Lull 944E-42 Service Manual Bedienungsanleitung

An Oshkosh Corporation CompanyService ManualModel944E-42S/N 0160041827 & After31200355OriginalDecember 31, 2011

Safety Practices1-2 944E-421.1 INTRODUCTIONThis service manual provides general directions for accomplishing service and repair procedures. Following

Transmission6-14 944E-426.11 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that may occur during oper

6-15944E-42Transmission2. Oil leaking from transfer case. 1. Breather blocked. 1. Clean or replace breather.2. Plugs or fittings loose. 2. Tighten plu

Transmission6-16 944E-42This Page Intentionally Left Blank

7-1944E-42Section 7EngineContentsPARAGRAPH TITLE PAGE7.1 Introduction - Cummins QSB 4.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine7-2 944E-427.1 INTRODUCTION - CUMMINS QSB 4.57.1.1 Disclaimer and ScopeThese instructions are written for worldwide use. In territories where le

7-3944E-42Engine7.1.2 Component TerminologyTo understand the safety, operation and maintenance information presented in this section, it is necessary

Engine7-4 944E-427.2 ENGINE SERIAL NUMBERThe Cummins QSB 4.5 serial number is stamped on a plate which is typically located on the engine rocker cover

7-5944E-42Engine12. Label and disconnect the air intercooler hoses (7). Inspect the hoses and replace if necessary.13. Label and disconnect the radiat

Engine7-6 944E-42position, engage the parking brake, and shut the engine OFF.2. Place a Do Not Operate Tag on both the ignition key switch and steerin

7-7944E-42Enginef. Fuel Tank Installation1. Set the fuel tank on to the tank support.2. Secure the fuel tank retaining panel with the two previously r

1-3944E-42Safety Practices1.6 SAFETY INSTRUCTIONSFollowing are general safety statements to consider before performing maintenance procedures on the t

Engine7-8 944E-422. Install the flex pipe (3) and secure with clamp (8).3. Install the exhaust pipe (2) and secure with clamps (7 & 8).4. Align th

7-9944E-42Engine7.9 ENGINE REPLACEMENT 7.9.1 Engine RemovalNote: The radiator and oil cooler must be removed from the machine before engine removal.

Engine7-10 944E-4222. Remove the engine frame skirt (4) to gain access to the hydraulic reservoir.23. Remove the hydraulic reservoir support bracket (

7-11944E-42Engine31. Connect a suitable engine hoist to the front engine lift bracket (11) and the transmission lifting bracket (10).32. Remove the tw

Engine7-12 944E-42Note: Torque all fittings as specified in Section 2.2, “Torque Charts.”23. Properly connect the batteries.24. Refill hydraulic rese

7-13944E-42Engine7.10 TROUBLESHOOTING Trouble Possible Causes (see key, below)Low Cranking PowerWill Not StartDifficult StartingLack of PowerMisfiring

Engine7-14 944E-42This Page Intentionally Left Blank

8-1944E-42Section 8Hydraulic SystemContentsPARAGRAPH TITLE PAGE8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System8-2 944E-428.1 HYDRAULIC COMPONENT TERMINOLOGYTo understand the safety, operation and service information presented in this section, i

8-3944E-42Hydraulic System8.2 SAFETY INFORMATIONPetroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid increase

Safety Practices1-4 944E-421.6.4 Operational HazardsENGINE: Stop the engine before performing any service unless specifically instructed otherwise.VEN

Hydraulic System8-4 944E-428.3 HYDRAULIC PRESSURE DIAGNOSISTwo kits are available to use for hydraulic system maintenance and troubleshooting. The kit

8-5944E-42Hydraulic System7. Check the pressure gauge reading. It should read as specified in the Pressure Readings column of the charts found in Sect

Hydraulic System8-6 944E-42c. Hydraulic Testing - Dual JoysticksMU6830A4657G389CFRONT STEERINGCYLINDERATTACHMENT TILTCYLINDERREAR STEERINGCYLINDERFRON

8-7944E-42Hydraulic SystemEngine InformationIdle . . . . . . . . . . . . . . . . . . . . . . . . . . 950 rpmFull Speed . . . . . . . . . . . . . . .

Hydraulic System8-8 944E-42TEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE TEST PROCEDURES82—DAuxil

8-9944E-42Hydraulic Systema. Hydraulic Testing - Single JoystickMU6840A4657G389CFRONT STEERINGCYLINDERATTACHMENT TILTCYLINDERREAR STEERINGCYLINDERFRON

Hydraulic System8-10 944E-42Engine InformationIdle . . . . . . . . . . . . . . . . . . . . . . . . . . 950 rpmFull Speed . . . . . . . . . . . . . .

8-11944E-42Hydraulic SystemTEST SEQUENCETEST LOCATIONValve PortADJUST. LOCATIONCOMPONENT DESCRIPTIONPRESSURE READINGSPRESSURE TEST PROCEDURES82—DAuxil

Hydraulic System8-12 944E-428.4.2 Hydraulic Schematic, 944EPP1LTDUAL JOYSTICK CONFIGURATIONFOR SINGLE JOYSTICKOPTION ONLYFRAME TILTSTABILTRAKHOISTEXTE

8-13944E-42Hydraulic System8.5 HYDRAULIC RESERVOIRThe hydraulic reservoir (1) is located on the right side of the machine. The reservoir is held in pl

2-1944E-42Section 2General Information and SpecificationsContentsPARAGRAPH TITLE PAGE2.1 Replacement Parts and Warranty Information . . . . . . . . .

