Lull 1044C-54 Series II Telehandler Parts Manual – PDF DOWNLOAD
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Lull 1044C-54 Series II Telehandler Parts Manual – PDF DOWNLOAD
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Language: English
Brand: LULL
TABLE OF CONTENTS:
Lull 1044C-54 Series II Telehandler Parts Manual – PDF DOWNLOAD
SECTION 1 – FRAME AND ATTACHING PARTS 9
FIGURE 1-1 MAIN FRAME ASSEMBLY 10
FIGURE 1-2 OUTRIGGER ASSEMBLY 14
SECTION 2 – BOOM 17
FIGURE 2-1 FIRST BOOM SECTION (Prior to SN 0160037900, Excluding 0160037855) 18
FIGURE 2-2 FIRST BOOM SECTION (SN 0160037900 to Present, Including 0160037855) 22
FIGURE 2-3 BEARING PADS, SPACERS AND SHIMS, (FIRST BOOM SECTION) (Prior to SN 0160037900, Excluding 0160037855) 26
FIGURE 2-4 BEARING PADS, SPACERS AND SHIMS, (FIRST BOOM SECTION) (SN 0160037900 to Present, Including 0160037855) 28
FIGURE 2-5 SECOND BOOM SECTION (Prior to SN 0160037900, Excluding 0160037855) 30
FIGURE 2-6 SECOND BOOM SECTION (SN 0160037900 to Present, Including 0160037855) 32
FIGURE 2-7 BEARING PADS, SPACERS AND SHIMS, (SECOND BOOM SECTION) (Prior to SN 0160037900, Excluding 0160037855) 36
FIGURE 2-8 BEARING PADS, SPACERS AND SHIMS, (SECOND BOOM SECTION) (SN 0160037900 to Present, Including 0160037855) 38
FIGURE 2-9 THIRD BOOM SECTION (Prior to SN 0160037900, Excluding 0160037855) 40
FIGURE 2-10 THIRD BOOM SECTION (SN 0160037900 to Present, Including 0160037855) 44
FIGURE 2-11 FOURTH BOOM SECTION (Prior to SN 0160037900, Excluding 0160037855) 48
FIGURE 2-12 FOURTH BOOM SECTION (SN 0160037900 to Present, Including 0160037855) 50
FIGURE 2-13 TRANSFER CARRIAGE/BOOM CRADLE ASSEMBLY 52
FIGURE 2-14 QUICK ATTACH GROUP INSTALLATION (Prior to SN 0160037900, Excluding 0160037855) 54
FIGURE 2-15 QUICK ATTACH GROUP INSTALLATION (SN 0160037900 to Present, Including 0160037855) 56
SECTION 3 – ATTACHMENTS 59
FIGURE 3-1 CARRIAGE ASSEMBLY (Prior to SN 0160037900, Excluding 0160037855) 60
FIGURE 3-2 CARRIAGE ASSEMBLY (SN 0160037900 through 0160051920, Including 0160037855) 62
FIGURE 3-3 CARRIAGE ASSEMBLY (SN 0160051921 to Present) 64
FIGURE 3-4 TILT CARRIAGE ASSEMBLY (Prior to SN 0160037900, Excluding 0160037855) 66
FIGURE 3-5 TILT CARRIAGE ASSEMBLY (SN 0160037900 to Present, Including 0160037855) 68
FIGURE 3-6 SWING CARRIAGE ASSEMBLY (Prior to SN 0160037900, Excluding 0160037855) 70
FIGURE 3-7 SWING CARRIAGE ASSEMBLY (SN 0160037900 to Present, Including 0160037855) 72
