Lull 944E-42 Manuals

Manuals and User Guides for Lull 944E-42. We have 2 Lull 944E-42 manuals available for free PDF download: Service Manual

Lull 944E-42 Service Manual (844 pages)

Brand: Lull | Category: Forklifts | Size: 63 MB

Section Contents

3
- Table of Contents
  3
- Subject
  4
- Safety Practices
  8
- Introduction
  8
- Owners/Operators Manual
  8
- Training Mechanics as Operators
  9
- Safety Information
  9
- Safety Alert Symbol
  9
- Accident Prevention Tag Usage
  10
- Hazard Statements
  10
- Safety Instructions
  11
- Personal Hazards
  11
- Equipment Hazards
  11
- Operational Hazards
  12
- Emergency Exit Rear Window
  12
- General Hazards
  12
- Hazard/Emergency Information Signs
  13
General Information, Specifications and Maintenance

16
- 42 / 944E-42 Component Terminology
  17
- Introduction
  18
- Torques
  19
- Metric Conversion Factors
  21
- Specifications
  24
- Axles (Differential Housings)
  37
- Fluids, Lubricants and Capacities
  37
- Wheel Ends
  37
- Engine
  38
- Lubrication Points (Grease Fittings)
  38
- Transfer Case
  39
- Transmission
  39
- Drive Shaft Splines
  40
- General Anti-Corrosion
  40
- Cleaning
  41
- Paint
  41
- Thread Locking Compound
  41
- Hose and Tube Inspection
  42
- Hose and Tube Installation
  42
- Hoses and Tubes
  42
- Replacement
  42
- Bearing Cleaning
  43
- Bearing Removal
  43
- Bearings
  43
- Pressure Testing and Adjustment
  43
- After Brake System Service
  44
- After Electrical/Electronic Component Service
  44
- After Fuel System Service
  44
- After Hydraulic Component Service
  44
- After Service Startup
  44
- After Service Startup and Checks
  44
- After Axle Service
  45
- After Boom Service
  45
- After Engine Service
  45
- After Tire and Wheel Service
  45
- After Transmission Service or Replacement
  45
Section 3 Boom

47
- Boom System Component Terminology
  48
- Boom Assembly Maintenance
  49
- Boom System
  49
- Boom System Description
  49
- Boom System Operation
  49
- Inner Boom Replacement
  50
- Intermediate Boom Replacement
  64
- Outer Boom Replacement
  68
- Boom Chain Inspection
  74
- Boom Chains
  74
- Boom Chain Tension Check
  81
- Chain Lubrication
  81
- Boom Chain Tension Adjustment
  82
- Boom Extend and Retract Chains Removal and Replacement
  85
- Boom Wear Pad Replacement
  90
- Boom Wear Pads
  90
- Boom Wear Pad Lubrication
  92
- Connecting to an Attachment
  93
- Disconnecting from an Attachment
  93
- Quick Attach Assembly
  93
- Quick Attach Disassembly
  94
- Quick Attach Installation
  95
- Attachment Tilt Cylinder Removal
  96
- Troubleshooting
  97
Section 4 Cab and Covers

103
- Operator's Cab and Covers Component Terminology
  104
- Operator's Cab
  105
- Operator's Cab Description
  105
- Serial Number Decal
  105
- Open Cab Components
  106
- Seat and Seat Belt
  106
- Select Lever
  107
- Steering Column and Valve Replacement
  109
- Steer Select Valve
  111
- Brake Valve and Service Brake Pedal
  114
- Throttle Pedal Replacement
  117
- Throttle Position Sensor Replacement (944E-42 Only)
  118
- Front, Rear and Frame Sway Joystick Assembly Replacement
  120
- Single Joystick Assembly Replacement (Optional)
  122
- Electrical Components
  123
- Enclosed Cab Components
  125
- Enclosed Cab (Optional) Components
  126
- Front Windshield Wiper Motor
  126
- Front Windshield Wiper Switch
  126
- Heater/Defroster System
  126
- Rear Wiper Switch/Motor
  126
- Skylight Wiper Motor
  126
- Skylight Wiper Washer & Rear Window Washer Switch
  126
- Windshield Washer Control
  126
- Windshield/Skylight/Rear Wiper Washer Reservoir W/Pump
  126
- Cab Removal
  130
- Cab Installation
  133
- Valve Plate
  136
- Valve Plate Removal
  136
- Valve Plate Installation
  137
- Access Panel and Cover Replacement
  138
- Access Panels and Covers
  138
- Engine Hood
  140
Section 5 Axles, Drive Shafts, Wheels, Tires and Brakes

