Lull 644B Operation Manual
Operators and Safety Manual
Model
644B
10709799
May 1997
ANSI
CONTENTS
Section Page No.
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
INSTRUMENTS AND CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9
GENERAL OPERATING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FLUID AND LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SERVICE/LUBRICATION SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SAMPLE LOAD CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SAFETY ALERT SYMBOL
This Safety Alert Symbol means:
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
When you see this symbol, be alert to the possibility of personal
injury or death. Follow the instructions in the safety message.
Three Reasons Why Safety is Important to You:
1. Accidents disable and kill.
2. Accidents cost.
3. Accidents can be avoided.
W1027
i
INTRODUCTION
INTRODUCTION
You are about to operate one of the finest forklifts available on the market today. To ensure that your forklift will
provide years of safe dependable service, only trained and authorized persons should operate and service the
forklift. It is the responsibility of the operator to read, fully understand and follow all operational and safety related
instructions contained in this manual. Do not operate the forklift until you have read and fully understand these
instructions. Remember, al ways use good safety practices to protect yourself and those around you.
REGISTRATION
The Warranty Registration card must be filled out by the dealer and returned to the
“Warranty Administrator” indicating the date the machine went into
service. The Pre-Delivery Inspection Form must be signed by the customer when the machine is delivered.
IMPORTANT
This operators man ual must remain with the machine at all times!
®
LULL
However, because of owner requirements, equipment and control variations may exist between machines. I n
addition, due to LULL
between machines and the descriptions and information contained herein.
LULL
obligation. LULL
Copyright © 1997 LULL INTERNATIONAL, INC., St. Paul, MN. All rights reserved. This document may
not be duplicated, including electronic digitization, in whole or in part without the expressed written consent of
LULL INTERNATIONAL, INC.
has made every effort to provide information as complete and accurate as possible for its forklifts.
®
policy of continually st ri ving to improve its products, occasional discrepancies may exist
®
reserves the right to make changes and improvements to its products at any time without public notice or
®
also reserves the right to discontinue manufacturing any product at its discretion at any time.
ii
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. For a copy of this standard write to:
W
CAUTION, WARNING, & DANGER:
WHAT THEY MEAN
Hazards are identified by the “Safety Alert Symbol” and
followed by a signal word: Caution, Warning, or Danger.
CAUTION
CAUTION
hazardous an d MAY result in persona l injury if
not avoided.
CAUTION
practices.
means that a situation COULD be
is also used to alert against unsafe
The American Society of Mechanica l Engine ers
United Engineering Center
345 East 47th Street
New York, NY 10017
DECALS
The decals on the machine provide instructions for safe
and correct operation.
Never make modif ications affecting safe operation or
capacity without the expressed written approval of
LULL
When LULL
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.
®
.
®
approved modifications are made, the
ROLL OVER PROTECTIVE
WARNING
W ARNING
hazardous and M AY result in ser ious inj ury or
death if not avoided.
means that a situation COULD be
DANGER
DANGER
means that a situation
HAZARDOUS AND WILL
injury or death if not avoided.
IS
result in serious
STRUCTURE (ROPS) &
FALLING OBJECT PROTECTIVE
STRUCTURE (FOPS)
This machine is equipped with a Roll-Over Protective
Structure (ROPS) to guard the operator if the machine
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 f rom 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 mount ing
brackets, will affect the ROPS/FOPS capability to
provide the required protection.
Any modification or repair without the specific written
approval of LULL INTERNATIONAL, INC.
will void the ROPS/FOPS certif ic at io n. Contact your
authorized LULL INTERNATIONAL, INC.
dealer before making any modifications or repairs.
Failure to do so may v oid the ROPS/FOPS certification.
1
SAFETY
REFUELING SAFETY
Never smoke near the machine during refueling.
Do not permit anyone to be on the machine 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 f uel
level in the ta nk .
Never fill the fuel tank with the engine running.
Make sure you have adequate ventilation during
fueling.
OPERATOR QUALIFICATIONS AND
TRAINING
Only trained and authorized persons should
operate and service the mac hine. To be qualified,
you must understand the written instructions
supplied by t he manufacturer, have training
(including actual operation of this machine) and
know the safety rules and regulations for the
jobsite. A self-training course available from the
Mason Contractors Association of America is
highly recommended.
LULL
video that i s available on VHS tape. Thi s video
shows safe operating and maintenance prac tices
for your forklift. Contact your LULL
dealer to obtain a copy of this video.