FIGURE 3-8 UTILITY BUCKET (Prior to SN 0160037900, Excluding 0160037855) 74
FIGURE 3-9 50IN SINGLE FORK POSITIONING CARRIAGE ASSEMBLY (Prior to SN 0160037900, Excluding 0160037855) 76
FIGURE 3-10 50IN DUAL FORK POSITIONING CARRIAGE ASSEMBLY (Prior to SN 0160037900, Excluding 0160037855) 78
FIGURE 3-11 50IN DUAL FORK POSITIONING CARRIAGE ASSEMBLY (SN 0160037900 to Present, Including 0160037855) 80
FIGURE 3-12 TRUSS BOOM ASSEMBLY (Prior to SN 0160037900, Excluding 0160037855) 82
FIGURE 3-13 TRUSS BOOM ASSEMBLY (SN 0160037900 to Present, Including 0160037855) 84
FIGURE 3-14 12FT TRUSS BOOM WITH WINCH (Prior to SN 0160037900, Excluding 0160037855) 86
FIGURE 3-15 12FT TRUSS BOOM WITH WINCH (SN 0160037900 to Present, Including 0160037855) 88
FIGURE 3-16 CARRIAGE ASSEMBLY WITH 8FT VERTICAL MAST (NON-TILT) (Prior to SN 0160037900, Excluding 0160037855) 90
FIGURE 3-17 CARRIAGE ASSEMBLY WITH 8FT VERTICAL MAST (TILT) (Prior to SN 0160037900, Excluding 0160037855) 92
FIGURE 3-18 8FT VERTICAL MAST ASSEMBLY (Prior to SN 0160037900, Excluding 0160037855) 96
FIGURE 3-19 FORKS 98
FIGURE 3-20 FORK MOUNTED PLATFORM 100
FIGURE 3-21 SWEEPER ASSEMBLY (SN 0160037900 to Present, Including 0160037855) 104
FIGURE 3-22 GRAPPLE BUCKET (SN 0160037900 to Present, Including 0160037855) 106
FIGURE 3-23 FORK MOUNTED LIFTING HOOK (SN 0160037900 to Present, Including 0160037855) 108
FIGURE 3-24 8FT MAST ASSEMBLY (SN 0160037900 to Present, Including 0160037855) 110
FIGURE 3-25 BUCKETS (SN 0160037900 to Present, Including 0160037855) 112
FIGURE 3-26 FORK PIN LOCK INSTALLATION (SN 0160037900 to Present, Including 0160037855) 114
FIGURE 3-27 SHEET MATERIAL HANDLER 116
FIGURE 3-28 50IN SIDE SHIFT CARRIAGE (SN 0160037900 to Present, Including 0160037855) 118
SECTION 4 – ENGINE AND ATTACHING PARTS 121
FIGURE 4-1 ENGINE INSTALLATION (SN 0160009654 through 0160018506, Including 0160008714) 122
FIGURE 4-2 ENGINE INSTALLATION (SN 0160018507 through 0160040407, Excluding 0160037824 and 0160038521) 126
FIGURE 4-3 ENGINE INSTALLATION (SN 0160040413 to Present, Including 0160037824 and 0160038521) 130
FIGURE 4-4 ENGINE (SN 0160009654 through 0160018506, Including 0160008714) 136
FIGURE 4-5 ENGINE (SN 0160018507 through 0160040407, Excluding 0160037824 and 0160038521)
FIGURE 4-6 ENGINE (SN 0160040413 to Present, Including 0160037824 and 0160038521) 142
FIGURE 4-7 RADIATOR ASSEMBLY (SN 0160018507 through 0160040407, Excluding 0160037824 and 0160038521) 144
FIGURE 4-8 RADIATOR ASSEMBLY (SN 0160040413 to Present, Including 0160037824 and 0160038521) 148
