Lull 944E-42 Operation Manual User Manual

Operation & SafetyManualOriginal InstructionsKeep this manual with machine at all times.An Oshkosh Corporation CompanyModels644E-42&944E-42S/N

Table of Contentsiv 312003547.5 Operator Maintenance Instructions ... 7-8Fuel System...

Section 5 - Attachments5-28 31200354BucketUse Appropriate Bucket Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/Fork Ca

Section 5 - Attachments5-2931200354Equipment Damage Precautions• Except for lifting or dumping a load, the boom must be fully retracted for allbucket

Section 5 - Attachments5-30 31200354Grapple BucketUse Grapple Bucket Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachment/For

Section 5 - Attachments5-3131200354Operation:• Raise or lower boom to appropriate height and open grapple for loading materialfrom stockpile.• Align t

Section 5 - Attachments5-32 31200354Personnel Work PlatformUse Appropriate Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “

Section 5 - Attachments5-3331200354Preparation and Setup:1. Ensure the telehandler is on a firm surface and is level.2. Engage the park brake. Blockin

Section 5 - Attachments5-34 31200354This Page Intentionally Left Blank

Section 6 - Emergency Procedures6-131200354SECTION 6 - EMERGENCY PROCEDURES6.1 TOWING A DISABLED PRODUCTThe following information assumes the telehand

Section 6 - Emergency Procedures6-2 312003546.2 EMERGENCY LOWERING OF BOOMIn the event of total loss of engine power or hydraulic pump failure with an

Section 7 - Lubrication and Maintenance7-131200354SECTION 7 - LUBRICATION AND MAINTENANCE7.1 INTRODUCTIONService the product in accordance with the ma

Section 1 - General Safety Practices1-131200354SECTION 1 - GENERAL SAFETY PRACTICES1.1 HAZARD CLASSIFICATION SYSTEMSafety Alert System and Safety Sign

Section 7 - Lubrication and Maintenance7-2 312003547.2 GENERAL MAINTENANCE INSTRUCTIONSPrior to performing any service or maintenance on the telehandl

Section 7 - Lubrication and Maintenance7-3312003547.3 SERVICE AND MAINTENANCE SCHEDULE10 & 50 Hour Maintenance ScheduleOU2232Check BoomWear PadsCh

Section 7 - Lubrication and Maintenance7-4 312003541st 100, 250 & 1st 500 Hour Maintenance ScheduleNote: Engine oil and filter service interval c

Section 7 - Lubrication and Maintenance7-531200354500, 1000 & 2000 Hour Maintenance ScheduleOU22532000EVERYChangeEngine Coolant500EVERYChange Fuel

Section 7 - Lubrication and Maintenance7-6 312003547.4 LUBRICATION SCHEDULES50 Hour Lubrication ScheduleOU243050EVERY22

Section 7 - Lubrication and Maintenance7-731200354This Page Intentionally Left Blank

Section 7 - Lubrication and Maintenance7-8 312003547.5 OPERATOR MAINTENANCE INSTRUCTIONSFuel SystemA. Fuel Level Check1. Check fuel gauge (1) located

Section 7 - Lubrication and Maintenance7-931200354B. Drain Fuel/Water Separator1. Perform “Shut-Down Procedure” on page 4-4.2. Open the engine cover.3

Section 7 - Lubrication and Maintenance7-10 31200354Engine OilA. Engine Oil Level Check1. Perform “Shut-Down Procedure” on page 4-4.2. Open the engine

Section 7 - Lubrication and Maintenance7-1131200354Hydraulic OilA. Hydraulic Oil Level Check1. Be sure all cylinders and transfer carriage are fully r

Section 1 - General Safety Practices1-2 312003541.3 OPERATION SAFETYElectrical Hazards• This machine is not insulated and does not provide protection

Section 7 - Lubrication and Maintenance7-12 31200354Engine Cooling SystemA. Engine Coolant Level CheckBefore S/N 0160041827 excluding 01600416301. Per

Section 7 - Lubrication and Maintenance7-1331200354S/N 0160041827 & After including 01600416301. Perform “Shut-Down Procedure” on page 4-4.2. Open

Section 7 - Lubrication and Maintenance7-14 31200354TiresA. Tire Air Pressure Check1. Perform “Shut-Down Procedure” on page 4-4.2. Remove valve stem c

