Lull 1001182758 Setup guide

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The following instructions describe the preparation and
installation of the Transfer Carriage Rear Tilt Cylinder Lug
Kit.
1.1 GENERAL GUIDELINES
•This repair procedure provides repair information for
a specific discrepancy. It is the responsibility of the
entity performing the repairs to determine if the
discrepancy can be corrected by this procedure. This
procedure is for the repair of the transfer carriage
rear tilt cylinder mount only.
•During inspection, if any cracks or deformities exist
beyond the radius of the transfer carriage frame at
the rear tilt cylinder mount, the transfer carriage
MUST be replaced.
•After inspection, if any cracks or deformities Do Not
exist beyond the radius of the transfer carriage frame
at the rear tilt cylinder mount, complete the transfer
carriage rear tilt cylinder lug repair instructions.
1.2 MODELS AFFECTED
1044C-54
1.3 WELD REPAIR GUIDELINES
•All welding must be in accordance with ANSI/AWS
D1.1 Standard.
•Disconnect the battery of the machine being repaired
prior to welding.
•Ground only to the component being welded. Do not
ground to any adjacent component or allow pins,
wear pads, wire ropes, bearings, gears, seals,
valves, electrical wiring, or hoses to be between the
grounding position and the area to be welded.
1.4 PARTS REQUIRED
Transfer Carriage Rear Tilt Cylinder Lug Kit:
P/N 1001182758
1.4.1 PARTS LIST
Note: Quantities listed are for one side only. Two Kits
required to repair both RH and LH Rear Tilt Cylinder
Mounting Lugs.
Some weld-on parts may not be available or may require
long lead times for delivery. Please consult with the Parts
Department prior to ordering the parts outlined above to
check on availability.
1.5 TOOLS & EQUIPMENT REQUIRED
1. Stands and lifting equipment capable of
lifting/supporting the affected components
2. Portable power grinder
3. Drilling and reaming equipment
4. Air carbon-arc equipment
5. Electric welding equipment
6. AWS 70 grade, low hydrogen rod or wire
7. Standard mechanic tools
8. Standard welder tools
9. Paint
1.6 PERSONNEL REQUIRED
1. Qualified Lull equipment mechanic
2. Certified Welder
CAUTION
Use all applicable Safety precautions while working
on, around or under any machinery.
NOTICE
Failure to comply with the above weld repair
guidelines may result in component damage.
P/N Qty Description
10136503 1 Rear Carriage Rear Tilt
Cylinder Mounting Lug
3575665 2 Reinforcement Plate
8050001 1 Bearing, Spherical
10136464 1 Pin, Rear Tilt Cylinder to
Transfer Carriage
3841709 1 Rod, Keeper,
1/2 Dia X 3.25 LG
10715272 1 Fitting, 1/8 Grease
10732689 1 Cover, Grease Zerk
For Kit 1001182758
A
7/14
31212010
Transfer Carriage Rear Tilt Cylinder Lug
Repair Instructions

