Lull PLACEACE Series User manual

SECTION CONTENTS
Section Subject Page
2004 JLG Industries, Inc.
Model 644E-42/944E-42 Rev. 6/04 i
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Training Mechanics as Operators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.4 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.5 Accident Prevention Tag Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5
1.7 Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.8 Hazard/Emergency Information Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
Section 2
General Information, Specifications and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 644E-42 / 944E-42 Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.3 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.4 Metric Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.5 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.6 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
2.7 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
2.8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
2.9 Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2.10 Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
2.11 Pressure Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
2.12 After Service Startup and Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Section 3
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Boom System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.4 Boom Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
3.5 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
3.6 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
3.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3
4.3 Open Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.4 Enclosed Cab (Optional) Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
4.5 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28
4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
4.7 Valve Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
4.8 Access Panels and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36

Section Subject Page
ii Model 644E-42/944E-42 Rev. 6/04
Section 5
Axles, Drive Shafts, Wheels, Tires and Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
Section 6
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 . . . . . . . . . . . . . . . . 6.1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.6 Transmission Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.7 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15
6.9 Towing a Disabled Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
6.10 Transfer Case Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
6.11 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
6.12 Transfer Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
6.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.24
Section 7
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.5 Standard Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.6 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.7 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
7.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.23
7.9 Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
7.10 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32
7.11 Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.49
7.12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.50

Section Subject Page
iii
Model 644E-42/944E-42 Rev. 6/04
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.4 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.5 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.6 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.7 Hydraulic System Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.8 Hydraulic Circuits and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.55
8.9 Steer Indexing Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.163
8.10 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.165
8.11 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.166
8.12 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.177
8.13 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.207
8.14 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.213
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.2 Service Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.4 Effective Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.5 Grounding Straps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.6 Wiring Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.7 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9.8 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9.9 Transmission Gear Selection Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.140
9.10 Dash Panel Warning Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.148
9.11 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.163
9.12 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.167
9.13 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.176
9.14 Switches and Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.209

Section Subject Page
iv Model 644E-42/944E-42 Rev. 6/04
Section 10
Stabil-TRAK™ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
10.1 Stabil-TRAK™ System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
10.2 Stabil-TRAK™ Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
10.3 Stabil-TRAK™ Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
10.4 Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting
(644E-42, SN 20118 & Before, SN 0160002519 thru 0160003877)
(944E-42, SN 20123 & Before, SN 0160002514 thru 0160003881) . . . . . . . . . . . . . . . 10.10
10.5 Stabil-TRAK™ System Test
(644E-42, SN 20118 & Before, SN 0160002519 thru 0160003877)
(944E-42, SN 20123 & Before, SN 0160002514 thru 0160003881) . . . . . . . . . . . . . . . 10.17
10.6 Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting
(644E-42, 0160003878 & After) (944E-42, 0160003882 & After) . . . . . . . . . . . . . . . . . 10.20
10.7 Stabil-TRAK™ System Test
(644E-42, 0160003878 & After) (944E-42, 0160003882 & After) . . . . . . . . . . . . . . . . . 10.26
10.8 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting. . . . . . . . . . . . . . . . . . 10.30
Section 11
Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
11.1 Transfer Carriage Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
11.2 Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.3
11.3 Transfer Carriage Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
11.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.30
Section 12
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Accident Prevention Tags

1.1
Model 644E-42/944E-42 Rev. 6/04
Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.4 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.4.1 Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.4.2 Hazard Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.5 Accident Prevention Tag Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.6.3 General Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.7 Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.8 Hazard/Emergency Information Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

