JLG Lull Telehandlers 644B, 6K, 844C,8K, 1044C &10K ANSI Illustrated Master Parts List Manual ! (P/N - 1100820)
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
Illustrated Parts Manual
Models
644B, 6K, 844C,
8K, 1044C &
10K
P/N - 1100820
Revised
April 24, 2009
EFFECTIVITY PAGE
1100820
644B/6K/844C/8K/1044C/10K
June 23, 2003 - B-009 - Revised Manual
February 25, 2005 - C - Replaced all branding with JLG
April 24, 2009 - D - Revised Manual
i
EFFECTIVITY PAGE
1100820
644B/6K/844C/8K/1044C/10K
ii
TABLE OF CONTENTS
1
Using this book
Serial Number Locations
Section 1 — Drive Train
Drive Train Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.1
Drive Train Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2
Front Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1
Drive Train Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.3
Front Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.2
Rear Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.1
Rear Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.2
Differential Carrier Assembly - Front Axle (PS 7036) . . . . . . . . . . . . . 1.4.1
Differential Carrier Assembly - Rear Axle (PS 7036) . . . . . . . . . . . . . 1.5.1
Steer Axle Shafts & Knuckle Assembly (PS 7036) . . . . . . . . . . . . . . . 1.6.1
Steer Axle Shafts & Knuckle Assembly (PS 7036) . . . . . . . . . . . . . . . 1.6.2
Wheel End Assembly - With Wet Disc Brakes (PS 7036). . . . . . . . . . 1.7.1
Wheel End Assembly - With Wet Disc Brakes (PS 7036). . . . . . . . . . 1.7.2
Drive Flange Assembly (PS 7036) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8.1
Tie Rod & Steer Cylinder Mounting Assembly (PS 7036). . . . . . . . . . 1.9.1
Steer Cylinder Assembly (PS 7036) . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.1
Steer Cylinder Assembly (PS 7036) . . . . . . . . . . . . . . . . . . . . . . 1.10.1.1
Differential Carrier Assembly - Front Axle (PS 8036) . . . . . . . . . . . . 1.14.1
Differential Carrier Assembly - Rear Axle (PS 8036) . . . . . . . . . . . . 1.15.1
Steer Axle Shafts & Knuckle Assembly (PS 8036) . . . . . . . . . . . . . . 1.16.1
Wheel End Assembly - With Wet Disc Brakes (PS 8036). . . . . . . . . 1.17.1
Wheel End Assembly - With DRY Disc Brakes (PS 8036) . . . . . . . . 1.17.2
Drive Flange Assembly (PS 8036) . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18.1
Tie Rod & Steer Cylinder Mounting Assembly (PS 8036). . . . . . . . . 1.19.1
Steer Cylinder Assembly (PS 8036) . . . . . . . . . . . . . . . . . . . . . . . . . 1.20.1
Converter & Flex Plate (3WG 100) . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.1
Gearbox Housing (3WG 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25.1
Input Group (3WG 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26.1
Clutch Pack, Forward, 1st Gear (3WG 100) (1 of 2) . . . . . . . . . . . . . 1.27.1
Clutch Pack, Forward, 1st Gear (3WG 100) (2 of 2). . . . . . . . . . . . 1.27.1
Clutch Pack, Reverse, 2nd Gear (3WG 100) (1 of 2) . . . . . . . . . . . 1.28.1
Clutch Pack, Reverse, 2nd Gear (3WG 100) (2 of 2) . . . . . . . . . . . 1.28.1
Clutch Pack, 3rd Gear (3WG 100) (1 of 2) . . . . . . . . . . . . . . . . . . . 1.29.1
Clutch Pack, 3rd Gear (3WG 100) (2 of 2) . . . . . . . . . . . . . . . . . . . 1.29.1
Output Group (3WG 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30.1
Power Take-Off & Filter (3WG 100). . . . . . . . . . . . . . . . . . . . . . . . . 1.31.1
Gearshift System (3WG 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32.1
Control Valve (3WG 100). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33.1
Oil Tubes & Dipstick (3WG 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34.1
Converter & Flex Plate (4WG 100) . . . . . . . . . . . . . . . . . . . . . . . . . 1.38.1
Gearbox Housing (4WG 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.39.1
Input Group & Layshaft (4WG 100) . . . . . . . . . . . . . . . . . . . . . . . . . 1.40.1
