Lull Pleace Ace 944E-42 Owner's/Operator's Manual
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Lull Pleace Ace 944E-42 Owner's/Operator's Manual

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OWNERS/OPERATORS MANUAL
Model 944E-42
(S/N 0160003882 thru 0160037751)
MU4941
Keep this manual with the vehicle at all times.
3120039 B
Printed in U.S.A. 3/09
Courtesy of Crane.Market

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Summary of Contents for Lull Pleace Ace 944E-42

  • Page 1 OWNERS/OPERATORS MANUAL Model 944E-42 (S/N 0160003882 thru 0160037751) MU4941 Keep this manual with the vehicle at all times. 3120039 B Printed in U.S.A. 3/09 Courtesy of Crane.Market...
  • Page 2 WARNING: Improper operation of this vehicle can cause injury or death. Only trained and authorized operators should operate this vehicle. Before starting the engine, do the following: 1. Read this owner/operators manual. 2. Read all the safety decals on the vehicle. 3.

  • Page 3: Table Of Contents

    Table of Contents Introduction 1. Lubrication Points.....106 2. Air Cleaner .......107 The Manual........2 3. Optional Closed Cab Air Replacement Parts ......2 Filters ........109 Reports ..........2 4. Engine Cooling System..110 Disclaimer........3 5. Engine Oil and Filter..114 Safety Practices 6. Engine Fuel System ..118 Hazard Classification System..3 7.

  • Page 4: Introduction The Manual

    This report activates the warranty period, assuring that your claims during the warranty period will be processed promptly. To guarantee full warranty service, make sure your Lull Distributor has returned the business reply card of this form to JLG.

  • Page 5: Disclaimer

    Safety Practices Disclaimer JLG reserves the right to make changes on and to add improvements upon its products at any time without public notice or obligation. JLG also reserves the right to discontinue manufacturing any product at its discretion at any time. NOTICE: Under OSHA rules, it is the responsibility of the employer to provide operator training.
  • Page 6 Safety Practices Signal Word A signal word is a distinctive word located on hazard decals and used throughout this manual that alerts the viewer to the existence of and relative degree of the hazard. DANGER: The signal word ìDANGERî indicates an imminently hazardous situation which, if not avoided, will result in death or serious personal injury.

  • Page 7: Accident Prevention Tags

    Safety Practices Accident Prevention Tags Before beginning any maintenance or service, place an Accident Prevention Tag (1) on both the starter key switch (2) and the steering wheel (3), stating that the vehicle should not be operated. Actual Accident Prevention Tags, which can be punched out and used, are included as the last page of this manual.

  • Page 8: Instructional Symbols

    Safety Practices Instructional Symbols The following symbol definitions will help you understand all hazard related decals and load charts used on this vehicle. OP0330 OH2100 Safety Alert Read Operatorís Symbol Manual OH3100 OH2090 Always Connect Fasten Seat Couplers On Belt Hydraulically Powered Attachments 80"...

  • Page 9: Instructional Symbols (Cont'd)

    Safety Practices Instructional Symbols (contíd) OU1620 OU1630 Standard Side Tilt Carriages Carriages OU1610 OU1640 Single or Dual Swing Carriages Fork Positioning Carriages OU1590 OU1600 10 Ft. Truss 10 Ft. Truss Boom w/Winch Boom OU1560 3 Ft. Truss Boom w/Winch Model 944E Origin 3/04 Courtesy of Crane.Market...

  • Page 10: Hazard Symbols

    Safety Practices Hazard Symbols OH2110 OH2120 OH2130 Lead Acid Batteries Rotating Fan Vehicle Tipover Generate Explosive Blades Can Cut Can Crush Gases OH2150 OH2140 OH2300 Electrocution Can Vehicle Roll Away Rotating Belts Cause Death Or Can Cause Death Or Can Cut Or Serious Injury Serious Injury Entangle...

  • Page 11: Avoidance Symbols

    Safety Practices Avoidance Symbols OH2320 OH2330 Keep Flames and Keep Lit Cigarettes Ignition Sources Away Away OH2280 OH2270 Do Not Raise Boom Do Not Travel With While On A Slope Boom Raised OH2240 OH2250 Do Not Travel With Keep Clear Of Power Personnel In Work Lines Platform...

  • Page 12: Avoidance Symbols (Cont'd)

    Safety Practices Avoidance Symbols (contíd) OH2290 OH2260 Engage Parking Brake Maintain Proper Air Pressure In Tire OH2170 OH2230 Use Only Compliant Work Platforms To Carry No Riders Raise Or Lower Personnel OH2220 DO NOT JUMP OU1460 ï Brace Yourself and Stay DO NOT Use Ether Or With Vehicle Other High Energy...

  • Page 13: Avoidance Symbols (Cont'd)

    Safety Practices Avoidance Symbols (contíd) OU1530 OU1540 Keep Truss Avoid Rope Boom Horizontal Damage. DO When Using NOT Tilt Truss Winch Boom DOWN When Using Winch OU1550 Avoid Rope OU1520 Damage. DO Stop Operation NOT Tilt Truss At This Point Boom UP When Using Winch OU1510...

  • Page 14: Personal Considerations

    Safety Practices Personal Considerations 1. Seat Belt Always fasten the seat belt before starting the engine. 2. Clothing and Safety Gear DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts. Wear protective clothing and personal safety gear issued or called for by job conditions.
  • Page 15 Safety Practices DO NOT use ether or any other high energy starting aids during cold ENGINE EXPLOSION can DO NOT use Ether or other starting. An engine result in death or serious high energy starting aids. explosion can result in personal injury.
  • Page 16 Safety Practices Battery Charging WARNING: DO NOT charge a frozen battery, it may explode and cause serious injury. Let the battery thaw out before putting on a battery charger. Under normal conditions, the engine alternator will have no problem keeping the batteries charged.

  • Page 17: Operational Considerations

    Safety Practices 5. Moving Parts Hazard DO NOT place limbs near moving parts. Severing of any body part can result. Turn off engine and wait until fan and belts stop moving before servicing. MOVING PARTS can cut. Keep clear of fan and belts while engine is running.
  • Page 18 Safety Practices 2. Clearances Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you do not have a clear view of conditions that affect clearances. Travel with the boom fully retracted and lowered as far as possible while still maintaining enough ground clearance for conditions.
  • Page 19 Safety Practices 6. Elevating Personnel Use only a compliant work platform meeting the ASME B56.6 standards for lifting and lowering personnel. NEVER transport personnel in a work platform for even the shortest distance. Death or serious personal injury can occur if these rules are not obeyed. Riders can fall and be crushed or run over.
  • Page 20 Safety Practices 8. Tip Over Hazard DANGER VEHICLE DO NOT DO NOT raise MAINTAIN TIPOVER travel boom while proper tire can result with the on a slope pressure at in death or boom unless load all times. serious injury. raised. is level.
  • Page 21 Safety Practices 10. Tire Pressure DANGER VEHICLE DO NOT DO NOT raise MAINTAIN TIPOVER travel boom while proper tire can result with the on a slope pressure at in death or unless load all times. boom serious injury. raised. is level. OS0085 MAINTAIN proper tire pressures at all times.

