Lull 944E-42 Service Manual Download

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8.149

Model 644E-42/944E-42

Rev. 6/04

Hydraulic System

8.8.52

Boom Extend/Retract Circuit
Description (Single Joystick)

Hydraulic flow is applied in the Boom Extend/Retract
circuit (see page 8.76 and page 8.80) by the secondary
section of the Hydraulic Gear Pump through the Main
Control Valve. The primary section of the pump provides
hydraulic flow to the “P” Port through the Accumulator
Charge/Secondary Function Valve out the “EF” Port to
the Main Control Valve. System pressure is directed to
either side of the Extend/Retract Cylinder by the shifting
of the spool in the Main Control Valve. The spool is
shifted by pilot pressure provided from the Accumulator
Charge/Secondary Function Valve out the “PIL” Port, to
the Single Joystick Pilot Select Valve “P” Port and to the
Single Joystick “P” Port. The pressure is regulated by the
position of the joystick.

a. Boom Extend Position (See page 8.76)

When the joystick is in the boom EXTEND
position, pilot pressure from Port “2” of the
Single Joystick flows to Port “P2” on the Single
Joystick Pilot Select Valve and out the “EB” Port

to the Main Control Valve. Then shifts the Extend Spool
on the Main Control Valve and opens up the Extend Port
on the Main Control Valve providing 2900 psi (200 bar) to
the “Extend” Port on the Extend/Retract Cylinder. The
pressure now in the Extend/Retract Cylinder passes the
Counterbalance Valve and is sent up into the base of the
cylinder and extends the piston. The return flow passes
the Pilot-Operated Check Valve and exits the Extend/
Retract Cylinder “Retract” Port and enters the Main
Control Valve through the “Retract” Port and out the
“Outlet” Port flowing to the Hydraulic Oil Cooler. The oil
then passes through the Return Filter and returns the oil
to the Hydraulic Reservoir.

If system pressure exceeds 2900 psi (200 bar), the
extend port relief will open and allow hydraulic oil to return
to the reservoir. If the return filter becomes plugged the
indicator light will come ON indicating that return
hydraulic oil will bypass the filter when pressure reaches
25 psi (1,7 bar) and return to the reservoir unfiltered.

b. Boom Retract Position (See page 8.80)

When the joystick is in the boom RETRACT
position, pilot pressure from Port “1” of the
Single Joystick flows to Port “P1” on the Single
Joystick Pilot Select Valve and out the “EA” Port

to the Main Control Valve. Then shifts the Retract Spool
on the Main Control Valve and opens up the “Retract”
Port providing up to 3400 psi (234 bar) to the “Retract”
Port on the Extend/Retract Cylinder. The flow passes the
Pilot-Operated Check Valve to the rod end of the piston

and passes through the Counterbalance Valve before
exiting the Extend/Retract Cylinder “Extend” Port. The oil
then flows to the Main Control Valve entering through the
“Extend” Port and out the “Outlet” Port flowing to the
Hydraulic Oil Cooler. From the Hydraulic Oil Cooler the oil
passes through the Return Filter and returns the oil to the
Hydraulic Reservoir.

If system pressure reaches 3400 psi (234 bar), the main
relief valve opens, allowing hydraulic oil to return to the
reservoir. If the return filter becomes plugged the
indicator light will come ON indicating that return
hydraulic oil will bypass the filter when pressure reaches
25 psi (1,7 bar) and return to the reservoir unfiltered.

The Extend/Retract Cylinder includes a counterbalance
valve and a pilot-operated check valve. The valves serve
two main functions. One of the functions is to help prevent
component damage.

The other valve functions can be described as follows:

• If the vehicle is travelling and the boom runs into a

solid object, pressure will build up on the base end of
the of the cylinder. Without a counterbalance valve,
the cylinder rod would bend, damaging the cylinder.
With the counterbalance valve installed, the
pressure will build up until it reaches 4000 psi
(276 bar) and then the counterbalance valve will be
internally piloted open, allowing the pressure to
return to the reservoir. This condition will only exist if
the cylinder has been extended. If the cylinder is fully
retracted, the counterbalance valve will have no
effect and damage can result.

• Should any of the hydraulic lines going to the

Extend/Retract Cylinder fail, there will be a loss of
hydraulic system pressure to the cylinder. For
example, if there was a hydraulic line failure in the
pressurized retract line during retracting, the
counterbalance valve would lose pilot pressure,
closing off flow returning to the reservoir. The oil in
the base end of the cylinder would then be trapped,
which would immediately stop boom retraction,
preventing an elevated load from uncontrolled
retraction. The load can be lowered safely to the
ground by following the “Emergency Boom
Lowering” procedures in the Owner/Operators
Manual that came with your vehicle.

IMPORTANT: DO NOT attempt to reset a
counterbalance valve cartridge. In the event that a
counterbalance valve cartridge was disabled for
emergency boom lowering or any unauthorized
adjustments are ever made to this cartridge, remove and
replace the cartridge with a new part. Failure to replace
this cartridge with a new part may alter the holding
characteristics of the counterbalance valve, creating an
unsafe condition for vehicle operation.

Lull 944E-42, Service Manual

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