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Lull 1044C-54, Series II Telehandler Service Manual

382 pages · Publication 31200079

$69.95
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Models
1044C-54, Series II
Manual type
Service Manual
Pages
382
Publication
31200079
Condition
Brand new
Lull 1044C-54, Series II Telehandler Service Manual, publication 31200079

What's inside

From the manual's own table of contents: 167 sections, 424 entries. See sample pages (PDF, 341 KB)

Section 1 — Safety General
Caution, Warning, and Danger
Safety Standard
Maintenance Safety
General
Mounting and Dismounting
Before Servicing the Machine
Fuel Hazards
Engine Coolant Hazards
Hydraulic System Hazards
Electrical System Hazards
Tire and Wheels Hazards
Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS)
Decals and Placards
Cleaning Decals
Attaching Decals
Decal Locations
Section 2 — Identification and Specifications Serial Number Locations
Machine Serial Number
Engine Serial Number, John Deere
Axle Serial Number
Attachment Serial Number Plate
Identification
Specifications
Show all 167 sections
Engine Specifications
John Deere 4045T
Section 3 — General Maintenance General Instructions
Service Preparation Procedures
Service And Repair Procedures
Replacement Parts
Lubrication1 topic
  • Table of Contents Fluid and Lubricant Specifications
General Specifications
Engine Oil Specifications
Transmission Oil Specifications
Fuel Requirements
Grease
Care and Cleaning
Cleaning Exterior Surfaces
Cleaning the Cab
Storage
Preparing the Machine for Long-Term Storage
Preparing the Machine After Long-Term Storage
Torque Specifications
General Torques for Standard Bolts, Capscrews, and Nuts
Hydraulic Fitting Torques
Jump Starting Procedures
Conversion Charts
Section 4 — Reference Diagrams Mid-Inlet Hydraulic Schematic
Control Valve
Electrical Schematic
Section 5 — Supply, Pressure, and Return Hydraulics General
Major System Components
General Description
Hydraulic Systems
General Hydraulic Maintenance Practices
Safe Maintenance Practices
Cleanliness
Checking Hydraulic Lines
Hydraulic Reservoir
Description
Filling Hydraulic Reservoir
Reservoir Drain and Refill
Removal
Installation1 topic
  • Table of Contents Sight Gauge
Suction Strainer
Removal and Cleaning
Hydraulic Return Filter
Checking Filter Condition
Replacing Return Filter Element
Reservoir Breather
Removal and Installation
Hydraulic Pressure Filter
Replacing Pressure Filter Element
Hydraulic Pump
Troubleshooting Pump Problems
Checking Pump Flow Rate
Mid-Inlet Control Valve
Rear Axle Stabilizer Control Valve
Removal, Rear Axle Stabilizer Control Valve
Boom Extend Lockout Valve
Hydraulic Diagnostic Ports
Roll-Back Hose Tray
Section 6 — Boom and Transfer Boom and Transfer Hydraulics
Joystick Controls
Disassembly
Hydraulic Cylinders
Checking Cylinder Condition
Boom Hoist Cylinder
Overhaul
Front Carriage Tilt Cylinder
Rear Carriage Tilt Cylinder
Selector Valve
Troubleshooting
Boom Slide Pads — General
Slide Pad Inspection
Slide Area Surface Finish
Replacing and Shimming Boom Slide Pads — General
Quick Attach
Disconnecting an Attachment
