Lull 6K Service Manual User Manual

An Oshkosh Truck Corporation CompanyService ManualModels644B, 6K, 844C, 8K, 1044C, 10K10709790RevisedFebruary 18, 2005

6 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KTable of ContentsBoom Slide Pads — General . . . . . . . . . . . . . . . . . . . . . . . . . .

Reference Diagrams4-13Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KPSI160 PSI2450XXVENTT1BOOM TELESCOPE CYLINDERACCUMULATORBOOM ROLL BACK HOS

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-14XXNOTE: HUSCO VALVE ASSEMBLY IS ORIENTATEDSO THAT THE "A" PORTS

Reference Diagrams4-15Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3175 PSIL.H.OUTRIGGERR.H.OUTRIGGERFRAME TILTTRANSFERCARRIAGETILTAUX. 1AAAA

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-16NOTESSchematic, Models 644B, 844C, 1044C-42 w/Turbocharged Engine, Mid-Inl

Reference Diagrams4-17Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KX2VENTT1BOOM TELESCOPE CYLINDERACCUMULATORBOOM ROLL BACK HOSESVALVE@ 3150

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-18XX2800PSI2800PSI3175 PSIL.H.OUTRIGGERR.H.OUTRIGGERFRAME TILT TRANSFERCARRI

Reference Diagrams4-19Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3175 PSIL.H.OUTRIGGERR.H.OUTRIGGERFRAME TILTTRANSFERCARRIAGETILTAUX. 1AAAA

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-20NOTESSchematic, Model 1044C-54, Mid-Inlet Hydraulic System - Diagram 5

Reference Diagrams4-21Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KE7285 308786 87 IGN.ACC.ST.BAT.121110987654321H B SIGNITIO

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-22BACK-UPALARMOUTPUT+–925 CCA12VBATTERYMOTORSTARTER123456789101112–+OIL PRES

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 7Table of ContentsTransfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reference Diagrams4-23Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KThis diagram applies to the following Model(s) and serial numbers:644B-37

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-24NOTESElectrical Diagram, Models 644B and 6K w/Control Manifold Hydraulic S

Reference Diagrams4-25Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KENGINEWATERTEMPERATUREENGINEPRESSUREOIL VOLTAGEBATTERYFUELLOCKOSCREARBRAKE

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-26ABCABABABABBLACKBLUEINPOWERBROWNGROUNDCLOSED WITH BOOM ANGLE LESS THAN 40°

Reference Diagrams4-27Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KThis diagram applies to the following Model(s) and serial numbers:644B-37

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-28NOTESRear Oscillation Lock System Operation, Control Manifold Hydraulic Sy

Reference Diagrams4-29Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KR4 RELAYIGNITION SWITCH RELAYR5 RELAYINSTRPARKINLCPDSTPPLTPRPUP1GSTBOR2PFL

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-30BAINOUTCARRAUXTRANSFRAMEBAPBA1 B1P2P1B3A3HOISTTELESCOPEINAINBOUTENGI

Reference Diagrams4-31Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KThis diagram applies to the following Model(s) and serial numbers:644B-37

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-32NOTESBoom/Transfer Extend Lockout Circuit Operation, Control Manifold Hydr

8 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KTable of ContentsOscillation Control Block . . . . . . . . . . . . . . . . . . . . . . . . . .

Reference Diagrams4-33Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KENGINEWATERTEMPERATUREENGINEPRESSUREOIL VOLTAGEBATTERYFUELLOCKOSCREARBRAKE

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-34STABILIZER CONTROL VALVESOLENOID VALVE ON REAR AXLEABBLACK-14ABCBLACK-16WH

Reference Diagrams4-35Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KThis diagram applies to the following Model(s) and serial numbers:644B-37

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-36NOTESRear Oscillation Lock System Operation, Mid-Inlet Hysraulic System -

Reference Diagrams4-37Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRear Axle Stabilizer Control Valve Operation, Mid-Inlet Hydraulic System -

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-38Rear Axle Stabilizer Control Valve Operation, Mid-Inlet Hydraulic System -

Reference Diagrams4-39Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRear Axle Stabilizer Control Valve Operation, Mid-Inlet Hydraulic System -

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-40Rear Axle Stabilizer Control Valve Operation, Mid-Inlet Hydraulic System -

Reference Diagrams4-41Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KR4 RELAYIGNITION SWITCH RELAYR5 RELAYINSTRUMENT PANPARKING BRAKE VA18&quo

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-4217-1/2A3246520A10A10A30A10AENGINEWATERTEMPERATUREENGINEPRESSUREOIL VOLTAGE

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 9Table of ContentsAccumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reference Diagrams4-43Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KThis diagram applies to the following Model(s) and serial numbers:644B-37

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-44NOTESBoom/Transfer Extend Lockout Circuit Operation, Mid-Inlet Hydraulic S

Reference Diagrams4-45Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KABDCFemalePinsABDCShifterMalePinsABDCPluggedN/AN/AN/AABDCFE181735153332141

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-46FADEmissiononnectorSensornector604608652654682Wire Groups Having Common Wi

Reference Diagrams4-47Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KThis diagram applies to the following Model(s) and serial numbers:644B-37

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-48NOTESElectrical Diagram, ZF DW-2/EST-19 System Harness - Diagram 12

Reference Diagrams4-49Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KElectrical Diagram, ZF DW-3 System Harness - Diagram 13

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-50Electrical Diagram, ZF DW-3 System Harness - Diagram 13

Reference Diagrams4-51Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KThis diagram applies to the following Model(s) and serial numbers:644B-37

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-52NOTESElectrical Diagram, ZF DW-3 System Harness - Diagram 13

10 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KList of FiguresFig. 1-1: Decals and Placards . . . . . . . . . . . . . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K iSection 5 — Supply, Pressure, and Return HydraulicsTable of ContentsGeneral . . . . . . . . .

ii Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KHydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K iiiFig. 5-4: Hydraulic Reservoir Location . . . . . . . . . . . . . . . . . . . . . . . . . .

iv Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 5-43: Hydraulic Control Manifold Removal/Installation. . . . . . . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-1Section 5 — Supply, Pressure, and Return HydraulicsGeneralMajor System ComponentsFig. 5-1: Ma

Supply, Pressure, and Return Hydraulics5-2Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KThese circuits are supplied by a two-section, gear-typ

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-3Hydraulic SystemsControl Manifold Hydraulic System6K-3

Supply, Pressure, and Return Hydraulics5-4Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KThe term “mid-inlet hydraulic system” is used to refer

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-5KEEP DIRT AND OTHER CONTAMINANTS OUT OF THE SYSTEM! Sm

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 11List of FiguresFig. 5-14: Return Filter Pressure Gauge . . . . . . . . . . . . . . . . . . .

Supply, Pressure, and Return Hydraulics5-6Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K• Hydraulic oil leakage at any threaded or clamped joi

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-7Fig. 5-5: Hydraulic Reservoir(Ref. Fig. 5-5) The hydra

Supply, Pressure, and Return Hydraulics5-8Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFilling Hydraulic ReservoirPreferred MethodCAUTION: Do

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-97. Start engine and allow hydraulic system to warm up.

Supply, Pressure, and Return Hydraulics5-10Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. The machine must be parked on a level surface and

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-11Reservoir Drain and RefillFig. 5-8: Hydraulic Reservo

Supply, Pressure, and Return Hydraulics5-12Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6. Clean the strainer (Item 2) by back flushing with

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-13RemovalHydraulic Reservoir and Fuel TankFig. 5-9: Hyd

Supply, Pressure, and Return Hydraulics5-14Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K(Ref. Fig. 5-9) The following procedure describes rem

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-1514. Remove the fuel tank drain plug. Clean the inside

12 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KList of FiguresFig. 5-52: Mid-Inlet Control Valve Configurations, Models 6K, 8K, 10K . . . .

Supply, Pressure, and Return Hydraulics5-16Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KSight GaugeDescriptionFig. 5-10: Hydraulic Reservoir

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-17RemovalSight GaugeFig. 5-11: Reservoir Sight Gauge In

Supply, Pressure, and Return Hydraulics5-18Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6. Remove the sight gauge (Item 1) along with the two

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-19Suction StrainerDescriptionFig. 5-12: Suction Straine

Supply, Pressure, and Return Hydraulics5-20Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemoval and CleaningSuction StrainerModels with Contr

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-21InstallationSuction StrainerModels with Control Manif

Supply, Pressure, and Return Hydraulics5-22Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KHydraulic Return FilterDescriptionFig. 5-13: Hydrauli

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-23The return filter pressure gauge is located on the si

Supply, Pressure, and Return Hydraulics5-24Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2. Loosen four (4) flange nuts (Item 2) that secure c

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-25Replacement, Return Filter Element(Ref. Fig. 5-16) Th

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 13List of FiguresFig. 6-28: Selector Valve Assembly – Models with Mid-Inlet Hydraulics . . . .

