Lull 944E-42 Service Manual User Manual Page 550
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- Table of contents
- TROUBLESHOOTING
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Electrical System
9.40
Model 644E-42/944E-42 Rev. 6/04
FRG 9.52 14 BLK
Fuel Shutoff Relay (Pin 4) To Splice 95
(644E-42 SN 20118 & Before, 0160002519 thru 0160003689 and 944E-42 Only)
FS2 9.53 14 BLU/ORG
Optional Cold Start, 3 Pin Female, Connector (Pin C) To Splice 330
(644E-42 SN 0160003690 & After Only)
FSG
9.52
12 BLK
Fuel Shutoff Solenoid, 3 Pin Female, Connector (Pin C) To Splice 95
(644E-42 SN 20118 & Before, 0160002519 thru 0160003689 and 944E-42 Only)
9.53
Optional Cold Start, 3 Pin Female, Connector (Pin C) To Splice 95
(644E-42 SN 0160003690 & After Only)
9.54 6 RED Grid Heater Relay 1 (Pin 1) To Engine Grid Heater (Pin 1) (944E-42 Only)
GB1
9.52,
9.53 or
9.54
12 BLK Power Bulkhead, 6 Pin Male, Connector (Pin D) To Ground Buss Bar
GB2
9.52,
9.53 or
9.54
12 BLK Power Bulkhead, 6 Pin Male, Connector (Pin E) To Ground Buss Bar
GH1 9.54 18 BLK
Splice 8
To Engine Control Module, 50 Pin Female, Engine Connector, P2 (Pin 41) (944E-42 Only)
GH1A 9.54 16 BLK Splice 8 To Diode VESPAK Connector P10 (Pin A) (944E-42 Only)
GH1B 9.54 16 BLK Splice 8 To Grid Heater Relay 1 (Pin 3) (944E-42 Only)
GH2 9.54 18 BLK
Splice 9
To Engine Control Module, 50 Pin Female, Engine Connector, P2 (Pin 31) (944E-42 Only)
GH2A 9.54 16 BLK Splice 9 To Diode VESPAK Connector P10 (Pin B) (944E-42 Only)
GH2B 9.54 16 BLK Splice 9 To Grid Heater Relay 2 (Pin 3) (944E-42 Only)
GH3 9.54 16 BLK Grid Heater Relay 1 (Pin 1) To Diode VESPAK Connector P11 (Pin A) (944E-42 Only)
GH4 9.54 16 BLK Grid Heater Relay 2 (Pin 1) To Diode VESPAK Connector P11 (Pin F) (944E-42 Only)
GHG 9.54 16 BLK Splice 7 To Diode 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 Battery 2, Negative (-) Terminal To Splice 7 (944E-42 Only)
9.54 6 RED Grid Heater Relay 2 (Pin 1) To Engine Grid Heater (Pin 2) (944E-42 Only)
H1
9.48 or
9.50
16 ORG/GRN Vehicle Bulkhead, 15 Pin Female, Connector (Pin A3) To Splice 40
H1A
9.49 or
9.51
16 ORG/GRN
Vehicle Bulkhead, 15 Pin Male, Connector (Pin A3)
To Horn, Female, Connector (Pin A)
H2
9.49 or
9.51
16 ORG/WHT
Horn, Female, Connector (Pin B)
To Vehicle Bulkhead, 15 Pin Male, Connector (Pin A4)
H2A
9.48 or
9.50
16 ORG/WHT Vehicle Bulkhead, 15 Pin Female, Connector (Pin A4) To Horn Switch (1)
HG
9.48 or
9.50
16 BLK Horn Switch (2) to Splice 85
IG1
9.48 or
9.50
16 TAN Ignition Relay (Pin 85) To Splice 10
IG2
9.48 or
9.50
14 RED/ORG Ignition Fuse (F5) (Pin E) To Splice 35
IG2A
9.48 or
9.50
14 RED/ORG Splice 35 To Power Bulkhead, 6 Pin Female, Connector (Pin B)
IG2B
9.48 or
9.50
14 RED/ORG Splice 35 To Power Bulkhead, 6 Pin Female, Connector (Pin C)
9.52,
9.53 or
9.54
1/0 BLK Ground Buss Bar To Engine Compartment Firewall Ground Stud
J87H 9.54 18 RED
Engine Control Module, 50 Pin Female, Engine Connector, P2 (Pin 49)
To Engine Control Module, 9 Pin Male, Diagnostic Connector, P7 (Pin F) (944E-42 Only)
J87L 9.54 18 BLK
Engine Control Module, 50 Pin Female, Engine Connector, P2 (Pin 50)
To Engine Control Module, 9 Pin Male, Diagnostic Connector, P7 (Pin G) (944E-42 Only)
9.54 1/0 BLK Battery 1 Negative (-) Terminal To Battery 2 Negative (-) Terminal (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.
G
H
J
K
- 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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