Connecting an Attachment1 topic
  • Table of Contents Boom Angle Inclinometer
Replacement
4-Section Boom
Shimming Procedures
Inspection Procedures
Boom Removal
Boom Disassembly
Assembly
Boom Extend and Retract Chains
Chain Lubrication
Boom Chain Tension Check
Boom Hose Replacement
Extension Cylinder
Boom Extension Proximity Switch
Adjustments
Transfer Carriage
Rollers, Bushings, and Shims
Section 7 — Frame Tilt and Oscillation Frame Tilt System
Circuit Description
Frame Tilt Control Valve
Frame Tilt Cylinder
Counterbalance Valve Cartridge
Frame Level Indicator
Adjustment1 topic
  • Table of Contents Rear Oscillation Lock System
General Description, Models with Control Manifold Hydraulics
Theory of Operation and Circuit Logic
Testing Rear Oscillation Lock Circuit
Rear Oscillation Lock Cylinder
Oscillation Control Block
Boom Elevation Proximity Switch
Section 8 — Transmission Transmission Assembly Component Terminology
Transmission Description
Transmission Operation
Transmission Specifications
Transmission General Specification
Transmission Performance Specification
Transmission Lubrication
Transmission Maintenance
Transmission Removal
Transmission Inspection and Internal Repair
Transmission Installation
After Transmission Service or Replacement
Transmission Shift Logic
Transmission Troubleshooting
Section 9 — Axles and Brakes Axle and Drive Shaft Component Terminology
General Information
Axle Assembly
Axle Inspection, Internal Service and Repair1 topic
  • Table of Contents Axle Installation
Axle Service and Troubleshooting
Drive Shafts
Drive Shaft Maintenance
DriveShaft Removal
Transmission-to-Axle Drive Shaft
Drive Shaft Disassembly
Drive Shaft Assembly
Service Brakes
Service Brake Pressure Switch Replacement
Accumulator
Precautions
Pre-Charging Accumulator
Checking Pre-charge
Towing a Disabled Machine
Manually Releasing the Park Brake
Manually Resetting the Park Brake
Section 10 — Outriggers Outriggers
Outrigger Cylinders
Differential Pressure Switch
Outrigger Control Valves252 topics
  • Fig. 1-1: Decals and Placards
  • Fig. 1-2: Instrument Panel Decals
  • Fig. 1-3: Control Decals
  • Fig. 1-4: Disconnect Battery Decal and Slow Moving Vehicle Sign
  • Fig. 1-5: Steer Selector Plate
  • Fig. 1-6: Hydraulic Reservoir/Fuel Tank Decals
  • Fig. 1-7: Fork Carriage Decals
  • Fig. 2-1: Machine Serial Number Plate
  • Fig. 2-2: Engine Serial Number — John Deere
  • Fig. 2-3: Axle Serial Number
  • Fig. 2-4: Attachment Serial Number Plate
  • Fig. 2-5: Top View
  • Fig. 2-6: Left Side View
  • Fig. 3-1: SAE Grade Identification
  • Fig. 3-4: Metric Class Identification
  • Fig. 5-1: Major Hydraulic Components
  • Fig. 5-2: Mid-Inlet Hydraulic Components
  • Fig. 5-3: Hydraulic Reservoir Location
  • Fig. 5-4: Hydraulic Reservoir
  • Fig. 5-5: Recommended Reservoir Filling Method
  • Fig. 5-6: Alternate Reservoir Filling Method
  • Fig. 5-7: Hydraulic Reservoir Drain and Refill
  • Fig. 5-8: Hydraulic Reservoir/Fuel Tank Installation
  • Fig. 5-9: Hydraulic Reservoir Sight Gauge
  • Fig. 5-10: Reservoir Sight Gauge Installation
  • Fig. 5-11: Suction Strainer Installation
