JLG Telehandler 1644 Parts Catalog 31211281

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JLG Telehandler 1644 Parts Catalog 31211281
Size: 63.85 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Telehandler
Type of Manual: Parts Catalog
Model: JLG 1644 Telehandler
Part Number: 31211281
Publication Date: 2025
Number of Pages: 960 Pages

Contents:
SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-1. FRAME WELDMENT​

FIGURE 1-2. GROMMETS INSTALLATION​

FIGURE 1-3. TANK INSTALLATION​

FIGURE 1-4. FUEL TANK INSTALLATION​

FIGURE 1-5. HYDRAULIC TANK INSTALLATION​

FIGURE 1-6. TANK SUPPORT INSTALLATION​

FIGURE 1-7. FUEL TANK ASSEMBLY​

FIGURE 1-8. LOCKING FUEL CAP​

FIGURE 1-9. HYDRAULIC TANK ASSEMBLY​

FIGURE 1-10. COUNTERWEIGHT INSTALLATION​

FIGURE 1-11. ENGINE ENCLOSURE INSTALLATION​

FIGURE 1-12. ENGINE ENCLOSURE ASSEMBLY​

FIGURE 1-13. HOOD ASSEMBLY​

FIGURE 1-14. HOOD ASSEMBLY​

FIGURE 1-15. COVER INSTALLATION (ULS)​

FIGURE 1-16. FRAME COVER INSTALLATION​

FIGURE 1-17. FRONT LOWER COVER INSTALLATION​

FIGURE 1-18. MIRROR INSTALLATION​

SECTION 2 - BOOM

FIGURE 2-1. BOOM INSTALLATION​

FIGURE 2-2. BOOM ASSEMBLY​

FIGURE 2-3. FIRST BOOM SECTION ASSEMBLY​

FIGURE 2-4. SECOND BOOM SECTION ASSEMBLY​

FIGURE 2-5. THIRD BOOM SECTION ASSEMBLY​

FIGURE 2-6. COUPLER INSTALLATION (MANUAL)​

FIGURE 2-7. COUPLER INSTALLATION (HYDRAULIC)​

FIGURE 2-8. COUPLER LOCKING CYLINDER ASSEMBLY​

FIGURE 2-9. MANUAL COUPLER PIN HOLDER INSTALLATION​

FIGURE 2-10. BOOM BRUSHES INSTALLATION​

FIGURE 2-11. BOOM PROP BRACKET ASSEMBLY​

SECTION 3 - ATTACHMENTS

FIGURE 3-1. ATTACHMENT RECOGNITION INSTALLATION​

FIGURE 3-2. COMPONENTS ATTACHMENT RECOGNITION INSTALLATION​

FIGURE 3-3. CARRIAGE ASSEMBLY, (60IN/1524MM)​

FIGURE 3-4. CARRIAGE ASSEMBLY, (72IN/1829MM)​

FIGURE 3-5. CARRIAGE ASSEMBLY, (87IN/2290MM)​

FIGURE 3-6. DUAL FORK POSITIONING SIDE SHIFT CARRIAGE, (75IN/1899MM)​

FIGURE 3-7. DUAL FORK POSITIONING CARRIAGE, (72IN/1829MM)​

FIGURE 3-8. BUCKET (2.6 YD³/2.0M³)​

FIGURE 3-9. BUCKET (5.23 YD3)​

FIGURE 3-10. 4 IN 1 BUCKET (1.3 YD³/1.0M³)​

FIGURE 3-11. GRAPPLE BUCKET (1.7 YD³/1.3M³)​

FIGURE 3-12. TRUSS BOOM (7.6 TON)​

FIGURE 3-13. CRANE HOOK (7.6 TON)​

FIGURE 3-14. BALE HANDLER (ROUND)​

FIGURE 3-15. BALE HANDLER (SQUARE)​

FIGURE 3-16. PIPE HANDLER CARRIAGE​

FIGURE 3-17. LOG HANDLER CARRIAGE​

FIGURE 3-18. STEEL COIL HANDLER CARRIAGE​

