Lull 944E-42 Service Manual User Manual

An Oshkosh Corporation CompanyService ManualModels644E-42944E-42644E-42 - S/N 17569 thru 20123 and 0160002514 & After944E-42 - S/N 17569 thru 2012

Safety Practices1.2 Model 644E-42/944E-42 Rev. 6/041.1 INTRODUCTIONJLG Industries, Inc. (hereafter, JLG) actively promotes safe practices in the use a

Boom3.52 Model 644E-42/944E-42 Rev. 6/043. Drooping chain, or jerky boom extend or retract functions.1. Chain(s) tension not properly adjusted.2. Chai

3.53Model 644E-42/944E-42 Rev. 6/04Boom4. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes and/or connection leaks.2. Lift/Lower hydra

Boom3.54 Model 644E-42/944E-42 Rev. 6/048. Lift/Lower cylinder pivot pin noise and/or wear.1. Insufficient lubrication.2. Worn self-aligning bearing(s

3.55Model 644E-42/944E-42 Rev. 6/04Boom11. Excessive chain wear. 1. Improper chain adjustment.2. Chain sheave(s) not properly lubricated.3. Chain shea

Boom3.56 Model 644E-42/944E-42 Rev. 6/04This Page Intentionally Left Blank

4.1Model 644E-42/944E-42 Rev. 6/04Section 4Cab and CoversContentsPARAGRAPH TITLE PAGE4.1 Operator’s Cab and Covers Component Terminology. . . . . . .

Cab and Covers4.2 Model 644E-42/944E-42 Rev. 6/044.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGYTo understand the safety, operation and maintenanc

4.3Model 644E-42/944E-42 Rev. 6/04Cab and Covers4.2 OPERATOR’S CAB4.2.1 Operator’s Cab DescriptionThe welded metal cab features a modular design, allo

Cab and Covers4.4 Model 644E-42/944E-42 Rev. 6/044.3 OPEN CAB COMPONENTS4.3.1 Seat and Seat Belta. Seat RemovalNote: Two types of seating are availab

4.5Model 644E-42/944E-42 Rev. 6/04Cab and Coversb. Seat InstallationNote: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure pr

1.3Model 644E-42/944E-42 Rev. 6/04Safety Practices1.3 TRAINING MECHANICS AS OPERATORSBecause it is necessary to move the vehicle to service or maintai

Cab and Covers4.6 Model 644E-42/944E-42 Rev. 6/04c. Transmission Travel and Gear Select Lever Removal1. Park the vehicle on a firm, level surface. Lev

4.7Model 644E-42/944E-42 Rev. 6/04Cab and Coversf. Turn Signal Select Lever (Optional) Installation1. Install the two screws (11) securing the transmi

Cab and Covers4.8 Model 644E-42/944E-42 Rev. 6/048. Support the bottom of the steering valve (1), and remove the four flange capscrews (2) and lockwas

4.9Model 644E-42/944E-42 Rev. 6/04Cab and Covers12. Start the engine and check the operation of steering system. Check for hydraulic fluid leaks. Chec

Cab and Covers4.10 Model 644E-42/944E-42 Rev. 6/046. Remove the retaining nut (1) that secures the steer selector knob and pull off the knob.7. Remove

4.11Model 644E-42/944E-42 Rev. 6/04Cab and Covers2. After connecting the hoses, insert the selector valve (9) through the opening (12) on the left sid

Cab and Covers4.12 Model 644E-42/944E-42 Rev. 6/044.3.5 Brake Valve and Service Brake PedalThe service brake valve is secured at the base of the steer

4.13Model 644E-42/944E-42 Rev. 6/04Cab and Covers6. Remove the two capscrews (4), flat washers (5) and nuts (6) attaching the service brake valve (7)

Cab and Covers4.14 Model 644E-42/944E-42 Rev. 6/04c. Service Brake Pedal Removal1. Park the vehicle on a firm, level surface. Level the vehicle, groun

4.15Model 644E-42/944E-42 Rev. 6/04Cab and Covers4.3.6 Throttle Pedal Replacementa. Throttle Pedal Removal1. Park the vehicle on a firm, level surface

Safety Practices1.4 Model 644E-42/944E-42 Rev. 6/041.4.2 Hazard StatementsSignal words and messages are used in conjunction with the safety alert symb

Cab and Covers4.16 Model 644E-42/944E-42 Rev. 6/044.3.7 Throttle Position Sensor Replacement (944E-42 Only)a. Throttle Position Sensor RemovalThe thro

4.17Model 644E-42/944E-42 Rev. 6/04Cab and Coversb. Installation1. Slide the sensor (17) onto the linkage assembly shaft (18).2. Lock in place on shaf

Cab and Covers4.18 Model 644E-42/944E-42 Rev. 6/044.3.8 Front, Rear and Frame Sway Joystick Assembly Replacementa. Front, Rear and Frame Sway Joystick

4.19Model 644E-42/944E-42 Rev. 6/04Cab and Coversb. Front, Rear and Frame Sway Joystick Assembly InstallationNote: Use new oiled o-rings as required.

Cab and Covers4.20 Model 644E-42/944E-42 Rev. 6/044.3.9 Single Joystick Assembly Replacement (Optional)a. Single Joystick Assembly Removal1. Park the

4.21Model 644E-42/944E-42 Rev. 6/04Cab and Coversb. Single Joystick Assembly InstallationNote: Use new oiled o-rings as required. ALWAYS replace seal

Cab and Covers4.22 Model 644E-42/944E-42 Rev. 6/044.3.11 Miscellaneous Cab Components1. Mirror Assembly2. Capscrew (2)3. Frame Level Indicator4. Step5

4.23Model 644E-42/944E-42 Rev. 6/04Cab and Covers4.3.12 Enclosed Cab ComponentsMU600012. Skylight Glass13. Right Side Window Glass14. Top Windshield R

Cab and Covers4.24 Model 644E-42/944E-42 Rev. 6/044.4 ENCLOSED CAB (OPTIONAL) COMPONENTS4.4.1 Front Windshield Wiper SwitchRefer to Section 9.13.4, “F

4.25Model 644E-42/944E-42 Rev. 6/04Cab and Covers5. Transfer the coolant to a container with a cover, and label as “Used Antifreeze.” Dispose of the u

1.5Model 644E-42/944E-42 Rev. 6/04Safety Practices1.6 SAFETY INSTRUCTIONSFollowing are general safety statements to consider before performing mainten

Cab and Covers4.26 Model 644E-42/944E-42 Rev. 6/0411. Remove all duct hoses (1) at the heater assembly (2).Note: Tag and mark all hoses for correct r

4.27Model 644E-42/944E-42 Rev. 6/04Cab and Covers5. Connect heater wiring (10) to the cab harness (11).6. Install the seat mounting panel (12) using t

Cab and Covers4.28 Model 644E-42/944E-42 Rev. 6/044.5 CAB REMOVALIMPORTANT: To help ensure safety and optimum performance, replace the cab if it is d

4.29Model 644E-42/944E-42 Rev. 6/04Cab and Covers4. Block (7) the boom sufficiently enough to provide access to the hydraulic hoses between the cab, h

Cab and Covers4.30 Model 644E-42/944E-42 Rev. 6/0410. (644E Only) Remove the clevis pin clip (1) from the throttle cable yoke (2). Remove throttle cab

4.31Model 644E-42/944E-42 Rev. 6/04Cab and Covers16. If the throttle cable is still wire tied to any of the cables or hoses being removed from the veh

Cab and Covers4.32 Model 644E-42/944E-42 Rev. 6/0411. Connect all of the electrical connections (1) that run from the cab out to the frame and engine

4.33Model 644E-42/944E-42 Rev. 6/04Cab and Covers16. Unplug and connect the hydraulic hoses going from the hydraulic cylinders, brakes and engine comp

Cab and Covers4.34 Model 644E-42/944E-42 Rev. 6/044.7 VALVE PLATE 4.7.1 Valve Plate Removal1. Park the vehicle on a firm level surface, fully retract

4.35Model 644E-42/944E-42 Rev. 6/04Cab and Covers9. Remove the two cotter pins (15), washers (16) and valve plate hinge pins (17).10. Disconnect, labe

Safety Practices1.6 Model 644E-42/944E-42 Rev. 6/041.6.3 General HazardsSOLVENTS: Only use approved solvents, and solvents that are known to be safe f

Cab and Covers4.36 Model 644E-42/944E-42 Rev. 6/044.8 ACCESS PANELS AND COVERS4.8.1 Access Panel and Cover ReplacementThe vehicle is equipped with var

4.37Model 644E-42/944E-42 Rev. 6/04Cab and CoversThis Page Intentionally Left Blank

Cab and Covers4.38 Model 644E-42/944E-42 Rev. 6/044.8.2 Engine Hooda. Engine Hood RemovalNote: Depending on the part that requires replacing, not all

4.39Model 644E-42/944E-42 Rev. 6/04Cab and Covers7. Remove the bottom spring clip (11) from the stud ball (12) and disconnect the left support strut (

Cab and Covers4.40 Model 644E-42/944E-42 Rev. 6/04b. Engine Hood Installation1. Park the vehicle on a firm, level surface. Level the vehicle, ground t

4.41Model 644E-42/944E-42 Rev. 6/04Cab and Covers12. Gently strike the bottom of the right support strut (20) towards the stud ball (22) to pop the ri

Cab and Covers4.42 Model 644E-42/944E-42 Rev. 6/04This Page Intentionally Left Blank

5.1Model 644E-42/944E-42 Rev. 6/04Section 5Axles, Drive Shafts, Wheels, Tires and BrakesContentsPARAGRAPH TITLE PAGE5.1 Axle, Drive Shaft and Wheel Co

Axles, Drive Shafts, Wheels, Tires and Brakes5.2 Model 644E-42/944E-42 Rev. 6/045.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGYTo understand the

5.3Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and Brakes5.2 GENERAL INFORMATIONIMPORTANT: To help ensure optimum performance,

1.7Model 644E-42/944E-42 Rev. 6/04Safety Practices1.8 HAZARD/EMERGENCY INFORMATION SIGNSLocations of vehicle hazard and other emergency information si

Axles, Drive Shafts, Wheels, Tires and Brakes5.4 Model 644E-42/944E-42 Rev. 6/045.3.3 Axle Serial Number PlateThe front axle serial number plate (1) i

5.5Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and BrakesCLEANING: Clean parts with machined or ground surfaces (such as gears,

Axles, Drive Shafts, Wheels, Tires and Brakes5.6 Model 644E-42/944E-42 Rev. 6/044. If the vehicle has dual batteries, disconnect both negative battery

5.7Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and BrakesNote: The axle will oscillate freely when the cylinder mounting pin is

Axles, Drive Shafts, Wheels, Tires and Brakes5.8 Model 644E-42/944E-42 Rev. 6/04b. Axle Inspection, Internal Service and RepairNote: Detailed axle se

5.9Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and BrakesNote: If new frame sway (front) or stabilizer (rear) cylinder bearings

Axles, Drive Shafts, Wheels, Tires and Brakes5.10 Model 644E-42/944E-42 Rev. 6/04Note: ALWAYS use new o-rings when servicing the vehicle.10. Uncap an

5.11Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and Brakes19. Bleed the brakes, refer to Section 8.12.10, d. “Brake Test.”20. St

Axles, Drive Shafts, Wheels, Tires and Brakes5.12 Model 644E-42/944E-42 Rev. 6/045.3.7 Axle Service and TroubleshootingThis section provides an easy r

5.13Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and Brakes4. Oil leaking from axle (differential housing and/or axle housings).1

Safety Practices1.8 Model 644E-42/944E-42 Rev. 6/04This Page Intentionally Left Blank

Axles, Drive Shafts, Wheels, Tires and Brakes5.14 Model 644E-42/944E-42 Rev. 6/047. Axle overheating. 1. Oil level too high.2. Axle and/or wheel end h

5.15Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and Brakes5.3.9 Axle Internal Component TroubleshootingNote: The following cond

Axles, Drive Shafts, Wheels, Tires and Brakes5.16 Model 644E-42/944E-42 Rev. 6/045.4 DRIVE SHAFTS5.4.1 Drive Shaft Inspection and ServiceWhenever serv

5.17Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and Brakes5.4.4 Drive Shaft InstallationIMPORTANT: To help ensure optimum perfo

Axles, Drive Shafts, Wheels, Tires and Brakes5.18 Model 644E-42/944E-42 Rev. 6/045. Raise the drive shaft assembly (1) into position. The slip yoke-en

5.19Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and Brakes5.5 WHEELS AND TIRESWelded 9'' x 24'' steel wheels

Axles, Drive Shafts, Wheels, Tires and Brakes5.20 Model 644E-42/944E-42 Rev. 6/045.5.1 Removing Wheel and Tire Assembly from Vehicle1. Park the vehicl

5.21Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and Brakes7. (644E Only) Remove lug nuts in an alternating pattern (A - H). Ther

Axles, Drive Shafts, Wheels, Tires and Brakes5.22 Model 644E-42/944E-42 Rev. 6/045.5.4 Installing Wheel and Tire Assembly Onto VehicleIMPORTANT: The

5.23Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and Brakes5.5.5 Tiresa. Dismounting Tire from Wheelb. Wheel Inspection and Repla

2.1Model 644E-42/944E-42 Rev. 6/04Section 2General Information, Specifications and MaintenanceContentsPARAGRAPH TITLE PAGE2.1 644E-42 / 944E-42 Compon

Axles, Drive Shafts, Wheels, Tires and Brakes5.24 Model 644E-42/944E-42 Rev. 6/04c. Tire and Wheel LubricationPrior to mounting the tire onto the rim,

5.25Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and Brakese. Tire Speed and Road Surface LimitationsThe tires and axles on this

Axles, Drive Shafts, Wheels, Tires and Brakes5.26 Model 644E-42/944E-42 Rev. 6/045.6 BRAKES5.6.1 Brake Disc InspectionCheck the brake discs for wear e

5.27Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and BrakesNote: If the brake discs are worn beyond the gaps given, the brake di

Axles, Drive Shafts, Wheels, Tires and Brakes5.28 Model 644E-42/944E-42 Rev. 6/04b. Rear Axle1. Block all four wheels to help prevent the vehicle from

5.29Model 644E-42/944E-42 Rev. 6/04Axles, Drive Shafts, Wheels, Tires and BrakesNote: If the brake discs are worn beyond .0.167" (4,25 mm), the

Axles, Drive Shafts, Wheels, Tires and Brakes5.30 Model 644E-42/944E-42 Rev. 6/04This Page Intentionally Left Blank

6.1Model 644E-42/944E-42 Rev. 6/04Section 6Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 ContentsPARAGRAPH TITLE PAGE6.1 Transmission

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.2 Model 644E-42/944E-42 Rev. 6/046.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGYTo und

6.3Model 644E-42/944E-42 Rev. 6/04Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.2 TRANSMISSION DESCRIPTION Instructions in this sect

General Information, Specifications and Maintenance2.2 Model 644E-42/944E-42 Rev. 6/042.6 Fluids, Lubricants and Capacities. . . . . . . . . . . . . .

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.4 Model 644E-42/944E-42 Rev. 6/046.5 TRANSMISSION SPECIFICATIONS6.5.1 Transmission Gen

6.5Model 644E-42/944E-42 Rev. 6/04Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.6.2 Transmission Maintenance ScheduleComplete transm

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.6 Model 644E-42/944E-42 Rev. 6/046.7 TRANSMISSION REPLACEMENTNote: Contact your local

6.7Model 644E-42/944E-42 Rev. 6/04Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46. Raise the vehicle up and place all four wheels on b

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.8 Model 644E-42/944E-42 Rev. 6/0410. Remove the four capscrews (1) securing the inlet

6.9Model 644E-42/944E-42 Rev. 6/04Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I416. Label and disconnect the wire harness connections

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.10 Model 644E-42/944E-42 Rev. 6/046.7.2 Transmission Inspection and Internal RepairRef

6.11Model 644E-42/944E-42 Rev. 6/04Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I49. Position the transmission mount plate (7) in place

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.12 Model 644E-42/944E-42 Rev. 6/0416. Assemble the front outlet hose (1) onto the fron

6.13Model 644E-42/944E-42 Rev. 6/04Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I423. Reassemble the driveshafts. Refer to Section 5.4.

