JLG GRADALL 544D-10 Operation & Safety Manual Download

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Operation & Safety

Manual

Keep this manual with machine at all times.

An Oshkosh Corporation Company

Model

544D-10

S/N 0160003969 & After

including 0160003856

31200172

Revised

January 14, 2009

Summary of Contents for GRADALL 544D-10

Page 1: ...Operation Safety Manual Keep this manual with machine at all times An Oshkosh Corporation Company Model 544D 10 S N 0160003969 After including 0160003856 31200172 Revised January 14 2009...

Page 2: ...ead 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...

Page 3: ...a 31200172 Revision Log REVISION LOG January 8 2007 A Original Issue of Manual November 25 2008 B Revised covers and pages c 2 3 2 4 3 4 3 9 3 10 3 11 7 8 and Transfer of Ownership January 14 2009 C R...

Page 4: ...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...

Page 5: ...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 Re...

Page 6: ...Illustrated Parts Manual 91364001 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...

Page 7: ...8 Driving Hazards on Slopes 1 9 Pinch Points and Crush Hazards 1 10 Fall Hazard 1 12 Chemical Hazards 1 13 Section 2 Pre Operation and Inspection 2 1 Pre Operation Check and Inspection 2 1 2 2 Safety...

Page 8: ...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 Lev...

Page 9: ...ion 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 Section...

Page 10: ...iv 31200172 Section 8 Additional Checks Section 9 Specifications 9 1 Product Specifications 9 1 Fluid and Lubrication Capacities 9 1 Tires 9 2 Performance 9 3 Dimensions 9 4 Index Inspection Maintenan...

Page 11: ...dicates 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...

Page 12: ...ctrical 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 co...

Page 13: ...lehandler 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 unles...

Page 14: ...ications 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...

Page 15: ...l rigging slings etc must be included as part of load Start travel turn and stop slowly to prevent load from swinging When driving with the boom raised DO NOT exceed walking speed Beware of wind Wind...

Page 16: ...n 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 vi...

Page 17: ...afety Practices 1 7 31200172 Load Falling Hazard Never suspend load from forks or other parts of carriage DO NOT burn or drill holes in fork s Forks must be centered under load and spaced apart as far...

Page 18: ...ices 1 8 31200172 Lifting Personnel When lifting personnel USE ONLY a JLG approved personnel work platform with proper capacity chart displayed in the cab DO NOT drive machine from cab when personnel...

Page 19: ...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...

Page 20: ...inch 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 object...

Page 21: ...fety Practices 1 11 31200172 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 OW0240 O...

Page 22: ...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 pa...

Page 23: ...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...

Page 24: ...Section 1 General Safety Practices 1 14 31200172 This Page Intentionally Left Blank...

Page 25: ...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 f...

Page 26: ...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 op...

Page 27: ...R CLEANER ELEMENTS FUEL FILTERS OIL FILTER OIL 12 QT DIESEL FUEL 38 GAL HYD TANK BREATHER FILTER CAP QUICK SWITCH 1 FITTING TIRES RADIAL 70 PSI FRONT AXLE PIVOT 2 FITTINGS ALL BEARINGS PADS HEAD PIN 2...

Page 28: ...SYSTEM IS PRESSURIZED REMOVE CAP SLOWLY HOT FLUID CAN CAUSE BURNS 91083492 BEFORE S N 0160036260 1706300 S N 0160036260 AFTER 91143282 9114 3282 STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNI...

Page 29: ...8060 3037 A PINCH POINT KEEP OUT REACHING INTO BOOM HOLES AND OTHER PINCH POINTS CAN CAUSE SERIOUS INJURY OR DEATH 4105262 91143282 9114 3282 STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING B...

Page 30: ...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 E...

Page 31: ...n tread cuts tears or other discrepancies 9 Stabilizer Cylinder Pins secure hydraulic hoses undamaged not leaking 10 Rear Axle Steer cylinders undamaged not leaking pivot pins secure hydraulic hoses u...

Page 32: ...en engine warms perform an operational check 1 Service brake and parking brake operation 2 Forward and reverse travel 3 Steering in both directions with engine at low idle 4 Horn and back up alarm Mus...

Page 33: ...sed ROPS FOPS cab WARNING Never operate telehandler unless the overhead guard and cab structure are in good condition Any modification to this machine must be approved by JLG to assure compliance with...