FIGURE 3-19. PALLET FORK (2.25X6X48)​

FIGURE 3-20. PALLET FORK (2.25X6X60)​

FIGURE 3-21. PALLET FORK (2.25X6X72)​

FIGURE 3-22. PALLET FORK (2.25X6X96)​

FIGURE 3-23. FORK RETENTION INSTALLATION​

FIGURE 3-24. HOOK ATTACH, FORK MOUNTED​

SECTION 4 - ENGINE AND ATTACHING PARTS

FIGURE 4-1. ENGINE POD COMPONENT INSTALLATION (ULS)​

FIGURE 4-2. ENGINE POD COMPONENT INSTALLATION (MINING) (ULS)​

FIGURE 4-3. ENGINE INSTALLATION (ULS)​

FIGURE 4-4. ENGINE (100KW - ULS)​

FIGURE 4-5. ENGINE (100KW - ULS)​

FIGURE 4-6. ENGINE MOUNT INSTALLATION​

FIGURE 4-7. AIR INTAKE INSTALLATION (ULS)​

FIGURE 4-8. AIR INTAKE DUCT INSTALLATION​

FIGURE 4-9. AIR CLEANER INSTALLATION​

FIGURE 4-10. AIR CLEANER ASSEMBLY (90/100KW)​

FIGURE 4-11. PRIMARY FUEL FILTER INSTALLATION (ULS)​

FIGURE 4-12. REMOTE FUEL PUMP INSTALLATION​

FIGURE 4-13. FUEL LINES INSTALLATION​

FIGURE 4-14. HYDROSTATIC ADAPTOR INSTALLATION​

FIGURE 4-15. DUAL DRIVE SUPPORT ASSEMBLY​

FIGURE 4-16. HYDROSTATIC DRIVE PUMP INSTALLATION​

FIGURE 4-17. HYDROSTATIC DRIVE PUMP ASSEMBLY​

FIGURE 4-18. IMPLEMENT PUMP INSTALLATION​

FIGURE 4-19. IMPLEMENT PUMP ASSEMBLY​

FIGURE 4-20. DEF COOLANT LINES INSTALLATION (ULS)​

FIGURE 4-21. DEF COOLANT LINES INSTALLATION (ULS)​

FIGURE 4-22. CAC LINES INSTALLATION​

FIGURE 4-23. COOLING PACKAGE INSTALLATION​

FIGURE 4-24. COOLING PACKAGE INSTALLATION​

FIGURE 4-25. RADIATOR​

FIGURE 4-26. COOLANT LINES INSTALLATION​

FIGURE 4-27. RADIATOR LINES INSTALLATION​

FIGURE 4-28. SURGE TANK INSTALLATION​

FIGURE 4-29. TRANSMISION OIL COOLER LINES INSTALLATION​

FIGURE 4-30. FAN GUARD INSTALLATION​

FIGURE 4-31. FAN GUARD (REVERSING) INSTALLATION​

FIGURE 4-32. COOLING FAN INSTALLATION​

FIGURE 4-33. REVERSE COOLING FAN INSTALLATION​

FIGURE 4-34. COMPRESSOR COVER INSTALLATION​

FIGURE 4-35. EXHAUST INSTALLATION (ULS)​

FIGURE 4-36. DEF CONTROL MODULE INSTALLATION​

FIGURE 4-37. DEF LINES INSTALLATION​

FIGURE 4-38. DEF LINES INSTALLATION​

FIGURE 4-39. DEF TANK INSTALLATION​

FIGURE 4-40. DEF TANK INSTALLATION​

FIGURE 4-41. DEF TANK ASSEMBLY​

FIGURE 4-42. DEF TANK ASSEMBLY​

FIGURE 4-43. HEATER LINES INSTALLATION (ULS)​

FIGURE 4-44. A/C PUMP INSTALLATION​

FIGURE 4-45. A/C LINES INSTALLATION​

FIGURE 4-46. BLOCK HEATER INSTALLATION (115V) (ULS)​

FIGURE 4-47. HEATED BREATHER TUBE INSTALLATION​

SECTION 5 - DRIVETRAIN

FIGURE 5-1. DRIVETRAIN INSTALLATION​

FIGURE 5-2. FRONT AXLE INSTALLATION​

