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Lull 944E-42 Service Manual Manuel d'utilisateur (846 pages)


marque: Lull | Catégorie: Machines spéciales | Taille: 53.08 MB |

 

Table des matières

Service Manual

1

EFFECTIVITY PAGE

3

SECTION CONTENTS

5

Section Subject Page

6

Section 1

9

1.1 INTRODUCTION

10

1.2 OWNERS/OPERATORS MANUAL

10

1.3 TRAINING MECHANICS AS

11

OPERATORS

11

1.4 SAFETY INFORMATION

11

DANGER:

12

WARNING:

12

CAUTION:

12

1.6 SAFETY INSTRUCTIONS

13

Safety Practices

14

1.6.3 General Hazards

14

1.6.4 Operational Hazards

14

1.8 HAZARD/EMERGENCY

15

INFORMATION SIGNS

15

(717)-485-6472

15

Section 2

17

TERMINOLOGY

19

2.2 INTRODUCTION

20

to the torque

21

MA10,0820

22

2.4 METRIC CONVERSION FACTORS

23

2.5 SPECIFICATIONS

26

2.5.4 Attachment Weights

29

° and Emergency Brake Engaged

30

2.5.7 Electrical System

31

2.5.11 Hydraulic System

36

2.5.12 Tires

37

XXXX - 24

38

2.6 FLUIDS, LUBRICANTS AND

39

CAPACITIES

39

2.6.4 Hydraulic System

40

2.6.5 Engine

40

2.6.6 Transmission

41

2.6.7 Transfer Case

41

2.6.8 Drive Shaft Splines

42

2.6.9 General Anti-Corrosion

42

2.7 CLEANING

43

2.8 REPLACEMENT

44

2.9 HOSES AND TUBES

44

2.10 BEARINGS

45

2.11 PRESSURE TESTING AND

45

ADJUSTMENT

45

Section 3

49

3.1 BOOM SYSTEM COMPONENT

50

3.2 BOOM SYSTEM

51

3.3 BOOM ASSEMBLY MAINTENANCE

51

3.3.1 Inner Boom Replacement

52

3.3.3 Outer Boom Replacement

70

3.4 BOOM CHAINS

76

3.4.2 Chain Lubrication

83

Removal and Replacement

87

3.5 BOOM WEAR PADS

92

3.6 QUICK ATTACH ASSEMBLY

95

3.7 TROUBLESHOOTING

99

Section 4

105

Cab and Covers

105

COMPONENT TERMINOLOGY

106

4.2 OPERATOR’S CAB

107

4.3 OPEN CAB COMPONENTS

108

Select Lever

109

Replacement

111

4.3.4 Steer Select Valve

113

(944E-42 Only)

120

Assembly Replacement

122

Replacement (Optional)

