Lull 1044C-54 Operation Manual

Operator & Safety Manual

Keep this manual with machine at all times.

Model

1044C-54

Series II

Before S/N 0160037900

31200070

Revised

February 23, 2009

An Oshkosh Corporation Company

Revision Log

March 9, 2005 - A - Original Issue of Manual

July 12, 2005 - B - Revised pages 6, 23, 24, 27 & inside rear cover.

February 23, 2009 - C - Revised covers and pages c, 30 & 31.

REVISION LOG

Revision Log

Read This First

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

Operator Qualifications

The operator of the machine must not operate the machine until this manual has been read, training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator. Operation within the U.S.A. requires training per OSHA 1910.178.

Operators of this equipment must possess a valid, applicable driver’s license, be in good physical and mental condition, have normal reflexes and reaction time, good vision and depth perception and normal hearing. Operator must not be using medication which could impair abilities nor be under the influence of alcohol or any other intoxicant during the work shift.

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

• This Operator & Safety Manual

• Telehandler Safety Manual

• All 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.

Modifications

Any modification to this machine must be approved by JLG.

Read This First

This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local authorized JLG representative for information regarding safety-related bulletins which may have been issued for this product.

JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.

JLG Industries, Inc. must be notified immediately in all instances where JLG products have been involved in an accident involving bodily injury or death of personnel or when damage has occurred to personal property or the JLG product.

FOR:

• Accident Reporting and Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Applications and Safety

• Standards and Regulations Compliance Information

• Questions Regarding Product Modifications

CONTACT:

Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 USA

or Your Local JLG Office (Addresses on back cover)

In USA

Toll Free: 1-877-JLG-SAFE (1-877-554-7233)

Outside USA

Phone: +1-717-485-6591

E-mail

ProductSafety@JLG.com

Other Publications Available

Illustrated Parts Manual ......................................31200069

Service Manual ................................................... 31200079

Read This First

This Page Intentionally Left Blank

Revision Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

Read This First. . . . . . . . . . . . . . . . . . . . . . . . . . . . . b

Operator Qualifications . . . . . . . . . . . . . . . . . . . . b

Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . b

Other Publications Available . . . . . . . . . . . . . . . . c

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Danger, Warning, & Caution: What They Mean . .1

Safety Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Operators Protective Structure . . . . . . . . . . . . . . .1

Refueling Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Vehicle Stability . . . . . . . . . . . . . . . . . . . . . . . . . .2

Starting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . 3

Before Operating the Machine . . . . . . . . . . . . . . . . . 8

Check the Equipment . . . . . . . . . . . . . . . . . . . . . . 8

Know the Work Area . . . . . . . . . . . . . . . . . . . . . . 8

Plan Your Work . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Safe Vehicle Operation . . . . . . . . . . . . . . . . . . . . 9

Know the Rules . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Protect Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Mount and Dismount Properly . . . . . . . . . . . . . . 10

Instruments and Controls . . . . . . . . . . . . . . . . . . . . 12

Gauges and Lights . . . . . . . . . . . . . . . . . . . . . . . 12

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Drive Lockout Override Foot Switch . . . . . . . . . . 14

Park Brake Control . . . . . . . . . . . . . . . . . . . . . . . 14

Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Direction Control . . . . . . . . . . . . . . . . . . . . . 15