  • Page 22: Equipment Considerations

    DO NOT by-pass or disconnect any electrical or hydraulic circuits. Consult the JLG Service Department or your local Lull Distributor if any circuit is malfunctioning. DO check for frayed or cut seat belt webbing, damaged buckles or loose mounting brackets.
  • Page 23 Safety Practices WARNING 1. Read operator's 2. Fasten 3. Allow 4. Use a compliant SAFETY manual before seat work platform to lift AVOID INSTRUCTIONS operating. belt. riders. or lower personnel. CRUSHING, 4110361 falling off vehicle can cause death or serious injury °F RPM X 100...
  • Page 24 Safety Practices WARNING FALLING OFF ATTACHMENT, can result in death or serious injury. 200cm 190cm 180cm 170cm 160cm 150cm 140cm 130cm 120cm 110cm 100cm 90cm 80cm 70cm 60cm 50cm 40cm 30cm 20cm 10cm 4110356 Lift or lower personnel DO NOT TRAVEL only in a compliant with personnel in work platform.

  • Page 25: Operation

    Operation Operation Pre-Operation Inspection 1. Check seat belt for damage. Check for frayed or cut seat belt webbing, damaged buckles or loose mounting brackets. Make any necessary repairs before operating the vehicle. 2. Check all four tires and rims for damage. Check for proper tire pressure, add air if required.
  • Page 26 Operation Operators Seat Adjustments Enter the cab using the hand holds. The operatorís seat can be adjusted as follows: Fore and Aft Adjustment (all styles of seat) Pull the handle (1) under the front of the seat (2) to the left and move the seat forward and backward.
  • Page 27 Operation Seat Belt WARNING: Serious bodily injury or death may result from failure to wear the seat belt installed on this vehicle. The seat belt is a critical component of the Operatorís Protective Structure, and is provided for the operators protection in case of vehicle upset. The seat belt MUST be worn whenever this vehicle is operated.

  • Page 28: Operator Controls

    Operation Operator Controls Accelerator Pedal Pressing down the accelerator pedal (1) increases engine speed and the speed of the hydraulic system. The pedal is spring-loaded to return to idle speed. NOTE: The accelerator pedal is also used to activate the Cummins ECM diagnostic system.
  • Page 29 Operation Ignition Switch The ignition switch is located on the lower right side of the front dash. Using the ignition switch key (5), the key may be turned clockwise from the OFF (6) position to the RUN (7) and START (8) positions. The START position is spring-loaded to return to the RUN position and must be manually held in place for starting.
  • Page 30 Operation 1. Four Wheel Steering Mode WARNING: NEVER use the Four Wheel Steering Mode when traveling at high speed. Rapid turning in this mode can cause tipover. Use only the Front Wheel Steering Mode at higher speeds and slow the vehi- cle when turning.
  • Page 31 Operation 3. Crab Steering Mode WARNING: NEVER use the Crab Steering Mode when travelling at high speed. Rapid turning in this mode can cause tipover. Use only the Front Wheel Steering Mode at higher speeds and slow the vehicle when turning.
  • Page 32 Operation Parking Brake Switch The Parking Brake Switch (1) is located on the left side of the front dash and has two positions: ENGAGED ....toggle switch downward DISENGAGED ....toggle switch upward OS1323 OS0121 The Parking Brake Switch must be ENGAGED to permit engine starting. A red LED, on the parking brake switch, will indicate the brake is ENGAGED.
  • Page 33 Operation With the transmission disconnect activated, when the service brake pedal is applied, the transmission will be disconnected allowing the engine speed to be increased without the need to place the transmission shifter in the (N) NEUTRAL DETENT. This feature eliminates the need to shift the transmission to the (N) NEUTRAL DETENT before operating the hydraulic system at high engine speed.
  • Page 34 Operation Travel Select Lever The Travel Select Lever (1) has three positions to select direction of travel: F = FORWARD (2) ......all the way UP N = NEUTRAL DETENT (3) ....CENTER position R = REVERSE (4) ....... all the way DOWN OS0340 OU0400 Starting Travel...
  • Page 35 Operation Changing Travel Direction 1. Stop the vehicle by applying the service brakes. 2. Grasp the travel select lever (1), pull it toward the steering wheel, then move the lever up or down in the opposite direction; (R) REVERSE (4) or (F) FORWARD (2). When the Travel Select Lever is shifted to REVERSE, the back-up alarm will automatically sound.
  • Page 36 Operation Stopping Travel 1. Apply the service brake pedal and downshift the vehicle to a lower gear if necessary to slow the vehicle until it comes to a complete stop. 2. Move the travel select lever (1) to the (N) NEUTRAL DETENT position and engage the parking brake switch.
  • Page 37 Operation Joystick Operation (Standard) The standard vehicle is equipped with three separate joysticks. ï The front joystick (5) controls attachment tilt and PlaceAceô transfer carriage operation. The button (6) on the front joystick controls the auxiliary hydraulic function. ï The middle joystick (7) controls boom lift/lower and extend/retract functions. ï...
  • Page 38 Operation Front Joystick (Attachment Tilt & Transfer Carriage) The front joystick (1) controls the attachment tilt and the PlaceAceô transfer carriage operation. The joystick can be moved from the center position into any of these quadrants. The joystick will return to the center position when released. The button on the top of the joystick controls the auxiliary hydraulics function.
  • Page 39 Operation Middle Joystick (Boom Lift/Lower & Boom Extend/Retract) The middle joystick (6) controls the boom lift/lower and boom extend/retract functions. The joystick can be moved from the center position into any of these quadrants. The joystick will return to the center position when released. Boom Lift (7) ........
  • Page 40 Operation Frame Sway Joystick The frame sway joystick (1) is equipped with a lock ring (2) to prevent unintentional operation of the frame sway control. Lift up and hold the lock ring while moving the handle to the left or right. When frame sway is complete, center the handle and lower the lock ring to lock the handle in the center position.
  • Page 41 Operation Leveling The Vehicle When placing a load while on a slope, use the frame sway control. Keep the vehicle level. The operator should observe the frame level indicator (5) to assure that the vehicle is level at all times. The frame sway is capable of tilting the vehicle 12 in either direction.
  • Page 42 Operation Auxiliary Hydraulic Control The auxiliary hydraulic control is used to control the functions of an optional attachment that is mounted to the vehicle and requires a hydraulic supply for operation. Some of the optional attachments that require auxiliary hydraulics are: Side Tilt Carriage, Swing Carriage, 3 ft Truss Boom w/Winch, 10 ft Truss Boom w/Winch, Single Fork Positioning Carriage, Dual Fork Positioning Carriage and Auger.
  • Page 43 Operation While holding the button down and moving the joystick to the right (3) will provide hydraulic system pressure through the female disconnect coupling for the auxiliary attachment. Hydraulic fluid will return to the tank through the male disconnect coupling. While holding the button down and moving the joystick to the left (4) will provide hydraulic system pressure through the male disconnect coupling for the auxiliary attachment.
  • Page 44 Operation Joystick Operation (Single Joystick Option) The single joystick option is an assembly containing a single joystick (1) to control boom functions, auxiliary hydraulics, attachment tilt and the PlaceAceô transfer carriage operation. The frame sway is controlled by a separate frame sway joystick (2) which is located behind the single joystick assembly.
  • Page 45 Operation Boom Lift/Lower and Extend/Retract (Default Mode) Front button (3), not depressed, operates the following boom functions. The joystick can be moved from the center position into any of these quadrants. The joystick will return to the center position when released. Boom Lift (5) ........
  • Page 46 Operation Transfer Carriage Extend/Retract and Auxiliary Hydraulic Male Pressurized/ Female Pressurized (Secondary Mode) Front button (1) depressed and held against the joystick handle operates the following transfer carriage and auxiliary hydraulic functions. The joystick can be moved from the center position into any of these quadrants. The joystick will return to the center position when released.
  • Page 47 Operation While holding the button in and moving the joystick to the right (4) will provide hydraulic system pressure through the female disconnect coupling for the auxiliary attachment. Hydraulic fluid will return to the tank through the male disconnect coupling. While holding the button in and moving the joystick to the left (5) will provide hydraulic system pressure through the male disconnect coupling for the auxiliary attachment.
  • Page 48 Operation Attachment Tilt (Thumb Control) Operates in Default Mode or Secondary Mode The thumb control (1), on the topside of the joystick, controls the attachment tilt function and is not affected by the button (2) on the front of the joystick. With your thumb, move the thumb control BACKWARD for attachment tilt UP (3).
  • Page 49 Operation Leveling The Vehicle When placing a load while on a slope, use the frame sway control. Keep the vehicle level. The operator should observe the frame level indicator (9) to assure that the vehicle is level at all times. The frame sway is capable of tilting the vehicle 12 in either direction.

