Lull 944E-42 Operation Manual User Manual
Lull Special machinery
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Table of contents
Document Outline
- 3120039_B_944E_Lull_OperMnl
- Table of Contents
- Introduction
- Safety Practices
- Hazard Classification System
- Accident Prevention Tags
- New or Additional Operators
- Instructional Symbols
- Instructional Symbols (cont’d)
- Hazard Symbols
- Avoidance Symbols
- Avoidance Symbols (cont’d)
- Avoidance Symbols (cont’d)
- Personal Considerations
- Operational Considerations
- 1. Preparation and Prevention
- 2. Clearances
- 3. Visual Obstruction
- 4. Underground Hazards
- 5. Electrocution Hazards
- 6. Elevating Personnel
- 7. Transfer Carriage Operation
- 8. Tip Over Hazard
- 9. Emergency Exit Rear Window
- 10. Tire Pressure
- 11. Do Not Jump
- 12. Slopes
- 13. Falling Load Hazard
- 14. Ventilation
- Equipment Considerations
- Operation
- Pre-Operation Inspection
- 1. Check seat belt for damage. Check for frayed or cut seat belt webbing, damaged buckles or loos...
- 2. Check all four tires and rims for damage. Check for proper tire pressure, add air if required....
- 3. Check and add engine oil if required. This procedure is explained in greater detail on page114.
- 4. Check and add transmission oil if required. This procedure is explained in greater detail on p...
- 5. Check the cooling system overflow bottle for coolant. Add coolant if required. This procedure ...
- 6. Check the hydraulic oil level sight glass and add hydraulic oil if required. This procedure is...
- 7. Visually inspect the batteries for cleanliness. Check terminals for corrosion. Check the cable...
- 8. Walk around the vehicle and check for oil leakage as well as damaged or missing parts. Make an...
- 9. Check ALL lighting systems (if so equipped) for proper operation.
- 10. Adjust rear view mirrors as required to obtain proper field of vision to the rear.
- 11. Test the back-up alarm and horn for proper operation.
- 12. Check condition of cab glass (if so equipped), looking for cracks or other damage.
- 13. Visually check the condition of the air conditioner condenser (if so equipped). Remove any de...
- Operators Seat Adjustments
- Seat Belt
- 1. Grasp the retractable end of the belt or the male end of the seat belt and make certain that t...
- 2. With your back straight in the seat, couple the retractable end or the male end of the belt in...
- 3. With the belt as low on your body as possible, pull the retractable end of the belt or the fre...
- 4. To release the belt latch, depress the red button (5) and pull the free end (6) from the buckle.
- Operator Controls
- Accelerator Pedal
- Service Brake Pedal
- Steering Wheel
- Horn Button
- 2
- 1. Four Wheel Steering Mode
- 2. Front Wheel Steering Mode
- 3. Crab Steering Mode
- Four Wheel Steer Indexing
- If the vehicle does not drive “straight,” the steering could be “out of phase.” Perform the follo...
- 1. Select the four wheel steer mode with the steer mode selector.
- 2. Turn the steering wheel all the way to the right until it reaches the stop.
- 3. Select the front wheel steer mode with the steer mode selector.
- 4. Turn the steering wheel to the left, about one complete revolution.
- 5. Select the four wheel steer mode with the steer mode selector.
- 6. Turn the steering wheel all the way to the right until it reaches the stop. This will ensure t...
- 7. Select the front wheel steer mode with the steer mode selector.
- 8. Turn the steering wheel all the way to the right until it reaches the stop.
- 9. Select the four wheel steer mode with the steer mode selector.
- 10. Turn the steering wheel to the left, until the wheels are pointing straight ahead.
- 11. Drive the vehicle forward a short distance to check the wheel tracking.
- 12. The vehicle should now be properly indexed in Four Wheel Steering. If the wheels are still ou...
- Parking Brake Switch
- Transmission Disconnect Switch
- Engine Function Indicator Lights
- Travel Select Lever
- 1
- Starting Travel
- 1. Enter the operator cab, fasten the seat belt, start the engine, apply the service brake pedal ...
- 2. Rotate the twist grip (5) of the range select lever to 1st gear.
- 3. Pull the travel select lever (1) toward the steering wheel and move the travel select lever (1...
- 4. Slowly remove your foot from the service brake pedal and press the accelerator pedal to start ...
- Changing Travel Direction
- Gear Select Twist Grip
- Shifting Gears
- Starting Travel
- Recommended Gear/Speed for Various Load/Travel Conditions (Forward Direction Only)
- Load Size
- Surface
- Gear
- Speed
- Front Dash Panel
- Optional Features
- Worklights (Front, Rear & Boom)
- Parking Lights, Headlights & High/Low Beam Switch
- Directional Signals
- Emergency Flashers
- Beacon Light or Strobe Light
- Door Latches (Closed Cab Only)
- Door Window Latch (Closed Cab Only)
- Rear Window Latch (Closed Cab Only)
- Front Windshield (Closed Cab Only)
- 1. The front windshield (4) can be removed from the cab to provide additional ventilation.
- 2. Remove the windshield wiper arm assembly (5) from the wiper shaft. Reinstall the two nuts (6) ...
- 3. To remove the windshield, remove the five capscrews (7) holding the lower retainer plate (8) t...
