Lull 644E-42 Operation Manual User Manual

3120038 BPrinted in U.S.A. 3/09OWNERS/OPERATORS MANUALModel 644E-42(S/N 0160003878 thru 0160037404)Keep this manual with the vehicle at all times.MU05

8Model 644E Origin 3/04Safety PracticesHazard Symbols-OH2110Lead Acid Batteries Generate Explosive GasesOH2130Vehicle Tipover Can CrushOH2120OH2140Rot

98Model 644E Origin 3/04Emergency OperationsThis section discusses emergency boom lowering procedures:Part l: In case of loss of engine power or hydr

Emergency Operations99Model 644E Origin 3/04In any case of hydraulic line failure, it is critical to correctly identify which hydraulic line has faile

100Model 644E Origin 3/04Emergency Operations1. Clear the area of any unnecessary personnel.2. Block all four wheels.3. If the load is in a position w

Emergency Operations101Model 644E Origin 3/045. Replace the failed hydraulic line with a new part.ï Boom Extend Line - Extend Cylinder to Block (1)ï B

102Model 644E Origin 3/04Emergency OperationsUSE IN CASE OF:BOOM LIFT LINE FAILURE - Lift Cylinder to Block (1)BOOM LIFT LINE FAILURE - Block to Frame

Emergency Operations103Model 644E Origin 3/04OU10604123

104Model 644E Origin 3/04General MaintenanceGeneral MaintenanceThis section of the manual contains a maintenance schedule and checklist with reference

General Maintenance105Model 644E Origin 3/04Maintenance Schedule and Checklist102502000100050LB-FT (Nm)100POU0510

106Model 644E Origin 3/04General MaintenanceLubricate the following grease fittings using Multi-Purpose Grease (MPG) every 50 hours:NOTE: Shorten the

General Maintenance107Model 644E Origin 3/04The front dash panel illuminates an indicator light that will alert the operator when it senses restricted

Safety Practices9Model 644E Origin 3/04Avoidance SymbolsOH2320Keep Lit Cigarettes AwayOH2330Keep Flames and Ignition Sources AwayOH2270Do Not Travel W

108Model 644E Origin 3/04General Maintenance2. Remove the primary element (1). Inspect the element for damage. Dam-aged elements should never be reuse

General Maintenance109Model 644E Origin 3/04The optional closed cab has two air filters. These filters require periodic maintenance.Recirculation Air

110Model 644E Origin 3/04General MaintenanceA. Engine Coolant Level Check (10 Hour Intervals)1. Level the vehicle, ground the attach-ment, place the t

General Maintenance111Model 644E Origin 3/04B. Drain and Flush Radiator (2000 Hour Intervals)1. Level the vehicle, ground the attach-ment, place the t

112Model 644E Origin 3/04General Maintenance4. Locate the petcock (1) on the bottom of the radiator. Place a hose (2) onto the petcock and channel the

General Maintenance113Model 644E Origin 3/049. Fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace the radiator ca

114Model 644E Origin 3/04General MaintenanceEngine Oil RecommendationsThe use of quality engine oil combined with the appropriate oil and filter chang

General Maintenance115Model 644E Origin 3/04B. Oil and Filter Change(250 Hour Intervals)1. Operate the engine until warm (approximately 5 minutes).2.

116Model 644E Origin 3/04General Maintenance 7. Remove the oil filter (1) and clean the filter sealing surface.8. Apply a thin coat of clean engine oi

General Maintenance117Model 644E Origin 3/0410. Install the drain plug (2) into the oil pan and tighten securely.11. Remove the engine oil fill cap (3

10Model 644E Origin 3/04Safety PracticesAvoidance Symbols (contíd)OH2290Maintain Proper Air Pressure In TireOH2260Engage Parking BrakeOH2230Carry No R

118Model 644E Origin 3/04General MaintenanceA. Drain Water from Fuel Water Separator/Filter(10 Hour Intervals)Unlatch and open the engine cover. Loose

General Maintenance119Model 644E Origin 3/04B. Change Fuel Filter (250 Hour Intervals)The fuel filter (2) must be changed at shorter intervals with ev

120Model 644E Origin 3/04General MaintenanceC. Replace In-line Fuel Strainer(250 Hour Intervals)1. Unlatch and open the engine cover.2. The fuel strai

