Lull PLACEACE Series Service Manual

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Page 3: Table Of Contents
SECTION CONTENTS Section Subject Page Section 1 Safety Practices ............Introduction .
Page 4: Subject
Section Subject Page Section 5 Axles, Drive Shafts, Wheels, Tires and Brakes ....... Axle, Drive Shaft and Wheel Component Terminology .
Page 5 Section Subject Page Section 8 Hydraulic System ............Hydraulic Component Terminology .
Page 6 Section Subject Page Section 10 Stabil-TRAK™ System ..........10.1 10.1 Stabil-TRAK™...
Page 7 Section 1 Safety Practices Contents PARAGRAPH TITLE PAGE Introduction ............Owners/Operators Manual .
Page 8: Safety Practices
The service technician must therefore Read, understand and follow the information in this read, understand and follow the instructions in the Lull manual, and obey all locally approved safety practices, 644E-42 and 944E-42 Telescopic Material Handler procedures, rules, codes, regulations and laws.
Page 9: Training Mechanics As Operators
OSHA indicate property-damage-only hazards. regulations listed in the NOTICE below, and reads and understands the Lull 644E-42 and 944E-42 Telescopic Material Handler Owners/Operators Manual before operating or maintaining the vehicle. NOTICE: Under OSHA rules, it is the responsibility of the employer to provide operator training.
Page 10: Accident Prevention Tag Usage
Safety Practices 1.4.2 Hazard Statements ACCIDENT PREVENTION TAG USAGE Signal words and messages are used in conjunction with the safety alert symbol to create hazard statements. These hazard statements convey important information about safety. Four types of hazard statements are used in this manual. Each statement indicates the existence and degree of relative risk of the hazard described within the statement that follows the signal word.
Page 11: Safety Instructions
Safety Practices SAFETY INSTRUCTIONS 1.6.2 Equipment Hazards OWNERS/OPERATORS MANUAL: Before operating the Following are general safety statements to consider vehicle, carefully read, understand and follow the before performing maintenance procedures on a vehicle. Owners/Operators Manual. Additional statements related to specific tasks and OPERATIONAL PROTECTION: Before operating the procedures are located throughout this manual and are vehicle or returning it for operational use, check that the...
Page 12: Emergency Exit Rear Window
Safety Practices 1.6.3 General Hazards pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, causing SOLVENTS: Only use approved solvents, and solvents infection, gangrene, and other serious personal injury. that are known to be safe for use. Relieve all pressure before disconnecting any HOUSEKEEPING: Keep the work area and operator’s component, part, line or hose.
Page 13: Hazard/Emergency Information Signs
Safety Practices HAZARD/EMERGENCY If a replacement sign is needed, refer to the Owners/ Operators Manual and parts catalog for the latest parts INFORMATION SIGNS numbers and ordering information. Or, contact the JLG Parts Department directly at: Locations of vehicle hazard and other emergency information signs are shown below.
Page 14 Safety Practices This Page Intentionally Left Blank Model 644E-42/944E-42 Rev. 6/04...
Page 15 Section 2 General Information, Specifications and Maintenance Contents PARAGRAPH TITLE PAGE 644E-42 / 944E-42 Component Terminology......Introduction .
Page 16 General Information, Specifications and Maintenance Fluids, Lubricants and Capacities ........2.23 2.6.1 Axles (Differential Housings) .
Page 17: 42 / 944E-42 Component Terminology
General Information, Specifications and Maintenance 644E-42 / 944E-42 COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this manual, it is necessary that the operator/mechanic be familiar with the name and location of the major assemblies on this vehicle. The following illustration identifies the components that are referred to throughout this manual.
Page 18: Introduction
IMPORTANT: Before you operate this vehicle, read the A warranty registration form must be filled out by the Lull manual completely and carefully, so that you will distributor, signed by the purchaser, and returned to JLG understand the safety instructions and the operation of when the vehicle is sold and/or put into use.
Page 19: Torques
General Information, Specifications and Maintenance TORQUES 2.3.1 SAE Flat Face O-Ring Seal Hydraulic Fittings a. Assembly Procedure Improper assembly of this type of joint will result in leaking joints. Under tightening will result in the joint loosening during normal usage. Foreign material on either seal surfaces will cause damage to one or both mating parts when the joint is tightened resulting in a leaking joint.
Page 20 General Information, Specifications and Maintenance c. Adjustable (Angle) O-Ring Boss Fittings To d. Pipe Fittings to Pipe Ports O-Ring Boss Ports Improper assembly of this joint will result in a leaking joint Improper assembly of this joint will result in a leaking joint. and possible damage to the port.
Page 21: Metric Conversion Factors
General Information, Specifications and Maintenance METRIC CONVERSION FACTORS AIR PRESSURE Pounds per square inch (psi) 6.895 Kilopascals (kPa) 2.4.1 Approximate American to Metric Conversions HYDRAULIC PRESSURE Pounds per When this is known Multiply by To Find square inch (psi) 0.069 TORQUE (moment of force) TEMPERATURE (exact) Pound-feet (lb-ft)
Page 22 General Information, Specifications and Maintenance VOLUME Milliliters (ml) 0,03 Fluid ounces (fl oz) Milliliters (ml) 0,06 Cubic inches (in Liters (l) Pints (pt) Liters (l) 1,06 Quarts (qt) Liters (l) 0,26 Gallons (gal) Cubic meters (m Cubic feet (ft Cubic meters (m Cubic yards (yd AIR PRESSURE Kilopascals (kPa)
Page 23 General Information, Specifications and Maintenance This Page Intentionally Left Blank Model 644E-42/944E-42 Rev. 6/04...
Page 24: Specifications
General Information, Specifications and Maintenance SPECIFICATIONS 2.5.1 Vehicle Dimensions With Standard Tires: 13.00-24 (644E-42), 15.50-25 (944E-42) Description 644E-42 944E-42 (A) Length (without Forks and TC Rearward) 253" (6.426 mm) 253" (6.426 mm) (B) TransAction Distance 80" (2.032 mm) 80" (2.032 mm) (C) Width 98"...
Page 25 General Information, Specifications and Maintenance 24.0" MU5820 2.11 Model 644E-42/944E-42 Rev. 6/04...
Page 26 General Information, Specifications and Maintenance 2.5.2 Vehicle Weights - 644E-42 Curb Weight (Vehicle curb weight is figured with 48” carriage, two 48” pallet forks, 12%-full fuel tank and standard tires [no hydrofill]): Open Cab: 24,267 lb (11.007 kg) Closed Cab: 24,708 lb (11.207 kg) Operating Load 6,000 lb (2.721 kg)
Page 27 General Information, Specifications and Maintenance 2.5.4 Attachment Weights 644E-42 944E-42 Std 48" Carriage with Shaft 435 lb (198 kg) 435 lb (198 kg) Std 50" Carriage with Shaft 489 lb (222 kg) 489 lb (222 kg) Std 60" Carriage with Shaft 500 lb (227 kg) 500 lb (227 kg) Std 72"...
Page 28 General Information, Specifications and Maintenance 2.5.5 Performance Specifications Note: Performance criteria is based on full throttle engine speed unless otherwise specified or not applicable. Travel Speed (Standard Tires, No Load) 644E-42 944E-42 First Gear 0 - 3.5 mph (0-5,6 km/hr) 0 - 3.5 mph (0-5,6 km/hr) Second Gear 0 - 6.0 mph (0-9,7 km/hr)
Page 29 General Information, Specifications and Maintenance 2.5.7 Electrical System Description 644E-42 944E-42 Battery: Type, Rating 12 VDC, Negative (-) Ground, Maintenance Free Standard Vehicle Quantity Cold Start Option Quantity (644E-42 Only) Standard Vehicle Reserve Capacity 850 Cold Cranking amps @ 0° F (-18° C) With Cold Start Option Reserve Capacity 1700 Cold Cranking amps @ 0°...
Page 30 General Information, Specifications and Maintenance Fuses - Standard Blade Style: 644E-42 944E-42 F25 - Lights Main (Option) 40 amps 40 amps F26 - Condenser Fan (Option) 25 amps 25 amps F27 - Open — — F28 - Open — — Relays: E1 - Transmission Control 12 volt...
Page 31 General Information, Specifications and Maintenance 2.5.8 Engine Performance Specifications - 644E-42 Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting. Description Engine Make/Model Cummins Turbo/4BT3.9-C99 (SN 20118 & Before, 0160002519 thru 0160003689) Displacement 239 in (3,9 liters) Horsepower...
Page 32 General Information, Specifications and Maintenance 2.5.9 Engine Performance Specifications - 944E-42 Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting. Description Engine Make/Model Cummins Turbo/QSB 4.5T Displacement 275 in (4,5 liters) Horsepower 110 HP @ 2500 rpm Number of Cylinders Engine High Idle with No Load 2,650 ±100...
Page 33 General Information, Specifications and Maintenance 2.5.10 Fluid and Lubricant Capacities Fluid & Lubricant Description 644E-42 and 944E-42 Engine Crankcase Oil: Capacity with Filter Change 10.5 qt (10 liters) Filter Capacity 0.85 qt (0,80 liters) Oil Type SAE 15W40 Diesel Engine Oil. (Refer to Section 2.6.5, “Engine.”) Fuel Tank: Total Capacity 50.2 gal (190 liters)
Page 34 General Information, Specifications and Maintenance Hydraulic System: 644E-42 and 944E-42 System Capacity 50.2 gal (190 liters) Reservoir Capacity 33.5 gal (127 liters) Type of Oil ISO Grade 46 Anti-Wear Hydraulic Oil Refer to Section 2.6.4, “Hydraulic System.” 2.5.11 Hydraulic System Description 644E-42 and 944E-42 Valve Relief Settings:...
Page 35 General Information, Specifications and Maintenance 2.5.12 Tires Description 644E-42 944E-42 Standard Tire Size 13.00 - 24, 12-ply 15.50 - 25, 12-ply Rock Tire Size (Optional) 13.00 - 24, 12 ply 15.50 - 25, 12 ply Radial Tire Size (Optional) 13R24, 1 star 15R25, 2 star Wheel Lug Nut Torque 430-470 lb-ft (583-637 Nm)
Page 36 General Information, Specifications and Maintenance 2.5.14 Tamper Proofing WARNING: A tamper-proof means is in place on the following DO NOT exceed the total adjustable components prior to machine shipment. This rated capacity of the specific pair of forks being can either be tamper-proof paint, or a steel tamper-proof used.
Page 37: Fluids, Lubricants And Capacities
General Information, Specifications and Maintenance FLUIDS, LUBRICANTS AND 2.6.2 Wheel Ends CAPACITIES a. Wheel-End Lubricants In general, use a Universal Tractor Fluid that meets the 2.6.1 Axles (Differential Housings) following specifications: a. Axle Lubricants Nominal viscosity at 104° F (40° C) .......55 cSt Minimum viscosity at 212°...
Page 38: Lubrication Points (Grease Fittings)
General Information, Specifications and Maintenance 2.6.3 Lubrication Points (Grease Fittings) b. Hydraulic System Capacity Lubricants System capacity ........ 50.2 gal (190 liters) When lubricating any component via the grease fittings, Reservoir capacity......33.5 gal (127 liters) use multi-purpose lithium-based grease with EP additives that meets NLGI Grade 2 specifications.
Page 39: Transmission
General Information, Specifications and Maintenance b. Engine Capacities 2.6.7 Transfer Case 1. Engine Oil Capacity a. Transfer Case Fluid Capacity w/filter change ....... 10.5 qt (10 liters) Approved Universal Tractor Fluid Filter ..........0.85 qt (0,80 liters) John Deere JDM J20C (HY-GARD) 2.
Page 40: Drive Shaft Splines
General Information, Specifications and Maintenance 2.6.8 Drive Shaft Splines Note: Anti-corrosion protection is especially important in frame rails and stabilizer cylinder pin support bores for IMPORTANT: DO NOT disassemble any of the drive protection from fretting corrosion wear. shafts (refer to Section 5, “Axles, Drive Shafts, Wheels, Tires and Brakes,”...
Page 41: Cleaning
Loctite Corporation, are recommended. Contact: a. Orange Paint Loctite Corporation Durable, premium Lull orange paint is available in both a 1001 Trout Brook Crossing convenient 16-ounce (480 ml) spray can for touch-ups, Rocky Hill, CT 06067 USA and in a production-sized one gallon (3,8 liters) container Phone: 1-800-LOCTITE (1-800-562-8483) for extensive repainting.
Page 42: Replacement
General Information, Specifications and Maintenance REPLACEMENT 2.9.2 Hose and Tube Installation 1. When installing a new hose, loosely connect each ALWAYS use the correct tool when removing or replacing end and verify that the hose takes up the designed any part or performing any service. position before tightening the connection completely.
Page 43: Bearings
General Information, Specifications and Maintenance 2.10 BEARINGS 2.11 PRESSURE TESTING AND ADJUSTMENT 2.10.1 Bearing Removal Prior to pressure testing or adjustment, verify that all 1. NEVER remove bearings unless absolutely hoses and tubes are in good condition and that all fittings necessary! Always use the recommended puller to are tight.
Page 44: After Service Startup And Checks
General Information, Specifications and Maintenance 2.12 AFTER SERVICE STARTUP AND 5. Start engine and bleed hydraulic system of air. Operate all boom functions through their full range of CHECKS motion several times. Cycle the hoist and extend cylinders to bleed air from the system. Visually 2.12.1 After Service Startup check for leaks.
Page 45: After Transmission Service Or Replacement
General Information, Specifications and Maintenance 2.12.6 After Transmission Service or 12. Recheck the level of fluid in the transmission with the Replacement engine running at idle. 13. Add oil as necessary to bring the fluid level up to the 1. Check transmission oil level and fill to level with oil FULL mark on the transmission dipstick.
Page 46 General Information, Specifications and Maintenance This Page Intentionally Left Blank 2.32 Model 644E-42/944E-42 Rev. 6/04...
Page 47 Section 3 Boom Contents PARAGRAPH TITLE PAGE Boom System Component Terminology ....... . Boom System .
Page 48: Boom System Component Terminology
Boom BOOM SYSTEM COMPONENT the operator/mechanic be familiar with the name and location of the major assemblies of the boom system. The TERMINOLOGY following illustration identifies the components that are referred to throughout this section. To understand the safety, operation and maintenance information presented in this section, it is necessary that Wear Pad Boom...
Page 49: Boom System
Boom BOOM ASSEMBLY MAINTENANCE WARNING: DO NOT service the vehicle without following all safety precautions as The boom assembly consists of the inner, intermediate outlined in the “Safety Practices” section of this and outer booms and supporting hardware. manual. Failure to follow the safety practices IMPORTANT: Boom replacement must be completed in may result in death or serious injury.
Page 50: Inner Boom Replacement
Boom 3.3.1 Inner Boom Replacement 4. At the front of the intermediate boom, remove the capscrews (2) and flat washers (3) holding the top WARNING: and side wear pads (4) and shims (5) to the inside of Wear protective footwear the intermediate boom.
Page 51 Boom 6. Loosen the extend chain locknut (10), located at the rear of the outer boom (11), half way. The locknut must remain fully engaged on the threads of the extend chain clevis. MU0180 7. Return to the cab, fasten your seat belt and start the engine.
Page 52 Boom WARNING: Hydraulic fluid leaking under pressure can penetrate the skin, cause infec- tion, gangrene, and death or serious personal injury. If injured, see a doctor immediately. Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any parts or component.
Page 53 Boom 17. Label, disconnect and plug the attachment tilt hoses (16) at the fittings at the front of the inner boom section. Cap the fittings on the tilt cylinder to prevent dirt and debris from entering the hydraulic system. 18. Label, disconnect and plug the auxiliary hydraulic hoses (17) at the fittings at the front of the inner boom section.
Page 54 Boom 24. Install a lifting eye (1) to the nut on the attachment tilt Note: The Inner Boom’s center of gravity is at about six cylinder (2). Attach suitable overhead lifting device feet (2 m) in from the top front of the boom when all and sling to the lifting eye.
Page 55 Boom Note: If replacing the inner boom assembly with a new (944E-42 Only) Remove and mark the position of the inner boom, the hose guide, retract chain, remaining top wear pads (15), side wear pads (16), bottom wear pads and the attachment tilt cylinder should be wear pads (17), shims (18), hose clamp mounts (19), removed at this time.
Page 56 (3) and secure it with washers (2) and capscrews (1). Torque the middle capscrews (1) to 34. Inspect the boom and welds. Contact your local Lull 10 - 19 lb-ft (14 - 26 Nm) and torque the rear end distributor or the JLG Service Department, if capscrews (4) to 21 - 38 lb-ft (29 - 52 Nm).
Page 57 Boom ® 3. Coat the capscrew (8) with Loctite 242 (blue). At the (944E-42 Only) Replace the rear inner boom top rear of the inner boom (5), attach the retract chain (6) wear pads (13), side wear pads (14), bottom wear to the same hole in the anchor link (7) using one pads (15), shims (16), hose clamp mounts (17), capscrew (8), one flat washer (9).
Page 58 Boom Note: The 644E inner boom, without attachments, 8. Coat clevis pin (9) with anti-seize compound. Attach weighs 1,050 lbs (480 kg). The 944E inner boom, with- the extend chain yoke (7) to the inner boom (8) with out attachments, weighs 1,250 lbs (565 kg). the clevis pin (9) and two retaining rings (10).
Page 59 Boom ® 12. Coat the capscrews (14) with Loctite 242 (blue). Use a socket wrench and long extension to install the four capscrews (14) (two-upper and two-lower) and four washers (15) securing the cylinder trunnion clamps (16) to the intermediate boom. Torque capscrews (14) to 245 - 274 lb-ft (333 - 372 Nm).
Page 60 Boom Note: ALWAYS use new o-rings when servicing the vehicle. 17. Install new o-rings into the fittings. Lubricate o-rings with clean hydraulic oil. 18. Loosely install the female coupler, male nipple and bulkhead fittings to the bulkhead plate inside the gooseneck.
Page 61 Boom 25. Working from the rear of the boom, move the Note: ALWAYS use new o-rings when servicing the attachment tilt and auxiliary hydraulic hoses (10) until vehicle. there is approximately a 0.5" (12 mm) gap between the 27. Install new o-rings into the fittings. Lubricate o-rings Extend/Retract cylinder trunnion (11) and the hoses.
Page 62 Boom 29. If needed, pull the intermediate boom out slightly to 31. Clean up all debris, hydraulic fluid, etc., in, on, near align the extend chain yoke (2) with the bracket. and around the vehicle. Route the extend chain yoke and chains around the 32.
Page 63 Boom 35. Install the boom rear cover (12) using four capscrews WARNING: Avoid prolonged engine (13) and flat washers (14). Coat the capscrews with ® operation in closed areas without adequate Loctite 242 (blue). Torque to 21 - 38 lb-ft (29 - ventilation.
Page 64: Intermediate Boom Replacement
Boom 3.3.2 Intermediate Boom Replacement 3. At the rear of the boom, remove the capscrew (6), sheave pin (7) and sheave (8). WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from slipping or falling.
Page 65 Failure to comply can result in four capscrews (20) and two hose guides (21). death or severe personal injury. 11. Inspect the boom and welds. Contact your local Lull distributor or the JLG Service Department, if structural damage is detected.
Page 66 Boom b. Intermediate Boom Installation Note: The 644E intermediate boom weighs 890 lbs (400 kg). The 944E intermediate boom, weighs 1,115 lbs WARNING: (505 kg). Wear protective footwear with reinforced toe caps and slip-resistant 3. Use a suitable overhead lifting device and sling to raise soles.
Page 67 Boom 6. At the front of the intermediate boom, coat the 8. Continue installing the intermediate boom until it sheave pin (15) and bore with anti-seize compound. makes contact with the front of the outer boom. ® Coat the capscrew (13) with Loctite 242 (blue).
Page 68: Outer Boom Replacement
Boom 3.3.3 Outer Boom Replacement 4. Remove all clamps (7) securing the attachment tilt (8) and auxiliary hydraulic tubes (9) and rear WARNING: hydraulic hoses (10) to the outer boom and frame. Wear protective footwear Label and remove the tubes. Cap hose ends. with reinforced toe caps and slip-resistant soles.
Page 69 Boom 7. Use a suitable overhead lifting device and sling to support the outer boom and allow for the detachment of the lift/lower cylinder. 8. Use a suitable overhead lifting device and sling attached to the lift/lower cylinder (14). Remove slack from the sling.
Page 70 Attach another sling around the outer boom near the death or severe personal injury. front and secure it to the hoist. Remove slack from 19. Inspect the boom and welds. Contact your local Lull the slings. distributor or the JLG Service Department, if 2.
Page 71 Boom 4. Secure the pivot pin with the clevis pin (9) and a 8. Use a suitable overhead lifting device and sling cotter pin (10). attached to the lift/lower cylinder. Remove slack from the hoist sling, and raise the lift/lower cylinder (17) into its mount boss on the underside of the outer boom.
Page 72 Boom 12. As required, install the hydraulic clamps (1) on the 15. Insert the inside boom proximity sensor (9) with the outer boom and secure the attachment tilt (2) and inside jam nut (7) closer to the back of the sensor. auxiliary hydraulic tubes (3) and hoses (4) within the Replace the jam nut (8) and secure proximity clamps on the boom and frame according to their...
Page 73 Boom Note: If you are replacing the outer boom with a new 19. Install the inner boom, Extend/Retract cylinder and outer boom, also install the following items. extend chain and attaching hardware. (Refer to Section 3.3.1, “Inner Boom Replacement.”) 16. At the front of the outer boom, install the socket head 20.
Page 74: Boom Chains
Boom BOOM CHAINS • Temperature - Low temperature reduces chain strength by embrittlement. Going in and out of cold storage results in moisture from This vehicle uses a single extend chain to extend the condensation. boom and a single retract chain to retract the boom. The extend chain is constructed of 1"...
Page 75 Boom a. Inspection Guidelines Inspect Plates for Edge Wear Check the chain for wear on the link plate edges caused Expose the extend and retract chains (refer to Section by running back and forth over the sheave. The maximum 3.4.1, b. “Expose Extend Chain for Inspection,” or Section reduction of material must not exceed 5%.
Page 76 Boom Turning or Protruding Pins • Fatigue Cracking - Fatigue cracks (4) are a result of repeated cyclic loading beyond the chain’s Highly loaded chain, operating with inadequate endurance limit. The size of the load and the lubrication, can generate abnormal frictional forces frequency of its occurrence are factors which between pin and link plates.
Page 77 Boom Other Modes of Failure b. Expose Extend Chain for Inspection • Ultimate Strength Failure - These types of 1. Park the vehicle on level ground. Place the travel failures are caused by overloads far in excess of select lever in the (N) NEUTRAL DETENT position, the design load.
Page 78 Boom c. Expose Retract Chain for Inspection 4. At the front underside of the boom, record the amount of threads extending beyond the elastic locknut (5). This The retract chain must be removed from the boom in measurement will be the starting point for adjustment order to be visually inspected.
Page 79 Boom 7. Remove the elastic locknut (10) and flat washer (11) 11. DO NOT attempt to repair a chain. Replace a holding the retract chain threaded clevis (12) to the stretched or damaged chain with a new part. Always mounting tab. Save the flat washer and discard the replace both the chain and the clevis.
Page 80 Boom 15. Coat the threads of the threaded clevis (1) with multi-purpose grease. Note: Have a second person help with the installation of the retract chain between the intermediate and outer boom assemblies. 16. From the rear of the boom, one person should push the threaded clevis end (1) under the chain sheave and down between the intermediate boom (3) and the outer boom.
Page 81: Chain Lubrication
Boom 3.4.2 Chain Lubrication 3.4.3 Boom Chain Tension Check After inspection and before being returned to service, 1. Make sure the carriage is attached to the gooseneck chains must be lubricated with a quality chain lubricant before doing the tension check. (“LUBRIPLATE”...
Page 82: Boom Chain Tension Adjustment
Boom 3.4.4 Boom Chain Tension Adjustment Note: Always perform Section 3.4.3, “Boom Chain Ten- sion Check,” 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 83 Boom 12. Move the extend chain clevis (11) to the next hole Note: If the extend chain still cannot be adjusted within toward the rear of the mounting plates. Coat the the range of 3.00" (76 mm) and 4.00" (102 mm) the mounting pin (10) and bore with an anti-seize clevis can be repositioned into the last hole in the compound and reinsert the pin through the mounting...
Page 84 Boom a. Component/Assembly Verification 5. If the extend chain clevis is in the last hole, the locknut is fully threaded onto the clevis, and the The inner to intermediate boom separation should be distance is less than 8-1/2" (216 mm); the chain may checked when assembling new boom sections or chains, be the incorrect size or over elongated and needs or when the rear retract chain clevis has been moved...
Page 85: Boom Extend And Retract Chains Removal And Replacement
(8). Coat the capscrews with Loctite (blue). Torque to 21 - 38 lb-ft (29 - 52 Nm). Note: If the inner to intermediate boom separation distance cannot be achieved, contact your local Lull distributor or the JLG Service Department. MU0170 3.39...
Page 86 Boom 4. At the rear of the inner boom (1), remove one capscrew (2) and washer (3) securing the extend chain (4) to the anchor link (5). Disconnect the retract chain. MU4860 7. Attach a string or wire to the extend chain yoke (8). MU0260 The string or wire must be long enough to pull the extend chain through the boom in between the inner...
Page 87 Boom 11. If needed, pull the boom out slightly to align the b. Retract Chain Removal and Replacement extend chain yoke (8) with the sheave (14). Route 1. Park the vehicle on a hard, level surface. the extend chain around the sheave (14) on the 2.
Page 88 Boom 6. Attach a threaded eye (2) or a flat washer tack 8. Remove two retaining rings (6) and clevis pin (7) to welded to a capscrew (3) to the retract chain disconnect the retract chain yoke (8) from the rear of clevis (1).
Page 89 Boom 12. From the rear of the boom, one person should push 18. Adjust retract chain tension. (Refer to Section 3.4.4, the threaded clevis end (11) of the retract chain under a. “Component/Assembly Verification.”) the chain sheave (10) and down between the 19.
Page 90: Boom Wear Pads
Boom BOOM WEAR PADS 3.5.1 Boom Wear Pad Replacement When replacing a wear pad on the boom, replace both The wear pads (1) on this vehicle, are for the most part, wear pads on that side of the boom; e.g.: replace top front flat rectangular wear pads with metal inserts (2).
Page 91 Boom Use shims (8) under the upper rear wear pads as required b. Intermediate Boom to maintain a maximum gap of 0.09" (2,3 mm) (9) at the ® Coat all wear pad capscrews with Loctite 242 (blue) front edge of the top wear pads and maintain a total before installation.
Page 92: Boom Wear Pad Lubrication
Boom c. Outer Boom d. Extend/Retract Cylinder All outer boom pads (1) are mounted on the front of the The Extend/Retract cylinder (4) must be removed from outer boom. Remove the top wear pads before removing the vehicle to allow removal of the wear pads (3) on the the bottom wear pads.
Page 93: Quick Attach Assembly
Boom QUICK ATTACH ASSEMBLY 3.6.2 Connecting to an Attachment 1. Perform this procedure on a hard level surface. This vehicle is equipped with a quick attach system for Position the vehicle directly behind the attachment to easy attachment changes. be mounted. 2.
Page 94: Quick Attach Disassembly
Boom 3.6.3 Quick Attach Disassembly 6. Inspect the pin (6) for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If 1. Remove one capscrew (1) and elastic locknut (2). damaged or if it cannot be repaired the pin must be Tap out lower attachment tilt cylinder pin (3).
Page 95: Quick Attach Installation
Boom 3.6.4 Quick Attach Installation 1. Install the lock pin (17). 2. Assemble the flat washer (18), quick attach lever/ latch (19), spacer (20), and spring (21) to the capscrew (22). Position straight end of spring as shown in illustration. Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening.
Page 96: Attachment Tilt Cylinder Removal
Boom 3.6.5 Attachment Tilt Cylinder Removal 1. Remove hydraulic hoses (1) from the attachment tilt cylinder. Cap and label hoses and ports on attachment tilt cylinder. MU0270 MU4870 2. Remove quick attach. (Refer to Section 3.6.3, “Quick Attach Disassembly.”) 3. Install a 1/2”-13 lifting eye bolt (2) to the nut on the attachment tilt cylinder (3).
Page 97: Troubleshooting
Boom TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Boom Troubleshooting Problem Cause Remedy 1. Boom will not extend or 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s) retract.
Page 98 Boom Boom Troubleshooting (Continued) Problem Cause Remedy 3. Drooping chain, or jerky 1. Chain(s) tension not properly 1. Adjust chain(s). (Refer to boom extend or retract adjusted. Section 3.4.4, “Boom Chain functions. Tension Adjustment.”) 2. Chain(s) stretched or binding. 2. Replace chain(s) as needed. (Refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”)
Page 99 Boom Boom Troubleshooting (Continued) Problem Cause Remedy 4. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s) and/or connection leaks. or tube(s), tighten connections. 2. Lift/Lower hydraulic system(s) 2. Refer to Section 8.7, “Hydraulic not operating properly.
Page 100 Boom Boom Troubleshooting (Continued) Problem Cause Remedy 8. Lift/Lower cylinder pivot pin 1. Insufficient lubrication. 1. Lubricate at regular intervals. noise and/or wear. (Refer to the appropriate Owners/Operators Manual for lubrication information.) Replace worn pins as needed. 2. Worn self-aligning bearing(s). 2.
Page 101 Boom Boom Troubleshooting (Continued) Problem Cause Remedy 11. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. (Refer to Section 3.4.4, “Boom Chain Tension Adjustment.”) Replace chain(s) as needed. (Refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”) 2.
Page 102 Boom This Page Intentionally Left Blank 3.56 Model 644E-42/944E-42 Rev. 6/04...
Page 103 Section 4 Cab and Covers Contents PARAGRAPH TITLE PAGE Operator’s Cab and Covers Component Terminology..... Operator’s Cab........... . . 4.2.1 Operator’s Cab Description .
Page 104: Operator's Cab And Covers Component Terminology
Cab and Covers OPERATOR’S CAB AND COVERS the operator/mechanic be familiar with the names and locations of the major assemblies of the vehicle cab and COMPONENT TERMINOLOGY covers. The following illustration identifies the components that are referred to throughout this section. To understand the safety, operation and maintenance information presented in this section, it is necessary that Operator’s...
Page 105: Operator's Cab
Cab and Covers 4.2.2 Serial Number Decal WARNING: DO NOT service the vehicle The cab serial number decal (1) is located on the inside without following all safety precautions as of the cab, above the rear window opening. Information outlined in the “Safety Practices” section of this specified on the serial number plate includes the cab manual.
Page 106: Open Cab Components
Cab and Covers OPEN CAB COMPONENTS 1. Park the vehicle on a firm, level surface. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DETENT position, 4.3.1 Seat and Seat Belt engage the parking brake switch and shut the engine OFF.
Page 107: Select Lever
Cab and Covers b. Seat Installation Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 1. Position the seat (4) on the seat riser (10). Align the studs on the seat with the mounting holes (17) in the seat riser.
Page 108 Cab and Covers c. Transmission Travel and Gear Select Lever e. Turn Signal Select Lever (Optional) Removal Removal 1. Park the vehicle on a firm, level surface. Level the 1. Park the vehicle on a firm, level surface. Level the vehicle, ground the attachment, place the travel vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DETENT position,...
Page 109: Steering Column And Valve Replacement
Cab and Covers Turn Signal Select Lever (Optional) Installation WARNING: Wait for the hydraulic fluid 1. Install the two screws (11) securing the transmission to cool before servicing any hydraulic component. travel and gear selector lever (12), shims (13), and Hot hydraulic oil can cause severe burns.
Page 110 Cab and Covers 8. Support the bottom of the steering valve (1), and 3. Connect the load sense hose (5) to the “LS” port on remove the four flange capscrews (2) and the left side of the steering valve. lockwashers (3). Remove the steering valve through 4.
Page 111: Steer Select Valve
Cab and Covers a. Steer Select Valve Removal WARNING: Hydraulic oil leaking under 1. Park the vehicle on a firm, level surface, fully retract pressure can penetrate the skin and cause all hydraulic cylinders, ground the attachment (if severe personal injury. DO NOT use your hand any), place the travel select lever in the (N) or any part of your body to check for hydraulic NEUTRAL DETENT position, engage the park brake...
Page 112 Cab and Covers 6. Remove the retaining nut (1) that secures the steer 4. Reinstall the steer select valve into the dash. Refer selector knob and pull off the knob. to the reassembly procedure in Steer Select Valve Installation 4.3.4, d for installation procedures. 7.
Page 113 Cab and Covers 2. After connecting the hoses, insert the selector valve 8. Check the routing of all hoses, wiring and tubing for (9) through the opening (12) on the left side of the sharp bends or interference with any rotating dash and secure the valve in place with four members, and install tie wraps and/or protective capscrews (13).
Page 114: Brake Valve And Service Brake Pedal
Cab and Covers 4.3.5 Brake Valve and Service Brake Pedal The service brake valve is secured at the base of the steering column support inside the dash, concealed by the lower dash panel. The service brakes are part of the axles (the park brake is part of the front axle only).
