Lull Pleace Ace 944E-42 Owner's manual
WARNING: Improper operation of this vehicle can
cause injury or death. Only trained and authorized operators
should operate this vehicle.
Before starting the engine, do the following:
1. Read this owner/operators manual.
2. Read all the safety decals on the vehicle.
3. Clear the area of other persons.
Learn and practice safe use of vehicle controls in a safe,
clear area before you operate this vehicle on a worksite.
It is your responsibility to observe applicable laws and
regulations and to follow manufacturer's instructions on
vehicle operation and maintenance.
CALIFORNIA
Proposition 65 Warning
Diesel Engine exhaust and some of its constituents
are known to the State of California to cause
cancer, birth defects and other reproductive harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and birth defects or other reproductive harm.
Wash hands after handling.
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Table of Contents
1
2004 JLG Industries, Inc.
Introduction
The Manual....................................2
Replacement Parts........................2
Reports ..........................................2
Disclaimer......................................3
Safety Practices
Hazard Classification System........3
Accident Prevention Tags..............5
New or Additional Operators .........5
Instructional Symbols ....................6
Instructional Symbols (cont’d) .......7
Hazard Symbols ............................8
Avoidance Symbols.......................9
Avoidance Symbols (cont’d) ........10
Avoidance Symbols (cont’d) ........11
Personal Considerations .............12
Operational Considerations .........15
Equipment Considerations ..........20
Operation
Pre-Operation Inspection.............23
Operator Controls ........................26
Front Dash Panel.........................48
Optional Features ........................55
Carriages .....................................66
Indicators.....................................68
Fork Rating ..................................70
Using the Capacity Chart.............71
Stabil-TRAK System....................74
Stabil-TRAK™ System Test ........77
Refueling .....................................83
Normal Starting............................85
Cold Starting................................86
Jump Starting ..............................87
How To Pick, Carry & Place A
Load..........................................88
Elevating Personnel.....................89
Using Other Attachments ............93
Shut-Off .......................................95
Emergency Operations
Towing a Disabled Vehicle ..........96
Emergency Boom Lowering ........98
General Maintenance
Introduction................................104
Maintenance Schedule and
Checklist .................................105
1. Lubrication Points.............106
2. Air Cleaner .......................107
3. Optional Closed Cab Air
Filters ................................109
4. Engine Cooling System.....110
5. Engine Oil and Filter..........114
6. Engine Fuel System ..........118
7. Engine Fan Belt.................123
8. Air Conditioner Compressor
Belt (Optional) ...................124
9. Hydraulic Oil and Filter......125
10. Transmission Oil and
Filter ..................................128
11. Transfer Case Oil ..............131
12. Axle Oil..............................133
13. Brake Disc Inspection .......135
14. Wheel End Oil ...................138
15. Wheels and Tires ..............140
16. Battery...............................142
17. Fuse & Relay
Replacement .....................143
18. Boom Chains and Wear
Pads ..................................150
19. Transfer Carriage Rollers and
Wear Pads ........................163
Storage and Transport ..............170
Storage......................................170
Transport ...................................171
Test Procedures
Parking Brake/Transmission
De-Clutch Test Procedures ....172
Specifications
Fluid & Lubrication Capacities...174
Tires ..........................................175
Weights .....................................175
Vehicle Dimensions...................176
Electrical System.......................177
Engine .......................................177
Index.............................................179
Load Charts
Accident Prevention Tags
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2Model 944E Origin 3/04
Introduction
Introduction
This Owners/Operators Manual provides the information you need to operate and
maintain this vehicle.
IMPORTANT! Before you operate this vehicle, read this manual completely and
carefully so you will understand the instructions and the operation of the controls
and equipment. You must comply with all Danger, Warning, and Caution notices;
they are for your benefit.
All references to the right side, left side, front, or rear are given from the operator's
seat looking forward.
JLG Industries, Inc. is hereinafter referred to as JLG.
For easy reference when ordering
replacement parts or making service
inquiries on this vehicle, record its model
and serial number on the back cover of
this manual. The serial number is
stamped into the serial number plate (1)
which is located on the vehicleís frame.
IMPORTANT! The replacement of any
part on this vehicle by anything other than
a JLG authorized replacement part may
adversely affect the performance,
durability or safety of this vehicle and may
void the warranty. JLG assumes no
liability for unauthorized replacement
parts which adversely affect the
performance, durability or safety of this vehicle.