145
- Axle, Drive Shaft and Wheel Component Terminology
  146
- Axles, Drive Shafts, Wheels, Tires and Brakes
  146
- Axle Assemblies
  147
- Axle Assembly Description
  147
- Axle Assembly Operation
  147
- General Information
  147
- Axle Maintenance
  148
- Axle Serial Number Plate
  148
- Axle Specifications
  148
- Axle Replacement
  149
- Axle Assembly and Drive Shaft Troubleshooting
  156
- Axle Service and Troubleshooting
  156
- Axle Internal Component Troubleshooting
  159
- Drive Shaft Inspection and Service
  160
- Drive Shaft Maintenance
  160
- Drive Shaft Removal
  160
- Drive Shafts
  160
- Drive Shaft Installation
  161
- Wheels and Tires
  163
- Removing Wheel and Tire Assembly from Vehicle
  164
- Wheel Cleaning
  165
- Wheel Inspection and Replacement
  165
- Installing Wheel and Tire Assembly Onto Vehicle
  166
- Tires
  167
- Brake Disc Inspection
  170
- Brakes
  170
Section 6 Transmission: Zf 4Wg-92/98 Tsc & Transfer Case: Zf Tb92-I4

175
- Transmission Assembly Component Terminology
  176
- Transmission Description
  177
- Transmission Operation
  177
- Transmission Serial Number
  177
- Maintenance Introduction
  178
- Transmission General Specifications
  178
- Transmission Lubrication
  178
- Transmission Maintenance
  178
- Transmission Performance Specifications
  178
- Transmission Specifications
  178
- Transmission-Related Fuse/Relay Ratings
  178
- Transmission Maintenance Schedule
  179
- Transmission Removal
  180
- Transmission Replacement
  180
- Transmission Inspection and Internal Repair
  184
- Transmission Installation
  184
- After Transmission Service or Replacement
  188
- Transmission Troubleshooting
  189
- Troubleshooting
  189
- Towing a Disabled Vehicle
  192
- Transfer Case Component Terminology
  193
- General Information
  194
- Serial Number Plate
  194
- Transfer Case
  194
- Transfer Case Description
  194
- Transfer Case Operation
  194
- Transfer Case Specifications
  194
- Further Information
  195
- Technical Data
  195
- Transfer Case Inspection and Service
  195
- Transfer Case Maintenance
  195
- Transfer Case Removal
  196
- Internal Transfer Case Repair
  197
- Transfer Case Installation
  197
- Transfer Case Troubleshooting
  198
- Troubleshooting
  198
- Transfer Case Internal Component Troubleshooting
  200
Section 7 Engine: Cummins 4Bt 3.9, B4.5T and Qsb 4.5T

201
- Disclaimer and Scope
  203
- Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T
  203
- Introduction
  203
- Component Terminology
  204
- Safety Information
  205
- Capscrews and Metric Parts
  207
- Cleanliness
  207
- Engine Serial Number
  207
- Gaskets and O-Rings
  207
- Left and Right Sides of the Engine
  207
- Specifications and Maintenance Information
  207
- Standard Practices
  207
- Engine Cooling System
  208
- Radiator Pressure Cap
  208
- Thermostat Replacement
  208
- Drain and Flush Radiator
  212
- Radiator, Transmission Oil Cooler and Hydraulic Oil Cooler Replacement
  214
- Engine Electrical System
  223
- Fuel System
  223
- Diesel Fuel
  224
- Fuel Tank
  224
- Fuel Level Sender and Gauge
  225
- Fuel Lift Pump Testing
  226
- Bleeding Air from the Fuel System
  227
- Fuel Filter Replacement
  227
- Fuel Injectors
  228
- After Fuel System Service
  229
- Engine Exhaust System
  230
- Exhaust System Removal
  230
- Exhaust System Installation
  231
- Engine Removal
  232
- Engine Replacement
  232
- Engine Disassembly, Inspection and Service
  240
- Engine Installation
  241
- Engine Storage
  249
- Troubleshooting
  250
Section 8 Hydraulic System

