Many
Manuals
search
Categories
Brands
Home
Lull
Special machinery
944E-42 Service Manual
User Manual
Lull 944E-42 Service Manual User Manual Page 427
Download
Share
Sharing
Add to my manuals
Print
Page
/
846
Table of contents
TROUBLESHOOTING
BOOKMARKS
Rated
.
/ 5. Based on
customer reviews
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
842
843
844
845
846
8.175
Model
644E-42/944E-42
Rev
.
6/04
Hydraulic System
This P
age Intentionall
y Left Blank
1
2
...
422
423
424
425
426
427
428
429
430
431
432
...
845
846
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
Comments to this Manuals
No comments
Publish
Related products and manuals for Special machinery Lull 944E-42 Service Manual
Special machinery Lull 944E-42 Service Manual User Manual
(266 pages)
Print document
Print page 427
Comments to this Manuals