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Lull 944E-42 Service Manual

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Service Manual
Model
944E-42
S/N 0160041827 & After
31200355
Original
December 31, 2011
An Oshkosh Corporation Company

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  • Page 1 Service Manual Model 944E-42 S/N 0160041827 & After 31200355 Original December 31, 2011 An Oshkosh Corporation Company...
  • Page 3 EFFECTIVITY PAGE December 31, 2011 - A - Original Issue 31200355 944E-42...
  • Page 4 EFFECTIVITY PAGE 944E-42 31200355...

  • Page 5: Table Of Contents

    Valve Plate ............4.12 944E-42...
  • Page 6 Hydraulic Cylinders ........... . 8.38 944E-42...
  • Page 7 Troubleshooting ............11.22 944E-42...
  • Page 8 Section Subject Page 944E-42...
  • Page 9 Safety Decals ............944E-42...

  • Page 10: Safety Practices

    An Operation & Safety Manual is supplied with each machine and must be kept in the manual holder located in the cab. In the event that the Operation & Safety Manual is missing, consult the local distributor before proceeding. 944E-42...

  • Page 11: Safety Instructions

    Always support equipment with the proper capacity blocks or stands properly rated for the load. 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. 944E-42...

  • Page 12: Safety Decals

    NEVER drain or store fluids in an open container. Engine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion. DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion. 944E-42...
  • Page 13 Lubrication Schedules ..........2-18 944E-42...

  • Page 14: Replacement Parts And Warranty Information

    Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to JLG. 944E-42...

  • Page 15: Torque Charts

    2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND ND Industries P/N JLG P/N Loctite® P/N Description 0100011 Vibra-TITE Medium Strength (Blue) 0100019 Vibra-TITE High Strength (Red) 0100071 Vibra-TITE Medium - High Strength (Red) MY4650J 944E-42...
  • Page 16 4835 3200 4350 2665 3625 NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER MY4660J 944E-42...

  • Page 17: Sae Fastener Torque Chart

    *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4670J 944E-42...
  • Page 18 *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4680J 944E-42...
  • Page 19 *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4690J 944E-42...
  • Page 20 *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, MY4700J ADDITIONAL TESTING IS REQUIRED. 944E-42...
  • Page 21 *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4710J 944E-42...
  • Page 22 4. Torque wrench must be held at the center of the grip. Apply constant force until it clicks. 5. After the connection has been properly tightened, mark a straight line across the connecting parts indicating that the connection has been properly tightened. 2-10 944E-42...

  • Page 23: Specifications

    (boom retracted, raised above 40 and emergency brake engaged) 2.3.3 Electrical System Battery Type, Rating 12 VDC, Negative (-) Ground, Maintenance Free Quantity Reserve Capacity 850 Cold Cranking Amps @ 0° F (-18° C) Group/Series Group 27 Alternator 12V, 100 Amps 944E-42 2-11...

  • Page 24: Engine Performance Specifications

    798 lb (362 kg) Pneumatic 65 psi (4,5 bar) 15.50 x 25 G-3/L-3 Bias-Ply Rock 12 Ply Foam 798 lb (362 kg) Pneumatic 76 psi (5,2 bar) 370/75x28 DuraForce 14 Ply Foam-Approx 464 lb 73 psi (5,0 bar) (210 kg) 2-12 944E-42...

  • Page 25: Fluid And Lubricant Capacities

    Axles Differential Housing Capacity Front 12.7 quarts (12,0 liters) Rear 12.5 quarts (11,8 liters) Wheel End Capacity Front 2.1 quarts (2,0 liters) Rear 2.2 quarts (2,1 liters) ® Type of Fluid Mobilfluid 424 Tractor Hydraulic Fluid (ISO 46) 944E-42 2-13...
  • Page 26 General Information and Specifications Air Conditioning System (if equipped) System Capacity 2.5 lb (1134 g) Type of Fluid Refrigerant R-134a - Tetrafluorethane Window Washer Bottle Capacity 2.1 quart (2 liters) 2-14 944E-42...

  • Page 27: Service And Maintenance Schedules

    General Information and Specifications SERVICE AND MAINTENANCE SCHEDULES 2.5.1 10 & 50 Hour 944E-42 2-15...

  • Page 28: 1St 100, 250 & 1St 500 Hour

    General Information and Specifications 2.5.2 1st 100, 250 & 1st 500 Hour 2-16 944E-42...

  • Page 29: 500, 1000 & 2000 Hour

    General Information and Specifications 2.5.3 500, 1000 & 2000 Hour 1000 2000 944E-42 2-17...

  • Page 30: Lubrication Schedules

    General Information and Specifications LUBRICATION SCHEDULES a. 50 Hour 2-18 944E-42...
  • Page 31 Hydraulic Hose Replacement - Step 1 ......3-28 3.9.5 Hydraulic Hose Replacement - Step 2 ......3-29 944E-42...

  • Page 32: Boom System Component Terminology

    RETRACT BOOM ANGLE BOOM EXTEND FIRST BOOM INDICATOR CHAINS SECTION THIRD BOOM SECTION BOOM PIVOT PIN BOOM RETRACT AUXILIARY CHAIN HYDRAULIC SECOND BOOM COUPLERS ATTACHMENT SECTION TILT HYDRAULIC TUBES ATTACHMENT TILT CYLINDER BOOM PROXIMITY SENSOR QUICK ATTACH SLAVE CYLINDERS 944E-42...

  • Page 33: Boom System

    Read, understand and follow these instructions. WARNING NEVER weld or drill the boom unless approved in writing by the manufacturer. The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling. 944E-42...
  • Page 34 12. Label, disconnect and cap the hydraulic hoses (4) attached to the Extend/Retract cylinder. Plug all fittings to keep dirt & debris from entering the hydraulic system. 15. Remove the tie wraps from the two hose guards (6) and remove the hose guards from the cylinder hoses. 944E-42...
  • Page 35 20. Completely remove the Extend/Retract cylinder. Readjust the position of the sling as needed to help balance the cylinder during withdraw. When the cylinder is clear of the machine, carefully lower it to the ground. 944E-42...
  • Page 36 (10), shims and hardware. Label all parts for installation. 28. Inspect all wear pads for wear. Refer to Section 3.5, “Boom Wear Pads.” 29. At the rear of the third boom section, disconnect the retract chain (11) from the anchor link (12). 944E-42...

  • Page 37: Second Boom Section Removal

    Set the second boom section down on blocks on a hard, level surface. 5. Remove the remaining wear pads. Label all parts for installation. 8. Remove the chain sheave (17). 6. Inspect all wear pads for wear. Refer to Section 3.5, “Boom Wear Pads.” 944E-42...
  • Page 38 5. Remove the boom proximity sensor (2) from the 3. Remove all clamps (1) securing the hydraulic tubes boom. and rear hydraulic hoses to the boom and frame. Label and remove the tubes. Cap all hose ends. 944E-42...
  • Page 39 8. Working on the top of each slave cylinder, remove the cylinder mount pin (4). Lower each cylinder against the transfer carriage. DO NOT stretch or damage the hydraulic hoses. 944E-42...

  • Page 40: First Boom Section Installation

    Torque clamp capscrews to 4-8 lb-ft (6-11 Nm). 9. Install new o-rings into the fittings. Lubricate o-rings with clean hydraulic oil. 10. Uncap and connect the previously labeled hydraulic fittings to their appropriate locations. 3-10 944E-42...

  • Page 41: Second Boom Section Installation

    1. Install the hose guide (9) to its original orientation. Secure in place with the previously used hardware. ® Loctite 242™ all capscrews. Torque the middle capscrews to 10-19 lb-ft (14-26 Nm) and torque the rear capscrews to 21-38 lb-ft (29-52 Nm). 944E-42 3-11...
  • Page 42 Readjust the sling as needed to help balance the 5. Grease the sections of the boom in areas where the cylinder in the sling during installation. wear pads will slide. 3-12 944E-42...
  • Page 43 Loctite 242™ and torque all capscrews to 21-38 lb-ft (29-52 Nm). 15. Remove the sling and hoist. 16. Attach a suitable overhead lifting device and sling to the lifting eye of the attachment tilt cylinder. 944E-42 3-13...

  • Page 44: Boom Extend And Retract Chains

    32. Close and secure the engine cover. connections between the chain components. Cracking can be (and often is) microscopic. Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time. 3-14 944E-42...

