Lull 944E-42 Service Manual - Manual (Page 435)

8.183 Model 644E-42/944E-42 Rev. 6/04
Hydraulic System
Inlet Section Assembly
1. Install the main relief valve (1) with new seals into
the side of the inlet section (2). Torque the main
relief valve to 33 ±3.5 lb-ft (45 ± 4,8 Nm). Refer to
the Parts Manual for seal kits.
2. Install the unloader valve (3) with new seals into the
side of the inlet section (2). Torque the unloader
valve to 48 ±5 lb-ft (65 ±7 Nm). Refer to the Parts
Manual for seal kits.
3. Insert the four hex socket head capscrews (4)
through the inlet section.
Transfer Carriage Section Assembly
1. Install the relief valve (5) preset at 3700 psi (255 bar)
with new seals into the “A” side of the transfer
carriage section (7). Torque the relief valve to
33 ±3.5 lb-ft (45 ± 4,8 Nm). Refer to the Parts
Manual for seal kits.
2. Install the relief valve (6) preset at 2400 psi (165 bar)
with new seals into the “B” side of the transfer
carriage section (7). Torque the relief valve to
33 ±3.5 lb-ft (45 ± 4,8 Nm). Refer to the Parts
Manual for seal kits.
3. Install the spring (8) and plunger (9) into the spool
end housing (10). Place the spool end housing with
a new oiled o-ring (11) into position on the end of the
spool. Be sure the spool end housing rests square
on the side of the transfer carriage section (7).
Secure the spool end housing in place with the two
hex socket head capscrews (12). Torque the
capscrews to 7 ±1 lb-ft (9,5 ±1,4 Nm). Repeat for the
other side of the section.
4. Place the lower compensator plunger (13) followed
by the spring (14) and the upper compensator
plunger (15) into the cavity on the top of the transfer
carriage section (7). Secure in place with the hex
plug (16) and new oiled o-ring (17). Torque the plug
to 48 ±5 lb-ft (65 ±7 Nm).
5. Place the three new oiled o-rings (18) in place on the
transfer carriage section (7). Place the new oiled o-
ring (19) in place on the transfer carriage section.
Carefully slide the transfer carriage section onto the
capscrews (4). Slide the section tight against the
inlet section.
Auxiliary Hydraulic Section Assembly
1. Install the relief valves (20) preset at 2900 psi
(200 bar) with new seals into the “A” side and the “B”
side of the auxiliary hydraulic section (21). Torque
the relief valves to 33 ±3.5 lb-ft (45 ± 4,8 Nm). Refer
to the Parts Manual for seal kits.
2. Install the spring (22) and plunger (23) into the spool
end housing (24). Place the spool end housing with
a new oiled o-ring (25) into position on the end of the
spool. Be sure the spool end housing rests square
on the side of the auxiliary hydraulic section (21).
Secure the spool end housing in place with the two
hex socket head capscrews (26). Torque the
capscrews to 7 ±1 lb-ft (9,5 ±1,4 Nm). Repeat for the
other side of the section.
3. Place the lower compensator plunger (27) followed
by the spring (28) and the upper compensator
plunger (29) into the cavity on the top of the auxiliary
hydraulic section (21). Secure in place with the hex
plug (30) and new oiled o-ring (31).Torque the plug
to 48 ±5 lb-ft (65 ±7 Nm).
4. Place the three new oiled o-rings (32) in place on the
auxiliary hydraulic section (21). Place the new oiled
o-ring (33) in place on the auxiliary hydraulic section.
Carefully slide the auxiliary hydraulic section onto
the capscrews (4). Slide the section tight against the
transfer carriage section.
5. Place the three new oiled o-rings (34) in place on the
mono block section (35). Place the new oiled o-ring
(36) in place on the mono block section.
6. Carefully place the auxiliary hydraulic section (21),
transfer carriage section (7) and inlet sections (2)
against the mono block (35). Tighten the four hex
socket head capscrews to hold all the sections
together. Torque the four capscrews to 25 ±2.5 lb-ft
(34 ±3,4 Nm).