Page 34: ...Cab Door Window if equipped Cab door 1 must be closed during operation During operation the cab door window 2 must either be latched open or closed Open the cab door window and secure it in the latch...

Page 35: ...l functions Note The manufacturer has no direct control over machine application and operation The user and operator are responsible for conforming with good safety practices NOTICE EQUIPMENT DAMAGE W...

Page 36: ...ice Brake Inching Travel Pedal Operates service brakes on front axle Permits slow travel speed while engine speed is kept high for other telehandler functions The further the pedal is depressed the sl...

Page 37: ...rive motors Rear drive motors are engaged for four wheel drive 7 Park Brake Switch See page 3 6 for details 8 Auxiliary Electrics Switches if equipped Enables functions of attachments that require aux...

Page 38: ...ches if equipped Enables functions of attachments that require auxiliary electrics See Section 5 Attachments for approved attachments and control instructions 20 4x4 Indicator Illuminates when four wh...

Page 39: ...ge is available for all electrical functions Full clockwise rotation to START engages starter motor Counter clockwise rotation to OFF stops engine and removes voltage from all electrical functions OX0...

Page 40: ...sing service brake stop telehandler in an appropriate parking area 2 Follow Shut Down Procedure on page 4 4 WARNING MACHINE ROLL AWAY HAZARD Always move park brake switch to ON position lower boom to...

Page 41: ...will automatically sound Drive in reverse and turn only at slow rates of speed Do not increase engine speed with the transmission in forward or reverse and the service brake depressed in an attempt t...

Page 42: ...easing engine speed will also increase function speed For two simultaneous boom functions move the joystick between quadrants For example moving the joystick forward and to the left will lower and ret...

Page 43: ...k to rotate frame right A level indicator is located above the front cab window to permit operator to determine whether the telehandler frame is level Auxiliary Hydraulics if equipped The auxiliary hy...

Page 44: ...evers back to raise outriggers Use outriggers to increase stability and or load capacity and in leveling the telehandler Study capacity charts to determine maximum load capacities with and without out...

Page 45: ...ght to rotate frame right A level indicator is located in the upper front window frame to permit operator to determine whether the telehandler frame is level Attachment Tilt if equipped Move joystick...

Page 46: ...Two speed fan Press fan switch down for slow speed press switch up for fast speed Return switch to middle position to turn off 2 Heater Fan Switch On Off switch OX0234 ALT 4X2 OFF 0 0 0 0 0 0 QUARTZ D...

Page 47: ...ng engine adjust seat for position and comfort Before S N 0160016097 1 Fore Aft Pull up on handle to move seat fore and aft 2 Seat Belt Always fasten seat belt during operation If required a 3 in 76 m...

Page 48: ...ropriate setting Turn clockwise to increase stiffness Turn counterclockwise to reduce stiffness 2 Fore Aft Pull up on handle to move seat fore and aft 3 Arm Rest Arm rest can be moved up or down for c...

Page 49: ...ngled 2 With back straight in the seat couple the retractable end male end of the belt into the receptacle buckle end of the belt 3 With belt buckle positioned as low on the body as possible pull the...

Page 50: ...oom Use this indicator to determine the boom angle when using the capacity chart see Use of the Capacity Chart on page 5 4 Boom extension indicators 2 are located on the left side of the boom Use thes...

Page 51: ...immediately when engine starts If engine fails to start within 20 seconds release key and allow starting motor to cool for a few minutes before trying again 4 After engine starts observe oil pressure...

Page 52: ...matically injected if needed to keep engine running A second battery is added for additional cold cranking capacity Cummins Engine Cummins engines are equipped with preheat for cold weather starting R...

Page 53: ...onnect the negative jumper cable to negative post on booster battery Connect opposite end of negative jumper cable to ground point on machine away from discharged battery Follow standard starting proc...

Page 54: ...n to your supervisor or maintenance personnel Avoid prolonged idling If the engine is not being used turn it off Shut Down Procedure When parking the telehandler park in a safe location on flat level...

Page 55: ...f the terrain Adjust travel speed and reduce amount of load if conditions warrant Avoid lifting double tiered loads Make sure load is clear of any adjacent obstacles Adjust spacing of forks so they en...

