Lull OmniQuip 644D-34 Owner's manual

Part No. 68998A Rev. AC T99062

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CONTENTS
Section Page No.
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY..............................................................1
INSTRUMENTSANDCONTROLS.........................................8
BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GENERAL OPERATING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE/LUBRICATIONSCHEDULEMODEL644D-34......................22
SAMPLE LOAD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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.
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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 Lull “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.
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 International, Inc. 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.
HIGHLANDER™is a trademark of and , LULL®are registered trademarks of Lull International, Inc.,
3045 Highway 13, St. Paul, MN 55121.
Copyright © 1997 Lull International, Inc.,St. Paul, MN. All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any
means (electronic, mechanical, recording, photocopy, or otherwise) without prior written permission from the
copyright holder.
IMPORTANT
This operators manual must remain with the machine at all times!
Should it become damaged or lost, immediately contact any authorized Lull International, Inc.
dealer or contact the Lull Service Parts Department at [phone] for replacement.
Lull also recommends that the engine manufacturer’s operators manual be kept with the machine.
Failure to follow engine manufacturer’s recommendations may affect engine warranty.
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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.
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.
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 International, Inc.
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.
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
dealer before making any modifications or repairs.
FailuretodosomayvoidtheROPS/FOPScertification.
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SAFETY
REFUELING SAFETY
Never smoke near the machine during refueling.
Donotpermitanyonetobeonthemachineduring
refueling.
Spilled fuel must be cleaned up, 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 fuel
level in the tank.
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 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.
Lull has produced an operational safety video that
is available on VHS tape. This video shows safe
operating and maintenance practices for your
forklift. A copy this video is shipped with each new
machine. You can also contact your Lull
authorized dealer to obtain a copy.
Do not operate the machine until you fully
understand the function of all controls, indicators
and instruments.
PERSONAL SAFETY
Wear all the protective clothing and personal safety
devices issued to you or called for by job conditions.
You may need…
WA hard hat
WSafety shoes
WSafety glasses, goggles, or face shield
WHeavy gloves
WHearing protection
WReflective clothing
WWet weather gear
WRespirator or filter mask
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 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:
WGround and surface conditions.
WSurface grade.
WWeight and configuration of the attachment.
WImproper tire inflation.
WOperator judgement.
WExcessive tilting of the fork carriage or other
attachmentswithanelevatedloadcancause
machine instability. The amount of allowable tilt is
governed by conditions such as boom elevation,
weight of load, and terrain.
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.

SAFETY
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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 working habits and be aware of
hazardous working conditions.
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 16.
To 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.
If 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…
WBring the machine to a full stop.
WApply the park brake.
WLower the boom.
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Before Leaving the Machine Unattended…
WStop the engine.
WBlock the wheels if parked on an incline.
WLower 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
operatoris25feetormorefromthemachineandthe
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.
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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 least 50
feet away from power lines. Contacting electrical
power lines WILL result in serious personal injury
or death!
Always check for enough overheard clearance for the
boom.
Ensure that correct tire pressure levels are maintained.
Never attempt to discharge a load by stopping the
forklift suddenly.
Never lift a load using one fork.
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KEEP ALL PARTS OF
MACHINE AT LEAST 50
FEET FROM POWER
LINES. CONTACTING
ENERGIZED POWER
LINES WILL CAUSE
SERIOUS PERSONAL
INJURY OR DEATH!
DANGER
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SAFETY
5
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.
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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 know the weight of a load and always check
the load charts before picking up a load.
Never add unauthorized counterweights.
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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…
WTilt the attachment back and raised only
enough to clear the ground.
WAvoid turning. If it cannot be avoided, turn
slowly and with extreme caution.
WTravel straight up and down grades.
WWhen loaded and traveling up or down
grades, travel only with the load uphill.
WWhen unloaded, travel only with the forks or
attachment downhill.
WProceed slowly and with extreme caution.
WDo not travel across excessively steep
slopes.
The machine can be levelled side to-side a total of 10°
in each direction (18% 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…
WMake sure the machine is equipped with all
necessary lights and safety signs required
for traveling on roadways.
WObserve all traffic laws and speed limits.
WKeep to the correct side of the roadway.
WKeep a safe distance from other vehicles.
WMaintain control of the machine at all times.
WYield the right-of-way to pedestrians and
emergency vehicles.
WDo not pass another vehicle at intersections,
blind spots, or other dangerous locations.
WAvoid running over loose objects and debris.
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