FIGURE 4-9 AIR CLEANER INSTALLATION (SN 0160018507 through 0160040407, Excluding 0160037824 and 0160038521) 152
FIGURE 4-10 AIR CLEANER INSTALLATION (SN 0160040413 to Present, Including 0160037824 and 0160038521) 154
FIGURE 4-11 EXHAUST INSTALLATION (SN 0160009654 through 0160040407, Excluding 0160037824 and 0160038521) 156
FIGURE 4-12 EXHAUST INSTALLATION (SN 0160040413 to Present, Including 0160037824 and 0160038521) 158
SECTION 5 – DRIVE TRAIN 161
FIGURE 5-1 DRIVE TRAIN COMPONENTS 162
FIGURE 5-2 FRONT AXLE ASSEMBLY 164
FIGURE 5-3 FRONT AXLE – INPUT 166
FIGURE 5-4 FRONT AXLE – LIMITED SLIP DIFFERENTIAL 170
FIGURE 5-5 FRONT AXLE – AXLE CASING 172
FIGURE 5-6 FRONT AXLE – M-DISC BRAKE 174
FIGURE 5-7 FRONT AXLE – BRAKE 178
FIGURE 5-8 FRONT AXLE – JOINT HOUSING 180
FIGURE 5-9 FRONT AXLE – PLANETARY DRIVE 182
FIGURE 5-10 REAR AXLE ASSEMBLY 184
FIGURE 5-11 REAR AXLE – INPUT 186
FIGURE 5-12 REAR AXLE – DIFFERENTIAL 190
FIGURE 5-13 REAR AXLE – AXLE CASING 192
FIGURE 5-14 REAR AXLE – M-DISC BRAKE 194
FIGURE 5-15 REAR AXLE – BRAKE 198
FIGURE 5-16 REAR AXLE – JOINT HOUSING 200
FIGURE 5-17 REAR AXLE – PLANETARY DRIVE 204
FIGURE 5-18 ZF TRANSMISSION – CONVERTER AND INPUT 206
FIGURE 5-19 ZF TRANSMISSION – GEARBOX HOUSING 208
FIGURE 5-20 ZF TRANSMISSION – REVERSING GEAR KV 210
FIGURE 5-21 ZF TRANSMISSION – REVERSING GEAR KR 212
FIGURE 5-22 ZF TRANSMISSION – COUPLING GROUP K1 214
FIGURE 5-23 ZF TRANSMISSION – COUPLING GROUP K2 216
FIGURE 5-24 ZF TRANSMISSION – COUPLING GROUP K3 218
FIGURE 5-25 ZF TRANSMISSION – COUPLING GROUP K4 220
FIGURE 5-26 ZF TRANSMISSION – OUTPUT 222
FIGURE 5-27 ZF TRANSMISSION – CONTROL UNIT 224
FIGURE 5-28 ZF TRANSMISSION – GEARSHIFT SYSTEM 226
FIGURE 5-29 ZF TRANSMISSION – GEARSHIFT SYSTEM 228
FIGURE 5-30 ZF TRANSMISSION – OIL PUMP, FILTER AND DIPSTICK 230
FIGURE 5-31 DRIVE SHAFT 232
FIGURE 5-32 TIRES AND RIMS 234
SECTION 6 – CAB 237
FIGURE 6-1 OPERATORS COMPARTMENT ASSEMBLY 238
FIGURE 6-2 CAB ENCLOSURE KIT 242
FIGURE 6-3 WINDSHIELD WIPER ASSEMBLY 244
FIGURE 6-4 WINDSHIELD ASSEMBLY 246
FIGURE 6-5 WINDOW ASSEMBLY 248
FIGURE 6-6 DOOR ASSEMBLY 250
FIGURE 6-7 INSULATION INSTALLATION 252
FIGURE 6-8 INSTRUMENT PANEL ASSEMBLY 254
FIGURE 6-9 OPERATOR’S SEAT (SN 0160009654 through 0160013146, Including 0160008714) 256
FIGURE 6-10 OPERATOR’S SEAT (SN 0160013147 to Present) 258
FIGURE 6-11 HEATER AND AIR CONDITIONING SYSTEM (Prior to SN 0160040413, Excluding 0160037824 and 0160038521) 260