Hydraulic System8-14 944E-425. Clean and reinstall the drain plug (1) into the reservoir. Torque the drain plug to 25-40 lb-ft (34-54 Nm).6. Loosen th

8-15944E-42Hydraulic Systemc. Cleaning and DryingIf contaminated oil or foreign material is in the reservoir, the reservoir can usually be cleaned.Not

Hydraulic System8-16 944E-428.6 HYDRAULIC SYSTEM PUMP8.6.1 Pump DescriptionHydraulic system pressure begins at the pump. Various factors are involved

8-17944E-42Hydraulic System2. Place the pump (2) and a new, oiled o-ring (3) into position on the transmission. Align the pump shaft with the internal

Hydraulic System8-18 944E-425. Thoroughly clean the main control valve and surrounding area, including all hoses and fittings, before proceeding.6. La

8-19944E-42Hydraulic System3. Remove the three capscrews (10) securing the main control valve to the valve plate.4. Remove the main control valve from

Hydraulic System8-20 944E-42Disassemble each Valve Section1. Carefully separate the inlet section (12) from the transfer carriage section (13). 2. Rem

8-21944E-42Hydraulic System2. Install the relief valve (15) preset to 2400 psi (165 bar) into the “B” side of the transfer carriage section. Torque th

Hydraulic System8-22 944E-429. Start the engine and run at approximately one-third to one-half throttle for about one minute without moving the machin

8-23944E-42Hydraulic System8.7.4 Pilot Select Valve (Dual Joystick)Pilot pressure from the front joystick flows to the pilot select valve (15). The pi

General Information and Specifications2-2 944E-422.1 REPLACEMENT PARTS AND WARRANTY INFORMATIONBefore ordering parts or initiating service inquiries,

Hydraulic System8-24 944E-424. Start the machine and run at approximately one-third to one-half throttle for about one minute without moving the machi

8-25944E-42Hydraulic System8.7.6 Single Joystick Pilot Select ValvePilot pressure from the joystick flows to the single joystick pilot select valve (1

Hydraulic System8-26 944E-42c. Single Joystick Pilot Select Valve Installation1. Position the pilot select valve back onto the valve plate. Install an

8-27944E-42Hydraulic Systema. Auxiliary Hydraulic Pressure Release Valve Removal1. Park the machine on a firm, level surface, level the machine, fully

Hydraulic System8-28 944E-426. Inspect the release valve for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF.7.

8-29944E-42Hydraulic SystemNote: Check for leaks, and repair as required before continuing. Add hydraulic fluid to the reservoir as needed.8. Wipe up

Hydraulic System8-30 944E-428.7.12 Steer Select ValveThe machine can be used in the front-wheel, four-wheel or crab steering mode. The steer select va

8-31944E-42Hydraulic System5. Install the left front dash panel (7) and secure with the five washers and capscrews.6. Install the selector knob and se

Hydraulic System8-32 944E-428.7.13 Accumulator Charge/Secondary Function ValveHydraulic oil from the front pump flows into the accumulator charge/seco

8-33944E-42Hydraulic System6. Install the load shuttle cartridge (2), with new seals and torque to 20 lb-ft (27 Nm).7. Install the accumulator charge

2-3944E-42General Information and Specifications2.2 TORQUE CHARTS2.2.1 SAE Fastener Torque ChartREFERENCE JLG ANEROBIC THREAD LOCKING COMPOUNDDescript

Hydraulic System8-34 944E-428.7.15 General InformationEach accumulator (1) is a 3,000 psi (207 bar) diaphragm type accumulator. Each accumulator has a

8-35944E-42Hydraulic SystemNEVER charge an accumulator to a pressure more than specified. The proper pressure for these accumulators is 450 ± 35 psi (

Hydraulic System8-36 944E-428.7.16 Checking Pre-Chargea. Gas Leaks1. If an external leak is suspected, apply soapy water to the gas valve (10) and the

8-37944E-42Hydraulic System8.7.17 Accumulator Charge TroubleshootingProblem Cause Remedy1. Accumulator charging cycle repeats frequently when accumula

Hydraulic System8-38 944E-428.8 HYDRAULIC CYLINDERS1. Remove any attachment from the machine. Park the machine on a firm level surface and fully retra

8-39944E-42Hydraulic SystemSome cylinder parts are sealed with a special organic sealant and locking compound. Before attempting to disassemble these

Hydraulic System8-40 944E-42e. Cylinder Installation1. Grease the bushings at the ends of the hydraulic cylinder. Using an appropriate sling, lift the

8-41944E-42Hydraulic System8.8.3 Cylinder Torque Specificationsa. Lift/Lower Cylinderb. Extend/Retract Cylinderc. Tilt Cylinderd. Sway Cylindere. Tran

Hydraulic System8-42 944E-42h. Swing Carriage Cylinder (optional)i. Side Tilt Carriage Cylinder (optional)Piston Set Screw Head Valves440-500 lb-ft (5

9-1944E-42Section 9Electrical SystemContentsPARAGRAPH TITLE PAGE9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . .

General Information and Specifications2-4 944E-422.2.1 SAE Fastener Torque Chart (Continued)Size TPI Bolt DiaTensileStress AreaClamp LoadIn Sq In4 40

Electrical System9-2 944E-429.11 Switches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21

9-3944E-42Electrical System9.1 ELECTRICAL COMPONENT TERMINOLOGYTo understand the safety, operation, and service information presented in this section,

Electrical System9-4 944E-429.2 SPECIFICATIONSElectrical system specifications are listed in Section 2, “General Information and Specifications.”9.3 S

9-5944E-42Electrical System9.4.3 Cab Harness Fuses and RelaysE6E1E7 E2E3E44015157.520101010F15F16F17F18F1F2F3F4F5F6F7F19F20F21F22F23F24F25F26F27F8F9F1

Electrical System9-6 944E-429.5 ELECTRICAL SCHEMATICS9.5.1 Electrical Symbols Directory The following directory shows the most common electrical symbo

9-7944E-42Electrical System9.5.2 944E-42 Electrical SchematicsBAT1NBAT1PPB4PB2PB5NS2PB1NS1ST4IG2AAG2ST1ST2BU2H1H1AH2 H2AS1S2CG3PB6PB6ATR1ATR2BTR5ATR4A

Electrical System9-8 944E-42D1D2D3D4 D4AD9AD10AD11D12AD6AD13D7D6D9D5D12PHLP2LP3LP4AW1D8D1AD1012V_BUSSBAR12V_BUSSBARGND_BUSSBARGND_BUSSBARSG3SG4AD1EG6S

9-9944E-42Electrical System12V_BUSSBAR12V_BUSSBARGND_BUSSBARBC1ALP5LP6CAB_GND_STUDBL1WL1HZ1WLHBRL1HZ3HZ4RT1WL3LB1HB1BL2WL1CWL2AWL2WL3BWL3AWL3CHZ2RT1AB

Electrical System9-10 944E-42GND_BUSSBARCAB_GND_STUDWL4 WL4AWL4BWL4CWL5WL6WL5ALP5AWL5B WL5CWL5EWL5DWL6AWL6BWL6CWORKLIGHTS ONLYEG8WLG5WLG10WLG9WLG7WLG6

9-11944E-42Electrical SystemAH1BAH1C LE LEBLEATA TA ATABSCOFTARTARTBFTBPWMGSJG4SJG5SJG6SJG7SJG3SJG1SJG2AH1ASINGLE JOYSTICK OPTIONCONNECT TO JOY_3F CON

2-5944E-42General Information and Specifications2.2.1 SAE Fastener Torque Chart (Continued)Size TPI Bolt DiaTensileStress AreaClamp LoadSee Note 4In S

Electrical System9-12 944E-429.6 CIRCUIT BREAKDOWNS9.6.1 Constant Power Circuit from BatteryBAT1PPB1ST112V_BUSSBARBA1ABA1CHASSIS CIRCUITAB_FABBA2BA3BA

9-13944E-42Electrical System9.6.2 Start & Charge CircuitMU7540BAT1PPB4PB2NS2PB1NS1ST4IG2AST1 ST2BU2H1 H1A H2 H2AS1 S2PB6PB6ATR6ATR7AS1BBP1AS1DBP1A

Electrical System9-14 944E-429.7 ENGINE START CIRCUIT9.7.1 StarterThe starter (1) is located on the left side of the engine.a. Testing the Starter on

9-15944E-42Electrical System9.8 CHARGING CIRCUITBefore using a battery charger, an attempt can be made to recharge the battery by jump-starting the ma

Electrical System9-16 944E-429.9 WINDOW WIPER/WASHER WINDSHIELD WIPER MOTOR9.9.1 Windshield Wiper Motora. RemovalNote: It may be necessary to remove

9-17944E-42Electrical System8. Install wiper arm assembly to the wiper motor shaft. The blade should be parallel with the left side of the windshield.

Electrical System9-18 944E-423. With the help of an assistant, insert the wiper motor through the roof hole and have the assistant thread the nut onto

9-19944E-42Electrical System3. Reconnect the cab harness to the wiper motor assembly and with the help of an assistant, insert the wiper motor through

Electrical System9-20 944E-429.10 CAB HEATER AND FAN 9.10.1 Cab Heater ControlsNote: If the suspect component is found to be within the heater box, t

9-21944E-42Electrical System9.11 SWITCHES AND SOLENOIDS9.11.1 Ignition Key SwitchThe ignition switch is located on the lower right side of the dash.a.

General Information and Specifications2-6 944E-422.2.1 SAE Fastener Torque Chart (Continued)Size TPI Bolt DiaTensileStress AreaClamp LoadSee Note 4In

Electrical System9-22 944E-423. Open the engine cover. Allow the system fluids to cool.4. Properly disconnect the batteries.5. Label and disconnect th

9-23944E-42Electrical System9.11.4 Auxiliary Hydraulic Pressure Release SwitchThe auxiliary hydraulic pressure release switch (1) is located in the up

Electrical System9-24 944E-42c. Inspection and ReplacementInspect switch wiring for continuity and shorting in both the ENGAGED and DISENGAGED positio

9-25944E-42Electrical System9.11.7 Transmission Shift Control SwitchThe transmission control switch and travel select lever (4) is located on the left

Electrical System9-26 944E-42Note: If the transmission is not shifting properly, the transmission shift control switch (travel select lever), wiring