  • Fig. 5-12: Hydraulic Return Filter
  • Fig. 5-13: Return Filter Pressure Gauge
  • Fig. 5-14: Filter Housing Cover
  • Fig. 5-15: Filter Element Assembly
  • Fig. 5-16: Return Filter Assembly
  • Fig. 5-17: Reservoir Breather
  • Fig. 5-18: Hydraulic Pressure Filter – Control Manifold Hydraulics
  • Fig. 5-19: Hydraulic Pressure Filter Element
  • Fig. 5-20: Hydraulic Pressure Filter Assembly
  • Fig. 5-21: Hydraulic Pump Location
  • Fig. 5-22: Hydraulic Pump Hoses – Mid-Inlet Hydraulics
  • Fig. 5-23: Hydraulic Pump Installation – Mid-Inlet Hydraulics
  • Fig. 5-24: Checking Hydraulic Pump Flow Rate
  • Fig. 5-25: Mid-Inlet Control Valve Location
  • Fig. 5-26: Mid-Inlet Control Valve Components
  • Fig. 5-27: Mid-Inlet Control Valve Configurations
  • Fig. 5-28: Mid-Inlet Control Valve Installation
  • Fig. 5-29: Rear Axle Stabilizer Control Valve Location
  • Fig. 5-30: Rear Axle Stabilizer Control Valve Ports
  • Fig. 5-31: Rear Axle Stabilizer Control Valve
  • Fig. 5-32: Boom Extend Lockout Valve
  • Fig. 5-33: Hydraulic Diagnostic Ports - Models with Mid-Inlet Hydraulics
  • Fig. 5-34: Roll-Back Hose Frame Location - Control Manifold Hydraulics
  • Fig. 5-35: Roll-Back Tray Installation - Mid-Inlet Hydraulics
  • Fig. 6-1: Major Boom and Transfer Hydraulic Components
  • Fig. 6-2: Joystick
  • Fig. 6-3: Joystick Installation
  • Fig. 6-4: Joystick Components
  • Fig. 6-5: Pilot Pressure Diagnostic Port
  • Fig. 6-6: Pilot Pressure Plug
  • Fig. 6-7: Boom Hoist Cylinders
  • Fig. 6-8: Boom Hoist Cylinder Installation
  • Fig. 6-9: Boom Hoist Cylinder Assembly
  • Fig. 6-10: Front Carriage Tilt Cylinder
  • Fig. 6-11: Front Carriage Tilt Cylinder Installation
  • Fig. 6-12: Front Carriage Tilt Cylinder Assembly
  • Fig. 6-13: Rear Carriage Tilt Cylinder
  • Fig. 6-14: Rear Carriage Tilt Cylinder Installation
  • Fig. 6-15: Rear Carriage Tilt Cylinder Assembly
  • Fig. 6-16: Selector Valve
  • Fig. 6-17: Selector Valve Installation
  • Fig. 6-18: Selector Valve Assembly
  • Fig. 6-19: Load Bearing Pad
  • Fig. 6-20: Pad Worn, But Still OK
  • Fig. 6-21: Pad Must Be Replaced
  • Fig. 6-22: Bolted Boom Slide Pad
  • Fig. 6-23: Slide Pad Without Chamfers – 3 and 4-Section Boom
  • Fig. 6-24: Damaged Slide Surface
  • Fig. 6-25: Slide Surface Repair
  • Fig. 6-26: Slide Pad Installation (2-Section Shown)
  • Fig. 6-27: Positioning Retaining Block
  • Fig. 6-28: Determining Capscrew Length
  • Fig. 6-29: Correctly Installed Capscrew
  • Fig. 6-30: Quick Attach Rear View
  • Fig. 6-31: Release Handle
  • Fig. 6-32: Lock Plate
  • Fig. 6-33: Rotating Quick Attach Downwards
  • Fig. 6-34: Lowering Boom
  • Fig. 6-35: Retracting Boom
  • Fig. 6-36: Extending Boom
  • Fig. 6-37: Raising Boom
  • Fig. 6-38: Rotating Quick Attach Forward
  • Fig. 6-39: Lock Plate Engaged
  • Fig. 6-40: Lower Pivot of Carriage Tilt Cylinder
  • Fig. 6-41: Quick Attach Pivot
  • Fig. 6-42: Boom Angle Inclinometer
  • Fig. 6-43: Boom Angle Inclinometer Installation
  • Fig. 6-44: 4-Section Boom
  • Fig. 6-45: Boom Slide Pad Locations – 4-Section Boom
  • Fig. 6-46: Boom Section Gaps – Front of 4-Section Boom