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Transfer Carriage Rear Tilt Cylinder Lug Repair Instructions For Kit 1001182758
1.7 REPAIR PROCEDURE
1.7.1 MOUNTING LUG / REINFORCEMENT
PLATE REMOVAL
1. Park the machine on a firm, level surface, fully retract
the boom, lower the boom, place the transmission in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Support the boom assembly with a suitable support
or crane.
3. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
4. If equipped, open the engine access door. Allow the
system fluids to cool.
5. Properly disconnect the battery.
6. Remove pin securing barrel end of the carriage rear
tilt cylinder.
7. Refer to the appropriate service manual for detailed
removal procedure.
8. Raise and secure the carriage rear tilt cylinder away
from the mounting lug area.
9. Protect any hoses, wires and hydraulic cylinder rods
before preparing or welding in the immediate area.
10. Thoroughly clean each repair area (i.e, dirt, grease,
rust, paint, etc.)
11. Remove the mounting lug and reinforcement plates
around the damaged rear carriage rear tilt cylinder
mounting lugs from the transfer carriage weldment
using a hand-held grinder or air carbon-arc
equipment.
12. Inspect the transfer carriage weldment using the
magnetic or dye-penetrant inspection methods to
assure there are no cracks or deformities. If any
cracks or deformities exist, grind to remove affected
area(s) and repair.
13. Grind the top of frame flush. Thoroughly clean each
repair area (i.e, dirt, grease, rust, paint, etc.)
1.7.2 MOUNTING LUG / REINFORCEMENT
PLATE INSTALLATION
1. Locate the Transfer Carriage Rear Tilt Cylinder
Mounting Lug (1) P/N 10136503 into position and
mark location as shown on the applicable illustration.
(Refer to Section 1.9. "Mounting Lug / Reinforcement
Plate Weldment")
2. Tack weld the mounting lug in place.
3. Ensure mounting lug is properly located.
4. Weld the mounting lug as noted in the applicable
illustration. (Refer to Section 1.9. "Mounting Lug /
Reinforcement Plate Weldment")
5. Inspect welds using the magnetic or dye-penetrant
inspection methods to assure there are no cracks or
deformities. If any cracks or deformities exist, grind to
remove affected area(s) and repeat the weld and
inspection procedures.
6. Locate the Reinforcement Plate (2) P/N 3575665 into
position and mark location as shown on the
applicable illustration. (Refer to Section 1.9.
"Mounting Lug / Reinforcement Plate Weldment")
7. Tack weld the reinforcement plate in place.
8. Ensure reinforcement plate is properly located.
9. Weld the reinforcement plate as noted in the
applicable illustration. (Refer to Section 1.9.
"Mounting Lug / Reinforcement Plate Weldment")
10. Inspect welds using the magnetic or dye-penetrant
inspection methods to assure there are no cracks or
deformities. If any cracks or deformities exist, grind to
remove affected area(s) and repeat the weld and
inspection procedures.
NOTICE
Do not damage the parent metal during this procedure.

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Transfer Carriage Rear Tilt Cylinder Lug Repair Instructions For Kit 1001182758
1.7.3 MOUNTING LUG MACHINING
1. The mounting lug will require drilling and/or
machining. This operation can be performed in house
if the proper equipment is available. If not, a
reputable machine shop will be required to perform
the machining.
2. Refer to Section 1.10. "Mounting Lug Machining" for
exact machining sizes and tolerances.
3. Drill and ream a new hole in the new transfer carriage
rear tilt cylinder mounting lug (1). (Refer to Section
1.10. "Mounting Lug Machining")
4. Clean, prime and paint the affected areas.
1.8 TRANSFER CARRIAGE REAR TILT
CYLINDER ASSEMBLY
1. If required, replace all damaged transfer carriage
slave cylinder components.
2. Reassemble all components incorporating new
Spherical Bearing P/N 8050001, Pin P/N 10136464,
Keeper Rod P/N 3841709, Grease Fitting P/N
10715272 and Cover P/N 10732689.
3. Refer to the appropriate service manual for detailed
assembly procedure.
4. Remove all protective coverings from any hoses,
wires and hydraulic cylinder rods.
5. Properly connect the battery.
6. Load the unit with the rated capacity and cycle the
boom functions throughout their full range a minimum
of five times to ensure safe and proper operation.
7. Inspect the repair areas for discrepancies.
8. If equipped, close engine access door.
9. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel.
10. Return machine to service.

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Transfer Carriage Rear Tilt Cylinder Lug Repair Instructions For Kit 1001182758
1.9 MOUNTING LUG / REINFORCEMENT PLATE WELDMENT
23.750in
0.375in
2.12in
SECTION A-A
TYP TOP & BOTTOM BEFORE
WELDING REINFORCEMENT
PLATES 1/4
A
A
35.06in
23.43in
NOTE: FULLY WELD AROUND
CYLINDER PIVOT BEFORE
LOCATING REINFORCEMENT
PLATES.
TOP
5/16
BOTTOM
5/16
BOTH ENDS OF PLATES TIE ALL
WELDS TOGETHER TYP-2 PLCS
MAP28950
2
1
2

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Transfer Carriage Rear Tilt Cylinder Lug Repair Instructions For Kit 1001182758
1.10 MOUNTING LUG MACHINING
35.063in
9.516in
2 HOLES IN LINE
2.436 - 2.437
36.331in
MAP28960

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Transfer Carriage Rear Tilt Cylinder Lug Repair Instructions For Kit 1001182758
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