Lull 944E-42 Service Manual User Manual Page 549
- Page / 846
- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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9.39
Model 644E-42/944E-42 Rev. 6/04
Electrical System
EG3
9.49 or
9.51
16 BLK Splice 100 To Ground Buss Bar
EG4
9.49 or
9.51
16 BLK Back-Up Alarm, Female, Connector (Pin B) To Splice 90
EG5
9.49 or
9.51
16 BLK Splice 80 To Splice 90
EG6
9.49 or
9.51
16 BLK Splice 110 To Ground Buss Bar
9.54 6 RED 125 Amp Fuse To Grid Heater Relay 1 (Pin 2) (944E-42 Only)
FJ1
9.48 or
9.50
Bare Metal Connector Transmission Fuse (F3) (Pin 3) To Fuel Solenoid Fuse (F4) (Pin 4)
FJ2
9.48 or
9.50
Bare Metal Connector Fuel Solenoid Fuse (F4) (Pin 4) To Ignition Fuse (F5) (Pin 5)
FJ3
9.48 or
9.50
Bare Metal Connector Ignition Fuse (F5) (Pin 5) To Back-Up Alarm/Horn Fuse (F6) (Pin 6)
FJ4
9.48 or
9.50
Bare Metal Connector Back-Up Alarm/Horn Fuse (F6) (Pin 6) To Stabilizer Fuse (F7) (Pin 7)
FJ5
9.48 or
9.50
Bare Metal Connector Stabilizer Fuse (F7) (Pin 7) To Dash Panel Fuse (F8) (Pin 8)
FJ6
9.48 or
9.50
Bare Metal Connector Dash Panel Fuse (F8) (Pin 8) To Open (F9) (Pin 9)
FJ7
9.48 or
9.50
Bare Metal Connector Open (F9) (Pin 9) To Auxiliary Hydraulic Fuse (F10) (Pin 10)
FJ8
9.48 or
9.50
Bare Metal Connector Auxiliary Hydraulic Fuse (F10) (Pin 10) To Open Fuse (F11) (Pin 11)
FJ9
9.48 or
9.50
Bare Metal Connector Open Fuse (F11) (Pin 11) To Open Fuse (F12) (Pin 12)
FJ10
9.48 or
9.50
Bare Metal Connector Open Fuse (F12) (Pin 12) To Open (F13) (Pin 13)
FJ11
9.48 or
9.50
Bare Metal Connector Open (F13) (Pin 13) To ECM Indicator Light Fuse (F14) (Pin 14)
FJ12
9.48 or
9.50
Bare Metal Connector
Optional Front Wiper Fuse (F16) (Pin 16)
To Optional Heater Fan Fuse (F17) (Pin 17)
FJ13
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 Optional Rear Wiper Fuse (F19) (Pin 19)
FJ15
9.48 or
9.50
Bare Metal Connector
Optional Lighting Power Relay Fuse (F20) (Pin 20)
To Optional Lighting Brake Switch Fuse (F21) (Pin 21)
FJ16
9.48 or
9.50
Bare Metal Connector
Optional Lighting Brake Switch Fuse (F21) (Pin 21)
To Optional Headlights Fuse (F22) (Pin 22)
FJ17
9.48 or
9.50
Bare Metal Connector
Optional Headlights Fuse (F22) (Pin 22)
To Optional Lighting Hazard Switch Fuse (F23) (Pin 23)
FJ18
9.48 or
9.50
Bare Metal Connector
Optional Lighting Hazard Switch Fuse (F23) (Pin 23)
To Optional Lighting Worklight Switch Fuse (F24) (Pin 24)
FJ19
9.48 or
9.50
Bare Metal Connector
Optional Lighting Main Fuse (F25) (Pin 25)
To Optional Air Conditioning Condenser Fan Fuse (F26) (Pin 26)
FJ20
9.48 or
9.50
Bare Metal Connector Optional Air Conditioning Condenser Fan Fuse (F26) (Pin 26) To Open (F27) (Pin 27)
FJ21
9.48 or
9.50
Bare Metal Connector Open (F27) (Pin 27) To Open (F28) (Pin 28)
FR1 9.52 12 RED
Fuel Shutoff Relay (Pin 1) To 12V Buss Bar
(644E-42 SN 20118 & Before, 0160002519 thru 0160003689 and 944E-42 Only)
FR2 9.52 12 WHT
Fuel Shutoff Relay (Pin 2)
To Fuel Shutoff Solenoid, 3 Pin Female, Connector (Pin B)
(644E-42 SN 20118 & Before, 0160002519 thru 0160003689 and 944E-42 Only)
FR3 9.52 14 BLU/ORG
Engine Start Relay (Pin 3) To Fuel Shutoff Relay (Pin 3)
(644E-42 SN 20118 & Before, 0160002519 thru 0160003689 and 944E-42 Only)
Wire No. Page Gauge Color From - Function - To
These wires are not part of a wire harness. Refer to the appropriate Parts Manual for part number information.