Supply, Pressure, and Return Hydraulics5-26Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalReturn Filter AssemblyFig. 5-17: Return Filter

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-276. Remove the diffuser (Item 7) and clean with solven

Supply, Pressure, and Return Hydraulics5-28Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemoval and InstallationReservoir Breather1. Loosen a

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-29Checking Filter Element ConditionFig. 5-20: Pressure

Supply, Pressure, and Return Hydraulics5-30Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KReplacing Pressure Filter ElementFig. 5-21: Hydraulic

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-312. Clean hydraulic pressure filter assembly to avoid

Supply, Pressure, and Return Hydraulics5-32Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. Follow preparation procedures as outlined in Secti

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-33Hydraulic PumpDescriptionFig. 5-23: Hydraulic Pump Lo

Supply, Pressure, and Return Hydraulics5-34Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KTroubleshooting Pump ProblemsProblem Probable Cause S

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-35RemovalHydraulic PumpModels with Control Manifold Hyd

14 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KList of FiguresFig. 6-66: Inner Boom Cross-Section at Window . . . . . . . . . . . . . . . .

Supply, Pressure, and Return Hydraulics5-36Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3. While watching test gauge, press brake pedal numer

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-37Models with Mid-Inlet Hydraulics6K-37 (S/N 318–)6K-42

Supply, Pressure, and Return Hydraulics5-38Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4. For models 644B, 844C, and 1044C, refer to roll-ba

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-39(Ref. Fig. 5-26) The following procedures completes t

Supply, Pressure, and Return Hydraulics5-40Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4. Clean exposed areas of hydraulic pump with appropr

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-414. Remove caps and clean hydraulic hose ends (Items 5

Supply, Pressure, and Return Hydraulics5-42Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7. Install hydraulic hose (Item 18) from check valve

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-43Checking Pump Flow RateFig. 5-27: Checking Hydraulic

Supply, Pressure, and Return Hydraulics5-44Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6. Adjust pressure relief valve setting to 100 psi ov

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-45Multi-Spool Control ValveDescription6K-37 (S/N 101–31

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 15List of FiguresFig. 6-104: Upper Chains - Third Type . . . . . . . . . . . . . . . . . . . .

Supply, Pressure, and Return Hydraulics5-46Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KMulti-Spool Control Valve Configurations, Models 644B

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-47Multi-Spool Control Valve Configurations, Models 6K,

Supply, Pressure, and Return Hydraulics5-48Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KControl Valve OperationFig. 5-31: Multi-Spool Control

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-49RemovalMulti-Spool Control ValveFig. 5-32: Multi-Spoo

Supply, Pressure, and Return Hydraulics5-50Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4. Stop engine and check for hydraulic leaks. Tighten

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-51Assembly, Multi-Spool Control Valve(Ref. Fig. 5-33) T

Supply, Pressure, and Return Hydraulics5-52Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. Loosen and remove four (4) each socket head capscr

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-534. Apply type II, grade O, thread locking compound on

Supply, Pressure, and Return Hydraulics5-54Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4. Remove O-ring (Item 5) and backup washer (Item 4)

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-55Disassembly, CRA AssemblyFig. 5-36: CRA AssemblyK1070

16 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KList of FiguresFig. 6-142: Front Slide Pads Installation, Outer Boom . . . . . . . . . . . .

Supply, Pressure, and Return Hydraulics5-56Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K(Ref. Fig. 5-36) The following procedure describes di

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-57Assembly, CRA Assembly(Ref. Fig. 5-36) The following

Supply, Pressure, and Return Hydraulics5-58Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KInlet and Outlet CoversFig. 5-37: Outlet and Inlet Co

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-59Disassembly, Outlet Cover(Ref. Fig. 5-37) The followi

Supply, Pressure, and Return Hydraulics5-60Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KAssembly, Inlet Cover(Ref. Fig. 5-37) The following p

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-613. Remove O-ring (Item 5) and backup ring (Item 4) fr

Supply, Pressure, and Return Hydraulics5-62Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KDisassembly, Main Relief AssemblyFig. 5-39: Main Reli

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-635. Remove relief poppet (Item 15) and pilot spring (I

Supply, Pressure, and Return Hydraulics5-64Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KHydraulic Control ManifoldDescription6K-37 (S/N 101–3

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-65Fig. 5-42: Hydraulic Control Manifold PortsFig. 5-42

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 17List of FiguresFig. 6-180: Upper Front Slide Pad Removal – Middle (Rear) Boom Section . . .

Supply, Pressure, and Return Hydraulics5-66Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KTable 5-1: Manifold MarkingsView Marking DescriptionA

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-67Control Valve FunctionsThe following is a description

Supply, Pressure, and Return Hydraulics5-68Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KLogic ValveThe Logic (LC) valve opens and closes depe

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-69Pilot Unloading Valve (PU)The Pilot Unloading (PU) va

Supply, Pressure, and Return Hydraulics5-70Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KHydraulic Manifold Assembly FunctionsAccumulator Char

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-71RemovalControl ManifoldFig. 5-43: Hydraulic Control M

Supply, Pressure, and Return Hydraulics5-72Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. Follow preparation procedures as outlined in Secti

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-735. Inspect and replace any damaged fittings or O-ring

Supply, Pressure, and Return Hydraulics5-74Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6. Clean valve cartridges using an solvent. Dry with

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-75Installation, Hydraulic Control Manifold Plugs and Ca

18 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KList of FiguresFig. 6-218: Lower Chain Installation – Middle (Forward) Boom Section . . . . .

Supply, Pressure, and Return Hydraulics5-76Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. Install low brake pressure switch (Item 1) into SW

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-77Pump Unloader ValveGeneral644B-37 (S/N 101–590, 592–6

Supply, Pressure, and Return Hydraulics5-78Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalPump Unloader ValveFig. 5-47: Pump Unloader Va

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-796. Tag and slowly loosen six (6) hydraulic hoses (Ite

Supply, Pressure, and Return Hydraulics5-80Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K(Ref. Fig. 5-48) The following procedures describes o

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-81Fig. 5-50: Mid-Inlet Control Valve Components(Ref. Fi

Supply, Pressure, and Return Hydraulics5-82Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 5-51: Mid-Inlet Control Valve Configurations, Mo

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-83Fig. 5-52: Mid-Inlet Control Valve Configurations, Mo

Supply, Pressure, and Return Hydraulics5-84Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalMid-Inlet Control ValveFig. 5-53: Mid-Inlet Co

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-85InstallationMid-Inlet Control Valve1. (Ref. Fig. 5-53

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 19List of FiguresFig. 6-256: Transfer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . .

Supply, Pressure, and Return Hydraulics5-86Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 5-55 illustrates views of the control valve, sho

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-87Table 5-5: Rear Axle Stabilizer Control Valve Marking

Supply, Pressure, and Return Hydraulics5-88Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemoval, Rear Axle Stabilizer Control ValveFig. 5-56:

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-89(Ref. Fig. 5-56) The following procedure describes re

Supply, Pressure, and Return Hydraulics5-90Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KBoom Extend Lockout ValveDescriptionFig. 5-57: Boom E

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-91(Ref. Fig. 5-58) The hydraulic ports on models with c

Supply, Pressure, and Return Hydraulics5-92Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K• Brakes – Used for reading pressure of the brake cir

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-93RemovalRoll-Back Hose TrayModels with Control Manifol

Supply, Pressure, and Return Hydraulics5-94Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 5-61: Roll-Back Tray Installation - Control Mani

Supply, Pressure, and Return HydraulicsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5-95Models with a Mid-Inlet Hydraulic System6K-37 (S/N 31

20 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KList of FiguresFig. 8-7: Typical Shunt Diode Application . . . . . . . . . . . . . . . . . .