Safety Practices
1.2 Model 644E-42/944E-42 Rev. 6/04
1.1 INTRODUCTION
JLG Industries, Inc. (hereafter, JLG) actively promotes
safe practices in the use and maintenance of its products
through training programs, instructional manuals and the
pro-active efforts of all employees involved in engineering,
design, manufacture, marketing and service.
This manual is designed to provide service technicians
with complete information on the maintenance and repair
of the Lull 644E-42 and 944E-42 Telescopic Material
Handler.
Particular effort has been made to produce a manual to
serve as a reference handbook for the experienced
service technician, but also provide essential step-by-
step procedures for the professional development of the
less experienced person. Remember, even the best
manual in the world is no substitute for an appropriate
education, skill development that comes through
experience alone, safety, wise and judicious
discernment, and ultimately, proper performance of
service procedures.
This service manual provides general directions for
accomplishing service and repair procedures with tested,
effective techniques. Following the procedures in this
manual will help assure safety and equipment reliability.
Read, understand and follow the information in this
manual, and obey all locally approved safety practices,
procedures, rules, codes, regulations and laws. Prior to
performing any maintenance on the vehicle, consider all
factors, circumstances and conditions which can have an
effect upon the safety of personnel and equipment, and
take appropriate action to ensure the safety of all
involved.
These instructions cannot cover all details or variations in
the equipment, procedures or processes described, nor
provide directions for meeting every possible contingency
during operation, maintenance or testing. When
additional information is desired to satisfy a situation not
covered sufficiently, consult your local Lull distributor or
the JLG Service Department at [phone] or
[phone].
Many factors contribute to unsafe conditions;
carelessness, fatigue, overload, inattentiveness,
unfamiliarity, even drugs and alcohol, among others.
Although equipment damage can usually be repaired in a
brief period of time, death and irreparable injury are
permanent. For optimal safety, encourage everyone to
think, and to act, safely.
Appropriate service methods and proper repair
procedures are essential for the safety of the individual
doing the work, for the safety of the operator, and for the
safe, reliable operation of the vehicle.
All references to the right side, left side, front, and rear
are given from the operator’s seat looking in a forward
direction.
Provisions for supplementary information are made by
JLG in the form of Service Bulletins, Service Campaigns,
Service Training Schools, the JLG web site, other
literature, and through updates to the manual itself.
Comments and suggestions for improvement are
welcome and encouraged.
All information, illustrations and specifications contained
in this manual are based on the latest product information
available at the time of publication approval. JLG
reserves the right to make changes and improvements to
its products, and to discontinue the manufacture of any
product, at its discretion at any time without public notice
or obligation.
1.2 OWNERS/OPERATORS MANUAL
The vehicle must be driven and operated as a
consequence of performing service, maintenance and
test procedures. The service technician must therefore
read, understand and follow the instructions in the Lull
644E-42 and 944E-42 Telescopic Material Handler
Owners/Operators Manual.
An Owners/Operators and AEM Safety Manuals are
supplied with each vehicle and must be kept in the
pouch (1) on the back of the drivers seat.
In the event that the Owners/Operators or Safety
Manuals are missing, consult your local Lull distributor or
the JLG Service Department at [phone] or
[phone].