FIGURE 5-3. FRONT AXLE MOUNTING INSTALLATION​

FIGURE 5-4. FRONT AXLE LINES INSTALLATION​

FIGURE 5-5. REAR AXLE INSTALLATION​

FIGURE 5-6. REAR AXLE MOUNTING INSTALLATION​

FIGURE 5-7. REAR AXLE LINES INSTALLATION​

FIGURE 5-8. FRONT AXLE​

FIGURE 5-9. FRONT AXLE, CENTRAL HOUSING​

FIGURE 5-10. FRONT AXLE, DIFFERENTIAL​

FIGURE 5-11. FRONT AXLE, HUB REDUCTION​

FIGURE 5-12. FRONT AXLE, BRAKES​

FIGURE 5-13. FRONT AXLE, STEERING​

FIGURE 5-14. FRONT AXLE, TRUNION​

FIGURE 5-15. REAR AXLE​

FIGURE 5-16. REAR AXLE, CENTRAL HOUSING​

FIGURE 5-17. REAR AXLE, DIFFERENTIAL​

FIGURE 5-18. REAR AXLE, HUB REDUCTION​

FIGURE 5-19. REAR AXLE, BRAKES​

FIGURE 5-20. REAR AXLE, STEERING​

FIGURE 5-21. REAR AXLE, TRUNION​

FIGURE 5-22. DIFFERENTIAL KIT​

FIGURE 5-23. DIFFERENTIAL KIT​

FIGURE 5-24. STEERING CASE ASSEMBLY (LH STEER LINK)​

FIGURE 5-25. STEERING CASE ASSEMBLY (RH STEER LINK)​

FIGURE 5-26. TRUNION KIT​

FIGURE 5-27. RING GEAR SUPPORT KIT​

FIGURE 5-28. REDUCTION BUSHING KIT​

FIGURE 5-29. PLANET GEAR CARRIER KIT​

FIGURE 5-30. RALP INSTALLATION​

FIGURE 5-31. RALP MECHANICAL INSTALLATION​

FIGURE 5-32. GEARBOX INSTALLATION​

FIGURE 5-33. GEAR BOX​

FIGURE 5-34. HYDROSTATIC MOTOR INSTALLATION​

FIGURE 5-35. HYDROSTATIC MOTOR ASSEMBLY​

FIGURE 5-36. DRIVE SHAFT INSTALLATION​

FIGURE 5-37. TIRE/WHEEL SET (AIR 17.5-25 - 20 PLY)​

FIGURE 5-38. RIGHT TIRE/WHEEL ASSEMBLY (AIR 17.5-25 - 20 PLY)​

FIGURE 5-39. LEFT TIRE/WHEEL ASSEMBLY (AIR 17.5-25 - 20 PLY)​

FIGURE 5-40. TIRE/WHEEL SET (FOAM 17.5-25 - 20 PLY)​

FIGURE 5-41. TIRE/WHEEL SET (AIR 17.5 R25 - RADIAL)​

FIGURE 5-42. RIGHT TIRE/WHEEL ASSEMBLY (AIR 17.5 R25 - RADIAL)​

FIGURE 5-43. LEFT TIRE/WHEEL ASSEMBLY (AIR 17.5 R25 - RADIAL)​

FIGURE 5-44. FENDER INSTALLATION​

FIGURE 5-45. RH FENDER ASSEMBLY​

FIGURE 5-46. LH FENDER ASSEMBLY​

SECTION 6 - CAB

FIGURE 6-1. CAB MOUNTING INSTALLATION​

FIGURE 6-2. FRONT CAB MOUNT BRACKET INSTALLATION​

FIGURE 6-3. CAB MOUNTS INSTALLATION​

FIGURE 6-4. CAB COMPONENTS INSTALLATION​

FIGURE 6-5. CAB INSTALLATION​

FIGURE 6-6. CAB ASSEMBLY​

FIGURE 6-7. CAB DOOR INSTALLATION​

FIGURE 6-8. CAB DOOR ASSEMBLY​

FIGURE 6-9. CAB DOOR WINDOW INSTALLATION​

FIGURE 6-10. CAB LATCH ASSEMBLY​

FIGURE 6-11. CAB DOOR​

FIGURE 6-12. CAB DOOR TRIGGER ASSEMBLY​

FIGURE 6-13. DOOR STRAP INSTALLATION​

FIGURE 6-14. REAR WINDOW INSTALLATION​

FIGURE 6-15. REAR WINDOW GROUP​