Page 115 Cab and Covers 6. Remove the two capscrews (4), flat washers (5) and 1. Transfer the fittings (9) to the new brake valve. Note nuts (6) attaching the service brake valve (7) to the the orientation of each fitting before removing them. steering column support (8).
Page 116 Cab and Covers c. Service Brake Pedal Removal 1. Park the vehicle on a firm, level surface. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and shut the engine OFF.
Page 117: Throttle Pedal Replacement
Cab and Covers 4.3.6 Throttle Pedal Replacement b. Throttle Pedal Installation Note: The bushings (24) are a self-lubricating soft a. Throttle Pedal Removal material and should be inspected for reuse prior to 1. Park the vehicle on a firm, level surface. Level the installation.
Page 118: Throttle Position Sensor Replacement (944E-42 Only)
Cab and Covers 4.3.7 Throttle Position Sensor Replacement (944E-42 Only) a. Throttle Position Sensor Removal The throttle position sensor (1) controls the engine speed. It is designed to sense the position of the throttle pedal and sends the signal to the engine control module. The sensor is located on the bracket (2) below the dash where the throttle pedal is attached.
Page 119 Cab and Covers b. Installation 7. After achieving desired maximum rpm, hold the limit- stop screw (20) while tightening the locking nut (21) 1. Slide the sensor (17) onto the linkage assembly against the weldment bracket. shaft (18). 8. Check the distance between the front edge of the 2.
Page 120: Front, Rear And Frame Sway Joystick Assembly Replacement
Cab and Covers 4.3.8 Front, Rear and Frame Sway Joystick WARNING: Hydraulic fluid leaking under Assembly Replacement pressure can penetrate the skin, cause infection, gangrene, and death or serious personal a. Front, Rear and Frame Sway Joystick Assembly injury. If injured, see a doctor immediately. Removal Relieve all pressure before disconnecting any 1.
Page 121 Cab and Covers b. Front, Rear and Frame Sway Joystick Assembly Note: Check the routing of all hoses, wiring and tubing Installation for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit Note: Use new oiled o-rings as required. ALWAYS as required.
Page 122: Single Joystick Assembly Replacement (Optional)
Cab and Covers 4.3.9 Single Joystick Assembly 5. Disconnect and plug the hydraulic hoses (5) and cap Replacement (Optional) the fittings (8) on the joystick valve (9). 6. Unplug the electrical connector (7). a. Single Joystick Assembly Removal 1. Park the vehicle on a firm, level surface. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and shut the...
Page 123: Electrical Components
Cab and Covers b. Single Joystick Assembly Installation Note: Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating Note: Use new oiled o-rings as required. ALWAYS members, and install tie wraps and/or protective conduit replace seals, o-rings, gaskets etc., with new parts to as required.
Page 124 Cab and Covers 4.3.11 Miscellaneous Cab Components MU4490 1. Mirror Assembly 5. Flat Washer (8) 9. Arm Rest 2. Capscrew (2) 6. Capscrew (8) 10. Self-Tapping Screw (6) 3. Frame Level Indicator 7. Locknut (2) 11. Brush Strip Assembly (2) 4.
Page 125: Enclosed Cab Components
Cab and Covers 4.3.12 Enclosed Cab Components MU6000 12. Skylight Glass 17. Door Window Latch 22. Left Side Rear Window Glass 13. Right Side Window Glass 18. Top Door Frame 23. Door Stop Strap 14. Top Windshield Retainer 19. Door Window Glass 24.
Page 126: Enclosed Cab (Optional) Components
Cab and Covers ENCLOSED CAB (OPTIONAL) 4.4.8 Heater/Defroster System COMPONENTS a. Heater Assembly Removal 1. Park the vehicle on a firm, level surface. Level the 4.4.1 Front Windshield Wiper Switch vehicle, ground the attachment, place the travel Refer to Section 9.13.4, “Front Windshield Wiper Switch,” select lever in the (N) NEUTRAL DETENT position, for removal and installation information.
Page 127 Cab and Covers 9. Remove five capscrews (5) and flat washers (6) securing the right side console access panel (7). Remove the access panel. MU1390 5. Transfer the coolant to a container with a cover, and SU0060 label as “Used Antifreeze.” Dispose of the used coolant at an approved recycling facility.
Page 128 Cab and Covers 11. Remove all duct hoses (1) at the heater assembly (2). SU0100 SU0090 b. Heater Assembly Installation Note: Tag and mark all hoses for correct reassembly Note: For vehicles equipped with air conditioning, 12. Loosen and remove hose clamps (4) securing before the heater assembly can be installed, the air coolant hoses (5) to heater assembly (6) and remove conditioning hoses and electrical connections must be...
Page 129 Cab and Covers 5. Connect heater wiring (10) to the cab harness (11). 7. Install the operators seat. Refer to Section 4.3.1, b. “Seat Installation.” 8. Install the right side console access panel (15) using five capscrews (16) and flat washers (17). Torque capscrews to 7 - 8 lb-ft (9,5 - 10,6 Nm).
Page 130: Cab Removal
3. If the vehicle has dual batteries, disconnect both damage, a cracked weld and/or fatigued metal is negative battery cables (1 and 2) from both discovered, replace the cab. Contact your local Lull batteries. distributor or the JLG Service Department, with any To access the lower battery (3), loosen the knob (4) questions about the suitability or condition of a cab.
Page 131 Cab and Covers 4. Block (7) the boom sufficiently enough to provide 8. Remove the right side console access panel (13). access to the hydraulic hoses between the cab, hydraulic valve plate and the engine compartment. MU3880 MU4880 Note: Record the location, and label all electrical cables to ensure correct installation 5.
Page 132 Cab and Covers 10. (644E Only) Remove the clevis pin clip (1) from the 13. Remove the four capscrews (13), four washers (14) throttle cable yoke (2). Remove throttle cable (3) and four sheer pins (15) that secure the cab mount from the throttle pedal lever (4).
Page 133: Cab Installation
Cab and Covers 16. If the throttle cable is still wire tied to any of the CAB INSTALLATION cables or hoses being removed from the vehicle with the cab, note the position of the wire ties for WARNING: reassembly and snip wire ties as necessary. When Wear protective footwear all wiring harnesses (engine and lighting) and all with reinforced toe caps and slip-resistant...
Page 134 Cab and Covers 11. Connect all of the electrical connections (1) that run 13. Connect the supply and return fuel lines (3) at the from the cab out to the frame and engine fuel tank (4). (Refer to Section 7.8.2, “Fuel Tank.”) compartment.
Page 135 Cab and Covers 16. Unplug and connect the hydraulic hoses going from the hydraulic cylinders, brakes and engine compartment to the cab. All of the hoses may be accessed either above (6) or below (7) the frame. MU0650 19. Carefully examine all cab components, fasteners, MU4880 etc., one last time before engine start-up.
Page 136: Valve Plate
Cab and Covers VALVE PLATE 4. Attach a suitable lifting device to the cab step (7) and remove the slack. 5. Remove four capscrews (8) and washers (9) from 4.7.1 Valve Plate Removal the cab step (7) and lower the cab step to the 1.
Page 137: Valve Plate Installation
Cab and Covers 9. Remove the two cotter pins (15), washers (16) and 4.7.2 Valve Plate Installation valve plate hinge pins (17). 1. Use a suitable lifting device to lift the valve plate (18) into position under the cab. 2. Reconnect all of the electrical and hydraulic connections to their previously labeled positions.
Page 138: Access Panels And Covers
Removal and installation are easily accomplished hardware. by observing the mounting configurations as shown in the illustration. MU4950 1. Engine Cover 4. Lull Logo Plate 2. Engine Mount Skirt 5. Black Backing Plate 3. Window Screen 4.36 Model 644E-42/944E-42 Rev. 6/04...
Page 139 Cab and Covers This Page Intentionally Left Blank 4.37 Model 644E-42/944E-42 Rev. 6/04...
Page 140: Engine Hood
Cab and Covers 4.8.2 Engine Hood Note: If performing this procedure outside where blow- ing wind is a factor, control hood movement at all times. a. Engine Hood Removal Wind can cause the hood to move unexpectedly. 4. Open engine hood and attach a suitable lifting WARNING: Contact with hot engine or device to the engine hood (7) and remove the slack.
Page 141 Cab and Covers 7. Remove the bottom spring clip (11) from the stud ball (12) and disconnect the left support strut (10) from the stud ball (12). Save parts for reassembly. 8. Gently strike the top of the right support strut (13) away from the stud ball (14) to pop the right support strut (13) off the stud ball (14).
Page 142 Cab and Covers b. Engine Hood Installation WARNING: Contact with hot engine or other components will cause burns. Allow the engine and components to cool completely before proceeding. Failure to comply will result in personal injury. 1. Park the vehicle on a firm, level surface. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake switch and shut the...
Page 143 Cab and Covers 12. Gently strike the bottom of the right support strut (20) towards the stud ball (22) to pop the right support strut (20) into the stud ball (22). MU4970 13. Replace four capscrews (23), washers (24), nuts (25) and hood latch (26) onto the engine MU6050 hood (27).
Page 144 Cab and Covers This Page Intentionally Left Blank 4.42 Model 644E-42/944E-42 Rev. 6/04...
Page 145 Section 5 Axles, Drive Shafts, Wheels, Tires and Brakes Contents PARAGRAPH TITLE PAGE Axle, Drive Shaft and Wheel Component Terminology ....General Information .
Page 146: Axles, Drive Shafts, Wheels, Tires And Brakes
Axles, Drive Shafts, Wheels, Tires and Brakes AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheel and tires.
Page 147: General Information
Axles, Drive Shafts, Wheels, Tires and Brakes 5.3.2 Axle Assembly Operation WARNING: DO NOT service the vehicle Power from the engine is transmitted to the transmission without following all safety precautions as by way of a driveshaft. The transmission distributes outlined in the “Safety Practices”...
Page 148: Axle Serial Number Plate
Axles, Drive Shafts, Wheels, Tires and Brakes 5.3.3 Axle Serial Number Plate WARNING: Risk of death or serious The front axle serial number plate (1) is located on a personal injury if components are assembled mounting pad on the inboard portion of the right beam improperly, if incompatible, worn or damaged trumpet.
Page 149: Axle Replacement
Axles, Drive Shafts, Wheels, Tires and Brakes CLEANING: Clean parts with machined or ground 5.3.6 Axle Replacement surfaces (such as gears, bearings and shafts) with emulsion cleaners or petroleum-based cleaners. DO a. Removal NOT steam clean internal components, and the interior of WARNING: the planetary hub and axle housing.
Page 150 Axles, Drive Shafts, Wheels, Tires and Brakes 4. If the vehicle has dual batteries, disconnect both 6. Label, disconnect and cap the steering and brake negative battery cables (1 and 2) from both hydraulic hoses at the tube connections (8) on the batteries.
Page 151 Axles, Drive Shafts, Wheels, Tires and Brakes Note: The axle will oscillate freely when the cylinder 14. Remove the axle (20-Front or 21-Rear), from the mounting pin is removed. vehicle using the jack, hoist or overhead crane and sling supporting the axle. DO NOT raise or otherwise 12.
Page 152 Axles, Drive Shafts, Wheels, Tires and Brakes b. Axle Inspection, Internal Service and Repair 4. On the rear axle, if applicable, uncap and install the service brake (4) and steering hydraulic fittings (5) Note: Detailed axle service instructions (covering axle, and hoses in their previously marked positions.
Page 153 Axles, Drive Shafts, Wheels, Tires and Brakes MU0610 Note: If new frame sway (front) or stabilizer (rear) 7. Move the cylinder (12) into position on the axle cylinder bearings (11) have been installed in the axle, cylinder anchor (13). Insert a cylinder mount pin (14) the fracture in the bearing race must be positioned at the through the cylinder and cylinder anchor.
Page 154 Axles, Drive Shafts, Wheels, Tires and Brakes Note: ALWAYS use new o-rings when servicing the 18. If the vehicle has dual batteries, connect both vehicle. negative battery cables (2 and 3) to both batteries. Connect the lower negative battery cable (2) to the 10.
Page 155 Axles, Drive Shafts, Wheels, Tires and Brakes WARNING: Avoid prolonged engine operation in closed areas without adequate ventilation. Failure to properly ventilate exhaust fumes can result in death or severe personal injury. WARNING: Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury.
Page 156: Axle Service And Troubleshooting
Repair Manual, Model MS-T 3045, JLG P/N 8990419 (ZF operation of the axles. P/N 5871 550 002). Note: Contact your local Lull distributor or the JLG The axle should be checked, serviced and repaired only Service Department at (877) 554-5438 or...
Page 157 Axles, Drive Shafts, Wheels, Tires and Brakes 5.3.8 Axle Assembly and Drive Shaft Troubleshooting (Continued) Problem Cause Remedy 4. Oil leaking from axle 1. Drain and/or inspection plugs 1. Replace o-rings as needed and (differential housing and/or loose and/or o-rings damaged tighten plugs to 96 lb-ft axle housings).
Page 158 Axles, Drive Shafts, Wheels, Tires and Brakes 5.3.8 Axle Assembly and Drive Shaft Troubleshooting (Continued) Problem Cause Remedy 7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with Universal Tractor Fluid. (Refer to the appropriate Owners/ Operators Manual.) 2.
Page 159: Axle Internal Component Troubleshooting
Axles, Drive Shafts, Wheels, Tires and Brakes 5.3.9 Axle Internal Component Troubleshooting Note: The following conditions may be noticed when inspecting parts during axle repair. Perform all remedies that apply to the conditions noticed. Problem Cause Remedy (See Note) 1. Differential ring gear teeth 1.
Page 160: Drive Shafts
Axles, Drive Shafts, Wheels, Tires and Brakes DRIVE SHAFTS 3. If the vehicle has dual batteries, disconnect both negative battery cables (1 and 2) from both batteries. 5.4.1 Drive Shaft Inspection and Service To access the lower battery (3), loosen the knob (4) Whenever servicing the vehicle, conduct a visual far enough so that the lip (5) on the upper battery box inspection of the drive shafts, and cross and bearing...
Page 161: Drive Shaft Installation
Axles, Drive Shafts, Wheels, Tires and Brakes 4. If the vehicle has dual batteries, disconnect both negative battery cables (12 and 13) from both batteries. To access the lower battery (14), loosen the knob (15) far enough so that the lip (16) on the upper battery box clears the knob.
Page 162 Axles, Drive Shafts, Wheels, Tires and Brakes 5. Raise the drive shaft assembly (1) into position. The 8. If the vehicle has dual batteries, connect both slip yoke-end of the drive shaft mounts toward the negative battery cables (6 and 7) to both batteries. axle.
Page 163: Wheels And Tires
Axles, Drive Shafts, Wheels, Tires and Brakes WHEELS AND TIRES WARNING: Risk of death or serious personal injury. Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tire) may compromise vehicle stability and may cause vehicle to tip over. Welded 9'' x 24'' steel wheels are used on the Model 644E.
Page 164: Removing Wheel And Tire Assembly From Vehicle
Axles, Drive Shafts, Wheels, Tires and Brakes 5.5.1 Removing Wheel and Tire Assembly from Vehicle WARNING: Risk of death or serious per- sonal injury, if proper safety procedures are not followed. When removing wheel and tire assembly from the vehicle, follow the instruc- tions in the “Wheel Removal Instruction”...
Page 165: Wheel Cleaning
Axles, Drive Shafts, Wheels, Tires and Brakes 7. (644E Only) Remove lug nuts in an alternating 5.5.2 Wheel Cleaning pattern (A - H). There are separate lockwashers (7) WARNING: under the lug nuts (8). Be sure the to save both the Dirt and rust prevent the tire lockwashers and lug nuts for reassembly.
Page 166: Installing Wheel And Tire Assembly Onto Vehicle
Axles, Drive Shafts, Wheels, Tires and Brakes 5.5.4 Installing Wheel and Tire Assembly 3. (644E Only) Use the torque sequence diagram Onto Vehicle (A - H), to alternately check the torque of each of the eight lug nuts. Torque 430 - 470 lb-ft (583 - 637 Nm). IMPORTANT: The tires must be installed onto the wheels to rotate in the proper direction.
Page 167: Tires
Axles, Drive Shafts, Wheels, Tires and Brakes 5.5.5 Tires b. Wheel Inspection and Replacement a. Dismounting Tire from Wheel WARNING: Damaged, modified, repaired or mis-matched wheels and tires, or WARNING: Risk of death or serious dirt and rust prevent the tire from seating personal injury.
Page 168 Axles, Drive Shafts, Wheels, Tires and Brakes c. Tire and Wheel Lubrication 1. Read, understand and follow the above warning message. WARNING: 2. Clean, inspect and replace the wheel if necessary. Risk of death or serious DO NOT use a damaged or cracked wheel. personal injury.
Page 169 Axles, Drive Shafts, Wheels, Tires and Brakes e. Tire Speed and Road Surface Limitations Tires should not be stored outside or in direct sunlight. If there is no other alternative, tires stored outside must be The tires and axles on this vehicle are designed for covered or otherwise protected from sunlight, wind and low-speed operations not to exceed 25 mph (40 km/h).
Page 170: Brakes
Axles, Drive Shafts, Wheels, Tires and Brakes BRAKES CAUTION: DO NOT exceed 650 psi (45 bar) when pressurizing the park brake. Apply- 5.6.1 Brake Disc Inspection ing too much pressure may damage the brake Check the brake discs for wear every seals.
Page 171 Axles, Drive Shafts, Wheels, Tires and Brakes Note: If the brake discs are worn beyond the gaps given, the brake disc must be replaced on both sides of Approved Universal Tractor Fluid the axle at the same time. 7. Repeat steps 5 and 6 for the other side of the axle. John Deere JDM J20C (HY-GARD) 8.
Page 172 Axles, Drive Shafts, Wheels, Tires and Brakes b. Rear Axle CAUTION: DO NOT exceed 650 psi (45 WARNING: BLOCK ALL FOUR bar) when pressurizing the park brake. Apply- WHEELS. Failure to do so could result in death ing too much pressure may damage the brake or serious injury from vehicle roll-away seals.
Page 173 Axles, Drive Shafts, Wheels, Tires and Brakes Note: If the brake discs are worn beyond .0.167" (4,25 mm), the brake disc must be replaced on both Approved Universal Tractor Fluid sides of the axle at the same time. 7. Repeat steps 5 and 6 for the other side of the axle. John Deere JDM J20C (HY-GARD) 8.
Page 174 Axles, Drive Shafts, Wheels, Tires and Brakes This Page Intentionally Left Blank 5.30 Model 644E-42/944E-42 Rev. 6/04...
Page 175 Section 6 Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 Contents PARAGRAPH TITLE PAGE Transmission Assembly Component Terminology ..... . . Transmission Description .
Page 176: Transmission Assembly Component Terminology
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 TRANSMISSION ASSEMBLY the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. COMPONENT TERMINOLOGY The following illustration identifies the components that are referred to throughout this section. To understand the safety, operation and maintenance information presented in this section, it is necessary that Torque...
Page 177: Transmission Description
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 transmission. The pump is driven by the central shaft, WARNING: DO NOT service the vehicle which in turn is connected to the impeller of the torque without following all safety precautions as converter.
Page 178: Transmission Specifications
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 TRANSMISSION SPECIFICATIONS TRANSMISSION MAINTENANCE 6.5.1 Transmission General Specifications 6.6.1 Maintenance Introduction General transmission specifications are found in Section WARNING: 2, “General Information, Specifications and To help avoid severe burns, Maintenance.” Transmission fluid information is found in DO NOT attempt this procedure when the Section 2.6.6, “Transmission.”...
Page 179: Transmission Maintenance Schedule
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 CAUTION: DO NOT exceed 165 psi (39.6 bar) when back flushing the oil cooler. Applying too much pressure may damage the oil cooler/radiator. Disconnect and back flush the oil cooler portion of the radiator with oil and compressed air until all foreign material is removed.
Page 180: Transmission Replacement
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 TRANSMISSION REPLACEMENT Note: Contact your local Lull distributor or the JLG Service Department at (877) 554-5438 or (717) 485-6657, if internal transmission repair is required during the warranty period. IMPORTANT: To help ensure safety and optimum performance, replace the transmission if it is damaged.
Page 181 Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 MT1070 9. Label and remove the transmission inlet hose (12) and transmission outlet hose (13) from the fittings on the transmission only. Cap and plug all fittings and MU1770 hose ends to prevent contamination from entering. WARNING: An improperly supported vehicle can fall, causing death or severe...
Page 182 Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 10. Remove the four capscrews (1) securing the inlet 14. Connect a lifting strap or chain to the lifting ring (18) flange halves (2) to the pump (3). Remove the inlet at the top of transmission, and to a suitable hoist or tube (4) and o-ring (5).
Page 183 Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 16. Label and disconnect the wire harness connections from the solenoids (20) on the transmission. CAUTION: Prevent damage to the transmission flex plate. Use care when separating the engine and transmission. DO NOT allow flex plate to catch on any part of engine.
Page 184: Transmission Inspection And Internal Repair
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 6.7.2 Transmission Inspection and Internal 5. Connect a lifting strap or chain to the lifting ring (5) at Repair the top of transmission, and to a suitable hoist or overhead crane. Operate the hoist or crane to Refer to the ZF 4WG-92/98 TSC Transmission Repair remove any slack prior to lifting, but DO NOT raise Manual, JLG P/N 8990495 (ZF P/N 5871.134.002) for...
Page 185 Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 9. Position the transmission mount plate (7) in place at the front of the transmission. 10. Reinstall the two front transmission isolator mounts (8). Install the 5/8-11 x 3-3/4" grade 8 capscrews from the top through the isolators.
Page 186 Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 16. Assemble the front outlet hose (1) onto the front port of the pump (2). Place a new oiled o-ring (3) into position over the opening and secure the front outlet hose (1) with two flange halves (4) and four capscrews (5).
Page 187 Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 23. Reassemble the driveshafts. Refer to Section 5.4.4, 27. If the vehicle has dual batteries, connect both “Drive Shaft Installation,” for front and rear drive negative battery cables (20 and 21) to both shafts.
Page 188: After Transmission Service Or Replacement
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 6.7.4 After Transmission Service or 9. Reassemble all components and fill the transmission Replacement with clean, fresh Universal Tractor Fluid through the dipstick tube opening (1). Remove the dipstick and Refer to the ZF 4WG-92/98 TSC Repair Manual, JLG P/N fill with approximately 15.9 qt (15 liters) of Universal 8990495 (ZF part number 5871.134.002) for information Tractor Fluid.
Page 189: Troubleshooting
8990495 (ZF part number 5871.134.002). of the transfer case. The transmission should be checked, serviced and Note: Contact your local Lull distributor or the JLG repaired only by experienced service technicians who are Service Department at (877) 554-5438 or aware of all safety instructions and particular component (717) 485-6657, if internal transfer case repair is features.
Page 190 Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 6.8.1 Transmission Troubleshooting (Continued) Problem Cause Remedy 3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level with Universal Tractor Fluid. (Refer to the appropriate Owners/Operators Manual.) 2.
Page 191 Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 6.8.1 Transmission Troubleshooting (Continued) Problem Cause Remedy 5. Transmission overheating 1. Low oil level. 1. Fill transmission to correct level with Universal Tractor Fluid. (oil above 248° F [120° C]). (Refer to the appropriate Owners/Operators Manual.) 2.
Page 192: Towing A Disabled Vehicle
Carefully follow the procedures from start to finish. Consult your local Lull distributor or the JLG service department, if you are unsure about any part of the procedure, or for specific instructions for your particular situation.
Page 193: Transfer Case Component Terminology
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 6.10 TRANSFER CASE COMPONENT the operator/mechanic be familiar with the name and location of the major assemblies of the transfer case. The TERMINOLOGY following illustration identifies the components that are referred to throughout this section. To understand the safety, operation and maintenance information presented in this section, it is necessary that Engine...
Page 194: General Information
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 (ZF part number 5871.134.002). For example, transfer WARNING: DO NOT service the vehicle case shaft bearing adjustment is accomplished during without following all safety precautions as out- disassembly/reassembly procedures not covered in this lined in the “Safety Practices”...
Page 195: Further Information
(housing) itself. 5. Total Reduction Ratio: 6. Input Rotation: Reversible; clockwise Note: Contact your local Lull distributor or the JLG and counter-clockwise Service Department at (877) 554-5438 or (717) 485-6657, if internal transfer case repair is 7. Maximum Input RPM: 3,300 required during the warranty period.
Page 196: Transfer Case Removal
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 6.12.9 Transfer Case Removal 5. Prior to unbolting the transfer case, make certain that a suitable lift/support device is in position to Note: This operation can be performed with the engine/ carry the 350 + lbs (159 Kg) that the transfer case transmission/transfer case still attached to the power weighs.
Page 197: Internal Transfer Case Repair
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 6.12.10 Internal Transfer Case Repair Detailed transfer case service instructions covering repair, disassembly, reassembly, adjustment and troubleshooting information are provided in the ZF Model TB92-I4 Transfer Case Operating and Repair Manual, JLG P/N 8990495 (ZF part number 5871.134.002).
Page 198: Troubleshooting
(ZF part number 5871.134.002). of the transfer case. The transfer case should be checked, serviced and Note: Contact your local Lull distributor or the JLG repaired only by experienced service technicians who are Service Department at (877) 554-5438 or aware of all safety instructions and particular component (717) 485-6657, if internal transfer case repair is features.
Page 199 Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 6.13.1 Transfer Case Troubleshooting (Continued) Problem Cause Remedy 3. Noise when coasting: even 1. Worn splines on input flange 1. Replace worn parts as needed. slight transfer case noise can and/or gears. be heard when vehicle is coasting.
Page 200: Transfer Case Internal Component Troubleshooting
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4 6.13.2 Transfer Case Internal Component Troubleshooting Note: The following conditions may be noticed when inspecting parts during transfer case repair. Perform all remedies that apply to the conditions noticed. Problem Cause Remedy (See Note) 1.
Page 201 Section 7 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T Contents PARAGRAPH TITLE PAGE Introduction ............7.1.1 Disclaimer and Scope .
Page 202 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T This Page Intentionally Left Blank Model 644E-42/944E-42 Rev. 6/04...
Page 203: Engine: Cummins 4Bt 3.9, B4.5T And Qsb 4.5T
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T INTRODUCTION A gradual running-in (break-in) of a new engine is not necessary. Full load can be applied to a new engine as soon as the engine is put into service and the coolant 7.1.1 Disclaimer and Scope temperature is at least 140°...
Page 204: Component Terminology
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 7.1.2 Component Terminology To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the engine components. The following illustration identifies the components that are referred to throughout this section.
Page 205: Safety Information
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T SAFETY INFORMATION Preparation WARNING: Wear protective glasses and General Vehicle Operation protective shoes. WARNING: • Verify that the work area is capable of Before attempting to start supporting the weight of the vehicle the engine and/or operate the vehicle, read the and the torque created by any Owners/Operators Manual.
Page 206 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T Rotating Parts and Fan Blades Engine Oil WARNING: WARNING: Keep away from parts which Engine oil can cause skin rotate; the fan blades can appear invisible disorders and other personal injury. Avoid when the fan is rotating.
Page 207: Engine Serial Number
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T ENGINE SERIAL NUMBER 7.5.2 Cleanliness Cleanliness is very important during engine repair. The serial number (1) is stamped on the front of the Contamination of the engine during repair will reduce the engine block, near the fan pulley.
Page 208: Engine Cooling System
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T ENGINE COOLING SYSTEM WARNING: DO NOT attempt this proce- dure when the engine is hot. Wait for the The engine cooling system is a closed, pressurized engine, muffler, and tailpipes to cool down system that consists of coolant passages in the engine, before proceeding.
Page 209 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 6. Remove the upper radiator hose (10) by loosening WARNING: Hot coolant can cause the upper and lower hose clamps (11) attaching the severe burns or eye injury. NEVER remove the radiator hose to the thermostat housing (12). radiator cap while the engine is hot.
Page 210 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 8. Insert a 3/8” drive rachet into the automatic belt 10. Remove the lower alternator bracket capscrew on tensioner housing (1), and remove the tension from the bottom of the alternator (8). Remove the upper the fan drive belt (2) by rotating the tensioner inward.
Page 211 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T b. Thermostat Installation 7. Install the upper radiator hose (20). Torque both hose clamps (21 and 22) to 60 lb-in (6 Nm). Note: Ensure that notched edge of thermostat seal (16) is facing thermostat. 1.
Page 212: Drain And Flush Radiator
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 9. If the vehicle has dual batteries, connect both WARNING: DO NOT attempt this proce- negative battery cables (1 and 2) to both batteries. dure when the engine is hot. Wait for the Connect the lower negative battery cable (1) to the engine, muffler, and tailpipes to cool down negative (-) terminal on the lower battery (3).
Page 213 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 8. Drain the contents of the overflow reservoir (10) by removing the overflow tube (11) from the radiator. The lower portion of the tube is connected to the overflow reservoir. Use the tube to channel the coolant into a container.
Page 214: Radiator, Transmission Oil Cooler And Hydraulic Oil Cooler Replacement
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 7.6.4 Radiator, Transmission Oil Cooler and Hydraulic Oil Cooler Replacement Before considering radiator or oil cooler replacement for other than obvious damage, conduct a cooling system pressure test, check the coolant specific gravity, coolant level, fan belt tension and dash panel temperature indicator.
Page 215 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 8. Remove three capscrews (12) securing the fan guard (13). MU1540 MU1390 9. Remove the upper radiator hose (14) by loosening 7. Drain the contents of the overflow reservoir (10) by the upper hose clamp (15) and the clamp attaching removing the overflow tube (11) from the radiator.
Page 216 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 10. Remove both hydraulic oil cooler inlet (1) and CAUTION: Radiator assembly is heavy return (2) hoses from the hydraulic oil cooler (3). and bulky. Before attempting to remove the Cap off the hose ends and hydraulic oil cooler radiator assembly, prepare an adequate work opening to prevent contaminants from entering the area.
Page 217 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 16. At the inner side of the radiator assembly are four 21. Working from the front, remove six (three top and capscrews (16) and four nuts (17) that fasten the three bottom) capscrews (29) securing the spacer transmission oil cooler (18) and hydraulic oil shroud assembly (28).
Page 218 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T b. Radiator, Transmission Oil Cooler and Hydraulic 5. Working from the front, attach the fan shroud (12) to Oil Cooler Installation the spacer shroud assembly (13). Secure with eight capscrews (11). Torque capscrews to 6-11 lb-ft 1.
Page 219 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 9. Working from the inner side of the radiator assembly, 11. Carefully set the radiator assembly (25) onto the rear secure the transmission oil cooler and hydraulic oil of the engine mount frame (26), aligning the cooler to the frame assembly with four previously mounting holes (28) of the engine mount frame to removed capscrews (21) and four nuts (22).
Page 220 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 16. Uncap and connect the hydraulic oil inlet (1) and outlet (2) hoses Check all fittings for o-rings before making connections. Torque hose fittings to 165 ± 35 lb-ft (224 ± 47 Nm). Torque all fittings with clean oiled threads.
Page 221 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T c. Engine Block Heater Removal 5. Slowly turn the radiator cap (14), (located near the upper radiator hose), to the first stop and allow any 1. Park the vehicle on a firm, level, surface. Level the pressure to escape.
Page 222 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 7. Loosen the clamp (1) securing the air intake hose to d. Engine Block Heater Installation the turbocharger, but do not remove. 1. Apply Teflon tape to engine block heater element 8. Disconnect the air intake sensor (2) threads (5) and install element.
Page 223: Engine Electrical System
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T ENGINE ELECTRICAL SYSTEM fuel return line (18) and fuel tank drain plug (24). The threaded fuel filler (23) has a fuel cap (16) and The engine electrical system, including the starter, permits entry of diesel fuel into the tank. alternator and primary wiring, is described in Section The fuel level sender (14) and dash panel gauge are 9.11, “Engine Start Circuit,”...
Page 224: Diesel Fuel
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 7.8.1 Diesel Fuel 7.8.2 Fuel Tank The fuel tank (1) is located directly behind the operator’s WARNING: Engine fuel is flammable cab. and can cause a fire or an explosion. Keep sparks and open flames away from the vehicle a.
Page 225: Fuel Level Sender And Gauge
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T c. Cleaning and Drying e. Assembly and Replacement If contaminated fuel or foreign material is in the tank, the 1. Install the fuel sender, with gasket, (6) to the fuel tank can usually be cleaned. Replace a leaking or tank (1).
Page 226: Fuel Lift Pump Testing
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 7.8.4 Fuel Lift Pump Testing lower negative battery cable (11). Disconnect the lower negative battery cable. To test the diaphragm, remove the fuel inlet line (1 or 6) from the fuel lift pump (2 or 7). Block the fuel inlet with a finger and operate the hand plunger (3 or 8).
Page 227: Fuel Filter Replacement
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 7.8.5 Fuel Filter Replacement The fuel filter (4 or 9) 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 (4 or 9). 3.
Page 228: Fuel Injectors
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 7.8.7 Fuel Injectors To test a fuel injector: The engine uses Bosch closed nozzle hole-type injectors. 1. Remove the fuel injector (1) from the cylinder head. The injectors have different part numbers for different (Refer to Section 7.8.7, b.