General Maintenance121Model 644E Origin 3/04D. Bleeding Fuel SystemAir must be vented from the fuel system whenever any component between the fuel tan

122Model 644E Origin 3/04General Maintenance4. To vent the high pressure fuel lines (1), loosen one fitting (2) at the injector (3).5. Turn the igniti

General Maintenance123Model 644E Origin 3/04Engine Fan Belt Check(1000 Hour Intervals)1. Level the vehicle, ground the attachment, place the travel se

124Model 644E Origin 3/04General MaintenanceAir Conditioner Compressor Belt Check(1000 Hour Intervals)1. Level the vehicle, ground the attachment, pla

General Maintenance125Model 644E Origin 3/04A. Hydraulic Oil Level Check(10 Hour Intervals)1. Level the vehicle, place the travel select lever in the

126Model 644E Origin 3/04General MaintenanceB. Hydraulic Oil & Filter Change(First 100 Hours - Filter Only)(1000 Hour Intervals - Oil & Filter

General Maintenance127Model 644E Origin 3/0413. Place a receptacle under the hydraulic reservoir drain plug (10). The recep-tacle must be large enough

Safety Practices11Model 644E Origin 3/04Avoidance Symbols (contíd)OU1530Keep Truss Boom Horizontal When Using WinchOU1540Avoid Rope Damage. DO NOT Til

128Model 644E Origin 3/04General MaintenanceA. Transmission Oil Level Check(10 Hour Intervals)1. Level the vehicle, ground the attach-ment, place the

General Maintenance129Model 644E Origin 3/04B. Transmission Oil & Filter Change(First 100 Hours)(1000 Hour Intervals)1. Level the vehicle, ground

130Model 644E Origin 3/04General Maintenance5. If your vehicle is equipped with the optional cold staring aid (dual batteries) (4), loosen, do not rem

General Maintenance131Model 644E Origin 3/04A. Transfer Case Oil Level Check(250 Hour Intervals)1. Place the vehicle on level ground, ground the attac

132Model 644E Origin 3/04General MaintenanceB. Transfer Case Oil Change(First 100 Hour Intervals) and (1000 Hour Intervals)1. Place the vehicle on lev

General Maintenance133Model 644E Origin 3/04A. Axle Oil Level Check(250 Hour Intervals)1. Level the vehicle, ground the attachment, place the travel s

134Model 644E Origin 3/04General MaintenanceB. Axle Oil Change(First 100 Hours)(1000 Hour Intervals)NOTE: At the 1000 Hour Interval Oil Change also in

General Maintenance135Model 644E Origin 3/04Brake Disc Wear Check(1000 Hour Intervals)Check the brake discs for wear every 1,000 hours of operation or

136Model 644E Origin 3/04General Maintenance4. Turn the ignition switch to the ON position (with the engine not running), release the park brake (park

General Maintenance137Model 644E Origin 3/04B. Rear Axle1. Working through the level plug hole (1), carefully use a screwdriver to spread the brake di

12Model 644E Origin 3/04Safety Practices1. Seat BeltAlways fasten the seat belt before starting the engine.2. Clothing and Safety GearDO NOT wear loos

138Model 644E Origin 3/04General MaintenanceA. Wheel End Oil Level Check(250 Hour Intervals)1. Position the vehicle on level ground, move the vehicle

General Maintenance139Model 644E Origin 3/04B. Wheel End Oil Change(First 100 Hours)(1000 Hour Intervals)1. Position the vehicle on level ground, move

140Model 644E Origin 3/04General MaintenanceA. Tire Air Pressure Check(10 Hour Intervals)Check all four tires:1. Remove the valve stem cap.2. Check ti

General Maintenance141Model 644E Origin 3/04B. Wheel Lug Nut Torque Check(First 100 Hours)1. Wire brush the area around the lug nuts if necessary. The

142Model 644E Origin 3/04General MaintenanceThe batteries in this vehicle are a maintenance free battery and shipped in the vehicle filled with electr

General Maintenance143Model 644E Origin 3/04Fuses and Relays (Fuse Block)The fuses and relays in this vehicle protect the electrical system. The fuses

144Model 644E Origin 3/04General MaintenanceRelay Locations12345678910111213141516171819202122232425262728E10E5E4E9E3E8E2E7E1E6MU338011