IMPORTANT! A Warranty Registration form must be filled out by the Lull Distributor,
signed by the purchaser, and returned to JLG once the product is sold and/or put
into service. This report activates the warranty period, assuring that your claims
during the warranty period will be processed promptly. To guarantee full warranty
service, make sure your Lull Distributor has returned the business reply card of this
form to JLG.
The Manual
Replacement Parts
Reports
OU0220
1
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Safety Practices
3
Model 944E Origin 3/04
JLG reserves the right to make changes on and to add improvements upon its
products at any time without public notice or obligation. JLG also reserves the right
to discontinue manufacturing any product at its discretion at any time.
NOTICE: Under OSHA rules, it is the responsibility of the employer to provide
operator training. Successful completion and certification of Safety Training for
Rough Terrain Forklifts is required. Operator Training Kits are available by calling
Ken Cook Company at (414) 466-6060. An order form for these kits is available
through our website, http://www.jlg.com.
The information in this manual does not replace any safety rules and laws used in
your area. Before operating this vehicle, learn the rules and laws for your area. Make
sure the vehicle has the correct equipment according to these rules and laws.
Your safety and the safety of others in the worksite depend significantly upon your
knowlege and understanding of all correct operating practices and procedures for
this vehicle.
Safety Practices
This safety alert symbol is used with the following signal words to attract your
attention to messages found within the manual and on hazard decals located on the
vehicle. They are reproduced herein and pertain to proper operation and procedure
messages contained throughout the manual. The message that follows the symbol
contains important information about Safety. To avoid possible death or serious
personal injury, carefully read and follow the messages! Be sure to fully understand
the potential causes of death or injury.
Disclaimer
WARNING: DO NOT modify or alter (weld, drill, etc.) any part of
this vehicle without consulting JLG. Modifications can weaken the struc-
ture creating a hazard that can cause death or serious personal injury.
Hazard Classification System
OP0330
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4Model 944E Origin 3/04
Safety Practices
Signal Word
A signal word is a distinctive word located on hazard decals and used throughout
this manual that alerts the viewer to the existence of and relative degree of the
hazard.
The signal word ìDANGERî indicates an imminently hazardous situation which, if
not avoided, will result in death or serious personal injury.
The signal word ìWARNINGî indicates a potentially hazardous situation which, if not
avoided, could result in death or serious personal injury.
The signal word ìCAUTIONî indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
The signal word ìCAUTIONî, used without the safety alert symbol, indicates a
potentially hazardous situation which, if not avoided, may result in property damage.
For safe maintenance of the vehicle, read, understand and follow all DANGER,
WARNING and CAUTION information.
DANGER:
WARNING:
CAUTION:
CAUTION:
Courtesy of Crane.Market
Safety Practices
5
Model 944E Origin 3/04
Before beginning any maintenance or service, place an Accident Prevention Tag (1)
on both the starter key switch (2) and the steering wheel (3), stating that the vehicle
should not be operated. Actual Accident Prevention Tags, which can be punched out
and used, are included as the last page of this manual. Retain these Accident
Prevention Tags for reuse at a later date.
At the time of original purchase, the purchaser of this vehicle was instructed by the
seller on its proper use. If this vehicle is to be used by an employee or is loaned or
rented to someone other than the purchaser, make certain that the new operator is
trained and authorized, in accordance with the OSHA regulations referenced on
page 3, and reads and understands this Operators Manual before operating the
vehicle.
In addition, make sure that the new operator has completed a walk-around
inspection of the vehicle, is familiar with all decals on the vehicle, and has
demonstrated the correct use of all controls.
Accident Prevention Tags
New or Additional Operators
DANGER
DANGER
MU0291
2
1
3
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6Model 944E Origin 3/04
Safety Practices
The following symbol definitions will help you understand all hazard related
decals and load charts used on this vehicle.