  • Page 50: Front Dash Panel

    Operation Front Dash Panel The front dash panel (1) provides the operator with important information. It is ìuser friendlyî and only provides the operator with the information needed at any given time. Front Dash Panel Light Test °F RPM X 100 °C r/min 0000000...
  • Page 51 Operation Function Indicator Lights There are four ìhiddenî function indicator lights in the front dash panel that illuminate only when a specific function has been activated. They are: Parking Brake Indicator (2) This light illuminates any time the parking brake is applied and the OH2260 ignition switch is in the RUN position.
  • Page 52 Operation Warning Indicator Lights There are seven additional ìhiddenî indicator lights in the front dash panel that will illuminate during critical circumstances. All seven warning indicator lights demand immediate attention and vehicle servicing. In many cases, the vehicle should be shut down AS SOON AS PRACTICAL to prevent serious mechanical failure.
  • Page 53 Operation Alternator Charging Warning Indicator (4) This light illuminates to indicate a weak or improperly working charging system or the OH2560 batteries are dead. Service the engine alternator or batteries. Engine Air Filter Restriction Warning Indicator (5) This light illuminates when a restricted engine air filter is detected.
  • Page 54 (N) NEUTRAL DETENT position, engage the parking brake switch and turn the engine OFF. Have the service brake system serviced before using the vehicle again. Contact your local Lull Distributor immediately to repair the system. °F RPM X 100 °C...
  • Page 55 Operation Gauges and Indicators Fuel Level Gauge (2) Make sure the vehicle is level to ensure an accurate fuel level OH24701 reading. The fuel gauge located on the left side of the front dash panel, indicates the amount of fuel in the fuel tank. Refuel before the fuel gauge reaches the ìEî...
  • Page 56 Operation Optional Indicator Lights There are two additional ìhiddenî indicator lights in the front dash panel that will illuminate only when the vehicle is equipped with the optional road light package. High Beam Indicator (1) Whenever the headlights are on ìhighî...

  • Page 57: Optional Features

    Operation Optional Features Worklights (Front, Rear & Boom) The worklights are activated with a single rocker OH2570 switch (3) located in the upper switch bank on the right side. There are three positions - OFF, Front Worklights and Front and Rear Worklights. The lights only work when the ignition switch is in the RUN position.
  • Page 58 Operation Parking Lights, Headlights & High/Low Beam Switch OS1900 These lights will only work when the ignition switch is in the RUN position. Use the turn signal switch (1) to control the high/low beam headlights and to turn ON the parking lights and headlights. Turn the twist grip end (2) of the turn signal switch counterclockwise to the first position (3) to turn the parking lights ON.
  • Page 59 Operation Directional Signals The directional signals are OS1910 ACTIVATED from the lever (6) on the right side of the steering wheel and will only work when the ignition switch is in the RUN position. To activate the left turn signal (7); RAISE the lever. To activate the right turn signal (8);...
  • Page 60 Operation Emergency Flashers The emergency flashers are OS1920 activated by a single rocker switch (1) located in the upper bank of switches on the right side of the dash. ï To DEACTIVATE the emergency flashers, push the TOP of the rocker switch IN. OH2591 ï...
  • Page 61 Operation Door Latches (Closed Cab Only) There are two door latches for the lower door. The outside latch (3) is a key lockable pull-to-release type. The inside latch (4) is a pull-to-release latch. Door Window Latch (Closed Cab Only) The door window (5) can be swung open by releasing the window from inside the cab.
  • Page 62 Operation Rear Window Latch (Closed Cab Only) The rear window (1) can be partially opened and secured in place with the rear window latch. To open the window, grab the latch handle (2), PULL UP and then push the window OUTWARD. To close and secure the window, pull the latch handle UP and then INWARD.
  • Page 63 Operation OU1010 Windshield Installation IMPORTANT! Be sure the windshield retainer plate is secured in place after installing the windshield back into the cab. Never operate the vehicle with the windshield in place and the retainer plate missing. 1. With the seal bulb on the windshield toward the cab, place the top of the windshield under the upper retainer (9).
  • Page 64 Operation Front Windshield Wiper (Closed Cab Only) OS19301 This three position rocker switch (1) is located in the lower bank of switches on the right side of the dash. This single rocker switch controls the speed of the front windshield wiper. ï...
  • Page 65 Operation Windshield Washer Control (Closed Cab Only) This rocker switch (2) is spring loaded to return to the OFF position when released. OS19401 The switch is located in the lower bank of switches on the right side of the dash. ï...
  • Page 66 Operation Rear Window Wiper (Closed Cab Only) The rear window wiper rocker switch (1) is located on the OM1530 motor housing of the rear wiper. The switch has two positions: wiper ON (2) and wiper OFF (3). OU0170 Cab Heater/Air Conditioning Controls (Closed Cab Only) OS1960 OS1950...
  • Page 67 Operation To heat the cab: ï turn A/C switch (6) to OS1950 the OFF position, ï turn temperature control knob (7) to far right position (RED = HOT), ï direct desired air flow by adjusting vent louvers, ï turn fan control (5) to position ì3î (8) to assure rapid warm-up. To defrost the cab: ï...

  • Page 68: Carriages

    Operation Carriages Quick Attach This vehicle is equipped with a quick attach system for easy attachment changing. Attachment Removal Be sure you are performing this procedure on level ground. 1. Come to a complete stop, place the travel select lever in the (N) NEUTRAL DETENT position and engage the parking brake switch.
  • Page 69 Operation Attachment Reconnect Be sure you are performing this procedure on level ground. 1. Position the vehicle directly behind the attachment to be mounted. 2. Tilt the quick attach backward. 3. Extend the boom approximately 10 feet (3 meters) and drive the vehicle forward until the attachment pivot pins are below and between the two hooks on the attachment.

  • Page 70: Indicators

    Operation Indicators Boom Angle Indicator The boom angle indicator (1) is a bubble type indicator with angular graduations (2) from -20 to +80 . It is located on the left side of the outer boom (3) and is visible from the operators position. Use this indicator to determine the boom angle when reading the capacity chart (see ìUsing the Capacity Chartî...
  • Page 71 Operation Transfer Carriage Extension Indicator The transfer carriage extension indicator (6) shows the operator the distance the transfer carriage has moved from the fully retracted position. Use this indicator along with the boom extension indicator, boom angle indicator and the load chart booklet supplied with the vehicle to determine safe load placement.

  • Page 72: Fork Rating

    Operation Fork Rating All approved forks for this vehicle are marked with a maximum load capacity rating. This rating is stamped on the left edge of the fork (1) just below the fork pivot shaft (2). The rating is listed in U.S. pounds and based upon a 24" (610 mm) load center (3).

