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Lull 944E-42, Service Manual

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Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4

6.24 

Model 644E-42/944E-42

Rev. 6/04

6.13

TROUBLESHOOTING

This section provides an easy reference guide covering 
the most common problems that occur during operation 
of the transfer case.

Note:  Contact your local Lull distributor or the JLG 
Service Department at (877) 554-5438 or 
(717) 485-6657, if internal transfer case repair is 
required during the warranty period.

Detailed transfer case service instructions covering repair, 
disassembly, reassembly, adjustment and troubleshooting 
information is provided in the ZF Model TB92-I 4 Transfer 
Case Operating and Repair Manual, JLG P/N 8990495

 

(ZF part number 5871.134.002).

The transfer case should be checked, serviced and 
repaired only by experienced service technicians who are 
aware of all safety instructions and particular component 
features.

6.13.1

Transfer Case Troubleshooting

Problem

Cause

Remedy

1. Excessive transfer case 

noise.

1. Oil level too low.

2. Transfer case filled with 

incorrect oil.

3. Excessive bearing “end play.”

4. Worn or damage bearings.

5. Worn or broken gear teeth.

6. Contamination in the transfer 

case.

7. Incorrect assembly of parts.

1. Fill oil to correct level (Refer to 

Section 2.5.10, “Fluid and 
Lubricant Capacities.”)

2. Drain transfer case and fill to 

correct level with Universal 
Tractor Fluid (Refer to Section 
2.6.7, a. “Transfer Case Fluid.”)

3. Check bearing end play and 

correct with shims as needed.

4. Replace bearings as needed.

5. Replace gears as needed.

6. Check for foreign particles.

7. Check assembly of transfer 

case components.

2. Oil leaking from transfer case.

1. Breather blocked.

2. Plugs or fittings loose.

3. Incorrect oil level.

4. Gaps in sealant between 

housing halves.

5. Worn, damaged or improperly 

seated seals and/or worn or 
damaged input/output shaft 
sealing surfaces.

6. Damaged housing.

1. Clean or replace breather.

2. Tighten plugs and fittings.

3. Fill oil to correct level (Refer to 

Section 2.5.10, “Fluid and 
Lubricant Capacities.”)

4. Clean housing mating surfaces, 

apply new sealant (Loctite

®

 518) 

and torque housing capscrews 
to 34 lb-ft (46 Nm).

5. Replace seals and/or input/

output gear assemblies as 
needed.

6. Replace housing.

Summary of Contents for 944E-42

Page 1: ......

Page 2: ......

Page 3: ...nversion Factors 2 7 2 5 Specifications 2 10 2 6 Fluids Lubricants and Capacities 2 23 2 7 Cleaning 2 27 2 8 Replacement 2 28 2 9 Hoses and Tubes 2 28 2 10 Bearings 2 29 2 11 Pressure Testing and Adju...

Page 4: ...6 3 6 5 Transmission Specifications 6 4 6 6 Transmission Maintenance 6 4 6 7 Transmission Replacement 6 6 6 8 Troubleshooting 6 15 6 9 Towing a Disabled Vehicle 6 18 6 10 Transfer Case Component Term...

Page 5: ...ulic System Pump 8 166 8 12 Valves and Manifolds 8 177 8 13 Accumulators 8 207 8 14 Hydraulic Cylinders 8 213 Section 9 Electrical System 9 1 9 1 Electrical Component Terminology 9 5 9 2 Service Warni...

Page 6: ...44E 42 SN 20118 Before SN 0160002519 thru 0160003877 944E 42 SN 20123 Before SN 0160002514 thru 0160003881 10 17 10 6 Stabil TRAK Electrical Circuit Operation and Troubleshooting 644E 42 0160003878 Af...

Page 7: ...anics as Operators 1 3 1 4 Safety Information 1 3 1 4 1 Safety Alert Symbol 1 3 1 4 2 Hazard Statements 1 4 1 5 Accident Prevention Tag Usage 1 4 1 6 Safety Instructions 1 5 1 6 1 Personal Hazards 1 5...

Page 8: ...to satisfy a situation not covered sufficiently consult your local Lull distributor or the JLG Service Department at 877 554 5438 or 717 485 6657 Many factors contribute to unsafe conditions carelessn...

Page 9: ...ON The following information provides general safety instructions including examples of hazard statements with signal words notification of hazards methods to help avoid hazards and the consequences o...

Page 10: ...which if not avoided could result in death or serious injury The signal word CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury The signal...

Page 11: ...VER lift a heavy object without the help of at least one assistant or a suitable sling and hoist 1 6 2 Equipment Hazards OWNERS OPERATORS MANUAL Before operating the vehicle carefully read understand...

Page 12: ...e Obtain assistance block all wheels and add supports if necessary before beginning any work SUPPORTS AND STRAPS Install safe stable supports slings or straps beneath or around a component or structur...

Page 13: ...LOSION 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 5Ft 6Ft 120cm 110cm 100cm 90cm 80cm...

Page 14: ...Safety Practices 1 8 Model 644E 42 944E 42 Rev 6 04 This Page Intentionally Left Blank...

Page 15: ...merican to Metric Conversions 2 7 2 4 2 Approximate Metric to American Conversions 2 7 2 5 Specifications 2 10 2 5 1 Vehicle Dimensions 2 10 2 5 2 Vehicle Weights 644E 42 2 12 2 5 3 Vehicle Weights 94...

Page 16: ...ement 2 28 2 9 Hoses and Tubes 2 28 2 9 1 Hose and Tube Inspection 2 28 2 9 2 Hose and Tube Installation 2 28 2 10 Bearings 2 29 2 10 1 Bearing Removal 2 29 2 10 2 Bearing Cleaning 2 29 2 11 Pressure...

Page 17: ...is necessary that the operator mechanic be familiar with the name and location of the major assemblies on this vehicle The following illustration identifies the components that are referred to throug...

Page 18: ...derstand the safety instructions and the operation of the controls and safety equipment You must comply with all Danger Warning and Caution notices They are for your benefit 2 2 3 Replacement Parts an...

Page 19: ...the fitting 6 Complete the joint by tightening the nut to the torque specified in the table For hoses and swivel fittings use a second wrench to keep the female connector from moving during tightening...

Page 20: ...g as required but not more than one turn 6 Using two wrenches hold the fitting in the desired position and tighten the locknut 4 to the appropriate torque value listed in the table in Section 2 3 1 b...

Page 21: ...inches in3 16 Milliliters ml Fluid ounces fl oz 30 Milliliters ml Cups c 0 24 Liters l Pints pt 0 47 Liters l Quarts qt 0 95 Liters l Gallons gal 3 8 Liters l Cubic feet ft3 0 03 Cubic meters m3 Cubic...

Page 22: ...Liters l 2 1 Pints pt Liters l 1 06 Quarts qt Liters l 0 26 Gallons gal Cubic meters m3 35 Cubic feet ft3 Cubic meters m3 1 3 Cubic yards yd3 AIR PRESSURE Kilopascals kPa 0 145 Pounds per square inch...

Page 23: ...2 9 Model 644E 42 944E 42 Rev 6 04 General Information Specifications and Maintenance This Page Intentionally Left Blank...

Page 24: ...Below Grade Depth Boom Extended 2 73 0 8 m 2 6 0 8 m M Max Reach from Front of Front Tires TC Retracted 29 8 8 m 29 8 8 m N Max Reach from Front of Front Tires TC Extended 35 66 10 9 m 35 66 10 9 m O...

Page 25: ...11 Model 644E 42 944E 42 Rev 6 04 General Information Specifications and Maintenance T C E x t e n d e d T C R e t r a c t e d MU5820 24 0 0 0 A B C D E K L M N O U V W X Y Z AA F G H I J P Q R S T L...

Page 26: ...8 carriage two 48 pallet forks 12 full fuel tank and standard tires no hydrofill Open Cab 24 267 lb 11 007 kg Closed Cab 24 708 lb 11 207 kg Operating Load 6 000 lb 2 721 kg Curb Weight Vehicle curb w...

Page 27: ...Bucket 1 25 yd3 0 956 m3 795 lb 361 kg 795 lb 361 kg Broom 8 foot 2 44 m 1 100 lb 495 kg 1 100 lb 495 kg Pallet Forks 1 75 x 4 x 48 4 4 x 10 x 122 cm quantity 2 250 lb 113 kg 250 lb 113 kg Pallet Fork...

Page 28: ...d Gear 0 14 mph 0 23 km hr 0 14 mph 0 23 km hr Fourth Gear 0 20 mph 0 32 km hr 0 20 mph 0 32 km hr Function Approximate Times Boom Extend 11 to 15 seconds Boom Retract 13 to 17 seconds Boom Lift Retra...

Page 29: ...mps F3 Transmission 15 amps 15 amps F4 Fuel Solenoid 7 5 amps 7 5 amps F5 Ignition Power 20 amps 20 amps F6 Back Up Alarm Horn 10 amps 10 amps F7 Stability Circuit 10 amps 10 amps F8 Dash 10 amps 10 a...

Page 30: ...Up Alarm 12 volt 12 volt E5 Stability Brake 644E 42 SN 0160003877 944E 42 SN 0160003881 Before E5 Open 644E 42 SN 0160003878 944E 42 SN 0160003882 After 12 volt 12 volt E6 Stability Lock 12 volt 12 vo...

Page 31: ...gine Low Idle 950 50 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type Replaceable Primary and Safety Elements Peak Torque 278 lb ft 1500 rpm Average Fuel Consumption Depending on Load Duty 2 gal...

Page 32: ...rb this setting Description Engine Make Model Cummins Turbo QSB 4 5T Displacement 275 in3 4 5 liters Horsepower 110 HP 2500 rpm Number of Cylinders 4 Engine High Idle with No Load 2 650 100 Engine Low...

Page 33: ...13 8 liters Overflow Bottle Capacity 3 2 qt 3 0 liters Type of Fluid 50 50 mix of ethylene glycol and water Refer to Section 2 6 5 Engine Transmission Capacity w Filter Change 15 9 qt 15 liters Filte...

Page 34: ...ief Aux 3 000 100 psi 206 8 6 9 bar Transfer Carriage Cylinder Base Port Relief 2 500 100 psi 172 4 7 bar Transfer Carriage Cylinder Base Port Relief 3 750 100 psi 258 6 6 9 bar Extend Base Port Relie...

Page 35: ...tandard Tire 775 lb 351 Kg 798 lb 362 Kg Tire Footprint Area Gross area over entire footprint established under maximum tip load Vehicle with Standard Tires and Rated Load 230 in2 1 484 cm2 263 in2 1...

Page 36: ...sed in multiples the total rating of any combination of forks will be the sum of their rated capacity All forks should be used in matched pairs 644E Only The maximum load capacity for this vehicle is...

Page 37: ...m viscosity at 212 F 10 C 9 1 cSt Pour point Maximum 32 F 36 C Flash point Minimum 392 F 200 C Minimum viscosity index 135 DO NOT add additional friction modifier to factory filled wheel ends All whee...

Page 38: ...e ISO 46 HYDRAULIC OIL GULF HARMONY 46 AW AMOCO RYKON 46 MOBIL DTE 25 ARCO DURO AW S 215 SHELL TULLUS 46 BENZ PETRAULIC 46 7C SUN SUNVIS 821 WR CHEVRON AW HYDRAULIC OIL 46 TEXACO RANDO HD 46 CITGO PAC...

Page 39: ...um 392 F 200 C Minimum viscosity index 135 b Transmission Capacity Capacity w filter change 15 9 qt 15 liters Filter 1 qt 1 liter 2 6 7 Transfer Case a Transfer Case Fluid In general use a oil that me...

Page 40: ...ctive film two ten thousandths of an inch 0 0002 or 0 00005 mm thick One such rust inhibitor that is specifically formulated for this purpose is LPS 3 It is marketed by LPS Laboratories Inc 4647 Hugh...

Page 41: ...e Corporation 1001 Trout Brook Crossing Rocky Hill CT 06067 USA Phone 1 800 LOCTITE 1 800 562 8483 FAX 860 571 2460 Internet http www loctite com Loctite is a registered trademark of Loctite Corporati...

Page 42: ...ition have failed and must be replaced ALWAYS replace the entire hose or tube assembly if the fittings are damaged 2 Hoses must remain in good condition Obvious signs of external hose wear or hydrauli...

Page 43: ...as shafts and gears PUSH FIT into static locations such as reduction gear housings 3 Always install the bearing into the rotating part first whenever possible 4 Use a press or the proper installation...

Page 44: ...Check connectors for broken frayed or loose wires 5 Check for brittle or frayed wire shielding 6 Connect the negative battery cable terminal s to the battery or batteries if it is disconnected 7 Check...

Page 45: ...the transmission dipstick 11 Run engine for two minutes at idle to help prime the torque converter and transmission lines 12 Recheck the level of fluid in the transmission with the engine running at...

Page 46: ...General Information Specifications and Maintenance 2 32 Model 644E 42 944E 42 Rev 6 04 This Page Intentionally Left Blank...

Page 47: ...nspection 3 28 3 4 2 Chain Lubrication 3 35 3 4 3 Boom Chain Tension Check 3 35 3 4 4 Boom Chain Tension Adjustment 3 36 3 4 5 Boom Extend and Retract Chains Removal and Replacement 3 39 3 5 Boom Wear...

Page 48: ...location of the major assemblies of the boom system The following illustration identifies the components that are referred to throughout this section MU0160 Quick Attach Attachment Tilt Cylinder Inner...

Page 49: ...rs via action of the lift lower cylinder 3 3 BOOM ASSEMBLY MAINTENANCE The boom assembly consists of the inner intermediate and outer booms and supporting hardware IMPORTANT Boom replacement must be c...

Page 50: ...lace the travel select lever in the N NEUTRAL DETENT position engage the parking brake and shut the engine OFF 4 At the front of the intermediate boom remove the capscrews 2 and flat washers 3 holding...

Page 51: ...stating that the vehicle should not be operated Refer to Section 1 5 Accident Prevention Tag Usage 10 Unlock and open the engine compartment cover Allow the engine transmission and hydraulic fluid to...

Page 52: ...cylinder tube trunnion clamps 12 to the intermediate boom 16 Remove the three tie wraps 13 from the two hose guards 14 and remove the hose guards from the tilt cylinder hoses 15 WARNING Hydraulic flu...

Page 53: ...e couplers to the gooseneck of the new inner boom 19 Remove four capscrews holding the hose clamps 18 to their boom mounts at the rear of the inner boom 20 Use a suitable overhead lifting device and s...

Page 54: ...ing device and sling attached to the inner boom remove slack from the hoist sling and withdraw the inner boom six feet 2 m Note The Inner Boom s center of gravity is at about six feet 2 m in from the...

Page 55: ...top wear pads 8 side wear pads 9 bottom wear pads 10 shims 11 hose clamp mounts 12 washers 13 and capscrews 14 944E 42 Only Remove and mark the position of the top wear pads 15 side wear pads 16 botto...

Page 56: ...hose guide and wear pads should be installed at this time If the inner boom is not to be replaced with a new inner boom proceed to Step 5 1 Coat the capscrews 1 with Loctite 242 blue Insert hose guide...

Page 57: ...e clamp mounts 11 washers 10 and capscrews 12 according to their previously marked positions Coat the wear pad capscrews with Loctite 242 blue Torque capscrews 12 to 34 38 lb ft 46 52 Nm 944E 42 Only...

Page 58: ...ontacts the front of the intermediate boom Remove the sling and hoist 8 Coat clevis pin 9 with anti seize compound Attach the extend chain yoke 7 to the inner boom 8 with the clevis pin 9 and two reta...

Page 59: ...plate 21 and elastic locknut 22 to secure the extend cylinder trunnion clamps to the intermediate boom Be sure to assemble the right and left shim s and key plate as noted in disassembly Check that th...

Page 60: ...ide of the hoses 4 The guard edges should overlap inside and outside of the other hose guard 21 Loosely secure the hose guards 3 to the tilt cylinder hoses 4 with a tie wrap 5 Push the hose guards up...

Page 61: ...Connect the attachment tilt hose clamp 13 and auxiliary hydraulic hose clamp 14 to their mounting brackets at the rear of the intermediate boom Torque capscrews to 4 8 lb ft 6 11 Nm Note ALWAYS use n...

Page 62: ...s for measurement and adjustment procedures Note If you are replacing the inner boom with a new inner boom reinstall the quick attach 5 to the inner boom Refer to Section 3 6 4 Quick Attach Installati...

Page 63: ...242 blue Torque to 21 38 lb ft 29 52 Nm 36 If required replace any decals according to their previous positions Refer to the proper Parts Manual for correct locations WARNING Avoid prolonged engine op...

Page 64: ...g device and slings to lift and withdraw the intermediate boom from the outer boom until you can gain access to the outer boom bottom front wear pads 5 At the front of the outer boom remove the capscr...

Page 65: ...es 21 10 At the front of the boom remove the capscrew 22 locknut 23 sheave pin 24 and sheave 25 11 Inspect the boom and welds Contact your local Lull distributor or the JLG Service Department if struc...

Page 66: ...kg 3 Use a suitable overhead lifting device and sling to raise the intermediate boom and insert it into the outer boom Continually insert the intermediate boom until it extends approximately 6 inches...

Page 67: ...hickness requirements Add or remove shims as required Replace the wear pads with new ones if needed 10 Install the inner boom Extend Retract cylinder and extend chain and attaching hardware Refer to S...

Page 68: ...he outer boom and frame Label and remove the tubes Cap hose ends 5 Pull the hydraulic hoses out of the Outer boom Label the hoses for later installation 6 Loosen the inside boom proximity sensor ring...

Page 69: ...crew 19 washer 20 and one locknut 21 at the slave cylinder mount pin 22 13 Remove the slave cylinder mount pin 22 and carefully lower each slave cylinder against the transfer carriage DO NOT stretch o...

Page 70: ...ad lifting device and sling attached to the loop 6 on back of the outer boom Attach another sling around the outer boom near the front and secure it to the hoist Remove slack from the slings 2 Careful...

Page 71: ...knut 16 Torque capscrews to 18 31 lb ft 13 23 Nm 8 Use a suitable overhead lifting device and sling attached to the lift lower cylinder Remove slack from the hoist sling and raise the lift lower cylin...

Page 72: ...into the fittings Lubricate o rings with clean hydraulic oil 14 Remove the plugs and caps from the hoses and fittings and connect the auxiliary hydraulic 5 and attachment tilt 6 hoses to the boom tube...

Page 73: ...oom Extend Retract cylinder and extend chain and attaching hardware Refer to Section 3 3 1 Inner Boom Replacement 20 Clean up all debris hydraulic fluid etc in on near and around the vehicle 21 Start...

Page 74: ...Chemical Solutions or Vapors Corrosive attack on the chain components and or the mechanical connections between the chain components Cracking can be and often is microscopic Going from microscopic cr...

Page 75: ...pin center to pin center For the Retract Chain measure across a span of 17 pins 4 at the center of the retract chain Measure from pin center to pin center The maximum measurement allowed is 12 3 8 313...

Page 76: ...ract Chains Removal and Replacement Fatigue Cracking Fatigue cracks 4 are a result of repeated cyclic loading beyond the chain s endurance limit The size of the load and the frequency of its occurrenc...

Page 77: ...and Retract Chains Removal and Replacement b Expose Extend Chain for Inspection 1 Park the vehicle on level ground Place the travel select lever in the N NEUTRAL DETENT position engage the parking br...

Page 78: ...oom and raise the boom to a horizontal position Place the travel select lever in the N NEUTRAL DETENT position engage the parking brake switch and shut the engine OFF 3 Remove four capscrews 1 and fla...

Page 79: ...eplace a stretched or damaged chain with a new part Always replace both the chain and the clevis It is recommended that when any chain is replaced that all chains and clevis be replaced at the same ti...

Page 80: ...Remove the string or wire and the threaded eye or capscrew with flat washer from the end of the clevis Once the threaded clevis is through the tab on the outer boom 19 Reassemble the flat washer 6 sa...

Page 81: ...on Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated In extremely dusty conditions it may be necessary to lubricate the chains more often 3...

Page 82: ...urement is still less than 3 00 76 mm the boom chain need to be readjusted Note If all the adjustment has been used up on the retract chain adjustment nut and the extend chain is not within the range...

Page 83: ...excess slack from the chains 15 Make sure that the chain system is properly tensioned Refer to Section 3 4 3 Boom Chain Tension Check and Section 3 4 4 Boom Chain Tension Adjustment Note If the exten...

Page 84: ...he chain tension Refer to Section 3 4 3 Boom Chain Tension Check and Section 3 4 4 Boom Chain Tension Adjustment 4 Measure the distance again and tighten the locknut 3 until the distance is between 8...

Page 85: ...orque to 21 38 lb ft 29 52 Nm Note If the inner to intermediate boom separation distance cannot be achieved contact your local Lull distributor or the JLG Service Department 3 4 5 Boom Extend and Retr...

Page 86: ...ocknut 13 and remove the sheave pin 15 Remove the sheave 14 from the outer boom 7 Attach a string or wire to the extend chain yoke 8 The string or wire must be long enough to pull the extend chain thr...

Page 87: ...the capscrews with Loctite 242 blue Torque to 21 38 lb ft 29 52 Nm b Retract Chain Removal and Replacement 1 Park the vehicle on a hard level surface 2 Fully retract the boom and raise the boom to a h...

Page 88: ...ect the retract chain yoke 8 from the rear of the inner boom 9 Lay the chain assembly flat behind the inner boom 9 From the rear of the boom pull the retract chain out of the rear of the boom 10 Inspe...

Page 89: ...the retract yoke 8 on the rear of the inner boom 9 with the clevis pin 7 and two retaining rings 6 16 Remove the string or wire from the end of the clevis 17 Secure the threaded clevis in place with...

Page 90: ...e front of the Extend Retract cylinder 6 Note All shims are used to maintain a maximum total gap of 0 09 2 3 mm between the wear pad and the boom 3 5 1 Boom Wear Pad Replacement When replacing a wear...

Page 91: ...the fasteners securing them to the top sides and bottom of the boom When removing pads move the boom sections as needed to gain access for removal and installation of wear pads Mark or otherwise label...

Page 92: ...cle to allow removal of the wear pads 3 on the front of the cylinder Refer to Section 3 3 1 a Inner Boom Removal Steps 1 20 for information on removing the Extend Retract cylinder Coat all wear pad ca...

Page 93: ...Connecting to an Attachment 1 Perform this procedure on a hard level surface Position the vehicle directly behind the attachment to be mounted 2 Tilt the quick attach backward 3 Extend the boom appro...

Page 94: ...c locknut 5 Tap out upper boom pivot pin 6 5 Remove the quick attach assembly 7 from the inner boom gooseneck 8 retain shim washers 9 for reinstallation 6 Inspect the pin 6 for nicks or surface corros...

Page 95: ...Coat the upper pin with anti seize compound Tap upper 24 pin through quick attach assembly 25 and shim washers 26 equally placed on both sides as required and inner boom gooseneck 28 Note ALWAYS repl...

Page 96: ...der 3 gently to the ground 7 Remove all fittings from the attachment tilt cylinder 3 6 6 Attachment Tilt Cylinder Installation 1 Install a lifting eye bolt 2 to the nut on the attachment tilt cylinder...