  • Page 45: Inspection Guidelines

    5. Inspect the retract chains every 1000 hours of operation. 6. Inspect the chains for the following conditions: MY1360 If the distance measured (3) is 3% greater than the normal length (4), discard and replace the chain. 944E-42 3-15...
  • Page 46 If the problem is caused by dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re-installing the chain. If the problem is caused by corrosion and rust or bent pins, replace the chain. 3-16 944E-42...

  • Page 47: Expose Chains For Inspection

    3. Slowly, fully extend the boom and retract it about halfway. Fully extend the boom, then retract it 2 in (51 mm) (one inch per section). Turn the engine OFF. 944E-42 3-17...

  • Page 48: Boom Chain Tension Adjustment

    4. If the chain sag measurement is less than 3.0 in (76 mm), the retract chain adjustment nut needs to be tightened. If the chain sag measurement is more than 4.0 in (102 mm), the retract chain adjustment nut needs to be loosened. 3-18 944E-42...
  • Page 49 8.5 in (216 mm) and service distributor. 9.5 in (241 mm). 5. Install the rear boom cover. 6. If the third to second boom separation distance cannot be achieved, contact your local authorized service distributor. 944E-42 3-19...

  • Page 50: Extend Chains Removal And Replacement

    Lay the chain assembly flat machine should not be operated. against the third boom section. 3. Properly disconnect the battery. 4. Remove the boom rear cover. 3-20 944E-42...
  • Page 51 17. Check and adjust retract chain tension. Refer to Section 3.4.5, “Boom Chain Tension Check.” 18. Install the boom rear cover. 19. Properly connect the battery. 944E-42 3-21...

  • Page 52: Boom Wear Pads

    20. Clean and lightly grease the hose carrier guide bar • The number of shims can vary at each shim point. pathways with Mystik Tetrimoly grease. • The bottom wear pads must be shimmed equally on each side. 3-22 944E-42...

  • Page 53: Quick Attach Assembly

    3. Align the quick attach with the tilt cylinder rod end Maximum difference in height of fork tips is 3 percent of the length of the blade (10). and insert the tilt cylinder pin. Align the tilt cylinder pin and screw in the locking bolt. Torque as required. 944E-42 3-23...

  • Page 54: Troubleshooting

    4. Excessive Compensation 1. Insufficient lubrication. 1. Lubricate at regular intervals. cylinder pivot pin noise and/ Refer to Section 2.6, or wear. “Lubrication Schedules.” Replace worn pins as needed. 2. Worn bushing(s). 2. Replace bushing(s) and lubricate at regular intervals. 3-24 944E-42...
  • Page 55 Refer to Section 2.5, “Service and Maintenance Schedules.” Replace worn pins as needed. Refer to Section 8.7.17, “Accumulator Charge Troubleshooting.” 2. Worn self-aligning bushing(s). 2. Replace bushing(s) and lubricate at regular intervals. Refer to Section 2.6, “Lubrication Schedules.” 944E-42 3-25...
  • Page 56 3. Lubricate chain sheave. Refer to freely. Section 2.5, “Service and Maintenance Schedules.” Repair or replace chain sheave(s) as needed. 4. Improper chain lubrication. 4. Lubricate at regular intervals. Refer to Section 2.5, “Service and Maintenance Schedules.” Replace chains as needed. 3-26 944E-42...

  • Page 57: Emergency Boom Lowering

    Authorized distributor for specific instructions on your particular situation. Note: For boom retract and lower, the hydraulic lines MUST be replaced, then retracted and lower the boom in it’s normal fashion. 944E-42 3-27...

  • Page 58: Hydraulic Hose Replacement - Step 1

    16. Recheck hydraulic oil level. Add oil if necessary. • Boom Extend line - Extend Cylinder to Block (1) • Boom Retract Line - Extend Cylinder to Block (2) • Boom Extend line - Block to Frame Bulkhead (3) 3-28 944E-42...

  • Page 59: Hydraulic Hose Replacement - Step 2

    12. Cycle the lift/lower and extend/retract cylinders several times to bleed air from the system. Check for leaks. 13. Recheck hydraulic oil level. Add oil if necessary. 14. Transfer any waste oil to a properly labeled container and dispose of accordingly. 944E-42 3-29...
  • Page 60 Boom This Page Intentionally Left Blank 3-30 944E-42...
  • Page 61 Valve Plate Installation ........4-12 944E-42...

  • Page 62: Operator's Cab And Covers Component Terminology

    OPERATOR’S CAB HOOD MIRROR OPTIONAL SINGLE JOYSTICK STEERING WHEEL ATTACHMENT TILT & TRANSFER CARRIAGE JOYSTICK AND AUXILIARY HYDRAULIC BUTTON BOOM LIFT/LOWER, EXTEND/RETRACT TRANSMISSION JOYSTICK CONTROL LEVER FRAME SWAY JOYSTICK SERVICE BRAKE PEDAL SEAT ACCELERATOR PEDAL 944E-42...

  • Page 63: Operator's Cab

    2. Place a Do Not Operate Tag on both the ignition key sense hose on the left of the steering valve. Cap the switch and the steering wheel, stating that the fitting on the steering valve. machine should not be operated. 944E-42...

  • Page 64: Service Brake Valve And Pedal

    11. Start the engine and check the operation of steering system. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required. 12. Install the lower dash panels. 13. Close and secure the engine cover. 944E-42...

  • Page 65: Throttle Pedal

    2. Secure the throttle pedal in place with previously used hardware. 3. Reconnect the wire harness plug to the front of the throttle pedal. 4. Attach the return spring to the throttle pedal. 5. Properly connect the batteries. 944E-42...

  • Page 66: Throttle Position Sensor Replacement

    6. Slide the sensor (2) and linkage assembly out of the ohms, with the throttle at rest and change to slot on the mounting plate. approximately 4,000 ohms, with the throttle pedal fully depressed. 2. Replace the sensor if the readings are not as described in step 1. 944E-42...

  • Page 67: Joystick Assemblies

    5. Install the access panel. 6. Properly connect the batteries. 7. Test all joystick functions for proper performance. 4. Remove the access (1) and console panel (2) in the cab. Note: Record the location, and label all hydraulic hoses to ensure correct installation. 944E-42...

  • Page 68: Enclosed Cab (Optional) Components

    10. Remove the right side console access panel (7). 3. Open the engine cover. Allow the system fluids to 11. Disconnect the heater wire from the cab harness. cool. 12. Label and remove all duct hoses at the heater 4. Properly disconnect the batteries. assembly. 944E-42...

  • Page 69: Cab Removal

    3. Open the engine cover. Allow the system fluids to 8. Install the right side console access panel. cool. 9. Refill the cooling system. Refer to Section 2.4, “Fluid 4. Properly disconnect the batteries. and Lubricant Capacities.” 10. Properly connect the batteries. 944E-42...
  • Page 70 12. Remove the mirror from the left side of the cab. 7. Disconnect the supply and return fuel lines (4) at the fuel tank (5). 8. Disconnect the electrical connection (6) to the fuel level sending unit. 4-10 944E-42...

  • Page 71: Cab Installation

    4. Attach a suitable overhead lifting device to the top of 18. Wait for the engine to cool and check the coolant the cab. level. Add coolant to the overflow bottle as required to bring the coolant to the proper level. 944E-42 4-11...

  • Page 72: Valve Plate

    8. Disconnect the two tethers (3) from the cab into position under the cab. mounting frame. 7. Replace the four capscrews and washers securing the cab step. Torque the capscrews to 43 - 78 lb-ft (59 - 106 Nm). 8. Properly disconnect the batteries. 4-12 944E-42...
  • Page 73 Towing a Disabled Machine ......... . 5-13 944E-42...

  • Page 74: Axles, Drive Shafts, Wheels And Tires

    The following illustration identifies the components that are referred to throughout this section. STABILIZER CYLINDER FRAME SWAY CYLINDER SUPPORT TRUNNIONS REAR STEERING CYLINDER FRONT STEER ING CYLINDER REAR DRIVE REAR AXLE SHAFT ASSEMBLY FRONT DRIVE SHAFT FRONT AXLE ASSEMBLY SUPPORT TRUNNIONS 944E-42...

  • Page 75: General Information

    General axle specifications are found in Section 2.4, reassembly. If replacement of a damaged bearing cup or “Fluid and Lubricant Capacities.” cone is necessary, replace the cup and cone as a set. 944E-42...

  • Page 76: Axle Replacement

    (2) to the cylinder. as “Used Oil.” Dispose of used oil at an approved Tap the cylinder mount pin out, and move the recycling facility. cylinder to prevent it from interfering with axle removal. 944E-42...

