An hour from now you could be checking boom slide pad wear on your telescoping forklift against factory limits, working from this 382-page Lull 1044C-54 service manual PDF (OEM ID 31200079), which also covers the Series II. The mid-inlet hydraulic schematic traces every circuit from pump through control valve, while the electrical schematic maps the wiring behind the shift logic and proximity switches. Removal, installation, and overhaul procedures work through the four-section boom, transfer carriage, frame tilt, transmission, axles, and outriggers, backed by troubleshooting charts for pump and transmission faults. Set the boom extension proximity switch gap at 0.19 to 0.25 inch, then torque the new transmission filter to 20-25 lb-ft (27-34 Nm) at the 50-hour first change. A guessed pressure figure costs a seal, or a hand. Bookmarked and keyword-searchable, with exploded views that show exactly which piece you're ordering before you call the parts counter.
What's Inside This Lull 1044C-54 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 23-34 | General (Caution, Warning, And Danger, Safety Standard) |
| Identification and Specifications | 35-44 | Serial Number Locations (Machine Serial Number, Engine Serial Number, John Deere, Axle Serial Number, Attachment Serial Number Plate), Identification, Specifications |
| General Maintenance | 45-66 | Service Preparation Procedures, Service and Repair Procedures, Replacement Parts (General), Lubrication (General) |
| Reference Diagrams | 67-82 | Mid-Inlet Hydraulic Schematic, Control Valve, Electrical Schematic |
| Supply, Pressure, and Return Hydraulics | 83-142 | General (Major System Components, Hydraulic Systems, Safe Maintenance Practices, Cleanliness, Checking Hydraulic Lines) |
| Boom and Transfer | 143-282 | Boom and Transfer Hydraulics, Joystick Controls (Removal, Installation, Disassembly), Hydraulic Cylinders (Description, Checking Cylinder Condition) |
| Frame Tilt and Oscillation | 283-324 | Frame Tilt System (Circuit Description), Frame Tilt Control Valve (Description, Removal, Installation, Overhaul) |
| Transmission | 325-344 | Transmission Assembly Component Terminology, Transmission Description, Transmission Operation |
| Axles and Brakes | 345-364 | Axle and Drive Shaft Component Terminology (Axle Assembly), Axle Inspection, Internal Service and Repair, Axle Installation (Axle Service and Troubleshooting) |
| Outriggers | 365-382 | General, Removal, Installation |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Boom extension proximity switch gap | 0.19 inch to 0.25 inch | p. 261 |
| Boom elevation proximity switch gap | 0.19 in to 0.25 in | p. 321 |
| Transmission oil and filter change interval | 1,000 hour | p. 329 |
| Transmission filter change interval (first) | 50 hours | p. 329 |
| Transmission fuse rating | 7.5 amp | p. 338 |
| Lift and Carry Capacity | 10,000 lbs. | p. 39 |
| Maximum Lift Height | 54 Feet | p. 39 |
| Hydraulic System Capacity | 65 Gallons | p. 39 |
| Fuel Tank Capacity | 36 Gallons | p. 39 |
| Transmission Drain and Refill Capacity | 19 Quarts | p. 39 |
| Boom Hoist and Extend Valve Relief Pressure | 3000 psi | p. 40 |
| Steering System Pressure | 2355 psi | p. 40 |
Lull 1044C-54 Common Problems This Manual Covers
Lull 1044C-54 boom won't extend or retract, joystick moves but boom stays put
Check the extension chains and chain anchors for breaks before pulling any cylinder. Inspect every boom hydraulic line for leaks, then test system pressure against the 3000 psi boom hoist and extend relief spec on page 40. If pressure holds, pull the extension cylinder and check the piston seals using the procedures starting on page 254.
Manual Section: Boom and Transfer p. 254Engine starts then dies after 30 to 40 seconds, restarts only after waiting
Inspect the safety interlock inputs and control circuit diodes before condemning the fuel system. Test the 7.5 amp transmission fuse listed on page 338, then trace shutdown circuit power with the wiring diagram on page 73. Verify fuel supply from the 36 gallon tank is clean and the pickup is not sucking air.
Manual Section: Reference Diagrams p. 73Oscillation lock light stays on after sensor replacement and the machine will not move
Adjust the boom elevation proximity switch gap to 0.19 to 0.25 inch as specified on page 321; a misadjusted or miswired switch latches the lock circuit. Check the connector pinout against the wiring diagram on page 73, and test switch continuity at several boom angles before replacing the sensor again.
Manual Section: Frame Tilt and Oscillation p. 321Forward travel feels like the service brakes are dragging while reverse drives normally
Test the brake solenoid for constant power in forward using a test light and the wiring diagram on page 73. Jack the front axle, spin each wheel, and feel for drag. If a hub binds, open the axle per the procedures on page 345; dragging brakes also push transmission oil past its 104 to 230°F range.
Manual Section: Axles and Brakes p. 345Transmission will not shift or lacks power, whines and clunks under load
Change the transmission filter if it has more than 1,000 hours on it; torque the new filter to 20-25 lb-ft (27-34 Nm) per page 336 and refill with 19 quarts. Check the 7.5 amp fuse on page 338 and shifter power supply before pulling the transmission; clutch pressure diagnostics start on page 325.
Manual Section: Transmission p. 325Frequently Asked Questions
What is the hydraulic pressure setting for the boom hoist and extend valve relief on the Lull 1044C-54?
The boom hoist and extend valve relief pressure is set to 3000 psi. p. 40
What are the replacement specifications for the transmission filter on the Lull 1044C-54?
The transmission filter is a spin-on type. When changing the filter, apply a thin film of clean Mobil 424 Tractor/Hydraulic Fluid to the new transmission filter gasket and torque the filter to 20-25 lb-ft (27-34 Nm). p. 336
What is the capacity of the hydraulic reservoir on the Lull 1044C-54?
The hydraulic reservoir has a capacity of 47 gallons. p. 39
What is the torque specification for the transmission-to-axle drive shaft bearing cross straps on the Lull 1044C-54?
The four capscrews and two straps securing the bearing crosses to the transmission should be torqued to 60 lb-ft (81 Nm). p. 355
What is the pre-charge pressure for the accumulator on the Lull 1044C-54?
The accumulator must be pre-charged with dry nitrogen to a pressure of 400 psi. p. 357
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