  • Page 73: Using The Capacity Chart

    ìLoad Chartî section at the end of this manual. If a load chart for an attachment you would like to use is not included in this manual, contact your Lull Distributor or the JLG Service Department at: (877) 554-5438 or (717) 485-6657 to confirm the attachment you are interested in using may be used and whether a load chart is required.
  • Page 74 Operation To accurately use the capacity chart, the operator must first determine three important things: 1. Weight of the load being lifted. 2. Height of the structure where the load is to be placed. 3. Distance where the load will ultimately be placed in front of the front tires. Reading Capacity Charts Example: (1) 1.
  • Page 75 Operation Sample Capacity Chart 4110427 Use with Lull approved carriages only. 944E-42 0" 0 ft. 66° 60° SAFETY INSTRUCTIONS 50° Always connect couplers on hydraulically powered 40° attachments. 30° 20° 0" 10° 24" 0° 0 ft. ASME B56.6-2002 Part lll -5°...

  • Page 76: Stabil-Trak System

    Operation Stabil-TRAK System Understanding the Stabil-TRAKô System The following describes the three basic modes of the patented Stabil-TRAK system. The vehicle may operate in OS1970 any one of these three modes. Free Pivot Mode With the boom below 40 (1), the Stabil-TRAK system is in the FREE PIVOT MODE (2) and the rear axle is allowed to pivot freely.
  • Page 77 Operation Locked Mode With the boom above 40 (4) and by activating one or more of the functions (as follows), the Stabil-TRAK system is in the LOCKED MODE (5). The rear axle is locked so it is rigid with the frame. The Stabil-TRAK lock light on the front dash panel will be ON (6).
  • Page 78 Operation Slow Pivot Mode With the boom above 40 (1), the Stabil-TRAK System is now in the SLOW PIVOT MODE (2) when the service brake pedal is not applied and the transmission is in gear. In this mode the rear axle is UNLOCKED and is allowed to pivot but will respond SLOWLY to changes in terrain.

  • Page 79: Stabil-Trak™ System Test

    If the Stabil-TRAK lock light goes OFF and the front left tire lowers to the ground consistently during Steps 4 through 7, the Stabil-TRAK system is not functioning properly and the test should be stopped immediately. Contact your local Lull Distributor immediately to repair the system.
  • Page 80 Operation Stabil-TRAK System Test Procedures Step 1 a. Place the vehicle on a level surface with 0 sway. b. Have the boom fully retracted and horizontal. c. Place an 8" (203 mm) wood or cement block in front of the front left tire. d.
  • Page 81 Operation Stabil-TRAK System Test Procedures Step 4 a. Use your left foot to depress the service brake pedal. b. Move the travel select lever to the (R) REVERSE position and the range selector to the (2) SECOND gear position. c. Ease your left foot partially off the service brake pedal, just keeping the Stabil-TRAKô...
  • Page 82 Operation Stabil-TRAK System Test Procedures Step 7 a. With the parking brake switch ON, move the travel select lever to the (N) NEUTRAL DETENT position. b. Lower the boom to exactly 45 . c. Frame sway the vehicle no more than 5 to the left. d.
  • Page 83 Note: If Steps 1-9 prove positive, the Stabil-TRAKô system is functioning properly, and the vehicle can be returned to service. If any of these steps indicate that the Stabil-TRAKô system is not functioning properly, contact your local Lull Distributor immediately to repair the system. Model 944E Origin 3/04...
  • Page 84 Operation This Page Intentionally Left Blank Model 944E Origin 3/04 Courtesy of Crane.Market...

  • Page 85: Refueling

    Operation Refueling Make sure the vehicle is level to assure an accurate fuel level reading. The fuel tank is capable of holding 45 gallons (171 liters) of diesel fuel. Fuel Types OS0860 The preferred fuel is ASTM #2 diesel fuel with a minimum Cetane rating of 40. #2 diesel fuel gives the best fuel economy and performance under most operating conditions.
  • Page 86 Operation Fuel Cap The fuel cap (1) is conveniently located on the left side of the vehicle. The fuel cap meets EPA standards. To remove the fuel cap: 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and turn the ignition switch to the OFF position.

  • Page 87: Normal Starting

    Operation Normal Starting 1. Enter the cab and adjust the seat for comfortable operation. 2. Adjust the mirrors to obtain the best rear view from the operatorís position. WARNING: DO NOT start the engine unless you are in the seat with the seat belt fastened around you.

  • Page 88: Cold Starting

    Operation Cold Starting The engine is equipped with a 120 volt 750 watt block heater. Block heaters are recommended when temperatures drop below 10 F (-12 C). (Temperature ranges will vary when using different oil weights. Consult the engine manufacturerís manual for other variables.

  • Page 89: Jump Starting

    Operation Jump Starting WARNING: NEVER jump start the vehicle directly to the starter solenoid. Death or serious personal injury could result from the vehicle lurching forward or backward and running over the person attempting to jump start the vehicle directly to the starter. WARNING: To avoid death or serious personal injury when jump starting with another vehicle, be certain that the two vehicles are not...

  • Page 90: How To Pick, Carry & Place A Load

    Operation How To Pick, Carry & Place A Load To pick a load, move the forks inward or outward on the fork shaft so that they are aligned with the openings in the pallet. Extend the boom slowly so the forks slide into the openings in the pallet.

  • Page 91: Elevating Personnel

    Operation Elevating Personnel This vehicle is designed to lift and transport materials and should not be used to elevate personnel except as explained in this section. Only equipment designed and approved for elevating personnel should be used. If the vehicle must be used to elevate personnel, use only a compliant work platform. Refer to ìDefining Platforms For Elevating Personnelî...
  • Page 92 Operation 7. The platform must have a restraining means such as a guardrail or a means of securing personnel such as a body belt or lanyard for each occu- pant of the platform. 8. The guardrail or similar structure shall have a nominal height to the plat- form floor of 42"...
  • Page 93 Operation Preparation and Set-up WARNING: Never allow anyone to alter or modify any part of the work platform. Any modification to the platform which could result in seri- ous personal injury to anyone on the platform. 1. DO NOT alter or modify the work platform in any manner. 2.
  • Page 94 Operation Elevating Personnel WARNING: Never operate the Attachment Tilt function to tilt the platform forward or rearward when elevating with personnel aboard. Death or serious personal injury could result. DANGER: Never operate this or any equipment in an area in which overhead or underground cables or power sources exist without first requesting that the appropriate power company or utility company de-energize the lines or take other suitable precautions.

  • Page 95: Using Other Attachments

    Operation Using Other Attachments Numerous attachments, marketed by JLG are available for this vehicle. The capacity charts attached to this vehicles dash are to be used with JLG approved attachments only. Hydraulically powered attachments must only be used on vehicles equipped with auxiliary hydraulics.
  • Page 96 Operation The attachments listed below are supplied with their own individual set of capacity charts as shown in the last section of this manual: ï 72" Swing Carriage ï 10 Foot Truss Boom ï 10 Foot Truss Boom w/Winch ï 3 Foot Truss Boom w/Winch Hydraulically actuated attachments also have a maximum hydraulic pressure rating.

  • Page 97: Shut-Off

    Operation Shut-Off 1. Bring the vehicle to a complete stop using the service brakes. 2. Park the vehicle on level ground. WARNING: To prevent death or serious personal injury, be cer- tain to lower the boom, engage the parking brake switch, and shut off the engine prior to exiting the vehicle.

  • Page 98: Emergency Operations

    IMPORTANT! In the event the vehicle is disabled and cannot be moved under engine power, the situation must be properly evaluated and dealt with on an individual basis. Contact your local Lull Distributor or the JLG Service Department at (877) 554-5438 or (717) 485-6657 for specific instructions for your particular situation.
  • Page 99 Emergency Operations 11. Pressurize the park brake with the pressurizing unit. Pump pressure into the park brake system. 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.