F
- Service Manual 1
- EFFECTIVITY PAGE 3
- SECTION CONTENTS 5
- Section Subject Page 6
- Section 1 9
- 1.1 INTRODUCTION 10
- 1.2 OWNERS/OPERATORS MANUAL 10
- 1.3 TRAINING MECHANICS AS 11
- OPERATORS 11
- 1.4 SAFETY INFORMATION 11
- DANGER: 12
- WARNING: 12
- CAUTION: 12
- 1.6 SAFETY INSTRUCTIONS 13
- Safety Practices 14
- 1.6.3 General Hazards 14
- 1.6.4 Operational Hazards 14
- 1.8 HAZARD/EMERGENCY 15
- INFORMATION SIGNS 15
- (717)-485-6472 15
- Section 2 17
- TERMINOLOGY 19
- 2.2 INTRODUCTION 20
- to the torque 21
- MA10,0820 22
- 2.4 METRIC CONVERSION FACTORS 23
- 2.5 SPECIFICATIONS 26
- 2.5.4 Attachment Weights 29
- ° and Emergency Brake Engaged 30
- 2.5.7 Electrical System 31
- 2.5.11 Hydraulic System 36
- 2.5.12 Tires 37
- XXXX - 24 38
- 2.6 FLUIDS, LUBRICANTS AND 39
- CAPACITIES 39
- 2.6.4 Hydraulic System 40
- 2.6.5 Engine 40
- 2.6.6 Transmission 41
- 2.6.7 Transfer Case 41
- 2.6.8 Drive Shaft Splines 42
- 2.6.9 General Anti-Corrosion 42
- 2.7 CLEANING 43
- 2.8 REPLACEMENT 44
- 2.9 HOSES AND TUBES 44
- 2.10 BEARINGS 45
- 2.11 PRESSURE TESTING AND 45
- ADJUSTMENT 45
- Section 3 49
- 3.1 BOOM SYSTEM COMPONENT 50
- 3.2 BOOM SYSTEM 51
- 3.3 BOOM ASSEMBLY MAINTENANCE 51
- 3.3.1 Inner Boom Replacement 52
- 3.3.3 Outer Boom Replacement 70
- 3.4 BOOM CHAINS 76
- 3.4.2 Chain Lubrication 83
- Removal and Replacement 87
- 3.5 BOOM WEAR PADS 92
- 3.6 QUICK ATTACH ASSEMBLY 95
- 3.7 TROUBLESHOOTING 99
- Section 4 105
- Cab and Covers 105
- COMPONENT TERMINOLOGY 106
- 4.2 OPERATOR’S CAB 107
- 4.3 OPEN CAB COMPONENTS 108
- Select Lever 109
- Replacement 111
- 4.3.4 Steer Select Valve 113
- (944E-42 Only) 120
- Assembly Replacement 122
- Replacement (Optional) 124
- 4.3.10 Electrical Components 125
- 4.4 ENCLOSED CAB (OPTIONAL) 128
- COMPONENTS 128
- 4.5 CAB REMOVAL 132
- 4.6 CAB INSTALLATION 135
- 4.7 VALVE PLATE 138
- 4.8 ACCESS PANELS AND COVERS 140
- 4.8.2 Engine Hood 142
- Section 5 147
- 5.2 GENERAL INFORMATION 149
- 5.3 AXLE ASSEMBLIES 149
- 5.3.4 Axle Specifications 150
- 5.3.5 Axle Maintenance 150
- 5.3.6 Axle Replacement 151
- Troubleshooting 161
- 5.4 DRIVE SHAFTS 162
- 5.5 WHEELS AND TIRES 165
- WARNING: Damaged, modified 167
- Onto Vehicle 168
- WARNING: BLOCK ALL FOUR 172
- Section 6 177
- 6.1 TRANSMISSION ASSEMBLY 178
- 6.2 TRANSMISSION DESCRIPTION 179
- 6.3 TRANSMISSION OPERATION 179
- 6.6 TRANSMISSION MAINTENANCE 180
- 6.7 TRANSMISSION REPLACEMENT 182
- MU1890MU1890 184
- 6.8 TROUBLESHOOTING 191
- Problem Cause Remedy 191
- 6.9 TOWING A DISABLED VEHICLE 194
- 6.10 TRANSFER CASE COMPONENT 195
- 6.11 GENERAL INFORMATION 196
- 6.12 TRANSFER CASE 196
- 6.12.5 Further Information 197
- 6.12.6 Technical Data 197
- 6.12.9 Transfer Case Removal 198
- 6.13 TROUBLESHOOTING 200
- Section 7 203
- 7.1 INTRODUCTION 205
- 7.1.2 Component Terminology 206
- 7.2 SAFETY INFORMATION 207
- 7.3 ENGINE SERIAL NUMBER 209
- 7.4 SPECIFICATIONS AND 209
- MAINTENANCE INFORMATION 209
- 7.5 STANDARD PRACTICES 209
- 7.6 ENGINE COOLING SYSTEM 210
- (60,4 mm) 221
- 7.7 ENGINE ELECTRICAL SYSTEM 225
- 7.8 FUEL SYSTEM 225
