1044C-54

Lull 1044C-54 Operation Manual

Operation & Safety

An Oshkosh Corporation Company

Manual

Keep this manual with machine at all times.

Model

1044C-54

Series II

S/N 0160037900 & After

31200608

Revised

September 30, 2014

CALIFORNIA PROPOSITION 65

BATTERY WARNING

Battery posts,

terminals and related

accessories contain

lead and lead compounds,

chemical known to the

State of California

to cause cancer and

reproductive harm.

WASH HANDS

AFTER HANDLING!

CALIFORNIA PROPOSITION 65

EXHAUST WARNING

Diesel Engine exhaust and

some of its constituents

are known to the State of

California to cause cancer,

birth defects and other

reproductive harm.

Revision Log

February 23, 2009 - A - Original Issue of Manual

September 25, 2009 - B - Revised pages b, 1-5, 1-6, 2-3, 2-4, 3-3, 3-4, 3-5, 3-17, 3-19, 4-1, 4-2, 7-2, 7-5, 7-11, 7-14, 7-16, 7-17, 7-23, 7-24, 8-1, 8-2 & 9-1.

December 21, 2010 - C - Revised pages 7-18, 9-2 & 9-4.

September 30, 2014 - D - Revised pages 1-6, 1-7, 5-2, 5-14 thru 5-39 & 9-4.

REVISION LOG

a31200608

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 Operation & Safety Manual

• Telehandler Safety Manual (ANSI only)

• 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.

b 31200608

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 safetyrelated 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

c31200608

Read This First

Other Publications Available

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

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

Note: The following standards may be referenced in this manual: ANSI is compliant to ANSI/ITSDF B56.6 AUS is compliant to AS 1418.19 CE is compliant to EN1459 Refer to the machine Serial Number Plate to identify the applicable compliance standard.

d 31200608

Table of Contents

TABLE OF CONTENTS

Revision Log

Read This First

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

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

Other Publications Available .............................................. d

Table of Contents

Section 1 - General Safety Practices

1.1 Hazard Classification System ..............................................1-1

Safety Alert System and Safety Signal Words................1-1

1.2 General Precautions ............................................................1-1

1.3 Operation Safety..................................................................1-2

Electrical Hazards ...........................................................1-2

Tip Over Hazard..............................................................1-3

Travel Hazard ................................................................. 1-6

Load Falling Hazard ........................................................1-7

Lifting Personnel .............................................................1-8

Driving Hazards on Slopes .............................................1-9

Pinch Points and Crush Hazards ..................................1-10

Fall Hazard....................................................................1-12

Chemical Hazards.........................................................1-13

Table of Contents

Section 2 - Pre-Operation and Inspection

2.1 Pre-Operation Check and Inspection...................................2-1

2.2 Safety Decals.......................................................................2-3

2.3 Walk-Around Inspection.......................................................2-6

2.4 Warm-Up and Operational Checks ......................................2-8

Warm-Up Check ............................................................. 2-8

Operational Check .......................................................... 2-8

2.5 Operator Cab .......................................................................2-9

2.6 Windows ............................................................................2-10

Cab Door Window (if equipped)....................................2-10

Section 3 - Controls and Indicators

3.1 General ................................................................................3-1

3.2 Controls ............................................................................... 3-2

Instrument Panel and Switches ......................................3-4

Ignition ............................................................................ 3-6

Park Brake ......................................................................3-7

Parking Procedure ..........................................................3-7

Transmission Control Lever ............................................3-8

Front Joystick ................................................................3-10

Middle Joystick..............................................................3-11

i31200608

Table of Contents

Outrigger Joysticks ....................................................... 3-12

Frame Level Joystick.................................................... 3-13

Heater and Air Conditioning Controls (if equipped)...... 3-14

Accessory Control Lever (if equipped) ......................... 3-15

3.3 Steer Modes ...................................................................... 3-16

Steer Mode Change ..................................................... 3-16

3.4 Rear Oscillation Lock System ........................................... 3-17

3.5 Drive Lockout System ....................................................... 3-18

3.6 Boom/Transfer Extend Lock System ................................. 3-19

3.7 Operator Seat.................................................................... 3-20

Adjustments.................................................................. 3-20