124

4.3.10 Electrical Components

125

4.4 ENCLOSED CAB (OPTIONAL)

128

COMPONENTS

128

4.5 CAB REMOVAL

132

4.6 CAB INSTALLATION

135

4.7 VALVE PLATE

138

4.8 ACCESS PANELS AND COVERS

140

4.8.2 Engine Hood

142

Section 5

147

5.2 GENERAL INFORMATION

149

5.3 AXLE ASSEMBLIES

149

5.3.4 Axle Specifications

150

5.3.5 Axle Maintenance

150

5.3.6 Axle Replacement

151

Troubleshooting

161

5.4 DRIVE SHAFTS

162

5.5 WHEELS AND TIRES

165

WARNING: Damaged, modified

167

Onto Vehicle

168

WARNING: BLOCK ALL FOUR

172

Section 6

177

6.1 TRANSMISSION ASSEMBLY

178

6.2 TRANSMISSION DESCRIPTION

179

6.3 TRANSMISSION OPERATION

179

6.6 TRANSMISSION MAINTENANCE

180

6.7 TRANSMISSION REPLACEMENT

182

MU1890MU1890

184

6.8 TROUBLESHOOTING

191

Problem Cause Remedy

191

6.9 TOWING A DISABLED VEHICLE

194

6.10 TRANSFER CASE COMPONENT

195

6.11 GENERAL INFORMATION

196

6.12 TRANSFER CASE

196

6.12.5 Further Information

197

6.12.6 Technical Data

197

6.12.9 Transfer Case Removal

198

6.13 TROUBLESHOOTING

200

Section 7

203

7.1 INTRODUCTION

205

7.1.2 Component Terminology

206

7.2 SAFETY INFORMATION

207

7.3 ENGINE SERIAL NUMBER

209

7.4 SPECIFICATIONS AND

209

MAINTENANCE INFORMATION

209

7.5 STANDARD PRACTICES

209

7.6 ENGINE COOLING SYSTEM

210

(60,4 mm)

221

7.7 ENGINE ELECTRICAL SYSTEM

225

7.8 FUEL SYSTEM

225

7.8.1 Diesel Fuel

226

7.8.2 Fuel Tank

226

7.8.4 Fuel Lift Pump Testing

228

7.8.5 Fuel Filter Replacement

229

7.8.7 Fuel Injectors

230

7.9 ENGINE EXHAUST SYSTEM

232

7.10 ENGINE REPLACEMENT

234

7.10.3 Engine Installation

243

7.11 ENGINE STORAGE

251

7.12 TROUBLESHOOTING

252

Section 8

253

Hydraulic System

253

8.1 HYDRAULIC COMPONENT

257

8.2 SAFETY INFORMATION

258

8.3 SPECIFICATIONS

259

8.4 HYDRAULIC FLUID

259

8.7 HYDRAULIC SYSTEM TESTING

264

Hydraulic Pump Flow Test

265

8.7.3 Hydraulic Testing

272

8.7.5 Hydraulic Testing

280

8.7.8 Hydraulic Testing

292

8.7.10 Hydraulic Testing

300

8.8 HYDRAULIC CIRCUITS AND

307

TROUBLESHOOTING

307

(Dual Joystick)

358

(Single Joystick)

360

Description (Dual Joystick)

400

Description (Single Joystick

406

Description (Single Joystick)

413

8.9 STEER INDEXING PROCEDURES

415

8.10 HYDRAULIC RESERVOIR

416

8.11 HYDRAULIC SYSTEM PUMP

417

8.11.1 Pump Failure Analysis

418

8.11.2 Pump Replacement

418

8.12 VALVES AND MANIFOLDS

428

8.12.2 Main Control Valve

429

Valve (Early Production)

444

8.12.10 Service Brake Valve

450

8.12.11 Power Steering Valve

453

8.12.12 Steer Select Valve

454

Function Valve

456

8.13 ACCUMULATORS

458

8.13.1 General Information

459

8.13.3 Checking Pre-Charge

461

8.14 HYDRAULIC CYLINDERS

464

8.14.5 Slave Cylinders

469

8.14.7 Lift/Lower Cylinder

477

8.14.8 Frame Sway Cylinder

482

8.14.9 Stabilizer Cylinder

487

8.14.10 Steering Cylinders

491

Section 9

511

Electrical System

511

9.1 ELECTRICAL COMPONENT

515

9.1.2 General Overview

516

9.2 SERVICE WARNINGS

528

9.3 SPECIFICATIONS

528

9.5 GROUNDING STRAPS

529

9.6 WIRING HARNESSES

529

9.7 FUSES AND RELAYS

531

9.8 ELECTRICAL SYSTEM

537

Multimeter (DMM)