Page 229: After Fuel System Service
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T b. Injector Replacement 6. Install a new o-ring into the recessed groove in the top of the hold-down nut. Make sure the o-ring is not Preparatory steps: cut or twisted during installation. •...
Page 230: Engine Exhaust System
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T ENGINE EXHAUST SYSTEM WARNING: DO NOT attempt this procedure when the engine is hot. Wait for the WARNING: engine, muffler, and tailpipes to cool down Exhaust fumes contain before proceeding. Failure to do so could result carbon monoxide, a colorless, odorless gas in severe burns.
Page 231: Exhaust System Installation
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 3. Loosen the lower clamp (7) attaching the flex 5. Slide the flex pipe (8) between the muffler (9) and pipe (8) to the muffler (9). Loosen and remove the the exhaust pipe (19). Align the flex pipe (8) with the two screws (10) securing the bracket (11) to the muffler (9) and the exhaust pipe (19).
Page 232: Engine Replacement
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 7.10 ENGINE REPLACEMENT Removal and installation of the engine should be done with the transmission attached. For information on removing the transmission from, and installing it to the engine. (Refer to Section 6.7.1, “Transmission Removal.”) 7.10.1 Engine Removal...
Page 233 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 7. Remove three capscrews (12) securing the fan guard (13). MU1540 MU1390 8. Remove the upper radiator hose (14) by loosening 6. Drain the contents of the overflow reservoir (10) by both upper and lower hose clamp (15) from the removing the overflow tube (11) from the radiator.
Page 234 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 9. Remove both hydraulic oil inlet (1) and return (2) CAUTION: Radiator assembly is heavy hoses from the hydraulic oil cooler (3). Cap off the and bulky. Before attempting to remove the hose ends and hydraulic oil cooler openings to radiator assembly, prepare an adequate work prevent contaminants from entering the system.
Page 235 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 15. Remove all of the hydraulic oil from the reservoir and 19. Refer to Section 5.4.3, “Drive Shaft Removal,” system. The receptacle must be large enough to procedures, for the removal of the drive shafts from hold 50 gallons of oil.
Page 236 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 23. Remove hydraulic vent hoses (1, 2, and 3), and 27. Disconnect the transmission oil hoses (8) from the secure them out of the way next to the firewall. reservoir retainer assembly (9) and from the transmission (10).
Page 237 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 30. Loosen and remove three capscrews (17) and three a. 644E-42 Fuel Lines and Throttle Disconnect locknuts (18) securing the battery tray (19) to the 35. Disconnect the fuel inlet line (23) at the fuel lift engine mount frame.
Page 238 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 41. Label and disconnect these alternator wires: 43. At the positive starter stud (7), label and disconnect • [AG1] and [AG2] from G terminal (1) the positive (+) battery cable (8) and starter positive •...
Page 239 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 49. Label and disconnect the engine coolant 53. At the back of the engine mount frame, remove the temperature switch lead (19) and (unplug) the oil two elastic locknuts (30), two rebound washers (31), pressure switch lead (20).
Page 240: Engine Disassembly, Inspection And Service
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 55. Begin removing the engine/transmission from the 7.10.2 Engine Disassembly, Inspection and vehicle with the hoist or crane. Service 56. Carefully lift the engine/transmission out and away Engine disassembly, internal inspection, service, repair from the vehicle.
Page 241: Engine Installation
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 7.10.3 Engine Installation 1. Attach the transmission, if removed, to the engine by following the procedure in Section 6.7.3, “Transmission Installation.” 2. If removed during engine work, install the front engine mounts (11 and 12) using six previously removed capscrews (13) to the appropriate locations on the engine.
Page 242 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 9. Connect the shift solenoid wiring harness 14. Connect the positive (+) battery cable (13) and connectors (1, 2, 3, 4, 5, and 6). Connect the starter positive buss bar (14), with the wires (15) still transmission temperature switch lead (7).
Page 243 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 18. At the rear of the alternator, reattach all wires to their 944E-42 Fuel Lines and ECM Connections proper terminals: 23. Connect the fuel inlet line (33) to the fuel lift pump. •...
Page 244 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 26. Position the air cleaner hose over the turbocharger 29. Battery installation. Refer to Section 9.12.2, “Battery intake opening. Install the air cleaner, aligning the or Batteries,” for installation procedures. mounting band with the firewall, sliding the hex 30.
Page 245 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 31. Install the transmission oil hoses (14) from the 33. Install hydraulic vent hoses (20, 21, and 22). Torque reservoir retainer assembly (15) to the each hose end to 57 ± 7 lb-ft (77 ± 10 Nm). transmission.
Page 246 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 36. Attach the engine mount frame skirt (1) by installing four lower (3) capscrews and two (2) (front and back) capscrews. Torque to 13-22 lb-ft (17-31 Nm). MU1710 CAUTION: MU2080 Radiator assembly is heavy and bulky.
Page 247 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 43. Install the previously removed upper mounting capscrew (17), flat washer (18), plain washer (19), and locknut (20). 44. Torque all three radiator mounting capscrews to 25-45 lb-ft (34-61 Nm). 45. Uncap and connect the transmission inlet (21) and outlet (22) hoses.
Page 248 Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 50. Install the fan guard (1) using three (2) previously removed capscrews. Torque capscrews to 13-22 lb-ft (17-31 Nm). MU1540 51. Refill the cooling system. Refer to Section 7.6.3, MU0650 “Drain and Flush Radiator,” for procedures to refill 55.
Page 249: Engine Storage
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 62. Obtain and connect an appropriate engine analyzer 9. Remove the fuel injectors and spray clean engine or tachometer. Check the engine rpm at full throttle. lubricating oil into cylinder bores, 4 oz. (118,3 ml) of If the engine rpm is not 2600-2800 rpm, readjust the lubricating oil divided evenly between the four throttle limit-stop screw at the throttle pedal within...
Page 250: Troubleshooting
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T 7.12 TROUBLESHOOTING Trouble Possible Causes (see key, below) Low Cranking Power 1, 2, 3, 4 Will Not Start 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33 Difficult Starting 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, Lack of Power...
Page 251 Section 8 Hydraulic System Contents PARAGRAPH TITLE PAGE 8.1 Hydraulic Component Terminology ........... . 8.2 Safety Information .
Page 252 Hydraulic System 8.8.12 Boom Retract Circuit & Troubleshooting (Dual Joystick) ......8.78 8.8.13 Boom Retract Circuit &...
Page 253 Hydraulic System 8.8.48 Joystick Circuit Description (Dual Joystick) ........8.146 8.8.49 Joystick Circuit Description (Single Joystick) .
Page 254 Hydraulic System 8.14.4 Attachment Tilt Cylinder............8.213 8.14.5 Slave Cylinders .
Page 255: Hydraulic System
Hydraulic System HYDRAULIC COMPONENT TERMINOLOGY To understand the safety, operation, and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the vehicle. The following illustration identifies the components that are referred to throughout this section.
Page 256: Safety Information
Hydraulic System SAFETY INFORMATION To relieve hydraulic pressure: Whenever you disconnect a hydraulic line, coupler, WARNING: fitting, or other component, slowly and cautiously loosen DO NOT service the vehicle the part involved. A hissing sound or slow seepage of without following all safety precautions as hydraulic fluid may occur in most cases.
Page 257: Specifications
Hydraulic System SPECIFICATIONS Contamination Contamination, or dirt, can be any material other than Refer to Section 2.5.11, “Hydraulic System,” for hydraulic hydraulic fluid that causes harm or decreases the system specifications. performance of the system. Contaminants include solids, liquids and gases. Some contaminants are abrasive in HYDRAULIC FLUID nature, causing rapid wear or damage to the system.
Page 258: Hoses, Tube Lines, Fittings, Etc
Hydraulic System HOSES, TUBE LINES, FITTINGS, ETC. Removal and replacement of hoses, tube lines, fittings, etc. usually involves straight forward procedures. When removing a hydraulic hose or other component, be aware There are numerous hydraulic hoses, tubes, fittings, etc. that o-rings are used throughout the hydraulic system. used on this vehicle.
Page 259 Hydraulic System b. Inspection a. Disconnection Procedure These fittings are designed to be connected and WARNING: Relieve hydraulic pressure disconnected repeatedly without replacing the o-ring (9) before servicing any hydraulic component. or back-up ring (10) unless leakage or damage is Escaping hydraulic fluid under pressure can observed.
Page 260: Hydraulic Pressure Diagnosis
Hydraulic System HYDRAULIC PRESSURE DIAGNOSIS Flowmeter Kit The flowmeter test kit (2) is used to pinpoint hydraulic JLG Parts Department has two kits available to use for system faults. It includes a flowmeter with load valve, hydraulic system maintenance and troubleshooting; the magnetic base, photo tachometer head and flex arm.
Page 261: Pressure Checks And Adjustments
Hydraulic System 8.6.1 Pressure Checks and Adjustments WARNING: Avoid prolonged engine When diagnosing trouble in the hydraulic system, use the operation in closed areas with inadequate hydraulic testing information in Section 8.7, “Hydraulic ventilation. Failure to properly ventilate exhaust System Testing.” fumes can result in death or serious injury.
Page 262: Hydraulic System Testing
Hydraulic System HYDRAULIC SYSTEM TESTING 8.7.1 Hydraulic Testing (SN 18460 and Before, Dual Joystick, 644E Only) MU0483 8.12 Model 644E-42/944E-42 Rev. 6/04...
Page 263 Hydraulic System Equipment Needed to Perform Tests Engine Information Idle ..... . . 950 ±50 rpm from Hydraulic Diagnostic Test Kit Full Speed .
Page 264 Hydraulic System TEST TEST Valve ADJUST. COMPONENT PRESSURE PRESSURE TEST PROCEDURES SEQUENCE LOCATION Port LOCATION DESCRIPTION READINGS With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold Auxiliary 2,900-3,100 psi over relief and check pressure.
Page 265 Hydraulic System This Page Intentionally Left Blank 8.15 Model 644E-42/944E-42 Rev. 6/04...
Page 266: Hydraulic Testing (Sn 18461 Thru 18927, Dual Joystick, 644E Only)
Hydraulic System 8.7.2 Hydraulic Testing (SN 18461 thru 18927, Dual Joystick, 644E Only) MU5712 8.16 Model 644E-42/944E-42 Rev. 6/04...
Page 267 Hydraulic System Equipment Needed to Perform Tests Engine Information Idle ..... . . 950 ±50 rpm from Hydraulic Diagnostic Test Kit Full Speed .
Page 268 Hydraulic System TEST TEST Valve ADJUST. COMPONENT PRESSURE PRESSURE TEST PROCEDURES SEQUENCE LOCATION Port LOCATION DESCRIPTION READINGS With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold Auxiliary 2,900-3,100 psi over relief and check pressure.
Page 269 Hydraulic System This Page Intentionally Left Blank 8.19 Model 644E-42/944E-42 Rev. 6/04...
Page 270: Hydraulic Testing
Hydraulic System 8.7.3 Hydraulic Testing (SN 18928 thru 20118, 0160002519 thru 0160003087, Dual Joystick, 644E Only) MU6272 8.20 Model 644E-42/944E-42 Rev. 6/04...
Page 271 Hydraulic System Equipment Needed to Perform Tests Engine Information Idle ..... . . 950 ±50 rpm from Hydraulic Diagnostic Test Kit Full Speed .
Page 272 Hydraulic System TEST TEST Valve ADJUST. COMPONENT PRESSURE PRESSURE TEST PROCEDURES SEQUENCE LOCATION Port LOCATION DESCRIPTION READINGS With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold Auxiliary 2,900-3,100 psi over relief and check pressure.
Page 273 Hydraulic System This Page Intentionally Left Blank 8.23 Model 644E-42/944E-42 Rev. 6/04...
Page 274: Hydraulic Testing (Sn 0160003088 And After, Dual Joystick, 644E Only)
Hydraulic System 8.7.4 Hydraulic Testing (SN 0160003088 and After, Dual Joystick, 644E Only) MU6430 8.24 Model 644E-42/944E-42 Rev. 6/04...
Page 275 Hydraulic System Equipment Needed to Perform Tests Engine Information Idle ..... . . 950 ±50 rpm from Hydraulic Diagnostic Test Kit Full Speed .
Page 276 Hydraulic System TEST TEST Valve ADJUST. COMPONENT PRESSURE PRESSURE TEST PROCEDURES SEQUENCE LOCATION Port LOCATION DESCRIPTION READINGS With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold Auxiliary 2,900-3,100 psi over relief and check pressure.
Page 277 Hydraulic System This Page Intentionally Left Blank 8.27 Model 644E-42/944E-42 Rev. 6/04...
Page 278: Hydraulic Testing
Hydraulic System 8.7.5 Hydraulic Testing (SN 18928 thru 20118, 0160002519 thru 0160003087 Single Joystick, 644E Only) MU5242 8.28 Model 644E-42/944E-42 Rev. 6/04...
Page 279 Hydraulic System Equipment Needed to Perform Tests Engine Information Idle ..... . . 950 ±50 rpm from Hydraulic Diagnostic Test Kit Full Speed .
Page 280 Hydraulic System TEST TEST Valve ADJUST. COMPONENT PRESSURE PRESSURE TEST PROCEDURES SEQUENCE LOCATION Port LOCATION DESCRIPTION READINGS With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold Auxiliary 2,900-3,100 psi over relief and check pressure.
Page 281 Hydraulic System This Page Intentionally Left Blank 8.31 Model 644E-42/944E-42 Rev. 6/04...
Page 282: Hydraulic Testing (Sn 0160003088 And After Single Joystick, 644E Only)
Hydraulic System 8.7.6 Hydraulic Testing (SN 0160003088 and After Single Joystick, 644E Only) MU6440 8.32 Model 644E-42/944E-42 Rev. 6/04...
Page 283 Hydraulic System Equipment Needed to Perform Tests Engine Information Idle ..... . . 950 ±50 rpm from Hydraulic Diagnostic Test Kit Full Speed .
Page 284 Hydraulic System TEST TEST Valve ADJUST. COMPONENT PRESSURE PRESSURE TEST PROCEDURES SEQUENCE LOCATION Port LOCATION DESCRIPTION READINGS With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold Auxiliary 2,900-3,100 psi over relief and check pressure.
Page 285 Hydraulic System This Page Intentionally Left Blank 8.35 Model 644E-42/944E-42 Rev. 6/04...
Page 286: Hydraulic Testing (Sn 18927 And Before, Dual Joystick, 944E Only)
Hydraulic System 8.7.7 Hydraulic Testing (SN 18927 and Before, Dual Joystick, 944E Only) MU5712 8.36 Model 644E-42/944E-42 Rev. 6/04...
Page 287 Hydraulic System Equipment Needed to Perform Tests Engine Information Idle ..... . . 950 ±50 rpm from Hydraulic Diagnostic Test Kit Full Speed .
Page 288 Hydraulic System TEST TEST Valve ADJUST. COMPONENT PRESSURE PRESSURE TEST PROCEDURES SEQUENCE LOCATION Port LOCATION DESCRIPTION READINGS With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold Auxiliary 2,900-3,100 psi over relief and check pressure.
Page 289 Hydraulic System This Page Intentionally Left Blank 8.39 Model 644E-42/944E-42 Rev. 6/04...
Page 290: Hydraulic Testing
Hydraulic System 8.7.8 Hydraulic Testing (SN 18928 thru 20123, 0160002514 thru 0160003085, Dual Joystick, 944E Only) MU6272 8.40 Model 644E-42/944E-42 Rev. 6/04...
Page 291 Hydraulic System Equipment Needed to Perform Tests Engine Information Idle ..... . . 950 ±50 rpm from Hydraulic Diagnostic Test Kit Full Speed .
Page 292 Hydraulic System TEST TEST Valve ADJUST. COMPONENT PRESSURE PRESSURE TEST PROCEDURES SEQUENCE LOCATION Port LOCATION DESCRIPTION READINGS With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold Auxiliary 2,900-3,100 psi over relief and check pressure.
Page 293 Hydraulic System This Page Intentionally Left Blank 8.43 Model 644E-42/944E-42 Rev. 6/04...
Page 294: Hydraulic Testing (Sn 0160003086 And After, Dual Joystick, 944E Only)
Hydraulic System 8.7.9 Hydraulic Testing (SN 0160003086 and After, Dual Joystick, 944E Only) MU6430 8.44 Model 644E-42/944E-42 Rev. 6/04...
Page 295 Hydraulic System Equipment Needed to Perform Tests Engine Information Idle ..... . . 950 ±50 rpm from Hydraulic Diagnostic Test Kit Full Speed .
Page 296 Hydraulic System TEST TEST Valve ADJUST. COMPONENT PRESSURE PRESSURE TEST PROCEDURES SEQUENCE LOCATION Port LOCATION DESCRIPTION READINGS With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold Auxiliary 2,900-3,100 psi over relief and check pressure.
Page 297 Hydraulic System This Page Intentionally Left Blank 8.47 Model 644E-42/944E-42 Rev. 6/04...
Page 298: Hydraulic Testing
Hydraulic System 8.7.10 Hydraulic Testing (SN 18928 thru 20123, 0160002514 thru 0160003085, Single Joystick, 944E Only) MU5242 8.48 Model 644E-42/944E-42 Rev. 6/04...
Page 299 Hydraulic System Equipment Needed to Perform Tests Engine Information Idle ..... . . 950 ±50 rpm from Hydraulic Diagnostic Test Kit Full Speed .
Page 300 Hydraulic System TEST TEST Valve ADJUST. COMPONENT PRESSURE PRESSURE TEST PROCEDURES SEQUENCE LOCATION Port LOCATION DESCRIPTION READINGS With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold Auxiliary 2,900-3,100 psi over relief and check pressure.
Page 301 Hydraulic System This Page Intentionally Left Blank 8.51 Model 644E-42/944E-42 Rev. 6/04...
Page 302: Hydraulic Testing (Sn 0160003086 And After Single Joystick, 944E Only)
Hydraulic System 8.7.11 Hydraulic Testing (SN 0160003086 and After Single Joystick, 944E Only) MU6440 8.52 Model 644E-42/944E-42 Rev. 6/04...
Page 303 Hydraulic System Equipment Needed to Perform Tests Engine Information Idle ..... . . 950 ±50 rpm from Hydraulic Diagnostic Test Kit Full Speed .
Page 304 Hydraulic System TEST TEST Valve ADJUST. COMPONENT PRESSURE PRESSURE TEST PROCEDURES SEQUENCE LOCATION Port LOCATION DESCRIPTION READINGS With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold Auxiliary 2,900-3,100 psi over relief and check pressure.
Page 305: Hydraulic Circuits And Troubleshooting
Hydraulic System HYDRAULIC CIRCUITS AND 3. Check for air in the hydraulic system. Erratic machine performance and/or spongy cylinder TROUBLESHOOTING operation are signs of air in the hydraulic system. This section covers the hydraulic circuits and includes a WARNING: circuit drawing, troubleshooting chart, and description of Wait for hydraulic fluid to the circuit for each function.
Page 306: Pump & Cooling Circuit & Troubleshooting (Dual Joystick, Sn 18460 And Before)
Hydraulic System 8.8.1 Pump & Cooling Circuit & Troubleshooting (Dual Joystick, SN 18460 and Before) (Refer to Section 8.8.46, “Pump and Cooling Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) MU0721 8.56 Model 644E-42/944E-42 Rev. 6/04...
Page 307 Hydraulic System If the pump is not functioning properly Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the Check suction line from following: Repair/replace suction line. reservoir to the pump. 1. Hydraulic oil level in the reservoir If OK 2.
Page 308: Pump & Cooling Circuit & Troubleshooting (Dual Joystick, Sn 18461 And After)
Hydraulic System 8.8.2 Pump & Cooling Circuit & Troubleshooting (Dual Joystick, SN 18461 and After) (Refer to Section 8.8.46, “Pump and Cooling Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) MU5550 8.58 Model 644E-42/944E-42 Rev. 6/04...
Page 309 Hydraulic System If the pump is not functioning properly Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the Check suction line from following: Repair/replace suction line. reservoir to the pump. 1. Hydraulic oil level in the reservoir If OK 2.
Page 310: Pump & Cooling Circuit & Troubleshooting (Single Joystick)
Hydraulic System 8.8.3 Pump & Cooling Circuit & Troubleshooting (Single Joystick) (Refer to Section 8.8.47, “Pump and Cooling Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) MU5430 8.60 Model 644E-42/944E-42 Rev. 6/04...
Page 311 Hydraulic System If the pump is not functioning properly Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the Check suction line from following: Repair/replace suction line. reservoir to the pump. 1. Hydraulic oil level in the reservoir If OK 2.
Page 312: Joystick Circuit & Troubleshooting (Front - Dual Joystick)
Hydraulic System 8.8.4 Joystick Circuit & Troubleshooting (Front - Dual Joystick) (Refer to Section 8.8.48, “Joystick Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) “P1” Pressure “PPG” Pressure Pressure Reducing Cartridge MU0701 MU0701 8.62 Model 644E-42/944E-42 Rev. 6/04...
Page 313 Hydraulic System If the joystick is not functioning. Before troubleshooting any hydraulic circuit, ALWAYS Check the pilot pressure at Adjust the pressure reducing begin by checking the “PPG” port of accumulator cartridge on the accumulator following: charge/secondary function charge/secondary function valve.
Page 314: Joystick Circuit & Troubleshooting (Rear - Dual Joystick)
Hydraulic System 8.8.5 Joystick Circuit & Troubleshooting (Rear - Dual Joystick) (Refer to Section 8.8.48, “Joystick Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) “P1” Pressure “PPG” Pressure Pressure Reducing Cartridge MU0711 8.64 Model 644E-42/944E-42 Rev. 6/04...
Page 315 Hydraulic System If the joystick is not functioning. Before troubleshooting any hydraulic circuit, ALWAYS Check the pilot pressure at Adjust the pressure reducing begin by checking the “PPG” port of accumulator cartridge on the accumulator following: charge/secondary function charge/secondary function valve.
Page 316: Joystick Circuit & Troubleshooting (Single Joystick)
Hydraulic System 8.8.6 Joystick Circuit & Troubleshooting (Single Joystick) (Refer to Section 8.8.49, “Joystick Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) “P1” Pressure Pressure Reducing Cartridge “PPG” Pressure MU5380 8.66 Model 644E-42/944E-42 Rev. 6/04...
Page 317 Hydraulic System If the joystick is not functioning. Before troubleshooting any Check the pilot pressure at Adjust the pressure reducing hydraulic circuit, ALWAYS “PPG” port of accumulator cartridge on the accumulator begin by checking the charge/secondary function charge/secondary function following: valve.
Page 318: Park Brake Circuit & Troubleshooting
Hydraulic System 8.8.7 Park Brake Circuit & Troubleshooting (Refer to Section 8.8.50, “Brake Circuit Description,” for a more detailed explanation of this circuit.) Parking Brake ON (No Oil Pressure) Parking Brake Solenoid Valve “CV2” Check Valve “PBG” Pressure Tap Pressure Reducing Cartridge Parking Brake OFF (Oil Pressure to Parking Brake) Parking Brake...
Page 319 Hydraulic System If park brake fails to hold, check the “PBG” port on the accumulator charge/secondary Before troubleshooting any function valve. Should read 0 psi. hydraulic circuit, ALWAYS If park brake fails to release, begin by checking the check the “PBG” port on the Adjust/repair/replace following: accumulator charge/secondary...
Page 320: Service Brake Circuit & Troubleshooting
Hydraulic System 8.8.8 Service Brake Circuit & Troubleshooting (Refer to Section 8.8.50, “Brake Circuit Description,” for a more detailed explanation of this circuit.) Front Axle Pressure Tap Rear Axle Pressure Tap MU0530 8.70 Model 644E-42/944E-42 Rev. 6/04...
Page 321 Hydraulic System Check the function of the accumulator charge/ secondary function valve. See “Accumulator Charge/ Before troubleshooting any Secondary Function Valve” hydraulic circuit, ALWAYS on page 8.204. begin by checking the following: If service brakes are not 1. Hydraulic oil level in the Replace brake valve.
Page 322: Emergency Towing Park Brake Release Circuit & Troubleshooting
Hydraulic System 8.8.9 Emergency Towing Park Brake Release Circuit & Troubleshooting (Refer to Section 8.8.50, “Brake Circuit Description,” for a more detailed explanation of this circuit.) Connect Port-a-Power to this port (“PBG”) to release front axle park brake for emergency towing.
Page 323 Hydraulic System If park brake fails to release Recheck Port-a-Power device with park brake gauge port for proper connection and pressurized. pressure setting. Before troubleshooting any hydraulic circuit, ALWAYS If OK begin by checking the following: Check for external leaks, Tighten fittings or lines, or loose fittings or lines replace fittings or lines...
Page 324: Boom Extend Circuit & Troubleshooting (Dual Joystick)
Hydraulic System 8.8.10 Boom Extend Circuit & Troubleshooting (Dual Joystick) (Refer to Section 8.8.51, “Boom Extend/Retract Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) “PPG” Pilot Pressure Supply Line Pressure Reducing Cartridge Relief Valve Main Relief Valve Implement Unloader...
Page 325 Hydraulic System The extend/retract cylinder does not extend. Check the standby pump pressure Replace unloader cartridge Before troubleshooting any at implement pump pressure tap. on main control valve. hydraulic circuit, ALWAYS begin by checking the If OK following: Adjust/repair/replace Check pilot pressure at “PPG” port 1.
Page 326: Boom Extend Circuit & Troubleshooting (Single Joystick)
Hydraulic System 8.8.11 Boom Extend Circuit & Troubleshooting (Single Joystick) (Refer to Section 8.8.52, “Boom Extend/Retract Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) Pressure Reducing Cartridge “PPG” Pressure Pilot Supply Line Relief Valve Main Relief Valve Implement Pump...
Page 327 Hydraulic System The extend/retract cylinder does not extend. Check the standby pump pressure at Before troubleshooting any Replace unloader cartridge implement pump pressure tap. hydraulic circuit, ALWAYS on main control valve. begin by checking the If OK following: 1. Hydraulic oil level in the Adjust/repair/replace Check pilot pressure at “PPG”...
Page 328: Boom Retract Circuit & Troubleshooting (Dual Joystick)
Hydraulic System 8.8.12 Boom Retract Circuit & Troubleshooting (Dual Joystick) (Refer to Section 8.8.51, “Boom Extend/Retract Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) “PPG” Pressure Pressure Reducing Cartridge Pilot Supply Line Main Relief Valve Unloader MU0571 Implement Cartridge...
Page 329 Hydraulic System The extend/retract cylinder does not retract. Before troubleshooting any Check the standby pump pressure Replace unloader cartridge at implement pump pressure tap. hydraulic circuit, ALWAYS on main control valve. begin by checking the following: If OK 1. Hydraulic oil level in the reservoir Adjust/repair/replace Check pilot pressure at “PPG”...
Page 330: Boom Retract Circuit & Troubleshooting (Single Joystick)
Hydraulic System 8.8.13 Boom Retract Circuit & Troubleshooting (Single Joystick) (Refer to Section 8.8.52, “Boom Extend/Retract Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) Pressure Reducing Cartridge “PPG” Pressure Pilot Supply Line Main Relief Valve Implement Pump Pressure Unloader...
Page 331 Hydraulic System The extend/retract cylinder does not retract. Before troubleshooting any Check the standby pump pressure at Replace unloader cartridge hydraulic circuit, ALWAYS implement pump pressure tap. on main control valve. begin by checking the following: If OK 1. Hydraulic oil level in the Adjust/repair/replace reservoir Check pilot pressure at “PPG”...
Page 332: Boom Lift Circuit & Troubleshooting (Dual Joystick)
Hydraulic System 8.8.14 Boom Lift Circuit & Troubleshooting (Dual Joystick) (Refer to Section 8.8.53, “Boom Lift/Lower Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) “PPG” Pressure Pressure Pilot Supply Reducing Line Cartridge Main Relief Valve MU0591 Unloader Implement Cartridge...
Page 333 Hydraulic System The lift/lower cylinder does not raise. Before troubleshooting any Check the standby pump pressure at Replace unloader cartridge hydraulic circuit, ALWAYS implement pump pressure tap. on main control valve. begin by checking the If OK following: Adjust/repair/replace 1. Hydraulic oil level in the Check pilot pressure at “PPG”...
Page 334: Boom Lift Circuit & Troubleshooting (Single Joystick)
Hydraulic System 8.8.15 Boom Lift Circuit & Troubleshooting (Single Joystick) (Refer to Section 8.8.54, “Boom Lift/Lower Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) Pressure Reducing Cartridge “PPG” Pressure Pilot Supply Line Main Relief Implement Valve Pump Pressure MU5300...
Page 335 Hydraulic System The lift/lower cylinder does not raise. Before troubleshooting any Check the standby pump pressure at Replace unloader cartridge hydraulic circuit, ALWAYS implement pump pressure tap. on main control valve. begin by checking the If OK following: 1. Hydraulic oil level in the Adjust/repair/replace Check pilot pressure at “PPG”...
Page 336: Boom Lower Circuit & Troubleshooting (Dual Joystick)
Hydraulic System 8.8.16 Boom Lower Circuit & Troubleshooting (Dual Joystick) (Refer to Section 8.8.53, “Boom Lift/Lower Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) “PPG” Pressure Pressure Reducing Cartridge Pilot Supply Line Main Relief Valve Unloader Implement Pump MU0601 Cartridge...
Page 337 Hydraulic System The lift/lower cylinder does not lower. Before troubleshooting any Check the standby pump pressure Replace unloader cartridge hydraulic circuit, ALWAYS at implement pump pressure tap. on main control valve. begin by checking the following: If OK 1. Hydraulic oil level in the Adjust/repair/replace reservoir Check pilot pressure at “PPG”...
Page 338: Boom Lower Circuit & Troubleshooting (Single Joystick)
Hydraulic System 8.8.17 Boom Lower Circuit & Troubleshooting (Single Joystick) (Refer to Section 8.8.54, “Boom Lift/Lower Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) Pressure Reducing Cartridge “PPG” Pressure Pilot Supply Line Main Relief Implement Valve Pump Pressure Unloader...
Page 339 Hydraulic System The lift/lower cylinder does not lower. Before troubleshooting any Check the standby pump pressure Replace unloader cartridge hydraulic circuit, ALWAYS at implement pump pressure tap. on main control valve. begin by checking the following: If OK 1. Hydraulic oil level in the Adjust/repair/replace reservoir Check pilot pressure at “PPG”...
Page 340: Frame Sway (Left), Stabilizer Circuit & Troubleshooting (Sn 18460 And Before)
Hydraulic System 8.8.18 Frame Sway (Left), Stabilizer Circuit & Troubleshooting (SN 18460 and Before) (Refer to Section 8.8.55, “Frame Sway Circuit Description,” for a more detailed explanation of this circuit.) Orifice, Part Of Orifice, Part Of Check Valve Check Valve Fittings Fittings Relief...
Page 341 Hydraulic System NOTE: Refer to Section 2.5.6, “Hydraulic Cylinder Performance Specifications,” for approximate Before troubleshooting any cylinder cycle times. The operation of the system hydraulic circuit, ALWAYS function should approximate the times listed. begin by checking the following: NOTE: 1. Hydraulic oil level in the When checking pressures in reservoir circuits, refer to Section 8.7,...
Page 342: Frame Sway (Left), Stabilizer Circuit & Troubleshooting (Sn 18461 And After)
Hydraulic System 8.8.19 Frame Sway (Left), Stabilizer Circuit & Troubleshooting (SN 18461 and After) (Refer to Section 8.8.55, “Frame Sway Circuit Description,” for a more detailed explanation of this circuit.) Orifice, Part Of Orifice, Part Of Check Valve Check Valve Fitting Fitting Relief...
Page 343 Hydraulic System NOTE: Refer to Section 2.5.6, “Hydraulic Cylinder Performance Specifications,” for approximate Before troubleshooting any cylinder cycle times. The operation of the system hydraulic circuit, ALWAYS function should approximate the times listed. begin by checking the following: NOTE: 1. Hydraulic oil level in the When checking pressures in reservoir circuits, refer to Section 8.7,...
Page 344: Frame Sway (Right), Stabilizer Circuit & Troubleshooting ( Sn 18460 And Before)
Hydraulic System 8.8.20 Frame Sway (Right), Stabilizer Circuit & Troubleshooting ( SN 18460 and Before) (Refer to Section 8.8.55, “Frame Sway Circuit Description,” for a more detailed explanation of this circuit.) Orifice, Part Of Orifice, Part Of Check Valve Check Valve Fitting Fitting Relief...
Page 345 Hydraulic System NOTE: Refer to Section 2.5.6, “Hydraulic Cylinder Performance Specifications,” for approximate Before troubleshooting any cylinder cycle times. The operation of the system function should approximate the times listed. hydraulic circuit, ALWAYS begin by checking the following: NOTE: When checking pressures in 1.
Page 346: Frame Sway (Right), Stabilizer Circuit & Troubleshooting (Sn 18461 And After)
Hydraulic System 8.8.21 Frame Sway (Right), Stabilizer Circuit & Troubleshooting (SN 18461 and After) (Refer to Section 8.8.55, “Frame Sway Circuit Description,” for a more detailed explanation of this circuit.) Orifice, Part Of Orifice, Part Of Check Valve Check Valve Fitting Fitting Relief...
