Safety Decals - JLG 544D-10 Operation & Safety Manual

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.
Model
Serial Number
Maximum Weight Without Attachments (lbs/kg) Maximim Capacity (lbs/kg)*
Refer to load capacity chart for truck with attachment, and individual load ratings stamped
on forks, if equipped. Use lowest capacity of all rattings.
As released from factory this truck meets design specifications in ASME B56.6-2002 Part III
One or more of the following patents may apply to this truck: U.S. Nos. 4,954,041 6,349,969
5,639,119 5,813,697 5,230,399 5,052,532. Other patents pending.
Manufactured by
JLG Industries Inc.
McConnellsburg, PA
17233-9533 USA
1705882
(S/N 0160003969
thru 0160035922)
THE PROTECTION OFFERED BY THIS ROPS
WILL BE IMPAIRED IF IT HAS BEEN
SUBJECTED TO ANY MODIFICATION,
STRUCTURAL DAMAGE, OR HAS BEEN
INVOLVED IN AN OVERTURN INCIDENT. THIS
ROPS MUST BE REPLACED AFTER A ROLL -
OVER. SEAT BELTS MUST BE WORN WHILE
OPERATING VEHICLE.
91164094
READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.
WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM.
WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN CAB WITH PERSONNEL
OPERATE CONTROLS LIGHTLY AND CAUTIOUSLY WHEN LIFTING PERSONNEL.
READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL BEFORE LIFTING PERSONNEL.
DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL
HANDLER/PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN CAB.
31200172
Section 2 - Pre-Operation and Inspection
Year of Manufacture
1705882
1705881
(S/N 0160036260
& After)
A
A
000850
90553027
DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.
IN DIRECT LINE OF SIGHT.
FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.
9055-3027 REV. A
91363142
JLG HANDLER
SERVICE INTERVALS
SERVICE INSTRUCTIONS
DAILY WEEKLY EVERY 3 MO. 6 MO. ANNUALLY
FOR: 544D-10 OR OR 5WKS OR OR OR TYPE OR
OR EQUIVALENT
10 HRS 50 HRS 250 HRS 500 HRS 1000 HRS 1500 HRS
DIESEL ENGINE
AIR CLEANER ELEMENTS - - - - - - - - - - - - - - - * * - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
FUEL FILTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHANGE - - - - - - - - - - - -
OIL FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHANGE - - - - - - - - - - - - - - - - - - -
OIL (12 QT.) - - - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - CHANGE - - - - - - - - - - - - - - - - - - - SAE 15W-40-CD ***
DIESEL FUEL #2
DIESEL FUEL (38 GAL.) - - - - - - - - - - - - - - - FILL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MOBIL 424
OIL (47 GAL.) - - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - INSPECT - - - - - - CHANGE
FILTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHANGE
HYD.TANK BREATHER/FILTER CAP - - - - - - - - - - - - - - - - - - - CHECK - - - - - - CHANGE - - - - - -
FRONT AXLE
(5 GAL) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - MOBIL 424
REAR AXLE WHEEL END LUBE(4 PT.) - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - MOBIL 424
WHEEL NUT TORQUE-350/400 FT-LBS - - - - - - - - - - - - - - - - - - - - - - - - TORQUE - - - - - - - - - - - -
BATTERY & TERMINALS - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - - - - - - -
RADIATOR
3 GAL. WATER ETHYLENE GLYCOL
3 GAL ANTI-FREEZE - - - - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - - - - - - - ANTI-FREEZE
TIRES: 13.00x24(12 PLY) 65 PSI - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - - - - - - -
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
TIRES: 14.00x24(12 PLY) 65 PSI CHECK
TIRES: RADIAL 70 PSI - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - - - - - - -
CYLINDER FITTINGS EACH END - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - MYSTIK TETRIMOLY
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
REAR AXLE (12) FITTINGS GREASE MYSTIK TETRIMOLY
FRONT AXLE PIVOT (2) FITTINGS - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - MYSTIK TETRIMOLY
ALL BEARINGS PADS - - - - - - - - - - - - - - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - MYSTIK TETRIMOLY
FRONT BOTTOM BEARING PADS - - - - - - - - - - - - - - GREASE CHECK - - - - - - - - - - - - - - - - - - - MYSTIK TETRIMOLY
BOOM PIVOT (2) FITTINGS - - - - - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - MYSTIK TETRIMOLY
HEAD PIN (2) FITTINGS - - - - - - - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - MYSTIK TETRIMOLY
BOOM SHEAVES (3) FITTINGS - - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - MYSTIK TETRIMOLY
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
QUICK SWITCH (1) FITTING GREASE MYSTIK TETRIMOLY
RETRACT & EXTEND CABLE - - - - - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - -
SEE OPERATOR & MAINTENANCE MANUAL
THIS CHART MUST BE USED IN CONJUNCTION WITH SERVICE MANUAL AND RECOMMENDED PROCEDURE.
* CHECK INDICATOR ON HYDRAULIC FILTER. CHANGE FILTER IF NEEDLE IS IN YELLOW
AT FULL THROTTLE & AT OPERATING TEMPERATURE.
* * CHECK AIR CLEANER RESTRICTION INDICATOR. CLEAN OR CHANGE PRIMARY FILTER IF NECESSARY.
SAFETY ELEMENT TO BE CHANGED EVERY 3RD CHANGE OF PRIMARY FILTER ELEMENT.
* * * CONSULT DEALER FOR RECOMMENDATIONS AT EXTREME TEMPERATURES.
* * * *
DAILY SERVICE MAY BE REQUIRED FOR OPTIMUM LIFE DEPENDING UPON APPLICATION SEVERITY.
