Lull 644E-42 Operation Manual

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Page 1

OWNERS/OPERATORS MANUAL

Model 644E-42

(S/N 0160003878 thru 0160037404)

MU0501

Keep this manual with the vehicle at all times.

Printed in U.S.A. 3/09

3120038 B

Page 2

WARNING: Improper operation of this vehicle can

cause injury or death. Only trained and authorized operators should operate this vehicle.

Before starting the engine, do the following:

1. Read this owner/operators manual.

2. Read all the safety decals on the vehicle.

3. Clear the area of other persons.

Learn and practice safe use of vehicle controls in a safe, clear area before you operate this vehicle on a worksite.

It is your responsibility to observe applicable laws and regulations and to follow manufacturer's instructions on vehicle operation and maintenance.

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

Page 3

Introduction

The Manual....................................2

Replacement Parts........................2

Reports..........................................2

Disclaimer......................................3

Safety Practices

Hazard Classification System........3

Accident Prevention Tags..............5

New or Additional Operators .........5

Instructional Symbols ....................6

Instructional Symbols (cont’d) .......7

Hazard Symbols ............................8

Avoidance Symbols.......................9

Avoidance Symbols (cont’d)........10

Avoidance Symbols (cont’d)........11

Personal Considerations .............12

Operational Considerations.........15

Equipment Considerations ..........20

Operation

Pre-Operation Inspection.............23

Operator Controls........................26

Front Dash Panel.........................48

Optional Features........................55

Carriages.....................................66

Indicators.....................................68

Fork Rating..................................70

Using the Capacity Chart.............71

Stabil-TRAK System....................74

Stabil-TRAK™ System Test........77

Refueling .....................................83

Normal Starting............................85

Cold Starting................................86

Jump Starting ..............................87

How To Pick, Carry & Place A

Load..........................................88

Elevating Personnel.....................89

Using Other Attachments ............93

Shut-Off .......................................95

Emergency Operations

Towing a Disabled Vehicle..........96

Emergency Boom Lowering ........98

General Maintenance

Introduction................................104

Maintenance Schedule and

Checklist.................................105

1. Lubrication Points.............106

2. Air Cleaner .......................107

3. Optional Closed Cab Air

Filters ................................109

4. Engine Cooling System.....110

5. Engine Oil and Filter..........114

6. Engine Fuel System..........118

7. Engine Fan Belt.................123

8. Air Conditioner Compressor

Belt (Optional) ...................124

9. Hydraulic Oil and Filter......125

10. Transmission Oil and

Filter ..................................128

11. Transfer Case Oil..............131

12. Axle Oil..............................133

13. Brake Disc Inspection .......135

14. Wheel End Oil ...................138

15. Wheels and Tires ..............140

16. Battery...............................142

17. Fuse & Relay

Replacement.....................143

18. Boom Chains and Wear

Pads..................................149

19. Transfer Carriage Rollers and

Wear Pads ........................162

Storage and Transport ..............169

Storage......................................169

Transport...................................170

Test Procedures

Parking Brake/Transmission

De-Clutch Test Procedures....171

Specifications

Fluid & Lubrication Capacities...173

Tires ..........................................174

Weights .....................................174

Vehicle Dimensions...................175

Electrical System.......................176

Engine.......................................176

Index.............................................177

Load Charts Accident Prevention Tags

 2004 JLG Industries, Inc.

Page 4

Introduction

The Manual

This Owners/Operators Manual provides the information you need to operate and maintain this vehicle.

IMPORTANT! Before carefully so you will understand the instructions and the operation of the controls and equipment. You must comply with all Danger, Warning, and Caution notices; they are for your benefit.

All references to the right side, left side, front, or rear are given from the operator's seat looking forward.

JLG Industries, Inc. is hereinafter referred to as JLG.

you operate this vehicle, read this manual completely and

Replacement Parts

For easy reference when ordering replacement parts or making service inquiries on this vehicle, record its model and serial number on the back cover of this manual. The serial number is stamped into the serial number plate (1) which is located on the vehicleís frame.

IMPORTANT! The replacement of any part on this vehicle by anything other than a JLG authorized replacement part may adversely affect the performance, durability or safety of this vehicle and may void the warranty. JLG assumes no liability for unauthorized replacement parts which adversely affect the performance, durability or safety of this vehicle.

OU0220

Reports

IMPORTANT! A Warranty Registration form must be filled out by the Lull Distributor, signed by the purchaser, and returned to JLG once the product is sold and/or put into service. This report activates the warranty period, assuring that your claims during the warranty period will be processed promptly. To guarantee full warranty service, make sure your Lull Distributor has returned the business reply card of this form to JLG.

Model 644E Origin 3/04

Page 5

Safety Practices

Disclaimer

JLG reserves the right to make changes on and to add improvements upon its

products at any time without public notice or obligation. JLG also reserves the right to discontinue manufacturing any product at its discretion at any time.

NOTICE: Under OSHA rules, it is the responsibility of the employer to provide operator training. Successful completion and certification of Safety Training for Rough Terrain Forklifts is required. Operator Training Kits are available by calling Ken Cook Company at (414) 466-6060. An order form for these kits is available through our website, http://www.jlg.com.

The information in this manual does not replace any safety rules and laws used in your area. Before operating this vehicle, learn the rules and laws for your area. Make sure the vehicle has the correct equipment according to these rules and laws.

Your safety and the safety of others in the worksite depend significantly upon your knowlege and understanding of all correct operating practices and procedures for this vehicle.

WARNING: DO NOT modify or alter (weld, drill, etc.) any part of

this vehicle without consulting JLG. Modifications can weaken the structure creating a hazard that can cause death or serious personal injury.

Safety Practices

Hazard Classification System

OP0330

This safety alert symbol is used with the following signal words to attract your attention to messages found within the manual and on hazard decals located on the vehicle. They are reproduced herein and pertain to proper operation and procedure messages contained throughout the manual. The message that follows the symbol contains important information about Safety. To avoid possible death or serious personal injury, carefully read and follow the messages! Be sure to fully understand the potential causes of death or injury.

Model 644E Origin 3/04

Page 6

Safety Practices

Signal Word

A signal word is a distinctive word located on hazard decals and used throughout this manual that alerts the viewer to the existence of and relative degree of the hazard.

DANGER:

The signal word ìDANGERî indicates an imminently hazardous situation which, if not avoided, will result in death or serious personal injury.

WARNING:

The signal word ìWARNINGî indicates a potentially hazardous situation which, if not avoided, could result in death or serious personal injury.

CAUTION:

The signal word ìCAUTIONî indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION:

The signal word ìCAUTIONî, used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, may result in property damage.

For safe maintenance of the vehicle, read, understand and follow all DANGER, WARNING and CAUTION information.

Model 644E Origin 3/04

Page 7

Safety Practices

Accident Prevention Tags

Before beginning any maintenance or service, place an Accident Prevention Tag (1) on both the starter key switch (2) and the steering wheel (3), stating that the vehicle should not be operated. Actual Accident Prevention Tags, which can be punched out and used, are included as the last page of this manual. Retain these Accident Prevention Tags for reuse at a later date.

DANGER

MU0291

New or Additional Operators

At the time of original purchase, the purchaser of this vehicle was instructed by the seller on its proper use. If this vehicle is to be used by an employee or is loaned or rented to someone other than the purchaser, make certain that the new operator is trained and authorized, in accordance with the OSHA regulations referenced on page 3, and reads and understands this Operators Manual before vehicle.

In addition, make sure that the new operator has completed a walk-around inspection of the vehicle, is familiar with all decals on the vehicle, and has demonstrated the correct use of all controls.

Model 644E Origin 3/04

operating the

Page 8

Safety Practices

Instructional Symbols

The following symbol definitions will help you understand all hazard related decals and load charts used on this vehicle.

Safety Alert

Symbol

OH2090

Fasten Seat

Belt

80" 1"

Transfer Carriage

Forward

Movement

OP0330

OU1570

OH2100

Read Operatorís

Manual

OH3100

Always Connect

Couplers On

Hydraulically Powered

Attachments

OU1580

Transfer

Carriage Fully

Retracted

OS0900

Always Maintain

Proper Tire

Pressure

Model 644E Origin 3/04

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Safety Practices

Instructional Symbols (contíd)

OU1620

Standard

Carriages

OU1640

Swing Carriages

OU1600

10 Ft. Truss

Boom

OU1630

Side Tilt

Carriages

OU1610

Single or Dual

Fork Positioning

Carriages

OU1590

10 Ft. Truss

Boom w/Winch

Model 644E Origin 3/04

OU1560

3 Ft. Truss Boom

w/Winch

Page 10

Safety Practices

Hazard Symbols

OH2110

Lead Acid Batteries Generate Explosive

Gases

OH2150

Electrocution Can

Cause Death Or

Can Cause Death Or

Serious Injury

OH2161

FALLING OFF ATTACHMENT

Can Result In Death Or Serious

Injury

OH2120

Rotating Fan

Blades Can Cut

OH2140

Vehicle Roll Away

Serious Injury

AVOID CRUSHING, Falling Off

Vehicle Can Cause Death Or

OH2130

Vehicle Tipover

Can Crush

OH2300

Rotating Belts

Can Cut Or

Entangle

OH3160

Serious Injury

Swinging Loads Can Cause

Vehicle Tipover Which Can

Result In Death Or Serious

Injury

OH3110

OU1450

ENGINE EXPLOSION Can

Result In Death Or Serious

Injury

(Optional Grid Heater Cold

Starting Aid)

Model 644E Origin 3/04

Page 11

Safety Practices

Avoidance Symbols

OH2320

Keep Lit Cigarettes

Away

OH2280

Do Not Raise Boom

While On A Slope

OH2240

OH2330

Keep Flames and

Ignition Sources Away

OH2270

Do Not Travel With

Boom Raised

Do Not Travel With

Personnel In Work

Platform

Model 644E Origin 3/04

OH2250

Keep Clear Of Power

Lines

OH2310

Keep Away From

Rotating Fan Blades

Page 12

Safety Practices

Avoidance Symbols (contíd)

OH2290

Maintain Proper Air

Pressure In Tire

OH2230

Carry No Riders

OH2220

DO NOT JUMP

ï Brace Yourself and Stay

With Vehicle ï Keep Seat Belt Fastened ï Hold On Firmly ï Lean Away From The Point

Of Impact

OH2260

Engage Parking Brake

OH2170

Use Only Compliant

Work Platforms To

Raise Or Lower

Personnel

OU1460

DO NOT Use Ether Or

Other High Energy

Starting Aids.

Engine Equipped With

Grid Heating System.

(Optional Grid Heater Cold

Starting Aid)

OH3120

To Avoid Vehicle Tipover ALWAYS: ï Travel Slowly ï Rig Properly ï Use Two Tethers

Model 644E Origin 3/04

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Safety Practices

Avoidance Symbols (contíd)

Keep Truss

Boom Horizontal

When Using

Winch

Avoid Rope

Damage. DO

NOT Tilt Truss

Boom UP When

Using Winch

OU1530

OU1540

Avoid Rope

Damage. DO

NOT Tilt Truss

Boom DOWN

When Using

Winch

OU1550

OU1520

Stop Operation

At This Point

OU1510

Prohibition

Symbol. DO NOT

Operate

Model 644E Origin 3/04

Page 14

Safety Practices

Personal Considerations

1. Seat Belt

Always fasten the seat belt before starting the engine.

2. Clothing and Safety Gear

DO NOT wear loose clothing or jewelry that can get caught on controls or

moving parts. Wear protective clothing and personal safety gear issued or called for by job conditions.

3. Dismounting

DO NOT get off the vehicle until you:

ï level the vehicle, ï ground the carriage, ï place the travel select lever in the (N)

NEUTRAL DETENT position,

ï engage the parking brake switch, ï turn the engine off, if appropriate, ï unbuckle the seat belt, ï exit the vehicle using the hand holds.

4. Chemical Hazards

WARNING

VEHICLE

ROLLAWAY

can cause

death or

serious

injury

ALWAYS

engage parking brake

before dismounting

OU0340

A. Exhaust Fumes

Fumes from the engine exhaust can cause death or serious personal injury. DO NOT operate vehicle in an enclosed area without a ventilation system capable of routing the hazardous fumes outdoors.

B. Explosive Fuel

Engine fuel is flammable and can cause a fire and/or an explosion. Avoid danger by keeping sparks, open flames and smoking materials away from the vehicle and from fuel during refueling or when servicing the fuel system. Know where fire extinguishers are kept on the worksite and how to use them.

C. Ether or High Energy Starting Aids (Optional)

The engine utilizes an optional grid heating system inside the induction manifold for cold starting conditions.

WARNING: This diesel engine uses a grid heating system inside

the induction manifold. DO NOT use ether or any high energy fuels to assist starting. An explosion may cause death or serious personal injury or engine damage.

Model 644E Origin 3/04

Page 15

DO NOT use ether or any other high energy starting aids during cold starting. An engine explosion can result in death or serious personal injury.

ENGINE EXPLOSION can result in death or serious personal injury.

Safety Practices

DO NOT use Ether or other high energy starting aids.

Engine equipped with grid heating system.

D. Hydraulic Fluid

4110460

DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin causing death or serious personal injuries.

HOT HYDRAULIC FLUID WILL CAUSE SEVERE BURNS. Wait for fluid to cool down before disconnecting lines.

DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid.

Hydraulic fluid can cause permanent eye injury. Wear appropriate eye protection and stop engine. Relieve pressure before disconnecting lines. Pressure can typically be relieved by slowly

and cautiously loosening one

end of a hose at the swivel connection. If anyone is injured by or if any hydraulic fluid is injected into the skin, obtain

medical attention immediately or gangrene may result.

E. Batteries

The following WARNING is intended to supplement and does not replace the warnings and information provided on the battery by the battery manufacturer.

When jump starting the vehicle, carefully follow instructions found under ìJump Startingî on page 87.

Keep sparks, flames and lit smoking materials away from the battery at all times. Lead acid batteries generate explosive gases. Severe chemical burns can result from improper handling of battery electrolyte. Wear safety glasses and proper protective gear when handling batteries to prevent electrolyte from coming in contact with eyes, skin or clothing.

WARNING

EXPLOSIVE GASES can cause serious injury.

Keep sparks, flames and lighted materials away from batteries.

OU1470

4110368

OU0350

Model 644E Origin 3/04

Page 16

Safety Practices

Battery Charging

WARNING: DO NOT charge a frozen battery, it may explode and

cause serious injury. Let the battery thaw out before putting on a battery charger.

Under normal conditions, the engine alternator will have no problem keeping the battery or batteries charged. The only condition in which the battery may cause a problem is when the battery or batteries have been completely discharged for an extended period of time. Under this condition, the alternator may not be able to recharge the battery or batteries. A battery charger will be required for recharging.

Before using a battery charger, an attempt can be made to recharge the battery or batteries using the engine alternator by first starting the vehicle and letting the engine run. See ìJump Startingî on page 87.

WARNING: Fluid in electric storage batteries contains sulfuric

acid which is POISON and can cause SEVERE CHEMICAL BURNS. Avoid all contact of fluid with eyes, skin or clothing. Use protective gear when handling batteries. DO NOT tip a battery beyond a 45 angle in any direction. If contact does occur, follow the First Aid suggestions that follows.

Battery Electrolyte First Aid:

ï External Contact ó Flush with water. ï Eyes ó Flush with water for at least 15 minutes and

get medical attention immediately

ï Internal Contact ó Drink large quantities of water. Follow

with Milk of Magnesia, beaten egg or vegetable oil. Get medical attention immediately.

IMPORTANT! In case of internal contact, DO NOT give fluids that would induce vomiting!

Model 644E Origin 3/04

Page 17

Safety Practices

5. Moving Parts Hazard

DO NOT place limbs near moving parts. Severing of

any body part can result. Turn off engine and wait until fan and belts stop

moving before servicing.

MOVING PARTS can cut.

Keep clear of fan and belts while engine is running.

MOVING PARTS can entangle.

6. Lowering Boom or Falling Load Hazard

DO NOT get under a raised boom unless it is blocked up safely. Always empty

the attachment of any load and block the boom up before doing any servicing that would require the boom to be raised.

NEVER allow anyone to walk or stand under the boom. A lowering boom or falling load can result in death or serious personal injury.

OT0810

Operational Considerations

1. Preparation and Prevention

Know the location and function of all vehicle controls. Make sure all persons are away from the vehicle and that the travel select lever

is in the (N) NEUTRAL DETENT position and the parking brake switch engaged before starting the engine.

Holes, obstructions, debris and other worksite hazards can cause death or serious personal injury. Always walk around and look for these and other hazards before operating the vehicle in a new worksite.

Prevent accidents when you move the vehicle around the worksite. Know the rules for movement of people and vehicles on the worksite. Have a person act as a lookout for you. Follow the instructions of signals and signs.

DO NOT operate the vehicle unless all hazard and instructional decals are in place and readable. (Replace all missing, illegible, or damaged decals.)

Model 644E Origin 3/04

Page 18

Safety Practices

2. Clearances

Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you do not have a clear view of conditions that affect clearances. Travel with the boom fully retracted and lowered as far as possible while still maintaining enough ground clearance for conditions.

Always check boom clearances carefully before driving underneath door openings, bridges, etc.

Always check for power lines when raising the boom. Beware of overhead wires. Contact with electrical power lines can result in electrocution. See Electrocution Hazards.

3. Visual Obstruction

Dust, smoke, fog, etc. can decrease vision and cause an accident. Always stop or slow the vehicle until the obstruction clears and the worksite is visible again. Have a lookout person assist you.

Where the load will obstruct the operatorís vision, it is recommended that the vehicle be operated in REVERSE, looking backwards in the direction of travel. Travel at a slower speed and get someone to direct you.

4. Underground Hazards

Know the location of all underground hazards before operating this vehicle in a new area or worksite. Electrical cables, gas and water pipes, sewer, or other underground objects can cause death or serious personal injury. Contact your local underground utility service or diggers hotline to mark all underground hazards.

5. Electrocution Hazards

NEVER operate this vehicle in an area where overhead power lines, overhead

or underground cables, or other power sources may exist without first requesting that the appropriate power or utility company de-energize the lines, or take other suitable precautions.

Model 644E Origin 3/04

OS0063

Page 19

Safety Practices

6. Elevating Personnel

Use only a compliant work platform meeting the ASME B56.6 standards for lifting and lowering personnel. NEVER transport personnel in a work platform for even the shortest distance.

Death or serious personal injury can occur if these rules are not obeyed. Riders can fall and be crushed or run over. Avoid accidents.

For other specific precautions, See ìElevating Personnelî on page 89.

WARNING

AVOID

CRUSHING,

falling off

vehicle can

cause death

or serious

Allow no riders

injury

OH3180

Lift or lower personnel only in a compliant work platform.

WARNING

FALLING OFF ATTACHMENT,

can result in death or

serious injury.

DO NOT TRAVEL with personnel in a work platform.

OU0620

4110389

7. Transfer Carriage Operation

Before any operation of the PlaceAceô transfer carriage is started, be sure to clear the path of travel in front of the boom and the transfer carriage of any personnel or objects.

Be sure there is enough room in front of the boom for complete transfer carriage movement.

IMPORTANT! When transfer carriage movement is started in the forward direction, the lifting capacity of the vehicle will be reduced. Refer to ìUsing the Capacity Chartî on page 71 and the ìLoad Chartî section at the end of this manual for vehicle capacities during transfer carriage operation.

If load cannot be safely transfered forward, position the vehicle closer to the landing point of the load.

Model 644E Origin 3/04

Page 20

Safety Practices

8. Tip Over Hazard

DANGER

VEHICLE TIPOVER can result in death or serious injury.

DO NOT travel with the boom raised.

DO NOT raise boom while on a slope unless load is level.

Traveling with the boom raised is dangerous and can cause tipover. Keep the boom as low as possible. Travel with extreme caution and at the slowest possible speed.

Keep the vehicle under control at all times. When negotiating turns, slow down and turn the steering wheel in a smooth sweeping motion. Avoid jerky turns, starts or stops. Reduce vehicle speed on rough ground and slopes.

DO NOT exceed the rated lift capacity of the vehicle as structural damage and unstable conditions will result.

To ensure that the vehicle is positioned in the most stable condition before operating an attachment, use the frame sway control (frame tilt) to level the vehicle. The vehicle is level when the frame level indicator gauge reaches (0 ) zero degrees.

If the vehicle cannot be leveled using the frame sway control, reposition the vehicle.

Frame swaying left or right with the boom raised above horizontal is dangerous. Always use the frame sway control to level the vehicle before raising the boom above horizontal, with or without a load. If the vehicle cannot be leveled using the frame sway control, reposition the vehicle.

9. Emergency Exit Rear Window

The rear window (1) in the optional enclosed cab can be used as an emergency exit by removing the latch pin (2) located on the window latch (3). The window is then free to swing open.

MAINTAIN proper tire pressure at all times.

OS0086

OU0920

Model 644E Origin 3/04

Page 21

10.Tire Pressure

Safety Practices

VEHICLE TIPOVER can result in death or serious injury.

DO NOT travel with the boom raised.

MAINTAIN proper tire pressures at all times. An underpressurized tire(s) adversely affects vehicle stability. If proper tire pressures are not maintained, this vehicle can tip over.

To ensure proper vehicle stability, check all four tire pressures before operating the vehicle.

DO NOT raise boom while on a slope unless load is level.

MAINTAIN proper tire pressure at all times.

OS0085

11.Do Not Jump

DANGER

If a vehicle ever becomes unstable and starts to tip over:

ï BRACE YOURSELF and STAY WITH THE

VEHICLE,

ï KEEP YOUR SEAT BELT FASTENED, ï HOLD ON FIRMLY and ï LEAN AWAY FROM THE POINT OF

IMPACT.

Indecision and trying to escape from a tipping vehicle can result in death or serious personal

DANGER

AVOID CRUSHING

if vehicle tips.

Jumping can

result in death

or serious

injury.

 DO NOT JUMP.  Brace yourself.  Stay in cab.  Keep seat belt on.

OH3190

injury.

12.Slopes

DO NOT park the vehicle on an incline and leave it unattended.

ï Driving across a slope is dangerous, as unexpected changes in the

slope can cause tipover. Ascend or descend slopes slowly caution.

ï Ascend or descend slopes with the heavy end of the vehicle pointing up

the slope.

NOTE: The rear of the vehicle is normally considered the heavy end unless the carriage is fully loaded. In this case the front of the vehicle is now the heavy end.

ï Unloaded vehicles should be operated on all slopes with the carriage

pointing down

the slope.

ï On all slopes, the load must be tilted back and raised only as far as

necessary to clear the ground.

ï When operating on a downhill slope, reduce travel speed and downshift

to a low gear to permit compression braking by the engine and aid the application of the service brakes.

and with

Model 644E Origin 3/04

Page 22

Safety Practices

13.Falling Load Hazard

DO NOT exceed the total rated load capacity of the specific type fork being

used. Each fork is stamped with a maximum load capacity. If the capacity is exceeded, forks may break. See ìFork Ratingî on page 70.

DO NOT downshift at a high ground speed. Sudden slowing can cause the load to drop off the forks.

14.Ventilation

Sparks from the electrical system and the engine exhaust can cause an explosion. DO NOT operate this vehicle in an area with flammable dust or vapors unless good ventilation has removed the hazard.

Carbon monoxide fumes from the engine exhaust can cause suffocation in an enclosed area. Good ventilation is very important when operating this vehicle.

Equipment Considerations

WARNING: DO NOT modify or alter (weld, drill, etc.) any part of

this vehicle without first consulting JLG. Modifications can weaken the structure creating a hazard that can cause death or serious personal injury.

DO NOT by-pass or disconnect any electrical or hydraulic circuits. Consult the JLG Service Department or your local Lull Distributor if any circuit is

malfunctioning. DO check for frayed or cut seat belt webbing, damaged buckles or loose

mounting brackets. Replace immediately if required.

ALWAYS wear a seat belt when operating the vehicle. DO check tire pressure on all four tires. Add air if required. DO check the condition of all four rims. Check for bent flanges and/or bead

mounting areas. DO check the parking brake/transmission de-clutch operation. Refer to the test

procedures on page 171. Repair immediately if required. DO keep all non-skid surfaces clean and free of debris. Replace if worn,

damaged or missing. DO check the condition of decals. Replace decals if missing, damaged or

illegible. The following pages show the proper location of the decals.

Model 644E Origin 3/04

Page 23

Safety Practices

WARNING

CRUSHING,

falling off

vehicle can

cause death

or serious

Allow no riders

AVOID

injury

SAFETY

INSTRUCTIONS

Item Part Number Quantity Decal Description

1 2 4110358 1 Vehicle Rollaway Warning 3 4108991 1 Electrocution Danger 4 7300628 1 Load Chart Booklet 5 4110137 1 Tipover Danger 6 4110358 1 Do Not Jump Danger 7 4110361 1 Safety Instructions

4110358 1 No Riders Warning

1. Read operator's manual before operating.

1/2

RPM X 100

r/min

0000000

DANGER

AVOID CRUSHING

°F 176

104

248 80 °C

120

if vehicle tips.

Jumping can

result in death

or serious

injury.

 DO NOT JUMP.  Brace yourself.  Stay in cab.  Keep seat belt on.

2. Fasten seat belt.

3. Allow no riders.

4. Use a compliant work platform to lift or lower personnel.

4110361

OU07611

Model 644E Origin 3/04

Page 24

Safety Practices

WARNING

FALLING OFF ATTACHMENT,

can result in death or

serious injury.

Lift or lower personnel only in a compliant work platform.

MOVING PARTS can cut.

Keep clear of fan and belts while engine is running.

MOVING PARTS can entangle.

DO NOT TRAVEL with personnel in a work platform.

4110389

A B

ENGINE EXPLOSION can result in death or serious personal injury.

DO NOT use Ether or other high energy starting aids.

Engine equipped with grid heating system.

120cm

110cm 100cm 90cm 80cm 70cm 60cm 50cm 40cm 30cm 20cm 10cm130cm140cm150cm160cm170cm180cm190cm200cm

4110356

WARNING

EXPLOSIVE GASES can cause serious injury.

4110460

Keep sparks, flames and lighted materials away from batteries.