- 4. Carefully push the bottom of the windshield out. Pull the top of the windshield out from under...
- 2. Place the bottom of the windshield (4) into the windshield opening in the cab. Secure the wind...
- 3. Remove the two nuts (6) from the wiper arm shafts. Reassemble the wiper arm assembly (5) to th...
- Front Windshield Wiper (Closed Cab Only)
- Windshield Washer Control (Closed Cab Only)
- Skylight Wiper/Washer & Rear Window Washer (Closed Cab Only)
- Rear Window Wiper (Closed Cab Only)
- 1
- Carriages
- Quick Attach
- Attachment Removal
- 1. Come to a complete stop, place the travel select lever in the (N) NEUTRAL DETENT position and ...
- 2. Extend the boom approximately 10 feet (3 meters) and tilt the carriage backward.
- 3. Exit the vehicle using both hand holds.
- 4. Raise the quick attach pin lock lever (1) and pull out the pin (2) at the bottom of the quick ...
- 5. Return to the operators compartment, fasten the seat belt and lower the attachment to the grou...
- 6. Lower and then retract the boom until the ends of the attachment pivot pin has disconnected fr...
- Attachment Reconnect
- 1. Position the vehicle directly behind the attachment to be mounted.
- 2. Tilt the quick attach backward.
- 3. Extend the boom approximately 10 feet (3 meters) and drive the vehicle forward until the attac...
- 4. Raise the boom until the attachment pivot pins have seated fully in the hooks of the attachment.
- 5. Tilt the attachment up slightly. The quick attach link should be tight against the rear of the...
- 6. Place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake swi...
- 7. Lift the quick attach lock lever (1). Insert the quick attach pin (2) completely through the a...
- 8. Return to the cab, fasten the seat belt and resume operation.
- Indicators
- Fork Rating
- Using the Capacity Chart
- Stabil-TRAK System
- Stabil-TRAK™ System Test
- Refueling
- Normal Starting
- 1. Enter the cab and adjust the seat for comfortable operation.
- 2. Adjust the mirrors to obtain the best rear view from the operator’s position.
- 3. Fasten the seat belt.
- 4. Make sure the parking brake switch is ENGAGED.
- 5. Place the travel select lever in the (N) NEUTRAL DETENT position.
- 6. Turn the ignition switch to the START position (fully clockwise) to crank the engine. Release ...
- 7. After the engine starts, run engine at partial throttle for 30 to 60 seconds before operating ...
- 8. Disengage the parking brake switch before you start operating.
- Cold Starting
- 1. Enter the cab and adjust the operator’s seat.
- 2. Fasten the seat belt. Adjust the mirrors if necessary.
- 3. Make sure the parking brake switch is ENGAGED.
- 4. Make sure the travel select lever is in the (N) NEUTRAL DETENT position.
- 5. Turn the ignition switch to the RUN position. Wait for the engine air-intake heater light on t...
- 6. Turn the ignition switch to the START position to crank the starter.
- 7. As the engine starts, release the ignition switch to the RUN position. Depress the accelerator...
- 8. The engine oil pressure warning indicator light should go OFF within five seconds after starti...
- Jump Starting
- 1. Connect the positive (+) jumper cable to the positive (+) post of the discharged battery.
- 2. Connect the other end of the positive (+) jumper cable to the positive (+) post of the booster...
- 3. Connect one end of the negative (-) jumper cable to the negative (-) post of the booster battery.
- 4. Make the final connection to the furthest point from the battery.
- 5. Follow the steps in “Normal Starting” on page85.
- 6. Remove the jumper cables in the reverse order of their connection (i.e. negative ground connec...
- How To Pick, Carry & Place A Load
- Elevating Personnel
- Defining Platforms For Elevating Personnel
- 1. The platform floor must have a slip resistant surface not more than 8"(200mm) above the norm...
- 2. The platform floor dimensions shall not exceed:
- a. Two times the load center distance as listed on the load chart that is attached to the vehicle...
- b. Width of the platform shall not be wider than the width of the vehicle, measured across the lo...
- c. Minimum space requirements for each person on the platform shall not be less than 18" (450 mm)...
- 3. The platform shall have a 4" (100 mm) minimum high toe plate around the perimeter of the platf...
- 4. Protection must be provided for the personnel on the work platform from any pinch points or mo...
- 5. Information prominently indicated on the work platform shall include:
- 6. Provide a means to securely mount and attach the platform so it can:
- 7. The platform must have a restraining means such as a guardrail or a means of securing personne...
- 8. The guardrail or similar structure shall have a nominal height to the platform floor of 42" (1...
- 9. The guardrail shall be capable of withstanding a concentrated horizontal force of 200 lb (890 ...
- 10. A body belt and lanyard is to have an attaching point for freedom of movement, and its length...
- 11. Lanyards, when provided, shall be arranged so as not to cause a tripping hazard.
- 12. Body belts, when provided, should have a width of at least 1.75 in. (44mm).
- 13. Structural safety factor - all load supporting structural elements of the work platform shall...
- Capacity Limitations
- Preparation and Set-up
- 1. DO NOT alter or modify the work platform in any manner.
- 2. Make sure that the work platform is securely attached to the quick attach or forks. Follow the...
- 3. Make sure the platform, carriage and forks are secured to prevent them from pivoting from side...