  • Page 100: Emergency Boom Lowering

    If you are unsure about any part of these procedures contact your local Lull Distributor or the JLG Service Department at (877) 554-5438 or (717) 485-6657 for specific instructions for your particular situation.
  • Page 101 Emergency Operations In any case of hydraulic line failure, it is critical to correctly identify which hydraulic line has failed. Identify the hydraulic line that has failed and use the table on page 100 to determine which Step to follow to retract and lower the boom. The hydraulic lines are: ï...
  • Page 102 Emergency Operations NORMAL STEPS FOLLOW THIS FOLLOW THIS HYDRAULIC LINE STEP IF PARTS STEP IF PARTS THAT FAILED ARE NOT ARE AVAILABLE AVAILABLE BOOM LIFT LINE (LIFT CYLINDER TO BLOCK OR STEP 1 STEP 2 BLOCK TO FRAME BULKHEAD) BOOM LOWER LINE (LIFT CYLINDER TO BLOCK OR STEP 1 Refer to STEP 1...
  • Page 103 Emergency Operations 5. Replace the failed hydraulic line with a new part. ï Boom Extend Line - Extend Cylinder to Block (1) ï Boom Retract Line - Extend Cylinder to Block (2) ï Boom Extend Line - Block to Frame Bulkhead (3) ï...
  • Page 104 Emergency Operations STEP 2 USE IN CASE OF: BOOM LIFT LINE FAILURE - Lift Cylinder to Block (1) BOOM LIFT LINE FAILURE - Block to Frame Bulkhead (2) BOOM EXTEND LINE FAILURE - Extend Cylinder to Block (3) BOOM EXTEND LINE FAILURE - Block to Frame Bulkhead (4) 1.
  • Page 105 Emergency Operations OU1060 Model 944E Origin 3/04 Courtesy of Crane.Market...

  • Page 106: General Maintenance Introduction

    General Maintenance General Maintenance Introduction This section of the manual contains a maintenance schedule and checklist with references to pertinent procedures and instructions. To prevent problems before they occur, follow the maintenance schedule. NOTE: The Lubrication (1) and Maintenance Chart (2) decals are located inside the engine cover (3).

  • Page 107: Maintenance Schedule And Checklist

    General Maintenance Maintenance Schedule and Checklist 1000 2000 OU0510 Model 944E Origin 3/04 Courtesy of Crane.Market...

  • Page 108: Lubrication Points

    General Maintenance 1. Lubrication Points Lubricate the following grease fittings using Multi-Purpose Grease (MPG) every 50 hours: OS1750 OH2680 NOTE: Shorten the lubrication interval on all lube points when operating in severe conditions or during high cycling operation. OU0520 Model 944E Origin 3/04 Courtesy of Crane.Market...

  • Page 109: Air Cleaner

    General Maintenance 2. Air Cleaner The front dash panel illuminates an indicator light that will alert the operator when it senses restricted air flow to the engine. This indicates the air filter(s) needs servicing. NEVER operate the vehicle without the air cleaner assembly and both filters in place.
  • Page 110 General Maintenance 2. Remove the primary element (1). Inspect the element for damage. Dam- aged elements should never be reused. OU0200 3. Thoroughly clean the interior of the air filter canister (2) and vacuator valve (3). 4. If replacing the inner element (4) at this time, carefully slide the element out.

  • Page 111: Optional Closed Cab Air Filters

    General Maintenance 3. Optional Closed Cab Air Filters The optional closed cab has two air filters. These filters require periodic maintenance. Recirculation Air Filter Periodically remove and inspect the recirculation air filter (7) located directly behind the seat. Remove the two thumb screws (8) holding the vent cover and filter (7) to the heater assembly housing (9).

  • Page 112: Engine Cooling System

    General Maintenance 4. Engine Cooling System A. Engine Coolant Level Check (10 Hour Intervals) 1. Level the vehicle, ground the attach- ment, place the travel select lever in OS0800 OH2660 the (N) NEUTRAL DETENT position, engage the parking brake switch and shut off the engine.
  • Page 113 General Maintenance B. Drain and Flush Radiator (2000 Hour Intervals) 2000 1. Level the vehicle, ground the attach- ment, place the travel select lever in OH2700 OS0810 the (N) NEUTRAL DETENT posi- tion, engage the parking brake switch and shut off the engine. WARNING: DO NOT attempt this procedure when the engine is hot.
  • Page 114 General Maintenance 4. Locate the petcock (1) on the bottom of the radiator. Place a hose (2) onto the petcock and channel the coolant into a container. Open the petcock and allow the coolant to drain. 5. Flush the radiator with clean water and allow to drain. After radiator is drained, close the petcock and remove the hose.
  • Page 115 General Maintenance MU13802 9. Fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace the radiator cap. Add coolant to the overflow bottle until the bottle is 1/2 to 3/4 full. This ìoverfillingî will compensate for any air in the cooling system.

  • Page 116: Engine Oil And Filter

    General Maintenance 5. Engine Oil and Filter Engine Oil Recommendations The use of quality engine oil combined with the appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability. Use 15W40 motor oil that at least meets the manufacturers minimum recommended oil specifications as defined in their operator manual.
  • Page 117 General Maintenance B. Oil and Filter Change (250 Hour Intervals) 1. Operate the engine until OS0830 warm (approximately 5 OH2710 minutes). 2. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DETENT position, come to a complete stop, engage the parking brake switch and shut off the engine.
  • Page 118 General Maintenance OU1280 7. Remove the oil filter (1) and clean the filter sealing surface. 8. Apply a thin coat of clean engine oil to the new filter mating surface. 9. Install the new oil filter and hand tighten. Use an oil filter wrench or strap to tighten the filter down another 1/4 to 1/2 turn.
  • Page 119 General Maintenance 10. Install the drain plug (2) into the oil pan and tighten securely. OU0303 11. Remove the engine oil fill cap (3) and add 15W40 motor oil. (Refer to engine manufacturers manual for recommended oil type for various condi- tions.) Engine oil capacity with filter change is 10.5 quarts (10 liters).

  • Page 120: Engine Fuel System

    General Maintenance 6. Engine Fuel System A. Drain Water from Fuel Water Separator/Filter (10 Hour Intervals) OH2660 Unlatch and open the engine cover. OS0851 Loosen the drain cock (1) on the underside of the fuel filter (2) and allow all the water to drain into a container until clear fuel is visible.
  • Page 121 General Maintenance B. Change Fuel Filter (250 Hour Intervals) OS0870 OH2710 The fuel filter (2) must be changed at shorter intervals with evidence of water or contaminated fuel. 1. Unlatch and open the engine cover. 2. Clean around the fuel filter head (3). 3.
  • Page 122 General Maintenance C. Replace In-line Fuel Strainer (250 Hour Intervals) OH2710 1. Unlatch and open the engine cover. 2. The fuel strainer (1) is located down line from the engines lift pump (2). Loosen the two hose clamps (3) that secure the strainer in place. 3.
  • Page 123 General Maintenance D. Bleeding Fuel System Air must be vented from the fuel system whenever any component between the fuel tank and the injection pump has been disconnected, or when the system has been emptied or run out of fuel. WARNING: DO NOT bleed the fuel system of a hot engine.
  • Page 124 General Maintenance WARNING: KEEP CLEAR of spraying fuel. Fuel can spray when venting high pressure lines. The fuel pressure is sufficient to penetrate the skin and cause serious bodily injury. Wear protective clothing and safety glasses. 4. To vent the high pressure fuel lines (1), loosen one fitting (2) at the injector (3).

  • Page 125: Engine Fan Belt

    General Maintenance 7. Engine Fan Belt Engine Fan Belt Check (1000 Hour Intervals) 1000 1. Level the vehicle, ground the OH2690 OS08802 attachment, place the travel select lever in the (N) NEU- TRAL DETENT position, engage the parking brake switch and shut off the engine.