Page 97: ...s or anchors 1 Locate break replace hose s or tube s tighten connections 2 Refer to Section 8 7 Hydraulic System Testing and or Section 8 14 6 Extend Retract Cylinder 3 Repair cylinder Refer to Sectio...

Page 98: ...nsion Adjustment 2 Replace chain s as needed Refer to Section 3 4 5 Boom Extend and Retract Chains Removal and Replacement 3 Replace wear pads Refer to Section 3 5 1 Boom Wear Pad Replacement 4 Remove...

Page 99: ...mmed 2 Incorrect wear pad gap or shimming or wear pads excessively worn 1 Re shim the boom to a maximum total gap of 0 09 2 3 mm with shims distributed evenly on both sides of the boom pivot pin Refer...

Page 100: ...nd Retract Chains Removal and Replacement 2 Check wear pads and replace as needed Refer to Section 3 5 1 Boom Wear Pad Replacement 10 Rapid boom pad wear 1 Incorrect wear pad gap 2 Rapid cycle times w...

Page 101: ...to Section 3 4 5 Boom Extend and Retract Chains Removal and Replacement 2 Lubricate chain sheave Refer to Section 3 4 2 Chain Lubrication 3 Lubricate chain sheave Refer to Section 3 4 2 Chain Lubricat...

Page 102: ...Boom 3 56 Model 644E 42 944E 42 Rev 6 04 This Page Intentionally Left Blank...

Page 103: ...me Sway Joystick Assembly Replacement 4 18 4 3 9 Single Joystick Assembly Replacement Optional 4 20 4 3 10 Electrical Components 4 21 4 3 11 Miscellaneous Cab Components 4 22 4 3 12 Enclosed Cab Compo...

Page 104: ...or assemblies of the vehicle cab and covers The following illustration identifies the components that are referred to throughout this section MU6261 Seat Accelerator Pedal Operator s Protective Struct...

Page 105: ...ance replace the cab if it is damaged Refer to the appropriate parts manual for ordering information The cab contains the seat operating controls numerous panels steering and brake components and more...

Page 106: ...seat belt mounting hardware on the seat and at the other end are bolted to the seat riser 1 Park the vehicle on a firm level surface Level the vehicle ground the attachment place the travel select lev...

Page 107: ...the steering column a Steering Wheel Removal 1 Park the vehicle on a firm level surface Level the vehicle ground the attachment place the travel select lever in the N NEUTRAL DETENT position engage th...

Page 108: ...g the pin 5 with the hole 6 in the steering column 2 Attach travel and gear select lever with the collar 4 and two hex socket head screws 2 Tighten the screws and nuts securely but DO NOT overtighten...

Page 109: ...3 2 a Steering Wheel Removal 4 Remove the transmission travel and gear selector lever Refer to Section 4 3 2 c Transmission Travel and Gear Select Lever Removal 5 Working through the front display pan...

Page 110: ...elp ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 2 Install new o rings into the fittings Lubricate the o rings with clean hydraulic oil 3 Connect the load s...

Page 111: ...select lever in the N NEUTRAL DETENT position engage the park brake switch and shut the engine OFF 2 Unlatch and open the engine cover Allow the hydraulic fluid to cool 3 Remove the front 7 and lower...

Page 112: ...g and operation Lubricate seals and o rings with clean hydraulic fluid Note Torque all the fittings as specified in Section 2 3 Torques 1 Place the steer select valve 6 on a suitable work surface 2 Tr...

Page 113: ...ng members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps 9 Start the engine and run at approximately 1 3 1 2 throttle for about one minute without moving...

Page 114: ...the engine off 2 Unlatch and open the engine cover Allow the hydraulic fluid to cool 3 Pump the brake several times to relieve all of the stored pressure in the accumulator system 4 Remove the lower d...

Page 115: ...shers 5 and flange nuts 6 3 Attach the hydraulic hoses to the service brake valve 4 Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members and insta...

Page 116: ...ll fall from the brake pedal support once the brake pedal shaft 3 is removed 6 Remove the bushings 8 from the brake pedal tube 6 d Service Brake Pedal Installation Note The bushings 8 are a self lubri...

Page 117: ...he throttle pedal 20 from the cab 8 Remove the bushings 24 and shims 22 from the throttle pedal assembly 20 Remove the throttle pedal assembly from the cab pedal bracket 17 b Throttle Pedal Installati...

Page 118: ...tachment place the travel select lever in the N NEUTRAL DETENT position engage the parking brake switch and shut the engine OFF 2 Disconnect the ECM cab harness connector 3 from the throttle position...

Page 119: ...is above or below the specification 2650 2750 rpm adjust the limit stop screw 25 5 Remove the screws on the lower dash panel 26 and side console access panel 27 6 To adjust loosen the locking nut 21 o...

Page 120: ...k only Note The rear and frame sway joysticks do not have electrical features 7 Remove the four capscrews 10 on the front or rear joysticks and or two flat washers and two capscrews on the frame sway...

Page 121: ...ve electrical features 3 Connect the electrical plug 9 front joystick only Note Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members and install t...

Page 122: ...g hardware 8 Remove the four capscrews 12 and flat washers 13 securing the joystick assembly 11 to the joystick console assembly 14 9 Lift the joystick assembly 11 out of the joystick console assembly...

Page 123: ...Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required 4 Place the joystick console 3 on...

Page 124: ...3 11 Miscellaneous Cab Components 1 Mirror Assembly 2 Capscrew 2 3 Frame Level Indicator 4 Step 5 Flat Washer 8 6 Capscrew 8 7 Locknut 2 8 Flat Washer 2 9 Arm Rest 10 Self Tapping Screw 6 11 Brush St...

Page 125: ...s 14 Top Windshield Retainer 15 Windshield Glass 16 Bottom Windshield Retainer 17 Door Window Latch 18 Top Door Frame 19 Door Window Glass 20 Top Door Hinges 21 Bottom Door 22 Left Side Rear Window Gl...

Page 126: ...ater Assembly Removal 1 Park the vehicle on a firm level surface Level the vehicle ground the attachment place the travel select lever in the N NEUTRAL DETENT position engage the parking brake switch...

Page 127: ...3 1 a Seat Removal 7 Remove the windshield washer fluid reservoir Refer to Section 9 13 9 Windshield Skylight Rear Wiper Washer Reservoir w Pump 8 Remove the two capscrews 2 and flat washers 3 securin...

Page 128: ...embly back to clear the seat support riser b Heater Assembly Installation Note For vehicles equipped with air conditioning before the heater assembly can be installed the air conditioning hoses and el...

Page 129: ...crews to 6 6 lb ft 9 Nm 7 Install the operators seat Refer to Section 4 3 1 b Seat Installation 8 Install the right side console access panel 15 using five capscrews 16 and flat washers 17 Torque caps...

Page 130: ...er battery 3 loosen the knob 4 far enough so that the lip 5 on the upper battery box clears the knob Lift up the upper battery box 6 and swing it out so that the box clears the hydraulic tank support...

Page 131: ...of the hoses may be accessed either above 8 or below 9 the frame 6 Disconnect the supply and return fuel lines 10 at the fuel tank 11 See Section 7 8 2 Fuel Tank 7 Disconnect the electrical connection...

Page 132: ...mirror 13 Remove the four capscrews 13 four washers 14 and four sheer pins 15 that secure the cab mount supports 11 and 12 to the frame 14 If equipped remove skylight glass Refer to Section 4 3 12 Enc...

Page 133: ...nt support to the front 11 and rear 12 of the cab Use four capscrews 16 rebound washers 17 and cab isolators 18 Torque capscrews to 225 350 lb ft 305 474 Nm 2 Install valve plate assembly onto new rep...

Page 134: ...2 using capscrews and flat washers Torque capscrews to 7 8 lb ft 9 5 10 6 Nm 13 Connect the supply and return fuel lines 3 at the fuel tank 4 Refer to Section 7 8 2 Fuel Tank 14 Connect the electrical...

Page 135: ...nob 19 Carefully examine all cab components fasteners etc one last time before engine start up Rectify any faulty conditions 20 Start the engine and check the operation of all controls Check for hydra...

Page 136: ...access the lower battery 3 loosen the knob 4 far enough so that the lip 5 on the upper battery box clears the knob Lift up the upper battery box 6 and swing it out so that the box clears the hydraulic...

Page 137: ...tion 2 3 Torques 3 Replace the hinge plate pins 17 washers 16 and cotter pins 15 to secure valve plate 10 to the cab mount frame 13 4 Reconnect the two tethers 14 to the cab mount frame 13 5 Lift the...

Page 138: ...equipped with various access panels and covers Removal and installation are easily accomplished by observing the mounting configurations as shown in the illustration Note Refer to appropriate parts ma...

Page 139: ...4 37 Model 644E 42 944E 42 Rev 6 04 Cab and Covers This Page Intentionally Left Blank...

Page 140: ...attery box clears the knob Lift up the upper battery box 6 and swing it out so that the box clears the hydraulic tank support bracket to gain access to the lower negative battery cable 1 Disconnect th...

Page 141: ...d remove the two stud balls 9 and 14 from the strut bracket 16 on the engine hood 7 11 If required remove the two stud balls 22 on the engine compartment strut bracket 23 and the two capscrews 24 and...

Page 142: ...ghten into the two hinges 9 on the engine firewall 10 5 Lift engine hood 6 at corners closest to the engine firewall 10 as far as possible and tighten capscrews 7 6 Open engine hood 6 and attach a sui...

Page 143: ...oosen the skirt mounting hardware 31 Lower the engine hood 28 to the closed position Adjust the rear corners of the skirt 30 downward so that the top of the skirt just meets the rear of the engine hoo...

Page 144: ...Cab and Covers 4 42 Model 644E 42 944E 42 Rev 6 04 This Page Intentionally Left Blank...

Page 145: ...Repair Manual 944E Front Model MS T 3060 JLG P N 8990430 ZF P N 5871 560 002 and 944E Rear 644E Front and Rear Model MS T 3045 JLG P N 8990419 ZF P N 5871 550 002 5 3 6 Axle Replacement 5 5 5 3 7 Axle...

Page 146: ...ary that the operator mechanic be familiar with the names and locations of the major assemblies of the axles drive shafts wheel and tires The following illustration identifies the components that are...

Page 147: ...tment to the bevel gear set Internal axle service and adjustment procedures are not the scope of this publication and are thoroughly covered in the appropriate ZF axle manual The beveled ring gear is...

Page 148: ...cement parts provided by other than the original manufacturer is not recommended as such use may cause axle failure and affect vehicle safety Some service operations require the use of tools specifica...

Page 149: ...of a damaged bearing cup or cone is necessary replace the cup and cone as a set 5 3 6 Axle Replacement a Removal The front and rear axle assemblies differ in that the front axle assembly is equipped...

Page 150: ...abel disconnect and cap the steering and brake hydraulic hoses at the tube connections 8 on the frame Wipe up any spilled oil 7 Block the front and rear of both tires on the axle that is not being rem...

Page 151: ...nuts 16 and eight hardened washers 17 securing the front 18 or rear 19 axle supports rotating trunnions to the vehicle frame 14 Remove the axle 20 Front or 21 Rear from the vehicle using the jack hois...

Page 152: ...the frame and lower the vehicle onto the supports allowing enough room for axle installation Ensure that the vehicle will remain in place during axle installation 3 On the front axle if applicable unc...

Page 153: ...inder 12 into position on the axle cylinder anchor 13 Insert a cylinder mount pin 14 through the cylinder and cylinder anchor Secure the cylinder mount pin 14 with one capscrew 15 and a new elastic lo...

Page 154: ...as the yoke on the transmission 13 Install the wheel and tire assemblies Refer to Section 5 5 4 Installing Wheel and Tire Assembly Onto Vehicle 14 Carefully remove the jack hoist or overhead crane and...

Page 155: ...n or repair as necessary WARNING Avoid prolonged engine operation in closed areas without adequate ventilation Failure to properly ventilate exhaust fumes can result in death or severe personal injury...

Page 156: ...gears 4 Incorrect pinion input shaft bearing preload 5 Worn or damaged bearings 6 Worn or broken gear teeth 7 Contamination in the axle 8 Axle housing damaged 1 Fill oil to correct level Refer to the...

Page 157: ...alignment and bearing preload as described in the ZF Repair Manual 5 Replace o rings and seals 6 Tighten housing nuts and capscrews to 288 lb ft 390 Nm 7 Replace housing s as needed 5 Oil leaking from...

Page 158: ...ulic system not operating properly 2 Steering cylinder leaking internally 1 Refer to Section 8 8 Hydraulic Circuits and Troubleshooting 2 Repair or replace steering cylinder as needed 10 Excessive noi...

Page 159: ...ent lubrication 2 Lubricant contaminated 3 Incorrect lubricant Replace ring and pinion gears Drain axle and fill to correct level with Universal Tractor Fluid Refer to the appropriate Owners Operators...

Page 160: ...alled Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration a Transmission to Axle Drive Shafts 1 Level the vehicle ground the carriage place the travel s...

Page 161: ...king brake switch and shut the engine OFF 2 Place an Accident Prevention Tag on both the ignition key switch and steering wheel stating that the vehicle should not be operated Refer to Section 1 5 Acc...

Page 162: ...capscrews 2 and two straps 3 securing the bearing crosses to the transmission Torque the capscrews to 60 lb ft 81 Nm 7 Install the four capscrews 4 and two straps 5 securing the bearing crosses to the...

Page 163: ...handling characteristics of the vehicle especially under load JLG does not recommend the use of hydrofill as a tire fill substance because of possible environmental impact Large bore valve stems are...

Page 164: ...gain access to the lower negative battery cable 1 Disconnect the lower negative battery cable 4 Loosen the lug nuts 1 4 to 1 2 turn only DO NOT remove the lug nuts on the wheel and tire assembly to be...

Page 165: ...or cracked wheel NEVER rework heat weld or braze a wheel rim Inspect the valve core and stem Replace the entire valve if either component is damaged A B C E G H F D OU0140 7 8 A B C E G J K H F D MU52...

Page 166: ...ide toward the rim under the lug nuts 2 and 4 3 644E Only Use the torque sequence diagram A H to alternately check the torque of each of the eight lug nuts Torque 430 470 lb ft 583 637 Nm 944E Only Us...

Page 167: ...y under inflated without removing the tire from the wheel and checking for tire and wheel rim damage NEVER hit a tire or wheel rim with a hammer or ANY object Use the appropriate specialty tools and e...

Page 168: ...another source may be interfering with proper mounting DO NOT increase inflation pressure to seat the beads Remove the valve core and completely deflate the tire Break both beads loose from the rim a...

Page 169: ...9 kPa Store tires indoors in a cool dark dry area away from drafts Heat and light can cause oxidation on the tire surface which leads to decomposition crazing and weather checking NEVER store tires o...

Page 170: ...mounted on the valve plate Note DO NOT Turn the key switch to the ON DO NOT release the parking brake switch Oil pressure will be lost and Parking Brake will be engaged 4 Pressurize the parking brake...

Page 171: ...t 9 liters for the front axle of the 644E Fill axle slowly the oil has to run across the differential Allow time for the oil to run across the differential Axle level is correct when oil is up to both...

Page 172: ...l be engaged 4 Pressurize the parking brake with the pressurizing unit Close the needle valve on the pressurizing unit 5 Working through the level plug hole 5 carefully use a screwdriver to spread the...

Page 173: ...ear axle Fill axle slowly the oil has to run across the differential Allow time for the oil to run across the differential Axle level is correct when oil is up to both level plugs 9 Reassemble the lev...

Page 174: ...Axles Drive Shafts Wheels Tires and Brakes 5 30 Model 644E 42 944E 42 Rev 6 04 This Page Intentionally Left Blank...

Page 175: ...Transmission Inspection and Internal Repair 6 10 6 7 3 Transmission Installation 6 10 6 7 4 After Transmission Service or Replacement 6 14 6 8 Troubleshooting 6 15 6 8 1 Transmission Troubleshooting...

Page 176: ...is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the transmission The following illustration identifies the components that are referred to t...

Page 177: ...stem Pressurized oil for the valve control circuits and torque converter is supplied by a pump located at the rear of the transmission The pump is driven by the central shaft which in turn is connecte...

Page 178: ...ransmission Transfer Box Repair Manual JLG P N 8990517 ZF P N 5871 133 002 for information on transmission internal component replacement Refer to the ZF 4WG 92 98 TSC Transmission Technical Data and...

Page 179: ...outlet hose 3 connects to tubing that transports the oil to the transmission oil cooler inlet hose 5 that is in turn routed to the return oil cooler fitting located near the right front of the transm...

Page 180: ...key switch and steering wheel stating that the vehicle should not be operated Refer to Section 1 5 Accident Prevention Tag Usage Unlock and open the engine compartment cover Allow the engine transmis...

Page 181: ...gine baring tool or similar device to prevent the flywheel from turning while removing the capscrews 9 Label and remove the transmission inlet hose 12 and transmission outlet hose 13 from the fittings...

Page 182: ...to prevent unnecessary fluid spillage 13 Remove the four plain flat washers 14 and capscrews 15 securing the pump 16 to the transmission Remove the pump and o ring 17 from the transmission 14 Connect...

Page 183: ...oint that the fan contacts the radiator fins 22 Use the hoist connected to the transmission to lower the transmission down onto a skid and remove the transmission from under the engine pod 23 Secure t...

Page 184: ...strap or chain to the lifting ring 5 at the top of transmission and to a suitable hoist or overhead crane Operate the hoist or crane to remove any slack prior to lifting but DO NOT raise the transmis...

Page 185: ...Working through the engine flywheel inspection and access hole 10 rotate and align a flywheel screw hole with a diaphragm plate hole Install a previously removed hex head capscrew 11 and torque the ca...

Page 186: ...attaching the inlet tube 10 19 Place a new oiled o ring 11 into position over the opening and secure the inlet tube 10 with two flange halves 12 and four capscrews 13 Torque the capscrews to 50 90 lb...

Page 187: ...5 25 Nm Torque the air cleaner hose clamp 18 to 75 lb in 8 8 Nm Reconnect the wire harness to the air intake sensor 19 25 Reassemble the engine hood to the firewall Refer to Section 4 8 2 b Engine Hoo...

Page 188: ...irection of normal oil flow does not adequately clean the cooler If needed remove the radiator from the vehicle IMPORTANT DO NOT use flushing compounds for cleaning purposes 9 Reassemble all component...

Page 189: ...wiring harness 3 Transmission valve body solenoids not functioning properly 4 Pilot operated shift valves not operating properly 5 Pump output pressure low 6 Clutch piston o rings damaged 7 Clutch di...

Page 190: ...ng 4 Lack of power 1 Park or service brake dragging 2 Low engine rpm causes converter stall 3 Pump output pressure is low 4 Clutch discs worn or damaged 5 Transmission overheating 1 Refer to Section 8...

Page 191: ...dle the engine 5 Replace cooler hoses 6 Repair or replace pump assembly 7 Replace engine thermostat Refer to Section 7 6 2 Thermostat Replacement 6 Grinding or clunking noise from transmission 1 Oil l...

Page 192: ...3 Hose fittings loose 4 Oil leaking at valve bodies possible valve body gaskets damaged or missing and or mounting capscrews not tight 5 Housing capscrews loose 6 Oil leaking at pump possible pump to...

Page 193: ...tion presented in this section it is necessary that the operator mechanic be familiar with the name and location of the major assemblies of the transfer case The following illustration identifies the...

Page 194: ...ive axles via two drive shafts one for the front axle one for the rear axle The transfer case is equipped with a set of four gears having a 1 1 drive ratio Detailed transfer case service instructions...

Page 195: ...se Inspection and Service Whenever servicing the vehicle conduct a visual inspection of the transfer case A few moments spent doing this can help prevent further problems and downtime later Inspect th...

Page 196: ...pper battery box 6 and swing it out so that the box clears the hydraulic tank support bracket to gain access to the lower negative battery cable 1 Disconnect the lower negative battery cable 4 Refer t...

Page 197: ...the transmission 11 and also the input spline of the transfer case with the output shaft 10 of the transmission Carefully press the transfer case onto the output shaft until the mating surfaces of bot...

Page 198: ...se filled with incorrect oil 3 Excessive bearing end play 4 Worn or damage bearings 5 Worn or broken gear teeth 6 Contamination in the transfer case 7 Incorrect assembly of parts 1 Fill oil to correct...

Page 199: ...l too high or low 3 Transfer case filled with incorrect oil or oil contaminated 4 Incorrect bearing end play 5 Worn or damage bearings 1 Remove mud and or debris from the transfer case exterior 2 Fill...

Page 200: ...ratures transfer case oil above 230 F 110 C Refer to Section 6 13 1 Transfer Case Troubleshooting Problem 4 Transfer case overheating oil above 230 F 110 C Replace gear s as needed Fill transfer case...

Page 201: ...t Replacement 7 8 7 6 3 Drain and Flush Radiator 7 12 7 6 4 Radiator Transmission Oil Cooler and Hydraulic Oil Cooler Replacement 7 14 7 7 Engine Electrical System 7 23 7 8 Fuel System 7 23 7 8 1 Dies...

Page 202: ...Engine Cummins 4BT 3 9 B4 5T and QSB 4 5T 7 2 Model 644E 42 944E 42 Rev 6 04 This Page Intentionally Left Blank...

Page 203: ...troubleshooting of the engine Refer to the local Cummins Engine Distributor and the applicable Cummins engine service manual for assistance with comprehensive engine diagnosis repair and component re...

Page 204: ...sary that the operator mechanic be familiar with the name and location of the engine components The following illustration identifies the components that are referred to throughout this section Altern...

Page 205: ...created by any suspended load DO NOT work on an engine or a vehicle that is supported ONLY by a hoist or lift jacks Use blocks or suitable stands WARNING Operate the engine in a well ventilated area o...

Page 206: ...es Batteries produce hydrogen gas which can explode and cause severe personal injury and property damage Battery fluid can burn the skin and injure the eyes If you come in contact with battery acid fl...

Page 207: ...Thoroughly clean the engine and engine compartment area before attempting to service or repair the engine DO NOT steam clean the following parts Electrical Components Wiring Injectors Fuel Pump Belts...

Page 208: ...ndicator If the engine seems to take a long time to warm up the thermostat may be stuck in the open position and requires replacement If the engine runs hot check the temperature of the upper radiator...

Page 209: ...o drain into the funnel Transfer the coolant into a properly labeled container Dispose of properly Close the radiator petcock when finished and then remove the hose 8 6 Remove the upper radiator hose...

Page 210: ...ove the lower alternator bracket capscrew on the bottom of the alternator 8 Remove the upper alternator mounting capscrew 9 and remove the alternator from it s place 11 Remove the three capscrews 10 s...

Page 211: ...g the V band clamp 6 and tube onto the turbo exhaust opening Then align and join the exhaust tube with the upper lap joint tube clamp 5 Secure the lower exhaust bracket 3 with the two capscrews 4 remo...

Page 212: ...3 Unlatch and open the engine cover Allow the engine to cool before proceeding Draining the cooling system while the engine is hot can cause cracks in the engine block 4 If the vehicle has dual batte...

Page 213: ...the overflow bottle until the bottle is 1 2 to 3 4 full This overfilling will compensate for any air in the cooling system 10 Clean any dirt or debris from the radiator fins and core 11 If the vehicl...

Page 214: ...cool before proceeding Draining the cooling system while the engine is hot can cause cracks in the engine block 4 Remove the engine hood Refer to Section 4 8 2 a Engine Hood Removal for proper remova...