General Maintenance145Model 644E Origin 3/04FlasherThe flasher (1) for the optional roadlights is located in the upper right hand corner of the fuse b

146Model 644E Origin 3/04General MaintenanceFuse Locations12345678910111213141516171819202122232425262728E10E5E4E9E3E8E2E7E1E6MU3390

General Maintenance147Model 644E Origin 3/04No. Amp Color Circuit Protected140 Amp Orange Open Cab Vehicle Main215 Amp Blue Ignition Control315 Amp Bl

Safety Practices13Model 644E Origin 3/04DO NOT use ether or any other high energy starting aids during cold starting. An engine explosion can result i

148Model 644E Origin 3/04General MaintenanceCold Start Grid Heater Fuses (Optional)The two 125 amp fuses (1) that protect the cold start grid heater a

General Maintenance149Model 644E Origin 3/04A. Boom Chain Tension Check(250 Hour Intervals)Check the boom chain tension by measuring the top boom exte

150Model 644E Origin 3/04General MaintenanceB. Top Boom Chain Tension Adjustment(As required)NOTE: Always perform the ìBoom Chain Tension Checkî on pa

General Maintenance151Model 644E Origin 3/043. Return to the cab, start the engine and cycle the boom all the way out and all the way in several times

152Model 644E Origin 3/04General MaintenanceReposition Extend Chain ClevisNOTE: Before proceeding with the repositioning of the extend chain clevis, c

General Maintenance153Model 644E Origin 3/044. At the front top of the outer boom (4), remove one of the retaining rings (5) from the clevis mounting

154Model 644E Origin 3/04General MaintenanceC. Boom Chain InspectionExtend Chains(250 Hour Intervals)Retract Chains(1000 Hour Intervals)Under normal o

General Maintenance155Model 644E Origin 3/04The above load cycles and environmental conditions make it impossible to predict chain life. It is therefo

156Model 644E Origin 3/04General MaintenanceElongation - Extend Chain OnlyWhen the original length (1) of 12.00" (305 mm) per foot of new chain h

General Maintenance157Model 644E Origin 3/04Turning or Protruding PinsHighly loaded chain, operating with inadequate lubrication can generate abnormal

14Model 644E Origin 3/04Safety PracticesBattery ChargingUnder normal conditions, the engine alternator will have no problem keeping the battery or bat

158Model 644E Origin 3/04General MaintenanceCracked PlatesInspect the chains very carefully, front and back as well as side to side, for any evidence

General Maintenance159Model 644E Origin 3/04D. Chain LubricationExtend Chains(250 Hour Intervals)Retract Chains(1000 Hour Intervals or Annually)After

160Model 644E Origin 3/04General MaintenanceE. Wear Pad Inspection (Boom)(50 Hour Intervals)Visually inspect the boom wear pads between the boom secti

General Maintenance161Model 644E Origin 3/04F. Wear Pad Replacement (Boom)(As Wear Pad Indicators Indicate)Each boom wear pad (1) is manufactured with

162Model 644E Origin 3/04General MaintenanceTransfer Carriage Rear Wear Pad Check(50 Hour Intervals)NOTE: The attachment should remain attached to the

General Maintenance163Model 644E Origin 3/04Wear Pad Shimming(As Required)NOTE: The attachment should remain attached to the quick attach for this pro

164Model 644E Origin 3/04General Maintenance3. This procedure will require the gap check to be made in three separate locations. Transfer carriage all

General Maintenance165Model 644E Origin 3/04Front Roller Gap Check(50 Hour Intervals)NOTE: The attachment should remain attached to the quick attach f

166Model 644E Origin 3/04General MaintenanceFront Upstop Wear Pad Check(250 Hour Intervals)The front upstop wear pads (1) are located under the frame

General Maintenance167Model 644E Origin 3/04Front Upstop Wear Pad Gap Check(250 Hour Intervals)NOTE: The attachment should remain attached to the quic

Safety Practices15Model 644E Origin 3/045. Moving Parts HazardDO NOT place limbs near moving parts. Severing of any body part can result.Turn off engi

168Model 644E Origin 3/04General MaintenanceRoll Back Hose Inspection(50 Hour Intervals)With the transfer carriage fully forward, check the roll back

General Maintenance169Model 644E Origin 3/04StorageA. Before StoringPerform the following steps prior to placing the vehicle in storage:1. Clean the e

170Model 644E Origin 3/04General MaintenanceTransportWhen transporting the vehicle, make use of all tie down locations on the vehicles frame. NOTE: Th

Test Procedures171Model 644E Origin 3/04Test ProceduresTo check that the parking brake/transmission de-clutch system is functioning properly, perform

172Model 644E Origin 3/04Test ProceduresTest 3 - Park Brake Hold Performancea. With the rated load of 6,000 lbs (2.721 Kg) on the forks, drive the veh

Specifications173Model 644E Origin 3/04SpecificationsEngine Crankcase Oil:Capacity with Filter Change ...