Seat Belt ....................................................................... 3-21

3.8 Indicators ........................................................................... 3-22

Boom Angle and Extension Indicators.......................... 3-22

Transfer Carriage Extension......................................... 3-22

Section 4 - Operation

4.1 Engine ................................................................................. 4-1

Starting the Engine ......................................................... 4-1

Cold Weather Starting Aids ............................................ 4-2

Battery Boosted Starting................................................. 4-3

Normal Engine Operation ............................................... 4-4

Shut-Down Procedure .................................................... 4-4

4.2 Operating with a Non-Suspended Load .............................. 4-5

Lift Load Safely............................................................... 4-5

Picking Up a Load .......................................................... 4-5

Transporting a Load ....................................................... 4-6

Leveling Procedure......................................................... 4-6

Placing a Load................................................................ 4-7

Disengaging a Load........................................................ 4-7

4.3 Operating with a Suspended Load ...................................... 4-8

Lift Load Safely............................................................... 4-8

Picking Up a Suspended Load ....................................... 4-8

Transporting a Suspended Load .................................... 4-9

Leveling Procedure......................................................... 4-9

Placing a Suspended Load........................................... 4-10

Disengaging a Suspended Load .................................. 4-10

4.4 Loading and Securing for Transport .................................. 4-11

Tiedown ........................................................................ 4-11

Lifting ............................................................................ 4-12

Section 5 - Attachments

5.1 Approved Attachments ........................................................ 5-1

5.2 Unapproved Attachments.................................................... 5-1

5.3 JLG Supplied Attachments.................................................. 5-2

ii 31200608

5.4 Telehandler/Attachment/Fork Capacity................................5-3

5.5 Use of the Capacity Chart....................................................5-4

Capacity Indicator Locations ...........................................5-4

Sample Capacity Chart ...................................................5-5

Example ..........................................................................5-7

5.6 Attachment Installation ........................................................5-9

Hydraulic Operated Attachment ....................................5-11

5.7 Adjusting/Moving Forks......................................................5-12

5.8 Attachment Operation ........................................................5-13

Carriage w/Forks...........................................................5-14

Side Tilt Carriage .......................................................... 5-16

Side Shift Carriage ........................................................5-18

Dual Fork Positioning Carriage .....................................5-20

Fork Extension ..............................................................5-22

Swing Carriage .............................................................5-24

Mast Carriage ...............................................................5-26

Mast Carriage w/Side Tilt ..............................................5-28

Fork Mounted Hook ......................................................5-30

Truss Boom...................................................................5-32

Bucket ...........................................................................5-34

Grapple Bucket .............................................................5-36

Personnel Work Platform ..............................................5-38

Section 6 - Emergency Procedures

6.1 Towing a Disabled Product ..................................................6-1

Moving Short Distances ..................................................6-1

Moving Longer Distances ............................................... 6-1

6.2 Emergency Lowering of Boom.............................................6-2

6.3 Emergency Exit from Enclosed Cab ....................................6-2

Table of Contents

Section 7 - Lubrication and Maintenance

7.1 Introduction ..........................................................................7-1

Clothing and Safety Gear................................................7-1

7.2 General Maintenance Instructions .......................................7-2

7.3 Service and Maintenance Schedule .................................... 7-3

10 & 1st 50 Hour Maintenance Schedule .......................7-3

50, 250 & 1st 500 Hour Maintenance Schedule .............7-4

500, 1000 & 2000 Hour Maintenance Schedule .............7-5

7.4 Lubrication Schedules .........................................................7-6

10 Hour Lubrication Schedule.........................................7-6

50 Hour Lubrication Schedule.........................................7-7

250 Hour Lubrication Schedule.......................................7-8

7.5 Operator Maintenance Instructions....................................7-10

Fuel System ..................................................................7-10

Air Intake System ..........................................................7-12

iii31200608

Table of Contents

Engine Oil ..................................................................... 7-14

Hydraulic Oil ................................................................. 7-15

