544D MATERIAL HANDLER OWNER/OPERATOR MANUAL m a t e r i a l h a n d l e r COVERING OPERATION & PERIODIC MAINTENANCE IMPORTANT! Read and understand this Manual and the Gradall Material Handler Safety Manual before starting, operating or performing maintenance procedures on this machine. KEEP OPERATOR AND SAFETY MANUALS IN CAB A ® Company Form No. 20220 COVERS MATERIAL HANDLER MODEL 544D-10 STARTING SERIAL NUMBER 0355001 thru 0455632 & 0160000192 thru 0160003968 excluding 0160003856 ® Part No.
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REVISIONS This page is provided so you may determine that this Manual is complete and current with respect to Gradall Engineering Specifications. Page Cover Form No. 20220 z Date Revision 6/03 Original Issue, replaces Owner/Op Manual 9136-4024 (Form #20047). 01/07 Revised ending serial number.
TABLE OF CONTENTS IMPORTANT SAFETY NOTICE ..................................................... TABLE OF CONTENTS INTRODUCTION General Operator Qualifications Orientation Related Manuals & Decals Serial Number Location NOMENCLATURE SAFETY HIGHLIGHTS ............................................................... DECALS ................................................................................. Decals Inside Cab Decals Outside Cab OPERATORS CAB ..........................................................
INTRODUCTION General This Manual provides important information regarding safe operating and maintenance requirements for GRADALL Material Handlers. If you have any questions regarding the material handler, contact your GRADALL Material Handler Distributor. Operator Qualifications Operators of the material handler must be in good physical and mental condition, have normal reflexes and reaction time, good vision and depth perception and normal hearing.
1.0 SAFETY HIGHLIGHTS Read and understand all manuals and instructional material listed on cover, inside front cover and introduction page of this Manual before starting, operating or performing maintenance procedures on this equipment. Operators of this equipment must have successfully completed a training course in the safe operation of this type of material handling equipment. WATCH FOR THESE SYMBOLS ; THEY CALL YOUR ATTENTION TO SAFETY NOTICES.
1.1 Keep all windows and mirror(s) clean. Adjust mirror(s) as required for maximum visibility, before and during operation. Never permit diesel engine to run out of fuel. Doing so can cause severe engine damage. DO NOT burn or drill holes in forks. Modifying any part of machine or attachment may affect machine capacity and/or stability. Keep head, arms, hands, legs and all other body parts inside the operator’s cab at all times.
DECALS 2.0 INSIDE THE CAB USE CAPACITY CHART FOR SPECIFIC ATTACHMENT ON MACHINE. SA FOR OTHER ATTACHMENTS CONSULT A GRADALL DEALER FOR LOAD RATINGS NOT LISTED. MP LE USE LARGEST NUMBER VISIBLE FROM THE CAB TO DETERMINE BOOM EXTENSION. ON MATCH WITH BOOM ANGLE TO DETERMINE ALLOWABLE LOAD. LY -U FIGURES SHOWN ARE STACKING CAPACITY TRUCK LEVEL.
SAMPLE ONLY - USE CHART IN CAB 2.1 INSIDE THE CAB TRACTION LOCK SWITCH SWITCH LOCATED ON FLOOR. SWITCH HYDRAULICALLY LOCKS FRONT AND REAR WHEELS TOGETHER FOR INCREASED TRACTION. DO NOT ENGAGE WHEN WHEELS ARE IN MOTION OR ON IMPROVED SURFACES. MACHINE MUST BE IN 4 WHEEL DRIVE. TURBOCHARGER DAMAGE CAN RESULT FROM QUICK START-UP & SHUTDOWN. FOR LONGER TURBOCHARGER LIFE AND TO MINIMIZE TURBOCHARGER DAMAGE, IDLE ENGINE AT LEAST 3-5 MINUTES AFTER START-UP AND BEFORE SHUTDOWN.