- 4. On side tilt or swing carriages, the carriage must be centered and/or leveled horizontally and...
- 5. Ensure the vehicle has a firm footing and is level.
- 6. Be sure the vehicle is in a level position (side to side) before any operation is begun. Use t...
- 7. Place the travel select lever in the (N) NEUTRAL DETENT position.
- 8. Engage the parking brake switch. Blocking the wheels is also recommended.
- 9. Level the platform in both the side-to-side and front-to-back directions before use.
- 10. Before lifting or lowering personnel, be sure the vehicle lifting mechanism operates smoothly...
- 11. Be sure any lift limiting devices and latches are functioning properly.
- 12. Any body belt, lanyard or deceleration devices which have sustained any deformation or damage...
- 13. Before elevating personnel, the area around and under the work platform should be marked to w...
- 14. Protection must be provided for the personnel on the work platform from any pinch points or m...
- 15. Provide any overhead protection device as required by worksite conditions or if requested by ...
- Elevating Personnel
- 1. Make sure there are no overhead obstructions or electrical wires above the platform before lif...
- 2. A trained operator must operate the controls from the operators compartment and must remain wi...
- 3. Personnel aboard the work platform must maintain a firm footing at all times.
- 4. Be certain the personnel and related equipment on the platform do not exceed the available spa...
- 5. The platform shall be lowered to the ground level for personnel to enter or exit the platform ...
- 6. Always position the platform in the travel position (approximately one foot above ground level...
- Defining Platforms For Elevating Personnel
- Using Other Attachments
- Shut-Off
- 1. Bring the vehicle to a complete stop using the service brakes.
- 2. Park the vehicle on level ground.
- 3. Place the travel select lever in the (N) NEUTRAL DETENT position and engage the parking brake ...
- 4. Lower the boom and ground the attachment.
- 5. Turn the ignition switch to the OFF position and remove the key.
- Pre-Operation Inspection
- Emergency Operations
- Towing a Disabled Vehicle
- 1. Remove the load from the vehicle.
- 2. Fully retract the transfer carriage.
- 3. Fully retract the boom. Position the forks approximately 24" above the ground. Refer to “Emerg...
- 4. Block all four wheels to prevent any unexpected movement of the vehicle after the parking brak...
- 5. Position the towing vehicle in place. Attach a rigid tow bar to the disabled vehicle.
- 6. Remove the cover (1) from the cab floor to gain access to the valve plate under the cab.
- 7. Attach a remote portable hydraulic pressurizing unit to the park brake gauge port (2) on the a...
- 8. Clear the area of any unnecessary personnel.
- 9. Have an operator seated in the seat.
- 10. Turn the ignition switch to the ON position (with the engine not running), release the park b...
- 11. Pressurize the park brake with the pressurizing unit. Pump pressure into the park brake syste...
- 12. Watch the pressure gauge on the pressurizing unit to ensure that the pressure in the park bra...
- 13. Carefully remove the blocks from the four wheels of the vehicle.
- 14. The vehicle can now be towed or pushed out of the way. Tow or push the vehicle at a very slow...
- 15. Place the cab floor plate back inside the cab when towing is complete. Reinstall the capscrew...
- Emergency Boom Lowering
- Part l
- Loss of Engine Power or Hydraulic Pump Failure
- 1. Clear the area around the vehicle of all personnel.
- 2. Block all four wheels.
- 3. Section off a large area under the boom with string or tape to restrict any personnel from ent...
- 4. Temporarily block up or support the outer boom so it cannot be lowered.
- 5. If the load is in a position where it can be removed safely, completely remove the load from t...
- 6. Place an accident prevention tag on both the ignition switch and steering wheel. If you do not...
- Part ll Hydraulic Line Failure
- STEP 1
- 1. Clear the area of any unnecessary personnel.
- 2. Block all four wheels.
- 3. If the load is in a position where it can be removed safely, completely remove the load from t...
- 4. Temporarily block up or support the outer boom.
- 5. Replace the failed hydraulic line with a new part.
- 6. Check the hydraulic oil level, add oil if needed.
- 7. Remove the blocking or support from the outer boom.
- 8. Return to the cab, fasten your seat belt and start the engine.
- 9. Tilt the carriage upward, if necessary, for clearance before retracting the boom. It may also ...
- 10. Slowly retract the boom.
- 11. Slowly lower the boom and ground the carriage.
- 12. Shut off the engine.
- 13. Completely remove the load from the carriage, if you haven’t already done so.
- 14. Return to the cab, fasten your seat belt and start the engine.
- 15. Cycle the lift/lower and extend/retract cylinders several times to bleed air from the system....
- 16. Recheck the hydraulic oil level. Add oil if necessary.
- STEP 2
- 1. Clear the area of any unnecessary personnel.
- 2. Block all four wheels.
- 3. Place a container under the failed hose to catch any hydraulic oil that may escape during this...
- 4. Return to the cab, fasten your seat belt and start the engine.
- 5. Slowly retract the boom.
- 6. Slowly lower the boom and ground the carriage.
- 7. Shut off the engine.
- 8. Completely remove the load from the carriage.
- 9. Place an accident prevention tag on both the ignition switch and steering wheel. If you do not...
- 10. Have the vehicle serviced immediately. Replace any failed hydraulic lines with new parts.
