Lull 944E-42 Service Manual User Manual Page 254
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Hydraulic System
8.2
Model 644E-42/944E-42 Rev. 6/04
8.8.12 Boom Retract Circuit & Troubleshooting (Dual Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.78
8.8.13 Boom Retract Circuit & Troubleshooting (Single Joystick). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.80
8.8.14 Boom Lift Circuit & Troubleshooting (Dual Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.82
8.8.15 Boom Lift Circuit & Troubleshooting (Single Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.84
8.8.16 Boom Lower Circuit & Troubleshooting (Dual Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.86
8.8.17 Boom Lower Circuit & Troubleshooting (Single Joystick). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.88
8.8.18 Frame Sway (Left), Stabilizer Circuit & Troubleshooting (SN 18460 and Before) . . . . . . . . . . . 8.90
8.8.19 Frame Sway (Left), Stabilizer Circuit & Troubleshooting (SN 18461 and After) . . . . . . . . . . . . . 8.92
8.8.20 Frame Sway (Right), Stabilizer Circuit & Troubleshooting ( SN 18460 and Before). . . . . . . . . . 8.94
8.8.21 Frame Sway (Right), Stabilizer Circuit & Troubleshooting (SN 18461 and After). . . . . . . . . . . . 8.96
8.8.22 Attachment Tilt (Down), Slave Cylinder Circuit & Troubleshooting (Dual Joystick) . . . . . . . . . . 8.98
8.8.23 Attachment Tilt (Down), Slave Cylinder Circuit & Troubleshooting (Single Joystick) . . . . . . . . . 8.100
8.8.24 Attachment Tilt (Up), Slave Cylinder Circuit & Troubleshooting (Dual Joystick). . . . . . . . . . . . . 8.102
8.8.25 Attachment Tilt (Up), Slave Cylinder Circuit & Troubleshooting (Single Joystick) . . . . . . . . . . . 8.104
8.8.26 Transfer Carriage Cylinder Extend (Carriage Back) Circuit & Troubleshooting (Dual Joystick) . 8.106
8.8.27 Transfer Carriage Cylinder Extend (Carriage Back) Circuit & Troubleshooting (Single Joystick) 8.108
8.8.28 Transfer Carriage Cylinder Retract (Carriage Fwd) Circuit & Troubleshooting (Dual Joystick) . 8.110
8.8.29 Transfer Carriage Cylinder Retract (Carriage Fwd) Circuit & Troubleshooting (Single Joystick) 8.112
8.8.30 Front-Wheel Steering Circuit (Left Turn) & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.114
8.8.31 Front-Wheel Steering Circuit (Right Turn) & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 8.116
8.8.32 Four-Wheel Steering Circuit (Left Turn) & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.118
8.8.33 Four-Wheel Steering Circuit (Right Turn) & Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.120
8.8.34 Crab Steering Circuit (Left Turn) & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.122
8.8.35 Crab Steering Circuit (Right Turn) & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.124
8.8.36 Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Dual Joystick)
(644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108)
(944E-42, SN 20123 & Before, SN 0160002514 thru 0160003106) . . . . . . . . . . . . . . . . . . . . . 8.126
8.8.37 Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Dual Joystick)
(644E-42, SN 0160003109 & After) (944E-42, SN 0160003107 & After) . . . . . . . . . . . . . . . . . 8.128
8.8.38 Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Single Joystick)
(644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108)
(944E-42, SN 20123 & Before, SN 0160002514 thru 0160003106) . . . . . . . . . . . . . . . . . . . . . 8.130
8.8.39 Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Single Joystick)
(644E-42, SN 0160003109 & After) (944E-42, SN 0160003107 & After) . . . . . . . . . . . . . . . . . 8.132
8.8.40 Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Dual Joystick)
(644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108)