Page 347 Hydraulic System NOTE: Refer to Section 2.5.6, “Hydraulic Cylinder Performance Specifications,” for approximate Before troubleshooting any cylinder cycle times. The operation of the system function should approximate the times listed. hydraulic circuit, ALWAYS begin by checking the following: NOTE: 1. Hydraulic oil level in the When checking pressures in circuits, refer to Section 8.7, reservoir...
Page 348: Attachment Tilt (Down), Slave Cylinder Circuit & Troubleshooting (Dual Joystick)
Hydraulic System 8.8.22 Attachment Tilt (Down), Slave Cylinder Circuit & Troubleshooting (Dual Joystick) (Refer to Section 8.8.56, “Attachment Tilt and Slave Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) “PPG” Pressure Pressure Reducing Cartridge Relief Valve Main Relief Valve...
Page 349 Hydraulic System If the attachment tilt cylinder retracts slowly. Check the cycle times for Before troubleshooting any boom LIFT and boom hydraulic circuit, ALWAYS EXTEND to determine pump begin by checking the Inspect pump. Refer to performance. Pump flow Hydraulic Testing following: directly controls these cycle pages 8.12 through 8.54.
Page 350: Attachment Tilt (Down), Slave Cylinder Circuit & Troubleshooting (Single Joystick)
Hydraulic System 8.8.23 Attachment Tilt (Down), Slave Cylinder Circuit & Troubleshooting (Single Joystick) (Refer to Section 8.8.57, “Attachment Tilt and Slave Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) Pressure Reducing Cartridge “PPG” Pressure Relief Pilot Supply Valve Line Main...
Page 351 Hydraulic System If the attachment tilt cylinder retracts slowly. Check the cycle times for Before troubleshooting any boom LIFT and boom hydraulic circuit, ALWAYS EXTEND to determine pump begin by checking the Inspect pump. Refer to performance. Pump flow Hydraulic Testing following: directly controls these cycle pages 8.12 through 8.54.
Page 352: Attachment Tilt (Up), Slave Cylinder Circuit & Troubleshooting (Dual Joystick)
Hydraulic System 8.8.24 Attachment Tilt (Up), Slave Cylinder Circuit & Troubleshooting (Dual Joystick) (Refer to Section 8.8.56, “Attachment Tilt and Slave Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) “PPG” Pressure Pressure Reducing Cartridge Main Relief Valve Relief Implement...
Page 353 Hydraulic System If the attachment tilt cylinder extends slowly. Before troubleshooting any Check the cycle times for boom LIFT and boom hydraulic circuit, ALWAYS EXTEND to determine pump begin by checking the performance. Pump flow Inspect pump. Refer to following: directly controls these cycle Hydraulic Testing times.
Page 354: Attachment Tilt (Up), Slave Cylinder Circuit & Troubleshooting (Single Joystick)
Hydraulic System 8.8.25 Attachment Tilt (Up), Slave Cylinder Circuit & Troubleshooting (Single Joystick) (Refer to Section 8.8.57, “Attachment Tilt and Slave Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) Priority Cartridge Pressure Reducing Cartridge “PPG” Pressure Main Relief Valve...
Page 355 Hydraulic System If the attachment tilt cylinder extends slowly. Check the cycle times for Before troubleshooting any boom LIFT and boom hydraulic circuit, ALWAYS EXTEND to determine pump begin by checking the performance. Pump flow Inspect pump. Refer to following: directly controls these cycle Hydraulic Testing times.
Page 356: Transfer Carriage Cylinder Extend (Carriage Back) Circuit & Troubleshooting (Dual Joystick)
Hydraulic System 8.8.26 Transfer Carriage Cylinder Extend (Carriage Back) Circuit & Troubleshooting (Dual Joystick) (Refer to Section 8.8.58, “Transfer Carriage Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit) “PPG” Pressure Pressure Reducing Cartridge Main Implement Relief Pump Valve Pressure...
Page 357 Hydraulic System If the transfer carriage cylinder extends slowly. Before troubleshooting any Check the cycle times for hydraulic circuit, ALWAYS boom LIFT and boom begin by checking the EXTEND to determine pump following: performance. Pump flow Inspect pump. Refer to directly controls these cycle Hydraulic Testing 1.
Page 358: Transfer Carriage Cylinder Extend (Carriage Back) Circuit & Troubleshooting (Single Joystick)
Hydraulic System 8.8.27 Transfer Carriage Cylinder Extend (Carriage Back) Circuit & Troubleshooting (Single Joystick) (Refer to Section 8.8.59, “Transfer Carriage Circuit Description (Single Joystick),” for a more detailed explanation of this circuit) Priority Cartridge Pressure Reducing Cartridge “PPG” Pressure Main Relief Valve Implement...
Page 359 Hydraulic System If the transfer carriage cylinder extends slowly. Before troubleshooting any Check the cycle times for hydraulic circuit, ALWAYS boom LIFT and boom begin by checking the EXTEND to determine pump following: performance. Pump flow Inspect pump. Refer to directly controls these cycle Hydraulic Testing 1.
Page 360: Transfer Carriage Cylinder Retract (Carriage Fwd) Circuit & Troubleshooting (Dual Joystick)
Hydraulic System 8.8.28 Transfer Carriage Cylinder Retract (Carriage Fwd) Circuit & Troubleshooting (Dual Joystick) (Refer to Section 8.8.58, “Transfer Carriage Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) “PPG” Pressure Pressure Reducing Cartridge Relief Valve Main Implement Relief Pump...
Page 361 Hydraulic System If the transfer carriage cylinder retracts slowly. Before troubleshooting any Check the cycle times for hydraulic circuit, ALWAYS boom LIFT and boom begin by checking the EXTEND to determine pump following: performance. Pump flow Inspect pump. Refer to directly controls these cycle Hydraulic Testing 1.
Page 362: Transfer Carriage Cylinder Retract (Carriage Fwd) Circuit & Troubleshooting (Single Joystick)
Hydraulic System 8.8.29 Transfer Carriage Cylinder Retract (Carriage Fwd) Circuit & Troubleshooting (Single Joystick) (Refer to Section 8.8.59, “Transfer Carriage Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) Priority Cartridge Pressure Reducing Cartridge “PPG” Pressure Relief Valve Main Relief...
Page 363 Hydraulic System If the transfer carriage cylinder retracts slowly. Before troubleshooting any Check the cycle times for hydraulic circuit, ALWAYS boom LIFT and boom begin by checking the EXTEND to determine pump following: performance. Pump flow Inspect pump. Refer to directly controls these cycle Hydraulic Testing 1.
Page 364: Front-Wheel Steering Circuit (Left Turn) & Troubleshooting
Hydraulic System 8.8.30 Front-Wheel Steering Circuit (Left Turn) & Troubleshooting (Refer to Section 8.8.60, “Steering Circuit Descriptions,” for a more detailed explanation of this circuit.) Check Valve “P1” Pressure Relief Valve “LSG” Pressure MU0751 8.114 Model 644E-42/944E-42 Rev. 6/04...
Page 365 Hydraulic System If the steering is slow or difficult, check the pressure at the “P1” port of the accumulator charge/secondary function valve by bottoming out the Before troubleshooting steering and noting the relief any hydraulic circuit, pressure. ALWAYS begin by checking the following: Increase engine rpm to see if pressure If So...
Page 366: Front-Wheel Steering Circuit (Right Turn) & Troubleshooting
Hydraulic System 8.8.31 Front-Wheel Steering Circuit (Right Turn) & Troubleshooting (Refer to Section 8.8.60, “Steering Circuit Descriptions,” for a more detailed explanation of this circuit.) Check Valve “P1” Pressure Relief Valve “LSG” Pressure MU0761 8.116 Model 644E-42/944E-42 Rev. 6/04...
Page 367 Hydraulic System If the steering is slow or difficult, check the pressure at the “P1” port of the accumulator charge/secondary function valve by bottoming out the Before troubleshooting steering and noting the relief any hydraulic circuit, pressure. ALWAYS begin by checking the following: Increase engine rpm to see if pressure If So...
Page 368: Four-Wheel Steering Circuit (Left Turn) & Troubleshooting
Hydraulic System 8.8.32 Four-Wheel Steering Circuit (Left Turn) & Troubleshooting (Refer to Section 8.8.60, “Steering Circuit Descriptions,” for a more detailed explanation of this circuit.) Check Valve “P1” Pressure Relief Valve “LSG” Pressure Tap MU0771 8.118 Model 644E-42/944E-42 Rev. 6/04...
Page 369 Hydraulic System If the steering is slow or difficult, check the pressure at the “P1” port of the accumulator charge/secondary function valve by bottoming out the Before troubleshooting steering and noting the relief any hydraulic circuit, pressure. ALWAYS begin by checking the following: Increase engine rpm to see if pressure If So...
Page 370: Four-Wheel Steering Circuit (Right Turn) & Troubleshooting
Hydraulic System 8.8.33 Four-Wheel Steering Circuit (Right Turn) & Troubleshooting (Refer to Section 8.8.60, “Steering Circuit Descriptions,” for a more detailed explanation of this circuit.) Check Valve “P1” Pressure Relief Valve “LSG” Pressure MU0781 8.120 Model 644E-42/944E-42 Rev. 6/04...
Page 371 Hydraulic System If the steering is slow or difficult, check the pressure at the “P1” port of the accumulator charge/secondary function valve by bottoming out the Before troubleshooting steering and noting the relief any hydraulic circuit, pressure. ALWAYS begin by checking the following: Increase engine rpm to see if pressure If So...
Page 372: Crab Steering Circuit (Left Turn) & Troubleshooting
Hydraulic System 8.8.34 Crab Steering Circuit (Left Turn) & Troubleshooting (Refer to Section 8.8.60, “Steering Circuit Descriptions,” for a more detailed explanation of this circuit.) Check Valve “P1” Pressure Relief Valve “LSG” Pressure MU0791 8.122 Model 644E-42/944E-42 Rev. 6/04...
Page 373 Hydraulic System If the steering is slow or difficult, check the pressure at the “P1” port of the accumulator charge/secondary function valve by bottoming out the Before troubleshooting steering and noting the relief any hydraulic circuit, pressure. ALWAYS begin by checking the following: Increase engine rpm to see if pressure If So...
Page 374: Crab Steering Circuit (Right Turn) & Troubleshooting
Hydraulic System 8.8.35 Crab Steering Circuit (Right Turn) & Troubleshooting (Refer to Section 8.8.60, “Steering Circuit Descriptions,” for a more detailed explanation of this circuit.) Check Valve “P1” Pressure Relief Valve “LSG” Pressure MU0801 8.124 Model 644E-42/944E-42 Rev. 6/04...
Page 375 Hydraulic System If the steering is slow or difficult, check the pressure at the “P1” port of the accumulator charge/secondary function valve by bottoming out the Before troubleshooting steering and noting the relief any hydraulic circuit, pressure. ALWAYS begin by checking the following: Increase engine rpm to see if pressure If So...
Page 376: Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Dual Joystick) (644E-42, Sn 20118 & Before, Sn 0160002519 Thru 0160003108) (944E-42, Sn 20123 & Before, Sn 0160002514 Thru 0160003106)
Hydraulic System 8.8.36 Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Dual Joystick) (644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108) (944E-42, SN 20123 & Before, SN 0160002514 thru 0160003106) (Refer to Section 8.8.61, “Auxiliary Hydraulic Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) Female Male...
Page 377 Hydraulic System There are no auxiliary hydraulic functions. Before troubleshooting any Check the standby pump pressure hydraulic circuit, ALWAYS Replace unloader cartridge at implement pump pressure tap. begin by checking the on main control valve. following: If OK 1. Hydraulic oil level in the reservoir Install pressure gauge in the pilot Install pressure gauge in the pilot...
Page 378: Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Dual Joystick) (644E-42, Sn 0160003109 & After) (944E-42, Sn 0160003107 & After)
Hydraulic System 8.8.37 Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Dual Joystick) (644E-42, SN 0160003109 & After) (944E-42, SN 0160003107 & After) (Refer to Section 8.8.61, “Auxiliary Hydraulic Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) Female Male Coupler...
Page 379 Hydraulic System There are no auxiliary hydraulic functions. Before troubleshooting any hydraulic circuit, ALWAYS Check the standby pump pressure Replace unloader cartridge begin by checking the at implement pump pressure tap. on main control valve. following: If OK 1. Hydraulic oil level in the reservoir Install pressure gauge in the pilot Install pressure gauge in the pilot...
Page 380: Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Single Joystick) (644E-42, Sn 20118 & Before, Sn 0160002519 Thru 0160003108) (944E-42, Sn 20123 & Before, Sn 0160002514 Thru 0160003106)
Hydraulic System 8.8.38 Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Single Joystick) (644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108) (944E-42, SN 20123 & Before, SN 0160002514 thru 0160003106) (Refer to Section 8.8.62, “Auxiliary Hydraulics Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) Female Male...
Page 381 Hydraulic System There are no auxiliary hydraulic functions. Before troubleshooting any hydraulic circuit, ALWAYS Check the standby pump pressure at Replace unloader cartridge begin by checking the implement pump pressure tap. on main control valve. following: 1. Hydraulic oil level in the If OK reservoir Install pressure gauge in the pilot...
Page 382: Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Single Joystick) (644E-42, Sn 0160003109 & After) (944E-42, Sn 0160003107 & After)
Hydraulic System 8.8.39 Auxiliary Hydraulic Circuit & Troubleshooting (Male Coupler Pressurized - Single Joystick) (644E-42, SN 0160003109 & After) (944E-42, SN 0160003107 & After) (Refer to Section 8.8.62, “Auxiliary Hydraulics Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) Female Male Coupler...
Page 383 Hydraulic System There are no auxiliary hydraulic functions. Before troubleshooting any hydraulic circuit, ALWAYS Check the standby pump pressure at Replace unloader cartridge begin by checking the implement pump pressure tap. on main control valve. following: 1. Hydraulic oil level in the If OK reservoir Install pressure gauge in the pilot...
Page 384: Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Dual Joystick) (644E-42, Sn 20118 & Before, Sn 0160002519 Thru 0160003108) (944E-42, Sn 20123 & Before, Sn 0160002514 Thru 0160003106)
Hydraulic System 8.8.40 Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Dual Joystick) (644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108) (944E-42, SN 20123 & Before, SN 0160002514 thru 0160003106) (Refer to Section 8.8.61, “Auxiliary Hydraulic Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) Female Male...
Page 385 Hydraulic System There are no auxiliary hydraulic functions. Before troubleshooting any hydraulic circuit, ALWAYS Check the standby pump pressure Replace unloader cartridge at implement pump pressure tap. on main control valve. begin by checking the following: 1. Hydraulic oil level in the If OK reservoir Install pressure gauge in the pilot...
Page 386: Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Dual Joystick) (644E-42, Sn 0160003109 & After) (944E-42, Sn 0160003107 & After)
Hydraulic System 8.8.41 Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Dual Joystick) (644E-42, SN 0160003109 & After) (944E-42, SN 0160003107 & After) (Refer to Section 8.8.61, “Auxiliary Hydraulic Circuit Description (Dual Joystick),” for a more detailed explanation of this circuit.) Female Male Coupler...
Page 387 Hydraulic System There are no auxiliary hydraulic functions. Before troubleshooting any hydraulic circuit, ALWAYS Check the standby pump pressure Replace unloader cartridge at implement pump pressure tap. on main control valve. begin by checking the following: 1. Hydraulic oil level in the If OK reservoir Install pressure gauge in the pilot...
Page 388: Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Single Joystick) (644E-42, Sn 20118 & Before, Sn 0160002519 Thru 0160003108) (944E-42, Sn 20123 & Before, Sn 0160002514 Thru 0160003106)
Hydraulic System 8.8.42 Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Single Joystick) (644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108) (944E-42, SN 20123 & Before, SN 0160002514 thru 0160003106) (Refer to Section 8.8.62, “Auxiliary Hydraulics Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) Female Male...
Page 389 Hydraulic System There are no auxiliary hydraulic functions. Before troubleshooting any hydraulic circuit, ALWAYS Check the standby pump pressure at Replace unloader cartridge begin by checking the implement pump pressure tap. on main control valve. following: 1. Hydraulic oil level in the If OK reservoir 2.
Page 390: Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Single Joystick) (644E-42, Sn 0160003109 & After) (944E-42, Sn 0160003107 & After)
Hydraulic System 8.8.43 Auxiliary Hydraulic Circuit & Troubleshooting (Female Coupler Pressurized - Single Joystick) (644E-42, SN 0160003109 & After) (944E-42, SN 0160003107 & After) (Refer to Section 8.8.62, “Auxiliary Hydraulics Circuit Description (Single Joystick),” for a more detailed explanation of this circuit.) Female Male Coupler...
Page 391 Hydraulic System There are no auxiliary hydraulic functions. Before troubleshooting any hydraulic circuit, ALWAYS Check the standby pump pressure at Replace unloader cartridge begin by checking the on main control valve. implement pump pressure tap. following: 1. Hydraulic oil level in the If OK reservoir 2.
Page 392: Auxiliary Hydraulic Pressure Release Circuit & Troubleshooting (Dual Joystick) (644E-42, Sn 20118 & Before, Sn 0160002519 Thru 0160003108) (944E-42, Sn 20123 & Before, Sn 0160002514 Thru 0160003106)
Hydraulic System 8.8.44 Auxiliary Hydraulic Pressure Release Circuit & Troubleshooting (Dual Joystick) (644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108) (944E-42, SN 20123 & Before, SN 0160002514 thru 0160003106) (Refer to Section 8.8.63, “Auxiliary Hydraulic Pressure Release Valve (644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108) (944E-42, SN 20123 &...
Page 393 Hydraulic System If the auxiliary hydraulic If the auxiliary hydraulic connection can’t connect connection can’t connect or disconnect. Before troubleshooting any Refer to Section 9.14.5, hydraulic circuit, ALWAYS Push the auxiliary hydraulic “Auxiliary Hydraulic Pressure begin by checking the pressure release switch. Release Switch 644E-42, following: If OK...
Page 394: Auxiliary Hydraulic Pressure Release Circuit & Troubleshooting (Single Joystick) (644E-42, Sn 20118 & Before, Sn 0160002519 Thru 0160003108) (944E-42, Sn 20123 & Before, Sn 0160002514 Thru 0160003106)
Hydraulic System 8.8.45 Auxiliary Hydraulic Pressure Release Circuit & Troubleshooting (Single Joystick) (644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108) (944E-42, SN 20123 & Before, SN 0160002514 thru 0160003106) (Refer to Section 8.8.63, “Auxiliary Hydraulic Pressure Release Valve (644E-42, SN 20118 & Before, SN 0160002519 thru 0160003108) (944E-42, SN 20123 &...
Page 395 Hydraulic System If the auxiliary hydraulic If the auxiliary hydraulic connection can’t connect connection can’t connect or disconnect. Before troubleshooting any Refer to Section 9.14.5, hydraulic circuit, ALWAYS Push the auxiliary hydraulic “Auxiliary Hydraulic Pressure begin by checking the pressure release switch. Release Switch 644E-42, following: If OK...
Page 396: Pump And Cooling Circuit Description (Dual Joystick)
Hydraulic System 8.8.46 Pump and Cooling Circuit Description The Main Control Valve regulates main system pressure. (Dual Joystick) When oil from the Main Control Valve is returned to the reservoir, it exits the “Outlet” Port and is sent through the In the Pump and Cooling Circuit (pages 8.56 and 8.58), Hydraulic Oil Cooler first.
Page 397: Brake Circuit Description
Hydraulic System 8.8.50 Brake Circuit Description b. Service Brake Circuit (See page 8.70) The brake system circuit (see pages 8.68 thorough 8.72) With the engine running, oil flows from the Hydraulic includes the park brake and the service brakes, along Pump to the Accumulator Charge/Secondary Function with the main control valve, accumulator charge/ Valve, Port “P.”...
Page 398: Boom Extend/Retract Circuit Description (Dual Joystick)
Hydraulic System 8.8.51 Boom Extend/Retract Circuit If system pressure reaches 3400 psi (234 bar), the Main Relief Valve Opens, allowing hydraulic oil to return to the Description (Dual Joystick) Hydraulic Reservoir. If the return filter becomes plugged, Hydraulic flow is applied in the Boom Extend/Retract the indicator light will come ON indicating that return circuit (see page 8.74 and page 8.78) by the secondary hydraulic oil will bypass the filter when pressure reaches...
Page 399: Boom Extend/Retract Circuit Description (Single Joystick)
Hydraulic System 8.8.52 Boom Extend/Retract Circuit and passes through the Counterbalance Valve before Description (Single Joystick) exiting the Extend/Retract Cylinder “Extend” Port. The oil then flows to the Main Control Valve entering through the Hydraulic flow is applied in the Boom Extend/Retract “Extend”...
Page 400: Boom Lift/Lower Circuit Description (Dual Joystick)
Hydraulic System 8.8.53 Boom Lift/Lower Circuit Description b. Boom Lower Circuit (See page 8.86) (Dual Joystick) With the Joystick in the boom LOWER position, pilot pressure from the Joystick Port “4” shifts the Hydraulic flow is applied in the Lift/Lower circuit (see Lift/Lower Spool in the Main Control Valve to page 8.82 and page 8.86) by the secondary section of MT3830...
Page 401: Boom Lift/Lower Circuit Description (Single Joystick)
Hydraulic System 8.8.54 Boom Lift/Lower Circuit Description If system pressure exceeds 3400 psi (234 bar), the Main (Single Joystick) Relief Valve will open allowing oil to return to the Hydraulic Reservoir. If the return filter becomes plugged Hydraulic flow is applied in the Lift/Lower Circuit (see the indicator light will come ON, indicating that return page 8.84 and page 8.88) by the secondary section of hydraulic oil will bypass the filter when pressure reaches...
Page 402: Frame Sway Circuit Description
Hydraulic System 8.8.55 Frame Sway Circuit Description a. Frame Sway LEFT (See page 8.90 or page 8.92) Hydraulic flow is applied in the frame sway circuit (see With the Joystick moved to the LEFT, pilot page 8.90 or page 8.92, and page 8.94 or page 8.96) by pressure from Port “1,”...
Page 403: Attachment Tilt And Slave Circuit Description (Dual Joystick)
Hydraulic System 8.8.56 Attachment Tilt and Slave Circuit b. Attachment Tilt Up Circuit (See page 8.102) Description (Dual Joystick) With the joystick moved BACKWARD, pilot System pressure is applied in the Attachment Tilt and pressure from Port “3” on the Joystick moves the Slave Cylinder circuit (see page 8.98 and page 8.102) by Attachment Tilt spool in the Main Control Valve MT3790...
Page 404: Attachment Tilt And Slave Circuit Description (Single Joystick)
Hydraulic System 8.8.57 Attachment Tilt and Slave Circuit c. Attachment Tilt Up Circuit (See page 8.104) Description (Single Joystick With the switch moved DOWN, the attachment tilts UP. When the switch is in the DOWN System pressure is applied in the attachment tilt and position the Thumb Switch Solenoid directs pilot slave cylinder circuit (see page 8.100 and page 8.104) MT3790...
Page 405: Transfer Carriage Circuit Description (Dual Joystick)
Hydraulic System 8.8.58 Transfer Carriage Circuit Description b. Transfer Carriage Cylinder Retract Circuit (Dual Joystick) (Carriage Forward) (See page 8.110) Hydraulic flow is applied in the transfer carriage circuit With the joystick moved RIGHT, the transfer (see page 8.106 and page 8.110) by the secondary carriage is EXTENDED (moved forward) by the section of the Hydraulic Gear Pump to the “Inlet”...
Page 406: Transfer Carriage Circuit Description (Single Joystick)
Hydraulic System 8.8.59 Transfer Carriage Circuit Description b. Transfer Carriage Cylinder Retract Circuit (Single Joystick) (See page 8.112) Hydraulic flow is applied in the transfer carriage circuit With the joystick trigger button PRESSED and the sick moved FOREWARD, the transfer (see page 8.108 and page 8.112) by the secondary carriage is EXTENDED (moved ahead) by the section of the Hydraulic Gear Pump through the Main...
Page 407 Hydraulic System This Page Intentionally Left Blank 8.157 Model 644E-42/944E-42 Rev. 6/04...
Page 408: Steering Circuit Descriptions
Hydraulic System MU0840 8.8.60 Steering Circuit Descriptions Valve Port “R,” exiting through Port “P” and to the LEFT rod end of the Front Steering Cylinder. Vehicle steering includes front-wheel steering (see Oil from the RIGHT rod end of the Front Steering Cylinder page 8.114 and page 8.116), four-wheel steering (see flows to the Power Steering Unit Port “R”...
Page 409 Hydraulic System MU0850 b. Four-Wheel Steering Oil from the RIGHT rod end of the Front Steering Cylinder flows to the Power Steering Unit Port “R” and exiting When the Steer Select Valve (5) is in the Four- through Port “T” to the Main Control Valve, through the Oil Wheel Steer (LEFT) position (6), the Front Cooler and then to the Return Filter in the Hydraulic Wheels (7) will steer in the direction the steering...
Page 410 Hydraulic System MU0860 c. Crab Steering Mode Oil from the RIGHT rod end of the Front Steering Cylinder flows to the Power Steering Unit Port “R,” exiting Port “T” When the Steer Select Valve (1) is in the Crab flowing to the Main Control Valve, exiting the “Outlet” Port Steer (RIGHT) position (2), the front wheels (3) and passing through the Oil Cooler and then to the Return will steer in the direction the steering wheel is...
Page 411: Auxiliary Hydraulic Circuit Description (Dual Joystick)
Hydraulic System 8.8.61 Auxiliary Hydraulic Circuit Description b. Female Coupler Pressurized (page 8.134 or (Dual Joystick) page 8.136) The auxiliary hydraulic circuit (page 8.126, With the Button held down on the top of the Front page 8.128, page 8.134 or page 8.136) Joystick, and the joystick moved to the RIGHT, functions can be achieved by pushing the pilot pressure from the Accumulator Charge/...
Page 412: Auxiliary Hydraulic Pressure Release Valve
Hydraulic System a. Male Coupler Pressurized (page 8.130 or a. Auxiliary Hydraulic Pressure Release Switch page 8.132) (Dual Joystick page 8.142) With the Trigger Button held down on the Single When the Auxiliary Hydraulic Pressure Release Switch is Joystick, and the joystick moved to the LEFT, pressed for two seconds, the Auxiliary Hydraulic pilot pressure from the joystick from the Pressure Release Valve is opened by a solenoid shifting...
Page 413: Steer Indexing Procedures
Hydraulic System STEER INDEXING PROCEDURES 8.9.1 Four-Wheel Steer Indexing Procedure If the vehicle does not drive “straight,” the steering could be out-of-phase. Perform the following Four Wheel Steer Indexing Procedure to synchronize the front and rear steering. 1. Select the four wheel steer mode (2) with the steer mode selector (3).
Page 414: Hydraulic Reservoir
Hydraulic System 8.10 HYDRAULIC RESERVOIR The hydraulic reservoir (1) is located on the right side of the vehicle. The reservoir is held inside the engine pod with a angle retainer (2) mounted to the engine pod. The engine pod skirt (3) is mounted around the outside of the engine pod and hydraulic reservoir.
Page 415: Hydraulic System Pump
3/4" inside diameter hose to the Accumulator the reservoir be removed from the vehicle and must be Charge/Secondary Function Valve. Hydraulic system replaced in its entirety. Contact your local Lull distributor pressure begins at the pump. Various factors are or the JLG Service Department, should reservoir involved in creating the relatively high pressure used in replacement be required.
Page 416: Pump Failure Analysis
Hydraulic System 8.11.1 Pump Failure Analysis WARNING: Escaping hydraulic fluid The pump is the “heart” of the hydraulic system, and under pressure can penetrate the skin, causing whenever there is a problem in the system, the pump death or serious injury. Relieve hydraulic often is blamed.
Page 417 Hydraulic System b. Tools Required for Pump Repair c. General Repair Precautions The following tools are required for servicing the pump: 1. To facilitate repair of the pump and before any work is done, read and understand all of the steps used in 1.
Page 418 Hydraulic System MM3561 d. Pump Disassembly 7. Remove the plastic seal retainer (9) with the seal gland (10) from the mounting flange housing (5). 1. Plug all ports and thoroughly clean the outside of the Discard the seal retainer with seal gland. pump (1) before starting to disassemble the pump.
Page 419 Hydraulic System 13. Remove the square cross section o-ring (18) from e. Pump Cleaning the ported section (14). Discard the o-ring. Clean all pump components with a suitable cleaner such 14. Remove the eight stud bolts (4) from the ported as trichlorethylene.
Page 420 Hydraulic System MM3561 g. Pump Assembly 3. Coat both the new seal gland (3) and new plastic seal retainer (4) with graphite grease. Carefully IMPORTANT: It is important that the relationship of the install the seal gland in the groove in the seal front cover, front center section, ported section and retainer, make sure the seal gland is seated center section is correct.
Page 421 Hydraulic System 8. Lubricate the drive gear (7) with clean hydraulic oil. 16. Line up the alignment notches or the alignment Very carefully insert the shaft through the wear marks and install the secondary section cover (12) plate (5). onto the rear center section (9). It may be necessary to use a plastic mallet to seat the secondary section 9.
Page 422 Hydraulic System MM3561 22. Apply a light coating of graphite grease to the new 26. Lubricate the steel side of the bronze wear plate (5) square cross section o-ring (1) and carefully install with graphite grease and install over the seal retainer into the groove in the ported section (2).
Page 423 Hydraulic System 30. Apply a light coating of graphite grease to the new 34. Lubricate the steel side of the bronze wear plate (14) square cross section o-ring (10) and carefully install with graphite grease and install over the seal retainer into the groove in the mounting flange housing (11).
Page 424 Hydraulic System h. Pump Installation 1. Place the pump (1) and a new oiled o-ring (2) into position on the transmission. Align the pump gear shaft coupling with the internal transmission gear so that the machined teeth mesh together. 2. Align the bolt holes with the pump mount holes. Secure the pump to the transmission with four plain washers (3) and capscrews (4).
Page 425 Hydraulic System This Page Intentionally Left Blank 8.175 Model 644E-42/944E-42 Rev. 6/04...
Page 426: Valves And Manifolds
Hydraulic System 8.12 VALVES AND MANIFOLDS a. Sub Plate w/Valve Plate Lowering 1. Park the vehicle on a firm, level surface, fully retract Valves are devices that open or close passageways. all hydraulic cylinders, raise the boom, place the Manifolds contain circuit passageways involved in the travel select lever in the [N] NEUTRAL DETENT distribution of hydraulic fluid flowing under pressure.
Page 427: Main Control Valve
Hydraulic System 10. After the capscrews are removed, slowly lower the a. Main Control Valve Removal from Valve Plate sub plate down until the sub plate is supported on Before disassembling the main control valve, remove it the two tethers mounted to the cab support. from the valve plate assembly.
Page 428 Hydraulic System MU4100 8.178 Model 644E-42/944E-42 Rev. 6/04...
Page 429 Hydraulic System b. Main Control Valve Disassembly 3. Remove the hex socket head capscrews (15) holding the spool end housings (16) to the section. Remove 1. To disassemble the main control valve (1), remove the housings, o-rings (17), springs (18) and pistons the four hex socket head capscrews (2) which hold (19).
Page 430 Hydraulic System MU4100 8.180 Model 644E-42/944E-42 Rev. 6/04...
Page 431 Hydraulic System Mono Block Disassembly e. Main Control Valve Assembly The mono block section (1) contains the relief valves, Note: ALWAYS replace seals, o-rings, gaskets, etc., spools and compensators for the attachment tilt (2), with new parts to help ensure proper sealing and frame sway (3), boom lift/lower (4) and boom extend/ operation.
Page 432 Hydraulic System MU4140 8.182 Model 644E-42/944E-42 Rev. 6/04...
Page 433 Hydraulic System Inlet Section Assembly Auxiliary Hydraulic Section Assembly 1. Install the main relief valve (1) with new seals into 1. Install the relief valves (20) preset at 2900 psi the side of the inlet section (2). Torque the main (200 bar) with new seals into the “A”...
Page 434 Hydraulic System Main Control Valve Installation 7. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating 1. Place the assembled main control valve (1) into members, and install tie wraps and/or protective position on the valve plate assembly (2) aligning the conduit as required.
Page 435: Joystick Valve (Dual Joystick)
Hydraulic System 8.12.3 Joystick Valve (Dual Joystick) a. Front and Rear Joystick Capsule Replacement The individual joystick valves are mounted on the right 1. Lift up the boot (12) and remove the handle (13) side console in the cab. The front joystick (10) has an from the joystick joint assembly (14).
Page 436: Pilot Select Valve (Dual Joystick)
Hydraulic System 8.12.4 Pilot Select Valve (Dual Joystick) 3. Unlatch and open the engine cover. Allow the hydraulic fluid to cool. Pilot pressure from the front joystick flows to the pilot 4. Remove the access plate from the floor of the cab. select valve (1).
Page 437 Hydraulic System 4. Reconnect any wire harness connectors. “A3” WARNING: Avoid prolonged engine Port operation in closed areas with inadequate ventilation. Failure to properly ventilate exhaust fumes can result in death or serious injury. 5. Start the engine and run at approximately one-third “A1”...