2.3Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenance2.1 644E-42 / 944E-42 COMPONENT TERMINOLOGYTo understand the safe

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.14 Model 644E-42/944E-42 Rev. 6/046.7.4 After Transmission Service or ReplacementRefer

6.15Model 644E-42/944E-42 Rev. 6/04Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.8 TROUBLESHOOTINGThis section provides an easy refe

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.16 Model 644E-42/944E-42 Rev. 6/043. Low clutch pressure. 1. Incorrect oil level.2. Ma

6.17Model 644E-42/944E-42 Rev. 6/04Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I45. Transmission overheating (oil above 248° F [120° C

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.18 Model 644E-42/944E-42 Rev. 6/046.9 TOWING A DISABLED VEHICLETowing a disabled vehic

6.19Model 644E-42/944E-42 Rev. 6/04Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.10 TRANSFER CASE COMPONENT TERMINOLOGYTo understand

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.20 Model 644E-42/944E-42 Rev. 6/046.11 GENERAL INFORMATIONIMPORTANT: To help ensure o

6.21Model 644E-42/944E-42 Rev. 6/04Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.12.5 Further InformationDetailed transfer case serv

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.22 Model 644E-42/944E-42 Rev. 6/046.12.9 Transfer Case RemovalNote: This operation can

6.23Model 644E-42/944E-42 Rev. 6/04Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.12.10 Internal Transfer Case RepairDetailed transfe

General Information, Specifications and Maintenance2.4 Model 644E-42/944E-42 Rev. 6/042.2 INTRODUCTION2.2.1 Service MethodsAppropriate service methods

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.24 Model 644E-42/944E-42 Rev. 6/046.13 TROUBLESHOOTINGThis section provides an easy re

6.25Model 644E-42/944E-42 Rev. 6/04Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I43. Noise when coasting: even slight transfer case noi

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I46.26 Model 644E-42/944E-42 Rev. 6/046.13.2 Transfer Case Internal Component Troubleshoot

7.1Model 644E-42/944E-42 Rev. 6/04Section 7Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5TContentsPARAGRAPH TITLE PAGE7.1 Introduction . . . . . . . . . .

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.2 Model 644E-42/944E-42 Rev. 6/04This Page Intentionally Left Blank

7.3Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.1 INTRODUCTION7.1.1 Disclaimer and ScopeThese instructions are written

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.4 Model 644E-42/944E-42 Rev. 6/047.1.2 Component TerminologyTo understand the safety, operation and maint

7.5Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.2 SAFETY INFORMATIONGeneral Vehicle OperationPreparationEngine Operatio

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.6 Model 644E-42/944E-42 Rev. 6/04Rotating Parts and Fan BladesEngine Coolant (anti-freeze/anti-boil over)

7.7Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.3 ENGINE SERIAL NUMBERThe serial number (1) is stamped on the front of

2.5Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenance2.3 TORQUES2.3.1 SAE Flat Face O-Ring Seal Hydraulic Fittingsa. A

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.8 Model 644E-42/944E-42 Rev. 6/047.6 ENGINE COOLING SYSTEMThe engine cooling system is a closed, pressuri

7.9Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T5. Slowly turn the radiator cap (7), located in the upper radiator hose,

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.10 Model 644E-42/944E-42 Rev. 6/048. Insert a 3/8” drive rachet into the automatic belt tensioner housing

7.11Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5Tb. Thermostat InstallationNote: Ensure that notched edge of thermostat

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.12 Model 644E-42/944E-42 Rev. 6/049. If the vehicle has dual batteries, connect both negative battery cab

7.13Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T6. Flush the radiator with clean water and allow to drain again. Upon co

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.14 Model 644E-42/944E-42 Rev. 6/047.6.4 Radiator, Transmission Oil Cooler and Hydraulic Oil Cooler Replac

7.15Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7. Drain the contents of the overflow reservoir (10) by removing the ove

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.16 Model 644E-42/944E-42 Rev. 6/0410. Remove both hydraulic oil cooler inlet (1) and return (2) hoses fro

7.17Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T16. At the inner side of the radiator assembly are four capscrews (16) a

General Information, Specifications and Maintenance2.6 Model 644E-42/944E-42 Rev. 6/04c. Adjustable (Angle) O-Ring Boss Fittings To O-Ring Boss PortsI

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.18 Model 644E-42/944E-42 Rev. 6/04b. Radiator, Transmission Oil Cooler and Hydraulic Oil Cooler Installat

7.19Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T9. Working from the inner side of the radiator assembly, secure the tran

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.20 Model 644E-42/944E-42 Rev. 6/0416. Uncap and connect the hydraulic oil inlet (1) and outlet (2) hoses

7.21Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5Tc. Engine Block Heater Removal1. Park the vehicle on a firm, level, surf

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.22 Model 644E-42/944E-42 Rev. 6/047. Loosen the clamp (1) securing the air intake hose to the turbocharge

7.23Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.7 ENGINE ELECTRICAL SYSTEMThe engine electrical system, including the

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.24 Model 644E-42/944E-42 Rev. 6/047.8.1 Diesel FuelFuel represents a major portion of vehicle operating c

7.25Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5Tc. Cleaning and DryingIf contaminated fuel or foreign material is in the

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.26 Model 644E-42/944E-42 Rev. 6/047.8.4 Fuel Lift Pump TestingTo test the diaphragm, remove the fuel inle

7.27Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.8.5 Fuel Filter ReplacementThe fuel filter (4 or 9) must be changed at

2.7Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenance2.4 METRIC CONVERSION FACTORS2.4.1 Approximate American to Metric

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.28 Model 644E-42/944E-42 Rev. 6/047.8.7 Fuel InjectorsThe engine uses Bosch closed nozzle hole-type injec

7.29Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5Tb. Injector ReplacementPreparatory steps:• Thoroughly clean around the i

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.30 Model 644E-42/944E-42 Rev. 6/047.9 ENGINE EXHAUST SYSTEMThe exhaust system is supported by the engine

7.31Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T3. Loosen the lower clamp (7) attaching the flex pipe (8) to the muffler

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.32 Model 644E-42/944E-42 Rev. 6/047.10 ENGINE REPLACEMENT Removal and installation of the engine should b

7.33Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T6. Drain the contents of the overflow reservoir (10) by removing the ove

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.34 Model 644E-42/944E-42 Rev. 6/049. Remove both hydraulic oil inlet (1) and return (2) hoses from the hy

7.35Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T15. Remove all of the hydraulic oil from the reservoir and system. The r

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.36 Model 644E-42/944E-42 Rev. 6/0423. Remove hydraulic vent hoses (1, 2, and 3), and secure them out of t

7.37Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T30. Loosen and remove three capscrews (17) and three locknuts (18) secur

General Information, Specifications and Maintenance2.8 Model 644E-42/944E-42 Rev. 6/04VOLUMEMilliliters (ml) 0,03 Fluid ounces (fl oz)Milliliters (ml)

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.38 Model 644E-42/944E-42 Rev. 6/0441. Label and disconnect these alternator wires:• [AG1] and [AG2] from

7.39Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T49. Label and disconnect the engine coolant temperature switch lead (19)

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.40 Model 644E-42/944E-42 Rev. 6/0455. Begin removing the engine/transmission from the vehicle with the ho

7.41Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.10.3 Engine Installation 1. Attach the transmission, if removed, to th

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.42 Model 644E-42/944E-42 Rev. 6/049. Connect the shift solenoid wiring harness connectors (1, 2, 3, 4, 5,

7.43Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T18. At the rear of the alternator, reattach all wires to their proper te

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.44 Model 644E-42/944E-42 Rev. 6/0426. Position the air cleaner hose over the turbocharger intake opening.

7.45Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T31. Install the transmission oil hoses (14) from the reservoir retainer

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.46 Model 644E-42/944E-42 Rev. 6/0436. Attach the engine mount frame skirt (1) by installing four lower (3

7.47Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T43. Install the previously removed upper mounting capscrew (17), flat wa

2.9Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and MaintenanceThis Page Intentionally Left Blank

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.48 Model 644E-42/944E-42 Rev. 6/0450. Install the fan guard (1) using three (2) previously removed capscr

7.49Model 644E-42/944E-42 Rev. 6/04Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T62. Obtain and connect an appropriate engine analyzer or tachometer. Che

Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T7.50 Model 644E-42/944E-42 Rev. 6/047.12 TROUBLESHOOTINGTrouble Possible Causes (see key, below)Low Crankin

8.1Model 644E-42/944E-42 Rev. 6/04Section 8Hydraulic SystemContentsPARAGRAPH TITLE PAGE8.1 Hydraulic Component Terminology . . . . . . . . . . . . . .

Hydraulic System8.2 Model 644E-42/944E-42 Rev. 6/048.8.12 Boom Retract Circuit & Troubleshooting (Dual Joystick) . . . . . . . . . . . . . . . . .

8.3Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.8.48 Joystick Circuit Description (Dual Joystick) . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System8.4 Model 644E-42/944E-42 Rev. 6/048.14.4 Attachment Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.1 HYDRAULIC COMPONENT TERMINOLOGYTo understand the safety, operation, and service information pres

Hydraulic System8.6 Model 644E-42/944E-42 Rev. 6/048.2 SAFETY INFORMATIONPetroleum-based hydraulic fluids are used in this vehicle. The temperature of

8.7Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.3 SPECIFICATIONSRefer to Section 2.5.11, “Hydraulic System,” for hydraulic system specifications.8

General Information, Specifications and Maintenance2.10 Model 644E-42/944E-42 Rev. 6/042.5 SPECIFICATIONS2.5.1 Vehicle Dimensions With Standard Tires:

Hydraulic System8.8 Model 644E-42/944E-42 Rev. 6/048.5 HOSES, TUBE LINES, FITTINGS, ETC. There are numerous hydraulic hoses, tubes, fittings, etc. use

8.9Model 644E-42/944E-42 Rev. 6/04Hydraulic Systema. Disconnection Procedure1. Relieve the hydraulic pressure in the appropriate circuit before attemp

Hydraulic System8.10 Model 644E-42/944E-42 Rev. 6/048.6 HYDRAULIC PRESSURE DIAGNOSISJLG Parts Department has two kits available to use for hydraulic s

8.11Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.6.1 Pressure Checks and AdjustmentsWhen diagnosing trouble in the hydraulic system, use the hydra

Hydraulic System8.12 Model 644E-42/944E-42 Rev. 6/048.7 HYDRAULIC SYSTEM TESTING8.7.1 Hydraulic Testing (SN 18460 and Before, Dual Joystick, 644E Only

8.13Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemEngine InformationIdle . . . . . . . . . . . . . . . . . . . . . . .950 ±50 rpmFull Speed . . . .

Hydraulic System8.14 Model 644E-42/944E-42 Rev. 6/04TEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE

8.15Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemThis Page Intentionally Left Blank

Hydraulic System8.16 Model 644E-42/944E-42 Rev. 6/048.7.2 Hydraulic Testing (SN 18461 thru 18927, Dual Joystick, 644E Only)MU5712ATTACHTILTFRAMEEXT/RE

8.17Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemEngine InformationIdle . . . . . . . . . . . . . . . . . . . . . . .950 ±50 rpmFull Speed . . . .

2.11Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and MaintenanceTCExtendedTCRetractedMU582024.0"0.0ABCDEKLMNOUVWXYZAAFGHIJP

Hydraulic System8.18 Model 644E-42/944E-42 Rev. 6/04TEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE

8.19Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemThis Page Intentionally Left Blank

Hydraulic System8.20 Model 644E-42/944E-42 Rev. 6/048.7.3 Hydraulic Testing (SN 18928 thru 20118, 0160002519 thru 0160003087, Dual Joystick, 644E Only

8.21Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemEngine InformationIdle . . . . . . . . . . . . . . . . . . . . . . .950 ±50 rpmFull Speed . . . .

Hydraulic System8.22 Model 644E-42/944E-42 Rev. 6/04TEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE

8.23Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemThis Page Intentionally Left Blank

Hydraulic System8.24 Model 644E-42/944E-42 Rev. 6/048.7.4 Hydraulic Testing (SN 0160003088 and After, Dual Joystick, 644E Only)1465773893FRONT STEERIN

8.25Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemEngine InformationIdle . . . . . . . . . . . . . . . . . . . . . . .950 ±50 rpmFull Speed . . . .

Hydraulic System8.26 Model 644E-42/944E-42 Rev. 6/04TEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE

8.27Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemThis Page Intentionally Left Blank

General Information, Specifications and Maintenance2.12 Model 644E-42/944E-42 Rev. 6/042.5.2 Vehicle Weights - 644E-422.5.3 Vehicle Weights - 944E-42C

Hydraulic System8.28 Model 644E-42/944E-42 Rev. 6/048.7.5 Hydraulic Testing (SN 18928 thru 20118, 0160002519 thru 0160003087 Single Joystick, 644E Onl

8.29Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemEngine InformationIdle . . . . . . . . . . . . . . . . . . . . . . .950 ±50 rpmFull Speed . . . .

Hydraulic System8.30 Model 644E-42/944E-42 Rev. 6/04TEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE

8.31Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemThis Page Intentionally Left Blank

Hydraulic System8.32 Model 644E-42/944E-42 Rev. 6/048.7.6 Hydraulic Testing (SN 0160003088 and After Single Joystick, 644E Only)1465773893FRONT STEERI

8.33Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemEngine InformationIdle . . . . . . . . . . . . . . . . . . . . . . .950 ±50 rpmFull Speed . . . .

Hydraulic System8.34 Model 644E-42/944E-42 Rev. 6/04TEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE

8.35Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemThis Page Intentionally Left Blank

Hydraulic System8.36 Model 644E-42/944E-42 Rev. 6/048.7.7 Hydraulic Testing (SN 18927 and Before, Dual Joystick, 944E Only)MU5712ATTACHTILTFRAMEEXT/RE

8.37Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemEngine InformationIdle . . . . . . . . . . . . . . . . . . . . . . .950 ±50 rpmFull Speed . . . .

2.13Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenance2.5.4 Attachment Weights644E-42 944E-42Std 48" Carriage wit

Hydraulic System8.38 Model 644E-42/944E-42 Rev. 6/04TEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE

8.39Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemThis Page Intentionally Left Blank

Hydraulic System8.40 Model 644E-42/944E-42 Rev. 6/048.7.8 Hydraulic Testing (SN 18928 thru 20123, 0160002514 thru 0160003085, Dual Joystick, 944E Only

8.41Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemEngine InformationIdle . . . . . . . . . . . . . . . . . . . . . . .950 ±50 rpmFull Speed . . . .

Hydraulic System8.42 Model 644E-42/944E-42 Rev. 6/04TEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE

8.43Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemThis Page Intentionally Left Blank

Hydraulic System8.44 Model 644E-42/944E-42 Rev. 6/048.7.9 Hydraulic Testing (SN 0160003086 and After, Dual Joystick, 944E Only)1465773893FRONT STEERIN

8.45Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemEngine InformationIdle . . . . . . . . . . . . . . . . . . . . . . .950 ±50 rpmFull Speed . . . .

Hydraulic System8.46 Model 644E-42/944E-42 Rev. 6/04TEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE

8.47Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemThis Page Intentionally Left Blank

EFFECTIVITY PAGE8990461 644E-42/944E-42 iJune 2004 - C - Revised ManualJanuary 17, 2012 - D - Revised covers.

General Information, Specifications and Maintenance2.14 Model 644E-42/944E-42 Rev. 6/042.5.5 Performance SpecificationsNote: Performance criteria is

Hydraulic System8.48 Model 644E-42/944E-42 Rev. 6/048.7.10 Hydraulic Testing (SN 18928 thru 20123, 0160002514 thru 0160003085, Single Joystick, 944E O

8.49Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemEngine InformationIdle . . . . . . . . . . . . . . . . . . . . . . .950 ±50 rpmFull Speed . . . .

Hydraulic System8.50 Model 644E-42/944E-42 Rev. 6/04TEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE

8.51Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemThis Page Intentionally Left Blank

Hydraulic System8.52 Model 644E-42/944E-42 Rev. 6/048.7.11 Hydraulic Testing (SN 0160003086 and After Single Joystick, 944E Only)1465773893FRONT STEER

8.53Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemEngine InformationIdle . . . . . . . . . . . . . . . . . . . . . . .950 ±50 rpmFull Speed . . . .