FIGURE 6-16. CAB PLUG GROUP​

FIGURE 6-17. BASIC MIRROR INSTALLATION​

FIGURE 6-18. INTERIOR MIRROR INSTALLATION​

FIGURE 6-19. INTERIOR MIRROR​

FIGURE 6-20. FRONT WIPER INSTALLATION​

FIGURE 6-21. WASHER TANK INSTALLATION​

FIGURE 6-22. WASHER BOTTLE​

FIGURE 6-23. FRONT COVER INSTALLATION​

FIGURE 6-24. FRONT DUCT COVER​

FIGURE 6-25. FILTER TRAY PANEL​

FIGURE 6-26. LEVEL INDICATOR INSTALLATION​

FIGURE 6-27. REAR WIPER INSTALLATION​

FIGURE 6-28. MULTIFUNCTION DISPLAY INSTALLATION​

FIGURE 6-29. SEAT INSTALLATION (MECHANICAL)​

FIGURE 6-30. SEAT ASSEMBLY (MECHANICAL)​

FIGURE 6-31. SEAT INSTALLATION (AIR SUSPENSION - STANDARD)​

FIGURE 6-32. SEAT ASSEMBLY (AIR SUSPENSION - STANDARD)​

FIGURE 6-33. SEAT INSTALLATION (AIR SUSPENSION - PREMIUM)​

FIGURE 6-34. SEAT ASSEMBLY (AIR SUSPENSION - PREMIUM)​

FIGURE 6-35. UPPER SEAT ASSEMBLY​

FIGURE 6-36. HEATER INSTALLATION (CAB PARTS)​

FIGURE 6-37. HEATER AND A/C INSTALLATION (CAB PARTS)​

FIGURE 6-38. CAB CONDENSER ASSEMBLY​

FIGURE 6-39. CONDENSER​

FIGURE 6-40. A/C RECEIVER DRIER​

FIGURE 6-41. HEATER ASSEMBLY​

FIGURE 6-42. HEATER AND A/C ASSEMBLY​

FIGURE 6-43. HVAC CAB ACTUATOR​

FIGURE 6-44. HEATER​

FIGURE 6-45. HEATER​

FIGURE 6-46. HEATER AND A/C​

FIGURE 6-47. ROOF WIPER INSTALLATION​

FIGURE 6-48. HEADLINER INSTALLATION​

FIGURE 6-49. HEADLINER/RADIO READY PACKAGE INSTALLATION​

FIGURE 6-50. CAB TRIM INSTALLATION​

FIGURE 6-51. DASH COVER ASSEMBLY​

FIGURE 6-52. REAR PANEL COVER ASSEMBLY​

FIGURE 6-53. ADJUSTABLE ARMREST INSTALLATION​

FIGURE 6-54. ARMREST​

FIGURE 6-55. FIXED ARMREST BRACKET​

FIGURE 6-56. MOVING ARMREST BRACKET​

FIGURE 6-57. ROOF CAP INSTALLATION (NO A/C)​

FIGURE 6-58. ROOF CAP INSTALLATION (A/C)​

FIGURE 6-59. RETRACTABLE SUNSCREEN INSTALLATION​

FIGURE 6-60. FLOOR MAT INSTALLATION​

FIGURE 6-61. SEAT BELT INSTALLATION (3IN)​

FIGURE 6-62. SEAT BELT INSTALLATION (2IN)​

FIGURE 6-63. ENCLOSED CAB FRONT COVER INSTALLATION​

FIGURE 6-64. CAB GUARD INSTALLATION (TOP)​

FIGURE 6-65. CAB GUARD INSTALLATION (FRONT)​

FIGURE 6-66. CAB GUARD INSTALLATION (TOP AND FRONT)​

FIGURE 6-67. EXTERNAL WINDOW RELEASE INSTALLATION (ANSI - ENGLISH)​

FIGURE 6-68. EXTERNAL WINDOW RELEASE INSTALLATION (ANSI - ENGLISH/FRENCH)​

FIGURE 6-69. SUSPENSION KIT​

SECTION 7 - CONTROLS

FIGURE 7-1. ACCELERATOR PEDAL INSTALLATION​

FIGURE 7-2. ACCELERATOR PEDAL​

FIGURE 7-3. BRAKE PEDAL INSTALLATION​

