Lull 944E-42 Service Manual User Manual Page 586
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Electrical System
9.76
Model 644E-42/944E-42 Rev. 6/04
9.8.26 944E-42 Engine Start Circuit & Troubleshooting
Schematic is drawn with the ignition switch in the START position.
OPEN RELAY
POSITION
86
85
87A 87
30
BPD
BPM
BNW
BPS
BNP
BNH
BNF
BNE
BPC
BPB
ST4A
A
B
C
D
E
F
H
M
P
S
W
P1
ENGINE CONTROL
MODULE FEMALE
CONNECTOR
12
3
4
ENGINE GRID
HEATER RELAY 2
ENGINE GRID
HEATER RELAY 1
12
3
4
GH2A
GROUND BUSS BAR
12V BUSS BAR
A
B
C
BA1
ST2
ST1
ENGINE
BLOCK
AB1
AB2
AG1
AG2
AG1
ALTERNATOR
7
GHG
GHG3
GH1B
GH1
GHG1
GHG1
GH3
THS
THP
THG
GHG2
GH3
GH4
PH1A
GH4
GH2B
P11
DIODE PACK
F
E
B
A
GHG3
125
Amp
Fuse
125
Amp
Fuse
PH1A
P10
DIODE PACK
A
B
C
F
AG2
GHG
GH2A
GH1A
P2
ENGINE
CONTROL
MODULE
FEMALE
CONNECTOR
GH2
GH1
THS
THP
THG
GH2
BPS
BPL1
BPL2
BPS1
BPM
BPM1
A
B
C
D
E
F
10
10
10
BPD1
BPC
BPD
BPC1
BPB
BPB1
A
B
C
D
E
F
7.5
7.5
7.5
BN
BPL1
P6
ENGINE CONTROL
MODULE FUSES
P5
ENGINE CONTROL
MODULE FUSES
ENGINE CONTROL
MODULE POWER
MALE AND FEMALE
CONNECTOR
PH1
ENGINE
BLOCK
ENGINE GRID
HEATER
1
2
THROTTLE
ROTARY
POSITION
SENSOR
2
3
1
THS1
THP1
THG1
TR9
TR7
8
6
SHIFTER
ZF TRANSMISSION
8
6
B+
NEUTRAL
F
N
R
4
1
2
3
IGNITION
SWITCH
ACC
IGN
B+
OFF
ACC
IGN
ST
VP1 DIODE PACK
A B C F
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
BACK-UP
ALARM
RELAY
87A 87
30
86
85
RG2
RG6
RG9
RG3
RG4
RG5
RG7
RG8
TR8
F1 40
OPEN CAB
VEHICLE MAIN
DG
F2 15
IGNITION
CONTROL
BA1A
BA3
B
BA4
C
A
B
BA1A
PB3A
10
PB2A
PARK BRAKE SWITCH
E
D
E
1
2
3
4
5
6
7
8
D
1
2
D
F4 20
FUEL
SOLENOID
TRANSMISSION
F3 15
C
4
3
2
1
STABIL.
LOCK
RELAY
87A 87
30
86
85
25
TR7
PB2
5
PB3
PB3
NS1
IG1
1
7
6
3
RG6
PB1
PB6
15
PB6B
CAB
GRND
STUD
CG3
85
PB6A
PB6A
POWER
MALE
AND FEMALE
CONNECTOR
TR7A
PB3A
A
FJ1
PB1
PB2B
2
5
8
PH
SENSOR
FEMALE AND MALE
CONNECTOR
PH
PH1
9
8
GH1A
ENGINE
START
RELAY
12
3
4
ST1 ST2
SRG
ST3
SRG
8 9 10 11
INSTRUMENT
PANEL
J8
GROUND
J9
POWER
TURN SIGNAL
(OPTIONAL)
J10
ENGINE PRE-HEAT
J11
K
K
A
B
C
A
B
C
A
B
C
D
E
F
ST4A
ST3
POWER
FEMALE
AND MALE
CONNECTOR
A
B
C
D
E
F
NS2
ST4
BPD1
BPM1
BPC1
BPS1
BPB1
BPL2
BN
BNE
BNP
BNF
BNH
BNW
P7
DIAGNOSTIC
PLUG
A
B
STARTER
GND (-)
+
19
20
25
26
29
30
31
35
36
37
41
BATTERY 2
+
-
BATTERY 1
+
-
B+
D+
GND (-)
W
FRAME
GROUND
MU5621
Brake Relay on early
production units.
See page 9.48.
- 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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