Section 7 - Lubrication and Maintenance7-1531200354C. Tire and Wheel ReplacementIt is recommended that a replacement tire to be the same size, ply and

Section 7 - Lubrication and Maintenance7-16 31200354E. Wheel InstallationTorque lug nuts before first use and after each wheel removal.Note: If machi

Section 7 - Lubrication and Maintenance7-1731200354Transmission OilA. Transmission Oil Level Check1. Apply park brake, shift transmission to "Neu

Section 7 - Lubrication and Maintenance7-18 31200354BatteryA. Battery CheckBefore S/N 0160041827 excluding 01600416301. Perform “Shut-Down Procedure”

Section 7 - Lubrication and Maintenance7-1931200354S/N 0160041827 & After including 01600416301. Perform “Shut-Down Procedure” on page 4-4.2. Remo

Section 7 - Lubrication and Maintenance7-20 31200354Air Intake SystemA. Air Filter CheckBefore S/N 0160041827 excluding 01600416301. Perform “Shut-Dow

Section 7 - Lubrication and Maintenance7-2131200354B. Element Change (as restriction indicator indicates)If air filter restriction indicator remains o

Section 1 - General Safety Practices1-331200354Tip Over HazardGeneral• For additional load requirements, refer to the appropriate capacity chart.• Nev

Section 7 - Lubrication and Maintenance7-22 31200354S/N 0160041827 & After including 01600416301. Perform “Shut-Down Procedure” on page 4-4.2. Ope

Section 7 - Lubrication and Maintenance7-2331200354B. Element Change (as restriction indicator indicates)If air filter restriction indicator remains o

Section 7 - Lubrication and Maintenance7-24 31200354This Page Intentionally Left Blank

Section 8 - Additional Checks8-131200354SECTION 8 - ADDITIONAL CHECKS8.1 STABIL-TRAK™ A. Stabil-Trak Indicator TestStabil-Trak system operates in thre

Section 8 - Additional Checks8-2 312003545. Depress service brake pedal and lower boom below 40°.6. Depress service brake pedal (5) and shift transmis

Section 9 - Specifications9-131200354SECTION 9 - SPECIFICATIONS9.1 PRODUCT SPECIFICATIONSCapacitiesEngine Crankcase OilCapacity with Filter ChangeBefo

Section 9 - Specifications9-2 31200354AxlesDifferential Housing Capacity644E-42Before S/N 0160039830 excluding S/N 0160036724, 0160036811,0160036907 &

Section 9 - Specifications9-331200354Tires644E-4213.00 x 24, G-2/L-2 Bias Ply Traction - 12 plyPneumatic...

Section 9 - Specifications9-4 31200354PerformanceMaximum Lift Capacity644E-42Transfer Carriage Fully Retracted ...

Section 9 - Specifications9-531200354DimensionsOverall Height...95.5 in

Section 1 - General Safety Practices1-4 31200354• MAINTAIN proper tire pressure at all times. If proper tire pressures are notmaintained, this machine

Section 9 - Specifications9-6 31200354This Page Intentionally Left Blank

Index131200354AAccessory Control Lever ... 3-17Additional Checks... 8-1Adjusting/Moving Forks...

Index2 31200354LLeveling Procedure...4-6, 4-9Lifting Personnel... 1-8Load Falling Hazard ...

Index331200354WWalk-Around Inspection ... 2-10Warm-Up Check... 2-12Wheel Installation...

Index4 31200354

Inspection, Maintenance and Repair LogSerial Number ______________________________Date CommentsInspection, Maintenance and Repair Log

Inspection, Maintenance and Repair LogDate Comments

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

Hand SignalsSpecial Signals - When signals for auxiliary equipment functions or conditions not covered are required, they shall be agreed upon in adva

Section 1 - General Safety Practices1-531200354Non-Suspended Load• DO NOT drive with boom raised.Suspended Load• Tether suspended loads to restrict mo

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

Section 1 - General Safety Practices1-6 31200354Travel Hazard• Steering characteristics differ between steer modes. Identify the steer modesettings of

Section 1 - General Safety Practices1-731200354Load Falling Hazard• Never suspend load from forks or other parts of carriage.• DO NOT burn or drill ho

Section 1 - General Safety Practices1-8 31200354Lifting Personnel• When lifting personnel, USE ONLY a JLG approved personnel work platform,with proper

Section 1 - General Safety Practices1-931200354Driving Hazards on SlopesTo maintain sufficient traction and braking capabilities, travel on slopes as