2.2 INSIDE THE CAB Box 61 NO RIDERS PERMITTED ON HANDLER. OPERATOR ONLY IN MACHINE WHILE RUNNING. RIDERS COULD FALL OFF MACHINE CAUSING SERIOUS INJURY OR DEATH. 9114-3283 Located on left cab wall P/N 9114-3283 SA MP LE SD GRADALL MATER MAX WEIGHT : 2150 MEETS SAE : J1040 MA MEETS ISO : 3471 (94) / 3 MEETS ANSI : B56.6 - 8.
2.3 OUTSIDE THE CAB Located on valve access cover in cab Located on hydraulic reservoir P/N 9108-3492 Genuine Parts HYDRAULIC SYSTEM WHEN REPLACING COOLANT OR IN CASE OF COOLANT LOSS PURGE AIR BY OPENING DE-AERATION PETCOCK WHILE ENGINE IS RUNNING. FILL WITH TRACTOR HYDRAULIC FLUID R or equivalent. For Mobil Product Information, Call 1-800-662-4525.
2.4 OUTSIDE THE CAB COOLING SYSTEM IS PRESSURIZED. REMOVE CAP SLOWLY. HOT FLUID CAN CAUSE BURNS. EXHAUST SYSTEMS CAN BE HOT. KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT. HOT EXHAUST COMPONENTS CAN CAUSE SEVERE BURNS.
2.5 OUTSIDE THE CAB GRADALL HANDLER SERVICE INSTRUCTIONS FOR: 544D-10 SERVICE INTERVALS DAILY OR 10 HRS WEEKLY OR 50 HRS EVERY 5WKS OR 250 HRS 3 MO. OR 500 HRS 6 MO.
3.0 OPERATOR’S CAB OPERATOR’S CAB The standard cab permits vision from all sides and includes an overhead guard to provide protection from falling objects. A fully-enclosed cab with windows and a lockable door is available as an option. The top half of the cab door must be secured in the fully-opened or closed position. The bottom half of the cab door can be secured in the closed position only. Be sure the door is fully secured when operating the handler.
3.1 Accelerator Pedal: Depress pedal to increase speed and release pedal to decrease speed. Alternator Indicator Light: Glows (red) to indicate alternator is not charging. Attachment Tilt Lever: This lever controls tilt of the fork carriage. Speed is proportional to lever actuation and engine RPM. Push lever forward to tilt down; pull lever back to tilt up. Attachment Tilt Switch (optional): Depress front of switch to tilt down; depress rear of switch to tilt up.
3.2 Parking Brake Indicator Light: Glows (red) to indicate brake is applied. Rotating Beacon Switch (optional): This switch controls operation of rotating beacon. Seat Lock Release Lever: This lever unlocks and locks seat position adjustment. Service Brake/Inching Travel Pedal: This pedal operates the service brakes on the front axle. It also permits slow travel speed while engine speed is kept high for other handler functions. The further the pedal is depressed, the slower the travel speed.
4.0 CHECKS & SERVICES BEFORE STARTING ENGINE To be performed at the beginning of each work shift. • If spark arrestors are required, be sure they are in place and in good working order. • Check to be certain that windows and mirror(s) are clean and undamaged. Also make certain that mirror(s) are properly adjusted for operator’s view. ! WARNING Use extreme caution when checking items beyond your normal reach. Use an approved safety ladder.
5.0 WARM-UP & OPERATIONAL CHECKS To be performed at beginning of each work shift. The safety, efficiency and service life of your handler will be increased by performing the operational checks listed below. If any of the items in the following checks are not operating properly, have them repaired prior to the machine being placed into service. Items preceded by an asterisk (*) are optional and may not be furnished on a standard machine. Before entering the operator’s cab, check: 1.
6.0 ENGINE OPERATION Starting the Engine 1. Make sure all controls are in “Neutral” and all electrical components (lights, heater, defroster, etc.) are turned off. Set parking brake. 2. Depress accelerator pedal approximately 1/4 to 1/3 of travel from top. 3. Turn ignition switch to “START” to engage starting motor. Release key 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.