Clutch Pack, Forward, 1st Gear (4WG 100) (1 of 2) . . . . . . . . . . . . 1.41.1
Clutch Pack, Forward, 1st Gear (4WG 100) (2 of 2). . . . . . . . . . . . 1.41.1
Clutch Pack, Reverse, 2nd Gear (4WG 100) (1 of 2) . . . . . . . . . . . 1.42.1
Clutch Pack, Reverse, 2nd Gear (4WG 100) (2 of 2) . . . . . . . . . . . 1.42.1
Clutch Pack, 3rd Gear (4WG 100) (1 of 2) . . . . . . . . . . . . . . . . . . . 1.43.1
Clutch Pack, 3rd Gear (4WG 100) (2 of 2) . . . . . . . . . . . . . . . . . . . 1.43.1
Clutch Pack, 4th Gear (4WG 100) (1 of 2) . . . . . . . . . . . . . . . . . . . 1.44.1
Clutch Pack, 4th Gear (4WG 100) (2 of 2) . . . . . . . . . . . . . . . . . . . 1.44.1
Output Group (4WG 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45.1
Power TakE-Off & Filter (4WG 100) . . . . . . . . . . . . . . . . . . . . . . . . 1.46.1
Gearshift System (4wg 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.47.1
Control Valve (4WG 100). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48.1
Oil Tubes & Dipstick (4WG 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.49.1
Transmission Oil Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1.53.1
Transmission Oil Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1.53.1.1
Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54.1
Park Brake Cylinder Mounting & Linkage Assembly . . . . . . . . . . . 1.55.1
Park Brake Cylinder Mounting & Linkage Assembly . . . . . . . . . . 1.55.1.1
Section 2 — Power Plant
TABLE OF CONTENTS
2
Engine Mounting & Fuel Lines (Deere 4039D) . . . . . . . . . . . . . . . . . . 2.1.1
Exhaust Assembly (Deere 4039D) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1
Air Cleaner Assembly (Deere 4039D) . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1
Radiator Group Assembly (Deere 4039D) . . . . . . . . . . . . . . . . . . . . . 2.4.1
Throttle Group Assembly (Deere 4039D) . . . . . . . . . . . . . . . . . . . . . . 2.5.1
Throttle Group Assembly (Deere 4039D) . . . . . . . . . . . . . . . . . . . . 2.5.1.1
Engine Mounting & Fuel Lines (Deere 4039T) . . . . . . . . . . . . . . . . . . 2.6.1
Exhaust Assembly (Deere 4039T) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.1
Air Cleaner Assembly (Deere 4039T) . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1
Radiator Group Assembly (Deere 4039T) . . . . . . . . . . . . . . . . . . . . . 2.9.1
Throttle Group Assembly (Deere 4039T) . . . . . . . . . . . . . . . . . . . . . 2.10.1
Throttle Group Assembly (Deere 4039T) . . . . . . . . . . . . . . . . . . . 2.10.1.1
Engine Mounting & Fuel Lines (Deere 4045T 100 hp) . . . . . . . . . . . 2.11.1
Exhaust Assembly (Deere 4045T 100 hp) . . . . . . . . . . . . . . . . . . . . 2.12.1
Air Cleaner Assembly (Deere 4045T 100 hp ) . . . . . . . . . . . . . . . . . 2.13.1
Radiator Group Assembly (Deere 4045T 100 hp) . . . . . . . . . . . . . . 2.14.1
Throttle Group Assembly (Deere 4045T 100 hp) . . . . . . . . . . . . . 2.15.1
Engine Mounting & Fuel Lines (Deere 4045T 115 hp) . . . . . . . . . . . 2.16.1
Exhaust Assembly (Deere 4045T 115 hp) . . . . . . . . . . . . . . . . . . . . 2.17.1
Air Cleaner Assembly (Deere 4045T 115 hp) . . . . . . . . . . . . . . . . . . 2.18.1
Radiator Group Assembly (Deere 4045T 115 hp) . . . . . . . . . . . . . . 2.19.1
Throttle Group Assembly (Deere 4045t 115 hp) . . . . . . . . . . . . . . 2.20.1
Throttle Group Assembly (Deere 4045T 115 hp) . . . . . . . . . . . . 2.20.1.1
Engine Mounting & Fuel Lines (Deere 6068D) . . . . . . . . . . . . . . . . . 2.21.1
Exhaust Assembly (Deere 6068D) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22.1
Air Cleaner Assembly (Deere 6068D) . . . . . . . . . . . . . . . . . . . . . . . . 2.23.1
Radiator Group Assembly (Deere 6068D) . . . . . . . . . . . . . . . . . . . . 2.24.1
Throttle Group Assembly (Deere 6068D) . . . . . . . . . . . . . . . . . . . 2.25.1