FIGURE 7-4. BRAKE PEDAL ASSEMBLY​

FIGURE 7-5. BRAKE SENSOR INSTALLATION​

FIGURE 7-6. SWITCH PLATE ASSEMBLY​

FIGURE 7-7. PARK BRAKE INSTALLATION​

FIGURE 7-8. TILT STEERING COLUMN INSTALLATION​

FIGURE 7-9. TILT STEERING COLUMN​

FIGURE 7-10. COLUMN SHIFT INSTALLATION (2 SPEED)​

FIGURE 7-11. COLUMN SHIFT INSTALLATION (0 SPEED)​

FIGURE 7-12. STEERING WHEEL INSTALLATION​

FIGURE 7-13. STEERING WHEEL​

FIGURE 7-14. HORN BUTTON INSTALLATION​

FIGURE 7-15. JOYSTICK INSTALLATION (2 SPEED)​

FIGURE 7-16. JOYSTICK INSTALLATION (0 SPEED)​

FIGURE 7-17. WIPER-TURN SWITCH​

SECTION 8 - HYDRAULIC CIRCUITS

FIGURE 8-1. MAIN HYDRAULIC INSTALLATION​

FIGURE 8-2. BOOM HYDRAULIC INSTALLATION​

FIGURE 8-3. REMOTE GREASE INSTALLATION​

FIGURE 8-4. FRAME LEVEL INSTALLATION​

FIGURE 8-5. FRAME LEVEL CYLINDER INSTALLATION​

FIGURE 8-6. FRAME LEVEL VALVE ASSEMBLY​

FIGURE 8-7. BOOM RAISE HOSE INSTALLATION (NO RIDE CONTROL)​

FIGURE 8-8. BOOM RAISE COUNTERBALANCE VALVE (NO RIDE CONTROL)​

FIGURE 8-9. BOOM RAISE HOSE INSTALLATION (RIDE CONTROL)​

FIGURE 8-10. RIDE AND FLOAT VALVE ASSEMBLY​

FIGURE 8-11. BOOM AUX HYDRAULIC INSTALLATION (MANUAL - SINGLE)​

FIGURE 8-12. BOOM AUX HYDRAULIC INSTALLATION (MANUAL - TWIN)​

FIGURE 8-13. DIVERTER VALVE ASSEMBLY​

FIGURE 8-14. BOOM AUX HYDRAULIC INSTALLATION (HYDRAULIC - SINGLE)​

FIGURE 8-15. DIVERTER VALVE ASSEMBLY​

FIGURE 8-16. BOOM AUX HYDRAULIC INSTALLATION (HYDRAULIC - TWIN)​

FIGURE 8-17. DIVERTER VALVE ASSEMBLY​

FIGURE 8-18. RALP HYDRAULIC LINES INSTALLATION​

FIGURE 8-19. MAIN CONTROL VALVE INSTALLATION​

FIGURE 8-20. MAIN CONTROL VALVE ASSEMBLY​

FIGURE 8-21. STEERING SELECT VALVE INSTALLATION​

FIGURE 8-22. STEERING SELECT VALVE ASSEMBLY​

FIGURE 8-23. FRAME LEVEL VALVE INSTALLATION​

FIGURE 8-24. FRAME LEVEL VALVE ASSEMBLY​

FIGURE 8-25. CAB HYDRAULICS INSTALLATION​

FIGURE 8-26. SOLENOID VALVE INSTALLATION​

FIGURE 8-27. SOLENOID VALVE ASSEMBLY​

FIGURE 8-28. CHECK VALVE INSTALLATION​

FIGURE 8-29. CHECK VALVE ASSEMBLY​

FIGURE 8-30. SPEED CONTROL VALVE INSTALLATION​

FIGURE 8-31. SPEED CONTROL VALVE ASSEMBLY​

FIGURE 8-32. ENGINE BAY HYDRAULIC INSTALLATION​

FIGURE 8-33. INCHING VALVE INSTALLATION​

FIGURE 8-34. INCHING VALVE ASSEMBLY​

FIGURE 8-35. CHARGE FILTER LINES INSTALLATION​

FIGURE 8-36. CHARGE FILTER INSTALLATION​

FIGURE 8-37. IMPLEMENT PUMP FILTER ASSEMBLY​

FIGURE 8-38. FRAME HYDRAULIC INSTALLATION​

FIGURE 8-39. MANIFOLD INSTALLATION​