FIGURE 6-12 HEATER AND AIR CONDITIONING SYSTEM (SN 0160040413 to Present, Including 0160037824 and 0160038521) 264
SECTION 7 – CONTROLS 267
FIGURE 7-1 JOYSTICK (Prior to SN 0160048698) 268
FIGURE 7-2 JOYSTICK (SN 0160048698 to Present) 270
FIGURE 7-3 FRAME LEVEL AND OUTRIGGER JOYSTICK ASSEMBLY (Prior to SN 0160048698) 272
FIGURE 7-4 FRAME LEVEL AND OUTRIGGER JOYSTICK ASSEMBLY (SN 0160048698 to Present)
FIGURE 7-5 STEER COLUMN ASSEMBLY (Prior to SN 0160049803) 276
FIGURE 7-6 STEER COLUMN ASSEMBLY (SN 0160049803 to Present) 278
FIGURE 7-7 BRAKE VALVE ASSEMBLY 280
FIGURE 7-8 ACCELERATOR PEDAL 282
SECTION 8 – HYDRAULIC CIRCUITS 285
FIGURE 8-1 PUMP, SUCTION – RETURN 286
FIGURE 8-2 BOOM HYDRAULIC CYLINDER 288
FIGURE 8-3 HOIST AND REAR CARRIAGE TILT 292
FIGURE 8-4 SECOND AUXILIARY CIRCUIT 294
FIGURE 8-5 TRANSFER CYLINDER 298
FIGURE 8-6 OUTRIGGER CYLINDER AND JOYSTICK 300
FIGURE 8-7 FRAME LEVEL AND REAR AXLE STABILIZER 302
FIGURE 8-8 STEERING CYLINDER 306
FIGURE 8-9 JOYSTICK CONTROL CIRCUIT 308
FIGURE 8-10 SERVICE BRAKE CIRCUIT 312
FIGURE 8-11 PARK BRAKE CIRCUIT 314
FIGURE 8-12 TEST PORT HYDRAULIC ASSEMBLY 316
SECTION 9 – HYDRAULIC COMPONENTS 319
FIGURE 9-1 FRONT CARRIAGE TILT CYLINDER (Prior to SN 0160037900, Excluding 0160037855) 320
FIGURE 9-2 FRONT CARRIAGE TILT CYLINDER (SN 0160037900 to Present, Including 0160037855) 322
FIGURE 9-3 REAR CARRIAGE TILT CYLINDER 324
FIGURE 9-4 FRAME TILT CYLINDER 326
FIGURE 9-5 HOIST CYLINDER 328
FIGURE 9-6 BOOM EXTENSION CYLINDER 330
FIGURE 9-7 TRANSFER CYLINDER 332
FIGURE 9-8 OUTRIGGER CYLINDER (Prior to SN 0160058596) 334
FIGURE 9-9 OUTRIGGER CYLINDER (SN 0160058596 to Present) 336
FIGURE 9-10 REAR STABILIZER CYLINDER (Including 1001140447) 338
FIGURE 9-11 STEERING CYLINDER 340
FIGURE 9-12 HYDRAULIC CONTROL VALVE ASSEMBLY 342
FIGURE 9-13 TANDEM PUMP 346
FIGURE 9-14 ACCUMULATOR CHARGE VALVE 348
FIGURE 9-15 6-PORT CIRCUIT SELECTOR VALVE ASSEMBLY 350
FIGURE 9-16 HYDRAULIC RETURN LINE FILTER ASSEMBLY 352
FIGURE 9-17 PRESSURE FILTER ASSEMBLY 354
FIGURE 9-18 INLINE FILTER ASSEMBLY 356
FIGURE 9-19 ACCUMULATOR ASSEMBLY 358
FIGURE 9-20 REAR AXLE STABILIZER CONTROL VALVE, (UNDER CAB) 360
FIGURE 9-21 REAR AXLE STABILIZER VALVE, (ON REAR AXLE) 362
FIGURE 9-22 FUEL/HYDRAULIC TANK ASSY 364
FIGURE 9-23 BOOM EXTEND LOCKOUT VALVE ASSEMBLY 366
FIGURE 9-24 PARK BRAKE VALVE ASSEMBLY 368
FIGURE 9-25 VALVE PLATE COMPONENTS ASSEMBLY 370
FIGURE 9-26 SIDE TILT CARRIAGE CYLINDER 372
FIGURE 9-27 72IN 90, SWING CARRIAGE CYLINDER 374