Page 56: ...no more than 11 8 in 300 mm above ground surface 4 Observe level indicator to determine whether machine must be leveled prior to lifting load Level machine with frame level joystick see page 3 9 or p...

Page 57: ...then extend boom slowly until load is just above area where it is to be placed Lower the boom until the load rests in position and the forks are free to retract Disengaging a Load Once the load has be...

Page 58: ...warrant Avoid lifting double tiered loads Make sure load is clear of any adjacent obstacles NEVER operate telehandler without a proper and legible capacity chart in the operator cab for the telehandl...

Page 59: ...in visual contact with the operator at all times Never place the guide men between the suspended load and the telehandler Only transport the load at walking speed 0 9 mph 0 4 m s or less Leveling Proc...

Page 60: ...e 5 4 Align load at the level load is to be placed then position boom slowly until load is just above area where it is to be placed Ensure that the guide men and operator remain in constant communicat...

Page 61: ...e 5 Do not tie down front of boom Note The user assumes all responsibility for choosing the proper method of transportation and tie down devices making sure the equipment used is capable of supporting...

Page 62: ...evice and equipment to ensure the machine will be level when elevated The machine must remain level at all times while being lifted Ensure that the lifting device and equipment is adequately rated and...

Page 63: ...wered attachments that require auxiliary electrics must only be used on machines equipped with auxiliary hydraulics and electrics S N 0160037689 After The attachment type weight dimensions and load ce...

Page 64: ...be established An overextended or overloaded telehandler can tip over with little or no warning and cause serious injury or death to the operator and or those working nearby The ability of a non appro...

Page 65: ...3 Total attachment capacity is multiplied by the number of forks on the attachment if equipped up to the maximum capacity of the attachment Maximum capacity as indicated on the proper capacity chart...

Page 66: ...is to be placed 5 On the Capacity Chart find the line for the height and follow it over to the distance 6 The number in the load zone where the two cross is the maximum capacity for this lift If the t...

Page 67: ...Section 5 Attachments 5 5 31200172 This Page Intentionally Left Blank...

Page 68: ...E WITH 1234 5678 48 CARRIAGE 8765 4321 72 CARRIAGE RATED CAPACITY 2 FT LOAD CENTER 48 44 40 36 32 28 24 20 16 12 8 4 0 4 8 1 2 3 4 5 6 69 60 50 40 30 20 10 0 6 9 0 0 0 L B S 7 0 0 0 L B S 6 0 0 0 L B...

Page 69: ...y the proper capacity chart on telehandlers equipped with outriggers refer to the following icons which may be located on the capacity chart Use when lifting a load with outriggers up Use when lifting...

Page 70: ...XXXXXX 30 50 XXXXXXXXXX X ANSI ITSDF B56 6 2005 X X X X L B S X X X X L B S L X X X X B S L X X X X B S X X X X B L S XXXX S LB 4 0 10 20 40 60 71 1 2 3 4 5 6 7 8 9 10 XXXX XX MAX XX XX XXXX XX MAX XX...

Page 71: ...ntify the proper load chart on telehandlers equipped with outriggers refer to the following icons which may be located on the load chart Use when lifting a load with outriggers up Use when lifting a l...

Page 72: ...xx and corresponds with machine configuration being used Below are examples with various conditions the contractor may encounter and whether or not the load may be lifted Note This is a sample capacit...

Page 73: ...witch attachment tilt control in cab see page 3 8 WARNING CRUSH HAZARD Always be certain that carriage or attachment is properly positioned on boom and is secured by lock pin and retainer pin Failure...

Page 74: ...n 2 Align attachment pin with recess in attachment Raise boom slightly to engage attachment pin in recess 3 Tilt quick switch forward to engage attachment 4 Remove retainer pin and slide lock pin in f...

Page 75: ...removed 2 Align attachment pin with recess in attachment Raise boom slightly to engage attachment pin in recess 3 Tilt quick switch forward to engage attachment 4 Lift retainer pin and insert lock pi...

Page 76: ...Operated Attachment 1 Install attachment see page 5 11 2 Lower attachment to ground and perform Shut Down Procedure on page 4 4 3 Connect attachment hoses to both auxiliary fittings 2 OX0740 2 OY1720...

