Lull 944E-42 Service Manual User Manual Page 783
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Model 644E-42/944E-42 Rev. 6/04
Stabil-TRAK™ System
644E-42, 0160003878 & After
944E-42, 0160003882 & After
Stabil-TRAK™ Electrical Circuit
Locked Mode III
LOCKED MODE III 1. Ignition “ON” 4. Transmission in Neutral
Conditions
2. Boom Above 40°
3. PB “OFF” & SB Released
OPEN
RELAY
POSITION
(E5)
86
85
87A 87
30
STARTER
GND (-)
+
+
-
BATTERY 1
ENGINE
BLOCK
BLU
BRN
BLK
+
-
O
STABIL.
LOCK
RELAY
(E6)
86
85
87A 87
30
DE
DE
TRANS.
CONTROL
RELAY
(E1)
86
85
87A 87
30
2
3
8
1
7
2
TRANSMISSION
DISCONNECT
SWITCH
S1B
S2A
S3
TCG
S2A
8 3
7 2
S1B
3
7
6
CAB
POWER
RELAY
(OPTION)
(E9)
86
85
87A 87
30
70
RG1
CAB
GRND
STUD
CG3
85
PB6A
15
PB6A
AA
BB
X7 X7
A A
X6 X6
TRG3
TR3A
TRG5
TR1A
TRG6
TR2B
EG3
TR6A
TR5A
TR4A
TR3A
TR2B
TR1A
A
B
C
D
E
F
EG5
80
STG5
EG1
90
GROUND BUSS BAR
A
B
C
BA1
S12C
BP1A
S11
S8A
BP3
A5
A4
A3
A2
B5
B4
B3
B2
B1
S8A
S11
CAB
GRND
STUD
BP1A
BP3
BP2
BOOM
PROXIMITY
SENSOR
A A
X5 X5
A A
X9 X9
A A
X8 X8
B B
X8 X8
B B
X9 X9
TR6A
TRG4
TR5A
TRG1
TRG2
TR4A
AA
BB
X10 X10
Y5
E
Y4
E
Y6
E
Y2
E
Y1
E
Y3
E
100
B B
X6 X6
B B
X5 X5
CBA
TRANSMISSION
VEHICLE
FEMALE & MALE
CONNECTOR
65
TRANSMISSION
FEMALE & MALE
CONNECTOR
TR8
TR9
PB6B
IG1 BA4
BA3
DG
BP3A
S1D
RG6
RG9
RG4
RG5
RG7
RG8
TR8
S1
FJ3
5
FJ4
6
7
F1 40
OPEN CAB
VEHICLE MAIN
DG
S10C
F2 15
IGNITION
CONTROL
BA1A
BA2
BA3
A
B
BA4
C
A
B
S10B
BP1
A5
A4
A3
A2
B5
B4
B3
B2
B1
TR5
TR6
TR1
TR4
TR3
TR2A
A
B
C
D
E
F
10
PB2B
PB2A
PB5
STABILIZER
BRAKE
SWITCH
S1A
50
F7 10
STABILITY
CIRCUIT
G
F
F6 10
BACK-UP
ALARM/HORN
F5 20
IGNITION
POWER
E
D
F4 20
FUEL
SOLENOID
TRANSMISSION
F3 15
C
FJ2
4
FJ1
3
2
1
S6
S9
S10
75
S12
S12A
S12B
PB2
TR7
55
S2
S2B
S1
S1D
BP1
PB2
PB3
15 15723 208964 19181716131210 11 14
IG1
1
2
5
8
S10B
S10C
2 1
RG6
GEAR
GEAR
FORWARD
GEAR
B+
REVERSE
NEUTRAL
GEAR
TR9
TR2
TR7
TR6
TR4
TR5
TR3
TR1
30
PB1
PB6B
20
PBG1
S12B
S12A
S8
CAB
GRND
STUD
CG3
85
CG3A
IGNITION
SWITCH
ACC
IGN
B+
OFF
ACC
IGN
ST
SOL.
3
SOL.
4A
SOL.
4B
SOL.
12A
SOL.
12B
DE
S12C
STG4
S11A
STG3
S11B
60
STG1 STG2
S8B S8C
STG5
PARK
BRAKE
SOLENOID
IGNITION
RELAY
(E2)
86
85
87A 87
30
BACK-UP
ALARM
RELAY
(E4)
86
85
87A 87
30
LIGHT
POWER
RELAY
(OPTION)
(E8)
86
85
87A 87
30
NEUTRAL
START
RELAY
(E3)
86
85
87A 87
30
12V BUSS BAR
RIGHT
TRANSMISSION
COILS
LEFT
TRANSMISSION
COILS
8
7
6
5
4
3
2
1
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
PB4
RG2
RG3
RELAY LOCATIONS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
E1
E2
E3
E4
E5
E6
E7
E8
E9
E10
E
DE
DE
BPG
BP2
E
DE
DE
DE
LEGEND
= De-energized
= Energized
= Open
= Closed
= Active Circuit
O
C
E
DE
DE
BOOM
SWITCH
RELAY
(E7)
86
85
87A 87
30
E
PARK BRAKE SWITCH
E
D
E
1
2
3
4
5
6
7
8
D
1
2
E
E
DE
O
DE
E
E
E
O
E
DE
8
7
6
5
4
3
2
1
SHIFTER
TRANSMISSION
F
N
R
NEUTRAL
S3
VP2 DIODE PACK
A B C F
VP1 DIODE PACK
A B C F
PB3A
PB4 S5
S4
S2B
S6
25
S5
5
PB3
S8
POWER MALE &
FEMALE CONNECTOR
MU6700
- 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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