Lull 944E-42 Service Manual User Manual Page 560
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Electrical System
9.50
Model 644E-42/944E-42 Rev. 6/04
9.8.8 Main Electrical Schematic
(644E-42, SN 0160003878 & After, 944E-42, SN 0160003882 & After)
Schematic is drawn with the ignition switch in the OFF position.
A
A
B
C
AUX HYD
SOLENOIDS
VEHICLE
FEMALE
CONNECTOR
65
VP2 DIODE PACK
A B C F
VP1 DIODE PACK
A B C F
ACC
IGN
B+
OFF
ACC
IGN
ST
IGNITION
SWITCH
TRANSMISSION
FEMALE
CONNECTOR
A
B
C
D
E
F
POWER
FEMALE
CONNECTOR
CG2
NS2
ST4
CG1
IG2B
LP4
LP2
LP3
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
86
85
IG1 BA4
BA3
TR7A
NEUTRAL
START
RELAY
87A 87
30
86
85
NS2
NS1
CAB
POWER
RELAY
(OPTION)
87A 87
30
86
85
DG
BOOM
SWITCH
RELAY
87A 87
30
86
85
BP3A
S1D
BU1
BACK-UP
ALARM
RELAY
87A 87
30
86
85
BU3
BU2A
RG2
RG6
RG9
RG3
RG4
RG5
RG7
RG8
TR8
S1
FJ3
5
FJ4
6
FJ5
7
FJ6
8
FJ7
9
FJ8
10
FJ9
FJ10
12
FJ11
15
FJ12
16
FJ13
17
FJ14
18
19
FJ15
20
FJ16
21
F1 40
OPEN CAB
VEHICLE MAIN
INSTRUMENT
PANEL
J1
PARK BRAKE
J5
FUEL GAUGE
J15
ALARM
BUZZER
J7
BACK LIGHT
J2
ALTERNATOR
J3
ENGINE OIL
PRESSURE
J20
TRANSMISSION
TEMPERATURE
J8
GROUND
J9
POWER
J6
HOURMETER/
TACHOMETER
J4
WATER
TEMPERATURE
GAUGE
J19
HYDRAULIC OIL
TEMPERATURE
J18
AIR CLEANER
STABIL-TRAK
LOCKED MODE
J17
HYDRAULIC
OIL FILTER
J16
J13
ACCUJMULATOR
BRAKE PRESSURE
STABIL-TRAK
SLOW PIVOT MODE
J12
TURN SIGNAL
(OPTIONAL)
J10
ENGINE PRE-HEAT
(OPTIONAL)
J11
HIGH BEAM
(OPTIONAL)
J14
D13
PB3B
D6 D4 D3 D2 DG D1
S10C
D7 D8 D10
S12B
D12 D9 D5
F2 15
IGNITION
CONTROL
BA1A
BA2
BA3
A
B
PB1
BA4
D1A
D1A
PH
CG2
CAB
GRND
STUD
C
A
B
POWER
MALE
CONNECTOR
BB1A
BA1A
BC1A
SENSOR
FEMALE
CONNECTOR
D5
D6
D13
D12
D10
D2
D9
D4
BP3A
S10B
S12A
BU3A
BP1
H2A
H1
S8
BPG
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
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
(OPTION)
P
F17 25
HEATER FAN
(OPTION)
Q
F18 7.5
SKYLIGHT WIPER
(OPTION)
R
F19 7.5
REAR WIPER
(OPTION)
S
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
F25 40
LIGHTS MAIN
(OPTION)
Y
LP5
F26 25
CONDENSER FAN
(OPTION)
Z
FJ21
28
FJ21
FJ20
26
FJ19
25
FJ18
23
24
FJ17
22
FJ2
4
FJ1
3
2
1
11
K
13
M
14
N
AA
27
AB
28
BB1A
CP3
LP6
BC1A
2
3
8
1
7
2
TRANSMISSION
DISCONNECT
SWITCH
S1B
S2A
S3
TCG
BUZZER
STABIL.
LOCK
RELAY
87A 87
30
86
85
S6
S9
S10
75
S12
S12A
S12B
CG3
BPG
PB2
LP1
LP1
CP1
PB6A
25
TR7
S5
55
S2
S2B
S1
S1D
S1B
BP1
BU1
45
40
H1
BU3A
BU3C
PB2
5
PB3B
PB3
S8
35
PB3
NS1
15 15723 208964 19181716131210 11 14
TR7A
OPTION
HARNESS
OPTION
HARNESS
OPTION
HARNESS
OPTION
HARNESS
OPTION
HARNESS
OPTION
HARNESS
OPTION
HARNESS
OPTION
HARNESS
OPTION
HARNESS
OPTION
HARNESS
OPTION
HARNESS
RG1
CP2
IG1
PBG
1
2
5
8
7
6
3
8 3
7 2
S10B
S10C
2 1
RG6
LP6
CP3
8
7
6
5
4
3
2
1
SHIFTER
TRANSMISSION
GEAR
GEAR
FORWARD
GEAR
B+
REVERSE
NEUTRAL
GEAR
F
N
R
4
1
2
3
TR9
TR2
TR7
TR6
TR4
TR5
TR3
TR1
8
7
6
5
4
3
2
1
30
OPTION HARNESS
PB1
PB6
F12
OPEN
IG2A
F9
OPEN
F11
OPEN
F13
OPEN
F14 3
ECM INDICATOR
LIGHT
F27
OPEN
F28
OPEN
15
PB6B
FUEL
LEVEL
SENDER
A
B
SG1
SG2
ACCUMULATOR
BRAKE
PRESSURE
SWITCH
AB
85
A
B
A
B
AHG2
AHG1
105
AH2A
20
PARK
BRAKE
SOLENOID
AH2B
PB6A
PB5
D7
TCG
PBG
CG3A
CG3A
SG2
SG1
BU2A
LP5
B
A
CD
AH A
A
B
AH B
A
B
PH
CMP
C
D
E
F
G
H
J
A
K
B
CMP
BU3C
E
D
E
1
2
3
4
5
6
7
8
D
1
2
PARK
BRAKE
SWITCH
AH3A
290
CG1
HORN
BUTTON
21
HG
AH3
AH3
PBG1
AB
AB
PB A
PBG1
AH1
AH2
AUX HYD
JOYSTICK
A
B
C
OPEN RELAY
POSITION
86
85
87A 87
30
12345678
AH3B
AH4
295
A
B
AHG4
AHG3
AH4
AHG6
AHG5
S2A
MU65101
Brake Relay on early
production units.
See page 9.48.
Connectors used on
early production
units only.
Seepage9.48.
= See Pages 9.63, 9.110 or 9.112.
- 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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