- 11. Return to the cab, fasten your seat belt and start the engine.
- 12. Cycle the lift/lower and extend/retract cylinders several times to bleed air from the system....
- 13. Recheck the hydraulic oil level. Add oil if necessary.
- 14. Transfer any waste oil to a container with a cover and label as used oil. Dispose of properly.
- Towing a Disabled Vehicle
- General Maintenance
- Introduction
- Maintenance Schedule and Checklist
- 1. Lubrication Points
- 2. Air Cleaner
- A. Element: Change
- 5
- 3. Thoroughly clean the interior of the air filter canister (2) and vacuator valve (3).
- 4. If replacing the inner element (4) at this time, carefully slide the element out. Always disca...
- 5. Slide the new primary element over the inner element making sure the sealing edge is flush wit...
- 6. Position the canister cover (5) in place, turn clockwise to lock into position and secure in p...
- B. Air Intake System-Inspection
- A. Engine Coolant Level Check
- B. Drain and Flush Radiator
- (2000 Hour Intervals)
- 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DET...
- 2. Unlatch and open the engine cover. Allow time for the engine to cool down before proceeding. D...
- 3. Slowly turn the radiator cap (2) to the first stop and allow any pressure to escape. Remove th...
- 4. Locate the petcock (1) on the bottom of the radiator. Place a hose (2) onto the petcock and ch...
- 5. Flush the radiator with clean water and allow to drain. After radiator is drained, close the p...
- 6. Transfer to used coolant to a properly labeled container and dispose of properly.
- 7. Drain the contents of the overflow bottle (3) by removing the overflow hose (4) from the radia...
- 8. Reattach the overflow hose to the radiator fill neck.
- 9. Fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace the ra...
- 10. Clean any dirt and debris from the radiator fins and core.
- 11. Start the engine and run the vehicle to the normal operating temperature, then shut off the e...
- 12. Allow the engine to cool. Check the coolant level in the radiator again, top off the radiator...
- 13. The overflow bottle should be 1/4 to 1/2 full. If not, fill to this level with a 50/50 mixtur...
- 14. Close and latch the engine cover.
- 5. Engine Oil and Filter
- (2000 Hour Intervals)
- A. Oil Level Check
- (10 Hour Intervals)
- B. Oil and Filter Change (250 Hour Intervals)
- 1. Operate the engine until warm (approximately 5 minutes).
- 2. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DET...
- 3. Unlatch and open the engine cover.
- 4. Place a receptacle under the engines oil pan drain plug (4). The drain plug is located under t...
- 5. Remove the drain plug (4) and drain the oil from the engine oil pan.
- 6. Allow the oil to drain completely into the receptacle. Transfer the oil to a container with a ...
- 7. Remove the oil filter (1) and clean the filter sealing surface.
- 8. Apply a thin coat of clean engine oil to the new filter mating surface.
- 9. Install the new oil filter and hand tighten. Use an oil filter wrench or strap to tighten the ...
- 10. Install the drain plug (2) into the oil pan and tighten securely.
- 11. Remove the engine oil fill cap (3) and add 15W40 motor oil. (Refer to engine manufacturers ma...
- 12. Reinstall oil fill cap (3). Start engine and allow to run for several minutes.
- 13. Shut off engine. Wait several minutes and check the oil level on the dipstick (4). Add oil if...
- 14. Look for oil leaks at the filter and drain plug. Tighten if necessary.
- 6. Engine Fuel System
- A. Drain Water from Fuel Water Separator/Filter
- B. Change Fuel Filter
- (250 Hour Intervals)
- 1. Unlatch and open the engine cover.
- 2. Clean around the fuel filter head (3).
- 3. Unscrew the fuel filter and dispose of properly.
- 4. Clean the gasket surface of the filter head and replace the o-ring.
- 5. Fill the new fuel filter with clean No. 2 diesel fuel.
- 6. Lubricate the o-ring seal with clean No. 2 diesel fuel.
- 7. Install the fuel-filled filter and hand tighten. DO NOT overtighten.
- 8. Close and latch the engine cover.
- (250 Hour Intervals)
- C. Replace In-line Fuel Strainer
- (250 Hour Intervals)
- 1. Unlatch and open the engine cover.
- 2. The fuel strainer (1) is located down line from the engines lift pump (2). Loosen the two hose...
- 3. Remove the old strainer and dispose of properly.
- 4. Install the new strainer with arrow (4) pointing toward the lift pump.
- 5. Assemble the hoses to the strainer and tighten the hose clamps.
- 6. Remove air from the fuel system (see “Bleeding Fuel System” on page121).
- 7. Close and latch the engine cover.
- (250 Hour Intervals)
- D. Bleeding Fuel System
- 1. To vent the low pressure lines and fuel filter, open the vent screw (5) located on the filter ...
- 2. Operate the hand plunger (6) on the lift pump (2) until fuel flowing from the fitting is free ...
- 3. Tighten the vent screw (5) and torque to 7 lb-ft (9 Nm).
- 4. To vent the high pressure fuel lines (1), loosen one fitting (2) at the injector (3).
- 5. Turn the ignition switch to the START position and crank the engine for a maximum of 15 second...
- 6. Tighten the fitting. Torque to 22 lb-ft (30 Nm).
- 7. Repeat Steps 4-6 for each fitting until the engine runs smoothly.