  • Page 77: Axle Installation

    13. Remove the blocks from the front and rear of both tires on the other axle. Note: ALWAYS use new o-rings when servicing the machine. 14. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil. 944E-42...
  • Page 78 Check for hydraulic leaks, and tighten or repair as necessary. Note: The service brake circuit will need to bled after axle installation. Refer to Section 8.7.10, “Brake Test.” 18. Close and secure the engine cover. 944E-42...

  • Page 79: Axle Assembly And Drive Shaft Troubleshooting

    1. Drive shaft universal joint 1. Tighten capscrews to correct when traveling. assembly(ies) incorrectly torque. tightened. 2. Drive shaft universal joint(s) 2. Repair or replace universal worn or damaged. joints as needed. 3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as unbalanced. needed. 944E-42...
  • Page 80 1. Hose fittings loose. 1. Tighten fittings. cylinder. 2. Steering cylinder o-rings and/or 2. Replace o-rings and seals. seals worn or damaged. 3. Piston rod seal worn or 3. Replace piston rod seal. damaged. 4. Cylinder tube damaged. 4. Replace cylinder tube. 944E-42...
  • Page 81 Refer to Section 2.4, “Fluid and reduced. Lubricant Capacities.” 2. Brake (hydraulic) system not 2. Refer to Section 8.4, “Hydraulic operating properly. Circuits.” 3. Brake piston o-rings and seals 3. Replace o-rings and seals. damaged (leaking). 944E-42...

  • Page 82: Drive Shafts

    5. Repeat the above procedure on the rear drive shaft. 6. Properly connect the battery. 7. Close and secure the engine cover. 8. Unblock the wheels. 9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 5-10 944E-42...

  • Page 83: Wheels And Tires

    7. Remove the wheel and tire assembly from the respective of the directional tread pattern of the tire; this machine. produces a left or right tire and wheel assembly. 944E-42 5-11...

  • Page 84: Brakes

    4. Tighten lug nuts in an alternating pattern as damage the brake seals. indicated in figure. Torque to 430-470 lb-ft (583-637 4. Pressurize the parking brake with the pressurizing Nm). unit. Close the needle valve on the pressurizing unit. 5. Remove machine from supports. 5-12 944E-42...

  • Page 85: Towing A Disabled Machine

    24 in (607 mm) above the ground. 9. Reassemble the level plugs using new o-rings. Refer to Section 3.9, “Emergency Boom Lowering,” if needed. 10. Install the axle fill plug into axle housing. 11. Remove the remote portable hydraulic pressurizing unit from the port. 944E-42 5-13...
  • Page 86 DO NOT exceed 650 psi (45 bar). Close the pump needle valve on the pressurizing unit. CAUTION DO NOT exceed 650 psi (45 bar) when pressurizing the park brake. Applying to much pressure may damage the brake seals. 5-14 944E-42...
  • Page 87 6-14 6.11.1 Transfer Case Troubleshooting ....... . . 6-14 944E-42...

  • Page 88: Transmission Assembly Component Terminology

    The following illustration identifies the components that are referred to throughout this section. THERMAL TORQUE BYPASS VALVE CONVERTER RADIATOR/OIL COOLER INLET (TRANSMISSION) HOSE OUTLET (TRANSMISSION) HOSE OIL FILTER DIPSTICK AND FILL TUBE OUTLET (COOLER) HOSE INLET (COOLER) MU7290 HOSE 944E-42...

  • Page 89: Transmission Serial Number

    Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other electrical components. 10. Working through the engine flywheel inspection and access hole (1), remove the four hex head capscrews (2) securing the converter diaphragm to 944E-42...
  • Page 90 Remove any slack prior to lifting, but DO NOT raise the transmission at this time. Connect another suitable lifting device to the lifting device on the flywheel end of the engine. Remove the slack, but do not lift the engine. 944E-42...

  • Page 91: Transmission Installation

    Torque to 106-191 lb-ft (14-259 Nm). 10. Line up the holes in the plate with the mounting holes in the transmission. Secure the mounting plate with six capscrews (13) and torque to 107-192 lb-ft (145-260 Nm). 944E-42...
  • Page 92 15. Uncap and connect the previously labeled 9. Recheck all drain plugs, lines, connections, etc., for transmission oil cooler inlet and out hoses at the leaks, and tighten where necessary. transmission. Torque all fittings as specified in Section 2.2, “Torque Charts.” 944E-42...

  • Page 93: Troubleshooting

    “Transmission Troubleshooting,” Problem 2. “Low or no pump flow or pressure.” 6. Clutch piston o-rings damaged. 6. Replace o-rings. 7. Clutch discs worn or damaged. 7. Replace clutch discs. 8. Coupling shafts or gear teeth 8. Replace couplings. damaged. 944E-42...
  • Page 94 Problem 2. “Low or no pump flow or pressure.” 4. Clutch discs worn or damaged. 4. Replace clutch discs. 5. Transmission overheating. 5. Refer to Section 6.5.1, “Transmission Troubleshooting,” Problem 5. “Transmission overheating (oil above 248° F (120° C)).” 944E-42...
  • Page 95 “Transmission Solenoid Valves.” 4. Internal damage. 4. Repair or replace parts as needed. 5. Broken diaphragm (flex plate). 5. Replace diaphragm (flex plate). Refer to Section 6.4.1, “Transmission Removal.” 6. Loose diaphragm (flex plate) 6. Tighten capscrews. mounting capscrews. 944E-42...
  • Page 96 7. Replace converter and/or input (possible converter leak and/or shaft seal. input shaft seal damage). 8. Oil leaking at output shaft 8. Replace output shaft seal. (output shaft seal damaged). 9. Housing damaged. 9. Replace housing as needed. 6-10 944E-42...

  • Page 97: Transfer Case Component Terminology

    The following illustration identifies the components that are referred to throughout this section. ENGINE SUPPORT STRUCTURE (REFERENCE) TRANSMISSION ASSEMBLY FRONT AXLE OUTPUT SHAFT TRANSFER CASE ASSEMBLY REAR AXLE OUTPUT SHAFT 944E-42 6-11...

  • Page 98: Transfer Case

    /or changing the transfer case oil is located in Section 2, “General Information and Specifications.” Detailed transfer case service instructions covering repair, disassembly, reassembly, adjustment and troubleshooting information is provided in the ZF Model TB92-I4 Transfer Case Operating and Repair Manual, JLG P/N 8990495 (ZF P/N 5871.134.022). 6-12 944E-42...
  • Page 99 4. Refer to Section 5.4.5, “Drive Shaft Installation,” for installation of the drive shafts. 5. Properly connect the batteries. 6. Close and secure the engine cover. 8. Remove the fourteen capscrews (2-rear, 12-front)(3) securing the transfer case to the transmission. 944E-42 6-13...

  • Page 100: Troubleshooting

    4. Replace bearings as needed. 5. Worn or broken gear teeth. 5. Replace gears as needed. 6. Contamination in transfer case. 6. Check for foreign particles. 7. Incorrect assembly of parts. 7. Check assembly of transfer case components. 6-14 944E-42...
  • Page 101 Mobilfluid 424 (ISO Grade 46). (Refer to Section 2.4, “Fluid and Lubricant Capacities.”) 4. Incorrect bearing “end play”. 4. Check bearing end play and correct with shims as needed. 5. Worn or damaged bearings. 5. Replace bearings as needed. 944E-42 6-15...
  • Page 102 Transmission This Page Intentionally Left Blank 6-16 944E-42...
  • Page 103 Troubleshooting ........... 7-13 944E-42...

  • Page 104: Introduction - Cummins Qsb 4.5

    60° C (140° F). Extended light-load operation during the early life of the engine is not recommended. DO NOT run the engine at high, no-load speeds. DO NOT apply an overload to the engine. 944E-42...

  • Page 105: Component Terminology

    The following illustration identifies the components that are referred to throughout this section. TURBOCHARGER STARTER ALTERNATOR PRIMARY FUEL FILTER SECONDARY FUEL FILTER ECM MODULE MU7400 944E-42...

  • Page 106: Engine Serial Number

    1. Park the machine on a firm, level surface, level the 11. Unplug the electrical connection (5) at the radiator machine, fully retract the boom, lower the boom, fan (6). place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 944E-42...

  • Page 107: Engine Electrical System

    1. Park the machine on a firm, level surface, level the coolant level in the overflow bottle and fill, or drain, machine, fully retract the boom, lower the boom, as necessary. place the travel select lever in the (N) NEUTRAL 9. Close and secure the engine cover. 944E-42...
  • Page 108 The fuel level indicator can be removed and cracked or damaged area. reused on the new replacement tank. Dispose of the old tank according to local regulations concerning hazardous materials disposal. 944E-42...