Page 215: ...olant into a properly labeled container Dispose of properly Reconnect the overflow tube to the radiator upon completion 8 Remove three capscrews 12 securing the fan guard 13 9 Remove the upper radiato...

Page 216: ...enings 13 Remove the upper transmission oil hose 6 Cap both the hose end and cooler to prevent contaminates from entering the openings Position the hose out of the way to allow the radiator assembly t...

Page 217: ...two on the right one on the left remove these to remove the shroud 22 20 Working from the front remove eight capscrews 26 that secure the fan shroud 27 to the spacer shroud assembly 28 21 Working fro...

Page 218: ...lb ft 34 61 Nm 4 Working from the front install the spacer shroud assembly 13 Secure with six capscrews 14 three top and three bottom Torque capscrews to 6 11 lb ft 9 15 Nm 5 Working from the front at...

Page 219: ...mounting holes 28 of the engine mount frame to the radiator frame assembly 27 12 Install the two previously removed lower mounting capscrews 29 flat washers 30 washers 31 and locknuts 32 13 Install t...

Page 220: ...ain and Flush Radiator for procedures of refilling the cooling system 20 If the vehicle has dual batteries connect both negative battery cables 8 and 9 to both batteries Connect the lower negative bat...

Page 221: ...nd swing it out so that the box clears the hydraulic tank support bracket to gain access to the lower negative battery cable 8 Disconnect the lower negative battery cable 5 Slowly turn the radiator ca...

Page 222: ...110 volt cord 6 2 Position the air cleaner hose over the turbocharger intake opening Install the air cleaner aligning the mounting band with the firewall sliding the hex bolts 3 into the slots Torque...

Page 223: ...22 fuel supply hose 17 fuel return line 18 and fuel tank drain plug 24 The threaded fuel filler 23 has a fuel cap 16 and permits entry of diesel fuel into the tank The fuel level sender 14 and dash pa...

Page 224: ...No 1 Diesel fuel may be used however fuel economy will be reduced Use a low sulfur content fuel with a cloud point the temperature at which wax crystals form in diesel fuel at least 10 below the lowes...

Page 225: ...or other damage Replace a leaking or damaged tank DO NOT attempt to repair plug or patch a leaking or damaged fuel tank The tank is manufactured using an injection molding process and cannot be repai...

Page 226: ...pump 2 or 7 3 Disconnect the fuel inlet line 1 or 6 4 Remove the capscrews 5 or 10 gasket and fuel lift pump 2 or 7 b Cleaning and Drying Clean the exterior of the pump with mineral spirits and blow...

Page 227: ...the lift pump will result due to lack of proper lubrication 1 To vent the low pressure lines and fuel filter open the vent screw 17 located on the filter head 2 Operate the hand plunger 3 or 8 on the...

Page 228: ...e pipe union nut on each fuel injector in turn with the engine running at a fast tick over If after slackening a pipe union nut the engine revolutions remain constant a faulty fuel injector has been i...

Page 229: ...o ring into the recessed groove in the top of the hold down nut Make sure the o ring is not cut or twisted during installation 7 Apply a light coat of anti seize compound to the threads of the injecto...

Page 230: ...ely 7 9 1 Exhaust System Removal 1 Park the vehicle on a firm level surface Level the vehicle ground the attachment place the travel select lever in the N NEUTRAL DETENT position engage the parking br...

Page 231: ...t muffler bracket 21 onto the hanger on the frame 22 Apply Loctite 242 blue to the screws and loosely secure front of muffler in place with two screws 13 and washers 15 4 Lift the rear of the muffler...

Page 232: ...on the upper battery box clears the knob Lift up the upper battery box 6 and swing it out so that the box clears the hydraulic tank support bracket to gain access to the lower negative battery cable 1...

Page 233: ...the coolant into a properly labeled container Dispose of properly Reconnect the overflow tube to the radiator upon competition 7 Remove three capscrews 12 securing the fan guard 13 8 Remove the upper...

Page 234: ...ng the system 12 Remove the upper transmission oil hose 6 Cap both the hose end and cooler to prevent contaminates from entering the system Position the hose out of the way to allow the radiator assem...

Page 235: ...ft 34 54 Nm 17 Remove the lower section of the hydraulic suction hose 17 by loosening and removing the upper 18 and lower 19 hose clamps 18 Disconnect the hydraulic oil temperature switch connector 20...

Page 236: ...engine mount frame 7 27 Disconnect the transmission oil hoses 8 from the reservoir retainer assembly 9 and from the transmission 10 Cap the ends of each hose tubing and transmission hose fittings to...

Page 237: ...and Remove the air cleaner assembly a 644E 42 Fuel Lines and Throttle Disconnect 35 Disconnect the fuel inlet line 23 at the fuel lift pump Install a plug in the end of the fuel inlet line 36 Disconne...

Page 238: ...s bar 14 with the wires still connected 45 For jump start protection a protective plastic cover 10 is installed around the starter solenoid terminal and mounting screw A removable tethered cap 15 allo...

Page 239: ...d 27 Remove any clips securing the wiring harness to the transmission and move the wiring harness safely out of the way 52 Connect a suitable engine hoist to the front engine lift bracket 28 and trans...

Page 240: ...Cummins service manual Several special engine service tools are required to properly service the Cummins engine Contact the local Cummins Service Distributor for further information Note If the engine...

Page 241: ...5 Carefully install the engine onto the engine and transmission isolators 16 Note ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening 6 At the back of the engine...

Page 242: ...ness 13 Secure the negative battery cable 11 to the starter ground stud 12 Torque mounting hardware to 40 45 lb ft 54 61 Nm 14 Connect the positive battery cable 13 and starter positive buss bar 14 wi...

Page 243: ...the clamp to 4 lb in 0 45 Nm 21 Install the throttle bracket 32 using two previously removed capscrews Torque to 44 59 lb ft 59 80 Nm 22 Connect the throttle cable 30 at the engine throttle lever 31...

Page 244: ...capscrews 4 and three elastic locknuts 5 securing the battery tray s 6 to the engine mount frame Torque capscrews to 13 22 lb ft 17 31 Nm 29 Battery installation Refer to Section 9 12 2 Battery or Ba...

Page 245: ...ne 33 Install hydraulic vent hoses 20 21 and 22 Torque each hose end to 57 7 lb ft 77 10 Nm 34 Install the hydraulic oil return hose 23 Connect plug in the return oil filter pressure switch 24 Note Us...

Page 246: ...e to the radiator outlet Rotate the hose so that the water pump connection end is perpendicular 8 with the engine mount frame Torque the hose clamp to 60 lb in 6 Nm Note ALWAYS replace elastic locknut...

Page 247: ...s specified in Section 2 3 1 SAE Flat Face O Ring Seal Hydraulic Fittings 46 Uncap and connect the hydraulic oil inlet 23 and outlet 24 hoses Note Use new oiled o rings as required ALWAYS replace seal...

Page 248: ...x 6 in and make sure that the lip 7 on the upper battery box slides below the knob 8 Secure in place with the knob 8 55 Install the engine hood with the help of at least one assistant Refer to Section...

Page 249: ...id If a preservative fluid is used it must be drained and replaced with regular lubricating oil before the engine is returned to service 6 Drain the cooling system To provide protection against corros...

Page 250: ...0 Clogged fuel filter 11 Restricted air cleaner 12 Air in fuel system 13 Faulty fuel injection pump 14 Faulty fuel injectors or incorrect type 15 Incorrect use of cold start equipment 16 Faulty cold s...

Page 251: ...32 8 7 7 Hydraulic Testing SN 18927 and Before Dual Joystick 944E Only 8 36 8 7 8 Hydraulic Testing SN 18928 thru 20123 0160002514 thru 0160003085 Dual Joystick 944E Only 8 40 8 7 9 Hydraulic Testing...

Page 252: ...8 122 8 8 35 Crab Steering Circuit Right Turn Troubleshooting 8 124 8 8 36 Auxiliary Hydraulic Circuit Troubleshooting Male Coupler Pressurized Dual Joystick 644E 42 SN 20118 Before SN 0160002519 thru...

Page 253: ...xing Procedures 8 163 8 9 1 Four Wheel Steer Indexing Procedure 8 163 8 10 Hydraulic Reservoir 8 164 8 10 1 Hydraulic Reservoir Replacement 8 165 8 11 Hydraulic System Pump 8 165 8 11 1 Pump Failure A...

Page 254: ...8 217 8 14 6 Extend Retract Cylinder 8 221 8 14 7 Lift Lower Cylinder 8 225 8 14 8 Frame Sway Cylinder 8 230 8 14 9 Stabilizer Cylinder 8 235 8 14 10 Steering Cylinders 8 239 8 14 11 Transfer Carriage...

Page 255: ...mponents that are referred to throughout this section MU0331 Extend Retract Cylinder Lift Lower Cylinder Slave Cylinders Attachment Tilt Cylinder Stabilizer Cylinder Hydraulic Filter Fill Cap Steer Se...

Page 256: ...ap Lock Fittings Special Tools for bleeding procedure Hydraulic system maintenance will at times require that the engine be operated Always follow safety precautions A major cause of hydraulic compone...

Page 257: ...on can produce a loud crackling sound as though rocks or marbles were being forced through the system Cavitation can be due to a low hydraulic oil level in the reservoir a restricted intake line or im...

Page 258: ...to using markers include color coded tie wraps number tag sets alpha numeric stampings or markings and suitably labeled pieces of tape Select an appropriate marking method for the conditions and proce...

Page 259: ...age is observed 1 Inspect both the male 11 and female 12 connectors to ensure they are in good condition free of nicks scratches and contamination If damage is observed the fittings need to be replace...

Page 260: ...nd hoses Laminates of test diagrams and test procedures 13 x 18 x 7 durable carrying case Flowmeter Kit The flowmeter test kit 2 is used to pinpoint hydraulic system faults It includes a flowmeter wit...

Page 261: ...e appropriate joystick in the position needed to operate the particular vehicle function being checked Continue holding the joystick in position until pressure readings are taken 7 Check the pressure...

Page 262: ...AY CYLINDER FTR FTB AUXILIARY HYDRAULICS BRAKE VALVE P P A A T STABILIZER CYLINDER FTR V P T G1 ACCUMULATORS HYDRAULIC OIL COOLER E R R E TRANSFER CYLINDER 041 048 1 2 3 4 T P 1 2 3 4 T P R E R E R E...

Page 263: ...to the outlet port on the primary pump Connect the flow meter to the outlet port on the secondary pump Flow rate should be 13 2 15 5 GPM 49 9 58 7 liter min IMPORTANT When testing on the secondary pu...

Page 264: ...450 550 psi 31 38 bar With engine at idle depress and hold brake pedal Check pressure for the rear axle If pressure is incorrect check accumulator pressure using test sequence 6 16 N A Brake Valve Se...

Page 265: ...8 15 Model 644E 42 944E 42 Rev 6 04 Hydraulic System This Page Intentionally Left Blank...

Page 266: ...ER FTR FTB AUXILIARY HYDRAULICS BRAKE VALVE P P A A T STABILIZER CYLINDER FTR V P T G1 ACCUMULATORS HYDRAULIC OIL COOLER E R R E R E TRANSFER CYLINDER 041 048 1 2 3 4 T P 1 2 3 4 T P R E R E R E R T P...

Page 267: ...to the outlet port on the primary pump Connect the flow meter to the outlet port on the secondary pump Flow rate should be 13 2 15 5 GPM 49 9 58 7 liter min IMPORTANT When testing on the secondary pu...

Page 268: ...450 550 psi 31 38 bar With engine at idle depress and hold brake pedal Check pressure for the rear axle If pressure is incorrect check accumulator pressure using test sequence 6 16 N A Brake Valve Se...

Page 269: ...8 19 Model 644E 42 944E 42 Rev 6 04 Hydraulic System This Page Intentionally Left Blank...

Page 270: ...AUXILIARY HYDRAULICS BRAKE VALVE P P A A T STABILIZER CYLINDER FTR V P T G1 ACCUMULATORS HYDRAULIC OIL COOLER E R R E R E TRANSFER CYLINDER 041 048 1 2 3 4 T P 1 2 3 4 T P R E R E R E R T P L LS ACCUM...

Page 271: ...to the outlet port on the primary pump Connect the flow meter to the outlet port on the secondary pump Flow rate should be 13 2 15 5 GPM 49 9 58 7 liter min IMPORTANT When testing on the secondary pu...

Page 272: ...450 550 psi 31 38 bar With engine at idle depress and hold brake pedal Check pressure for the rear axle If pressure is incorrect check accumulator pressure using test sequence 6 16 N A Brake Valve Se...

Page 273: ...8 23 Model 644E 42 944E 42 Rev 6 04 Hydraulic System This Page Intentionally Left Blank...

Page 274: ...R FTR FTB AUXILIARY HYDRAULICS BRAKE VALVE P P A A T STABILIZER CYLINDER FTR V P T G1 ACCUMULATORS HYDRAULIC OIL COOLER E R R E R E TRANSFER CYLINDER 041 048 1 2 3 4 T P 1 2 3 4 T P R E R E R E R T P...

Page 275: ...to the outlet port on the primary pump Connect the flow meter to the outlet port on the secondary pump Flow rate should be 13 2 15 5 GPM 49 9 58 7 liter min IMPORTANT When testing on the secondary pu...

Page 276: ...450 550 psi 31 38 bar With engine at idle depress and hold brake pedal Check pressure for the rear axle If pressure is incorrect check accumulator pressure using test sequence 6 16 N A Brake Valve Se...

Page 277: ...8 27 Model 644E 42 944E 42 Rev 6 04 Hydraulic System This Page Intentionally Left Blank...

Page 278: ...DRAULICS BRAKE VALVE P P A A T STABILIZER CYLINDER FTR V P T G1 ACCUMULATORS HYDRAULIC OIL COOLER E R R E R E TRANSFER CYLINDER 041 048 R E R E R E R T P L LS ACCUMULATOR CHARGE SECONDARY FUNCTION VAL...

Page 279: ...to the outlet port on the primary pump Connect the flow meter to the outlet port on the secondary pump Flow rate should be 13 2 15 5 GPM 49 9 58 7 liter min IMPORTANT When testing on the secondary pu...

Page 280: ...450 550 psi 31 38 bar With engine at idle depress and hold brake pedal Check pressure for the rear axle If pressure is incorrect check accumulator pressure using test sequence 6 16 N A Brake Valve Se...

Page 281: ...8 31 Model 644E 42 944E 42 Rev 6 04 Hydraulic System This Page Intentionally Left Blank...

Page 282: ...XILIARY HYDRAULICS BRAKE VALVE P P A A T STABILIZER CYLINDER FTR V P T G1 ACCUMULATORS HYDRAULIC OIL COOLER E R R E R E TRANSFER CYLINDER 041 048 R E R E R E R T P L LS ACCUMULATOR CHARGE SECONDARY FU...

Page 283: ...to the outlet port on the primary pump Connect the flow meter to the outlet port on the secondary pump Flow rate should be 13 2 15 5 GPM 49 9 58 7 liter min IMPORTANT When testing on the secondary pu...

Page 284: ...450 550 psi 31 38 bar With engine at idle depress and hold brake pedal Check pressure for the rear axle If pressure is incorrect check accumulator pressure using test sequence 6 16 N A Brake Valve Se...

Page 285: ...8 35 Model 644E 42 944E 42 Rev 6 04 Hydraulic System This Page Intentionally Left Blank...

Page 286: ...ER FTR FTB AUXILIARY HYDRAULICS BRAKE VALVE P P A A T STABILIZER CYLINDER FTR V P T G1 ACCUMULATORS HYDRAULIC OIL COOLER E R R E R E TRANSFER CYLINDER 041 048 1 2 3 4 T P 1 2 3 4 T P R E R E R E R T P...

Page 287: ...nnect to the outlet port on the primary pump Connect the flow meter to the outlet port on the secondary pump Flow rate should be 16 5 19 5 GPM 62 5 73 8 liter min When testing on the secondary pump is...

Page 288: ...450 550 psi 31 38 bar With engine at idle depress and hold brake pedal Check pressure for the rear axle If pressure is incorrect check accumulator pressure using test sequence 6 16 N A Brake Valve Se...

Page 289: ...8 39 Model 644E 42 944E 42 Rev 6 04 Hydraulic System This Page Intentionally Left Blank...

Page 290: ...AUXILIARY HYDRAULICS BRAKE VALVE P P A A T STABILIZER CYLINDER FTR V P T G1 ACCUMULATORS HYDRAULIC OIL COOLER E R R E R E TRANSFER CYLINDER 041 048 1 2 3 4 T P 1 2 3 4 T P R E R E R E R T P L LS ACCUM...

Page 291: ...to the outlet port on the primary pump Connect the flow meter to the outlet port on the secondary pump Flow rate should be 16 5 19 5 GPM 62 5 73 8 liter min IMPORTANT When testing on the secondary pu...

Page 292: ...450 550 psi 31 38 bar With engine at idle depress and hold brake pedal Check pressure for the rear axle If pressure is incorrect check accumulator pressure using test sequence 6 16 N A Brake Valve Se...

Page 293: ...8 43 Model 644E 42 944E 42 Rev 6 04 Hydraulic System This Page Intentionally Left Blank...

Page 294: ...R FTR FTB AUXILIARY HYDRAULICS BRAKE VALVE P P A A T STABILIZER CYLINDER FTR V P T G1 ACCUMULATORS HYDRAULIC OIL COOLER E R R E R E TRANSFER CYLINDER 041 048 1 2 3 4 T P 1 2 3 4 T P R E R E R E R T P...

Page 295: ...to the outlet port on the primary pump Connect the flow meter to the outlet port on the secondary pump Flow rate should be 16 5 19 5 GPM 62 5 73 8 liter min IMPORTANT When testing on the secondary pu...

Page 296: ...450 550 psi 31 38 bar With engine at idle depress and hold brake pedal Check pressure for the rear axle If pressure is incorrect check accumulator pressure using test sequence 6 16 N A Brake Valve Se...

Page 297: ...8 47 Model 644E 42 944E 42 Rev 6 04 Hydraulic System This Page Intentionally Left Blank...

Page 298: ...YDRAULICS BRAKE VALVE P P A A T STABILIZER CYLINDER FTR V P T G1 ACCUMULATORS HYDRAULIC OIL COOLER E R R E R E TRANSFER CYLINDER 041 048 R E R E R E R T P L LS ACCUMULATOR CHARGE SECONDARY FUNCTION VA...

Page 299: ...to the outlet port on the primary pump Connect the flow meter to the outlet port on the secondary pump Flow rate should be 16 5 19 5 GPM 62 5 73 8 liter min IMPORTANT When testing on the secondary pu...

Page 300: ...450 550 psi 31 38 bar With engine at idle depress and hold brake pedal Check pressure for the rear axle If pressure is incorrect check accumulator pressure using test sequence 6 16 N A Brake Valve Se...

Page 301: ...8 51 Model 644E 42 944E 42 Rev 6 04 Hydraulic System This Page Intentionally Left Blank...

Page 302: ...UXILIARY HYDRAULICS BRAKE VALVE P P A A T STABILIZER CYLINDER FTR V P T G1 ACCUMULATORS HYDRAULIC OIL COOLER E R R E R E TRANSFER CYLINDER 041 048 R E R E R E R T P L LS ACCUMULATOR CHARGE SECONDARY F...

Page 303: ...to the outlet port on the primary pump Connect the flow meter to the outlet port on the secondary pump Flow rate should be 16 5 19 5 GPM 62 5 73 8 liter min IMPORTANT When testing on the secondary pu...

Page 304: ...450 550 psi 31 38 bar With engine at idle depress and hold brake pedal Check pressure for the rear axle If pressure is incorrect check accumulator pressure using test sequence 6 16 N A Brake Valve Se...

Page 305: ...cylinders retracted 2 Check hoses tubes fittings and other hydraulic components for leaks bends kinks interference etc 3 Check for air in the hydraulic system Erratic machine performance and or spongy...

Page 306: ...uit Suction Return Load Sense Pressure Pilot Pressure PUMP HYDRAULIC RESERVOIR ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE INLET...

Page 307: ...14 4 Dual Hydraulic Oil Temperature Switch Clean radiator and cooler Not OK Repair replace suction line Check suction line from reservoir to the pump NOTE When checking pressures in circuits refer to...

Page 308: ...uit Suction Return Load Sense Pressure Pilot Pressure PUMP HYDRAULIC RESERVOIR ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE INLET...

Page 309: ...14 4 Dual Hydraulic Oil Temperature Switch Clean radiator and cooler Not OK Repair replace suction line Check suction line from reservoir to the pump NOTE When checking pressures in circuits refer to...

Page 310: ...CHECK VALVE SINGLE JOYSTICK PILOT SELECT VALVE P1 TB TA AUX2 AUX1 EB EA HB HA CTB CTA T P P2 P3 P4 SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9 bar HYDRAULIC RESERVOIR Suction Return L...

Page 311: ...14 4 Dual Hydraulic Oil Temperature Switch Clean radiator and cooler Not OK Repair replace suction line Check suction line from reservoir to the pump NOTE When checking pressures in circuits refer to...

Page 312: ...essure Pilot Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL...

Page 313: ...ect pressure readings If OK Replace Joystick NOTE Before pressure checking circuits refer to Section 9 8 29 Dual Joystick Auxiliary Hydraulic Circuit Troubleshooting to ensure the electrical circuits...

Page 314: ...n Return Load Sense Pressure Pilot Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB P...

Page 315: ...he joystick is not functioning If OK Replace Joystick Adjust the pressure reducing cartridge on the accumulator charge secondary function valve Not OK Install new seal kit in the pressure reducing car...

Page 316: ...ETURN FILTER 25 PSI 1 7 BAR BYPASS CHECK VALVE SINGLE JOYSTICK PILOT SELECT VALVE P1 TB TA AUX2 AUX1 EB EA HB HA CTB CTA T P P2 P3 P4 SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9 bar HY...

Page 317: ...t OK Replace the pressure reducing cartridge on the accumulator charge secondary function valve NOTE When checking pressures in circuits refer to Section 8 7 Hydraulic System Testing for correct press...

Page 318: ...ALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW Suction Return Load Sense Pressure Pilot Pressure FRONT AXLE HYDRAULIC RESERVOIR PUMP ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1...

Page 319: ...Manual Model MS T 3045 ZF part 5871 550 002 JLG part 8990419 644E Only or ZF Axle Repair Manual Model MS T 3060 ZF part 5871 560 002 JLG part 8990430 944E Only Install seal kit replace solenoid valve...

Page 320: ...tion for a more detailed explanation of this circuit REAR AXLE Suction Return Load Sense Pressure Pilot Pressure FRONT AXLE HYDRAULIC RESERVOIR PUMP ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAI...

Page 321: ...ZF part 5871 560 002 JLG part 8990430 944E Only If OK NOTE When checking pressures in circuits refer to Section 8 7 Hydraulic System Testing for correct pressure readings Not OK Check front and rear...

Page 322: ...Circuit Description for a more detailed explanation of this circuit Suction Return Load Sense Pressure Pilot Pressure FRONT AXLE HYDRAULIC RESERVOIR PUMP ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS...

Page 323: ...es in circuits refer to Section 8 7 Hydraulic System Testing for correct pressure readings Recheck Port a Power device for proper connection and pressure setting Refer to ZF Axle Repair Manual Model M...