FIGURE 9-28 GRAPPLE BUCKET CYLINDER 376
FIGURE 9-29 50IN SIDE SHIFT CARRIAGE CYLINDER (SN 0160037900 to Present, Including 0160037855) 378
FIGURE 9-30 SHUTTLE VALVE (SN 0160048698 to Present) 380
SECTION 10 – ELECTRICAL 383
FIGURE 10-1 FRAME HARNESS INSTALLATION (SN 0160009654 through 0160017144, Including 0160008714) 384
FIGURE 10-2 FRAME HARNESS INSTALLATION (SN 0160017145 to Present) 386
FIGURE 10-3 OUTRIGGER/BOOM EXTEND LOCKOUT HARNESS INSTALLATION 388
FIGURE 10-4 ENGINE ELECTRICAL GROUP (Prior to SN 0160040407, Excluding 0160037824 and 0160038521) 390
FIGURE 10-5 ENGINE ELECTRICAL GROUP (SN 0160040413 to Present, Including 0160037824 and 0160038521) 392
FIGURE 10-6 TRANSMISSION HARNESS INSTALLATION 396
FIGURE 10-7 OPERATOR’S COMPARTMENT ELECTRICAL GROUP INSTALLATION 398
FIGURE 10-8 FUSES, RELAYS AND BUZZER MOUNTING PANEL 400
FIGURE 10-9 ENGINE ECU HARNESS (SN 0160040413 to Present, Including 0160037824 and 0160038521) 402
FIGURE 10-10 ECM POWER HARNESS (SN 0160040413 to Present, Including 0160037824 and 0160038521) 404
FIGURE 10-11 ELECTRICAL OPTIONS HARNESS (SN 0160032761 to Present
SECTION 11 – DECALS 409
FIGURE 11-1 DECAL GROUP 410
SECTION 12 – OPTIONS 415
FIGURE 12-1 WORKLIGHT OPTION INSTALLATION (SN 0160009654 through 0160019928, Including 0160008714) 416
FIGURE 12-2 WORKLIGHT OPTION INSTALLATION (SN 0160019929 through 0160030844) 418
FIGURE 12-3 WORKLIGHT OPTION INSTALLATION (SN 0160030845 to Present) 420
FIGURE 12-4 ROADWAY LIGHT OPTION INSTALLATION (SN 0160009654 through 0160032760, Including 0160008714) 422
FIGURE 12-5 ROADWAY LIGHT OPTION INSTALLATION (SN 0160032761 through 0160051139, Excluding 0160050734 and 0160050735) 426
FIGURE 12-6 ROADWAY LIGHT OPTION INSTALLATION (SN 0160051140 to Present, Including 0160050734 and 0160050735) 430
FIGURE 12-7 STROBE/ROTATING BEACON LIGHT OPTION INSTALLATION (SN 0160009654 through 0160032760, Including 0160008714) 434
FIGURE 12-8 STROBE/ROTATING BEACON LIGHT OPTION INSTALLATION (SN 0160032761 to Present) 436
FIGURE 12-9 TILTING CARRIAGE CYLINDER 438
FIGURE 12-10 TOWER CYLINDER 440
FIGURE 12-11 FORK POSITIONING CYLINDER 442
FIGURE 12-12 LOCKABLE ENGINE SIDE PANELS INSTALLATION 444
FIGURE 12-13 BATTERY COLD START INSTALLATION 446
FIGURE 12-14 FRAME LEVEL AND OUTRIGGER JOYSTICK REPAIR KIT (Prior to SN 0160048698) 448
SECTION 13 – RECOMMENDED SPARE PARTS 451
FIGURE 13-1 RECOMMENDED SPARE PARTS 452
PART NUMBER INDEX
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