Supply, Pressure, and Return Hydraulics5-96Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KInstallationRoll-Back Hose TrayModels with Control Ma

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K iSection 6 — Boom and TransferTable of ContentsBoom and Transfer Hydraulics . . . . . . . . .

ii Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KTroubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K iiiTransfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-23: Selector Valve – Models with Control Manifold Hydraulics . . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K vFig. 6-62: Clearances Between Boom Sections Rear of 2-Section Boom. . . . . . . . . . . . . .

vi Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-101: Middle Boom Cross-Section at Window . . . . . . . . . . . . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K viiFig. 6-140: Rod End of Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . .

viii Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-179: Extension Cylinder Removal – 4-Section Boom . . . . . . . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K ixFig. 6-218: Lower Chain Installation – Middle (Forward) Boom Section . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 21List of FiguresFig. 10-11: Outrigger Control Valve Installation. . . . . . . . . . . . . . .

x Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-257: Transfer Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-1Section 6 — Boom and TransferBoom and Transfer HydraulicsGeneral DescriptionFig. 6-1: Major B

Boom and Transfer6-2Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KJoystick ControlsGeneral DescriptionFig. 6-2: Joystick(Ref. Fig. 6-2) The jo

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-3RemovalJoystickFig. 6-3: Joystick Installation(Ref. Fig. 6-3) The following

Boom and Transfer6-4Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3. Tag, loosen, and remove two (2) swivel tees (Item 11) from connectors (It

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-5DisassemblyJoystickFig. 6-4: Joystick Components(Ref. Fig. 6-4) The followin

Boom and Transfer6-6Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. Pull back boot (Item 17) so that access to retainer (Item 19) and flange

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-7e. Clean all remaining parts of joystick body assembly, including the body’s

Boom and Transfer6-8Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7. Install boot (Item 17) on stem (Item 14) making sure that the top lip of

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-9Fig. 6-6: Pilot Pressure Plugc. (Ref. Fig. 6-6) If the pilot pressure is not

22 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KList of TablesTable 3-1: General Fluid and Lubricant Specifications . . . . . . . . . . . . .

Boom and Transfer6-10Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kdownstream hydraulic line failure or leakage through the control valves or

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-112. Install brake pressure diagnostic port test gauge into brake diagnostic

Boom and Transfer6-12Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalBoom Hoist CylinderFig. 6-8: Boom Hoist Cylinder Installation(Ref. F

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-13WARNING: To avoid personal and/or equipment damage, support the hydraulic c

Boom and Transfer6-14Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KOverhaulBoom Hoist CylinderFig. 6-9: Boom Hoist Cylinder Assembly(Ref. Fig.

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-15a. Place socket wrench over counterbalance valve cartridge (Item 8). Wrap a

Boom and Transfer6-16Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K16. Inspect counterbalance valve cartridge (Item 8), including O-rings, for

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-17Front Carriage Tilt CylinderDescriptionFig. 6-11: Front Carriage Tilt Cylin

Boom and Transfer6-18Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalFront Carriage Tilt CylinderFig. 6-12: Front Carriage Tilt Cylinder

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-19WARNING: To avoid personal and/or equipment damage, support the hydraulic c

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K iSection 1 — SafetyTable of ContentsGeneral . . . . . . . . . . . . . . . . . . . . . . . . .

Boom and Transfer6-20Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KOverhaulFront Carriage Tilt CylinderFig. 6-13: Front Carriage Tilt Cylinder

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-21a. Place socket wrench over counterbalance valve cartridge (Item 5). Wrap a

Boom and Transfer6-22Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K13. Inspect inner surface of barrel, outer surface of piston, and length of

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-23Rear Carriage Tilt CylinderDescriptionFig. 6-14: Rear Carriage Tilt Cylinde

Boom and Transfer6-24Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalRear Carriage Tilt CylinderFig. 6-15: Rear Carriage Tilt Cylinder In

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-253. Tag and disconnect two (2) hydraulic hoses (Item 7) from elbows on both

Boom and Transfer6-26Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5. Clean hydraulic hose ends with solvent. Attach two (2) hoses (Item 7) to

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-27Note: 10K and 1044C models have three (3) holes in the side of the rod bear

Boom and Transfer6-28Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K644B-37 (S/N 101–434), 644B-42 (S/N 101–130), 6K-37 (S/N 101–229), 6K-42 (S

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-29The boom hydraulic control valve is located near the middle of the machine

Boom and Transfer6-30Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K(Ref. Fig. 6-18) The following procedures describes disassembly for the boo

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-31InstallationBoom Hydraulic Control Valve (Control Manifold System)644B-37 (

Boom and Transfer6-32Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFitting Removal* This fitting is a tee on models with a pump unloader valve

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-33Boom Control Valve DisassemblyFig. 6-20: Control Valve Components(Ref. Fig.

Boom and Transfer6-34Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6. Remove the two (2) O-rings (Items 10 and 12) from the spool retainer (It

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-35(Ref. Fig. 6-21) The following procedure describes disassembly and overhaul

Boom and Transfer6-36Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRelief Valve AssemblyFig. 6-22: Relief Valve Assembly(Ref. Fig. 6-22) The f

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-377. Remove piston (Item 7) and poppet (Item 4) from poppet (Item 3).8. Remov

Boom and Transfer6-38Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. Install the four (4) elbows/tees (Items 5, 6, 8, and 9) on the ends of t

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-39RemovalSelector Valve (Control Manifold System)644B-37 (S/N 101–590, 592–66

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1-1Section 1 — SafetyGeneralObserving basic safety rules and precautions can eliminate accidents

Boom and Transfer6-40Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K8. Remove two (2) each nuts (Item 8), lockwashers (Item 7), and capscrews (

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-41OverhaulSelector Valve (Control Manifold System)644B-37 (S/N 101–590, 592–6

Boom and Transfer6-42Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6. Remove O-rings and backup rings (Items 11, thru 15) from solenoid cartri

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-43Selector Valve (Mid-Inlet System)Description644B-37 (S/N 591, 667–)644B-42

Boom and Transfer6-44Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalSelector Valve (Mid-Inlet System)644B-37 (S/N 591, 667–)644B-42 (S/N

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-45InstallationSelector Valve (Mid-Inlet System)644B-37 (S/N 591, 667–)644B-42

Boom and Transfer6-46Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. Loosen and remove four (4) connectors (Item 9) from valve body (Item 10)

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-47TroubleshootingProblem Probable Cause Solution Reference1. Boom fails to ex

Boom and Transfer6-48Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KBoom Slide Pads — GeneralDescriptionWithin the slide boom assemblies, there

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-49Slide Pads with ChamfersFig. 6-30: Pad Worn, But Still OK(Ref. Fig. 6-30) I

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KSection No.Quick ReferenceSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety1-2Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KSafety StandardThe ASME/ANSI B56.6 safety standard for rough terrain forklift trucks de

Boom and Transfer6-50Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KSlide Pads without ChamfersFig. 6-33: Slide Pad Without Chamfers – 3 and 4-

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-51Another option is to install/replace boom wear strips. Contact the JLG Serv

Boom and Transfer6-52Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KReplacing and Shimming Boom Slide Pads — GeneralFig. 6-36: Slide Pad Instal

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-53Adding or removing shims from bolted pads may require a different capscrew

Boom and Transfer6-54Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KQuick AttachDescriptionFig. 6-40: Quick Attach Rear View(Ref. Fig. 6-40) Th

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-558. Pull release handle (1) back.Fig. 6-42: Lock Plate9. The lock pin (2) sh

Boom and Transfer6-56Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-45: Retracting Boom12. Retract the boom until quick attach (5) is cl

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-57Fig. 6-48: Rotating Quick Attach Forward3. Rotate the quick attach (5) upwa

Boom and Transfer6-58Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalQuick Attach1. Disconnect attachment from quick attach.2. Fully retr

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-59Fig. 6-51: Quick Attach Pivot5. (Ref. Fig. 6-51) Remove nut (Item 4), lockw

SafetyService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1-3• Make certain there is adequate light and ventilation.• Remove any foreign substances

Boom and Transfer6-60Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KBoom Angle InclinometerDescriptionFig. 6-52: Boom Angle Inclinometer(Ref. F

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-612-Section BoomDescriptionFig. 6-54: 2-Section BoomThe 2-section boom is use

Boom and Transfer6-62Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. Park machine on firm, level surface and apply park brake. Level the fram

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-63Fig. 6-57: Lower Shim Installation – Front of 2-Section Boom4. (Ref. Fig. 6

Boom and Transfer6-64Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-59: Boom Section Gaps – Rear of 2-Section Boom6. (Ref. Fig. 6-59) Me

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-65Fig. 6-61: Upper Shim Installation – Rear of 2-Section Boom8. (Ref. Fig. 6-

Boom and Transfer6-66Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-63: Gaps Between Pads and Boom – Rear of 2-Section Boom10. (Ref. Fig

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-6711. (Ref. Fig. 6-64) Position inner boom section to obtain the indicated di

Boom and Transfer6-68Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-66: Inner Boom Cross-Section at Window2. (Ref. Fig. 6-66) Place a st

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-695. (Ref. Fig. 6-67) Look through the rear of the boom. Using a 12-inch stra

Safety1-4Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KHydraulic System HazardsThe hydraulic system is under pressure whenever the engine is r

Boom and Transfer6-70Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K8. Place sling around inner boom section, at the front. Chains with hooks m

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-71CAUTION: Use suitable blocking to support the cylinder and prevent damage t

Boom and Transfer6-72Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KCAUTION: Make sure slings and chains are secure and crane is supporting the

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-7312. Cycle all boom hydraulics several times to remove air from system. Retr

Boom and Transfer6-74Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-72: Rear Slide Pads, Inner Boom5. (Ref. Fig. 6-72) Remove four (4) u

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-75Fig. 6-73: Extension Cylinder Rear Support6. (Ref. Fig. 6-73) Place a block

Boom and Transfer6-76Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-74: Extension Cylinder Rod End10. (Ref. Fig. 6-74) Loosen the two (2

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-77Fig. 6-76: Rear Boom Extension Cylinder Mount Support Installation12. (Ref.