(944E-42, SN 20123 & Before, SN 0160002514 thru 0160003106) . . . . . . . . . . . . . . . . . . . . . 8.134
8.8.41 Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Dual Joystick)
(644E-42, SN 0160003109 & After) (944E-42, SN 0160003107 & After) . . . . . . . . . . . . . . . . . 8.136
8.8.42 Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Single Joystick)
(644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108)
(944E-42, SN 20123 & Before, SN 0160002514 thru 0160003106) . . . . . . . . . . . . . . . . . . . . . 8.138
8.8.43 Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Single Joystick)
(644E-42, SN 0160003109 & After) (944E-42, SN 0160003107 & After) . . . . . . . . . . . . . . . . . 8.140
8.8.44 Auxiliary Hydraulic Pressure Release Circuit & Troubleshooting (Dual Joystick)
(644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108)
(944E-42, SN 20123 & Before, SN 0160002514 thru 0160003106) . . . . . . . . . . . . . . . . . . . . . 8.142
8.8.45 Auxiliary Hydraulic Pressure Release Circuit & Troubleshooting (Single Joystick)
(644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108)
(944E-42, SN 20123 & Before, SN 0160002514 thru 0160003106) . . . . . . . . . . . . . . . . . . . . . 8.144
8.8.46 Pump and Cooling Circuit Description (Dual Joystick). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.146
8.8.47 Pump and Cooling Circuit Description (Single Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.146
- Service Manual 1
- EFFECTIVITY PAGE 3
- SECTION CONTENTS 5
- Section Subject Page 6
- Section 1 9
- 1.1 INTRODUCTION 10
- 1.2 OWNERS/OPERATORS MANUAL 10
- 1.3 TRAINING MECHANICS AS 11
- OPERATORS 11
- 1.4 SAFETY INFORMATION 11
- DANGER: 12
- WARNING: 12
- CAUTION: 12
- 1.6 SAFETY INSTRUCTIONS 13
- Safety Practices 14
- 1.6.3 General Hazards 14
- 1.6.4 Operational Hazards 14
- 1.8 HAZARD/EMERGENCY 15
- INFORMATION SIGNS 15
- (717)-485-6472 15
- Section 2 17
- TERMINOLOGY 19
- 2.2 INTRODUCTION 20
- to the torque 21
- MA10,0820 22
- 2.4 METRIC CONVERSION FACTORS 23
- 2.5 SPECIFICATIONS 26
- 2.5.4 Attachment Weights 29
- ° and Emergency Brake Engaged 30
- 2.5.7 Electrical System 31
- 2.5.11 Hydraulic System 36
- 2.5.12 Tires 37
- XXXX - 24 38
- 2.6 FLUIDS, LUBRICANTS AND 39
- CAPACITIES 39
- 2.6.4 Hydraulic System 40
- 2.6.5 Engine 40
- 2.6.6 Transmission 41
- 2.6.7 Transfer Case 41
- 2.6.8 Drive Shaft Splines 42
- 2.6.9 General Anti-Corrosion 42
- 2.7 CLEANING 43
- 2.8 REPLACEMENT 44
- 2.9 HOSES AND TUBES 44
- 2.10 BEARINGS 45
- 2.11 PRESSURE TESTING AND 45
- ADJUSTMENT 45
- Section 3 49
- 3.1 BOOM SYSTEM COMPONENT 50
- 3.2 BOOM SYSTEM 51
- 3.3 BOOM ASSEMBLY MAINTENANCE 51
- 3.3.1 Inner Boom Replacement 52
- 3.3.3 Outer Boom Replacement 70
- 3.4 BOOM CHAINS 76
- 3.4.2 Chain Lubrication 83
- Removal and Replacement 87
- 3.5 BOOM WEAR PADS 92
- 3.6 QUICK ATTACH ASSEMBLY 95
- 3.7 TROUBLESHOOTING 99
- Section 4 105
- Cab and Covers 105
- COMPONENT TERMINOLOGY 106
- 4.2 OPERATOR’S CAB 107
- 4.3 OPEN CAB COMPONENTS 108
- Select Lever 109
- Replacement 111
- 4.3.4 Steer Select Valve 113
- (944E-42 Only) 120
- Assembly Replacement 122
- Replacement (Optional) 124
- 4.3.10 Electrical Components 125
- 4.4 ENCLOSED CAB (OPTIONAL) 128
- COMPONENTS 128
- 4.5 CAB REMOVAL 132
- 4.6 CAB INSTALLATION 135
- 4.7 VALVE PLATE 138
- 4.8 ACCESS PANELS AND COVERS 140
- 4.8.2 Engine Hood 142
- Section 5 147
- 5.2 GENERAL INFORMATION 149
- 5.3 AXLE ASSEMBLIES 149
- 5.3.4 Axle Specifications 150
- 5.3.5 Axle Maintenance 150
- 5.3.6 Axle Replacement 151
- Troubleshooting 161
- 5.4 DRIVE SHAFTS 162
- 5.5 WHEELS AND TIRES 165
- WARNING: Damaged, modified 167
- Onto Vehicle 168
- WARNING: BLOCK ALL FOUR 172
- Section 6 177
- 6.1 TRANSMISSION ASSEMBLY 178
- 6.2 TRANSMISSION DESCRIPTION 179