4110368

Item Part Number Quantity Decal Description

4110184 2 Moving Parts Warning 2 4110368 1 Explosive Gases Warning 3 4110389 1 Carrying Personnel Warning 4 4110130 1 Boom Extend Stripes 5 4110356 1 Transfer Carriage Extension

6 4110460 2

Ether Starting Warning (Optional Grid Heater Cold Start Aid)

Model 644E Origin 3/04

OU1440

Page 25

Operation

Pre-Operation Inspection

1. Check seat belt for damage. Check for frayed or cut seat belt webbing, damaged buckles or loose mounting brackets. Make any necessary repairs before operating the vehicle.

2. Check all four tires and rims for damage. Check for proper tire pressure, add air if required. Observe the condition of each tire looking specifically for punctures, cracks, cuts, gouges, bulges or any other damage. Check the condition of each rim for bent flanges or any other damage. Make any necessary repairs before operating the vehicle.

3. Check and add engine oil if required. This procedure is explained in greater detail on page 114.

4. Check and add transmission oil if required. This procedure is explained in greater detail on page 128.

5. Check the cooling system overflow bottle for coolant. Add coolant if required. This procedure is explained in greater detail on page 110. Remove any debris blocking the radiator cooling fins.

6. Check the hydraulic oil level sight glass and add hydraulic oil if required. This procedure is explained in greater detail on page 125.

7. Visually inspect the battery or batteries for cleanliness. Check terminals for corrosion. Check the cable connections to ensure proper tightness.

8. Walk around the vehicle and check for oil leakage as well as damaged or missing parts. Make any necessary repairs before operating the vehicle.

9. Check ALL lighting systems (if so equipped) for proper operation.

10. Adjust rear view mirrors as required to obtain proper field of vision to the rear.

11. Test the back-up alarm and horn for proper operation.

12. Check condition of cab glass (if so equipped), looking for cracks or other damage.

13. Visually check the condition of the air conditioner condenser (if so equipped). Remove any debris from the cooling fins of the air conditioner condenser located at the top rear of the cab. Clean the fins as needed.

Model 644E Origin 3/04

Page 26

Operation

Operators Seat Adjustments

Enter the cab using the hand holds. The operatorís seat can be adjusted as follows:

Fore and Aft Adjustment (all styles of seat)

Pull the handle (1) under the front of the seat (2) to the left and move the seat forward and backward. Release the handle to lock the seat in the desired position. Depending on the style of seat, this handle may be on the right side or the left side of the seat.

Suspension Adjustment (for seats equipped with adjustable suspensions only)

Turn the knob (3) on the front of the seat to adjust the suspension to correspond with the operatorís weight. Turn the knob clockwise to increase stiffness. Turn the knob counterclockwise to reduce stiffness.

Backrest Angle Adustment (for seats equipped with adjustable backrests only)

The angle of the seat backrest can be adjusted to suit the operator. Move the lever (4) located on the left side of the seat backrest to adjust the angle.

Model 644E Origin 3/04

OU0490

Page 27

Operation

Seat Belt

WARNING: Serious bodily injury or death may result from failure

to wear the seat belt installed on this vehicle. The seat belt is a critical component of the Operatorís Protective Structure, and is provided for the operators protection in case of vehicle upset. The seat belt MUST be worn whenever this vehicle is operated.

IMPORTANT! Inspect the seat belt every time it is used, looking for cut or worn webbing, or any defect in the latch assembly. If any wear or damage is noted, DO NOT operate the vehicle until the seat belt is replaced.

Before the engine is started, adjust the seat as required for position and comfort. Then adjust the seat belt as follows:

1. Grasp the retractable end of the belt or the male end of the seat belt and make certain that the belt webbing is not twisted or entangled in any portion of the seat assembly.

2. With your back straight in the seat, couple the retractable end or the male end of the belt into the receptacle (buckle) end of the belt.

3. With the belt as low on your body as possible, pull the retractable end of the belt or the free end of the belt away from the buckle until it is tight across the lap.

4. To release the belt latch, depress the red button (5) and pull the free end (6) from the buckle.

An optional 3 inch wide seat belt is available for those locations that require a 3 inch seat belt.

Model 644E Origin 3/04

OM0720

Page 28

Operation

Operator Controls

Accelerator Pedal

Pressing down the accelerator pedal (1) increases engine speed and the speed of the hydraulic system. The pedal is spring-loaded to return to idle speed.

Service Brake Pedal

Pressing down the brake pedal (2) decreases the speed of the vehicle by applying the service brakes located in the axles. In the event of engine power loss, the service brake pedal can also be used for braking. It also activates and locks the rear axle to frame lock system when the boom angles are greater than 40 , as long as the pedal is depressed.

Steering Wheel

Turning the steering wheel (3) to the left or right steers the vehicle in the corresponding direction. Any one of the steering modes are selectable. Refer to ìSteering Mode Selectorî on page 27.

Horn Button

Pressing the horn button (4) located in the center of the steering wheel sounds the horn.

OU0361

Model 644E Origin 3/04

Page 29

Operation

Ignition Switch

The ignition switch is located on the lower right side of the front dash. Using the ignition switch key (5), the key may be turned clockwise from the OFF (6) position to the RUN (7) and START (8) positions. The START position is spring-loaded to return to the RUN position and must be manually held in place for starting.

OFF position (6) ó The entire electrical system is shut down. RUN position (7) ó All controls and indicators are operable. START position (8) ó Engages starter motor to crank the engine when the parking

brake switch is engaged and the transmission is in NEUTRAL.

10 1112

OU0371

Steering Mode Selector

Three Mode Steer Select

The steering mode selector (9) is located on the left side of the front dash. The selector has three positions.

ï Front Wheel Steer (10). ï Crab Steer (11). ï Four Wheel Steer (12).

Turn the steer mode selector until the notch on the top of the knob points to the desired steering mode selection. You will feel the knob of the selector slip into a detent position for each mode. Refer to the individual steering modes starting on page 28 for a detailed explanation.

Model 644E Origin 3/04

Page 30

Operation

1. Four Wheel Steering Mode

WARNING: NEVER use the Four Wheel Steering Mode when

traveling at high speed. Rapid turning in this mode can cause tipover. Use only the Front Wheel Steering Mode at higher speeds and slow the vehicle when turning.

The front wheels will steer in the direction that the steering wheel is turned; the rear wheels will steer in the opposite direction. This steering mode allows an extremely short turning radius and enables the rear wheels to follow the tracking of the front wheels which can be an advantage in mud and sand conditions.

OS0280

2. Front Wheel Steering Mode

The front wheels will steer in the direction that the steering wheel is turned. The rear wheels will remain in a fixed forward position. This steering mode should be used when loading or unloading the vehicle from a trailer and for on-highway travel at higher speeds.

OS0290

Model 644E Origin 3/04

Page 31

Operation

3. Crab Steering Mode

WARNING: NEVER use the Crab Steering Mode when travelling

at high speed. Rapid turning in this mode can cause tipover. Use only the Front Wheel Steering Mode at higher speeds and slow the vehicle when turning.

All wheels will steer in the same direction that the steering wheel is turned. This steering mode allows the operator to move the vehicle ìsidewaysî toward the landing point of a load. This is especially useful on a congested worksite in order to line up at the exact spot in front of the loading location.

OS0310

Four Wheel Steer Indexing

If the vehicle does not drive ìstraight,î the steering could be ìout of phase.î Perform the following procedure to synchronize the front and rear steering.

1. Select the four wheel steer mode with the steer mode selector.

2. Turn the steering wheel all the way to the right until it reaches the stop.

3. Select the front wheel steer mode with the steer mode selector.

4. Turn the steering wheel to the left, about one complete revolution.

5. Select the four wheel steer mode with the steer mode selector.

6. Turn the steering wheel all the way to the right until it reaches the stop. This will ensure the rear wheels are fully against the right stop.

7. Select the front wheel steer mode with the steer mode selector.

8. Turn the steering wheel all the way to the right until it reaches the stop.

9. Select the four wheel steer mode with the steer mode selector.

10. Turn the steering wheel to the left, until the wheels are pointing straight ahead.

11. Drive the vehicle forward a short distance to check the wheel tracking.

12. The vehicle should now be properly indexed in Four Wheel Steering. If the wheels are still out-of-phase, repeat the above procedure.

Model 644E Origin 3/04

Page 32

Operation

1/2

Parking Brake Switch

The Parking Brake Switch (1) is located on the left side of the front dash and has two positions:

ENGAGED....................toggle switch downward

DISENGAGED...................toggle switch upward

OS0121

OS1323

The Parking Brake Switch must be ENGAGED to permit engine starting. A red LED, on the parking brake switch, will indicate the brake is ENGAGED. The parking brake engaged light (2) will illuminate on the front dash panel any time the parking brake is engaged.

The parking brake may be used to stop in an EMERGENCY situation. However, use caution because the stop will be abrupt and the operator and the load may be jolted forward unexpectedly.

With boom angles greater than 40 , this switch activates the locked mode of the Stabil-TRAK system.

OU0381

Model 644E Origin 3/04

Page 33

Operation

Transmission Disconnect Switch

The Transmission Disconnect Switch (3) is located on the left side of the front dash and has two positions:

ï Push the TOP of the rocker switch in to

DEACTIVATE the transmission disconnect function.

OH2591

ï Push the BOTTOM of the rocker switch in to

ACTIVATE the transmission disconnect function.

OH2611

With the transmission disconnect activated, when the service brake pedal is applied, the transmission will be disconnected allowing the engine speed to be increased without the need to place the transmission shifter in the (N) NEUTRAL DETENT.

This feature eliminates the need to shift the transmission to the (N) NEUTRAL DETENT before operating the hydraulic system at high engine speed. When the transmission disconnect is active, the drivetrain is disconnected and the hydraulic system has full engine power.

IMPORTANT! With the disconnect feature active and the service brake pedal being released, the transmission will be reconnected in the same gear and direction of travel as when it was originally disconnected. The service brakes must remain fully applied for this feature to be functional.

Model 644E Origin 3/04

Page 34

Operation

Travel Select Lever

The Travel Select Lever (1) has three positions to select direction of travel:

F = FORWARD (2) ..............................all the way UP

N = NEUTRAL DETENT (3)................CENTER position

R = REVERSE (4)...............................all the way DOWN

OS0340

1st

2nd

3rd 4th

OU0400

Starting Travel

1. Enter the operator cab, fasten the seat belt, start the engine, apply the service brake pedal and disengage the parking brake switch.

2. Rotate the twist grip (5) of the range select lever to 1st gear.

3. Pull the travel select lever (1) toward the steering wheel and move the travel select lever (1) to (F) FORWARD (2) to travel in a forward direction or to (R) REVERSE (4) to travel backward.

4. Slowly remove your foot from the service brake pedal and press the accelerator pedal to start travel.

IMPORTANT! Check for warning lights and the gauges frequently during operation. Any abnormal indication should be corrected as soon as practical.

Model 644E Origin 3/04

Page 35

Operation

Changing Travel Direction

1. Stop the vehicle by applying the service brakes.

2. Grasp the travel select lever (1), pull it toward the steering wheel, then move the lever up or down in the opposite direction; (R) REVERSE (4) or (F) FORWARD (2).

When the Travel Select Lever is shifted to REVERSE, the back-up alarm will automatically sound.

NOTE: The Travel Select Lever must be in the (N) NEUTRAL DETENT (3) position to permit engine starting.

Gear Select Twist Grip

The Gear Select Twist Grip (5) is at the end of the travel select lever (1). The twist grip handle has four positions 1st gear thru 4th gear.

Shifting Gears

1. Rotate the twist grip of the gear select lever to the next desired gear. The transmission has four forward gears and three reverse gears.

2. Use first gear for highest torque and pulling power. Use higher gears for higher ground speed. The recommendations listed in the table that follows is a guideline only. Always use good judgement when traveling with a load.

Recommended Gear/Speed for Various Load/Travel Conditions

(Forward Direction Only)

Load Size Surface Gear Speed

No Load Smooth 4th* 0 to 20 mph (0 to 32 km/h)

Improved 3rd 0 to 14 mph (0 to 23 km/h)

Rough 2nd 0 to 6 mph (0 to 9.7 km/h)

Load Smooth 3rd 0 to 14 mph (0 to 23 km/h)

up to 4,500 lbs Improved 2nd 0 to 6 mph (0 to 9.7 km/h)

(up to 2.041 kg)

Load Smooth 2nd 0 to 6 mph (0 to 9.7 km/h)

4,500 to 6,000 lbs Improved 2nd 0 to 6 mph (0 to 9.7 km/h)

(2.041 to 2.721 kg)

Rough 2nd 0 to 6 mph (0 to 9.7 km/h)

Rough 1st 0 to 3.5 mph (0 to 5.6 km/h)

*NEVER travel in 4th gear when carrying a load.

NOTE: Shifting to the next higher gear may be done while the vehicle is in motion. IMPORTANT! When downshifting, allow the engine speed to slow down before

shifting to the next lower gear.

Model 644E Origin 3/04

Page 36

Operation

Stopping Travel

1. Apply the service brake pedal and downshift the vehicle to a lower gear if necessary to slow the vehicle until it comes to a complete stop.

2. Move the travel select lever (1) to the (N) NEUTRAL DETENT position and engage the parking brake switch.

Maximum Fork Sweep (During Travel)

CAUTION: Allow for adequate clearance between the attach-

ment and rear counterweight and other objects when turning.