Boom and Transfer6-78Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K15. Remove the extension cylinder from the inner boom section.16. Rotate th

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-79Assembly2-Section Boom1. (Ref. Fig. 6-79) With the inner boom section lying

SafetyService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1-5To avoid personal injury…• Electrolyte in batteries contains sulfuric acid which is a p

Boom and Transfer6-80Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KExtension Cylinder2-Section BoomDescriptionFig. 6-80: 2-Section Boom Extens

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-81Fig. 6-81: Extension Cylinder Rod End5. (Ref. Fig. 6-81) Level the boom. Th

Boom and Transfer6-82Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7. (Ref. Fig. 6-82) Tag and disconnect two (2) hoses (Item 3) at the boom e

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-8310. (Ref. Fig. 6-84) Remove four (4) capscrews, lockwashers, and flatwasher

Boom and Transfer6-84Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-86: 2-Section Boom Extension Cylinder Assembly12. (Ref. Fig. 6-86) R

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-8514. (Ref. Fig. 6-86) Remove the hardware securing the hose tray assembly(ie

Boom and Transfer6-86Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K11. (Ref. Fig. 6-81) Secure the extension cylinder to the mounting block wi

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-87Overhaul, Boom Extension CylinderFig. 6-87: 2-Section Boom Extension Cylind

Boom and Transfer6-88Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2. Mount or support the cylinder vertically with the rod end down. Hydrauli

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-8915. Inspect counterbalance valve cartridges (Items 14 and 16), including O-

Safety1-6Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K• NEVER reinflate a tire that has been run flat or seriously under inflated WITHOUT rem

Boom and Transfer6-90Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3-Section BoomDescriptionFig. 6-88: 3-Section BoomThe 3-section boom is use

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-91Shimming Procedures3-Section BoomFig. 6-89: Boom Slide Pad Locations, 3-Sec

Boom and Transfer6-92Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-90: Boom Section Gaps – Front of 3-Section Boom3. (Ref. Fig. 6-90) M

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-93Fig. 6-92: Upper Shim Installation – Front of 3-Section Boom5. (Ref. Fig. 6

Boom and Transfer6-94Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6. (Ref. Fig. 6-93) Measure the gaps between the inner and middle boom sect

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-95Fig. 6-96: Clearances Between Boom Sections – Rear of 3-Section Boom9. Adju

Boom and Transfer6-96Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-98: Clearances Between Boom Sections – Front of 3-Section Boom11. Ad

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-9712. (Ref. Fig. 6-99) Install/remove shim(s) under the indicated pads to obt

Boom and Transfer6-98Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-101: Middle Boom Cross-Section at Window4. (Ref. Fig. 6-101) Place a

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-99644B-42 (S/N 101–141)844C-42 (S/N 101–433)1044C-42 (S/N 101–110)6K-42 (S/N

SafetyService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1-7Attaching DecalsThe surface on which a decal is to be attached must be dry and free of

Boom and Transfer6-100Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K644B-42 (S/N 142–264)844C-42 (S/N 434–856)1044C-42 (S/N 111–120)6K-42 (S/N

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-101644B-42 (S/N 265–)844C-42 (S/N 857–)1044C-42 (S/N 121–)6K-42 (S/N 138–)8K-

Boom and Transfer6-102Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-105: Upper Chain Roller7. (Ref. Fig. 6-105) Remove the capscrew (It

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-103Fig. 6-107: Rear Hose Connections, Inner Boom9. (Ref. Fig. 6-107) Tag and

Boom and Transfer6-104Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-108: Front Slide Pads, Outer Boom12. (Ref. Fig. 6-108) Remove the s

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-10513. (Ref. Fig. 6-109) Remove six (6) capscrews (Item 3) and lockwashers (I

Boom and Transfer6-106Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-111: Rod End of Extension Cylinder15. (Ref. Fig. 6-111) Loosen two

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-107Fig. 6-112: Hose Connections, Outer Boom17. (Ref. Fig. 6-112) Remove three

Boom and Transfer6-108Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-113: Hose Connections, 3-Section Boom21. (Ref. Fig. 6-113) Disconne

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-109Fig. 6-114: Cylinder Pivot Pins23. (Ref. Fig. 6-114) Remove four (4) capsc

Safety1-8Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 1-1: Decals and PlacardsFig. 1-2: Instrument Panel Decals3FT2FTNOTICEFORKLIFT SIGN

Boom and Transfer6-110Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K26. (Ref. Fig. 6-114) Continue with each of the two (2) hoist cylinders (I

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-11129. (Ref. Fig. 6-115) Carefully lift the outer boom (Item 7) clear of the

Boom and Transfer6-112Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-117: Boom Extension Cylinder Removal – 3-Section Boom33. (Ref. Fig.

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-113Fig. 6-118: Hose Tensioner35. (Ref. Fig. 6-118) Remove the hose tensioner

Boom and Transfer6-114Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-119: Attaching Chain to Rear Anchor36. (Ref. Fig. 6-119) Remove the

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-11537. (Ref. Fig. 6-120) Remove the rear chain roller assembly from the rear

Boom and Transfer6-116Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-123: Rear Chain Anchor42. (Ref. Fig. 6-123) Remove the upper and lo

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-117Fig. 6-124: Rear Slide Pads, Inner Boom43. (Ref. Fig. 6-124) Remove slide

Boom and Transfer6-118Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-125: Front Carriage Tilt Cylinder44. (Ref. Fig. 6-125) Remove the n

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-11950. Turn the inner boom upside down.51. (Ref. Fig. 6-125) Remove the capsc

SafetyService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1-9Fig. 1-3: Control DecalsFig. 1-4: Disconnect Battery Decal and Slow Moving Vehicle Sign

Boom and Transfer6-120Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-126: Rear Chain Anchor10. (Ref. Fig. 6-126) Install the upper chain

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-121Fig. 6-127: Front Slide Pads, Middle Boom13. (Ref. Fig. 6-127) Install the

Boom and Transfer6-122Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K14. (Ref. Fig. 6-128) Install rear slide pads and shims on the inner boom

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-123Fig. 6-130: Chain Roller Installation, Middle Boom16. (Ref. Fig. 6-130) In

Boom and Transfer6-124Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-131: Lower Chain Installation17. (Ref. Fig. 6-131) Install the lowe

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-125Fig. 6-132: Hose Tensioner Mounting18. (Ref. Fig. 6-132) Install the hose

Boom and Transfer6-126Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K19. (Ref. Fig. 6-133) Position chain adjustment block (Item 3) tight again

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-1272). Secure cylinder stop to extension cylinder with capscrew (Item 1), loc

Boom and Transfer6-128Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K23. (Ref. Fig. 6-135) Install the auxiliary and carriage tilt hydraulic tu

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-129Fig. 6-137: 3-Section Outer Boom Installation27. (Ref. Fig. 6-137) Partial

Safety1-10Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 1-5: Steer Selector PlateFig. 1-6: Hydraulic Reservoir/Fuel Tank DecalsFig. 1-7:

Boom and Transfer6-130Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-138: Cylinder Pivot Pin Installation29. (Ref. Fig. 6-138) Align the

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-131Fig. 6-139: Hose Connections, 3-Section Boom31. (Ref. Fig. 6-139) Connect

Boom and Transfer6-132Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-140: Rod End of Extension Cylinder37. (Ref. Fig. 6-140) Install the

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-13338. (Ref. Fig. 6-141) Install the anchor base assembly to the bottom of th

Boom and Transfer6-134Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-143: Securing Lower Chain40. (Ref. Fig. 6-143) Adjust the lower cha

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-135644B-42 (S/N 101–141)844C-42 (S/N 101–433)1044C-42 (S/N 101–110)6K-42 (S/N

Boom and Transfer6-136Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K644B-42 (S/N 142–264)844C-42 (S/N 434–856)1044C-42 (S/N 111–120)6K-42 (S/N

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-137644B-42 (S/N 265–)844C-42 (S/N 857–)1044C-42 (S/N 121–)6K-42 (S/N 138–)8K-

Boom and Transfer6-138Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-147: Rear Hose Connections, Inner Boom42. (Ref. Fig. 6-147) Install

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-139Fig. 6-148: Access Cover Installation, Outer Boom49. (Ref. Fig. 6-148) Ins

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K iSection 2 — Identification and SpecificationsTable of ContentsSerial Number Locations . . . .