Hydraulic System8.54 Model 644E-42/944E-42 Rev. 6/04TEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE

8.55Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.8 HYDRAULIC CIRCUITS AND TROUBLESHOOTINGThis section covers the hydraulic circuits and includes a

Hydraulic System8.56 Model 644E-42/944E-42 Rev. 6/048.8.1 Pump & Cooling Circuit & Troubleshooting (Dual Joystick, SN 18460 and Before)(Refer

8.57Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKIf the pump is not functioning properlyNot OKInspect the check valve in the cooler hydraulic

2.15Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenance2.5.7 Electrical SystemDescription 644E-42 944E-42Battery:Type,

Hydraulic System8.58 Model 644E-42/944E-42 Rev. 6/048.8.2 Pump & Cooling Circuit & Troubleshooting (Dual Joystick, SN 18461 and After)(Refer t

8.59Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKIf the pump is not functioning properlyNot OKInspect the check valve in the cooler hydraulic

Hydraulic System8.60 Model 644E-42/944E-42 Rev. 6/048.8.3 Pump & Cooling Circuit & Troubleshooting (Single Joystick)(Refer to Section 8.8.47,

8.61Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKIf the pump is not functioning properlyNot OKInspect the check valve in the cooler hydraulic

Hydraulic System8.62 Model 644E-42/944E-42 Rev. 6/048.8.4 Joystick Circuit & Troubleshooting (Front - Dual Joystick)(Refer to Section 8.8.48, “Joy

8.63Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKReplace capsules or o-ring seals.Not OKCheck the pilot pressure at “PPG” port of accumulator

Hydraulic System8.64 Model 644E-42/944E-42 Rev. 6/048.8.5 Joystick Circuit & Troubleshooting (Rear - Dual Joystick)(Refer to Section 8.8.48, “Joys

8.65Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for cor

Hydraulic System8.66 Model 644E-42/944E-42 Rev. 6/048.8.6 Joystick Circuit & Troubleshooting (Single Joystick)(Refer to Section 8.8.49, “Joystick

8.67Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKReplace capsules or o-ring seals.Not OKCheck the pilot pressure at “PPG” port of accumulator

General Information, Specifications and Maintenance2.16 Model 644E-42/944E-42 Rev. 6/04Fuses - Standard Blade Style: 644E-42 944E-42F25 - Lights Main

Hydraulic System8.68 Model 644E-42/944E-42 Rev. 6/048.8.7 Park Brake Circuit & Troubleshooting(Refer to Section 8.8.50, “Brake Circuit Description

8.69Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKNot OKNot OKIf park brake fails to hold, check the “PBG” port on the accumulator charge/secon

Hydraulic System8.70 Model 644E-42/944E-42 Rev. 6/048.8.8 Service Brake Circuit & Troubleshooting(Refer to Section 8.8.50, “Brake Circuit Descript

8.71Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKNot OKNot OKCheck pressure at front and rear axles.If service brakes are not holding, check t

Hydraulic System8.72 Model 644E-42/944E-42 Rev. 6/048.8.9 Emergency Towing Park Brake Release Circuit & Troubleshooting(Refer to Section 8.8.50, “

8.73Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKNot OKCheck for external leaks, loose fittings or linesIf park brake fails to release with pa

Hydraulic System8.74 Model 644E-42/944E-42 Rev. 6/048.8.10 Boom Extend Circuit & Troubleshooting (Dual Joystick)(Refer to Section 8.8.51, “Boom Ex

8.75Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKThe extend/retract cylinder does not extend.If OKReplace unloader cartridge on main control v

Hydraulic System8.76 Model 644E-42/944E-42 Rev. 6/048.8.11 Boom Extend Circuit & Troubleshooting (Single Joystick)(Refer to Section 8.8.52, “Boom

8.77Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for cor

2.17Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenance2.5.8 Engine Performance Specifications - 644E-42Note: Engine m

Hydraulic System8.78 Model 644E-42/944E-42 Rev. 6/048.8.12 Boom Retract Circuit & Troubleshooting (Dual Joystick)(Refer to Section 8.8.51, “Boom E

8.79Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for cor

Hydraulic System8.80 Model 644E-42/944E-42 Rev. 6/048.8.13 Boom Retract Circuit & Troubleshooting (Single Joystick)(Refer to Section 8.8.52, “Boom

8.81Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for cor

Hydraulic System8.82 Model 644E-42/944E-42 Rev. 6/048.8.14 Boom Lift Circuit & Troubleshooting (Dual Joystick)(Refer to Section 8.8.53, “Boom Lift

8.83Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKCheck seals on lift/lower cylinder. Repair/replace lift/lower cylinder.If OKIf OKNot OKCheck

Hydraulic System8.84 Model 644E-42/944E-42 Rev. 6/048.8.15 Boom Lift Circuit & Troubleshooting (Single Joystick)(Refer to Section 8.8.54, “Boom Li

8.85Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKCheck seals on lift/lower cylinder. Repair/replace lift/lower cylinder.If OKIf OKNot OKCheck

Hydraulic System8.86 Model 644E-42/944E-42 Rev. 6/048.8.16 Boom Lower Circuit & Troubleshooting (Dual Joystick)(Refer to Section 8.8.53, “Boom Lif

8.87Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for cor

General Information, Specifications and Maintenance2.18 Model 644E-42/944E-42 Rev. 6/042.5.9 Engine Performance Specifications - 944E-42Note: Engine

Hydraulic System8.88 Model 644E-42/944E-42 Rev. 6/048.8.17 Boom Lower Circuit & Troubleshooting (Single Joystick)(Refer to Section 8.8.54, “Boom L

8.89Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for cor

Hydraulic System8.90 Model 644E-42/944E-42 Rev. 6/048.8.18 Frame Sway (Left), Stabilizer Circuit & Troubleshooting (SN 18460 and Before)(Refer to

8.91Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemRefer to Section 10.3, “Stabil-TRAK™ Operation,” for information on troubleshooting the frame sway

Hydraulic System8.92 Model 644E-42/944E-42 Rev. 6/048.8.19 Frame Sway (Left), Stabilizer Circuit & Troubleshooting (SN 18461 and After)(Refer to S

8.93Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemRefer to Section 10.3, “Stabil-TRAK™ Operation,” for information on troubleshooting the frame sway

Hydraulic System8.94 Model 644E-42/944E-42 Rev. 6/048.8.20 Frame Sway (Right), Stabilizer Circuit & Troubleshooting ( SN 18460 and Before)(Refer t

8.95Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemRefer to Section 10.3, “Stabil-TRAK™ Operation,” for information on troubleshooting the frame sway

Hydraulic System8.96 Model 644E-42/944E-42 Rev. 6/048.8.21 Frame Sway (Right), Stabilizer Circuit & Troubleshooting (SN 18461 and After)(Refer to

8.97Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemRefer to Section 10.3, “Stabil-TRAK™ Operation,” for information on troubleshooting the frame sway

2.19Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenance2.5.10 Fluid and Lubricant CapacitiesFluid & Lubricant Descr

Hydraulic System8.98 Model 644E-42/944E-42 Rev. 6/048.8.22 Attachment Tilt (Down), Slave Cylinder Circuit & Troubleshooting (Dual Joystick)(Refer

8.99Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKReplace counterbalance and/or pilot-operated check valves on the attachment tilt cylinder.Che

Hydraulic System8.100 Model 644E-42/944E-42 Rev. 6/048.8.23 Attachment Tilt (Down), Slave Cylinder Circuit & Troubleshooting (Single Joystick)(Ref

8.101Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for co

Hydraulic System8.102 Model 644E-42/944E-42 Rev. 6/048.8.24 Attachment Tilt (Up), Slave Cylinder Circuit & Troubleshooting (Dual Joystick)(Refer t

8.103Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for co

Hydraulic System8.104 Model 644E-42/944E-42 Rev. 6/048.8.25 Attachment Tilt (Up), Slave Cylinder Circuit & Troubleshooting (Single Joystick)(Refer

8.105Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for co

Hydraulic System8.106 Model 644E-42/944E-42 Rev. 6/048.8.26 Transfer Carriage Cylinder Extend (Carriage Back) Circuit & Troubleshooting (Dual Joys

8.107Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKInspect pump. Refer to Hydraulic Testing pages 8.12 through 8.54.Check the cycle times for b

General Information, Specifications and Maintenance2.20 Model 644E-42/944E-42 Rev. 6/042.5.11 Hydraulic SystemHydraulic System: 644E-42 and 944E-42Sys

Hydraulic System8.108 Model 644E-42/944E-42 Rev. 6/048.8.27 Transfer Carriage Cylinder Extend (Carriage Back) Circuit & Troubleshooting (Single Jo

8.109Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKInspect pump. Refer to Hydraulic Testing pages 8.12 through 8.54.Check the cycle times for b

Hydraulic System8.110 Model 644E-42/944E-42 Rev. 6/048.8.28 Transfer Carriage Cylinder Retract (Carriage Fwd) Circuit & Troubleshooting (Dual Joys

8.111Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for co

Hydraulic System8.112 Model 644E-42/944E-42 Rev. 6/048.8.29 Transfer Carriage Cylinder Retract (Carriage Fwd) Circuit & Troubleshooting (Single Jo

8.113Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for co

Hydraulic System8.114 Model 644E-42/944E-42 Rev. 6/048.8.30 Front-Wheel Steering Circuit (Left Turn) & Troubleshooting(Refer to Section 8.8.60, “S

8.115Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKNot OKRepair/replace steering cylinder(s).Check the power steering unit.Replace power steeri

Hydraulic System8.116 Model 644E-42/944E-42 Rev. 6/048.8.31 Front-Wheel Steering Circuit (Right Turn) & Troubleshooting(Refer to Section 8.8.60, “

8.117Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKNot OKFront or rear wheels are not parallel in front or four-wheel steering mode.Perform ind

2.21Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenance2.5.12 Tires 2.5.13 Miscellaneous SpecificationsDescription 644E

Hydraulic System8.118 Model 644E-42/944E-42 Rev. 6/048.8.32 Four-Wheel Steering Circuit (Left Turn) & Troubleshooting(Refer to Section 8.8.60, “St

8.119Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKIf there is no four-wheel or crab steering, check the steer select valve.Inspect/replace the

Hydraulic System8.120 Model 644E-42/944E-42 Rev. 6/048.8.33 Four-Wheel Steering Circuit (Right Turn) & Troubleshooting(Refer to Section 8.8.60, “S

8.121Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKIf there is no four-wheel or crab steering, check the steer select valve.Inspect/replace the

Hydraulic System8.122 Model 644E-42/944E-42 Rev. 6/048.8.34 Crab Steering Circuit (Left Turn) & Troubleshooting(Refer to Section 8.8.60, “Steering

8.123Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKIf there is no four-wheel or crab steering, check the steer select valve.Inspect/replace the

Hydraulic System8.124 Model 644E-42/944E-42 Rev. 6/048.8.35 Crab Steering Circuit (Right Turn) & Troubleshooting(Refer to Section 8.8.60, “Steerin

8.125Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKIf there is no four-wheel or crab steering, check the steer select valve.Inspect/replace the

Hydraulic System8.126 Model 644E-42/944E-42 Rev. 6/048.8.36 Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Dual Joystic

8.127Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKCheck the flow at the end of the circuit at the male coupler.Repair/replace pumpNOTE:When ch

General Information, Specifications and Maintenance2.22 Model 644E-42/944E-42 Rev. 6/042.5.14 Tamper ProofingA tamper-proof means is in place on the f

Hydraulic System8.128 Model 644E-42/944E-42 Rev. 6/048.8.37 Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Dual Joystic

8.129Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKCheck the flow at the end of the circuit at the male coupler.Repair/replace pumpNOTE:When ch

Hydraulic System8.130 Model 644E-42/944E-42 Rev. 6/048.8.38 Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Single Joyst

8.131Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKCheck the flow at the end of the circuit at the male coupler.Repair/replace pumpNOTE:When ch

Hydraulic System8.132 Model 644E-42/944E-42 Rev. 6/048.8.39 Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Single Joyst

8.133Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKCheck the flow at the end of the circuit at the male coupler.Repair/replace pumpNOTE:When ch

Hydraulic System8.134 Model 644E-42/944E-42 Rev. 6/048.8.40 Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Dual Joyst

8.135Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKCheck the flow at the end of the circuit at the female coupler.Repair/replace pumpNOTE:When

Hydraulic System8.136 Model 644E-42/944E-42 Rev. 6/048.8.41 Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Dual Joyst

8.137Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKCheck the flow at the end of the circuit at the female coupler.Repair/replace pumpNOTE:When

2.23Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenance2.6 FLUIDS, LUBRICANTS AND CAPACITIES2.6.1 Axles (Differential H

Hydraulic System8.138 Model 644E-42/944E-42 Rev. 6/048.8.42 Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Single Joy

8.139Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKCheck the flow at the end of the circuit at the female coupler.Repair/replace pumpNOTE:When

Hydraulic System8.140 Model 644E-42/944E-42 Rev. 6/048.8.43 Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Single Joy

8.141Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNot OKCheck the flow at the end of the circuit at the female coupler.Repair/replace pumpNOTE:When

Hydraulic System8.142 Model 644E-42/944E-42 Rev. 6/048.8.44 Auxiliary Hydraulic Pressure Release Circuit & Troubleshooting (Dual Joystick) (644E-4

8.143Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for co

Hydraulic System8.144 Model 644E-42/944E-42 Rev. 6/048.8.45 Auxiliary Hydraulic Pressure Release Circuit & Troubleshooting (Single Joystick) (644E

8.145Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for co

Hydraulic System8.146 Model 644E-42/944E-42 Rev. 6/048.8.46 Pump and Cooling Circuit Description (Dual Joystick) In the Pump and Cooling Circuit (page

8.147Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.8.50 Brake Circuit DescriptionThe brake system circuit (see pages 8.68 thorough 8.72) includes t

General Information, Specifications and Maintenance2.24 Model 644E-42/944E-42 Rev. 6/042.6.3 Lubrication Points (Grease Fittings)LubricantsWhen lubric

Hydraulic System8.148 Model 644E-42/944E-42 Rev. 6/048.8.51 Boom Extend/Retract Circuit Description (Dual Joystick)Hydraulic flow is applied in the Bo

8.149Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.8.52 Boom Extend/Retract Circuit Description (Single Joystick) Hydraulic flow is applied in the

Hydraulic System8.150 Model 644E-42/944E-42 Rev. 6/048.8.53 Boom Lift/Lower Circuit Description (Dual Joystick)Hydraulic flow is applied in the Lift/L

8.151Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.8.54 Boom Lift/Lower Circuit Description (Single Joystick)Hydraulic flow is applied in the Lift/

Hydraulic System8.152 Model 644E-42/944E-42 Rev. 6/048.8.55 Frame Sway Circuit Description Hydraulic flow is applied in the frame sway circuit (see pa

8.153Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.8.56 Attachment Tilt and Slave Circuit Description (Dual Joystick)System pressure is applied in

Hydraulic System8.154 Model 644E-42/944E-42 Rev. 6/048.8.57 Attachment Tilt and Slave Circuit Description (Single Joystick)System pressure is applied

8.155Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.8.58 Transfer Carriage Circuit Description (Dual Joystick)Hydraulic flow is applied in the trans

Hydraulic System8.156 Model 644E-42/944E-42 Rev. 6/048.8.59 Transfer Carriage Circuit Description (Single Joystick)Hydraulic flow is applied in the tr

8.157Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemThis Page Intentionally Left Blank

2.25Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenanceb. Engine Capacities1. Engine Oil CapacityCapacity w/filter chan

Hydraulic System8.158 Model 644E-42/944E-42 Rev. 6/048.8.60 Steering Circuit DescriptionsVehicle steering includes front-wheel steering (see page 8.11

8.159Model 644E-42/944E-42 Rev. 6/04Hydraulic Systemb. Four-Wheel SteeringWhen the Steer Select Valve (5) is in the Four-Wheel Steer (LEFT) position (

Hydraulic System8.160 Model 644E-42/944E-42 Rev. 6/04c. Crab Steering ModeWhen the Steer Select Valve (1) is in the Crab Steer (RIGHT) position (2), t

8.161Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.8.61 Auxiliary Hydraulic Circuit Description (Dual Joystick)The auxiliary hydraulic circuit (pag

Hydraulic System8.162 Model 644E-42/944E-42 Rev. 6/04a. Male Coupler Pressurized (page 8.130 or page 8.132)With the Trigger Button held down on the Si

8.163Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.9 STEER INDEXING PROCEDURES8.9.1 Four-Wheel Steer Indexing ProcedureIf the vehicle does not driv

Hydraulic System8.164 Model 644E-42/944E-42 Rev. 6/048.10 HYDRAULIC RESERVOIRThe hydraulic reservoir (1) is located on the right side of the vehicle.