  • Page 126: Air Conditioner Compressor Belt (Optional)

    General Maintenance 8. Air Conditioner Compressor Belt (Optional) Air Conditioner Compressor Belt Check (1000 Hour Intervals) 1000 1. Level the vehicle, ground the attachment, place OH2690 the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and shut off the engine.

  • Page 127: Hydraulic Oil And Filter

    General Maintenance 9. Hydraulic Oil and Filter A. Hydraulic Oil Level Check (10 Hour Intervals) OH2660 OS0660 1. Level the vehicle, place the travel select lever in the (N) NEUTRAL DETENT position and engage the parking brake switch. 2. Lower and retract the boom, level and lower the attachment to the ground, transfer the transfer carriage to the rear position and shut off the engine.
  • Page 128 General Maintenance B. Hydraulic Oil & Filter Change (First 100 Hours - Filter Only) OT0840 OU0530 (1000 Hour Intervals - Oil & Filter) 1000 OS0840 Change the hydraulic oil filter after the OH2690 first 100 hours of operation and change the hydraulic oil and filter every 1000 hours of operation thereafter.
  • Page 129 General Maintenance OU1310 13. Place a receptacle under the hydraulic reservoir drain plug (10). The recep- tacle must be large enough to hold 35 gallons (132 liters) of oil. Remove the drain plug and allow the oil to drain into the receptacle. Transfer the oil to a container with a cover and label the container as used oil.

  • Page 130: Transmission Oil And Filter

    General Maintenance 10. Transmission Oil and Filter Approved Universal Tractor Fluid JOHN DEERE JDM J20C (HY-GARD) FORD/NEW HOLLAND ESN-M2C134-D (HYDRAULIC OIL 134) MASSEY FERGUSON M-1141 (PERMATRAN lll) CHEVRON CHEVRON 1000 THF A. Transmission Oil Level Check (10 Hour Intervals) 1. Level the vehicle, ground the attach- ment, place the travel select lever in OH2660 OS0890...
  • Page 131 General Maintenance B. Transmission Oil & Filter Change (First 100 Hours) 1000 (1000 Hour Intervals) OS0950 OU0530 OH2690 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and shut off the engine.
  • Page 132 General Maintenance 5. Loosen, do not remove the upper battery tray retainer bolt (1). Swing the upper battery tray out to gain access to the transmission filter. 6. Remove the filter (2) and dispose of properly. Clean the mating surface where the filter mounts.

  • Page 133: Transfer Case Oil

    General Maintenance 11. Transfer Case Oil Approved Universal Tractor Fluid JOHN DEERE JDM J20C (HY-GARD) FORD/NEW HOLLAND ESN-M2C134-D (HYDRAULIC OIL 134) MASSEY FERGUSON M-1141 (PERMATRAN lll) CHEVRON CHEVRON 1000 THF A. Transfer Case Oil Level Check (250 Hour Intervals) OH2710 OU0560 1.
  • Page 134 General Maintenance B. Transfer Case Oil Change OU0530 (First 100 Hour Intervals) and (1000 Hour Intervals) OU0550 1000 1. Place the vehicle on level OH2690 ground, ground the attach- ment, level the vehicle side to side, place the travel select lever in the (N) NEUTRAL DETENT position, engage the park brake switch and shut off the engine.

  • Page 135: Axle Oil

    General Maintenance 12. Axle Oil A. Axle Oil Level Check (250 Hour Intervals) OH2710 OU0610 Approved Universal Tractor Fluid JOHN DEERE JDM J20C (HY-GARD) FORD/NEW HOLLAND ESN-M2C134-D (HYDRAULIC OIL 134) MASSEY FERGUSON M-1141 (PERMATRAN lll) CHEVRON CHEVRON 1000 THF 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and shut off the engine.
  • Page 136 General Maintenance B. Axle Oil Change (First 100 Hours) OU0530 (1000 Hour Intervals) 1000 NOTE: At the 1000 Hour Interval OU0600 Oil Change also inspect the brake OH2690 disc wear. Refer to ìBrake Disc Inspectionî on page 135 and follow the inspection procedure. After brake disc inspection is complete, reassemble the level plugs using new o-rings.

  • Page 137: Brake Disc Inspection

    General Maintenance 8. Reassemble the level plugs (2) using new o-rings. Torque to 37 lb-ft (50 Nm). 9. Re-install the axle fill plug (1) into axle housing. Torque to 37 lb-ft (50 Nm). 13. Brake Disc Inspection Brake Disc Wear Check (1000 Hour Intervals) 1000 Check the brake discs for wear every...
  • Page 138 General Maintenance 4. Turn the ignition switch to the ON position (with the engine not running), release the park brake (park brake switch OFF). 5. Pressurize the park brake with the pressurizing unit. Pump pressure into the park brake system. DO NOT exceed 650 psi (45 bar). Close the pump needle valve on the pressurizing unit.
  • Page 139 General Maintenance MT2840 B. Rear Axle 1. Working through the level plug hole (1), carefully use a screwdriver to spread the brake discs apart. IMPORTANT! DO NOT damage the surfaces of the brake discs when spreading the brake discs. 2. Using a feeler gauge, check the gap (2) between the brake discs (3). If the gap is greater than .167"...

  • Page 140: Wheel End Oil

    General Maintenance 14. Wheel End Oil WARNING: DO NOT perform service or maintenance on this vehicle with the engine running. Contact with moving parts can cause death or serious personal injury. Approved Universal Tractor Fluid JOHN DEERE JDM J20C (HY-GARD) FORD/NEW HOLLAND ESN-M2C134-D (HYDRAULIC OIL 134) MASSEY FERGUSON...
  • Page 141 General Maintenance B. Wheel End Oil Change (First 100 Hours) OU0530 (1000 Hour Intervals) 1. Position the vehicle on level 1000 ground, move the vehicle OU0580 OH2690 forward or backward enough to ensure that the wheel end fill/drain plug (4) is in the 6 oíclock position (5). OT02902 2.

  • Page 142: Wheels And Tires

    General Maintenance 15. Wheels and Tires A. Tire Air Pressure Check (10 Hour Intervals) OS0900 OH2660 DANGER: LOW TIRE PRESSURE can result in tipover. MAIN- TAIN proper tire pressure at all times. Check all four tires: 1. Remove the valve stem cap. 2.
  • Page 143 General Maintenance B. Wheel Lug Nut Torque Check (First 100 Hours) 1. Wire brush the area around the lug OU0530 nuts if necessary. There are separate OU0150 lockwashers (1) under the lug nuts (2). Be sure the lockwashers are installed under each lug nut. 2.

  • Page 144: Battery

    General Maintenance 16. Battery WARNING: Lead-acid batteries produce flammable and poten- tially explosive gases. To avoid personal injury when checking, testing or charging batteries: ï DO NOT use smoking materials near batteries. ï Keep arcs, sparks and open flames away from batteries. ï...

