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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 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, always 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 manual must remain with the machine at all times!
LULL® has made every effort to provide information as complete and accurate as possible for its forklifts. However, because of owner requirements, equipment and control variations may exist between machines. In addition, due to LULL® policy of continually striving to improve its products, occasional discrepancies may exist between machines and the descriptions and information contained herein.
LULL® reserves the right to make changes and improvements to its products at any time without public notice or obligation. LULL® also reserves the right to discontinue manufacturing any product at its discretion at any time.
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.
ii
SAFETY
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 means that a situation COULD be hazardous and MAY result in personal injury if not avoided.
CAUTION is also used to alert against unsafe practices.
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:
The American Society of Mechanical Engineers
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 modifications affecting safe operation or capacity without the expressed written approval of
LULL®.
When LULL® 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.
WARNING
WARNING means that a situation COULD be hazardous and MAY result in serious injury or death if not avoided.
DANGER
DANGER means that a situation IS HAZARDOUS AND WILL result in serious injury or death if not avoided.
ROLL OVER PROTECTIVE 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 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.
Any modification or repair without the specific written approval of LULL INTERNATIONAL, INC. will void the ROPS/FOPS certification. Contact your authorized LULL INTERNATIONAL, INC. dealer before making any modifications or repairs. Failure to do so may void the ROPS/FOPS certification.
1
SAFETY
REFUELING SAFETY
YNever smoke near the machine during refueling.
YDo not permit anyone to be on the machine during refueling.
YSpilled fuel must be completely absorbed or evaporated before starting the engine.
YMake sure the fuel cap is in place before starting the engine.
YNever use an open flame when checking the fuel level in the tank.
YNever fill the fuel tank with the engine running. Make sure you have adequate ventilation during fueling.
OPERATOR QUALIFICATIONS AND TRAINING
YOnly trained and authorized persons should operate and service the machine. To be qualified, you must understand the written instructions supplied by the 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.
YLULL® has produced an operational safety video that is available on VHS tape. This video shows safe operating and maintenance practices for your forklift. Contact your LULL® authorized dealer to obtain a copy of this video.
YDo not operate the machine until you fully understand the function of all controls, indicators and instruments.
YAvoid 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.
YKnow the pinch points and rotating parts on the machine.
YAlways know where to get assistance in case 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
STARTING SAFETY
Before Starting the Engine…
Important: Warn all others in the area that you are going to start the forklift.
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.
2
SAFETY
OPERATION SAFETY
YSafe operation is the responsibility of the operator.
YImproper use of the machine can lead to dangerous situations for yourself, those around you, the machine and the work area. You must have safe working habits and be aware of hazardous working conditions.
YThoroughly read and understand this entire manual. Follow all safety rules and practices explained in this manual.
YThe machine must be checked every day or at the start of each shift. See “Check The Equipment” on page 19.
YTo meet the requirements of different operating conditions, LULL® offers optional lighting 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® dealer for available lighting packages.
YIf 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.
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.
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 operator’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 allow passengers on the machine.
3
SAFETY
Always check clearances under power lines and overhead structures before driving under them.
YDO 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 least 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!
Always check for enough overheard clearance for the boom.
Ensure that correct tire pressure and tire ballast levels are maintained.
Never attempt to discharge a load by stopping the forklift suddenly.
Never lift a load using one fork.
4
SAFETY
Never place loads that exceed scaffold capacity or subject scaffold to unnecessary “shock” loads.
Never stack a load on uneven ground.
Always be aware of load width.
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.
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.
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 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.
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.
Drive slow and carry the load as low as possible.
When Traveling on Roadways…
•Make sure the machine 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 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
SAFETY
Additional Safety Instructions:
•
•
•
•
•
Maneuver the machine carefully. Do not cause the load to shift or the 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 susceptible to tipping over on its side.
•Do not continue to operate the machine if an unsafe condition is 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.
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 operating 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 |
INDICATOR LIGHTS |
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1 |
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2 |
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3 |
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240 |
°F |
280 |
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140 |
115 |
°C |
138 |
320 |
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240 |
WATER |
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FUEL |
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F |
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60 |
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160 |
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190 |
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3/4 |
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P |
160 |
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1/2 |
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TRANS |
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130 |
°F |
1/4 |
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E |
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100 |
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PARK BRAKE |
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80 |
OIL |
16 |
BATT. |
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REAR |
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60 |
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14 |
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BRAKE |
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40 |
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OSC |
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QUARTZ |
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20 |
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12 |
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LOCK |
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psi |
V |
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0 0 0 0 0 |
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0 |
10 |
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1 |
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10 |
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HOURS |
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4 |
5 |
6 |
TRANSMISSION
DECLUTCH
H1042
Gauges
Note: Gauges and indicator lights operate only when the ignition switch is in the ON position.
(1) Engine Water Temperature—Registers from 100 to 240 °F. Normal operating temperature is 180 to 185 °F.
(2)Fuel Level—Shows fuel level in fuel tank.
(3)Transmission Oil Temperature—Registers from 140 to 320 °F with Celsius equivalents. If the temperature rises above 230 °F (110 °C) stop the vehicle immediately, shift to neutral 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 Pressure—Shows operating engine oil pressure. Gauge registers from 0 to 80 PSI. Normal operating pressure is 55 to 60 PSI.
(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.
1 |
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240 °F |
280 |
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140 |
115 |
138 |
320 |
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240 |
WATER |
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FUEL |
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°C |
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F |
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60 |
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160 |
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190 |
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3/4 |
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P |
160 |
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1/2 |
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TRANS |
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1/4 |
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130 |
°F |
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E |
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100 |
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PARK BRAKE |
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80 |
OIL |
16 |
BATT. |
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REAR |
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60 |
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14 |
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BRAKE |
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40 |
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OSC |
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QUARTZ |
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20 |
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12 |
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LOCK |
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psi |
V |
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0 0 0 0 0 |
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0 |
10 |
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1 |
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10 |
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HOURS |
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3 2
TRANSMISSION
DECLUTCH
H1042
Indicator Lights
(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—Red lamp lights and 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 after 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—The rear oscillation lock light will come on when the boom angle is above 40°.
8
INSTRUMENTS AND CONTROLS
IGNITION SWITCH
1 |
H1007 |
Ignition Switch Location
The ignition switch (1) is located on the dash, near the right side.
Note: The starter will not engage unless the shift selector is placed in the NEUTRAL position.
THROTTLE |
H1009 |
Engine Throttle Pedal
Push throttle pedal (1) down to increase engine speed.
|
1 |
BRAKE PEDAL |
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4 |
2 |
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3 |
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H1021 |
Ignition Switch Positions |
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The ignition switch has four positions: |
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H1009 |
(1)OFF: The key may be removed or inserted only at this position. The engine and all electrical circuits except the horn circuit are shut down at this position.
(2)ON: All electrical circuits except the engine starter circuit are operational.
(3)START: Activates the engine starter. When the 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.
Service Brake Pedal
Push brake pedal (2) down to slow or stop machine.
9
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