251
Section 9 Electrical System

509
Section 10 Stabil-Trak™ System

757
Section 11 Transfer Carriage

801
- Transfer Carriage Component Terminology
  802
- Transfer Carriage
  803
- Transfer Carriage Description
  803
- Transfer Carriage Maintenance
  803
- Transfer Carriage Operation
  803
- Transfer Carriage Installation
  804
- Transfer Carriage Removal
  804
- Rear Wear Pad Check
  813
- Rear Wear Pad Shimming
  813
- Front Upstop Wear Pad Check
  814
- Front Upstop Wear Pad Gap Check
  814
- Rear Wear Pad Replacement
  814
- Front Upstop Wear Pad Shimming
  815
- Front Upstop Wear Pad Replacement
  816
- Rear Roller Gap Check
  816
- Rear Roller Shimming
  817
- Front Roller Gap Check
  819
- Front Roller Shimming
  820
- Front Scraper Plate Replacement
  821
- Front Roller and Bushing Replacement
  822
- Rear Roller and Bushing Replacement
  823
- Boom Pivot Bushing Replacement
  825
- Slave Cylinder Pivot Bushing Replacement
  826
- Transfer Cylinder Replacement
  827
- Transfer Carriage Troubleshooting
  830
- Troubleshooting
  830

Lull 944E-42 Service Manual (266 pages)

Brand: Lull | Category: Forklifts | Size: 19 MB

Section

5
- Table of Contents
  5
- Safety Practices
  10
  - Introduction
    10
  - Disclaimer
    10
  - Operation & Safety Manual
    10
  - Do Not Operate Tags
    10
  - Safety Information
    10
    
    Safety Alert System and Signal Words
    10
  - Safety Instructions
    11
    
    Equipment Hazards
    11
    
    General Hazards
    11
    
    Personal Hazards
    11
  - Safety Decals
    12
    
    Operational Hazards
    12
Section 2 General Information and Specifications

13
- Replacement Parts and Warranty Information
  
  14
- Torque Charts
  
  15
  - SAE Fastener Torque Chart
    17
- Specifications
  
  23
  - Travel Speeds
    23
    
    Electrical System
    23
    
    Hydraulic Cylinder Performance
    23
    
    Engine Performance Specifications
    24
    
    Tires
    24
- Fluid and Lubricant Capacities
  
  25
- Service and Maintenance Schedules
  
  27
  - 50 Hour
    27
    
    1St 100, 250 & 1St 500 Hour
    28
    
    500, 1000 & 2000 Hour
    29
- Lubrication Schedules
  
  30
Section 3 Boom

31
- Boom System Component Terminology
  
  32
- Boom System
  
  33
- Boom Assembly Maintenance
  
  33
  - Third Boom Section Removal
    33
    
    Second Boom Section Removal
    37
    
    First Boom Section Installation
    40
    
    Second Boom Section Installation
    41
    
    Third Boom Section Installation
    41
- Boom Extend and Retract Chains
  
  44
  - Boom Chain Inspection
    44
    
    Inspection Guidelines
    45
    
    Boom Chain Tension Check
    47
    
    Chain Lubrication
    47
    
    Expose Chains for Inspection
    47
    
    Boom Chain Tension Adjustment
    48
    
    Extend Chains Removal and Replacement
    50
- Boom Wear Pads
  
  52
  - Wear Pad Inspection
    52
    
    Wear Pad Installation and Lubrication
    52
- Quick Attach Assembly
  
  53
- Forks
  
  53
  - Quick Attach Removal
    53
    
    Quick Attach Installation
    53
- Troubleshooting
  
  54
- Emergency Boom Lowering
  
  57
  - Loss of Engine Power or Hydraulic Pump Failure
    57
    
    Hydraulic Line Failure
    57
    
    Hydraulic Hose Replacement - Step 1
    58
    
    Hydraulic Hose Replacement - Step 2
    59
Section 4 Cab and Covers

61
- Operator's Cab and Covers Component Terminology
  
  62
- Cab Components
  
  63
  - Cab Safety
    63
    
    Serial Number Decal
    63
    
    Steering Column and Steering Valve
    63
    
    Service Brake Valve and Pedal
    64
    
    Throttle Pedal
    65
    
    Throttle Position Sensor Replacement
    66
    
    Joystick Assemblies
    67
- Operator's Cab
  
  63
- Enclosed Cab (Optional) Components
  
  68
  - Front Windshield Wiper Switch
    68
    
    Front Windshield Wiper Motor
    68
    
    Heater/Defroster System
    68
    
    Rear Wiper Switch/Motor
    68
    
    Skylight Wiper Motor
    68
    
    Skylight Wiper Washer & Rear Window Washer Switch
    68
    
    Windshield Washer Control
    68
    
    Windshield/Skylight/Rear Wiper Washer Reservoir W/Pump
    68
- Cab Removal
  
  69
- Cab Installation
  
  71
- Valve Plate
  
  72
  - Valve Plate Removal
    72
Section 5 Axles, Drive Shafts, Wheels and Tires

