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.

3120038 B

Printed in U.S.A. 3/09

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

The Manual

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

IMPORTANT! Before you operate this vehicle, read this manual completely and 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.

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	1	OU0220
	void the warranty. JLG assumes no
	liability for unauthorized replacement
	parts which adversely affect the
	performance, durability or safety of this vehicle.

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 [phone]. 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.

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 operating the 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

5

Safety Practices

Instructional Symbols

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

OP0330	OH2100
Safety Alert	Read Operatorís
Symbol	Manual

			OH3100
		OH2090	Always Connect
	Fasten Seat		Couplers On
			Hydraulically Powered
	Belt
			Attachments
	80"	1"	0"

OU1570

	Transfer Carriage	OU1580
		Transfer
	Forward
		Carriage Fully
	Movement
		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

OU1560

3 Ft. Truss Boom

w/Winch

OU1630

Side Tilt

Carriages

OU1610

Single or Dual Fork Positioning Carriages

OU1590

10 Ft. Truss Boom w/Winch

Model 644E Origin 3/04

7

Safety Practices

Hazard Symbols

OH2110

OH2120

OH2130

-

Lead Acid Batteries	Rotating Fan	Vehicle Tipover
Generate Explosive	Blades Can Cut	Can Crush
Gases
OH2150	OH2140	OH2300

Electrocution Can	Vehicle Roll Away	Rotating Belts
Cause Death Or	Can Cause Death Or	Can Cut Or
Serious Injury	Serious Injury	Entangle
	OH2161	OH3160

FALLING OFF ATTACHMENT	AVOID CRUSHING, Falling Off
Can Result In Death Or Serious	Vehicle Can Cause Death Or
Injury	Serious Injury
OH3110	OU1450

Swinging Loads Can Cause	ENGINE EXPLOSION Can
Vehicle Tipover Which Can	Result In Death Or Serious
Result In Death Or Serious	Injury
Injury	(Optional Grid Heater Cold
	Starting Aid)

8	Model 644E Origin 3/04

Safety Practices

Avoidance Symbols

OH2320

Keep Lit Cigarettes

Away

OH2280

Do Not Raise Boom

While On A Slope

OH2240

Do Not Travel With

Personnel In Work

Platform

OH2330

Keep Flames and

Ignition Sources Away

OH2270

Do Not Travel With

Boom Raised

OH2250

Keep Clear Of Power

Lines

OH2310

Keep Away From

Rotating Fan Blades

Model 644E Origin 3/04

9

Safety Practices

Avoidance Symbols (contíd)

OH2290	OH2260
Maintain Proper Air	Engage Parking Brake
Pressure In Tire

OH2170

OH2230

Use Only Compliant

Work Platforms To

Carry No Riders Raise Or Lower

Personnel

OH2220

DO NOT JUMP

			OU1460
ï Brace Yourself and Stay			DO NOT Use Ether Or
	With Vehicle		Other High Energy
ï Keep Seat Belt Fastened			Starting Aids.
			Engine Equipped With
ï	Hold On Firmly
			Grid Heating System.
ï	Lean Away From The Point	(Optional Grid Heater Cold
	Of Impact		Starting Aid)
		To Avoid Vehicle Tipover
		ALWAYS:
		ï	Travel Slowly
		ï	Rig Properly
		ï	Use Two Tethers
		OH3120

10	Model 644E Origin 3/04

Safety Practices

Avoidance Symbols (contíd)

	OU1530
	Keep Truss	OU1540
		Avoid Rope
	Boom Horizontal
	When Using	Damage. DO
	Winch	NOT Tilt Truss
		Boom DOWN
		When Using
		Winch

OU1550

Avoid Rope

	Damage. DO	OU1520
		Stop Operation
	NOT Tilt Truss
		At This Point
	Boom UP When
	Using Winch

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:

ïlevel the vehicle,

ïground the carriage,

ïplace the travel select lever in the (N) NEUTRAL DETENT position,

ïengage the parking brake switch,

ïturn the engine off, if appropriate,

ïunbuckle the seat belt,

ïexit the vehicle using the hand holds.