Instructional Symbols
80" 1" 0"
OP0330
OH2100
OH2090
Safety Alert
Symbol Read Operatorís
Manual
Fasten Seat
Belt
OH3100
Always Connect
Couplers On
Hydraulically Powered
Attachments
OS0900
Always Maintain
Proper Tire
Pressure
OU1570
Transfer Carriage
Forward
Movement
OU1580
Transfer
Carriage Fully
Retracted
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8Model 944E Origin 3/04
Safety Practices
Hazard Symbols
-
OH2110
Lead Acid Batteries
Generate Explosive
Gases
OH2130
Vehicle Tipover
Can Crush
OH2120
OH2140
Rotating Fan
Blades Can Cut
Vehicle Roll Away
Can Cause Death Or
Serious Injury
OH2300
OH2150
Rotating Belts
Can Cut Or
Entangle
Electrocution Can
Cause Death Or
Serious Injury
OH2161
FALLING OFF ATTACHMENT
Can Result In Death Or Serious
Injury
OH3160
OH3110
Swinging Loads Can Cause
Vehicle Tipover Which Can
Result In Death Or Serious
Injury
AVOID CRUSHING, Falling Off
Vehicle Can Cause Death Or
Serious Injury
ENGINE EXPLOSION Can
Result In Death Or Serious
Injury
OU1450
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Safety Practices
9
Model 944E Origin 3/04
Avoidance Symbols
OH2320
Keep Lit Cigarettes
Away
OH2330
OH2270
Do Not Travel With
Boom Raised
OH2280
Do Not Raise Boom
While On A Slope
OH2240
Do Not Travel With
Personnel In Work
Platform
OH2310
Keep Away From
Rotating Fan Blades
Keep Flames and
Ignition Sources Away
OH2250
Keep Clear Of Power
Lines
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10 Model 944E Origin 3/04
Safety Practices
Avoidance Symbols (contíd)
OH2290
Maintain Proper Air
Pressure In Tire
OH2260
Engage Parking Brake
OH2230
Carry No Riders
OH2220
DO NOT JUMP
ï Brace Yourself and Stay
With Vehicle
ï Keep Seat Belt Fastened
ï Hold On Firmly
ï Lean Away From The Point
Of Impact
OH2170
Use Only Compliant
Work Platforms To
Raise Or Lower
Personnel
OH3120
To Avoid Vehicle Tipover
ALWAYS:
ï Travel Slowly
ï Rig Properly
ï Use Two Tethers
DO NOT Use Ether Or
Other High Energy
Starting Aids.
Engine Equipped With
Grid Heating System.
OU1460
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Safety Practices
11
Model 944E Origin 3/04
Avoidance Symbols (contíd)
OU1530
Keep Truss
Boom Horizontal
When Using
Winch
OU1540
Avoid Rope
Damage. DO
NOT Tilt Truss
Boom DOWN
When Using
Winch
OU1550
OU1520
Stop Operation
At This Point
OU1510
Prohibition
Symbol. DO NOT
Operate
Avoid Rope
Damage. DO
NOT Tilt Truss
Boom UP When
Using Winch
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12 Model 944E Origin 3/04
Safety Practices
1. Seat Belt
Always fasten the seat belt before starting the engine.
2. Clothing and Safety Gear
DO NOT wear loose clothing or jewelry that can get caught on controls or
moving parts. Wear protective clothing and personal safety gear issued or
called for by job conditions.
3. Dismounting
DO NOT get off the vehicle until you:
ïlevel the vehicle,
ïground the carriage,
ïplace the travel select lever in the (N)
NEUTRAL DETENT position,
ïengage the parking brake switch,
ïturn the engine off, if appropriate,
ïunbuckle the seat belt,
ïexit the vehicle using the hand holds.
4. Chemical Hazards
A. Exhaust Fumes
Fumes from the engine exhaust can cause death or serious personal injury.
DO NOT operate vehicle in an enclosed area without a ventilation system
capable of routing the hazardous fumes outdoors.
B. Explosive Fuel
Engine fuel is flammable and can cause a fire and/or an explosion. Avoid
danger by keeping sparks, open flames and smoking materials away from
the vehicle and from fuel during refueling or when servicing the fuel
system. Know where fire extinguishers are kept on the worksite and how to
use them.
C. Ether or High Energy Starting Aids
The engine utilizes a grid heating system inside the induction manifold for
cold starting conditions.
Personal Considerations
WARNING: This diesel engine uses a grid heating system inside
the induction manifold. DO NOT use ether or any high energy fuels to
assist starting. An explosion may cause death or serious personal injury
or engine damage.
ALWAYS
engage parking brake
before dismounting
WARNING
V HICL
ROLLAWAY
can cause
death or
serious
injury
OU0340
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Safety Practices
13
Model 944E Origin 3/04
DO NOT use ether or any
other high energy
starting aids during cold
starting. An engine
explosion can result in
death or serious personal
injury.
D. Hydraulic Fluid
DO NOT attempt to repair or tighten any hydraulic hoses or fittings while
the engine is running or when the hydraulic system is under pressure. Fluid
in the hydraulic system is under enough pressure that it can penetrate the
skin causing death or serious personal injuries.