73
- Axle, Drive Shaft and Wheel Component Terminology
  
  74
- Axles, Drive Shafts, Wheels and Tires
  
  74
- General Information
  
  75
- Axle Assemblies
  
  75
  - Axle Serial Number Plate
    75
    
    Axle Internal Service
    75
    
    Axle Maintenance
    75
    
    Axle Specifications
    75
    
    Axle Replacement
    76
    
    Axle Installation
    77
    
    Axle Assembly and Drive Shaft Troubleshooting
    79
- Drive Shafts
  
  82
  - Drive Shaft Inspection and Service
    82
    
    Drive Shaft Cleaning and Drying
    82
    
    Drive Shaft Installation
    82
    
    Drive Shaft Maintenance
    82
    
    Drive Shaft Removal
    82
- Wheels and Tires
  
  83
  - Removing Wheel and Tire Assembly from Machine
    83
- Brakes
  
  84
  - Installing Wheel and Tire Assembly Onto Machine
    84
    
    Brake Disc Inspection
    84
- Towing a Disabled Machine
  
  85
Section 6 Transmission

87
- Transmission Assembly Component Terminology
  88
- Transmission Replacement
  89
  - Transmission Removal
    89
    
    Transmission Installation
    91
- Transmission Serial Number
  89
- Transmission Specifications and Maintenance Information
  89
- Troubleshooting
  93
  - Transmission Troubleshooting
    93
- Transfer Case Component Terminology
  97
- Transfer Case
  98
- Transfer Case Maintenance
  98
- Transfer Case Replacement
  98
  - Transfer Case Description
    98
    
    Transfer Case Installation
    98
    
    Transfer Case Removal
    98
- Transfer Case Serial Number
  98
- Troubleshooting
  100
  - Transfer Case Troubleshooting
    100
Section 7 Engine

103
- Introduction - Cummins QSB 4.5
  
  104
- Introduction - Cummins QSB
  
  104
  - Disclaimer and Scope
    104
  - Component Terminology
    105
- Specifications and Maintenance Information
  
  106
- Engine Serial Number
  
  106
- Engine Cooling System
  
  106
  - Radiator Pressure Cap
    106
    
    Radiator/Oil Cooler and Replacement
    106
- Engine Electrical System
  
  107
- Fuel System
  
  107
  - Diesel Fuel
    107
    
    Fuel Tank
    107
- Engine Exhaust System
  
  109
  - After Fuel System Service
    109
    
    Exhaust System Installation
    109
    
    Exhaust System Removal
    109
- Air Cleaner Assembly
  
  110
  - Air Cleaner Assembly Removal
    110
    
    Air Cleaner Assembly Installation
    110
- Engine Replacement
  
  111
  - Engine Removal
    111
    
    Engine Installation
    113
- Troubleshooting
  
  115
Section 8 Hydraulic System

117
- Hydraulic Component Terminology
  
  118
- Safety Information
  
  119
- Hydraulic Pressure Diagnosis
  
  120
- Hydraulic Circuits
  
  121
  - Hydraulic Pressures
    121
    
    Hydraulic Schematic, 944E
    128
- Hydraulic Reservoir
  
  129
  - Hydraulic Oil Reservoir Draining
    129
    
    Hydraulic Oil Reservoir Filling
    129
    
    Hydraulic Oil Reservoir Replacement
    129
- Hydraulic System Pump
  
  132
  - Pump Description
    132
    
    Pump Failure Analysis
    132
    
    Pump Replacement
    132
- Valves and Manifolds
  
  133
  - Valve Plate Assembly
    133
    
    Joystick Valve (Dual Joystick)
    138
    
    Pilot Select Valve (Dual Joystick)
    139
    
    Joystick Valve (Single Joystick)
    140
    
    Single Joystick Pilot Select Valve
    141
    
    Frame Sway Joystick Valve
    142
    
    Service Brake Valve
    144
    
    Brake Test
    145
    
    Power Steering Valve
    145
    
    Steer Select Valve
    146
    
    Accumulator Charge Troubleshooting
    153
    
    Accumulator Charge/Secondary Function Valve
    153
    
    Accumulators
    153
    
    Checking Pre-Charge
    153
- Hydraulic Cylinders
  
  154
  - Cylinder Pressure Checking
    156
    
    Steering Cylinders
    156
    
    Cylinder Torque Specifications
    157
Section 9 Electrical System

159
- Electrical System
  
  161
- Electrical Component Terminology
  
  161
  - General Overview
    161
- Fuses and Relays
  
  162
  - Engine Compartment
    162
    
    Cab
    162
    
    Starter
    162
  - Electrical Schematics
    164
  - Circuit Breakdowns
    170
  - Engine Start Circuit
    172
  - Charging Circuit
    173
  - Window Wiper/Washer Windshield Wiper Motor
    174
  - Cab Heater and Fan
    178
- Specifications
  