The attachment and the rear counterweight extends beyond the vehicle. The operator must be aware of the maximum sweep of the attachment (3) and the rear counterweight (4) when turning in order to avoid hitting personnel and other objects in the area.

OU0390

the end of

OU0730

Model 644E Origin 3/04

Page 37

Operation

Joystick Operation

This vehicle is equipped with three separate joysticks.

ï The front joystick (5) controls attachment tilt and PlaceAceô transfer

carriage operation. The button (6) on the front joystick controls the auxiliary hydraulic function.

ï The middle joystick (7) controls boom lift/lower and extend/retract functions. ï The rear joystick (8) is a single axis joystick with a lift to shift lock ring

detent and controls the frame sway to the left and right.

OU0410

Two functions can be accomplished at the same time by moving the front or middle joysticks in between quadrants. For example; moving the middle joystick forward and to the left will lower and retract the boom simultaneously.

The speed of the function depends directly upon the amount of joystick travel in the corresponding direction. Increasing the engine speed will also increase the function speed.

Model 644E Origin 3/04

Page 38

Operation

Front Joystick (Attachment Tilt & Transfer Carriage)

The front joystick (1) controls the attachment tilt and the PlaceAceô transfer carriage operation. The joystick can be moved from the center position into any of these quadrants. The joystick will return to the center position when released. The button on the top of the joystick controls the auxiliary hydraulics function. Refer to ìAuxiliary Hydraulic Controlî on page 40 for a detailed explanation.

Attachment Tilt Up (2).................... move handle backward

Attachment Tilt Down (3) ...............move handle forward

Transfer Carriage Extend (4).......... move handle to the right

Transfer Carriage Retract (5) ......... move handle to the left

OU0080

OU0420

Model 644E Origin 3/04

Page 39

Operation

Middle Joystick (Boom Lift/Lower & Boom Extend/Retract)

The middle joystick (6) controls the boom lift/lower and boom extend/retract functions. The joystick can be moved from the center position into any of these quadrants. The joystick will return to the center position when released.

Boom Lift (7)................................move handle backward

Boom Lower (8)...........................move handle forward

Boom Extend (9) ......................... move handle to the right

Boom Retract (10)....................... move handle to the left

OU0060

OU0430

Model 644E Origin 3/04

Page 40

Operation

Frame Sway Joystick

The frame sway joystick (1) is equipped with a lock ring (2) to prevent unintentional operation of the frame sway control.

Lift up and hold the lock ring while moving the handle to the left or right. When frame sway is complete, center the handle and lower the lock ring to lock the handle in the center position.

Frame Sway Right (3).......LIFT lock ring and move handle to the RIGHT

Frame Sway Left (4)......... LIFT lock ring and move handle to the LEFT

OU0070

OU0440

Model 644E Origin 3/04

Page 41

Operation

Leveling The Vehicle

When placing a load while on a slope, use the frame sway control. Keep the vehicle level. The operator should observe the frame level indicator (5) to assure that the vehicle is level at all times. The frame sway is capable of tilting the vehicle 12 in either direction.

OS0232

DANGER: Use of the frame sway control with the boom raised

above horizontal can cause tipover resulting in death or serious personal injury. Always use the frame sway control to level the vehicle before raising the boom above horizontal. If the vehicle cannot be leveled using the frame sway control, reposition the vehicle.

Frame Level Indicator

The frame level indicator (5) is mounted on the top inside of the cab. It is a bubble type indicator which allows the operator to tell if the vehicle has been positioned in a level condition. Always frame sway the vehicle either right or left until the indicator reads zero degrees (0 ). If zero cannot be achieved, then reposition the vehicle until it is level before placing the load.

Model 644E Origin 3/04

Page 42

Operation

Auxiliary Hydraulic Control

The auxiliary hydraulic control is used to control the functions of an optional attachment that is mounted to the vehicle and requires a hydraulic supply for operation. Some of the optional attachments that require auxiliary hydraulics are: Side Tilt Carriage, Swing Carriage, 3 ft Truss Boom w/Winch, 10 ft Truss Boom w/Winch, Single Fork Positioning Carriage, Dual Fork Positioning Carriage and Auger.

The button (1) to activate the auxiliary hydraulics is located on the top of the front joystick (2). Pressing the button with your thumb activates the auxiliary hydraulic function. The button must be held down while moving the joystick to the right or left.

IMPORTANT! Releasing the button while moving the joystick to the left or right will change the function of the joystick back to the transfer carriage extend/retract mode of operation.

OU0450

Model 644E Origin 3/04

Page 43

Operation

While holding the button down and moving the joystick to the right (3)

will provide hydraulic system pressure through the female disconnect coupling for the auxiliary attachment. Hydraulic fluid will return to the tank through the male disconnect coupling.

While holding the button down and moving the joystick to the left (4)

will provide hydraulic system pressure through the male disconnect coupling for the auxiliary attachment. Hydraulic fluid will return to the tank through the female disconnect coupling.

OU0090

Side Tilt Carriage Operation:

ï Control Lever Right (5)..............Tilt Right

ï Control Lever Left (6)................Tilt Left

Swing Carriage Operation:

ï Control Lever Right (5)..............Swing Right

ï Control Lever Left (6)................Swing Left

Auger Operation:

ï Control Lever Right (5)..............Auger Dig

ï Control Lever Left (6)................Auger Retract

10 Ft. Truss Boom w/Winch or 3 Ft. Truss Boom w/Winch Operation:

ï Control Lever Right (5)..............Cable Extends

ï Control Lever Left (6)................Cable Retracts

Single Fork Positioning Carriage Operation:

ï Control Lever Right (5)..............Right Fork Moves to the Right

ï Control Lever Left (6)................Right Fork Moves to the Left

Dual Fork Positioning Carriage Operation:

ï Control Lever Right (5)..............Both Forks Move Apart (toward outside)

ï Control Lever Left (6)................Both Forks Move Together (toward center)

The joystick will provide the following typical functions for each specific attachment if they are connected properly. Operation will be reversed if incorrectly connected. We recommend reversing the disconnect couplings on the hoses that are supplied with the attachment if operation is reversed.

Model 644E Origin 3/04

Page 44

Operation

Joystick Operation (Single Joystick Option)

The single joystick option is an assembly containing a single joystick (1) to control boom functions, auxiliary hydraulics, attachment tilt and the PlaceAceô transfer carriage operation. The frame sway is controlled by a separate frame sway joystick (2) which is located behind the single joystick assembly.

The joystick can be operated in two separate modes of operation: without button (3) depressed ìBoom Lift/Lower and Extend/Retractî (Default Mode) and with button (3) depressed and held ìTransfer Carriage Extend/Retract and Auxiliary Hydraulic Male Pressurized/Female Pressurizedî (Secondary Mode). The joystick also has a thumb control (4), on the topside of the joystick, for attachment tilt control which operates in either mode.

IMPORTANT! The button (3) must be held against the joystick handle during operation of the Secondary Mode. Releasing the button (3) from the Secondary Mode will immediately change the joystick back to the Default Mode of operation.

OU1201

Model 644E Origin 3/04

Page 45

Operation

Boom Lift/Lower and Extend/Retract (Default Mode)

Front button (3), not depressed, operates the following boom functions. The joystick can be moved from the center position into any of these quadrants. The joystick will return to the center position when released.

Boom Lift (5)................................move handle backward

Boom Lower (6)...........................move handle forward

Boom Extend (7) ......................... move handle to the right

Boom Retract (8)......................... move handle to the left

OU0060

OU1221

Model 644E Origin 3/04

Page 46

Operation

Transfer Carriage Extend/Retract and Auxiliary Hydraulic Male Pressurized/ Female Pressurized (Secondary Mode)

Front button (1) depressed and held against the joystick handle operates the following transfer carriage and auxiliary hydraulic functions. The joystick can be moved from the center position into any of these quadrants. The joystick will return to the center position when released.

Transfer Carriage Extend (2)............................move handle forward

Transfer Carriage Retract (3) ........................... move handle backward

Auxiliary Hydraulic - Female Pressurized (4)... move handle to the right

OU1230

Auxiliary Hydraulic - Male Pressurized (5) ....... move handle to the left

OU1242

Model 644E Origin 3/04

Page 47

Operation

While holding the button in and moving the joystick to the right (4) will

provide hydraulic system pressure through the female disconnect coupling for the auxiliary attachment. Hydraulic fluid will return to the tank through the male disconnect coupling.

While holding the button in and moving the joystick to the left (5) will

provide hydraulic system pressure through the male disconnect coupling for the auxiliary attachment. Hydraulic fluid will return to the tank through the female disconnect coupling.

OU0090

Side Tilt Carriage Operation:

ï Control Lever Right (6)..............Tilt Right

ï Control Lever Left (7)................Tilt Left

Swing Carriage Operation:

ï Control Lever Right (6)..............Swing Right

ï Control Lever Left (7)................Swing Left

Auger Operation:

ï Control Lever Right (6)..............Auger Dig

ï Control Lever Left (7)................Auger Retract

10 Ft. Truss Boom w/Winch or 3 Ft. Truss Boom w/Winch Operation:

ï Control Lever Right (6)..............Cable Extends

ï Control Lever Left (7)................Cable Retracts

Single Fork Positioning Carriage Operation:

ï Control Lever Right (6)..............Right Fork Moves to the Right

ï Control Lever Left (7)................Right Fork Moves to the Left

Dual Fork Positioning Carriage Operation:

ï Control Lever Right (6)..............Both Forks Move Apart (toward outside)

ï Control Lever Left (7)................Both Forks Move Together (toward center)

Model 644E Origin 3/04

Page 48

Operation

Attachment Tilt (Thumb Control) Operates in Default Mode or Secondary Mode

The thumb control (1), on the topside of the joystick, controls the attachment tilt function and is not affected by the button (2) on the front of the joystick. With your thumb, move the thumb control BACKWARD for attachment tilt UP (3). Move the thumb control FORWARD for attachment tilt DOWN (4). The thumb control will return to the center position when released.

Attachment Tilt UP (3) .................move thumb control BACKWARD

Attachment Tilt DOWN (4) ...........move thumb control FORWARD.

OU1210

Frame Sway Joystick

The frame sway joystick (5) is equipped with a lock ring (6) to prevent unintentional operation of the frame sway control.

Lift up and hold the lock ring while moving the handle to the left or right. When frame sway is complete, center the handle and lower the lock ring to lock the handle in the center position.

Frame Sway Right (7).......LIFT lock ring and move handle to the RIGHT

Frame Sway Left (8)......... LIFT lock ring and move handle to the LEFT

OU0070

Model 644E Origin 3/04

OU1252

Page 49

Operation

Leveling The Vehicle

When placing a load while on a slope, use the frame sway control. Keep the vehicle level. The operator should observe the frame level indicator (9) to assure that the vehicle is level at all times. The frame sway is capable of tilting the vehicle 12 in either direction.

OS0232

DANGER: Use of the frame sway control with the boom raised

Frame Level Indicator

The frame level indicator (9) is mounted on the top inside of the cab. It is a bubble type indicator which allows the operator to tell if the vehicle has been positioned in a level condition. Always frame sway the vehicle either right or left until the indicator reads zero degrees (0 ). If zero cannot be achieved, then reposition the vehicle until it is level before placing the load.

Model 644E Origin 3/04

Page 50

Operation

Front Dash Panel

The front dash panel (1) provides the operator with important information. It is ìuser friendlyî and only provides the operator with the information needed at any given time.

Front Dash Panel Light Test

1/2

RPM X 100

r/min

0000000

°F 176

104

248 80 °C

120

OU0010

To test the front dash panel lights; turn the ignition switch to the RUN position, ALL the lights (13 total) will come ON for three seconds as a test function. During this time an audible alarm will sound. Replace any bulbs that DO NOT come ON during this test.

Do not forget to refasten your seat belt before operation. Always wear the seat belt when operating the vehicle.

Model 644E Origin 3/04

Page 51

Operation

Function Indicator Lights

There are four ìhiddenî function indicator lights in the front dash panel that illuminate only when a specific function has been activated. They are:

Parking Brake Indicator (2)

This light illuminates any time the parking brake is applied and the ignition switch is in the RUN position.

Stabil-TRAK Mode Indicator Lights (3 & 4)

One of these lights will illuminate when the Stabil-TRAK system has been ACTIVATED in the ìLockedî Mode (3) or the ìSlow Pivotî Mode (4). Refer to ìUnderstanding the Stabil-TRAKô Systemî on page 74 for a detailed explanation.

Engine Air-Intake Heater Indicator (5)

This light illuminates with the ignition switch in the RUN position any time the ambient temperature drops below 40 F (4 C). The engine grid heater then becomes active and the engine should not be cranked until the light goes OFF. Once the light goes OFF it indicates that the grid heater is at the proper temperature and the engine is ready to start.

NOTE: This indicator light may come ON when the engine is running to indicate that the post heat function is active. This is a normal condition when ambient temperatures are below 40 F (4 C).

OS1970

OU0040

OH2260

OU0050

Model 644E Origin 3/04

Page 52

Operation

Warning Indicator Lights

There are seven additional ìhiddenî indicator lights in the front dash panel that will illuminate during critical circumstances. All seven warning indicator lights demand immediate attention and vehicle servicing. In many cases, the vehicle should be shut down AS SOON AS PRACTICAL to prevent serious mechanical failure.