- 8. With the engine running, visually check for leaks. Turn ignition switch OFF.
- 7. Engine Fan Belt
- Engine Fan Belt Check
- (1000 Hour Intervals)
- 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DET...
- 2. Unlatch and open the engine cover.
- 3. Inspect the fan belt (4). Replace if cracked or frayed.
- 4. This engine is equipped with an automatic belt tensioner (5). Inspect the tensioner bearing. S...
- 5. Spin the fan and check for wobble or excessive play. Maximum play should be .006 inch (0,15 mm).
- 6. To install the fan belt (4); first position the belt over the fan pulley (6), crankshaft pulle...
- 7. Close and latch the engine cover.
- 8. Air Conditioner Compressor Belt (Optional)
- (1000 Hour Intervals)
- Air Conditioner Compressor Belt Check
- (1000 Hour Intervals)
- 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DET...
- 2. Unlatch and open the engine cover.
- 3. Inspect the air conditioner compressor belt (1). Replace if cracked or frayed.
- 4. Check the tension of the belt midway between the fan pulley (2) and the compressor pulley (3)....
- 5. Adjust the tension on the belt by loosening the bolts (4) on the compressor bracket (5). Adjus...
- 6. Close and latch the engine cover.
- 9. Hydraulic Oil and Filter
- (1000 Hour Intervals)
- A. Hydraulic Oil Level Check
- (10 Hour Intervals)
- 1. Level the vehicle, place the travel select lever in the (N) NEUTRAL DETENT position and engage...
- 2. Lower and retract the boom, level and lower the attachment to the ground, transfer the transfe...
- 3. Unlatch and open the engine cover.
- 4. Allow the hydraulic oil to cool.
- 5. Locate the sight glass (7) along the rear wall of the hydraulic tank. Check the level of the h...
- 6. Reinstall the hydraulic oil fill cap (8) on the tank or the cap (9) on the fill tube on top of...
- 7. Close and latch the engine cover.
- (10 Hour Intervals)
- B. Hydraulic Oil & Filter Change
- (First 100 Hours - Filter Only)
- (1000 Hour Intervals - Oil & Filter)
- 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DET...
- 2. Fully retract all hydraulic cylinders and shut off the engine.
- 3. Unlatch and open the engine cover. Allow the oil to cool.
- 4. Clean around the hydraulic filter head cover (1). Loosen but do not remove the washer head bol...
- 5. Rotate the cover clockwise and remove the cover (1). Retain the o-ring seal (4) located in the...
- 6. Remove the spring (5) from the top of the filter. Remove the filter (6) with center assembly f...
- 7. Remove the center assembly (7) from the filter, discard the filter.
- 8. Inspect the inside of the filter chamber (8), if contamination is evident, the chamber can be ...
- 9. Install a new filter (6) onto the center assembly (7). Push the filter all the way on.
- 10. Insert the filter into the filter chamber (8) and seat completely over the tube at the bottom...
- 11. Reposition the spring (5) with the wide side up, on top of the filter.
- 12. Reposition the cover on top of the housing, rotate the cover counterclockwise into position u...
- 4
- 13. Place a receptacle under the hydraulic reservoir drain plug (10). The receptacle must be larg...
- 14. Re-install the drain plug (10) into the reservoir. Torque the drain plug to 25-40 lb-ft (34-5...
- 15. Remove the fill cap (11) located toward the front of the hydraulic reservoir. It is recommend...
- 16. Close and latch the engine cover.
- 17. Run vehicle and operate all hydraulic functions. Cycle all modes of controls to purge air fro...
- 18. Check for leaks.
- 10. Transmission Oil and Filter
- Approved Universal Tractor Fluid
- A. Transmission Oil Level Check
- (10 Hour Intervals)
- 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DET...
- 2. Check the transmission oil level with the engine at idle and the oil at normal operating tempe...
- 3. Remove the transmission dipstick (1). Check oil level.
- 4. Add Universal Tractor Fluid to transmission as required to bring the level up to the full mark.
- (10 Hour Intervals)
- B. Transmission Oil & Filter Change
- (First 100 Hours) (1000 Hour Intervals)
- 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DET...
- 2. Unlatch and open the engine cover. Allow the engine and transmission to cool.
- 3. Place a receptacle under the transmission drain plug (2). Remove the drain plug and allow the ...
- 4. Clean and re-install the drain plug into the transmission housing. Torque the drain plug (2) t...
- 5. Loosen, do not remove the upper battery tray retainer bolt (1). Swing the upper battery tray o...
- 6. Remove the filter (2) and dispose of properly. Clean the mating surface where the filter mounts.
- 7. Apply a thin film of clean Universal Tractor Fluid to the new filter gasket. Carefully install...
- 8. Swing the upper battery tray back into position and tighten the battery tray retainer bolt.
- 9. Remove the dipstick (3) and fill with Universal Tractor Fluid. The maximum capacity of the ent...
- 10. Check the transmission level and add oil as required following the procedures outlined in “Tr...
- 11. Close and latch the engine cover.
- 11. Transfer Case Oil
- (First 100 Hours) (1000 Hour Intervals)
- A. Transmission Oil Level Check
- Approved Universal Tractor Fluid
- A. Transfer Case Oil Level Check
- (250 Hour Intervals)
- 1. Place the vehicle on level ground, ground the attachment, level the vehicle side-to-side, plac...
