Lull 0160003882 Owner'S/Operator'S Manual Download

Page: 1 / 200

3120039 B

Printed in U.S.A. 3/09

OWNERS/OPERATORS MANUAL

Model 944E-42

(S/N 0160003882 thru 0160037751)

Keep this manual with the vehicle at all times.

MU4941

Courtesy of Crane.Market

Summary of Contents for 0160003882

Page 1: ...3120039 B Printed in U S A 3 09 OWNERS OPERATORS MANUAL Model 944E 42 S N 0160003882 thru 0160037751 Keep this manual with the vehicle at all times MU4941 Courtesy of Crane Market...

Page 2: ...site It is your responsibility to observe applicable laws and regulations and to follow manufacturer s instructions on vehicle operation and maintenance CALIFORNIA Proposition 65 Warning Diesel Engine...

Page 3: ...ut Off 95 Emergency Operations Towing a Disabled Vehicle 96 Emergency Boom Lowering 98 General Maintenance Introduction 104 Maintenance Schedule and Checklist 105 1 Lubrication Points 106 2 Air Cleane...

Page 4: ...serial number is stamped into the serial number plate 1 which is located on the vehicle s frame IMPORTANT The replacement of any part on this vehicle by anything other than a JLG authorized replaceme...

Page 5: ...pment according to these rules and laws Your safety and the safety of others in the worksite depend significantly upon your knowlege and understanding of all correct operating practices and procedures...

Page 6: ...ord WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious personal injury The signal word CAUTION indicates a potentially hazardous situation which...

Page 7: ...vehicle was instructed by the seller on its proper use If this vehicle is to be used by an employee or is loaned or rented to someone other than the purchaser make certain that the new operator is tra...

Page 8: ...on this vehicle Instructional Symbols 80 1 0 OP0330 OH2100 OH2090 Safety Alert Symbol Read Operator s Manual Fasten Seat Belt OH3100 Always Connect Couplers On Hydraulically Powered Attachments OS090...

Page 9: ...l Symbols cont d OU1620 Standard Carriages OU1630 Side Tilt Carriages OU1640 Swing Carriages OU1610 Single or Dual Fork Positioning Carriages OU1600 10 Ft Truss Boom OU1590 10 Ft Truss Boom w Winch OU...

Page 10: ...Injury OH2300 OH2150 Rotating Belts Can Cut Or Entangle Electrocution Can Cause Death Or Serious Injury OH2161 FALLING OFF ATTACHMENT Can Result In Death Or Serious Injury OH3160 OH3110 Swinging Load...

Page 11: ...s Away OH2330 OH2270 Do Not Travel With Boom Raised OH2280 Do Not Raise Boom While On A Slope OH2240 Do Not Travel With Personnel In Work Platform OH2310 Keep Away From Rotating Fan Blades Keep Flames...

Page 12: ...ace Yourself and Stay With Vehicle Keep Seat Belt Fastened Hold On Firmly Lean Away From The Point Of Impact OH2170 Use Only Compliant Work Platforms To Raise Or Lower Personnel OH3120 To Avoid Vehicl...

Page 13: ...Truss Boom Horizontal When Using Winch OU1540 Avoid Rope Damage DO NOT Tilt Truss Boom DOWN When Using Winch OU1550 OU1520 Stop Operation At This Point OU1510 Prohibition Symbol DO NOT Operate Avoid...

Page 14: ...n an enclosed area without a ventilation system capable of routing the hazardous fumes outdoors B Explosive Fuel Engine fuel is flammable and can cause a fire and or an explosion Avoid danger by keepi...

Page 15: ...loosening one end of a hose at the swivel connection If anyone is injured by or if any hydraulic fluid is injected into the skin obtain medical attention immediately or gangrene may result E Batteries...

Page 16: ...zen battery it may explode and cause serious injury Let the battery thaw out before putting on a battery charger WARNING Fluid in electric storage batteries contains sulfuric acid which is POISON and...

Page 17: ...ns are away from the vehicle and that the travel select lever is in the N NEUTRAL DETENT position and the parking brake switch engaged before starting the engine Holes obstructions debris and other wo...

Page 18: ...n clears and the worksite is visible again Have a lookout person assist you Where the load will obstruct the operator s vision it is recommended that the vehicle be operated in REVERSE looking backwar...

Page 19: ...f any personnel or objects Be sure there is enough room in front of the boom for complete transfer carriage movement IMPORTANT When transfer carriage movement is started in the forward direction the l...

Page 20: ...cle The vehicle is level when the frame level indicator gauge reaches 0 zero degrees If the vehicle cannot be leveled using the frame sway control reposition the vehicle Frame swaying left or right wi...

Page 21: ...opes slowly and with caution Ascend or descend slopes with the heavy end of the vehicle pointing up the slope NOTE The rear of the vehicle is normally considered the heavy end unless the car riage is...

Page 22: ...e Department or your local Lull Distributor if any circuit is malfunctioning DO check for frayed or cut seat belt webbing damaged buckles or loose mounting brackets Replace immediately if required ALW...