9-27944E-42Electrical System4. Label and disconnect the wire harness connector plug (1) on the solenoid valve (2) to be replaced.5. Remove the solenoi

Electrical System9-28 944E-421. Remove the joystick valve assembly (6) from the side console. Refer to Section 4.3.6, “Joystick Assemblies.”2. Secure

9-29944E-42Electrical System4. Disconnect the single joystick harness connector (3) from the joystick connector (4).Check the single joystick harness

Electrical System9-30 944E-42c. Single Joystick Function Solenoid ValvesThe single joystick commands are actuated, both electrically and hydraulically

9-31944E-42Electrical System5. Unplug the engine boom angle sensor connector (1) from the wiring harness connector.6. Loosen and remove the sensor loc

2-7944E-42General Information and Specifications2.2.2 Metric Fastener Torque ChartSize PITCHTensileStressAreaClampLoadTorque(Dry or Loctite®263TM)Torq

Electrical System9-32 944E-42c. Coolant Temperature Switch Installation1. Thread the switch into the engine. Tighten securely.2. Connect the previousl

9-33944E-42Electrical Systemb. Fuel Level Circuit TestsIf the fuel level gauge is suspected of giving a false reading, perform the following checks:1.

Electrical System9-34 944E-429.11.16 Stabilizer Brake SwitchThe stabilizer brake switch (2) works in conjunction with the Stabil-Trak system. With the

9-35944E-42Electrical System5. Install the dust cover (11).6. Connect the cab harness electrical connectors to the service brake switch connectors.7.

Electrical System9-36 944E-42Threaded Mounting HolePosition the brake switch so the Stabil-TRAK “Locked” Mode indicator comes ON at the 150 ±50 psi (1

9-37944E-42Electrical System9.13 TROUBLESHOOTING9.13.1 Engine Fault Codes Retrieval1. Park the machine on a firm, level surface, level the machine, fu

Electrical System9-38 944E-42134 974 4 Red Remote Accelerator Remote Accelerator Pedal or Lever Position Sensor Circuit - Voltage Below Normal, or Sho

9-39944E-42Electrical System194 520199 4 Amber Cruise Control Cruise Control (Resistive) Signal Circuit - Voltage Below Normal, or Shorted to Low Sour

Electrical System9-40 944E-42237 644 2 Amber External Speed Input External Speed Input (Multiple Unit Synchronization) - Data Erratic, Intermittent, o

9-41944E-42Electrical System281 1347 7 Amber Fuel Pump Pressurizing Assembly #1High Fuel Pressure Solenoid Valve #1 - Mechanical System Not Responding

General Information and Specifications2-8 944E-422.2.2 Metric Fastener Torque Chart (Continued)Size PITCHTensileStressAreaClampLoadK = 0.20K= 0.18K=0.

Electrical System9-42 944E-42324 653 5 Amber Injector Cylinder #03 Injector Solenoid Cylinder #3 Circuit - Current Below Normal, or Open Circuit325 65

9-43944E-42Electrical System425 175 2 Amber Oil Temperature Engine Oil Temperature - Data Erratic, Intermittent, or Incorrect428 97 3 Amber Water in F

Electrical System9-44 944E-42527 702 3 Amber Circuit - Voltage Auxiliary Input/Output 2 Circuit - Voltage Above Normal, or Shorted to High Source528 9

9-45944E-42Electrical System599 640 14 Red Engine External Protection InputAuxiliary Commanded Dual Output Shutdown -Special Instructions649 1378 31 M

Electrical System9-46 944E-421117 627 2 None Power Supply Power Lost With Ignition On - Data Erratic, Intermittent, or Incorrect1139 651 7 Amber Injec

9-47944E-42Electrical System2113 52 16 Amber Coolant Temperature Coolant Temperature 2 - Data Valid but Above Normal Operational Range - Moderately Se

Electrical System9-48 944E-422263 1800 16 Amber Battery Temperature Battery Temperature - Data Valid but Above Normal Operational Range - Moderately S

9-49944E-42Electrical System2368 1112 3 Amber Engine Brake Output #3Engine Brake Actuator Driver 3 Circuit - Voltage Above Normal, or Shorted to High

Electrical System9-50 944E-429.13.3 Troubleshooting with a Digital Multimeter (DMM)Note: Circuits which include any solid-state control modules shoul

9-51944E-42Electrical SystemMeasuring Voltage DropThe following test determines the difference in voltage potential between two points.1. Set the rota

2-9944E-42General Information and Specifications2.2.2 Metric Fastener Torque Chart (Continued)Size PITCHTensileStressAreaClamp LoadSee Note 4K = .17K

Electrical System9-52 944E-42Testing for Short to GroundThe following procedures test for a short to ground in a circuit.With a DMM1. Remove the power

9-53944E-42Electrical System8. Apply the proper voltage to the relay coil at terminal 86 (8) and attach the ground (-) probe to terminal 85 (9), groun

Electrical System9-54 944E-429. To test the operation of the relays, connect a 12-volt DC positive lead to the positive terminal (1 or 6). Connect the

10-1944E-42Section 10Stabil-TRAK™ System ContentsPARAGRAPH TITLE PAGE10.1 Stabil-TRAK™ System Component Terminology. . . . . . . . . . . . . . . . .

