Document Outline

• 3120039_B_944E_Lull_OperMnl
  • Table of Contents
  • Introduction
    • The Manual
    • Replacement Parts
    • Reports
    • Disclaimer
  • Safety Practices
    • Hazard Classification System
      • Signal Word
    • 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
      • 1. Seat Belt
      • 2. Clothing and Safety Gear
      • 3. Dismounting
      • 4. Chemical Hazards
        • A. Exhaust Fumes
        • B. Explosive Fuel
        • C. Ether or High Energy Starting Aids
        • D. Hydraulic Fluid
        • E. Batteries
        • Battery Electrolyte First Aid:
      • 5. Moving Parts Hazard
      • 6. Lowering Boom or Falling Load Hazard
    • 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
        • 2
      • 10. Tire Pressure
      • 11. Do Not Jump
      • 12. Slopes
      • 13. Falling Load Hazard
      • 14. Ventilation
    • Equipment Considerations
      • 2
      • 3
      • 4
      • 5
      • 6
      • 7
      • 2
      • 3
      • 4
      • 5
      • 6
  • 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
        • Ignition Switch
        • Steering Mode Selector
      • 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
              • 1. Stop the vehicle by applying the service brakes.
              • 2. Grasp the travel select lever (1), pull it toward the steering wheel, then move the lever up o...
            • Gear Select Twist Grip
            • Shifting Gears
              • 1. Rotate the twist grip of the gear select lever to the next desired gear. The transmission has ...
              • 2. Use first gear for highest torque and pulling power. Use higher gears for higher ground speed....
          • Recommended Gear/Speed for Various Load/Travel Conditions (Forward Direction Only)
          • Load Size
          • Surface
          • Gear
          • Speed
            • Stopping Travel
              • 1. Apply the service brake pedal and downshift the vehicle to a lower gear if necessary to slow t...
              • 2. Move the travel select lever (1) to the (N) NEUTRAL DETENT position and engage the parking bra...
            • 1
              • Maximum Fork Sweep (During Travel)
              • Joystick Operation (Standard)
              • Front Joystick (Attachment Tilt & Transfer Carriage)
            • 5
              • Middle Joystick (Boom Lift/Lower & Boom Extend/Retract)
            • 6
              • Frame Sway Joystick
              • Leveling The Vehicle
              • Frame Level Indicator
              • Auxiliary Hydraulic Control
              • Joystick Operation (Single Joystick Option)
              • Frame Sway Joystick
              • Leveling The Vehicle
              • Frame Level Indicator
    • Front Dash Panel
      • Front Dash Panel Light Test
      • Function Indicator Lights
      • Warning Indicator Lights
      • Gauges and Indicators
      • Optional Indicator Lights
    • 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...
          • 1. With the seal bulb on the windshield toward the cab, place the top of the windshield under the...
        • 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
        • Cab Heater/Air Conditioning Controls (Closed Cab Only)
        • To heat the cab:
        • To defrost the cab:
        • To cool the cab:
    • 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
      • Boom Angle Indicator
      • Boom Extension Indicator
      • Transfer Carriage Extension Indicator
      • Rear View Mirrors
    • Fork Rating
    • Using the Capacity Chart
      • 8
        • 1. Weight of the load being lifted.
        • 2. Height of the structure where the load is to be placed.
        • 3. Distance where the load will ultimately be placed in front of the front tires.
        • Reading Capacity Charts
          • 1. The operator has placed the load onto the forks, fully retracted the boom, positioned the vehi...
          • 2. The operator determines that:
          • 3. After applying the height of the structure and the distance of load placement away from the ve...
        • Sample Capacity Chart
      • 1
    • Stabil-TRAK System
      • Understanding the Stabil-TRAK™ System
      • Free Pivot Mode
      • Locked Mode
      • Slow Pivot Mode
    • Stabil-TRAK™ System Test
      • Stabil-TRAK™ System Test Instructions
      • This Page Intentionally Left Blank
    • Refueling
      • Fuel Types
      • Fuel Cap
      • To remove the fuel cap:
        • 1. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL DET...
        • 2. Slowly unscrew the cap and wait for any “hissing” noise to stop. Then unscrew the cap all the ...
      • To install the fuel cap:
    • 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:
          • a. Maximum work load including personnel and equipment.
          • b. Weight of the empty platform.
        • 6. Provide a means to securely mount and attach the platform so it can:
          • a. Only be centered laterally on the vehicle and retained against the vertical face of the forks,...
          • b. Prevent the platform from inadvertent pivoting.
        • 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...
    • 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.
  • 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.
  • General Maintenance
    • Introduction
      • Lowering Engine Cover
    • Maintenance Schedule and Checklist
      • 1. Lubrication Points
      • 2. Air Cleaner
      • A. Element: Change
        • 1. Pull the air cleaner cover lock (1) OUT, turn the air cleaner cover (2) counterclockwise and r...
        • 2. Remove the primary element (1). Inspect the element for damage. Damaged elements should never ...
      • 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
          • (1000 Hour Intervals)
            • 3. Optional Closed Cab Air Filters
            • 4. Engine Cooling System
        • A. Engine Coolant Level Check
          • (10 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. Check the coolant level in the overflow bottle (1). When the coolant is hot, the bottle should...
        • 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
        • A. Oil Level Check
          • (10 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. Remove the engine dipstick (1). Check the oil mark on the dipstick. The oil should be between ...
            • 4. Add oil if necessary. Replace the dipstick.
          • 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
          • (10 Hour Intervals)
        • 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.
        • 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.
        • 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)
        • 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
        • 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.
        • 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.
        • 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
      • 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).
        • 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
        • A. Axle Oil Level Check
          • (250 Hour Intervals)
      • 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
        • 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
      • 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).
        • 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
          • (10 Hour Intervals)
            • 1. Remove the valve stem cap.
            • 2. Check tire pressure using a good quality gauge. You cannot tell if a tire is properly inflated...
            • 3. Add air if required. Fill the tire(s) to:
            • 4. DO NOT overinflate.
            • 5. Replace the valve stem cap.
        • B. Wheel Lug Nut Torque Check
          • (First 100 Hours)
            • 1. Wire brush the area around the lug nuts if necessary. There are separate lockwashers (1) under...
            • 2. Using the torque sequence (A thru K) shown below, alternately check the torque of each of the ...
        • 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
        • Fuses and Relays (Fuse Block)
        • Relay Locations
        • Flasher
        • Fuse Locations
          • 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
        • 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...
        • 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...
              • 1. Return to the cab, start the engine and fully retract the boom. With the boom horizontal, exte...
            • 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...
        • 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:
        • D. Chain Lubrication
          • Extend Chains
          • (250 Hour Intervals)
          • (1000 Hour Intervals or Annually)
        • E. Wear Pad Inspection (Boom)
          • (50 Hour Intervals)
        • F. Wear Pad Replacement (Boom)
          • (As Wear Pad Indicators Indicate)
            • 19. Transfer Carriage Rollers and Wear Pads
        • 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...
        • 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).
        • 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.
        • Rear Roller Shimming
          • (As Required)
        • 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.
        • Front Roller Shimming
          • (As Required)
        • Front Upstop Wear Pad Check
          • (250 Hour Intervals)
        • Front Upstop Wear Pad Gap Check
          • (250 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. Check the gap (1) between the top of the wear pad (2) and the bottom of the rail (3). The maxi...
        • Front Upstop Wear Pad Shimming
          • (As Required)
        • Refer to the Service Manual for proper shimming procedures.
        • Front Upstop Wear Pad Replacement
          • (As Wear Pad Indicator Indicates)
        • Roll Back Hose Inspection
          • (50 Hour Intervals)
    • 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 ...
    • 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.
        • a. Remove your foot from the throttle pedal.
      • 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.
        • a. With the vehicle unloaded, disengage the parking brake.
      • 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.
        • a. With the rated load of 9,000 lbs (4.082 Kg) on the forks, drive the vehicle forward up a 15% g...
      • 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.
        • 1. Immediately remove the vehicle from service.
      • 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...
  • Specifications
    • Fluid & Lubrication Capacities
      • Engine Crankcase Oil:
      • Fuel Tank:
      • Cooling System:
      • Hydraulic System:
      • Transmission:
      • Axles:
      • Wheel Ends:
      • Transfer Case:
    • Tires
      • Air Pressure:
      • Tire ballast (Minimum per Tire):
      • Maximum Ground Pressure (w/full load):
      • Footprint (w/full load):
    • Weights
      • Basic Vehicle With 48" Standard Carriage:
    • Vehicle Dimensions
      • With Standard 15.5 - 25, 12 Ply Tires:
    • Electrical System
    • Engine
      • Turbocharged Cummins:
      • This Page Intentionally Left Blank
  • Index
  • Load Charts
  • Accident Prevention Tags
  • Transfer of Ownership