  • Page 145: Fuse & Relay Replacement

    General Maintenance 17. Fuse & Relay Replacement Fuses and Relays (Fuse Block) The fuses and relays in this vehicle protect the electrical system. The fuses most often fail if there is a short or grounded wire in the applicable circuit. The fuses will have to be replaced if they fail.
  • Page 146 General Maintenance Relay Locations MU33801 Model 944E Origin 3/04 Courtesy of Crane.Market...
  • Page 147 General Maintenance Volt Circuit Controlled 12 Volt Transmission Control 12 Volt Ignition 12 Volt Neutral Start 12 Volt Back-Up Alarm ñ Open 12 Volt Stability Lock 12 Volt Boom Proximity 12 Volt Light Power (Opt) 12 Volt Cab Power (Opt) ñ...
  • Page 148 General Maintenance Fuse Locations MU3390 Model 944E Origin 3/04 Courtesy of Crane.Market...
  • Page 149 General Maintenance Color Circuit Protected 40 Amp Orange Open Cab Vehicle Main 15 Amp Blue Ignition Control 15 Amp Blue Transmission 7.5 Amp Brown Fuel Solenoid 20 Amp Yellow Ignition Power 10 Amp Back-Up Alarm/Horn 10 Amp Stability Circuit 10 Amp Dash ñ...
  • Page 150 General Maintenance Cold Start Grid Heater Fuses The two 125 amp fuses (1) that protect the cold start grid heater are located under the engine hood and are mounted on the lip of the engine panel. 1. Unlatch and open the engine cover. 2.
  • Page 151 General Maintenance ECM Fuses and Relay The two fuse holders (6), that protect the ECM diagnostic system, are located under the engine hood and are tie wrapped to the wire harness on the top of the engine bell housing. One holder contains three 7.5 amp (brown) fuses and the other holder contains three 10 amp (red) fuses.

  • Page 152: Boom Chains And Wear Pads

    General Maintenance 18. Boom Chains and Wear Pads A. Boom Chain Tension Check (250 Hour Intervals) OH2710 OU0840 Check the boom chain tension by measuring the top boom extend chain sag. NOTE: The attachment should remain attached to the quick attach for these checks. 1.
  • Page 153 General Maintenance B. Top Boom Chain Tension Adjustment (As required) NOTE: Always perform the ìBoom Chain Tension Checkî on page 150 before adjusting the boom chain tension. 1. Park the vehicle on level ground. Place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and raise the boom to a horizontal (level) position.
  • Page 154 General Maintenance 3. Return to the cab, start the engine and cycle the boom all the way out and all the way in several times. 4. Fully extend the boom, then retract it 2" (51 mm) (one inch per section). Turn the vehicle OFF.
  • Page 155 General Maintenance Reposition Extend Chain Clevis NOTE: Before proceeding with the repositioning of the extend chain clevis, check the chain for any chain stretch that might have occurred. Refer to ìElongation - Extend Chain Onlyî on page 157. 1. Return to the cab, start the engine and fully retract the boom. With the boom horizontal, extend the boom out approximately 2 ft (610 mm) and shut the vehicle OFF.
  • Page 156 General Maintenance 4. At the front top of the outer boom (1), remove one of the retaining rings (2) from the clevis mounting pin (3). Remove the pin from the mounting plates. Inspect the pin for wear or other damage. Replace the pin if damaged. 5.
  • Page 157 General Maintenance C. Boom Chain Inspection Extend Chains (250 Hour Intervals) OH2710 Retract Chains OU0850 (1000 Hour Intervals) 1000 OH2690 OU0870 WARNING: Worn pins, stretched or cracked links or corrosive environments can cause chain failure. A chain failure could result in uncontrolled boom movement, loss of load or vehicle instability and could cause death or serious injury and/or property damage.
  • Page 158 General Maintenance The above load cycles and environmental conditions make it impossible to predict chain life. It is therefore necessary to conduct frequent inspections until replacement life can be predicted. The boom chainís normal life expectancy can be expressed as a maximum percent of elongation.
  • Page 159 General Maintenance Elongation - Extend Chain Only When the original length (3) of 12.00" (305 mm) per foot of new chain has elongated from wear to a length (4) of 12.36" (313 mm), the chain must be discarded and replaced. It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation.
  • Page 160 Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system. This condition damages the chain as well as increases frictional loading and should be corrected. Contact your local Lull Distributor or the JLG Service Department at (877) 554-5438 or (717) 485-6657 for specific instructions.
  • Page 161 General Maintenance Cracked Plates Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain should be replaced in its entirety. it is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself.
  • Page 162 Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration. It is important that a reputable lubrication specialist, a Lull Distributor or the vehicle distributor be consulted for guidance. Model 944E Origin 3/04 Courtesy of Crane.Market...
  • Page 163 General Maintenance E. Wear Pad Inspection (Boom) (50 Hour Intervals) OH2680 OU0820 Visually inspect the boom wear pads between the boom sections at the rear and front of the boom for excessive wear. The average expected life of the wear pads will vary depending upon vehicle use, weight of the loads, operating conditions and the location of the boom pads inside the boom.
  • Page 164 Contact your local Lull Distributor. OS1230 Replacement of boom wear pads must be performed by a Lull Distributor when the wear pads indicate. IMPORTANT! The boom has been factory lubricated for proper wear pad break-in and will normally not require further lubrication.

  • Page 165: Transfer Carriage Rollers And Wear Pads

    .06" (1,5 mm). If the gap is greater than .06" (1,5 mm) the wear pads require shimming. NOTE: Additional shims are available by contacting your local Lull Distributor. OU0950 5. Check the thickness of the wear pads. The wear pad has a total thickness of .75"...
  • Page 166 General Maintenance Wear Pad Shimming (As Required) NOTE: The attachment should remain attached to the quick attach for this proce- dure. 1. Park the vehicle on level ground. Place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and raise the boom to a horizontal (level) position.
  • Page 167 General Maintenance 3. This procedure will require the gap check to be made in three separate locations. Transfer carriage all the way retracted, transfer carriage all the way forward and the transfer carriage moved forward about halfway. 4. With the transfer carriage all the way retracted, use a rawhide hammer to tap the rollers (5) against the rails (6).
  • Page 168 General Maintenance Front Roller Gap Check (50 Hour Intervals) OH2680 OU1030 NOTE: The attachment should remain attached to the quick attach for these checks. 1. Park the vehicle on level ground. Place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and raise the boom to a horizontal (level) position.
  • Page 169 General Maintenance Front Upstop Wear Pad Check (250 Hour Intervals) OU1050 OH2710 The front upstop wear pads (5) are located under the frame rails at the front of the transfer carriage. OU1000 Each wear pad (5) is manufactured with a convenient wear pad indicator. This is the angled cut (6) at each end of all wear pads The total thickness (7) of a new wear pad (5) is .625"...
  • Page 170 General Maintenance Front Upstop Wear Pad Gap Check (250 Hour Intervals) OU1040 OH2710 NOTE: The attachment should remain attached to the quick attach for these checks. 1. Park the vehicle on level ground. Place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and raise the boom to a horizontal (level) position.
  • Page 171 General Maintenance Roll Back Hose Inspection (50 Hour Intervals) With the transfer carriage fully forward, OU1180 OH2680 check the roll back hoses and hose protector sleeves for wear. ï Inspect all hoses (5) for wear. Replace any hoses when the steel braids are first visible.

  • Page 172: Storage And Transport

    General Maintenance Storage and Transport Storage A. Before Storing Perform the following steps prior to placing the vehicle in storage: 1. Clean the entire vehicle. DO NOT remove the grease coating from the boom chains. 2. Apply corrosion inhibitor to the exposed metal on the top of the frame rails in front of the transfer carriage rollers.

  • Page 173: Transport

    General Maintenance Transport When transporting the vehicle, make use of all tie down locations on the vehicles frame. 4109801 4109801 OU02301 NOTE: The user assumes all responsibility for choosing the proper method of trans- portation, and the proper selection and use of transportation and tiedown devices, making sure the equipment used is capable of supporting the weight of the vehicle being transported and that all manufacturerís instructions and warnings, regulations and safety rules of their employer, the Department of Transportation and/or any...