FIGURE 8-40. MANIFOLD ASSEMBLY​

FIGURE 8-41. BOOM HYDRAULIC LINES INSTALLATION​

FIGURE 8-42. PRIORITY MANIFOLD INSTALLATION​

FIGURE 8-43. PRIORITY VALVE ASSEMBLY​

FIGURE 8-44. PRIORITY VALVE ASSEMBLY (PLATFORM READY)​

FIGURE 8-45. PRIORITY MANIFOLD INSTALLATION (PLATFORM READY)​

FIGURE 8-46. CYLINDER ASSEMBLY​

FIGURE 8-47. CYLINDER ASSEMBLY​

SECTION 9 - HYDRAULIC COMPONENTS

FIGURE 9-1. CYLINDER GROUP INSTALLATION​

FIGURE 9-2. LIFT CYLINDER INSTALLATION​

FIGURE 9-3. LIFT CYLINDER​

FIGURE 9-4. COMPENSATION CYLINDER INSTALLATION​

FIGURE 9-5. COMPENSATION CYLINDER​

FIGURE 9-6. COUPLER LOCKING CYLINDER​

FIGURE 9-7. EXTEND/RETRACT CYLINDER INSTALLATION​

FIGURE 9-8. EXTEND/RETRACT CYLINDER​

FIGURE 9-9. TILT CYLINDER​

FIGURE 9-10. FRAME LEVEL CYLINDER​

FIGURE 9-11. RALP CYLINDER INSTALLATION​

FIGURE 9-12. FORK POSITIONING CYLINDER ASSEMBLY​

FIGURE 9-13. SIDE SHIFT CYLINDER ASSEMBLY​

FIGURE 9-14. UPPER CYLINDER ASSEMBLY​

FIGURE 9-15. LOWER CYLINDER ASSEMBLY​

FIGURE 9-16. REAR AXLE LOCK VALVE INSTALLATION​

FIGURE 9-17. LOG HANDLER CARRIAGE CYLINDER ASSEMBLY​

FIGURE 9-18. HYDROSTATIC MOTOR​

FIGURE 9-19. HYDROSTATIC PUMP​

FIGURE 9-20. IMPLEMENT PUMP​

FIGURE 9-21. MAIN CONTROL VALVE​

FIGURE 9-22. STEERING SELECT VALVE​

FIGURE 9-23. FRAME LEVEL VALVE​

FIGURE 9-24. SOLENOID VALVE​

FIGURE 9-25. INCHING VALVE​

FIGURE 9-26. PRIORITY VALVE ASSEMBLY​

FIGURE 9-27. BOOM RAISE VALVE (RIDE CONTROL)​

FIGURE 9-28. DIVERTOR VALVE​

FIGURE 9-29. DIVERTOR VALVE​

FIGURE 9-30. STEER UNIT VALVE​

FIGURE 9-31. COUNTERBALANCE VALVE INSTALLATION​

FIGURE 9-32. COUNTERBALANCE VALVE​

FIGURE 9-33. COUNTERBALANCE VALVE​

FIGURE 9-34. COUNTERBALANCE VALVE​

FIGURE 9-35. SPEED CONTROL VALVE​

SECTION 10 - ELECTRICAL

FIGURE 10-1. MAIN ELECTRICAL INSTALLATION (ULS)​

FIGURE 10-2. MAIN ELECTRICAL INSTALLATION, MINING (ULS)​

FIGURE 10-3. FRAME ELECTRICAL INSTALLATION​

FIGURE 10-4. ENGINE POD ELECTRICAL INSTALLATION (ULS)​

FIGURE 10-5. ENGINE POD COMPONENT INSTALLATION (MINING) (ULS)​

FIGURE 10-6. FRAME WIRING INSTALLATION​

FIGURE 10-7. FRAME WIRING INSTALLATION, MINING​

FIGURE 10-8. ENGINE BAY ELECTRICAL INSTALLATION (ULS)​

FIGURE 10-9. POWER DISTRIBUTION ELECTRICAL BOX​

FIGURE 10-10. REAR FRAME MODULE INSTALLATION​

FIGURE 10-11. ENGINE WIRING INSTALLATION (ULS)​

FIGURE 10-12. ENGINE WIRING INSTALLATION (MINING) (ULS)​