Page 77: ...nt Installation on page 5 11 2 Elevate attachment to approximately 5 ft 1 5 m and tilt carriage forward until fork heel is free from attachment 3 Stand at the side of the carriage To slide fork toward...

Page 78: ...nce right hand attachment tilt and left hand auxiliary hydraulics controls Refer to pages 3 9 or 3 11 if equipped with a different configuration NOTICE EQUIPMENT DAMAGE Some attachments may contact th...

Page 79: ...Section 5 Attachments 5 17 31200172 This Page Intentionally Left Blank...

Page 80: ...Pallet 2x6x72 in Before S N 0160037689 90553018 Fork Pallet 2x6x72 in Before S N 0160037689 91123132 Drywall Carriage 66 in Before S N 0160037689 90455053 Carriage 50 in Before S N 0160037689 1170020...

Page 81: ...tilt Move lever back to tilt up Move lever forward to tilt down Installation Procedure Refer to Attachment Installation on page 5 11 Equipment Damage Precautions Do not use forks as a lever to pry ma...

Page 82: ...let 2x4x48 in Before S N 0160037689 90453002 Fork Pallet 2 25x4x48 in Before S N 0160037689 90453048 Fork Pallet 2 36x5x48 in S N 0160037689 After 2340038 Fork Pallet 2x6x48 in Before S N 0160037689 9...

Page 83: ...centered on load and stop telehandler Level telehandler before side tilting carriage to engage load Side tilt carriage to left or right to align forks with load and engage load Raise load slightly and...

Page 84: ...002 Fork Pallet 2 25x4x48 in Before S N 0160037689 90453048 Fork Pallet 2 36x5x48 in S N 0160037689 After 2340038 Fork Pallet 2x6x48 in Before S N 0160037689 90553005 Fork Dual Taper 1 75x7x60 in S N...

Page 85: ...Section 1 General Safety Practices Equipment Damage Precautions Do not use forks as a lever to pry material Excessive prying forces could damage forks or machine structure Do not attempt to lift loads...

Page 86: ...let 2 25x4x48 in Before S N 0160037689 90453048 Fork Pallet 2 36x5x48 in S N 0160037689 After 2340038 Fork Pallet 2x6x48 in Before S N 0160037689 90553005 Fork Dual Taper 1 75x7x60 in S N 0160037689 A...

Page 87: ...ge 5 11 Operation Always lower forks fully in mast before engaging load To drive with a load lower forks fully in mast and travel in accordance with the requirements set forth in Section 1 General Saf...

Page 88: ...ls lift lower and extend retract movement of the boom The tilt lever 2 controls the mast tilt Move lever back to tilt up Move lever forward to tilt down To Swing Pull Swing Switch 5 located on dash pa...

Page 89: ...t and position forks straight ahead before engaging load To drive with a load lower forks fully in mast keep forks pointed forward and travel in accordance with the requirements set forth in Section 1...

Page 90: ...y Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls the...

Page 91: ...fully in mast and travel in accordance with the requirements set forth in Section 1 General Safety Practices Use a signal person to assist in positioning load if necessary Equipment Damage Precaution...

Page 92: ...requirements set forth in Section 1 General Safety Practices The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls the fork mounted hook tilt Move lever...

Page 93: ...rating must be used Do not use with cubing or block forks Weight of fork mounted hook and rigging must be included as part of total load being lifted Do not use fork mounted hook with attachments cap...

Page 94: ...et forth in Section 1 General Safety Practices The joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls the fork mounted hook tilt Move lever back to tilt u...

Page 95: ...priate load rating must be used Do not use with cubing or block forks Weight of rigging must be included as part of total load being lifted Do not use fork mounted hook with attachments capable of rot...

Page 96: ...opriate Truss Boom Attachment Capacity Chart To determine maximum capacity refer to Telehandler Attachment Fork Capacity on page 5 3 Suspend loads in accordance with requirements set forth in Section...

Page 97: ...1200172 Installation Procedure Refer to Attachment Installation on page 5 11 WARNING CRUSH HAZARD Maintain a minimum of three wraps of wire rope on the cable drum at all times Failure to comply could...

Page 98: ...00823 Bucket 102 in 2 0 yd3 S N 0160037689 After 1001100824 Concrete Hopper 0 75 yd3 Before S N 0160037689 91123115 Use Appropriate Bucket Capacity Chart To determine maximum capacity refer to Telehan...