Page 23: ...erator s manual before operating 2 Fasten seat belt 3 Allow no riders 4 Use a compliant work platform to lift or lower personnel 0000000 RPM X 100 5 10 15 30 20 25 F 1 2 E 104 176 80 248 120 C F D r m...

Page 24: ...RTS can entangle 4110460 ENGINE EXPLOSION can result in death or serious personal injury DO NOT use Ether or other high energy starting aids Engine equipped with grid heating system 0 1Ft 2Ft 3Ft 4Ft...

Page 25: ...ained in greater detail on page 110 Remove any debris blocking the radiator cooling fins 6 Check the hydraulic oil level sight glass and add hydraulic oil if required This procedure is explained in gr...

Page 26: ...on the right side or the left side of the seat Suspension Adjustment for seats equipped with adjustable suspensions only Turn the knob 3 on the front of the seat to adjust the suspension to correspon...

Page 27: ...retractable end or the male end of the belt into the receptacle buckle end of the belt 3 With the belt as low on your body as possible pull the retractable end of the belt or the free end of the belt...

Page 28: ...e speed of the vehicle by applying the service brakes located in the axles In the event of engine power loss the service brake pedal can also be used for braking It also activates and locks the rear a...

Page 29: ...TART position 8 Engages starter motor to crank the engine when the parking brake switch is engaged and the transmission is in NEUTRAL Steering Mode Selector Three Mode Steer Select The steering mode s...

Page 30: ...d sand conditions 2 Front Wheel Steering Mode The front wheels will steer in the direction that the steering wheel is turned The rear wheels will remain in a fixed forward position This steering mode...

Page 31: ...ft about one complete revolution 5 Select the four wheel steer mode with the steer mode selector 6 Turn the steering wheel all the way to the right until it reaches the stop This will ensure the rear...

Page 32: ...rking brake may be used to stop in an EMERGENCY situation However use caution because the stop will be abrupt and the operator and the load may be jolted forward unexpectedly With boom angles greater...

Page 33: ...ivate the system and read the code as indicated by the light Contact your local Cummins dealer for an explanation of these codes or refer to the Cummins Engine Owners Manual or call the Cummins Custom...

Page 34: ...itch 2 Rotate the twist grip 5 of the range select lever to 1st gear 3 Pull the travel select lever 1 toward the steering wheel and move the travel select lever 1 to F FORWARD 2 to travel in a forward...

Page 35: ...for highest torque and pulling power Use higher gears for higher ground speed The recommendations listed in the table that follows is a guideline only Always use good judgement when traveling with a l...

Page 36: ...rking brake switch Maximum Fork Sweep During Travel CAUTION Allow for adequate clearance between the attach ment and rear counterweight and other objects when turning The attachment and the rear count...

Page 37: ...e rear joystick 8 is a single axis joystick with a lift to shift lock ring detent and controls the frame sway to the left and right Two functions can be accomplished at the same time by moving the fro...

Page 38: ...s The joystick will return to the center position when released The button on the top of the joystick controls the auxiliary hydraulics function Refer to Auxiliary Hydraulic Control on page 40 for a d...

Page 39: ...retract functions The joystick can be moved from the center position into any of these quadrants The joystick will return to the center position when released Boom Lift 7 move handle backward Boom Lo...

Page 40: ...control Lift up and hold the lock ring while moving the handle to the left or right When frame sway is complete center the handle and lower the lock ring to lock the handle in the center position Fram...

Page 41: ...tor which allows the operator to tell if the vehicle has been positioned in a level condition Always frame sway the vehicle either right or left until the indicator reads zero degrees 0 If zero cannot...

Page 42: ...Truss Boom w Winch Single Fork Positioning Carriage Dual Fork Positioning Carriage and Auger The button 1 to activate the auxiliary hydraulics is located on the top of the front joystick 2 Pressing t...

Page 43: ...incorrectly connected We recommend reversing the disconnect couplings on the hoses that are supplied with the attachment if operation is reversed Side Tilt Carriage Operation Control Lever Right 5 Ti...

Page 44: ...of operation without button 3 depressed Boom Lift Lower and Extend Retract Default Mode and with button 3 depressed and held Transfer Carriage Extend Retract and Auxiliary Hydraulic Male Pressurized...

Page 45: ...unctions The joystick can be moved from the center position into any of these quadrants The joystick will return to the center position when released Boom Lift 5 move handle backward Boom Lower 6 move...

Page 46: ...2 move handle forward Transfer Carriage Retract 3 move handle backward Auxiliary Hydraulic Female Pressurized 4 move handle to the right Auxiliary Hydraulic Male Pressurized 5 move handle to the left...

Page 47: ...ncorrectly connected We recommend reversing the disconnect couplings on the hoses that are supplied with the attachment if operation is reversed Side Tilt Carriage Operation Control Lever Right 6 Tilt...

Page 48: ...r position when released Attachment Tilt UP 3 move thumb control BACKWARD Attachment Tilt DOWN 4 move thumb control FORWARD Frame Sway Joystick The frame sway joystick 5 is equipped with a lock ring 6...

Page 49: ...tor which allows the operator to tell if the vehicle has been positioned in a level condition Always frame sway the vehicle either right or left until the indicator reads zero degrees 0 If zero cannot...