FIGURE 10-13. ENGINE ECU INSTALLATION​

FIGURE 10-14. ENGINE ECU INSTALLATION​

FIGURE 10-15. BATTERY INSTALLATION​

FIGURE 10-16. DUAL BATTERY INSTALLATION​

FIGURE 10-17. ARTIC BATTERY PACKAGE INSTALLATION (115V)​

FIGURE 10-18. ARCTIC BATTERIES INSTALLATION (115V)​

FIGURE 10-19. HYDRAULIC TANK HEATER INSTALLATION (115V)​

FIGURE 10-20. BACKUP ALARM INSTALLATION​

FIGURE 10-21. BACKUP ALARM INSTALLATION (WHITE NOISE)​

FIGURE 10-22. EMERGENCY STOP EXTERNAL INSTALLATION​

FIGURE 10-23. CAB ELECTRICAL INSTALLATION​

FIGURE 10-24. DASH ELECTRICAL INSTALLATION​

FIGURE 10-25. LIGHT SWITCH INSTALLATION​

FIGURE 10-26. BOOM HARNESS INSTALLATION​

FIGURE 10-27. BOOM HARNESS INSTALLATION​

FIGURE 10-28. BOOM AUX HARNESS INSTALLATION​

FIGURE 10-29. DRIVING LIGHT INSTALLATION (RH DIP)​

FIGURE 10-30. DRIVING LIGHT INSTALLATION (LED) (RH DIP)​

FIGURE 10-31. CAB WORKLIGHTS INSTALLATION (NO A/C - LED)​

FIGURE 10-32. CAB WORKLIGHTS INSTALLATION (A/C - LED)​

FIGURE 10-33. BOOM WORK LIGHTS (LED)​

FIGURE 10-34. BOOM WORK LIGHT INSTALLATION (LED)​

FIGURE 10-35. BEACON INSTALLATION​

FIGURE 10-36. BEACON INSTALLATION (LED)​

FIGURE 10-37. BEACON (REMOTE BOOM CONTROL) INSTALLATION​

FIGURE 10-38. BEACON (LED) (REMOTE BOOM CONTROL) INSTALLATION​

FIGURE 10-39. REVERSE CAMERA INSTALLATION​

FIGURE 10-40. REVERSE SENSOR INSTALLATION​

FIGURE 10-41. TELEMATICS READY INSTALLATION​

FIGURE 10-42. CLEARSKY INSTALLATION (NO A/C - SHORT ROOF CAP) (SN 0160000001 through 0160087899)​

FIGURE 10-43. CLEARSKY INSTALLATION (A/C - LONG ROOF CAP) (SN 0160000001 through 0160087899)​

FIGURE 10-44. INSTALLATION, TELEMATICS CANBUS ASSEMBLY (CLEARSKY 2) (SN 0160087899 through 0160100942)​

FIGURE 10-45. LSI INSTALLATION​

FIGURE 10-46. LSI DISPLAY INSTALLATION​

FIGURE 10-47. LSI SENSOR INSTALLATION​

FIGURE 10-48. LMIS INSTALLATION (HIGH END DISPLAY)​

FIGURE 10-49. LMIS BEACON LIGHT INSTALLATION​

FIGURE 10-50. LMIS CONTROL PACKAGE INSTALLATION​

FIGURE 10-51. LMIS WIRING INSTALLATION​

FIGURE 10-52. RIDE CONTROL WIRING INSTALLATION​

FIGURE 10-53. BOOM RIDE CONTROL HARNESS​

FIGURE 10-54. TILT SENSOR INSTALLATION​

FIGURE 10-55. LMIS CONTROLLER INSTALLATION​

FIGURE 10-56. LMIS CABLE REEL INSTALLATION​

FIGURE 10-57. BOOM ANGLE SENSOR INSTALLATION (LMIS)​

FIGURE 10-58. BOOM ANGLE SENSOR INSTALLATION (NO LMIS)​

FIGURE 10-59. BOOM RETRACT SENSOR INSTALLATION​

FIGURE 10-60. ENGINE HARNESS (ULS)​