CALIFORNIA PROPOSITION 65BATTERY WARNINGBattery posts,terminals and relatedaccessories containlead and lead compounds,chemical known to theState of Ca

Section 1 - General Safety Practices1-10 31200354Pinch Points and Crush HazardsStay clear of pinch points and rotating parts on the telehandler.• Stay

Section 1 - General Safety Practices1-1131200354• Keep clear of boom holes.• Keep arms and hands clear of attachment tilt cylinder.• Keep hands and fi

Section 1 - General Safety Practices1-12 31200354Fall Hazard• Enter using the proper hand holds and steps provided. Always maintain 3-pointcontact whe

Section 1 - General Safety Practices1-1331200354Chemical HazardsExhaust Fumes• DO NOT operate machine in an enclosed area without proper ventilation.•

Section 1 - General Safety Practices1-14 31200354This Page Intentionally Left Blank

Section 2 - Pre-Operation and Inspection2-131200354SECTION 2 - PRE-OPERATION AND INSPECTION2.1 PRE-OPERATION CHECK AND INSPECTIONNote: Complete all r

Section 2 - Pre-Operation and Inspection2-2 312003548. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operatio

Section 2 - Pre-Operation and Inspection2-3312003542.2 SAFETY DECALSEnsure all DANGER, WARNING, CAUTION and instructional decals and propercapacity

Section 2 - Pre-Operation and Inspection2-4 31200354OU1791ANGUS-PALM 005413914042997301379170630073013807301380410980141098014110392Pressure Tap Func

Section 2 - Pre-Operation and Inspection2-531200354OU18014110350102502000100050LB-FT (Nm)100P1001103931411034922411034917070791707079-WARNINGEXPLOSIVE

Revision Loga31200354Revision LogREVISION LOGMarch 18, 2009 - A - Original Issue of ManualApril 23, 2009 - B - Revised page 9-2.December 21, 2010 - C

Section 2 - Pre-Operation and Inspection2-6 31200354S/N 0160041827 & After including 0160041630OU24400000000RPM X 10051015302025F1/2E1041768024812

Section 2 - Pre-Operation and Inspection2-731200354OU2450ANGUS-PALM 005413914042997301379170630073013807301380410980141098014110392Pressure Tap Funct

Section 2 - Pre-Operation and Inspection2-8 31200354OU25304110350102502000100050LB-FT (Nm)100P10011363734110349224110349170711417071141706300(BOTH SID

Section 2 - Pre-Operation and Inspection2-931200354This Page Intentionally Left Blank

Section 2 - Pre-Operation and Inspection2-10 312003542.3 WALK-AROUND INSPECTIONBegin your walk-around inspection at item 1, as noted below. Continue t

Section 2 - Pre-Operation and Inspection2-11312003545. Cab and Electrical - • General appearance; no visible damage.• Frame level indicator and window

Section 2 - Pre-Operation and Inspection2-12 312003542.4 WARM-UP AND OPERATIONAL CHECKSWarm-Up CheckDuring warm-up period, check:1. Heater, defroster

Section 2 - Pre-Operation and Inspection2-13312003542.5 OPERATOR CABThe telehandler is equipped with an open or enclosed ROPS/FOPS cab.WARNINGNever op

Section 2 - Pre-Operation and Inspection2-14 312003542.6 WINDOWSKeep all windows and mirrors clean and unobstructed.Cab Door Window (if equipped)• Cab

Section 3 - Controls and Indicators3-131200354SECTION 3 - CONTROLS AND INDICATORS3.1 GENERALThis section provides the necessary information needed to

Read This Firstb 31200354Read This FirstThis manual is a very important tool! Keep it with the machine at all times.The purpose of this manual is to p

Section 3 - Controls and Indicators3-2 312003543.2 CONTROLS1. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic speed.2. Ignit

Section 3 - Controls and Indicators3-33120035411. Front Joystick: See page 3-12.12. Middle Joystick: See page 3-13.13. Frame Level Joystick: See page

Section 3 - Controls and Indicators3-4 31200354Instrument Panel1. Fuel Gauge: Indicates amount of fuel in fuel tank.2. Engine Air-Intake Heater Indica

Section 3 - Controls and Indicators3-53120035411. Air Filter Restriction Indicator: Illuminates when air filter(s) require maintenance.12. Hydraulic O