Page 50: ...ts turn the ignition switch to the RUN position ALL the lights 13 total will come ON for three seconds as a test function During this time an audible alarm will sound Replace any bulbs that DO NOT com...

Page 51: ...Refer to Understanding the Stabil TRAK System on page 74 for a detailed explanation Engine Air Intake Heater Indicator 5 This light illuminates with the ignition switch in the RUN position any time th...

Page 52: ...ehicle with the transmission in N Neutral allowing time for cooling If the light does not go out after two minutes shut the vehicle down Hydraulic Oil Temperature Warning Indicator 2 This light illumi...

Page 53: ...Warning Indicator 5 This light illuminates when a restricted engine air filter is detected If the light is ON service the air filter s Hydraulic Oil Filter Restriction Warning Indicator 6 This light...

Page 54: ...ke pressure light or buzzer is on If the low brake pressure light or buzzer remains ON place the travel select lever in the N NEUTRAL DETENT position engage the parking brake switch and turn the engin...

Page 55: ...he gauge in the center of the front dash panel and indicates speed of the engine in revolutions per minute rpm Hourmeter 4 The hourmeter records engine operating hours and has a total readout of 99 99...

Page 56: ...ator 1 Whenever the headlights are on high beam this light will illuminate and remain ON until the headlights are switched to low beam Turn Signal Indicator 2 The turn signal indicator light will illu...

Page 57: ...Worklights and Front and Rear Worklights The lights only work when the ignition switch is in the RUN position Push the TOP of the rocker switch in to turn all the worklights OFF To turn the front work...

Page 58: ...ip end 2 of the turn signal switch counterclockwise to the first position 3 to turn the parking lights ON Turn the twist grip to the second position 4 to turn the headlights and parking lights ON Turn...

Page 59: ...only work when the ignition switch is in the RUN position To activate the left turn signal 7 RAISE the lever To activate the right turn signal 8 LOWER the lever To deactivate either directional signa...

Page 60: ...of the rocker switch IN Beacon Light or Strobe Light The beacon light or strobe light are activated by a single rocker switch 2 located in the upper bank of switches on the right side of the dash This...

Page 61: ...pen Swing the window all the way open and lock in place on the outside of the cab The window can be released from inside the cab using the window release located on the inside of the cab or from the o...

Page 62: ...ee to swing open Front Windshield Closed Cab Only Windshield Removal 1 The front windshield 4 can be removed from the cab to provide additional ventilation 2 Remove the windshield wiper arm assembly 5...

Page 63: ...windshield under the upper retainer 9 Push the windshield up as far as possible 2 Place the bottom of the windshield 4 into the windshield opening in the cab Secure the windshield in place with the lo...

Page 64: ...the dash This single rocker switch controls the speed of the front windshield wiper Push the TOP of the rocker switch in to turn the front wiper OFF Place the rocker switch in the MIDDLE position to...

Page 65: ...sher switch 3 is located in the lower bank of switches on the right side of the dash This single rocker switch controls the skylight roof wiper skylight roof washer along with the rear window washer W...

Page 66: ...dash From left to right the control panel consists of a variable speed fan control 5 an A C on off switch 6 and a temperature control 7 Control of air flow is made by opening closing or redirecting th...

Page 67: ...he cab turn temperature control knob 7 to the far right position RED HOT direct desired air flow by adjusting vent louvers turn fan control 5 to position 3 8 to assure rapid defrost To cool the cab tu...

Page 68: ...et 3 meters and tilt the carriage backward 3 Exit the vehicle using both hand holds 4 Raise the quick attach pin lock lever 1 and pull out the pin 2 at the bot tom of the quick attach link 3 5 Return...

Page 69: ...ght against the rear of the attachment and the holes in the link and the attachment should be aligned 6 Place the travel select lever in the N NEUTRAL DETENT position engage the parking brake switch a...

Page 70: ...ngle when reading the capacity chart see Using the Capacity Chart on page 71 Boom Extension Indicator The boom extension indicator is a series of letters 4 that become visible as the boom is extended...

Page 71: ...hree rear view mirrors are provided to aid the operator s rear visibility One mirror is mounted on the front left upper corner of the cab 7 one inside the cab 8 and the other mirror is mounted on the...

Page 72: ...in matched pairs Block forks should be used in matched sets The maximum load capacity for this vehicle is 9 000 pounds 4 082 Kg The matched pair or set of forks used on this vehicle should have total...

Page 73: ...equipped with three indicators that will assist the operator in determining how to accurately use the capacity chart These indicators are boom extend letters 5 boom angle indicator 6 transfer carriage...

Page 74: ...not started to show and the boom angle indicator reading does not go below approximately 48 and the transfer carriage will remain fully retracted This condition is however a maximum limit for this wei...

Page 75: ...AFETY INSTRUCTIONS Always connect couplers on hydraulically powered attachments 2 0 0 ft 4 8 12 16 20 24 28 32 0 ft 24 0 0 ft 14 19 23 29 6 7 10 13 16 4 4 8 12 16 20 24 28 32 36 40 44 40 60 50 30 5 20...