Page 324: ...HYDRAULIC RESERVOIR ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE INLET OUTLET HYDRAULIC OIL COOLER REAR JOYSTICK 3 4 T P 1 2 CHEC...

Page 325: ...nstall pressure gauge in the pilot supply line between the rear joystick and the extend retract section of main control valve Check pilot pressure With the joystick moved all the way to the right the...

Page 326: ...K VALVE SINGLE JOYSTICK PILOT SELECT VALVE P1 TB TA AUX2 AUX1 EB EA HB HA CTB CTA T P P2 P3 P4 SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9 bar HYDRAULIC RESERVOIR Suction Return Load S...

Page 327: ...OK Adjust replace main relief cartridge on main control valve If OK Not OK Repair replace joystick Check the main relief pump pressure at implement pump pressure tap Refer to Section 8 7 Hydraulic Sys...

Page 328: ...e PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW INLET OUTLET HYDRAULIC OIL COOLE...

Page 329: ...ry function valve If OK Not OK Adjust replace main relief cartridge on main control valve If OK Not OK Repair replace rear joystick Check the main relief pump pressure at implement pump pressure tap R...

Page 330: ...SS CHECK VALVE SINGLE JOYSTICK PILOT SELECT VALVE P1 TB TA AUX2 AUX1 EB EA HB HA CTB CTA T P P2 P3 P4 SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9 bar HYDRAULIC RESERVOIR Suction Return...

Page 331: ...valve If OK Not OK Adjust replace main relief cartridge on main control valve If OK Not OK Repair replace joystick Check the main relief pump pressure at implement pump pressure tap Refer to Section 8...

Page 332: ...PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS E R ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW INLET OUTLET HYDRAULIC OIL CO...

Page 333: ...ndary function valve If OK Not OK Adjust replace main relief cartridge on main control valve If OK Not OK Repair replace rear joystick Check the main relief pump pressure at implement pump pressure ta...

Page 334: ...CHECK VALVE SINGLE JOYSTICK PILOT SELECT VALVE P1 TB TA AUX2 AUX1 EB EA HB HA CTB CTA T P P2 P3 P4 SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9 bar HYDRAULIC RESERVOIR Suction Return L...

Page 335: ...on valve If OK Not OK Adjust replace main relief cartridge on main control valve If OK Not OK Repair replace joystick Check the main relief pump pressure at implement pump pressure tap Refer to Sectio...

Page 336: ...PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS E R ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW INLET OUTLET HYDRAULIC OIL CO...

Page 337: ...ary function valve If OK Not OK Adjust replace main relief cartridge on main control valve If OK Not OK Repair replace rear joystick Check the main relief pump pressure at implement pump pressure tap...

Page 338: ...R BYPASS CHECK VALVE SINGLE JOYSTICK PILOT SELECT VALVE P1 TB TA AUX2 AUX1 EB EA HB HA CTB CTA T P P2 P3 P4 SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9 bar HYDRAULIC RESERVOIR Suction...

Page 339: ...l pressure gauge in the pilot supply line between the rear joystick and the extend retract section of main control valve Check pilot pressure With the joystick moved all the way to the right the press...

Page 340: ...nse Pressure Pilot Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN C...

Page 341: ...K If OK Not OK Inspect pilot operated check valves on frame sway cylinder Repair tighten connections Ensure frame sway section of main control valve is functioning Check orifice in check valve fitting...

Page 342: ...ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE INLET OUTLET HYDRAULIC OIL COOLER FRAME...

Page 343: ...K If OK Not OK Inspect pilot operated check valves on frame sway cylinder Repair tighten connections Ensure frame sway section of main control valve is functioning Check orifice in check valve fitting...

Page 344: ...R ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE INLET OUTLET HYDRAULIC OIL COOLER FRAM...

Page 345: ...K If OK Inspect pilot operated check valves on frame sway cylinder Repair tighten connections Ensure frame sway section of main control valve is functioning NOTE Refer to Section 2 5 6 Hydraulic Cylin...

Page 346: ...R ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE INLET OUTLET HYDRAULIC OIL COOLER FRAM...

Page 347: ...K If OK Inspect pilot operated check valves on frame sway cylinder Repair tighten connections Ensure frame sway section of main control valve is functioning NOTE Refer to Section 2 5 6 Hydraulic Cylin...

Page 348: ...Suction Return Load Sense Pressure Pilot Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF P...

Page 349: ...valve Not OK Check counterbalance valve on attachment tilt cylinder Replace the counterbalance valve Not OK Check pilot operated check valve on attachment tilt cylinder Replace the pilot operated chec...

Page 350: ...NGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9 bar HYDRAULIC RESERVOIR Suction Return Load Sense Pressure Pilot Pressure 1 3 T P 4 2 PUMP ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAI...

Page 351: ...ontrol valve Replace the relief valve on attachment tilt section of main control valve Not OK Check seals in attachment tilt cylinder Repair replace attachment tilt cylinder Check the cycle times for...

Page 352: ...re PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE INLET OUTLET...

Page 353: ...alve Not OK Check seals in attachment tilt cylinder Repair replace attachment tilt cylinder Not OK Inspect pump Refer to Hydraulic Testing pages 8 12 through 8 54 Check the cycle times for boom LIFT a...

Page 354: ...VALVE SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9 bar HYDRAULIC RESERVOIR Suction Return Load Sense Pressure Pilot Pressure 1 3 T P 4 2 PUMP ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE...

Page 355: ...alve Not OK Check seals in attachment tilt cylinder Repair replace attachment tilt cylinder Not OK Inspect pump Refer to Hydraulic Testing pages 8 12 through 8 54 Check the cycle times for boom LIFT a...

Page 356: ...t Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE INLE...

Page 357: ...adings NOTE Before checking any hydraulic circuits verify that the transfer carriage is not binding and that the rollers and pads are operating freely and have the proper clearance Refer to Section 11...

Page 358: ...5 PSI 1 7 BAR BYPASS CHECK VALVE SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9 bar HYDRAULIC RESERVOIR Suction Return Load Sense Pressure Pilot Pressure 1 3 T P 4 2 PUMP ACCUMULATOR CHAR...

Page 359: ...adings NOTE Before checking any hydraulic circuits verify that the transfer carriage is not binding and that the rollers and pads are operating freely and have the proper clearance Refer to Section 11...

Page 360: ...t Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE INLE...

Page 361: ...re at PPG port of accumulator charge secondary function valve Adjust repair replace pressure reducing cartridge on accumulator charge secondary function valve Not OK Check port relief at main control...

Page 362: ...5 PSI 1 7 BAR BYPASS CHECK VALVE SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9 bar HYDRAULIC RESERVOIR Suction Return Load Sense Pressure Pilot Pressure 1 3 T P 4 2 PUMP ACCUMULATOR CHAR...

Page 363: ...re at PPG port of accumulator charge secondary function valve Adjust repair replace pressure reducing cartridge on accumulator charge secondary function valve Not OK Check port relief at main control...

Page 364: ...ilot Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE O...

Page 365: ...the steering and noting the relief pressure NOTE When checking pressures in circuits refer to Section 8 7 Hydraulic System Testing for correct pressure readings Pump the brake pedal to start the accum...

Page 366: ...Pilot Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE...

Page 367: ...w or difficult check the pressure at the P1 port of the accumulator charge secondary function valve by bottoming out the steering and noting the relief pressure Pump the brake pedal to start the accum...

Page 368: ...ilot Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE O...

Page 369: ...eering unit LSG P1 Pressure OK If So If the steering is slow or difficult check the pressure at the P1 port of the accumulator charge secondary function valve by bottoming out the steering and noting...

Page 370: ...ilot Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE O...

Page 371: ...eering unit LSG P1 Pressure OK If So If the steering is slow or difficult check the pressure at the P1 port of the accumulator charge secondary function valve by bottoming out the steering and noting...

Page 372: ...t Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE OUTL...

Page 373: ...eering unit LSG P1 Pressure OK If So If the steering is slow or difficult check the pressure at the P1 port of the accumulator charge secondary function valve by bottoming out the steering and noting...

Page 374: ...t Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW MAIN CONTROL VALVE OUTL...

Page 375: ...eering unit LSG P1 Pressure OK If So If the steering is slow or difficult check the pressure at the P1 port of the accumulator charge secondary function valve by bottoming out the steering and noting...

Page 376: ...NS Suction Return Load Sense Pressure Pilot Pressure PUMP HYDRAULIC RESERVOIR ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW INLET OUTLET HYDRAULIC OI...

Page 377: ...times Refer to Section 2 5 6 Hydraulic Cylinder Performance Specifications for correct cycle times Not OK Check the standby pump pressure at implement pump pressure tap If OK If OK If OK If OK Replac...

Page 378: ...TRANS Suction Return Load Sense Pressure Pilot Pressure PUMP HYDRAULIC RESERVOIR ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW INLET OUTLET HYDRAULIC...

Page 379: ...times Refer to Section 2 5 6 Hydraulic Cylinder Performance Specifications for correct cycle times Not OK Check the standby pump pressure at implement pump pressure tap If OK If OK If OK If OK Replac...

Page 380: ...ATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW RETURN FILTER 25 PSI 1 7 BAR BYPASS CHECK VALVE SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9 ba...

Page 381: ...ge on accumulator charge secondary function valve Not OK Inspect pump Refer to Hydraulic Testing pages 8 12 through 8 54 Check the cycle times for boom LIFT and boom EXTEND to determine pump performan...

Page 382: ...MULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW RETURN FILTER 25 PSI 1 7 BAR BYPASS CHECK VALVE SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9...

Page 383: ...ge on accumulator charge secondary function valve Not OK Inspect pump Refer to Hydraulic Testing pages 8 12 through 8 54 Check the cycle times for boom LIFT and boom EXTEND to determine pump performan...

Page 384: ...Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW INLET OUTLET HYDRAULIC O...

Page 385: ...ain control valve If OK Not OK Repair replace front joystick Install pressure gauge in the pilot supply line between the rear joystick and the extend retract section of main control valve Check pilot...

Page 386: ...TRANS Suction Return Load Sense Pressure Pilot Pressure PUMP HYDRAULIC RESERVOIR ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW INLET OUTLET HYDRAULI...

Page 387: ...ain control valve If OK Not OK Repair replace front joystick Install pressure gauge in the pilot supply line between the rear joystick and the extend retract section of main control valve Check pilot...

Page 388: ...LATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW RETURN FILTER 25 PSI 1 7 BAR BYPASS CHECK VALVE SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5 9 b...

Page 389: ...dge on accumulator charge secondary function valve Not OK Inspect pump Refer to Hydraulic Testing pages 8 12 through 8 54 Check the cycle times for boom LIFT and boom EXTEND to determine pump performa...

Page 390: ...UMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW RETURN FILTER 25 PSI 1 7 BAR BYPASS CHECK VALVE SINGLE JOYSTICK HYDRAULIC OIL COOLER CHECK VALVE 85 PSI 5...

Page 391: ...dge on accumulator charge secondary function valve Not OK Inspect pump Refer to Hydraulic Testing pages 8 12 through 8 54 Check the cycle times for boom LIFT and boom EXTEND to determine pump performa...

Page 392: ...Suction Return Load Sense Pressure Pilot Pressure PUMP HYDRAULIC RESERVOIR ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PI...

Page 393: ...42 Not OK Check auxiliary hydraulic pressure release valve NOTE Before pressure checking circuits refer to Section 9 8 29 Dual Joystick Auxiliary Hydraulic Circuit Troubleshooting to ensure the elect...

Page 394: ...OUTLET ATTACH TILT FRAME EXT RET LFT LWR AUX TRANS ACCUMULATOR CHARGE SECONDARY FUNCTION VALVE LS DRAIN P1 LSG ACR SW P ACF EF CF PIL PB PBG PPG SW RETURN FILTER 25 PSI 1 7 BAR BYPASS CHECK VALVE SIN...

Page 395: ...42 Not OK Check auxiliary hydraulic pressure release valve NOTE Before pressure checking circuits refer to Section 9 8 29 Dual Joystick Auxiliary Hydraulic Circuit Troubleshooting to ensure the elect...

Page 396: ...o the reservoir it exits the Outlet Port and is sent through the Hydraulic Oil Cooler first A Check Valve located in the line will allow oil to bypass the cooler and return to the Hydraulic Reservoir...

Page 397: ...ck to the reservoir because of the Check Valve in the Accumulator Charge Secondary Function Valve b Service Brake Circuit See page 8 70 With the engine running oil flows from the Hydraulic Pump to the...

Page 398: ...ter and then to the Hydraulic Reservoir If system pressure reaches 3400 psi 234 bar the Main Relief Valve Opens allowing hydraulic oil to return to the Hydraulic Reservoir If the return filter becomes...

Page 399: ...passes the Pilot Operated Check Valve to the rod end of the piston and passes through the Counterbalance Valve before exiting the Extend Retract Cylinder Extend Port The oil then flows to the Main Co...

Page 400: ...Spool in the Main Control Valve to direct system pressure to the Lift Lower Cylinder Oil enters the cylinder through the Retract Port and passes the Pilot Operated Check Valve at the base end of the L...

Page 401: ...s to the Single Joystick Pilot Select Valve Port P4 and exits Port HA Then flows to and shifts the Lift Lower Spool in the Main Control Valve to direct system pressure to the Lift Lower Cylinder Oil e...

Page 402: ...pressure out the T Port of the Stabilizer Cylinder Block and send it to the Hydraulic Reservoir unfiltered a Frame Sway LEFT See page 8 90 or page 8 92 With the Joystick moved to the LEFT pilot press...

Page 403: ...ttachment Tilt Cylinder and the Slave Cylinders back to the Main Control Valve and out the Outlet port to the Hydraulic Oil Cooler through the Return Filter to the Hydraulic Reservoir If circuit press...

Page 404: ...through the Oil Cooler to the Return Filter and then drains to the Hydraulic Reservoir If circuit pressure reaches 4000 psi 276 bar the port relief valve will open and allow hydraulic oil to return t...

Page 405: ...ts the R Port and passes through the transfer carriage spool exiting the Outlet Port Oil then passes through the Oil Cooler to the Return Filter and to the Hydraulic Reservoir If system pressure reach...

Page 406: ...l directs system pressure to the E Port on the Transfer Carriage Cylinder and rod end of the cylinder Return oil from the base end of the cylinder exits the R Port and passes through the transfer carr...

Page 407: ...8 157 Model 644E 42 944E 42 Rev 6 04 Hydraulic System This Page Intentionally Left Blank...

Page 408: ...r Steering Unit exiting through Port L where it is channeled through the Steer Selector Valve Port R exiting through Port P and to the LEFT rod end of the Front Steering Cylinder Oil from the RIGHT ro...

Page 409: ...rt P becoming system pressure and flowing to the Front Steering Cylinder LEFT rod end Oil from the RIGHT rod end of the Front Steering Cylinder flows to the Power Steering Unit Port R and exiting thro...

Page 410: ...end of the Front Steering Cylinder Oil from the RIGHT rod end of the Front Steering Cylinder flows to the Power Steering Unit Port R exiting Port T flowing to the Main Control Valve exiting the Outlet...

Page 411: ...il Cooler to the Return Filter and then to the Hydraulic Reservoir b Female Coupler Pressurized page 8 134 or page 8 136 With the Button held down on the top of the Front Joystick and the joystick mov...

Page 412: ...rough the Outlet Port to the Oil Cooler to the Return Filter and then to the Hydraulic Reservoir 8 8 63 Auxiliary Hydraulic Pressure Release Valve 644E 42 SN 20118 Before SN 0160002519 thru 0160003108...

Page 413: ...g wheel 4 all the way to the right until it reaches the stop This will ensure the rear wheels are fully against the right stop 7 Select the front wheel steer mode 5 with the steer mode selector 3 8 Tu...

Page 414: ...he hydraulic reservoir 1 is located on the right side of the vehicle The reservoir is held inside the engine pod with a angle retainer 2 mounted to the engine pod The engine pod skirt 3 is mounted aro...

Page 415: ...driven by the pump main shaft via meshing with an internal transmission gear The pump draws fluid through a 2 inside diameter tube via negative displacement Fluid is forced from the secondary section...

Page 416: ...stating that the vehicle should not be operated Refer to Section 1 5 Accident Prevention Tag Usage 3 Unlatch and open the engine cover Allow the hydraulic fluid to cool 4 Remove the four capscrews 1...

Page 417: ...a clean area It is important to service hydraulic equipment in as clean an environment as possible 3 If it becomes necessary to separate the sections use a plastic mallet to separate the sections NEV...

Page 418: ...wear plate on a clean surface 7 Remove the plastic seal retainer 9 with the seal gland 10 from the mounting flange housing 5 Discard the seal retainer with seal gland 8 Remove the square cross sectio...

Page 419: ...olding the inner shaft seal 38 in the mounting flange housing Discard the snap ring outer seal and inner shaft seal 25 Remove the weep hole plug 39 from the side of the pump mounting flange Discard th...

Page 420: ...not twist in the groove The o ring must be flat in the groove for proper sealing of the pump when assembled 3 Coat both the new seal gland 3 and new plastic seal retainer 4 with graphite grease Caref...

Page 421: ...icate the steel side of the bronze wear plate 15 with graphite grease and install over the seal retainer and seal gland assembly When properly installed the bronze face will be next to the gears and f...

Page 422: ...ss This assembly must be seated completely in the recess to allow proper installation of the bronze wear plate 5 26 Lubricate the steel side of the bronze wear plate 5 with graphite grease and install...

Page 423: ...ed recess This assembly must be seated completely in the recess to allow proper installation of the bronze wear plate 14 34 Lubricate the steel side of the bronze wear plate 14 with graphite grease an...

Page 424: ...h two flange halves 15 and four capscrews 16 Torque the capscrews to 50 90 lb ft 68 122 Nm 7 Check all routing of hoses wiring and tubing for sharp bends or interference with any rotating members All...

Page 425: ...8 175 Model 644E 42 944E 42 Rev 6 04 Hydraulic System This Page Intentionally Left Blank...

Page 426: ...ion switch and the steering wheel stating that the vehicle should not be operated Refer to Section 1 5 Accident Prevention Tag Usage 3 Unlatch and open the engine cover Allow the hydraulic fluid to co...

Page 427: ...2 1 Valve Plate Assembly a Main Control Valve Removal from Valve Plate Before disassembling the main control valve remove it from the valve plate assembly Tag and remove all the hoses from the fitting...

Page 428: ...Hydraulic System 8 178 Model 644E 42 944E 42 Rev 6 04 MU4100 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 29 30 31 32 33 34 35 36...

Page 429: ...ternal parts of the relief valves are not serviceable Replace the entire relief valve if necessary 3 Remove the hex socket head capscrews 15 holding the spool end housings 16 to the section Remove the...

Page 430: ...Hydraulic System 8 180 Model 644E 42 944E 42 Rev 6 04 MU4100 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 6 6 16...

Page 431: ...he spools from each section and inspect for contamination scratches scoring or discoloration If any damage is noted the sections with spools must be replaced as a complete assembly The spools are not...

Page 432: ...Hydraulic System 8 182 Model 644E 42 944E 42 Rev 6 04 MU4140 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 29 30 31 32 33 34 35 36 20...

Page 433: ...n place on the transfer carriage section 7 Place the new oiled o ring 19 in place on the transfer carriage section Carefully slide the transfer carriage section onto the capscrews 4 Slide the section...

Page 434: ...ive conduit as required Tighten all tube and hose clamps 8 Start the engine and run at approximately one third to one half throttle for about one minute without moving the vehicle or operating any hyd...

Page 435: ...ot 12 and remove the handle 13 from the joystick joint assembly 14 Refer to Section 9 14 10 Dual Joystick to remove the handle 2 Remove the joint assembly 14 from the valve body 15 3 Remove the capsul...

Page 436: ...evention Tag Usage 3 Unlatch and open the engine cover Allow the hydraulic fluid to cool 4 Remove the access plate from the floor of the cab 5 Label or otherwise mark the hydraulic hoses in relation t...

Page 437: ...Reattach and secure all hoses and fittings 4 Reconnect any wire harness connectors 5 Start the engine and run at approximately one third to one half throttle for about one minute without moving the v...

Page 438: ...onnection 2 4 Lift up the boot 3 and remove the capscrews 4 that secure the joint and handle assembly 5 to the valve body 6 Lift the joint and handle assembly from the top of the valve body 5 Remove t...

Page 439: ...NEUTRAL DETENT position engage the park brake switch and shut the engine OFF 2 Place an Accident Prevention Tag on both the ignition switch and the steering wheel stating that the vehicle should not...

Page 440: ...ished surfaces within the single joystick pilot select valve 6 Secure the single joystick pilot select valve block 2 in a bench vise or by other suitable means 7 Install the elbow fittings into the P...

Page 441: ...7 Hydraulic System Testing 8 12 7 Frame Sway Joystick Valve The frame sway joystick 18 controls the frame sway only and is only pilot operated If the frame sway is not functioning properly check the...

Page 442: ...8 Auxiliary Hydraulic Pressure Release Valve Early Production The auxiliary hydraulic pressure release valve is attached to a bracket which is attached to the pilot select valve at the top center of t...

Page 443: ...the auxiliary hydraulic pressure release valve DO NOT display an ultra smooth polished finish or components are damaged in any way replace the auxiliary hydraulic pressure release valve or appropriat...

Page 444: ...heck for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 7 Wipe up any hydraulic fluid spillage in on near and around the vehicle work area and tools 8 Re...

Page 445: ...e the park brake switch and shut the engine OFF 2 Place an Accident Prevention Tag on both the ignition switch and the steering wheel stating that the vehicle should not be operated Refer to Section 1...

Page 446: ...nternal seals and damage to the polished surfaces within the auxiliary hydraulic pressure release valve 6 Secure the auxiliary hydraulic pressure release valve block 2 in a bench vise or by other suit...

Page 447: ...und the vehicle work area and tools 8 Reinstall the access plate 14 to the cab floor Secure in place with the capscrews 15 Torque the capscrews to 18 lb ft 25 Nm d Auxiliary Hydraulic Pressure Release...

Page 448: ...rated Refer to Section 1 5 Accident Prevention Tag Usage 3 Unlatch and open the engine cover Allow the hydraulic fluid to cool 4 To remove the service brake valve the lower dash panel must be removed...

Page 449: ...n securely 6 Transfer the double elbow 5 to the lower pressure port P on the side of the new brake valve Tighten securely c Service Brake Valve Installation 1 Reinstall the brake valve into the dash R...

Page 450: ...he tubing must be below the oil level in the container 4 DO NOT open the brake bleeder without holding the tubing firmly on the bleeder There is pressure at the brakes Carefully open the bleeder with...

Page 451: ...d power steering valve are mounted together DO NOT attempt to disassemble the steering valve b Power Steering Valve Reassembly Note Use new oiled o rings as required ALWAYS replace seals o rings gaske...

Page 452: ...unction valve Refer to Section 8 7 Hydraulic System Testing 8 12 12 Steer Select Valve With the steer select valve the vehicle can be used in the front wheel four wheel or crab steering mode The steer...

Page 453: ...nduit as required Tighten all tube and hose clamps 3 Start the engine and run at approximately 1 3 1 2 throttle for about one minute without moving the vehicle or operating any hydraulic functions 4 I...

Page 454: ...ure from the accumulators Apply the service brake pedal and then release Do this several times until all hydraulic pressure has been relieved from the accumulators 5 Remove the access plate from the f...