  • Page 109: Engine Exhaust System

    1. Install the outlet exhaust pipe (10) to the engine engine OFF. turbo outlet and tighten the V-band clamp (9) ONLY enough to hold the outlet exhaust pipe in place. 944E-42...

  • Page 110: Air Cleaner Assembly

    6. Close and secure the engine cover. 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 944E-42...

  • Page 111: Engine Replacement

    12. Label, disconnect and cap the engine oil filter inlet hose at the engine. 13. Label, disconnect and cap the engine oil filter return hose from the engine. 14. Remove the engine oil filter assembly. 15. Remove the engine-to-transmission drive shaft. Refer to Section 5.4.3, “Drive Shaft Removal.” 944E-42...
  • Page 112 24. Label, disconnect and cap all hydraulic hoses attached to the hydraulic reservoir. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system. MU7420 30. Install a lifting bracket to the top of the transmission (10). 7-10 944E-42...

  • Page 113: Engine Installation

    44-78 lb-ft (59-106 Nm). Torque help ensure proper sealing and operation. Lubricate the REAR (2) mounting bolts to 107-192 lb-ft seals and o-rings with clean hydraulic oil. (145-260 Nm). 944E-42 7-11...
  • Page 114 30. Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times. Check the hydraulic oil level. 31. Check for proper operation of all components. 32. Turn the engine OFF. 33. Install the engine cover. 7-12 944E-42...

  • Page 115: Troubleshooting

    40. Pressure relief valve sticking open 61. Turbo impeller damaged or dirty 19. Incorrect valve timing 41. Pressure relief valve sticking closed 62. Turbo lubricating oil seal leak 20. Poor compression 42. Broken relief valve spring 63. Induction system leaks 944E-42 7-13...
  • Page 116 Engine This Page Intentionally Left Blank 7-14 944E-42...
  • Page 117 8-40 8.8.3 Cylinder Torque Specifications ....... . . 8-41 944E-42...

  • Page 118: Hydraulic Component Terminology

    STEERING CYLINDER (rear) SINGLE JOYSTICK FRAME SWAY CYLINDER DUAL JOYSTICKS PILOT SELECT FRAME SWAY VALVE JOYSTICK POWER ATTACHMENT STEERING TILT VALVE CYLINDER VALVE PLATE ASSEMBLY STEERING CYLINDER MAIN CONTROL (front) VALVE STEER SELECT VALVE ACCUMULATORS ACCUMULATOR CHARGE/SECONDARY FUNCTION VALVE 944E-42...

  • Page 119: Safety Information

    Note: Residual pressure may remain in hydraulic circuit also. Refer to Section 9.5, “Electrical Schematics.” cylinders, hoses, valve bodies, components, etc. If the in this manual. hydraulic lines going to or coming from a component are taut, slowly and cautiously relieve (“bleed off”) pressure. 944E-42...

  • Page 120: Hydraulic Pressure Diagnosis

    5. Refer to Section 8.4.1, “Hydraulic Pressures,” for testing procedures. 6. Fully depress the accelerator pedal if required. Place and hold the joystick in the position needed to operate the particular machine function being checked. Continue holding the joystick in position until pressure readings are taken. 944E-42...

  • Page 121: Hydraulic Circuits

    Bleed air from the system. machine off, install the safety cap and remove the gauge from the test port. 4. If the proper pressure cannot be set, use the accompanying hydraulic schematic and/or the electrical schematic to help troubleshoot and correct the problem. 944E-42...
  • Page 122 Hydraulic System c. Hydraulic Testing - Dual Joysticks 944E-42...
  • Page 123 With engine at high idle, use the boom control lever to fully retract the boom. Hold over relief and check pressure. If Main System 3,400-3,600 psi — pressure is incorrect, adjust or replace cartridge located in the Relief (234-248 bar) end section of the main control valve. 944E-42...
  • Page 124 Consult with JLG Technical Service Department for additional Load Sense — — — — (Steering) testing information. Consult with JLG Technical Service Department for additional Load Sense — — — — testing information. (Implement) 944E-42...
  • Page 125 Hydraulic System a. Hydraulic Testing - Single Joystick 944E-42...
  • Page 126 With engine at high idle, use the boom control lever to fully retract the boom. Hold over relief and check pressure. If Main System 3,400-3,600 psi — pressure is incorrect, adjust or replace cartridge located in the Relief (234-248 bar) end section of the main control valve. 8-10 944E-42...
  • Page 127 CAUTION: GAUGE DAMAGE may occur. Malfunctioning hydraulic system circuits may have excessive pressure and can cause hydraulic pressure spikes. Test circuit with the highest reading pressure gauge first. If this gauge cannot record an accurate pressure reading, use the next lower pressure gauge. 944E-42 8-11...

  • Page 128: Hydraulic Schematic, 944E

    Hydraulic System 8.4.2 Hydraulic Schematic, 944E MU7430B 8-12 944E-42...

  • Page 129: Hydraulic Reservoir

    5. Open the filler cap on the hydraulic oil reservoir. evacuating the oil through the filler tube. Remove the drain plug on the side of the hydraulic oil reservoir. 944E-42 8-13...
  • Page 130 Cap all fittings and openings to keep dirt and debris from entering removed and reused on the new replacement reservoir. Dispose of old reservoir according to local regulations the hydraulic system. concerning hazardous materials disposal. 8-14 944E-42...
  • Page 131 1. Slide the Hydraulic reservoir under the engine and onto the frame. 2. Uncap and connect the previously labeled hydraulic hoses to there appropriate locations. 3. Connect the temperature and filter pressure switches. 4. Install the hydraulic reservoir support bracket. 5. Install the engine frame skirt. 944E-42 8-15...

  • Page 132: Hydraulic System Pump

    3. Temporarily block up or support the raised boom. 4. Open the engine cover. Allow the system fluids to cool. 5. Properly disconnect the batteries. 6. Drain the hydraulic reservoir. Refer to Section 8.5.1, “Hydraulic Oil Reservoir Draining.” 8-16 944E-42...

  • Page 133: Valves And Manifolds

    3. Open the engine cover. Allow the system fluids to cool. 4. Remove the access plate from the cab floor to gain access to the hose and tube fittings on the valve plate which is located under the cab. 944E-42 8-17...
  • Page 134 Sub Plate with Valve Plate Removal Refer to Section 4.5, “Cab Removal,” for sub plate removal procedure and reassembly procedure. 8-18 944E-42...
  • Page 135 (11), remove the four hex socket head Adjustments.” to properly test and reset any relief valve capscrews which hold the inlet section (12), transfer pressure settings if necessary. carriage section (13), auxiliary hydraulic section (14) to the mono block section. 944E-42 8-19...
  • Page 136 Transfer Carriage Section Assembly 1. Install the relief valve (15) preset to 3700 psi (255 bar) into the “A” side of the transfer carriage section. Torque the relief valve to 33 ± 3.5 lb-ft (45 ± 4,8 Nm). 8-20 944E-42...
  • Page 137 25 ± 2.5 lb-ft (34 ± 3,4 Nm). conduit as required. Tighten all tube and hose clamps. 8. Fill the hydraulic fluid reservoir. Refer to Section 8.5.2, “Hydraulic Oil Reservoir Filling.” 944E-42 8-21...

  • Page 138: Joystick Valve (Dual Joystick)

    Torque the handle assembly to replacement of the front joystick. Refer to Section 9.5.2, 33 ± 3.5 lb-ft (44,7 ± 4,7 Nm). “944E-42 Electrical Schematics.” After replacing a joystick valve assembly, check for The rear joystick (7) has no electrical connections and is proper function of all joystick functions.

  • Page 139: Pilot Select Valve (Dual Joystick)

    1. Position the pilot select valve back onto the valve plate. Install and tighten the two capscrews. 2. Uncap and reconnect the previously labeled hydraulic hoses. 3. Reconnect any electrical connections to the appropriate locations. 944E-42 8-23...

  • Page 140: Joystick Valve (Single Joystick)

    Verify the correct operation of the joystick switches and circuit solenoids before considering replacement of the 9. Reassemble the joint and handle assembly (7) to the joystick valve. Refer to Section 9.5.2, “944E-42 Electrical valve body (8). Torque the four capscrews (6) to Schematics.”...

