Lull 644E-42 Operation Manual
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
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
.
Table of Contents
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.
1
Introduction
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.
1
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.
2
Model 644E Origin 3/04
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
3
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.
4
Model 644E Origin 3/04
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.
3
2
DANGER
DANGER
1
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
5
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
0"
OU1580
Transfer
Carriage Fully
Retracted
OS0900
Always Maintain
Proper Tire
Pressure
6
Model 644E Origin 3/04
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
7
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
8
OH3110
OU1450
ENGINE EXPLOSION Can
Result In Death Or Serious
Injury
(Optional Grid Heater Cold
Starting Aid)
Model 644E Origin 3/04
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
9
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)
10
OH3120
To Avoid Vehicle Tipover
ALWAYS:
ï Travel Slowly
ï Rig Properly
ï Use Two Tethers
Model 644E Origin 3/04
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
11
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.
12
Model 644E Origin 3/04
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
13
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!
.
14
Model 644E Origin 3/04
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
15
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.
16
Model 644E Origin 3/04
OS0063
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
17
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
2
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.
3
1.
MAINTAIN
proper tire
pressure at
all times.
2.
OS0086
1
3.
OU0920
18
Model 644E Origin 3/04
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
19
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.
20
Model 644E Origin 3/04
Safety Practices
3
1
WARNING
CRUSHING,
falling off
vehicle can
cause death
or serious
Allow no riders
AVOID
injury
SAFETY
INSTRUCTIONS
2
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.
15
20
10
1/2
RPM X 100
F
E
25
5
D
30
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.
6
5
4110361
7
4
OU07611
Model 644E Origin 3/04
21
Safety Practices
WARNING
FALLING OFF ATTACHMENT,
can result in death or
serious injury.
3
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
4
1
6
ENGINE EXPLOSION can
result in death or serious
personal injury.
Ft
6
5
DO NOT use Ether or other
high energy starting aids.
Engine equipped with
grid heating system.
Ft
5
Ft
Ft
3
4
120cm
110cm 100cm 90cm 80cm 70cm 60cm 50cm 40cm 30cm 20cm 10cm130cm140cm150cm160cm170cm180cm190cm200cm
Ft
Ft
1
2
0
4110356
WARNING
-
EXPLOSIVE GASES can
cause serious injury.
4110460
Keep sparks, flames
and lighted materials
away from batteries.
4110368
2
Item Part Number Quantity Decal Description
1
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
22
Ether Starting Warning (Optional Grid
Heater Cold Start Aid)
Model 644E Origin 3/04
OU1440
Operation
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
23
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.
24
2
1
2
3
1
Model 644E Origin 3/04
4
OU0490
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.
5
6
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
25
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.
26
4
3
1
2
OU0361
Model 644E Origin 3/04
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
6
7
8
9
5
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
27
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
28
Model 644E Origin 3/04
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