- 2. Clean the area around the transfer case oil fill/level plug (4).
- 3. Remove the oil fill/level plug from the transfer case and check the oil level.
- 4. Add oil as required through the oil fill/level plug hole (4). Bring the oil level up even with...
- 5. Clean and re-install the oil fill/level plug (4) and torque to 26 lb-ft (35 Nm).
- (250 Hour Intervals)
- B. Transfer Case Oil Change
- (First 100 Hour Intervals) and (1000 Hour Intervals)
- 1. Place the vehicle on level ground, ground the attachment, level the vehicle side to side, plac...
- 2. Clean the area around the transfer case oil fill/level plug (1) and the oil drain plug (2).
- 3. Place a receptacle under the transfer case drain plug.
- 4. Remove the oil fill/level plug (1).
- 5. Remove the oil drain plug (2) from the transfer case (3).
- 6. Allow the oil to drain completely into the receptacle. Transfer the oil into a container with ...
- 7. Clean and re-install the transfer case oil drain plug (2). Torque to 26 lb-ft (35 Nm).
- 8. Fill the transfer case with oil through the oil fill/level plug hole (1). Fill until the level...
- 9. Clean and re-install the oil fill/level plug (1). Torque to 26 lb-ft (35 Nm).
- 12. Axle Oil
- (First 100 Hour Intervals) and (1000 Hour Intervals)
- A. Axle Oil Level Check
- A. Transfer Case Oil Level Check
- Approved Universal Tractor Fluid
- 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DET...
- 2. Clean the area around the axle fill plug (4) and the axle level plugs (5) and remove the plugs...
- 3. Add Universal Tractor Fluid to bring the oil level up and even with the level plug holes.
- 4. Re-install the axle fill plug (4) and torque to 37 lb-ft (50 Nm).
- 5. Re-install the axle level plugs (5) and torque to 37 lb-ft (50 Nm).
- B. Axle Oil Change
- (First 100 Hours)
- 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DET...
- 2. Clean the area around the axle drain plug (3), the axle fill plug (1) and the axle level plugs...
- 3. Place a receptacle under the axle drain plug (3). Remove the plug from the axle housing and al...
- 4. Transfer the oil to a container with a cover and label the container as used oil. Dispose of p...
- 5. Clean off the axle drain plug (3) and re-install. Remove the axle fill plug (1) and the axle l...
- 6. Fill the axle with Universal Tractor Fluid through the axle fill hole until the oil level is e...
- 7. Fill axle slowly, the oil has to run across the differential. Allow time for the oil to run ac...
- 8. Reassemble the level plugs (2) using new o-rings. Torque to 37 lb-ft (50Nm).
- 9. Re-install the axle fill plug (1) into axle housing. Torque to 37 lb-ft (50 Nm).
- 13. Brake Disc Inspection
- (First 100 Hours)
- Brake Disc Wear Check
- (1000 Hour Intervals)
- A. Front Axle
- 1. Block all four wheels to prevent any unexpected movement of the vehicle after the parking brak...
- 2. Remove the cover (4) from the cab floor to gain access to the valve plate under the cab.
- 3. Attach a remote portable hydraulic pressurizing unit to the park brake gauge port (5) on the a...
- 4. Turn the ignition switch to the ON position (with the engine not running), release the park br...
- 5. Pressurize the park brake with the pressurizing unit. Pump pressure into the park brake system...
- 6. Working through the level plug hole (1), carefully use a screwdriver to spread the brake discs...
- 7. Using a feeler gauge, check the gap (2) between the brake discs (3). If the gap is greater tha...
- 8. Repeat step 6 and step 7 for the other side of the axle.
- 9. Continue with step 6 of “B. Axle Oil Change” on page134.
- B. Rear Axle
- 1. Working through the level plug hole (1), carefully use a screwdriver to spread the brake discs...
- 2. Using a feeler gauge, check the gap (2) between the brake discs (3). If the gap is greater tha...
- 3. Repeat step 1 and step 2 for the other side of the axle.
- 4. Continue with step 6 of “B. Axle Oil Change” on page134.
- 14. Wheel End Oil
- A. Front Axle
- (1000 Hour Intervals)
- Approved Universal Tractor Fluid
- A. Wheel End Oil Level Check
- (250 Hour Intervals)
- 1. Position the vehicle on level ground, move the vehicle forward or backward enough to ensure th...
- 2. Ground the attachment, place the travel select lever in the (N) NEUTRAL DETENT position, engag...
- 3. Clean the area around the wheel end fill/drain plug (2). Slowly remove the plug. Check the oil...
- 4. Add Universal Tractor Fluid to bring the oil level up and even with the plug hole.
- 5. Clean and re-install the wheel end fill/drain plug (2). Torque to 37 lb-ft (50Nm).
- (250 Hour Intervals)
- B. Wheel End Oil Change
- (First 100 Hours)
- (1000 Hour Intervals)
- 1. Position the vehicle on level ground, move the vehicle forward or backward enough to ensure th...
- 2. Ground the attachment, place the travel select lever in the (N) NEUTRAL DETENT position, engag...
- 3. Clean the area around the wheel end fill/drain plug (5). Slowly loosen the plug. Hold a recept...