Boom and Transfer6-140Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KExtension Cylinder3-Section BoomDescriptionFig. 6-150: 3-Section Boom Exte

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-141Removal, Boom Extension CylinderFig. 6-151: Boom Extension Cylinder Remova

Boom and Transfer6-142Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KWARNING: To avoid personal and/or equipment damage, support the hydraulic

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-1431). Install cylinder stop halves (Item 14) on extension cylinder with two

Boom and Transfer6-144Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KOverhaul, Extension CylinderFig. 6-152: 3-Section Boom Extension Cylinder

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-1455. Remove eight (8) capscrews (Item 9) securing rod bearing head (Item 8)

Boom and Transfer6-146Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K23. Lubricate threads on eight (8) capscrews (Item 9) with hydraulic oil.

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-147Shimming Procedures4-Section BoomFig. 6-154: Boom Slide Pad Locations – 4-

Boom and Transfer6-148Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3. (Ref. Fig. 6-155) Measure the gap between boom sections at all upper fr

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-1495. (Ref. Fig. 6-157) Install/remove shim(s) under indicated pads to obtain

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRevision RecordRev. No. Inserted By Date001 Lull (initial release) 12/97B JLG(replace branding w

ii Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KList of FiguresFig. 2-1: Machine Serial Number Plate . . . . . . . . . . . . . . . . . . . .

Boom and Transfer6-150Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-160: Upper Shim Installation – Rear of 4-Section Boom8. (Ref. Fig.

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-151Fig. 6-162: Gaps Between Pads and Boom – Rear of 4-Section Boom10. (Ref. F

Boom and Transfer6-152Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K11. (Ref. Fig. 6-163) Adjust boom positions to obtain clearances between b

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-153Fig. 6-165: Inner Boom Cross-Section at Window2. (Ref. Fig. 6-165) Place a

Boom and Transfer6-154Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4. (Ref. Fig. 6-166) Place a straight edge against the bottom surface of t

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-155Fig. 6-168: 4-Section Boom Cover Installation5. (Ref. Fig. 6-168) Remove s

Boom and Transfer6-156Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K8. (Ref. Fig. 6-169) Tag and disconnect two (2) hoses at boom extension cy

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-157CAUTION: Make sure each cylinder is fully supported so it does not fall an

Boom and Transfer6-158Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-172: Upper Rear Slide Pad Removal – Middle (Forward) Boom Section16

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-15917. (Ref. Fig. 6-173) Remove upper rear slide pads from inner boom section

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-1Section 2 — Identification and SpecificationsSerial Number LocationsMachine Serial NumberFig.

Boom and Transfer6-160Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-175: 4-Section Boom Pivot Pins19. (Ref. Fig. 6-175) Remove two (2)

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-161installation4-Section Boom1. Prepare replacement boom for installation by

Boom and Transfer6-162Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Ka. With the outriggers up, extend the boom, noting that Boom Extension pro

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-163Fig. 6-176: Slide Pad Removal – Outer Boom Section3. (Ref. Fig. 6-176) Rem

Boom and Transfer6-164Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-177: Lower Front Slide Pad Removal – Middle (Rear) Boom Section4. (

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-165Fig. 6-178: Disconnecting Hoses Between Sections5. (Ref. Fig. 6-178) Disco

Boom and Transfer6-166Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KCAUTION: Be sure to note orientation of the hose guard during removal. You

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-1676. (Ref. Fig. 6-179) Remove extension cylinder as follows:a. Support the e

Boom and Transfer6-168Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-180: Upper Front Slide Pad Removal – Middle (Rear) Boom Section9. (

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-169Fig. 6-182: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections1

Identification and Specifications2-2Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KEngine Serial Number, John DeereFig. 2-3: Engine Serial Numb

Boom and Transfer6-170Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K14. (Ref. Fig. 6-183) Remove chain roller pin, two (2) guide washers (Item

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-17116. (Ref. Fig. 6-185) Disconnect chains from rear of middle (forward) boom

Boom and Transfer6-172Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-187: Slide Pad Removal – Middle (Forward) Boom Section20. (Ref. Fig

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-173c. (Ref. Fig. 6-187) Remove lower slide pads from front of middle (forward

Boom and Transfer6-174Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-189: Rear Chain Roller Removal - Middle (Forward) Boom Section27. (

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-175Fig. 6-190: Hose and Tube Removal – Inner Boom Section30. (Ref. Fig. 6-190

Boom and Transfer6-176Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-191: Upper Chain Assembly31. (Ref. Fig. 6-191) Remove nut (Item 4)

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-17732. (Ref. Fig. 6-192) Remove capscrew (Item 9), lockwasher (Item 8), and l

Boom and Transfer6-178Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-194: Slide Pads – Middle (Rear) Boom Section36. (Ref. Fig. 6-194) R

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-179Fig. 6-195: Chain and Hose Guide Assembly37. (Ref. Fig. 6-195) Remove chai

Identification and SpecificationsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-3Axle Serial NumberFig. 2-5: Axle Serial Number(Ref. Fig. 2-5

Boom and Transfer6-180Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-196: Tubes and Hoses – Middle (Rear) and Outer Boom Sections38. (Re

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-181b. Bleed any remaining oil into a suitable container and remove hoses from

Boom and Transfer6-182Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-198: Outer Boom Tubes and Hoses42. (Ref. Fig. 6-198) Remove outer b

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-183b. Remove hoses from inside outer boom section (Item 1). Cap and tag hoses

Boom and Transfer6-184Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KNote: This procedure assumes that the boom has been completely disassemble

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-185a. Install two (2) each auxiliary and front carriage tilt hydraulic hoses

Boom and Transfer6-186Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-200: Extension Cylinder Installation3. (Ref. Fig. 6-200) Install ex

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-187For Models 1044C-54 (S/N 144–) and 10K-54 (S/N 104–):Use two (2) each nuts

Boom and Transfer6-188Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kc. Position chain adjustment block tight against back of anchor base (Item

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-189Fig. 6-203: Tubes and Hoses – Middle (Rear) Boom Sections9. (Ref. Fig. 6-2

Identification and Specifications2-4Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KModels 644B-37 and 6K-37IdentificationFig. 2-7: Top View — M

Boom and Transfer6-190Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFor Models 1044C-54 (S/N 145–147 and 149–) and 10K-54 (S/N 103–):a. Instal

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-19110. (Ref. Fig. 6-204) Install chain and hose guide assembly on rear of mid

Boom and Transfer6-192Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Ka. Install chain adjustment block (Item 5) on lower chain with shoulder bo

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-193e. Install grease fitting (Item 6) and grease fitting cover (Item 5) on ch

Boom and Transfer6-194Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kf. Repeat the preceding steps to install chain roller assembly to the rear

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-195a. Install bottom slide pad (Item 17) and shim(s) (Item 16) to rear of boo

Boom and Transfer6-196Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-209: Hydraulic Hose and Tube Installation – Inner Boom Section23. (

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-197Fig. 6-210: Slide Pad Installation – Inner Boom Section26. (Ref. Fig. 6-21

Boom and Transfer6-198Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kb. Install two (2) bulkhead adapters (Item 4) on rear of inner boom sectio

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-199Fig. 6-213: Upper Slide Pad Installation – Front of Middle (Forward) Boom

Identification and SpecificationsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-5Models 644B-37 and 6K-37 (cont’d.)SpecificationsGeneral Oper

Boom and Transfer6-200Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K33. (Ref. Fig. 6-214) Install upper chains and hose reel assembly on middl

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-201Fig. 6-216: Front Slide Pad Installation – Outer and Middle (Rear) Boom Se

Boom and Transfer6-202Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-217: Lower Chain Installation – Inner Boom Section39. Install lower

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-203Fig. 6-219: Upper Chains – Middle (Rear) to Outer Boom Sections41. (Ref. F

Boom and Transfer6-204Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-220: Upper Chain – Middle (Forward) to Middle (Rear) Boom Sections4

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-205Fig. 6-222: Securing Boom Extension Cylinder44. (Ref. Fig. 6-222) Secure e

Boom and Transfer6-206Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-223: Connecting Hoses Between Sections45. (Ref. Fig. 6-223) Connect

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-207a. Bring auxiliary and front carriage tilt hoses (Items 7 and 8) from insi