Page 76: ...e three modes Free Pivot Mode With the boom below 40 1 the Stabil TRAK system is in the FREE PIVOT MODE 2 and the rear axle is allowed to pivot freely The frame sway control will function normally Bot...

Page 77: ...lock light on the front dash panel will be ON 6 The Stabil TRAK slow pivot light on the front dash panel will be OFF 7 Engaging the parking brake switch Placing the travel select lever in the N NEUTRA...

Page 78: ...l respond SLOWLY to changes in terrain The Stabil TRAK slow pivot light on the front dash panel will be ON 3 The Stabil TRAK lock light on the front dash panel will be OFF 4 The frame sway control wil...

Page 79: ...FF and the front left tire lowers to the ground at any time during Steps 4 through 7 the test was not performed properly or the Stabil TRAK system is not functioning properly Carefully repeat the step...

Page 80: ...rn the ignition switch and start the engine b Turn the parking brake switch OFF c Move the range select lever to 1 FIRST gear d Move the travel select lever to the F FORWARD position e Drive the vehic...

Page 81: ...off the ground If the front left tire drops to the ground repeat steps 1 thru 4 IMPORTANT Perform Steps 5 thru 9 with the engine rpm at idle Step 5 a Keep the service brake pedal depressed b Move the...

Page 82: ...raise or lower during frame sway g Frame sway back toward 0 leaving the vehicle swayed to the right approximately 1 to 2 Step 8 a Depress the service brake pedal fully b Disengage the parking brake s...

Page 83: ...should immediately lower when the frame sway function is stopped g Frame sway the vehicle back to 0 and pause briefly h Frame sway the vehicle no more than 5 to the right i Check that the front right...

Page 84: ...82 Model 944E Origin 3 04 Operation This Page Intentionally Left Blank Courtesy of Crane Market...

Page 85: ...Fuels with Cetane ratings higher than 40 may be needed in higher altitudes or extremely low ambient temperatures to prevent misfiring and excessive smoke When operating at temperatures above 32 F 0 C...

Page 86: ...tion switch to the OFF position Remove the keys from the igni tion 2 Slowly unscrew the cap and wait for any hissing noise to stop Then unscrew the cap all the way and remove the cap from the filler n...

Page 87: ...ne and starter come to a com plete stop before cranking the engine again IMPORTANT DO NOT crank the starting motor continuously for more than 30 seconds Stop cranking the starter and allow the starter...

Page 88: ...ter light on the front dash panel to turn OFF When the light turns OFF the engine grid heater is at the proper temperature and the engine is ready to start 6 Turn the ignition switch to the START posi...

Page 89: ...85 6 Remove the jumper cables in the reverse order of their connection i e negative ground connection first etc Jump Starting WARNING NEVER jump start the vehicle directly to the starter solenoid Dea...

Page 90: ...lacing the load use the capacity chart to determine safe boom extension range for the applicable load To place a load align the forks at the level the load is to be placed and then extend the boom slo...

Page 91: ...le b Width of the platform shall not be wider than the width of the vehicle measured across the load bearing tires plus 10 250 mm on each side c Minimum space requirements for each person on the platf...

Page 92: ...hing point for freedom of move ment and its length is to limit free fall to 5 feet 1500 mm measured from the point of attachment to the operator The complete system shall be capable of withstanding th...

Page 93: ...9 Level the platform in both the side to side and front to back directions before use 10 Before lifting or lowering personnel be sure the vehicle lifting mechanism operates smoothly through the entir...

Page 94: ...nnel to enter or exit the platform through the appropriate platform access opening Person nel must not climb on any part of the vehicle or over the platform guardrails in an attempt to enter or exit t...

Page 95: ...used with an attachment that would alter the center of gravity or stability of this vehicle JLG assumes no liability for any third party attachment that would alter the center of gravity or stability...

Page 96: ...Truss Boom 10 Foot Truss Boom w Winch 3 Foot Truss Boom w Winch Hydraulically actuated attachments also have a maximum hydraulic pressure rating Ensure that the maximum rated hydraulic pressure of th...

Page 97: ...N NEUTRAL DETENT position and engage the parking brake switch 4 Lower the boom and ground the attachment 5 Turn the ignition switch to the OFF position and remove the key Shut Off WARNING To prevent...

Page 98: ...move the load from the vehicle 2 Fully retract the transfer carriage 3 Fully retract the boom Position the forks approximately 24 above the ground Refer to Emergency Boom Lowering on page 98 for prope...

Page 99: ...system does not drop during the towing operation 13 Carefully remove the blocks from the four wheels of the vehicle 14 The vehicle can now be towed or pushed out of the way Tow or push the vehicle at...

Page 100: ...If the load is in a position where it can be removed safely completely remove the load from the carriage otherwise leave the load in place 6 Place an accident prevention tag on both the ignition swit...

Page 101: ...to follow to retract and lower the boom The hydraulic lines are Boom Extend Line Extend Cylinder to Block 1 Boom Retract Line Extend Cylinder to Block 2 Boom Extend Line Block to Frame Bulkhead 3 Boom...