174Model 644E Origin 3/04SpecificationsAir Pressure:Standard Tire: 13.00 - 24, (12 Ply minimum)... 65 psi (448 kPa)Optio

Specifications175Model 644E Origin 3/04With Standard 13.00 - 24, 12 Ply Tires:(A) Length (less forks)...

176Model 644E Origin 3/04SpecificationsRating:... 12V DC Negative GroundNumber of

Index177Model 644E Origin 3/04AAccelerator Pedal ...26Accident Prevention Tags ...5Additional Operators ...

16Model 644E Origin 3/04Safety Practices2. ClearancesLook out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you

Index178Model 644E Origin 3/04Front Dash Panel ... 48Front Dash Panel Light Test ... 48Front Joystick ...

Index179Model 644E Origin 3/04Parking Brake Switch ...30Parking Brake/Transmission De-Clutch Test Procedures ...171Parking Lights

Index180Model 644E Origin 3/04This Page Intentionally Left Blank

Load Charts181Model 644E Origin 3/04Load ChartsThis Section Contains Representations Of All The Load Charts Contained In The Operators Cab Of This Veh

182Model 644E Origin 3/04Load ChartsStandard Carriage & Side Tilt Carriage (48" & 50"), Single Fork Positioning Carriages and Dual F

Load Charts183Model 644E Origin 3/04Standard Carriage & Side Tilt Carriage (48" & 50"), Single Fork Positioning Carriages and Dual F

184Model 644E Origin 3/04Load ChartsStandard Carriage & Side Tilt Carriage (60" & 72"), Single Fork Positioning Carriages and Dual F

Load Charts185Model 644E Origin 3/04Standard Carriage & Side Tilt Carriage (60" & 72"), Single Fork Positioning Carriages and Dual F

186Model 644E Origin 3/04Load ChartsSwing Carriage (Transfer Carriage Forward Movement)ACEFDB644E-42Use with Lullapproved carriages only.4110416ASME B

Load Charts187Model 644E Origin 3/04Swing Carriage (Transfer Carriage Fully Retracted)0 ft.48121620242832360 ft.7.21317202429.64644E-42Use with Lullap

Safety Practices17Model 644E Origin 3/046. Elevating PersonnelUse only a compliant work platform meeting the ASME B56.6 standards for lifting and lowe

188Model 644E Origin 3/04Load Charts10 Ft. Truss Boom & 10 Ft. Truss Boom Winch(Transfer Carriage Forward Movement)0 ft.20.8ACEFDB644E-42Use with

Load Charts189Model 644E Origin 3/0410 Ft. Truss Boom & 10 Ft. Truss Boom Winch(Transfer Carriage Fully Retracted)0 ft.14.1ACEFDB3136.5644E-42Use

190Model 644E Origin 3/04Load Charts3 Ft. Truss Boom Winch(Transfer Carriage Forward Movement)0 ft.14ACEFDB36.3SAFETY INSTRUCTIONSAlways connect coupl

Load Charts191Model 644E Origin 3/043 Ft. Truss Boom Winch(Transfer Carriage Fully Retracted)0 ft.ACEFDB29.6 20246SAFETY INSTRUCTIONSAlways connect co

192Model 644E Origin 3/04Load ChartsThis Page Intentionally Left Blank

Accident Prevention TagsAccident Prevention Tags8990401 Origin 5/00OS2180

Accident Prevention TagsOS21808990401 Origin 5/00

TRANSFER OF OWNERSHIPTo Product Owner:If you now own but ARE NOT the original purchaser of the product covered by this manual, we would like to know w

WARNING: Improper operation of this vehicle can cause injury or death. Only trained and authorized operators should operate this vehicle.Before start