Page 455: ...nd o rings with clean hydraulic oil 16 Secure the accumulator charge secondary function valve 7 in a bench vise or by other suitable means 17 Install the load shuttle cartridge 8 with new seals and to...

Page 456: ...as required before continuing Add hydraulic fluid to the reservoir as needed 10 Wipe up any hydraulic fluid spillage in on near and around the vehicle work area and tools d Accumulator Charge Valve Te...

Page 457: ...accumulator must be pre charged with gas before use in the service brake system This is done by filling the gas chamber with dry nitrogen to a pressure of 450 35 psi 3103 241 kPa The gas valve 7 locat...

Page 458: ...information Use the following steps to properly pre charge each accumulator 1 Remove the floor plate 1 to gain access to the two accumulators 2 Thoroughly clean the top of each accumulator 2 3 Make s...

Page 459: ...it all the way out counter clockwise Bleed the pressure from the hose by turning the gas valve bleed valve out to relieve the pressure 15 Turn the gas valve bleed valve 6 all the way in and remove the...

Page 460: ...ord the highest pressure observed when the accumulator charge valve shifts and unloads the pump This pressure should be 1900 2100 psi 131 145 bar and is the high limit If the accumulator charge valve...

Page 461: ...cannot be reached 3 Inoperative accumulator charging valve UP cartridge or valve adjusted too high 1 Increase engine RPM to see if pressure rises to high limit 2 Check relief valve and or replace Ref...

Page 462: ...c sealant and locking compound Before attempting to disassemble these parts remove any accessible seals from the area of the bonded parts Wipe off any hydraulic oil then heat the part s uniformly to b...

Page 463: ...commended for the cylinder Check for external leakage and for free movement in both directions 10 Retract the piston fully Cap the hydraulic fittings 8 14 4 Attachment Tilt Cylinder The attachment til...

Page 464: ...TANT Protect the finish on the rod at all times Damage to the surface of the rod can cause seal failure 6 Using a pin spanner wrench unscrew the head gland 6 from the tube 2 The head gland was origina...

Page 465: ...n a soft jawed vise or other suitable holding device Carefully press the bushings from the rod 17 Remove the grease fitting 20 from the base end of the cylinder tube c Attachment Tilt Cylinder Cleanin...

Page 466: ...nder tube 2 in a soft jawed vise or other acceptable holding equipment if possible IMPORTANT When sliding the rod and piston assembly in the tube prevent the threaded end of the tube from damaging the...

Page 467: ...Section 8 7 Hydraulic System Testing 2 With no accessory installed on the quick attach start with the lift lower and attachment tilt cylinders fully retracted 3 Fully extend the attachment tilt cylin...

Page 468: ...using excess force when clamping the cylinder in a vise Apply only enough force to hold the cylinder securely Excessive force can damage the cylinder tube 2 2 Place the slave cylinder in a soft jawed...

Page 469: ...ce of the cylinder 2 Discard all seals back up rings and o rings Replace with new items from a complete seal kit 16 to help ensure proper cylinder function 3 Clean all metal parts with an approved cle...

Page 470: ...y in the tube prevent the threaded end of the tube from damaging the piston 5 Keep the rod centered within the tube to help prevent binding Protect the finish on the rod at all times Damage to the sur...

Page 471: ...chment tilt cylinders fully retracted 3 Fully extend the attachment tilt cylinder Monitor pressure while fully raising the lift lower cylinder 4 Fully retract the attachment tilt cylinder Monitor pres...

Page 472: ...Extend the rod 5 as required to allow access to the base of the cylinder IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause seal failure 5 Using a pin span...

Page 473: ...ing 16 back up ring 17 and o ring 18 from the head gland 6 Remove them from the rod 5 15 Remove the head gland 6 from the rod 16 From within the head gland 6 remove one of the precision wearbands 19 t...

Page 474: ...e the piston to 330 390 lb ft 447 529 Nm 8 Turn the rod spacer 10 as required to align the piston setscrew hole The setscrew is used to provide a secondary lock on the piston Apply Loctite Threadlocke...

Page 475: ...sure Checking and Circuit Bleeding 1 Attach a 5000 psi 345 bar gauge to the main control valve to test the extend retract cylinder hydraulic system circuit pressure The unit is equipped with test fitt...

Page 476: ...ring may be discarded as it served only in a temporarily protective role 1 Clean the lift lower cylinder 1 with a suitable cleaner Remove all dirt debris and grease from the cylinder IMPORTANT Avoid u...

Page 477: ...is a deformed thread type nut installed with Loctite 271 red and torqued to 2200 2600 lb ft 2983 3525 Nm 13 Remove the piston 11 from the rod 8 Note It may be necessary to apply heat to break the bon...

Page 478: ...s 1 Install a new oiled o ring 19 back up ring 18 and o ring 17 on the head gland 10 2 Install the sealed outside diameter heavy duty rod wiper 22 The wiper lip 25 should be away from the head gland I...

Page 479: ...he cylinder Torque the plug to 10 12 lb ft 14 16 Nm 17 If the self aligning bearings 6 and 9 require replacement support the rod 8 in a soft jawed vise or other suitable holding device Carefully press...

Page 480: ...tween the frame and axle to prevent the frame from leaning to one side 5 Disconnect and cap all hoses and fittings etc 6 Use a sling and hoist or other suitable lifting device to support the cylinder...

Page 481: ...remove the locknut 8 from the threaded end of the rod Discard the nut a new nut will be required for reassembly Note Heating the nut 8 to approximately 300 F 150 C may also be required to break the se...

Page 482: ...ent install a new rod e Frame Sway Cylinder Assembly Note Follow Section 8 14 3 General Cylinder Assembly Instructions 1 Install the deep Z seal with rod back up 17 into the head gland orienting the e...

Page 483: ...and carefully insert the rod into the tube 5 Avoid scratching nicking or damaging the tube while installing the rod 15 Begin threading the head gland 4 into the tube 5 Place the locking insert 3 in i...

Page 484: ...tle for about one minute without moving the vehicle or operating any hydraulic functions Operate the joystick to fully sway the frame left and right at least five times each 8 Inspect for leaks and ch...

Page 485: ...e 3 Unlatch and open the engine cover Allow the hydraulic fluid to cool 4 Label or otherwise mark the hydraulic hoses in relation to the cylinder being removed Safely position suitable supports betwee...

Page 486: ...ations stamped on the manifold Remove the solenoid cartridges from the manifold Note The head gland 8 is installed at a torque of 300 400 lb ft 407 542 Nm Use suitable tools to remove the head gland 4...

Page 487: ...solvent such as trichlorethylene Carefully clean cavities grooves threads etc d Stabilizer Cylinder Inspection and Repair 1 Inspect all parts for wear and damage If inner surfaces of the cylinder 1 d...

Page 488: ...Keep the rod 11 straight and carefully insert the rod into the tube 2 Avoid scratching nicking or damaging the tube while installing the rod 15 Begin threading the head gland 8 into the tube 2 Place...

Page 489: ...the joystick to fully sway the frame left and right at least five times each 9 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Add hydraulic fluid to...

Page 490: ...he vehicle should not be operated Refer to Section 1 5 Accident Prevention Tag Usage 3 Unlatch and open the engine cover Allow the hydraulic fluid to cool 4 Label or otherwise mark the hydraulic hoses...

Page 491: ...inally torqued at 250 300 lb ft 339 407 Nm so a considerable amount of force is required to remove it Carefully slide the head gland down along the rod toward the eyelet end away from the cylinder tub...

Page 492: ...do not display an ultra smooth polished finish or are damaged in any way replace the damaged part Often dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces with...

Page 493: ...or damaging the seals and o rings when installing the piston 5 and head gland 4 into the cylinder When sliding the rod and piston assembly in the tube DO NOT damage the piston by scraping it against t...

Page 494: ...si 345 bar gauge to the main control valve to test the transfer carriage cylinder hydraulic system circuit pressure The unit is equipped with test fittings from the factory Refer to Section 8 7 Hydrau...

Page 495: ...s 11 from the mounting plates 12 on carriage 12 Identify and mark the location of the 1 1 2 I D shims 13 at the base end of the cylinder 13 Remove the cylinders 5 from the pivot mount 9 and the mounti...

Page 496: ...device Carefully press the bearing out of the rod eyelet 5 Extend the rod 4 to access the cylinder base IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause...

Page 497: ...ep Z seal 19 and from the other end remove the square ring 20 and the rod wiper 21 c Swing Carriage Cylinder Cleaning 1 Remove all hydraulic fluid dirt and debris from the swing carriage cylinder 1 2...

Page 498: ...filtered hydraulic oil 12 Apply a compression sleeve or other suitable tool to the head gland 5 in order to compress the o rings 15 and 16 IMPORTANT When sliding the rod and piston assembly in the tub...

Page 499: ...he swing carriage is normal no jerks or spongy feel 7 Shut the engine OFF Check the hydraulic level and fill as required g Swing Carriage Cylinder Pressure Checking and Circuit Bleeding 1 Attach a 500...

Page 500: ...vehicle should not be operated Refer to Section 1 5 Accident Prevention Tag Usage 6 Unlock unlatch and open the engine cover Allow the hydraulic fluid to cool 7 Remove all dirt and grease from the si...

Page 501: ...8 251 Model 644E 42 944E 42 Rev 6 04 Hydraulic System MT1950 2 3 4 5 6 7 8 5 5...

Page 502: ...to the base of the cylinder IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause seal failure 7 Using a pin spanner wrench unscrew the head gland 7 from the...

Page 503: ...the sealant between the locknut 16 and the rod 6 before the parts can be removed Some parts of cylinders are sealed with a special organic sealant and locking compound Before attempting to disassemble...

Page 504: ...nt damage to the rod 5 Carefully slide the head gland 7 onto the rod 6 If necessary use a soft hammer to drive the head gland onto the rod 6 Install a new small oiled o ring 17 inside the rod end of t...

Page 505: ...t check valves 5 Lubricate the valve and rings with clean filtered hydraulic oil Install and torque to 30 35 lb ft 41 47 Nm Refer to the Parts Manual for seal kits 15 If necessary install both grease...

Page 506: ...l and fill as required g Side Tilt Carriage Cylinder Pressure Checking and Circuit Bleeding 1 Attach a 5000 psi 345 bar gauge to the main control valve to test the swing carriage cylinder hydraulic sy...

Page 507: ...8 257 Model 644E 42 944E 42 Rev 6 04 Hydraulic System MT1950 1 2 3 4 5 6 7 4 4...

Page 508: ...Hydraulic System 8 258 Model 644E 42 944E 42 Rev 6 04 This Page Intentionally Left Blank...

Page 509: ...ptional Roadlight Harness 9 14 9 1 11 General Overview Optional Worklight Harness 9 15 9 1 12 General Overview Vehicle Ground Strap Locations 9 16 9 2 Service Warnings 9 18 9 2 1 General 9 18 9 2 2 Ba...

Page 510: ...ooting 9 70 9 8 26 944E 42 Engine Start Circuit Troubleshooting 9 76 9 8 27 944E 42 Electronic Throttle Circuit Troubleshooting 9 82 9 8 28 Charging Circuit Troubleshooting 9 84 9 8 29 Dual Joystick A...

Page 511: ...dicator Troubleshooting 9 155 9 10 8 Hydraulic Oil Filter Restriction Warning Indicator Troubleshooting 9 156 9 10 9 Park Brake Warning Indicator Troubleshooting 9 157 9 10 10 Low Brake Pressure Indic...

Page 512: ...SN 20123 Before 0160002514 thru 0160003106 9 218 9 14 6 Parking Brake Switch 9 220 9 14 7 Transmission Disconnect Switch 9 222 9 14 8 Transmission Shift Control Switch 9 224 9 14 9 Transmission Soleno...

Page 513: ...erred to throughout this section 9 1 1 General Overview Open Cab Harness A A Front Dash Panel MU4641 Horn Button Travel Select Lever Cab to Frame Ground Strap Stabil TRAK Brake Switch Park Brake Switc...

Page 514: ...04 9 1 2 General Overview 644E 42 SN 20118 Before 0160002519 thru 0160003689 Vehicle Power Harness MU4610 Fuel Shut Off Relay Engine Start Relay Fuel Shut Off Solenoid Engine Starter Engine Alternato...

Page 515: ...ystem 9 1 3 General Overview 644E 42 SN 0160003690 After Vehicle Power Harness MU6630 Engine Start Relay Engine Starter Engine Alternator Cab Fuse and Relay Access Vehicle Power Harness Fusible Link F...

Page 516: ...Heater Engine Starter Engine Alternator Diagnostic Connector To Cab Bulkhead Connectors Cold Start Grid Heater Fuse Cold Start Grid Heater Relay Cold Start Grid Heater Fuse Terminating Resistor ECM Co...

Page 517: ...verview Vehicle Sensor Harness Engine Water Temperature Switch Air Filter Pressure Switch Hydraulic Oil Temperature Switch Hydraulic Oil Pressure Switch Transmission Temperature Switch Engine Oil Pres...

Page 518: ...10 Model 644E 42 944E 42 Rev 6 04 9 1 6 General Overview Vehicle Control Harness MU4680 Boom Proximity Switch Back Up Alarm Stabilizer Cylinder Solenoid Connections Cab Fuse and Relay Access Horn Vehi...

Page 519: ...9 11 Model 644E 42 944E 42 Rev 6 04 Electrical System 9 1 7 General Overview Vehicle Transmission Harness MU4690 Vehicle Transmission Harness Transmission Solenoid Connectors Y6 Y4 Y5 Y3 Y1 Y2...

Page 520: ...tick Pilot Select Valve Single Joystick Relay Single Joystick Valve Assembly Frame Sway Joystick Valve Assembly Cab Harness Single Joystick Harness Single Joystick Pilot Select Valve Single Joystick R...

Page 521: ...Motor Rear Window Wiper and Motor Front Windshield Wiper and Motor Skylight Wiper andSkylight Rear Washer Switch Air Conditioning On Off Switch AC Heater Temperature Control AC Heater Fan Switch Fron...

Page 522: ...Overview Optional Roadlight Harness MU6010 Roadlight Harness Front Headlights Turn Signals Boom Worklight Rear Worklights Lighting Fuses Light Power Relay Brake Switch Worklight Hazard Light Switches...

Page 523: ...1 11 General Overview Optional Worklight Harness MU5980 Vehicle Worklight Harness Cab Worklight Harness Boom Worklight Harness Lighting Fuses Worklight Switch Boom Worklight Front Worklights Rear Work...

Page 524: ...42 Rev 6 04 9 1 12 General Overview Vehicle Ground Strap Locations MU6420 Cab to Cab Support Ground Strap Cab Support to Vehicle Frame Ground Strap Engine MountFrame to Vehicle Frame Ground Strap Engi...

Page 525: ...9 17 Model 644E 42 944E 42 Rev 6 04 Electrical System This Page Intentionally Left Blank...

Page 526: ...A short circuit or wrong connection creating reverse polarity will immediately and permanently ruin internal components within the electrical system MU5510 944E 42 Only 1 2 3 CAUTION DO NOT momentaril...

Page 527: ...HARNESSES Wiring on the standard 644E 42 vehicle is contained within five separate wiring harnesses the open cab harness vehicle power harness vehicle transmission harness vehicle sensors harness and...

Page 528: ...07 C 9 6 4 Inspection and Repair Replace a harness only if it is damaged or unusable If a splice or repair must be made to a wire always use rosin core solder to bond wires together Use heat shrink tu...

Page 529: ...it the fusible element will melt 2 and create an open or incomplete circuit Fuses are a one time protection device and must be replaced each time the circuit is overloaded To determine if a fuse is op...

Page 530: ...c Fuse Locations OU0670 1 2 3 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 MU33802 4 No Volt Circuit Controlled E1 12 Volt Transmission Co...

Page 531: ...amp fuses and the other holder contains three 10 amp fuses 7 10 Amp Stability Circuit 8 10 Amp Dash 9 Open 10 5 Amp Auxiliary Hydraulic 11 Open 12 15 Amp Outriggers Option Some Models 13 Open 14 3 Amp...

Page 532: ...s There are three relays located inside the engine compartment mounted on the firewall One relay 3 controls the engine starter and the other two relays 4 control the engine grid heater There is an eng...

Page 533: ...y straight out and away ALWAYS install the correct amp rated fuse or relay a 944E 42 Engine Compartment Fuse Replacement Cold Start Grid Heater Fuses 1 To access the fuses 13 open the protective cover...

Page 534: ...securing the fuse holders to the wire harness b 644E 42 Engine Compartment Relay Removal To remove the relays 3 and 4 from inside the engine compartment remove the mounting screws and washers 5 When...

Page 535: ...arate wiring harnesses the open cab harness vehicle power harness vehicle transmission harness vehicle sensors harness and vehicle control harness The wiring on the standard 944E 42 vehicle is contain...

Page 536: ...detected while the key switch is in the RUN position during the operation of the vehicle itself If a fault becomes active currently detected at this time a fault is logged in memory and a snapshot of...

Page 537: ...unction on a DMM shows how much resistance exists between two points along a circuit Low resistance in a circuit means good continuity IMPORTANT Disconnect the power feed from the suspect circuit when...

Page 538: ...nals Use care in order to avoid deforming the terminal either by forcing the test probe too far into the cavity or by using too large of a test probe After back probing any connector inspect for termi...

Page 539: ...hort to ground in a circuit With a DMM 1 Remove the power feed i e fuse control module from the suspect circuit 2 Disconnect the load 3 Set the rotary dial of the DMM to the Ohm position 4 Connect one...

Page 540: ...cables 1 and 2 from both batteries To access the lower battery 3 loosen the knob 4 far enough so that the lip 5 on the upper battery box clears the knob Lift up the upper battery box 6 and swing it ou...

Page 541: ...s 1 and 2 from both batteries To access the lower battery 3 loosen the knob 4 far enough so that the lip 5 on the upper battery box clears the knob Lift up the upper battery box 6 and swing it out so...

Page 542: ...erminal on the lower battery 8 Swing the upper battery box 9 in and make sure that the lip 10 on the upper battery box slides below the knob 11 Secure in place with the knob 11 11 Close and lock the e...

Page 543: ...male Connector Pin 8 To Splice 290 AH3B 9 48 or 9 50 16 RED WHT Auxiliary Hydraulic Pressure Release Switch 8 Pin Female Connector Pin 2 To Splice 290 AH4 9 48 or 9 50 16 RED Auxiliary Hydraulic Press...

Page 544: ...ity Sensor 3 Pin Female Connector Pin C To Vehicle Bulkhead 15 Pin Male Connector Pin B2 BP3 9 49 or 9 51 16 TAN Boom Proximity Sensor 3 Pin Female Connector Pin B To Vehicle Bulkhead 15 Pin Male Conn...

Page 545: ...r 3 Pin Female Connector P4 Pin A 944E 42 Only CNH2 9 54 18 YEL Splice 4 To Engine Control Module 9 Pin Male Diagnostic Connector P7 Pin C 944E 42 Only CNH3 9 54 18 YEL Splice 4 To Resistor 3 Pin Fema...

Page 546: ...51 16 YEL PUR Sensor Bulkhead 10 Pin Male Connector Pin F To Hydraulic Oil Filter Pressure Switch Male Connector Pin A D11 9 49 or 9 51 16 PNK Hydraulic Oil Filter Pressure Switch Female Connector Pin...

Page 547: ...3 9 48 or 9 50 Bare Metal Connector Optional Heater Fan Fuse F17 Pin 17 To Optional Skylight Wiper Fuse F18 Pin 18 FJ14 9 48 or 9 50 Bare Metal Connector Optional Skylight Wiper Fuse F18 Pin 18 To Opt...

Page 548: ...VESPAK Connector P10 Pin F 944E 42 Only GHG1 9 54 16 BLK Splice 7 To Grid Heater Relay 1 Pin 4 944E 42 Only GHG2 9 54 16 BLK Splice 7 To Grid Heater Relay 2 Pin 4 944E 42 Only GHG3 9 54 16 BLK Batter...

Page 549: ...ine Connector P2 Pin 26 944E 42 Only PB1 9 48 or 9 50 14 RED TAN Ignition Control Fuse F2 Pin B To Ignition Switch B PB2 9 48 or 9 50 16 TAN Ignition Switch IGN To Splice 10 PB2A 9 48 or 9 50 16 TAN S...

Page 550: ...55 S2A 9 48 or 9 50 16 DK BLU ORG Splice 55 To Transmission Disconnect Switch 4 Pin Female Connector Pin 2 S2B 9 48 or 9 50 16 DK BLU ORG Diode VESPAK Connector VP2 Pin C To Splice 55 S2C 9 48 16 DK...

Page 551: ...e Connector Pin B To Splice 20 SG2 9 48 or 9 50 16 BLK Accumulator Brake Pressure Switch Female Connector Pin B To Splice 20 SG3 9 49 or 9 51 16 BLK Dual Hydraulic Oil Temperature Switch 3 Pin Female...

Page 552: ...54 18 RED Engine Control Module Bulkhead 23 Pin Female Connector Pin B To Engine Control Module 50 Pin Female Engine Connector P2 Pin 29 944E 42 Only THP1 9 54 18 RED Engine Control Module Bulkhead 2...

Page 553: ...100 TRG2 9 49 or 9 51 18 BLK Transmission Y4 Solenoid Connector X8 Pin B To Splice 100 TRG3 9 49 or 9 51 18 BLK Transmission Y3 Solenoid Connector X7 Pin B To Splice 100 TRG4 9 49 or 9 51 18 BLK Trans...

Page 554: ...Electrical System 9 46 Model 644E 42 944E 42 Rev 6 04 This Page Intentionally Left Blank...

Page 555: ...ctrical schematics and circuit diagrams in this section 1 M TRG6 2 30 MU0130 Relay resistor Fuse Relay contacts In line bulkhead connector pin Wire name Pressure activated switch Lamp or switch Proxim...

Page 556: ...A5 A4 A3 A2 B5 B4 B3 B2 B1 TR5 TR6 TR1 TR4 TR3 TR2A A B C D E F CP1 S3 PB3A PB4 S5 S4 S2B S6 10 PB2B PB2A PB5 STABILIZER BRAKE SWITCH S1A 50 F8 10 DASH PANEL H D1 F7 10 STABILITY CIRCUIT G F BU2 F6 10...

Page 557: ...ONNECTOR S12C BU3B BP1A H2 H1A S11 S8A BP2 BP3 A5 A4 A3 A2 B5 B4 B3 B2 B1 60 S8C S8A S8B S11B CAB GRND STUD EG5 EG4 A B A B RIGHT TRANSMISSION COILS LEFT TRANSMISSION COILS D12A EG6 S11A D4A COOLANT T...

Page 558: ...BU2 F6 10 BACK UP ALARM HORN F5 20 IGNITION POWER E IG2 D ST4 F4 20 FUEL SOLENOID TRANSMISSION F3 15 C I F10 5 AUXILIARY HYDRAULICS J AH1 L F15 40 CLOSED CAB MAIN OPTION O CP2 F16 10 FRONT WIPER OPTI...

Page 559: ...NNECTOR S12C BU3B BP1A H2 H1A S11 S8A BP2 BP3 A5 A4 A3 A2 B5 B4 B3 B2 B1 60 S8C S8A S8B S11B CAB GRND STUD EG5 EG4 A B A B RIGHT TRANSMISSION COILS LEFT TRANSMISSION COILS D12A EG6 S11A D4A COOLANT TE...