The warning indicator lights are:

Transmission Temperature Warning Indicator (1)

This light illuminates when the transmission oil temperature is too high; above 250 F (121 C). An audible alarm will also sound. Stop and idle the vehicle with the transmission in (N) Neutral, allowing time for cooling. If the light does not go out after two minutes, shut the vehicle down.

Hydraulic Oil Temperature Warning Indicator (2)

This light illuminates when the hydraulic oil temperature is too high; above 195 F (91 C). Stop and idle the engine, allow time for cooling. If the light does not go out after five minutes, shut the vehicle down.

Engine Oil Pressure Warning Indicator (3)

This indicator light will come ON if the engine is not started. This is normal. If the light comes ON while the engine is running, this indicates that the engine oil pressure is too low. When the engine is running an audible alarm will also sound when the low oil pressure light is ON. SHUT THE VEHICLE DOWN AS SOON AS PRACTICAL.

OT0990

OT1000

OT1010

Model 644E Origin 3/04

Page 53

Alternator Charging Warning Indicator (4)

This light illuminates to indicate a weak or improperly working charging system or the batteries are dead. Service the engine alternator or batteries.

Engine Air Filter Restriction Warning Indicator (5)

This light illuminates when a restricted engine air filter is detected. If the light is ON, service the air filter(s).

Hydraulic Oil Filter Restriction Warning Indicator (6)

This light illuminates when a restricted hydraulic oil filter is detected. If the light is ON, service the hydraulic oil filter.

1/2

RPM X 100

r/min

0000000

Operation

OH2560

OT1020

OT1030

°F

176

104

248 80 °C

120

Model 644E Origin 3/04

OU0010

Page 54

Operation

Low Brake Pressure Warning Indicator (1)

This light is located on the lower right side of the front dash panel.

The light will come ON and the 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 vehicle operation, shut off engine immediately, investigate, and repair before operating. DO NOT operate vehicle when low brake pressure light or buzzer is on.

WARNING: Operating the vehicle with the service brake system

malfunctioning will cause reduced braking ability or no braking ability when the service brake pedal is depressed. Death or serious personal injury could result from the inability to stop or slow the vehicle.

If the low brake pressure light or buzzer remains ON, place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and turn the engine OFF.

Have the service brake system serviced before using the vehicle again. Contact your local Lull Distributor immediately to repair the system.

OM1600

1/2

RPM X 100

r/min

0000000

°F

176

104

80 °C

120

248

OU0010

Model 644E Origin 3/04

Page 55

Gauges and Indicators

Fuel Level Gauge (2)

Make sure the vehicle is level to ensure an accurate fuel level reading. The fuel gauge located on the left side of the front dash panel, indicates the amount of fuel in the fuel tank. Refuel before the fuel gauge reaches the ìEî to prevent running out of fuel. Capacity of the fuel tank is

50.2 gallons (190 liters) total capacity with a usable capacity of 45 gallons (171 liters). If the engine ever runs out of fuel, the fuel system will need to be bled. Refer to ìBleeding Fuel Systemî page 121.

Engine Tachometer (3)

The tachometer is the gauge in the center of the front dash panel and indicates speed of the engine in revolutions per minute (rpm).

Hourmeter (4)

The hourmeter records engine operating hours and has a total readout of 99,999.99 hours. It is located on the front dash panel in the lower portion of the tachometer.

Engine Coolant Temperature Gauge (5)

The engine coolant temperature gauge is located on the right side of the front dash panel. Glance at the gauge on a regular basis during operation. The gauge monitors the temperature at which the engine is operating. If the gauge goes over 210 F (99 C) the engine coolant is too hot. Idle the engine for 1 minute prior to shutting the vehicle down. If the radiator is boiling over, SHUT THE VEHICLE DOWN AS SOON AS PRACTICAL.

r/min

Operation

OH24701

OU0020

OU0030

OT0980

Model 644E Origin 3/04

Page 56

Operation

Optional Indicator Lights

There are two additional ìhiddenî indicator lights in the front dash panel that will illuminate only when the vehicle is equipped with the optional road light package.

High Beam Indicator (1)

Whenever the headlights are on ìhighî beam this light will illuminate and remain ON until the headlights are switched to ìlowî beam.

Turn Signal Indicator (2)

The turn signal indicator light will illuminate and flash when the turn signals are activated in either direction or when the hazard lights have been activated.

OS1900

OH2510

1/2

RPM X 100

r/min

0000000

104

°F

176

248 80 °C

120

OU0010

Model 644E Origin 3/04

Page 57

Operation

Optional Features

Worklights (Front, Rear & Boom)

The worklights are activated with a single rocker switch (3) located in the upper switch bank on the right side. There are three positions - OFF, Front Worklights and Front and Rear Worklights. The lights only work when the ignition switch is in the RUN position.

ï Push the TOP of the rocker switch in to turn all the

worklights OFF.

ï To turn the front worklights ON, position the rocker

switch to the CENTER position.

ï Push the BOTTOM of the rocker switch in to turn all

the worklights ON.

OH2570

OH2591

OH2601

OH2611

Model 644E Origin 3/04

OU0501

Page 58

Operation

Parking Lights, Headlights & High/Low Beam Switch

These lights will only work when the ignition switch is in the RUN position. Use the turn signal switch (1) to control the high/low beam headlights and to turn ON the parking lights and headlights.

Turn the twist grip end (2) of the turn signal switch counterclockwise to the first position (3) to turn the parking lights ON. Turn the twist grip to the second position (4) to turn the headlights and parking lights ON. Turn the twist grip clockwise to the OFF position (5) to turn all the lights OFF. Pull the turn signal switch toward you to switch from low beam to high beam. When the high beam is ON the high beam indicator light on the front dash panel will illuminate.

OS1900

OU0651

Model 644E Origin 3/04

Page 59

Operation

Directional Signals

The directional signals are ACTIVATED from the lever (6) on the right side of the steering wheel and will only work when the ignition switch is in the RUN position.

To activate the left turn signal (7); RAISE the lever. To activate the right turn signal (8); LOWER the lever. To deactivate either directional signal, the lever must be manually returned to the CENTER position. The lever will not cancel automatically after a turn.

OS1910

Model 644E Origin 3/04

OU0661

Page 60

Operation

Emergency Flashers

The emergency flashers are activated by a single rocker switch (1) located in the upper bank of switches on the right side of the dash.

ï To DEACTIVATE the emergency flashers, push the

TOP of the rocker switch IN.

ï To ACTIVATE the emergency flashers, push the

BOTTOM of the rocker switch IN.

Beacon Light or Strobe Light

The beacon light or strobe light are activated by a single rocker switch (2) located in the upper bank of switches on the right side of the dash. This light will only work when the ignition switch is in the RUN position.

ï Push the TOP of the rocker switch in to turn the

beacon light or strobe light OFF.

ï Push the BOTTOM of the rocker switch in to turn the

beacon light or strobe light ON.

OS1920

OH2591

OH2611

OH2580

OH2591

OH2611

Model 644E Origin 3/04

OU0501

Page 61

Operation

Door Latches (Closed Cab Only)

There are two door latches for the lower door. The outside latch (3) is a key lockable pull-to-release type. The inside latch (4) is a pull-to-release latch.

Door Window Latch (Closed Cab Only)

The door window (5) can be swung open by releasing the window from inside the cab. Release the window from the door with the window latch handle (6). Pivot the handle out of the way and swing the window open. Swing the window all the way open and lock in place on the outside of the cab. The window can be released from inside the cab using the window release located on the inside of the cab or from the outside, using the outside release (7) located on the cab door window. The inside and outside latches are both turn to release locks.

CAUTION: DO NOT operate the vehicle with the door window

swinging free. Damage to the door window could result if door window is not secured in the OPEN or CLOSED position.

The door window must be latched in the OPEN position or the CLOSED position during operation of the vehicle.

Model 644E Origin 3/04

OU1190

Page 62

Operation

Rear Window Latch (Closed Cab Only)

The rear window (1) can be partially opened and secured in place with the rear window latch. To open the window, grab the latch handle (2), PULL UP and then push the window OUTWARD. To close and secure the window, pull the latch handle UP and then INWARD.

NOTE: In an emergency situation, the operator can exit through the rear window opening by removing the latch pin (3) on the window latch. The window is then free to swing open.

OU0920

Front Windshield (Closed Cab Only)

Windshield Removal

1. The front windshield (4) can be removed from the cab to provide additional ventilation.

2. Remove the windshield wiper arm assembly (5) from the wiper shaft. Reinstall the two nuts (6) onto the shafts to protect the threads of each shaft. Store the wiper arm assembly in a safe place.

3. To remove the windshield, remove the five capscrews (7) holding the lower retainer plate (8) to the cab. Remove the retainer plate.

4. Carefully push the bottom of the windshield out. Pull the top of the windshield out from under the top retainer (9). Store the windshield in a safe place.

Model 644E Origin 3/04

Page 63

Operation

Windshield Installation

IMPORTANT! Be sure the windshield retainer plate is secured in place after installing the windshield back into the cab. Never operate the vehicle with the windshield in place and the retainer plate missing.

1. With the seal bulb on the windshield toward the cab, place the top of the windshield under the upper retainer (9). Push the windshield up as far as possible.

2. Place the bottom of the windshield (4) into the windshield opening in the cab. Secure the windshield in place with the lower retainer plate (8) and the five capscrews (7). Tighten all five capscrews securely to hold the windshield in place.

3. Remove the two nuts (6) from the wiper arm shafts. Reassemble the wiper arm assembly (5) to the shafts and secure in place with the two nuts. Reconnect the washer hose to the hose barb.

OU1010

Model 644E Origin 3/04

Page 64

Operation

Front Windshield Wiper (Closed Cab Only)

This three position rocker switch (1) is located in the lower bank of switches on the right side of the dash. This single rocker switch controls the speed of the front windshield wiper.

ï Push the TOP of the rocker switch in to turn the front

wiper OFF.

ï Place the rocker switch in the MIDDLE position to

operate the wiper at LOW speed.

ï Push the BOTTOM of the rocker switch in to operate

the wiper at HIGH speed.

OS19301

OH2591

OH2601

OH2611

OU0501

Model 644E Origin 3/04

Page 65

Windshield Washer Control (Closed Cab Only)

Operation

This rocker switch (2) is spring loaded to return to the OFF position when released.

OS19401

The switch is located in the lower bank of switches on the right side of the dash.

ï Release the switch to deactivate the washer control.

OH2591

ï Press and hold the BOTTOM of the rocker switch in

to activate the windshield washer. The rocker switch is spring loaded and will return to the OFF position when released.

OH2611

Skylight Wiper/Washer & Rear Window Washer (Closed Cab Only)

OS2100

The skylight (roof) wiper/washer rocker switch and rear window washer switch (3) is located in the lower bank of switches on the right side of the dash. This single rocker switch controls the skylight (roof) wiper, skylight (roof) washer along with the rear window washer. When the skylight (roof) washer is activated the rear window washer is also activated.

ï Push the TOP of the rocker switch in to turn the

skylight (roof) wiper OFF.

ï Place the rocker switch in the MIDDLE position to

turn the skylight (roof) wiper ON. This wiper is a single speed wiper.

OM1520

OH2591

OH2601

ï Press and hold the BOTTOM of the rocker switch to

activate the skylight (roof) and rear window washers. The rocker switch is spring loaded and will return to the skylight (roof) wiper ON position when the washer position is released.

Model 644E Origin 3/04

OH2611

Page 66

Operation

Rear Window Wiper (Closed Cab Only)

The rear window wiper rocker switch (1) is located on the motor housing of the rear wiper.

The switch has two positions: wiper ON (2) and wiper OFF (3).

OM1530

OU0170

Cab Heater/Air Conditioning Controls (Closed Cab Only)

The cab heater and air conditioning controls

OS1950

(4) are located in the lower bank of switches on the right side of the dash. From left to right the control panel consists of: a variable speed fan control (5), an A/C on-off switch (6) and a temperature control (7).

Control of air flow is made by opening, closing or redirecting the air vent louvers in seperate locations inside the cab. For instance, if the front glass needs rapid defrosting, redirect the air flow at the front vents (directing the vent louvers toward the glass) and close the remaining vents. This will increase the volume of air flow to the front glass and speed defrosting.

OS1960

OU0501

Model 644E Origin 3/04

Page 67

To heat the cab:

Operation

ï turn A/C switch (6) to

the OFF position,

ï turn temperature control knob (7) to far right position

(RED = HOT),

ï direct desired air flow by adjusting vent louvers, ï turn fan control (5) to position ì3î (8) to assure rapid warm-up.

To defrost the cab:

ï turn temperature control

knob (7) to the far right position (RED = HOT),

ï direct desired air flow by adjusting vent louvers, ï turn fan control (5) to position ì3î (8) to assure rapid defrost.

To cool the cab:

ï turn A/C switch (6) to the

ON position,

ï turn temperature control

knob (7) to the far left position (BLUE = COOL),

ï direct desired air flow by adjusting vent louvers, ï turn fan control (5) to position ì3î (8) to assure rapid cool-down.

OS1950

OA1390

OS1960

Model 644E Origin 3/04

OU0930

Page 68

Operation

Carriages

Quick Attach

This vehicle is equipped with a quick attach system for easy attachment changing.