6.1 Normal Engine Operation Observe gauges frequently to be sure all engine systems are functioning properly. The voltmeter shows the “charge/discharge” state of the battery charging system. With the engine running, meter should indicate 13.5 to 14 volts. With engine stopped, meter indicates battery charge (12 volts). The alternator indicator light glows (red) to indicate alternator is not charging. ! CAUTION Always keep engine cover closed while engine is running.
7.0 BRAKE SYSTEM General The brake system includes a service brake and a parking brake. Service and parking brakes are applied through wet disc brake packs located within axle housing. Because service braking and “inching” (slow travel) functions overlap, some features of inching will be discussed here. See “Drive Train” Section, Page 10.0, for additional information on inching travel.
8.0 PARKING THE HANDLER Precautions • Avoid parking on slopes or near an excavation. • Park on level ground and chock wheels. • Avoid parking on roads or highways. If it cannot be avoided,be sure to display warning flags during day and flares or flashing lights at night. • Position boom-head or attachment on ground; never leave machine with boom in air. • If parking on a slope cannot be avoided, position the handler at a right angle across the slope, straighten rear wheels and chock all wheels.
10.0 DRIVE TRAIN General The Material Handler covered by this Manual is equipped with hydrostatic drive. From the operator’s standpoint, operation is similar to driving a vehicle equipped with an automatic transmission. Major components of the system include a front drive axle with a differential and planetaries. The differential receives torque from a variable-displacement piston pump and a motor.
11.0 LEVELING THE HANDLER “Leveling” means positioning the handler so that it is level from side to side (left to right). A level indicator is located in the upper right corner of front window frame to permit operator to determine whether handler frame level.
11.1 Leveling Procedure: 1. Position machine in best location to lift or place load and apply parking brake. 2. Observe level indicator to determine whether machine must be leveled. Note position of indicator for later realignment. 3. If necessary to level handler, position boom in carry position and level machine with the lever. 4. Lift or place load as appropriate. 5. Retract and lower boom to carry position. 6. Realign frame to position noted in step 2.
12.0 OPERATING PROCEDURE & TECHNIQUES Hydraulic Controls All boom and attachment movements are governed by hydraulic controls. Rapid, jerky operation of hydraulic controls will cause rapid, jerky movement of the load. Such movements can cause the load to shift or fall or may cause the machine to tip over. Feathering Feathering is a control operation technique used for smooth operation.
12.1 Rated Capacity Chart The rated capacity chart, located on dashboard, indicates maximum load capacities for handlers equipped with GRADALL-furnished carriage/fork combination. These capacities apply to standard carriage/fork combinations except as stated on the capacity chart. Figure 12-3 60' STABILIZERS DOWN 56' 16' B DO NOT TIP THE MACHINE FORWARD TO DETERMINE ALLOWABLE LOAD.
12.2 Items needed to Use a Capacity Chart There are five items you must know and/or have in order to properly use a Capacity Chart: 1. 2. 3. 4. 5. The weight of the load to be lifted The angle of the boom How much boom extension will be needed The proper Capacity Chart A Gradall-approved Attachment Every Gradall attachment comes with its own Identification Plate. This Plate has the Attachment Serial Number, Part Number, Attachment Capacity and Attachment Weight stamped on it.
12.3 Figure 12-4 Where to look on the machine. BOOM ANGLE INDICATOR BOOM EXTENSION NUMBER ATTACHMENT IDENTIFICATION PLATE H UB T OR Q UE R FORK WEIGHT STAMP MACHINE SERIAL NUMBER PLATE Figure 12-5 Description of items on a Capacity Chart. Capacity Chart Part No.
13.0 ATTACHMENTS Approved Attachments Although the carriage/fork combination is most frequently used, several other GRADALL-approved attachments are available for use with your material handler. Contact your GRADALL Material Handler Distributor for information on approved attachments designed to solve special material handling problems. The serial number plate lists attachments approved for use with your handler. However, there may be additional approved attachments available.
