2m) from ground - OR - when such movement will not change the level condition of the handler.

Always determine best position for handler to raise load from its present location and also to position load at its destination. THEN determine which method of leveling will be required at each location.

FINALLY, consider terrain between present location of load and its destination. Never attempt to transport a load across terrain which could cause handler to tip over.

Leveling Handler Frame:

The handler is designed to permit tilting main frame 8° to left or right to compensate for uneven ground conditions.

The rear axle pivots at the midpoint of the main frame to help ensure that all wheels will remain in contact with the ground.

A hydraulic cylinder provides a rigid connection between front axle and main frame to help ensure a solid work platform and to tilt main frame to left or right.

The 544D-10 is equipped with rear-axle stabilization. This system includes a hydraulic cylinder attached between the frame and the rear axle, as well as flow-restricting valving. This system dampens rear-axle oscillation whenever the boom is raised over 40° from level. However, the system never locks

the rear axle and is not designed to increase lateral stability.

WARNING

Always move boom to carry position (horizontal or below) before leveling frame. Attempting to level machine with boom raised could cause it to tip over.

11.1

Leveling Procedure:

1. Position machine in best location to lift or place load and apply parking brake.

WARNING

2. Observe level indicator to determine whether machine must be leveled. Note position of indicator for later realignment.

3. If necessary to level handler, position boom in carry position and level machine with the lever.

4. Lift or place load as appropriate.

5. Retract and lower boom to carry position.

6. Realign frame to position noted in step 2.

Frame-Leveling Controls

Figure 11-1

TILT FRAME

TO LEFT

OPTIONAL

TILT FRAME

TO RIGHT

STANDARD

TO LEFT

TILT FRAME

TO RIGHT

If handler cannot be leveled using leveling system, do not attempt to raise or place load. Have surface leveled.

Form No. 20220

544D-10 Owner/Operator Manual

12.0

OPERATING PROCEDURE & TECHNIQUES

Hydraulic Controls

All boom and attachment movements are governed by hydraulic controls. Rapid, jerky operation of hydraulic controls will cause rapid, jerky movement of the load. Such movements can cause the load to shift or fall or may cause the machine to tip over.

Feathering

Feathering is a control operation technique used for smooth operation. To feather controls, move control lever very slowly until function begins to move, then gradually move lever further until function is moving at desired speed. Gradually move lever toward “Neutral” as load approaches destination. Continue to reduce load speed to bring load to a smooth stop. Feathering effect can be increased by reducing engine speed at beginning and near end of load movement.

Boom Control Joystick

The boom control joystick can be positioned to activate individual boom movements or combinations of boom movements as illustrated:

Figure 12-1

LOWER &

RETRACT

BOOM

RETRACT

BOOM

LOWER

BOOM

LOWER &

EXTEND

BOOM

EXTEND

BOOM

FRONT OF

MACHINE

NOTE!

Much of the material in this section may be new to even the experienced operator.

WARNING

Do not permit lift cylinders to hit the end of their stroke. The jolt could topple loads, causing a hazard to personnel and equipment nearby.

RAISE &

RETRACT

BOOM

RAISE BOOM

RAISE & EXTEND

BOOM

With boom raised above horizontal, forks can be inserted under a load by moving boom control joystick forward and to the right until forks move forward horizontally.

With boom raised above horizontal, forks can be removed from a load by moving boom control joystick back and to the left until forks move rearward horizontally.

With boom lowered below horizontal, forks can be inserted under

a load by moving

boom control joystick back and to the right until forks move forward horizontally.

With boom lowered below horizontal, forks can be removed from a load by moving boom control joystick forward and to the left until forks move rearward horizontally.

The closer the boom to horizontal, the less boom raise/lower movement required for inserting and removing forks.

Carriage Tilt Controls

Figure 12-2

TILT FORKS DOWN

TILT

FORKS

TILT

FORKS

STANDARD OPTIONAL OPTIONAL

TILT

FORKS

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