Attachment Removal

Be sure you are performing this procedure on level ground.

1. Come to a complete stop, place the travel select lever in the (N) NEUTRAL DETENT position and engage the parking brake switch.

2. Extend the boom approximately 10 feet (3 meters) and tilt the carriage backward.

3. Exit the vehicle using both hand holds.

4. Raise the quick attach pin lock lever (1) and pull out the pin (2) at the bottom of the quick attach link (3).

5. Return to the operators compartment, fasten the seat belt and lower the attachment to the ground in a level position. Tilt the attachment forward. This will rotate the quick attach link back away from the attachment.

6. Lower and then retract the boom until the ends of the attachment pivot pin has disconnected from the attachment.

Model 644E Origin 3/04

OS03312

Page 69

Operation

Attachment Reconnect

Be sure you are performing this procedure on level ground.

1. Position the vehicle directly behind the attachment to be mounted.

2. Tilt the quick attach backward.

3. Extend the boom approximately 10 feet (3 meters) and drive the vehicle forward until the attachment pivot pins are below and between the two hooks on the attachment.

4. Raise the boom until the attachment pivot pins have seated fully in the hooks of the attachment.

5. Tilt the attachment up slightly. The quick attach link should be tight against the rear of the attachment and the holes in the link and the attachment should be aligned.

6. Place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and exit the vehicle using both hand holds.

7. Lift the quick attach lock lever (1). Insert the quick attach pin (2) completely through the attachment and the quick attach link. Be sure the quick attach lock lever has lowered and seated itself into the groove in the quick attach pin.

WARNING: DO NOT operate this vehicle unless you are in the

seat with the seat belt fastened around you. Death or serious personal injury could result if the belt is not securely fastened.

8. Return to the cab, fasten the seat belt and resume operation.

Model 644E Origin 3/04

Page 70

Operation

Indicators

Boom Angle Indicator

The boom angle indicator (1) is a bubble type indicator with angular graduations (2) from -20 to +80 . It is located on the left side of the outer boom (3) and is visible from the operators position. Use this indicator to determine the boom angle when reading the capacity chart (see ìUsing the Capacity Chartî on page 71).

OU0460

Boom Extension Indicator

The boom extension indicator is a series of letters (4) that become visible as the boom is extended. It is located on the left side of the intermediate boom (5) and is visible from the operators position. Use this indicator to determine the boom extension when reading the capacity chart (see ìUsing the Capacity Chartî on page 71).

A B

OU0470

Model 644E Origin 3/04

Page 71

Operation

Transfer Carriage Extension Indicator

The transfer carriage extension indicator (6) shows the operator the distance the transfer carriage has moved from the fully retracted position. Use this indicator along with the boom extension indicator, boom angle indicator and the load chart booklet supplied with the vehicle to determine safe load placement.

OU0540

Rear View Mirrors

Three rear view mirrors are provided to aid the operatorís rear visibility. One mirror is mounted on the front left upper corner of the cab (7), one inside the cab (8) and the other mirror is mounted on the front right side of the vehicle (9). All the mirrors are adjustable and need to be adjusted to obtain the best rear view possible for the operator.

NOTE: To adjust the front mirror (9) on the right side of the frame, the mounting bolt for the mirror must be loosened to permit the mirror head to be adjusted. Tighten the mounting bolt after adjustment is complete.

Model 644E Origin 3/04

OU0720

Page 72

Operation

Fork Rating

All approved forks for this vehicle are marked with a maximum load capacity rating. This rating is stamped on the left edge of the fork (1) just below the fork pivot shaft (2). The rating is listed in U.S. pounds and based upon a 24" (610 mm) load center (3). This rating specifies the maximum load capacity that the individual fork can safely carry at the maximum load center (4) of 24" (610 mm)

Since forks are always used in multiples, the total rating of any combination of forks will be the sum of their rated capacity. Other than block forks, all forks should be used in matched pairs. Block forks should be used in matched sets.

XXXX - 24

OU0131

WARNING: DO NOT exceed the total rated capacity of the spe-

cific pair of forks being used. Forks can break causing loss of load and possible death or serious personal injury to the operator or personnel in the area. If the total rated capacity of the forks exceeds the vehicle, the vehicle capacity should not be exceeded.

The maximum load capacity for this vehicle is 6,000 pounds (2.721 Kg). The matched pair or set of forks used on this vehicle should have total load ratings which equal or exceed 6,000 pounds (2.721 Kg). When the load rating of the vehicle differs from the load capacity of the forks, the lower value becomes the overall load capacity.

the capacity of

Model 644E Origin 3/04

Page 73

Operation

Using the Capacity Chart

The individual capacity charts are located on the dash on the right side of the operatorís compartment. Capacity charts are provided to assist the operator in determining how far in front, how high and at what angle a specific load can be safely handled with this vehicle.

IMPORTANT! Always determine whether a load chart is required whenever using an attachment with this telescopic material handler. Reproductions of the load charts for all attachments, available as of the date of this publication, are included in the ìLoad Chartî section at the end of this manual. If a load chart for an attachment you would like to use is not included in this manual, contact your local Lull Distributor or the JLG Service Department at: (877) 554-5438 or (717) 485-6657 to confirm the attachment you are interested in using may be used and whether a load chart is required.

The vehicle is equipped with three indicators that will assist the operator in determining how to accurately use the capacity chart. These indicators are:

ï boom extend letters (5) ï boom angle indicator (6) ï transfer carriage extension indicator (7)

As the boom is extended, boom extend letters (5) become visible on the left side of the intermediate boom (8). These letters indicate the point (zone) of boom extension and correspond to the capacity chart. For example, when the boom extend ìBî first appears, the boom is at the point of boom extension corresponding to an arc of line ìBî on the capacity chart.

A B

The boom angle indicator (6), located on the left side of the outer boom, indicates the angle of the boom and also corresponds with the angles indicated on the capacity chart.

The transfer carriage extension indicator (7) shows the operator the distance the transfer carriage has moved from the fully retracted position. Use this indicator in conjunction with the boom extend letters and the boom angle indicator to accurately read and use the capacity charts.

Model 644E Origin 3/04

OU0470

OU0540

Page 74

Operation

To accurately use the capacity chart, the operator must first determine three important things:

1. Weight of the load being lifted.

2. Height

3. Distance where the load will ultimately be placed in front of the front tires.

Reading Capacity Charts

Example: (1)

1. The operator has placed the load onto the forks, fully retracted the boom,

2. The operator determines that:

3. After applying the height of the structure and the distance of load place-

This condition is, however, a maximum limit for this weight, height and distance away from the vehicle. The operator should move the vehicle closer to the structure to assure that the vehicle will not exceed the maximum limits for placing the load.

of the structure where the load is to be placed.

positioned the vehicle perpendicular to the structure and leveled the vehicle.

ï The weight ï The height of the structure the load is to be placed upon is 27 feet

(8 meters) from ground level.

ï The distance where the load will ultimately be placed in front of the

vehicle is 13 feet (4 meters) from the front of the tires.

ï The transfer carriage will remain fully retracted (0").

ment away from the vehicle to the sample capacity chart, the operator knows that it will be safe to place the load if the boom extend letter for zone ìEî has not started to show and the boom angle indicator reading does not go below approximately 45 and the transfer carriage will remain fully retracted.

of the load is 6,000 pounds (2.721 kg).

WARNING: DO NOT exceed rated capacities! Any attempt to lift

or carry loads in excess of those shown on the capacity chart may cause vehicle tipover, loss of load or structural damage which could result in death or serious personal injury.

IMPORTANT! When using the PlaceAceô transfer carriage to place a load, be sure to refer to the appropriate load chart that depicts the operation (movement) of the transfer carriage (1" to 80"). This chart applies to any movement of the transfer carriage. The load charts are reproduced at the end of this manual in the ìLoad Chartî section.

To accurately identify the load charts that apply, refer to the following icons which are also located in the upper right hand corner of each load chart.

ï Use for any forward movement (1" to 80") of the

transfer carriage.

ï Use for 0" of transfer carriage movement. Fully

retracted position only.

80" 1"

OU1080

Model 644E Origin 3/04

Page 75

Sample Capacity Chart

Operation

approved carriages only.

644E-42

0 ft.

-4

10°

-5°

20°

30°

1 5 0 0

2 0 0 0

40°

3 0 0 0

Use with Lull

60°

50°

4 0 0 0

4110409

0 ft.4812162024283236

66°

SAFETY INSTRUCTIONS

Always connect couplers on hydraulically powered attachments.

0 0 0

24"

ASME B56.6-2002 Part lll

0 ft.

Model 644E Origin 3/04

48" & 50"

OU0682

Page 76

Operation

Stabil-TRAK System

Understanding the Stabil-TRAKô System

The following describes the three basic modes of the patented Stabil-TRAK system. The vehicle may operate in any one of these three modes.

Free Pivot Mode

With the boom below 40 (1), the Stabil-TRAK system is in the FREE PIVOT MODE (2) and the rear axle is allowed to pivot freely. The frame sway control will function normally. Both Stabil-TRAK lights on the front dash panel will be OFF (3).

RPM X 100

0000000

1/2

r/min

OS1970

°F

176

104

248 80 °C

120

OU0100

Model 644E Origin 3/04

Page 77

Operation

Locked Mode

With the boom above 40 (4) and by activating one or more of the functions (as follows), the Stabil-TRAK system is in the LOCKED MODE (5). The rear axle is locked so it is rigid with the frame. The Stabil-TRAK lock light on the front dash panel will be ON (6). The Stabil-TRAK slow pivot light on the front dash panel will be OFF (7).

ï Engaging the parking brake switch ï Placing the travel select lever in the (N) NEUTRAL DETENT position ï Depressing and holding the service brake pedal

The frame sway control will function slower than normal in this mode.

1/2

RPM X 100

0000000

104

r/min

°F 176

248 80 °C

120

OU0110

Model 644E Origin 3/04

Page 78

Operation

Slow Pivot Mode

With the boom above 40 (1), the Stabil-TRAK System is now in the SLOW PIVOT MODE (2) when the service brake pedal is not applied and the transmission is in gear. In this mode the rear axle is UNLOCKED and is allowed to pivot but will respond SLOWLY to changes in terrain. The Stabil-TRAK slow pivot light on the front dash panel will be ON (3). The Stabil-TRAK lock light on the front dash panel will be OFF (4).

The frame sway control will function normally in this mode.

1/2

RPM X 100

0000000

104

r/min

°F

176

248 80 °C

120

OU0120

To check that the Stabil-TRAK System is functioning properly, refer to the test procedure on page 77 for the proper system function.

Model 644E Origin 3/04

Page 79

Operation

Stabil-TRAKô System Test

To test the function of the Stabil-TRAK system, read the Stabil-TRAK System Test Instructions on this page and follow Steps 1 through 9 of the Stabil-TRAK System Test Procedures.

Stabil-TRAKô System Test Instructions

ï Test the Stabil-TRAK system with the vehicle on a level surface. ï Remove any attachment from the quick attach before performing the test. ïDO NOT extend the boom at any time during the test. Perform the test with

the boom fully retracted.

ïDO NOT transfer the carriage forward any time during the test. Keep the

transfer carriage in the fully retracted position.

ïDO NOT raise the boom above 60 for Steps 3 through 6. ïDO NOT raise the boom above 45 for Steps 7 through 9. ï Follow Steps 1 through 9 of the Stabil-TRAK system test procedure exactly

as written.

IMPORTANT! If the Stabil-TRAK lock light goes OFF and the front left tire lowers to the ground at any time during Steps 4 through 7, the test was not performed properly or the Stabil-TRAK system is not functioning properly. Carefully repeat the steps starting with Step 1.

If the Stabil-TRAK lock light goes OFF and the front left tire lowers to the ground consistently during Steps 4 through 7, the Stabil-TRAK system is not functioning properly and the test should be stopped immediately. Contact your local Lull Distributor immediately to repair the system.

IMPORTANT! Be sure the transmission disconnect system switch is DEACTIVATED BEFORE the Stabil-TRAK System test is started, and remains deactivated during the entire test.

NOTE: The front left tire off of the ground during the test is a visible indication that the stability system is in the locked mode.

WARNING: DO NOT operate this vehicle unless you are in the

seat with the seat belt fastened around you. Death or serious personal injury could result if the belt is not securely fastened.

Model 644E Origin 3/04

Page 80

Operation

Step 1

Step 2

FREE PIVOT MODE

Step 3

Service Brake Test

Stabil-TRAK System Test Procedures

a. Place the vehicle on a level surface with 0 sway. b. Have the boom fully retracted and horizontal. c. Place an 8" (203 mm) wood or cement block in front of

the front left tire. d. Enter the vehicle. e. Fasten the seat belt.

f. Turn the ignition switch to the RUN position.

g. Check to be sure the Stabil-TRAKô lock light and

the slow pivot light are both OFF.

a. Turn the ignition switch and start the engine. b. Turn the parking brake switch OFF. c. Move the range select lever to (1) FIRST gear. d. Move the travel select lever to the (F) FORWARD

position. e. Drive the vehicle up on the block and stop the vehicle.

f. Use the frame sway control to level the vehicle back to 0 .

a. Depress the service brake pedal. b. Move the travel select lever to the (N) NEUTRAL

DETENT position. c. Raise the boom to exactly 60

. The Stabil-TRAKô lock light should come ON when the boom angle is at about 40 and remain ON. The Stabil-TRAKô slow pivot light should be OFF.