Stabil-TRAK™ System10-2 944E-4210.1 STABIL-TRAK™ SYSTEM COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented

10-3944E-42Stabil-TRAK™ System10.2 STABIL-TRAK™ DESCRIPTIONThe patented rear axle lock or Stabil-TRAK™ system works to stabilize the machine under var

Stabil-TRAK™ System10-4 944E-4210.3 STABIL-TRAK™ ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING Note: Before using the 944E Stabil-TRAK System Tro

10-5944E-42Stabil-TRAK™ SystemS1BS3238172TRANSMISSIONDISCONNECTSWITCHS1BS2AS3TCGS2A8 37 2376LEGEND=De-energized= Energized= Open= Closed= Active Circu

Stabil-TRAK™ System10-6 944E-422STARTERGND (-)++-BATTERY 1ENGINEBLOCKDEPARK BRAKE SWITCHEDE12345678D12DETRANS.CONTROLRELAY(E1)868587A 8730S3238172TRAN

10-7944E-42Stabil-TRAK™ SystemSTARTERGND (-)++-BATTERY 1ENGINEBLOCKBLUBRNBLK+-OSTABIL.LOCKRELAY(E6)868587A 8730DETRANS.CONTROLRELAY(E1)868587A 8730238

General Information and Specifications2-10 944E-422.2.3 Hydraulic Hose Torque ChartNote: By definition the “Flats Method“ will contain some variance.

Stabil-TRAK™ System10-8 944E-42OPENRELAYPOSITION(E5)868587A 8730STARTERGND (-)++-BATTERY 1ENGINEBLOCKBLUBRNBLK+-OSTABIL.LOCKRELAY(E6)868587A 8730DEDET

10-9944E-42Stabil-TRAK™ SystemOPENRELAYPOSITION(E5)868587A 8730STARTERGND (-)++-BATTERY 1ENGINEBLOCKBLUBRNBLK+-OSTABIL.LOCKRELAY(E6)868587A 8730DEDETR

Stabil-TRAK™ System10-10 944E-4210.4 STABIL-TRAK™ SYSTEM TESTNote: The operator must know that the Stabil-TRAK™ system is active and functioning prop

10-11944E-42Stabil-TRAK™ SystemStabil-TRAK™ System Test ProceduresStep 1a. Place the vehicle on a level surface with 0° sway.b. Have the boom fully re

Stabil-TRAK™ System10-12 944E-42Step 7a. With the parking brake switch ON, move the travel select lever to the (N) NEUTRAL DETENT position.b. Lower th

10-13944E-42Stabil-TRAK™ System10.5 STABIL-TRAK™ HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOOTINGThe function of the Stabil-TRAK™ system varies under

Stabil-TRAK™ System10-14 944E-4210.5.2 Stabil-TRAK™ Hydraulic Circuit The Stabil-TRAK™ hydraulic circuit can be tested using these basic guidelines. F

10-15944E-42Stabil-TRAK™ System10.5.4 Hydraulic Circuit Operation - Free Pivot Mode, Rod Oil OutConditions:• Boom angle is below 40°• Rear axle pivots

Stabil-TRAK™ System10-16 944E-4210.5.5 Hydraulic Troubleshooting - Free Pivot Mode, Rod Oil OutMU4261Front324568917Legend1. Stabilizer Cylinder2. Sole

10-17944E-42Stabil-TRAK™ System10.5.6 Hydraulic Circuit Operation - Free Pivot Mode, Base Oil OutConditions:• Boom angle is below 40°• Rear axle pivot

2-11944E-42General Information and Specifications2.3 SPECIFICATIONS2.3.1 Travel Speeds2.3.2 Hydraulic Cylinder PerformanceNote: Machine with no attac

Stabil-TRAK™ System10-18 944E-4210.5.7 Hydraulic Troubleshooting - Free Pivot Mode, Base Oil OutMU4261Front234568917Legend1. Stabilizer Cylinder2. Sol

10-19944E-42Stabil-TRAK™ System10.5.8 Hydraulic Circuit Operation - Slow Pivot Mode, Rod Oil OutConditions:• Boom angle is above 40° OR(On SN 01600038

Stabil-TRAK™ System10-20 944E-4210.5.9 Hydraulic Troubleshooting - Slow Pivot Mode, Rod Oil OutMU426178652101119Legend1. Stabilizer Cylinder2. Solenoi

10-21944E-42Stabil-TRAK™ System10.5.10 Hydraulic Circuit Operation - Slow Pivot Mode, Base Oil OutConditions:• Boom angle is above 40° OR(On SN 016000

Stabil-TRAK™ System10-22 944E-4210.5.11 Hydraulic Troubleshooting - Slow Pivot Mode, Base Oil OutMU426178652101119Legend1. Stabilizer Cylinder2. Solen

10-23944E-42Stabil-TRAK™ System10.5.12 Hydraulic Circuit Operation - Locked Modea. Conditions:• Boom angle is above 40°• Park brake ON, or service bra

Stabil-TRAK™ System10-24 944E-42MU4261Legend1. Solenoid 4A2. Solenoid 4B3. Solenoid 12A4. Solenoid 12B5. Solenoid 36. .030" Orifice Plug7. Check

10-25944E-42Stabil-TRAK™ System10.5.14 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway RightConditions:• Ignition ON, engine running• Boo

Stabil-TRAK™ System10-26 944E-4210.5.15 Hydraulic Circuit Operation - Locked Mode, Frame Sway Lefta. Conditions• Boom angle is above 40°• Park brake O

10-27944E-42Stabil-TRAK™ System10.5.16 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway LeftMU4261FrontLegend6. Solenoid 37. Check Valve 2

General Information and Specifications2-12 944E-422.3.4 Engine Performance SpecificationsNote: Engine manufacturer's maximum “high idle” setting

Stabil-TRAK™ System10-28 944E-42This Page Intentionally Left Blank

11-1944E-42Section 11Transfer CarriageContentsPARAGRAPH TITLE PAGE11.1 Transfer Carriage Component Terminology . . . . . . . . . . . . . . . . . . . .