1.3
Model 644E-42/944E-42 Rev. 6/04
Safety Practices
1.3 TRAINING MECHANICS AS
OPERATORS
Because it is necessary to move the vehicle to service or
maintain the vehicle, it is necessary that all mechanics
are OSHA trained and certified as operators. A mechanic
trained in the proper operation of the vehicle can better
determine whether all the functions are operating
correctly.
At the time of original purchase, the purchaser of this
vehicle was instructed by the seller on its proper use.
When this vehicle is to be serviced or maintained by
someone other than the purchaser, make certain that the
mechanic is trained, in accordance with the OSHA
regulations listed in the NOTICE below, and reads and
understands the Lull 644E-42 and 944E-42 Telescopic
Material Handler Owners/Operators Manual before
operating or maintaining the vehicle.
NOTICE: Under OSHA rules, it is the responsibility of the
employer to provide operator training. Successful
completion and certification of Safety Training for Rough
Terrain Forklifts is required. Operator Training Kits are
available by calling Ken Cook Company at
[phone]. An order form for these kits is available
through our web site, http://www.jlg.com.
In addition, make sure that the mechanic has completed
a walk-around inspection of the vehicle, is familiar with all
decals and/or decal plates on the vehicle, and has
demonstrated the correct use of all controls.
1.4 SAFETY INFORMATION
The following information provides general safety
instructions, including examples of hazard statements
with signal words, notification of hazards, methods to
help avoid hazards and the consequences of failing to
follow the safety information. To avoid possible death or
injury, carefully read and follow all safety messages. Fully
understand the potential causes of death or injury.
In the event of an accident, know where to obtain medical
assistance, use a first-aid kit and fire extinguisher/fire
suppression system. Keep emergency telephone
numbers (fire department, ambulance, rescue squad/
paramedics, police department, etc.) nearby. If working
alone, check with another person routinely to help ensure
personal safety.
The information in this manual does not replace any other
safety rules or proper judgment. Governmental
authorities and employers also have their own sets of
rules, codes, regulations and laws. Before starting work
at a worksite, check with the supervisor or safety
coordinator and ask about the safety policy. Learn the
safety requirements in effect before operating,
maintaining, servicing or testing the vehicle. Safety
depends on following safety requirements.
1.4.1 Safety Alert Symbol
The exclamation mark within a triangle is the Safety Alert
Symbol.
This symbol is used to indicate a potential personal
injury hazard only. The symbol will not be used to
indicate property-damage-only hazards.
This symbol means “Attention! Become Alert! Your
Safety Is Involved!” The symbol is used to attract
attention to safety hazards found on the vehicle safety
decals and/or decal plates throughout this manual.
1
MU0920
OP0330

Safety Practices
1.4 Model 644E-42/944E-42 Rev. 6/04
1.4.2 Hazard Statements
Signal words and messages are used in conjunction with
the safety alert symbol to create hazard statements.
These hazard statements convey important information
about safety.
Four types of hazard statements are used in this manual.
Each statement indicates the existence and degree of
relative risk of the hazard described within the statement
that follows the signal word.
Explanations of the types of hazard statements are as
follows:
The signal word “DANGER” indicates an imminently
hazardous situation which, if not avoided, will result in
death or serious injury.
The signal word “WARNING” indicates a potentially
hazardous situation which, if not avoided, could result in
death or serious injury.
The signal word “CAUTION” indicates a potentially
hazardous situation which, if not avoided, may result in
minor or moderate injury.
The signal word “CAUTION,” used without the safety
alert symbol, indicates a potentially hazardous situation
which, if not avoided, may result in property damage.
For safe maintenance of the vehicle, read, understand
and follow all DANGER, WARNING and CAUTION
information.
1.5 ACCIDENT PREVENTION
TAG USAGE
Before beginning any maintenance or service, place an
Accident Prevention Tag (1) on both the ignition
switch (2) and steering wheel (3), stating that the vehicle
should not be operated. Actual Accident Prevention
Tags, that can be punched out and used, are included as
the last page in this manual. Retain these Accident
Prevention Tags for reuse at a later date.
DANGER:
WARNING:
CAUTION:
CAUTION:
MC0690
1
DANGER
DANGER
2
3
1
MU0290