Engine Mounting & Fuel Lines (Cummins 4B3.9) . . . . . . . . . . . . . . . 2.26.1
Engine Mounting & Fuel Lines (Cummins 4B3.9) . . . . . . . . . . . . . 2.26.1.1
Exhaust Assembly (Cummins 4B3.9) . . . . . . . . . . . . . . . . . . . . . . . . 2.27.1
Air Cleaner Assembly (Cummins 4B3.9) . . . . . . . . . . . . . . . . . . . . . 2.28.1
Radiator Group Assembly (Cummins 4B3.9) . . . . . . . . . . . . . . . . . . 2.29.1
Radiator Group Assembly (Cummins 4B3.9) . . . . . . . . . . . . . . . . . 2.29.1.1
Throttle Group Assembly (Cummins 4B3.9) . . . . . . . . . . . . . . . . . . 2.30.1
Throttle Group Assembly (Cummins 4B3.9) . . . . . . . . . . . 2.30.1.1
Engine Mounting & Fuel Lines (Cummins 4BT3.9) . . . . . . . . . . . . . 2.31.1
Engine Mounting & Fuel Lines (Cummins 4BT3.9) . . . . . . . . . . 2.31.1.1
Exhaust Assembly (Cummins 4BT3.9) . . . . . . . . . . . . . . . . . . . . . . 2.32.1
Air Cleaner Assembly (Cummins 4BT3.9) . . . . . . . . . . . . . . . . . . . . 2.33.1
Air Cleaner Assembly (Cummins 4BT3.9) . . . . . . . . . . . . . . . . . . . 2.33.1.1
Radiator Group Assembly (Cummins 4BT3.9) . . . . . . . . . . . . . . . . 2.34.1
Radiator Group Assembly (Cummins 4BT3.9) . . . . . . . . . . . . . . . 2.34.1.1
Throttle Group Assembly (Cummins 4BT3.9) . . . . . . . . . . . . . . . . . 2.35.1
Throttle Group Assembly (Cummins 4BT3.9) . . . . . . . . . . 2.35.1.1
Throttle Group Assembly (Cummins 4BT3.9) . . . . . . . . . . 2.35.1.2
Engine Mounting & Fuel Lines (Cummins 6B5.9) . . . . . . . . . . . . . . 2.36.1
Exhaust Assembly (Cummins 6B5.9) . . . . . . . . . . . . . . . . . . . . . . . 2.37.1
Air Cleaner Assembly (Cummins 6B5.9) . . . . . . . . . . . . . . . . . . . . . 2.38.1
Radiator Group Assembly (Cummins 6B5.9) . . . . . . . . . . . . . . . . . . 2.39.1
Throttle Group Assembly (Cummins 6b5.9) . . . . . . . . . . . . . . . . . . 2.40.1
Throttle Group Assembly (Cummins 6B5.9) . . . . . . . . . . . . . . . . . 2.40.1.1
Engine Mounting & Fuel Lines (Deere 4045D) . . . . . . . . . . . . . . . . 2.41.1
Exhaust Assembly (Deere 4045D) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.42.1
Air Cleaner Assembly (Deere 4045D) . . . . . . . . . . . . . . . . . . . . . . . 2.43.1
Radiator Group Assembly (Deere 4045D) . . . . . . . . . . . . . . . . . . . . 2.44.1
Throttle Group Assembly (Deere 4045D) . . . . . . . . . . . . . . . . . . . 2.45.1
Section 3 — Frame and Operator’s Compartment
Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1
Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1.1
Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2
Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.3
Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.3.1
Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.4
Operator’s Compartment Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1
Operator’s Compartment Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1.1
TABLE OF CONTENTS
3
Operator’s Compartment Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2
Operator’s Compartment Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2.1
Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1
Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1.1
Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1.2
Steer Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.1
Outrigger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1
Section 4 — Boom and Transfer Carriage
Transfer Carriage/Boom Cradle Assembly . . . . . . . . . . . . . . . . . . . . . 4.1.1
Transfer Carriage/Boom Cradle Assembly . . . . . . . . . . . . . . . . . . . . . 4.1.2
Outer Boom Assembly (2-Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1
Outer Boom Assembly (2-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1.1
Inner Boom Assembly (2-Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1
Outer Boom Assembly (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1