Do not operate the machine until you fully
understand the function of all controls, indicators
and instruments.
®
has produced an operational safety
®
authorized
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.
Know the pinch points and rotating parts on the
machine.
Always know where to get assistance in ca se of
an emergency. Know how to use a first aid kit and
fire extinguisher.
MACHINE STABILITY
Your LULL® rough terrain forklift 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
machine instability. The amount of allowable tilt is
governed by conditions such as boom elevation,
weight of load, and terrain.
PERSONAL SAFETY
Wear all the protective clothing and personal safety
devices issued to you or called for by job conditions.
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
2
STARTING SAFETY
Before Starting the Engine…
Important:
1. Check underneath and around the machine and
make sure all personnel are clear.
2. Be properly seated.
3. Set the park brake.
4. Make sure shift selector is locked in the
NEUTRAL position.
5. Apply the brakes.
Warn all others in the area that you are
going to start the forklift.
SAFETY
OPERATION SAFETY
Safe operation is the responsibility of the operator.
Improper use of the machine can lead to
dangerous situations for yourself, those around
you, the machine and the work area. You must
have safe worki ng habits and be aware of
hazardous working c onditions.
Thoroughly read and understand this entire
manual. Follow all safety rules and practices
explained in this manual.
The machine must be checked every day or at the
start of each shift. See “Check The Equipment” on
page 19.
To meet the requirements of different operating
conditions, LULL
packages for your machine. Do not operate the
machine if it is not equipped with lights when
conditions require them. If your machine is not
equipped with the proper lights, contact your
authorized LULL
packages.
If operating in an enclosed or partially enclosed
environment, make sure there is enough
ventilation. Engine exhaust fumes can be deadl y
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.
®
offers optional lighting
®
dealer for available lighting
Before Leaving the Machine Unattended…
•
Stop the engine.
•
Block the wheels if parked on an incline.
•
Lower the boom.
The machine is considered “attended” when the
operator is less than 25 feet from the machine and it
remains in the operat or’s view.
The machine is considered “unattended” when the
operator is 25 feet or more from the machine and the
machine is in the operator’s view, or whenever the
machine is not in the operator’s view.
Never stand or walk under a raised boom. Do not allow
others to do so.
Never operate the machine 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 machine to a full stop.
•
Apply the park brake.
•
Lower the boom.
Never allow passengers on the machine.
3
SAFETY
Always check clearances under power lines and
overhead structures before driving under them.
DO NOT operate the machine 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 machine at leas t 50
feet away from power lines. Contacting electrical
power lines WILL result in serious personal injury
or death!
DANGER
KEEP ALL PARTS OF
MACHINE AT LEAST 50
FEET FROM POWER
LINES. CONTACTING
ENERGIZED POWER
LINES WILL CAUSE
SERIOUS PERSONAL
INJURY OR DEATH!
Ensure that correct tire pressure and tire ballast levels
are maintained.
Never attempt to discharge a load by stopping the
forklift suddenly.
Always check for enough overheard clearance for the
boom.
4
Never lift a load using one fork.
Never place loads that exceed scaffold capacity or
subject scaffold to unnecessary “shock” loads.
SAFETY
Drive carefully and avoid sudden stops and changes of
direction.
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.
Always be aware of load width.
Always check the load charts before picking up a load.
Never add unauthorized counterweights.
5
SAFETY
Always pick up the load at its center of gravity.
The machine can be levelled side to-side a total of
12.5° in each direction (22% 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 raised only
enough to clear the ground.
•
Avoid turning. If it cannot be avoided, turn
slowly and with ext reme caution.
•
Travel straight up and down grades.
•
When loaded and traveling up or down
grades, travel only with the load uphill.
•
When unloaded, tr avel only with the forks or
attachment downhill.
•
Proceed slowly and with extreme caution.
•
Do not travel across excessively steep
slopes.
Drive slow and carry the load as low as possible.
When Traveling on Roadways…
•
Make sure the machi ne is equipped with all
necessary lights and safety signs required
for traveling on roadways.
•
Observe all t ra ffic law s and spe e d limits.
•
Keep to the correct side of the roadway.
•
Keep a safe dist ance from other vehicles.
•
Maintain control of the machine 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.
6
Additional Safety Instructions:
•
Maneuver the machine carefully. Do not cause t he
load to shift or t he machine 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 machine is more suscept ible to tipping over on
its side.
