Document Outline

• 31200355_A_944E-42_Lull_Service
  • Effectivity Page
  • Table of Contents
  • Section 1 Safety Practices
    • 1.1 Introduction
    • 1.2 Disclaimer
    • 1.3 Operation & Safety Manual
    • 1.4 Do Not Operate Tags
    • 1.5 Safety Information
      • 1.5.1 Safety Alert System and Signal Words
    • 1.6 Safety Instructions
      • 1.6.1 Personal Hazards
      • 1.6.2 Equipment Hazards
      • 1.6.3 General Hazards
      • 1.6.4 Operational Hazards
    • 1.7 Safety Decals
  • Section 2 General Information and Specifications
    • 2.1 Replacement Parts and Warranty Information
    • 2.2 Torque Charts
      • 2.2.1 SAE Fastener Torque Chart
      • 2.2.2 Metric Fastener Torque Chart
      • 2.2.3 Hydraulic Hose Torque Chart
    • 2.3 Specifications
      • 2.3.1 Travel Speeds
      • 2.3.2 Hydraulic Cylinder Performance
      • 2.3.3 Electrical System
      • 2.3.4 Engine Performance Specifications
      • 2.3.5 Tires
    • 2.4 Fluid and Lubricant Capacities
    • 2.5 Service and Maintenance Schedules
      • 2.5.1 10 & 50 Hour
      • 2.5.2 1st 100, 250 & 1st 500 Hour
      • 2.5.3 500, 1000 & 2000 Hour
    • 2.6 Lubrication Schedules
  • Section 3 Boom
    • 3.1 Boom System Component Terminology
    • 3.2 Boom System
      • 3.2.1 Boom System Operation
    • 3.3 Boom Assembly Maintenance
      • 3.3.1 Third Boom Section Removal
      • 3.3.2 Second Boom Section Removal
      • 3.3.3 First Boom Section Removal
      • 3.3.4 First Boom Section Installation
      • 3.3.5 Second Boom Section Installation
      • 3.3.6 Third Boom Section Installation
    • 3.4 Boom Extend and Retract Chains
      • 3.4.1 Boom Chain Inspection
      • 3.4.2 Inspection Guidelines
      • 3.4.3 Expose Chains for Inspection
      • 3.4.4 Chain Lubrication
      • 3.4.5 Boom Chain Tension Check
      • 3.4.6 Boom Chain Tension Adjustment
      • 3.4.7 Extend Chains Removal and Replacement
      • 3.4.8 Retract Chain Removal and Replacement
    • 3.5 Boom Wear Pads
      • 3.5.1 Wear Pad Inspection
      • 3.5.2 Wear Pad Installation and Lubrication
    • 3.6 Quick Attach Assembly
      • 3.6.1 Quick Attach Removal
      • 3.6.2 Quick Attach Installation
    • 3.7 Forks
    • 3.8 Troubleshooting
    • 3.9 Emergency Boom Lowering
      • 3.9.1 Loss of Engine Power or Hydraulic Pump Failure
      • 3.9.2 Hydraulic Line Failure
      • 3.9.3 Hydraulic Hose Replacement
      • 3.9.4 Hydraulic Hose Replacement - Step 1
      • 3.9.5 Hydraulic Hose Replacement - Step 2
  • Section 4 Cab and Covers
    • 4.1 Operator’s Cab and Covers Component Terminology
    • 4.2 Operator’s Cab
      • 4.2.1 Cab Safety
      • 4.2.2 Serial Number Decal
    • 4.3 Cab Components
      • 4.3.1 Steering Column and Steering Valve
      • 4.3.2 Steer Select Valve
      • 4.3.3 Service Brake Valve and Pedal
      • 4.3.4 Throttle Pedal
      • 4.3.5 Throttle Position Sensor Replacement
      • 4.3.6 Joystick Assemblies
    • 4.4 Enclosed Cab (Optional) Components
      • 4.4.1 Front Windshield Wiper Switch