Section 3 - Controls and Indicators3-6 31200354Dash Panel1. Steer Mode Selector: Three positions: 4-wheel circle steer, 4-wheel crab steer and 2-wheel

Section 3 - Controls and Indicators3-7312003547. Work Lights Switch (if equipped): Three position switch. Move switch to middle position to turn on fr

Section 3 - Controls and Indicators3-8 31200354Ignition• In the "RUN" position, voltage is available for all electrical functions.• Full clo

Section 3 - Controls and Indicators3-931200354Park BrakePark brake switch controls the application and release of the park brake. Indicator onswitch i

Section 3 - Controls and Indicators3-10 31200354Transmission Control LeverDirection of Travel SelectionTransmission control lever (1) engages forward

Section 3 - Controls and Indicators3-1131200354Gear SelectionGear selection is located on the twist grip handle (2) of transmission control lever.• Tw

Read This Firstc31200354This product must comply with all safety related bulletins. Contact JLG Industries,Inc. or the local authorized JLG representa

Section 3 - Controls and Indicators3-12 31200354Front JoystickThe front joystick (1) controls attachment tilt, transfer carriage and auxiliary hydraul

Section 3 - Controls and Indicators3-1331200354Middle JoystickThe middle joystick (3) controls boom functions.Boom Functions• Move the joystick back t

Section 3 - Controls and Indicators3-14 31200354Single Joystick (if equipped)The single joystick (1) controls boom, attachment tilt, transfer carriage

Section 3 - Controls and Indicators3-1531200354• The speed of functions depends upon the amount of joystick travel incorresponding direction. Increasi

Section 3 - Controls and Indicators3-16 31200354Frame Level JoystickThe frame level joystick (1) controls the left to right frame level.• Lift detent

Section 3 - Controls and Indicators3-1731200354Accessory Control Lever (if equipped)The accessory control lever (3) operates the turn signals, parking

Section 3 - Controls and Indicators3-18 312003543.3 STEER MODESThree steer modes are available for operator use.Note: 2-Wheel Front Steer mode is req

Section 3 - Controls and Indicators3-19312003543.4 STABIL-TRAK™ SYSTEMFree Pivot ModeWith boom below 40° (1), the Stabil-Trak system is in free pivot

Section 3 - Controls and Indicators3-20 312003543.5 OPERATOR SEATAdjustmentsPrior to starting engine adjust seat for position and comfort.1. Suspensio

Section 3 - Controls and Indicators3-2131200354Seat BeltFasten seat belt as follows:1. Grasp both free ends of the belt making certain that belt webbi

Read This Firstd 31200354Other Publications AvailableService ManualBefore S/N 0160041827 excluding 0160041630 ...899046

Section 3 - Controls and Indicators3-22 312003543.6 INDICATORSBoom Angle and Extension• The boom angle indicator (1) is located on the left side of th

Section 4 - Operation4-131200354SECTION 4 - OPERATION4.1 ENGINEStarting the EngineThis machine can be operated under normal conditions in temperatures

Section 4 - Operation4-2 31200354Cold Weather Starting AidsIf the telehandler is equipped with an engine air-intake heater, the following applies:• Ai

Section 4 - Operation4-331200354Battery Boosted StartingIf battery-boost starting (jump-start) is necessary, proceed as follows:• Never allow vehicles

Section 4 - Operation4-4 31200354Normal Engine Operation• Observe gauges and indicators frequently to be sure all engine systems arefunctioning proper

Section 4 - Operation4-5312003544.2 OPERATING WITH A NON-SUSPENDED LOADLift Load Safely• You must know the weight and load center of every load you li

Section 4 - Operation4-6 31200354Transporting a LoadAfter engaging the load and resting it against the backrest, tilt the load back toposition it for

Section 4 - Operation4-731200354Placing a LoadBefore placing any load be sure that:• The landing point can safely support the weight of the load.• The

Section 4 - Operation4-8 312003544.3 OPERATING WITH A SUSPENDED LOADLift Load Safely• You must know the weight and load center of every load you lift.

