Name: Gradall 544D-10
Brand: Gradall
SKU: 1589497
Rating: 4.7 (3 reviews)

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

®

4

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1

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6

1

6

1

6

1

6

1

6

1

6

1234567890123456789012345678901212345678901234567890123456789012123456

23456789012345678901234567890121234567890123456789012345678901212345

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.

23456789012345678901234567890121234567890123456789012345678901212345678901234567890123

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

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544D-10 Owner/Operator Manual

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

FT

A

24 24

IN

B

SAMPLE ONLY - USE CHART IN CAB

IN

24 24

C

FT

-.8

.8

D

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

5

55

FT

24

IN

24

FT

6.5

CAP# 1000

10 33,570

*

10

*

3

**

3

**

2

****

2

***

1.6 33,520

***

4 35,350

****

6 34,530

*

6 34,610

*

10

*

10

*

10

*

10

*

INCREASE ATTACHMENT CAPACITY.

B

A

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

C

D

FT

IN IN

34 24 24

FT

IN

24 24

34

FT

IN

34

24 24

FT

55 --- ---

FT

55 --- ---

FT

39

--- ---

FT

65

---

FT

65 --- ---

FT

IN IN

61

24 24

FT

IN IN

38

24 24

IN IN

FT

38

24 24

IN IN

FT

21

24 24

FT

IN IN

33

24 24

FT

IN IN

33

24 24

FT

IN IN

21

24 24

IN

---

9136-3011 (REV E)

DCBA

FT

-.8

FT

-.8

FT

-.8

FT

8.9

FT

9.4

FT

3.2

FT

7.4

FT

7.4

FT

8.7

FT

1.3

FT

1.3

FT

-2

FT

-.4

FT

-.4

FT

-2

Form No. 20220

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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

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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°

8'

4'

0°

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

10

9

8

10000 LBS

7

6

5

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

MODEL 544D-10

4

3

2

1

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

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Form No. 20220

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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

R

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

A

24 24

B

SAMPLE ONLY - USE CHART IN CAB

24 24

C

-.8

D

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

FT

IN

FT

5

55

FT

24

IN

24

FT

.8

6.5

CAP# 1000

10 33,570

*

10

*

**

****

***

1.6 33,520

***

****

*

10

*

10

*

10

*

10

*

INCREASE ATTACHMENT CAPACITY.

B

FT

IN

A

IN

FT

TRUCK &

ATTACHMENT

WEIGHT

33,670

33,68010

3

33,140

33,310

3

2

33,420

2

33,280

4 35,350

6 34,530

6 34,610

34,310

33,780

33,900

34,890

32,670 LBS

C

D

IN IN

FT

34 24 24

IN

FT

24 24

34

FT

IN

34

24 24

FT

55 --- ---

FT

55 --- ---

FT

39

--- ---

FT

65

---

FT

65 --- ---

FT

IN IN

61

24 24

FT

IN IN

38

24 24

FT

IN IN

38

24 24

FT

IN IN

21

24 24

FT

IN IN

33

24 24

FT

IN IN

33

24 24

FT

IN IN

21

24 24

IN

---

9136-3011 (REV E)

DCBA

FT

-.8

FT

-.8

FT

-.8

FT

8.9

FT

9.4

FT

3.2

FT

7.4

FT

7.4

FT

8.7

FT

1.3

FT

1.3

FT

-2

FT

-.4

FT

-.4

FT

-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

R

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

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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.

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

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

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

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

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

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

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

OR

10 HRS

50 HRS

CHECK

FILL

CHECK

*

CHECK

GREASE

****

GREASE

****

GREASE

****

GREASE

****

GREASE

****

GREASE

ANNUALLY

EVERY

5WKS OR

250 HRS

CHANGE CHANGE

CHECK

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

GREASE

CHECK

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

6 MO.

3 MO.

OR

500 HRS

CHANGE

INSPECT

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

TORQUE

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

CHECK

OR

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

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Form No. 20220

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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.

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Form No. 20220

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544D-10 Owner/Operator Manual

Gradall 544D-10 Operation Manual

IMPORTANT SAFETY NOTICE

REVISIONS

TABLE OF CONTENTS

INTRODUCTION

SAFETY HIGHLIGHTS

DECALS