      • 4.4.2 Front Windshield Wiper Motor
      • 4.4.3 Windshield Washer Control
      • 4.4.4 Skylight Wiper Washer & Rear Window Washer Switch
      • 4.4.5 Skylight Wiper Motor
      • 4.4.6 Windshield/Skylight/Rear Wiper Washer Reservoir w/Pump
      • 4.4.7 Rear Wiper Switch/Motor
      • 4.4.8 Heater/Defroster System
    • 4.5 Cab Removal
    • 4.6 Cab Installation
    • 4.7 Valve Plate
      • 4.7.1 Valve Plate Removal
      • 4.7.2 Valve Plate Installation
  • Section 5 Axles, Drive Shafts, Wheels and Tires
    • 5.1 Axle, Drive Shaft and Wheel Component Terminology
    • 5.2 General Information
    • 5.3 Axle Assemblies
      • 5.3.1 Axle Serial Number Plate
      • 5.3.2 Axle Specifications
      • 5.3.3 Axle Internal Service
      • 5.3.4 Axle Maintenance
      • 5.3.5 Axle Replacement
      • 5.3.6 Axle Installation
      • 5.3.7 Axle Assembly and Drive Shaft Troubleshooting
    • 5.4 Drive Shafts
      • 5.4.1 Drive Shaft Inspection and Service
      • 5.4.2 Drive Shaft Maintenance
      • 5.4.3 Drive Shaft Removal
      • 5.4.4 Drive Shaft Cleaning and Drying
      • 5.4.5 Drive Shaft Installation
    • 5.5 Wheels and Tires
      • 5.5.1 Removing Wheel and Tire Assembly from Machine
      • 5.5.2 Installing Wheel and Tire Assembly onto Machine
    • 5.6 Brakes
      • 5.6.1 Brake Disc Inspection
    • 5.7 Towing a Disabled Machine
  • Section 6 Transmission
    • 6.1 Transmission Assembly Component Terminology
    • 6.2 Transmission Serial Number
    • 6.3 Transmission Specifications And Maintenance Information
    • 6.4 Transmission Replacement
      • 6.4.1 Transmission Removal
      • 6.4.2 Transmission Inspection and Internal Repair
      • 6.4.3 Transmission Installation
      • 6.4.4 After Transmission Service or Replacement
    • 6.5 Troubleshooting
      • 6.5.1 Transmission Troubleshooting
    • 6.6 Transfer Case Component Terminology
    • 6.7 Transfer Case
      • 6.7.1 Transfer Case Description
    • 6.8 Transfer Case Serial Number
    • 6.9 Transfer Case Maintenance
    • 6.10 Transfer Case Replacement
      • 6.10.1 Transfer Case Removal
      • 6.10.2 Transfer Case Installation
    • 6.11 Troubleshooting
      • 6.11.1 Transfer Case Troubleshooting
  • Section 7 Engine
    • 7.1 Introduction - Cummins QSB 4.5
      • 7.1.1 Disclaimer and Scope
      • 7.1.2 Component Terminology
    • 7.2 Engine Serial Number
    • 7.3 Specifications and Maintenance Information
    • 7.4 Engine Cooling System
      • 7.4.1 Radiator Pressure Cap
      • 7.4.2 Radiator/Oil Cooler and Replacement
    • 7.5 Engine Electrical System
    • 7.6 Fuel System
      • 7.6.1 Diesel Fuel
      • 7.6.2 Fuel Tank
      • 7.6.3 After Fuel System Service
    • 7.7 Engine Exhaust System
      • 7.7.1 Exhaust System Removal
      • 7.7.2 Exhaust System Installation
    • 7.8 Air Cleaner Assembly
      • 7.8.1 Air Cleaner Assembly Removal
      • 7.8.2 Air Cleaner Assembly Installation
    • 7.9 Engine Replacement
      • 7.9.1 Engine Removal
      • 7.9.2 Engine Installation
