Lull 6K Service Manual manuals

Lull 6K Service Manual User Manual (636 pages)

Brand: Lull | Category: Special machinery | Size: 32.13 MB |

English

Table of contents

Service Manual

1

Quick Reference

3

Revision Record

4

Table of Contents

10

List of Figures

14

Section 1 — Safety

27

Maintenance Safety

30

Fuel Hazards

31

Engine Coolant Hazards

31

Electrical System Hazards

32

Hydraulic System Hazards

32

Tire and Wheels Hazards

33

Decals and Placards

34

Attaching Decals

35

Decal Locations

35

Fig. 1-1: Decals and Placards

36

Fig. 1-3: Control Decals

37

FRONT WHEEL STEER

38

ROUND STEER OBLIQUE STEER

38

Serial Number Locations

41

Engine Serial Number, Cummins

42

Axle Serial Number

43

Models 644B-37 and 6K-37

44

Specifications

45

Models 644B-42 and 6K-42

48

Models 844C-42 and 8K-42

52

Models 1044C-42 and 10K-42

56

Models 1044C-54 and 10K-54

60

Engine Specifications

64

John Deere 6068D

65

Cummins 4B3.9

65

Cummins 4BT3.9

65

Cummins 4BT3.9 (EPA)

66

Cummins 6B5.9

66

General Instructions

69

Service And Repair Procedures

70

Replacement Parts

71

General Specifications

72

Engine Oil Specifications

72

General Maintenance

73

Fuel Requirements

74

Care and Cleaning

75

Cleaning the Cab

76

Cleaning Decals

76

Torque Specifications

78

Hydraulic Fitting Torques

81

Jump Starting Procedures

83

Conversion Charts

85

644B-42 ........ S/N: 137-207

90

UPPER HYDRAULICS

100

LOWER HYDRAULICS

100

FRONT OF MACHINE

100

JOYSTICK CONTROL VALVES

101

Reference Diagrams

103

1044C-54 ...... S/N: 155

106

644B-42 ...... S/N: 101–207

110

List of Tables

144

Major System Components

145

General Description

145

Hydraulic Systems

147

Safe Maintenance Practices

148

Cleanliness

148

Checking Hydraulic Lines

149

Hydraulic Reservoir

150

Fig. 5-5: Hydraulic Reservoir

151

Filling Hydraulic Reservoir

152

Alternate Method

153

Reservoir Drain and Refill

155

Hydraulic Reservoir and

157

Fuel Tank

157

Installation

159

Description

160

Sight Gauge

161

Suction Strainer

163

Removal and Cleaning

164

Checking Filter Condition

166

Return Filter Assembly

170

Reservoir Breather

171

Hydraulic Pressure Filter

172

Pressure Filter Assembly

175

Hydraulic Pump

177

Troubleshooting Pump Problems

178

Checking Pump Flow Rate

187

Multi-Spool Control Valve

189

Overhaul

194

Fig. 5-34: Spool Assembly

195

Disassembly, CRA Assembly

199

Inlet and Outlet Covers

202

Fig. 5-39: Main Relief Valve

206

Hydraulic Control Manifold

208

Table 5-1: Manifold Markings

210

Control Valve Functions

211

Control Manifold

215

Assembly

219

Manifold Assembly

219

Pump Unloader Valve

221

Mid-Inlet Control Valve

224

(BASE END)

234

(ROD END)

234

REAR OSC

235

LOCK (G1)

235

LOCK (G2)

235

Roll-Back Hose Tray

236

Section 6 — Boom and Transfer

241

Joystick Controls

252

Joystick

253

Disassembly

255

Boom and Transfer

256

Hydraulic Cylinders

259

Checking Cylinder Condition

260

Boom Hoist Cylinder

261

REV. 001

262

Front Carriage Tilt Cylinder

267

Front Carriage Tilt

268

Cylinder

268

Rear Carriage Tilt Cylinder

273

Boom Hydraulic Control

279

Valve (Control Manifold

279

Selector Valve (Control

289

Manifold System)

289

Hydraulics

289

Selector Valve (Mid-Inlet

294

Troubleshooting

297

Boom Slide Pads — General

298

Inspect all pads weekly

299

Lubrication

300

Slide Area Surface Finish

300

0.030" Max

301

0.030"

301

Quick Attach

304

clearing the lock plate

305

Connecting an Attachment

306

Fig. 6-49: Lock Plate Engaged

307

Boom Angle Inclinometer

310

2-Section Boom

311

0.625"–0.688"

312

(5/8"–11/16")

312

Rear of Boom, Looking Forward

315

Inspection Procedures

317

These pads are

324

3-Section Boom

340

Shimming Procedures

341

1/4" (0.25") Max

347

3/16" (0.19")

347

644B-42 (S/N 101–141)

349

844C-42 (S/N 101–433)

349

1044C-42 (S/N 101–110)

349

6K-42 (S/N 101–113)

349

8K-42 (S/N 101–192)

349

Fig. 6-106: Boom Cover

352

Fig. 6-109: Anchor Base

354

Fig. 6-118: Hose Tensioner

363

Fig. 6-123: Rear Chain Anchor

366

Fig. 6-126: Rear Chain Anchor

370

Extension Cylinder

390

4-Section Boom

396

Locations for

409

Chain Attachment

409

10K-54 (S/N 101– 102):

434

Sections

451

Boom Extension

465

Proximity Switch

465

Adjustments

466

Setscrew

468

Rollers, Bushings, and Shims

476

Fig. 6-241: Scraper Plate

478

Transfer Cylinder

495

1044C-54

498

Frame Tilt System

503

Frame Tilt and Oscillation

504

Frame Tilt Control Valve

505

Frame Tilt

511

Frame Tilt Cylinder

512

Frame Level Indicator

519

Oscillation Control Block

533

Frame Tilt Lockout Valve

541

Adjustment

547

Section 8 — Transmission

548

3WG-100, 3-SPEED TRANSMISSION

563

4WG-100, 4-SPEED TRANSMISSION

563

Section 9 — Brakes

573

Brake Testing and Bleeding

576

Fig. 9-3: Diagnostic Ports

577

Fig. 9-4: Brake Bleeding

578

Accumulator Pre-charge

579

Service Brake Pedal and Valve

580

Reassembly

586

Accumulator

592

Precautions

593

Pre-Charging Accumulator

593

Checking Pre-charge

595

Park Brake

602

Inspection

603

Park Brake Pressure Switch

604

# Description

605

1 Park Brake Pressure Switch

605

2 Intermediate Wire Harness

605

Valve Removal, Park Brake

607

Cylinder Removal

610

Cylinder Installation

613

Adjustment, Park Brake

614

Drum Brake Repair/Replacement

616

Section 10 — Outriggers

617

Outriggers

620

Outrigger Cylinders

623

Outrigger Control Valves

632

Outrigger Control Valve

633

JLG Worldwide Locations

636

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