Engine Cooling System ................................................ 7-16

Tires.............................................................................. 7-18

Hydraulic Return Filter.................................................. 7-21

Transmission Oil........................................................... 7-22

Battery .......................................................................... 7-23

Section 8 - Additional Checks

8.1 Rear Oscillation Lock System ............................................. 8-1

8.2 Boom/Transfer Extend Lock System ................................... 8-2

Section 9 - Specifications

9.1 Product Specifications......................................................... 9-1

Capacities....................................................................... 9-1

Tires................................................................................ 9-2

Performance ................................................................... 9-3

Dimensions..................................................................... 9-4

Index

Inspection, Maintenance and Repair Log

iv 31200608

Section 1 - General Safety Practices

DANGER

OW0010

WARNING

OW0021

CAUTION

OW0031

SECTION 1 - GENERAL SAFETY PRACTICES

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER indicates an imminently hazardous situation which, if not avoided, will

result in death or serious injury.

WARNIN G indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentiality hazardous situation which, if not avoided, may result in minor or moderate injury.

1.2 GENERAL PRECAUTIONS

WARNING

Before operation, read and understand this manual. Failure to comply with the safety precautions listed in this manual could result in machine damage, property damage, personal injury or death.

1-131200608

Section 1 - General Safety Practices

OW0040

10 FT

(3 M)

1.3 OPERATION SAFETY

Electrical Hazards

• This machine is not insulated and does not provide protection from contact or being near electrical current.

• NEVER operate the telehandler in an area where overhead power lines, overhead or underground cables, or other power sources may exist without ensuring the appropriate power or utility company de-energizes the lines.

• Always check for power lines before raising the boom.

• Follow employer, local and governmental regulations for clearance from powerlines.

1-2 31200608

Section 1 - General Safety Practices

OW0050

OW0080

OW0100

4 FT

(1,2 M)

Tip Over Hazard

General

• For additional load requirements, refer to the appropriate capacity chart.

• Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler.

• Understand how to properly use the capacity charts located in cab.

• DO NOT exceed rated lift capacity.

• Be sure that the ground conditions are able to support the machine.

• DO NOT raise boom unless frame is level (0 degrees), unless otherwise noted on capacity chart.

• DO NOT level machine with boom/attachment above 4 ft (1,2 m). (AUS - DO NOT level machine with load more than 11.8 in (300 mm) above ground surface.)

1-331200608

Section 1 - General Safety Practices

OH2291

OH20911

OH2221

• MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over.

• Refer to manufacturer’s specifications for proper fill ratio and pressure requirements for tires equipped with ballast.

• Always wear the seat belt.

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

If the telehandler starts to tip over:

• DO NOT JUMP

• BRACE YOURSELF and STAY WITH THE MACHINE

• KEEP YOUR SEAT BELT FASTENED

• HOLD ON FIRMLY

• LEAN AWAY FROM THE POINT OF IMPACT

1-4 31200608

Non-Suspended Load

OW0060

OW0150

• DO NOT drive with boom raised.

Suspended Load

Section 1 - General Safety Practices

• Tether suspended loads to restrict movement.

• Weight of all rigging (slings, etc.) must be included as part of load.

• Beware of wind. Wind can cause a suspended load to swing and cause dangerous side loads - even with tag lines.

• DO NOT attempt to use telehandler frame-leveling to compensate for load swing.

• Keep heavy part of load closest to attachment.

• Never drag the load; lift vertically.

When driving with a suspended load:

• Start, travel, turn and stop slowly to prevent load from swinging.

• DO NOT extend boom.

• DO NOT raise the load more than 11.8 in (300 mm) above ground surface or the boom more than 45°.

• DO NOT exceed walking speed.

1-531200608

Section 1 - General Safety Practices

OAL2030

2-Wheel Front Steer 4-Wheel Circle Steer 4-Wheel Crab Steer

Travel Hazard

• Steering characteristics differ between steer modes. Identify the steer mode settings of the telehandler being operated.

• DO NOT change steer modes while traveling. Steer modes must be changed while telehandler is stationary.