  • Page 141: Single Joystick Pilot Select Valve

    7. Remove the two capscrews on the single joystick secure with two capscrews (4) each. Torque the pilot select valve and remove the valve. capscrews to 2.5 lb-ft (3 Nm). 9. Install the pressure reducing cartridge (5) and torque to 25 lb-ft (33 Nm). 944E-42 8-25...

  • Page 142: Frame Sway Joystick Valve

    The auxiliary hydraulic pressure release valve switch is joysticks. The joystick must be replaced in their entirety if located on the right console and when activated it replacement is necessary. Refer to Section 4.3.6, relieves all trapped pressure in the auxiliary hydraulic “Joystick Assemblies.” circuit. 8-26 944E-42...
  • Page 143 4. Properly connect the batteries operation. Lubricate seals and o-rings with clean 5. Start the machine and run at approximately one-third hydraulic oil. to one-half throttle for about one minute without moving the machine or operating any hydraulic function. 944E-42 8-27...

  • Page 144: Service Brake Valve

    7. Inspect the service brake valve and connections for leaks, and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. 8-28 944E-42...

  • Page 145: Brake Test

    Carefully open the bleeder with a 12 mm wrench. Have the assistant depress the brake pedal. Close the brake bleeder when air bubbles no longer appear in the oil. Release the brake pedal. Remove the tubing from the brake bleeder. 944E-42 8-29...

  • Page 146: Steer Select Valve

    8. Remove the four socket-head screws that secure the select valve to the dash 9. Remove the left front dash panel and pull the select valve through the dash opening. Label and remove the remaining hoses from the rear of the select valve. 8-30 944E-42...
  • Page 147 Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 13. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 14. Close and secure the engine cover. 944E-42 8-31...
  • Page 148 Apply the service brake pedal and then release. Do this several times until all hydraulic pressure has been relieved from the accumulators. 5. Properly disconnect the batteries 6. Remove the access plate from the floor of the cab. 8-32 944E-42...
  • Page 149 The following table depicts the accumulators pre-charged to 450 psi (3103 kPa), at a baseline temperature of 70° F c. Accumulator Charge/Secondary Function Valve (21° C). Installation 1. Reassemble all remaining fittings and test ports to the accumulator charge/secondary function valve. 944E-42 8-33...
  • Page 150 This diaphragm prevents the mixing of gas and oil and keeps the gas out of the hydraulic system. CAUTION Never fill an accumulator with air. When air is compressed, water vapor condenses and can cause corrosion. This corrosion may damage seals and ruin the accumulator. 8-34 944E-42...
  • Page 151 7. Turn the gas valve/bleed valve (7) on the accumulator fill kit all the way in. 8. Turn the “T” handle (5) all the way in to open the valve core on the accumulator. 9. Open the valve (8) on the nitrogen bottle. 944E-42 8-35...
  • Page 152 3. Remove the access plate from the cab floor. proceed to the next step. 12. If the nitrogen charge pressure is not correct, follow procedures in Section 8.7.16, “Checking Pre- Charge.” 8-36 944E-42...

  • Page 153: Accumulator Charge/Secondary Function Valve

    2. Increase engine RPM to see if not delivering full flow or valve starts charge cycle. pressure. 3. Charge rate orifice or filter in 3. Remove and clean charge rate accumulator charge/secondary orifice and filter. function valve partially plugged. 944E-42 8-37...

  • Page 154: Hydraulic Cylinders

    Remove all dirt, debris and grease before the piston can be removed. from the cylinder. 2. Clamp the barrel end of the cylinder in a soft-jawed vise or other acceptable holding equipment if possible. 8-38 944E-42...
  • Page 155 8. If applicable, install new counter balance valve into block on the cylinder barrel. 3. Check the piston rod assembly for run-out. If the rod is bent, it must be replaced. 944E-42 8-39...

  • Page 156: Cylinder Pressure Checking

    Activate the circuit and if pressure is obtained turn the main relief counter clockwise one half turn. Re-check the main relief setting and adjust if necessary. 8-40 944E-42...

  • Page 157: Cylinder Torque Specifications

    250-300 lb-ft (339-407 Nm) 500-550 lb-ft (678-746 Nm) Slave Cylinder Head Locknut 250-300 lb-ft (339-407 Nm) 445-515 lb-ft (603-698 Nm) g. Stabilizer Cylinder Head Locknut Valve 300-400 lb-ft (407-542 Nm) 1840-2025 lb-ft (2495-2745 Nm) 35-40 lb-ft (47-54 Nm) 944E-42 8-41...
  • Page 158 Head Valves 440-500 lb-ft (597-678 Nm) 85-95 lb-ft (115-129 Nm) 250-300 lb-ft (339-407 Nm) 30-35 lb-ft (41-47 Nm) Side Tilt Carriage Cylinder (optional) Locknut Head Valve 550-650 lb-ft (745-881 Nm) 300-400 lb-ft (407-542 Nm) 30-35 lb-ft (41-47 Nm) 8-42 944E-42...
  • Page 159 9.5.2 944E-42 Electrical Schematics ....... . . Circuit Breakdowns..........
  • Page 160 9-50 9.13.4 Probing Electrical Connectors........9-50 944E-42...

  • Page 161: Electrical System

    9.1.1 General Overview DASH SWITCHES FRONT DASH PANEL HEATER/AC CONTROLS IGNITION SWITCH BOOM PROXIMITY SWITCH FUSE & RELAY PANEL COOLANT TEMPERATURE ALTERNATOR SWITCH STARTER STABILIZER CYLINDER SOLENOIDS BATTERIES TRANSMISSION TEMPERATURE SWITCH MU7420 TRANSMISSION SOLENOIDS MU7630 944E-42...

  • Page 162: Specifications

    (5) are located inside the engine compartment and are mounted on the fuel filter bracket. The fuse holder that protects the ECM diagnostic system is located under the engine hood and is tie wrapped to the wire harness by the engine starter. 944E-42...
  • Page 163 10 Amp Front Wiper (Option) 12 Volt Boom Proximity 25 Amp Heater Fan (Option) 12 Volt Light Power (Option) 7.5 Amp Skylight Wiper (Option) 12 Volt Cab Power (Option) 7.5 Amp Rear Wiper (Option) Open 10 Amp Beacon/Strobe (Option) 944E-42...

  • Page 164: Electrical Schematics

    RELAY CONTACTS RELAY COIL SUPPRESSION DIODE RELAY RESISTOR WIRE NAME TRG6 SPLICE PROXIMITY SWITCH FUEL LEVEL BATTERY SENDER IN-LINE BULKHEAD LAMP or SWITCH CONNECTOR PIN DIODE TEMPERATURE ACTIVATED SWITCH PRESSURE MOMENTARY TYPE ACTIVATED SWITCH SWITCH ALARM / BUZZER MOTOR HORN 944E-42...
  • Page 165 Electrical System 9.5.2 944E-42 Electrical Schematics MU7490H 944E-42...
  • Page 166 Electrical System MU7500H 944E-42...
  • Page 167 Electrical System MU7510H 944E-42...
  • Page 168 Electrical System OEM 50 PIN OEM 50 PIN A CONNECTOR B CONNECTOR ON ECM ON ECM MU7520H 9-10 944E-42...
  • Page 169 Electrical System MU7530H 944E-42 9-11...

  • Page 170: Circuit Breakdowns

    AMPS AMPS 12V_BUSSBAR IR_NO sht 1 BA4B 12V_BUSSBAR 12V_BUSSBAR BA4B TCO_F CPR_NO BB1A PWR_BULK_3 AMPS STAB_BRAKE_SW AMPS BP_F BP1A FUSE_BOX_BUSSBAR_C VEH_BULK BOOM_PROX_SW ENCLOSED CAB OPTION BR_NO FUSE_BOX_BUSSBAR_A AUXILIARY HYDRAULICS LPR_NO BC1A PWR_BULK_3 AMPS 12V_BUSSBAR FUSE_BOX_BUSSBAR_E ROADLIGHT/WORKLIGHT OPTION MU7550 9-12 944E-42...
  • Page 171 FUSE_BOX_BUSSBAR_C ENCLOSED CAB OPTION SWITCH POTP sht2 BU3D AMPS ROAD LIGHT/WORK LIGHT OPTION VALVE DRIVE MODULE RDLIGHT_BULK_7 POT_3F POWER GROUND POT_3F VALVE POTENTIOMETER HVALVE_5F HVALVE_5F AMPS TOP_WIPE_WASH_SW R_WIPE_SW WIPER/WASHER SWITCH REAR FUSE_BOX_BUSSBAR_E WIPER MOTOR AMPS PARK GROUND MU7540 944E-42 9-13...