Outer Boom Assembly (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1.1
Outer Boom Assembly (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1.2
Outer Boom Assembly (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1.3
Middle Boom Assembly (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1
Middle Boom Assembly (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1.1
Middle Boom Assembly (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1.2
Middle Boom Assembly (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1.3
Middle Boom Assembly (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1.4
Middle Boom Assembly (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1.5
Inner Boom Assembly (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.1
Inner Boom Assembly (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.1.1
Outer Boom Assembly (4-Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.1
Outer Boom Assembly (4-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.1.1
Outer Boom Assembly (4-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.1.2
Outer Boom Assembly (4-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.1.3
Rear Middle Boom Assembly (4-Section) . . . . . . . . . . . . . . . . . . . . . . 4.8.1
Rear Middle Boom Assembly (4-Section) . . . . . . . . . . . . . . . . . . . . 4.8.1.1
forward Middle Boom Assembly (4-Section) . . . . . . . . . . . . . . . . . . . . 4.9.1
Forward Middle Boom Assembly (4-Section) . . . . . . . . . . . . . . . . . 4.9.1.1
Forward Middle Boom Assembly (4-Section) . . . . . . . . . . . . . . . . . 4.9.1.2
Inner Boom Assembly (4-Section) . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.1
Quick Attach Group Assembly (Weldment Type) . . . . . . . . . . . . 4.11.1
Quick Attach Group Assembly (Cast Type) . . . . . . . . . . . . . . . . 4.11.1.1
Quick Attach Group Assembly (Cast Type) . . . . . . . . . . . . . . . . 4.11.1.2
Section 5 — Boom and Transfer Hydraulics
Hoist & Rear Carriage Tilt Hydraulic circuit . . . . . . . . . . . . . . . . . . . . 5.1.1
Hoist & Rear Carriage Tilt Hydraulic circuit . . . . . . . . . . . . . . . . . . . 5.1.1.1
Hoist & Rear Carriage Tilt Hydraulic circuit . . . . . . . . . . . . . . . . . . . . 5.1.2
Hoist & Rear Carriage Tilt Hydraulic circuit . . . . . . . . . . . . . . . . . . . 5.1.2.1
Hoist & Rear Carriage Tilt Hydraulic circuit . . . . . . . . . . . . . . . . . . . 5.1.3
Hoist & Rear Carriage Tilt Hydraulic circuit . . . . . . . . . . . . . . . . . . . 5.1.3.1
Hoist & Rear Carriage Tilt Hydraulic circuit . . . . . . . . . . . . . . . . . . . 5.1.4
Hoist & Rear Carriage Tilt Hydraulic circuit . . . . . . . . . . . . . . . . . . . 5.1.4.1
Rear Carriage Tilt Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1
Rear Carriage Tilt Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . 5.2.1.1
Rear Carriage Tilt Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5.2.2
Hoist Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1
Hoist Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2
Transfer Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1
Transfer Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1.1
Transfer Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1
Transfer Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1.1
Boom Hydraulic Circuit (2-Section) . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.1
Boom Hydraulic Circuit (2-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.1.1
Boom Hydraulic Circuit (2-Section) . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.2
Boom Hydraulic Circuit (2-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.2.1
Boom Extension Cylinder Assembly (2-Section) . . . . . . . . . . . . . . . . 5.7.1
Boom Extension Cylinder Assembly (2-Section) . . . . . . . . . . . . . . . 5.7.1.1
Boom Hydraulic Circuit (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8.1