8.165Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemOccasionally, fluid may seep, leak or be more forcefully expelled from the filter head when system

Hydraulic System8.166 Model 644E-42/944E-42 Rev. 6/048.11.1 Pump Failure AnalysisThe pump is the “heart” of the hydraulic system, and whenever there i

8.167Model 644E-42/944E-42 Rev. 6/04Hydraulic Systemb. Tools Required for Pump RepairThe following tools are required for servicing the pump:1. A seal

General Information, Specifications and Maintenance2.26 Model 644E-42/944E-42 Rev. 6/042.6.8 Drive Shaft SplinesIMPORTANT: DO NOT disassemble any of

Hydraulic System8.168 Model 644E-42/944E-42 Rev. 6/04d. Pump Disassembly 1. Plug all ports and thoroughly clean the outside of the pump (1) before sta

8.169Model 644E-42/944E-42 Rev. 6/04Hydraulic System13. Remove the square cross section o-ring (18) from the ported section (14). Discard the o-ring.1

Hydraulic System8.170 Model 644E-42/944E-42 Rev. 6/04g. Pump AssemblyIMPORTANT: It is important that the relationship of the front cover, front cente

8.171Model 644E-42/944E-42 Rev. 6/04Hydraulic System8. Lubricate the drive gear (7) with clean hydraulic oil. Very carefully insert the shaft through

Hydraulic System8.172 Model 644E-42/944E-42 Rev. 6/0422. Apply a light coating of graphite grease to the new square cross section o-ring (1) and caref

8.173Model 644E-42/944E-42 Rev. 6/04Hydraulic System30. Apply a light coating of graphite grease to the new square cross section o-ring (10) and caref

Hydraulic System8.174 Model 644E-42/944E-42 Rev. 6/04h. Pump Installation1. Place the pump (1) and a new oiled o-ring (2) into position on the transmi

8.175Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemThis Page Intentionally Left Blank

Hydraulic System8.176 Model 644E-42/944E-42 Rev. 6/048.12 VALVES AND MANIFOLDSValves are devices that open or close passageways. Manifolds contain cir

8.177Model 644E-42/944E-42 Rev. 6/04Hydraulic System10. After the capscrews are removed, slowly lower the sub plate down until the sub plate is suppor

2.27Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenance2.6.10 PaintUnless otherwise specified, paint components, as ind

Hydraulic System8.178 Model 644E-42/944E-42 Rev. 6/04MU4100123456789101112131415161718192021222324252627282930313233343536

8.179Model 644E-42/944E-42 Rev. 6/04Hydraulic Systemb. Main Control Valve Disassembly1. To disassemble the main control valve (1), remove the four hex

Hydraulic System8.180 Model 644E-42/944E-42 Rev. 6/04MU41001234567891011121314156616

8.181Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemMono Block DisassemblyThe mono block section (1) contains the relief valves, spools and compensato

Hydraulic System8.182 Model 644E-42/944E-42 Rev. 6/04MU414012345678910111213141516171819202122232425262728293031323334353620

8.183Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemInlet Section Assembly1. Install the main relief valve (1) with new seals into the side of the inl

Hydraulic System8.184 Model 644E-42/944E-42 Rev. 6/04f. Main Control Valve Installation1. Place the assembled main control valve (1) into position on

8.185Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.12.3 Joystick Valve (Dual Joystick)The individual joystick valves are mounted on the right side

Hydraulic System8.186 Model 644E-42/944E-42 Rev. 6/048.12.4 Pilot Select Valve (Dual Joystick)Pilot pressure from the front joystick flows to the pilo

8.187Model 644E-42/944E-42 Rev. 6/04Hydraulic System4. Clean all components with a suitable cleaner before inspection.5. Inspect internal passageways

General Information, Specifications and Maintenance2.28 Model 644E-42/944E-42 Rev. 6/042.8 REPLACEMENTALWAYS use the correct tool when removing or rep

Hydraulic System8.188 Model 644E-42/944E-42 Rev. 6/048.12.5 Joystick Valve (Single Joystick)The joystick valve is part of the joystick assembly (1). J

8.189Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.12.6 Single Joystick Pilot Select ValvePilot pressure from the joystick flows to the single joys

Hydraulic System8.190 Model 644E-42/944E-42 Rev. 6/04b. Single Joystick Pilot Select Valve Disassembly, Inspection and ReassemblyNote: Use new oiled

8.191Model 644E-42/944E-42 Rev. 6/04Hydraulic System3. Re-attach and secure all hoses and fittings.4. Reconnect any wire harness connectors.5. Start t

Hydraulic System8.192 Model 644E-42/944E-42 Rev. 6/04a. Frame Sway Joystick Capsule Replacement1. Lift up the boot (1) and remove the handle assembly

8.193Model 644E-42/944E-42 Rev. 6/04Hydraulic Systemb. Auxiliary Hydraulic Pressure Release Valve Disassembly, Inspection and ReassemblyNote: Use new

Hydraulic System8.194 Model 644E-42/944E-42 Rev. 6/04c. Auxiliary Hydraulic Pressure Release Valve Installation1. Position the auxiliary hydraulic pre

8.195Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.12.9 Auxiliary Hydraulic Pressure Release Valve (644E-42, Late Production thru SN 20118, SN 0160

Hydraulic System8.196 Model 644E-42/944E-42 Rev. 6/04b. Auxiliary Hydraulic Pressure Release Valve Disassembly, Inspection and ReassemblyNote: Use ne

8.197Model 644E-42/944E-42 Rev. 6/04Hydraulic System5. Start the engine and run at approximately one-third to one-half throttle for about one minute w

2.29Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenance2.10 BEARINGS2.10.1 Bearing Removal1. NEVER remove bearings unle

Hydraulic System8.198 Model 644E-42/944E-42 Rev. 6/048.12.10 Service Brake ValveThe service brake valve is secured at the base of the steering column

8.199Model 644E-42/944E-42 Rev. 6/04Hydraulic Systemb. Service Brake Valve ReassemblyNote: Use new oiled o-rings as required. ALWAYS replace seals, o

Hydraulic System8.200 Model 644E-42/944E-42 Rev. 6/04d. Brake TestCarefully bleed the brake lines as soon as the brake valve is installed in the vehic

8.201Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.12.11 Power Steering ValveThe power steering valve (2) is located at the base of the steering wh

Hydraulic System8.202 Model 644E-42/944E-42 Rev. 6/04c. Power Steering Valve InstallationNote: ALWAYS replace seals, o-rings, gaskets, etc., with new

8.203Model 644E-42/944E-42 Rev. 6/04Hydraulic System3. Unlatch and open the engine cover. Allow the hydraulic fluid to cool.4. Label or otherwise mark

Hydraulic System8.204 Model 644E-42/944E-42 Rev. 6/048.12.13 Accumulator Charge/Secondary Function ValveHydraulic oil from the front pump flows into t

8.205Model 644E-42/944E-42 Rev. 6/04Hydraulic System3. Remove the load shuttle cartridge (8).4. Remove the accumulator charge logic cartridge (9). Thi

Hydraulic System8.206 Model 644E-42/944E-42 Rev. 6/04c. Accumulator Charge/Secondary Function Valve Installation1. Reassemble all the fittings and dia

8.207Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.13.1 General InformationEach accumulator is a 3000 psi (207 bar) diaphragm type accumulator. Eac

General Information, Specifications and Maintenance2.30 Model 644E-42/944E-42 Rev. 6/042.12 AFTER SERVICE STARTUP AND CHECKS2.12.1 After Service Start

Hydraulic System8.208 Model 644E-42/944E-42 Rev. 6/048.13.2 Pre-Charging AccumulatorNote: Replacement accumulators are not pre-charged when shipped.P

8.209Model 644E-42/944E-42 Rev. 6/04Hydraulic System13. Let the pre-charge on the accumulator set for 10-15 minutes. This will allow the gas temperatu

Hydraulic System8.210 Model 644E-42/944E-42 Rev. 6/04b. Checking Accumulator Recharge Pressure and Nitrogen Pre-Charge1. Park the vehicle on a firm, l

8.211Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.13.4 Accumulator Charge TroubleshootingProblem Cause Remedy1. Accumulator charging cycle repeats

Hydraulic System8.212 Model 644E-42/944E-42 Rev. 6/048.14 HYDRAULIC CYLINDERSThis section covers servicing the attachment tilt (1), slave (2), extend/

8.213Model 644E-42/944E-42 Rev. 6/04Hydraulic System4. ALWAYS use new oiled o-rings, seals, gaskets, etc. DO NOT over-stretch seals, wipers and o-ring

Hydraulic System8.214 Model 644E-42/944E-42 Rev. 6/04b. Attachment Tilt Cylinder DisassemblyNote: An additional o-ring may be included at the base of

8.215Model 644E-42/944E-42 Rev. 6/04Hydraulic System9. Remove the locknut (8) from the rod (4). The locknut is a deformed-thread type nut torqued at 1

Hydraulic System8.216 Model 644E-42/944E-42 Rev. 6/044. Install both precision wearbands (16) and the capped T-seal (17) onto the piston (7).Note: Th

8.217Model 644E-42/944E-42 Rev. 6/04Hydraulic Systemf. Attachment Tilt Cylinder Installation1. Attach a suitable sling to an overhead crane or other s

2.31Model 644E-42/944E-42 Rev. 6/04General Information, Specifications and Maintenance2.12.6 After Transmission Service or Replacement1. Check transmi

Hydraulic System8.218 Model 644E-42/944E-42 Rev. 6/044. Label or otherwise mark the hydraulic hoses (right side) or tubes (left side) in relation to t

8.219Model 644E-42/944E-42 Rev. 6/04Hydraulic System6. Fasten the rod end in a soft-jawed vise and put a padded support below and near the threaded en

Hydraulic System8.220 Model 644E-42/944E-42 Rev. 6/04Note: If a white, powdery residue remains on the threads and parts, clean the residue away with

8.221Model 644E-42/944E-42 Rev. 6/04Hydraulic System4. Use new oiled o-rings and reattach and secure the hydraulic hoses to the slave cylinder fitting

Hydraulic System8.222 Model 644E-42/944E-42 Rev. 6/04c. Extend/Retract Cylinder DisassemblyNote: An additional o-ring may be included at the base of

8.223Model 644E-42/944E-42 Rev. 6/04Hydraulic System7. Fasten the trunnion end of the rod in a soft-jawed vise and put a padded support below and near

Hydraulic System8.224 Model 644E-42/944E-42 Rev. 6/043. Install one of the precision wearbands (19), the buffer seal (20) with the angled edge (25) to

8.225Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemIMPORTANT: When sliding the rod (5) and piston assembly in the tube, prevent the threaded end of

Hydraulic System8.226 Model 644E-42/944E-42 Rev. 6/044. Label or otherwise mark the lift/lower cylinder hydraulic hoses. Disconnect and cap all hoses

8.227Model 644E-42/944E-42 Rev. 6/04Hydraulic System3. Slowly remove the counterbalance valve (3) and pilot-operated check valve (4) from the eyelet e

General Information, Specifications and Maintenance2.32 Model 644E-42/944E-42 Rev. 6/04This Page Intentionally Left Blank

Hydraulic System8.228 Model 644E-42/944E-42 Rev. 6/04d. Lift/Lower Cylinder Inspection1. Inspect internal surfaces and all parts for wear, damage, etc

8.229Model 644E-42/944E-42 Rev. 6/04Hydraulic System8. Apply Loctite Threadlocker #271 (red) to the threads of the rod (8). Thread the locknut (13) on

Hydraulic System8.230 Model 644E-42/944E-42 Rev. 6/04g. Lift/Lower Cylinder Pressure Checking and Circuit Bleeding1. Attach a 5000 psi (345 bar) gauge

8.231Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemIMPORTANT: Protect the finish on the rod at all times. Damage to the rod can cause premature seal

Hydraulic System8.232 Model 644E-42/944E-42 Rev. 6/04c. Frame Sway Cylinder Internal Cleaning1. Remove all hydraulic fluid, dirt and debris from the i

8.233Model 644E-42/944E-42 Rev. 6/04Hydraulic System11. Apply Loctite Primer “T” and Threadlocker #271 (red), to a new locknut (7) in accordance with

Hydraulic System8.234 Model 644E-42/944E-42 Rev. 6/04f. Frame Sway Cylinder Installation1. Use a sling and hoist or other suitable lifting device to h

8.235Model 644E-42/944E-42 Rev. 6/04Hydraulic System8.14.9 Stabilizer CylinderThe stabilizer cylinder (1) is attached to the left side of the frame at

Hydraulic System8.236 Model 644E-42/944E-42 Rev. 6/04b. Stabilizer Cylinder DisassemblyNote: An additional o-ring may be included at the base of the

8.237Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemIMPORTANT: When sliding the rod and piston assembly in the tube, DO NOT damage the piston (10) by

3.1Model 644E-42/944E-42 Rev. 6/04Section 3BoomContentsPARAGRAPH TITLE PAGE3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . .

Hydraulic System8.238 Model 644E-42/944E-42 Rev. 6/0410. Secure the rod eyelet in a soft-jawed vise or other suitable holding device. Place a padded s

8.239Model 644E-42/944E-42 Rev. 6/04Hydraulic Systemf. Stabilizer Cylinder Installation1. Use a sling and hoist or other suitable lifting device to he

Hydraulic System8.240 Model 644E-42/944E-42 Rev. 6/048.14.11 Transfer Carriage CylinderThe transfer carriage cylinder (1) is attached to the transfer

8.241Model 644E-42/944E-42 Rev. 6/04Hydraulic Systemb. Transfer Carriage Cylinder DisassemblyNote: An additional o-ring may be included at the base o

Hydraulic System8.242 Model 644E-42/944E-42 Rev. 6/04Note: It may be necessary to apply heat to break the bond of the sealant between the locknut (11

8.243Model 644E-42/944E-42 Rev. 6/04Hydraulic System11. Secure the rod eyelet in a soft-jawed vise or other suitable holding device. Place a padded su

Hydraulic System8.244 Model 644E-42/944E-42 Rev. 6/04f. Transfer Carriage Cylinder Installation1. Install the transfer carriage cylinder back onto the

8.245Model 644E-42/944E-42 Rev. 6/04Hydraulic System5. Place an Accident Prevention Tag on both the ignition key switch and the steering wheel, statin

Hydraulic System8.246 Model 644E-42/944E-42 Rev. 6/04b. Swing Carriage Cylinder DisassemblyNote: An additional o-ring may be included at the base of

8.247Model 644E-42/944E-42 Rev. 6/04Hydraulic System8. Fasten the rod end in a soft-jawed vise and put a padded support below and near the threaded en

SECTION CONTENTSSection Subject Page 2004 JLG Industries, Inc.Model 644E-42/944E-42 Rev. 6/04iSection 1Safety Practices . . . . . . . . . . . . . .

Boom3.2 Model 644E-42/944E-42 Rev. 6/043.1 BOOM SYSTEM COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented

Hydraulic System8.248 Model 644E-42/944E-42 Rev. 6/045. Install two new locking inserts (14) into their holes in the head gland threads.6. Install a n

8.249Model 644E-42/944E-42 Rev. 6/04Hydraulic System18. If the bearing (17) requires replacement, support the rod (6) in a soft-jawed vise or other su

Hydraulic System8.250 Model 644E-42/944E-42 Rev. 6/048.14.13 Side Tilt Carriage Cylinder (Optional)The optional side tilt carriage cylinder (1) provid

8.251Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemMT1950234567855

Hydraulic System8.252 Model 644E-42/944E-42 Rev. 6/04b. Side Tilt Carriage Cylinder DisassemblyNote: An additional o-ring may be included at the base

8.253Model 644E-42/944E-42 Rev. 6/04Hydraulic System11. Remove the locking inserts (9) from their holes in the head gland threads. Pry or drill out th

Hydraulic System8.254 Model 644E-42/944E-42 Rev. 6/04e. Side Tilt Carriage Cylinder AssemblyNote: Follow the general assembly instructions in Section

8.255Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemIMPORTANT: When sliding the rod and piston assembly in the tube, prevent the threaded end of the

Hydraulic System8.256 Model 644E-42/944E-42 Rev. 6/04f. Side Tilt Carriage Cylinder Installation1. Install the side tilt carriage cylinder (2) onto th

8.257Model 644E-42/944E-42 Rev. 6/04Hydraulic SystemMT1950123456744

3.3Model 644E-42/944E-42 Rev. 6/04Boom3.2 BOOM SYSTEM3.2.1 Boom System DescriptionThe boom operates via an interchange among the hydraulic and mechani

Hydraulic System8.258 Model 644E-42/944E-42 Rev. 6/04This Page Intentionally Left Blank

9.1Model 644E-42/944E-42 Rev. 6/04Section 9Electrical SystemContentsPARAGRAPH TITLE PAGE9.1 Electrical Component Terminology...

Electrical System9.2 Model 644E-42/944E-42 Rev. 6/049.8.7 Main Electrical Schematic (644E-42, SN 20118 & Before, 0160002519 thru 0160003877, 944E-

9.3Model 644E-42/944E-42 Rev. 6/04Electrical System9.9 Transmission Gear Selection Troubleshooting...

Electrical System9.4 Model 644E-42/944E-42 Rev. 6/049.14 Switches and Solenoids...