Page 99: ...Equipment Damage Precautions Except for lifting or dumping a load the boom must be fully retracted for all bucket operations Do not corner load bucket Distribute material evenly within the bucket Buck...

Page 100: ...he joystick 1 controls lift lower and extend retract movement of the boom The tilt lever 2 controls grapple bucket tilt Move lever back to tilt up Move lever forward to tilt down To open close grapple...

Page 101: ...ucket down to dump load Equipment Damage Precautions Except for lifting or dumping a load the boom must be fully retracted for all bucket operations Do not corner load bucket Distribute material evenl...

Page 102: ...in accordance with requirements set forth in Section 1 General Safety Practices The joystick 1 controls lift lower and extend retract movement of the boom The auxiliary hydraulic lever 3 controls the...

Page 103: ...ollow installation procedure on page 5 11 for JLG quick switch mounted personnel work platforms 2 Ensure the telehandler is on a firm surface and is level 3 Engage the park brake Blocking the wheels i...

Page 104: ...apacity on page 5 3 The operator and personnel in platform must read and understand the separate personnel work platform manual prior to installing and using a platform The joystick 1 controls lift lo...

Page 105: ...atform both side to side frame level and front to back attachment tilt 4 Keep area under platform free from personnel 5 When personnel are on platform the operator must remain seated in cab with perso...

Page 106: ...Section 5 Attachments 5 44 31200172 This Page Intentionally Left Blank...

Page 107: ...devices The steering system permits manual steering if engine or power assist feature fails however steering will be slow and will require much greater force DO NOT attempt to tow a telehandler that...

Page 108: ...ons Secure the telehandler using the following procedures 1 Clear the area around telehandler of all personnel 2 Engage the parking brake Place the transmission control lever in NEUTRAL 3 Block all fo...

Page 109: ...instructions that must be followed to keep this product in good operating condition The Operation Safety Manual and Service Manual contain more detailed service information with specific instructions...

Page 110: ...ight coating of engine oil to all linkage pivot points Intervals shown are for normal usage and conditions Adjust intervals for abnormal usage and conditions Drain engine and gear cases after operatin...

Page 111: ...ydraulic Return Filter Indicator Check Hydraulic Oil Level Air Filter Restriction Indicator Check Fuel Level Check Engine Oil Level 10 EVERY Check Tire Condition Pressure Change Front Axle Oil Change...

Page 112: ...ter Check Front Axle Oil Level Check Front Rear Wheel End Oil Levels Air Filter Vacuator Valve Check Fan Belt Check Boom Wear Pads Check Rear Axle Stabilization Lubrication Schedule 500 EVERY Check Bo...

Page 113: ...aintenance 7 5 31200172 1000 1500 Hour Maintenance Schedule OY1042 1500 EVERY Change Engine Coolant Change Hydraulic Fluid Filters 1000 EVERY Change Front Axle Oil Change Front Rear Wheel End Oil Chan...

Page 114: ...Section 7 Lubrication and Maintenance 7 6 31200172 7 4 LUBRICATION SCHEDULES 50 Hour Lubrication Schedule MX0052 EVERY 50 R...

Page 115: ...Section 7 Lubrication and Maintenance 7 7 31200172 250 Hour Lubrication Schedule MX0072 EVERY 250 R...

Page 116: ...er neck 4 Add diesel fuel as needed 5 Replace and secure fuel tank cap Note Replenish diesel fuel at end of each work shift to minimize condensation NOTICE EQUIPMENT DAMAGE Do not allow machine to run...

Page 117: ...re on page 4 4 2 Open the engine cover 3 Loosen drain cock 4 on underside of fuel filter 5 and allow all water to drain into a glass until clear fuel is visible 4 Tighten drain cock 5 Close and secure...

Page 118: ...eck restriction indicator 2 If red band is visible filter s must be replaced 3 Remove dust from vacuator valve 3 by squeezing bottom of valve to allow loose particles to fall out Note Only remove cani...

Page 119: ...and vacuator valve 4 Replace inner safety element 7 after every third primary element change If replacing the inner safety element at this time carefully slide the element out and replace with new ele...

Page 120: ...n the engine cover remove oil fill cap 4 and add motor oil to bring oil up to the full mark in the crosshatch area 4 Replace oil fill cap and dipstick 5 Close and secure the engine cover Note The stan...