Page 102: ...TEP 1 STEP 2 BOOM LOWER LINE LIFT CYLINDER TO BLOCK OR BLOCK TO FRAME BULKHEAD STEP 1 Refer to STEP 1 BOOM EXTEND LINE EXTEND CYLINDER TO BLOCK OR BLOCK TO FRAME BULKHEAD STEP 1 STEP 2 BOOM RETRACT LI...

Page 103: ...support from the outer boom 8 Return to the cab fasten your seat belt and start the engine 9 Tilt the carriage upward if necessary for clearance before retracting the boom It may also be necessary to...

Page 104: ...ge 9 Place an accident prevention tag on both the ignition switch and steering wheel If you do not have a safety tag place tape over the ignition switch 10 Have the vehicle serviced immediately Replac...

Page 105: ...Emergency Operations 103 Model 944E Origin 3 04 OU1060 4 1 2 3 Courtesy of Crane Market...

Page 106: ...is manual and the service manual except they contain a more detailed account of how to perform these specific maintenance operations Lowering Engine Cover To release and lower the engine cover from th...

Page 107: ...General Maintenance 105 Model 944E Origin 3 04 Maintenance Schedule and Checklist 10 250 2000 1000 50 LB FT Nm 100 P OU0510 Courtesy of Crane Market...

Page 108: ...wing grease fittings using Multi Purpose Grease MPG every 50 hours NOTE Shorten the lubrication interval on all lube points when operating in severe conditions or during high cycling operation 1 Lubri...

Page 109: ...s which could lead to engine damage Adopt the policy that all elements should be replaced with new and not cleaned Inner Element An inner element should never be washed or reused Always install a new...

Page 110: ...the filter in an attempt to get a more positive seal This will cause sealing surface damage and allow dirt to by pass the filter Use liquid dishwashing soap Ivory Dawn etc on the seal of the filter on...

Page 111: ...r by removing the recirculation filter to gain access to the fresh air filter Pull the fresh air filter out of the pocket in the heater assembly housing When operating in normal conditions inspect the...

Page 112: ...brake switch and shut off the engine 2 Unlatch and open the engine cover 3 Check the coolant level in the overflow bottle 1 When the coolant is hot the bottle should be 1 2 to 3 4 full When the coola...

Page 113: ...hile the engine is still hot can cause cracks in the engine block 3 Slowly turn the radiator cap 2 to the first stop and allow any pressure to escape Remove the radiator cap WARNING DO NOT attempt thi...

Page 114: ...fter radiator is drained close the petcock and remove the hose 6 Transfer to used coolant to a properly labeled container and dispose of properly 7 Drain the contents of the overflow bottle 3 by remov...

Page 115: ...ator fins and core 11 Start the engine and run the vehicle to the normal operating temperature then shut off the engine While the engine is cooling check for leaks 12 Allow the engine to cool Check th...

Page 116: ...n their operator manual A Oil Level Check 10 Hour Intervals 1 Level the vehicle ground the attach ment place the travel select lever in the N NEUTRAL DETENT position engage the parking brake switch an...

Page 117: ...parking brake switch and shut off the engine 3 Unlatch and open the engine cover 4 Place a receptacle under the engines oil pan drain plug 4 The drain plug is located under the engine on the frame si...

Page 118: ...nd clean the filter sealing surface 8 Apply a thin coat of clean engine oil to the new filter mating surface 9 Install the new oil filter and hand tighten Use an oil filter wrench or strap to tighten...

Page 119: ...mmended oil type for various condi tions Engine oil capacity with filter change is 10 5 quarts 10 liters 12 Reinstall oil fill cap 3 Start engine and allow to run for several minutes 13 Shut off engin...

Page 120: ...open the engine cover Loosen the drain cock 1 on the underside of the fuel filter 2 and allow all the water to drain into a container until clear fuel is visible Dispose of properly Tighten drain cock...

Page 121: ...l the new fuel filter with clean No 2 diesel fuel 6 Lubricate the o ring seal with clean No 2 diesel fuel 7 Install the fuel filled filter and hand tighten DO NOT overtighten NOTE Mechanical over tigh...

Page 122: ...osen the two hose clamps 3 that secure the strainer in place 3 Remove the old strainer and dispose of properly 4 Install the new strainer with arrow 4 pointing toward the lift pump 5 Assemble the hose...

Page 123: ...cated on the filter head 2 Operate the hand plunger 6 on the lift pump 2 until fuel flowing from the fitting is free of air 3 Tighten the vent screw 5 and torque to 7 lb ft 9 Nm The process to vent th...

Page 124: ...the injector fitting 6 Tighten the fitting Torque to 22 lb ft 30 Nm 7 Repeat Steps 4 6 for each fitting until the engine runs smoothly 8 With the engine running visually check for leaks Turn ignition...

Page 125: ...ots under hand pressure 5 Spin the fan and check for wobble or excessive play Maximum play should be 006 inch 0 15 mm 6 To install the fan belt 4 first position the belt over the fan pulley 6 crank sh...

Page 126: ...Replace if cracked or frayed 4 Check the tension of the belt midway between the fan pulley 2 and the compressor pulley 3 The belt deflection should be 3 16 4 8 mm with an applied force of 5 1 2 lb 2...