Page 438: Joystick Valve (Single Joystick)
Hydraulic System 8.12.5 Joystick Valve (Single Joystick) 7. Inspect internal passageways of the pilot select valve and its component parts for wear, damage, etc. The joystick valve is part of the joystick assembly (1). If inner surfaces of the pilot select valve DO NOT Joystick commands are actuated both electrically and display an ultra-smooth, polished finish, or hydraulically via a set of solenoid-operated control valves...
Page 439: Single Joystick Pilot Select Valve
Hydraulic System 8.12.6 Single Joystick Pilot Select Valve 2. Place an Accident Prevention Tag on both the ignition switch and the steering wheel, stating that Pilot pressure from the joystick flows to the single joystick the vehicle should not be operated. Refer to Section pilot select valve (8).
Page 440 Hydraulic System b. Single Joystick Pilot Select Valve Disassembly, 8. Install the straight fittings (8) into the “T,” “1,” “2,” “3,” Inspection and Reassembly and “4” ports on both ends of the block. Torque the straight fittings, 15 lb-ft (20 Nm). Note: Use new oiled o-rings as required.
Page 441: Frame Sway Joystick Valve
Hydraulic System 3. Re-attach and secure all hoses and fittings. Single Joystick Pilot Select Valve Test 4. Reconnect any wire harness connectors. Conduct a pressure check of the joystick circuit. Refer to Section 8.7, “Hydraulic System Testing.” WARNING: Avoid prolonged engine operation in closed areas with inadequate 8.12.7 Frame Sway Joystick Valve...
Page 442: Auxiliary Hydraulic Pressure Release Valve (Early Production)
Hydraulic System a. Frame Sway Joystick Capsule Replacement 8.12.8 Auxiliary Hydraulic Pressure Release Valve (Early Production) 1. Lift up the boot (1) and remove the handle assembly (2) from the pivot mechanism (3). The auxiliary hydraulic pressure release valve is attached to a bracket which is attached to the pilot select valve at 2.
Page 443: Auxiliary Hydraulic Pressure Release Valve (644E-42, Late Production Thru Sn 20118, Sn 0160002519 Thru 0160003108) (944E-42, Late Production Thru Sn 20123, Sn 0160002514 Thru 0160003106)
Hydraulic System 7. Install straight fitting (21) into auxiliary hydraulic pressure release valve block (18). Torque to 24-26 lb-ft (32-35 Nm). 8. Install the T block (20) onto the auxiliary hydraulic pressure release valve block (18). Torque to 24-26 lb-ft (32-35 Nm). 9.
Page 444 Hydraulic System c. Auxiliary Hydraulic Pressure Release Valve WARNING: Hydraulic oil leaking under Installation pressure can penetrate the skin and cause 1. Position the auxiliary hydraulic pressure release severe personal injury. DO NOT use your hand valve (1) back onto the bracket (2) on the pilot select or any part of your body to check for hydraulic valve located on the valve plate (3).
Page 445 Hydraulic System 8.12.9 Auxiliary Hydraulic Pressure Release 5. Label or otherwise mark the hydraulic hoses (10) Valve (644E-42, Late Production thru connected to the auxiliary hydraulic pressure release valve (11). Disconnect and cap all hoses and fittings. SN 20118, SN 0160002519 thru 0160003108) 6.
Page 446 Hydraulic System b. Auxiliary Hydraulic Pressure Release Valve Disassembly, Inspection and Reassembly Note: Use new oiled o-rings as required. ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. Note: Torque all the fittings as specified in Section 2.3, “Torques.”...
Page 447 Hydraulic System 5. Start the engine and run at approximately one-third 8. Reinstall the access plate (14) to the cab floor. to one-half throttle for about one minute without Secure in place with the capscrews (15). Torque the moving the vehicle or operating any hydraulic capscrews to 18 lb-ft (25 Nm).
Page 448: Service Brake Valve
Hydraulic System 8.12.10 Service Brake Valve 5. Pump the brake pedal several times to relieve all the stored pressure in the accumulator system. The service brake valve is secured at the base of the 6. Remove the brake valve from the dash. Refer to steering column support inside the dash, concealed by Section 4.3.5, “Brake Valve and Service Brake the lower dash cover.
Page 449 Hydraulic System b. Service Brake Valve Reassembly c. Service Brake Valve Installation Note: Use new oiled o-rings as required. ALWAYS 1. Reinstall the brake valve into the dash. Refer to the replace seals, o-rings, gaskets, etc., with new parts to reassembly procedure in Section 4.3.5, “Brake Valve help ensure proper sealing and operation.
Page 450 Hydraulic System MU2010 d. Brake Test WARNING: Escaping hydraulic fluid Carefully bleed the brake lines as soon as the brake valve under pressure can penetrate the skin, causing is installed in the vehicle. Air in the system will not allow death or serious injury.
Page 451: Power Steering Valve
Hydraulic System 8.12.11 Power Steering Valve 5. Remove the power steering valve from the dash. Refer to Section 4.3.3, “Steering Column and Valve The power steering valve (2) is located at the base of the Replacement,” for information on removing the steering wheel shaft, concealed by the lower dash cover.
Page 452: Steer Select Valve
Hydraulic System c. Power Steering Valve Installation 8.12.12 Steer Select Valve Note: ALWAYS replace seals, o-rings, gaskets, etc., With the steer select valve, the vehicle can be used in the with new parts to help ensure proper sealing and front-wheel, four-wheel or crab steering mode. The steer operation.
Page 453 Hydraulic System 2. Transfer the elbow (3) to the “T” port on the side of WARNING: Hot hydraulic fluid can the new steer select valve. cause severe burns. Wait for hydraulic fluid to 3. Transfer the straight connectors (4) to the individual cool before servicing any hydraulic component.
Page 454: Accumulator Charge/Secondary Function Valve
Hydraulic System 8.12.13 Accumulator Charge/Secondary 3. Unlatch and open the engine cover. Allow the Function Valve hydraulic fluid to cool. Hydraulic oil from the front pump flows into the WARNING: Escaping hydraulic fluid accumulator charge/secondary function valve and then is under pressure can penetrate the skin, causing directed to the power steering unit, the two accumulators death or serious injury.
Page 455 Hydraulic System 3. Remove the load shuttle cartridge (8). Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and 4. Remove the accumulator charge logic cartridge (9). operation. Lubricate seals and o-rings with clean This cartridge has two settings: Low Setting 1050 psi hydraulic oil.
Page 456: Accumulators
Hydraulic System c. Accumulator Charge/Secondary Function Valve WARNING: Hydraulic oil leaking under Installation pressure can penetrate the skin and cause 1. Reassemble all the fittings and diagnostic test severe personal injury. DO NOT use your hand nipples to the accumulator charge/secondary or any part of your body to check for hydraulic function valve.
Page 457: General Information
Hydraulic System 8.13.1 General Information Each accumulator is a 3000 psi (207 bar) diaphragm type Precharge Pressure/Temperature accumulator. Each accumulator has a total volume of 1 Range liter (gas & oil combined). Operating Actual Precharge The pneumatic accumulator is operated by compressed Temperature Pressure gas.
Page 458: Pre-Charging Accumulator
Hydraulic System 8.13.2 Pre-Charging Accumulator Use the following steps to properly pre-charge each accumulator: Note: Replacement accumulators are not pre-charged 1. Remove the floor plate (1) to gain access to the two when shipped. accumulators. WARNING: NEVER fill an accumulator with oxygen! An explosion could result if oil and oxygen mix under pressure.
Page 459: Checking Pre-Charge
Hydraulic System 13. Let the pre-charge on the accumulator set for 10-15 8.13.3 Checking Pre-Charge minutes. This will allow the gas temperature to stabilize. If the desired pre-charge range is a. Gas Leaks exceeded, turn the “T” handle (4) all the way in. With 1.
Page 460 Hydraulic System b. Checking Accumulator Recharge Pressure and Nitrogen Pre-Charge 1. Park the vehicle on a firm, level surface, fully retract all hydraulic cylinders, ground the attachment (if any), place the travel select lever in the [N] NEUTRAL DETENT position, engage the park brake switch and shut the engine OFF.
Page 461: Accumulator Charge Troubleshooting
Hydraulic System 8.13.4 Accumulator Charge Troubleshooting Problem Cause Remedy 1. Accumulator charging cycle 1. Incorrect accumulator gas 1. Check accumulator gas charge. repeats frequently when charge on one or both Refer to Section 8.13.2, “Pre- accumulator is not normally accumulators. Charging Accumulator.”...
Page 462: Hydraulic Cylinders
Hydraulic System 8.14 HYDRAULIC CYLINDERS 8.14.1 General Cylinder Disassembly Instructions This section covers servicing the attachment tilt (1), WARNING: slave (2), extend/retract (3), lift/lower (4), frame sway (5), To help prevent severe stabilizer (6), steering (7) and transfer carriage (8) burns, proceed with caution when applying cylinders on the vehicle.
Page 463: Attachment Tilt Cylinder
Hydraulic System 4. ALWAYS use new oiled o-rings, seals, gaskets, etc. a. Attachment Tilt Cylinder Removal DO NOT over-stretch seals, wipers and o-rings. After 1. Remove any attachment from the vehicle. Park the installing such parts, verify that they are not twisted vehicle on a firm, level surface, fully retract all in their grooves.
Page 464 Hydraulic System MU3540 b. Attachment Tilt Cylinder Disassembly 4. Slowly remove the 4000 psi (276 bar) counterbalance valves (5) from the attachment tilt Note: An additional o-ring may be included at the base cylinder block. of the cylinder rod. This additional o-ring may be 5.
Page 465 Hydraulic System 9. Remove the locknut (8) from the rod (4). The locknut c. Attachment Tilt Cylinder Cleaning is a deformed-thread type nut torqued at 1100-1250 1. Thoroughly clean the inner surface of the attachment lb-ft (1491-1695 Nm). tilt cylinder with trichlorethylene or another approved Note: It may be necessary to apply heat to break the cleaner.
Page 466 Hydraulic System MU3540 4. Install both precision wearbands (16) and the IMPORTANT: When sliding the rod and piston assembly capped T-seal (17) onto the piston (7). in the tube, prevent the threaded end of the tube from damaging the piston (7). Keep the rod centered within Note: The T-seal actually consists of four components;...
Page 467: Slave Cylinders
Hydraulic System Attachment Tilt Cylinder Installation 8.14.5 Slave Cylinders 1. Attach a suitable sling to an overhead crane or other Each slave cylinder (24) is secured to the transfer suitable device and to the attachment tilt cylinder at carriage and outer boom with cylinder mount pins, the eyelet or hook.
Page 468 Hydraulic System MU3570 1. Clean the slave cylinder (1) with a suitable cleaner WARNING: Escaping hydraulic fluid before inspection. Remove all dirt, debris and grease under pressure can penetrate the skin, causing from the cylinder. death or serious injury. Relieve hydraulic IMPORTANT: Avoid using excess force when clamping pressure before servicing any hydraulic the cylinder in a vise.
Page 469 Hydraulic System 6. Fasten the rod end in a soft-jawed vise and put a Note: If a white, powdery residue is present on threads padded support below and near the threaded end of and parts, it can be removed. Clean the residue away the rod to help prevent damage to the rod.
Page 470 Hydraulic System MU3570 Note: If a white, powdery residue remains on the 12. Install the bearing (20) into the rod end. When threads and parts, clean the residue away with a soft installing the bearing, the fracture in the bearing race brass wire brush prior to reassembly, and wipe with must be positioned perpendicular (21) to the force of Loctite “T”...
Page 471: Extend/Retract Cylinder
Hydraulic System 4. Use new oiled o-rings and reattach and secure the 8.14.6 Extend/Retract Cylinder hydraulic hoses to the slave cylinder fittings. The extend/retract cylinder (22) is located within the inner boom. WARNING: Avoid prolonged engine operation in closed areas with inadequate ventilation.
Page 472 Hydraulic System End of Cylinder Rod Rotated 180° For Clarity MU3690 c. Extend/Retract Cylinder Disassembly 3. Slowly remove the counterbalance valve (3) and the pilot-operated check valve (4). Note: An additional o-ring may be included at the base IMPORTANT: DO NOT tamper with or attempt to reset of the cylinder rod.
Page 473 Hydraulic System 7. Fasten the trunnion end of the rod in a soft-jawed d. Extend/Retract Cylinder Cleaning vise and put a padded support below and near the 1. Remove all hydraulic fluid, dirt and debris from the threaded end of the rod to help prevent damage to inner surface of the cylinder tube (2).
Page 474 Hydraulic System End of Cylinder Rod Rotated 180° For Clarity MU3690 3. Install one of the precision wearbands (19), the 8. Turn the rod spacer (10) as required to align the buffer seal (20) with the angled edge (25) toward the piston setscrew hole.
Page 475: Lift/Lower Cylinder
Hydraulic System IMPORTANT: When sliding the rod (5) and piston 4. Fully retract the attachment tilt cylinder. Hold the assembly in the tube, prevent the threaded end of the attachment tilt joystick at full retract while fully tube from damaging the piston (7). Keep the rod retracting the lift/lower cylinder.
Page 476 Hydraulic System MU3700 b. Lift/Lower Cylinder Disassembly WARNING: Escaping hydraulic fluid Note: An additional o-ring may be included at the base under pressure can penetrate the skin, causing of the cylinder rod. This additional o-ring may be death or serious injury. Relieve hydraulic discarded, as it served only in a temporarily protective role.
Page 477 Hydraulic System 3. Slowly remove the counterbalance valve (3) and Note: It may be necessary to apply heat to break the pilot-operated check valve (4) from the eyelet end of bond of the sealant between locknut (13) and the rod (8) the tube (2).
Page 478 Hydraulic System MU3700 d. Lift/Lower Cylinder Inspection 2. Install the sealed outside diameter heavy-duty rod wiper (22). The wiper lip (25) should be away from 1. Inspect internal surfaces and all parts for wear, the head gland. Install the DZR seal (21), orienting damage, etc.
Page 479 Hydraulic System 8. Apply Loctite Threadlocker #271 (red) to the threads of the rod (8). Thread the locknut (13) onto the rod (8). Torque to 2200-2600 lb-ft (2983-3525 Nm). 9. Install two new locking inserts (12) into the holes in the head gland threads.
Page 480: Frame Sway Cylinder
Hydraulic System g. Lift/Lower Cylinder Pressure Checking and WARNING: Escaping hydraulic fluid Circuit Bleeding under pressure can penetrate the skin, causing 1. Attach a 5000 psi (345 bar) gauge to the main death or serious injury. Relieve hydraulic control valve to test the lift/lower cylinder hydraulic pressure before servicing any hydraulic system circuit pressure.
Page 481 Hydraulic System MU3710 Note: Heating the nut (8) to approximately 300° F IMPORTANT: Protect the finish on the rod at all times. Damage to the rod can cause premature seal failure. (150° C) may also be required to break the seal formed by the Loctite Threadlocker #271 (red) applied to the nut 4.
Page 482 Hydraulic System c. Frame Sway Cylinder Internal Cleaning e. Frame Sway Cylinder Assembly 1. Remove all hydraulic fluid, dirt and debris from the Note: Follow Section 8.14.3, “General Cylinder inner surface of the cylinder. Assembly Instructions.” 2. Discard all seals, back-up rings and o-rings. Replace 1.
Page 483 Hydraulic System MU3710 11. Apply Loctite Primer “T” and Threadlocker #271 15. Begin threading the head gland (4) into the tube (5). (red), to a new locknut (7) in accordance with Loctite Place the locking insert (3) in its hole in the head instructions.
Page 484 Hydraulic System Frame Sway Cylinder Installation g. Frame Sway Cylinder Pressure Checking and Circuit Bleeding 1. Use a sling and hoist or other suitable lifting device to help install the cylinder. Orient the cylinder with 1. Attach a 5000 psi (345 bar) gauge to the main the cylinder base on top and the rod eyelet on the control valve to test the frame sway/stabilizer bottom.
Page 485: Stabilizer Cylinder
Hydraulic System 8.14.9 Stabilizer Cylinder 3. Unlatch and open the engine cover. Allow the hydraulic fluid to cool. The stabilizer cylinder (1) is attached to the left side of the frame at the rear axle and to the cast loop on the axle. WARNING: Escaping hydraulic fluid under pressure can penetrate the skin, causing...
Page 486 Hydraulic System MU3730 b. Stabilizer Cylinder Disassembly 3. Slowly remove the two pilot-operated check valves (3), the pressure reducing valve (4) and the Note: An additional o-ring may be included at the base five solenoid valves (5 and 6) on the manifold block of the cylinder rod.
Page 487 Hydraulic System IMPORTANT: When sliding the rod and piston assembly replace the damaged part. Often, dirty hydraulic fluid in the tube, DO NOT damage the piston (10) by scraping causes failure of internal seals and damage to the it against the threads in the tube. Keep the rod in line polished surfaces within the component.
Page 488 Hydraulic System MU3730 10. Secure the rod eyelet in a soft-jawed vise or other 15. Begin threading the head gland (8) into the tube (2). suitable holding device. Place a padded support Place the locking insert (9) in its hole in the head below the threaded end of the rod to help prevent gland threads just before the hole is threaded into damaging the rod.
Page 489: Steering Cylinders
Hydraulic System Stabilizer Cylinder Installation g. Stabilizer Cylinder Pressure Checking and Circuit Bleeding 1. Use a sling and hoist or other suitable lifting device to help install the cylinder. Orient the cylinder with 1. Attach a 5000 psi (345 bar) gauge to the main the cylinder base on top and the rod eyelet on the control valve to test the frame sway/stabilizer bottom.
Page 490: Transfer Carriage Cylinder
Hydraulic System 8.14.11 Transfer Carriage Cylinder 3. Unlatch and open the engine cover. Allow the hydraulic fluid to cool. The transfer carriage cylinder (1) is attached to the transfer carriage and to the inside of the left frame rail. WARNING: Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury.
Page 491 Hydraulic System MU3800 b. Transfer Carriage Cylinder Disassembly IMPORTANT: When sliding the rod and piston assembly in the tube, prevent the threaded end of the tube from Note: An additional o-ring may be included at the base damaging the piston (6). Keep the rod centered within of the cylinder rod.
Page 492 Hydraulic System Note: It may be necessary to apply heat to break the 3. Remove small scratches on the rod or inside of the bond of the sealant between the locknut (11) and the tube with very fine grit emery cloth. Use the emery rod (3) before the piston (5) can be removed.
Page 493 Hydraulic System MU3800 11. Secure the rod eyelet in a soft-jawed vise or other 15. Keep the rod (3) straight and carefully insert the rod suitable holding device. Place a padded support into the tube (2). Avoid scratching, nicking or below the threaded end of the rod to help prevent damaging the tube while installing the rod.
Page 494: Swing Carriage Cylinder (Optional)
Hydraulic System Transfer Carriage Cylinder Installation g. Transfer Carriage Cylinder Pressure Checking and Circuit Bleeding 1. Install the transfer carriage cylinder back onto the frame and transfer carriage. Refer to Section 1. Attach a 5000 psi (345 bar) gauge to the main 11.3.19, “Transfer Cylinder Replacement.”...
Page 495 Hydraulic System 5. Place an Accident Prevention Tag on both the 10. Use a sling and hoist or other suitable lifting device ignition key switch and the steering wheel, stating to support the cylinders (5). Remove the bolt (6) and that the vehicle should not be operated.
Page 496 Hydraulic System MT1910 b. Swing Carriage Cylinder Disassembly Note: An additional o-ring may be included at the base 3. Slowly remove the 3000 psi (207 bar) of the cylinder rod. This additional o-ring may be counterbalance cartridge (2) and the 2000 psi discarded, as it served only in a temporarily protective (138 bar) direct-acting relief valve (3) from the swing role.
Page 497 Hydraulic System 8. Fasten the rod end in a soft-jawed vise and put a c. Swing Carriage Cylinder Cleaning padded support below and near the threaded end of 1. Remove all hydraulic fluid, dirt and debris from the the rod to help prevent damage to the rod. swing carriage cylinder (1).
Page 498 Hydraulic System MU0020 5. Install two new locking inserts (14) into their holes in 12. Apply a compression sleeve or other suitable tool to the head gland threads. the head gland (5) in order to compress the o-rings (15 and 16). 6.
Page 499 Hydraulic System 18. If the bearing (17) requires replacement, support the 4. Remove all plugs and caps from the hydraulic lines rod (6) in a soft-jawed vise or other suitable holding and securely tighten the lines to the cylinder(s). device. Carefully press a new bearing into the rod WARNING: eyelet.
Page 500: Side Tilt Carriage Cylinder (Optional)
Hydraulic System 8.14.13 Side Tilt Carriage Cylinder (Optional) WARNING: Escaping hydraulic fluid The optional side tilt carriage cylinder (1) provides a way under pressure can penetrate the skin, causing to tilt the carriage attachment from side-to-side. The side death or serious injury. Relieve hydraulic tilt carriage includes a cylinder that operates to provide pressure before servicing any hydraulic the side tilt motion.
Page 501 Hydraulic System MT1950 8.251 Model 644E-42/944E-42 Rev. 6/04...
Page 502 Hydraulic System MT1920 b. Side Tilt Carriage Cylinder Disassembly Note: An additional o-ring may be included at the base 5. Slowly remove both pilot check valves (5) from the of the cylinder rod. This additional o-ring may be side tilt carriage cylinder. discarded, as it served only in a temporarily protective 6.
Page 503 Hydraulic System 11. Remove the locking inserts (9) from their holes in the 5. Remove the piston (8) and head gland (7) from the head gland threads. Pry or drill out the insert as rod (6). required. DO NOT damage the head gland threads. 6.
Page 504 Hydraulic System MU0030 e. Side Tilt Carriage Cylinder Assembly Note: Follow the general assembly instructions in 6. Install a new small oiled o-ring (17) inside the rod Section 8.14.3, “General Cylinder Assembly end of the piston (8). Instructions.” 7. Install the capped T-seal (14) and the precision wearband (13) on the piston (8).
Page 505 Hydraulic System IMPORTANT: When sliding the rod and piston assembly 16. Test the side tilt cylinder at low operating pressure in the tube, prevent the threaded end of the tube from (100 psi or 6,9 bar). Verify that the piston and rod damaging the piston seal (14).
Page 506 Hydraulic System Side Tilt Carriage Cylinder Installation g. Side Tilt Carriage Cylinder Pressure Checking and Circuit Bleeding 1. Install the side tilt carriage cylinder (2) onto the side tilt carriage (1). Secure the rod end to the side tilt 1. Attach a 5000 psi (345 bar) gauge to the main carriage with the cylinder rod pin (6) and snap control valve to test the swing carriage cylinder rings (4).
Page 507 Hydraulic System MT1950 8.257 Model 644E-42/944E-42 Rev. 6/04...
Page 508 Hydraulic System This Page Intentionally Left Blank 8.258 Model 644E-42/944E-42 Rev. 6/04...
Page 509 Section 9 Electrical System Contents PARAGRAPH TITLE PAGE 9.1 Electrical Component Terminology....................9.1.1 General Overview (Open Cab Harness) ................9.1.2 General Overview (644E-42, SN 20118 & Before, 0160002519 thru 0160003689 - Vehicle Power Harness). 9.1.3 General Overview (644E-42, SN 0160003690 & After - Vehicle Power Harness) ....9.1.4 General Overview (944E-42 ECM Vehicle Power &...
Page 510 Electrical System 9.8.7 Main Electrical Schematic (644E-42, SN 20118 & Before, 0160002519 thru 0160003877, 944E-42, SN 20123 & Before, 0160002514 thru 0160003881) .......... 9.48 9.8.8 Main Electrical Schematic (644E-42, SN 0160003878 & After, 944E-42, SN 0160003882 & After) ..................9.50 9.8.9 644E-42 Vehicle Power Harness Electrical Schematic (SN 20118 &...
Page 511 Electrical System 9.9 Transmission Gear Selection Troubleshooting................9.140 9.9.1 Transmission, Forward - First Gear Circuit................9.141 9.9.2 Transmission, Forward - Second Gear Circuit ..............9.142 9.9.3 Transmission, Forward - Third Gear Circuit ................ 9.143 9.9.4 Transmission, Forward - Fourth Gear Circuit ..............9.144 9.9.5 Transmission, Reverse - First Gear Circuit .................
Page 512 Electrical System 9.14 Switches and Solenoids........................ 9.209 9.14.1 Ignition Switch........................9.209 9.14.2 Fuel Shutoff Solenoid (644E-42, SN 20118 & Before, 0160002519 thru 0160003689)..9.212 9.14.3 Hydraulic Oil Filter Pressure Switch..................9.214 9.14.4 Dual Hydraulic Oil Temperature Switch................9.216 9.14.5 Auxiliary Hydraulic Pressure Release Switch 644E-42, SN 20118 & Before, 0160002519 thru 0160003108, 944E-42, SN 20123 &...
Page 513: Electrical Component Terminology
Electrical System ELECTRICAL COMPONENT TERMINOLOGY To understand the safety, operation, and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the electrical components of the vehicle. The following illustration identifies the components that are referred to throughout this section.
Page 514: (644E-42, Sn 20118 & Before, 0160002519 Thru 0160003689 - Vehicle Power Harness)
Electrical System 9.1.2 General Overview (644E-42, SN 20118 & Before, 0160002519 thru 0160003689 - Vehicle Power Harness) Engine Fuel Starter Shut-Off Solenoid Engine Alternator Fuel Engine Shut-Off Start Relay Relay Cab - Fuse and Relay Access Vehicle Power Harness MU4610 Model 644E-42/944E-42 Rev.
Page 515: General Overview (644E-42, Sn 0160003690 & After - Vehicle Power Harness)
Electrical System 9.1.3 General Overview (644E-42, SN 0160003690 & After - Vehicle Power Harness) Cold Start Option Connector Fuel Shut-Off Valve Engine Starter Fusible Link Engine Alternator Engine Start Relay Cab - Fuse and Relay Access Vehicle Power Harness MU6630 Model 644E-42/944E-42 Rev.
Page 516: General Overview (944E-42 Ecm Vehicle Power & Ecm Cab Harnesses)
Electrical System 9.1.4 General Overview (944E-42 ECM Vehicle Power & ECM Cab Harnesses) ECM Cab Harness Throttle Sensor Indicator Light Fuse Indicator Lights Engine Engine Grid Alternator Heater Cold Start Grid Heater Fuse Cold Start Cold Start Grid Heater Grid Heater Engine Relay Relay...
Page 517: General Overview (Vehicle Sensor Harness)
Electrical System 9.1.5 General Overview (Vehicle Sensor Harness) Hydraulic Oil Pressure Switch Engine Oil Vehicle Pressure Sensor Switch Harness Engine Water Air Filter Temperature Pressure Switch Switch Hydraulic Oil Temperature Switch Transmission Temperature Cab - Fuse and Switch Relay Access MU4670 Model 644E-42/944E-42 Rev.
Page 518: General Overview (Vehicle Control Harness)
Electrical System 9.1.6 General Overview (Vehicle Control Harness) Boom Proximity Switch Back-Up Alarm Vehicle Control Harness Stabilizer Cylinder Solenoid Connections Horn Cab - Fuse and Relay Access MU4680 9.10 Model 644E-42/944E-42 Rev. 6/04...
Page 519: General Overview (Vehicle Transmission Harness)
Electrical System 9.1.7 General Overview (Vehicle Transmission Harness) Transmission Solenoid Connectors Vehicle Transmission Harness MU4690 9.11 Model 644E-42/944E-42 Rev. 6/04...
Page 520: General Overview (Optional Single Joystick Harness)
Electrical System 9.1.8 General Overview (Optional Single Joystick Harness) Single Joystick Single Control Joystick Early Production Module Valve Assembly Frame Sway Joystick Valve Harness Assembly Single Joystick Relay Control Single Module Joystick Jumper Harness Harness Single Joystick Pilot Select Valve Late Production Single Joystick...
Page 521: General Overview (Optional Closed Cab Harness)
Electrical System 9.1.9 General Overview (Optional Closed Cab Harness) Conditioning Condenser Front Windshield Wiper and Motor Skylight Wiper and Motor Rear Window Wiper and Motor Fuse and Relay Box Skylight Wiper and Skylight/Rear Closed Cab Washer Switch Harness Front Windshield AC/Heater Washer Switch Fan Switch...
Page 522: General Overview (Optional Roadlight Harness)
Electrical System 9.1.10 General Overview (Optional Roadlight Harness) Rear Worklights Parking, Roadlight Headlight & Turn Harness Engine Signal Control Ground Worklight & Hazard Light Switches Boom Worklight Roadlight Harness Lighting Fuses Brake Front Switch Light Power Headlights & Relay Turn Signals MU6010 9.14 Model 644E-42/944E-42 Rev.
Page 523: General Overview (Optional Worklight Harness)
Electrical System 9.1.11 General Overview (Optional Worklight Harness) Boom Worklight Harness Boom Worklight Worklight Worklight Harness Engine Switch Ground Rear Worklights Worklight Harness Vehicle Worklight Harness Lighting Fuses Light Power Relay Front Worklights MU5980 9.15 Model 644E-42/944E-42 Rev. 6/04...
Page 524: General Overview (Vehicle Ground Strap Locations)
Electrical System 9.1.12 General Overview (Vehicle Ground Strap Locations) Engine Engine Block Mount Frame to Engine to Vehicle Mount Frame Frame Ground Ground Strap Strap Support to Cab to Cab Vehicle Support Frame Ground Ground Strap Strap MU6420 9.16 Model 644E-42/944E-42 Rev. 6/04...
Page 525 Electrical System This Page Intentionally Left Blank 9.17 Model 644E-42/944E-42 Rev. 6/04...
Page 526: Service Warnings
Electrical System SERVICE WARNINGS CAUTION: DO NOT momentarily or “flash” connect a terminal to check for current 9.2.1 General flow. No matter how brief the contact, internal components may be ruined. CAUTION: DO NOT disconnect any wiring without first stopping the engine, turning 9.2.2 Battery all electrical switches to the OFF position and...
Page 527: Effective Ground Connections
Electrical System EFFECTIVE GROUND CONNECTIONS GROUNDING STRAPS 1. Effective ground connections are essential to the There are four grounding straps located throughout the efficient operation of electrical components. If an vehicle. Before troubleshooting the electrical circuits, inadequate ground is suspected or determined, make sure that all of the ground straps are intact and establishing another ground may be desired.
Page 528: Removal And Replacement
Electrical System 9.6.1 Removal and Replacement 9.6.6 Wire Code and Color Remove a wiring harness only if damaged or unusable. The chart below indicates the wire code abbreviation and Install a new harness one terminal at a time as the old color as used on the electrical schematics.
Page 529: Fuses And Relays
Electrical System FUSES AND RELAYS Fuse Types Current Rating Amperes Color Fuses and relays help to protect the electrical system. In Auto Fuses, Mini Fuses general, a blown fuse is a symptom of another electrical problem. Address the true problem, not just the symptom. Black Simply replacing the fuse often will not solve the problem.
Page 530: Fuse And Relay Locations
Electrical System 9.7.2 Fuse and Relay Locations Volt Circuit Controlled 12 Volt Transmission Control The fuse and relay block is mounted under the lower right side of the operators side console (1). To gain access, 12 Volt Ignition remove the cover plate (2) from the right side console. 12 Volt Neutral Start Remove the plastic cover (3) from the fuse and relay...
Page 531 Electrical System Circuit Protected 10 Amp Stability Circuit 10 Amp Dash – Open 5 Amp Auxiliary Hydraulic – Open 15 Amp Outriggers (Option, Some Models) – Open 3 Amp ECM Indicator Light (944E-42 Only) 40 Amp Closed Cab Main (Option) 10 Amp Front wiper (Option) 25 Amp...
Page 532 Electrical System e. 644E-42 Engine Compartment Relay Locations 944E-42 Engine Compartment Relay Locations There are two relays located inside the engine There are three relays located inside the engine compartment, mounted on the firewall. One relay (1) compartment, mounted on the firewall. One relay (3) controls the fuel shut-off solenoid and the other relay (2) controls the engine starter and the other two relays (4) one controls the engine starter.
Page 533: Fuse And Relay Replacement
Electrical System 9.7.3 Fuse and Relay Replacement 3. Remove a suspect fuse (Refer to Section 9.7.2, “Fuse and Relay Locations,” for locations of fuses Shut off the engine and disconnect the batteries before and relays) from the fuse and relay panel by pulling checking the electrical system fuses or relays.
Page 534 Electrical System ECM Fuses 1. Locate the two fuse holders. Remove the clear plastic protective cover (1) from the holder (2). 2. Remove the failed fuse from the holder and replace with a new fuse. 3. Reassemble the plastic cover onto the fuse holder and securely snap the cover in place.
Page 535: Electrical System Troubleshooting
Electrical System d. After Relay Service ELECTRICAL SYSTEM TROUBLESHOOTING 1. If the vehicle has dual batteries, connect both negative battery cables (9 and 10) to both batteries. 9.8.1 Introduction Connect the lower negative battery cable (9) to the negative (-) terminal on the lower battery (11). Swing The electrical system produces, stores and distributes the upper battery box (12) in and make sure that the electricity in the operation of the vehicle.