1.5
Model 644E-42/944E-42 Rev. 6/04
Safety Practices
1.6 SAFETY INSTRUCTIONS
Following are general safety statements to consider
before performing maintenance procedures on a vehicle.
Additional statements related to specific tasks and
procedures are located throughout this manual and are
listed prior to any work instructions to provide safety
information before the hazard occurs.
For all safety messages, carefully read, understand and
follow the instructions before proceeding.
1.6.1 Personal Hazards
HAIR and CLOTHING:DO NOT wear loose clothing or
jewelry. Tie up or restrain hair. Wear the correct safety
equipment for the job (including but not limited to: hard
hat, safety shoes, safety glasses, goggles, face shield,
heavy gloves, hearing protection, reflective clothing, wet-
weather gear, respirator or filter mask).
EYE PROTECTION: Always wear appropriate eye
protection when chiseling, grinding, sanding, welding,
painting, repairing hydraulic systems, checking, testing or
charging the battery.
BREATHING PROTECTION: Wear respiratory
protection when grinding or painting.
HEARING PROTECTION: Always wear hearing
protection in a high-noise area.
FOOT PROTECTION: Wear protective footwear with
reinforced toe caps and slip-resistant soles.
LIFTING: NEVER lift a heavy object without the help of at
least one assistant or a suitable sling and hoist.
1.6.2 Equipment Hazards
OWNERS/OPERATORS MANUAL: Before operating the
vehicle, carefully read, understand and follow the
Owners/Operators Manual.
OPERATIONAL PROTECTION: Before operating the
vehicle or returning it for operational use, check that the
operator’s protective structure is intact, undamaged,
unmodified and secure.
LIFTING OF EQUIPMENT: Before using any lifting
equipment (chains, slings, brackets, hooks, etc.), verify
that it is of the proper capacity, in good working condition
and properly attached.
NEVER stand or otherwise become positioned under a
suspended load or under raised equipment. The load or
equipment could fall or tip.
DO NOT use a hoist or jack to support raised equipment.
A hoist or jack failure can allow the equipment to fall or tip.
Always support equipment with proper capacity blocks or
stands that are properly rated for the load.
COMPRESSED AIR: Before and during the use of
compressed air, wear eye protection and advise other
personnel in the work area that compressed air is about
to be used.
HAND TOOLS: Always use the proper tool for the job;
keep tools clean and in good working order, and use
special service tools only as recommended.
CAUTION: (944E-42 Only) When doing
welding anywhere on the vehicle disconnect
the wire harness (1and 2) from the Engine
Control Module (ECM) (3) on the engine.
MU5510
944E-42 Only
1
2
3

Safety Practices
1.6 Model 644E-42/944E-42 Rev. 6/04
1.6.3 General Hazards
SOLVENTS: Only use approved solvents, and solvents
that are known to be safe for use.
HOUSEKEEPING: Keep the work area and operator’s
cab clean and remove all hazards (debris, oil, tools, etc.).
FIRST AID: Immediately clean, dress and report all
injuries (cuts, abrasions, burns, etc.), no matter how
minor. Know the location of a first-aid kit, and know how
to use it.
CLEANLINESS: Wear eye protection, and clean all
components with a high-pressure or steam cleaner
before attempting service.
When removing hydraulic components, plug hose ends
and connections to prevent excess leakage and
contamination. Place a suitable catch basin beneath the
vehicle to capture fluid run-off.
1.6.4 Operational Hazards
OPERATIONAL CONSIDERATIONS: Before operating
the vehicle, carefully read, understand and follow the
Owners/Operators Manual.
ENGINE: Stop the engine before performing any service.
DANGEROUS START: Place Accident Prevention Tags
on both the ignition switch and steering wheel before
attempting to perform any service or maintenance.
Disconnect battery leads. Place a warning sign on
vehicles that are dangerous to start, if leaving the vehicle
unattended.
VENTILATION: Avoid prolonged engine operation in
enclosed areas without adequate ventilation.
RADIATOR CAP: Always wear steam-resistant, heat-
protective gloves when opening the radiator cap. Cover
cap with a clean, thick cloth and turn slowly to the first
stop to relieve pressure.
SOFT SURFACES AND SLOPES: NEVER work on a
vehicle that is parked on a soft surface or slope (inclined
ground or hill). The vehicle must be on a hard, level
surface with the wheels blocked when performing any
service. Obtain assistance, block all wheels, and add
supports if necessary, before beginning any work.
SUPPORTS AND STRAPS: Install safe, stable supports,
slings or straps, beneath or around a component or
structural member before beginning any work.
FLUID PRESSURE: Before loosening any hydraulic or
diesel fuel component, hose or tube, turn engine OFF.
Wear heavy, protective gloves and eye protection.
NEVER check for leaks using any part of your body; use
a piece of cardboard or wood instead. If injured, seek
medical attention immediately. Diesel fuel leaking under
pressure can explode. Hydraulic fluid and diesel fuel
leaking under pressure can penetrate the skin, causing
infection, gangrene, and other serious personal injury.
Relieve all pressure before disconnecting any
component, part, line or hose. Slowly loosen parts and
allow release of residual pressure before removing any
part or component. Before starting engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly, and tightened
to the proper torque. Capture fluid in an appropriate
container and dispose of it in accordance with prevailing
environmental regulations.
PRESSURE TESTING: When conducting any test, only
use test equipment that is correctly calibrated and in good
condition. Use the correct equipment in the proper
manner, and make changes or repairs as indicated by the
test procedures to achieve the desired results.
LEAVING VEHICLE: Lower the attachment to the ground
before leaving the vehicle.
TIRE PRESSURE: Always keep tires inflated to the
proper pressure to help prevent dangerous travel and
load-handling situations. DO NOT over-inflate tires.
1.7 EMERGENCY EXIT REAR WINDOW
The rear window (1), used on the optional enclosed cab
only, can be used as an emergency exit by removing the
latch pin (2) located on the window latch (3). The window
is then free to swing open.
2. 3.
1.
OU0902
1
2
3