  • Fig. 6-47: Lower Shim Installation – Front of 4-Section Boom
  • Fig. 6-48: Upper Shim Installation – Front of 4-Section Boom
  • Fig. 6-49: Boom Section Gaps – Rear of 4-Section Boom
  • Fig. 6-50: Lower Shim Installation - Rear of 4-Section Boom
  • Fig. 6-51: Upper Shim Installation – Rear of 4-Section Boom
  • Fig. 6-52: Clearances Between Boom Sections – Rear of 4-Section Boom
  • Fig. 6-53: Gaps Between Pads and Boom – Rear of 4-Section Boom
  • Fig. 6-54: Clearances Between Boom Sections – Front of 4-Section Boom
  • Fig. 6-55: Gaps Between Pads and Boom – Front of 4-Section Boom
  • Fig. 6-56: Inner Boom Cross-Section at Window
  • Fig. 6-57: Middle (Forward) Boom Cross-Section at Window
  • Fig. 6-58: Middle (Forward) Boom Cross-Section at Window
  • Fig. 6-59: 4-Section Boom Cover Installation
  • Fig. 6-60: Hose Connections, 4-Section Boom
  • Fig. 6-61: Cylinder Pivot Pins
  • Fig. 6-62: Upper Rear Slide Pad Removal – Middle (Rear) Boom Section
  • Fig. 6-63: Upper Rear Slide Pad Removal – Middle (Forward) Boom Section
  • Fig. 6-64: Upper Rear Slide Pad Removal – Inner Boom Section
  • Fig. 6-65: Locations for Chain Attachment – Inner Boom Section
  • Fig. 6-66: 4-Section Boom Pivot Pins
  • Fig. 6-67: Slide Pad Removal – Outer Boom Section
  • Fig. 6-68: Lower Front Slide Pad Removal – Middle (Rear) Boom Section
  • Fig. 6-69: Disconnecting Hoses Between Sections
  • Fig. 6-70: Extension Cylinder Removal – 4-Section Boom
  • Fig. 6-71: Upper Front Slide Pad Removal – Middle (Rear) Boom Section
  • Fig. 6-72: Upper Front Slide Pad Removal – Middle (Forward) Boom Section
  • Fig. 6-73: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections
  • Fig. 6-74: Upper Chain Roller Assembly – Middle (Forward) Boom Section
  • Fig. 6-75: Disconnecting Chains at Rear of Inner Boom
  • Fig. 6-76: Disconnecting Chains at Rear of Middle (Forward) Boom
  • Fig. 6-77: Slide Pad Removal – Inner Boom Section
  • Fig. 6-78: Slide Pad Removal – Middle (Forward) Boom Section
  • Fig. 6-79: Grease Hose Assembly
  • Fig. 6-80: Rear Chain Roller Removal - Middle (Forward) Boom Section
  • Fig. 6-81: Hose and Tube Removal – Inner Boom Section
  • Fig. 6-82: Upper Chain Assembly
  • Fig. 6-83: Upper Chain Roller Assembly – Middle (Rear) Boom Section
  • Fig. 6-84: Removing Lower Chains
  • Fig. 6-85: Slide Pads – Middle (Rear) Boom Section
  • Fig. 6-86: Chain and Hose Guide Assembly
  • Fig. 6-87: Tubes and Hoses – Middle (Rear) and Outer Boom Sections
  • Fig. 6-88: Side Slide Pads – Outer Boom Section
  • Fig. 6-89: Outer Boom Tubes and Hoses
  • Fig. 6-90: Outer Boom Tube and Hose Assembly
  • Fig. 6-91: Extension Cylinder Installation
  • Fig. 6-92: Lower Chains on Outer Boom Section
  • Fig. 6-93: Lower Rear Slide Pad Installation - Middle (Rear) Boom Section
  • Fig. 6-94: Tubes and Hoses – Middle (Rear) Boom Sections
  • Fig. 6-95: Chain and Hose Guide Assembly
  • Fig. 6-96: Installation of Lower Chain – Middle (Rear) Boom Section
  • Fig. 6-97: Upper Chain Roller Assembly – Middle (Rear) Boom Section
  • Fig. 6-98: Chain Roller Assemblies - Middle (Forward) Boom Section
