Lull 644E-42 Operation Manual User Manual

Page 3

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Table of Contents

1

2004 JLG Industries, Inc.

Introduction

The Manual....................................2
Replacement Parts ........................2
Reports ..........................................2
Disclaimer......................................3

Safety Practices

Hazard Classification System........3
Accident Prevention Tags..............5
New or Additional Operators .........5
Instructional Symbols ....................6
Instructional Symbols (cont’d) .......7
Hazard Symbols ............................8
Avoidance Symbols .......................9
Avoidance Symbols (cont’d) ........10
Avoidance Symbols (cont’d) ........11
Personal Considerations .............12
Operational Considerations .........15
Equipment Considerations ..........20

Operation

Pre-Operation Inspection.............23
Operator Controls ........................26
Front Dash Panel.........................48
Optional Features ........................55
Carriages .....................................66
Indicators .....................................68
Fork Rating ..................................70
Using the Capacity Chart.............71
Stabil-TRAK System....................74
Stabil-TRAK™ System Test ........77
Refueling .....................................83
Normal Starting............................85
Cold Starting................................86
Jump Starting ..............................87
How To Pick, Carry & Place A

Load..........................................88

Elevating Personnel.....................89
Using Other Attachments ............93
Shut-Off .......................................95

Emergency Operations

Towing a Disabled Vehicle ..........96
Emergency Boom Lowering ........98

General Maintenance

Introduction................................104
Maintenance Schedule and

Checklist .................................105

1. Lubrication Points.............106
2. Air Cleaner .......................107
3. Optional Closed Cab Air

Filters ................................109

4. Engine Cooling System.....110
5. Engine Oil and Filter..........114
6. Engine Fuel System ..........118
7. Engine Fan Belt.................123
8. Air Conditioner Compressor

Belt (Optional) ...................124

9. Hydraulic Oil and Filter ......125

10. Transmission Oil and

Filter ..................................128

11. Transfer Case Oil ..............131
12. Axle Oil ..............................133
13. Brake Disc Inspection .......135
14. Wheel End Oil ...................138
15. Wheels and Tires ..............140
16. Battery...............................142
17. Fuse & Relay

Replacement .....................143

18. Boom Chains and Wear

Pads ..................................149

19. Transfer Carriage Rollers and

Wear Pads ........................162

Storage and Transport ..............169
Storage......................................169
Transport ...................................170

Test Procedures

Parking Brake/Transmission

De-Clutch Test Procedures ....171

Specifications

Fluid & Lubrication Capacities...173
Tires ..........................................174
Weights .....................................174
Vehicle Dimensions...................175
Electrical System.......................176
Engine .......................................176

Index

.............................................177

Load Charts
Accident Prevention Tags

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