Model 644E Origin 3/04

Page 81

LOCKED MODE

Operation

Stabil-TRAK System Test Procedures

Step 4

a. Use your left foot to depress the service brake pedal.

b. Move the travel select lever to the (R) REVERSE position

and the range selector to the (2) SECOND gear position.

Service Brake TestNeutral TestPark Brake Test

c. Ease your left foot partially off the service brake pedal,

just keeping the Stabil-TRAKô lock light ON Approximately 3/4 pedal travel which will be 150 psi (10,3 bar) pressure in the brake valve.

d. With your right foot, increase the engine rpm slightly, as

necessary, to back the vehicle off the block. The Stabil-TRAKô lock light should remain ON while backing off the block, the front left tire should remain off the ground. If the front left tire drops to the ground, repeat steps 1 thru 4.

IMPORTANT: Perform Steps 5 thru 9 with the engine rpm at idle.

Step 5

a. Keep the service brake pedal

depressed.

b. Move the travel select lever to the (N) NEUTRAL

DETENT position.

c. Take your foot off the service brake pedal. The

Stabil-TRAKô lock light should remain ON and the front left tire should remain off the ground.

Step 6

a. With the travel select lever

in the (N) NEUTRAL DETENT

position, engage the parking brake switch.

b. Move the travel select lever to the (F) FORWARD

position. DO NOT depress the service brake pedal. The Stabil-TRAKô lock light should remain ON and the front left tire should remain off the ground.

Model 644E Origin 3/04

Page 82

Operation

Step 7

LOCKED MODE

Step 8

SLOW

PIVOT

MODE

LOCKE

MODE

Stabil-TRAK System Test Procedures

a. With the parking brake switch

ON, move the travel select

lever to the (N) NEUTRAL DETENT position.

b. Lower the boom to exactly 45 c. Frame sway the vehicle no more than 5

to the left. d. Frame sway the vehicle back to 0 . e. Frame sway the vehicle no more than 5

to the right.

Note: Observe that frame sway will be slower than normal during this test.

f. The Stabil-TRAKô lock light should remain ON and the

front left tire should remain off the ground. The front left tire should not raise or lower during frame sway.

g. Frame sway back toward 0 , leaving the vehicle swayed

to the right approximately 1 to 2 .

a. Depress the service brake pedal fully. b. Disengage the parking brake switch. c. With the range select lever in (1) FIRST gear, move the

travel select lever to the (R) REVERSE position.

d. Release the service brake pedal to deactivate the

Stabil-TRAKô system.

e. The Stabil-TRAKô lock light should go OFF and the

Stabil-TRAKô slow pivot light should come ON.

f. The front left tire should return to the ground while the

vehicle travels in reverse.

g. Depress the service brake pedal to stop the vehicle.

Model 644E Origin 3/04

Page 83

Operation

Stabil-TRAK System Test Procedures

Step 9

a. With the service brake pedal depressed and the boom

angle at exactly 45

MODE

LOCKED

SLOW PIVOT MODE

Note: If Steps 1-9 prove positive, the Stabil-TRAKô system is

functioning properly, and the vehicle can be returned to service. If any of these steps indicate that the Stabil-TRAKô system is not functioning properly, contact your local Lull Distributor immediately to repair the system.

THIRD gear. b. Move the travel select lever to (F) FORWARD. c. Release the service brake pedal to deactivate the

Stabil-TRAKô system. The Stabil-TRAKô lock light

should go OFF and the Stabil-TRAKô slow pivot light

should come ON.

d. Slowly drive the vehicle forward against the block to stop

the vehicle from moving forward.

e. With the front left tire against the block, frame sway the

vehicle no more than 5

f. Check that the front left tire remains on the ground. It is

normal for the front left tire to raise slightly when swaying

to the left, but the tire should immediately lower when the

frame sway function is stopped.

g. Frame sway the vehicle back to 0 and pause briefly. h. Frame sway the vehicle no more than 5

i. Check that the front right tire remains on the ground. It is

normal for the front right tire to raise slightly when

swaying to the right, but the tire should immediately lower

when the frame sway function is stopped.

j. Frame sway the vehicle back to 0 .

k. Depress the service brake pedal.

l. Shift the travel select lever to the (N) NEUTRAL DETENT

position.

m. Lower the boom.

, move the range select lever to (3)

to the left.

to the right.

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Operation

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Operation

Refueling

Make sure the vehicle is level to assure an accurate fuel level reading. The fuel tank is capable of holding 45 gallons (171 liters) of diesel fuel.

Fuel Types

OS0860

The preferred fuel is ASTM #2 diesel fuel with a minimum Cetane rating of 40. #2 diesel fuel gives the best fuel economy and performance under most operating conditions. Fuels with Cetane ratings higher than 40 may be needed in higher altitudes or extremely low ambient temperatures to prevent misfiring and excessive smoke.

ï When operating at temperatures above 32 F (0 C), use standard #2

diesel fuel.

ï When operating at temperatures below 32 F (0 C), use a blend of #1 &

#2 diesel fuels, most commonly known as ìwinterizedî #2 diesel.

WARNING: Engine fuel is flammable and can cause a fire or an

explosion. Keep sparks and open flames away from the vehicle and DO NOT use smoking materials while refueling.

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Operation

Fuel Cap

The fuel cap (1) is conveniently located on the left side of the vehicle. The fuel cap meets EPA standards.

To remove the fuel cap:

1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and turn the ignition switch to the OFF position. Remove the keys from the ignition.

OM1900

WARNING: REMOVE FUEL CAP SLOWLY. Fuel spray may

cause personal injury. Fuel can spray out on you if you open the cap too quickly or if you fill the tank too rapidly.

2. Slowly turn the cap in a counterclockwise rotation. Wait for any ìhissingî noise to stop. Then unscrew the cap all the way and remove the cap from the filler neck.

To install the fuel cap:

Turn the cap clockwise until the cap bottoms on the filler neck. The fuel cap is now properly installed.

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Operation

Normal Starting

1. Enter the cab and adjust the seat for comfortable operation.

2. Adjust the mirrors to obtain the best rear view from the operatorís position.

WARNING: DO NOT start the engine unless you are in the seat

with the seat belt fastened around you. Death or serious personal injury could result if the belt is not securely fastened.

3. Fasten the seat belt.

4. Make sure the parking brake switch is ENGAGED.

5. Place the travel select lever in the (N) NEUTRAL DETENT position.

6. Turn the ignition switch to the START position (fully clockwise) to crank the engine. Release the ignition switch when the engine starts. If the engine fails to start on the first try, wait until the engine and starter come to a complete stop before cranking the engine again.

IMPORTANT! DO NOT crank the starting motor continuously for more than 30 seconds. Stop cranking the starter and allow the starter to cool for 2 minutes before engaging the starter again.

7. After the engine starts, run engine at partial throttle for 30 to 60 seconds before operating the vehicle. Return to idle before engaging the travel or range select levers.

8. Disengage the parking brake switch before you start operating.

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Operation

Cold Starting

The engine is equipped with a 120 volt 750 watt block heater. Block heaters are recommended when temperatures drop below 10 F (-12 C). (Temperature ranges will vary when using different oil weights. Consult the engine manufacturerís manual for other variables.

FOR ENGINES EQUIPPED WITH OPTIONAL COLD STARTING AID

WARNING: This diesel engine uses a grid heating system inside

the induction manifold. DO NOT use ether or any high energy fuels to assist starting. An explosion may cause death or serious personal injury or engine damage.

The engine is equipped with a grid heater inside the induction manifold. If the temperature drops below 40 F (4 C) the air-intake heater system will be activated when the ignition switch is turned to the RUN position. When the system is active the air-intake heater light will illuminate on the front dash panel. DO NOT turn the ignition switch to START until the air-intake heater light goes OFF.

At temperatures below 10 F (-12 C), operate the engine at moderate speeds for 5 minutes before full loads are applied.

1. Enter the cab and adjust the operatorís seat.

WARNING: DO NOT start the engine unless you are in the seat

with the seat belt fastened around you. Death or serious personal injury could result if the belt is not securely fastened.

2. Fasten the seat belt. Adjust the mirrors if necessary.

3. Make sure the parking brake switch is ENGAGED.

4. Make sure the travel select lever is in the (N) NEUTRAL DETENT position.

5. Turn the ignition switch to the RUN position. Wait for the engine air-intake heater light on the front dash panel to turn OFF. When the light turns OFF the engine grid heater is at the proper temperature and the engine is ready to start.

6. Turn the ignition switch to the START position to crank the starter.

IMPORTANT! DO NOT crank the starting motor continuously for more than 30 seconds. Stop cranking the starter and allow the starter to cool for 2 minutes before engaging the starter again.

7. As the engine starts, release the ignition switch to the RUN position. Depress the accelerator pedal enough to provide a smooth idle speed.

8. The engine oil pressure warning indicator light should go OFF within five seconds after starting. If the light remains ON, turn the ignition switch OFF immediately and check the oil level or change to a lighter weight oil. Consult the engine manufacturerís manual for alternative oils for cold weather operation.

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Operation

Jump Starting

WARNING: NEVER jump start the vehicle directly to the starter

solenoid. Death or serious personal injury could result from the vehicle lurching forward or backward and running over the person attempting to jump start the vehicle directly to the starter.

WARNING: To avoid death or serious personal injury when jump

starting with another vehicle, be certain that the two vehicles are not touching. Never jump start the vehicle with a frozen battery as it will explode. Keep sparks, flames and lighted smoking materials away from the battery. Lead acid batteries generate explosive gases when charging. Wear safety glasses when working near batteries.

This booster battery must be a 12 volt type. The vehicle used for jump starting must have a negative ground electrical system. To jump start the vehicle, proceed as follows:

1. Connect the positive (+) jumper cable to the positive (+) post of the discharged battery.

2. Connect the other end of the positive (+) jumper cable to the positive (+) post of the booster battery.

3. Connect one end of the negative (-) jumper cable to the negative (-) post of the booster battery.

4. Make the final connection to the furthest point from the battery.

5. Follow the steps in ìNormal Startingî on page 85.

6. Remove the jumper cables in the reverse order of their connection (i.e. negative ground connection first, etc.).

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Operation

How To Pick, Carry & Place A Load

To pick a load, move the forks inward or outward on the fork shaft so that they are aligned with the openings in the pallet. Extend the boom slowly so the forks slide into the openings in the pallet. Raise the boom so that the load is lifted.

To carry a load, position the boom so that the load is as low as possible and the travel area is visible to the operator.

Before placing the load, use the capacity chart to determine safe boom extension range for the applicable load. To place a load, align the forks at the level the load is to be placed and then extend the boom slowly until the load is just above the area where it is to be placed. Lower the boom until the pallet rests in position and the forks are free to retract.

The transfer carriage extension can be used to place the load onto the landing point, being certain that the load on the forks is within the transfer limits shown on the individual capacity charts.

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Operation

Elevating Personnel

This vehicle is designed to lift and transport materials and should not be used to elevate personnel except as explained in this section. Only equipment designed and approved for elevating personnel should be used.

If the vehicle must be used to elevate personnel, use only a compliant work platform. Refer to ìDefining Platforms For Elevating Personnelî on page 89 for requirements. When using a work platform, the following precautions must be taken:

WARNING: Use only a compliant work platform to lift or lower

personnel. Never drive the vehicle with the work platform in a raised position or with personnel on board, even for a short distance.

Defining Platforms For Elevating Personnel

The requirements for platforms shall include the following:

1. The platform floor must have a slip resistant surface not more than 8" (200 mm) above the normal load supporting surface of the forks.

2. The platform floor dimensions shall not exceed:

a. Two times the load center distance as listed on the load chart that is

attached to the vehicle or shown in the ìLoad Chartî section at the end of this manual. This floor dimension is measured parallel to the longitudinal center plane of the vehicle.

b. Width of the platform shall not be wider than the width of the vehicle,

measured across the load bearing tires plus 10" (250 mm) on each side.

c. Minimum space requirements for each person on the platform shall not

be less than 18" (450 mm) in either direction.

3. The platform shall have a 4" (100 mm) minimum high toe plate around the perimeter of the platform. The toe plate may be omitted at the access opening.

4. Protection must be provided for the personnel on the work platform from any pinch points or moving parts while in their normal working position on the platform.

5. Information prominently indicated on the work platform shall include:

a. Maximum work load including personnel and equipment. b. Weight of the empty platform.

6. Provide a means to securely mount and attach the platform so it can:

a. Only be centered laterally on the vehicle and retained against the verti-

cal face of the forks, carriage or the lifting mechanism.

b. Prevent the platform from inadvertent pivoting.

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Operation

7. The platform must have a restraining means such as a guardrail or a means of securing personnel such as a body belt or lanyard for each occupant of the platform.

8. The guardrail or similar structure shall have a nominal height to the platform floor of 42" (1066 mm) around the perimeter of the platform and include a midrail. The guardrail openings may be used to provide alternate access openings provided the opening can be easily made by hinging or removing sections, but must be easily put back into original position when alternate openings are no longer required.

9. The guardrail shall be capable of withstanding a concentrated horizontal force of 200 lb (890 N) applied at the point of least resistance without permanent deformation.