Speed Range Selection . . . . . . . . . . . . . . . 15

Neutral Lock . . . . . . . . . . . . . . . . . . . . . . . . 15

Shutdown Override Switch . . . . . . . . . . . . . . . . . 15

Transmission Declutch Switch . . . . . . . . . . . . . .16

Steer Mode Selector . . . . . . . . . . . . . . . . . . . . .16

Front Wheel Steer Mode . . . . . . . . . . . . . . 17

Round Steer Mode . . . . . . . . . . . . . . . . . . . 17

Oblique Steer Mode . . . . . . . . . . . . . . . . . . 17

Synchronizing (Straightening) the Wheels . 17

Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . 19

General Description . . . . . . . . . . . . . . . . . . 19

Front Joystick . . . . . . . . . . . . . . . . . . . . . . . 19

Rear Joystick . . . . . . . . . . . . . . . . . . . . . . . 20

Auxiliary Controls . . . . . . . . . . . . . . . . . . . . 22

Tilting Carriage Control . . . . . . . . . . . . . . . . 22

Boom Angle Indicator . . . . . . . . . . . . . . . . . . . . .23

Boom Extension Indicator . . . . . . . . . . . . . . . . . 23

Transfer Carriage Extension Indicator . . . . . . . . 23

Frame Level Indicator . . . . . . . . . . . . . . . . . . . .23

Frame Tilt Control . . . . . . . . . . . . . . . . . . . . . . .24

Outrigger Controls . . . . . . . . . . . . . . . . . . . . . . .24

General Operating Procedures . . . . . . . . . . . . . . .26

Starting Procedures . . . . . . . . . . . . . . . . . . . . . . 26

Shutdown Procedures . . . . . . . . . . . . . . . . . . . . 26

Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Follow Safe Operating Procedures . . . . . . . . . .27

Lift the Load Safely . . . . . . . . . . . . . . . . . . . . . .27

Transport the Load Safely . . . . . . . . . . . . . . . . . 27

Safely Placing the Load . . . . . . . . . . . . . . . . . . .28

Elevated or Overhead Placement. . . . . . . . 28

Lifting Personnel . . . . . . . . . . . . . . . . . . . . . . . . 29

Quick Attach . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Disconnecting an Attachment . . . . . . . . . . . 30

Connecting an Attachment . . . . . . . . . . . . . 31

Stability Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .32

System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Rear Oscillation Lock System . . . . . . . . . . . . . .32

Drive Lockout Override . . . . . . . . . . . . . . . . . . .32

Theory of Normal Operation . . . . . . . . . . . . 32

General Description, Drive

Lockout Override System . . . . . . . . . . . . . . 33

Operation of the Drive

Lockout Override System . . . . . . . . . . . . . . 33

Boom/Transfer Extend Lock System . . . . . . . . .34

Fluid & Lubricant Specifications . . . . . . . . . . . . . . 36

General Fluid and Lubricant Specifications 36

Engine Oil Specifications . . . . . . . . . . . . . . . . . . 36

John Deere Engines . . . . . . . . . . . . . . . . . . 36

Transmission Oil Specifications . . . . . . . . . . . . .37

Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . 37

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

John Deere Engines . . . . . . . . . . . . . . . . . . 37

Service/Lubrication Schedule . . . . . . . . . . . . . . . .38

Sample Load Chart . . . . . . . . . . . . . . . . . . . . . . . . .40

TABLE OF CONTENTS

W1038

SAFETY

SAFETY STANDARD

The ASME/ANSI B56.6 safety standard for rough terrain forklift trucks defines safety requirements relating to the design, operation, and maintenance of these vehicles.

DANGER, WARNING, & CAUTION: WHAT THEY MEAN

Hazards are identified by the “Safety Alert Symbol” and followed by a signal word: Danger, Warning, or Caution.

DANGER

The signal word “DANGER” indicates an imminently hazardous situation which, if not avoided, will result in death or serious personal injury.

WARNING

The signal word “WARNING” indicates a potentially hazardous situation which, if not avoided, could result in death or serious personal injury.

DECALS

The decals on the vehicle provide instructions for safe and correct operation.

Never make modifications affecting safe operation or capacity without the expressed written approval of JLG.

When JLG approved modifications are made, the user is responsible for seeing that appropriate decals, load charts, and instructions are changed.

All plates and decals must be in place and legible at all times.

OPERATORS PROTECTIVE STRUCTURE

This vehicles Operators Protective Structure is equipped with a Roll-Over Protective Structure (ROPS) to guard the operator if the vehicle tips over. The Falling Object Protective Structure (FOPS) is built into the ROPS. The FOPS protects the operator from falling objects.

Despite the protection of the ROPS/FOPS, it cannot protect the operator from every possible hazard. Do not consider the ROPS/FOPS a substitute for safe practices and good common sense.

Any modification to a ROPS/FOPS, such as welding or drilling holes in the structural members for mounting brackets, will affect the ROPS/FOPS capability to provide the required protection.

CAUTION

The signal word “CAUTION” indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION

The signal word “CAUTION”, used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Any modification or repair without the specific written approval of JLG will void the ROPS/FOPS certification. Contact your authorized JLG dealer before making any modifications or repairs. Failure to do so may void the ROPS/FOPS certification.