Page 560: ...GROUND BUSS BAR 12V BUSS BAR A B C BB1 BA1 BC1 POWER FEMALE CONNECTOR A B C D E F ST4A ST3 GB2 GB1 POWER MALE CONNECTOR ENGINE START RELAY 1 2 3 4 1 2 3 4 FUEL SHUTOFF RELAY FR1 FR3 FRG ST1 ST2 SRG S...

Page 561: ...BUSS BAR 12V BUSS BAR A B C BB1 BA1 BC1 POWER FEMALE CONNECTOR A B C D E F ST4A ST3 GB2 GB1 POWER MALE CONNECTOR ENGINE START RELAY 1 2 3 4 ST1 ST2 SRG ST4F FSG FSG FR2 ST2 ST1 STARTER GND 95 C B A EG...

Page 562: ...THS THP ON1 SWR THG WSL ML WLS SL OFF1 J87H BPD BPM BNW BPS BNP BNH BNF BNE BPC BPB ST4A A B C D E F H M P S W P1 ENGINE CONTROL MODULE FEMALE CONNECTOR GHG2 GH2 BPS BPL1 BPL2 BPS1 BPM BPM1 A B C D E...

Page 563: ...9 56 or 9 57 18 GRN Diode VESPAK Connector VP4 Pin F To Engine Grid Heater Relay 2 Pin 1 GH2A 9 56 or 9 57 16 ORG Splice 280 To Engine Grid Heater Relay 2 Pin 3 GH2B 9 56 or 9 57 16 ORG Splice 280 To...

Page 564: ...2V BUSS BAR ENGINE BLOCK STARTER GND C A B A B C BA1 POWER MALE CONNECTOR IG1 BA4 BA3 F1 40 OPEN CAB VEHICLE MAIN F2 15 IGNITION CONTROL BA1A B 10 PB2A 2 PB2 IG1 PB1 To Transmission Fuse F3 To Park Br...

Page 565: ...BAR ENGINE BLOCK STARTER GND C A B A B C BA1 POWER MALE CONNECTOR IG1 BA4 BA3 F1 40 OPEN CAB VEHICLE MAIN F2 15 IGNITION CONTROL BA1A B 10 PB2A 2 PB2 IG1 PB1 To Transmission Fuse F3 To Park Brake Swit...

Page 566: ...Pin B To Splice 290 SJG6 16 BLK Single Joystick Pilot Select Valve AX Solenoid 2 Pin Connector Pin B To Splice 290 SJG7 16 BLK Single Joystick Pilot Select Valve EXT Solenoid 2 Pin Connector Pin B To...

Page 567: ...SION F3 15 C 4 3 2 1 A FJ1 PB1 FJ3 5 FJ4 6 FJ5 7 FJ6 8 FJ7 9 10 F8 10 DASH PANEL H F7 10 STABILITY CIRCUIT G F F6 10 BACK UP ALARM HORN F5 20 IGNITION POWER E I F10 5 AUXILIARY HYDRAULICS J AH1 FJ2 F9...

Page 568: ...le Joystick Pilot Select Valve CTB Solenoid 2 Pin Connector Pin A To Single Joystick 6 Pin Female Connector Pin 5 RTB 18 GRY Single Joystick Pilot Select Valve CTB Solenoid 2 Pin Connector Pin B To Sp...

Page 569: ...15 IGNITION CONTROL BA1A BA3 B BA4 D F4 20 FUEL SOLENOID TRANSMISSION F3 15 C 4 3 2 1 A FJ1 PB1 FJ3 5 FJ4 6 FJ5 7 FJ6 8 FJ7 9 10 F8 10 DASH PANEL H F7 10 STABILITY CIRCUIT G F F6 10 BACK UP ALARM HORN...

Page 570: ...in 3 To Front Washer Pump POWER FWG1 16 BLK Front Wiper Switch 10 Pin Female Connector Pin 7 To Splice 205 FWG2 14 BLK Front Wiper Motor GND To Splice 205 FWG3 16 BLK Front Washer Switch 8 Pin Female...

Page 571: ...1 7 8 5 5 5 5 5 5 5 5 5 6 3 1 7 THERMOSTAT 35 F F E HEATER AC BLOWER MOTOR POWER GND M BLOWER MOTOR RESISTOR PACK BLOWER B F C A D E HEATER VALVE POWER GROUND 7 8 10 D C A VALVE POTENTIOMETER SKYLIGHT...

Page 572: ...r Pin 1 LB1 9 66 14 RED Turn Signal Control Selector 12 Pin Female Connector Pin 5 To Roadlight Bulkhead 7 Pin Female Connector Pin B LB1A 9 67 14 RED Roadlight Bulkhead 7 Pin Male Connector Pin B To...

Page 573: ...ch 8 Pin Female Connector Pin 3 To Worklight Bulkhead Female Connector Pin A WL2A 9 67 14 LT BLU Worklight Bulkhead Male Connector Pin A To Boom Worklight Male Connector Pin A WL3 9 66 14 YEL Workligh...

Page 574: ...3 5 11 10 1 P O R L 1 P O High Beam High Beam Flash Low Beam F25 40 LIGHTS MAIN OPTION Y F26 25 CONDENSER FAN OPTION Z FJ21 28 FJ21 FJ20 26 FJ19 25 AA 27 AB 28 F27 OPEN F28 OPEN 12V BUSS BAR STARTER...

Page 575: ...WL2A WL3A ROADLIGHT MALE CONNECTOR WORKLIGHT MALE CONNECTOR RT1B BL2A LT1B HB1B LB1A PS1B GROUND BUSS BAR 165 PS1B PS1C PS1D PS1E PS1F LT1D PS1F PS1D 3 BRK 1 IND LEFT TAILLIGHT PS1C 135 LB1A LB1B LB1...

Page 576: ...To Splice 230 WL5B 14 LT BLU Worklight Bulkhead Male Connector Pin A To Splice 235 WL5C 14 LT BLU Boom Worklight Male Connector Pin A To Splice 235 WL5D 14 LT BLU Left Front Worklight Pin P To Splice...

Page 577: ...9 25 AA 27 AB 28 F27 OPEN F28 OPEN 12V BUSS BAR STARTER GND C A B A B C BA1 F1 40 OPEN CAB VEHICLE MAIN F2 15 IGNITION CONTROL BA1A 10 PB2A 2 PB2 IG1 PB1 To Park Brake Switch BA3 BB1 BC1 BC1A FJ15 20...

Page 578: ...R7 PB2 5 PB3 PB3 NS1 IG1 1 7 6 3 RG6 PB1 PB6 15 PB6B CAB GRND STUD CG3 85 PB6A PB6A 12V BUSS BAR A B C BA1 A B C D E F ST2 POWER MALE AND FEMALE CONNECTOR TR7A PB3A ST3 ST4A A FJ1 PB1 PB2B 2 5 8 ENGIN...

Page 579: ...start position check starter solenoid terminal wire ST2 BLU connection for battery voltage Replace starter Check for battery voltage at starter positive battery post RED cable Check negative cables f...

Page 580: ...25 TR7 PB2 5 PB3 PB3 NS1 IG1 1 7 6 3 RG6 PB1 PB6 15 PB6B CAB GRND STUD CG3 85 PB6A PB6A 12V BUSS BAR A B C BA1 A B C D E F ST2 POWER MALE AND FEMALE CONNECTOR TR7A PB3A ST3 ST4A A FJ1 PB1 PB2B 2 5 8...

Page 581: ...tch in start position check starter solenoid terminal wire ST2 BLU connection for battery voltage Repair replace open cab harness Check for power at engine start relay at wire ST1 RED Not OK Not OK If...

Page 582: ...25 TR7 PB2 5 PB3 PB3 NS1 IG1 1 7 6 3 RG6 PB1 PB6 15 PB6B CAB GRND STUD CG3 85 PB6A PB6A 12V BUSS BAR A B C BA1 A B C D E F ST2 POWER MALE AND FEMALE CONNECTOR TR7A PB3A ST3 ST4A A FJ1 PB1 PB2B 2 5 8...

Page 583: ...BLU at transmission control relay Not OK If OK Replace VP1 diode board Check power at wire PB3 BLK WHT at park brake switch Not OK If OK Replace transmission control relay Check power at wire PB6B RED...

Page 584: ...N R 4 1 2 3 IGNITION SWITCH ACC IGN B OFF ACC IGN ST VP1 DIODE PACK A B C F LIGHT POWER RELAY OPTION 87A 87 30 86 85 PB4 RG1 TR8 TR9 TRANS CONTROL RELAY 87A 87 30 86 85 PB6B IGNITION RELAY 87A 87 30 8...

Page 585: ...start position check starter solenoid terminal wire ST2 BLU connection for battery voltage Replace starter Check for battery voltage at starter positive battery post RED cable Check negative cables f...

Page 586: ...AL F N R 4 1 2 3 IGNITION SWITCH ACC IGN B OFF ACC IGN ST VP1 DIODE PACK A B C F LIGHT POWER RELAY OPTION 87A 87 30 86 85 PB4 RG1 TR8 TR9 TRANS CONTROL RELAY 87A 87 30 86 85 PB6B IGNITION RELAY 87A 87...

Page 587: ...start position check starter solenoid terminal wire ST2 BLU connection for battery voltage Repair replace open cab harness Check for power at engine start relay at wire ST1 RED Not OK Not OK If OK Re...

Page 588: ...AL F N R 4 1 2 3 IGNITION SWITCH ACC IGN B OFF ACC IGN ST VP1 DIODE PACK A B C F LIGHT POWER RELAY OPTION 87A 87 30 86 85 PB4 RG1 TR8 TR9 TRANS CONTROL RELAY 87A 87 30 86 85 PB6B IGNITION RELAY 87A 87...

Page 589: ...BLU at transmission control relay Not OK If OK Replace VP1 diode board Check power at wire PB3 BLK WHT at park brake switch Not OK If OK Replace transmission control relay Check power at wire PB6B RED...

Page 590: ...POWER MALE AND FEMALE CONNECTORS THROTTLE ROTARY POSITION SENSOR THS1 THP1 THG1 1 2 3 3 1 2 FJ11 14 N F14 3 ECM INDICATOR LIGHT SL1 WLS1 ENGINE FUNCTION INDICATOR LIGHTS 2A 1A 2B 1B 1 2 DLP 6 SL1 WLS...

Page 591: ...throttle position sensor male connector Resistance across pins 1 and 3 should be 4 000 6 000 ohms Resistance across pins 2 and 3 should vary from approximately 2 000 ohms with throttle pedal at rest...

Page 592: ...STABIL TRAK RESTRICTION MODE J12 TURN SIGNAL OPTIONAL J10 ENGINE PRE HEAT OPTIONAL J11 HIGH BEAM OPTIONAL J14 D13 D2 C D E F G H J A D13 D2 1 5 15 7 2 3 20 8 9 6 4 19 18 17 16 13 12 10 11 14 SENSOR F...

Page 593: ...uously Replace alternator At vehicle sensor harness connector at pin J wire AD1 RED check for battery voltage On alternator check wires AG1 BLK and AG2 BLK to ground Not OK Replace dash panel On alter...

Page 594: ...D AH4 AH3 A B C AH1 AH2 AUXILIARY HYDRAULIC JOYSTICK A B C AHG6 AHG6 HYD JOYSTICK CONNECTOR SN 19041 BEFORE A B AH1 AH2 AUX HYD JOYSTICK A B STARTER GND BATTERY 1 ENGINE BLOCK F1 40 OPEN CAB VEHICLE M...

Page 595: ...d verify that solenoids are magnetized by holding a metal object next to the solenoid Or test resistance in solenoid Refer to page 9 229 Replace failed solenoid Not OK If OK If OK If OK If OK If OK Pr...

Page 596: ...D STUD AH4 AH3 A B C AH1 AH2 AUXILIARY HYDRAULIC JOYSTICK A B C AHG6 AHG6 HYD JOYSTICK CONNECTOR SN 19041 BEFORE A B AH1 AH2 AUX HYD JOYSTICK A B STARTER GND BATTERY 1 ENGINE BLOCK F1 40 OPEN CAB VEHI...

Page 597: ...switch connector at pin 2 wire AH3B RED WHT check for battery voltage Repair replace open cab harness If OK Not OK At switch connector at pin 3 wire AH4 RED check for battery voltage Repair replace au...

Page 598: ...MALE CONNECTOR 4 3 2 1 6 5 12V DC B N C HALL EFFECT OUTPUT 5VDC SWITCH OUTPUT NO AGND PROPORTIONAL ROLLER TRIGGER SWITCH SINGLE JOYSTICK CONTROL JOYSTICK JUMPER HARNESS MALE CONNECTOR 3 4 5 6 1 2 JOYS...

Page 599: ...troubleshooting any electrical circuit ALWAYS begin by checking the following 1 All connections relating to circuit are clean and tight 2 All grounding straps are intact and securely fastened refer to...

Page 600: ...TICK MALE CONNECTOR 4 3 2 1 6 5 12V DC B N C HALL EFFECT OUTPUT 5VDC SWITCH OUTPUT NO AGND PROPORTIONAL ROLLER TRIGGER SWITCH SINGLE JOYSTICK CONTROL JOYSTICK JUMPER HARNESS MALE CONNECTOR 3 4 5 6 1 2...

Page 601: ...refer to Section 9 1 12 General Overview Vehicle Ground Strap Locations With switch in the ON position verify that solenoid on auxiliary hydraulic pressure release valve is magnetized by holding a me...

Page 602: ...YSTICK MALE CONNECTOR 4 3 2 1 6 5 12V DC B N C HALL EFFECT OUTPUT 5VDC SWITCH OUTPUT NO AGND PROPORTIONAL ROLLER TRIGGER SWITCH SINGLE JOYSTICK CONTROL JOYSTICK JUMPER HARNESS MALE CONNECTOR 3 4 5 6 1...

Page 603: ...wires TAB TAN and SJG5 BLK Check auxiliary hydraulic F10 5 amp fuse Not OK Not OK Not OK If OK If OK If OK If OK Check power at wire AH1C RED WHT at single joystick relay Not OK Verify wire AHG6 BLK...

Page 604: ...MALE CONNECTOR 4 3 2 1 6 5 12V DC B N C HALL EFFECT OUTPUT 5VDC SWITCH OUTPUT NO AGND PROPORTIONAL ROLLER TRIGGER SWITCH SINGLE JOYSTICK CONTROL JOYSTICK JUMPER HARNESS MALE CONNECTOR 3 4 5 6 1 2 JOYS...

Page 605: ...nections relating to circuit are clean and tight 2 All grounding straps are intact and securely fastened refer to Section 9 1 12 General Overview Vehicle Ground Strap Locations Unplug single joystick...

Page 606: ...LE CONNECTOR 4 3 2 1 6 5 12V DC B N C HALL EFFECT OUTPUT 5VDC SWITCH OUTPUT NO AGND PROPORTIONAL ROLLER TRIGGER SWITCH SINGLE JOYSTICK CONTROL JOYSTICK JUMPER HARNESS MALE CONNECTOR 3 4 5 6 1 2 JOYSTI...

Page 607: ...arness Verify that solenoid is magnetized by holding a metal object next to the solenoid Or test resistance in solenoid Refer to page 9 233 If OK Unplug single joystick harness at hyd joystick connect...

Page 608: ...ALE CONNECTOR 4 3 2 1 6 5 12V DC B N C HALL EFFECT OUTPUT 5VDC SWITCH OUTPUT NO AGND PROPORTIONAL ROLLER TRIGGER SWITCH SINGLE JOYSTICK CONTROL JOYSTICK JUMPER HARNESS MALE CONNECTOR 3 4 5 6 1 2 JOYST...

Page 609: ...bleshooting any electrical circuit ALWAYS begin by checking the following 1 All connections relating to circuit are clean and tight 2 All grounding straps are intact and securely fastened refer to Sec...

Page 610: ...ICK MALE CONNECTOR 4 3 2 1 6 5 12V DC B N C HALL EFFECT OUTPUT 5VDC SWITCH OUTPUT NO AGND PROPORTIONAL ROLLER TRIGGER SWITCH SINGLE JOYSTICK CONTROL JOYSTICK JUMPER HARNESS MALE CONNECTOR 3 4 5 6 1 2...

Page 611: ...tick harness late production Check for battery voltage at pin 1 wire AH1B RED WHT on the joystick harness female connector Early Production Replace joystick jumper harness and control module with new...

Page 612: ...4 3 2 1 STABIL LOCK RELAY 87A 87 30 86 85 25 TR7 PB2 5 PB3 PB3 NS1 IG1 1 7 6 3 RG6 PB1 PB6 15 PB6B CAB GRND STUD CG3 85 PB6A PB6A POWER MALE AND FEMALE CONNECTOR TR7A PB3A A FJ1 PB1 PB2B 2 5 8 PH SENS...

Page 613: ...start position check starter solenoid terminal wire ST2 BLU connection for battery voltage Replace starter Check for battery voltage at starter positive battery post RED cable Check negative cables f...

Page 614: ...15 C 4 3 2 1 STABIL LOCK RELAY 87A 87 30 86 85 25 TR7 PB2 5 PB3 PB3 NS1 IG1 1 7 6 3 RG6 PB1 PB6 15 PB6B CAB GRND STUD CG3 85 PB6A PB6A POWER MALE AND FEMALE CONNECTOR TR7A PB3A A FJ1 PB1 PB2B 2 5 8 PH...

Page 615: ...witch in start position check starter solenoid terminal wire ST2 BLU connection for battery voltage Repair replace open cab harness Check for power at engine start relay at wire ST1 RED Not OK Not OK...

Page 616: ...15 C 4 3 2 1 STABIL LOCK RELAY 87A 87 30 86 85 25 TR7 PB2 5 PB3 PB3 NS1 IG1 1 7 6 3 RG6 PB1 PB6 15 PB6B CAB GRND STUD CG3 85 PB6A PB6A POWER MALE AND FEMALE CONNECTOR TR7A PB3A A FJ1 PB1 PB2B 2 5 8 PH...

Page 617: ...BLU at transmission control relay Not OK If OK Replace VP1 diode board Check power at wire PB3 BLK WHT at park brake switch Not OK If OK Replace transmission control relay Check power at wire PB6B RE...

Page 618: ...10 8 7 10 B A C POWER GND M AC CONDENSER 87A 87 30 86 85 POWER GND M BLC BLB H L M B C B H C O L M BLOWER SWITCH CAB POWER RELAY 87A 87 30 86 85 CP2 CP3 FJ12 16 FJ13 17 FJ14 18 19 F16 10 FRONT WIPER...

Page 619: ...Check wire EVG BLK for proper ground Replace blower motor Check output voltage from blower switch on wires BLL YEL L BLM RED M and BLH ORG H Replace switch If OK If OK If OK Not OK Before troubleshoot...

Page 620: ...LAY 87A 87 30 86 85 IG1 BA4 BA3 F1 40 OPEN CAB VEHICLE MAIN F2 15 IGNITION CONTROL BA1A B 10 PB2A 2 PB2 PB1 IGNITION SWITCH ACC IGN B OFF ACC IGN ST To Transmission Fuse F3 To Park Brake Switch BA3 BC...

Page 621: ...age Replace thermostat Replace compressor Check wire AC1 WHT at high low pressure switch for battery voltage If OK If OK If OK Not OK Not OK Not OK Replace closed cab harness At pressure switch check...

Page 622: ...ALE CONNECTOR BB1 BC1 POWER FEMALE CONNECTOR CAB POWER RELAY 87A 87 30 86 85 CP2 CP3 FJ12 16 FJ13 17 FJ14 18 19 F16 10 FRONT WIPER OPTION P F17 25 HEATER FAN OPTION Q F18 7 5 SKYLIGHT WIPER OPTION R F...

Page 623: ...ge Not OK Replace closed cab harness Replace front wiper motor Check wire FW4 BLU at front wiper motor for battery voltage Check wires FWG1 BLK and FWG2 BLK for proper ground If OK Replace front wiper...

Page 624: ...FAN OPTION Z FJ21 28 FJ21 FJ20 26 FJ19 25 AA 27 AB 28 CP3 F27 OPEN F28 OPEN 15 F15 40 CLOSED CAB MAIN OPTION O IGNITION RELAY 87A 87 30 86 85 IG1 BA4 BA3 F1 40 OPEN CAB VEHICLE MAIN F2 15 IGNITION CO...

Page 625: ...tch in the skylight wiper ON middle position If OK Not OK Replace closed cab harness If OK Replace front wiper switch If OK Not OK Replace closed cab harness Skylight washer is inoperative Not OK Plac...

Page 626: ...ION R F19 7 5 REAR WIPER OPTION S F25 40 LIGHTS MAIN OPTION Y F26 25 CONDENSER FAN OPTION Z FJ21 28 FJ21 FJ20 26 FJ19 25 AA 27 AB 28 CP3 F27 OPEN F28 OPEN 15 F15 40 CLOSED CAB MAIN OPTION O IGNITION R...

Page 627: ...oltage Check ground wire RWG BLK for proper ground Rear wiper is inoperative Before troubleshooting any electrical circuit ALWAYS begin by checking the following 1 Fuses 2 All connections relating to...

Page 628: ...r 30 WORK ROADLIGHTS OR WORKLIGHTS OPTION X LP5 FJ18 23 24 FJ17 22 LP6 LP1 OPTION HARNESS LP6 LP5 LP4 LP2 LP3 To Back Up Alarm Relay 7 8 9 13 12 10 11 14 INSTRUMENT PANEL J7 BACK LIGHT J8 GROUND J9 PO...

Page 629: ...s main fuse If OK If OK Replace light power relay Check for battery voltage across light power relay coil pin 85 wire LP1 TAN Replace open cab harness Replace open cab harness Light power relay makes...

Page 630: ...28 FJ21 FJ20 26 FJ19 25 AA 27 AB 28 F27 OPEN F28 OPEN F1 40 OPEN CAB VEHICLE MAIN F2 15 IGNITION CONTROL BA1A 10 PB2A 2 PB2 IG1 PB1 To Park Brake Switch BA3 BC1A FJ15 20 FJ16 21 F20 10 BEACON STROBE O...

Page 631: ...r Replace cab roadlight harness If OK Replace vehicle roadlight harness Replace failed roadlight Replace cab roadlight harness Not OK Verify ground at roadlight connector pin 6 If OK Check for proper...

Page 632: ...NDENSER FAN OPTION Z FJ21 28 FJ21 FJ20 26 FJ19 25 AA 27 AB 28 F27 OPEN F28 OPEN F1 40 OPEN CAB VEHICLE MAIN F2 15 IGNITION CONTROL BA1A 10 PB2A 2 PB2 IG1 PB1 To Park Brake Switch BA3 BC1A FJ15 20 FJ16...

Page 633: ...dlight harness If OK Replace vehicle roadlight harness Replace cab roadlight harness If OK Replace failed roadlight Not OK Verify ground at roadlight connector pin 6 If OK Check for proper ground at w...

Page 634: ...N Z FJ21 28 FJ21 FJ20 26 FJ19 25 AA 27 AB 28 F27 OPEN F28 OPEN F1 40 OPEN CAB VEHICLE MAIN F2 15 IGNITION CONTROL BA1A 10 PB2A 2 PB2 IG1 PB1 To Park Brake Switch BA3 BC1A FJ15 20 FJ16 21 F20 10 BEACON...