Page 536 Electrical System The text discusses each circuit and component, as well Onboard Diagnostics as component function and replacement. Many of the a. Fault Detection circuits have a separate diagram specific to that circuit’s function which can be used for troubleshooting purposes. Faults are detected while the key switch is in the RUN Those same circuits also have their own troubleshooting position, during the operation of the vehicle itself.
Page 537 Electrical System 9.8.3 Troubleshooting with a Digital Example Fault Code Sequences Multimeter (DMM) Fault Code P = Pause IMPORTANT: Circuits which include any solid-state control modules should only be tested with a ten megohm or higher impedance digital multimeter (DMM), or damage could occur to the module.
Page 538 Electrical System 9.8.4 Probing Electrical Connectors Measuring Voltage Drop The following test determines the difference in voltage a. Front Probe potential between two points. Disconnect the connector and probe the terminals from the mating side (front) of the connector. Note: DO NOT insert test equipment probes into any connector or fuse block terminal.
Page 539 Electrical System Testing for Continuity Testing for Short to Ground The following procedures verify good continuity in a The following procedures test for a short to ground in a circuit. circuit. With a DMM With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 1.
Page 540 Electrical System Testing for Electrical Intermittence 4. Remove the cover plate (7) from the right side console (8). Perform the following procedure while wiggling the 5. Remove the plastic cover (9) from the fuse and relay harness from side to side. If possible, continue this at block.
Page 541 Electrical System 4. To remove the relays from inside the engine compartment, label and remove all the wires connected to the suspect relay. To access the terminal nuts and washers on the grid heater relays, lift the protective cover (14) and slide it along the wire, away from the mounting hardware.
Page 542 Electrical System 7. To test the operation of the relays, connect a 12-volt DC positive lead to the positive terminal (1 or 6). Connect the negative lead to the mounting bracket or negative post (2 or 7), listening for a “click”...
Page 543 Electrical System 9.8.5 Main Electrical Schematic Legend Wire No. Page Gauge Color From Function 9.52, 9.53 or 12V Buss Bar To Battery 1 Positive (+) Terminal 9.54 Alternator (Pin B+) To 12V Buss Bar 9.52 (644E-42 SN 20118 & Before, 0160002519 thru 0160003689 and 944E-42 Only) Alternator (Pin B+) To 12V Buss Bar 9.52 (644E-42 SN 20118 &...
Page 544 Electrical System Wire No. Page Gauge Color From Function 9.48 or RED/BLU Ignition Control Fuse (F2) (Pin 2) To Ignition Relay (Pin 30) 9.50 9.48 or RED/GRN Ignition Relay (Pin 87) To Transmission Fuse (F3) (Pin 3) 9.50 9.52, 9.53 or Power Bulkhead, 3 Pin Female, Connector (Pin B) To 12V Buss Bar 9.54 9.48 or...
Page 545 Electrical System Wire No. Page Gauge Color From Function 10 amp Mini Fuse VESPAK Connector P6 (Pin D) 9.54 RED/GRN To Engine Control Module, 23 Pin Female, Engine Connector, P1 (Pin S) (944E-42 Only) Battery 2, Positive (+) Terminal BPS1 9.54 RED/GRN To 10 amp Mini Fuse VESPAK Connector P6 (Pin C) (944E-42 Only)
Page 546 Electrical System Wire No. Page Gauge Color From Function 9.48 or RED/YEL Buzzer To Dash Panel Fuse (F8) (Pin H) 9.50 9.48 or Dash Panel, 20 Pin Female, Connector (Pin 6) 9.50 To Sensor Bulkhead, 10 Pin Female, Connector (Pin A) 9.48 or Dash Panel, 20 Pin Female, Connector (Pin 5) 9.50...
Page 547 Electrical System Wire No. Page Gauge Color From Function 9.49 or Splice 100 To Ground Buss Bar 9.51 9.49 or Back-Up Alarm, Female, Connector (Pin B) To Splice 90 9.51 9.49 or Splice 80 To Splice 90 9.51 9.49 or Splice 110 To Ground Buss Bar 9.51 9.54...
Page 548 Electrical System Wire No. Page Gauge Color From Function Fuel Shutoff Relay (Pin 4) To Splice 95 9.52 (644E-42 SN 20118 & Before, 0160002519 thru 0160003689 and 944E-42 Only) Optional Cold Start, 3 Pin Female, Connector (Pin C) To Splice 330 9.53 BLU/ORG (644E-42 SN 0160003690 &...
Page 549 Electrical System Wire No. Page Gauge Color From Function 9.54 Battery 1 Positive (+) Terminal To Battery 2 Positive (+) Terminal (944E-42 Only) 9.48 or Optional Lighting Power Relay (Pin 85) To Splice 10 9.50 9.48 or Cab Lighting, 4 Pin Male, Connector (Pin A) PUR/WHT 9.50 To Dash Panel, 20 Pin Female, Connector (Pin 10)
Page 550 Electrical System Wire No. Page Gauge Color From Function 9.48 or Transmission Disconnect Relay (Pin 86) To Splice 85 9.50 9.48 or Transmission Disconnect Relay (Pin 86) To Ignition Relay (Pin 86) 9.50 9.48 or Ignition Relay (Pin 86) To Neutral Start Relay (Pin 86) 9.50 9.48 or Neutral Start Relay (Pin 86) To Back-Up Alarm Relay (Pin 86)
Page 551 Electrical System Wire No. Page Gauge Color From Function 9.49 or PUR/WHT Stabilizer Solenoid 12B, Female, Connector (Pin A) To Splice 60 9.51 9.48 or LT BLU Boom Switch Relay (Pin 87A) To Stabilizer Lock Relay (Pin 30) 9.50 9.48 or ORG/WHT Stabilizer Lock Relay (Pin 87A) To Splice 65 9.50...
Page 552 Electrical System Wire No. Page Gauge Color From Function Power Bulkhead, 6 Pin Male, Connector (Pin A) 9.52 To Fuel Shutoff Solenoid, 3 Pin Female, Connector (Pin A) (644E-42 SN 20118 & Before, 0160002519 thru 0160003689 and 944E-42 Only) ST4A RED/BLK Power Bulkhead, 6 Pin Male, Connector (Pin A) 9.53...
Page 553 Electrical System Wire No. Page Gauge Color From Function 9.49 or Transmission Bulkhead, 6 Pin Male, Connector (Pin E) TR5A 9.51 To Transmission Y5 Solenoid Connector (X9) (Pin A) 9.48 or Transmission, 8 Pin Male, Connector (Pin 5) 9.50 To Transmission Bulkhead, 6 Pin Female, Connector (Pin F) 9.49 or Transmission Bulkhead, 6 Pin Male, Connector (Pin F) TR6A...
Page 554 Electrical System This Page Intentionally Left Blank 9.46 Model 644E-42/944E-42 Rev. 6/04...
Page 555 Electrical System 9.8.6 Electrical Symbols Directory The following directory shows the most common electrical symbols used in the electrical schematics and circuit diagrams in this section. Fuse Solenoid (Coil) Relay contacts Relay coil Suppression diode Relay resistor Wire name Splice Proximity switch Battery Fuel level sender...
Page 556: Main Electrical Schematic
Electrical System 9.8.7 Main Electrical Schematic (644E-42, SN 20118 & Before, 0160002519 thru 0160003877, 944E-42, SN 20123 & Before, 0160002514 thru 0160003881) Schematic is drawn with the ignition switch in the OFF position. = See Pages 9.63, 9.110 or 9.112. MU52801 9.48 Model 644E-42/944E-42 Rev.
Page 557 Electrical System Main Elect Schem Sht 2 (Before) Refer to pages 9.54, Refer to 9.56 or 9.57. pages 9.52, 9.53 or 9.54. = See Pages 9.63, 9.110 or 9.112. MU52802 9.49 Model 644E-42/944E-42 Rev. 6/04...
Page 558 Electrical System 9.8.8 Main Electrical Schematic (644E-42, SN 0160003878 & After, 944E-42, SN 0160003882 & After) Schematic is drawn with the ignition switch in the OFF position. Connectors used on Brake Relay on early early production production units. units only. See page 9.48.
Page 559 Electrical System Main Elect Schem Sht 2 (After) Refer to pages 9.54, Refer to 9.56 or 9.57. pages 9.52, 9.53 or 9.54. = See Pages 9.63, 9.110 or 9.112. MU65102 9.51 Model 644E-42/944E-42 Rev. 6/04...
Page 560: 42 Vehicle Power Harness Electrical Schematic
Electrical System 9.8.9 644E-42 Vehicle Power Harness Electrical Schematic (SN 20118 & Before, 0160002519 thru 0160003689) Schematic is drawn with the ignition switch in the OFF position. Refer to Main Electrical Schematics on pages 9.48 or 9.50. MU5271 9.52 Model 644E-42/944E-42 Rev. 6/04...
Page 561: 42 Vehicle Power Harness Electrical Schematic (Sn 0160003690 & After)
Electrical System 9.8.10 644E-42 Vehicle Power Harness Electrical Schematic (SN 0160003690 & After) Schematic is drawn with the ignition switch in the OFF position. Refer to Main Electrical Schematics on pages 9.48 or 9.50. Used Only With Cold Start Option. Refer to page 9.57.
Page 562: 42 Ecm Vehicle Power & Ecm Cab Harnesses Electrical Schematic
Electrical System 9.8.11 944E-42 ECM Vehicle Power & ECM Cab Harnesses Electrical Schematic Schematic is drawn with the ignition switch in the OFF position. Refer to Main Electrical Schematics on pages 9.48 or 9.50. Refer to Main Electrical Schematics on pages 9.48 or 9.50.
Page 563: Optional 644E-42 Cold Start Electrical Schematic Legend
Electrical System 9.8.12 Optional 644E-42 Cold Start Electrical Schematic Legend Wire No. Page Gauge Color From Function 9.56 or 9.57 Battery 2 Positive (+) Terminal To 125 Amp Fuse 9.56 or 9.57 Battery 2 Positive (+) Terminal To 125 Amp Fuse 9.56 or 9.57 125 Amp Fuse To Grid Heater Relay 2 (Pin 2) 9.56 or 9.57...
Page 564: Optional 644E-42 Cold Start Electrical Schematic (Sn 20118 & Before, 0160002519 Thru 0160003689)
Electrical System 9.8.13 Optional 644E-42 Cold Start Electrical Schematic (SN 20118 & Before, 0160002519 thru 0160003689) Schematic is drawn with the ignition switch in the OFF position. Refer to pages 9.48, 9.49, Refer to 9.50 or page 9.52. 9.51. MU5471 9.56 Model 644E-42/944E-42 Rev.
Page 565: Optional 644E-42 Cold Start Electrical Schematic (Sn 0160003690 & After)
Electrical System 9.8.14 Optional 644E-42 Cold Start Electrical Schematic (SN 0160003690 & After) Schematic is drawn with the ignition switch in the OFF position. Refer to Refer to pages page 9.53. 9.48, 9.49, 9.50 or 9.51. MU6530 9.57 Model 644E-42/944E-42 Rev. 6/04...
Page 566: Optional Single Joystick (Early Production) Electrical Schematic Legend
Electrical System 9.8.15 Optional Single Joystick (Early Production) Electrical Schematic Legend Wire No. Page Gauge Color From Function AH1A RED/WHT Single Joystick, 3 Pin Male, Connector (Pin A) To Splice 305 AH1B RED/WHT Single Joystick, 6 Pin Female, Connector (Pin 1) To Splice 305 AH1C RED/WHT Single Joystick Relay, 6 Pin Female, Connector (Pin 30) To Splice 305...
Page 567: Optional Single Joystick (Early Production) Electrical Schematic
Electrical System 9.8.16 Optional Single Joystick (Early Production) Electrical Schematic Schematic is drawn with the ignition switch in the OFF position. Refer to Refer to pages 9.48, pages 9.52, 9.49, 9.50 or 9.51. 9.53 or 9.54. MU5881 9.59 Model 644E-42/944E-42 Rev. 6/04...
Page 568: Optional Single Joystick (Late Production) Electrical Schematic Legend
Electrical System 9.8.17 Optional Single Joystick (Late Production) Electrical Schematic Legend Wire No. Page Gauge Color From Function AH1A RED/WHT Single Joystick, 3 Pin Male, Connector (Pin A) To Splice 305 AH1B RED/WHT Single Joystick, 6 Pin Female, Connector (Pin 1) To Splice 305 AH1C RED/WHT Single Joystick Relay, 6 Pin Female, Connector (Pin 30) To Splice 305...
Page 569: Optional Single Joystick (Late Production) Electrical Schematic
Electrical System 9.8.18 Optional Single Joystick (Late Production) Electrical Schematic Schematic is drawn with the ignition switch in the OFF position. Refer to Refer to pages 9.48, pages 9.52, 9.49, 9.50 or 9.51. 9.53 or 9.54. MU5521 9.61 Model 644E-42/944E-42 Rev. 6/04...
Page 570: Optional Closed Cab Electrical Schematic Legend
Electrical System 9.8.19 Optional Closed Cab Electrical Schematic Legend Wire No. Page Gauge Color From Function Heater Blower, 7 Pin Female, Connector (Pin E) To High/Low Pressure Switch Air Conditioning Switch (Pin 2) To Splice 195 AC2A Heater Blower, 7 Pin Female, Connector (Pin F) To Splice 195 Splice 200 To Cab Ground Stud ACG1 Air Conditioning Switch (Pin 3) To Splice 200...
Page 571: Optional Closed Cab Electrical Schematic
Electrical System 9.8.20 Optional Closed Cab Electrical Schematic Schematic is drawn with the ignition switch in the OFF position. Refer to Refer to pages 9.48, pages 9.52, 9.49, 9.50 9.53 or 9.54. or 9.51. = See Pages 9.48, 9.49, 9.50 or 9.51. MU0912 9.63 Model 644E-42/944E-42 Rev.
Page 572: Optional Roadlight Electrical Schematic Legend
Electrical System 9.8.21 Optional Roadlight Electrical Schematic Legend Wire No. Page Gauge Color From Function 9.66 RED/WHT Brake Light Switch, Female, Connector (Pin 1) To Brake Lights Fuse (F21) (Pin U) Brake Light Switch, Female, Connector (Pin 2) 9.66 To Roadlight Bulkhead, 7 Pin Female, Connector (Pin F) BL2A 9.67 Roadlight Bulkhead, 7 Pin Male, Connector (Pin F) To Splice 125...
Page 573 Electrical System Wire No. Page Gauge Color From Function RT1A 9.66 Roadlight Bulkhead, 7 Pin Female, Connector (Pin E) To Splice 115 RT1B 9.67 Roadlight Bulkhead, 7 Pin Male, Connector (Pin E) To Splice 155 RT1C 9.67 Right Roadlight, 6 Pin Female, Connector (Pin 3) To Splice 155 RT1D 9.67 Right Taillight, 4 Pin Female, Connector (Pin 2) To Splice 155...
Page 574: Optional Roadlight Electrical Schematic
Electrical System 9.8.22 Optional Roadlight Electrical Schematic Schematic is drawn with the ignition switch in the OFF position. Refer to Refer to pages 9.48, pages 9.52, 9.49, 9.50 9.53 or 9.54. or 9.51. MU18621 9.66 Model 644E-42/944E-42 Rev. 6/04...
Page 575 Electrical System OptRoadlightSchem MU18622 9.67 Model 644E-42/944E-42 Rev. 6/04...
Page 576: Optional Worklight Electrical Schematic Legend
Electrical System 9.8.23 Optional Worklight Electrical Schematic Legend Wire No. Page Gauge Color From Function Splice 245 To Ground Buss Bar LP5A LT BLU Cab Lighting, 4 Pin Female, Connector (Pin C) To Splice 230 RED/WHT Work/Roadlight Fuse (F24) (Pin X) To Splice 225 WL4A RED/WHT Worklight Switch, 8 Pin Female, Connector (Pin 8) To Splice 225...
Page 577: Optional Worklight Electrical Schematic
Electrical System 9.8.24 Optional Worklight Electrical Schematic Schematic is drawn with the ignition switch in the OFF position. Refer to Refer to pages 9.48, pages 9.52, 9.49, 9.50 9.53 or 9.54. or 9.51. MU1962 9.69 Model 644E-42/944E-42 Rev. 6/04...
Page 578: 42 Engine Start Circuit & Troubleshooting
Electrical System 9.8.25 644E-42 Engine Start Circuit & Troubleshooting Schematic is drawn with the ignition switch in the START position. Brake Relay on early production units. See page 9.48. SN 20118 & Before, 0160002519 thru 0160003689 Used Only With Cold Start Option.
Page 579 Electrical System Engine will not crank or starter solenoid does not engage. Check that transmission gear select lever is in the Before troubleshooting any NEUTRAL DETENT (N) electrical circuit, ALWAYS position. begin by checking the following: If OK 1. All connections relating to Check that parking brake circuit are clean and tight.
Page 580 Electrical System 9.8.25 644E-42 Engine Start Circuit & Troubleshooting (Continued) Schematic is drawn with the ignition switch in the START position. Brake Relay on early production units. See page 9.48. SN 20118 & Before, 0160002519 thru 0160003689 Used Only With Cold Start Option.
Page 581 Electrical System Continued from 9.71 With ignition switch in start position, check starter Not OK Before troubleshooting any solenoid terminal, electrical circuit, ALWAYS Repair/replace wire [ST2] (BLU) Check for power at engine begin by checking the vehicle power connection for start relay at wire [ST2] (BLU).
Page 582 Electrical System 9.8.25 644E-42 Engine Start Circuit & Troubleshooting (Continued) Schematic is drawn with the ignition switch in the START position. Brake Relay on early production units. See page 9.48. SN 20118 & Before, 0160002519 thru 0160003689 Used Only With Cold Start Option.
Page 583 Electrical System Continued from 9.73 Check power at wire Not OK [TR7A] (GRY) at neutral start relay. Replace Check for power at transmission transmission shifter at shifter. wire [TR9] (GRY/WHT). Not OK Check power Check for power at wire at wire Replace [PB4] (BLU) at transmission transmission...
Page 584 Electrical System 9.8.26 944E-42 Engine Start Circuit & Troubleshooting Schematic is drawn with the ignition switch in the START position. Brake Relay on early production units. See page 9.48. MU5621 9.76 Model 644E-42/944E-42 Rev. 6/04...
Page 585 Electrical System Engine will not crank or starter solenoid does not engage. Check that transmission gear select lever is in the Before troubleshooting any NEUTRAL DETENT (N) electrical circuit, ALWAYS position. begin by checking the following: If OK 1. All connections relating to Check that parking brake circuit are clean and tight.
Page 586 Electrical System 9.8.26 944E-42 Engine Start Circuit & Troubleshooting (Continued) Schematic is drawn with the ignition switch in the START position. Brake Relay on early production units. See page 9.48. MU5621 9.78 Model 644E-42/944E-42 Rev. 6/04...
Page 587 Electrical System Continued from 9.77 With ignition switch in start position, Before troubleshooting any check starter Not OK solenoid terminal, electrical circuit, ALWAYS Repair/replace wire [ST2] (BLU) Check for power at engine begin by checking the ECM vehicle connection for start relay at wire [ST2] (BLU).
Page 588 Electrical System 9.8.26 944E-42 Engine Start Circuit & Troubleshooting (Continued) Schematic is drawn with the ignition switch in the START position. Brake Relay on early production units. See page 9.48. MU5621 9.80 Model 644E-42/944E-42 Rev. 6/04...
Page 589 Electrical System Continued from 9.79 Check power at wire Not OK [TR7A] (GRY) at neutral start relay. Replace Check for power at transmission transmission shifter at shifter. wire [TR9] (GRY/WHT). Not OK Check power Check for power at wire at wire Replace [PB4] (BLU) at transmission transmission...
Page 590: 42 Electronic Throttle Circuit & Troubleshooting
Electrical System 9.8.27 944E-42 Electronic Throttle Circuit & Troubleshooting Schematic is drawn with the ignition switch in the RUN position. MU5732 9.82 Model 644E-42/944E-42 Rev. 6/04...
Page 591 Electrical System Engine speed drops to low idle and there is no response when the throttle pedal is depressed. At engine control module At P2 engine control power female harness module power female connector, at pin B, harness connector, at pin wire [THP] (RED), check 29, wire [THP] (RED), for 5 VDC.
Page 592: Charging Circuit & Troubleshooting
Electrical System 9.8.28 Charging Circuit & Troubleshooting Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to Electrical Electrical Schematics Schematics on pages on pages 9.48, 9.52 9.50 and and 9.54 9.53 MU6610 9.84 Model 644E-42/944E-42 Rev. 6/04...
Page 593 Electrical System Dash panel charge indicator ON continuously. Check fan drive belt. Refer to Section 7, “Engine: Cummins Replace fan drive belt. 4BT 3.9, B4.5T and QSB 4.5T.” Before troubleshooting any If OK electrical circuit, ALWAYS begin by checking the following: On alternator, at terminal “B+”, On alternator, check wires...
Page 594: Dual Joystick - Auxiliary Hydraulic Circuit & Troubleshooting
Electrical System 9.8.29 Dual Joystick - Auxiliary Hydraulic Circuit & Troubleshooting Schematic is drawn with the ignition switch in the RUN position. 644E-42, SN 20118 & Before, 0160002519 thru 0160003108, 944E-42, SN 20123 & Before, 0160002514 thru 0160003106 644E-42, SN 0160003109 & After, Connectors used on early production 944E-42, SN 0160003107 &...
Page 595 Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. Auxiliary hydraulics 2. All grounding straps are do not function. intact and securely fastened, refer to Section Check auxiliary hydraulic 9.1.12, “General Overview Replace fuse.
Page 596 Electrical System 9.8.29 Dual Joystick - Auxiliary Hydraulic Circuit & Troubleshooting (Continued) Schematic is drawn with the ignition switch in the RUN position. 644E-42, SN 20118 & Before, 0160002519 thru 0160003108, 944E-42, SN 20123 & Before, 0160002514 thru 0160003106 644E-42, SN 0160003109 & After, Connectors used on early production 944E-42, SN 0160003107 &...
Page 597 Electrical System Continued from 9.87 Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. 2. All grounding straps are intact and securely fastened, refer to Section 9.1.12, “General Overview Auxiliary hydraulic (Vehicle Ground Strap pressure release switch...
Page 598: Single Joystick - Auxiliary Hydraulic Circuit & Troubleshooting (Option)
Electrical System 9.8.30 Single Joystick - Auxiliary Hydraulic Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Early Late Production Production Single Joystick Single Joystick, Harness & Control Module 644E-42, SN 20118 & Before, 0160002519 thru 0160003108, 944E-42, SN 20123 &...
Page 599 Electrical System Auxiliary hydraulics do not function. Before troubleshooting any Check auxiliary hydraulic Replace fuse. electrical circuit, ALWAYS begin (F10) 5 amp fuse. by checking the following: If OK 1. All connections relating to circuit are clean and tight. Verify wire [AHG6] (BLK) Repair/secure ground ground connection at cab connection properly.
Page 600 Electrical System 9.8.30 Single Joystick - Auxiliary Hydraulic Circuit & Troubleshooting (Option) (Continued) Schematic is drawn with the ignition switch in the RUN position. Early Late Production Production Single Joystick Single Joystick, Harness & Control Module 644E-42, SN 20118 & Before, 0160002519 thru 0160003108, 944E-42, SN 20123 &...
Page 601 Electrical System Continued from 9.91 This part of the Single Joystick - Auxiliary Hydraulic Circuit & Troubleshooting (Option) Applies to Only: 644E-42, SN 20118 & Before, 0160002519 thru 0160003108, 944E-42, SN 20123 & Before, 0160002514 thru 0160003106 Auxiliary hydraulic pressure release switch does not release pressure from system.
Page 602: Single Joystick - Transfer Carriage Extend/Retract Circuit & Troubleshooting (Option)
Electrical System 9.8.31 Single Joystick - Transfer Carriage Extend/Retract Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Early Late Production Production Single Joystick Single Joystick, Harness & Control Module 644E-42, SN 20118 & Before, 0160002519 thru 0160003108, 944E-42, SN 20123 &...
Page 603 Electrical System Transfer carriage does not Before troubleshooting any move forward or backward. electrical circuit, ALWAYS begin by checking the following: Check auxiliary hydraulic Replace fuse. (F10) 5 amp fuse. 1. All connections relating to circuit are clean and tight. If OK 2.
Page 604: Single Joystick - Boom Extend/Retract Circuit & Troubleshooting (Option)
Electrical System 9.8.32 Single Joystick - Boom Extend/Retract Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Early Late Production Production Single Joystick Single Joystick, Harness & Control Module 644E-42, SN 20118 & Before, 0160002519 thru 0160003108, 944E-42, SN 20123 &...
Page 605 Electrical System Boom fails to extend or retract. Check auxiliary hydraulic Replace fuse. (F10) 5 amp fuse. Before troubleshooting any electrical circuit, ALWAYS If OK begin by checking the Verify wire [AHG6] (BLK) following: Repair/secure ground ground connection at cab connection properly.
Page 606: Single Joystick - Boom Lift/Lower Circuit & Troubleshooting (Option)
Electrical System 9.8.33 Single Joystick - Boom Lift/Lower Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Early Late Production Production Single Joystick Single Joystick, Harness & Control Module 644E-42, SN 20118 & Before, 0160002519 thru 0160003108, 944E-42, SN 20123 &...
Page 607 Electrical System Boom fails to lift or lower. Check auxiliary hydraulic Replace fuse. (F10) 5 amp fuse. Before troubleshooting any electrical circuit, ALWAYS If OK begin by checking the Verify wire [AHG6] (BLK) following: Repair/secure ground ground connection at cab connection properly.
Page 608: Single Joystick - Attachment Tilt Circuit & Troubleshooting (Option)
Electrical System 9.8.34 Single Joystick - Attachment Tilt Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Early Late Production Production Single Joystick Single Joystick, Harness & Control Module 644E-42, SN 20118 & Before, 0160002519 thru 0160003108, 944E-42, SN 20123 &...
Page 609 Electrical System Forks fail to move forward. Check auxiliary hydraulic Replace fuse. (F10) 5 amp fuse. Before troubleshooting If OK any electrical circuit, ALWAYS begin by Verify wire [AHG6] (BLK) ground Repair/secure ground checking the following: connection at cab ground stud. connection properly.
Page 610 Electrical System 9.8.34 Single Joystick - Attachment Tilt Circuit & Troubleshooting (Option) (Continued) Schematic is drawn with the ignition switch in the RUN position. Early Late Production Production Single Joystick Single Joystick, Harness & Control Module 644E-42, SN 20118 & Before, 0160002519 thru 0160003108, 944E-42, SN 20123 &...
Page 611 Electrical System Forks fail to move backward. Continued from 9.101 Check auxiliary hydraulic Replace fuse. (F10) 5 amp fuse. If OK Verify wire [AHG6] (BLK) ground Repair/secure ground connection at cab ground stud. connection properly. Before troubleshooting any electrical circuit, If OK ALWAYS begin by checking the following:...
Page 612: 42 Engine With Optional Cold Start Circuit & Troubleshooting
Electrical System 9.8.35 644E-42 Engine With Optional Cold Start Circuit & Troubleshooting Schematic is drawn with the ignition switch in the START position. Brake Relay on early production units. See page 9.48. Fuel Shutoff Solenoid used only on SN 0160003689 & Before.
Page 613 Electrical System Engine will not crank or starter solenoid does not engage. Check that transmission gear select lever is in the Before troubleshooting any NEUTRAL DETENT (N) electrical circuit, ALWAYS position. begin by checking the following: If OK 1. All connections relating to Check that parking brake circuit are clean and tight.
Page 614 Electrical System 9.8.35 644E-42 Engine With Optional Cold Start Circuit & Troubleshooting (Continued) Schematic is drawn with the ignition switch in the START position. Brake Relay on early production units. See page 9.48. Fuel Shutoff Solenoid used only on SN 0160003689 &...
Page 615 Electrical System Continued from 9.105 With ignition switch in start position, Not OK Before troubleshooting any check starter Repair/replace electrical circuit, ALWAYS solenoid terminal, Check for power at engine vehicle power begin by checking the wire [ST2] (BLU) start relay at wire [ST2] (BLU). harness.
Page 616 Electrical System 9.8.35 644E-42 Engine With Optional Cold Start Circuit & Troubleshooting (Continued) Schematic is drawn with the ignition switch in the START position. Brake Relay on early production units. See page 9.48. Fuel Shutoff Solenoid used only on SN 0160003689 &...
Page 617 Electrical System Continued from 9.107 Not OK Check power at wire [TR7A] (GRY) at neutral start relay. Replace Check for power at transmission transmission shifter at shifter. wire [TR9] (GRY/WHT). Not OK Check power Check for power at wire at wire Replace [PB4] (BLU) at transmission transmission...
Page 618: Cab Heater & Air Conditioning Blower Motor Circuit & Troubleshooting
Electrical System 9.8.36 Cab Heater & Air Conditioning Blower Motor Circuit & Troubleshooting Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 = See Pages 9.48, 9.49, 9.50 or 9.51. MU1621 9.110 Model 644E-42/944E-42 Rev.
Page 619 Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. Blower motor inoperative at 2. All connections relating to any speed. circuit are clean and tight. 3. All grounding straps are intact and securely fastened, refer to Section Check for voltage to wire 9.1.12, “General Overview [BLB] (YEL/GRN) to...
Page 620: Air Conditioning Circuit & Troubleshooting
Electrical System 9.8.37 Air Conditioning Circuit & Troubleshooting Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 = See Pages 9.48, 9.49, 9.50 or 9.51. MU1151 9.112 Model 644E-42/944E-42 Rev. 6/04...
Page 621 Electrical System Air Conditioning is inoperative. Before troubleshooting any Check wire [BLB] (YEL/GRN) Replace closed electrical circuit, ALWAYS to blower switch. cab harness. begin by checking the following: If OK 1. Fuses. With blower switch ON check 2. All connections relating to Replace blower wire [BLC] (YEL/ORG) from circuit are clean and tight.
Page 622: Front Wiper/Washer Circuit & Troubleshooting
Electrical System 9.8.38 Front Wiper/Washer Circuit & Troubleshooting Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 MU1811 9.114 Model 644E-42/944E-42 Rev. 6/04...
Page 623 Electrical System Before troubleshooting any electrical circuit, Front wiper is inoperative ALWAYS begin by checking the following: 1. Fuses. Check wire [FW1] (RED/WHT) Replace closed 2. All connections relating to circuit are to front wiper switch for cab harness. battery voltage. clean and tight.
Page 624: Skylight Wiper/Washer, Rear Washer Circuit & Troubleshooting
Electrical System 9.8.39 Skylight Wiper/Washer, Rear Washer Circuit & Troubleshooting Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 MU1831 9.116 Model 644E-42/944E-42 Rev. 6/04...
Page 625 Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Skylight wiper is 1. Fuses. inoperative 2. All connections relating to circuit are clean and tight. Check wire [TWP](YEL/ORG) 3. All grounding straps are intact and securely Replace closed at skylight wiper/washer cab harness.
Page 626: Rear Wiper Circuit & Troubleshooting
Electrical System 9.8.40 Rear Wiper Circuit & Troubleshooting Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 MU1821 9.118 Model 644E-42/944E-42 Rev. 6/04...
Page 627 Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. All connections relating to circuit are clean and tight. 3. All grounding straps are intact Rear wiper is inoperative and securely fastened, refer to Section 9.1.12, “General Overview (Vehicle Ground Strap Locations).”...
Page 628: Light Power Relay Circuit & Troubleshooting (Option)
Electrical System 9.8.41 Light Power Relay Circuit & Troubleshooting (Option) Refer to Refer to pages 9.52 page 9.48 or 9.54 MU5661 9.120 Model 644E-42/944E-42 Rev. 6/04...
Page 629 Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. All connections relating to circuit are clean and tight. 3. All grounding straps are intact and securely fastened, refer to Section 9.1.12, “General With the ignition ON and the turn signal control Overview (Vehicle Ground selector rotated to either...
Page 630: Roadlight High Beam Circuit & Troubleshooting (Option)
Electrical System 9.8.42 Roadlight High Beam Circuit & Troubleshooting (Option) Refer to Refer to pages 9.52 page 9.48 or 9.54 MU3261 9.122 Model 644E-42/944E-42 Rev. 6/04...
Page 631 Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: With the ignition ON and 1. Fuses. the turn signal control 2. All connections relating to selector rotated to 2nd circuit are clean and tight. position (Position Parking Lights &...
Page 632: Roadlight Low Beam Lights Circuit & Troubleshooting (Option)
Electrical System 9.8.43 Roadlight Low Beam Lights Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 MU3271 9.124 Model 644E-42/944E-42 Rev. 6/04...
Page 633 Electrical System Before troubleshooting any electrical circuit, ALWAYS begin With the ignition ON and the turn signal control by checking the following: selector rotated to 2nd 1. Fuses. position (Position Parking Lights & Headlights) and 2. All connections relating to pulled back for low beam circuit are clean and tight.
Page 634: Roadlight Parking Lights Circuit & Troubleshooting (Option)
Electrical System 9.8.44 Roadlight Parking Lights Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 MU3421 9.126 Model 644E-42/944E-42 Rev. 6/04...
