Lull 944E-42 Service Manual User Manual download pdf (Page 439)

100

101

8.187

Model 644E-42/944E-42 Rev. 6/04

Hydraulic System

4. Clean all components with a suitable cleaner before

inspection.

5. Inspect internal passageways of the pilot select

valve and its component parts for wear, damage, etc.

If inner surfaces of the pilot select valve DO NOT

display an ultra-smooth, polished finish, or

components are damaged in any way, replace the

pilot select valve or appropriate part. Often, dirty

hydraulic fluid causes failure of internal seals and

damage to the polished surfaces within the pilot

select valve.

6. Secure the pilot select valve block (7) in a bench vise

or by other suitable means.

7. Install the elbow fittings (6) into the “A3” and “B1”

ports on one side of the block (7) and into the “P1”

and “P2” ports on the other side.

8. Install the straight fittings (8) into the “A1” and “B3”

ports on one side of the block.

9. Install the two solenoid cartridges (9) into the block.

Torque the cartridges to 20 lb-ft (27 Nm). Torque the

solenoid nuts to 5 lb-ft (7 Nm).

c. Pilot Select Valve Installation

1. Position the pilot select valve (5) back onto the valve

plate.

2. Insert the two capscrews (4) through the pilot select

valve (5) and secure to the valve plate. Torque the

two capscrews to 5-9 lb-ft (7-12,5 Nm).

3. Reattach and secure all hoses and fittings.

4. Reconnect any wire harness connectors.

5. 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.

6. Inspect the pilot select valve for leaks and check the

level of the hydraulic fluid in the reservoir. Shut the

engine OFF.

Note: Check for leaks and repair as required before

continuing. Add hydraulic fluid to the reservoir as

needed.

7. Wipe up any hydraulic fluid spillage in, on, near and

around the vehicle, work area and tools.

8. Reinstall the access plate (10) to the cab floor.

Secure in place with the capscrews (11). Torque the

capscrews to 18 lb-ft (25 Nm).

d. Pilot Select Valve Test

Conduct a pressure check of the joystick circuit. Refer to

Section 8.7, “Hydraulic System Testing.”

MU40506

“A1” and “B3”

Ports

“B1”

Port

“A3”

Port

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: Hydraulic oil leaking under

pressure can penetrate the skin and cause

severe personal injury. DO NOT use your hand

or any part of your body to check for hydraulic

leaks. When checking for hydraulic leaks, wear

safety glasses and gloves to help provide

protection from spraying hydraulic oil. Use a

piece of cardboard or paper to search for

leaks.

MU3770

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