  • Page 172: Engine Start Circuit

    The starter drive or solenoid that pushes the drive forward to engage the flywheel may be defective. Missing or damaged teeth on the flywheel can also prevent the starter from cranking the engine. 9-14 944E-42...

  • Page 173: Charging Circuit

    3. Install a drive ratchet into the square hole in the serpentine belt tensioner bracket. 4. While lifting the automatic belt tensioner away from the belt, remove the fan serpentine belt. Note: Record how the alternator is installed to ensure correct installation later. 944E-42 9-15...

  • Page 174: Window Wiper/Washer Windshield Wiper Motor

    OFF position to “Park” the front wiper motor on 6. Disconnect the washer hose (3) from the hose the left side of the windshield. connector. 7. Remove the wiper arms (4), knurled driver (5) and rubber cap (6) from the motor shaft. 9-16 944E-42...
  • Page 175 1. Reconnect the previously labeled electrical connections (15). 2. Assemble the plastic case (16) onto the wiper motor. FRONT 7. From inside the cab, remove the screw (12) and acorn nut (13) from the plastic case of the wiper motor. 944E-42 9-17...
  • Page 176 1. Install the wiper switch into the plastic case. machine should not be operated. 2. Reconnect the previously labeled jumper wires 3. Open the engine cover. Allow the system fluids to between the switch and motor. cool. 4. Properly disconnect the batteries. 9-18 944E-42...
  • Page 177 OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 944E-42 9-19...

  • Page 178: Cab Heater And Fan

    6. Remove the screws and backing locknuts from the cab heater and fan control panel. 7. Pull the control panel out from the dash panel, and if removing variable speed fan control, remove the cab harness connector. 9-20 944E-42...

  • Page 179: Switches And Solenoids

    OFF. 2. Place a Do Not Operate Tag on both the ignition key If all terminals do not show proper continuity, replace the switch and the steering wheel, stating that the ignition switch. machine should not be operated. 944E-42 9-21...

  • Page 180: Dual Hydraulic Oil Temperature Switch

    5. Close and secure the engine cover. MU7390 The hydraulic oil temperature switch (6) is threaded into a fitting at the lower inside wall of the hydraulic oil reservoir. 9-22 944E-42...

  • Page 181: Auxiliary Hydraulic Pressure Release Switch

    2. Make sure the symbol is at the bottom of the switch, DO NOT disassemble the switch. The switch is not then press the switch into place in the benzel. serviceable. Replace switch if found to be defective. 3. Properly connect the batteries. 944E-42 9-23...

  • Page 182: Transmission Disconnect Switch

    Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 9-24 944E-42...

  • Page 183: Transmission Shift Control Switch

    Inspect switch wiring for continuity and shorting in each gear selection. Replace a defective or faulty switch with a new part. Inspect lever wiring for continuity and shorting in 944E-42 9-25...
  • Page 184 (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Properly disconnect the batteries. 9-26 944E-42...

  • Page 185: Dual Joystick

    This machine is equipped with three separate hydraulic joysticks. a. Front Joystick Button Testing 1. Remove the access panel from the side console. 2. Disconnect the cab wire harness connector plug (3) from the joystick connector plug (4). 944E-42 9-27...

  • Page 186: Optional Single Joystick

    (13). The suspect and should be replaced. If battery voltage is pilot select valve is located on the valve plate which is present, the harness is functioning properly. located under the cab floor. 9-28 944E-42...
  • Page 187 Slide the wire harness out through the slot. 5. Hold the nut on top of the joint assembly in place while loosening the locknut (9) on the handle assembly. 944E-42 9-29...

  • Page 188: Boom Angle Sensor

    Also inspect the valve cartridges, o-rings, and the other hydraulic and electrical components in the circuit to accurately determine the cause of the problem. If testing more than one coil, insure that the wire harness connectors are correctly re-connected. 9-30 944E-42...

  • Page 189: Coolant Temperature Switch

    DO NOT disassemble the Coolant Temperature Switch. frame, and adjust sensor distance (3) to Replace a defective switch with a new part. 0.120”- 0.190” (3,05 - 4,8 mm) and tighten locknut. 4. Properly connect the batteries. 5. Close and secure the engine cover. 944E-42 9-31...

  • Page 190: Transmission Temperature Switch

    4. Turn the ignition key switch to the OFF position. The cool. fuel level gauge needle should return to the EMPTY 4. Properly disconnect the batteries. position. 5. Unplug the transmission temperature sender connector from the wiring harness connector. 9-32 944E-42...

  • Page 191: Hourmeter

    Check the cab harness ground stud under the dash, the engine to chassis ground, and the negative (–) battery cable and ground stud cable. Examine the fuel level sender circuit in Section 9.5, “Electrical Schematics.” 944E-42 9-33...

  • Page 192: Stabilizer Brake Switch

    (N) NEUTRAL, engage the park brake and shut the mounting plate. engine OFF. 4. Use a wrench and fully tighten the top locknut against the service brake valve mounting plate. 9-34 944E-42...
  • Page 193 Have Threaded Mounting Hole Using the top and bottom locknuts in combination, position the brake switch so the Stabil-Trak “Slow Pivot” Mode indicator comes ON at the 150 ±50 psi (10,3±3,4 bar) brake pressure. When Service Brake Valve Mounting Plate Has 944E-42 9-35...

  • Page 194: Dash Switches

    3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the batteries. 5. Carefully pry the switch and wiring out of the mounting hole. 9-36 944E-42...

  • Page 195: Troubleshooting

    Accelerator Pedal Accelerator Pedal or Lever Position Sensor Position Circuit - Voltage Below Normal, or Shorted to Low Source Remote Accelerator Remote Accelerator Pedal or Lever Position Sensor Circuit - Voltage Above Normal, or Shorted to High Source 944E-42 9-37...
  • Page 196 3510 Amber 5 Volts DC Supply Sensor Supply Voltage #2 Circuit - Voltage Below Normal, or Shorted to Low Source 520199 Amber Cruise Control Cruise Control (Resistive) Signal Circuit - Voltage Above Normal, or Shorted to High Source 9-38 944E-42...
  • Page 197 Normal Operational Range - Moderately Severe Level Engine Speed Engine Speed High - Data Valid but Above Normal Operational Range - Most Severe Level Coolant Level Coolant Level Low - Data Valid but Below Normal Operational Range - Most Severe Level 944E-42 9-39...
  • Page 198 High Fuel Pressure Solenoid Valve Circuit - Pressurizing Voltage Below Normal, or Shorted to Low Assembly #1 Source 1347 Amber Fuel Pump High Fuel Pressure Solenoid Valve Circuit - Pressurizing Voltage Above Normal, or Shorted to High Assembly #1 Source 9-40 944E-42...
  • Page 199 Real Time Clock Power Interrupt - Data Erratic, Power Intermittent, or Incorrect Amber Injector Cylinder #01 Injector Solenoid Cylinder #1 Circuit - Current Below Normal, or Open Circuit Amber Injector Cylinder #05 Injector Solenoid Cylinder #5 Circuit - Current Below Normal, or Open Circuit 944E-42 9-41...
  • Page 200 Operational Range - Most Severe Level Maint. Water in Fuel Water in Fuel Indicator High - Data Valid but Indicator Above Normal Operational Range - Least Severe Level Amber Coolant Level Coolant Level - Data Erratic, Intermittent, or Incorrect 9-42 944E-42...
  • Page 201 Moderately Severe Level 1377 Amber Switch Circuit AEB15.60 Page 151 of 157 Multiple Unit Synchronization Switch Circuit - Data Erratic, Intermittent, or Incorrect Amber System Diagnostic OEM Intermediate (PTO) Speed switch code #1 Validation - Data Erratic, Intermittent, or Incorrect 944E-42 9-43...
  • Page 202 Electrical Charging System Voltage Low - Data (voltage) Valid but Below Normal Operational Range - Moderately Severe Level Alternate Potential Electrical Charging System Voltage Low - Data (voltage) Valid but Below Normal Operational Range - Most Severe Level 9-44 944E-42...
  • Page 203 Sensor #2 Erratic, Intermittent, or Incorrect Amber Auxiliary Equipment Warning Auxiliary Equipment Sensor Input #3 Sensor Input (OEM Switch) - Root Cause Not Known None Cylinder Power Cylinder Power Imbalance Between Cylinders - Data Erratic, Intermittent, or Incorrect 944E-42 9-45...
  • Page 204 Severe Level 2111 Amber Coolant Temperature Coolant Temperature 2 Sensor Circuit - Voltage Above Normal, or Shorted to High Source 2112 Amber Coolant Temperature Coolant Temperature 2 Sensor Circuit - Voltage Below Normal, or Shorted to Low Source 9-46 944E-42...
  • Page 205 Fuel Pump Delivery Pressure - Data Valid but Pressure Above Normal Operational Range - Least Severe Level 2262 Maint Fuel Delivery Fuel Pump Delivery Pressure - Data Valid but Pressure Below Normal Operational Range - Least Severe Level 944E-42 9-47...
  • Page 206 Engine Brake Actuator Driver Output 3 Circuit - Voltage Below Normal, or Shorted to Low Source 2367 1073 Amber Engine Compression Engine Brake Actuator Circuit #2 - Voltage Brake Output #2 Above Normal, or Shorted to High Source 9-48 944E-42...
  • Page 207 Normal, or Shorted to Low Source 2963 None Engine Coolant Engine Coolant Temperature High - Data Valid Temperature but Above Normal Operational Range - Least Severe Level 2973 Amber Boost Pressure Intake Manifold Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect 944E-42 9-49...