Page 635 Electrical System Before troubleshooting any With the ignition ON and electrical circuit, ALWAYS begin the turn signal control by checking the following: selector rotated to 1st position (Position Parking 1. Fuses. Lights Only), parking lights remain OFF. 2. All connections relating to circuit are clean and tight.
Page 636: Roadlight Hazard Lights Circuit & Troubleshooting (Option)
Electrical System 9.8.45 Roadlight Hazard Lights Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 MU3281 9.128 Model 644E-42/944E-42 Rev. 6/04...
Page 637 Electrical System With ignition switch OFF, hazard indicator and all hazard lights remain OFF with the 4 way hazard switch in the ON position. Check for battery voltage at Replace cab pin 3, wire [HZ6] (RED/WHT) roadlight harness. on hazard switch. If OK Check for battery voltage at Replace hazard switch.
Page 638: Roadlight Turn Signals Circuit & Troubleshooting (Option)
Electrical System 9.8.46 Roadlight Turn Signals Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 MU3291 9.130 Model 644E-42/944E-42 Rev. 6/04...
Page 639 Electrical System With the ignition ON and the turn signal control selector pushed up for left turn signal or down for right Before troubleshooting any turn signal, turn signal electrical circuit, ALWAYS begin indicator and turn signals by checking the following: remain OFF.
Page 640: Roadlight Brake Lights Circuit & Troubleshooting (Option)
Electrical System 9.8.47 Roadlight Brake Lights Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 MU3301 9.132 Model 644E-42/944E-42 Rev. 6/04...
Page 641 Electrical System With the ignition ON and the brake pedal depressed, brake lights remain OFF. If one brake light is not ON If neither brake light is ON with the brake pedal with the brake pedal depressed, check for depressed, check for battery battery voltage at that voltage at brake pedal switch taillight connector, pins 1 &...
Page 642: Flash High Beam Circuit & Troubleshooting (Option)
Electrical System 9.8.48 Flash High Beam Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 MU3321 9.134 Model 644E-42/944E-42 Rev. 6/04...
Page 643 Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. All connections relating to With the ignition ON, the worklight switch OFF and circuit are clean and tight. the turn signal control 3. All grounding straps are intact selector rotated to the 1st and securely fastened, refer to (Position Parking Lights...
Page 644: Roadlight Worklight Circuit & Troubleshooting (Option)
Electrical System 9.8.49 Roadlight Worklight Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 MU3311 9.136 Model 644E-42/944E-42 Rev. 6/04...
Page 645 Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Worklights remain OFF with ignition switch in the 1. Fuses. RUN position and the bottom of the worklight 2. All connections relating to switch pushed in. circuit are clean and tight. 3.
Page 646: Worklight (Without Roadlight) Circuit & Troubleshooting (Option)
Electrical System 9.8.50 Worklight (Without Roadlight) Circuit & Troubleshooting (Option) Schematic is drawn with the ignition switch in the RUN position. Refer to Refer to pages 9.52 page 9.48 or 9.54 MU2051 9.138 Model 644E-42/944E-42 Rev. 6/04...
Page 647 Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Worklights remain OFF with ignition switch in the 1. Fuses. RUN position and the bottom of the worklight 2. All connections relating to switch pushed in. circuit are clean and tight. 3.
Page 648: Transmission Gear Selection Troubleshooting
Electrical System TRANSMISSION GEAR SELECTION TROUBLESHOOTING The following seven electrical circuit schematics address each transmission position. Additional troubleshooting information can be found in Section 9.14.9, “Transmission Solenoid Valves.” 9.140 Model 644E-42/944E-42 Rev. 6/04...
Page 649: Transmission, Forward - First Gear Circuit
Electrical System 9.9.1 Transmission, Forward - First Gear Circuit Schematic is drawn with the ignition switch in the RUN position. Brake Relay on early production units. See page 9.48. MU1502 9.141 Model 644E-42/944E-42 Rev. 6/04...
Page 650: Transmission, Forward - Second Gear Circuit
Electrical System 9.9.2 Transmission, Forward - Second Gear Circuit Schematic is drawn with the ignition switch in the RUN position. Brake Relay on early production units. See page 9.48. MU1532 9.142 Model 644E-42/944E-42 Rev. 6/04...
Page 651: Transmission, Forward - Third Gear Circuit
Electrical System 9.9.3 Transmission, Forward - Third Gear Circuit Schematic is drawn with the ignition switch in the RUN position. Brake Relay on early production units. See page 9.48. MU1552 9.143 Model 644E-42/944E-42 Rev. 6/04...
Page 652: Transmission, Forward - Fourth Gear Circuit
Electrical System 9.9.4 Transmission, Forward - Fourth Gear Circuit Schematic is drawn with the ignition switch in the RUN position. Brake Relay on early production units. See page 9.48. MU1562 9.144 Model 644E-42/944E-42 Rev. 6/04...
Page 653: Transmission, Reverse - First Gear Circuit
Electrical System 9.9.5 Transmission, Reverse - First Gear Circuit Schematic is drawn with the ignition switch in the RUN position. Brake Relay on early production units. See page 9.48. MU1572 9.145 Model 644E-42/944E-42 Rev. 6/04...
Page 654: Transmission, Reverse - Second Gear Circuit
Electrical System 9.9.6 Transmission, Reverse - Second Gear Circuit Schematic is drawn with the ignition switch in the RUN position. Brake Relay on early production units. See page 9.48. MU1582 9.146 Model 644E-42/944E-42 Rev. 6/04...
Page 655: Transmission, Reverse - Third Gear Circuit
Electrical System 9.9.7 Transmission, Reverse - Third Gear Circuit Schematic is drawn with the ignition switch in the RUN position. Brake Relay on early production units. See page 9.48. MU1592 9.147 Model 644E-42/944E-42 Rev. 6/04...
Page 656: Dash Panel Warning Indicator Troubleshooting
Electrical System 9.10 DASH PANEL WARNING INDICATOR TROUBLESHOOTING The following troubleshooting flow charts discuss each dash panel indicator separately. Additional information for each indicator can be found by referring to the main electrical schematics on pages 9.48 through 9.51. The dash panel light bulbs can be replaced. Bulb function should be checked before proceeding to each troubleshooting chart.
Page 657: Engine Alternator Charging Warning Indicator Troubleshooting
Electrical System 9.10.1 Engine Alternator Charging Warning Indicator Troubleshooting MU4270 Engine Alternator Charging Warning Indicator Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. Engine alternator charging 4.
Page 658: Engine Coolant Temperature Gauge Troubleshooting
Electrical System 9.10.2 Engine Coolant Temperature Gauge Troubleshooting Engine Coolant MU4280 Temperature Gauge Before troubleshooting any electrical circuit, ALWAYS begin Engine coolant by checking the following: temperature gauge 1. Fuses. reads incorrectly. 2. Battery for proper charge. 3. All connections relating to Check radiator coolant level, circuit are clean and tight.
Page 659: Engine Oil Pressure Warning Indicator Troubleshooting
Electrical System 9.10.3 Engine Oil Pressure Warning Indicator Troubleshooting Engine Oil Pressure Warning Indicator MU4320 Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. 4.
Page 660: Engine Air Filter Restriction Warning Indicator Troubleshooting
Electrical System 9.10.4 Engine Air Filter Restriction Warning Indicator Troubleshooting MU4400 Engine Air Filter Restriction Warning Indicator Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Engine air filter 1. Fuses. restriction warning 2. Battery for proper charge. indicator stays ON while operating.
Page 661: Engine Tachometer & Hourmeter Indicator Troubleshooting
Electrical System 9.10.5 Engine Tachometer & Hourmeter Indicator Troubleshooting Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. MU4340 4. All grounding straps are intact and securely fastened, refer to Engine Hourmeter...
Page 662: Transmission Temperature Warning Indicator Troubleshooting
Electrical System 9.10.6 Transmission Temperature Warning Indicator Troubleshooting MU4290 Transmission Temperature Warning Indicator Transmission temperature warning indicator stays ON while operating and alarm sounds. Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Stop vehicle, place 1. Fuses. transmission in Neutral (N) and idle engine for 2.
Page 663: Dual Hydraulic Oil Temperature Warning Indicator Troubleshooting
Electrical System 9.10.7 Dual Hydraulic Oil Temperature Warning Indicator Troubleshooting MU4300 Dual Hydraulic Oil Temperature Warning Indicator Hydraulic oil temperature warning indicator stays ON while operating. Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Stop vehicle and idle engine 1.
Page 664: Hydraulic Oil Filter Restriction Warning Indicator Troubleshooting
Electrical System 9.10.8 Hydraulic Oil Filter Restriction Warning Indicator Troubleshooting MU4420 Hydraulic Oil Filter Restriction Warning Indicator Hydraulic oil filter restriction warning indicator stays ON while operating. Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. Check for plugged 2.
Page 665: Park Brake Warning Indicator Troubleshooting
Electrical System 9.10.9 Park Brake Warning Indicator Troubleshooting MU4310 Park Brake Warning Indicator Park brake warning indicator stays ON with park brake Before troubleshooting any disengaged. electrical circuit, ALWAYS begin by checking the following: 1. Fuses. Check park brake switch for 2.
Page 666: Low Brake Pressure Indicator Troubleshooting
Electrical System 9.10.10 Low Brake Pressure Indicator Troubleshooting MU4410 Low Brake Pressure Indicator Before troubleshooting any electrical circuit, ALWAYS begin Low Brake Pressure by checking the following: Indicator ON with engine running. 1. Fuses. 2. Battery for proper charge. Check both accumulator Recharge accumulators as 3.
Page 667: Fuel Level Gauge Troubleshooting
Electrical System 9.10.11 Fuel Level Gauge Troubleshooting Fuel Level Gauge MU4330 Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. Battery for proper charge. 3. All connections relating to Fuel level gauge reads circuit are clean and tight. EMPTY while operating.
Page 668: Stabil-Trak™ "Locked" Mode Indicator Troubleshooting
Electrical System 9.10.12 Stabil-TRAK™ “Locked” Mode Indicator Troubleshooting Stabil-TRAK™ “Locked” Mode Indicator Before troubleshooting any electrical circuit, ALWAYS begin MU4350 by checking the following: 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. 4.
Page 669: Stabil-Trak™ "Slow Pivot" Mode Indicator Troubleshooting
Electrical System 9.10.13 Stabil-TRAK™ “Slow Pivot” Mode Indicator Troubleshooting Stabil-TRAK™ “Slow Pivot” Mode Indicator Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. Battery for proper charge. MU4360 3. All connections relating to circuit are clean and tight. 4.
Page 670: Engine Air-Intake Heater Indicator Troubleshooting (644E-42 Option, 944E-42 Standard)
Electrical System 9.10.14 Engine Air-Intake Heater Indicator Troubleshooting (644E-42 Option, 944E-42 Standard) Engine Air-Intake Heater Indicator Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: MU4390 1. Fuses. Engine air-intake 2. Battery for proper charge. heater indicator 3. All connections relating to stays ON circuit are clean and tight.
Page 671: Engine Start Circuit
Electrical System 9.11 ENGINE START CIRCUIT 4. If the parking brake is set, current flows through contacts in the brake switch to the neutral start relay. The purpose of the engine start circuit is to energize the 5. If the transmission select lever is in NEUTRAL starter solenoid and engage the starter motor to start the DETENT (N), current flows through the neutral start engine.
Page 672: Starter
Electrical System 9.11.2 Starter a. Testing the Starter on the Engine The starter (1) is located on the left side of the engine, just If the starter does not engage when the ignition switch is inboard of the hydraulic oil reservoir. turned, check the following: 1.
Page 673 Electrical System c. Starter Removal 1. Unlock and open the engine cover (4). MU6560 OU0780 4. At the positive starter stud (14), label and disconnect 2. If the vehicle has dual batteries, disconnect both the positive (+) battery cable (15) and starter positive negative battery cables (6 and 7) from both buss bar (16).
Page 674 Electrical System 3. Connect the positive (+) battery cable (6) and starter positive buss bar (7), with the wires (8) still connected, at the positive starter stud (9). Torque mounting hardware to 40-45 lb-ft (54-61 Nm). MU6590 8. Loosen, but DO NOT remove, the two fasteners (1 and 2) securing the starter (3) to the flywheel housing.
Page 675: Charging Circuit
Electrical System Current flows from the positive (+) post of the battery to the (+) terminal on the starter motor. When the ignition switch is in the RUN position, excitation occurs and the alternator begins emitting a charge. Current flows from the alternator B+ terminal to the starter motor B terminal, then through the positive (+) battery cable to the battery.
Page 676 Electrical System Before using a battery charger, an attempt can be made to recharge the battery by jump starting the vehicle. (Refer to the appropriate Owners/Operators Manual.) Allow the engine to run, which enables the alternator to charge the battery. WARNING: DO NOT charge a frozen battery.
Page 677: Alternator
Electrical System 9.12.1 Alternator a. Alternator Removal 1. Unlock and open the engine cover (4). MU0650 OU0780 3. Insert a 3/8” square drive ratchet into the square 2. If the vehicle has dual batteries, disconnect both hole on the automatic belt tensioner bracket (11), negative battery cables (5 and 6) from both and remove the tension from the fan drive belt (12) batteries.
Page 678 Electrical System 4. Label and disconnect these alternator wires: 2. Align the lower alternator mount hole with the lower mounting tab (8) on the engine and insert the lower • [AG1] and [AG2] from G terminal (1) mounting capscrew (5). Tighten the lower capscrew •...
Page 679: Battery Or Batteries
Electrical System 9.12.2 Battery or Batteries WARNING: All lead acid batteries generate hydrogen gas, which is highly flammable. If ignited by a spark or flame, the gas may explode violently, causing spraying of acid, fragmentation of the battery, and possible severe personal injuries.
Page 680 Electrical System When starting the engine, allow the starter to crank for a 3. Remove the surface charge from any battery that maximum of 15 seconds only, then wait a minimum of two has just been charged (by a battery charger or by minutes to help avoid burning out the starter.
Page 681 Electrical System d. Battery Charging e. Battery Troubleshooting Charge rates between 3 and 50 amperes are generally If a battery has tested satisfactorily but then fails to satisfactory as long as spewing of electrolyte does not perform satisfactorily for no apparent reason, the occur, or the battery does not feel excessively hot (over following items are among the more popular factors that 125°...
Page 682 Electrical System Jump-Starting with an Auxiliary (“Booster”) 2. If the vehicle has dual batteries, disconnect both Battery negative battery cables (3 and 4) from both batteries. Note: Use this information in addition to that found in To access the lower battery (5), loosen the knob (6) the appropriate Owners/Operators Manual.
Page 683 Electrical System Battery Installation 1. Carefully slide the battery (12) into the battery box (17). 2. Make sure that the battery hold down bolts (15) are still hooked in the slots (16) in the battery box (17). 3. Install the battery hold down strap (11). Use two wing nuts (13) and flat washers (14) for each battery hold down bolts (15).
Page 684: Electrical System Components
Electrical System 9.13 ELECTRICAL SYSTEM The horn sound is produced by a solenoid-actuated diaphragm in the horn that develops a resonating air COMPONENTS column in the horn trumpet, which is shaped to project the sound. If the horn doesn’t sound when the horn button is Electrical components include warning devices such as pressed, check that the fuse is not blown.
Page 685 Electrical System Installation and Testing 1. Position the horn with bracket (1) on its mounting stud and secure with flat washer (6) and nut (5). Torque to 10 - 16 lb-ft (7 - 12 Nm) 2. Connect the wiring harness connector lead (4) to the horn.
Page 686 Electrical System b. Warning Indicator Lights There are seven additional “hidden” 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 687 Electrical System c. Engine Function Indicator Lights d. Back-Up Alarm The back-up alarm (11) is located at the rear of the vehicle, mounted on the left side plate (12) of the transfer carriage. MU5690 The engine function indicator lights (8) are located on the left side of the front dash between the park brake switch and the transmission disconnect switch.
Page 688 Electrical System Back-Up Alarm Removal 3. Label and disconnect the back-up alarm (9) wire connector (10), from the harness. 1. Unlock and open the engine cover (1). 4. Remove the two nuts (11) and flat washers (12) securing the back-up alarm (9) to weld studs on the transfer carriage (13).
Page 689: Front Dash Panel
Electrical System Installation and Testing 9.13.2 Front Dash Panel 1. Position the back-up alarm (9) on its mounting studs The information under this heading deals mainly with the and secure with two flat washers (12) and nuts (11). description and function of each indicator in the front Torque to 10 - 16 lb-ft (7 - 12 Nm) dash panel.
Page 690 Electrical System a. Power-Up Lights heater then becomes active and the engine should not be cranked until the light goes OFF. Once the light goes OFF When the ignition switch is turned to power up the it indicates that the grid heater is at the proper vehicle, all lights (13 total) in the front dash panel will temperature and the engine is ready to start.
Page 691 Electrical System d. Front Dash Panel Bulb Replacement 3. Remove the five capscrews (16) and flat washers (17) securing the front dash panel IMPORTANT: Static electricity can cause damage to the cover (18), with the front dash panel (19), to the front dash panel.
Page 692 Electrical System 7. Rotate the suspect bulb holder assembly 10. Replace the dash panel rear access plate (15). (1 through 14) 1/4 turn counterclockwise. Secure with four phillips screws, (16). 8. Remove and replace bulb. All bulbs should be replaced with a comparable OS 12V/1.2W bulb except the alternator indicator (8).
Page 693 Electrical System 14. If the vehicle has dual batteries, connect both Front Dash Panel Test negative battery cables (15 and 16) to both Check the following as the ignition switch (23) is turned to batteries. the RUN position (24): Connect the lower negative battery cable (15) to the negative (-) terminal on the lower battery (17).
Page 694: Throttle Position Sensor (944E-42 Only)
Electrical System 9.13.3 Throttle Position Sensor b. Removal (944E-42 Only) 1. Unlock and open the engine cover (6). The throttle position sensor (1) (944E-42 Only) controls the engine speed. It is designed to sense the position of the throttle pedal and sends the signal to the engine control module.
Page 695 Electrical System c. Disassembly DO NOT disassemble the sensor. The sensor is not serviceable. Replace the sensor if found to be defective. d. Cleaning and Drying Without submerging the sensor, clean the sensor with an approved solvent and dry with a clean, lint-free cloth. e.
Page 696: Front Windshield Wiper Switch
Electrical System 9.13.4 Front Windshield Wiper Switch a. Removal This three position rocker switch (1) is 1. Unlock and open the engine cover (2). located in the lower bank of switches on the right side of the dash. This single rocker switch controls the speed of the OS19301 front windshield wiper.
Page 697 Electrical System e. Installation and Testing 1. Connect the windshield wiper switch (1) to the cab harness connector. 2. Position the switch over the rectangular switch bezel, and snap into position. 3. If the vehicle has dual batteries, connect both negative battery cables (4 and 5) to both batteries.
Page 698: Front Windshield Wiper Motor
Electrical System 9.13.5 Front Windshield Wiper Motor a. Removal Note: It may be necessary to remove several hydraulic hoses from under the dash in order to remove and install the wiper motor housing. (Refer to Section 8.12.10, “Service Brake Valve,” or Section 8.12.11, “Power Steering Valve.”) 1.
Page 699 Electrical System 5. Remove the front wiper arm assembly (14) from the 9. Label and disconnect the three wire connector (26) wiper motor shaft (13) and the pivot mount from the back of the front wiper motor. Label the shaft (12). ground wire (28) and remove the screw (27) securing it to the wiper motor case.
Page 700 Electrical System e. Installation and Testing Note: An assistant will be required for the installation of the front windshield wiper motor. 1. Connect the closed cab harness to the front wiper motor (1). Push the three wire connector (2) all the way onto the terminals on the motor.
Page 701 Electrical System MU0650 MU6080 11. With the ignition switch (28) in the RUN position (29) press the front wiper switch (31) to the LOW (center) 14. Assemble the washer hose (37) onto the hose position and then to the OFF position to “Park” the connector on the wet kit adapter (38).
Page 702: Windshield Washer Switch
Electrical System 9.13.6 Windshield Washer Switch a. Removal This rocker switch (1) is spring loaded to 1. Unlock and open the engine cover (5). return to the OFF position when released. The switch is located in the lower bank of switches on the right side of the dash.
Page 703 Electrical System e. Installation and Testing 1. Connect the windshield washer switch to the cab harness connector. 2. Position the switch over the rectangular switch bezel, and snap into position. 3. If the vehicle has dual batteries, connect both negative battery cables (7 and 8) to both batteries. Connect the lower negative battery cable (7) to the negative (-) terminal on the lower battery (9).
Page 704: Skylight Wiper/Washer & Rear Window Washer Switch
Electrical System 9.13.7 Skylight Wiper/Washer & Rear a. Removal Window Washer Switch 1. Unlock and open the engine cover (5). OU0780 2. If the vehicle has dual batteries, disconnect both MU5910 negative battery cables (7 and 8) from both batteries. The skylight wiper/washer and rear window To access the lower battery (9), loosen the knob (10) washer rocker switch (1) is located in the lower...
Page 705 Electrical System e. Installation and Testing 1. Connect the skylight wiper/washer rocker and rear window washer switch to the cab harness connector. 2. Position the switch over the rectangular switch bezel and snap into position. 3. If the vehicle has dual batteries, connect both negative battery cables (7 and 8) to both batteries.
Page 706: Skylight Wiper Motor
Electrical System 9.13.8 Skylight Wiper Motor 3. Remove the skylight wiper arm (8) from the skylight wiper motor shaft (9). a. Removal 4. Disconnect the washer hose (10) from the top hose fitting (11). 1. Unlock and open the engine cover (1). Front OU0780 MU6150...
Page 707 Electrical System 8. Lift the tab (19) on the top plastic cover and unsnap e. Installation and Testing the two plastic covers (20) of the plastic case to Note: An assistant will be required for the installation of expose the skylight wiper motor (21). the skylight wiper motor.
Page 708: Windshield/Skylight/Rear Wiper Washer Reservoir W/Pump
Electrical System 8. If the vehicle has dual batteries, connect both 9.13.9 Windshield/Skylight/Rear Wiper negative battery cables (1 and 2) to both batteries. Washer Reservoir w/Pump Connect the lower negative battery cable (1) to the negative (-) terminal on the lower battery (3). Swing the upper battery box (4) in and make sure that the lip (5) on the upper battery box slides below the knob (6).
Page 709 Electrical System 2. If the vehicle has dual batteries, disconnect both e. Installation and Testing negative battery cables (1 and 2) from both 1. Connect the clear washer hose (19), from the front batteries. wiper, to the front washer pump (17) on the rear of To access the lower battery (3), loosen the knob (6) the wiper washer reservoir.
Page 710: Rear Wiper Switch/Motor
Electrical System 9.13.10 Rear Wiper Switch/Motor a. Removal 1. Unlock and open the engine cover (1). OU0780 Front 2. If the vehicle has dual batteries, disconnect both negative battery cables (2 and 3) from both MU6160 batteries. 4. From inside the cab, remove the phillips head To access the lower battery (4), loosen the knob (5) bolt (10), two flat washers (11), rubber grommet (12) far enough so that the lip (6) on the upper battery box...
Page 711 Electrical System 2. Install the adapter (29) to the “P” terminal (30) on the motor (23). 3. Install jumper wire (25) to one of the blades on the adapter (29) and the other end to the “+” terminal (31) on the switch (27). 4.
Page 712 Electrical System 12. If the vehicle has dual batteries, connect both negative battery cables (1 and 2) must be connected to both batteries. Connect the lower negative battery cable (1) to the negative (-) terminal on the lower battery (3). Swing the upper battery box (4) in and make sure that the lip (5) on the upper battery box slides below the knob (6).
Page 713 Electrical System 17. Position the skylight wiper/washer & rear window washer switch (13) in the center position to allow the skylight wiper to clear fluid from the skylight window. 18. Press the top of the skylight wiper/washer and rear window washer rocker switch (13) to turn the skylight wiper off.
Page 714: Cab Heater/Air Conditioning Controls
Electrical System 9.13.11 Cab Heater/Air Conditioning Controls a. To heat the cab: • turn A/C switch (5) to the OFF position, Note: If the suspect component is found to be within the heater box, the heater box must be removed as a •...
Page 715 Electrical System a. Cab Heater Controls Removal 3. Remove the setscrew from the variable speed fan control knob (7) or temperature control knob (6). Note: After determining which control knob is not 4. Remove the screws (9) and backing locknuts from functioning, remove only the suspect control knob.
Page 716 Electrical System e. Installation and Testing 9. If the vehicle has dual batteries, connect both negative battery cables (6 and 7) to both batteries. 1. Check that the variable speed fan control (1) is in the Connect the lower negative battery cable (6) to the OFF position.
Page 717: Switches And Solenoids
Electrical System 9.14 SWITCHES AND SOLENOIDS 9.14.1 Ignition Switch The ignition switch (14) is located on the lower right side of the dash. It is a key-operated switch used to start the engine and to run the vehicle. OU0780 13. Lower and lock engine cover. To release and lower the engine cover (12) from the fully raised position, MU1250 lift up slightly on the cover and push the upper part...
Page 718 Electrical System a. Ignition Switch Removal 1. Unlock and open the engine cover (1). OU0780 MU3350 4. Remove the knurled nut (11) securing the ignition 2. If the vehicle has dual batteries, disconnect both switch (12) to the dash. negative battery cables (3 and 4) from both batteries.
Page 719 Electrical System b. Disassembly d. Ignition Switch Installation DO NOT disassemble the ignition switch. Replace a 1. Use the nuts removed in step 6 and connect the wire defective switch with a new part. ends of the cab harness to the ignition switch as follows: c.
Page 720: Fuel Shutoff Solenoid (644E-42, Sn 20118 & Before, 0160002519 Thru 0160003689)
Electrical System e. Transmission Neutral Start Feature 9.14.2 Fuel Shutoff Solenoid (644E-42, SN 20118 & Before, 0160002519 thru The transmission neutral start feature is a safety feature 0160003689) designed to prevent the engine from starting with the transmission in FORWARD (F) or REVERSE (R). The fuel shutoff solenoid (6), located on the rear of the fuel injection pump is a solenoid that lets fuel enter the Shifting into NEUTRAL DETENT (N) activates the neutral...
Page 721 Electrical System 5. If the vehicle has dual batteries, connect both negative battery cables (11 and 12) to both batteries. Connect the lower negative battery cable (11) to the negative (-) terminal on the lower battery (13). Swing the upper battery box (16) in and make sure that the lip (15) on the upper battery box slides below the knob (14).
Page 722: Hydraulic Oil Filter Pressure Switch
Electrical System 9.14.3 Hydraulic Oil Filter Pressure Switch a. Hydraulic Oil Filter Pressure Switch Removal The hydraulic oil filter pressure switch (1) is threaded into 1. Unlock and open the engine cover (5). the top of the hydraulic oil filter, at the top rear of the hydraulic oil reservoir.
Page 723 Electrical System 3. Label and disconnect the hydraulic oil filter pressure e. Installation and Testing switch leads (3) from the harness connectors. 1. Apply clean hydraulic oil to the threads (4) on the 4. Remove the hydraulic oil filter pressure switch (1) hydraulic oil filter pressure switch (1).
Page 724: Dual Hydraulic Oil Temperature Switch
Electrical System 9.14.4 Dual Hydraulic Oil Temperature a. Hydraulic Oil Temperature Switch Removal Switch 1. Unlock and open the engine cover (6). The hydraulic oil temperature switch (1) is threaded into a fitting (2) at the lower inside wall of the hydraulic oil reservoir.
Page 725 Electrical System 3. Label and disconnect the switch wiring connector (4) 3. If the vehicle has dual batteries, connect both from the harness connector. negative battery cables (8 and 9) to both batteries. 4. Remove the switch (1) from the hydraulic reservoir Connect the lower negative battery cable (8) to the fitting (2).
Page 726 Electrical System 9.14.5 Auxiliary Hydraulic Pressure Release Switch 644E-42, SN 20118 & Before, 0160002519 thru 0160003108, 944E-42, SN 20123 & Before, 0160002514 thru 0160003106 The auxiliary hydraulic pressure release switch (1) is located in the upper bank of switches on the right side of the dash and is pressed or “snapped”...
Page 727 Electrical System d. Auxiliary Hydraulic Pressure Release Switch Installation and Testing 1. Route the wiring from the dash, through the bezel, then connect the wiring to the auxiliary hydraulic pressure release switch (1) as labeled during switch removal. 2. Make sure the symbol (4) is at the bottom of the switch (1), then press or “snap”...
Page 728: Parking Brake Switch
Electrical System 9.14.6 Parking Brake Switch The parking brake switch (1) is located on the dash to the left of the steering column and is pressed or “snapped” into a rectangular switch bezel. The parking brake switch must be ENGAGED to permit engine starting. Note: The parking brake may be used to stop in an EMERGENCY situation;...
Page 729 Electrical System 3. If the vehicle has dual batteries, connect both negative battery cables (10 and 11) to both batteries. Connect the lower negative battery cable (10) to the negative (-) terminal on the lower battery (12). Swing the upper battery box (15) in and make sure that the lip (14) on the upper battery box slides below the knob (13).
Page 730: Transmission Disconnect Switch
Electrical System 9.14.7 Transmission Disconnect Switch a. Transmission Disconnect Switch Removal The transmission disconnect switch (1) is located on the 1. Unlock and open the engine cover (5). dash to the left of the steering column and is pressed or “snapped”...
Page 731 Electrical System b. Transmission Disconnect Switch Disassembly 4. Lower and lock engine cover. To release and lower the engine cover (5) from the fully raised position, lift DO NOT disassemble the transmission disconnect up slightly on the cover and push the upper part of switch.
Page 732: Transmission Shift Control Switch
Electrical System 9.14.8 Transmission Shift Control Switch b. Gear Select Lever The gear select lever (5) is part of the transmission shift a. Travel Select Lever control switch, travel select lever (1). The lever has a The transmission shift control switch, travel select twist-grip handle with four positions.
Page 733 Electrical System If the transmission is not shifting properly, the 3. Check the harness side connector plugs on the transmission shift control switch/travel select lever (1), active solenoids corresponding to the direction and dash panel, wiring harness or transmission shift gear that has been selected with a DMM for battery solenoids should be checked in order to determine which voltage.
Page 734 Electrical System c. Transmission Solenoid Valve Removal 1. Unlock and open the engine cover (1). MU3990 d. Transmission Solenoid Valve Installation 1. Install the solenoid valve (10) along with the retaining bracket (12). OU0780 2. Install the socket head capscrew (11) and torque to 2.
Page 735: Dual Joystick
Electrical System 9.14.10 Dual Joystick a. Front Joystick Button Testing This vehicle is equipped with three separate hydraulic 1. Remove the six capscrews (18) (two not shown) joysticks. securing the access panel (19) to the side console (20). Remove the access panel. •...
Page 736 Electrical System 4. If the harness is functioning properly, test the joystick button (5) for continuity. With the joystick button pressed down, test across the two pins inside the joystick connector plug (13) for continuity and shorting. If there is no continuity, replace the joystick handle (9).
Page 737: Optional Single Joystick
Electrical System c. Front Joystick Function Solenoid Valves 9.14.11 Optional Single Joystick The front joystick commands are actuated, both This vehicle can be equipped with an optional single electrically and hydraulically, via a set of solenoid- joystick. operated cartridges within the pilot select valve (15). The The single joystick option is an assembly containing a pilot select valve is located on the valve plate which is single joystick (18) to control boom functions, auxiliary...
Page 738 Electrical System Joystick mode operation can be checked according to the The late production single joystick has the single joystick joystick operation instructions found in the Owners/ harness connector (11) plugged directly into the joystick Operators Manual for this vehicle. Operational checks will connector (10).
Page 739 Electrical System Early Production Single Joystick 4. If the single joystick harness (5) is functioning properly, the entire early production single joystick (9), control module (7) and jumper harness (8) should be replaced with a new single joystick assembly. Refer to Section 9.14.11, b. “Early Production Single Joystick Assembly Replacement.”...
Page 740 Electrical System c. Late Production Single Joystick Handle 8. Roll the boot (3) up to expose the jam nut (4) at the Replacement bottom of the handle assembly (5). 9. Thread the handle assembly (5) onto the joint 1. Remove the front joystick valve assembly (1) from assembly (8).
Page 741: Boom Sensor (Proximity Switch)
Electrical System 9.14.12 Boom Sensor (Proximity Switch) The boom lift sensor (22) is located at the rear of, and on the right side of the outer boom (23). When the boom is lifted above 40°, the boom sensor sends a signal to one of the Stabil-TRAK indicators on the dash panel.
Page 742 Electrical System 2. If the vehicle has dual batteries, disconnect both Boom Sensor Installation and Adjustment negative battery cables (1 and 2) from both 1. Place the sensor (14), with the inner sensor batteries. mounting nut (7), into the mounting hole (15) at the To access the lower battery (3), loosen the knob (4) rear of, and on the right side of the outer boom (16).
Page 743: Engine Low Oil Pressure Switch
Electrical System 5. Lower and lock engine cover (17). To release and The front dash panel indicator (20) illuminates when lower the engine cover from the fully raised position, engine oil pressure is too low to properly lubricate the lift up slightly on the cover and push the upper part engine.