HOT HYDRAULIC FLUID WILL CAUSE SEVERE BURNS. Wait for fluid to
cool down before disconnecting lines.
DO NOT use your hand to check for leaks. Use a piece of cardboard or
paper to search for leaks. Wear gloves to protect hands from spraying fluid.
Hydraulic fluid can cause permanent eye injury. Wear appropriate eye
protection and stop engine. Relieve pressure before disconnecting lines.
Pressure can typically be relieved by slowly and cautiously loosening one
end of a hose at the swivel connection.
If anyone is injured by or if any hydraulic fluid is injected into the skin, obtain
medical attention immediately or gangrene may result.
E. Batteries
The following WARNING is intended to
supplement and does not replace the
warnings and information provided on
the battery by the battery
manufacturer.
When jump starting the vehicle,
carefully follow instructions found
under ìJump Startingî on page 87.
Keep sparks, flames and lit smoking
materials away from the battery at all
times. Lead acid batteries generate
explosive gases. Severe chemical
burns can result from improper
handling of battery electrolyte. Wear
safety glasses and proper protective
gear when handling batteries to
prevent electrolyte from coming in
contact with eyes, skin or clothing.
4110460
ENGINE EXPLOSION can
result in death or serious
personal injury.
DO NOT use Ether or other
high energy starting aids.
Engine equipped ith
grid heating system.
OU1470
-
WARNING
XPLOSIV GAS S can
cause serious injury.
Keep sparks, flames
and lighted materials
away from batteries.
4110368
OU0350
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14 Model 944E Origin 3/04
Safety Practices
Battery Charging
Under normal conditions, the engine alternator will have no problem keeping the
batteries charged. The only condition in which the battery may cause a problem is
when the batteries have been completely discharged for an extended period of time.
Under this condition, the alternator may not be able to recharge the batteries. A
battery charger will be required for recharging.
Before using a battery charger, an attempt can be made to recharge the batteries
using the engine alternator by first starting the vehicle and letting the engine run.
See ìJump Startingî on page 87.
WARNING: DO NOT charge a frozen battery, it may explode and
cause serious injury. Let the battery thaw out before putting on a battery
charger.
WARNING: Fluid in electric storage batteries contains sulfuric
acid which is POISON and can cause SEVERE CHEMICAL BURNS.
Avoid all contact of fluid with eyes, skin or clothing. Use protective gear
when handling batteries. DO NOT tip a battery beyond a 45angle in any
direction. If contact does occur, follow the First Aid suggestions that fol-
lows.
Battery Electrolyte First Aid:
ï External Contact ó Flush with water.
ï Eyes ó Flush with water for at least 15 minutes and
get medical attention immediately.
ï Internal Contact ó Drink large quantities of water. Follow
with Milk of Magnesia, beaten egg or vegetable oil.
Get medical attention immediately.
IMPORTANT! In case of internal contact, DO NOT give fluids that would
induce vomiting!
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Safety Practices
15
Model 944E Origin 3/04
5. Moving Parts Hazard
DO NOT place limbs near moving parts. Severing of
any body part can result.
Turn off engine and wait until fan and belts stop
moving before servicing.
6. Lowering Boom or Falling Load Hazard
DO NOT get under a raised boom unless it is blocked up safely. Always empty
the attachment of any load and block the boom up before doing any servicing
that would require the boom to be raised.
NEVER allow anyone to walk or stand under the boom. A lowering boom or
falling load can result in death or serious personal injury.
1. Preparation and Prevention
Know the location and function of all vehicle controls.
Make sure all persons are away from the vehicle and that the travel select lever
is in the (N) NEUTRAL DETENT position and the parking brake switch engaged
before starting the engine.
Holes, obstructions, debris and other worksite hazards can cause death or
serious personal injury. Always walk around and look for these and other
hazards before operating the vehicle in a new worksite.
Prevent accidents when you move the vehicle around the worksite. Know the
rules for movement of people and vehicles on the worksite. Have a person act
as a lookout for you. Follow the instructions of signals and signs.
DO NOT operate the vehicle unless all hazard and instructional decals are in
place and readable. (Replace all missing, illegible, or damaged decals.)
Operational Considerations
MOVING PARTS can cut.
Keep clear of fan and belts
hile engine is running.
MOVING PARTS can entangle.