SAFETY

REFUELING SAFETY

 Never smoke near the vehicle during refueling.

 Do not permit anyone to be on the vehicle during

refueling.

 Spilled fuel must be completely absorbed or

evaporated before starting the engine.

 Make sure the fuel cap is in place before starting

the engine.

 Never use an open flame when checking the fuel

level in the tank.

 Never fill the fuel tank with the engine running.

Make sure you have adequate ventilation during fueling.

PERSONAL SAFETY

Wear all the protective clothing and personal safety devices issued to you or called for by job conditions.

VEHICLE STABILITY

Your JLG vehicle is proven to be stable when properly operated. However, improper operation, faulty maintenance, unauthorized modifications, or poor housekeeping may cause instability.

Some Conditions that Affect Stability:

• Ground and surface conditions.

• Surface grade.

• Weight and configuration of the attachment.

• Improper tire inflation and ballast content.

• Operator judgement.

• Excessive tilting of the fork carriage or other

attachments, with an elevated load, can cause vehicle instability. The amount of allowable tilt is governed by conditions such as boom elevation, weight of load, and terrain.

STARTING SAFETY

Before Starting the Engine…

You may need…

• A hard hat

• Safety shoes

• Safety glasses, goggles, or face shield

• Heavy gloves

• Hearing protection

• Reflective clothing

• Wet weather gear

• Respirator or filter mask

 Avoid entanglement hazards. Do not wear

clothing or jewelry that could catch on machinery. Keep your hands, hair, feet and clothing away from moving parts. Always keep your hands and feet inside the cab.

Important: Warn all others in the area that you are

going to start the vehicle.

1. Check underneath and around the vehicle and make sure all personnel are clear.

2. Be properly seated and seat belt secured.

3. Set the park brake.

4. Make sure shift selector is locked in the NEUTRAL position.

5. Apply the brakes.

 Know the pinch points and rotating parts on the

vehicle.

 Always know where to get assistance in case of

an emergency. Know how to use a first aid kit and fire extinguisher.

SAFETY

OPERATION SAFETY

 Safe operation is the responsibility of the operator.

 Improper use of the vehicle can lead to dangerous

situations for yourself, those around you, the vehicle and the work area. You must have safe working habits and be aware of hazardous working conditions.

 Thoroughly read and understand this entire

manual. Follow all safety rules and practices explained in this manual.

 The vehicle must be checked every day or at the

start of each shift. See “Check the Equipment” on page 8.

 To meet the requirements of different operating

conditions, JLG offers optional lighting packages for your vehicle. Do not operate the vehicle if it is not equipped with lights when conditions require them. If your vehicle is not equipped with the proper lights, contact your authorized JLG dealer for available lighting packages.

 If operating in an enclosed or partially enclosed

environment, make sure there is enough ventilation. Engine exhaust fumes can be deadly to you and those around you if precautions are not taken. Questions about the air quality in the working environment and sampling methods should be directed to a qualified person.

Before Leaving the Vehicle Unattended…

• Stop the engine.

• Block the wheels if parked on an incline.

• Lower the boom.

The vehicle is considered “attended” when the operator is less than 25 feet from the vehicle and it remains in the operator’s view.

The vehicle is considered “unattended” when the operator is 25 feet or more from the vehicle and the vehicle is in the operator’s view, or whenever the vehicle is not in the operator’s view.

W1009W1007

Never stand or walk under a raised boom. Do not allow others to do so.

Never operate the vehicle controls while you are outside the cab. You must be properly seated in the cab before operating any controls.

Before Leaving the Cab…

• Bring the vehicle to a full stop.

• Apply the park brake.

W1008

Never allow passengers on the vehicle.

• Lower the boom.

SAFETY

Always check clearances under power lines and overhead structures before driving under them.

 DO NOT operate the vehicle near energized

power lines. Always contact the electrical power company when operating near power lines. The lines should be moved, insulated, disconnected, or de-energized and grounded before operating in the area. Keep all parts of the vehicle at least 10 feet away from power lines. Contacting electrical power lines WILL result in death or serious personal injury!

W1011

Ensure that correct tire pressure and tire ballast levels are maintained.

W1017W1014W1013

W1010

DANGER

KEEP ALL PARTS OF MACHINE AT LEAST 10 FEET FROM POWER LINES. CONTACTING ENERGIZED POWER LINES WILL CAUSE DEATH OR SERIOUS PERSONAL INJURY!

