Description

Lull 944E-42 2011 Service Manual – Factory OEM Specifications for Boom, Axles & Hydraulics

You need the factory book for this machine, not some aftermarket knock-off. I’ve seen too many guys try to fudge torque values on a boom section and end up with a chain slipping. That’s how people get hurt. This manual is the real deal – 266 pages of Lull’s own specs, printed December 31, 2011, covering serial number 0160041827 and after. If you’re maintaining a Lull 944E-42 2011 Service Manual telehandler, you don’t guess – you follow the procedure Lull wrote for it.

Section 2 Torque Charts and Fluid Capacities

Section 2 starts with replacement parts and warranty info, then drops into three torque charts: SAE fastener, metric fastener, and hydraulic hose torque chart. Those aren’t suggestions – they’re the numbers that keep the boom from dropping on someone. Fluid and lubricant capacities are listed right after the specs, along with service schedules at 10, 50, 100, 250, 500, 1000, and 2000 hours. If you’re doing a full fluid change, those capacities save you from underfilling or overfilling a system that costs more than your truck.

How Does the Manual Handle Boom Chain Inspection?

Section 3.4 covers boom extend and retract chains in detail. There are inspection guidelines, chain exposure steps, lubrication procedures, and tension check and adjustment. This isn’t a quick visual – Lull tells you to expose the chains, measure tension, adjust if it’s off. I’ve seen chains fail because a tech thought “looks tight enough” was a spec. It’s not. Follow Section 3.4.6 for chain tension adjustment and you’ll never have that conversation with a safety officer.

Use the 10 & 50 Hour Service Schedule

Section 2.5.1 lists what needs attention at 10 and 50 hours. Bleeding brakes, checking hydraulic fluid level, inspecting boom wear pads. On a telehandler that gets hired out, those intervals come fast. Skip them and you’ll be replacing axle seals or worse. This manual lays out the schedule in a table – no ambiguity about what “50 hours” means.

Safety Section: Why It’s Not Just Filler

Section 1 runs from safety alert systems and signal words through personal, equipment, general, and operational hazards. Then it covers safety decal locations. If you’ve never worked on a Lull 944E-42, you need to read this section. The machine has pinch points, crush zones, and hydraulic pressures that can kill you instantly. Section 1.6.4 on operational hazards is especially relevant for anyone pulling the cab or boom.

5 Sections Covering the Boom Alone

Section 3 breaks the boom into: component terminology, system operation, assembly maintenance (removal and installation of all three boom sections), extend/retract chains, wear pads, quick attach assembly, forks, troubleshooting, and emergency lowering. The emergency lowering subsection is critical – it covers loss of engine power or pump failure, hydraulic line failure, and hose replacement step-by-step. You don’t want to learn that procedure on a job site with a load in the air.

Who Needs This Manual?

Fleet mechanics maintaining a rental yard full of Lull telehandlers. Owner-operators who do their own PMs. Shop techs who get handed a 944E-42 with a boom that won’t extend. This manual is also for the beginner who thinks working on a telehandler is like working on a car’s Manual Transmission. It’s not – the hydraulic circuits alone will fry your brain if you don’t have the factory diagram. If you’ve only ever worked on a Manual Transmission, you’ll appreciate how detailed the Lull boom section is.

Factory OEM Print, Not Aftermarket

This is the original JLG/Lull publication, part number 31200355. It’s not a third-party reprint or a scan of a scan. The effectivity page says “Original – December 31, 2011 – A” – that’s the same document Lull’s own techs use. Aftermarket manuals leave out torque values or flatten the wiring diagrams. This one has the actual hydraulic cylinder performance specs (Section 2.3.2) and axle assembly procedures (Section 5.3).

Two relevant factory resources to pair with this service manual: Lull 944E-42 644E-42 2014 Parts Catalog – OEM Factory Book for ordering parts, and Lull 944E-42 644E-42 2009 Parts Catalog – OEM Factory Manual if you have an earlier serial number. Also check Lull M15B 1983 Service Manual – Factory Shop Manual for Powered Buggy for older Lull equipment.

Does this manual cover the enclosed cab options?

Yes, Section 4.4 covers enclosed cab components: front windshield wiper switch/motor, skylight wiper, rear wiper, heater/defroster, and the washer reservoir with pump.

What torque values are listed?

Section 2.2 contains three separate torque charts: SAE fasteners (grade marking, torque in ft-lbs), metric fasteners (class, torque in Nm and ft-lbs), and hydraulic hose torque (for O-ring face seal and JIC fittings). In addition, Section 5.3.2 lists axle specifications with specific torque values for axle mounting bolts, and Section 2.3.2 gives hydraulic cylinder performance specs including retract and extend forces. The manual also includes engine performance specs (Section 2.3.4) and travel speeds (2.3.1). If you’re rebuilding the boom, you’ll need those numbers for the wear pad installation (3.5.2) and chain tension adjustment (3.4.6). There’s no generic “tighten until snug” in this book.

Access the Factory Manual and get the specs that keep this machine running safe.