Page 744 Electrical System MU4500 b. Engine Oil Pressure Switch Disassembly MU0650 DO NOT disassemble the switch. Replace a defective or 3. Lower and lock engine cover (10). To release and faulty switch. lower the engine cover from the fully raised position, lift up slightly on the cover and push the upper part of the right gas shock (11) (orange tab) to the left.
Page 745: Engine Coolant Temperature Sender
Electrical System 9.14.14 Engine Coolant Temperature Sender The engine coolant temperature sender (12) sends a signal to the temperature gauge (16) whenever the The engine coolant temperature sender (12) is threaded engine is running. The gauge monitors the temperature at into the engine block (13) and is connected via the vehicle which the engine is operating.
Page 746 Electrical System a. Engine Coolant Temperature Sender Removal 1. Unlock and open the engine cover (1). OU0780 2. If the vehicle has dual batteries, disconnect both negative battery cables (3 and 4) from both batteries. To access the lower battery (5), loosen the knob (6) MU4520 far enough so that the lip (7) on the upper battery box clears the knob.
Page 747: Transmission Temperature Switch
Electrical System lift up slightly on the cover and push the upper part When the transmission fluid temperature rises above of the right gas shock (2) (orange tab) to the left. 250° F (121° C), the switch heats up, closing contacts Line up the upper part of the shock lock tube with the within the sending unit.
Page 748 Electrical System b. Transmission Temperature Switch Disassembly DO NOT disassemble the switch. Replace a defective or faulty switch with a new part. c. Transmission Temperature Switch Inspection and Replacement Inspect the switch and the wiring harness connector terminals for continuity. Replace a defective or faulty switch.
Page 749: Engine Block Heater
Electrical System 9.14.16 Engine Block Heater b. Engine Block Heater Removal The engine is equipped with an engine block heater (12) For instructions for removing the engine block heater, that can be plugged into a standard 110/120V A.C. refer to Section 7.6.4, c. “Engine Block Heater Removal.” grounded outlet to heat the engine coolant.
Page 750: Fuel Level Gauge And Fuel Level Sender
Electrical System 9.14.17 Fuel Level Gauge and Fuel Level Sender The fuel level gauge (1) can be found on the operator’s dash panel. MU0010 The fuel level gauge (1) works in conjunction with the fuel level sender (2). The submerged, coil-type fuel level sender is secured to the fuel tank (3) and is connected to the operator’s dash panel via the cab wiring harness.
Page 751 Electrical System 3. Check that the ignition terminal has current and that the fuse in the fuse panel is not blown. 4. Check for broken, shorted, frayed, disconnected or damaged wiring between the fuel level gauge wiring at the operator’s dash panel, fuse and relay panel, ignition key switch, and from the fuel level sender on the fuel tank through the wiring in the cab.
Page 752: Hourmeter
Electrical System 9.14.18 Hourmeter 9.14.19 Stabilizer Brake Switch The hourmeter (1) is a non-repairable instrument that The stabilizer brake switch works in conjunction with the records hours of vehicle engine operation in tenths of an Stabil-TRAK™ system. With the boom above 40° and the hour increments and is located in the dash panel.
Page 753 Electrical System When Service Brake Valve Mounting Plate Has b. Stabilizer Brake Switch Installation Threaded Mounting Hole. When Service Brake Valve Mounting Plate Does Not Remove switch dust cover (17). Remove the Have Threaded Mounting Hole. stabilizer brake switch (18), by loosening the 1.
Page 754 Electrical System 7. If the vehicle has dual batteries, connect both negative battery cables (1 and 2) to both batteries. Connect the lower negative battery cable (1) to the negative (-) terminal on the lower battery (3). Swing the upper battery box (4) in and make sure that the lip (5) on the upper battery box slides below the knob (6).
Page 755 Electrical System MU4581 MU4600 6. If the vehicle has dual batteries, connect both negative battery cables (1 and 2) to both batteries. Connect the lower negative battery cable (1) to the WARNING: NEVER attempt to adjust negative (-) terminal on the lower battery (3). Swing the stabilizer brake switch without an assistant.
Page 756 Electrical System When Service Brake Valve Mounting Plate Has Threaded Mounting Hole. Position the brake switch so the Stabil-TRAK “Locked” Mode indicator (1) comes ON at the 150 ±50 psi (10,3 ±3,4 bar) brake pressure. If the brake switch needs to be adjusted, remove the wire leads from the switch, loosen the locknut (6) from the top of the switch mounting bracket (7) and thread the switch in or out until you hear an audible click.
Page 757 Section 10 Stabil-TRAK™ System Contents PARAGRAPH TITLE PAGE 10.1 Stabil-TRAK™ System Component Terminology......10.4 10.2 Stabil-TRAK™ Description ......... . . 10.5 10.3 Stabil-TRAK™...
Page 758 Stabil-TRAK™ System 10.8 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting ... 10.30 10.8.1 Troubleshooting Symptom Chart....... . 10.30 10.8.2 Stabilizer Cylinder Oil Flow .
Page 759 Stabil-TRAK™ System This Page Intentionally Left Blank 10.3 Model 644E-42/944E-42 Rev. 6/04...
Page 760: Stabil-Trak™ System Component Terminology
Stabil-TRAK™ System 10.1 STABIL-TRAK™ SYSTEM COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the Stabil-TRAK™ system. The following illustration identifies the components that are referred to throughout this section.
Page 761: Stabil-Trak™ Description
Stabil-TRAK™ System 10.2 STABIL-TRAK™ DESCRIPTION The patented rear axle lock or Stabil-TRAK™ system works to stabilize the vehicle under various conditions. The appropriate Owners/Operators manual contains basic Stabil-TRAK™ information; a copy of the owners/ operators manual should always be available in the storage compartment located in the pouch on the back of the seat.
Page 762: Stabil-Trak™ Operation
Stabil-TRAK™ System 10.3 STABIL-TRAK™ OPERATION In the LOCKED MODE, the exclusive Stabil-TRAK™ System provides a 4-point stability rectangle (5) by positively locking the frame to the rear axle through the The rough terrain forklift rarely operates on ground that is stabilizer cylinder.
Page 763 Stabil-TRAK™ System The following describes the three basic modes of the c. Slow Pivot Mode (11) patented Stabil-TRAK™ system. The vehicle may With the boom above 40°, the Stabil-TRAK™ system is operate in any one of the following three modes. now in the SLOW PIVOT MODE when the service brake pedal is not applied and the transmission is in gear.
Page 764: Stabil-Trak™ Solenoid Valves
Stabil-TRAK™ System 10.3.2 Stabil-TRAK™ Solenoid Valves 10.3.3 Relay Testing There are five Stabil-TRAK™ solenoid valves (1, 2, 3, If after checking the electrical system, a relay is suspect, 4 and 5) installed in the Stabil-TRAK™ manifold, attached test the relay as follows: to the stabilizer cylinder above the left side of the rear 1.
Page 765 Stabil-TRAK™ System This Page Intentionally Left Blank 10.9 Model 644E-42/944E-42 Rev. 6/04...
Page 766: Stabil-Trak™ Electrical Circuit Operation And Troubleshooting (644E-42, Sn 20118 & Before, Sn 0160002519 Thru 0160003877) (944E-42, Sn 20123 & Before, Sn 0160002514 Thru 0160003881)
Stabil-TRAK™ System 10.4 STABIL-TRAK™ ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (644E-42, SN 20118 & Before, SN 0160002519 thru 0160003877) (944E-42, SN 20123 & Before, SN 0160002514 thru 0160003881) Stabil-TRAK™ System Troubleshooting FREE PIVOT SLOW PIVOT SLOW PIVOT LOCKED LOCKED LOCKED MODE MODE I MODE II MODE I...
Page 767 Stabil-TRAK™ System 644E-42, SN 20118 & Before, SN 0160002519 FREE PIVOT MODE 1. Ignition “ON” 4. Transmission in Fwd. or Rev. thru 0160003877 944E-42, SN 20123 & Before, 2. Boom Below 40° SN 0160002514 thru 0160003881 Conditions Stabil-TRAK™ Electrical Circuit 3.
Page 768 Stabil-TRAK™ System 644E-42, SN 20118 & Before, SN 0160002519 SLOW PIVOT MODE I 1. Ignition “ON” 4. Transmission in Neutral, Fwd. or Rev. thru 0160003877 944E-42, SN 20123 & Before, 2. Boom Below 40° SN 0160002514 thru 0160003881 Conditions Stabil-TRAK™ Electrical Circuit 3.
Page 769 Stabil-TRAK™ System 644E-42, SN 20118 & Before, SN 0160002519 SLOW PIVOT MODE II 1. Ignition “ON” 4. Transmission in Fwd. or Rev. thru 0160003877 944E-42, SN 20123 & Before, 2. Boom Above 40° SN 0160002514 thru 0160003881 Conditions Stabil-TRAK™ Electrical Circuit 3.
Page 770 Stabil-TRAK™ System 644E-42, SN 20118 & Before, SN 0160002519 LOCKED MODE I 1. Ignition “ON” 4. Trans. in Neutral thru 0160003877 944E-42, SN 20123 & Before, 2. Boom Above 40° SN 0160002514 thru 0160003881 Conditions Stabil-TRAK™ Electrical Circuit 3. PB “ON” & SB Released Locked Mode I MU3642 10.14...
Page 771 Stabil-TRAK™ System 644E-42, SN 20118 & Before, SN 0160002519 LOCKED MODE II 1. Ignition “ON” 4. Transmission in Fwd. or Rev. thru 0160003877 944E-42, SN 20123 & Before, 2. Boom Above 40° SN 0160002514 thru 0160003881 Conditions Stabil-TRAK™ Electrical Circuit 3.
Page 772 Stabil-TRAK™ System 644E-42, SN 20118 & Before, SN 0160002519 1. Ignition “ON” 4. Transmission in Neutral LOCKED MODE III thru 0160003877 944E-42, SN 20123 & Before, 2. Boom Above 40° SN 0160002514 thru 0160003881 Conditions Stabil-TRAK™ Electrical Circuit 3. PB “OFF” & SB Released Locked Mode III MU3662 10.16...
Page 773: Sn 0160002519 Thru 0160003877)
Stabil-TRAK™ System 10.5 STABIL-TRAK™ SYSTEM TEST Note: The front left tire off of the ground during the test is a visible indication that the stability system is in the (644E-42, SN 20118 & Before, locked mode. SN 0160002519 thru 0160003877) (944E-42, SN 20123 &...
Page 774: Stabil-Trak System Test Procedures
Stabil-TRAK™ System 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 775 Stabil-TRAK™ System 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 776: Stabil-Trak™ Electrical Circuit Operation And Troubleshooting (644E-42, 0160003878 & After) (944E-42, 0160003882 & After)
Stabil-TRAK™ System 10.6 STABIL-TRAK™ ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (644E-42, 0160003878 & After) (944E-42, 0160003882 & After) Stabil-TRAK™ System Troubleshooting FREE PIVOT SLOW PIVOT LOCKED LOCKED LOCKED MODE MODE MODE I MODE II MODE III Reference Reference Reference Reference Reference page 10.21 page 10.22 page 10.23...
Page 777 Stabil-TRAK™ System 644E-42, 0160003878 & After FREE PIVOT MODE 1. Ignition “ON” 4. Transmission in Fwd. or Rev. 944E-42, 0160003882 & After 2. Boom Below 40° Stabil-TRAK™ Electrical Circuit Conditions Free Pivot Mode 3. PB “OFF” & SB Released MU6650 10.21 Model 644E-42/944E-42 Rev.
Page 778 Stabil-TRAK™ System 644E-42, 0160003878 & After SLOW PIVOT MODE 1. Ignition “ON” 4. Transmission in Fwd. or Rev. 944E-42, 0160003882 & After 2. Boom Above 40° Stabil-TRAK™ Electrical Circuit Conditions Slow Pivot Mode 3. PB “OFF” & SB Released MU6670 10.22 Model 644E-42/944E-42 Rev.
Page 779 Stabil-TRAK™ System 644E-42, 0160003878 & After LOCKED MODE I 1. Ignition “ON” 4. Trans. in Neutral 944E-42, 0160003882 & After 2. Boom Above 40° Stabil-TRAK™ Electrical Circuit Conditions Locked Mode I 3. PB “ON” & SB Released MU6680 10.23 Model 644E-42/944E-42 Rev. 6/04...
Page 780 Stabil-TRAK™ System 644E-42, 0160003878 & After LOCKED MODE II 1. Ignition “ON” 4. Transmission in Fwd. or Rev. 944E-42, 0160003882 & After 2. Boom Above 40° Stabil-TRAK™ Electrical Circuit Conditions Locked Mode II 3. PB “OFF” & SB Applied MU6690 10.24 Model 644E-42/944E-42 Rev.
Page 781 Stabil-TRAK™ System 644E-42, 0160003878 & After LOCKED MODE III 1. Ignition “ON” 4. Transmission in Neutral 944E-42, 0160003882 & After 2. Boom Above 40° Stabil-TRAK™ Electrical Circuit Conditions Locked Mode III 3. PB “OFF” & SB Released MU6700 10.25 Model 644E-42/944E-42 Rev. 6/04...
Page 782: Stabil-Trak™ System Test (644E-42, 0160003878 & After) (944E-42, 0160003882 & After)
Stabil-TRAK™ System 10.7 STABIL-TRAK™ SYSTEM TEST WARNING: DO NOT operate this vehicle (644E-42, 0160003878 & After) unless you are in the seat with the seat belt (944E-42, 0160003882 & After) fastened around you. Death or serious injury could result if the belt is not securely fastened. IMPORTANT: The operator must know that the Stabil-TRAK™...
Page 783 Stabil-TRAK™ System 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 784 Stabil-TRAK™ System 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 785 Stabil-TRAK™ System This Page Intentionally Left Blank 10.29 Model 644E-42/944E-42 Rev. 6/04...
Page 786: Stabil-Trak™ Hydraulic Circuit Operation And Troubleshooting
Stabil-TRAK™ System 10.8 STABIL-TRAK™ HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOOTING The function of the Stabil-TRAK™ system varies under The hydraulic operation and troubleshooting information for different operating conditions. The basic modes include each of these modes will be described on the following the FREE PIVOT MODE, SLOW PIVOT MODE and pages.
Page 787: Stabilizer Cylinder Oil Flow
Stabil-TRAK™ System 10.8.2 Stabilizer Cylinder Oil Flow In the FREE PIVOT and SLOW PIVOT MODES, oil flow from the stabilizer cylinder will be in one of two directions; ROD OIL OUT or BASE OIL OUT. ROD OIL OUT flow will occur when the left side of the rear axle is lower than the right side (left wheel in a pothole, or the right wheel passing over an obstruction), causing the cylinder to extend (1).
Page 788: Hydraulic Circuit Operation - Free Pivot Mode, Rod Oil Out
Stabil-TRAK™ System 10.8.3 Hydraulic Circuit Operation - Free Pivot Mode, Rod Oil Out MU4511 Conditions: Operation: • Boom angle is below 40° When the conditions are met, solenoids 12A and 12B are energized. As the left side of the rear axle moves down, •...
Page 789: Hydraulic Troubleshooting - Free Pivot Mode, Rod Oil Out
Stabil-TRAK™ System Legend 1. Stabilizer Cylinder 2. Solenoid 12B 3. Solenoid 12A 4. Pressure Reducing Cartridge 5. Solenoid 4A 6. Solenoid 4B 7. Solenoid 3 8. Check Valve 2A 9. Check Valve 2B Front MU4260 10.8.4 Hydraulic Troubleshooting - Free Pivot Mode, Rod Oil Out When frame swaying right, left front Conditions: tire comes off the ground...
Page 790: Hydraulic Circuit Operation - Free Pivot Mode, Base Oil Out
Stabil-TRAK™ System 10.8.5 Hydraulic Circuit Operation - Free Pivot Mode, Base Oil Out MU4761 Conditions: Operation: • Boom angle is below 40° When the conditions are met, solenoids 12A and 12B are energized. As the left side of the rear axle moves down, •...
Page 791: Hydraulic Troubleshooting - Free Pivot Mode, Base Oil Out
Stabil-TRAK™ System Legend 1. Stabilizer Cylinder 2. Solenoid 12A 3. Solenoid 12B 4. Pressure Reducing Cartridge 5. Solenoid 4A 6. Solenoid 4B 7. Solenoid 3 8. Check Valve 2A 9. Check Valve 2B Front MU4260 10.8.6 Hydraulic Troubleshooting - Free Pivot Mode, Base Oil Out With boom below 40°, when frame Conditions: swaying to the left, the right front tire...
Page 792: Hydraulic Circuit Operation - Slow Pivot Mode, Rod Oil Out
Stabil-TRAK™ System 10.8.7 Hydraulic Circuit Operation - Slow Pivot Mode, Rod Oil Out MU4771 Conditions: Operation: • Boom angle is above 40° OR As the boom is raised above 40°, the boom proximity (On SN 0160003881 & Before Only) below 40° switch is deactivated, causing solenoids 12A and 12B to de-energize and solenoids 4A and 4B to energize.
Page 793: Hydraulic Troubleshooting - Slow Pivot Mode, Rod Oil Out
Stabil-TRAK™ System Legend 1. Stabilizer Cylinder 2. Solenoid 4B 3. .060" Orifice with Solenoid Valve 4B 4. .060" Orifice with Solenoid Valve 4A 5. Solenoid 4A 6. Pressure Reducing Cartridge 7. Solenoid 12A 8. Solenoid 12B 9. Solenoid 3 10. Check Valve 2A 11.
Page 794: Hydraulic Circuit Operation - Slow Pivot Mode, Base Oil Out
Stabil-TRAK™ System 10.8.9 Hydraulic Circuit Operation - Slow Pivot Mode, Base Oil Out MU4801 Conditions: Operation: • Boom angle is above 40° OR As the boom is raised above 40°, the boom proximity (On SN 0160003881 & Before Only) below 40° switch is deactivated causing solenoids 12A and 12B to de-energize and solenoids 4A and 4B to energize.
Page 795: Hydraulic Troubleshooting - Slow Pivot Mode, Base Oil Out
Stabil-TRAK™ System Legend 1. Stabilizer Cylinder 2. Solenoid 4B 3. .060" Orifice with Solenoid Valve 4B 4. .060" Orifice with Solenoid Valve 4A 5. Solenoid 4A 6. Pressure Reducing Cartridge 7. Solenoid 12A 8. Solenoid 12B 9. Solenoid 3 10. Check Valve 2A 11.
Page 796: Hydraulic Circuit Operation - Locked Mode
Stabil-TRAK™ System 10.8.11 Hydraulic Circuit Operation - Locked Oil entering the Stabil-TRAK™ manifold at port V flows Mode through solenoid cartridge valve 3 (5), through a .030" orifice (6) and check valve 2A (7), to the base end of the a.
Page 797: Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Right
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 MU4260 Front 10.8.13 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Right With boom above 40°, when frame Conditions:...
Page 798: Hydraulic Circuit Operation - Locked Mode, Frame Sway Left
Stabil-TRAK™ System 10.8.14 Hydraulic Circuit Operation - opening the valve. Locked Mode, Frame Sway Left Oil from the rod end of the frame sway cylinder flows, through the check valve (4) opened by incoming pilot a. Conditions pressure oil, through the check valve with a .041" orifice (5), to the FTR port of the Stabil-TRAK™...
Page 799: Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Left
Stabil-TRAK™ System Legend 6. Solenoid 3 7. Check Valve 2B 8. Stabilizer Cylinder 9. Check Valve 2A 10. .030" Orifice Plug 11. Solenoid 4A 12. Solenoid 4B 13. Solenoid 12A 14. Solenoid 12B 15. Pressure Reducing Cartridge Front MU4260 10.8.15 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Left With boom above 40°, when frame Conditions:...
Page 800 Stabil-TRAK™ System This Page Intentionally Left Blank 10.44 Model 644E-42/944E-42 Rev. 6/04...
Page 801 Section 11 Transfer Carriage Contents PARAGRAPH TITLE PAGE 11.1 Transfer Carriage Component Terminology ......11.2 11.2 Transfer Carriage.
Page 802: Transfer Carriage Component Terminology
Transfer Carriage 11.1 TRANSFER CARRIAGE COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the major assemblies of the transfer carriage. The following illustration identifies the components that are referred to throughout this section.
Page 803: Transfer Carriage
Transfer Carriage 11.3 TRANSFER CARRIAGE WARNING: DO NOT service the vehicle MAINTENANCE without following all safety precautions as outlined in the “Safety Practices” section of this The transfer carriage assembly consists of the carriage, manual. Failure to follow the safety practices cylinder, hoses and supporting hardware.
Page 804: Transfer Carriage Removal
Transfer Carriage 11.3.1 Transfer Carriage Removal 9. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the 1. Level the vehicle, place the travel select lever in the vehicle should not be operated. (Refer to Section (N) NEUTRAL DETENT position, engage the 1.5, “Accident Prevention Tag Usage.”) parking brake.
Page 805 12. Remove the boom as described in Section 3.3.3, a. “Outer Boom Removal.” WARNING: 13. Remove locknuts (10), washers (11), Lull logo To avoid personal injury plate (12) and black backing (13) from the rear of the and/or equipment damage, supporting the lift/ vehicle (14).
Page 806 Transfer Carriage 18. Remove the four hydraulic hoses (1) connecting the slave cylinders (2) to the hydraulic tubes (3). Cap WARNING: and label the hoses. To avoid personal injury 19. Remove the capscrew (4) and mounting bracket (5). and/or equipment damage, supporting the Disconnect the hydraulic tubes (3) from the hydraulic slave cylinder is essential when lifting and junction manifold (6).
Page 807 Transfer Carriage 23. Disconnect the back-up alarm electrical 25. Remove pin bolt (20) and locknut (21) from rear connection (11) from the wire harness (12) and roller pin (22). Slide the roller pin out and remove the remove the locknuts (13) and washers (14) securing rear rollers (23) and shims (24) from both sides of the back-up alarm (15) to the transfer carriage (16).
Page 808 Transfer Carriage 28. Remove capscrews (1), shims (2), and rear wear pads (3). Count and label their position for later replacement. MU1790 32. Remove lifting straps, boom pivot pins and slave cylinder pins. MU1780 33. Inspect transfer carriage cylinder mount, boom pivot 29.
Page 809 Transfer Carriage ® 11.3.2 Transfer Carriage Installation 8. Coat the capscrews (15) with Loctite 242 (blue). Replace capscrews (15), washers (16) and 1. Insert front roller pin (11), front roller (13) and scrapers (17) on the front of the transfer carriage. shims (14) in their previously labeled positions.
Page 810 Transfer Carriage 10. Insert the rear roller pin (1), rear rollers (2) and 13. Lift the slave cylinder (9) into position and insert the ® shims (3) according to their previously labeled pin (10). Coat the bolt with Loctite 242 (blue). Install ®...
Page 811 Transfer Carriage MU1700 WARNING: To avoid personal injury MU1691 and/or equipment damage, supporting the lift/ ® lower cylinder is essential when lifting and 19. Coat the bolts (27) with Loctite 242 (blue). Replace reinstalling it back on the vehicle. Make sure the bolts (27) and stop blocks (28) at the rear, left that the lift/lower cylinder is properly supported and right side of the frame.
Page 812 242 (blue). Install 22. If the vehicle has dual batteries, connect both locknuts (1), washers (2), Lull logo plate (3) and negative battery cables (6 and 7) to both batteries. black backing (4) at the rear of the vehicle (5).
Page 813: Rear Wear Pad Check
Transfer Carriage 11.3.3 Rear Wear Pad Check 11.3.4 Rear Wear Pad Shimming Note: The attachment should remain attached to the Note: The attachment should remain attached to the quick attach for these checks. quick attach for this procedure. 1. Park the vehicle on level ground. Place the travel 1.
Page 814: Rear Wear Pad Replacement
Transfer Carriage 11.3.5 Rear Wear Pad Replacement 11.3.6 Front Upstop Wear Pad Check Note: The attachment should remain attached to the The front upstop wear pads (5) are located under the quick attach for this procedure. frame rails at the front of the transfer carriage. Each wear pad (5) is manufactured with a convenient 1.
Page 815: Front Upstop Wear Pad Shimming
Transfer Carriage 11.3.8 Front Upstop Wear Pad Shimming 5. Remove capscrews (18), shims (19), and front wear pads (20). Label their position for later replacement. 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 816: Front Upstop Wear Pad Replacement
Transfer Carriage 11.3.9 Front Upstop Wear Pad Replacement 11.3.10 Rear Roller Gap Check Note: The attachment should remain attached to the Note: The attachment should remain attached to the quick attach for this procedure. quick attach for these checks. 1. Park the vehicle on level ground. Place the travel 1.
Page 817: Rear Roller Shimming
(Refer to Section 1.5, “Accident Prevention Tag Usage.”) 9. Remove locknuts (14), washers (15), Lull logo 7. Open the engine compartment cover. Allow the plate (16) and black backing (17) from the rear of the engine, transmission and hydraulic fluid to cool.
Page 818 15. Coat the locknuts (9) with Loctite 242 (blue). Install locknuts (9), washers (10), Lull logo plate (11) and black backing (12) at the rear of the vehicle (13). Torque locknuts to, 29 - 51 lb-ft (40 - 70 Nm).
Page 819: Front Roller Gap Check
Transfer Carriage 16. If the vehicle has dual batteries, connect both 11.3.12 Front Roller Gap Check negative battery cables (14 and 15) to both Note: The attachment should remain attached to the batteries. quick attach for these checks. Connect the lower negative battery cable (14) to the 1.
Page 820: Front Roller Shimming
Transfer Carriage 11.3.13 Front Roller Shimming 8. Remove capscrew (7), washer (8), spacer (9) and locknut (10) from the front roller pin (11) and transfer Note: The attachment should remain attached to the carriage (12). quick attach. 9. Remove the front roller pin (11), front roller (13) and 1.
Page 821: Front Scraper Plate Replacement
Transfer Carriage 13. If the vehicle has dual batteries, connect both negative battery cables (1 and 2) to both batteries. Connect the lower negative battery cable (1) to the negative (-) terminal on the lower battery (3). Swing the upper battery box (6) in and make sure that the lip (5) on the upper battery box slides below the knob (4).
Page 822: Front Roller And Bushing Replacement
Transfer Carriage 11.3.15 Front Roller and Bushing Replacement Note: The attachment should remain attached to the quick attach. 1. Park the vehicle on firm 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 823: Rear Roller And Bushing Replacement
(5) on the upper battery box slides below the knob battery cable. (4). Secure in place with the knob (4). 8. Remove locknuts (16), washers (17), Lull logo 16. Close and lock the engine compartment cover. plate (18) and black backing (19) from the rear of the 17.
Page 824 15. Coat the locknuts (11) with Loctite 242 (blue). Install locknuts (11), washers (12), Lull logo plate (13) and black backing (14) at the rear of the vehicle (15). Torque locknuts to, 29 - 51 lb-ft (40 - 70 Nm).
Page 825: Boom Pivot Bushing Replacement
Transfer Carriage 16. If the vehicle has dual batteries, connect both 11.3.17 Boom Pivot Bushing Replacement negative battery cables (16 and 17) to both 1. Park the vehicle on firm level ground. Place the batteries. travel select lever in the (N) NEUTRAL DETENT Connect the lower negative battery cable (16) to the position, engage the parking brake switch and raise negative (-) terminal on the lower battery (18).
Page 826: Slave Cylinder Pivot Bushing Replacement
Transfer Carriage 11.3.18 Slave Cylinder Pivot Bushing Note: If new slave cylinder bearings (10) and (11) have Replacement been installed in the transfer carriage or slave cylinder, the fracture in the bearing race must be positioned 1. Park the vehicle on firm level ground. Place the perpendicular (12) to the force of the load.
Page 827: Transfer Cylinder Replacement
Transfer Carriage 11.3.19 Transfer Cylinder Replacement 4. Temporarily tape the pin in place so it will not fall out during the following procedure. The transfer cylinder is located on the left rear side of the 5. Move the transfer carriage all the way forward. main frame and is connected to the main frame and transfer carriage.
Page 828 Transfer Carriage 13. Disconnect two hydraulic lines (1) connected to the 4. Move the transfer carriage 5' 8'' (172 cm) so that the transfer cylinder (2). Plug, cap and label the hoses pin (4) connecting the transfer cylinder to the and fittings.
Page 829 Transfer Carriage MU5560 4. From under the vehicle remove the transfer cylinder bearing (18) from the transfer carriage mount (19). 5. Replace a new transfer cylinder bearing (18) into the transfer carriage mount (19). MU0650 7. Close and lock the engine compartment cover. 8.
Page 830: Troubleshooting
Transfer Carriage 11.4 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the transfer carriage. 11.4.1 Transfer Carriage Troubleshooting Problem Cause Remedy 1. Transfer carriage will not 1. Broken transfer cylinder 1.
Page 831 Transfer Carriage 11.4.1 Transfer Carriage Troubleshooting Problem Cause Remedy 3. Transfer carriage shifts to 1. Transfer carriage rollers 1. Re-shim the transfer carriage. right or left when extending. improperly shimmed. (Refer to Section 11.3.11, “Rear Roller Shimming,” and Section 11.3.13, “Front Roller Shimming.”) 2.
Page 832 Transfer Carriage This Page Intentionally Left Blank 11.32 Model 644E-42/944E-42 Rev. 6/04...
Page 833 Section 12 Index Numerics Axle, Drive Shaft and Wheel Brake Pedal, Service....... 4.12 Component Terminology ....5.2 Brake Valve, Service....... 4.12 Switches and Solenoids Drive Shafts.........5.16 Fuel Shutoff Solenoid ....9.212 General Information.......5.3 Wheels and Tires ......5.19 Cab and Covers Access Panels and Covers ..4.36 Access Panels and Covers Cab Installation ......
Page 834 Index Park Brake Warning Terminology........9.5 Optional Closed Cab Electrical Indicator ......... 9.157 Transmission Gear Selection Schematic ........ 9.63 Stabil-TRAK Troubleshooting......9.140 Optional Closed Cab Electrical "Locked" Mode Indicator ..9.160 Warning Devices .......9.176 Schematic Legend ....9.62 Stabil-TRAK "Slow Pivot" Warning Indicator Lights....9.178 Optional Roadlight Electrical Mode Indicator .......
Page 835 Index Enclosed Cab (Optional) Cleaning........2.27 Components ......... 4.24 Component Terminology....2.3 Fluids, Lubricants and Capacities Fluids, Lubricants and Enclosed Cab Components Axles (Differential Housings) ..2.23 Capacities ........ 2.23 Heater/Defroster System .... 4.24 Drive Shaft Splines......2.26 Hoses and Tubes......2.28 Windshield Wiper Assembly ..
Page 836 Index Auxiliary Hydraulic Frame Sway (Right) and Lift/Lower ........8.225 Pressure Release Circuit Stabilizer Circuit Side Tilt Carriage Cylinder (Dual Joystick) ....... 8.142 (SN 18461 and After) ....8.96 (Optional) ....... 8.250 Auxiliary Hydraulic Frame Sway Circuit Slave Cylinders ......8.217 Pressure Release Circuit Description ......8.152 Stabilizer Cylinder .....
Page 837 Index Rear Roller Shimming ....11.17 Final Positioning Mode, Base Oil Out......10.38 Rear Wear Pad Check....11.13 Lift/Lower Cylinder ......3.23 Final Positioning Mode, Rear Wear Pad Replacement..11.14 Rod Oil Out ......10.36 Rear Wear Pad Shimming.....11.13 Free Pivot Mode, Metric Conversion Factors Base Oil Out......
Page 838 Index Starter Cylinder Replacement ....11.27 Transmission Gear Selection Circuit Checks......9.164 Description ........11.3 Troubleshooting Cleaning and Drying ....9.166 Front Scraper Plate Forward First Gear Circuit..9.141 Installation......... 9.166 Replacement ......11.21 Forward Fourth Gear Circuit ..9.144 Periodic Maintenance ....9.166 Front Transfer Roller and Bushing Forward Second Gear Removal........
Page 839 Index Warning Devices ......9.176 Warning Indicator Lights ....9.178 Alternator Charging....9.178 Engine Air Filter Restriction ..9.178 Engine Oil Pressure....9.178 Hydraulic Oil Filter Restriction .. 9.178 Hydraulic Oil Temperature..9.178 Low Brake Pressure ....9.178 Transmission Temperature..9.178 Wheels and Tires Brakes.........
Page 840 Index 12.8 Model 644E-42/944E-42 Rev. 6/04...
Page 841 Accident Prevention Tags Accident Prevention Tags 8990403 Origin 5/00 OS2180...
Page 842 Accident Prevention Tags 8990403 Origin 5/00 OS2180...

This manual is also suitable for:

Placeace 644e-42 Placeace 944e-42

Lull PLACEACE Series Service Manual

Section Contents

General Information, Specifications and Maintenance

Section 3 Boom

Section 4 Cab and Covers

Section 5 Axles, Drive Shafts, Wheels, Tires and Brakes

Section 6 Transmission: Zf 4Wg-92/98 Tsc & Transfer Case: Zf Tb92-I4

Section 7 Engine: Cummins 4Bt 3.9, B4.5T and Qsb 4.5T

Section 8 Hydraulic System

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Summary of Contents for Lull PLACEACE Series