• Visually verify proper wheel alignment after each steer mode change.

• Ensure that adequate clearance is provided for both rear tail swing and front fork swing.

• Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you DO NOT have a clear view.

• Before moving be sure of a clear path and sound horn.

• When driving, retract boom and keep boom/attachment as low as possible while maintaining visibility of mirrors and maximum visibility of path of travel.

• Always look in the direction of travel.

• Always check boom clearances carefully before driving underneath overhead obstructions. Position attachment/load to clear obstacles.

• When driving in high speed, use only front wheel steer (if steering modes are selectable).

• Telehandlers equipped with solid tires should not be used in applications requiring excessive roading or driving extended distances. In the event an application requires excessive roading or driving expanded distances, JLG recommends the use of telehandlers not equipped with solid tires.

1-6 31200608

Section 1 - General Safety Practices

OW0130

Load Falling Hazard

• Never suspend load from forks or other parts of carriage weldment. Use only JLG approved lift points.

• DO NOT burn or drill holes in fork(s).

• Forks must be centered under load and spaced apart as far as possible.

1-731200608

Section 1 - General Safety Practices

OW0170

OW0190

Lifting Personnel

• When lifting personnel, USE ONLY an approved personnel work platform, with proper capacity chart displayed in the cab.

• DO NOT drive machine from cab when personnel are in platform.

1-8 31200608

Section 1 - General Safety Practices

OW0200

Driving Hazards on Slopes

To maintain sufficient traction and braking capabilities, travel on slopes as follows:

• When unloaded, drive with forks pointed downhill.

• When loaded, drive with the forks pointed uphill.

• For additional travel requirements, refer to the appropriate capacity chart.

• To avoid overspeeding the engine and drivetrain when driving down slopes, downshift to a lower gear and use the service brake as necessary to maintain a slow speed. DO NOT shift into neutral and coast downhill.

• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT drive across excessively steep slopes under any circumstances.

• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going downhill.

• DO NOT park on a slope.

1-931200608

Section 1 - General Safety Practices

OW0210

OW0220

OW0230

Pinch Points and Crush Hazards

Stay clear of pinch points and rotating parts on the telehandler.

• Stay clear of moving parts while engine is running.

• Keep clear of steering tires and frame or other objects.

• Keep clear from under boom.

1-10 31200608

Section 1 - General Safety Practices

OW0240

OW0250

OW0260

OW0960

• Keep clear of boom holes.

• Keep arms and hands clear of attachment tilt cylinder.

• Keep hands and fingers clear of carriage and forks.

• Keep others away while operating.

1-1131200608

Section 1 - General Safety Practices

OW0280

OW0290

Fall Hazard

• Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine.

• DO NOT get off the machine until the shutdown procedure on page 4-4 has been performed.

• DO NOT carry riders. Riders could fall off machine causing death or serious injury.

1-12 31200608

Section 1 - General Safety Practices

OW0300

OW0950

Chemical Hazards

Exhaust Fumes

• DO NOT operate machine in an enclosed area without proper ventilation.

• DO NOT operate the machine in hazardous environments unless approved for that purpose by JLG and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion.

Flammable Fuel

• DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or smoking materials. Engine fuel is flammable and can cause a fire and/or explosion.

Hydraulic Fluid

• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure.

• Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin.

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid.

1-1331200608

Section 1 - General Safety Practices

This Page Intentionally Left Blank

1-14 31200608

Section 2 - Pre-Operation and Inspection

OAH1000

PARENT METAL CRACK WELD CRACK

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1 PRE-OPERATION CHECK AND INSPECTION

Note: Complete all required maintenance before operating unit.

WARNING

FALL HAZARD. Use extreme caution when checking items beyond your normal

reach. Use an approved ladder.

The pre-operation check and inspection, performed at beginning of each work shift or at each change of operator, should include the following:

1. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.

3. Safety Decals - Ensure all safety decals are legible and in place. Clean or replace as required. See page 2-3 for details.

4. Operation and Safety Manuals - Operation & Safety Manual and AEM Safety Manual (as required) are located in cab manual holder.

