Lull 944E-42 Service Manual - Manual (Page 468)

Hydraulic System
8.216 Model 644E-42/944E-42 Rev. 6/04
4. Install both precision wearbands (16) and the
capped T-seal (17) onto the piston (7).
Note: The T-seal actually consists of four components; a
wide, flexible inner band, the flexible T-seal band itself,
and two supportive split caps that mount on either side of
the “T” itself.
5. Install the head gland (6) and piston (7) onto the
rod (4).
IMPORTANT: Protect the finish on the rod at all times.
Damage to the surface of the rod can cause seal failure.
6. Fasten the rod end in a soft-jawed vise and put a
padded support below and near the threaded end of
the rod to help prevent damage to the rod. Apply
Loctite #271 (red) and install a new locknut (8) onto
the rod (4). Torque the nut to 1100-1250 lb-ft
(1491-1695 Nm). The threads will deform upon
tightening, locking the nut in place.
IMPORTANT: Avoid using excess force when clamping
the cylinder in a vise. Apply only enough force to hold the
cylinder securely. Excessive force can damage the
cylinder.
7. Place the attachment tilt cylinder tube (2) in a soft-
jawed vise or other acceptable holding equipment if
possible.
IMPORTANT: When sliding the rod and piston assembly
in the tube, prevent the threaded end of the tube from
damaging the piston (7). Keep the rod centered within
the tube to help prevent binding.
8. Carefully insert the rod (4), with all attachments,
straight into the tube (2).
9. Using a pin spanner wrench, thread the head
gland (6) almost completely into the tube (2), leaving
just enough room to install a new locking insert (12)
into its hole in the head gland threads.
10. Install a new locking insert (12). Thread the head
gland (7) tightly into the tube and torque to
300-400 lb-ft (407-542 Nm).
11. Using new oiled o-rings, thread the 4000 psi
(276 bar) counterbalance valves (5) into the
attachment tilt cylinder block. Torque to 30-35 lb-ft
(41-47 Nm).
12. If necessary install the bushings (19) into the rod (4).
13. If necessary, install a grease fitting (3) into the
tapped hole in the end of the rod (4). Lubricate the
bushings in the rod end through the grease fitting
with multi-purpose grease before the vehicle is
operated.
14. Install the grease fitting (20) into the base end of the
cylinder.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
MU3540