1.7
Model 644E-42/944E-42 Rev. 6/04
Safety Practices
1.8 HAZARD/EMERGENCY
INFORMATION SIGNS
Locations of vehicle hazard and other emergency
information signs are shown below. As part of routine
maintenance, check that ALL hazard and emergency
information signs on the vehicle are present and
readable. Keep all signs clean.
If a replacement sign is needed, refer to the Owners/
Operators Manual and parts catalog for the latest parts
numbers and ordering information. Or, contact the JLG
Parts Department directly at:
(717)-485-6472
AB
FALLING OFF ATTACHMENT,
can result in death or
serious in ury.
DO NOT TRAVEL
with personnel in
a work platform.
4110389
Lift or lower personnel
only in a compliant
work platform.
WARNING
-
WARNING
EXPLOSIVE GASES can
cause serious injury.
Keep sparks flames
and lighted materials
away from batteries.
4110368
MOVING PARTS can cut.
Keep clear of fan and belts
while engine is running.
MOVING PARTS can entangle.
4110460
ENGINE EXPLOSION can
result in death or serious
personal in ury.
DO NOT use Ether or other
high energy starting aids.
Engine equipped with
grid heating system.
0
1Ft
2Ft 3Ft
4Ft
5Ft
6Ft
120cm 110cm 100cm 90cm 80cm 70cm 60cm 50cm 40cm 30cm 20cm 10cm130cm140cm150cm160cm170cm180cm190cm200cm 4110356
OU07602
OU07702
WARNING
Allow no riders
AVOID
CRUSHING
falling off
vehicle can
cause death
or serious
injury
 DO NOT JUMP.
 Brace yourself.
 Stay in cab.
 Keep seat belt on.
if vehicle tips.
Jumping can
result in death
or serious
injury.
DANGER
AVOID CRUSHING
SAFETY
INSTRUCTIONS
4110361
1. Read operator's
manual before
operating.
2. Fasten
seat
belt.
3. Allow
no
riders.
4. Use a compliant
work platform to lift
or lower personnel.
0000000
RPM X 100
5
10
15
30
20
25
F
1/2
E104
176
80 248
120
°C
°F
D
r/min
4
5
6
7
9
8
10 12
11
13
14
15
4. No Riders WARNING
5. Vehicle Rollaway WARNING
6. Electrocution DANGER
7. Load Chart Booklet
8. Tipover DANGER - Operating
9. Do Not Jump DANGER
10. Safety Instructions
11. Moving Parts WARNING
12. Explosive Gases WARNING
13. Falling Off Attachment WARNING
14. Boom Extend Stripes
15. Ether Starting Warning (Optional
Grid Heater Cold Start Aid)