- 4. Allow the oil to drain completely into the receptacle. Transfer the oil to a container with a ...
- 5. Reposition the vehicle so the wheel end fill/drain plug is positioned horizontally (3).
- 6. Fill the wheel end with Universal Tractor Fluid to the level of the drain plug (2). Wheel end ...
- 7. Clean and re-install the wheel end fill/drain plug (2). Torque to 37 lb-ft (50Nm).
- 15. Wheels and Tires
- A. Tire Air Pressure Check
- B. Wheel Lug Nut Torque Check
- C. Replacing Tires
- 16. Battery
- 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DET...
- 2. The batteries (1) are located inside the engine pod, in front of the hydraulic oil reservoir (...
- 3. Wearing safety glasses, visually inspect the batteries for cleanliness. Check terminals for co...
- 17. Fuse & Relay Replacement
- 16. Battery
- Fuses and Relays (Fuse Block)
- Relay Locations
- Flasher
- Fuse Locations
- Cold Start Grid Heater Fuses
- 1. Unlatch and open the engine cover.
- 2. To access the fuses; open the protective covers (2) from the engine panel side. Allow the cove...
- 3. Remove the two hex nuts (4) and lockwashers (5) securing the fuse (1) and wires to the fuse ho...
- 4. Place the new fuse and then the wires onto the studs of the holder. Secure the fuse and wires ...
- 5. Snap the protective cover back in place. Be sure the cover snaps securely in place on the holder.
- 6. Close and latch the engine cover when complete.
- ECM Fuses and Relay
- 1. Unlatch and open the engine cover.
- 2. Locate the two fuse holders. Remove the clear plastic protective cover (9) from the holder (6).
- 3. Remove the failed fuse from the holder and replace with a new fuse.
- 4. Reassemble the plastic cover onto the fuse holder and securely snap the cover in place. Replac...
- 5. Close and latch the engine cover.
- 18. Boom Chains and Wear Pads
- A. Boom Chain Tension Check
- (250 Hour Intervals)
- 1. Park the vehicle on level ground. Place the travel select lever in the (N) NEUTRAL DETENT posi...
- 2. Fully extend the boom, then retract it 2" (51 mm) (one inch per section). Turn the vehicle OFF.
- 3. Measure the sag (1) in the top boom extend chain (2) between the bottom of the chain and the t...
- (250 Hour Intervals)
- B. Top Boom Chain Tension Adjustment
- (As required)
- 1. Park the vehicle on level ground. Place the travel select lever in the (N) NEUTRAL DETENT posi...
- 2. Adjust the extend chain by tightening or loosening the retract chain adjustment nut (4) on the...
- 3. Return to the cab, start the engine and cycle the boom all the way out and all the way in seve...
- 4. Fully extend the boom, then retract it 2" (51 mm) (one inch per section). Turn the vehicle OFF.
- 5. Measure the sag (1) in the top boom extend chain (2) between the bottom of the chain and the t...
- 2. At the front underside of the outer boom (4), loosen the retract chain adjustment nut (5). Bac...
- 3. This step will require the help of an assistant. Return to the cab, start the engine. Have the...
- 4. At the front top of the outer boom (1), remove one of the retaining rings (2) from the clevis ...
- 5. Move the extend chain clevis (4) to the next hole toward the rear of the mounting plates. Coat...
- 6. Return to the cab, start the engine and fully retract the boom. Shut the vehicle OFF.
- 7. At the front underside of the outer boom (5), tighten the retract chain adjustment nut (6) to ...
- 8. Recheck extend chain tension. Refer to “Top Boom Chain Tension Adjustment” on page151, and re...
- (As required)
- C. Boom Chain Inspection
- Extend Chains (250 Hour Intervals)
- 1. Park the vehicle on level ground. Place the travel select lever in the (N) NEUTRAL DETENT posi...
- 2. Fully extend the boom until the extend chain is taut. Shut the engine off.
- 3. Inspect the retract chain every 1000 hours of operation. Refer to the Service Manual for prope...
- 4. Inspect the chains for the following conditions:
- Extend Chains (250 Hour Intervals)
- D. Chain Lubrication
- E. Wear Pad Inspection (Boom)
- F. Wear Pad Replacement (Boom)
- Transfer Carriage Rear Wear Pad Check
- (50 Hour Intervals)
- 1. Park the vehicle on level ground. Place the travel select lever in the (N) NEUTRAL DETENT posi...
- 2. Leave the transfer carriage completely retracted.
- 3. Fully extend the boom. The attachment must remain slightly off the ground. Turn the vehicle OFF.
- 4. At the rear of the transfer carriage, use a feeler gauge to check the gap (6) between the wear...
- 5. Check the thickness of the wear pads. The wear pad has a total thickness of .75" (19 mm). When...
- (50 Hour Intervals)
- Wear Pad Shimming
- (As Required)
- 1. Park the vehicle on level ground. Place the travel select lever in the (N) NEUTRAL DETENT posi...
- 2. Leave the transfer carriage completely retracted.
- 3. Fully extend the boom. The attachment must remain slightly off the ground. Turn the vehicle OFF.
- 4. Remove the two capscrews (1) holding each wear pad and shims to the transfer carriage (2).
- 5. Add the required shims (3) between the wear pad (4) and the transfer carriage (2).
- 6. Secure in place with the two capscrews (1) and torque to 28-49 lb-ft (38-67 Nm).
- (As Required)
- Rear Roller Gap Check
- (50 Hour Intervals)
- 1. Park the vehicle on level ground. Place the travel select lever in the (N) NEUTRAL DETENT posi...
- 2. Fully retract the boom and fully retract the transfer carriage. Shut the vehicle OFF.
- 3. This procedure will require the gap check to be made in three separate locations. Transfer car...
- 4. With the transfer carriage all the way retracted, use a rawhide hammer to tap the rollers (5) ...
- 5. Start the engine and move the transfer carriage all the way forward. Shut the vehicle OFF. Use...
- 6. Start the engine and move the transfer carriage about halfway back. Shut the vehicle OFF. Use ...
- 7. Find the location that had the smallest gap. This is the position that the roller gap will be ...
- 8. If the total gap is larger than .06" (1,5 mm), the rollers need to be shimmed.
- (50 Hour Intervals)
- Rear Roller Shimming
- Front Roller Gap Check
- (50 Hour Intervals)
- 1. Park the vehicle on level ground. Place the travel select lever in the (N) NEUTRAL DETENT posi...
- 2. Fully retract the boom and fully retract the transfer carriage. Shut the vehicle OFF.
- 3. This procedure will require the gap check to be made in three separate locations. Transfer car...
- 4. With the transfer carriage all the way retracted, use a rawhide hammer to tap the rollers (1) ...
- 5. Start the engine and move the transfer carriage all the way forward. Shut the vehicle OFF. Use...
- 6. Start the engine and move the transfer carriage about halfway back. Shut the vehicle OFF. Use ...
- 7. Find the location that had the smallest gap. This is the position that the roller gap will be ...
- 8. If the total gap is larger than .06" (1,5 mm), the rollers need to be shimmed.
- (50 Hour Intervals)
- Front Roller Shimming
- Front Upstop Wear Pad Check
- Front Upstop Wear Pad Gap Check
- Front Upstop Wear Pad Shimming
- Refer to the Service Manual for proper shimming procedures.
- Front Upstop Wear Pad Replacement
- Roll Back Hose Inspection
- A. Wheel End Oil Level Check
- Storage and Transport
- Storage
- A. Before Storing
- 1. Clean the entire vehicle. DO NOT remove the grease coating from the boom chains.
- 2. Apply corrosion inhibitor to the exposed metal on the top of the frame rails in front of the t...
- 3. Lubricate all grease fittings as described in “Maintenance Schedule and Checklist” on page105
- 4. Prepare the engine for storage (refer to the engine manual).
- 5. Apply multi-purpose grease to all exposed hydraulic cylinder rods.
- 6. Remove the batteries from the vehicle. Store the batteries in a dry place where the batteries ...
- 7. If the ambient temperature is expected to drop below freezing at anytime during the storage pe...
- 8. Preferably, store the vehicle inside where it will remain dry. If it must be stored outside, p...
- B. Removing From Storage
- 1. Reinstall the properly charged batteries. Secure the hold-down brackets and attach battery cab...
- 2. Change the engine oil and filter to remove condensation or other residuals.
- 3. If the coolant has been drained from the engine block and radiator, refill with a 50/50 mixtur...
- 4. Wipe off any multi-purpose grease that was applied to the vehicles hydraulic cylinder rods pri...
- 5. Pressure wash the areas in front of the transfer carriage to remove the corrosion inhibitor be...
- 6. Refer to “Maintenance Schedule and Checklist” on page105. Perform all the maintenance checks ...
- 7. Review and familiarize yourself and any other operator with all the safe and proper operating ...
- A. Before Storing
- Transport
- Test Procedures
- Parking Brake/Transmission De-Clutch Test Procedures
- a. Place the vehicle on a level surface.
- b. Clear the area in front and behind the vehicle of any obstacles.
- c. Fasten your seat belt.
- d. Turn the ignition switch and start the engine.
- e. With the parking brake applied, move the range select lever to (1) FIRST gear.
- f. Move the travel select lever to (F) FORWARD.
- g. Depress the throttle pedal fully. The unit should not move.
- b. Move the travel select lever to (R) REVERSE.
- c. Depress the throttle pedal fully. The unit should not move.
- d. Remove your foot from the throttle pedal.
- e. Move the travel select lever to the (N) NEUTRAL DETENT position.
- b. Move the travel select lever to (F) FORWARD.
- c. Move the unit slowly in a forward direction (approximately 1 mph [1,6 kmh]).
- d. Engage the parking brake. The unit should stop abruptly.
- b. Stop the vehicle using the service brakes, apply the park brake, shift the transmission into t...
- c. Take your foot off the service brake pedal. The vehicle should not move.
- d. Apply the service brakes, shift the transmission into REVERSE (R), move the park brake switch ...
- e. Repeat “Test 3” by backing up the grade and checking the park brake holding performance.
- 2. Block all four wheels to prevent the vehicle from moving.
- 3. Place the accident prevention tags (1) on the ignition switch (2) and steering wheel (3).
- 4. Service the parking brake immediately or contact your local Lull Distributor to repair the sys...
- Parking Brake/Transmission De-Clutch Test Procedures
- Specifications
- Index
- Load Charts
- Accident Prevention Tags
- Transfer of Ownership