5. Walk-Around Inspection - See page 2-6 for details.

6. Fluid Levels - Check fluids, including fuel, hydraulic oil, engine oil, transmission fluid and coolant. When adding fluids, refer to Section 7 - Lubrication and Maintenance and Section 9 - Specifications to determine proper type and intervals. 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.

7. Attachments/Accessories - Ensure correct capacity charts are installed on the telehandler. If provided, reference the Operation & Safety Manual of each attachment or accessory installed for specific inspection, operation and maintenance instructions.

2-131200608

Section 2 - Pre-Operation and Inspection

8. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operational check (see page 2-8) of all systems in an area free of overhead and ground level obstructions. See Section 3 - Controls and Indicators for more specific operating instructions.

WARNING

If telehandler does not operate properly, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use.

2-2 31200608

Section 2 - Pre-Operation and Inspection

OV0091

10135092

DISCONNECT BATTERY

CAUTION

BEFORE SERVICING

10135092

TIRE BALLAST

REQUIRED

REFER TO LUBRICATION SCHEDULE

10124751

FT FT

150

cmcm

160170cm180cm190cm200

10438305

10121319

SHUT DOWN ENGINE

BEFORE ANY SERVICE

DONT BE CARELESS

TIRE BALLAST

REQUIRED

REFER TO LUBRICATION SCHEDULE

10124751

10121319

SHUT DOWN ENGINE

BEFORE ANY SERVICE

DONT BE

CARELESS

TIRE BALLAST

REQUIRED

REFER TO LUBRICATION SCHEDULE

10124751

TIRE BALLAST

REQUIRED

REFER TO LUBRICATION SCHEDULE

10124751

1705883

7301379

7301380

7301379

7301380

HYDRAULIC

OIL ONLY

10120988

HYDRAULIC BREATHER

DO NOT FILL

10139619

DIESEL

FUEL ONLY

CHECK & FILL ON LEVEL GROUND

10120989

10135092

DISCONNECT BATTERY

CAUTION

BEFORE SERVICING

10135092

2.5 GPM

9.5 lpm

MAX

1001109053 REV A

1001109053

DO NOT use Ether or other high energy starting aids.

Engine equipped with Pre-heating system.

ENGINE EXPLOSION could result in death or serious injury.

1706300C

1706300

VIEW A-A

CAB SIDE VIEW OF FRAME

TANK SIDE VIEW OF FRAME

TOP VIEW OF HYDRAULIC

AND FUEL TANKS

VIEW B-B

(IF EQUIPPED WITH CUMMINS ENGINE)

VIEW OF BATTERY BOX

(IF EQUIPPED WITH

JOHN DEERE ENGINE)

2.2 SAFETY DECALS

Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required.

2-331200608

Section 2 - Pre-Operation and Inspection

OV0100

DO NOT OPERATE MACHINE WHEN

LOW BRAKE PRESSURE LIGHT IS ON.

10124906

10167809

Carry load in low position.

CAUTION

10167810

Consult operators manual before using drive lockout override switch.

WARNING

10167808

Stabilizer System Operation

 With boom below 20°, rear axle oscillates freely.  With boom between 20° and 40°:

Transmission is limited to first or second gear.

Rear axle is in restricted oscillation mode. Frame tilt function operates at reduced speed at any boom

angle above 20°.

 With boom above 40°:

Transmission is locked out and rear axle oscillation is locked to frame. Frame tilt function still operates at reduced speed.

 With boom above 40° and foot switch depressed:

Transmission is limited to first gear. Rear axle is in very restricted oscillation mode.

 Fully depressing brake pedal locks rear axle at any boom angle.