Page 127: ...oil level should be in the center of the sight glass when oil is cold If oil is not visible remove the hydraulic oil fill cap 8 or 9 and add hydraulic oil ISO Grade 46 Hydraulic Oil until the oil lev...

Page 128: ...e o ring seal 4 located in the groove on top of the filter housing 6 Remove the spring 5 from the top of the filter Remove the filter 6 with center assembly from the filter chamber 7 Remove the center...

Page 129: ...hydraulic reservoir It is recommended that the fill port 12 be used to add oil The oil is added through the filter which will help to prevent contaminates from entering the hydraulic system Fill with...

Page 130: ...with the engine at idle and the oil at normal operating temperature 3 Remove the transmission dipstick 1 Check oil level 4 Add Universal Tractor Fluid to transmission as required to bring the level u...

Page 131: ...the engine cover Allow the engine and transmission to cool 3 Place a receptacle under the transmission drain plug 2 Remove the drain plug and allow the Universal Tractor Fluid to drain into the recept...

Page 132: ...o position and tighten the battery tray retainer bolt 9 Remove the dipstick 3 and fill with Universal Tractor Fluid The maximum capacity of the entire transmission system is 15 9 quarts 15 liters Re i...

Page 133: ...ve the oil fill level plug from the transfer case and check the oil level 4 Add oil as required through the oil fill level plug hole 4 Bring the oil level up even with the oil fill level plug hole Ref...

Page 134: ...fill level plug 1 5 Remove the oil drain plug 2 from the transfer case 3 6 Allow the oil to drain completely into the receptacle Transfer the oil into a container with a cover and label the container...

Page 135: ...vel plugs 5 and remove the plugs from the axle housing 3 Add Universal Tractor Fluid to bring the oil level up and even with the level plug holes 4 Re install the axle fill plug 4 and torque to 37 lb...

Page 136: ...3 Remove the plug from the axle housing and allow the oil to drain completely 4 Transfer the oil to a container with a cover and label the container as used oil Dispose of properly 5 Clean off the ax...

Page 137: ...who are aware of all safety instructions and particular component features A Front Axle 1 Block all four wheels to prevent any unexpected movement of the vehicle after the parking brake is disabled 2...

Page 138: ...rake discs apart IMPORTANT DO NOT damage the surfaces of the brake discs when spreading the brake discs 7 Using a feeler gauge check the gap 2 between the brake discs 3 If the gap is greater than 22 5...

Page 139: ...ding the brake discs 2 Using a feeler gauge check the gap 2 between the brake discs 3 If the gap is greater than 167 4 25 mm replace the brake discs NOTE If the brake discs are worn beyond 167 4 25 mm...

Page 140: ...nd the wheel end fill drain plug 2 Slowly remove the plug Check the oil level 4 Add Universal Tractor Fluid to bring the oil level up and even with the plug hole 5 Clean and re install the wheel end f...

Page 141: ...y loosen the plug Hold a receptacle under the wheel end and remove the plug from the wheel end 4 Allow the oil to drain completely into the receptacle Transfer the oil to a container with a cover and...

Page 142: ...ly inflated simply by looking at it 3 Add air if required Fill the tire s to Standard Tires 15 5 25 12 ply 65 psi 448 kPa Optional Rock Tire 15 5 25 12 ply 65 psi 448 kPa Optional Radial Tire 15 5R25...

Page 143: ...h of the ten lug nuts The recommended torque should be 430 470 lb ft 583 637 Nm C Replacing Tires IMPORTANT The Standard Tire size and ply rating for this vehicle is 15 5 25 12 PLY Make sure any repla...

Page 144: ...tteries 1 are located inside the engine pod in front of the hydraulic oil reservoir 2 The upper battery must be rotated out of the way to gain access to the lower battery 3 Wearing safety glasses visu...

Page 145: ...s grounds or defective electrical components The fuse and relay block is mounted under the lower right side of the operators side console 3 To gain access remove the cover plate 4 from the right side...

Page 146: ...4 Model 944E Origin 3 04 General Maintenance Relay Locations 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E10 E5 E4 E9 E3 E8 E2 E7 E1 E6 MU33801 1 Courtesy of Crane Marke...

Page 147: ...er of the fuse block Pull the flasher straight out to replace No Volt Circuit Controlled E1 12 Volt Transmission Control E2 12 Volt Ignition E3 12 Volt Neutral Start E4 12 Volt Back Up Alarm E5 Open E...

Page 148: ...146 Model 944E Origin 3 04 General Maintenance Fuse Locations 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E10 E5 E4 E9 E3 E8 E2 E7 E1 E6 MU3390 Courtesy of Crane Market...

Page 149: ...ary Hydraulics 11 Open 12 Open 13 Open 14 3 Amp Violet ECM Indicator Light 15 40 Amp Orange Closed Cab Main Opt 16 10 Amp Red Front wiper Opt 17 25 Amp Clear Heater Fan Opt 18 7 5 amp Brown Roof Wiper...

Page 150: ...the tethers on the engine side of the holder 3 3 Remove the two hex nuts 4 and lockwashers 5 securing the fuse 1 and wires to the fuse holder 3 Remove the fuse and replace with a new fuse 4 Place the...

