Lull 944E-42 Service Manual User Manual Page 604
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Electrical System
9.94
Model 644E-42/944E-42 Rev. 6/04
9.8.31 Single Joystick - Transfer Carriage Extend/Retract Circuit & Troubleshooting (Option)
Schematic is drawn with the ignition switch in the RUN position.
A
B
AX
A
B
TR
A
B
HO
A
B
EXT
A
B
CTA
A
B
CTB
A
B
SOLENOIDS
PROPORTIONAL
SOLENOIDS
SJG6
PWM DRIVER
BOARD
JOYSTICK
MALE
CONNECTOR
34561
2
RED
-
+12V DC / B+
EC2
BLACK
-
GROUND / B-
GREY
-
PWM RETURN
PURPLE - PWM F TILT
EC3
YELLOW
-
SWITCH CONTROL OUTPUT (NO)
EC1
(+5V)
ORANGE
-
PWM R TILT
PROPORTIONAL
ROLLER
TRIGGER
SWITCH
SINGLE
JOYSTICK
CONTROL
IGNITION
RELAY
87A 87
30
86
85
IG1 BA4
BA3
RG3
To
Transmission
Control Relay
To
Neutral
Start
Relay
12V BUSS BAR
HYD
JOYSTICK
CONNECTOR
F1 40
OPEN CAB
VEHICLE MAIN
F2 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
F5 20
IGNITION
POWER
E
I
F10 5
AUXILIARY
HYDRAULICS
J
FJ2
F9
OPEN
A
B
A
B
AHG2
AHG1
105
AH2A
20
AUXILIARY
HYDRAULIC
SOLENOIDS
AH2B
AH2
10
PB2A
PB2
IG1
PB1
To
Park Brake
Switch
A
B
AH A
A
B
AH B
AH1
AH2
AHG6
C
B
A
C
A
B
BA1A
POWER
MALE & FEMALE
CONNECTORS
A
B
C
BA1
AH2B
IGNITION
SWITCH
ACC
IGN
B+
OFF
ACC
IGN
ST
JOYSTICK
MALE
CONNECTOR
43216
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
34561
2
JOYSTICK
JUMPER
HARNESS
FEMALE
CONNECTOR
43216
5
Black
Red
Green
Grey
White
Purple
Orange
Blue
Black
Red
Green
Grey
White
Blue
Purple
Orange
Red
YellowYellow
CONTROL
MODULE
JUMPER
HARNESS
FEMALE
CONNECTOR
3
4
5
6
1
2
9
10
11
12
7
8
15
16
17
18
13
14
21
22
23
19
20
3
4
5
6
1
2
9
10
11
12
7
8
15
16
17
18
13
14
21
22
23
19
20
SINGLE
JOYSTICK
CONTROL
MODULE
+5VDC
PWM Return
Ground
Power
AGND
Hall Effect Output
PWM Forward Tilt
PWM Reverse Tilt
TAA
300
SJG1
AH1A
SCO
AH1C
SJG3
TA
JOYSTICK
FEMALE
CONNECTOR
SCO
34561
2
SJG2
AH1B
315
SJG2
SJG3
305
AH1A
AH1C
SINGLE
JOYSTICK
CONNECTOR
SINGLE
JOYSTICK
RELAY
86
85
87A 87
30
SINGLE
JOYSTICK
PILOT SELECT
VALVE
STARTER
GND (-)
+
+
-
BATTERY 1
ENGINE
BLOCK
AHG5
CAB GRND
STUD
AH3A
290
12345678
AH3B
AH4
295
A
B
AHG3
AH4
AHG6
AH3
C
B
A
RG2
AH1
SJG1
7
3
2
8
295
A
B
AHG4
AUXILIARY HYDRAULIC
PRESSURE RELEASE
VALVE SOLENOID
A
B
AHG5AHG3AH3A
AH3B
290
AH4
AUXILIARY
HYDRAULIC
PRESSURE
RELEASE
SWITCH
2
3
78
1
CAB GRND
STUD
AH4
AH3
AHG6
Hyd. Joystick Conn.
Aux.
Hyd.
Fuse
MU6730
Late Production
Single Joystick
Early
Production
Single Joystick,
Harness &
Control Module
644E-42, SN 20118 & Before,
0160002519 thru 0160003108,
944E-42, SN 20123 & Before,
0160002514 thru 0160003106
- 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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