10135193

PULL TO APPLY

PUSH TO RELEASE

PARKING BRAKE

10135193

10135082

TRANSMISSION

DECLUTCH

HAZARD LIGHTS

10138460

(IF EQUIPPED)

BEACON

LIGHT

10139648

(IF EQUIPPED)

WORK

LIGHTS

10138409

(IF EQUIPPED)

ROOF WIPER

10139610

(IF EQUIPPED)

10138377

(IF EQUIPPED)

STROBE

LIGHT

WINDSHIELD

WIPER

10138410

(IF EQUIPPED)

ROUND STEER

FRONT WHEEL STEER

OBLIQUE STEER

10112750

10130487

FRAME

TILT LEFT

FRAME

TILT

RIGHT

10135091

FORK TILT DOWN

FORK TILT UP

TRANSFER

AUXILIARY

PRESS AND HOLD BUTTON FOR AUXILIARY FUNCTION

TRANSFER

OUT

AUXILIARY

10135090

BOOM DOWN

BOOM UP

BOOM IN

AUXILIARY

PRESS AND HOLD BUTTON FOR AUXILIARY FUNCTION

BOOM OUT

AUXILIARY

10138929

RAISE LOWER

RIGHT

RAISE LOWER

LEFT

OUTRIGGERS

10438304

102030

110 90

120

100

PRESSURE TEST PORTS

PUMP 1 PUMP 2

LOCK (G1)

REAR OSC. REAR OSC.

LOCK (G2)

BRAKES STEERING PILOT

ACCUM.

10339962

LUBRICATION SCHEDULE.

11. TIRES MUST BE CALCIUM CHLORIDE FILLED! REFER TO

FIND OUT FORK CAPACITY BEFORE USING MACHINE.

10. NEVER LIFT LOADS HEAVIER THAN THE CAPACITY OF THE FORKS.

9. KEEP THE WORK AREA CLEAN OF DEBRIS.

AND IN PLACE.

8. OPERATE ONLY WITH GUARDS AND SAFETY EQUIPMENT FUNCTIONING

MANUFACTURER'S PRIOR WRITTEN APPROVAL.

7. DO NOT MODIFY OR ALTER THIS MACHINE WITHOUT THE

OR MOVING THE MACHINE.

6. EVALUATE GROUND-BEARING CONDITIONS BEFORE MAKING LIFTS

FROM THE CYLINDERS.

THROUGH FULL STROKE IN EACH DIRECTION TO ELIMINATE AIR

TILT-FRAME CYLINDER AND FORK-CARRIAGE TILT CYLINDER

5. TWICE DAILY, WITH THE FORKS NEAR GROUND ELEVATION, CYCLE

MANUAL AND THE LUBRICATION SCHEDULE.

4. SERVICE THE MACHINE AS RECOMMENDED IN THE OPERATOR'S

THIS MACHINE AS A WORK PLATFORM.

3. THIS MACHINE IS NOT EQUIPPED TO LIFT PERSONNEL. NEVER USE

FORKS ABOVE EYE LEVEL MAY CAUSE THE MACHINE TO TIP OVER.

KEPT AT OR BELOW EYE LEVEL POSITION. TRAVELING WITH THE

2. WHEN TRAVELING WITH OR WITHOUT LOADS, THE FORKS MUST BE

KEEP THE OPERATOR'S MANUAL WITH THE MACHINE.

THOROUGHLY FAMILIAR WITH THE OPERATOR'S MANUAL! ALWAYS

1. DO NOT OPERAE THIS MACHINE UNTIL YOU HAVE READ AND ARE

NOTICE

10220963

STOP RAISE LOAD LOWER LOAD

TILT FORKS RIGHT TILT FORKS LEFT TILT FORKS UP

TILT FORKS DOWN MOVE LOAD BACKWARD MOVE LOAD FORWARD

FORKLIFT SIGNALS

INSTRUCTIONS TO SIGNALMAN

1. ONLY ONE PERSON TO BE SIGNALMAN.

2. MAKE SURE THE OPERATOR CAN SEE YOU AND IS ABLE TO ACKNOWLEDGE THE SIGNAL GIVEN.

3. SIGNALMAN MUST WATCH THE LOAD, THE OPERATOR IS WATCHING YOU.

4. NEVER RAISE OR LOWER THE LOAD OVER THE OTHER WORKMEN. WARN THEM TO KEEP OUT OF THE WAY.

5. WATCH FOR OVERHEAD LINES OR OTHER OBSTRUCTIONS.

10239617

1. DO NOT OPERATE THIS MACHINE UNTIL YOU HAVE READ AND ARE THOROUGHLY FAMILIAR WITH THE OPERATOR'S MANUAL! ALWAYS KEEP THE OPERATOR'S MANUAL WITH THE MACHINE.