  162
- Safety Information
  
  162
- Switches and Solenoids
  
  179
  - Ignition Key Switch
    179
    
    Hydraulic Oil Filter Pressure Switch
    179
    
    Dual Hydraulic Oil Temperature Switch
    180
    
    Auxiliary Hydraulic Pressure Release Switch
    181
    
    Parking Brake Switch
    181
    
    Transmission Disconnect Switch
    182
    
    Transmission Shift Control Switch
    183
    
    Transmission Solenoid Valves
    183
    
    Dual Joystick
    185
    
    Optional Single Joystick
    186
    
    Boom Angle Sensor
    188
    
    Coolant Temperature Switch
    189
    
    Fuel Level Gauge and Fuel Level Sender
    190
    
    Transmission Temperature Switch
    190
    
    Hourmeter
    191
    
    Stabilizer Brake Switch
    192
- Dash Switches
  
  194
- Troubleshooting
  
  195
  - Engine Fault Codes Retrieval
    195
    
    Engine Fault Codes Chart
    195
    
    Probing Electrical Connectors
    208
    
    Troubleshooting with a Digital Multimeter (DMM)
    208
Section 10 Stabil-Trak™ System

213
Section 11 Transfer Carriage

241
- Transfer Carriage
  
  242
- Transfer Carriage Component Terminology
  
  242
- Transfer Carriage Maintenance
  
  243
  - Transfer Carriage Description
    243
    
    Transfer Carriage Operation
    243
  - Transfer Carriage Installation
    247
  - Rear Wear Pad Check
    249
  - Rear Wear Pad Shimming
    250
  - Rear Wear Pad Replacement
    250
  - Front Upstop Wear Pad Check
    251
  - Front Upstop Wear Pad Gap Check
    251
  - Front Upstop Wear Pad Shimming
    251
  - Front Upstop Wear Pad Replacement
    252
  - Rear Roller Gap Check
    252
  - Rear Roller Shimming
    253
  - Front Roller Gap Check
    254
  - Front Roller Shimming
    255
  - Front Scraper Plate Replacement
    255
  - Front Roller and Bushing Replacement
    256
  - Rear Roller and Bushing Replacement
    257
  - Boom Pivot Bushing Replacement
    257
  - Slave Cylinder Pivot Bushing Replacement
    258
  - Transfer Cylinder Replacement
    259
- Troubleshooting
  
  262
  - Transfer Carriage Troubleshooting
    263

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Lull 944E-42 Manuals

Lull 944E-42 Service Manual (844 pages)

Table of Contents

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

Section 9 Electrical System

Section 10 Stabil-Trak™ System

Section 11 Transfer Carriage

Lull 944E-42 Service Manual (266 pages)

Table of Contents

Section

Section 2 General Information and Specifications

Replacement Parts and Warranty Information

Torque Charts

Specifications

Fluid and Lubricant Capacities

Service and Maintenance Schedules

Lubrication Schedules

Section 3 Boom

Boom System Component Terminology

Boom System

Boom Assembly Maintenance

Boom Extend and Retract Chains

Boom Wear Pads

Quick Attach Assembly

Forks

Troubleshooting

Emergency Boom Lowering

Section 4 Cab and Covers

Operator's Cab and Covers Component Terminology

Cab Components

Operator's Cab

Enclosed Cab (Optional) Components

Cab Removal

Cab Installation

Valve Plate

Section 5 Axles, Drive Shafts, Wheels and Tires

Axle, Drive Shaft and Wheel Component Terminology

Axles, Drive Shafts, Wheels and Tires

General Information

Axle Assemblies

Drive Shafts

Wheels and Tires

Brakes

Towing a Disabled Machine

Section 6 Transmission

Section 7 Engine

Introduction - Cummins QSB 4.5

Introduction - Cummins QSB

Specifications and Maintenance Information

Engine Serial Number

Engine Cooling System

Engine Electrical System

Fuel System

Engine Exhaust System

Air Cleaner Assembly

Engine Replacement

Troubleshooting

Section 8 Hydraulic System

Hydraulic Component Terminology

Safety Information

Hydraulic Pressure Diagnosis

Hydraulic Circuits

Hydraulic Reservoir

Hydraulic System Pump

Valves and Manifolds

Hydraulic Cylinders

Section 9 Electrical System

Electrical System

Electrical Component Terminology

Fuses and Relays

Specifications

Safety Information

Switches and Solenoids