  • Page 208: Troubleshooting With A Digital Multimeter (Dmm)

    2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. Voltage at the wire should be displayed. 9-50 944E-42...
  • Page 209 5. The DMM displays the difference in voltage between the two points. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. 944E-42 9-51...
  • Page 210 6. Refer to the relay location chart, on page 9.4, for the analog tester displays voltage in order to find which location of the relays within the fuse block. circuit is shorted. 7. Remove the suspect relay from the machine. 9-52 944E-42...
  • Page 211 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the batteries. 944E-42 9-53...
  • Page 212 (4 or 9) to a maximum of 95 lb-in (11 Nm). Torque the other nuts (5 or 10), to a maximum of 40 lb-in (4,5 Nm). 12. Properly connect the batteries. 13. Close and secure the engine cover. 9-54 944E-42...
  • Page 213 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Right . . 10-25 10.5.15 Hydraulic Circuit Operation - Locked Mode, Frame Sway Left ..10-26 10.5.16 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Left . . . 10-27 944E-42 10-1...

  • Page 214: Stabil-Trak™ System

    Stabil-TRAK™ system. The following illustration identifies the components that are referred to throughout this section. BOOM PROXIMITY SWITCH FRAME SWAY CYLINDER STABILIZER CYLINDER STABIL-TRAK™ MANIFOLD 10-2 944E-42...

  • Page 215: Stabil-Trak™ Description

    In general, if there is a problem with the Stabil-TRAK™ system beyond common electrical troubles, the involved electrical and hydraulic circuits should each be checked and the exact source of the problem diagnosed before any parts are replaced. 944E-42 10-3...

  • Page 216: Stabil-Trak™ Electrical Circuit Operation And Troubleshooting

    Neutral Start Relay (E3) Park Brake Solenoid Park Brake Switch Stabilizer Brake Switch Transmission Control Relay (E1) Definitions: PB = Park Brake SB = Service Brake DE = De-energized E = Energized C = Closed O = Open 10-4 944E-42...
  • Page 217 Stabil-TRAK™ System FREE PIVOT MODE 944E-42 10-5...
  • Page 218 Stabil-TRAK™ System SLOW PIVOT MODE 10-6 944E-42...
  • Page 219 Stabil-TRAK™ System LOCKED MODE l 944E-42 10-7...
  • Page 220 Stabil-TRAK™ System LOCKED MODE ll 10-8 944E-42...
  • Page 221 Stabil-TRAK™ System LOCKED MODE lll 944E-42 10-9...

  • Page 222: Stabil-Trak™ System Test

    Note: If the Stabil-TRAK™ light goes OFF and the front left tire lowers to the ground at any time during Steps 4 through 7, the test was not performed properly or the Stabil-TRAK™ system is not functioning properly. Carefully repeat the steps starting with Step 1. 10-10 944E-42...
  • Page 223 With the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch. b. Move the travel select lever to the (F) FORWARD position. DO NOT depress the service brake pedal. The Stabil-TRAK™ lock light should remain ON and the front left tire should remain off the ground. 944E-42 10-11...
  • Page 224 Note: If Steps 1-9 prove positive, the Stabil-TRAK™ system is functioning properly, and the vehicle can be returned to service. If any of these steps indicate that the Stabil-TRAK™ system is not functioning properly, follow the procedures in Section 10.5.2, “Stabil-TRAK™ Hydraulic Circuit,” to repair the system. 10-12 944E-42...

  • Page 225: Stabil-Trak™ Hydraulic Circuit Operation And Troubleshooting

    Boom angle is above 40° front tire comes off the ground. Sway Left,” and Section 10.5.16, Travel select lever is in (N) NEUTRAL, or Park “Hydraulic Troubleshooting - Locked brake ON, or Service brake ENGAGED Mode, Will Not Frame Sway Left.” 944E-42 10-13...

  • Page 226: Stabil-Trak™ Hydraulic Circuit

    BASE OIL OUT flow will occur when the right side of the rear axle is lower than the left (right wheel in a pothole, or the left wheel passing over an obstruction), causing the cylinder to compress (2). 10-14 944E-42...

  • Page 227: Hydraulic Circuit Operation - Free Pivot Mode, Rod Oil Out

    Because the volume of oil needed on the base side is greater than that needed on the rod side, the extra oil needed is supplied from the main hydraulic system through a 100 psi (7 bar) reducing cartridge (4) in the Stabil-TRAK™ manifold. 944E-42 10-15...

  • Page 228: Hydraulic Troubleshooting - Free Pivot Mode, Rod Oil Out

    If OK Inspect check valves on frame sway cylinder. Refer to Section 8.8, “Hydraulic Replace check valve(s). Cylinders.” If OK Inspect check valves 2A and 2B on the stabilizer cylinder. Refer to Section 8.8, Replace check valve(s). “Hydraulic Cylinders.” 10-16 944E-42...

  • Page 229: Hydraulic Circuit Operation - Free Pivot Mode, Base Oil Out

    Because the volume of oil needed on the rod side is less than that needed on the base side, excess oil is returned to the tank through a 100 psi (7 bar) reducing cartridge (4) in the Stabil-TRAK™ manifold. 944E-42 10-17...

  • Page 230: Hydraulic Troubleshooting - Free Pivot Mode, Base Oil Out

    If OK Inspect check valves on frame sway cylinder. Refer to Section 8.8, “Hydraulic Replace check valve(s). Cylinders.” If OK Inspect check valves 2A and 2B on the stabilizer cylinder. Refer to Section 8.8, Replace check valve(s). “Hydraulic Cylinders.” 10-18 944E-42...

  • Page 231: Hydraulic Circuit Operation - Slow Pivot Mode, Rod Oil Out

    Because of the greater volume of oil required, extra oil is required from the system through the 100 psi (7 bar) reducing cartridge (6) in the Stabil-TRAK™ manifold. The restrictions produce the slow movement, or SLOW PIVOT mode. 944E-42 10-19...

  • Page 232: Hydraulic Troubleshooting - Slow Pivot Mode, Rod Oil Out

    If OK Inspect check valves on frame sway cylinder. Refer to Section 8.8, “Hydraulic Replace check valve(s). Cylinders.” If OK Inspect check valves 2A and 2B on the stabilizer cylinder. Refer to Section 8.8, Replace check valve(s). “Hydraulic Cylinders.” 10-20 944E-42...

  • Page 233: Hydraulic Circuit Operation - Slow Pivot Mode, Base Oil Out

    Because of the greater volume of oil in the base end, extra oil is returned to the tank through the 100 psi (7 bar) reducing cartridge (6) in the Stabil-TRAK™ manifold. The restrictions produce the slow movement, or SLOW PIVOT mode. 944E-42 10-21...

  • Page 234: Hydraulic Troubleshooting - Slow Pivot Mode, Base Oil Out

    If OK Inspect check valves on frame sway cylinder. Refer to Section 8.8, “Hydraulic Replace check valve(s). Cylinders.” If OK Inspect check valves 2A and 2B on the stabilizer cylinder. Refer to Section 8.8, Replace check valve(s). “Hydraulic Cylinders.” 10-22 944E-42...

  • Page 235: Hydraulic Circuit Operation - Locked Mode

    4A (1), 4B (2), 12A (3) and 12B (4). oil to flow through the valve, to the Stabil-TRAK™ manifold, port V. ENERGIZED Pressure Return Pilot Pressure Suction Load Sense 944E-42 10-23...
  • Page 236 Stabil-TRAK™ System Legend 1. Solenoid 4A 2. Solenoid 4B 3. Solenoid 12A 4. Solenoid 12B 5. Solenoid 3 6. .030" Orifice Plug 7. Check Valve 2A 8. Stabilizer Cylinder 9. Check Valve 2B 10. Pressure Reducing Cartridge Front 10-24 944E-42...