13.1 Attachment Installation ! WARNING This installation procedure is designed for one-man operation. If a helper is involved, shut off the engine before proceeding to steps 4, 5, and 6. 1. Retract Quick Switch™ (attachment tilt lever forward) to provide clearance. Check to be sure lock pin is secured in out position with retainer pin. 2. Align boom head pivot with recess in attachment. Raise boom slightly to engage boom head pivot in recess. 3. Engage Quick Switch™ (attachment tilt lever backward). 4.
13.2 Fork Positioner Capacity: Maximum load capacity for fork positioner carriage is the same as standard carriage without fork positioner. Refer to Attachment Capacity Chart. Capacity varies with boom extension and elevation positions. Controls: Figure 13-1 AUXILIARY CONTROL LEVER OPEN FORKS CLOSE FORKS The auxiliary control lever is used to adjust fork position. Pull lever back to close forks, push lever forward to open forks. Installation Procedure: 1.
13.3 Operation: • Raise or lower boom to appropriate height for loading material from stockpile. • Align handler with face of stockpile and drive slowly and smoothly into pile to load bucket. Do not corner-load bucket. • Tilt bucket up far enough to retain load and back away from pile. • Lower bucket to carry position 4 feet (1.2m) or less above ground and travel carefully to unloading point. Turn bucket down to dump load. Mast (6' [1.8m] with 4’ [1.2m] or 6’ [1.
13.4 Attachment Tilt Controls: Figure 13-4 SWING LEFT AUXILIARY CONTROL LEVER SWING RIGHT forward The carriage tilt cylinder is used to tilt the swing forks up and down and the carriage tilt lever controls fork tilt. The auxiliary control lever is used to swing the forks to the left and right. Pull lever back to swing forks right; push lever to swing forks left. Installation Procedure: 1. Remove carriage/fork combination or other attachment from boom head. (See Page 13.1) 2.
13.5 • Tilt carriage to left or right to align forks with load and engage load. • Raise load slightly and then level carriage. • Travel with load lowered to travel position 4 feet (1.2m) or less above ground. Boom Head-Mounted Winch Capacity: The boom head-mounted winch maximum load capacity is shown on the standard carriage capacity chart. However, maximum capacity may be used only in areas where it does not exceed capacities shown on standard carriage/ fork capacity chart (located on dashboard).
13.6 Truss Boom & Truss Boom with Winch Capacity: Maximum capacity for the truss boom (with or without winch) is shown on attachment serial number plate. However, maximum lift capacity applies only to certain areas within boom extension/elevation pattern of handler/truss boom combination. A separate capacity chart must be used for handlers equipped with truss boom. Study and understand this chart before attempting to handle a load with truss boom.
13.7 • Open clamps at heel of truss boom far enough to clear load and tilt truss boom up until truss/bundle contacts heel of truss boom. • Close clamps to hold load lightly and secure clamps. • Transport load to delivery site and attach tag lines if load will be freely suspended. Swing Mast Capacity: Maximum lift capacity is shown on attachment serial number plate. However, maximum lift capacity applies only to certain areas within boom extension/ elevation pattern of handler/swing mast combination.
13.8 Personnel Work Platform The material handler operator and personnel in the platform must read and understand the separate personnel work platform manual, included with the attachment, prior to using the platform. Capacity: The Gradall personnel work platform is designed to carry a maximum of 3 occupants. The load includes personnel, materials, tools, etc. The maximum capacity of your work platform is based on specific model material handler/ work platform combination.
14.0 OBTAINING HYDRAULIC OIL SAMPLE 1. Operate unit until hydraulic oil reaches normal operating temperature. 2. Apply parking brake, lower boom to ground and shift Forward/Reverse lever to “Neutral.” Observe Hydraulic Filter Bypass Indicator with engine running at full throttle. Replace filter elements if necessary. 3. Obtain a container to receive waste oil and a CLEAN container to receive oil sample. 4.
15.0 LOADING & SECURING FOR TRANSPORT Loading & Securing Handler For Transport 1. Level the material handler prior to loading. 2. Using a spotter, load the handler with boom as low as possible to keep a low center of gravity. 3. Once loaded, apply parking brake and lower boom until boom or attachment is resting on deck. Move all controls to “Neutral,” stop engine and remove ignition key. ! WARNING Before loading handler for transport, make sure deck, ramps and handler wheels are free of mud, snow and ice.