Boom Hydraulic Circuit (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 5.8.1.1
TABLE OF CONTENTS
4
Boom Hydraulic Circuit (3-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 5.8.1.2
Boom Hydraulic Circuit (3 Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8.2
Boom Hydraulic Circuit (3 Section) . . . . . . . . . . . . . . . . . . . . . . . . . 5.8.2.1
Boom Hydraulic Circuit (3 Section) . . . . . . . . . . . . . . . . . . . . . . . . . 5.8.2.2
Boom Extension Cylinder Assembly (3-Section) . . . . . . . . . . . . . . . . 5.9.1
Boom Hydraulic Circuit (4-Section) . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.1
Boom Hydraulic Circuit (4-Section) . . . . . . . . . . . . . . . . . . . . . . . . 5.10.1.1
Boom Hydraulic Circuit (4-Section) . . . . . . . . . . . . . . . . . . . . . . 5.10.1.2
Boom Hydraulic Circuit (4-Section) . . . . . . . . . . . . . . . . . . . . . 5.10.1.3
Boom Hydraulic circuit (4-Section) . . . . . . . . . . . . . . . . . . . . . . 5.10.1.4
Boom Hydraulic Circuit (4-Section) . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.2
Boom Hydraulic Circuit (4-Section) . . . . . . . . . . . . . . . . . . . . . . 5.10.2.1
Boom Hydraulic Circuit (4-Section) . . . . . . . . . . . . . . . . . . . . . . 5.10.2.2
Boom Hydraulic Circuit (4-Section) . . . . . . . . . . . . . . . . . . . . . . 5.10.2.3
Boom Extension Cylinder Assembly (4-Section) . . . . . . . . . . . . . . . 5.11.1
Front Carriage Tilt Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . 5.12.1
Front Carriage Tilt Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . 5.12.2
Section 6 — Pump, Suction - Return and Valve Plate
Components
Pump, Suction - Return Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . 6.1.1
Pump, Suction - Return Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . 6.1.1.1
Pump, Suction - Return Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . 6.1.2
Valve Plate Components Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1
Valve Plate Components Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.2
6 - Port Circuit Selector Valve Assembly . . . . . . . . . . . . . . . . . . . . . . 6.3.1
Frame Tilt Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.1
Hydraulic boom Control Valve Assembly (2-Spool) . . . . . . . . . . . . . . 6.5.1
Relief Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.1
Hydraulic Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7.1
Hydraulic Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7.2
Valve Section Ass’y - transfer/Auxiliary/Frame Tilt/Outriggers . . . . . . 6.8.1
Valve Section Assembly - Carriage Fork Tilt . . . . . . . . . . . . . . . . . . . 6.9.1
Control Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.1
Pump Unloader Circuit (Natural Engines Only) . . . . . . . . . . . . . . . . 6.11.1
Pump unloader Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12.1
Pump, Suction - Return Hydraulic Circuit - Mid Inlet . . . . . . . . . . . . 6.15.1
Pump, Suction - Return Hydraulic Circuit - Mid Inlet . . . . . . . . . . . . 6.15.2
Valve Plate Components Assembly (Mid Inlet) . . . . . . . . . . . . . . . . 6.16.1
Valve Plate Components Assembly (Mid Inlet) . . . . . . . . . . . . . . . 6.16.1.1
Valve Plate Components Assembly (Mid Inlet) . . . . . . . . . . . . . . . . 6.16.2
Valve Plate Components Assembly (Mid Inlet) . . . . . . . . . . . . . . . 6.16.2.1
6 - Port Circuit Selector Valve Assembly . . . . . . . . . . . . . . . . . . . . . 6.17.1
Pump-Valve Sub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18.1
Pump-Valve Sub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18.1.1
Hydraulic Control Valve Assembly - (Mid Inlet) . . . . . . . . . . . . . . . . 6.19.1
Hydraulic Control Valve Assembly - (Mid Inlet) . . . . . . . . . . . . . . . . 6.19.2
Hydraulic Control Valve Assembly - (Mid Inlet) . . . . . . . . . . . . . . . . 6.19.3