  • Fig. 6-99: Slide Pad Installation – Middle (Forward) Boom Section
  • Fig. 6-100: Hydraulic Hose and Tube Installation – Inner Boom Section
  • Fig. 6-101: Slide Pad Installation – Inner Boom Section
  • Fig. 6-102: Grease Hose Installation
  • Fig. 6-103: Upper Chain Installation – Inner Boom Section
  • Fig. 6-104: Upper Slide Pad Installation – Front of Middle (Forward) Boom Section
  • Fig. 6-105: Upper Chain and Hose Reel Assembly – Middle (Forward) Boom
  • Fig. 6-106: Rear Slide Pad Installation
  • Fig. 6-107: Front Slide Pad Installation – Outer and Middle (Rear) Boom Sections
  • Fig. 6-108: Lower Chain Installation – Inner Boom Section
  • Fig. 6-109: Lower Chain Installation – Middle (Forward) Boom Section
  • Fig. 6-110: Upper Chains – Middle (Rear) to Outer Boom Sections
  • Fig. 6-111: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections
  • Fig. 6-112: Securing Lower Chains – Middle (Rear) and Outer Boom Sections
  • Fig. 6-113: Securing Boom Extension Cylinder
  • Fig. 6-114: Connecting Hoses Between Sections
  • Fig. 6-115: Boom Tension Check
  • Fig. 6-116: 4-Section Boom Extension Cylinder
  • Fig. 6-117: 4-Section Boom Extension Cylinder Installation
  • Fig. 6-118: 4-Section Boom Extension Cylinder Assembly
  • Fig. 6-119: Boom Extension Proximity Switch
  • Fig. 6-120: Boom Extension Proximity Switch Operation
  • Fig. 6-121: Boom Extension Proximity Switch Assembly
  • Fig. 6-122: Boom Extension Proximity Switch Adjustment
  • Fig. 6-123: Transfer Carriage
  • Fig. 6-124: Disconnecting Transfer Cylinder from Transfer Carriage
  • Fig. 6-125: Boom Elevation Proximity Switch Wiring
  • Fig. 6-126: Boom Cover Installation
  • Fig. 6-127: Boom Extension Proximity Switch Wiring
  • Fig. 6-128: Disconnecting Hydraulic Hoses from Transfer Carriage
  • Fig. 6-129: Transfer Carriage with Boom Installation
  • Fig. 6-130: Transfer Carriage Installation
  • Fig. 6-131: Transfer Carriage – Front Rollers, Bushings, and Shims
  • Fig. 6-132: Shims for Front Transfer Rollers
  • Fig. 6-133: Scraper Plate
  • Fig. 6-134: Transfer Carriage – Rear Rollers, Bushings, and Shims
  • Fig. 6-135: Spacer Washers for Rear Transfer Rollers
  • Fig. 6-136: Rear Slide Block Installation
  • Fig. 7-1: Frame Tilt System Components
  • Fig. 7-2: Frame Tilt Control Valve
  • Fig. 7-3: Frame Tilt Control Valve Installation
  • Fig. 7-4: Frame Tilt Control Valve (Exploded View)
  • Fig. 7-5: Frame Tilt Cylinder
  • Fig. 7-6: Frame Tilt Cylinder Installation
  • Fig. 7-7: Frame Tilt Cylinder (Exploded View)
  • Fig. 7-8: Counterbalance Valve Cartridges, Frame Tilt Cylinder
  • Fig. 7-9: Frame Level Indicator
  • Fig. 7-10: Leveling the Frame
  • Fig. 7-11: Circuit Operation Below 40°
  • Fig. 7-12: Circuit Operation Above 40°
  • Fig. 7-13: Circuit Operation Above 20° Below 40°
  • Fig. 7-14: Circuit Operation Above 20° Below 40° with Service Brake Applied
  • Fig. 7-15: Circuit Operation Below 20° With the Service Brake Applied
  • Fig. 7-16: Rear Oscillation Lock Cylinder
  • Fig. 7-17: Rear Oscillation Lock Cylinder Installation
