Lull 6K Service Manual - Manual (Page 329)

Boom and Transfer
Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K 6-79
Assembly
2-Section Boom 1. (Ref. Fig. 6-79) With the inner boom section lying upside down,
position two (2) hose carriers (with hoses) in the boom, secure each
carrier with four (4) screws, lockwashers, and washers. Apply thread
locking compound to the screws before installing them.
2. (Ref. Fig. 6-78) Connect two (2) carriage tilt and two (2) auxiliary
hydraulics hoses to the fittings in the boom.
3. Apply EP lithium based grease to the bottom surface of the inner boom
section (slide pad slide areas).
4. Rotate the inner boom section to an upright position.
5. Apply EP lithium based grease to the inside, top surface of the outer
boom section (slide pad slide areas).
6. (Ref. Fig. 6-77) Align the slide pad on the extension cylinder with the
channel in the boom, then slide the cylinder partially into the boom so
that the lower hose carrier brackets may be attached to the hose trays.
Apply thread locking compound to the screws. Secure each hose
carrier with four (4) screws, lockwashers, and washers.
7. (Ref. Fig. 6-75) Continue to slide the extension cylinder into the boom
section until it is nearly fully inserted. Connect two (2) carriage tilt and
two (2) auxiliary hydraulics hoses to the fittings at the extension
cylinder.
8. (Ref. Fig. 6-74) Align the rod end of the extension cylinder with the
hole in the boom mounting block. Fully insert the cylinder into the
boom.
9. (Ref. Fig. 6-74) Install a washer and nut onto the cylinder rod end.
Torque the nut to 1,640 ft-lbs and secure it with two (2) setscrews.
10. (Ref. Fig. 6-74) For models with a 2" diameter rod in the boom
extension cylinder, install a cotter pin. Models with a 2.25" diameter rod
do not have a cotter pin; proceed to Step 11.
11. Support the inner boom section and carefully slide it into the outer
boom section until the rear of the inner section is visible in the forward
window of the outer boom section.
12. Install two (2) lower rear slide pads and attaching hardware onto the
inner boom.
13. (Ref. Fig. 6-73) Fully insert the inner boom section into the outer
section. Secure the extension cylinder to the rear cylinder support with
two (2) capscrews and lockwashers. Torque the capscrews to 280 ft-
lbs.
14. Install the slide pads and shims according to drawing specifications.
15. Install the front carriage tilt cylinder. See page 6-19.