Valve Section Assembly - boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20.1
Valve Section Assembly - Fr. Tilt./Transfer/Aux./Outrig./Unloader . 6.21.1
Valve Section Assembly - Carriage Fork Tilt . . . . . . . . . . . . . . . . . . 6.22.1
Relief Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23.1
Relief Valve Assembly - Mid inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24.1
Hydraulic Return Line Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . 6.27.1
Pressure Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28.1
Pressure Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28.1.1
Section 7 — Control Hydraulics
Joystick Control Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1
Joystick Control Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2
Frame Tilt & Rear Oscillation Lock Hydraulic Circuit . . . . . . . . . . . . . 7.2.1
Frame Tilt & Rear Oscillation Lock Hydraulic Circuit . . . . . . . . . . . . . 7.2.2
Test Port Hydraulics Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.1
Oscillation Control Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.1
Joystick Control Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . . . 7.7.1
Joystick Control Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . . 7.7.1.1
TABLE OF CONTENTS
5
Joystick Control Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . . . 7.7.2
Joystick Control Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . 7.7.2.1
Joystick Control Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . . . 7.7.3
Joystick Control Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . 7.7.3.1
Joystick Control Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . . . 7.7.4
Joystick Control Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . 7.7.4.1
Frame Tilt & Rear Oscillation Lock Hydraulic Circuit . . . . . . . . . . . . . 7.8.1
Frame Tilt & Rear Oscillation Lock Hydraulic Circuit . . . . . . . . . . . 7.8.1.1
Frame Tilt & Rear Oscillation Lock Hydraulic Circuit . . . . . . . . . . . 7.8.1.2
Frame Tilt & Rear Oscillation Lock Hydraulic Circuit . . . . . . . . . . . . . 7.8.2
Frame Tilt & Rear Oscillation Lock Hydraulic Circuit . . . . . . . . . . . 7.8.2.1
Frame Tilt & Rear Oscillation Lock Hydraulic Circuit . . . . . . . . . . . 7.8.2.2
Rear Axle Stabilizer Control Valve Assembly . . . . . . . . . . . . . . . . . . . 7.9.1
Rear Axle Stabilizer Control Valve Assembly . . . . . . . . . . . . . . . . . 7.9.1.1
Test Port Hydraulics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10.1
Test Port Hydraulics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10.1.1
Oscillation Control Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.1
Oscillation Control Block Assembly . . . . . . . . . . . . . . . . . . . . . . . 7.11.1.1
Inline fliter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12.1
Joystick Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14.1
Frame Tilt Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 7.15.1
Frame Tilt Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16.1
Frame Tilt Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16.1.1
Rear Oscillation Lock Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . 7.17.1
Outrigger Hydraulics Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20.1
Outrigger Hydraulics Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20.1.1
Outrigger Hydraulics Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20.1.2
Outrigger Hydraulics Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20.1.3
Outrigger Control valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21.1
3 Handle Single Axis Control Valve Assembly . . . . . . . . . . . . . . . 7.21.1.1
Outrigger Over-Ride Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7.22.1
Outrigger Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23.1
Boom Extend Lockout Valve Assembly . . . . . . . . . . . . . . . . . . . . . . 7.24.1