18Model 644E Origin 3/04Safety Practices8. Tip Over HazardTraveling with the boom raised is dangerous and can cause tipover. Keep the boom as low as p

JLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: +1-717-485-5161Customer Support Toll Free: 1-877-554-5438Fax: +1-717-485-6417JLG

Safety Practices19Model 644E Origin 3/0410.Tire PressureMAINTAIN proper tire pressures at all times. An underpressurized tire(s) adversely affects veh

20Model 644E Origin 3/04Safety Practices13.Falling Load HazardDO NOT exceed the total rated load capacity of the specific type fork being used. Each f

Safety Practices21Model 644E Origin 3/04WARNINGAllow no ridersAVOIDCRUSHING,falling offvehicle cancause deathor seriousinjury DO NOT JUMP. Brace you

22Model 644E Origin 3/04Safety PracticesA BFALLING OFF ATTACHMENT,can result in death orserious injury.DO NOT TRAVELwith personnel ina work platform.4

Operation23Model 644E Origin 3/04Operation1. Check seat belt for damage. Check for frayed or cut seat belt webbing, damaged buckles or loose mounting

24Model 644E Origin 3/04OperationOperators Seat AdjustmentsEnter the cab using the hand holds.The operatorís seat can be adjusted as follows:Fore and

Operation25Model 644E Origin 3/04Seat BeltIMPORTANT! Inspect the seat belt every time it is used, looking for cut or worn webbing, or any defect in th

26Model 644E Origin 3/04OperationAccelerator PedalPressing down the accelerator pedal (1) increases engine speed and the speed of the hydraulic system

Operation27Model 644E Origin 3/04Ignition SwitchThe ignition switch is located on the lower right side of the front dash. Using the ignition switch ke

Table of Contents1 2004 JLG Industries, Inc.IntroductionThe Manual...2Replacement Parts...2Repo

28Model 644E Origin 3/04Operation1. Four Wheel Steering ModeThe front wheels will steer in the direction that the steering wheel is turned; the rear

Operation29Model 644E Origin 3/043. Crab Steering ModeAll wheels will steer in the same direction that the steering wheel is turned. This steering mo

30Model 644E Origin 3/04OperationParking Brake SwitchThe Parking Brake Switch (1) is located on the left side of the front dash and has two positions:

Operation31Model 644E Origin 3/04Transmission Disconnect SwitchThe Transmission Disconnect Switch (3) is located on the left side of the front dash an

32Model 644E Origin 3/04OperationTravel Select LeverThe Travel Select Lever (1) has three positions to select direction of travel:F = FORWARD (2) ...

Operation33Model 644E Origin 3/04Changing Travel Direction1. Stop the vehicle by applying the service brakes.2. Grasp the travel select lever (1), pul

34Model 644E Origin 3/04OperationStopping Travel1. Apply the service brake pedal and downshift the vehicle to a lower gear if necessary to slow the ve

Operation35Model 644E Origin 3/04Joystick OperationThis vehicle is equipped with three separate joysticks.ï The front joystick (5) controls attachment

36Model 644E Origin 3/04OperationFront Joystick (Attachment Tilt & Transfer Carriage)The front joystick (1) controls the attachment tilt and the P

Operation37Model 644E Origin 3/04Middle Joystick (Boom Lift/Lower & Boom Extend/Retract)The middle joystick (6) controls the boom lift/lower and b

2Model 644E Origin 3/04IntroductionIntroductionThis Owners/Operators Manual provides the information you need to operate and maintain this vehicle.IMP

38Model 644E Origin 3/04OperationFrame Sway JoystickThe frame sway joystick (1) is equipped with a lock ring (2) to prevent unintentional operation of

Operation39Model 644E Origin 3/04Leveling The VehicleWhen placing a load while on a slope, use the frame sway control. Keep the vehicle level. The ope

40Model 644E Origin 3/04OperationAuxiliary Hydraulic ControlThe auxiliary hydraulic control is used to control the functions of an optional attachment

Operation41Model 644E Origin 3/04While holding the button down and moving the joystick to the right (3) will provide hydraulic system pressure through

42Model 644E Origin 3/04OperationJoystick Operation (Single Joystick Option)The single joystick option is an assembly containing a single joystick (1)

Operation43Model 644E Origin 3/04Boom Lift/Lower and Extend/Retract (Default Mode)Front button (3), not depressed, operates the following boom functio

