Lull 6K Service Manual User Manual Page 457
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Boom and Transfer
Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K
6-207
a. Bring auxiliary and front carriage tilt hoses (Items 7 and 8) from
inside the middle (rear) boom section (Item 9) up and around the
two (2) hose reels (Item 19) at the rear of the middle (forward)
boom section (Item 3).
b. Connect the hydraulic hoses to the hydraulic tubes (Items 1 and 2)
at the rear of the inner boom section. Torque swivel nut on
hydraulic hoses to 50–58 ft-lbs.
c. Install hose guard (Item 4) on rear of inner boom section with two
(2) each lockwashers (Item 5) and capscrews (Item 6). Torque
capscrews to 280 ft-lbs.
CAUTION: Make sure hose guard is installed in the same orientation as it
was before being removed. The hose guard may be different
from that shown above. If hose guard is reversed, equipment
damage may occur during operation of machine.
d. Bring auxiliary and front carriage tilt hoses (Items 14 and 15) from
inside the outer boom section (Item 18) up and around the hose
rollers (Item 20) at the rear of the middle (rear) boom section.
e. Connect the hydraulic hoses to the hydraulic tubes (Items 10 and
11) at the rear of the middle (rear) boom section. Torque swivel nut
on hydraulic hoses to 50–58 ft-lbs.
f. For model 1044C-54 (S/N 101–106), attach four (4) half clamps
(Item 12) to each set of hoses with round head screws (Item 13),
lockwashers (Item 16) and nuts (Item 17). Torque nuts to 50 in-lbs.
46. Install assembled 4-section boom on machine as described on
page 6-161.
- Service Manual 1
- Quick Reference 3
- Revision Record 4
- Table of Contents 10
- List of Figures 14
- Section 1 — Safety 27
- Maintenance Safety 30
- Fuel Hazards 31
- Engine Coolant Hazards 31
- Electrical System Hazards 32
- Hydraulic System Hazards 32
- Tire and Wheels Hazards 33
- Decals and Placards 34
- Attaching Decals 35
- Decal Locations 35
- Fig. 1-1: Decals and Placards 36
- Fig. 1-3: Control Decals 37
- FRONT WHEEL STEER 38
- ROUND STEER OBLIQUE STEER 38
- Serial Number Locations 41
- Engine Serial Number, Cummins 42
- Axle Serial Number 43
- Models 644B-37 and 6K-37 44
- Specifications 45
- Models 644B-42 and 6K-42 48
- Models 844C-42 and 8K-42 52
- Models 1044C-42 and 10K-42 56
- Models 1044C-54 and 10K-54 60
- Engine Specifications 64
- John Deere 6068D 65
- Cummins 4B3.9 65
- Cummins 4BT3.9 65
- Cummins 4BT3.9 (EPA) 66
- Cummins 6B5.9 66
- General Instructions 69
- Service And Repair Procedures 70
- Replacement Parts 71
- General Specifications 72
- Engine Oil Specifications 72
- General Maintenance 73
- Fuel Requirements 74
- Care and Cleaning 75
- Cleaning the Cab 76
- Cleaning Decals 76
- Torque Specifications 78
- Hydraulic Fitting Torques 81
- Jump Starting Procedures 83
- Conversion Charts 85
- 644B-42 ........ S/N: 137-207 90
- UPPER HYDRAULICS 100
- LOWER HYDRAULICS 100
- FRONT OF MACHINE 100
- JOYSTICK CONTROL VALVES 101
- Reference Diagrams 103
- 1044C-54 ...... S/N: 155 106
- 644B-42 ...... S/N: 101–207 110
- List of Tables 144
- Major System Components 145
- General Description 145
- Hydraulic Systems 147
- Safe Maintenance Practices 148
- Cleanliness 148
- Checking Hydraulic Lines 149
- Hydraulic Reservoir 150
- Fig. 5-5: Hydraulic Reservoir 151
- Filling Hydraulic Reservoir 152
- Alternate Method 153
- Reservoir Drain and Refill 155
- Hydraulic Reservoir and 157
- Fuel Tank 157
- Installation 159
- Description 160
- Sight Gauge 161
- Suction Strainer 163
- Removal and Cleaning 164