Transfer Carriage11-2 944E-4211.1 TRANSFER CARRIAGE COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented in

11-3944E-42Transfer Carriage11.2 TRANSFER CARRIAGE11.2.1 Transfer Carriage DescriptionThe transfer carriage, along with the transfer cylinder, make up

Transfer Carriage11-4 944E-4211.3.1 Transfer Carriage Removal1. Level the vehicle, place the travel select lever in the (N) NEUTRAL DETENT position, e

11-5944E-42Transfer Carriage18. Remove the pin (8) from lift cylinder (6). Lower and place the cylinder on support blocks on a firm level surface.19.

Transfer Carriage11-6 944E-4226. Remove pin bolt and locknut from rear roller pin (1). Slide the roller pin out and remove the rear rollers (2) and sh

11-7944E-42Transfer Carriage11.3.2 Transfer Carriage Installation1. Insert front roller pin (6), front roller (7) and shims (8) in their previously la

Transfer Carriage11-8 944E-4214. Coat the capscrew with Loctite® 242 (blue). Replace the hydraulic tubes (15) and mounting bracket with capscrew. Torq

11-9944E-42Transfer Carriage18. Coat the bolts with Loctite® 242 (blue). Replace the bolts and stop blocks (7) at the rear, left and right side of the

2-13944E-42General Information and Specifications2.4 FLUID AND LUBRICANT CAPACITIESEngine Crankcase OilCapacity with Filter Change 13.5 quarts (12.8 l

Transfer Carriage11-10 944E-4211.3.4 Rear Wear Pad ShimmingNote: The attachment should remain attached to the quick attach for this procedure.1. Park

11-11944E-42Transfer Carriage11.3.6 Front Upstop Wear Pad CheckThe front upstop wear pads (5) are located under the frame rails at the front of the tr

Transfer Carriage11-12 944E-4211.3.9 Front Upstop Wear Pad ReplacementNote: The attachment should remain attached to the quick attach for this proced

11-13944E-42Transfer Carriage11.3.11 Rear Roller ShimmingNote: The attachment should remain attached to the quick attach.1. Park the machine on a fir

Transfer Carriage11-14 944E-4213. Coat the bolts with Loctite® 242 (blue). Replace the bolts and stop blocks (10) at the rear, left and right side of

11-15944E-42Transfer Carriage11.3.13 Front Roller ShimmingNote: The attachment should remain attached to the quick attach.1. Park the machine on a fi

Transfer Carriage11-16 944E-4211.3.15 Front Roller and Bushing ReplacementNote: The attachment should remain attached to the quick attach.1. Park the

11-17944E-42Transfer Carriage11.3.16 Rear Roller and Bushing ReplacementNote: The attachment should remain attached to the quick attach.1. Park the m

Transfer Carriage11-18 944E-42Note: DO NOT apply any grease or anti-seize compound to bushing or roller pin.3. Inspect the boom pivot bushings (5). I

11-19944E-42Transfer CarriageNote: If new slave cylinder bearings (4) have been installed in the transfer carriage or slave cylinder, the fracture in

General Information and Specifications2-14 944E-42Air Conditioning System (if equipped)System Capacity 2.5 lb (1134 g)Type of Fluid Refrigerant R-134a

Transfer Carriage11-20 944E-427. If you are replacing the pin, remove the bottom snap ring (7).8. Shut the engine OFF.9. Place a Do Not Operate Tag on

11-21944E-42Transfer Carriagec. Transfer Carriage Bearing Replacement1. Park the machine on a firm, level surface, level the machine, fully retract th

Transfer Carriage11-22 944E-4211.4 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur during op

11-23944E-42Transfer Carriage3. Transfer carriage shifts to right or left when extending.1. Transfer carriage rollers improperly shimmed.1. Re-shim th

Transfer Carriage11-24 944E-42This Page Intentionally Left Blank

JLG Worldwide LocationsAn Oshkosh Corporation Companywww.jlg.com31200355JLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: +1-717-4

2-15944E-42General Information and Specifications2.5 SERVICE AND MAINTENANCE SCHEDULES2.5.1 10 & 50 HourMU7640Check BoomWear PadsCheckBatteryLubri

General Information and Specifications2-16 944E-422.5.2 1st 100, 250 & 1st 500 Hour MU73005001stChangeAxle OilChange WheelEnd Oil1001stChangeHydra

2-17944E-42General Information and Specifications2.5.3 500, 1000 & 2000 HourMU76502000EVERYChangeEngine Coolant500EVERYChange FuelFiltersChange En