44Model 644E Origin 3/04OperationTransfer Carriage Extend/Retract and Auxiliary Hydraulic Male Pressurized/Female Pressurized (Secondary Mode)Front bu

Operation45Model 644E Origin 3/04While holding the button in and moving the joystick to the right (4) will provide hydraulic system pressure through t

46Model 644E Origin 3/04OperationAttachment Tilt (Thumb Control) Operates in Default Mode or Secondary ModeThe thumb control (1), on the topside of th

Operation47Model 644E Origin 3/04Leveling The VehicleWhen placing a load while on a slope, use the frame sway control. Keep the vehicle level. The ope

Safety Practices3Model 644E Origin 3/04JLG reserves the right to make changes on and to add improvements upon its products at any time without public

48Model 644E Origin 3/04OperationThe front dash panel (1) provides the operator with important information. It is ìuser friendlyî and only provides th

Operation49Model 644E Origin 3/04Function Indicator LightsThere are four ìhiddenî function indicator lights in the front dash panel that illuminate o

50Model 644E Origin 3/04OperationWarning Indicator LightsThere are seven additional ìhiddenî indicator lights in the front dash panel that will illumi

Operation51Model 644E Origin 3/04Alternator Charging Warning Indicator (4)This light illuminates to indicate a weak or improperly working charging sys

52Model 644E Origin 3/04OperationLow Brake Pressure Warning Indicator (1)This light is located on the lower right side of the front dash panel.The lig

Operation53Model 644E Origin 3/04Gauges and IndicatorsFuel Level Gauge (2)Make sure the vehicle is level to ensure an accurate fuel level reading. The

54Model 644E Origin 3/04OperationOptional Indicator LightsThere are two additional ìhiddenî indicator lights in the front dash panel that will illumin

Operation55Model 644E Origin 3/04Worklights (Front, Rear & Boom)The worklights are activated with a single rocker switch (3) located in the upper

56Model 644E Origin 3/04OperationParking Lights, Headlights & High/Low Beam SwitchThese lights will only work when the ignition switch is in the R

Operation57Model 644E Origin 3/04Directional SignalsThe directional signals are ACTIVATED from the lever (6) on the right side of the steering wheel a

4Model 644E Origin 3/04Safety PracticesSignal WordA signal word is a distinctive word located on hazard decals and used throughout this manual that al

58Model 644E Origin 3/04OperationEmergency FlashersThe emergency flashers are activated by a single rocker switch (1) located in the upper bank of swi

Operation59Model 644E Origin 3/04Door Latches (Closed Cab Only)There are two door latches for the lower door. The outside latch (3) is a key lockable

60Model 644E Origin 3/04OperationRear Window Latch (Closed Cab Only)The rear window (1) can be partially opened and secured in place with the rear win

Operation61Model 644E Origin 3/04Windshield InstallationIMPORTANT! Be sure the windshield retainer plate is secured in place after installing the wind

62Model 644E Origin 3/04OperationFront Windshield Wiper (Closed Cab Only)This three position rocker switch (1) is located in the lower bank of switche

Operation63Model 644E Origin 3/04Windshield Washer Control (Closed Cab Only)This rocker switch (2) is spring loaded to return to the OFF position when

64Model 644E Origin 3/04OperationRear Window Wiper (Closed Cab Only)The rear window wiper rocker switch (1) is located on the motor housing of the rea

Operation65Model 644E Origin 3/04To heat the cab:ï turn A/C switch (6) to the OFF position,ï turn temperature control knob (7) to far right position (

66Model 644E Origin 3/04OperationQuick AttachThis vehicle is equipped with a quick attach system for easy attachment changing.Attachment RemovalBe sur

Operation67Model 644E Origin 3/04Attachment ReconnectBe sure you are performing this procedure on level ground.1. Position the vehicle directly behind

Safety Practices5Model 644E Origin 3/04Before beginning any maintenance or service, place an Accident Prevention Tag (1) on both the starter key switc

68Model 644E Origin 3/04OperationBoom Angle IndicatorThe boom angle indicator (1) is a bubble type indicator with angular graduations (2) from -20 t

Operation69Model 644E Origin 3/04Transfer Carriage Extension IndicatorThe transfer carriage extension indicator (6) shows the operator the distance th