Boom and Transfer6-208Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KExtension Cylinder4-Section BoomDescriptionFig. 6-224: 4-Section Boom Exte

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-209Removal, Extension CylinderFig. 6-225: 4-Section Boom Extension Cylinder I

Identification and Specifications2-6Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KModels 644B-37 and 6K-37 (cont’d.)Pressures Hydraulic:Contro

Boom and Transfer6-210Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KDANGER: Support of the boom is essential to avoid the possibility of injur

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-2113. Secure cylinder to outer boom section with hardware as follows.For Mode

Boom and Transfer6-212Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. Remove base mount from the cylinder barrel as follows:For Models 1044C-

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-21313. Inspect inner surface of barrel, outer surface of piston, and length o

Boom and Transfer6-214Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KBoom Extension Proximity SwitchDescriptionFig. 6-227: Boom Extension Proxi

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-215Fig. 6-228: Boom Extension Proximity Switch Operation(Ref. Fig. 6-228) The

Boom and Transfer6-216Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K(Ref. Fig. 6-229) The following procedure describes removal of the boom ex

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-2171. Loosen, but do not remove the two (2) jam nuts on the proximity switch

Boom and Transfer6-218Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KThe transfer carriage, along with the transfer cylinder, make up the “Tran

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-219Fig. 6-233: Boom Elevation Proximity Switch Wiring6. (Ref. Fig. 6-233) Rem

Identification and SpecificationsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-7Models 644B-37 and 6K-37 (cont’d.)Service Brakes Manufacture

Boom and Transfer6-220Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kb. Remove six (6) each nuts (Item 3), lockwashers (Item 1), and flatwasher

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-221Fig. 6-236: Disconnecting Hydraulic Hoses from Transfer Carriage9. (Ref. F

Boom and Transfer6-222Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-237: Transfer Carriage with Boom Installation12. (Ref. Fig. 6-237)

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-223e. Slowly lift the boom and transfer carriage assembly up and away from th

Boom and Transfer6-224Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kg. (Ref. Fig. 6-238) Remove the two (2) spindle nuts. Remove spacer washer

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-225WARNING: To avoid personal and/or equipment damage, support the transfer c

Boom and Transfer6-226Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kd. Secure the wiring harness and switch connection wire to the boom with s

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-2271. Follow preparation procedures as outlined in Section 3 of this manual.2

Boom and Transfer6-228Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kc. Measure the gap between the lip of the transfer roller and the inner ed

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-229Rear Mount Rollers, Bushings, and Spacer WashersFig. 6-242: Transfer Carri

Identification and Specifications2-8Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KModels 644B-42 and 6K-42IdentificationFig. 2-9: Top View — M

Boom and Transfer6-230Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K8. Secure spindle to transfer carriage with spindle nut.Fig. 6-243: Spacer

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-2314. Reinstall boom and shims as described earlier in this section.5. Remove

Boom and Transfer6-232Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KBoom CradleDescriptionFig. 6-245: Boom CradleThe boom cradle is a stationa

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-233Fig. 6-246: Boom Elevation Proximity Switch Wiring3. (Ref. Fig. 6-246) Rem

Boom and Transfer6-234Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kb. Remove six (6) each nuts (Item 3), lockwashers (Item 1), and flatwasher

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-235Fig. 6-249: Disconnecting Hydraulic Hoses from Boom Cradle6. (Ref. Fig. 6-

Boom and Transfer6-236Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 6-250: Boom Cradle with Boom Installation9. (Ref. Fig. 6-250) The fol

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-237e. Slowly lift the boom and boom cradle assembly up and away from the mach

Boom and Transfer6-238Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kg. Slowly lift the boom cradle assembly up and away from the machine. Plac

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-239d. Install the two (2) slide blocks (Item 4) to the front of the transfer

Identification and SpecificationsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-9Models 644B-42 and 6K-42 (cont’d.)SpecificationsGeneral Oper

Boom and Transfer6-240Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFront Support Blocks and ShimsFig. 6-252: Boom Cradle – Front Support Bloc

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-241Fig. 6-253: Shims for Front Support Blocks8. (Ref. Fig. 6-253) Check to se

Boom and Transfer6-242Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRear Spacer Blocks, Support Blocks, and ShimsFig. 6-254: Boom Cradle – Rea

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-2437. Remove capscrew (Item 7), flatwasher (Item 8), spacer block (Item 6), s

Boom and Transfer6-244Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KBoom Cradle/Boom Pivot Bushings(Ref. Fig. 6-254) The following steps are r

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-245RemovalTransfer CylinderFig. 6-257: Transfer Cylinder Installation(Ref. Fi

Boom and Transfer6-246 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4. Remove elbow (Item 9) from transfer cylinder. Cap cylinder orifice.5.

Boom and TransferService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6-247OverhaulTransfer CylinderFig. 6-258: Transfer Cylinder Assembly(Ref. Fig.

Note: Older production models do not have a stroke limiter. This includes S/N 101–433 for 644B-37, S/N 101–130 for 644B-42, S/N 101–323 and 326–328 fo

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K iSection 7 — Frame Tilt and OscillationTable of ContentsFrame Tilt System . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 1Table of ContentsSection 1 — SafetyGeneral . . . . . . . . . . . . . . . . . . . . . . . . .

Identification and Specifications2-10Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KModels 644B-42 and 6K-42 (cont’d.)Pressures Hydraulic:Contr

ii Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KBoom Elevation Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K iiiList of TablesTable 7-1: Rear Oscillation Lock Circuit Test Matrix . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-1Section 7 — Frame Tilt and OscillationFrame Tilt SystemGeneral DescriptionFig. 7-1: Frame Til

Frame Tilt and Oscillation7-2Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KCircuit DescriptionReference Fig. 7-1 above and Section 4, “Referen

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-3Frame Tilt DisabledUnder certain conditions the frame tilt system i

Frame Tilt and Oscillation7-4Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KTo level the frame, move the lever in the direction you want the ba

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-5Note: “K” Models have 90° elbows instead of tee fittings.5. Remove

Frame Tilt and Oscillation7-6Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KOverhaulFrame Tilt Control ValveFig. 7-4: Frame Tilt Control Valve

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-7Disassembly, Frame Tilt Control Valve1. Note locations of fittings

Identification and SpecificationsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-11Models 644B-42 and 6K-42 (cont’d.)Service Brakes Manufactur

Frame Tilt and Oscillation7-8Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4. Check surface of each plunger (Item 17) and guide (Item 12) for

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-9Frame Tilt CylinderDescriptionFig. 7-5: Frame Tilt Cylinder(Ref. Fi

Frame Tilt and Oscillation7-10Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalFrame Tilt Cylinder644B-37 (S/N 101–170)6K-37 (S/N 101–144)

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-11(Ref. Fig. 7-6) The following procedures are required to remove th

Frame Tilt and Oscillation7-12Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kb. Install mounting block (with lock pin hole) (Item 10) to rear o

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-13OverhaulFrame Tilt CylinderFig. 7-7: Frame Tilt Cylinder (Exploded

Frame Tilt and Oscillation7-14Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KDisassembly, Frame Tilt Cylinder(Ref. Fig. 7-7) The following step

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-152. Install new bushings so they are flush with outer edge boss to

Frame Tilt and Oscillation7-16Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KNote: Swivel fittings are not used with the latest production mode

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-17Installation, Counterbalance Valve1. Lubricate O-rings with clean

Identification and Specifications2-12Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KModels 844C-42 and 8K-42IdentificationFig. 2-11: Top View —

Frame Tilt and Oscillation7-18Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. (Ref. Fig. 7-11) Park the machine on a firm, level surface. Pla

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-19Theory of Operation and Circuit LogicFig. 7-12: Rear Oscillation L

Frame Tilt and Oscillation7-20Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KBoom Positioned Above 40°Fig. 7-13: Circuit Operation Above 40°(Re

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-21Boom Positioned Below 40°Fig. 7-14: Circuit Operation Below 40°(Re

Frame Tilt and Oscillation7-22Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5. When the proximity switch (S1) energizes the proximity switch r

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-234. When the proximity switch (S1) energizes the proximity switch r

Frame Tilt and Oscillation7-24Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRear Oscillation Lock CylinderDescriptionFig. 7-16: Rear Oscillati

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-25Removal644B-37 (S/N 101–170)6K-37 (S/N 101–144)844C-42 (S/N 101–16

Frame Tilt and Oscillation7-26Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K(Ref. Fig. 7-17) The following steps are required to remove the re

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-273. If necessary (models with a cylinder as illustrated in View A),

Identification and SpecificationsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-13Models 844C-42 and 8K-42 (cont’d.)SpecificationsGeneral Ope

Frame Tilt and Oscillation7-28Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KOverhaulRear Oscillation Lock CylinderFig. 7-18: Rear Oscillation

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-29Disassembly, Rear Oscillation Lock Cylinder(Ref. Fig. 7-18) Disass

Frame Tilt and Oscillation7-30Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KAssembly, Rear Oscillation Lock Cylinder1. Lubricate new O-ring wi

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-31Oscillation Control BlockDescriptionFig. 7-20: Oscillation Control

Frame Tilt and Oscillation7-32Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KThe functions of these components depend upon the mode of the osci

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-33RemovalOscillation Control BlockFig. 7-21: Oscillation Control Blo

Frame Tilt and Oscillation7-34Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5. Place a suitable drip pan under rear oscillation lock cylinder.