- 6.3 TRANSMISSION OPERATION 179
- 6.6 TRANSMISSION MAINTENANCE 180
- 6.7 TRANSMISSION REPLACEMENT 182
- MU1890MU1890 184
- 6.8 TROUBLESHOOTING 191
- Problem Cause Remedy 191
- 6.9 TOWING A DISABLED VEHICLE 194
- 6.10 TRANSFER CASE COMPONENT 195
- 6.11 GENERAL INFORMATION 196
- 6.12 TRANSFER CASE 196
- 6.12.5 Further Information 197
- 6.12.6 Technical Data 197
- 6.12.9 Transfer Case Removal 198
- 6.13 TROUBLESHOOTING 200
- Section 7 203
- 7.1 INTRODUCTION 205
- 7.1.2 Component Terminology 206
- 7.2 SAFETY INFORMATION 207
- 7.3 ENGINE SERIAL NUMBER 209
- 7.4 SPECIFICATIONS AND 209
- MAINTENANCE INFORMATION 209
- 7.5 STANDARD PRACTICES 209
- 7.6 ENGINE COOLING SYSTEM 210
- (60,4 mm) 221
- 7.7 ENGINE ELECTRICAL SYSTEM 225
- 7.8 FUEL SYSTEM 225
- 7.8.1 Diesel Fuel 226
- 7.8.2 Fuel Tank 226
- 7.8.4 Fuel Lift Pump Testing 228
- 7.8.5 Fuel Filter Replacement 229
- 7.8.7 Fuel Injectors 230
- 7.9 ENGINE EXHAUST SYSTEM 232
- 7.10 ENGINE REPLACEMENT 234
- 7.10.3 Engine Installation 243
- 7.11 ENGINE STORAGE 251
- 7.12 TROUBLESHOOTING 252
- Section 8 253
- Hydraulic System 253
- 8.1 HYDRAULIC COMPONENT 257
- 8.2 SAFETY INFORMATION 258
- 8.3 SPECIFICATIONS 259
- 8.4 HYDRAULIC FLUID 259
- 8.7 HYDRAULIC SYSTEM TESTING 264
- Hydraulic Pump Flow Test 265
- 8.7.3 Hydraulic Testing 272
- 8.7.5 Hydraulic Testing 280
- 8.7.8 Hydraulic Testing 292
- 8.7.10 Hydraulic Testing 300
- 8.8 HYDRAULIC CIRCUITS AND 307
- TROUBLESHOOTING 307
- (Dual Joystick) 358
- (Single Joystick) 360
- Description (Dual Joystick) 400
- Description (Single Joystick 406
- Description (Single Joystick) 413
- 8.9 STEER INDEXING PROCEDURES 415
- 8.10 HYDRAULIC RESERVOIR 416
- 8.11 HYDRAULIC SYSTEM PUMP 417
- 8.11.1 Pump Failure Analysis 418
- 8.11.2 Pump Replacement 418
- 8.12 VALVES AND MANIFOLDS 428
- 8.12.2 Main Control Valve 429
- Valve (Early Production) 444
- 8.12.10 Service Brake Valve 450
- 8.12.11 Power Steering Valve 453
- 8.12.12 Steer Select Valve 454
- Function Valve 456
- 8.13 ACCUMULATORS 458
- 8.13.1 General Information 459
- 8.13.3 Checking Pre-Charge 461
- 8.14 HYDRAULIC CYLINDERS 464
- 8.14.5 Slave Cylinders 469
- 8.14.7 Lift/Lower Cylinder 477
- 8.14.8 Frame Sway Cylinder 482
- 8.14.9 Stabilizer Cylinder 487
- 8.14.10 Steering Cylinders 491
- Section 9 511
- Electrical System 511
- 9.1 ELECTRICAL COMPONENT 515
- 9.1.2 General Overview 516
- 9.2 SERVICE WARNINGS 528
- 9.3 SPECIFICATIONS 528
- 9.5 GROUNDING STRAPS 529
- 9.6 WIRING HARNESSES 529
- 9.7 FUSES AND RELAYS 531
- 9.8 ELECTRICAL SYSTEM 537
- Multimeter (DMM) 539
- SN 19041 558
- & BEFORE 558
- Brake Relay on early 580
- See page 9.48 580
- TAILLIGHT 642
- 9.11 ENGINE START CIRCUIT 673
- 9.11.2 Starter 674
- 9.12 CHARGING CIRCUIT 677
- 9.12.1 Alternator 679
- 9.12.2 Battery or Batteries 681
- 9.13 ELECTRICAL SYSTEM 686
- 9.13.2 Front Dash Panel 691
- 9.13.8 Skylight Wiper Motor 708
- 9.14 SWITCHES AND SOLENOIDS 719
- 9.14.6 Parking Brake Switch 730
- 9.14.10 Dual Joystick 737
- 9.14.16 Engine Block Heater 751
- Level Sender 752
- RPM X 100 754
- Section 10 759
- Stabil-TRAK™ System 759
- 10.1 STABIL-TRAK™ SYSTEM 762
- 10.2 STABIL-TRAK™ DESCRIPTION 763
- 10.3 STABIL-TRAK™ OPERATION 764
- 10.3.3 Relay Testing 766
- BATTERY 1 769
- SN 0160002514 thru 0160003881 770
- Locked Mode, Frame Sway Right 798
- Locked Mode, Frame Sway Left 800
- Section 11 803
- Transfer Carriage 803
- 11.2 TRANSFER CARRIAGE 805
- 11.3 TRANSFER CARRIAGE 805
- MAINTENANCE 805
- 11.3.3 Rear Wear Pad Check 815
- 11.3.4 Rear Wear Pad Shimming 815
- 11.3.10 Rear Roller Gap Check 818
- 11.3.11 Rear Roller Shimming 819
- 11.3.13 Front Roller Shimming 822
- 11.4 TROUBLESHOOTING 832
- Section 12 835
- 8990403 Origin 5/00 843
- Accident Prevention Tags 843
- JLG Worldwide Locations 846
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