Section 8 — Steering and Brake Hydraulics
Steering Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.1
Service Brake Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.1
Service Brake Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1
Park Brake Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.1
Steering Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.1
Service Brake Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . . . . 8.8.1
Service Brake Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . . . 8.8.1.1
Service Brake Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . . . . 8.8.2
Service Brake Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . . . 8.8.2.1
Service Brake Valve Assembly (Mid Inlet) . . . . . . . . . . . . . . . . . . . . . 8.9.1
Park Brake Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . . . . . . 8.10.1
Park Brake Hydraulic Circuit (Mid Inlet) . . . . . . . . . . . . . . . . . . . . . 8.10.1.1
Park Brake Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13.1
Accumulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14.1
Section 9 — Electrical
Electrical Group - Operator’s Compartment . . . . . . . . . . . . . . . . . . . 9.1.1
Electrical Group - Operator’s Compartment . . . . . . . . . . . . . . . . . . 9.1.1.1
Electrical Group - Operator’s Compartment . . . . . . . . . . . . . . . . . . 9.1.1.2
Electrical Mounting Panel - Fuses, Relays & Buzzer. . . . . . . . . . . . . 9.2.1
Electrical Mounting Panel - Fuses, Relays & Buzzer. . . . . . . . . . . . 9.2.1.1
Electrical Mounting Panel - Fuses, Relays & Buzzer. . . . . . . . . . . . 9.2.1.2
Electrical Group - Transmission Control . . . . . . . . . . . . . . . . . . . . . . 9.3.1
Electrical Group - Transmission Control . . . . . . . . . . . . . . . . . . . . . 9.3.1.1
Electrical Group - Transmission Control . . . . . . . . . . . . . . . . . . . . . 9.3.1.2
Electrical Group - Frame (Valve Plate) . . . . . . . . . . . . . . . . . . . . . . . . 9.4.1
Electrical Group - Frame (Valve Plate) . . . . . . . . . . . . . . . . . . . . . . 9.4.1.1
Electrical Group - Frame (Valve Plate) . . . . . . . . . . . . . . . . . . . . . . 9.4.1.2
Electrical Group - Frame (Valve Plate) . . . . . . . . . . . . . . . . . . . . . . 9.4.1.3
Electrical Group - Outrigger/Boom Extend Lockout . . . . . . . . . . . . . . 9.5.1
Electrical Group - Outrigger/Boom Extend Lockout . . . . . . . . . . . . . 9.5.1.1
TABLE OF CONTENTS
6
Electrical Group - Engine (Deere) 4039D & 4039T. . . . . . . . . . . . . . 9.6.1
Electrical Group - Engine (Deere) 4045D, 4045T & 6068D . . . . . . . . 9.6.2
Electrical Group - Engine (Deere) 4045D, 4045T & 6068D . . . . . . 9.6.2.1
Electrical Group - Engine (Cummins) 4BT3.9 . . . . . . . . . . . . . . . . . . . 9.7.1
Electrical Group - Engine (Cummins) 4BT3.9 . . . . . . . . . . . . . . . . 9.7.1.1
Electrical Group - Engine (Cummins) 4B3.9 . . . . . . . . . . . . . . . . . . . 9.7.2
Electrical Group - Engine (Cummins) 4B3.9 EPA . . . . . . . . . . . . . . 9.7.2.1
Electrical Group - Engine (Cummins) 6BT5.9 . . . . . . . . . . . . . . . . . . . 9.7.3
Section 10 — Decals
Section 10 — Optional Equipment
Decal Group Common . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1.1
Decal Group Common . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1.1.1
Decal Group & Flip Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.1
(Optional) Hydraulic Oil Cooler Assembly. . . . . . . . . . . . . . . . . . . . . 10.6.1
(Optional) Hydraulic Oil Cooler Assembly. . . . . . . . . . . . . . . . . . . . 10.6.1.1
Window Assembly, Enclosed Cab . . . . . . . . . . . . . . . . . . . . . . . . . 10.10.1
Door Assembly, Enclosed Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11.1
Windshield Assembly, Enclosed Cab . . . . . . . . . . . . . . . . . . . . . . . 10.12.1
Windshield Wiper Assembly, Enclosed Cab . . . . . . . . . . . . . . . . . . 10.13.1