Never attempt to discharge a load by stopping the vehicle suddenly.

Never lift a load using one fork.

Always check for enough overheard clearance for the boom.

SAFETY

W1016

Never place loads that exceed scaffold capacity or subject scaffold to unnecessary “shock” loads.

W1021

Drive carefully and avoid sudden stops and changes of direction.

W1020

W1015W1019

Ensure that the load is stable and secure. Check to see that there are no loose articles that may fall off the fork.

Never stack a load on uneven ground.

W1022

Don’t overload the vehicle.

W1023

Never add unauthorized counterweights.

Always be aware of load width.

SAFETY

Always pick up the load at its center of gravity.

W1026

W1043

W1024

The vehicle can be levelled side to-side a total of 10° in each direction (18% grade). Any slope or grade that exceeds this is considered excessively steep.

Avoid parking on slopes. If it is necessary to park on a slope, set the parking brake and block the wheels.

When Traveling On Inclines…

• Tilt the attachment back and raise only

enough to clear the ground.

• Avoid turning. If it cannot be avoided, turn

slowly and with extreme caution.

• Travel straight up and down grades.

• When loaded and traveling up or down

grades, travel only with the load uphill.

• When unloaded, travel only with the forks or

attachment downhill.

• Proceed slowly and with extreme caution.

• Do not travel across excessively steep

slopes.

W1018

Drive slow and carry the load as low as possible.

When Traveling on Roadways…

• Make sure the vehicle is equipped with all

necessary lights and safety signs required for traveling on roadways.

• Observe all traffic laws and speed limits.

• Keep to the correct side of the roadway.

• Keep a safe distance from other vehicles.

• Maintain control of the vehicle at all times.

• Yield the right-of-way to pedestrians and

emergency vehicles.

• Do not pass another vehicle at intersections,

blind spots, or other dangerous locations.

• Avoid running over loose objects and debris.

SAFETY

Additional Safety Instructions:

• Maneuver the vehicle carefully. Do not cause the

load to shift or the vehicle to tip.

• Slow down for wet and slippery surfaces and

changes in terrain.

• Turn the steering wheel smoothly and slow down

when turning.

• Do not make sharp turns at high speeds.

• Take special care when traveling without a load.

The vehicle is more susceptible to tipping over on its side.

• Do not continue to operate the vehicle if an unsafe

condition is found. Stop the vehicle and report the condition to the designated authority.

• Never make repairs or adjustments unless you are

authorized to do so.

• Always keep your hands and feet inside the cab.

• Never reach into the boom or attachments.

• Understand the limitations of the vehicle and drive

safely.

• Do not block access to fire lanes or fire equipment.

• Do not jump! If a vehicle ever becomes unstable

and starts to tip over: Brace yourself and stay with the vehicle, Keep your seat belt fastened, Hold on firmly and lean away from the point of impact.

• Never tamper with, modify, or bypass the stability

systems installed on your JLG vehicle. Never disconnect or bypass pressure switches or proximity switches.

Do not disconnect or bypass proximity switches.

Bypassing proximity switches may result in death or serious personal injury !

W1056

See “Stability Systems” on page 32 for more information on the stability systems installed on your vehicle.

• Watch for pedestrians, especially when backing up

or turning and where pedestrians may step into the path of the vehicle.

• The vehicle may add to the overall sound level of

the work area. Give consideration to the sound exposure of those working around you.

• If a fuel leak is found, do not operate the vehicle

until the problem is fixed.

• When approaching areas where vision is

obstructed, always slow down and sound the horn.

• Report all accidents involving personnel, building

structures, and equipment to your supervisor or as directed.

• Use caution when operating on ramps, platforms,

trenches, and other similar surfaces.

• Keep a clear view of the terrain and where the

vehicle is heading. Watch out for other vehicles, people, and structures.

• Where the load will obstruct the operator's vision, it

is recommended that the vehicle be operated in reverse, looking backwards in the direction of travel. Travel at a slower speed and get someone to direct you.

• Avoid excessively steep slopes or unstable

surfaces. If you must drive on a slope, level the vehicle, keep the load low and proceed with extreme caution. Do not, under any circumstances, drive across excessively steep slopes.

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