Page 121: ...4 4 3 Check level of hydraulic oil at the sight gauge 6 on the hydraulic tank 5 The oil level should be visible in the gauge window 4 If hydraulic oil is low open the tank cover and remove oil fill ca...

Page 122: ...move the product from service immediately Arrangements must be made for replacement of the tire or tire assembly For polyurethane foam filled tires when any of the following are discovered measures mu...

Page 123: ...imensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load Unless specifically approved by JLG do not replace a foam fille...

Page 124: ...al tread pattern arrows facing in the direction of forward travel 1 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 2 Tighten lug nuts in an alternating pat...

Page 125: ...emperature 3 Have an assistant open the tank cover 4 With the engine at full throttle and the assistant observing the indicator 2 located on the hydraulic return filter 1 extend and retract the boom 1...

Page 126: ...emove cap 1 Check coolant level in radiator Cummins Check coolant level in overflow bottle 2 When coolant is hot bottle should be 1 2 to 3 4 full When coolant is cool bottle should be 1 4 to 1 2 full...

Page 127: ...ocedure on page 4 4 2 Remove the front cover 3 Wearing eye protection visually inspect the battery 3 Check terminals for corrosion Replace battery if it has a cracked melted or damaged case 4 Replace...

Page 128: ...Section 7 Lubrication and Maintenance 7 20 31200172 This Page Intentionally Left Blank...

Page 129: ...Section 8 Additional Checks 8 1 31200172 SECTION 8 ADDITIONAL CHECKS This Page Intentionally Left Blank...

Page 130: ...Section 8 Additional Checks 8 2 31200172 This Page Intentionally Left Blank...

Page 131: ...ype of Fuel 2 Diesel Cooling System System Capacity John Deere Engine 24 8 quarts 23 5 liters Cummins Engine 22 quarts 20 8 liters Type of Coolant 50 50 ethylene glycol water Hydraulic System System C...

Page 132: ...b 283 kg Foam Approx 720 lb 327 kg 14 00 x 24 G 2 L 2 Radial 1 Star Pneumatic 70 psi 4 8 bar Water and Calcium Chloride Approx 623 lb 283 kg Foam Approx 720 lb 327 kg 14 00 x 24 G 3 L 3 Bias Ply Rock...

Page 133: ...ged 4 000 lb 1814 kg Maximum Forward Reach 42 ft 12 8 m Capacity at Maximum Forward Reach Outriggers Engaged Before S N 0160037689 3 000 lb 1361 kg S N 0160037689 After 2 400 lb 1089 kg Outriggers Not...

Page 134: ...4816 mm Overall Length less Forks 241 3 in 6129 mm Ground Clearance 20 8 in 528 mm Outside Turning Radius 175 in 4445 mm Maximum Gross Vehicle Weight no attachment 33 779 lb 15 322 kg Maximum Front A...

Page 135: ...em 9 1 D Decals 2 3 Dimensions 9 4 Disengaging a Load 4 7 Disengaging a Suspended Load 4 10 Driving Hazards on Slopes 1 9 E Electrical Hazards 1 2 Emergency Exit from Enclosed Cab 6 2 Emergency Loweri...

Page 136: ...lacing a Suspended Load 4 10 Pre Operation Check and Inspection 2 1 R Restriction Indicator 7 10 Return Filter Indicator 7 17 S Safety Decals 2 3 Safety Practices 1 1 Safety Signal Words 1 1 Seat Belt...

Page 137: ...Inspection Maintenance and Repair Log Serial Number ______________________________ Date Comments Inspection Maintenance and Repair Log...

Page 138: ...Inspection Maintenance and Repair Log Date Comments...

Page 139: ...rented units should not be included on this form Mfg Model _______________________________________________________________ Serial Number ____________________________________________________________ Pr...

Page 140: ......

Page 141: ...osed point thumb upward LOWER BOOM With either arm extended horizontally fingers closed point thumb downward MOVE SLOWLY Place one hand motionless in front of hand giving motion signal Raise load slow...

Page 142: ...hl Germany Phone 49 0 421 69 350 20 Fax 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong Phone 852 2639 5783 Fax 852 2639 5797 JLG Indu...

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JLG GRADALL 544D-10, Operation & Safety Manual

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