Page 151: ...er This relay controls the engine fuel pump To replace the relay remove the relay from the engine panel then remove the relay from the wire harness connector 8 1 Unlatch and open the engine cover 2 Lo...

Page 152: ...boom to a horizontal level position 2 Fully extend the boom then retract it 2 51 mm one inch per section Turn the vehicle OFF 3 Measure the sag 1 in the top boom extend chain 2 between the bottom of t...

Page 153: ...arking brake switch and raise the boom to a horizontal level position retract the boom completely and turn the vehicle OFF 2 Adjust the extend chain by tightening or loosening the retract chain adjust...

Page 154: ...e bottom of the chain and the top of the intermediate boom 3 at their closest point 1 Acceptable boom chain sag is between 3 00 76 mm and 4 00 102 mm If the measurement is still less than 3 00 76 mm t...

Page 155: ...pproximately 2 ft 610 mm and shut the vehicle OFF 2 At the front underside of the outer boom 4 loosen the retract chain adjust ment nut 5 Back the nut off until the top of the nut is flush with the en...

Page 156: ...ing 6 Return to the cab start the engine and fully retract the boom Shut the vehi cle OFF 7 At the front underside of the outer boom 5 tighten the retract chain adjustment nut 6 to remove the excess s...

Page 157: ...and or the mechanical connections between the chain components Cracking can be and often is microscopic Going from microscopic cracking to complete failure can be either abrupt or may require an exten...

Page 158: ...engine off The extend chains will be visible for inspection with the vehicle in this state While doing the chain inspection check all chain clevis ends for distortion or cracking and sheaves for bear...

Page 159: ...ts clevis terminals could give an inaccurate reading The ends of the chains near the clevis terminal will not have flexed as frequently if at all as nearer the middle of the chains Measure across a sp...

Page 160: ...laced immediately DO NOT attempt to repair the chain by welding or driving the pin s back into the chain Once the press fit integrity between outside plates and pins has been altered it cannot be rest...

Page 161: ...orrosion Fatigue Cracking Corrosion fatigue cracks are very similar to fatigue cracks in appearance Corrosion fatigue is the combined action of an aggressive environment and cyclic stress Other Modes...

Page 162: ...lubricant can penetrate to the working surfaces Lubricant may be applied with a narrow paint brush or directly poured on but the chain should be well flooded with lubricant and the boom should be exte...

Page 163: ...he vehicle in very dusty or dirty conditions the pads will wear much faster The pads that are under most stress from the weight of the load will also wear faster than other pads For example the lower...

Page 164: ...rfaces Contact your local Lull Distributor Replacement of boom wear pads must be performed by a Lull Distributor when the wear pads indicate IMPORTANT The boom has been factory lubricated for proper w...

Page 165: ...e attachment must remain slightly off the ground Turn the vehicle OFF 4 At the rear of the transfer carriage use a feeler gauge to check the gap 6 between the wear pads 7 and the top of the rail 8 Thi...

Page 166: ...Remove the two capscrews 1 holding each wear pad and shims to the transfer carriage 2 5 Add the required shims 3 between the wear pad 4 and the transfer car riage 2 6 Secure in place with the two cap...

Page 167: ...and again check the gap 7 between the roller and the existing shims of each roller with the transfer carriage in this position Record the gap of each roller 6 Start the engine and move the transfer c...

Page 168: ...llers and record the gap on each side 5 Start the engine and move the transfer carriage all the way forward Shut the vehicle OFF Use a rawhide hammer to tap the rollers against the rails and again che...

Page 169: ...he total thickness 7 of a new wear pad 5 is 625 16 mm The angled cut 6 will provide a total wear thickness 8 of 25 6 mm This will leave approximately 375 10 mm of total unused base material The pads m...

Page 170: ...cle OFF 3 Check the gap 1 between the top of the wear pad 2 and the bottom of the rail 3 The maximum gap should be 12 3 mm Front Upstop Wear Pad Shimming As Required Refer to the Service Manual for p...

Page 171: ...protector sleeves for wear Inspect all hoses 5 for wear Replace any hoses when the steel braids are first visible Hoses with protective sleeves 6 check the sleeves for worn areas If a worn area is de...

Page 172: ...ferably store the vehicle inside where it will remain dry If it must be stored outside park it on lumber laid on flat level ground or on a concrete slab and cover with a tarp B Removing From Storage A...

Page 173: ...rans portation and the proper selection and use of transportation and tiedown devices making sure the equipment used is capable of supporting the weight of the vehicle being transported and that all m...

Page 174: ...d not move Step 2 a Remove your foot from the throttle pedal b Move the travel select lever to R REVERSE c Depress the throttle pedal fully The unit should not move d Remove your foot from the throttl...

Page 175: ...h to the OFF position and back down off the grade e Repeat Test 3 by backing up the grade and checking the park brake holding performance If the parking brake or transmission de clutch does not pass t...

Page 176: ...Hydraulic System System Capacity 50 2 gallons 190 liters Reservoir Capacity to Full Mark 33 5 gallons 127 liters Type Of Oil ISO Grade 46 Hydraulic Oil Transmission Capacity with filter change 15 9 q...