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

2.1
Model 644E-42/944E-42 Rev. 6/04
Section 2
General Information, Specifications and Maintenance
Contents
PARAGRAPH TITLE PAGE
2.1 644E-42 / 944E-42 Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.1 Service Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.2 The Owners/Operators Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.3 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.4 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.3 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.3.1 SAE Flat Face O-Ring Seal Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . 2.5
2.4 Metric Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.4.1 Approximate American to Metric Conversions . . . . . . . . . . . . . . . . . . . . . 2.7
2.4.2 Approximate Metric to American Conversions . . . . . . . . . . . . . . . . . . . . . 2.7
2.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.5.1 Vehicle Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.5.2 Vehicle Weights - 644E-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
2.5.3 Vehicle Weights - 944E-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
2.5.4 Attachment Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
2.5.5 Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
2.5.6 Hydraulic Cylinder Performance Specifications . . . . . . . . . . . . . . . . . . . . 2.14
2.5.7 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
2.5.8 Engine Performance Specifications - 644E-42 . . . . . . . . . . . . . . . . . . . . . 2.17
2.5.9 Engine Performance Specifications - 944E-42 . . . . . . . . . . . . . . . . . . . . . 2.18
2.5.10 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
2.5.11 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
2.5.12 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
2.5.13 Miscellaneous Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
2.5.14 Tamper Proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
2.5.15 Fork Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

General Information, Specifications and Maintenance
2.2 Model 644E-42/944E-42 Rev. 6/04
2.6 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
2.6.1 Axles (Differential Housings). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
2.6.2 Wheel Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
2.6.3 Lubrication Points (Grease Fittings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
2.6.4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
2.6.5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
2.6.6 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
2.6.7 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
2.6.8 Drive Shaft Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
2.6.9 General Anti-Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
2.6.10 Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
2.6.11 Thread Locking Compound. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
2.7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
2.8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2.9 Hoses and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2.9.1 Hose and Tube Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2.9.2 Hose and Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2.10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
2.10.1 Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
2.10.2 Bearing Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
2.11 Pressure Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
2.12 After Service Startup and Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
2.12.1 After Service Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
2.12.2 After Electrical/Electronic Component Service . . . . . . . . . . . . . . . . . . . . . 2.30
2.12.3 After Hydraulic Component Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
2.12.4 After Brake System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
2.12.5 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
2.12.6 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 2.31
2.12.7 After Tire and Wheel Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
2.12.8 After Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
2.12.9 After Boom Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
2.12.10 After Axle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

2.3
Model 644E-42/944E-42 Rev. 6/04
General Information, Specifications and Maintenance
2.1 644E-42 / 944E-42 COMPONENT
TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this manual, it is necessary that
the operator/mechanic be familiar with the name and
location of the major assemblies on this vehicle. The
following illustration identifies the components that are
referred to throughout this manual.
MU4441
Operator’s
Protective
Structure
Stabilizer
Cylinder
Boom
Assembly
Hydraulic
Oil Tank
Carriage
Assembly
Engine
Compartment
Frame Sway
Cylinder
Slave
Cylinders (2)
(1 Not Visible)
Lift/Lower
Cylinder

