Lull 944E-42 Service Manual User Manual Page 573
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- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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9.63
Model 644E-42/944E-42 Rev. 6/04
Electrical System
9.8.20 Optional Closed Cab Electrical Schematic
Schematic is drawn with the ignition switch in the OFF position.
ENGINE
BLOCK
+
-
BATTERY
1
B
C
RWP
TWP
CNDP
AC
SWITCH
13
2
FRONT
WASHER
PUMP
MOTOR
POWER
GND
M
SKYLIGHT
& REAR
WASHER
PUMP
MOTOR
POWER
GND
M
COMPRESSOR
CLUTCH
BLP
190
FWP
205
CAB
GRND
STUD
WPG
FWG3
FWG1
FWG2
TWG1
210
GJ1
RWG
FWG4
GJ1
FW3
FW2
FWJ2
FWJ1
FW1
FW2 FW3 FW4
FWG1
FWJ3
FW1A
FW5
TW1
TWG1
TWJ
TWP
TW2TW3 TW4
ACG1
AC2
BLC
BLM
BLH
BLL
AC2A
BLM
BLHBLL EVG AC1
HVG
HV8
TWG2
TW2
HIGH/LOW
PRESSURE
SWITCH
LOW - (28 PSI)
HIGH - (455 PSI)
RWG
RWP
FWG4
FW5
TWG3
TW4
REAR
WIPER
SWITCH/
MOTOR
A
C
GND
M
PARK
RUN
POTG
ACG1
ACG
CNDP
CNDG
CNDS
EVG
CAB
GRND
STUD
CNDG
POTP
HVP
195
AC2A
AC2
CNDS
200
FWG2
FW4
FW1
FW1A
145
POTG
BLC
FRONT
WIPER
SWITCH
2
1
96431
752
257
9 6 34 1
P
L
GND
M
H
FRONT
WIPER
MOTOR
P
L
H
FRONT
WASHER
SWITCH
2
3
1
7
8
7 3
28
8 2
6
SKYLIGHT
WIPER/
WASHER
SWITCH
2
13
2
5
1
7
8
555555555
6317
THERMOSTAT
(35°F)
F
E
HEATER/AC
BLOWER
MOTOR
POWER
GND
M
BLOWER
MOTOR
RESISTOR
PACK
BLOWER
B F
C A D E
HEATER VALVE
POWER GROUND
7
8
10
D
C
A
VALVE
POTENTIOMETER
SKYLIGHT
WIPER
MOTOR
A
C
GND
M
PARK
RUN
B
A
C
POWER
GND
M
AC CONDENSER
87A 87
30
86
85
POWER
GND
M
TW3
TWG3
BLB
CAB
POWER
RELAY
87A 87
30
86
85
CP2
CP3
FJ12
16
FJ13
17
FJ14
18
19
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
F25 40
LIGHTS MAIN
(OPTION)
Y
F26 25
CONDENSER FAN
(OPTION)
Z
FJ21
28
FJ21
FJ20
26
FJ19
25
AA
27
AB
28
CP3
F27
OPEN
F28
OPEN
15
F15 40
CLOSED CAB
MAIN (OPTION)
O
12V BUSS BAR
STARTER
GND (-)
+
C
A
B
A
B
C
BA1
POWER
MALE
CONNECTOR
F1 40
OPEN CAB
VEHICLE MAIN
F2 15
IGNITION
CONTROL
BA1A
B
2
PB1
BA3
BB1
BC1
BC1A
BB1A
ACC
IGN
B+
OFF
ACC
IGN
ST
IGNITION
SWITCH
H
L
M
B
C
B
H
C
O
LM
BLOWER
SWITCH
A
POTP
INTERNAL
GROUND
TO ENGINE
POWER
FEMALE
CONNECTOR
CMP1A
IGNITION
RELAY
87A 87
30
86
85
IG1
BA4
BA3
10
PB2A
PB2
To
Transmission
Fuse (F3)
To
Park Brake
Switch
CP1
CP1
B
A
MU0912
Refer to
pages 9.52,
9.53 or 9.54.
Refer to
pages 9.48,
9.49, 9.50
or 9.51.
= See Pages 9.48, 9.49, 9.50 or 9.51.
- 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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