  • Fig. 7-18: Rear Oscillation Lock Cylinder (Exploded View)
  • Fig. 7-19: Oscillation Control Block
  • Fig. 7-20: Oscillation Control Block Installation
  • Fig. 7-21: Oscillation Control Block (Exploded View)
  • Fig. 7-22: Boom Elevation Proximity Switch
  • Fig. 7-23: Boom Elevation Proximity Switch Operation
  • Fig. 7-24: Boom Elevation Proximity Switch Assembly
  • Fig. 7-25: Boom Elevation Proximity Switch Adjustment
  • Fig. 8-1: ZF Transmission
  • Fig. 8-2: Transmission Serial Number Plate Location
  • Fig. 8-3: The Lubrication and Maintenance Flip Chart
  • Fig. 8-4: Transmission Oil Cooler Hose Connections
  • Fig. 8-5: Disconnect the Battery Negative (-) Cable
  • Fig. 8-6: Drain Transmission Oil
  • Fig. 8-7: Transmission Oil Cooler Hose Connections
  • Fig. 8-8: Remove Transmission from Frame
  • Fig. 8-9: Transmission External Components
  • Fig. 8-10: Install the Transmission
  • Fig. 8-11: Transmission Oil Cooler Hose Connections
  • Fig. 8-12: Transmission Shift Logic Schematic
  • Fig. 9-1: Axle and Drive Shaft
  • Fig. 9-2: Service Brake Pedal Pressure Switch
  • Fig. 9-3: Accumulator
  • Fig. 9-4: Accumulator Charging
  • Fig. 9-5: Park Brake Hoses
  • Fig. 10-1: Outriggers
  • Fig. 10-2: Outrigger Installation
  • Fig. 10-3: Outrigger Cylinders
  • Fig. 10-4: Outrigger Cylinder Installation
  • Fig. 10-5: Outrigger Cylinder Assembly
  • Fig. 10-6: Boom Extension Proximity Switch
  • Fig. 10-7: Boom Extension Proximity Switch Operation
  • Fig. 10-8: Boom Extension Proximity Switch Assembly
  • Fig. 10-9: Boom Extension Proximity Switch Adjustment
  • Fig. 10-10: Outrigger Controls
  • Fig. 10-11: Outrigger Control Valve Installation
  • Table 3-1: General Fluid and Lubricant Specifications
  • Table 3-2: John Deere Engine Oil Specifications
  • Table 3-3: ZF Transmission Oil Specifications
  • Table 3-4: Torque for JIC and SAE Female Swivel Nuts
  • Table 3-5: Torque for Non-adjustable O-ring Fittings
  • Table 3-6: Torque for Adjustable O-ring Fittings
  • Table 3-7: Torque for O-ring Plugs
  • Table 3-8: Pipe Thread Fittings (Steel)
  • Table 3-9: Inch Fraction, Decimal, and Metric Conversion Chart
  • Table 3-10: Miscellaneous Conversions
  • Table 5-1: Rear Axle Stabilizer Control Valve Markings
  • Table 7-1: Rear Oscillation Lock Circuit Test Matrix
  • Table of Contents General

Inside this manual

Real pages from this service manual (382 pages). Open the sample pages (PDF, 340 KB)

Sample pages from the Lull 1044C-54, Series II Telehandler Service Manual: Specifications, Diagram, Repair procedure
  • Specifications, page 48: General Maintenance
  • Diagram, page 68: Reference Diagrams
  • Repair procedure, page 318: Frame Tilt and Oscillation

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 382 pages

Quantity one is the manual described above.

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Other editions and similar models

Lull 1044C-54 Series IIOperator's Manual · 31200070 · $69.73Lull 1044C-54 Series IIOperator's Manual · 31200608 · $69.71Lull 1044C-54 Series IIParts Manual · 31200069 · $69.85

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