General Information, Specifications and Maintenance
2.4 Model 644E-42/944E-42 Rev. 6/04
2.2 INTRODUCTION
2.2.1 Service Methods
Appropriate service methods and proper repair
procedures are essential for safe, reliable operation of
this vehicle and the safety of the individual doing the
work. This Service Manual provides general direction for
accomplishing service and repair work with tested,
effective techniques. Following them will assure
reliability.
There are many variations in procedures, techniques,
tools, and parts for servicing vehicles, as well as work
skills. This Manual cannot possibly anticipate all such
variations and provide advice or cautions for each one.
Accordingly, anyone who intends to depart from the
instructions in this Manual must first consider personal
safety and then vehicle integrity.
IMPORTANT: JLG recommends the use of
environmentally sound waste storage and disposal
practices. NEVER drain fluids on the ground or into a
sewer or catch basin. Use suitable collection containers,
then store and/or dispose of waste products in an
approved and safe manner. Check and obey all Federal,
State and/or Local regulations regarding waste storage,
disposal and recycling.
2.2.2 The Owners/Operators Manual
The Owners/Operators Manual provides information you
need to properly operate and maintain this vehicle.
IMPORTANT: Before you operate this vehicle, read the
manual completely and carefully, so that you will
understand the safety instructions and the operation of
the controls and safety equipment. You must comply with
all Danger, Warning, and Caution notices. They are for
your benefit.
2.2.3 Replacement Parts and Warranty
Information
For reference when ordering replacement parts or making
service inquiries about the vehicle, the vehicle serial
number is required to help assure the provision of correct
parts and information. Before ordering parts or initiating
service inquiries, make note of the serial number.
The vehicle serial number plate (1) is located on the front
of the main frame.
IMPORTANT: The replacement of any part on this
vehicle with any other than a JLG authorized
replacement part can adversely affect the performance,
durability, or safety of the vehicle, and will void the
warranty. JLG disclaims liability for any claims or
damages, whether regarding property damage, personal
injury or death arising out of the use of unauthorized
replacement parts.
A warranty registration form must be filled out by the Lull
distributor, signed by the purchaser, and returned to JLG
when the vehicle is sold and/or put into use.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed. To
guarantee full warranty service, verify that the Lull
distributor has returned the business reply card of the
warranty registration form to JLG.
2.2.4 Disclaimer
JLG reserves the right to make changes to and to add
improvements upon its product at any time, without public
notice or obligation. JLG also reserves the right to
discontinue manufacturing any product at its discretion at
any time.
OU0220
1

2.5
Model 644E-42/944E-42 Rev. 6/04
General Information, Specifications and Maintenance
2.3 TORQUES
2.3.1 SAE Flat Face O-Ring Seal
Hydraulic Fittings
a. Assembly Procedure
Improper assembly of this type of joint will result in
leaking joints. Under tightening will result in the joint
loosening during normal usage. Foreign material on
either seal surfaces will cause damage to one or both
mating parts when the joint is tightened resulting in a
leaking joint. The absences of the fitting o-ring will cause
the joint to leak.
1. Inspect both the male (2) and female (3) sealing
surfaces for burrs, scratches, dents, other damage,
or foreign material. If any damage is found on either
surface, the part is to be rejected as unusable. Clean
off any foreign material from the sealing surfaces
before assembly.
2. Inspect the male fitting for the presence of the seal
o-ring (4). Inspect the o-ring for any sign of damage.
If the o-ring is missing or damaged replace it.
3. Apply clean petroleum based oil to the male thread.
4. Place the flat surface of the female connector (2) in
full contact with the o-ring (4) in the male connector.
5. Finger tighten the nut (5) onto the fitting.
6. Complete the joint by tightening the nut to the torque
specified in the table. For hoses and swivel fittings
use a second wrench to keep the female connector
from moving during tightening.
b. Straight O-Ring Boss Fittings To
O-Ring Boss Ports
Improper assembly of this joint will result in leaking joints.
Under tightening of the fitting will result in the fitting
loosening during normal operation and the joint leaking.
Damaging the o-ring during assembly will result in
immediate joint leakage.
1. Inspect components to ensure that male and female
port threads and sealing surfaces are free of burrs,
nicks, or scratches, or any foreign material. If any
damage is found the malfunctioning part must not be
used. Clean any foreign material from the mating
parts before assembly.
2. Lubricate the o-ring and male thread with a clean
petroleum based lubricant.
3. Screw the fitting into the port.
4. Torque the fitting to the values found in table.
O-Ring Boss Fittings To
O-Ring Boss Ports
SAE Size Torque lb-ft (Nm)
4 19 ± 5 (26 ± 7)
6 35 ± 5 (47 ± 7)
8 52 ± 7 (70 ± 10)
10 83 ± 17 (112 ± 23)
12 120 ± 20 (163 ± 27)
16 165± 35 (224 ± 47)
20 215 ± 65 (292 ± 88)
24 252 ± 77 (342 ± 104)
O-Ring Boss Fittings To
O-Ring Boss Ports
SAE Size Torque lb-ft (Nm)
4 15 ± 1 (20 ± 1)
6 25 ± 1 (34 ± 1)
8 55 ± 5 (75 ± 7)
10 76 ± 5 (103 ± 7)
12 130 ± 5 (176 ± 7)
16 210± 10 (285 ± 14)
20 245 ± 35 (332 ± 47)
24 315 ± 45 (427 ± 61)
2
MA10,0800
3
4
5