2. WHEN TRAVELING, FORKS MUST BE AT OR BELOW EYE LEVEL POSITION. NEVER TRAVEL WITH BOOM RAISED. FAILURE TO LOWER BOOM BEFORE TRAVELING COULD CAUSE MACHINE TO TIP AND RESULT IN SERIOUS INJURY OR DEATH.

3. ALWAYS LIFT & CARRY LOADS WITHIN MANUFACTURER'S RECOMMENDED CAPACITY. REFER TO LOAD CHART ON RIGHT SIDE OF OPERATOR'S

4. DO NOT USE THE MACHINE IF MALFUNCTIONING-REPAIR FIRST.

5. FAULTY MAINTENANCE, CARELESSNESS, LACK OF OPERATOR TRAINING, IMPROPER OPERATING PRACTICES, ETC. WILL AFFECT THE SAFETY AND CAPACITY OF THIS MACHINE.

6. ALWAYS LEVEL MACHINE BEFORE LIFTING A LOAD. IF LEVEL INDICATOR IS DAMAGED OR MISSING, REPLACE BEFORE USING MACHINE.

7. DO NOT USED FRAME TILT TO POSITION LOADS-LOWER LOAD TO A SAFE HEIGHT, REPOSITION MACHINE, LEVEL MACHINE AND RELIFT TO NEW POSITION.

8. WATCH FOR OVERHEAD OBSTRUCTIONS BEFORE AND WHILE MAKING A LIFT, ESPECIALLY ELECTRICAL WIRES. SERIOUS INJURY OR DEATH CAN RESULT FROM CONTACT WITH ELECTRICAL WIRES.

COMPARTMENT.

CAUTION

10220964

10139033

CAUTION

OUTRIGGERS PROVIDE A SUBSTANTIAL INCREASE IN STABILITY IF BOOM COAPACITIES ARE EXCEEDED WITH OUTRIGGERS DOWN, STRUCTURAL DAMAGE MAT CCUR BEFORE MACHINE INSTABILITY. CONSULT LOAD CHART FOR RATED CAPACITIES. DO NOT EXCEED RATED LIFT CAPACITIES.

1001103932

LUBRICATE BOOM WEAR PADS AND SLIDE AREAS MONTHLY WITH EP LITHIUM-BASED GREASE OR DRY-FILM LUBRICANT.

P/N 1706502 (A)

79 6

192221133

235423

198132117

24211824

1116

1722

16 10

241514

SERVICE/LUBRICATION SCHEDULE

MODEL 1044C-54 SERIES II

20 20

SEE OTHER SIDE OF THIS CARD FOR ADDITIONAL INFORMATION

SYSTEM CAPACITIES AND PRESSURES

HYDRAULIC RESERVOIR 47 GALS

FUEL TANK 36 GALS

COOLING SYSTEM 18 QTS

ENGINE CRANKCASE  DEERE 4 CYL. 14 QTS

TRANSMISSION  DRAIN/REFILL (APPROX.) 19 QTS

ACCUMULATOR (NITROGEN PRECHARGE)

TIRES  14.00 × 24

PER TIRE

400425 PSI

WET DISK BRAKES

HYDRAULIC SYSTEM & RESERVOIR 65 GALS

PRESSURE 65 PSI HYDRO-FILL TIRES SHOULD BE FILLED TO APPROXIMATELY 75% FULL (55 GALLONS/596LB) OF CALCIUM CHLORIDE TIRE FILL.

FRONT AXLE

DIFFERENTIAL 9.5 QTS

PLANETARY HUB (EACH) 54 OZ

REAR AXLE

DIFFERENTIAL 10.5 QTS

PLANETARY HUB (EACH) 40.5 OZ

APPROXIMATED WEIGHTS:

14.00 x 24 12 PLY SGG RB G2 BIAS BELTED HYDRO-FILLED

925 LBS

FOAM-FILLED

1050 LBS

14.00 x 24 GLA2 STEEL BELTED RADIAL HYDRO-FILLED

1000

LBS

FOAM-FILLED

1125 LBS

= C =

CF = R = CLN =

SHORTEN SERVICE INTERVALS ACCORDINGLY WHEN OPERATING UNDER DUSTY OR SEVERE CONDITIONS.