10. A body belt and lanyard is to have an attaching point for freedom of movement, and its length is to limit free fall to 5 feet (1500 mm) measured from the point of attachment to the operator. The complete system shall be capable of withstanding three consecutive drop tests to simulate a 250 lb (113 kg) person falling 6 feet (1800 mm) without allowing the test weight to fall free to the ground. A deceleration device may be included.

11. Lanyards, when provided, shall be arranged so as not to cause a tripping hazard.

12. Body belts, when provided, should have a width of at least 1.75 in. (44 mm).

13. Structural safety factor - all load supporting structural elements of the work platform shall have a structural safety factor of not less than 2 to 1 based on the minimum yield strength of materials used.

Capacity Limitations

The combined mass (weight in pounds) of the platform, load and personnel shall not exceed one-third (33%) of the capacity of the related load center position indicated on the capacity chart. Refer to ìUsing the Capacity Chartî on page 71.

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Operation

Preparation and Set-up

WARNING: Never allow anyone to alter or modify any part of the

work platform. Any modification to the platform which could result in serious personal injury to anyone on the platform.

1. DO NOT alter or modify the work platform in any manner.

2. Make sure that the work platform is securely attached to the quick attach or forks. Follow the platform manufacturerís instructions.

3. Make sure the platform, carriage and forks are secured to prevent them from pivoting from side to side.

4. On side tilt or swing carriages, the carriage must be centered and/or leveled horizontally and vertically. The hydraulic system quick disconnects must also be disconnected and plugged and the carriage securely fastened to prevent any tilting or side to side swinging motion.

5. Ensure the vehicle has a firm footing and is level.

6. Be sure the vehicle is in a level position (side to side) before any operation is begun. Use the frame sway to level the vehicle. If the vehicle cannot be leveled, reposition the vehicle.

7. Place the travel select lever in the (N) NEUTRAL DETENT position.

8. Engage the parking brake switch. Blocking the wheels is also recommended.

9. Level the platform in both the side-to-side and front-to-back directions before use.

10. Before lifting or lowering personnel, be sure the vehicle lifting mechanism operates smoothly through the entire lifting and lowering of the platform and maintains its self leveling function. The vehicle must operate smoothly both empty and loaded.

11. Be sure any lift limiting devices and latches are functioning properly.

12. Any body belt, lanyard or deceleration devices which have sustained any deformation or damage must be replaced before using the work platform again.

13. Before elevating personnel, the area around and under the work platform should be marked to warn anyone on the ground that overhead work is being done.

14. Protection must be provided for the personnel on the work platform from any pinch points or moving parts while in their normal working position on the platform.

15. Provide any overhead protection device as required by worksite conditions or if requested by the user of the platform.

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Operation

Elevating Personnel

WARNING: Never operate the Attachment Tilt function to tilt the

platform forward or rearward when elevating with personnel aboard. Death or serious personal injury could result.

DANGER: Never operate this or any equipment in an area in

which overhead or underground cables or power sources exist without first requesting that the appropriate power company or utility company de-energize the lines or take other suitable precautions.

1. Make sure there are no overhead obstructions or electrical wires above the platform before lifting.

2. A trained operator must operate the controls from the operators compartment and must remain with the vehicle at all times. Using extreme caution, lift and lower personnel smoothly and only at their request. The operator should move the platform up and down only in response to instruction from personnel on the platform. If the operator must move the platform, the operator must alert the personnel aboard the platform before moving.

3. Personnel aboard the work platform must maintain a firm footing at all times.

4. Be certain the personnel and related equipment on the platform do not exceed the available space of the platform.

5. The platform shall be lowered to the ground level for personnel to enter or exit the platform through the appropriate platform access opening. Personnel must not climb on any part of the vehicle or over the platform guardrails in an attempt to enter or exit the platform.

6. Always position the platform in the travel position (approximately one foot above ground level) before moving the vehicle.

IMPORTANT! Make sure that required restraining equipment such as railings, chains, cable, body belts with lanyards, etc. are in place and properly used. Never use railings, planks, ladders, etc. on the platform for the purpose of achieving additional reach or height.

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Operation

Using Other Attachments

Numerous attachments, marketed by JLG are available for this vehicle. The capacity charts attached to this vehicles dash are to be used with JLG approved attachments only. Hydraulically powered attachments must only be used on vehicles equipped with auxiliary hydraulics.

IMPORTANT! This vehicle is intended for the function of lifting not designed to PULL, TOW or DRAG other objects.

JLG makes no representations or warranties, expressed or implied, as to the design, manufacture or fitness for use with this vehicle of any third party source attachment. This vehicle is not intended to be used and should not be used with an attachment that would alter the center of gravity or stability of this vehicle. JLG assumes no liability for any third party attachment that would alter the center of gravity or stability.

IMPORTANT! DO NOT use unapproved attachments.

Following is a list of some of the attachments available through JLG for this vehicle model:

ï 48" Standard Carriage ï 48" Side Tilt Carriage ï 50" Standard Carriage ï 50" Side Tilt Carriage ï 60" Standard Carriage ï 60" Side Tilt Carriage ï 72" Framers Carriage ï 72" Framers Tilt Carriage ï Single Fork Positioning Carriage ï Dual Fork Positioning Carriage ï 1-1/4 Cubic Yard Bucket ï Auger Attachment ï Sweeper Attachment ï .5 Cubic Yard Concrete Hopper

The standard capacity chart, as shown in the last section of this manual, is applicable for the above listed attachments.

only. This vehicle is

Model 644E Origin 3/04

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Operation

The attachments listed below are supplied with their own individual set of capacity charts as shown in the last section of this manual:

ï 72" Swing Carriage ï 10 Foot Truss Boom ï 10 Foot Truss Boom w/Winch ï 3 Foot Truss Boom w/Winch

Hydraulically actuated attachments also have a maximum hydraulic pressure rating. Ensure that the maximum rated hydraulic pressure of the attachment is equal to or slightly greater than 3,000 psi (206,8 bar), which is the maximum pressure of the vehicleís auxiliary hydraulics at the quick disconnect couplers.

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Operation

Shut-Off

1. Bring the vehicle to a complete stop using the service brakes.

2. Park the vehicle on level ground.

WARNING: To prevent death or serious personal injury, be cer-

tain to lower the boom, engage the parking brake switch, and shut off the engine prior to exiting the vehicle.

3. Place the travel select lever in the (N) NEUTRAL DETENT position and engage the parking brake switch.

4. Lower the boom and ground the attachment.

5. Turn the ignition switch to the OFF position and remove the key.

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Page 98

Emergency Operations

Towing a Disabled Vehicle

Towing a disabled vehicle should only be attempted after exhausting all other options. Every effort should be made to repair the vehicle and move it under its own power. Towing the vehicle improperly can result in damage to the vehicle drivetrain.

IMPORTANT! In the event the vehicle is disabled and cannot be moved under engine power, the situation must be properly evaluated and dealt with on an individual basis. Contact your local Lull Distributor or the JLG Service Department at (877) 554-5438 or (717) 485-6657 for specific instructions for your particular situation.

If it is necessary to tow the vehicle a short situation such as being in an unsafe area on the worksite or on a roadway, prepare the vehicle for towing as follows;

1. Remove the load from the vehicle.

2. Fully retract the transfer carriage.

3. Fully retract the boom. Position the forks approximately 24" above the ground. Refer to ìEmergency Boom Loweringî on page 98 for proper procedure if required.

distance to avoid a potentially hazardous

WARNING: BLOCK ALL FOUR WHEELS. Failure to do so

could result in death or serious injury from vehicle roll-away.

4. Block all four wheels to prevent any unexpected movement of the vehicle after the parking brake is disabled.

5. Position the towing vehicle in place. Attach a rigid tow bar to the disabled vehicle.

6. Remove the cover (1) from the cab floor to gain access to the valve plate under the cab.

7. Attach a remote portable hydraulic pressurizing unit to the park brake gauge port (2) on the accumulator charge/secondary function valve (3) located under the cab floor.

8. Clear the area of any unnecessary personnel.

9. Have an operator seated in the seat.

10. Turn the ignition switch to the ON position (with the engine not running), release the park brake (park brake switch OFF).

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Emergency Operations

11. Pressurize the park brake with the pressurizing unit. Pump pressure into

the park brake system. DO NOT exceed 650 psi (45 bar). Close the pump needle valve on the pressurizing unit.

CAUTION: DO NOT exceed 650 psi (45 bar) when pressurizing

the park brake. Applying too much pressure may damage the brake seals.

12. Watch the pressure gauge on the pressurizing unit to ensure that the pressure in the park brake system does not drop during the towing operation.

13. Carefully remove the blocks from the four wheels of the vehicle.

14. The vehicle can now be towed or pushed out of the way. Tow or push the

vehicle at a very slow speed!

15. Place the cab floor plate back inside the cab when towing is complete. Reinstall the capscrews and torque the capscrews (4) to 18 lb-ft (25 Nm).

OU0741

Model 644E Origin 3/04

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Emergency Operations

Emergency Boom Lowering

This section discusses emergency boom lowering procedures:

Part l: In case of loss of engine power or hydraulic pump failure. Part ll: In case of hydraulic line failure.

Part l Loss of Engine Power or Hydraulic Pump Failure

IMPORTANT! In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis. Contact your local Lull Distributor or the JLG Service Department at (877) 554-5438 or (717) 485-6657 for specific instructions for your particular situation.

In any event, the vehicle should be secured until the situation has been properly evaluated. Secure the vehicle by following the procedures below:

1. Clear the area around the vehicle of all personnel.

2. Block all four wheels.

3. Section off a large area under the boom with string or tape to restrict any personnel from entering this potentially dangerous area.

WARNING: DO NOT get under a raised boom unless the boom

is blocked up. Always block the boom before requires the boom to be up.

doing any servicing that

4. Temporarily block up or support the outer boom so it cannot be lowered.

5. If the load is in a position where it can be removed safely, completely remove the load from the carriage, otherwise leave the load in place.

6. Place an accident prevention tag on both the ignition switch and steering wheel. If you do not have a safety tag, place tape over the ignition switch.

Part ll Hydraulic Line Failure

In case of hydraulic line failure, there are step-by-step procedures available to assist you in safely retracting and then lowering the boom. Read Part II from start to finish before performing any of these procedures so you fully understand the process and the danger involved. If you are unsure about any part of these procedures contact your local Lull Distributor or the JLG Service Department at (877) 554-5438 or (717) 485-6657 for specific instructions for your particular situation.

IMPORTANT! For boom retract and lower, the hydraulic lines MUST be replaced, then retract and lower the boom in its normal fashion.

IMPORTANT! Be aware that the boom must first be retracted and then lowered to avoid vehicle tipover.

Model 644E Origin 3/04

Lull 644E-42 Operation Manual

Table of Contents

Introduction

The Manual

Replacement Parts

Reports

Safety Practices

Disclaimer

Hazard Classification System

Signal Word

Accident Prevention Tags

New or Additional Operators

Instructional Symbols

Hazard Symbols

Avoidance Symbols

Personal Considerations

1. Seat Belt

2. Clothing and Safety Gear

3. Dismounting

4. Chemical Hazards

A. Exhaust Fumes

B. Explosive Fuel

C. Ether or High Energy Starting Aids (Optional)

D. Hydraulic Fluid

E. Batteries

Battery Electrolyte First Aid:

5. Moving Parts Hazard

6. Lowering Boom or Falling Load Hazard

Operational Considerations

1. Preparation and Prevention

2. Clearances

3. Visual Obstruction

4. Underground Hazards

5. Electrocution Hazards

6. Elevating Personnel

7. Transfer Carriage Operation

8. Tip Over Hazard

9. Emergency Exit Rear Window

10.Tire Pressure

11.Do Not Jump

12.Slopes

13.Falling Load Hazard

14.Ventilation

Equipment Considerations

Operation

Pre-Operation Inspection

9. Check ALL lighting systems (if so equipped) for proper operation.

10. Adjust rear view mirrors as required to obtain proper field of vision to the rear.

11. Test the back-up alarm and horn for proper operation.

12. Check condition of cab glass (if so equipped), looking for cracks or other damage.

Operators Seat Adjustments

Seat Belt

4. To release the belt latch, depress the red button (5) and pull the free end (6) from the buckle.

Operator Controls

Accelerator Pedal

Service Brake Pedal

Steering Wheel

Horn Button

Ignition Switch

Steering Mode Selector

1. Four Wheel Steering Mode

2. Front Wheel Steering Mode

3. Crab Steering Mode

Four Wheel Steer Indexing

1. Select the four wheel steer mode with the steer mode selector.

2. Turn the steering wheel all the way to the right until it reaches the stop.

3. Select the front wheel steer mode with the steer mode selector.

4. Turn the steering wheel to the left, about one complete revolution.

5. Select the four wheel steer mode with the steer mode selector.

7. Select the front wheel steer mode with the steer mode selector.

8. Turn the steering wheel all the way to the right until it reaches the stop.

9. Select the four wheel steer mode with the steer mode selector.

10. Turn the steering wheel to the left, until the wheels are pointing straight ahead.

11. Drive the vehicle forward a short distance to check the wheel tracking.

Parking Brake Switch

Transmission Disconnect Switch

Travel Select Lever

Starting Travel

2. Rotate the twist grip (5) of the range select lever to 1st gear.

Changing Travel Direction