- Checking Filter Condition 166
- Return Filter Assembly 170
- Reservoir Breather 171
- Hydraulic Pressure Filter 172
- Pressure Filter Assembly 175
- Hydraulic Pump 177
- Troubleshooting Pump Problems 178
- Checking Pump Flow Rate 187
- Multi-Spool Control Valve 189
- Overhaul 194
- Fig. 5-34: Spool Assembly 195
- Disassembly, CRA Assembly 199
- Inlet and Outlet Covers 202
- Fig. 5-39: Main Relief Valve 206
- Hydraulic Control Manifold 208
- Table 5-1: Manifold Markings 210
- Control Valve Functions 211
- Control Manifold 215
- Assembly 219
- Manifold Assembly 219
- Pump Unloader Valve 221
- Mid-Inlet Control Valve 224
- (BASE END) 234
- (ROD END) 234
- REAR OSC 235
- LOCK (G1) 235
- LOCK (G2) 235
- Roll-Back Hose Tray 236
- Section 6 — Boom and Transfer 241
- Joystick Controls 252
- Joystick 253
- Disassembly 255
- Boom and Transfer 256
- Hydraulic Cylinders 259
- Checking Cylinder Condition 260
- Boom Hoist Cylinder 261
- REV. 001 262
- Front Carriage Tilt Cylinder 267
- Front Carriage Tilt 268
- Cylinder 268
- Rear Carriage Tilt Cylinder 273
- Boom Hydraulic Control 279
- Valve (Control Manifold 279
- Selector Valve (Control 289
- Manifold System) 289
- Hydraulics 289
- Selector Valve (Mid-Inlet 294
- Troubleshooting 297
- Boom Slide Pads — General 298
- Inspect all pads weekly 299
- Lubrication 300
- Slide Area Surface Finish 300
- 0.030" Max 301
- 0.030" 301
- Quick Attach 304
- clearing the lock plate 305
- Connecting an Attachment 306
- Fig. 6-49: Lock Plate Engaged 307
- Boom Angle Inclinometer 310
- 2-Section Boom 311
- 0.625"–0.688" 312
- (5/8"–11/16") 312
- Rear of Boom, Looking Forward 315
- Inspection Procedures 317
- These pads are 324
- 3-Section Boom 340
- Shimming Procedures 341
- 1/4" (0.25") Max 347
- 3/16" (0.19") 347
- 644B-42 (S/N 101–141) 349
- 844C-42 (S/N 101–433) 349
- 1044C-42 (S/N 101–110) 349
- 6K-42 (S/N 101–113) 349
- 8K-42 (S/N 101–192) 349
- Fig. 6-106: Boom Cover 352
- Fig. 6-109: Anchor Base 354
- Fig. 6-118: Hose Tensioner 363
- Fig. 6-123: Rear Chain Anchor 366
- Fig. 6-126: Rear Chain Anchor 370
- Extension Cylinder 390
- 4-Section Boom 396
- Locations for 409
- Chain Attachment 409
- 10K-54 (S/N 101– 102): 434
- Sections 451
- Boom Extension 465
- Proximity Switch 465
- Adjustments 466
- Setscrew 468
- Rollers, Bushings, and Shims 476
- Fig. 6-241: Scraper Plate 478
- Transfer Cylinder 495
- 1044C-54 498
- Frame Tilt System 503
- Frame Tilt and Oscillation 504
- Frame Tilt Control Valve 505
- Frame Tilt 511
- Frame Tilt Cylinder 512
- Frame Level Indicator 519
- Oscillation Control Block 533
- Frame Tilt Lockout Valve 541
- Adjustment 547
- Section 8 — Transmission 548
- 3WG-100, 3-SPEED TRANSMISSION 563
- 4WG-100, 4-SPEED TRANSMISSION 563
- Section 9 — Brakes 573
- Brake Testing and Bleeding 576
- Fig. 9-3: Diagnostic Ports 577
- Fig. 9-4: Brake Bleeding 578
- Accumulator Pre-charge 579
- Service Brake Pedal and Valve 580
- Reassembly 586
- Accumulator 592
- Precautions 593
- Pre-Charging Accumulator 593
- Checking Pre-charge 595
- Park Brake 602
- Inspection 603
- Park Brake Pressure Switch 604
- # Description 605
- 1 Park Brake Pressure Switch 605
- 2 Intermediate Wire Harness 605
- Valve Removal, Park Brake 607
- Cylinder Removal 610
- Cylinder Installation 613
- Adjustment, Park Brake 614
- Drum Brake Repair/Replacement 616
- Section 10 — Outriggers 617
- Outriggers 620
- Outrigger Cylinders 623
- Outrigger Control Valves 632
- Outrigger Control Valve 633
- JLG Worldwide Locations 636
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