OT0810
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16 Model 944E Origin 3/04
Safety Practices
2. Clearances
Look out for and avoid other personnel, machinery and vehicles in the area. Use
a spotter if you do not have a clear view of conditions that affect clearances.
Travel with the boom fully retracted and lowered as far as possible while still
maintaining enough ground clearance for conditions.
Always check boom clearances carefully before driving underneath door
openings, bridges, etc.
Always check for power lines when raising the boom. Beware of overhead wires.
Contact with electrical power lines can result in electrocution. See Electrocution
Hazards.
3. Visual Obstruction
Dust, smoke, fog, etc. can decrease vision and cause an accident. Always stop
or slow the vehicle until the obstruction clears and the worksite is visible again.
Have a lookout person assist you.
Where the load will obstruct the operatorís vision, it is recommended that the
vehicle be operated in REVERSE, looking backwards in the direction of travel.
Travel at a slower speed and get someone to direct you.
4. Underground Hazards
Know the location of all underground hazards before operating this vehicle in a
new area or worksite. Electrical cables, gas and water pipes, sewer, or other
underground objects can cause death or serious personal injury. Contact your
local underground utility service or diggers hotline to mark all underground
hazards.
5. Electrocution Hazards
NEVER operate this vehicle in an area where overhead power lines, overhead
or underground cables, or other power sources may exist without first
requesting that the appropriate power or utility company de-energize the lines,
or take other suitable precautions.
OS0063
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Safety Practices
17
Model 944E Origin 3/04
6. Elevating Personnel
Use only a compliant work platform meeting the ASME B56.6 standards for
lifting and lowering personnel. NEVER transport personnel in a work platform
for even the shortest distance.
Death or serious personal injury can occur if these rules are not obeyed. Riders
can fall and be crushed or run over. Avoid accidents.
For other specific precautions, See ìElevating Personnelî on page 89.
7. Transfer Carriage Operation
Before any operation of the PlaceAceô transfer carriage is started, be sure to
clear the path of travel in front of the boom and the transfer carriage of any
personnel or objects.
Be sure there is enough room in front of the boom for complete transfer carriage
movement.
IMPORTANT! When transfer carriage movement is started in the forward direction,
the lifting capacity of the vehicle will be reduced. Refer to ìUsing the Capacity Chartî
on page 71 and the ìLoad Chartî section at the end of this manual for vehicle
capacities during transfer carriage operation.
If load cannot be safely transfered forward, position the vehicle closer to the
landing point of the load.
WARNING
Allow no riders
AVOID
CRUSHING,
falling off
vehicle can
cause death
or serious
injury
FALLING OFF ATTACHMENT,
can result in death or
serious injury.
DO NOT TRAVEL
ith personnel in
a ork platform.
4110389
Lift or lo er personnel
only in a compliant
ork platform.
WARNING
OU0620
OH3180
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18 Model 944E Origin 3/04
Safety Practices
8. Tip Over Hazard
Traveling with the boom raised is dangerous and can cause tipover. Keep the
boom as low as possible. Travel with extreme caution and at the slowest
possible speed.
Keep the vehicle under control at all times. When negotiating turns, slow down
and turn the steering wheel in a smooth sweeping motion. Avoid jerky turns,
starts or stops. Reduce vehicle speed on rough ground and slopes.
DO NOT exceed the rated lift capacity of the vehicle as structural damage and
unstable conditions will result.
To ensure that the vehicle is positioned in the most stable condition before
operating an attachment, use the frame sway control (frame tilt) to level the
vehicle. The vehicle is level when the frame level indicator gauge reaches (0)
zero degrees.
If the vehicle cannot be leveled using the frame sway control, reposition the
vehicle.
Frame swaying left or right with the boom raised above horizontal is dangerous.
Always use the frame sway control to level the vehicle before raising the boom
above horizontal, with or without a load. If the vehicle cannot be leveled using
the frame sway control, reposition the vehicle.
9. Emergency Exit Rear
Window
The rear window (1) in the optional
enclosed cab can be used as an
emergency exit by removing the
latch pin (2) located on the window
latch (3). The window is then free
to swing open.
DANG R
DO NOT raise
boom while
on a slope
unless load
is level.
VE ICLE
TIPOVER
can result
in death or
serious injury.
DO NOT
travel
with the
boom
raised.
MAINTAIN
proper tire
pressure at
all times.
OS0086
2. 3.
1.
21
3
OU0920
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This manual suits for next models
2
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