16.0 MOVING HANDLER IN EMERGENCY The following information assumes the handler cannot be moved under its own power. Before moving the handler, read all of the following information to understand options available. Then select the appropriate method. The ability to steer the handler increases the safety of moving the unit in some situations. The steering system permits manual steering if engine or power assist feature fails.
16.1 TO RELEASE PARKING BRAKE MERITOR AXLE 1. Position unit on level ground, lower attachment to approximately one foot (.3m) from ground, move forward/reverse lever to “Neutral,” apply parking brake and stop engine. 2. Block all wheels to prevent inadvertent movement. Figure 16-2 RELEASE SCREW GUIDE PIN A A SPACER RELEASE SCREW SECTION A A 3. Working one side at a time, remove three release screws and spacers from side of differential housing (located at 12 o’clock, 4 o’clock and 8 o’clock). 4.
16.2 CARRARO AXLE 1. If possible position unit on level ground lower attachment to approximately one foot from ground, move forward/reverse lever to “Neutral”, apply parking brake and stop engine. 2. Block all wheels to prevent inadvertent movement. RELEASE SCREW (12 o’clock position) Figure 16-3 FRONT OF MACHINE RELEASE SCREW (4 o’clock position) RELEASE SCREW (8 o’clock position) 3.
E AG P IS TH T LEF Y ALL N TIO N E INT K.
17.
17.1 LUBRICATION & ROUTINE MAINTENANCE SYMBOLS = Lube Fitting = Other Service * = Service Both Sides Figure 17-2 2 3 4 1* 19* 5* 6 7 8* 9 10 11 12 13 14 20 8* 15* 16* 17* 18* 21 22 Lubrication Symbols AF CC CL DF EO HF HM - ANTI-FREEZE (permanent) COOLANT CONDITIONER CHAIN LUBE DIESEL FUEL ENGINE FUEL HYDRAULIC FLUID MOLY LUBE (extreme pressure) IMPORTANT NOTICE Be certain to check extend chain adjustment every 5 weeks or 250 hours and adjust as required.
! CAUTION Service intervals are based on machine usage of 1500 hours annually. Use of your unit may vary significantly and you must adjust service frequency for your usage to obtain maximum service life. Frequency headings in the following schedule indicate a calendar limit and an operating hour limit. Perform service at whichever interval occurs first. Lube No. of Symbol Points Daily or Shift (10 hour Maximum) Lubrication & Maintenance 9.
17.2 RECOMMENDED LUBRICANTS & CAPACITIES APPLICATION SYMBOL WHEN USED GRADE SPECIFICATION Boom Chain Adj. Threads HM (extreme pres. moly lube) All Year - 1440-3323 - - Boom Slide Bearing Paths HM (extreme pres. moly lube) All Year NLGI #2 1440-4595 - - Boom Extend Chains CL (chain lube) All Year - 1440-4751 Coolant Conditioner (Deere Only) CC (supplemental coolant additive) All Year - - 0.5 qts 0.
BOOM 17.3 CHECKING & ADJUSTING BOOM CHAINS Boom is extended by a cylinder and a set of chains within the boom. For more detailed information, including boom chain checks and adjustments, see the appropriate Service Manual. STABILIZER Stabilizers are furnished as standard equipment on all 544D-10 Material Handlers. Use stabilizers to increase stability and/or load capacity and in leveling the handler before picking or delivering a load.
18.
HAND SIGNALS Standard Signals - When handler work conditions require hand signals, they shall be provided or posted conspicuously for the use of both signalman and operator. No handler motions shall be made unless signals are clearly understood by both signalman and operator. Special Signals - When signals for auxiliary equipment functions or conditions not covered are required, they shall be agreed upon in advance by the operator and signalman.
CALIFORNIA Proposition 65 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. CALIFORNIA Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. 406 Mill Ave.