EFFECTIVITY PAGE31200355 944E-42 iDecember 31, 2011 - A - Original Issue

General Information and Specifications2-18 944E-422.6 LUBRICATION SCHEDULESa. 50 HourOU243050EVERY22

3-1944E-42Section 3BoomContentsPARAGRAPH TITLE PAGE3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3-2 944E-423.1 BOOM SYSTEM COMPONENT TERMINOLOGYThe following illustrations identify the components that are referred to throughout this section.M

3-3944E-42Boom3.2 BOOM SYSTEM3.2.1 Boom System OperationThe three section boom assembly consists of first, second and third boom section assemblies. B

Boom3-4 944E-425. Loosen the extend chain locknut (2) at the rear of the boom halfway. The locknut must remain fully engaged on the threads of the ext

3-5944E-42Boom16. Label, disconnect and cap the attachment tilt hoses at the fittings at the front of the third boom section. Cap all fittings to keep

Boom3-6 944E-4227. At the rear of the third boom section, remove the remaining wear pads (10), shims and hardware. Label all parts for installation.28

3-7944E-42Boom3.3.2 Second Boom Section Removal1. At the front of the first boom section, remove the top and side wear pads. Label all parts for insta

Boom3-8 944E-423.3.3 First Boom Section Removal1. At the front of the boom, remove the retract chain locknut (18) and washer.2. Label, disconnect and

3-9944E-42Boom6. Use a suitable overhead lifting device and sling (3) to support the first boom section. Remove any slack from the sling7. Block up or

EFFECTIVITY PAGE944E-42 31200355-ii

Boom3-10 944E-423.3.4 First Boom Section Installation1. Use a suitable overhead lifting device and sling and carefully lift the first boom section int

3-11944E-42Boom11. Install the boom proximity sensor. The gap between the sensor and the transfer carriage should be 0.12-0.19 in (3-5 mm). Torque the

Boom3-12 944E-422. Place the extend chain and clevis, as an assembly on top of the third boom section and allow the chains and clevis to overhang the

3-13944E-42Boom12. After the manifold clears the hoses and is inside the boom, push the hydraulic hoses the rest of the way into the boom.13. Install

Boom3-14 944E-4226. If needed, pull the second boom section out slightly to align the extend chain yoke with the bracket. Route the extend chain yoke

3-15944E-42Boom• Abrasives - Accelerated wearing and scoring of the articulating members of the chain (pins and plates), with a corresponding reductio

Boom3-16 944E-42Distorted or Battered Link PlatesDistorted or battered link plates (5) on a leaf chain can cause tight joints and prevent flexing.Turn

3-17944E-42Boom3.4.3 Expose Chains for Inspectionb. Extend Chains1. Park the machine on a firm, level surface. Place the transmission control lever in

Boom3-18 944E-424. Measure the sag (1) in the top boom extend chain between the bottom of the chain and the top of the boom at their closest point. Ac

3-19944E-42Booma. Component/Assembly VerificationThe third to second boom section separation should be checked when assembling new boom sections or ch

SECTION CONTENTSSection Subject Page944E-42iSection 1Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3-20 944E-423.4.7 Extend Chains Removal and Replacement1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, e

3-21944E-42Boom5. At the front underside of the boom, record the amount of threads extending beyond the locknut. This measurement will be the starting

Boom3-22 944E-423.5 BOOM WEAR PADSThe wear pads on this machine are flat rectangular wear pads with metal inserts.A total of 30 wear pads are installe

3-23944E-42Boom3.6 QUICK ATTACH ASSEMBLY 3.6.1 Quick Attach Removal1. Remove the lock bolt holding (6) the tilt cylinder rod end pin (7) to the quick

Boom3-24 944E-423.8 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur during operation of the

3-25944E-42Boom5. Drooping chain, or jerky boom extend or retract functions.1. Chain(s) tension not properly adjusted. 1. Adjust chain(s).2. Chain(s)

Boom3-26 944E-428. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section 3.5.2, “Wear Pad Ins

3-27944E-42Boom3.9 EMERGENCY BOOM LOWERING3.9.1 Loss of Engine Power or Hydraulic Pump FailureNote: In the event of total loss of engine power or hyd

Boom3-28 944E-423.9.3 Hydraulic Hose Replacement3.9.4 Hydraulic Hose Replacement - Step 11. Clear area of any unnecessary personnel.2. Block all four

3-29944E-42Boom3.9.5 Hydraulic Hose Replacement - Step 2USE IN CASE OF:BOOM LIFT LINE FAILURE - Lift Cylinder to Block (1)BOOM LIFT LINE FAILURE - Blo

Section Subject Pageii944E-42Section 5Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3-30 944E-42This Page Intentionally Left Blank

4-1944E-42Section 4Cab and CoversContentsPARAGRAPH TITLE PAGE4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . .

Cab and Covers4-2 944E-424.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented

4-3944E-42Cab and Covers4.2 OPERATOR’S CAB4.2.1 Cab Safety DO NOT weld, grind, drill, repair or modify the cab in any way. Any modification or damage

Cab and Covers4-4 944E-429. Disconnect the horn button wire from the cab wiring harness.10. Support the bottom of the steering valve, and remove the f

4-5944E-42Cab and Covers6. Disconnect the brake return spring (5).7. Remove the retaining clips and slide brake pedal shaft (6) out, toward the right

Cab and Covers4-6 944E-424.3.5 Throttle Position Sensor Replacementa. Throttle Position Sensor RemovalThe throttle position sensor controls the engine

4-7944E-42Cab and Covers4.3.6 Joystick Assemblies Refer to Section 8.7, “Valves and Manifolds,” for removal and installation instructions apply to the

Cab and Covers4-8 944E-424.4 ENCLOSED CAB (OPTIONAL) COMPONENTS4.4.1 Front Windshield Wiper SwitchRefer to Section 9.12.1, “Dash Switches.”4.4.2 Front

4-9944E-42Cab and Covers13. Label, disconnect and cap the heater hoses at the heater.14. Remove the three capscrews and washers securing the heater as

Section Subject Pageiii944E-42Section 9Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab and Covers4-10 944E-425. Block the boom (1) sufficiently enough to provide access to the hydraulic hoses between the cab, hydraulic valve plate an

4-11944E-42Cab and Covers13. Remove the four capscrews, washers and sheer pins (9) that secure the cab mount supports to the frame.14. If equipped, re

Cab and Covers4-12 944E-4219. Install the mirrors and all other cab components as needed, if removed.20. Unblock the wheels.21. Close and secure the r

5-1944E-42Section 5Axles, Drive Shafts, Wheels and TiresContentsPARAGRAPH TITLE PAGE5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . .

Axles, Drive Shafts, Wheels and Tires5-2 944E-425.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGYTo understand the safety, operation and maintenan

5-3944E-42Axles, Drive Shafts, Wheels and Tires5.2 GENERAL INFORMATIONNote: To help ensure optimum performance, the drive shaft assemblies are specia

Axles, Drive Shafts, Wheels and Tires5-4 944E-425.3.5 Axle Replacementc. Axle RemovalThe front and rear axle assemblies differ in that the front axle

5-5944E-42Axles, Drive Shafts, Wheels and TiresNote: The axle will oscillate freely when the cylinder mounting pin is removed.13. Remove the four cap

Axles, Drive Shafts, Wheels and Tires5-6 944E-4215. Uncap and connect the steering and brake lines at their axle fittings.16. Check wheel end and hydr

5-7944E-42Axles, Drive Shafts, Wheels and Tires5.3.7 Axle Assembly and Drive Shaft TroubleshootingProblem Cause Remedy1. Excessive axle noise while dr

Section Subject Pageiv944E-42

Axles, Drive Shafts, Wheels and Tires5-8 944E-424. Oil leaking from axle (differential housing and/or axle housings).1. Drain and/or inspection plugs

5-9944E-42Axles, Drive Shafts, Wheels and Tires7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with Mobilfluid 424® (ISO 46).

Axles, Drive Shafts, Wheels and Tires5-10 944E-425.4 DRIVE SHAFTS5.4.1 Drive Shaft Inspection and ServiceWhenever servicing the machine, conduct a vis

5-11944E-42Axles, Drive Shafts, Wheels and Tires5.5 WHEELS AND TIRESIt is recommended that a replacement tire to be the same size, ply and brand as or

Axles, Drive Shafts, Wheels and Tires5-12 944E-425.5.2 Installing Wheel and Tire Assembly onto MachineNote: The wheel and tire assemblies must be ins

5-13944E-42Axles, Drive Shafts, Wheels and Tires5. Working through the level plug hole (3), carefully use a screwdriver to spread the brake discs apar

Axles, Drive Shafts, Wheels and Tires5-14 944E-424. Block all four wheels to help prevent the machine from moving after the parking brake is disabled.

6-1944E-42Section 6Transmission ContentsPARAGRAPH TITLE PAGE6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . .

Transmission6-2 944E-426.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented in thi

6-3944E-42Transmission6.2 TRANSMISSION SERIAL NUMBERThe transmission serial number plate is located on the pump side (front) of the transmission at th

1-1944E-42Section 1Safety PracticesContentsPARAGRAPH TITLE PAGE1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission6-4 944E-42the engine flywheel. Use a engine baring tool or similar device, to prevent the flywheel from turning while removing the capscr

6-5944E-42Transmission6.4.2 Transmission Inspection and Internal RepairIf replacing the entire transmission, transfer the transmission temperature swi

Transmission6-6 944E-4211. Working through the engine flywheel inspection and access hole (14), install the four hex head capscrews (15) securing the

6-7944E-42Transmission6.5 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that may occur during operati

Transmission6-8 944E-422. Low or no pump flow or pressure.1. Low oil level. 1. Fill transmission to correct level with Mobilfluid 424® (ISO Grade 46).

6-9944E-42Transmission5. Transmission overheating (oil above 248° F (120° C)).1. Low oil level. 1. Fill transmission to correct level with Mobilfluid

Transmission6-10 944E-427. Oil leaking from transmission. 1. Oil leaking from vent (high oil level).1. Remove drain plug and drain oil as needed, unti

6-11944E-42Transmission6.6 TRANSFER CASE COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented in this sectio

Transmission6-12 944E-426.7 TRANSFER CASE6.7.1 Transfer Case DescriptionThe ZF Model TB92-I4 transfer case is a single speed, mechanical unit designed

6-13944E-42Transmission6.10.1 Transfer Case RemovalNote: This operation can be performed with the transmission/transfer case still attached to the po