BOOM PIVOT

HOIST PIVOTS

TILT CYLINDER PIVOTS

INSPECT ALL FLUID SYSTEMS AND CHANGE FLUID WHEN FLUID SHOWS TRACES OF CONTAMINATION OR HIGH TEMPERATURES, EVIDENCED BY STRONG ODOR, DISCOLORATION, OR SEPARATION

QUICK ATTACH PIVOT

OSCILLATION PIVOTS

FRAME TILT CYLINDER

REAR AXLE LOCK CYLINDER

DRIVE SHAFT SLIP

YOKES

TRANSFER ROLLERS

1ENGINE OIL

SEE ENGINE MANUAL

CF*CFC

2ENGINE OIL FILTER R*R

3FUEL FILTER(S)/WATER SEP. RC

4TRANSMISSION FLUID CF*CFC

5TRANSMISSION FILTER R*R

6HYD. RESERVOIR FLUID CFC

7HYD. RETURN FILTER R*RC

8HYD. PRESSURE FILTERR*RC

9HYD. TANK BREATHER

10AIR CLEANER RC

11ENGINE COOLANT CFC

12AXLE DIFFERENTIAL CFC*CF

13PLANETARY HUBS CFC*CF

2 GREASE FITTINGSLUBE

4 GREASE FITTINGSLUBE

6 GREASE FITTINGSLUBE

1 GREASE FITTINGSLUBE

4 GREASE FITTINGSLUBE

2 GREASE FITTINGSLUBE

4 GREASE FITTINGS

LUBE

FIRST HOURS OF OPERATION CHECK, SERVICE AS NECESSARY CHANGE FLUID REPLACE CLEAN CAREFULLY

SEE PARTS BOOK

SEE SERVICE MANUAL

SEE PARTS BOOK

SEE OTHER SIDE OF CARD

LUBE

LUBEOUTRIGGERS

9 GREASE FITTINGS

CHAIN GUIDES LUBE 5 GREASE FITTINGS

SEE ENGINE MANUAL

SEE PARTS BOOK

3 GREASE FITTINGS

SEE SERVICE MANUAL

HOURS OF OPERATION

SEE PARTS BOOK

HYD. CARTRIDGE FILTER

DESCRIPTIONDAILYWEEKLY

50100 2505001000 2000 REMARKS

SEE OTHER SIDE OF CARD

VIEW C-C

VIEW OF DASH PANEL

VIEW OF

JOYSTICK PANEL

CAPACITY

CHARTS

2-4 31200608

Section 2 - Pre-Operation and Inspection

OV0110

10267807

Do not disconnect or bypass proximity switches.

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

See operators manual for instructions.

10267807

10116346

4105262

-10

AB DCEFQRSTU

10239784

VIEW OF TRANSFER CARRIAGE

2-531200608

Section 2 - Pre-Operation and Inspection

OV0080

2.3 WALK-AROUND INSPECTION

Begin your walk-around inspection at item 1, as noted below. Continue to your right (counterclockwise when viewed from top) checking each item in sequence.

INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned. Inspect all structural members including attachment for cracks, excessive corrosion and other damage.

1. Boom Sections and Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders

• Check front, top, side and rear slider pads for presence of grease.

• Pivot pins secure; hydraulic hoses undamaged, not leaking.

2. Left Outrigger leaking.

3. Front Axle hydraulic hoses undamaged, not leaking.

4. Wheel/Tire Assembly nuts. Inspect for worn tread, cuts, tears or other discrepancies.

2-6 31200608

- Steer cylinders undamaged, not leaking; pivot pins secure;

- Pins secure; hydraulic hoses and cylinder undamaged, not

- Properly inflated and secured; no loose or missing lug

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