Lull 944E-42 Service Manual - Manual (Page 491)

8.239 Model 644E-42/944E-42 Rev. 6/04
Hydraulic System
f. Stabilizer 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. Connect all the wire harness connectors to the
proper solenoids and snap into place.
5. 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.
6. 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).
7. Remove all tools, etc. from the vehicle. Carefully
remove the blocking supporting the vehicle frame at
the front and rear axles.
8. 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.
9. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF. Add
hydraulic fluid to the reservoir as required.
10. Wipe up any hydraulic fluid spillage in, on, near and
around the vehicle, work area and tools.
g. Stabilizer 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. Level the frame.
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. Refer to Section 8.7, “Hydraulic
System Testing.”
4. Level the frame.
5. Repeat Steps 3 thru 4 five times.
8.14.10 Steering Cylinders
The steering cylinders (26 and 27) are a part of the axle
assemblies. Steer cylinders are covered in the
appropriate manufacturer’s axle literature. Refer to the
ZF Axle Repair Manual, (944E Front) Model MS-T 3060,
JLG P/N 8990430 (ZF P/N 5871 560 002) and (944E
Rear & 644E Front and Rear) Model MS-T 3045, JLG
P/N 8990419 (ZF P/N 5871 550 002).
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.
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