70Model 644E Origin 3/04OperationAll approved forks for this vehicle are marked with a maximum load capacity rating. This rating is stamped on the lef

Operation71Model 644E Origin 3/04The individual capacity charts are located on the dash on the right side of the operatorís compartment. Capacity char

72Model 644E Origin 3/04OperationTo accurately use the capacity chart, the operator must first determine three important things:1. Weight of the load

Operation73Model 644E Origin 3/04Sample Capacity Chart4110409ASME B56.6-2002 Part lll0 ft.48121620242832360 ft.48121620242832364044-40 ft.1418222629AC

74Model 644E Origin 3/04OperationUnderstanding the Stabil-TRAKô SystemThe following describes the three basic modes of the patented Stabil-TRAK syste

Operation75Model 644E Origin 3/04Locked ModeWith the boom above 40 (4) and by activating one or more of the functions (as follows), the Stabil-TRAK

76Model 644E Origin 3/04OperationSlow Pivot ModeWith the boom above 40 (1), the Stabil-TRAK System is now in the SLOW PIVOT MODE (2) when the servic

Operation77Model 644E Origin 3/04To test the function of the Stabil-TRAK system, read the Stabil-TRAK System Test Instructions on this page and follow

6Model 644E Origin 3/04Safety PracticesThe following symbol definitions will help you understand all hazard related decals and load charts used on thi

78Model 644E Origin 3/04OperationStabil-TRAK System Test ProceduresStep 1a. Place the vehicle on a level surface with 0 sway.b. Have the boom fully

Operation79Model 644E Origin 3/04Step 4a. Use your left foot to depress the service brake pedal.b. Move the travel select lever to the (R) REVERSE pos

80Model 644E Origin 3/04OperationStep 7a. With the parking brake switch ON, move the travel select lever to the (N) NEUTRAL DETENT position.b. Lower t

Operation81Model 644E Origin 3/04Step 9a. With the service brake pedal depressed and the boom angle at exactly 45, move the range select lever to (3)

82Model 644E Origin 3/04OperationThis Page Intentionally Left Blank

Operation83Model 644E Origin 3/04 Make sure the vehicle is level to assure an accurate fuel level reading. The fuel tank is capable of holding 45 gall

84Model 644E Origin 3/04OperationFuel CapThe fuel cap (1) is conveniently located on the left side of the vehicle.The fuel cap meets EPA standards.To

Operation85Model 644E Origin 3/041. Enter the cab and adjust the seat for comfortable operation.2. Adjust the mirrors to obtain the best rear view fro

86Model 644E Origin 3/04OperationThe engine is equipped with a 120 volt 750 watt block heater. Block heaters are recommended when temperatures drop be

Operation87Model 644E Origin 3/04This booster battery must be a 12 volt type. The vehicle used for jump starting must have a negative ground electrica

Safety Practices7Model 644E Origin 3/04Instructional Symbols (contíd)OU1620Standard CarriagesOU1630Side Tilt CarriagesOU1640Swing CarriagesOU1610Singl

88Model 644E Origin 3/04Operation To pick a load, move the forks inward or outward on the fork shaft so that they are aligned with the openings in the

Operation89Model 644E Origin 3/04This vehicle is designed to lift and transport materials and should not be used to elevate personnel except as explai

90Model 644E Origin 3/04Operation7. The platform must have a restraining means such as a guardrail or a means of securing personnel such as a body bel

Operation91Model 644E Origin 3/04Preparation and Set-up1. DO NOT alter or modify the work platform in any manner.2. Make sure that the work platform i

92Model 644E Origin 3/04OperationElevating Personnel1. Make sure there are no overhead obstructions or electrical wires above the platform before lift

Operation93Model 644E Origin 3/04Numerous attachments, marketed by JLG are available for this vehicle. The capacity charts attached to this vehicles d

94Model 644E Origin 3/04OperationThe attachments listed below are supplied with their own individual set of capacity charts as shown in the last secti

Operation95Model 644E Origin 3/041. Bring the vehicle to a complete stop using the service brakes.2. Park the vehicle on level ground.3. Place the tra

96Model 644E Origin 3/04Emergency OperationsEmergency OperationsTowing a disabled vehicle should only be attempted after exhausting all other options.

Emergency Operations97Model 644E Origin 3/0411. Pressurize the park brake with the pressurizing unit. Pump pressure into the park brake system. DO NOT