  • Page 174: Test Procedures

    Test Procedures Test Procedures Parking Brake/Transmission De-Clutch Test Procedures To check that the parking brake/transmission de-clutch system is functioning properly, perform the following tests. IMPORTANT! These tests should be performed in (1) FIRST gear only. WARNING: DO NOT operate this vehicle unless you are in the seat with the seat belt fastened around you.
  • Page 175 2. Block all four wheels to prevent the vehicle from moving. 3. Place the accident prevention tags (1) on the ignition switch (2) and steer- ing wheel (3). 4. Service the parking brake immediately or contact your local Lull Distributor to repair the system. MU0291 Model 944E Origin 3/04 Courtesy of Crane.Market...

  • Page 176: Specifications

    Specifications Specifications Fluid & Lubrication Capacities Engine Crankcase Oil: Capacity with Filter Change........... 10.5 quarts (10 liters) Filter Capacity.................0.85 quart (0,80 liter) Type Of Oil....................15W40 Fuel Tank: Total Capacity ..............50.2 gallons (190 liters) Usable Capacity ..............45 gallons (171 liters) Type of Fuel Below 32 F (0 C) ............

  • Page 177: Tires

    Specifications Transfer Case: Transfer Case Capacity ............1.7 quarts (1,6 liters) Type Of Fluid ......Universal Tractor Fluid (See Chart On page 131) Tires Air Pressure: Standard Tire: 15.5 - 25, (12 Ply minimum) ........65 psi (448 kPa) Optional Rock Tire: 15.5 - 25, 12 Ply ..........65 psi (448 kPa) Optional Radial Tire: 15.5R25 2 star ..........

  • Page 178: Vehicle Dimensions

    Specifications Vehicle Dimensions With Standard 15.5 - 25, 12 Ply Tires: (A) Length (less forks) ............253 inches (6.426 mm) (B) Width................101 inches (2.565 mm) (C) Height ................95.5 inches (2.426 mm) (D) Wheelbase..............131 inches (3.327 mm) (E) Ground Clearance ............. 16 inches (406 mm) (F) Tread Center ..............

  • Page 179: Electrical System

    Specifications Electrical System Rating: ................12V DC Negative Ground Number of Batteries: ................Two Type: Maintenance Free ........850 Cold Cranking Amps (Each Battery) Series of Battery: ..................27 Alternator Rating: .............12 Volt - 95 Amp Engine Turbocharged Cummins: Model ......................QSB4.5T Horsepower ................
  • Page 180 Specifications This Page Intentionally Left Blank Model 944E Origin 3/04 Courtesy of Crane.Market...

  • Page 181: Index

    Index Index Cold Starting ........86 Accelerator Pedal ......26 Coolant Drain and Flush ....111 Accident Prevention Tags ....5 Coolant Level ....... 110 Additional Operators ......5 Crab Steering Mode ....... 29 Air Cleaner ........107 Air Conditioning ......64 Decals ..........20 Air Pressure .........140 Defining Platforms For Elevating Alternator Charging Warning...
  • Page 182 Index Front Joystick ........ 36 Front Roller Gap Check ....166 Ignition Switch ........27 Front Roller Shimming ....166 In-line Fuel Strainer ......120 Front Upstop Wear Pad ....167 Inner Safety Element ....107 Front Upstop Wear Pad Gap ..168 Inspection - Pre-Operation .....23 Front Upstop Wear Pad Instructional Symbols .......6...
  • Page 183 Index Parking Brake/Transmission Tip Over Hazard ......18 De-Clutch Test Procedures ..172 Tires ..........141 Parking Lights ........56 Top Boom Chain Tension Pre-Operation Inspection ....23 Adjustment ....... 151 Preparation and Prevention ...15 Towing a Disabled Vehicle ..... 96 Transfer Carriage ......36 Radiator Drain and Flush .....111 Transfer Carriage Extension Reading Capacity Charts ....70...
  • Page 184 Index This Page Intentionally Left Blank Model 944E Origin 3/04 Courtesy of Crane.Market...

  • Page 185: Load Charts

    Load Charts Load Charts This Section Contains Representations Of All The Load Charts Contained In The Operators Cab Of This Vehicle Model 944E Origin 3/04 Courtesy of Crane.Market...
  • Page 186 Always connect couplers on hydraulically powered 40° attachments. 30° 20° 80" 1" 10° 24" 0° 0 ft. -5° ASME B56.6-2002 Part lll 13.3 35.7 0 ft. Use with Lull approved carriages only. 4110426 OU1362 Model 944E Origin 3/04 Courtesy of Crane.Market...
  • Page 187 Load Charts Standard Carriages, Side Tilt Carriages, Single Fork Posi- tioning Carriages and Dual Fork Positioning Carriages (Transfer Carriage Fully Retracted) 4110427 Use with Lull approved carriages only. 944E-42 0" 0 ft. 66° 60° SAFETY INSTRUCTIONS 50° Always connect couplers on hydraulically powered 40°...
  • Page 188 30° 20° 80" 1" 10° 24" 0 ft. ASME B56.6-2002 Part lll -5° 13.9 0 ft. 36.2 4500 1000 2000 3000 Use with Lull approved carriages only. 4110428 OU1381 Model 944E Origin 3/04 Courtesy of Crane.Market...
  • Page 189 Load Charts Swing Carriage (Transfer Carriage Fully Retracted) 4110429 Use with Lull approved carriages only. 0" 944E-42 0 ft. 66° SAFETY INSTRUCTIONS 50° Always connect couplers 40° on hydraulically powered attachments. 30° 20° 0" 10° 24" 0 ft. ASME B56.6-2002 Part lll -5°...
  • Page 190 10° • travel slowly • rig properly • use two tethers 0 ft. -5° ASME B56.6-2002 Part lll 32 28 43.1 20.8 0 ft. Use with Lull approved truss booms only. 4110430 OU1401 Model 944E Origin 3/04 Courtesy of Crane.Market...
  • Page 191 Load Charts 10 Ft. Truss Boom & 10 Ft. Truss Boom w/Winch (Transfer Carriage Fully Retracted) 4110431 Use with Lull approved truss booms only. 944E-42 0" 0 ft. SAFETY INSTRUCTIONS 66° 60° Always connect couplers on hydraulically powered attachments. 50°...
  • Page 192 1" 10° ALWAYS • travel slowly • rig properly • use two tethers 0 ft. -5° ASME B56.6-2002 Part lll 0 ft. 36.3 Use with Lull approved truss boom winch only. 4110432 OU1421 Model 944E Origin 3/04 Courtesy of Crane.Market...
  • Page 193 Load Charts 3 Ft. Truss Boom w/Winch (Transfer Carriage Fully Retracted) 4110433 Use with Lull approved truss boom winch only. 0" 944E-42 0 ft. SAFETY INSTRUCTIONS 66° 60° Always connect couplers 50° on hydraulically powered attachments. 40° 30° SWINGING LOADS can cause MACHINE TIPOVER 20°...
  • Page 194 Load Charts This Page Intentionally Left Blank Model 944E Origin 3/04 Courtesy of Crane.Market...

  • Page 195: Accident Prevention Tags

    Accident Prevention Tags Accident Prevention Tags 8990401 Origin 5/00 OS2180 Courtesy of Crane.Market...
  • Page 196 Accident Prevention Tags 8990401 Origin 5/00 OS2180 Courtesy of Crane.Market...
  • Page 197 TRANSFER OF OWNERSHIP An Oshkosh Corporation Company To Product Owner: If you now own but ARE NOT the original purchaser of the product covered by this manual, we would like to know who you are. For the purpose of receiving safety-related bulletins, it is very important to keep JLG Industries, Inc.
  • Page 198 Courtesy of Crane.Market...
  • Page 199 Courtesy of Crane.Market...
  • Page 200 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 P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House 11 Bolwarra Road 80-Suite 71...

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