    • 7.10 Troubleshooting
  • Section 8 Hydraulic System
    • 8.1 Hydraulic Component Terminology
    • 8.2 Safety Information
    • 8.3 Hydraulic Pressure Diagnosis
      • 8.3.1 Pressure Checks and Adjustments
    • 8.4 Hydraulic Circuits
      • 8.4.1 Hydraulic Pressures
      • 8.4.2 Hydraulic Schematic, 944E
    • 8.5 Hydraulic Reservoir
      • 8.5.1 Hydraulic Oil Reservoir Draining
      • 8.5.2 Hydraulic Oil Reservoir Filling
      • 8.5.3 Hydraulic Oil Reservoir Replacement
    • 8.6 Hydraulic System Pump
      • 8.6.1 Pump Description
      • 8.6.2 Pump Failure Analysis
      • 8.6.3 Pump Replacement
    • 8.7 Valves and Manifolds
      • 8.7.1 Valve Plate Assembly
      • 8.7.2 Main Control Valve
      • 8.7.3 Joystick Valve (Dual Joystick)
      • 8.7.4 Pilot Select Valve (Dual Joystick)
      • 8.7.5 Joystick Valve (Single Joystick)
      • 8.7.6 Single Joystick Pilot Select Valve
      • 8.7.7 Frame Sway Joystick Valve
      • 8.7.8 Auxiliary Hydraulic Pressure Release Valve
      • 8.7.9 Service Brake Valve
      • 8.7.10 Brake Test
      • 8.7.11 Power Steering Valve
      • 8.7.12 Steer Select Valve
      • 8.7.13 Accumulator Charge/Secondary Function Valve
      • 8.7.14 Accumulators
      • 8.7.15 General Information
      • 8.7.16 Checking Pre-Charge
      • 8.7.17 Accumulator Charge Troubleshooting
    • 8.8 Hydraulic Cylinders
      • 8.8.1 Cylinder Pressure Checking
      • 8.8.2 Steering Cylinders
      • 8.8.3 Cylinder Torque Specifications
  • Section 9 Electrical System
    • 9.1 Electrical Component Terminology
      • 9.1.1 General Overview
    • 9.2 Specifications
    • 9.3 Safety Information
    • 9.4 Fuses and Relays
      • 9.4.1 Engine Compartment
      • 9.4.2 Cab
      • 9.4.3 Cab Harness Fuses and Relays
    • 9.5 Electrical Schematics
      • 9.5.1 Electrical Symbols Directory
      • 9.5.2 944E-42 Electrical Schematics
    • 9.6 Circuit Breakdowns
      • 9.6.1 Constant Power Circuit from Battery
      • 9.6.2 Start & Charge Circuit
    • 9.7 Engine Start Circuit
      • 9.7.1 Starter
    • 9.8 Charging Circuit
      • 9.8.1 Alternator
    • 9.9 Window Wiper/Washer Windshield Wiper Motor
      • 9.9.1 Windshield Wiper Motor
      • 9.9.2 Skylight Wiper Motor
      • 9.9.3 Rear Wiper Switch/Motor
      • 9.9.4 Windshield Washer Reservoir and Pump
    • 9.10 Cab Heater and Fan
      • 9.10.1 Cab Heater Controls
    • 9.11 Switches and Solenoids
      • 9.11.1 Ignition Key Switch
      • 9.11.2 Hydraulic Oil Filter Pressure Switch
      • 9.11.3 Dual Hydraulic Oil Temperature Switch
      • 9.11.4 Auxiliary Hydraulic Pressure Release Switch
      • 9.11.5 Parking Brake Switch
      • 9.11.6 Transmission Disconnect Switch
      • 9.11.7 Transmission Shift Control Switch
      • 9.11.8 Transmission Solenoid Valves
      • 9.11.9 Dual Joystick
      • 9.11.10 Optional Single Joystick
      • 9.11.11 Boom Angle Sensor
      • 9.11.12 Coolant Temperature Switch
      • 9.11.13 Transmission Temperature Switch
      • 9.11.14 Fuel Level Gauge and Fuel Level Sender