Insulation Assembly, Enclosed Cab . . . . . . . . . . . . . . . . . . . . . . . . 10.14.1
Second Auxiliary Hydraulic Circuit (4-Section) . . . . . . . . . . . . . . . . 10.20.1
Second Auxiliary Hydraulic Circuit (4-Section) . . . . . . . . . . . . . . 10.20.1.1
Second Auxiliary Hydraulic circuit (4-Section) . . . . . . . . . . . . . . . 10.20.1.2
Second Auxiliary Hydraulic circuit (4-Section) . . . . . . . . . . . . . . . 10.20.1.3
(Optional) Drive Lockout Override . . . . . . . . . . . . . . . . . . . . . . . . . 10.22.1
(Optional) Transmission Disconnect Override Valve . . . . . . . . . . . 10.23.1
(Optional) Worklight Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25.1
(Optional) Worklight Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25.1.1
(Optional) Roadway Lights Assembly . . . . . . . . . . . . . . . . . . . . . . . 10.26.1
(Optional) Roadway Lights Assembly (Mid Inlet) . . . . . . . . . . . . . 10.26.1.1
(Optional) Roadway Lights Dash Harness w/o Circuit Board . . . . . 10.27.1
(Optional) Roadway Lights Dash Harness w/Circuit Board . . . . . 10.27.1.1
(Optional) Strobe/ Rotating Beacon Lights . . . . . . . . . . . . . . . . . . . 10.28.1
Section 11 — Attachments
Standard (Non-Tilt) Fork Carriage Assembly, Model 8 50 . . . . . . . . . 11.1.1
Standard (Non-Tilt) Fork Carriage Assembly, Model 10 50 . . . . . . . . 11.1.2
Framers (Non-Tilt) Fork Carriage Assembly, Model 8 74 . . . . . . . . . 11.2.1
Framers (Non-Tilt) Fork Carriage Assembly, Model 10 74 . . . . . . . . 11.2.2
Standard Tilting Fork Carriage Assembly, Model 8T50 . . . . . . . . . . . 11.3.1
Standard Tilting Fork Carriage Assembly, Model 10T50 . . . . . . . . . . 11.3.2
Framers Tilting Fork Carriage Assembly, Model 8T74 . . . . . . . . . . . 11.4.1
Framers Tilting Fork Carriage Assembly, Model 10T74 . . . . . . . . . . 11.4.2
Tilting Carriage Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5.1
Tower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10.1
Carriage Assembly, Tower, Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11.1
Carriage Assembly Tower (Non-Tilt) . . . . . . . . . . . . . . . . . . . . . . . . 11.12.1
Tower Quick Attach Lock Plate Assembly . . . . . . . . . . . . . . . . . . . 11.13.1
Tower Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14.1
Carriage Assembly Single Fork Positioning. . . . . . . . . . . . . . . . . . . 11.16.1
Carriage Assembly Dual Fork Positioning . . . . . . . . . . . . . . . . . . . . 11.17.1
Fork Positioning Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . 11.18.1
Truss Boom Assembly, Model 2TB10 . . . . . . . . . . . . . . . . . . . . . . . 11.20.1
Truss Boom Assembly With Winch, Model 2TBW10 . . . . . . . . . . . . 11.21.1
Utility Bucket 1.25 Cu. Yd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22.1
You're Reading a Preview
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$31.99
Viewed 68 Times Today
Secure transaction
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$31.99
This comprehensive parts manual is designed for the JLG Lull Telehandlers 644B, 6K, 844C, 8K, 1044C, and 10K ANSI models. It is a valuable resource for both professional mechanics and DIY repair enthusiasts.
The manual offers detailed illustrations and diagrams to facilitate understanding and covers the following sections:
- Drive Train
- Power Plant
- Frame & Operator's Compartment
- Boom & Transfer Carriage
- Boom & Transfer Hydraulics
- Suction Pump - Return & Valve Plate Components
- Control Hydraulics
- Steering & Brake Hydraulics
- Electrical
- Decals & Optional Equipment
- Attachments
This manual is ideally suited for those who need a reliable tool for maintaining and repairing the specified telehandler models. It allows users to quickly access essential diagrams and component details, making it an indispensable addition to any toolkit for repair projects.