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-35InstallationOscillation Control BlockRear Oscillation Lock Cylinde

Frame Tilt and Oscillation7-36Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KOverhaulOscillation Control Block Fig. 7-22: Oscillation Control B

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-37(Ref. Fig. 7-22) Follow the guidelines for cleanliness as stated i

Identification and Specifications2-14Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KModels 844C-42 and 8K-42 (cont’d.)Pressures Hydraulic:Contr

Frame Tilt and Oscillation7-38Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3. Install two (2) SAE #2 plugs (Items 8 and 34). Torque plugs to

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-3915. Lubricate O-rings and backup ring on each check valve cartridg

Frame Tilt and Oscillation7-40Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalFrame Tilt Lockout ValveFig. 7-24: Frame Tilt Lockout Valve

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-41InstallationFrame Tilt Lockout Valve(Ref. Fig. 7-24) The following

Frame Tilt and Oscillation7-42Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K(Ref. Fig. 7-25) Follow the guidelines for cleanliness as stated i

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-43Boom Elevation Proximity SwitchDescriptionFig. 7-26: Boom Elevatio

Frame Tilt and Oscillation7-44Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalBoom Elevation Proximity SwitchFig. 7-28: Boom Elevation Pr

Frame Tilt and OscillationService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K7-45AdjustmentBoom Elevation Proximity SwitchFig. 7-29: Boom Elevation

i Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KSection 8 — TransmissionTable of ContentsDescription . . . . . . . . . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 8-1Section 8 — TransmissionFig. 8-1: ZF TransmissionDescriptionZF Transmission with DW-2 Shifte

Identification and SpecificationsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-15Models 844C-42 and 8K-42 (cont’d.)Service Brakes Manufactur

Transmission8-2 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3. 3- or 4-Speed Transmissiona. 38369A — 3-Speed Transmissionb. 38370A — 4-Speed

TransmissionService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 8-3The 3- or 4-speed WG100 transmission consists of a torque converter coupled to a

Transmission8-4 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KTroubleshooting and Test ProceduresTroubleshooting OptionsZF Transmission with D

TransmissionService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 8-59. Check short harness. It connects the solenoids to the transmission valve conn

Transmission8-6 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9. Check transmission pressure. Control pressure should be 230–260 psi (16–18 ba

TransmissionService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 8-7ZF Transmission with DW-3 Shifter6K-37 (S/N 398–)6K-42 (S/N 132–)644B-37 (S/N 88

Transmission8-8 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2. Make sure the parking brake is disengaged and the service brake is not applie

TransmissionService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 8-93. Because the proximity switch can also declutch the transmission, the boom ele

Transmission8-10 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KInductive sensor failure can be eliminated as soon as the sensor signal is sens

TransmissionService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 8-11Fig. 8-4: DW-3 Signal/Wire Combinations for a 3WG-100 TransmissionNo power at R

Identification and Specifications2-16Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KModels 1044C-42 and 10K-42IdentificationFig. 2-13: Top View

Transmission8-12 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kg. Ignition Relay (37383X):i. Check resistance between pin 86 and pin 85: 76 Wi

TransmissionService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 8-13Fig. 8-5: DW-3 Signal/Wire Combinations for a 4WG-100 TransmissionNo power at R

Transmission8-14 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10Kii. Check ground connection to pin 85 through the horn button ground.h. Ignitio

TransmissionService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 8-15Fig. 8-6: DW-3 Controller Signal Combinations Measured At Valve Solenoids6. If

Transmission8-16 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KShunt Diodes DescriptionFig. 8-7: Typical Shunt Diode ApplicationFig. 8-7 repre

TransmissionService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 8-172. Measure forward voltage by connecting the black DMM lead to the cathode side

Transmission8-18 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KA symptom of a failed park brake (or service brake) pressure switch is a transm

TransmissionService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 8-19Machines w/ DW-3 ShifterFor machines equipped with a DW-3 shifter, a closed pre

Transmission8-20 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRear Oscillation Lock Proximity Switch and RelayGeneralFig. 8-9: Rear Oscillati

TransmissionService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 8-21Rear Oscillation Lock Proximity Switch Integrity Test1. Disconnect the plug con

Identification and SpecificationsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-17Models 1044C-42 and 10K-42 (cont’d.)SpecificationsGeneral O

Transmission8-22 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3. Using a DMM set to meter resistance, test for resistance between blade 86 an

TransmissionService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 8-23ZF Transmission Pressure ChecksFig. 8-12: Transmission Pressure Check Ports(Ref

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K iSection 9 — BrakesTable of ContentsService Brakes . . . . . . . . . . . . . . . . . . . . . .

ii Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 9-6: Service Brake and Valve Installation — Models with Control Manifold Hydraulics . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-1Section 9 — BrakesService BrakesDescription, Models with Control Manifold Hydraulics6K-37 (S/

Brakes9-2Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KBrake Testing and BleedingThe following procedure may be used to check brake components

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-33. Remove the two (2) capscrews (Item 1), valve guard (Item 2), and gas valve cap (Item

Brakes9-4Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9. Open bleeder screw at left rear wheel (see Fig. 9-4) and slowly apply brake pedal un

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-5The brake testing and bleeding procedure is complete.Accumulator Pre-charge15. The foll

Identification and Specifications2-18Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KModels 1044C-42 and 10K-42 (cont’d.)Pressures Hydraulic:Con

Brakes9-6Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KService Brake Pedal and ValveAdjustmentService Brake Valve - Models with Control Manifo

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-71. With the engine off, connect a 0–600 psi gauge to the test port marked “BRAKES” loca

Brakes9-8Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K16. Install the rubber boot (Item 9) onto the body (Item 19). Apply a quality adhesive

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-9RemovalService Brake Pedal and Valve – Models with Control Manifold Hydraulics6K-37 (S/

Brakes9-10Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KThe following service brake removal procedure refers to Fig. 9-6.1. Follow preparation

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-11DisassemblyService Brake Valve – Models with Control Manifold Hydraulics6K-37 (S/N 101

Brakes9-12Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4. Discard rubber boot (Item 8), O-ring (Item 10), and seal (Item 11).5. Clean remaini

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-13Service Brake Adjustment ProceduresModels with Control Manifold Hydraulics6K-42 (S/N 1

Brakes9-14Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 9-9: Cab Front Cover Installation – Early Production3. (Ref. Fig. 9-9) Remove the

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-1511. Install the brake pedal (Item 1) onto the actuator base (Item 5) by pushing the pe

Identification and SpecificationsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-19Models 1044C-42 and 10K-42 (cont’d.)Wheels/Tires Lugs . . .

Brakes9-16Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KService Brake Pressure Switch ReplacementModels with Control Manifold Hydraulics6K-37

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-17Models with Mid-Inlet Hydraulics6K-37 (S/N 318–)6K-42 (S/N 120–)8K-42 (S/N 221–)10K-42

Brakes9-18Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KAccumulatorGeneralThe accumulator is a 3000 psi piston-type accumulator. It has a oil

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-19Precautions WARNING: Never fill an accumulator with oxygen! An explosion could result

Brakes9-20Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 9-13: Accumulator ChargingPre-charge the accumulator using the following steps (s

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-2110. Turn “T” handle all the way down. This will depress (open) the core in the gas val

Brakes9-22Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5. Record the lowest pressure observed before the accumulator recharges. The pressure

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-23RemovalAccumulator Models with Control Manifold Hydraulics6K-37 (S/N 101–317)6K-42 (S/

Brakes9-24Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3. While watching test gauge, press brake pedal numerous times until pressure gauge re

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-25OverhaulAccumulator Fig. 9-15: Accumulator AssemblyThe following procedure refers to F

2 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KTable of ContentsEngine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification and Specifications2-20Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KModels 1044C-54 and 10K-54IdentificationFig. 2-15: Top View

Brakes9-26Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K5. Remove piston (Item 9) by pushing it out with a bar from hydraulic end of accumulat

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-2718. Use a hammer and wood block to tap piston into the bore until it is about two inch