      • 9.11.15 Hourmeter
      • 9.11.16 Stabilizer Brake Switch
    • 9.12 Dash Switches
      • 9.12.1 Dash Switches
    • 9.13 Troubleshooting
      • 9.13.1 Engine Fault Codes Retrieval
      • 9.13.2 Engine Fault Codes Chart
      • 9.13.3 Troubleshooting with a Digital Multimeter (DMM)
      • 9.13.4 Probing Electrical Connectors
  • Section 10 Stabil-TRAK™ System
    • 10.1 Stabil-TRAK™ System Component Terminology
    • 10.2 Stabil-TRAK™ Description
      • 10.2.1 Stabil-TRAK™ Solenoid Valves
    • 10.3 Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting
    • 10.4 Stabil-TRAK™ System Test
      • 10.4.1 Stabil-TRAK™ System Test Instructions
      • 10.4.2 Stabil-TRAK™ System Test Procedures
    • 10.5 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting
      • 10.5.1 Troubleshooting Symptom Chart
      • 10.5.2 Stabil-TRAK™ Hydraulic Circuit
      • 10.5.3 Stabilizer Cylinder Oil Flow
      • 10.5.4 Hydraulic Circuit Operation - Free Pivot Mode, Rod Oil Out
      • 10.5.5 Hydraulic Troubleshooting - Free Pivot Mode, Rod Oil Out
      • 10.5.6 Hydraulic Circuit Operation - Free Pivot Mode, Base Oil Out
      • 10.5.7 Hydraulic Troubleshooting - Free Pivot Mode, Base Oil Out
      • 10.5.8 Hydraulic Circuit Operation - Slow Pivot Mode, Rod Oil Out
      • 10.5.9 Hydraulic Troubleshooting - Slow Pivot Mode, Rod Oil Out
      • 10.5.10 Hydraulic Circuit Operation - Slow Pivot Mode, Base Oil Out
      • 10.5.11 Hydraulic Troubleshooting - Slow Pivot Mode, Base Oil Out
      • 10.5.12 Hydraulic Circuit Operation - Locked Mode
      • 10.5.13 Hydraulic Circuit Operation - Locked Mode, Frame Sway Right
      • 10.5.14 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Right
      • 10.5.15 Hydraulic Circuit Operation - Locked Mode, Frame Sway Left
      • 10.5.16 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Left
  • Section 11 Transfer Carriage
    • 11.1 Transfer Carriage Component Terminology
    • 11.2 Transfer Carriage
      • 11.2.1 Transfer Carriage Description
      • 11.2.2 Transfer Carriage Operation
    • 11.3 Transfer Carriage Maintenance
      • 11.3.1 Transfer Carriage Removal
      • 11.3.2 Transfer Carriage Installation
      • 11.3.3 Rear Wear Pad Check
      • 11.3.4 Rear Wear Pad Shimming
      • 11.3.5 Rear Wear Pad Replacement
      • 11.3.6 Front Upstop Wear Pad Check
      • 11.3.7 Front Upstop Wear Pad Gap Check
      • 11.3.8 Front Upstop Wear Pad Shimming
      • 11.3.9 Front Upstop Wear Pad Replacement
      • 11.3.10 Rear Roller Gap Check
      • 11.3.11 Rear Roller Shimming
      • 11.3.12 Front Roller Gap Check
      • 11.3.13 Front Roller Shimming
      • 11.3.14 Front Scraper Plate Replacement
      • 11.3.15 Front Roller and Bushing Replacement
      • 11.3.16 Rear Roller and Bushing Replacement
      • 11.3.17 Boom Pivot Bushing Replacement
      • 11.3.18 Slave Cylinder Pivot Bushing Replacement
      • 11.3.19 Transfer Cylinder Replacement
    • 11.4 Troubleshooting
      • 11.4.1 Transfer Carriage Troubleshooting