539

SN 19041

558

& BEFORE

558

Brake Relay on early

580

See page 9.48

580

TAILLIGHT

642

9.11 ENGINE START CIRCUIT

673

9.11.2 Starter

674

9.12 CHARGING CIRCUIT

677

9.12.1 Alternator

679

9.12.2 Battery or Batteries

681

9.13 ELECTRICAL SYSTEM

686

9.13.2 Front Dash Panel

691

9.13.8 Skylight Wiper Motor

708

9.14 SWITCHES AND SOLENOIDS

719

9.14.6 Parking Brake Switch

730

9.14.10 Dual Joystick

737

9.14.16 Engine Block Heater

751

Level Sender

752

RPM X 100

754

Section 10

759

Stabil-TRAK™ System

759

10.1 STABIL-TRAK™ SYSTEM

762

10.2 STABIL-TRAK™ DESCRIPTION

763

10.3 STABIL-TRAK™ OPERATION

764

10.3.3 Relay Testing

766

BATTERY 1

769

SN 0160002514 thru 0160003881

770

Locked Mode, Frame Sway Right

798

Locked Mode, Frame Sway Left

800

Section 11

803

Transfer Carriage

803

11.2 TRANSFER CARRIAGE

805

11.3 TRANSFER CARRIAGE

805

MAINTENANCE

805

11.3.3 Rear Wear Pad Check

815

11.3.4 Rear Wear Pad Shimming

815

11.3.10 Rear Roller Gap Check

818

11.3.11 Rear Roller Shimming

819

11.3.13 Front Roller Shimming

822

11.4 TROUBLESHOOTING

832

Section 12

835

8990403 Origin 5/00

843

Accident Prevention Tags

843

JLG Worldwide Locations

846

Lull 944E-42 Service Manual Manuel d'utilisateur (266 pages)


marque: Lull | Catégorie: Machines spéciales | Taille: 20.73 MB |

 

Table des matières

Service Manual

1

EFFECTIVITY PAGE

3

SECTION CONTENTS

5

Section Subject Page

6

Section 1

9

Safety Practices

9

1.1 INTRODUCTION

10

1.2 DISCLAIMER

10

1.4 DO NOT OPERATE TAGS

10

1.5 SAFETY INFORMATION

10

1.6 SAFETY INSTRUCTIONS

11

1.7 SAFETY DECALS

12

Section 2

13

2.1 REPLACEMENT PARTS AND

14

WARRANTY INFORMATION

14

2.2 TORQUE CHARTS

15

(Continued)

16

SOCKET HEAD CAP SCREWS

17

CLASS 8.8 METRIC BOLTS

19

CLASS 8 METRIC NUTS

19

Magni Coating*

21

2.3 SPECIFICATIONS

23

2.3.5 Tires

24

2.5 SERVICE AND MAINTENANCE

27

SCHEDULES

27

LB/FT (Nm)

