Lull 944E-42 Service Manual - Manual (Page 486)

Hydraulic System
8.234 Model 644E-42/944E-42 Rev. 6/04
f. Frame Sway Cylinder Installation
1. Use a sling and hoist or other suitable lifting device
to help install the cylinder. Orient the cylinder with
the cylinder base on top and the rod eyelet on the
bottom.
2. Install the upper cylinder pin through the frame
mount, cylinder base and other frame mount. Secure
the pin with a capscrew, flat washer and the retainer
spacer. Torque to 43-78 lb-ft (59-106 Nm).
3. Use new oiled o-rings when installing the upper and
lower hydraulic hoses. Install and tighten the hoses
onto the appropriate fittings.
4. With the help of an assistant, start the engine.
Carefully and slowly, operate the joystick frame sway
function to properly align the rod with the anchor
plate as required. Turn the engine OFF.
5. Install the lower cylinder pin. Drive the cylinder pin
through the rod eyelet, anchor plate and self-aligning
bearing. Secure the pin with a capscrew and hex
locknut. Torque nut to 12-23 lb-ft (17-31 Nm).
6. Remove all tools, etc. from the vehicle. Carefully
remove the blocking supporting the vehicle frame at
the front and rear axles.
7. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the vehicle or operating any hydraulic
functions. Operate the joystick to fully sway the
frame left and right at least five times each.
8. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF. Add
hydraulic fluid if required.
9. Wipe up any hydraulic fluid spillage in, on, near and
around the vehicle, work area and tools.
g. Frame Sway Cylinder Pressure Checking and
Circuit Bleeding
1. Attach a 5000 psi (345 bar) gauge to the main
control valve to test the frame sway/stabilizer
cylinder hydraulic system circuit pressure. The unit is
equipped with test fittings from the factory. Refer to
Section 8.7, “Hydraulic System Testing.”
2. Start with the frame sway and stabilizer cylinders
balanced; that is, with the frame level.
3. Sway the vehicle fully left. Hold the joystick at full
sway left for several seconds, then sway the vehicle
fully right and hold the joystick at full sway right for
several seconds. Observe the readings on the
gauge. Refer to Section 8.7, “Hydraulic System
Testing.”
4. Level the frame.
5. Repeat Steps 3 thru 4 five times.
WARNING:
Avoid prolonged engine
operation in closed areas with inadequate
ventilation. Failure to properly ventilate exhaust
fumes can result in death or serious injury.
WARNING:
Escaping hydraulic fluid
under pressure can penetrate the skin, causing
death or serious injury.