Page 635: ...wire RLG3 BLK PS1D WHT Left RLG4 BLK PS1E WHT Right on roadlight connector or pins 1 3 wire RLG1 BLK PS1C WHT Left RLG2 BLK PS1F WHT Right on taillight connector Replace cab roadlight harness If OK R...

Page 636: ...MAIN OPTION Y F26 25 CONDENSER FAN OPTION Z FJ21 28 FJ21 FJ20 26 FJ19 25 AA 27 AB 28 F27 OPEN F28 OPEN F1 40 OPEN CAB VEHICLE MAIN F2 15 IGNITION CONTROL BA1A 10 PB2A 2 PB2 IG1 PB1 To Park Brake Switc...

Page 637: ...d Replace flasher Clean and tighten connection Not OK Check for battery voltage at pin D wire LT1A ORG and pin E wire RT1A GRN on roadlight female connector If OK Replace cab roadlight harness If OK R...

Page 638: ...IND BRK RIGHT TAILLIGHT BRK IND LEFT TAILLIGHT RLG2 RLG1 B A C D F25 40 LIGHTS MAIN OPTION Y F26 25 CONDENSER FAN OPTION Z FJ21 28 FJ21 FJ20 26 FJ19 25 AA 27 AB 28 F27 OPEN F28 OPEN F1 40 OPEN CAB VE...

Page 639: ...male connector pin D or E If OK Replace cab roadlight harness If OK Replace turn signal control Replace cab roadlight harness Before troubleshooting any electrical circuit ALWAYS begin by checking the...

Page 640: ...tch BA3 BC1A FJ15 20 FJ16 21 F20 10 BEACON STROBE OPTION T F21 7 5 BRAKE LIGHTS OPTION U F22 20 HEADLIGHTS OPTION V F23 15 TURN SIGNALS OPTION W F24 20 or 30 WORK ROADLIGHTS OR WORKLIGHTS OPTION X LP5...

Page 641: ...taillight connector pins 1 4 wire RLG1 BLK BL2C GRY Left RLG2 BLK BL2B GRY Right If OK Replace bulb Check for proper ground at wire EG7 BLK at ground buss bar Replace vehicle roadlight harness Not OK...

Page 642: ...ON Z FJ21 28 FJ21 FJ20 26 FJ19 25 AA 27 AB 28 F27 OPEN F28 OPEN F1 40 OPEN CAB VEHICLE MAIN F2 15 IGNITION CONTROL BA1A 10 PB2A 2 PB2 IG1 PB1 To Park Brake Switch BA3 BC1A FJ15 20 FJ16 21 F20 10 BEACO...

Page 643: ...e troubleshooting any electrical circuit ALWAYS begin by checking the following 1 Fuses 2 All connections relating to circuit are clean and tight 3 All grounding straps are intact and securely fastene...

Page 644: ...2 15 IGNITION CONTROL BA1A 10 PB2A 2 PB2 IG1 PB1 To Park Brake Switch BA3 BC1A FJ15 20 FJ16 21 F20 10 BEACON STROBE OPTION T F21 7 5 BRAKE LIGHTS OPTION U F22 20 HEADLIGHTS OPTION V F23 15 TURN SIGNAL...

Page 645: ...3 wire WL2 LT BLU and pin 6 wire WL3 YEL at worklight switch Worklights remain OFF with ignition switch in the RUN position and the bottom of the worklight switch pushed in Check for proper ground at...

Page 646: ...25 AA 27 AB 28 F27 OPEN F28 OPEN F1 40 OPEN CAB VEHICLE MAIN F2 15 IGNITION CONTROL BA1A 10 PB2A 2 PB2 IG1 PB1 To Park Brake Switch BA3 BC1A FJ15 20 FJ16 21 F20 10 BEACON STROBE OPTION T F21 7 5 BRAKE...

Page 647: ...front worklights Check for battery voltage at pin 3 wire WL5 LT BLU and pin 6 wire WL6 YEL at worklight switch Worklights remain OFF with ignition switch in the RUN position and the bottom of the work...

Page 648: ...42 Rev 6 04 9 9 TRANSMISSION GEAR SELECTION TROUBLESHOOTING The following seven electrical circuit schematics address each transmission position Additional troubleshooting information can be found in...

Page 649: ...RANSMISSION FEMALE AND MALE CONNECTOR IGNITION SWITCH ACC IGN B OFF ACC IGN ST LIGHT POWER RELAY OPTION 87A 87 30 86 85 RG1 TR8 TR9 TRANS CONTROL RELAY 87A 87 30 86 85 NEUTRAL START RELAY 87A 87 30 86...

Page 650: ...TRAL GEAR F N R 4 1 2 3 TRANSMISSION 10 IG1 IGNITION RELAY 87A 87 30 86 85 IG1 BA4 BA3 BOOM SWITCH RELAY 87A 87 30 86 85 RG7 C A B A B C POWER MALE AND FEMALE CONNECTOR 12V BUSS BAR BA1 LEFT TRANSMISS...

Page 651: ...NEUTRAL GEAR F N R 4 1 2 3 10 IG1 IGNITION RELAY 87A 87 30 86 85 IG1 BA4 BA3 BOOM SWITCH RELAY 87A 87 30 86 85 RG7 C A B A B C POWER MALE AND FEMALE CONNECTOR 12V BUSS BAR BA1 LEFT TRANSMISSION COILS...

Page 652: ...GEAR F N R 4 1 2 3 10 IG1 IGNITION RELAY 87A 87 30 86 85 IG1 BA4 BA3 BOOM SWITCH RELAY 87A 87 30 86 85 RG7 C A B A B C POWER MALE AND FEMALE CONNECTOR 12V BUSS BAR BA1 LEFT TRANSMISSION COILS IGNITIO...

Page 653: ...A B C POWER MALE AND FEMALE CONNECTOR 12V BUSS BAR BA1 IGNITION SWITCH ACC IGN B OFF ACC IGN ST LIGHT POWER RELAY OPTION 87A 87 30 86 85 RG1 TR8 TR9 TRANS CONTROL RELAY 87A 87 30 86 85 NEUTRAL START...

Page 654: ...POWER MALE AND FEMALE CONNECTOR 12V BUSS BAR BA1 IGNITION SWITCH ACC IGN B OFF ACC IGN ST LIGHT POWER RELAY OPTION 87A 87 30 86 85 RG1 TR8 TR9 TRANS CONTROL RELAY 87A 87 30 86 85 NEUTRAL START RELAY 8...

Page 655: ...ER MALE AND FEMALE CONNECTOR 12V BUSS BAR BA1 IGNITION SWITCH ACC IGN B OFF ACC IGN ST LIGHT POWER RELAY OPTION 87A 87 30 86 85 RG1 TR8 TR9 TRANS CONTROL RELAY 87A 87 30 86 85 NEUTRAL START RELAY 87A...

Page 656: ...arts discuss each dash panel indicator separately Additional information for each indicator can be found by referring to the main electrical schematics on pages 9 48 through 9 51 The dash panel light...

Page 657: ...0 C F D r min MU4270 Check terminal B wires AB1 RED and AB2 RED on alternator for battery voltage Repair replace harness If OK Check terminal D wire AD1 GRY on alternator for battery voltage If OK If...

Page 658: ...ck of dash panel If OK Repair as needed Replace engine coolant temperature sender and retest system If OK If OK Check circuit for grounded wire D4A LT BLU If grounded repair wire Refer to page 9 48 or...

Page 659: ...at harness Turn ignition ON and check for grounded circuit If indicator light is still on check wire D6A BRN Refer to pages 9 48 or 9 50 Engine oil pressure warning indicator stays ON while operating...

Page 660: ...or grounded wire D12A YEL ORG If grounded repair wire Refer to page 9 48 or 9 50 Replace dash panel If circuit tests OK 0000000 RPM X 100 5 10 15 30 20 25 F 1 2 E 104 176 80 248 120 C F r min D Engine...

Page 661: ...g when the engine is operating Engine Tachometer Does hourmeter indicator register operating hours Yes No Replace front dash panel Does hourmeter indicator register operating hours Is the engine tacho...

Page 662: ...h and retest system If OK If OK Check circuit for grounded wire D5A GRN If grounded repair wire Refer to page 9 48 or 9 50 Replace dash panel If circuit tests OK Stop vehicle place transmission in Neu...

Page 663: ...d retest system If OK If OK Check circuit for grounded wire D9A YEL GRN If grounded repair wire Refer to page 9 48 or 9 50 Replace dash panel If circuit tests OK Stop vehicle and idle engine for five...

Page 664: ...Replace air filter pressure switch and retest system If OK Check circuit for ground on wires D10 YEL PUR or D10A YEL PUR If grounded repair wire Refer to page 9 48 or 9 50 Replace front dash panel If...

Page 665: ...VP1 diode board Indicator light should go out Check park brake switch for battery voltage at wire PB3 BLK WHT with switch in OFF position Replace park brake switch Not OK Before troubleshooting any e...

Page 666: ...0 Check both accumulator charge pressures Refer to Section 8 13 Accumulators Recharge accumulators as necessary Refer to Section 8 13 Accumulators Yes Retest and see if Low Brake Pressure Indicator is...

Page 667: ...OK Replace dash panel Fuel Level Gauge MU4330 Not OK Full 31 ohms One Half 101 ohms Empty 255 ohms Refer to page 9 48 or 9 50 With jumper wire across harness connector wires D3 GRY and SG1 BLK fuel l...

Page 668: ...Check if boom sensor LED is ON If OK Check boom sensor to boom gap is 12 to 19 3 to 5 mm Unplug boom switch relay and indicator light should go OFF If OK Troubleshoot harness for short to B in locked...

Page 669: ...m Verify that stability brake switch contacts are open with pedal released If OK Troubleshoot harness for short to B in slow pivot circuit Check wires S11 ORG WHT S11A ORG WHT S11B ORG WHT S10 ORG WHT...

Page 670: ...ine Air Intake Heater Indicator Activate the ECM diagnostic system and read the code as indicated by the flashing lights on the indicator located on the left side of the dash between the park brake sw...

Page 671: ...is in NEUTRAL DETENT N current flows through the neutral start relay to energize the coil of the engine start relay This closes the contacts in the engine start relay The engine start relay contacts...

Page 672: ...e connectors at each end of the battery cables Also check the ground cable behind the starter mounting bolt and the frame ground stud just above the hydraulic oil reservoir fill cap 4 Check for broken...

Page 673: ...the negative battery cable 13 4 At the positive starter stud 14 label and disconnect the positive battery cable 15 and starter positive buss bar 16 Leave the wires 18 connected to the starter positive...

Page 674: ...with a new unit f Starter Installation 1 Position the starter 3 in its mounting opening on the flywheel housing Secure the starter with two fasteners 1 and 2 Torque fasteners to 32 lb ft 43 Nm 2 Secur...

Page 675: ...harge Current flows from the alternator B terminal to the starter motor B terminal then through the positive battery cable to the battery The circuit in the dash panel connects to the D terminal and d...

Page 676: ...perators Manual Allow the engine to run which enables the alternator to charge the battery If the alternator charging warning indicator illuminates perform the following checks 1 Check the battery cab...

Page 677: ...upper battery box clears the knob Lift up the upper battery box 10 and swing it out so that the box clears the hydraulic tank support bracket to gain access to the lower negative battery cable 5 Disc...

Page 678: ...Nm Fully tighten the upper mounting capscrew 7 and torque to 18 lb ft 24 Nm 3 At the rear of the alternator reattach all wires to their proper terminals AG1 and AG2 to G terminal 1 AB1 and AB2 SN 0160...

Page 679: ...priate Owners Operators Manual for general information a Battery Description The battery supplies power to the starter and ignition system to crank the engine and it provides extra power when the elec...

Page 680: ...t 1 Disconnect both the negative battery cable first and the positive battery cable from the battery Make sure that the negative and positive battery terminal posts are clean to help assure a good ele...

Page 681: ...y discharged battery the current accepted is very low at first Later as the charging current causes the electrolyte acid content to increase the charging current will likewise increase Charger Capacit...

Page 682: ...vehicle has dual batteries disconnect both negative battery cables 3 and 4 from both batteries To access the lower battery 5 loosen the knob 6 far enough so that the lip 7 on the upper battery box cle...

Page 683: ...1 Carefully slide the battery 12 into the battery box 17 2 Make sure that the battery hold down bolts 15 are still hooked in the slots 16 in the battery box 17 3 Install the battery hold down strap 1...

Page 684: ...Turn Signal Select Lever of this manual The horn sound is produced by a solenoid actuated diaphragm in the horn that develops a resonating air column in the horn trumpet which is shaped to project th...

Page 685: ...16 lb ft 7 12 Nm 2 Connect the wiring harness connector lead 4 to the horn 3 If the vehicle has dual batteries connect both negative battery cables 9 and 10 to both batteries Connect the lower negati...

Page 686: ...system or the batteries are dead Service the engine alternator or batteries Engine Air Filter Restriction Warning Indicator 5 This light illuminates when a restricted engine air filter is detected If...

Page 687: ...the system and read the code as indicated by the light Refer to your local Cummins dealer for an explanation of the code refer to the Cummins Engine Owners Manual or call the Cummins Customer Assista...

Page 688: ...cket to gain access to the lower negative battery cable 3 Disconnect the lower negative battery cable 3 Label and disconnect the back up alarm 9 wire connector 10 from the harness 4 Remove the two nut...

Page 689: ...o the reverse position The back up alarm should sound 9 13 2 Front Dash Panel The information under this heading deals mainly with the description and function of each indicator in the front dash pane...

Page 690: ...when the engine is running to indicate that the post heat function is active This is a normal condition when ambient temperatures are below 40 F 4 C c Gauges and Indicators Fuel Level Gauge Make sure...

Page 691: ...lip 14 on the upper battery box clears the knob Lift up the upper battery box 15 and swing it out so that the box clears the hydraulic tank support bracket to gain access to the lower negative batter...

Page 692: ...n place using the two nuts 19 and retaining brackets 20 12 Connect the wire harness connector 21 at the rear of the front dash panel 17 13 Install the front dash panel cover 18 with the front dash pan...

Page 693: ...the upper part of the right gas shock 22 orange tab to the left Line up the upper part of the shock lock tube with the lower part of the gas shock and pull the cover down to the closed position Front...

Page 694: ...ce reading should be approximately 2 000 ohms with the throttle pedal at rest and change to approximately 4 000 ohms with the throttle pedal fully depressed Refer to Section 9 8 27 944E 42 Electronic...

Page 695: ...y 20 with the hole on the throttle pedal stop plate 25 5 Secure clevis with the clevis locking pin 19 6 Secure the sensor to the cab mounting bracket 18 with two slotted pan head screws 21 flat washer...

Page 696: ...peed Push the BOTTOM of the rocker switch IN to operate the wiper at HIGH speed a Removal 1 Unlock and open the engine cover 2 2 If the vehicle has dual batteries disconnect both negative battery cabl...

Page 697: ...iper switch 1 to the cab harness connector 2 Position the switch over the rectangular switch bezel and snap into position 3 If the vehicle has dual batteries connect both negative battery cables 4 and...

Page 698: ...ttery 4 loosen the knob 5 far enough so that the lip 6 on the upper battery box clears the knob Lift up the upper battery box 7 and swing it out so that the box clears the hydraulic tank support brack...

Page 699: ...the three wire connector 26 from the back of the front wiper motor Label the ground wire 28 and remove the screw 27 securing it to the wiper motor case Place the screw back into the wiper motor case...

Page 700: ...gasket 14 over the wiper motor shaft with the pivot shaft 15 on the right side Secure to the front of the cab using two capscrews 16 Torque both screws to 7 5 lb ft 10 Nm 5 Replace any hydraulic or e...

Page 701: ...her hose 37 onto the hose connector on the wet kit adapter 38 15 Lower and lock engine cover To release and lower the engine cover 39 from the fully raised position lift up slightly on the cover and p...

Page 702: ...is spring loaded and will return to the OFF position when released a Removal 1 Unlock and open the engine cover 5 2 If the vehicle has dual batteries disconnect both negative battery cables 7 and 8 fr...

Page 703: ...er switch to the cab harness connector 2 Position the switch over the rectangular switch bezel and snap into position 3 If the vehicle has dual batteries connect both negative battery cables 7 and 8 t...

Page 704: ...the skylight wiper OFF Place the rocker switch in the MIDDLE position to turn the skylight wiper ON This wiper is a single speed wiper Press and hold the BOTTOM of the rocker switch to activate the s...

Page 705: ...window washer switch to the cab harness connector 2 Position the switch over the rectangular switch bezel and snap into position 3 If the vehicle has dual batteries connect both negative battery cabl...

Page 706: ...ttery cable 3 Remove the skylight wiper arm 8 from the skylight wiper motor shaft 9 4 Disconnect the washer hose 10 from the top hose fitting 11 5 From inside the cab remove the screw 12 three flat wa...

Page 707: ...to terminal H on the wiper motor Assemble the wire TW3 26 white brown stripe from the harness to terminal P on the wiper motor Assemble the black ground wire TWG2 27 to the bolt on the left side of th...

Page 708: ...7 to the RUN position 8 and turn skylight wiper switch to the ON position Ensure wiper stays on the window through a full stroke Turn the skylight wiper switch to the OFF position 10 Engage the washe...

Page 709: ...tion 9 8 39 Skylight Wiper Washer Rear Washer Circuit Troubleshooting e Installation and Testing 1 Connect the clear washer hose 19 from the front wiper to the front washer pump 17 on the rear of the...

Page 710: ...connect the lower negative battery cable 3 Remove the rear wiper arm 8 from the rear wiper motor shaft 9 4 From inside the cab remove the phillips head bolt 10 two flat washers 11 rubber grommet 12 an...

Page 711: ...ll the adapter 29 to the P terminal 30 on the motor 23 3 Install jumper wire 25 to one of the blades on the adapter 29 and the other end to the terminal 31 on the switch 27 4 Install female end of jum...

Page 712: ...the knob 6 Secure in place with the knob 13 With the ignition switch 7 in the RUN position 8 press the rear wiper switch 10 to the ON position and then to the OFF position to Park the rear wiper on t...

Page 713: ...switch 13 in the center position to allow the skylight wiper to clear fluid from the skylight window 18 Press the top of the skylight wiper washer and rear window washer rocker switch 13 to turn the s...

Page 714: ...he air flow at the front vents directing the vent louvers toward the glass and close the remaining vents This will increase the volume of air flow to the front glass and speed defrosting a To heat the...

Page 715: ...eater and fan control panel 10 5 Pull the control panel out from the dash panel and if removing variable speed fan control 7 remove the cab harness connector 6 If removing the temperature control knob...

Page 716: ...e dash panel 9 If the vehicle has dual batteries connect both negative battery cables 6 and 7 to both batteries Connect the lower negative battery cable 6 to the negative terminal on the lower battery...

Page 717: ...start the engine and to run the vehicle The ignition switch 14 is turned clockwise from the OFF 15 position to the RUN 16 position and then to the START 17 position The START position is spring loade...

Page 718: ...ve battery cable 3 Disconnect the lower negative battery cable 3 Remove the four button head screws 9 securing the lower dash cover 10 to the front dash Remove the lower dash cover 4 Remove the knurle...

Page 719: ...dash to work the ignition switch 12 into the mounting hole 17 on the lower right side of the dash 3 Align the ignition switch 22 so that when it is in the OFF 23 position the key slot 18 is positione...

Page 720: ...ngine Start Circuit Troubleshooting The neutral position contacts in the travel select lever are non repairable Replace the travel select lever if defective 9 14 2 Fuel Shutoff Solenoid 644E 42 SN 201...

Page 721: ...the fuel shut off solenoid lead 8 5 If the vehicle has dual batteries connect both negative battery cables 11 and 12 to both batteries Connect the lower negative battery cable 11 to the negative term...

Page 722: ...not serviced when the indicator light comes ON the return hydraulic oil will bypass the filter when pressure reaches 25 psi 1 7 bar and return to the reservoir unfiltered Examine the fluid in the hyd...

Page 723: ...r pressure switch leads 3 to the harness connectors 3 If the vehicle has dual batteries connect both negative battery cables 7 and 8 to both batteries Connect the lower negative battery cable 7 to the...

Page 724: ...in the system the oil level should be at the bottom of the sight glass with all hydraulic cylinders retracted and whether the fluid is contaminated Replace the hydraulic oil filter as required Explore...

Page 725: ...4 Nm 2 Connect the switch wiring connector 4 to the harness connector 3 If the vehicle has dual batteries connect both negative battery cables 8 and 9 to both batteries Connect the lower negative batt...

Page 726: ...hydraulic pressure release switch completes the auxiliary hydraulic pressure release circuit The auxiliary hydraulic pressure release solenoid 5 on the auxiliary hydraulic pressure release valve 6 is...

Page 727: ...sure the symbol 4 is at the bottom of the switch 1 then press or snap the switch into place in the bezel 3 If the vehicle has dual batteries connect both negative battery cables 9 and 10 to both batt...

Page 728: ...he front dash panel illuminates The parking brake solenoid 6 on the accumulator charge secondary function valve 7 is normally de energized allowing the parking brake to engage When the parking brake s...

Page 729: ...make sure that the lip 14 on the upper battery box slides below the knob 13 Secure in place with the knob 4 Lower and lock engine cover To release and lower the engine cover 8 from the fully raised po...

Page 730: ...raulic system has full engine power IMPORTANT With the disconnect feature active and the service brake pedal being released the transmission will be reconnected in the same gear and direction of trave...

Page 731: ...ttery box 12 in and make sure that the lip 11 on the upper battery box slides below the knob 10 Secure in place with the knob 4 Lower and lock engine cover To release and lower the engine cover 5 from...

Page 732: ...he gear select lever 5 is part of the transmission shift control switch travel select lever 1 The lever has a twist grip handle with four positions The vehicle has four forward and three reverse gears...

Page 733: ...n the position that is not functioning correctly 3 Check the harness side connector plugs on the active solenoids corresponding to the direction and gear that has been selected with a DMM for battery...

Page 734: ...Connect the wire harness connector plug 9 to the solenoid connector plug 13 4 If the vehicle has dual batteries connect both negative battery cables 3 and 4 to both batteries Connect the lower negativ...

Page 735: ...he left will retract the boom moving the joystick forward and to the left will both lower and retract the boom at the same time The speed of movement relates to the amount of joystick movement away fr...

Page 736: ...4 Lift the wire harness bushing 10 to clear the retaining hole 11 in the ring on the joint assembly 12 Slide the wire harness 13 out through the slot 5 Use a vise grip to remove the handle assembly 9...

Page 737: ...ssembly containing a single joystick 18 to control boom functions auxiliary hydraulics attachment tilt and the PlaceAce transfer carriage operation The frame sway is controlled by a separate frame swa...

Page 738: ...ting 1 Remove the capscrews and washers 1 securing the right side access panel 2 and joystick mounting console 3 Determine whether you have an early or late production single joystick The early produc...

Page 739: ...n 9 14 11 c Late Production Single Joystick Handle Replacement b Early Production Single Joystick Assembly Replacement 1 Disconnect the control module jumper harness connector 15 from the single joyst...

Page 740: ...y 5 8 Roll the boot 3 up to expose the jam nut 4 at the bottom of the handle assembly 5 9 Thread the handle assembly 5 onto the joint assembly 8 10 Make sure that the center line on the handle 10 is i...