4.Chemical Hazards

A. Exhaust Fumes

WARNING

VEHICLE

ROLLAWAY can cause death or serious

injury

ALWAYS engage parking brake

before dismounting

OU0340

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

Safety Practices

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.

DO NOT use Ether or other high energy starting aids.

D. Hydraulic Fluid

Engine equipped with	OU1470
grid heating system.
	4110460
	OU1470

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.

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.

ïEyes ó Flush with water for at least 15 minutes and get medical attention immediately.

ïInternal 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.

OT0810

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.

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.

OS0063

16	Model 644E Origin 3/04

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

WARNING

AVOID

CRUSHING, falling off vehicle can cause death or serious injury

Allow no riders

OH3180

FALLING OFF ATTACHMENT, can result in death or serious injury.

Lift or lower personnel						DO NOT TRAVEL
only in a compliant						with personnel in
work platform.						a work platform.

4110389

OU0620

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	DO NOT	DO NOT raise	MAINTAIN
TIPOVER	travel	boom while	proper tire
can result	with the	on a slope	pressure at
in death or	boom	unless load	all times.
serious injury.	raised.	is level.

OS0086

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	2	1
	Window
			1.
	The rear window (1) in the optional		2.
	enclosed cab can be used as an		3.
	emergency exit by removing the
	latch pin (2) located on the window
	latch (3). The window is then free
	to swing open.
		3
			OU0920

18	Model 644E Origin 3/04

Safety Practices

10.Tire Pressure

DANGER

VEHICLE	DO NOT	DO NOT raise	MAINTAIN
TIPOVER	travel	boom while	proper tire
can result	with the	on a slope	pressure at
in death or	boom	unless load	all times.
serious injury.	raised.	is level.

OS0085

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.

11.Do Not Jump

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

ïBRACE YOURSELF and STAY WITH THE VEHICLE,

ïKEEP YOUR SEAT BELT FASTENED,

ïHOLD ON FIRMLY and

ïLEAN AWAY FROM THE POINT OF IMPACT.

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

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

12.Slopes

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

ïDriving across a slope is dangerous, as unexpected changes in the slope can cause tipover. Ascend or descend slopes slowly and with caution.

ïAscend 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.

ïUnloaded vehicles should be operated on all slopes with the carriage pointing down the slope.

ïOn all slopes, the load must be tilted back and raised only as far as necessary to clear the ground.

ïWhen 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.

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

AVOID

CRUSHING, falling off

vehicle can

cause death

or serious

injury

Allow no riders

2

5

SAFETY	1. Read operator's	2. Fasten	3. Allow	4. Use a compliant
	manual before	seat	no	work platform to lift
INSTRUCTIONS	operating.	belt.	riders.	or lower personnel.
				4110361

7

	15
10	20
	RPM X 100
5	25
	30
	0000000

4

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.

6

OU07611

	Item	Part Number	Quantity	Decal Description
	1	4110358	1	No Riders Warning
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

Model 644E Origin 3/04

21

Safety Practices

WARNING

FALLING OFF ATTACHMENT,

can result in death or 3 serious injury.

Lift or lower personnel	DO NOT TRAVEL
only in a compliant	with personnel in
work platform.	a work platform.

A

B

4

6

6

5

4

3

2

1

0

5

MOVING PARTS can cut.

1

ENGINE EXPLOSION can DO NOT use Ether or other result in death or serious high energy starting aids. personal injury.

Keep clear of fan and belts while engine is running.

Engine equipped with grid heating system.

MOVING PARTS can entangle.

WARNING

-

EXPLOSIVE GASES can	2
cause serious injury.

Keep sparks, flames and lighted materials away from batteries.

4110368

OU1440

	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	Ether Starting Warning (Optional Grid
				Heater Cold Start Aid)

22	Model 644E Origin 3/04

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.

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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.

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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.

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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.

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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.

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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.

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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.

ïFront Wheel Steer (10).

ïCrab Steer (11).

ïFour 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.

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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.

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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.

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