Page 177: ...e Torque 430 470 lb ft 583 637 Nm Maximum Ground Pressure w full load Standard Tires 15 5 25 12 Ply 70 psi 483 kPa Optional Rock Tire 15 5 25 12 Ply 80 psi 552 kPa Optional Radial Tires 15 5R25 2 star...

Page 178: ...ce 16 inches 406 mm F Tread Center 84 inches 2 134 mm G Turning Clearance Curb to Curb Radius 150 inches 3 810 mm H Turning Clearance Radius 155 inches 3 940 mm J Max Forward Reach TC Rearward 29 feet...

Page 179: ...tive Ground Number of Batteries Two Type Maintenance Free 850 Cold Cranking Amps Each Battery Series of Battery 27 Alternator Rating 12 Volt 95 Amp Turbocharged Cummins Model QSB4 5T Horsepower 110 hp...

Page 180: ...178 Model 944E Origin 3 04 Specifications This Page Intentionally Left Blank Courtesy of Crane Market...

Page 181: ...Chemical Hazards 12 Clearances 16 Clothing and Safety Gear 12 Cold Start Grid Heater Fuses 148 Cold Starting 86 Coolant Drain and Flush 111 Coolant Level 110 Crab Steering Mode 29 D Decals 20 Definin...

Page 182: ...lter Change 126 Hydraulic Oil Filter Restriction Warning Indicator 51 Hydraulic Oil Level 125 Hydraulic Oil Temperature Warning Indicator 50 I Ignition Switch 27 In line Fuel Strainer 120 Inner Safety...

Page 183: ...g Wheel 26 Storage 170 Strobe Light 58 T Three Mode Steer Select 27 Tilt Steering Wheel Lever 26 Tip Over Hazard 18 Tires 141 Top Boom Chain Tension Adjustment 151 Towing a Disabled Vehicle 96 Transfe...

Page 184: ...Index 182 Model 944E Origin 3 04 This Page Intentionally Left Blank Courtesy of Crane Market...

Page 185: ...Load Charts 183 Model 944E Origin 3 04 Load Charts This Section Contains Representations Of All The Load Charts Contained In The Operators Cab Of This Vehicle Courtesy of Crane Market...

Page 186: ...Use with Lull approved carriages only 4110426 ASME B56 6 2002 Part lll SAFETY INSTRUCTIONS Always connect couplers on hydraulically powered attachments 80 1 24 80 1 A C E F D B 4 4 8 12 16 20 24 28 3...

Page 187: ...6 2002 Part lll Use with Lull approved carriages only 944E 42 SAFETY INSTRUCTIONS Always connect couplers on hydraulically powered attachments 2 0 0 ft 4 8 12 16 20 24 28 32 0 ft 24 0 0 ft 14 19 23 29...

Page 188: ...ASME B56 6 2002 Part lll SAFETY INSTRUCTIONS Always connect couplers on hydraulically powered attachments 0 ft 4 8 12 16 20 24 28 32 36 40 0 ft 4 8 12 16 20 24 28 32 36 40 44 4 0 ft 13 9 18 7 21 26 29...

Page 189: ...ved carriages only 4110429 ASME B56 6 2002 Part lll SAFETY INSTRUCTIONS Always connect couplers on hydraulically powered attachments 26 0 4500lb 6 5 4 3 2 1 A C E F D B 6 3 2 1 4 5 40 50 30 5 20 10 0...

Page 190: ...CTIONS Always connect couplers on hydraulically powered attachments 10 ALWAYS travel slowly rig properly use two tethers SWINGING LOADS can cause MACHINE TIPOVER which can result in death or serious i...

Page 191: ...6 6 2002 Part lll SAFETY INSTRUCTIONS Always connect couplers on hydraulically powered attachments ALWAYS travel slowly rig properly use two tethers SWINGING LOADS can cause MACHINE TIPOVER which can...

Page 192: ...l slowly rig properly use two tethers SWINGING LOADS can cause MACHINE TIPOVER which can result in death or serious injury 944E 42 Use with Lull approved truss boom winch only ASME B56 6 2002 Part lll...

Page 193: ...achments ALWAYS travel slowly rig properly use two tethers SWINGING LOADS can cause MACHINE TIPOVER which can result in death or serious injury 944E 42 Use with Lull approved truss boom winch only ASM...

Page 194: ...192 Model 944E Origin 3 04 Load Charts This Page Intentionally Left Blank Courtesy of Crane Market...

Page 195: ...Accident Prevention Tags Accident Prevention Tags 8990401 Origin 5 00 OS2180 Courtesy of Crane Market...

Page 196: ...Accident Prevention Tags OS2180 8990401 Origin 5 00 Courtesy of Crane Market...

Page 197: ...should not be included on this form Mfg Model _______________________________________________________________ Serial Number ____________________________________________________________ Previous Owner...

Page 198: ...Courtesy of Crane Market...

Page 199: ...Courtesy of Crane Market...

Page 200: ...350 20 Fax 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong Phone 852 2639 5783 Fax 852 2639 5797 JLG Industries Italia s r l Via Po 2...

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Lull 0160003882, Owner'S/Operator'S Manual

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