9.5Model 644E-42/944E-42 Rev. 6/04Electrical System9.1 ELECTRICAL COMPONENT TERMINOLOGYTo understand the safety, operation, and service information pr

Electrical System9.6 Model 644E-42/944E-42 Rev. 6/049.1.2 General Overview (644E-42, SN 20118 & Before, 0160002519 thru 0160003689 - Vehicle Power

9.7Model 644E-42/944E-42 Rev. 6/04Electrical System9.1.3 General Overview (644E-42, SN 0160003690 & After - Vehicle Power Harness)MU6630Engine Sta

Electrical System9.8 Model 644E-42/944E-42 Rev. 6/049.1.4 General Overview (944E-42 ECM Vehicle Power & ECM Cab Harnesses)AAMU6030Cold Start Grid

9.9Model 644E-42/944E-42 Rev. 6/04Electrical System9.1.5 General Overview (Vehicle Sensor Harness)Engine Water Temperature SwitchAir Filter Pressure S

Boom3.4 Model 644E-42/944E-42 Rev. 6/043.3.1 Inner Boom Replacementa. Inner Boom Removal1. Remove any attachment from the quick attach assembly. (Refe

Electrical System9.10 Model 644E-42/944E-42 Rev. 6/049.1.6 General Overview (Vehicle Control Harness)MU4680Boom Proximity SwitchBack-Up AlarmStabilize

9.11Model 644E-42/944E-42 Rev. 6/04Electrical System9.1.7 General Overview (Vehicle Transmission Harness)MU4690Vehicle Transmission HarnessTransmissio

Electrical System9.12 Model 644E-42/944E-42 Rev. 6/049.1.8 General Overview (Optional Single Joystick Harness)MU6330Cab HarnessSingle Joystick Harness

9.13Model 644E-42/944E-42 Rev. 6/04Electrical System9.1.9 General Overview (Optional Closed Cab Harness)MU4700Air Conditioning CondenserSkylight Wiper

Electrical System9.14 Model 644E-42/944E-42 Rev. 6/049.1.10 General Overview (Optional Roadlight Harness)MU6010Roadlight HarnessFront Headlights &

9.15Model 644E-42/944E-42 Rev. 6/04Electrical System9.1.11 General Overview (Optional Worklight Harness)MU5980Vehicle Worklight HarnessCab Worklight H

Electrical System9.16 Model 644E-42/944E-42 Rev. 6/049.1.12 General Overview (Vehicle Ground Strap Locations)MU6420Cab to Cab Support Ground StrapCab

9.17Model 644E-42/944E-42 Rev. 6/04Electrical SystemThis Page Intentionally Left Blank

Electrical System9.18 Model 644E-42/944E-42 Rev. 6/049.2 SERVICE WARNINGS9.2.1 General9.2.2 Battery9.3 SPECIFICATIONSElectrical system specifications

9.19Model 644E-42/944E-42 Rev. 6/04Electrical System9.4 EFFECTIVE GROUND CONNECTIONS1. Effective ground connections are essential to the efficient ope

3.5Model 644E-42/944E-42 Rev. 6/04Boom6. Loosen the extend chain locknut (10), located at the rear of the outer boom (11), half way. The locknut must

Electrical System9.20 Model 644E-42/944E-42 Rev. 6/049.6.1 Removal and ReplacementRemove a wiring harness only if damaged or unusable. Install a new h

9.21Model 644E-42/944E-42 Rev. 6/04Electrical System9.7 FUSES AND RELAYSFuses and relays help to protect the electrical system. In general, a blown fu

Electrical System9.22 Model 644E-42/944E-42 Rev. 6/049.7.2 Fuse and Relay LocationsThe fuse and relay block is mounted under the lower right side of t

9.23Model 644E-42/944E-42 Rev. 6/04Electrical Systemd. 944E-42 Engine Compartment Fuse Locations Cold Start Grid Heater FusesThe two 125 amp fuses (5)

Electrical System9.24 Model 644E-42/944E-42 Rev. 6/04e. 644E-42 Engine Compartment Relay Locations There are two relays located inside the engine comp

9.25Model 644E-42/944E-42 Rev. 6/04Electrical System9.7.3 Fuse and Relay ReplacementShut off the engine and disconnect the batteries before checking t

Electrical System9.26 Model 644E-42/944E-42 Rev. 6/04ECM Fuses1. Locate the two fuse holders. Remove the clear plastic protective cover (1) from the h

9.27Model 644E-42/944E-42 Rev. 6/04Electrical Systemd. After Relay Service1. If the vehicle has dual batteries, connect both negative battery cables (

Electrical System9.28 Model 644E-42/944E-42 Rev. 6/04The text discusses each circuit and component, as well as component function and replacement. Man

9.29Model 644E-42/944E-42 Rev. 6/04Electrical SystemOffboard DiagnosticsINSITE™, is the Windows®-based PC service/programming/diagnostic tool for 944E

Boom3.6 Model 644E-42/944E-42 Rev. 6/0413. Label, disconnect and plug or cap the extend (1) and retract (2) hoses and ports (3) on the Extend/Retract

Electrical System9.30 Model 644E-42/944E-42 Rev. 6/049.8.4 Probing Electrical Connectorsa. Front ProbeDisconnect the connector and probe the terminals

9.31Model 644E-42/944E-42 Rev. 6/04Electrical SystemTesting for ContinuityThe following procedures verify good continuity in a circuit.With a DMM1. Se

Electrical System9.32 Model 644E-42/944E-42 Rev. 6/04Testing for Electrical IntermittencePerform the following procedure while wiggling the harness fr

9.33Model 644E-42/944E-42 Rev. 6/04Electrical System9. When reassembling the cover (7) to the side console, torque the capscrews to 7 - 8 lb-ft (9,5 -

Electrical System9.34 Model 644E-42/944E-42 Rev. 6/047. To test the operation of the relays, connect a 12-volt DC positive lead to the positive termin

9.35Model 644E-42/944E-42 Rev. 6/04Electrical System9.8.5 Main Electrical Schematic LegendWire No. Page Gauge Color From - Function - To9.52, 9.53 or

Electrical System9.36 Model 644E-42/944E-42 Rev. 6/04BA39.48 or 9.5012 RED/BLU Ignition Control Fuse (F2) (Pin 2) To Ignition Relay (Pin 30)BA49.48 or

9.37Model 644E-42/944E-42 Rev. 6/04Electrical SystemBPS 9.54 14 RED/GRN10 amp Mini Fuse VESPAK Connector P6 (Pin D) To Engine Control Module, 23 Pin F

Electrical System9.38 Model 644E-42/944E-42 Rev. 6/04D1A9.48 or 9.5018 RED/YEL Buzzer To Dash Panel Fuse (F8) (Pin H)D29.48 or 9.5018 ORGDash Panel, 2

9.39Model 644E-42/944E-42 Rev. 6/04Electrical SystemEG39.49 or 9.5116 BLK Splice 100 To Ground Buss BarEG49.49 or 9.5116 BLK Back-Up Alarm, Female, Co

3.7Model 644E-42/944E-42 Rev. 6/04Boom17. Label, disconnect and plug the attachment tilt hoses (16) at the fittings at the front of the inner boom sec

Electrical System9.40 Model 644E-42/944E-42 Rev. 6/04FRG 9.52 14 BLKFuel Shutoff Relay (Pin 4) To Splice 95 (644E-42 SN 20118 & Before, 0160002519

9.41Model 644E-42/944E-42 Rev. 6/04Electrical System9.54 1/0 RED Battery 1 Positive (+) Terminal To Battery 2 Positive (+) Terminal (944E-42 Only)LP19

Electrical System9.42 Model 644E-42/944E-42 Rev. 6/04RG19.48 or 9.5016 BLK Transmission Disconnect Relay (Pin 86) To Splice 85RG29.48 or 9.5016 BLK Tr

9.43Model 644E-42/944E-42 Rev. 6/04Electrical SystemS8C9.49 or 9.5118 PUR/WHT Stabilizer Solenoid 12B, Female, Connector (Pin A) To Splice 60S99.48 or

Electrical System9.44 Model 644E-42/944E-42 Rev. 6/04ST4A9.5214 RED/BLKPower Bulkhead, 6 Pin Male, Connector (Pin A) To Fuel Shutoff Solenoid, 3 Pin F

9.45Model 644E-42/944E-42 Rev. 6/04Electrical SystemTR5A9.49 or 9.5118 BRNTransmission Bulkhead, 6 Pin Male, Connector (Pin E) To Transmission Y5 Sole

Electrical System9.46 Model 644E-42/944E-42 Rev. 6/04This Page Intentionally Left Blank

9.47Model 644E-42/944E-42 Rev. 6/04Electrical System9.8.6 Electrical Symbols DirectoryThe following directory shows the most common electrical symbols

Electrical System9.48 Model 644E-42/944E-42 Rev. 6/049.8.7 Main Electrical Schematic (644E-42, SN 20118 & Before, 0160002519 thru 0160003877, 944E

9.49Model 644E-42/944E-42 Rev. 6/04Electrical SystemMain Elect Schem Sht 2 (Before)70S11APH1VEHICLEMALECONNECTORB+D+GND (-)WAABBX7 X7110D10A D11A AX6

Boom3.8 Model 644E-42/944E-42 Rev. 6/0424. Install a lifting eye (1) to the nut on the attachment tilt cylinder (2). Attach suitable overhead lifting

Electrical System9.50 Model 644E-42/944E-42 Rev. 6/049.8.8 Main Electrical Schematic (644E-42, SN 0160003878 & After, 944E-42, SN 0160003882 &

9.51Model 644E-42/944E-42 Rev. 6/04Electrical SystemMain Elect Schem Sht 2 (After)70S11APH1VEHICLEMALECONNECTORB+D+GND (-)WAABBX7 X7110D10A D11A AX6 X

Electrical System9.52 Model 644E-42/944E-42 Rev. 6/049.8.9 644E-42 Vehicle Power Harness Electrical Schematic (SN 20118 & Before, 0160002519 thru

9.53Model 644E-42/944E-42 Rev. 6/04Electrical System9.8.10 644E-42 Vehicle Power Harness Electrical Schematic (SN 0160003690 & After)Schematic is

Electrical System9.54 Model 644E-42/944E-42 Rev. 6/049.8.11 944E-42 ECM Vehicle Power & ECM Cab Harnesses Electrical SchematicSchematic is drawn w

9.55Model 644E-42/944E-42 Rev. 6/04Electrical System9.8.12 Optional 644E-42 Cold Start Electrical Schematic LegendWire No. Page Gauge Color From - Fun

Electrical System9.56 Model 644E-42/944E-42 Rev. 6/049.8.13 Optional 644E-42 Cold Start Electrical Schematic (SN 20118 & Before, 0160002519 thru 0

9.57Model 644E-42/944E-42 Rev. 6/04Electrical System9.8.14 Optional 644E-42 Cold Start Electrical Schematic (SN 0160003690 & After)Schematic is dr

Electrical System9.58 Model 644E-42/944E-42 Rev. 6/049.8.15 Optional Single Joystick (Early Production) Electrical Schematic LegendWire No. Page Gauge

9.59Model 644E-42/944E-42 Rev. 6/04Electrical System9.8.16 Optional Single Joystick (Early Production) Electrical SchematicSchematic is drawn with the

3.9Model 644E-42/944E-42 Rev. 6/04BoomNote: If replacing the inner boom assembly with a new inner boom, the hose guide, retract chain, remaining wear

Electrical System9.60 Model 644E-42/944E-42 Rev. 6/049.8.17 Optional Single Joystick (Late Production) Electrical Schematic LegendWire No. Page Gauge

9.61Model 644E-42/944E-42 Rev. 6/04Electrical System9.8.18 Optional Single Joystick (Late Production) Electrical SchematicSchematic is drawn with the

Electrical System9.62 Model 644E-42/944E-42 Rev. 6/049.8.19 Optional Closed Cab Electrical Schematic LegendWire No. Page Gauge Color From - Function -

9.63Model 644E-42/944E-42 Rev. 6/04Electrical System9.8.20 Optional Closed Cab Electrical SchematicSchematic is drawn with the ignition switch in the

Electrical System9.64 Model 644E-42/944E-42 Rev. 6/049.8.21 Optional Roadlight Electrical Schematic LegendWire No. Page Gauge Color From - Function -

9.65Model 644E-42/944E-42 Rev. 6/04Electrical SystemRT1A 9.66 16 GRN Roadlight Bulkhead, 7 Pin Female, Connector (Pin E) To Splice 115RT1B 9.67 16 GRN

Electrical System9.66 Model 644E-42/944E-42 Rev. 6/049.8.22 Optional Roadlight Electrical SchematicSchematic is drawn with the ignition switch in the

9.67Model 644E-42/944E-42 Rev. 6/04Electrical SystemOptRoadlightSchemWLG1WL2ALEFTFRONTROADLIGHTSIDE LT INDLOWBEAMHIGHBEAMRIGHTFRONTROADLIGHTSIDE LTIND

Electrical System9.68 Model 644E-42/944E-42 Rev. 6/049.8.23 Optional Worklight Electrical Schematic LegendWire No. Page Gauge Color From - Function -

9.69Model 644E-42/944E-42 Rev. 6/04Electrical System9.8.24 Optional Worklight Electrical SchematicSchematic is drawn with the ignition switch in the O

Boom3.10 Model 644E-42/944E-42 Rev. 6/0433. Remove the capscrews (1 and 4) and washers (2) and hydraulic hose track (3) from inside the inner boom.34.

Electrical System9.70 Model 644E-42/944E-42 Rev. 6/049.8.25 644E-42 Engine Start Circuit & TroubleshootingSchematic is drawn with the ignition swi

9.71Model 644E-42/944E-42 Rev. 6/04Electrical SystemCheck 40 amp open cab vehicle main fuse (F1) and 15 amp ignition control fuse (F2).Check that tran

Electrical System9.72 Model 644E-42/944E-42 Rev. 6/049.8.25 644E-42 Engine Start Circuit & Troubleshooting (Continued)Schematic is drawn with the

9.73Model 644E-42/944E-42 Rev. 6/04Electrical SystemContinued on 9.75Not OKIf OKRepair/replace open cab harness.If OKRepair/replace open cab harness.R

Electrical System9.74 Model 644E-42/944E-42 Rev. 6/049.8.25 644E-42 Engine Start Circuit & Troubleshooting (Continued)Schematic is drawn with the

9.75Model 644E-42/944E-42 Rev. 6/04Electrical SystemIf OKIf OKRepair/replace open cab harness.Replace ignition switch.If OKReplace 15 amp ignition con

Electrical System9.76 Model 644E-42/944E-42 Rev. 6/049.8.26 944E-42 Engine Start Circuit & TroubleshootingSchematic is drawn with the ignition swi

9.77Model 644E-42/944E-42 Rev. 6/04Electrical SystemCheck 40 amp open cab vehicle main fuse (F1) and 15 amp ignition control fuse (F2).Check that tran

Electrical System9.78 Model 644E-42/944E-42 Rev. 6/049.8.26 944E-42 Engine Start Circuit & Troubleshooting (Continued)Schematic is drawn with the

9.79Model 644E-42/944E-42 Rev. 6/04Electrical SystemContinued on 9.81Not OKIf OKRepair/replace open cab harness.If OKRepair/replace open cab harness.R

3.11Model 644E-42/944E-42 Rev. 6/04Boom3. Coat the capscrew (8) with Loctite® 242 (blue). At the rear of the inner boom (5), attach the retract chain

Electrical System9.80 Model 644E-42/944E-42 Rev. 6/049.8.26 944E-42 Engine Start Circuit & Troubleshooting (Continued)Schematic is drawn with the

9.81Model 644E-42/944E-42 Rev. 6/04Electrical SystemIf OKIf OKRepair/replace open cab harness.Replace ignition switch.If OKReplace 15 amp ignition con

Electrical System9.82 Model 644E-42/944E-42 Rev. 6/049.8.27 944E-42 Electronic Throttle Circuit & TroubleshootingSchematic is drawn with the ignit

9.83Model 644E-42/944E-42 Rev. 6/04Electrical SystemNot OKRepair/replace ECM cab harness.Replace throttle position sensor.Not OKEngine speed drops to

Electrical System9.84 Model 644E-42/944E-42 Rev. 6/049.8.28 Charging Circuit & TroubleshootingSchematic is drawn with the ignition switch in the R

9.85Model 644E-42/944E-42 Rev. 6/04Electrical SystemBefore troubleshooting any electrical circuit, ALWAYS begin by checking the following:1. Fuses.2.