•
Do not continue to operate the machine if an
unsafe condition i s found. Stop the machine 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,
especially when in or around structures.
SAFETY
•
Never reach into the boom or attachments.
•
Understand the limitations of the machine and
drive safely.
•
Watch for pedestrians, especially when backing up
or turning and where pedestrians may step into the
path of the machine.
•
The machine 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 machine
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 operat ing on ramps, platforms,
trenches, and other similar surfaces.
•
Keep a clear view of the terrain and where the
machine is heading. Watch out for other vehicles,
people, and structures.
•
If the load blocks your forward view, then carefully
travel in reverse and use a signalman to guide you
if necessary.
•
Do not block access to fire lanes or fire equipment.
7
INSTRUMENTS AND CONTROLS
GAUGES
REAR
OSC
LOCK
P
PARK BRAKE
BRAKE
1
240
190
160
130
100
80
60
40
20
0
2
WATER FUEL
°F
OIL BATT.
psi
F
3/4
1/2
1/4
E
16
14
12
10
V
5
TRANSMISSION
DECLUTCH
Gauges
Note: Gauges and indicat or lights operate only when
the ignition switch is in the ON position.
(1)Engine Water Temperature
100 to 240 ° F. Normal operating temperature is
180 to 185 °F.
(2)
Fuel Level
(3)
Transmission Oil Temperature
from 140 to 320 °F with Celsius equivalents. If
the temperature rises above 230 °F (1 10 °C) stop
the vehicle immediately, shift to ne utral and run
the engine at half throttle. The temperature
should drop quickly. If the temperature does not
drop, shut off engine and investigate.
(4)
Engine Oil Pressu re
oil pressure. Gauge registers from 0 to 80 PSI .
Normal operating pressure is 55 to 60 PSI.
—Shows fuel level in fuel tank.
—Shows operating engine
3
°F
280
240
115
138
140
°C
160
60
TRANS
QUARTZ
0000
0
HOURS
64
H1042
—Registers fro m
—Registers
320
1
10
INDICATOR LIGHT S
1
WATER FUEL
240
190
160
130
°F
100
OIL BATT.
80
60
40
20
psi
0
TRANSMISSION
DECLUTCH
REAR
OSC
LOCK
3
P
PARK BRAKE
BRAKE
2
Indicat or Li gh t s
(1)
Park Brake
—Red lamp lights to show when park
brake is applied and goes out when park brake is
released.
(2)
Low Brake Pressure
buzzer sounds when service brake hydraulic
system pressure drops below the safe operating
level. Under normal conditions, the light and
buzzer will go out quickly aft er engine start. If the
light or buzzer does not go out or comes on
during machine operation, shut off engine
immediately, investigate, and repair before
operating. Do not operate machine when low
brake pressure light or buzzer is on.
(3)
Rear Oscillation Lock
light will come on when the boom angle i s above
40°.
F
3/4
1/2
1/4
E
16
14
12
V
10
—Red lamp lights and
—The rear oscillation lock
140
60
TRANS
0000
240
115
QUARTZ
HOURS
°F
280
138
320
°C
160
1
10
0
H1042
(5)
Voltmeter
—Indicates system voltage. Gauge
registers from 10 to 16 volts. Normal operating
voltage range is 14.5 to 15 volts. With ignition in
ON position and engine off, battery voltage is
indicated. This should normally be 12.6 volts.
(6)
Hourmeter
—
Registers total hours of machine
operation.
8
INSTRUMENTS AND CONTROLS
H1009
H1009
IGNITION SWITCH
Ignition Swit c h Loc a tion
(1)
The ignition switch
right side.
is located on the dash, near the
Note: The starter will not engage unless the shift
selector is placed in the NEUTRAL position.
THROTTLE
1
H1007
Engine Throttle Pedal
Push throttle pedal
(1)
down to increase engine speed.
1
4
2
3
Ignition Switch Posi tions
The ignition switch has four positions:
(1)
(2)
: The key may be removed or inserted only
OFF
at this position. The engine and all electrical
circuits except the horn circuit are shut down at
this position.
: All electrical circuits except the engine
ON
starter circuit are operational.
H1021
BRAKE PEDAL
Service Brak e Pedal
Push brake pedal
(2)
down to slow or stop machine.
(3)
START
key is released the switch will return to the ON
position and remain there.
(4)
This position is reserved for future use and
currently has no function.
: Activates the engine starter. When the
9
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