IT IS RECOMMENDED THAT FILTER ELEMENTS AND FRONT AXLE LUBRICANT BE CHANGED AFTER
FIRST 50 HRS ON NEW OR REBUILT UNITS.
9136-3142 REV -
NO RIDERS PERMITTED ON HANDLER.
OPERATOR ONLY IN MACHINE
WHILE RUNNING.
RIDERS COULD FALL OFF MACHINE
CAUSING SERIOUS INJURY OR DEATH.
9114-3283
91143283
80603022
AVOID HIGH VOLTAGE LINES.
IT IS UNLAWFUL TO PLACE
ANY PART OF THIS MACHINE
OR LOAD WITHIN 10 FEET
OF HIGH VOLTAGE LINES
UP TO 50,000 VOLTS.
DEATH OR INJURY MAY
RESULT FROM CONTACTING
ELECTRIC LINES.
VIEW A-A
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
CAUSE SERIOUS INJURY OR DEATH.
9114-3282
91143282
91303047
9130-3047
FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF
SERIOUS INJURY, READ AND OBSERVE THE FOLLOWING:
1. ONLY TRAINED AND AUTHORIZED PERSONNEL MAY 7. WHEN TRAVELING WITH LOAD, FULLY RETRACT BOOM AND 15. BEFORE ADJUSTING OR SERVICING, PLACE
OPERATE THIS MACHINE. PLACE FORKS IN CARRY POSITION (APPROX.12" ABOVE FORWARD/REVERSE LEVER IN NEUTRAL, REST BOOM ON
GROUND). TILT CARRIAGE BACK SLIGHTLY TO CRADLE GROUND OR SUPPORT, SET PARKING BRAKE, SHUT OFF
2. BEFORE OPERATING, READ AND UNDERSTAND ALL CAPACITY LOAD. USE EXTREME CAUTION WHEN TURNING. ENGINE AND CHOCK WHEELS.
CHARTS, OPERATOR MANUALS AND SAFETY MANUALS. IF
MANUALS ARE NOT AVAILABLE, CONSULT AN AUTHORIZED 8. ON INCLINES, TRAVEL WITH LOAD UP-GRADE. 16. BEFORE LEAVING MACHINE UNATTENDED, PLACE
JLG DEALER. UNDERSTAND ALL CONTROLS IN CAB AND FORWARD/REVERSE LEVER IN NEUTRAL, LOWER BOOM,
9. DO NOT USE BOOM AS WALKWAY.
CHECK FOR PROPER OPERATION. CLEAR LOOSE OBJECTS SET PARKING BRAKE,AND SHUT-OFF ENGINE. CHOCK
OFF MACHINE AND SOUND HORN BEFORE STARTING ENGINE. WHEELS IF MACHINE MUST PARK ON AN INCLINE.
10. USE TWO HANDS WHEN CLIMBING ON MACHINE.
3. OPERATOR MUST BE SEATED WITH SEAT BELT FASTENED. 17. LEVEL MACHINE BEFORE LIFTING ANY LOAD ABOVE 4
11. USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK
ASSURE FORWARD/REVERSE LEVER IS IN NEUTRAL,PARK FEET. (IF EQUIPPED WITH FRAME LEVELING).
PLATFORM FOR LIFTING PERSONNEL. NO RIDERS ON MACHINE,
BRAKE APPLIED AND ALL HYDRAULIC CONTROLS ARE IN
FORKS, LOAD, OR OTHER LIFTING ATTACHMENTS AT ANY 18. OPERATOR PROTECTION (SUCH AS HARD HATS, SAFETY
NEUTRAL BEFORE IGNITION SWITCH IS TURNED ON.
TIME. DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE GLASSES, AND/OR HEARING PROTECTION) SHOULD BE
4. DO NOT OPERATE MACHINE WITHOUT PROPER CAPACITY PROPER GRADALL MATERIAL HANDLER/PERSONNEL WORK WORN WHEN JOB CONDITIONS WARRANT. ALWAYS USE
CHART IN PLACE. PLATFORM CAPACITY CHART DISPLAYED IN THE CAB. DO NOT SEAT BELT.
DRIVE MACHINE WITH PERSONNEL IN PLATFORM.
19. IMPROPER USE OF MACHINE COULD RESULT IN MACHINE
5. BEFORE MOVING, BE SURE OF A CLEAR PATH AND SOUND
12. KEEP OTHERS AWAY FROM MACHINE WHILE OPERATING. TIPPING OVER. IF MACHINE STARTS TO TIP OVER, DO
HORN. WATCH FOR PEDESTRIANS AND OBSTRUCTIONS.
DO NOT STAND UNDER BOOM OR LOAD. NOT LEAVE OPERATORS SEAT. LEAN AWAY FROM TIP &
CHECK OVERHEAD AND SIDE CLEARANCES. ALWAYS LOOK
IN DIRECTION OF TRAVEL. BRACE YOURSELF.
13. USE EXTREME CARE WHEN HANDLING LONG, HIGH, OR
WIDE LOADS. DO NOT HANDLE UNSTABLE OR LOOSELY
6. START, TURN, AND BRAKE SMOOTHLY. REDUCE TRAVEL 20. KEEP MIRROR(S) CLEAN AND PROPERLY ADJUSTED.
STACKED LOADS. OBJECTS IN MIRROR ARE CLOSER THAN THEY APPEAR.
SPEEDS FOR TURNS, SLIPPERY, OR UNEVEN SURFACES.
AVOID RUNNING OVER LOOSE OBJECTS OR HOLES IN THE 14. FORKS TO BE CENTERED UNDER LOAD AND SPACED APART
ROADWAY SURFACE.
AS FAR AS POSSIBLE.
90553028
8060-3022
9055-3028 REV. A
2-3