FIGURE 10-61. ENGINE HARNESS (MINING) (ULS)​

FIGURE 10-62. FUEL PUMP HARNESS​

FIGURE 10-63. FUEL PUMP HARNESS (MINING) (ULS)​

FIGURE 10-64. GLOW PLUG RELAY HARNESS​

FIGURE 10-65. GLOW PLUG RELAY HARNESS (MINING) (ULS)​

FIGURE 10-66. BOOM HARNESS​

FIGURE 10-67. BOOM AUX HARNESS​

FIGURE 10-68. CAB HARNESS​

FIGURE 10-69. CAB HARNESS​

FIGURE 10-70. STANDARD ELECTRICAL BOARD ASSEMBLY​

FIGURE 10-71. OPTION 1 ELECTRICAL BOARD ASSEMBLY​

FIGURE 10-72. OPTION 2 ELECTRICAL BOARD ASSEMBLY​

FIGURE 10-73. CAB OPTION HARNESS​

FIGURE 10-74. FRONT FRAME HARNESS​

FIGURE 10-75. REAR FRAME HARNESS​

FIGURE 10-76. SEAT ADAPTOR HARNESS​

FIGURE 10-77. A/C OPTION HARNESS​

FIGURE 10-78. HVAC ACTUATORS HARNESS​

FIGURE 10-79. IGNITION SWITCH HARNESS​

FIGURE 10-80. REVERSE SENSOR HARNESS​

FIGURE 10-81. TELEMATICS READY HARNESS​

FIGURE 10-82. CLEARSKY HARNESS (A/C) (SN 0160000001 through 0160087899)​

FIGURE 10-83. CLEARSKY HARNESS (NO A/C) (SN 0160000001 through 0160087899)​

FIGURE 10-84. 4WARD TELEMATIC, HARNESS (CLEARSKY 2) (SN 0160087899 through 0160100942)​

FIGURE 10-85. LMIS CHASSIS OPTION HARNESS​

FIGURE 10-86. LMIS BOOM HARNESS​

FIGURE 10-87. PLATFORM READY HARNESS​

FIGURE 10-88. LMIS BEACON OPTION HARNESS​

FIGURE 10-89. PROXIMITY SENSOR HARNESS​

FIGURE 10-90. HEADLIGHT HARNESS​

FIGURE 10-91. BOOM WORKLIGHTS HARNESS​

FIGURE 10-92. LICENSE LIGHT HARNESS​

FIGURE 10-93. AIR SHUTOFF VALVE HARNESS​

FIGURE 10-94. AIR SHUT OFF VALVE HARNESS (ENGINE)​

FIGURE 10-95. TELEMATICS OPTION HARNESS (SN 0160087899 through 0160100942)​

FIGURE 10-96. CLEARSKY 3 WIRE TELEMATICS INSTALLATION​

FIGURE 10-97. CLEARSKY HARNESS - 3-WIRE TELEMATICS​

FIGURE 10-98. TELEMATICS INSTALLATION, UNITED RENTALS​

FIGURE 10-99. FRONT FRAME HARNESS​

FIGURE 10-100. REAR FRAME HARNESS​

FIGURE 10-101. BOOM HARNESS​

FIGURE 10-102. REVERSING FAN HARNESS​

FIGURE 10-103. VEHICLE SPEED PIGTAIL HARNESS​

SECTION 11 - DECALS

FIGURE 11-1. CAPACITY CHART HOLDER INSTALLATION​

FIGURE 11-2. REVERSE SENSOR SYSTEM DECAL (ENGLISH)​

FIGURE 11-3. REVERSE SENSING SYSTEM DECAL, (ENGLISH/FRENCH)​

FIGURE 11-4. CAPACITY CHART​

FIGURE 11-5. 1644 DECAL INSTALLATION​

FIGURE 11-6. DECAL INSTALLATION (ENGLISH)​

FIGURE 11-7. DECAL INSTALLATION (ENGLISH/FRENCH)​

FIGURE 11-8. CLEARSKY DECAL INSTALLATION​

SECTION 12 - RECOMMENDED SPARE PARTS

FIGURE 12-1. RECOMMENDED SPARE PARTS​

PART NUMBER INDEX