Electrical System9.86 Model 644E-42/944E-42 Rev. 6/049.8.29 Dual Joystick - Auxiliary Hydraulic Circuit & TroubleshootingSchematic is drawn with t

9.87Model 644E-42/944E-42 Rev. 6/04Electrical SystemNot OKRepair/replace open cab harness.Replace auxiliary joystick handle.Not OKUnplug harness at au

Electrical System9.88 Model 644E-42/944E-42 Rev. 6/049.8.29 Dual Joystick - Auxiliary Hydraulic Circuit & Troubleshooting (Continued)Schematic is

9.89Model 644E-42/944E-42 Rev. 6/04Electrical SystemAuxiliary hydraulic pressure release switch does not release pressure from system.Replace fuse.Che

Section Subject PageiiModel 644E-42/944E-42 Rev. 6/04Section 5Axles, Drive Shafts, Wheels, Tires and Brakes . . . . . . . . . . . . . . . . . . . . .

Boom3.12 Model 644E-42/944E-42 Rev. 6/04Note: The 644E inner boom, without attachments, weighs 1,050 lbs (480 kg). The 944E inner boom, with-out atta

Electrical System9.90 Model 644E-42/944E-42 Rev. 6/049.8.30 Single Joystick - Auxiliary Hydraulic Circuit & Troubleshooting (Option)Schematic is d

9.91Model 644E-42/944E-42 Rev. 6/04Electrical SystemIf OKIf OKNot OKReplace failed solenoid.Reconnect harness. When button is pressed, verify that sol

Electrical System9.92 Model 644E-42/944E-42 Rev. 6/049.8.30 Single Joystick - Auxiliary Hydraulic Circuit & Troubleshooting (Option) (Continued)Sc

9.93Model 644E-42/944E-42 Rev. 6/04Electrical SystemReplace fuse.Check auxiliary hydraulic (F10) 5 amp fuse.Not OKIf OKIf OKNot OKReplace failed solen

Electrical System9.94 Model 644E-42/944E-42 Rev. 6/049.8.31 Single Joystick - Transfer Carriage Extend/Retract Circuit & Troubleshooting (Option)S

9.95Model 644E-42/944E-42 Rev. 6/04Electrical SystemBefore troubleshooting any electrical circuit, ALWAYS begin by checking the following:1. All conne

Electrical System9.96 Model 644E-42/944E-42 Rev. 6/049.8.32 Single Joystick - Boom Extend/Retract Circuit & Troubleshooting (Option)Schematic is d

9.97Model 644E-42/944E-42 Rev. 6/04Electrical SystemIf OKNot OKNot OKReplace failed solenoid.Repair/replace single joystick harness.Replace single joy

Electrical System9.98 Model 644E-42/944E-42 Rev. 6/049.8.33 Single Joystick - Boom Lift/Lower Circuit & Troubleshooting (Option)Schematic is drawn

9.99Model 644E-42/944E-42 Rev. 6/04Electrical SystemBefore troubleshooting any electrical circuit, ALWAYS begin by checking the following:1. All conne

3.13Model 644E-42/944E-42 Rev. 6/04Boom12. Coat the capscrews (14) with Loctite® 242 (blue). Use a socket wrench and long extension to install the fou

Electrical System9.100 Model 644E-42/944E-42 Rev. 6/049.8.34 Single Joystick - Attachment Tilt Circuit & Troubleshooting (Option)Schematic is draw

9.101Model 644E-42/944E-42 Rev. 6/04Electrical SystemIf OKReplace failed solenoid.Repair/replace single joystick harness.Not OKPlug cab harness back i

Electrical System9.102 Model 644E-42/944E-42 Rev. 6/049.8.34 Single Joystick - Attachment Tilt Circuit & Troubleshooting (Option) (Continued)Schem

9.103Model 644E-42/944E-42 Rev. 6/04Electrical SystemBefore troubleshooting any electrical circuit, ALWAYS begin by checking the following:1. All conn

Electrical System9.104 Model 644E-42/944E-42 Rev. 6/049.8.35 644E-42 Engine With Optional Cold Start Circuit & TroubleshootingSchematic is drawn w

9.105Model 644E-42/944E-42 Rev. 6/04Electrical SystemCheck 40 amp open cab vehicle main fuse (F1) and 15 amp ignition control fuse (F2).Check that tra

Electrical System9.106 Model 644E-42/944E-42 Rev. 6/049.8.35 644E-42 Engine With Optional Cold Start Circuit & Troubleshooting (Continued)Schemati

9.107Model 644E-42/944E-42 Rev. 6/04Electrical SystemContinued on 9.109Not OKIf OKRepair/replace open cab harness.If OKRepair/replace open cab harness

Electrical System9.108 Model 644E-42/944E-42 Rev. 6/049.8.35 644E-42 Engine With Optional Cold Start Circuit & Troubleshooting (Continued)Schemati

9.109Model 644E-42/944E-42 Rev. 6/04Electrical SystemIf OKIf OKRepair/replace open cab harness.Replace ignition switch.If OKReplace 15 amp ignition co

Boom3.14 Model 644E-42/944E-42 Rev. 6/04Note: ALWAYS use new o-rings when servicing the vehicle.17. Install new o-rings into the fittings. Lubricate

Electrical System9.110 Model 644E-42/944E-42 Rev. 6/049.8.36 Cab Heater & Air Conditioning Blower Motor Circuit & TroubleshootingSchematic is

9.111Model 644E-42/944E-42 Rev. 6/04Electrical SystemReplace closed cab harness.Not OKBlower motor inoperative at any speed.Check for voltage to wire

Electrical System9.112 Model 644E-42/944E-42 Rev. 6/049.8.37 Air Conditioning Circuit & TroubleshootingSchematic is drawn with the ignition switch

9.113Model 644E-42/944E-42 Rev. 6/04Electrical SystemNot OKAir Conditioning is inoperative.Check wire [BLB] (YEL/GRN) to blower switch.With blower swi

Electrical System9.114 Model 644E-42/944E-42 Rev. 6/049.8.38 Front Wiper/Washer Circuit & TroubleshootingSchematic is drawn with the ignition swit

9.115Model 644E-42/944E-42 Rev. 6/04Electrical SystemNot OKClean, tighten and recheck.Check wires [FWG3] (BLK) and [FWG4] (BLK) for proper ground at p

Electrical System9.116 Model 644E-42/944E-42 Rev. 6/049.8.39 Skylight Wiper/Washer, Rear Washer Circuit & TroubleshootingSchematic is drawn with t

9.117Model 644E-42/944E-42 Rev. 6/04Electrical SystemBefore troubleshooting any electrical circuit, ALWAYS begin by checking the following:1. Fuses.2.

Electrical System9.118 Model 644E-42/944E-42 Rev. 6/049.8.40 Rear Wiper Circuit & TroubleshootingSchematic is drawn with the ignition switch in th

9.119Model 644E-42/944E-42 Rev. 6/04Electrical SystemReplace rear wiper switch/motor.If OKCheck wire [RWP] (GRN/YEL) to rear wiper switch/motor for ba

3.15Model 644E-42/944E-42 Rev. 6/04Boom25. Working from the rear of the boom, move the attachment tilt and auxiliary hydraulic hoses (10) until there

Electrical System9.120 Model 644E-42/944E-42 Rev. 6/049.8.41 Light Power Relay Circuit & Troubleshooting (Option)F25 40LIGHTS MAIN (OPTION)YF26 25

9.121Model 644E-42/944E-42 Rev. 6/04Electrical SystemNot OKWith the ignition ON and the turn signal control selector rotated to either the 1st or 2nd

Electrical System9.122 Model 644E-42/944E-42 Rev. 6/049.8.42 Roadlight High Beam Circuit & Troubleshooting (Option)ABCDEFGHB1BPS1BROADLIGHTFEMALE

9.123Model 644E-42/944E-42 Rev. 6/04Electrical SystemWith the ignition ON and the turn signal control selector rotated to 2nd position (Position Parki

Electrical System9.124 Model 644E-42/944E-42 Rev. 6/049.8.43 Roadlight Low Beam Lights Circuit & Troubleshooting (Option)Schematic is drawn with t

9.125Model 644E-42/944E-42 Rev. 6/04Electrical SystemWith the ignition ON and the turn signal control selector rotated to 2nd position (Position Parki

Electrical System9.126 Model 644E-42/944E-42 Rev. 6/049.8.44 Roadlight Parking Lights Circuit & Troubleshooting (Option)Schematic is drawn with th

9.127Model 644E-42/944E-42 Rev. 6/04Electrical SystemWith the ignition ON and the turn signal control selector rotated to 1st position (Position Parki

Electrical System9.128 Model 644E-42/944E-42 Rev. 6/049.8.45 Roadlight Hazard Lights Circuit & Troubleshooting (Option)Schematic is drawn with the

9.129Model 644E-42/944E-42 Rev. 6/04Electrical SystemWith ignition switch OFF, hazard indicator and all hazard lights remain OFF with the 4 way hazard

Boom3.16 Model 644E-42/944E-42 Rev. 6/0429. If needed, pull the intermediate boom out slightly to align the extend chain yoke (2) with the bracket. Ro

Electrical System9.130 Model 644E-42/944E-42 Rev. 6/049.8.46 Roadlight Turn Signals Circuit & Troubleshooting (Option)Schematic is drawn with the

9.131Model 644E-42/944E-42 Rev. 6/04Electrical SystemNot OKReplace cab roadlight harness.With the ignition ON and the turn signal control selector pus

Electrical System9.132 Model 644E-42/944E-42 Rev. 6/049.8.47 Roadlight Brake Lights Circuit & Troubleshooting (Option)Schematic is drawn with the

9.133Model 644E-42/944E-42 Rev. 6/04Electrical SystemWith the ignition ON and the brake pedal depressed, brake lights remain OFF.If one brake light is

Electrical System9.134 Model 644E-42/944E-42 Rev. 6/049.8.48 Flash High Beam Circuit & Troubleshooting (Option)Schematic is drawn with the ignitio

9.135Model 644E-42/944E-42 Rev. 6/04Electrical SystemWith the ignition ON, the worklight switch OFF and the turn signal control selector rotated to th

Electrical System9.136 Model 644E-42/944E-42 Rev. 6/049.8.49 Roadlight Worklight Circuit & Troubleshooting (Option)Schematic is drawn with the ign

9.137Model 644E-42/944E-42 Rev. 6/04Electrical SystemNot OKCheck for battery voltage at pin 2, wire [WL1A] (RED/WHT) and 5, wire [WL1C] (RED/WHT) at w

Electrical System9.138 Model 644E-42/944E-42 Rev. 6/049.8.50 Worklight (Without Roadlight) Circuit & Troubleshooting (Option)Schematic is drawn wi

9.139Model 644E-42/944E-42 Rev. 6/04Electrical SystemNot OKCheck for battery voltage at pin 2, wire [WL4B] (RED/WHT) and pin 5, wire [WL4C] (RED/WHT)

3.17Model 644E-42/944E-42 Rev. 6/04Boom33. Start the engine and operate all boom functions several times. Check the chain tension again and adjust as

Electrical System9.140 Model 644E-42/944E-42 Rev. 6/049.9 TRANSMISSION GEAR SELECTION TROUBLESHOOTINGThe following seven electrical circuit schematics

9.141Model 644E-42/944E-42 Rev. 6/04Electrical System9.9.1 Transmission, Forward - First Gear CircuitSchematic is drawn with the ignition switch in th

Electrical System9.142 Model 644E-42/944E-42 Rev. 6/049.9.2 Transmission, Forward - Second Gear CircuitSchematic is drawn with the ignition switch in

9.143Model 644E-42/944E-42 Rev. 6/04Electrical System9.9.3 Transmission, Forward - Third Gear CircuitSchematic is drawn with the ignition switch in th

Electrical System9.144 Model 644E-42/944E-42 Rev. 6/049.9.4 Transmission, Forward - Fourth Gear CircuitSchematic is drawn with the ignition switch in

9.145Model 644E-42/944E-42 Rev. 6/04Electrical System9.9.5 Transmission, Reverse - First Gear CircuitSchematic is drawn with the ignition switch in th

Electrical System9.146 Model 644E-42/944E-42 Rev. 6/049.9.6 Transmission, Reverse - Second Gear CircuitSchematic is drawn with the ignition switch in

9.147Model 644E-42/944E-42 Rev. 6/04Electrical System9.9.7 Transmission, Reverse - Third Gear CircuitSchematic is drawn with the ignition switch in th

Electrical System9.148 Model 644E-42/944E-42 Rev. 6/049.10 DASH PANEL WARNING INDICATOR TROUBLESHOOTINGThe following troubleshooting flow charts discu

9.149Model 644E-42/944E-42 Rev. 6/04Electrical System9.10.1 Engine Alternator Charging Warning Indicator TroubleshootingEngine alternator charging war

Boom3.18 Model 644E-42/944E-42 Rev. 6/043.3.2 Intermediate Boom Replacementa. Intermediate Boom Removal1. Remove the inner boom as described in Sectio

Electrical System9.150 Model 644E-42/944E-42 Rev. 6/049.10.2 Engine Coolant Temperature Gauge Troubleshooting0000000RPM X 10051015302025F1/2E104176802

9.151Model 644E-42/944E-42 Rev. 6/04Electrical System9.10.3 Engine Oil Pressure Warning Indicator TroubleshootingIf OK0000000RPM X 10051015302025F1/2E

Electrical System9.152 Model 644E-42/944E-42 Rev. 6/049.10.4 Engine Air Filter Restriction Warning Indicator TroubleshootingMU4400Check air filter ele

9.153Model 644E-42/944E-42 Rev. 6/04Electrical System9.10.5 Engine Tachometer & Hourmeter Indicator TroubleshootingIf OKNot OK0000000RPM X 1005101

Electrical System9.154 Model 644E-42/944E-42 Rev. 6/049.10.6 Transmission Temperature Warning Indicator Troubleshooting0000000RPM X 10051015302025F1/2

9.155Model 644E-42/944E-42 Rev. 6/04Electrical System9.10.7 Dual Hydraulic Oil Temperature Warning Indicator Troubleshooting0000000RPM X 1005101530202

Electrical System9.156 Model 644E-42/944E-42 Rev. 6/049.10.8 Hydraulic Oil Filter Restriction Warning Indicator Troubleshooting0000000RPM X 1005101530

9.157Model 644E-42/944E-42 Rev. 6/04Electrical System9.10.9 Park Brake Warning Indicator Troubleshooting0000000RPM X 10051015302025F1/2E10417680248120

Electrical System9.158 Model 644E-42/944E-42 Rev. 6/049.10.10 Low Brake Pressure Indicator TroubleshootingCheck accumulator charge valve pressures. Re

9.159Model 644E-42/944E-42 Rev. 6/04Electrical System9.10.11 Fuel Level Gauge TroubleshootingReplace cab harness.Not OKNot OKReplace fuel level sender

3.19Model 644E-42/944E-42 Rev. 6/04BoomNote: If you are replacing the intermediate boom with a new intermediate boom; remove the following parts and

Electrical System9.160 Model 644E-42/944E-42 Rev. 6/049.10.12 Stabil-TRAK™ “Locked” Mode Indicator Troubleshooting0000000RPM X 10051015302025F1/2E1041

9.161Model 644E-42/944E-42 Rev. 6/04Electrical System9.10.13 Stabil-TRAK™ “Slow Pivot” Mode Indicator Troubleshooting0000000RPM X 10051015302025F1/2E1

Electrical System9.162 Model 644E-42/944E-42 Rev. 6/049.10.14 Engine Air-Intake Heater Indicator Troubleshooting (644E-42 Option, 944E-42 Standard)Gri

9.163Model 644E-42/944E-42 Rev. 6/04Electrical System9.11 ENGINE START CIRCUITThe purpose of the engine start circuit is to energize the starter solen

Electrical System9.164 Model 644E-42/944E-42 Rev. 6/049.11.2 StarterThe starter (1) is located on the left side of the engine, just inboard of the hyd

9.165Model 644E-42/944E-42 Rev. 6/04Electrical Systemc. Starter Removal1. Unlock and open the engine cover (4).2. If the vehicle has dual batteries, d

Electrical System9.166 Model 644E-42/944E-42 Rev. 6/048. Loosen, but DO NOT remove, the two fasteners (1 and 2) securing the starter (3) to the flywhe

9.167Model 644E-42/944E-42 Rev. 6/04Electrical System7. Lower and lock engine cover. To release and lower the engine cover (19) from the fully raised

Electrical System9.168 Model 644E-42/944E-42 Rev. 6/04The negative (-) post of the battery is connected to the starter ground stud (1). The engine is

9.169Model 644E-42/944E-42 Rev. 6/04Electrical System9.12.1 Alternatora. Alternator Removal1. Unlock and open the engine cover (4).2. If the vehicle h