  • Page 237: Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Right

    ENGAGED Check solenoid cartridge 3 in the Stabil-TRAK™ manifold. Refer to Section Replace cartridge. 8.8, “Hydraulic Cylinders.” If OK Inspect check valves 2A and 2B on the stabilizer cylinder. Refer to Section 8.8, Replace check valve(s). “Hydraulic Cylinders.” 944E-42 10-25...

  • Page 238: Hydraulic Circuit Operation - Locked Mode, Frame Sway Left

    (4) on the return side of the frame sway cylinder, Pressurized oil entering the Stabil-TRAK™ manifold at opening the valve. port P is stopped at the four closed solenoid-operated valves 4A (11), 4B (12), 12A (13), and 12B (14). ENERGIZED Pressure Return Pilot Pressure Suction Load Sense 10-26 944E-42...

  • Page 239: Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Left

    ENGAGED Check solenoid cartridge 3 in the Replace cartridge. Stabil-TRAK™ manifold. Refer to Section 8.8, “Hydraulic Cylinders.” If OK Inspect check valves 2A and 2B on the stabilizer cylinder. Refer to Section 8.8, Replace check valve(s). “Hydraulic Cylinders.” 944E-42 10-27...
  • Page 240 Stabil-TRAK™ System This Page Intentionally Left Blank 10-28 944E-42...
  • Page 241 Troubleshooting ........... 11-22 11.4.1 Transfer Carriage Troubleshooting ......11-22 944E-42 11-1...

  • Page 242: Transfer Carriage

    The following illustration identifies the components that are referred to throughout this section. TRANSFER TRANSFER CARRIAGE CARRIAGE ROLLERS ASSEMBLY LIFT/LOWER CYLINDER MACHINE BOOM (REFERENCE) SLAVE CYLINDERS TRANSFER CYLINDER TRANSFER CARRIAGE GUIDE RAIL MACHINE FRAME (REFERENCE) 11-2 944E-42...

  • Page 243: Transfer Carriage Maintenance

    (Consult load charts and the vehicle’s Operator’s Manual for transfer capacities in the transferred or fully retracted positions.) The transfer carriage should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features. 944E-42 11-3...
  • Page 244 2. Move the transfer carriage 5 ft. 8 in. (172 cm) so that “Boom Assembly Maintenance.” the pin (1) connecting the transfer cylinder to the 14. Remove locknuts, washers, Lull logo plate and black transfer carriage is at a pin access hole (2) near the backing from the rear of the vehicle.
  • Page 245 24. Disconnect the back-up alarm electrical connection from the wire harness and remove the back-up alarm from the transfer carriage. 25. Remove the hydraulic junction manifold (7) from the transfer carriage. Lay hoses and hydraulic junction manifold behind frame. 944E-42 11-5...
  • Page 246 Damage to the bushings may result. 28. Lift and slide the transfer carriage out the back of the frame. Lower and place the transfer carriage onto support jacks, capable of supporting the weight of the transfer carriage, on a firm level surface. 11-6 944E-42...

  • Page 247: Transfer Carriage Installation

    12. Lift the slave cylinder (13) into position and insert the ® pin (14). Coat the bolt with Loctite 242 (blue). Install the bolt and locknut. Torque bolt to, 9 - 22 lb-ft (17 - 31 Nm). 13. Repeat steps 11 and 12 for the other slave cylinder. 944E-42 11-7...
  • Page 248 Torque the larger hose (4) to, 100 - 140 lb-ft (135 - 190 Nm). Torque the smaller hose (5) to, 45 - 59 lb-ft (61 - 80 Nm). 11-8 944E-42...

  • Page 249: Rear Wear Pad Check

    242 (blue). Install the 5. At the rear of the transfer carriage, use a feeler Lull logo plate (8) and black backing (9) at the rear of gauge to check the gap (10) between the wear the machine. Torque locknuts to, 29 - 51 lb-ft pads (11) and the top of the rail (12).

  • Page 250: Rear Wear Pad Shimming

    4. Add the required shims (3) between the wear pad (4) and the transfer carriage (2). ® 5. Coat the capscrews (1) with Loctite 242 (blue). Secure in place with the two capscrews (1). Torque capscrews to, 28 - 49 lb-ft (38 - 67 Nm). 11-10 944E-42...

  • Page 251: Front Upstop Wear Pad Check

    (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Check the gap (9) between the top of the wear pad and the bottom of the rail. The maximum gap should be 0.12" (3 mm). 944E-42 11-11...

  • Page 252: Front Upstop Wear Pad Replacement

    The maximum total gap of both sides should not exceed 0.08 in (2 mm). 7. If the total gap is larger than 0.08 in (2 mm), the rollers need to be shimmed. 11-12 944E-42...

  • Page 253: Rear Roller Shimming

    7. Properly disconnect the batteries. 10. Remove the rear roller pin (11). Slide the roller pin 8. Remove locknuts, washers, Lull logo plate (8) and out and remove the rollers and shims (12) from black backing (9) from the rear of the vehicle.

  • Page 254: Front Roller Gap Check

    14. Coat the locknuts with Loctite 242 (blue). Install carriage in this position. Record the gap of each locknuts, washers, Lull logo plate and black backing roller. at the rear of the vehicle. Torque locknuts to, 29 - 51 lb-ft (40 - 70 Nm).

  • Page 255: Front Roller Shimming

    8. Close and secure the engine cover. according to their new positions. 9. Replace capscrew, washer, spacer and locknut to secure pin (5) on transfer carriage. Torque capscrew to, 43 - 78 lb-ft (59 - 106 Nm). 10. Properly connect the batteries. 944E-42 11-15...

  • Page 256: Front Roller And Bushing Replacement

    If front roller is damaged, replace it with a new front roller. Note: It is reccomended to replace both bearings at the same time. Note: DO NOT apply any grease or anti-seize compound to bushing or roller pin. 11-16 944E-42...

  • Page 257: Rear Roller And Bushing Replacement

    (1) at the rear, left and right side of the frame. Torque bolt to, 302 - 390 lb-ft (410 - 530 Nm). 13. Install the Lull logo plate and black backing at the ® rear of the machine. Coat the locknuts with Loctite 242 (blue) and torque to, 29 - 51 lb-ft (40 - 70 Nm).

  • Page 258: Slave Cylinder Pivot Bushing Replacement

    6. Lift, lower and place the slave cylinder on support blocks on a firm level surface. 7. Inspect the slave cylinder bearings (4). If they are worn and visibly shake on the slave cylinder pins, replace with new bearings. 11-18 944E-42...

  • Page 259: Transfer Cylinder Replacement

    (5). cylinder. 4. Temporarily tape the pin in place so it will not fall out during the following procedure. 5. Move the transfer carriage all the way forward. 6. Remove the tape and the pin (5). 944E-42 11-19...
  • Page 260 5. Connect the transfer cylinder (3) to the transfer carriage mount (4) with the transfer cylinder pin (5) securing it with retaining rings (6). 6. Properly connect the batteries. 7. Close and secure the engine cover. 11-20 944E-42...
  • Page 261 9 o’clock (8) or 3 o’clock (9) position. The 12 o’clock and 6 o’clock positions are the direction the transfer carriage moves forward and reverse on the rails and is the force of the load. 944E-42 11-21...

  • Page 262: Troubleshooting

    3. Replace the damaged transfer carriage. (Refer to Section 11.3.1, “Transfer Carriage Removal.”) 4. Damaged rollers. 4. Replace the damaged rollers. (Refer to Section 11.3.15, “Front Roller and Bushing Replacement,” or Section 11.3.16, “Rear Roller and Bushing Replacement.”) 11-22 944E-42...

  • Page 263: Transfer Carriage Troubleshooting

    1. Transfer carriage cylinder 1. Replace transfer carriage forward on it’s own. malfunctioning. cylinder (Refer to Section 11.3.19, “Transfer Cylinder Replacement.”) 2. Transfer carriage cylinder 2. Replace transfer carriage control valve malfunctioning. cylinder control valve. (Refer to Section 8.4, “Hydraulic Circuits.”) 944E-42 11-23...
  • Page 264 Transfer Carriage This Page Intentionally Left Blank 11-24 944E-42...
  • Page 266 31200355 An Oshkosh Corporation Company JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O.

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