- 7.8.1 Diesel Fuel 226
- 7.8.2 Fuel Tank 226
- 7.8.4 Fuel Lift Pump Testing 228
- 7.8.5 Fuel Filter Replacement 229
- 7.8.7 Fuel Injectors 230
- 7.9 ENGINE EXHAUST SYSTEM 232
- 7.10 ENGINE REPLACEMENT 234
- 7.10.3 Engine Installation 243
- 7.11 ENGINE STORAGE 251
- 7.12 TROUBLESHOOTING 252
- Section 8 253
- Hydraulic System 253
- 8.1 HYDRAULIC COMPONENT 257
- 8.2 SAFETY INFORMATION 258
- 8.3 SPECIFICATIONS 259
- 8.4 HYDRAULIC FLUID 259
- 8.7 HYDRAULIC SYSTEM TESTING 264
- Hydraulic Pump Flow Test 265
- 8.7.3 Hydraulic Testing 272
- 8.7.5 Hydraulic Testing 280
- 8.7.8 Hydraulic Testing 292
- 8.7.10 Hydraulic Testing 300
- 8.8 HYDRAULIC CIRCUITS AND 307
- TROUBLESHOOTING 307
- (Dual Joystick) 358
- (Single Joystick) 360
- Description (Dual Joystick) 400
- Description (Single Joystick 406
- Description (Single Joystick) 413
- 8.9 STEER INDEXING PROCEDURES 415
- 8.10 HYDRAULIC RESERVOIR 416
- 8.11 HYDRAULIC SYSTEM PUMP 417
- 8.11.1 Pump Failure Analysis 418
- 8.11.2 Pump Replacement 418
- 8.12 VALVES AND MANIFOLDS 428
- 8.12.2 Main Control Valve 429
- Valve (Early Production) 444
- 8.12.10 Service Brake Valve 450
- 8.12.11 Power Steering Valve 453
- 8.12.12 Steer Select Valve 454
- Function Valve 456
- 8.13 ACCUMULATORS 458
- 8.13.1 General Information 459
- 8.13.3 Checking Pre-Charge 461
- 8.14 HYDRAULIC CYLINDERS 464
- 8.14.5 Slave Cylinders 469
- 8.14.7 Lift/Lower Cylinder 477
- 8.14.8 Frame Sway Cylinder 482
- 8.14.9 Stabilizer Cylinder 487
- 8.14.10 Steering Cylinders 491
- Section 9 511
- Electrical System 511
- 9.1 ELECTRICAL COMPONENT 515
- 9.1.2 General Overview 516
- 9.2 SERVICE WARNINGS 528
- 9.3 SPECIFICATIONS 528
- 9.5 GROUNDING STRAPS 529
- 9.6 WIRING HARNESSES 529
- 9.7 FUSES AND RELAYS 531
- 9.8 ELECTRICAL SYSTEM 537
- Multimeter (DMM) 539
- SN 19041 558
- & BEFORE 558
- Brake Relay on early 580
- See page 9.48 580
- TAILLIGHT 642
- 9.11 ENGINE START CIRCUIT 673
- 9.11.2 Starter 674
- 9.12 CHARGING CIRCUIT 677
- 9.12.1 Alternator 679
- 9.12.2 Battery or Batteries 681
- 9.13 ELECTRICAL SYSTEM 686
- 9.13.2 Front Dash Panel 691
- 9.13.8 Skylight Wiper Motor 708
- 9.14 SWITCHES AND SOLENOIDS 719
- 9.14.6 Parking Brake Switch 730
- 9.14.10 Dual Joystick 737
- 9.14.16 Engine Block Heater 751
- Level Sender 752
- RPM X 100 754
- Section 10 759
- Stabil-TRAK™ System 759
- 10.1 STABIL-TRAK™ SYSTEM 762
- 10.2 STABIL-TRAK™ DESCRIPTION 763
- 10.3 STABIL-TRAK™ OPERATION 764
- 10.3.3 Relay Testing 766
- BATTERY 1 769
- SN 0160002514 thru 0160003881 770
- Locked Mode, Frame Sway Right 798
- Locked Mode, Frame Sway Left 800
- Section 11 803
- Transfer Carriage 803
- 11.2 TRANSFER CARRIAGE 805
- 11.3 TRANSFER CARRIAGE 805
- MAINTENANCE 805
- 11.3.3 Rear Wear Pad Check 815
- 11.3.4 Rear Wear Pad Shimming 815
- 11.3.10 Rear Roller Gap Check 818
- 11.3.11 Rear Roller Shimming 819
- 11.3.13 Front Roller Shimming 822
- 11.4 TROUBLESHOOTING 832
- Section 12 835
- 8990403 Origin 5/00 843
- Accident Prevention Tags 843
- JLG Worldwide Locations 846
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