Brakes9-28Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KPark BrakeFig. 9-16: Park BrakeThe park brake is a drum type located on the output sha

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-29The version used in latter production is shown in Fig. 9-22. This version includes a c

Brakes9-30Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KPark Brake Pressure SwitchRemovalModels with Control Manifold Hydraulics6K-37 (S/N 101

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-314. Remove the brake pressure switch from the reducer bushing (Item 3). Discard pressur

Brakes9-32Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KInstallation, Park Brake Pressure SwitchModels with Control Manifold Hydraulics(Ref. F

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-33Valve Removal, Park BrakeFig. 9-19: Park Brake Assembly1. Follow preparation procedure

Brakes9-34Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6. Tag and slowly loosen hydraulic hoses (Items 6, 11 and 14) from elbow (Item 5), che

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-35f. Clean all remaining parts with appropriate solvent and dry with compressed air. Ins

Identification and SpecificationsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-21Models 1044C-54 and 10K-54 (cont’d.)SpecificationsGeneral O

Brakes9-36Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KCylinder RemovalModels with Horizontal Cylinder Mount644B-37 (S/N 101–383)644B-42 (S/N

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-371. Follow preparation procedures as outlined in Section 3 and in Section 5 of this man

Brakes9-38Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KModels with Vertical Cylinder Mount644B-37 (S/N 384–)644B-42 (S/N 120–)844C-42 (S/N 28

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-398. Remove cotter pin (Item 5) and clevis pin (Item 4) securing the park brake cylinder

Brakes9-40Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KNote: With the park brake cylinder (Item 5) fully extended and the brake cam (Item 15)

BrakesService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K9-41Models with Horizontal Cylinder Mount644B-37 (S/N 101–383)644B-42 (S/N 101–119)844C-42

Brakes9-42Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KModels with Vertical Cylinder Mount644B-37 (S/N 384–)644B-42 (S/N 120–)844C-42 (S/N 28

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K iSection 10 — OutriggersTable of ContentsOutriggers . . . . . . . . . . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K10-1Section 10 — OutriggersOutriggersGeneral Fig. 10-1: OutriggersOutriggers are standard on mod

Identification and Specifications2-22Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KModels 1044C-54 and 10K-54 (cont’d.)Pressures Hydraulic:Con

Outriggers10-2Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalOutriggersFig. 10-2: Outrigger Installation(Ref. Fig. 10-2) The following p

OutriggersService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K10-3DANGER: Support of the boom is essential to avoid the possibility of injury or dea

Outriggers10-4Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3. Temporarily install a capscrew (Item 20) into the orifice in the shaft assembly

OutriggersService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K10-5Outrigger CylindersGeneralFig. 10-3: Outrigger CylindersThe outrigger cylinders ha

Outriggers10-6Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KRemovalOutrigger CylindersFig. 10-4: Outrigger Cylinder Installation(Ref. Fig. 10-

OutriggersService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K10-75. Place blocking device under the top of the outrigger cylinder. Remove the capsc

Outriggers10-8Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KOverhaulOutrigger CylindersFig. 10-5: Outrigger Cylinder Assembly(Ref. Fig. 10-4)

OutriggersService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K10-94. Release pressure in each cylinder as follows:WARNING: The counterbalance valve

Outriggers10-10Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K15. Inspect inner surface of barrel, outer surface of piston, and length of rod f

OutriggersService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K10-11Boom Extension Proximity SwitchDescription1044C-5410K-54Fig. 10-6: Boom Extension

Identification and SpecificationsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-23Models 1044C-54 and 10K-54 (cont’d.)Wheels/Tires Lugs . . .

Outriggers10-12Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 10-7: Boom Extension Proximity Switch Operation(Ref. Fig. 10-7) The switch o

OutriggersService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K10-13(Ref. Fig. 10-8) The following procedure describes removal of the boom extension

Outriggers10-14Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. Loosen, but do not remove the two (2) jam nuts on the proximity switch body.2.

OutriggersService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K10-15RemovalOutrigger Control ValveFig. 10-11: Outrigger Control Valve Installation(Re

Outriggers10-16Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K6. Remove the two (2) nuts (Item 13), lockwashers (Item 12), and capscrews (Item

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Customer Support Toll Free:

Identification and Specifications2-24Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KEngine SpecificationsJohn Deere 4039DFuel. . . . . . . . .

Identification and SpecificationsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K2-25Engine Specifications (cont’d.)John Deere 6068DFuel. . . .

Identification and Specifications2-26Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KEngine Specifications (cont’d.)Cummins 4BT3.9 (EPA)Fuel. .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K iSection 3 — General MaintenanceTable of ContentsGeneral Instructions . . . . . . . . . . . .

ii Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KList of TablesTable 3-1: General Fluid and Lubricant Specifications . . . . . . . . . . . . .

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3-1Section 3 — General MaintenanceGeneral InstructionsPerformance of your machine is dependent o

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 3Table of ContentsSection 4 — Reference DiagramsSchematic, Model 644B w/ Naturally Aspirated En

General Maintenance3-2Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KService And Repair ProceduresCAUTION: Unless specifically told not to, low

General MaintenanceService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3-3Replacement PartsGeneralRecord the machine model, serial number, and compo

General Maintenance3-4Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFluid and Lubricant SpecificationsGeneral SpecificationsTable 3-1: General

General MaintenanceService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3-5Table 3-2: John Deere Engine Oil SpecificationsCummins Engines Use the tab

General Maintenance3-6Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KTable 3-4: ZF Transmission Oil SpecificationsFuel RequirementsDiesel fuels

General MaintenanceService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3-7• Lubricate all grease fittings with the specified grease. Hydraulic OilHy

General Maintenance3-8Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K• Avoid spraying water on electrical components such as the alternator, st

General MaintenanceService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3-9Preparing the Machine for Long-Term StoragePrior to placing the machine in

General Maintenance3-10Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K13. Shut the machine down and check for any hydraulic leaks and repair, a

General MaintenanceService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3-11Table 3-5: General Torques for Standard Bolts, Capscrews, and NutsSize SA

4 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KTable of ContentsReservoir Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Maintenance3-12Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KFig. 3-2: Metric Class IdentificationTable 3-6: General Torques for Metri

General MaintenanceService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3-13Hydraulic Fitting TorquesJIC and SAE Female Swivel NutsIt is recommended

General Maintenance3-14Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KAdjustable O-ring Fittings To install straight thread, adjustable O-ring

General MaintenanceService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3-15Pipe Thread FittingsTo install National Pipe Thread (NPT) fittings:1. App

General Maintenance3-16Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K1. Move the boost start machine (or auxiliary power source) close enough

General MaintenanceService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3-17Conversion ChartsTable 3-12: Inch Fraction, Decimal, and Metric Conversio

General Maintenance3-18Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KTable 3-13: Miscellaneous ConversionsMultiply ByTo Get or MultiplyBy To G

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K iSection 4 — Reference DiagramsTable of ContentsSchematic, Model 644B w/ Naturally Aspirated En

4-1Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KSection 4 — Reference DiagramsSchematic, Model 644B w/Naturally Aspirated Engine, Control Man

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-2Schematic, Model 644B w/Naturally Aspirated Engine, Control Manifold Hydrau

Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 5Table of ContentsSection 6 — Boom and TransferBoom and Transfer Hydraulics . . . . . . . . .

Reference Diagrams4-3Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KP1GP1STBP2ST LSCFPSGLC2200CSPF1200/1600PUPLTFPRPGCVPD.040OR1STP ACGEFTACSWB

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-4Cartridge IdentificationCS Compensator ValveCV Check ValveLC Logic ValvePD

Reference Diagrams4-5Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KXXBOOM TELESCOPE CYLINDERACCUMULATORBOOM ROLL BACK HOSESVALVE@ 3150 PSI@ 25

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-6XXX X3175 PSIFRAME TILTTRANSFERCARRIAGETILTAUX. 1 AAAABBBB2800PSIA6A4B4B6BO

Reference Diagrams4-7Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K3170 PSIFRAME TILTTRANSFERCARRIAGETILTAUX. 1 AAAABBBB2800PSIA6A4B4B6BOOM HO

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-8NOTESSchematic, Model 644B w/Naturally Aspirated Engine, Mid-Inlet Hydrauli

Reference Diagrams4-9Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KPump Unloader Valve Operation, Mid - Inlet Hydraulic System _Diagram 3

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-10Pump Unloader Valve Operation, Mid - Inlet Hydraulic System _Diagram 3

Reference Diagrams4-11Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10KPump Unloader Valve Operation, Mid - Inlet Hydraulic System _Diagram 3

Reference DiagramsService Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K4-12This page intentionally left blankPump Unloader Valve Operation, Mid - Inl