Boom3.20 Model 644E-42/944E-42 Rev. 6/04b. Intermediate Boom Installation IMPORTANT: Light lubrication of the boom wear surfaces with a rust inhibito

Electrical System9.170 Model 644E-42/944E-42 Rev. 6/044. Label and disconnect these alternator wires:• [AG1] and [AG2] from G terminal (1)• [AB1] and

9.171Model 644E-42/944E-42 Rev. 6/04Electrical System6. Lower and lock engine cover. To release and lower the engine cover (17) from the fully raised

Electrical System9.172 Model 644E-42/944E-42 Rev. 6/04When starting the engine, allow the starter to crank for a maximum of 15 seconds only, then wait

9.173Model 644E-42/944E-42 Rev. 6/04Electrical Systemd. Battery ChargingCharge rates between 3 and 50 amperes are generally satisfactory as long as sp

Electrical System9.174 Model 644E-42/944E-42 Rev. 6/04f. Jump-Starting with an Auxiliary (“Booster”) BatteryNote: Use this information in addition to

9.175Model 644E-42/944E-42 Rev. 6/04Electrical System4. Remove the battery hold down strap (11) on the battery (12) that is being replaced. Remove the

Electrical System9.176 Model 644E-42/944E-42 Rev. 6/049.13 ELECTRICAL SYSTEM COMPONENTSElectrical components include warning devices such as the indic

9.177Model 644E-42/944E-42 Rev. 6/04Electrical System3. Label and disconnect the wire connector (4) from the horn (1).4. Remove the nut (5) and flat w

Electrical System9.178 Model 644E-42/944E-42 Rev. 6/04b. Warning Indicator LightsThere are seven additional “hidden” indicator lights in the front das

9.179Model 644E-42/944E-42 Rev. 6/04Electrical Systemc. Engine Function Indicator LightsThe engine function indicator lights (8) are located on the le

3.21Model 644E-42/944E-42 Rev. 6/04Boom6. At the front of the intermediate boom, coat the sheave pin (15) and bore with anti-seize compound. Coat the

Electrical System9.180 Model 644E-42/944E-42 Rev. 6/04Back-Up Alarm Removal1. Unlock and open the engine cover (1).2. If the vehicle has dual batterie

9.181Model 644E-42/944E-42 Rev. 6/04Electrical SystemInstallation and Testing1. Position the back-up alarm (9) on its mounting studs and secure with t

Electrical System9.182 Model 644E-42/944E-42 Rev. 6/04a. Power-Up LightsWhen the ignition switch is turned to power up the vehicle, all lights (13 tot

9.183Model 644E-42/944E-42 Rev. 6/04Electrical Systemd. Front Dash Panel Bulb ReplacementIMPORTANT: Static electricity can cause damage to the front

Electrical System9.184 Model 644E-42/944E-42 Rev. 6/047. Rotate the suspect bulb holder assembly (1 through 14) 1/4 turn counterclockwise.8. Remove an

9.185Model 644E-42/944E-42 Rev. 6/04Electrical System14. If the vehicle has dual batteries, connect both negative battery cables (15 and 16) to both b

Electrical System9.186 Model 644E-42/944E-42 Rev. 6/049.13.3 Throttle Position Sensor (944E-42 Only)The throttle position sensor (1) (944E-42 Only) co

9.187Model 644E-42/944E-42 Rev. 6/04Electrical System4. Disconnect the bottom of the return spring (16) from the bolt (17) at the bottom of the mounti

Electrical System9.188 Model 644E-42/944E-42 Rev. 6/049.13.4 Front Windshield Wiper Switch This three position rocker switch (1) is located in the low

9.189Model 644E-42/944E-42 Rev. 6/04Electrical System3. Carefully pry the windshield wiper switch (1) and wire connector out of the mounting hole.4. D

Section Subject PageiiiModel 644E-42/944E-42 Rev. 6/04Section 8Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3.22 Model 644E-42/944E-42 Rev. 6/043.3.3 Outer Boom Replacementa. Outer Boom Removal1. Remove both the inner boom and intermediate boom as descri

Electrical System9.190 Model 644E-42/944E-42 Rev. 6/049.13.5 Front Windshield Wiper Motora. RemovalNote: It may be necessary to remove several hydrau

9.191Model 644E-42/944E-42 Rev. 6/04Electrical System5. Remove the front wiper arm assembly (14) from the wiper motor shaft (13) and the pivot mount s

Electrical System9.192 Model 644E-42/944E-42 Rev. 6/04e. Installation and TestingNote: An assistant will be required for the installation of the fron

9.193Model 644E-42/944E-42 Rev. 6/04Electrical System11. With the ignition switch (28) in the RUN position (29) press the front wiper switch (31) to t

Electrical System9.194 Model 644E-42/944E-42 Rev. 6/049.13.6 Windshield Washer SwitchThis rocker switch (1) is spring loaded to return to the OFF posi

9.195Model 644E-42/944E-42 Rev. 6/04Electrical System3. Carefully pry the windshield wiper switch and wire connector out of the mounting hole.4. Disco

Electrical System9.196 Model 644E-42/944E-42 Rev. 6/049.13.7 Skylight Wiper/Washer & Rear Window Washer Switch The skylight wiper/washer and rear

9.197Model 644E-42/944E-42 Rev. 6/04Electrical System3. Carefully pry the skylight wiper switch, bezel and wiring out of the mounting hole.4. Disconne

Electrical System9.198 Model 644E-42/944E-42 Rev. 6/049.13.8 Skylight Wiper Motora. Removal1. Unlock and open the engine cover (1).2. If the vehicle h

9.199Model 644E-42/944E-42 Rev. 6/04Electrical System8. Lift the tab (19) on the top plastic cover and unsnap the two plastic covers (20) of the plast

3.23Model 644E-42/944E-42 Rev. 6/04Boom7. Use a suitable overhead lifting device and sling to support the outer boom and allow for the detachment of t

Electrical System9.200 Model 644E-42/944E-42 Rev. 6/048. If the vehicle has dual batteries, connect both negative battery cables (1 and 2) to both bat

9.201Model 644E-42/944E-42 Rev. 6/04Electrical System2. If the vehicle has dual batteries, disconnect both negative battery cables (1 and 2) from both

Electrical System9.202 Model 644E-42/944E-42 Rev. 6/049.13.10 Rear Wiper Switch/Motora. Removal1. Unlock and open the engine cover (1).2. If the vehic

9.203Model 644E-42/944E-42 Rev. 6/04Electrical System7. Label and disconnect the cab harness (24) and the two jumper wires (25 and 26) from the wiper

Electrical System9.204 Model 644E-42/944E-42 Rev. 6/0412. If the vehicle has dual batteries, connect both negative battery cables (1 and 2) must be co

9.205Model 644E-42/944E-42 Rev. 6/04Electrical System15. Turn ignition switch (7) to the RUN position (8) and turn rear wiper switch (10) to the ON po

Electrical System9.206 Model 644E-42/944E-42 Rev. 6/049.13.11 Cab Heater/Air Conditioning ControlsNote: If the suspect component is found to be withi

9.207Model 644E-42/944E-42 Rev. 6/04Electrical Systema. Cab Heater Controls RemovalNote: After determining which control knob is not functioning, rem

Electrical System9.208 Model 644E-42/944E-42 Rev. 6/04e. Installation and Testing1. Check that the variable speed fan control (1) is in the OFF positi

9.209Model 644E-42/944E-42 Rev. 6/04Electrical System13. Lower and lock engine cover. To release and lower the engine cover (12) from the fully raised

Boom3.24 Model 644E-42/944E-42 Rev. 6/04Note: If you are replacing the outer boom with a new outer boom, also remove the following items in Step 18.1

Electrical System9.210 Model 644E-42/944E-42 Rev. 6/04a. Ignition Switch Removal1. Unlock and open the engine cover (1).2. If the vehicle has dual bat

9.211Model 644E-42/944E-42 Rev. 6/04Electrical Systemb. DisassemblyDO NOT disassemble the ignition switch. Replace a defective switch with a new part.

Electrical System9.212 Model 644E-42/944E-42 Rev. 6/04e. Transmission Neutral Start FeatureThe transmission neutral start feature is a safety feature

9.213Model 644E-42/944E-42 Rev. 6/04Electrical System3. Disconnect the wiring connector at the fuel shut-off solenoid lead (8), then remove the fuel s

Electrical System9.214 Model 644E-42/944E-42 Rev. 6/049.14.3 Hydraulic Oil Filter Pressure SwitchThe hydraulic oil filter pressure switch (1) is threa

9.215Model 644E-42/944E-42 Rev. 6/04Electrical System3. Label and disconnect the hydraulic oil filter pressure switch leads (3) from the harness conne

Electrical System9.216 Model 644E-42/944E-42 Rev. 6/049.14.4 Dual Hydraulic Oil Temperature SwitchThe hydraulic oil temperature switch (1) is threaded

9.217Model 644E-42/944E-42 Rev. 6/04Electrical System3. Label and disconnect the switch wiring connector (4) from the harness connector.4. Remove the

Electrical System9.218 Model 644E-42/944E-42 Rev. 6/049.14.5 Auxiliary Hydraulic Pressure Release Switch 644E-42, SN 20118 & Before, 0160002519 th

9.219Model 644E-42/944E-42 Rev. 6/04Electrical System3. Carefully pry the auxiliary hydraulic pressure release switch (1) and wiring out of the mounti

3.25Model 644E-42/944E-42 Rev. 6/04Boom4. Secure the pivot pin with the clevis pin (9) and a cotter pin (10).5. Raise each slave cylinder (11) into po

Electrical System9.220 Model 644E-42/944E-42 Rev. 6/049.14.6 Parking Brake SwitchThe parking brake switch (1) is located on the dash to the left of th

9.221Model 644E-42/944E-42 Rev. 6/04Electrical System3. Carefully pry the parking brake switch (1) and wiring out of the mounting hole.4. Label and di

Electrical System9.222 Model 644E-42/944E-42 Rev. 6/049.14.7 Transmission Disconnect SwitchThe transmission disconnect switch (1) is located on the da

9.223Model 644E-42/944E-42 Rev. 6/04Electrical Systemb. Transmission Disconnect Switch DisassemblyDO NOT disassemble the transmission disconnect switc

Electrical System9.224 Model 644E-42/944E-42 Rev. 6/049.14.8 Transmission Shift Control Switcha. Travel Select LeverThe transmission shift control swi

9.225Model 644E-42/944E-42 Rev. 6/04Electrical SystemIf the transmission is not shifting properly, the transmission shift control switch/travel select

Electrical System9.226 Model 644E-42/944E-42 Rev. 6/04c. Transmission Solenoid Valve Removal1. Unlock and open the engine cover (1).2. If the vehicle

9.227Model 644E-42/944E-42 Rev. 6/04Electrical System9.14.10 Dual JoystickThis vehicle is equipped with three separate hydraulic joysticks.• The front

Electrical System9.228 Model 644E-42/944E-42 Rev. 6/044. If the harness is functioning properly, test the joystick button (5) for continuity. With the

9.229Model 644E-42/944E-42 Rev. 6/04Electrical Systemc. Front Joystick Function Solenoid ValvesThe front joystick commands are actuated, both electric

Boom3.26 Model 644E-42/944E-42 Rev. 6/0412. As required, install the hydraulic clamps (1) on the outer boom and secure the attachment tilt (2) and aux

Electrical System9.230 Model 644E-42/944E-42 Rev. 6/04Joystick mode operation can be checked according to the joystick operation instructions found in

9.231Model 644E-42/944E-42 Rev. 6/04Electrical SystemEarly Production Single Joystick4. If the single joystick harness (5) is functioning properly, th

Electrical System9.232 Model 644E-42/944E-42 Rev. 6/04c. Late Production Single Joystick Handle Replacement1. Remove the front joystick valve assembly

9.233Model 644E-42/944E-42 Rev. 6/04Electrical Systeme. Solenoid Coil and Cartridge Valve ReplacementIf a solenoid coil (15 through 20) is suspected o

Electrical System9.234 Model 644E-42/944E-42 Rev. 6/042. If the vehicle has dual batteries, disconnect both negative battery cables (1 and 2) from bot

9.235Model 644E-42/944E-42 Rev. 6/04Electrical System5. Lower and lock engine cover (17). To release and lower the engine cover from the fully raised

Electrical System9.236 Model 644E-42/944E-42 Rev. 6/04b. Engine Oil Pressure Switch DisassemblyDO NOT disassemble the switch. Replace a defective or f

9.237Model 644E-42/944E-42 Rev. 6/04Electrical System9.14.14 Engine Coolant Temperature SenderThe engine coolant temperature sender (12) is threaded i

Electrical System9.238 Model 644E-42/944E-42 Rev. 6/04a. Engine Coolant Temperature Sender Removal1. Unlock and open the engine cover (1).2. If the ve

9.239Model 644E-42/944E-42 Rev. 6/04Electrical Systemlift up slightly on the cover and push the upper part of the right gas shock (2) (orange tab) to

3.27Model 644E-42/944E-42 Rev. 6/04BoomNote: If you are replacing the outer boom with a new outer boom, also install the following items.16. At the f

Electrical System9.240 Model 644E-42/944E-42 Rev. 6/04b. Transmission Temperature Switch DisassemblyDO NOT disassemble the switch. Replace a defective

9.241Model 644E-42/944E-42 Rev. 6/04Electrical System9.14.16 Engine Block HeaterThe engine is equipped with an engine block heater (12) that can be pl

Electrical System9.242 Model 644E-42/944E-42 Rev. 6/049.14.17 Fuel Level Gauge and Fuel Level SenderThe fuel level gauge (1) can be found on the opera

9.243Model 644E-42/944E-42 Rev. 6/04Electrical System4. Turn the ignition key switch to the OFF (8) position. The fuel level gauge needle should retur

Electrical System9.244 Model 644E-42/944E-42 Rev. 6/049.14.18 HourmeterThe hourmeter (1) is a non-repairable instrument that records hours of vehicle

9.245Model 644E-42/944E-42 Rev. 6/04Electrical SystemWhen Service Brake Valve Mounting Plate Has Threaded Mounting Hole.Remove switch dust cover (17).

Electrical System9.246 Model 644E-42/944E-42 Rev. 6/047. If the vehicle has dual batteries, connect both negative battery cables (1 and 2) to both bat

9.247Model 644E-42/944E-42 Rev. 6/04Electrical System6. If the vehicle has dual batteries, connect both negative battery cables (1 and 2) to both batt

Electrical System9.248 Model 644E-42/944E-42 Rev. 6/046. Ensure that the Stabil-TRAK “Slow Pivot” Mode indicator (1) is OFF.7. Slowly depress and hold

10.1Model 644E-42/944E-42 Rev. 6/04Section 10Stabil-TRAK™ SystemContentsPARAGRAPH TITLE PAGE10.1 Stabil-TRAK™ System Component Terminology. . . . . .