General Information, Specifications and Maintenance
2.6 Model 644E-42/944E-42 Rev. 6/04
c. Adjustable (Angle) O-Ring Boss Fittings To
O-Ring Boss Ports
Improper assembly of this joint will result in a leaking joint.
Failure to position the locknut properly will result in
damage to the o-ring. Under tightening of the fitting will
result in the fitting loosening during normal operation and
the joint leaking. Damaging the o-ring during assembly
will result in immediate joint leakage.
1. Inspect components to ensure that male and female
port threads and sealing surfaces are free of burrs,
nicks, or scratches, or any foreign material. If any
damage is found the malfunctioning part must not be
used. Clean any foreign material from the mating
parts before assembly.
2. Back off the locknut as far as possible (1). Make sure
the back-up washer is not loose. If the back-up
washer is loose the fitting must be rejected.
3. Lubricate the o-ring (2) and male thread with clean
petroleum based lubricant.
4. Screw the fitting into the port as far as possible by
hand (B & C).
5. To align the tube end (3) of the fitting to accept the
mating tube or hose, unscrew the fitting as required
but not more than one turn.
6. Using two wrenches, hold the fitting in the desired
position and tighten the locknut (4) to the appropriate
torque value listed in the table in Section 2.3.1, b.
“Straight O-Ring Boss Fittings To
O-Ring Boss Ports.”
d. Pipe Fittings to Pipe Ports
Improper assembly of this joint will result in a leaking joint
and possible damage to the port.
1. Inspect the port and fitting to insure that there are no
burrs, nicks, or foreign material. If any thread
damage is found the part must not be used. Clean
off any foreign material.
2. Apply sealant/lubricant to male pipe thread. If Teflon
tape is used it should be wrapped 1.5 to 2 turns in a
clockwise direction when viewed from the pipe
thread end. With any sealant the first 1 to 2 threads
should be left uncovered to avoid system
contamination.
3. Screw the connector into the port finger tight.
4. Wrench tighten the fitting to the appropriate Turns
From Finger Tight (TFFT) from Table 4. Make sure
that angle fittings are aligned with the mating tube or
hose within the listed number of turns. Never back
off (loosen) pipe thread connectors to achieve
alignment.
A
B
C
D
MA10,0820
1
2
3
4
Pipe Fittings To Pipe Ports
Pipe Thread Size Turns From Finger Tight
(T.F.F.T
1/8" 2 - 3
1/4" 2 - 3
3/8" 2 - 3
1/2" 2 - 3
3/4" 2 - 3
1" 1-1/2 - 2-1/2
1-1/4" 1-1/2 - 2-1/2
1-1/2" 1-1/2 - 2-1/2
2" 1-1/2 - 2-1/2