Page 741: ...ng more than one coil insure that the wire harness connectors are correctly re connected 9 14 12 Boom Sensor Proximity Switch The boom lift sensor 22 is located at the rear of and on the right side of...

Page 742: ...s connector 11 Boom Sensor Installation and Adjustment 1 Place the sensor 14 with the inner sensor mounting nut 7 into the mounting hole 15 at the rear of and on the right side of the outer boom 16 Th...

Page 743: ...e The warning indicator illuminates when oil pressure is below 8 7 psi 0 6 bar and an audible alarm will also sound When the engine has attained normal oil pressure the switch opens and the front dash...

Page 744: ...al on the lower battery 6 Swing the upper battery box 7 in and make sure that the lip 8 on the upper battery box slides below the knob 9 Secure in place with the knob 3 Lower and lock engine cover 10...

Page 745: ...gine coolant temperature sender 12 sends a signal to the temperature gauge 16 whenever the engine is running The gauge monitors the temperature at which the engine is operating Glance at the gauge on...

Page 746: ...le the sender Replace a defective or faulty sender c Engine Coolant Temperature Sender Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity Replace a...

Page 747: ...the switch heats up closing contacts within the sending unit The front dash panel indicator 16 illuminates and an audible alarm will sound Stop and idle the vehicle with the transmission in N Neutral...

Page 748: ...e upper battery box 9 in and make sure that the lip 8 on the upper battery box slides below the knob 7 Secure in place with the knob 3 Lower and lock engine cover 10 To release and lower the engine co...

Page 749: ...he heater If the heater element is functioning properly you will feel the heat at that location If the block is cold the heater element is defective and should be replaced b Engine Block Heater Remova...

Page 750: ...the fuel sender is 31 ohms for a full tank of fuel 101 ohms for 1 2 tank and 255 ohms for an empty tank The fuel level gauge in the operator s dash panel receives a signal from the fuel level float se...

Page 751: ...panel is not blown 4 Check for broken shorted frayed disconnected or damaged wiring between the fuel level gauge wiring at the operator s dash panel fuse and relay panel ignition key switch and from t...

Page 752: ...n the proper operation of the Stabil TRAK system refer to Section 10 Stabil TRAK System page 10 17 or page 10 26 a Stabilizer Brake Switch Removal 1 Unlock and open the engine cover 2 2 If the vehicle...

Page 753: ...Insert switch body 22 through the top of the service brake valve mounting plate 23 There should be approximately 5 threads on the switch shaft beyond the mounting plate 3 Thread the bottom locknut 24...

Page 754: ...efer to Section 9 14 19 c Stabilizer Brake Switch Adjustment When Service Brake Valve Mounting Plate Has Threaded Mounting Hole 1 Thread the locknut 9 onto the shaft of the switch body 10 Leave enough...

Page 755: ...switch Refer to Section 9 14 19 c Stabilizer Brake Switch Adjustment c Stabilizer Brake Switch Adjustment Note The stabilizer brake switch adjustment will require two people Enlist the help of an assi...

Page 756: ...hread the switch in or out until you hear an audible click 9 Repeat steps 6 through 8 until the Stabil TRAK Slow Pivot Mode indicator 1 comes ON at the 150 50 psi 10 3 3 4 bar brake pressure 10 After...

Page 757: ...03877 944E 42 SN 20123 Before SN 0160002514 thru 0160003881 10 17 10 5 1 Stabil TRAK System Test Instructions 644E 42 SN 20118 Before SN 0160002519 thru 0160003877 944E 42 SN 20123 Before SN 016000251...

Page 758: ...Pivot Mode Base Oil Out 10 35 10 8 7 Hydraulic Circuit Operation Slow Pivot Mode Rod Oil Out 10 36 10 8 8 Hydraulic Troubleshooting Slow Pivot Mode Rod Oil Out 10 37 10 8 9 Hydraulic Circuit Operation...

Page 759: ...10 3 Model 644E 42 944E 42 Rev 6 04 Stabil TRAK System This Page Intentionally Left Blank...

Page 760: ...rmation presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the Stabil TRAK system The following illustration ident...

Page 761: ...5 attached to the stabilizer cylinder above the left side of the rear axle The frame sway cylinder 6 is also involved in the Stabil TRAK system but only passively as hydraulic oil travels between the...

Page 762: ...nd closest to the rear apex of the stability triangle 10 3 1 Understanding the Stabil TRAK System The following information explains the difference between a typical telescopic handler and the benefit...

Page 763: ...normal in this mode c Slow Pivot Mode 11 With the boom above 40 the Stabil TRAK system is now in the SLOW PIVOT MODE when the service brake pedal is not applied and the transmission is in gear In this...

Page 764: ...2 4B 3 12A 4 and 12B 5 are identical and can be interchanged for diagnostic proposes IMPORTANT Make sure the 060 orifices are in place when installing solenoid valves 4A 2 and 4B 3 In general if there...

Page 765: ...10 9 Model 644E 42 944E 42 Rev 6 04 Stabil TRAK System This Page Intentionally Left Blank...

Page 766: ...ssion Neutral Fwd or Rev Ignition On Boom Above 40 PB OFF SB Released Transmission Fwd or Rev Ignition On Boom Above 40 PB ON SB Released Transmission Neutral Ignition On Boom Above 40 PB OFF SB Appli...

Page 767: ...IT G F F6 10 BACK UP ALARM HORN F5 20 IGNITION POWER E D F4 20 FUEL SOLENOID TRANSMISSION F3 15 C FJ2 4 FJ1 3 2 1 STABIL LOCK RELAY E6 S6 S9 S10 75 S12 S12A S12B PB2 25 TR7 S5 55 S2 S2B S1 S1D BP1 PB2...

Page 768: ...4 S5 S4 S2B S6 10 PB2B PB2A PB5 STABILIZER BRAKE SWITCH S1A 50 F7 10 STABILITY CIRCUIT G F F6 10 BACK UP ALARM HORN F5 20 IGNITION POWER E D F4 20 FUEL SOLENOID TRANSMISSION F3 15 C FJ2 4 FJ1 3 2 1 ST...

Page 769: ...WITCH S1A 50 F7 10 STABILITY CIRCUIT G F F6 10 BACK UP ALARM HORN F5 20 IGNITION POWER E D F4 20 FUEL SOLENOID TRANSMISSION F3 15 C FJ2 4 FJ1 3 2 1 STABIL LOCK RELAY E6 S6 S9 S10 75 S12 S12A S12B PB2...

Page 770: ...NITION POWER E D F4 20 FUEL SOLENOID TRANSMISSION F3 15 C FJ2 4 FJ1 3 2 1 S6 S9 S10 75 S12 S12A S12B PB2 TR7 55 S2 S2B S1 S1D BP1 PB2 S8 PB3 1 5 15 7 2 3 20 8 9 6 4 19 18 17 16 13 12 10 11 14 IG1 1 2...

Page 771: ...WITCH S1A 50 F7 10 STABILITY CIRCUIT G F F6 10 BACK UP ALARM HORN F5 20 IGNITION POWER E D F4 20 FUEL SOLENOID TRANSMISSION F3 15 C FJ2 4 FJ1 3 2 1 S6 S9 S10 75 S12 S12A S12B PB2 25 TR7 S5 55 S2 S2B S...

Page 772: ...N F5 20 IGNITION POWER E D F4 20 FUEL SOLENOID TRANSMISSION F3 15 C FJ2 4 FJ1 3 2 1 S6 S9 S10 75 S12 S12A S12B PB2 TR7 55 S2 S2B S1 S1D BP1 PB2 S8 PB3 1 5 15 7 2 3 20 8 9 6 4 19 18 17 16 13 12 10 11 1...

Page 773: ...written IMPORTANT If the Stabil TRAK lock light goes OFF and the front left tire lowers to the ground at any time during Steps 4 7 the test was not performed properly or the Stabil TRAK system is not...

Page 774: ...ight should be OFF Step 4 a Use your left foot to depress the service brake pedal b Move the travel select lever to the R REVERSE position and the range selector to the 2 SECOND gear position c Ease y...

Page 775: ...select lever to F FORWARD c Release the service brake pedal to deactivate the Stabil TRAK system The Stabil TRAK light should go OFF and the Stabil TRAK slow pivot light should come ON d Slowly drive...

Page 776: ...Boom Above 40 PB OFF SB Released Transmission Fwd or Rev Ignition On Boom Above 40 PB ON SB Released Transmission Neutral Ignition On Boom Above 40 PB OFF SB Applied Transmission Fwd or Rev Ignition...

Page 777: ...EL SOLENOID TRANSMISSION F3 15 C FJ2 4 FJ1 3 2 1 STABIL LOCK RELAY E6 S6 S9 S10 75 S12 S12A S12B PB2 25 TR7 S5 55 S2 S2B S1 S1D BP1 PB2 5 PB3 PB3 1 5 15 7 2 3 20 8 9 6 4 19 18 17 16 13 12 10 11 14 IG1...

Page 778: ...D F4 20 FUEL SOLENOID TRANSMISSION F3 15 C FJ2 4 FJ1 3 1 STABIL LOCK RELAY E6 S6 S9 S10 75 S12 S12A S12B PB2 25 TR7 S5 55 S2 S2B S1 S1D BP1 PB2 5 PB3 PB3 1 5 15 7 2 3 20 8 9 6 4 19 18 17 16 13 12 10...

Page 779: ...S12 S12A S12B PB2 TR7 55 S2 S2B S1 S1D BP1 PB2 PB3 1 5 15 7 2 3 20 8 9 6 4 19 18 17 16 13 12 10 11 14 IG1 1 2 5 8 S10B S10C 2 1 RG6 GEAR GEAR FORWARD GEAR B REVERSE NEUTRAL GEAR TR9 TR2 TR7 TR6 TR4 TR...

Page 780: ...BACK UP ALARM HORN F5 20 IGNITION POWER E D F4 20 FUEL SOLENOID TRANSMISSION F3 15 C FJ2 4 FJ1 3 2 1 S6 S9 S10 75 S12 S12A S12B PB2 25 TR7 S5 55 S2 S2B S1 S1D BP1 PB2 5 PB3 PB3 1 5 15 7 2 3 20 8 9 6...

Page 781: ...RANSMISSION F3 15 C FJ2 4 FJ1 3 2 1 S6 S9 S10 75 S12 S12A S12B PB2 TR7 55 S2 S2B S1 S1D BP1 PB2 PB3 1 5 15 7 2 3 20 8 9 6 4 19 18 17 16 13 12 10 11 14 IG1 1 2 5 8 S10B S10C 2 1 RG6 GEAR GEAR FORWARD G...

Page 782: ...and the front left tire lowers to the ground at any time during Steps 4 7 the test was not performed properly or the Stabil TRAK system is not functioning properly Carefully repeat the steps starting...

Page 783: ...pedal b Move the travel select lever to the R REVERSE position and the range selector to the 2 SECOND gear position c Ease your left foot partially off the service brake pedal just keeping the Stabil...

Page 784: ...el select lever to F FORWARD c Release the service brake pedal to deactivate the Stabil TRAK system The Stabil TRAK lock light should go OFF and the Stabil TRAK slow pivot light should come ON d Slowl...

Page 785: ...10 29 Model 644E 42 944E 42 Rev 6 04 Stabil TRAK System This Page Intentionally Left Blank...

Page 786: ...ver is in F FORWARD or R REVERSE Park brake OFF Service brake DISENGAGED Refer to Section 10 8 7 Hydraulic Circuit Operation Slow Pivot Mode Rod Oil Out and Section 10 8 8 Hydraulic Troubleshooting Sl...

Page 787: ...BASE OIL OUT ROD OIL OUT flow will occur when the left side of the rear axle is lower than the right side left wheel in a pothole or the right wheel passing over an obstruction causing the cylinder t...

Page 788: ...izer cylinder Because the volume of oil needed on the base side is greater than that needed on the rod side the extra oil needed is supplied from the main hydraulic system through a 100 psi 7 bar redu...

Page 789: ...ngle is below 40 Travel select lever in F FORWARD or R REVERSE Park brake OFF Service brake DISENGAGED Check solenoid coils 12A and 12B on the Stabil TRAK manifold for correct resistance 7 9 ohms Remo...

Page 790: ...side of the stabilizer cylinder Because the volume of oil needed on the rod side is less than that needed on the base side excess oil is returned to the tank through a 100 psi 7 bar reducing cartridg...

Page 791: ...re comes off the ground Check electrical wiring Check solenoid coils 12A and 12B on the Stabil TRAK manifold for correct resistance 7 9 ohms Replace solenoid s Remove solenoid cartridges 12A and 12B f...

Page 792: ...er cylinder The 060 orifices 3 and 4 in solenoid operated valves 4A 5 and 4B 2 will slow the movement of the rear axle in reaction to terrain changes The frame sway will react normally in this mode Be...

Page 793: ...REVERSE Park brake OFF Service brake DISENGAGED Inspect check valves 2A and 2B on the stabilizer cylinder Refer to Section 8 14 9 Stabilizer Cylinder Replace check valve s Check electrical wiring Chec...

Page 794: ...cylinder The 060 orifices 3 and 4 in solenoid operated valves 4A and 4B will slow the movement of the rear axle in reaction to terrain changes The frame sway will react normally in this mode Because...

Page 795: ...ile traveling ride feels spongy riding on 3 wheels Replace check valve s Inspect check valves 2A and 2B on the stabilizer cylinder Refer to Section 8 14 9 Stabilizer Cylinder Check electrical wiring C...

Page 796: ...end oil from the stabilizer cylinder flows through check valve 2B 9 opened by pilot pressure in the Stabil TRAK manifold The oil then flows through cartridge valve 3 5 out of the Stabil TRAK manifold...

Page 797: ...Boom angle is above 40 Travel select lever in N NEUTRAL or park brake ON or service brake ENGAGED Inspect check valves 2A and 2B on the stabilizer cylinder Refer to Section 8 14 9 Stabilizer Cylinder...

Page 798: ...rough check valve 2B 7 to the rod end of the stabilizer cylinder 8 Some of this oil is diverted to the pilot line of check valve 2A 9 opening the valve Oil from the base end of the stabilizer cylinder...

Page 799: ...nning Boom angle is above 40 Travel select lever in N NEUTRAL or park brake ON or service brake ENGAGED Inspect check valves 2A and 2B on the stabilizer cylinder Refer to Section 8 14 9 Stabilizer Cyl...

Page 800: ...Stabil TRAK System 10 44 Model 644E 42 944E 42 Rev 6 04 This Page Intentionally Left Blank...

Page 801: ...1 3 6 Front Upstop Wear Pad Check 11 14 11 3 7 Front Upstop Wear Pad Gap Check 11 14 11 3 8 Front Upstop Wear Pad Shimming 11 15 11 3 9 Front Upstop Wear Pad Replacement 11 16 11 3 10 Rear Roller Gap...

Page 802: ...that the operator mechanic be familiar with the name and location of the major assemblies of the transfer carriage The following illustration identifies the components that are referred to throughout...

Page 803: ...and repaired only by experienced service technicians who are aware of all safety instructions and particular component features 11 3 TRANSFER CARRIAGE MAINTENANCE The transfer carriage assembly consi...

Page 804: ...placing the pin remove the bottom snap ring 3 8 Shut the engine OFF 9 Place an Accident Prevention Tag on both the ignition switch and steering wheel stating that the vehicle should not be operated Re...

Page 805: ...hoses Plug the tube ports on the lift cylinder and the hydraulic junction manifold 16 Secure the lift cylinder with a sling and take up any slack 17 Remove the capscrew 20 washer 21 and pin 22 from li...

Page 806: ...fold 20 Secure the slave cylinder with a sling and take up any slack 21 Remove the bolt 7 and locknut 8 from the pin 9 Remove the pin from the slave cylinder 10 Lift lower and place the slave cylinder...

Page 807: ...n out and remove the rear rollers 23 and shims 24 from both sides of the transfer carriage 25 Count and label the rear rollers and shims for later replacement 26 Remove capscrews 26 washers 27 and scr...

Page 808: ...or later replacement 32 Remove lifting straps boom pivot pins and slave cylinder pins 33 Inspect transfer carriage cylinder mount boom pivot and slave pivot bushings Refer to Section 11 3 17 Boom Pivo...

Page 809: ...previously labeled positions Torque capscrews to 21 38 lb ft 29 52 Nm 6 Lift and slide the transfer carriage in through the back of the frame 7 Move the transfer carriage all the way forward on the f...

Page 810: ...12 Torque bolt to 9 22 lb ft 17 31 Nm 14 Repeat steps 12 and 13 for the other slave cylinder 15 Coat the capscrew 15 with Loctite 242 blue Replace the hydraulic tubes 13 and mounting bracket 14 with...

Page 811: ...hrough the hole in the transfer carriage Torque the larger hose 24 to 100 140 lb ft 135 190 Nm Torque the smaller hose 25 to 45 59 lb ft 61 80 Nm 19 Coat the bolts 27 with Loctite 242 blue Replace the...

Page 812: ...has dual batteries connect both negative battery cables 6 and 7 to both batteries Connect the lower negative battery cable 6 to the negative terminal on the lower battery 8 Swing the upper battery box...

Page 813: ...06 1 6 mm at the tightest location If the gap is greater than 0 06 1 6 mm the wear pads require shimming Note Additional shims are available by calling JLG Parts Department at 717 485 6472 6 Check the...

Page 814: ...d 5 is manufactured with a convenient wear pad indicator This is the angled cut 6 at each end of all wear pads The total thickness 7 of a new wear pad 5 is 0 625 16 mm The angled cut 6 will provide a...

Page 815: ...the hydraulic tank support bracket to gain access to the lower negative battery cable 12 Disconnect the lower negative battery cable 5 Remove capscrews 18 shims 19 and front wear pads 20 Label their p...

Page 816: ...le OFF 3 This procedure will require the gap check to be made in three separate locations Transfer carriage all the way retracted transfer carriage all the way forward and the transfer carriage moved...

Page 817: ...e engine OFF 6 Place an Accident Prevention Tag on both the ignition switch and steering wheel stating that the vehicle should not be operated Refer to Section 1 5 Accident Prevention Tag Usage 7 Open...

Page 818: ...rding to their new positions Coat the pin bolt 3 with Loctite 242 blue Replace pin bolt 3 and locknut 4 on the roller pin 5 Torque locknut to 43 78 lb ft 59 106 Nm 14 Coat the bolts 1 with Loctite 242...

Page 819: ...the way retracted transfer carriage all the way forward and the transfer carriage moved forward about halfway 4 With the transfer carriage all the way retracted use a rawhide hammer to tap the rollers...

Page 820: ...far enough so that the lip 5 on the upper battery box clears the knob Lift up the upper battery box 6 and swing it out so that the box clears the hydraulic tank support bracket to gain access to the l...

Page 821: ...he engine transmission and hydraulic fluid to cool 5 If the vehicle has dual batteries disconnect both negative battery cables 1 and 2 from both batteries To access the lower battery 3 loosen the knob...

Page 822: ...tment cover Allow the engine transmission and hydraulic fluid to cool 7 If the vehicle has dual batteries disconnect both negative battery cables 1 and 2 from both batteries To access the lower batter...

Page 823: ...ont Roller Shimming 11 3 16 Rear Roller and Bushing Replacement Note The attachment should remain attached to the quick attach 1 Park the vehicle on firm level ground Place the travel select lever in...

Page 824: ...ze compound to bushing or roller pin 12 Inspect the rear roller bearings If they are worn and visibly shake on the roller pin install a new self lubricating bearing 9 into the roller 10 13 Insert the...

Page 825: ...ired perform rear rollers shimming Refer to Section 11 3 11 Rear Roller Shimming 11 3 17 Boom Pivot Bushing Replacement 1 Park the vehicle on firm level ground Place the travel select lever in the N N...

Page 826: ...n installed in the transfer carriage or slave cylinder the fracture in the bearing race must be positioned perpendicular 12 to the force of the load 7 Install the lower bearing 10 into the transfer ca...

Page 827: ...replacing the pin remove the bottom snap ring 15 8 Shut the engine OFF 9 Place an Accident Prevention Tag on both the ignition switch and steering wheel stating that the vehicle should not be operated...

Page 828: ...ting the transfer cylinder to the transfer carriage is at a pin access hole 5 near the rear of the cab IMPORTANT Make sure the threaded hole of the transfer cylinder pin is facing downward during inst...

Page 829: ...hen new transfer cylinder bearings 18 are installed in the transfer carriage the fracture in the bearing race must be positioned perpendicular 16 to the force of the load The fracture in the bearing f...

Page 830: ...112 3 Repair cylinder Refer to Section 8 14 11 Transfer Carriage Cylinder 4 Check roller gap Refer to Section 11 3 10 Rear Roller Gap Check and Section 11 3 12 Front Roller Gap Check 2 Jerky transfer...

Page 831: ...tion 11 3 16 Rear Roller and Bushing Replacement 2 Clean roller areas 5 Premature transfer carriage pad wear 1 Incorrect front or rear wear pad gap 2 Rapid cycle times of transfer carriage with heavy...

Page 832: ...Transfer Carriage 11 32 Model 644E 42 944E 42 Rev 6 04 This Page Intentionally Left Blank...

Page 833: ...ection 9 172 Bearings Cleaning 2 29 Installation 2 29 Removal 2 29 Bleeding Air From The Fuel System 7 27 Boom Assembly Maintenance 3 3 Description 3 3 Operation 3 3 Quick Attach Assembly 3 47 System...

Page 834: ...42 Vehicle Power Harness Electrical Schematic 9 52 9 53 944E 42 ECM Vehicle Power ECM Cab Harnesses Electrical Schematic 9 54 944E 42 Electronic Throttle Circuit 9 82 944E 42 Engine Start Circuit 9 7...

Page 835: ...Filter Replacement 7 27 Fuel Injectors 7 28 Fuel Level Gauge 9 182 Fuel Level Indicator 9 242 Fuel Level Sender 9 242 Fuel Lift Pump Removal 7 26 Fuel Lift Pump Testing 7 26 Fuel System 7 23 After Fu...

Page 836: ...Circuit Description Dual Joystick Only 8 146 Pump and Cooling Circuit Description Single Joystick Only 8 146 Service Brake Circuit 8 70 Three Mode Steering Circuit Descriptions 8 158 Transfer Carriage...

Page 837: ...l 9 18 Single Joystick 9 229 Snap Lock Fittings 8 8 Solenoid Valves 9 224 Specifications Carriage Weights 2 13 Electrical System 2 15 Engine Performance Specifications 2 17 2 18 Fluid and Lubricant Ca...

Page 838: ...erminology 6 19 Description 6 20 Further Information 6 21 General Information 6 20 Inspection and Service 6 21 Installation 6 23 Internal Transfer Case Repair 6 23 Maintenance 6 21 Operation 6 20 Remo...

Page 839: ...178 Low Brake Pressure 9 178 Transmission Temperature 9 178 Wheels and Tires Brakes 5 26 Installing Wheel and Tire Assembly Onto Vehicle 5 22 Removing Wheel and Tire Assembly from Vehicle 5 20 Tires...

Page 840: ...12 8 Model 644E 42 944E 42 Rev 6 04 Index...

Page 841: ...Accident Prevention Tags OS2180 8990403 Origin 5 00 Accident Prevention Tags...

Page 842: ...Accident Prevention Tags OS2180 8990403 Origin 5 00...

Page 843: ......

Page 844: ......

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