Section 4 - Operation4-931200354Transporting a Suspended Load• Travel in accordance with the requirements set forth in Section 1 - GeneralSafety Pract

Table of Contentsi31200354TABLE OF CONTENTSRevision LogRead This FirstOperator Qualifications ...bM

Section 4 - Operation4-10 31200354Placing a Suspended LoadBefore placing any load be sure that:• The landing point can safely support the weight of th

Section 4 - Operation4-11312003544.4 LOADING AND SECURING FOR TRANSPORTTiedown1. Level the telehandler prior to loading.2. Using a spotter, load the t

Section 4 - Operation4-12 31200354Lifting• When lifting machine, it is very important that the lifting device and equipment isattached only to designa

Section 5 - Attachments5-131200354SECTION 5 - ATTACHMENTS5.1 APPROVED ATTACHMENTSTo determine if an attachment is approved for use on the specific tel

Section 5 - Attachments5-2 312003545.3 JLG SUPPLIED ATTACHMENTSAttachment Part NumberApplicable Model644E-42 944E-42Carriage, 50 in (1270 mm) 1170021

Section 5 - Attachments5-331200354This Page Intentionally Left Blank

Section 5 - Attachments5-4 312003545.4 TELEHANDLER/ATTACHMENT/FORK CAPACITYPrior to installing the attachment verify it is approved and the telehandle

Section 5 - Attachments5-5312003545.5 USE OF THE CAPACITY CHARTTo properly use the capacity chart (see page 5-6), the operator must first determineand

Section 5 - Attachments5-6 31200354Sample Capacity ChartNote: This is a sample capacity chart only! DO NOT use this chart, use the one located in you

Section 5 - Attachments5-731200354To identify the proper capacity chart on telehandlers equipped with transfer carriage,refer to the following icons w

Table of Contentsii 31200354Parking Procedure... 3-9Transmission Control Lever...

Section 5 - Attachments5-8 31200354ExampleA contractor owns a model xxxxx telehandler with a fork carriage. He knows thisattachment may be used with h

Section 5 - Attachments5-931200354This Page Intentionally Left Blank

Section 5 - Attachments5-10 312003545.6 ATTACHMENT INSTALLATION1. Attachment 2. Attachment Pin Recess 3. Attachment Pin 4. Lock Pin 5. Lock Lever 6. Q

Section 5 - Attachments5-1131200354This installation procedure is designed for one-person operation. Prior to exiting cab,perform “Shut-Down Procedure

Section 5 - Attachments5-12 31200354Hydraulic Operated Attachment1. Install attachment (see page 5-10).2. Lower attachment to ground and perform “Shut

Section 5 - Attachments5-13312003545.7 ADJUSTING/MOVING FORKSCarriages may have different locations where forks can be positioned. Two differentmethod

Section 5 - Attachments5-14 312003545.8 ATTACHMENT OPERATION• Capacities and range limits for the telehandler change depending on theattachment in use

Section 5 - Attachments5-1531200354Carriage w/ForksUse Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attachme

Section 5 - Attachments5-16 31200354Side Tilt CarriageUse Side Tilt Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Telehan

Section 5 - Attachments5-1731200354Operation:• Approach load with forks centered on load and stop telehandler.• Level telehandler before side tilting

Table of Contentsiii31200354Section 5 - Attachments5.1 Approved Attachments ...5-15.2 Unapproved

Section 5 - Attachments5-18 31200354Swing CarriageUse Swing Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Telehandler/Att

Section 5 - Attachments5-1931200354Operation:• To drive with a load, keep forks pointed forward and travel in accordance with therequirements set fort

Section 5 - Attachments5-20 31200354Dual Fork Positioning CarriageUse Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Teleh

Section 5 - Attachments5-2131200354Operation:• Travel in accordance with the requirements set forth in Section 1 - GeneralSafety Practices.Equipment D

Section 5 - Attachments5-22 31200354Mast CarriageUse Mast Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Telehandler/Attac

Section 5 - Attachments5-2331200354Operation:• Always lower forks fully in mast before engaging load.• To drive with a load, lower forks fully in mast

Section 5 - Attachments5-24 31200354Fork Mounted HookUse Appropriate Carriage Attachment Capacity ChartTo determine maximum capacity, refer to “Teleha

Section 5 - Attachments5-2531200354Operation:• Pallet or lumber forks of an appropriate load rating must be used. Do not use withcubing or block forks

Section 5 - Attachments5-26 31200354Truss BoomUse Appropriate Truss Boom Attachment Capacity ChartTo determine maximum capacity, refer to “Telehandler

Section 5 - Attachments5-2731200354Operation:• Weight of rigging must be included as part of total load being lifted.WARNINGCRUSH HAZARD. Maintain a m