28

2.6 LUBRICATION SCHEDULES

30

Section 3

31

3.1 BOOM SYSTEM COMPONENT

32

3.2 BOOM SYSTEM

33

BOOM EXTEND AND RETRACT

44

3.4.2 Inspection Guidelines

45

3.4.4 Chain Lubrication

47

3.5 BOOM WEAR PADS

52

3.6 QUICK ATTACH ASSEMBLY

53

3.7 FORKS

53

3.8 TROUBLESHOOTING

54

3.9 EMERGENCY BOOM LOWERING

57

Section 4

61

Cab and Covers

61

4.2 OPERATOR’S CAB

63

4.3 CAB COMPONENTS

63

4.3.2 Steer Select Valve

64

4.3.4 Throttle Pedal

65

4.3.6 Joystick Assemblies

67

4.4 ENCLOSED CAB (OPTIONAL)

68

COMPONENTS

68

4.5 CAB REMOVAL

69

4.6 CAB INSTALLATION

71

4.7 VALVE PLATE

72

Section 5

73

5.2 GENERAL INFORMATION

75

5.3 AXLE ASSEMBLIES

75

5.3.5 Axle Replacement

76

5.3.6 Axle Installation

77

To Transmission

82

5.5 WHEELS AND TIRES

83

Tread “arrows” must point

84

Install tires onto wheels to

84

5.7 TOWING A DISABLED MACHINE

85

Section 6

87

6.1 TRANSMISSION ASSEMBLY

88

AND MAINTENANCE INFORMATION

89

6.4 TRANSMISSION REPLACEMENT

89

6.5 TROUBLESHOOTING

93

6.6 TRANSFER CASE COMPONENT

97

6.7 TRANSFER CASE

98

6.9 TRANSFER CASE MAINTENANCE

98

6.10.1 Transfer Case Removal

99

6.11 TROUBLESHOOTING

100

Problem Cause Remedy

100

Transmission

102

Section 7

103

7.1.1 Disclaimer and Scope

104

7.1.2 Component Terminology

105

7.2 ENGINE SERIAL NUMBER

106

7.3 SPECIFICATIONS AND

106

MAINTENANCE INFORMATION

106

7.4 ENGINE COOLING SYSTEM

106

7.5 ENGINE ELECTRICAL SYSTEM

107

7.6 FUEL SYSTEM

107

7.7 ENGINE EXHAUST SYSTEM

109

7.8 AIR CLEANER ASSEMBLY

110

7.9 ENGINE REPLACEMENT

111

7.9.2 Engine Installation

113

7.10 TROUBLESHOOTING

115

Section 8

117

Hydraulic System

117

8.1 HYDRAULIC COMPONENT

118

TERMINOLOGY

118

8.2 SAFETY INFORMATION

119

8.4 HYDRAULIC CIRCUITS

121

Hydraulic Pump Flow Test

123

DUAL JOYSTICK CONFIGURATION

128

8.5 HYDRAULIC RESERVOIR

129

8.6 HYDRAULIC SYSTEM PUMP

132

8.7 VALVES AND MANIFOLDS

133

8.7.2 Main Control Valve

134

8.7.9 Service Brake Valve

144

8.7.10 Brake Test

145

8.7.11 Power Steering Valve

145

8.7.12 Steer Select Valve

146

Function Valve

148

8.7.14 Accumulators

149

8.7.15 General Information

150

8.7.16 Checking Pre-Charge

152

8.8 HYDRAULIC CYLINDERS

154

AFTER the head gland

155

AXLE CENTER SECTION

156

STEERING CYLINDER

156

Section 9

159

Electrical System

159

9.1 ELECTRICAL COMPONENT

161

9.2 SPECIFICATIONS

162

9.3 SAFETY INFORMATION

162

9.4 FUSES AND RELAYS

162

9.5 ELECTRICAL SCHEMATICS

164

CHASSIS CIRCUIT

170

AUXILIARY HYDRAULICS

170

ENCLOSED CAB OPTION

170

9.7 ENGINE START CIRCUIT

172

9.8 CHARGING CIRCUIT

173

9.9 WINDOW WIPER/WASHER

174

WINDSHIELD WIPER MOTOR

174

9.9.2 Skylight Wiper Motor

175

9.9.3 Rear Wiper Switch/Motor

176

9.10 CAB HEATER AND FAN

178

9.11 SWITCHES AND SOLENOIDS

179

PARK BRAKE INDICATOR

181

9.11.9 Dual Joystick

185

9.11.11 Boom Angle Sensor

188

9.11.15 Hourmeter

191

9.12 DASH SWITCHES

194

9.13 TROUBLESHOOTING

195

Multimeter (DMM)

208

Section 10

213

Stabil-TRAK™ System

213

10.1 STABIL-TRAK™ SYSTEM

214

COMPONENT TERMINOLOGY

214

10.2 STABIL-TRAK™ DESCRIPTION

215

10.4 STABIL-TRAK™ SYSTEM TEST

222

Locked Mode, Frame Sway Right

235

Section 11

241

Transfer Carriage

241

11.2 TRANSFER CARRIAGE

243

11.3 TRANSFER CARRIAGE

243

MAINTENANCE

243

11.3.3 Rear Wear Pad Check

249

11.3.4 Rear Wear Pad Shimming

250

11.3.10 Rear Roller Gap Check

252

11.3.11 Rear Roller Shimming

253

11.3.13 Front Roller Shimming

255

Replacement

256

11.4 TROUBLESHOOTING

262

31200355

266
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