Boom3.28 Model 644E-42/944E-42 Rev. 6/043.4 BOOM CHAINSThis vehicle uses a single extend chain to extend the boom and a single retract chain to retrac

Stabil-TRAK™ System10.2 Model 644E-42/944E-42 Rev. 6/0410.8 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . 10.3010

10.3Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ SystemThis Page Intentionally Left Blank

Stabil-TRAK™ System10.4 Model 644E-42/944E-42 Rev. 6/0410.1 STABIL-TRAK™ SYSTEM COMPONENT TERMINOLOGYTo understand the safety, operation and maintenan

10.5Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System10.2 STABIL-TRAK™ DESCRIPTIONThe patented rear axle lock or Stabil-TRAK™ system works to stabili

Stabil-TRAK™ System10.6 Model 644E-42/944E-42 Rev. 6/0410.3 STABIL-TRAK™ OPERATIONThe rough terrain forklift rarely operates on ground that is a smoot

10.7Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ SystemThe following describes the three basic modes of the patented Stabil-TRAK™ system. The vehicle m

Stabil-TRAK™ System10.8 Model 644E-42/944E-42 Rev. 6/0410.3.2 Stabil-TRAK™ Solenoid ValvesThere are five Stabil-TRAK™ solenoid valves (1, 2, 3, 4 and

10.9Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ SystemThis Page Intentionally Left Blank

Stabil-TRAK™ System10.10 Model 644E-42/944E-42 Rev. 6/0410.4 STABIL-TRAK™ ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (644E-42, SN 20118 & Be

10.11Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System644E-42, SN 20118 & Before, SN 0160002519 thru 0160003877 944E-42, SN 20123 & Before, S

3.29Model 644E-42/944E-42 Rev. 6/04Booma. Inspection GuidelinesExpose the extend and retract chains (refer to Section 3.4.1, b. “Expose Extend Chain f

Stabil-TRAK™ System10.12 Model 644E-42/944E-42 Rev. 6/04SLOW PIVOT MODE I 1. Ignition “ON” 4. Transmission in Neutral, Fwd. or Rev.644E-42, SN 20118 &

10.13Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System644E-42, SN 20118 & Before, SN 0160002519 thru 0160003877 944E-42, SN 20123 & Before, S

Stabil-TRAK™ System10.14 Model 644E-42/944E-42 Rev. 6/04LOCKED MODE I 1. Ignition “ON” 4. Trans. in Neutral644E-42, SN 20118 & Before, SN 01600025

10.15Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System644E-42, SN 20118 & Before, SN 0160002519 thru 0160003877 944E-42, SN 20123 & Before, S

Stabil-TRAK™ System10.16 Model 644E-42/944E-42 Rev. 6/04LOCKED MODE III 1.Ignition “ON”4.Transmission in Neutral 644E-42, SN 20118 & Before, SN 01

10.17Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System10.5 STABIL-TRAK™ SYSTEM TEST (644E-42, SN 20118 & Before, SN 0160002519 thru 0160003877) (

Stabil-TRAK™ System10.18 Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK System Test ProceduresStep 1a. Place the vehicle on a level surface with 0° sway.b

10.19Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ SystemStep 7a. With the parking brake switch ON, move the travel select lever to the (N) NEUTRAL DETE

Stabil-TRAK™ System10.20 Model 644E-42/944E-42 Rev. 6/0410.6 STABIL-TRAK™ ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (644E-42, 0160003878 &

10.21Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System644E-42, 0160003878 & After 944E-42, 0160003882 & After Stabil-TRAK™ Electrical Circuit

Boom3.30 Model 644E-42/944E-42 Rev. 6/04Turning or Protruding PinsHighly loaded chain, operating with inadequate lubrication, can generate abnormal fr

Stabil-TRAK™ System10.22 Model 644E-42/944E-42 Rev. 6/04SLOW PIVOT MODE 1. Ignition “ON” 4. Transmission in Fwd. or Rev.644E-42, 0160003878 & Afte

10.23Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System644E-42, 0160003878 & After 944E-42, 0160003882 & After Stabil-TRAK™ Electrical Circuit

Stabil-TRAK™ System10.24 Model 644E-42/944E-42 Rev. 6/04LOCKED MODE II 1. Ignition “ON” 4. Transmission in Fwd. or Rev.644E-42, 0160003878 & After

10.25Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System644E-42, 0160003878 & After 944E-42, 0160003882 & After Stabil-TRAK™ Electrical Circuit

Stabil-TRAK™ System10.26 Model 644E-42/944E-42 Rev. 6/0410.7 STABIL-TRAK™ SYSTEM TEST (644E-42, 0160003878 & After) (944E-42, 0160003882 & Aft

10.27Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ SystemStabil-TRAK System Test ProceduresStep 1a. Place the vehicle on a level surface with 0° sway.b.

Stabil-TRAK™ System10.28 Model 644E-42/944E-42 Rev. 6/04Step 7a. With the parking brake switch ON, move the travel select lever to the (N) NEUTRAL DET

10.29Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ SystemThis Page Intentionally Left Blank

Stabil-TRAK™ System10.30 Model 644E-42/944E-42 Rev. 6/0410.8 STABIL-TRAK™ HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOOTINGThe function of the Stabil-TR

10.31Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System10.8.2 Stabilizer Cylinder Oil FlowIn the FREE PIVOT and SLOW PIVOT MODES, oil flow from the st

3.31Model 644E-42/944E-42 Rev. 6/04BoomOther Modes of Failure• Ultimate Strength Failure - These types of failures are caused by overloads far in exce

Stabil-TRAK™ System10.32 Model 644E-42/944E-42 Rev. 6/0410.8.3 Hydraulic Circuit Operation - Free Pivot Mode, Rod Oil OutConditions:• Boom angle is be

10.33Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System10.8.4 Hydraulic Troubleshooting - Free Pivot Mode, Rod Oil OutMU4260Front324568917Legend1. Sta

Stabil-TRAK™ System10.34 Model 644E-42/944E-42 Rev. 6/0410.8.5 Hydraulic Circuit Operation - Free Pivot Mode, Base Oil OutConditions:• Boom angle is b

10.35Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System10.8.6 Hydraulic Troubleshooting - Free Pivot Mode, Base Oil OutFront234568917Legend1. Stabiliz

Stabil-TRAK™ System10.36 Model 644E-42/944E-42 Rev. 6/0410.8.7 Hydraulic Circuit Operation - Slow Pivot Mode, Rod Oil OutConditions:• Boom angle is ab

10.37Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System10.8.8 Hydraulic Troubleshooting - Slow Pivot Mode, Rod Oil OutMU426078652101119Legend1. Stabil

Stabil-TRAK™ System10.38 Model 644E-42/944E-42 Rev. 6/0410.8.9 Hydraulic Circuit Operation - Slow Pivot Mode, Base Oil OutConditions:• Boom angle is a

10.39Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System10.8.10 Hydraulic Troubleshooting - Slow Pivot Mode, Base Oil OutMU426078652101119Legend1. Stab

Stabil-TRAK™ System10.40 Model 644E-42/944E-42 Rev. 6/0410.8.11 Hydraulic Circuit Operation - Locked Modea. Conditions:• Boom angle is above 40°• Park

10.41Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System10.8.13 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway RightMU4260Legend1. Soleno

Section Subject PageivModel 644E-42/944E-42 Rev. 6/04Section 10Stabil-TRAK™ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3.32 Model 644E-42/944E-42 Rev. 6/04c. Expose Retract Chain for InspectionThe retract chain must be removed from the boom in order to be visually

Stabil-TRAK™ System10.42 Model 644E-42/944E-42 Rev. 6/0410.8.14 Hydraulic Circuit Operation - Locked Mode, Frame Sway Lefta. Conditions• Boom angle is

10.43Model 644E-42/944E-42 Rev. 6/04Stabil-TRAK™ System10.8.15 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway LeftMU4260FrontLegend6. So

Stabil-TRAK™ System10.44 Model 644E-42/944E-42 Rev. 6/04This Page Intentionally Left Blank

11.1Model 644E-42/944E-42 Rev. 6/04Section 11Transfer CarriageContentsPARAGRAPH TITLE PAGE11.1 Transfer Carriage Component Terminology . . . . . . . .

Transfer Carriage11.2 Model 644E-42/944E-42 Rev. 6/0411.1 TRANSFER CARRIAGE COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance i

11.3Model 644E-42/944E-42 Rev. 6/04Transfer Carriage11.2 TRANSFER CARRIAGE11.2.1 Transfer Carriage DescriptionThe transfer carriage, along with the tr

Transfer Carriage11.4 Model 644E-42/944E-42 Rev. 6/0411.3.1 Transfer Carriage Removal1. Level the vehicle, place the travel select lever in the (N) NE

11.5Model 644E-42/944E-42 Rev. 6/04Transfer Carriage12. Remove the boom as described in Section 3.3.3, a. “Outer Boom Removal.”13. Remove locknuts (10

Transfer Carriage11.6 Model 644E-42/944E-42 Rev. 6/0418. Remove the four hydraulic hoses (1) connecting the slave cylinders (2) to the hydraulic tubes

11.7Model 644E-42/944E-42 Rev. 6/04Transfer Carriage23. Disconnect the back-up alarm electrical connection (11) from the wire harness (12) and remove

3.33Model 644E-42/944E-42 Rev. 6/04Boom7. Remove the elastic locknut (10) and flat washer (11) holding the retract chain threaded clevis (12) to the m

Transfer Carriage11.8 Model 644E-42/944E-42 Rev. 6/0428. Remove capscrews (1), shims (2), and rear wear pads (3). Count and label their position for l

11.9Model 644E-42/944E-42 Rev. 6/04Transfer Carriage11.3.2 Transfer Carriage Installation1. Insert front roller pin (11), front roller (13) and shims

Transfer Carriage11.10 Model 644E-42/944E-42 Rev. 6/0410. Insert the rear roller pin (1), rear rollers (2) and shims (3) according to their previously

11.11Model 644E-42/944E-42 Rev. 6/04Transfer Carriage17. Lift and place the lift/lower cylinder (19) into position on the transfer carriage (20). Coat

Transfer Carriage11.12 Model 644E-42/944E-42 Rev. 6/0420. Coat the locknuts (1) with Loctite® 242 (blue). Install locknuts (1), washers (2), Lull logo

11.13Model 644E-42/944E-42 Rev. 6/04Transfer Carriage11.3.3 Rear Wear Pad CheckNote: The attachment should remain attached to the quick attach for th

Transfer Carriage11.14 Model 644E-42/944E-42 Rev. 6/0411.3.5 Rear Wear Pad ReplacementNote: The attachment should remain attached to the quick attach

11.15Model 644E-42/944E-42 Rev. 6/04Transfer Carriage11.3.8 Front Upstop Wear Pad Shimming1. Park the vehicle on level ground. Place the travel select

Transfer Carriage11.16 Model 644E-42/944E-42 Rev. 6/0411.3.9 Front Upstop Wear Pad ReplacementNote: The attachment should remain attached to the quic

11.17Model 644E-42/944E-42 Rev. 6/04Transfer Carriage11.3.11 Rear Roller ShimmingNote: The attachment should remain attached to the quick attach.1. P

Boom3.34 Model 644E-42/944E-42 Rev. 6/0415. Coat the threads of the threaded clevis (1) with multi-purpose grease.Note: Have a second person help wit

Transfer Carriage11.18 Model 644E-42/944E-42 Rev. 6/0410. Remove the bolts (1) and stop blocks (2) on both sides.11. Remove pin bolt (3) and locknut (

11.19Model 644E-42/944E-42 Rev. 6/04Transfer Carriage16. If the vehicle has dual batteries, connect both negative battery cables (14 and 15) to both b

Transfer Carriage11.20 Model 644E-42/944E-42 Rev. 6/0411.3.13 Front Roller ShimmingNote: The attachment should remain attached to the quick attach.1.

11.21Model 644E-42/944E-42 Rev. 6/04Transfer Carriage13. If the vehicle has dual batteries, connect both negative battery cables (1 and 2) to both bat

Transfer Carriage11.22 Model 644E-42/944E-42 Rev. 6/0411.3.15 Front Roller and Bushing ReplacementNote: The attachment should remain attached to the

11.23Model 644E-42/944E-42 Rev. 6/04Transfer CarriageNote: It is reccomended to replace both bearings at the same time.Note: DO NOT apply any grease

Transfer Carriage11.24 Model 644E-42/944E-42 Rev. 6/049. Remove the bolts (1) and stop blocks (2) on both sides.10. Remove pin bolt (3) and locknut (4

11.25Model 644E-42/944E-42 Rev. 6/04Transfer Carriage16. If the vehicle has dual batteries, connect both negative battery cables (16 and 17) to both b

Transfer Carriage11.26 Model 644E-42/944E-42 Rev. 6/0411.3.18 Slave Cylinder Pivot Bushing Replacement1. Park the vehicle on firm level ground. Place

11.27Model 644E-42/944E-42 Rev. 6/04Transfer Carriage11.3.19 Transfer Cylinder ReplacementThe transfer cylinder is located on the left rear side of th

3.35Model 644E-42/944E-42 Rev. 6/04Boom3.4.2 Chain LubricationAfter inspection and before being returned to service, chains must be lubricated with a

Transfer Carriage11.28 Model 644E-42/944E-42 Rev. 6/0413. Disconnect two hydraulic lines (1) connected to the transfer cylinder (2). Plug, cap and lab

11.29Model 644E-42/944E-42 Rev. 6/04Transfer Carriage7. Close and lock the engine compartment cover.8. Remove the Accident Prevention Tag on both the

Transfer Carriage11.30 Model 644E-42/944E-42 Rev. 6/0411.4 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common probl

11.31Model 644E-42/944E-42 Rev. 6/04Transfer Carriage3. Transfer carriage shifts to right or left when extending.1. Transfer carriage rollers improper

Transfer Carriage11.32 Model 644E-42/944E-42 Rev. 6/04This Page Intentionally Left Blank

12.1Model 644E-42/944E-42 Rev. 6/04Section 12IndexNumericsSwitches and SolenoidsFuel Shutoff Solenoid ... 9.212AAccess Panels and CoversRe

12.2 Model 644E-42/944E-42 Rev. 6/04IndexPark Brake Warning Indicator ... 9.157Stabil-TRAK "Locked" Mode Indic

12.3Model 644E-42/944E-42 Rev. 6/04IndexEnclosed Cab (Optional) Components ...4.24Enclosed Cab ComponentsHeater/Defroste

12.4 Model 644E-42/944E-42 Rev. 6/04IndexAuxiliary Hydraulic Pressure Release Circuit (Dual Joystick) ... 8.142Auxiliary Hydraulic

12.5Model 644E-42/944E-42 Rev. 6/04IndexLLift/Lower Cylinder ... 3.23MMetric Conversion FactorsAmerican to Metric Conversions..

Boom3.36 Model 644E-42/944E-42 Rev. 6/043.4.4 Boom Chain Tension AdjustmentNote: Always perform Section 3.4.3, “Boom Chain Ten-sion Check,” before ad

12.6 Model 644E-42/944E-42 Rev. 6/04IndexStarterCircuit Checks... 9.164Cleaning and Drying ... 9.166Installation

12.7Model 644E-42/944E-42 Rev. 6/04IndexWWarning Devices... 9.176Warning Indicator Lights ... 9.178Alternator Char

12.8 Model 644E-42/944E-42 Rev. 6/04Index

Accident Prevention TagsOS21808990403 Origin 5/00Accident Prevention Tags

Accident Prevention TagsOS21808990403 Origin 5/00

JLG Worldwide LocationsAn Oshkosh Corporation Companywww.jlg.com8990461JLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: +1-717-48

3.37Model 644E-42/944E-42 Rev. 6/04Boom12. Move the extend chain clevis (11) to the next hole toward the rear of the mounting plates. Coat the mountin

Boom3.38 Model 644E-42/944E-42 Rev. 6/04a. Component/Assembly VerificationThe inner to intermediate boom separation should be checked when assembling

3.39Model 644E-42/944E-42 Rev. 6/04Boom5. If the extend chain clevis is in the first hole, the locknut is fully loosened on the clevis, and the distan

Boom3.40 Model 644E-42/944E-42 Rev. 6/044. At the rear of the inner boom (1), remove one capscrew (2) and washer (3) securing the extend chain (4) to

3.41Model 644E-42/944E-42 Rev. 6/04Boom11. If needed, pull the boom out slightly to align the extend chain yoke (8) with the sheave (14). Route the ex

1.1Model 644E-42/944E-42 Rev. 6/04Section 1Safety PracticesContentsPARAGRAPH TITLE PAGE1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . .

Boom3.42 Model 644E-42/944E-42 Rev. 6/046. Attach a threaded eye (2) or a flat washer tack welded to a capscrew (3) to the retract chain clevis (1). T

3.43Model 644E-42/944E-42 Rev. 6/04Boom12. From the rear of the boom, one person should push the threaded clevis end (11) of the retract chain under t

Boom3.44 Model 644E-42/944E-42 Rev. 6/043.5 BOOM WEAR PADSThe wear pads (1) on this vehicle, are for the most part, flat rectangular wear pads with me

3.45Model 644E-42/944E-42 Rev. 6/04BoomUse shims (8) under the upper rear wear pads as required to maintain a maximum gap of 0.09" (2,3 mm) (9) a

Boom3.46 Model 644E-42/944E-42 Rev. 6/04c. Outer BoomAll outer boom pads (1) are mounted on the front of the outer boom. Remove the top wear pads befo

3.47Model 644E-42/944E-42 Rev. 6/04Boom3.6 QUICK ATTACH ASSEMBLYThis vehicle is equipped with a quick attach system for easy attachment changes.3.6.1

Boom3.48 Model 644E-42/944E-42 Rev. 6/043.6.3 Quick Attach Disassembly1. Remove one capscrew (1) and elastic locknut (2). Tap out lower attachment til

3.49Model 644E-42/944E-42 Rev. 6/04Boom3.6.4 Quick Attach Installation 1. Install the lock pin (17).2. Assemble the flat washer (18), quick attach lev

Boom3.50 Model 644E-42/944E-42 Rev. 6/043.6.5 Attachment Tilt Cylinder Removal1. Remove hydraulic hoses (1) from the attachment tilt cylinder. Cap and

3.51Model 644E-42/944E-42 Rev. 6/04Boom3.7 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur d