JLG Lull 1044C-54 II Series Manuals

Manuals and User Guides for JLG Lull 1044C-54 II Series. We have 1 JLG Lull 1044C-54 II Series manual available for free PDF download: Service Manual

JLG Lull 1044C-54 II Series Service Manual (382 pages)

Brand: JLG | Category: Boom Lifts | Size: 26 MB

July
3
Table of Contents
5
Section 1 - Safety

23
- General
  
  23
  - Caution, Warning, and Danger
    23
- Maintenance Safety
  
  24
  - General
    24
  - Mounting and Dismounting
    24
  - Before Servicing the Machine
    24
  - Fuel Hazards
    25
  - Engine Coolant Hazards
    25
  - Hydraulic System Hazards
    26
  - Electrical System Hazards
    26
  - Tire and Wheels Hazards
    27
  - Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS)
    28
  - Safety Standard
    24
- Decals and Placards
  
  28
Section 2 - Identification and Specifications

33
- Serial Number Locations
  
  35
  - Machine Serial Number
    35
  - Fig. 2-1: Machine Serial Number Plate
    35
    
    Engine Serial Number, John Deere
    36
  - Fig. 2-2: Engine Serial Number - John Deere
    36
    
    Attachment Serial Number Plate
    37
    
    Axle Serial Number
    37
  - Fig. 2-3: Axle Serial Number
    37
  - Fig. 2-4: Attachment Serial Number Plate
    37
    
    Identification
    38
  - Fig. 2-5: Top View
    38
  - Fig. 2-6: Left Side View
    38
    
    Specifications
    39
- Engine Specifications
  
  42
  - John Deere 4045T
    42
Section 3 - General Maintenance

43
Section 4 - Reference Diagrams

67
- Control Valve
  74
Section 5 - Supply, Pressure, and Return Hydraulics

79
- General
  83
  - Major System Components
    83
  - General Description
    83
- Fig. 5-1: Major Hydraulic Components
  83
  - Hydraulic Systems
    85
  - General Hydraulic Maintenance Practices
    85
    
    Safe Maintenance Practices
    85
- Fig. 5-2: MID-Inlet Hydraulic Components
  85
  - Cleanliness
    86
  - Checking Hydraulic Lines
    87
  - Hydraulic Reservoir
    88
    
    Description
    88
- Fig. 5-3: Hydraulic Reservoir Location
  88
- Fig. 5-4: Hydraulic Reservoir
  89
  - Filling Hydraulic Reservoir
    90
- Fig. 5-5: Recommended Reservoir Filling Method
  90
  - Hydraulic Reservoir
    90
  - Description
    90
- Fig. 5-6: Alternate Reservoir Filling Method
  91
  - Reservoir Drain and Refill
    93
- Fig. 5-7: Hydraulic Reservoir Drain and Refill
  93
  - Removal
    95
- Fig. 5-8: Hydraulic Reservoir/Fuel Tank Installation
  95
  - Installation
    97
- Sight Gauge
  
  98
  - Description
    98
  - Fig. 5-9: Hydraulic Reservoir Sight Gauge
    98
    
    Removal
    99
  - Fig. 5-10: Reservoir Sight Gauge Installation
    99
    
    Installation
    100
- Suction Strainer
  
  101
  - Description
    101
  - Fig. 5-11: Suction Strainer Installation
    101
    
    Installation
    102
    
    Removal and Cleaning
    102
- Hydraulic Return Filter
  
  103
  - Checking Filter Condition
    103
  - Description
    103
  - Fig. 5-12: Hydraulic Return Filter
    103
  - Fig. 5-13: Return Filter Pressure Gauge
    103
    
    Replacing Return Filter Element
    104
  - Fig. 5-14: Filter Housing Cover
    104
  - Fig. 5-15: Filter Element Assembly
    105
    
    Removal
    107
  - Fig. 5-16: Return Filter Assembly
    107
    
    Installation
    108
- Reservoir Breather
  
  108
  - Description
    108
  - Fig. 5-17: Reservoir Breather
    108
    
    Removal and Installation
    109
- Hydraulic Pressure Filter
  
  109
  - Description
    109
  - Fig. 5-18: Hydraulic Pressure Filter - Control Manifold Hydraulics
    109
    
    Replacing Pressure Filter Element
    110
  - Fig. 5-19: Hydraulic Pressure Filter Element
    110
    
    Removal
    111
  - Fig. 5-20: Hydraulic Pressure Filter Assembly
    111
    
    Installation
    112
- Hydraulic Pump
  
  112
  - Description
    112
  - Fig. 5-21: Hydraulic Pump Location
    112
    
    Troubleshooting Pump Problems
    113
- Removal
  
  115
- MID-Inlet Control Valve
  
  122
  - Description
    122
  - Fig. 5-25: MID-Inlet Control Valve Location
    122
  - Fig. 5-26: MID-Inlet Control Valve Components
    122
  - Fig. 5-27: MID-Inlet Control Valve Configurations
    124
    
    Removal
    125
  - Fig. 5-28: MID-Inlet Control Valve Installation
    125
    
    Installation
    126
- Rear Axle Stabilizer Control Valve
  
  126
- Boom Extend Lockout Valve
  
  131
- Hydraulic Diagnostic Ports
  
  131
  - General
    131
  - Fig. 5-34: Roll-Back Hose Frame Location - Control Manifold Hydraulics
    133
  - General
    133
  - Removal
    133
  - Fig. 5-35: Roll-Back Tray Installation - MID-Inlet Hydraulics
    134
    
    Installation
    135
- Roll-Back Hose Tray
  
  133
Section 6 - Boom and Transfer

143
Section 7 - Frame Tilt and Oscillation

279
- Frame Tilt System
  
  283
  - General Description
    283
  - Circuit Description
    283
  - Fig. 7-1: Frame Tilt System Components
    283
- Frame Tilt Control Valve
  
  285
  - Description
    285
  - Fig. 7-2: Frame Tilt Control Valve
    285
    
    Removal
    286
  - Fig. 7-3: Frame Tilt Control Valve Installation
    286
    
    Installation
    287
    
    Overhaul
    288
  - Fig. 7-4: Frame Tilt Control Valve (Exploded View)
    288
- Frame Tilt Cylinder
  
  290
  - Description
    290
  - Fig. 7-5: Frame Tilt Cylinder
    290
    
    Removal
    291
  - Fig. 7-6: Frame Tilt Cylinder Installation
    291
    
    Installation
    292
    
    Overhaul
    294
  - Fig. 7-7: Frame Tilt Cylinder (Exploded View)
    294
    
    Counterbalance Valve Cartridge
    297
  - Fig. 7-8: Counterbalance Valve Cartridges, Frame Tilt Cylinder
    297
- Frame Level Indicator
  
  298
  - Adjustment
    298
  - Description
    298
  - Fig. 7-10: Leveling the Frame
    298
- Rear Oscillation Lock System
  
  299
- Rear Oscillation Lock Cylinder
  
  306
  - Description
    306
  - Fig. 7-16: Rear Oscillation Lock Cylinder
    306
    
    Removal
    307
  - Fig. 7-17: Rear Oscillation Lock Cylinder Installation
    307
    
    Installation
    308
    
    Overhaul
    310
  - Fig. 7-18: Rear Oscillation Lock Cylinder (Exploded View)
    310
- Oscillation Control Block
  
  313
  - Description
    313
  - Fig. 7-19: Oscillation Control Block
    313
    
    Removal
    314
  - Fig. 7-20: Oscillation Control Block Installation
    314
    
    Installation
    316
    
    Overhaul
    317
  - Fig. 7-21: Oscillation Control Block (Exploded View)
    317
- Boom Elevation Proximity Switch
  
  319
  - Description
    319
  - Fig. 7-22: Boom Elevation Proximity Switch
    319
    
    Removal
    320
  - Fig. 7-23: Boom Elevation Proximity Switch Operation
    320
  - Fig. 7-24: Boom Elevation Proximity Switch Assembly
    320
    
    Adjustment
    321
    
    Installation
    321
  - Fig. 7-25: Boom Elevation Proximity Switch Adjustment
    321
Section 8 - Transmission

323
Section 9 - Axles and Brakes

343
- Axle and Drive Shaft Component Terminology
  
  345
  - General Information
    345
  - Fig. 9-1: Axle and Drive Shaft
    345
    
    Axle Assembly
    346
- Axle Installation
  
  349
  - Axle Service and Troubleshooting
    350
  - Drive Shafts
    351
  - Drive Shaft Maintenance
    352
  - Driveshaft Removal
    352
  - Transmission-To-Axle Drive Shaft
    353
- Axle Inspection, Internal Service and Repair
  
  349
- Drive Shaft Disassembly
  
  353
- Drive Shaft Assembly
  
  354
  - Fig. 9-2: Service Brake Pedal Pressure Switch
    356
- Service Brakes
  
  356
  - Service Brake Pressure Switch Replacement
    356
  - Fig. 9-3: Accumulator
    357
    
    Pre-Charging Accumulator
    358
    
    Precautions
    358
  - General
    357
  - Fig. 9-4: Accumulator Charging
    359
    
    Checking Pre-Charge
    360
- Accumulator
  
  357
- Towing a Disabled Machine
  
  361
  - Fig. 9-5: Park Brake Hoses
    361
    
    Manually Releasing the Park Brake
    362
    
    Manually Resetting the Park Brake
    362
Section 10 - Outriggers

365
- Outriggers
  
  365
  - Fig. 10-1: Outriggers
    365
    
    Removal
    366
  - General
    365
  - Fig. 10-2: Outrigger Installation
    366
    
    Installation
    367
- Outrigger Cylinders
  
  368
  - Fig. 10-3: Outrigger Cylinders
    368
    
    Removal
    369
  - General
    368
  - Fig. 10-4: Outrigger Cylinder Installation
    369
    
    Installation
    370
    
    Overhaul
    371
  - Fig. 10-5: Outrigger Cylinder Assembly
    371
- Differential Pressure Switch
  
  373
  - Description
    373
- Boom Extension Proximity Switch
  
  374
  - Description
    374
  - Fig. 10-6: Boom Extension Proximity Switch
    374
    
    Removal
    375
  - Fig. 10-7: Boom Extension Proximity Switch Operation
    375
  - Fig. 10-8: Boom Extension Proximity Switch Assembly
    375
    
    Adjustments
    376
    
    Installation
    376
  - Fig. 10-9: Boom Extension Proximity Switch Adjustment
    376
- Outrigger Control Valves
  
  377
  - Description
    377
  - Fig. 10-10: Outrigger Controls
    377
    
    Removal
    378
  - Fig. 10-11: Outrigger Control Valve Installation
    378
    
    Installation
    379

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JLG Lull 1044C-54 II Series Manuals

JLG Lull 1044C-54 II Series Service Manual (382 pages)

Table of Contents

Section 1 - Safety

General

Maintenance Safety

Decals and Placards

Section 2 - Identification and Specifications

Serial Number Locations

Engine Specifications

Section 3 - General Maintenance

General Instructions

Service Preparation Procedures

Service and Repair Procedures

Replacement Parts

Lubrication

Section 4 - Reference Diagrams

Section 5 - Supply, Pressure, and Return Hydraulics

Sight Gauge

Suction Strainer

Hydraulic Return Filter

Reservoir Breather

Hydraulic Pressure Filter

Hydraulic Pump

Removal

MID-Inlet Control Valve

Rear Axle Stabilizer Control Valve

Boom Extend Lockout Valve

Hydraulic Diagnostic Ports

Roll-Back Hose Tray

Section 6 - Boom and Transfer

Boom and Transfer Hydraulics

Joystick Controls

Hydraulic Cylinders

Boom Hoist Cylinder

Front Carriage Tilt Cylinder

Rear Carriage Tilt Cylinder

Selector Valve

Troubleshooting

Boom Slide Pads - General

Quick Attach

Boom Angle Inclinometer

4-Section Boom

Boom Extension Proximity Switch

Boom Extension Proximity Switch

Transfer Carriage

Section 7 - Frame Tilt and Oscillation

Frame Tilt System

Frame Tilt Control Valve

Frame Tilt Cylinder

Frame Level Indicator

Rear Oscillation Lock System

Rear Oscillation Lock Cylinder

Oscillation Control Block

Boom Elevation Proximity Switch

Section 8 - Transmission

Transmission Assembly Component Terminology

Transmission Description

Transmission Operation

Troubleshooting

Transmission Troubleshooting

Section 9 - Axles and Brakes

Axle and Drive Shaft Component Terminology

Axle Installation

Axle Inspection, Internal Service and Repair

Drive Shaft Disassembly

Drive Shaft Assembly

Service Brakes

Accumulator

Towing a Disabled Machine

Section 10 - Outriggers

Outriggers

Outrigger Cylinders

Differential Pressure Switch

Boom Extension Proximity Switch

Outrigger Control Valves

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