Lull 1001182758 - User Manual

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31212010

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

7/14

31212010

Transfer Carriage Rear Tilt Cylinder Lug

Repair Instructions

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Overview

Technical Specifications and Parts
Usage Features (Repair Procedure)
Maintenance Features (Tools and Personnel)
General Guidelines and Safety

This document outlines the repair instructions for the Transfer Carriage Rear Tilt Cylinder Lug, specifically for Kit 1001182758. The primary function of this kit is to provide a repair solution for a specific discrepancy related to the rear tilt cylinder mount on the transfer carriage. It's crucial to understand that this procedure is solely for the repair of the transfer carriage rear tilt cylinder mount. If, during inspection, any cracks or deformities extend beyond the radius of the transfer carriage frame at the rear tilt cylinder mount, the entire transfer carriage MUST be replaced. However, if cracks or deformities are confined within this radius, then these repair instructions can be followed.

Technical Specifications and Parts:

The kit, P/N 1001182758, includes several key components, with quantities listed per side (meaning two kits are required to repair both RH and LH Rear Tilt Cylinder Mounting Lugs):

Rear Carriage Rear Tilt Cylinder Mounting Lug (P/N 10136503): One unit. This is the primary component being replaced or repaired.
Reinforcement Plate (P/N 3575665): Two units. These plates are designed to strengthen the repaired area.
Bearing, Spherical (P/N 8050001): One unit. This bearing is critical for the smooth articulation of the cylinder.
Pin, Rear Tilt Cylinder to Transfer Carriage (P/N 10136464): One unit. This pin secures the cylinder to the transfer carriage.
Rod, Keeper, 1/2 Dia X 3.25 LG (P/N 3841709): One unit. This rod likely helps retain the pin or other components.
Fitting, 1/8 Grease (P/N 10715272): One unit. Essential for lubrication.
Cover, Grease Zerk (P/N 10732689): One unit. Protects the grease fitting.

It's noted that some weld-on parts might have long lead times, so checking availability with the Parts Department before ordering is recommended.

Usage Features (Repair Procedure):

The repair process is divided into several stages:

Preparation:
- The machine must be parked on a firm, level surface with the boom fully retracted and lowered.
- The transmission should be in NEUTRAL, the park brake engaged, and the engine OFF.
- The boom assembly needs to be supported by a suitable support or crane.
- A "Do Not Operate Tag" must be placed on both the ignition key switch and steering wheel.
- The engine access door should be opened (if equipped), and system fluids allowed to cool.
- The battery must be properly disconnected.
- The pin securing the barrel end of the carriage rear tilt cylinder needs to be removed.
- The carriage rear tilt cylinder should be raised and secured away from the mounting lug area.
- Hoses, wires, and hydraulic cylinder rods in the immediate area must be protected.
- The repair area needs thorough cleaning (removing dirt, grease, rust, paint, etc.).
Mounting Lug / Reinforcement Plate Removal:
- The damaged mounting lug and reinforcement plates are removed from the transfer carriage weldment using a hand-held grinder or air carbon-arc equipment.
- After removal, the transfer carriage weldment must be inspected using magnetic or dye-penetrant methods for cracks or deformities. Any found defects must be ground out and repaired.
- The top of the frame should be ground flush, and the area thoroughly cleaned again. A critical "NOTICE" warns against damaging the parent metal during this procedure.
Mounting Lug / Reinforcement Plate Installation:
- The new Transfer Carriage Rear Tilt Cylinder Mounting Lug (1) P/N 10136503 is positioned and tack welded in place, ensuring proper location as per the provided illustrations (Section 1.9).
- The mounting lug is then fully welded as per the illustration.
- Welds are inspected using magnetic or dye-penetrant methods for cracks or deformities. Any defects require grinding and re-welding.
- The Reinforcement Plate (2) P/N 3575665 is then positioned, tack welded, and fully welded as per the illustrations, with similar inspection requirements.
Mounting Lug Machining:
- The new mounting lug requires drilling and/or machining. This can be done in-house if equipment is available, otherwise, a reputable machine shop is needed.
- Specific machining sizes and tolerances are provided in Section 1.10.
- A new hole is drilled and reamed in the new transfer carriage rear tilt cylinder mounting lug.
- The affected areas are cleaned, primed, and painted.
Transfer Carriage Rear Tilt Cylinder Assembly:
- Any damaged transfer carriage slave cylinder components should be replaced.
- All components are reassembled, incorporating the new Spherical Bearing, Pin, Keeper Rod, Grease Fitting, and Grease Zerk Cover.
- Protective coverings are removed from hoses, wires, and hydraulic cylinder rods.
- The battery is properly reconnected.
- The unit is loaded with its rated capacity, and boom functions are cycled through their full range a minimum of five times to ensure safe operation.
- The repair areas are inspected for discrepancies.
- The engine access door is closed (if equipped).
- The "Do Not Operate Tag" is removed from the ignition key switch and steering wheel.
- The machine is then returned to service.

Maintenance Features (Tools and Personnel):

The repair requires specific tools and qualified personnel:

Tools & Equipment:
- Stands and lifting equipment capable of supporting components.
- Portable power grinder.
- Drilling and reaming equipment.
- Air carbon-arc equipment.
- Electric welding equipment.
- AWS 70 grade, low hydrogen rod or wire.
- Standard mechanic tools.
- Standard welder tools.
- Paint.
Personnel:
- A Qualified Lull equipment mechanic.
- A Certified Welder.

General Guidelines and Safety:

All welding must adhere to ANSI/AWS D1.1 Standard.
The battery must be disconnected before welding.
Grounding should only be to the component being welded, avoiding adjacent components or allowing pins, wear pads, wires, bearings, gears, seals, valves, electrical wiring, or hoses between the grounding position and the weld area. Failure to comply with these weld repair guidelines may result in component damage.
A general caution emphasizes using all applicable safety precautions when working on, around, or under any machinery.

The document includes detailed diagrams for "Mounting Lug / Reinforcement Plate Weldment" (Section 1.9) and "Mounting Lug Machining" (Section 1.10) to guide the repair process with precise measurements and locations.