JLG Telehandler 742 Parts Catalog 3122310700

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JLG Telehandler 742 Parts Catalog 3122310700
Size: 91.80 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Telehandler
Type of Manual: Parts Catalog
Model: JLG 742 Telehandler
Part Number: 3122310700
Publication Date: 2025
Number of Pages: 1208 Pages

Contents:
SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-1. ENGINE ENCLOSURE INSTALLATION​

FIGURE 1-2. ENGINE ENCLOSURE COVER INSTALLATION​

FIGURE 1-3. HOOD ASSEMBLY​

FIGURE 1-4. COVER INSTALLATION (NO OUTRIGGERS) (ULS)​

FIGURE 1-5. COVER INSTALLATION (NO OUTRIGGERS) (LS)​

FIGURE 1-6. TANK INSTALLATION​

FIGURE 1-7. FUEL TANK INSTALLATION (Prior to SN 0160131206)​

FIGURE 1-8. FUEL TANK INSTALLATION (SN 0160131430 to Present)​

FIGURE 1-9. HYDRAULIC TANK INSTALLATION​

FIGURE 1-10. FUEL CAP ASSEMBLY​

FIGURE 1-11. MIRROR INSTALLATION​

FIGURE 1-12. BOOM PROP INSTALLATION (ANSI)​

FIGURE 1-13. BOOM PROP INSTALLATION (CANADA)​

FIGURE 1-14. BOOM PROP BRACKET​

FIGURE 1-15. COUNTERWEIGHT INSTALLATION​

SECTION 2 - BOOM

FIGURE 2-1. BOOM ASSEMBLY​

FIGURE 2-2. FIRST BOOM SECTION ASSEMBLY​

FIGURE 2-3. SECOND BOOM SECTION ASSEMBLY​

FIGURE 2-4. THIRD BOOM SECTION ASSEMBLY​

FIGURE 2-5. RETRACT CHAIN INSTALLATION​

FIGURE 2-6. EXTEND CHAIN INSTALLATION​

FIGURE 2-7. PINS INSTALLATION​

FIGURE 2-8. RETRACT CHAIN SHEAVE​

FIGURE 2-9. CHAIN SHEAVE ASSEMBLY​

FIGURE 2-10. HOSE BRACKET INSTALLATION​

FIGURE 2-11. BOOM PINNING INSTALLATION​

FIGURE 2-12. LIFT CYLINDER PINS INSTALLATION​

FIGURE 2-13. COMPENSATION CYLINDER PINS INSTALLATION​

FIGURE 2-14. BOOM PIVOT PIN INSTALLATION​

FIGURE 2-15. MANUAL QUICK COUPLER INSTALLATION​

FIGURE 2-16. HYDRAULIC QUICK COUPLER INSTALLATION​

FIGURE 2-17. BOOM PIN INSTALLATION​

FIGURE 2-18. TILT CYLINDER PIN INSTALLATION​

FIGURE 2-19. BOOM ANGLE INDICATOR INSTALLATION​

FIGURE 2-20. BOOM BRUSHES INSTALLATION​

FIGURE 2-21. QUICK COUPLER ASSEMBLY​

SECTION 3 - ATTACHMENTS

FIGURE 3-1. BASKET, PERSONNEL - 4FT X 8FT (ASME)​

FIGURE 3-2. BASKET, PERSONNEL - 4FT X 8FT (DOMESTIC)​

FIGURE 3-3. BASKET, PERSONNEL - 4FT X 8FT (ISO)​

FIGURE 3-4. BASKET, FORK MOUNTED​

FIGURE 3-5. BOOM - ADJUSTABLE (CARRIAGE MOUNTED)​

FIGURE 3-6. BOOM - ADJUSTABLE (FORK MOUNTED)​

FIGURE 3-7. BOOM - 3FT WITH WINCH​

FIGURE 3-8. BOOM - 12FT WITH WINCH​

FIGURE 3-9. BOOM - 12FT WITHOUT WINCH​

FIGURE 3-10. BOOM - 15FT WITHOUT WINCH​

FIGURE 3-11. BUCKET - 60IN (1.3 CU YD) (FORK MOUNTED)​

FIGURE 3-12. BUCKET - 72IN (1.0 CU YD)​

FIGURE 3-13. BUCKET - 96IN (1.5 CU YD)​

FIGURE 3-14. BUCKET - 96IN GRAPPLE​

FIGURE 3-15. BUCKET - 102IN (2.0 CU YD)​

FIGURE 3-16. CARRIAGE ASSEMBLY - 48IN/12000# CAPACITY SIDE SHIFT​

FIGURE 3-17. CARRIAGE ASSEMBLY - 50IN/1270MM​

FIGURE 3-18. FORK POSITIONING CARRIAGE WITH FORKS (4.5 TON)​

FIGURE 3-19. CARRIAGE ASSEMBLY - 50IN/12000# CAPACITY SIDE TILT​

FIGURE 3-20. CARRIAGE ASSEMBLY - 60IN/1524MM​

FIGURE 3-21. CARRIAGE ASSEMBLY - 60IN/12000# CAPACITY SIDE TILT​

FIGURE 3-22. CARRIAGE ASSEMBLY - 72IN/1829MM​

FIGURE 3-23. CARRIAGE ASSEMBLY - 72IN - 90 DEGREE SWING​

FIGURE 3-24. CARRIAGE ASSEMBLY - 72IN/12000# CAPACITY SIDE TILT​

FIGURE 3-25. CARRIAGE ASSEMBLY - DRYWALL (SWING)​

FIGURE 3-26. CARRIAGE ASSEMBLY - DRYWALL SWING CARRIAGE​

FIGURE 3-27. CARRIAGE ASSEMBLY - DRYWALL BOARD HANDLER​

FIGURE 3-28. CARRIAGE ASSEMBLY - DRYWALL PIVOT FRAME​

FIGURE 3-29. CARRIAGE ASSEMBLY - DRYWALL CYLINDER​

FIGURE 3-30. CARRIAGE ASSEMBLY - DRYWALL HYDRAULICS​

FIGURE 3-31. CARRIAGE ASSEMBLY - DRYWALL VALVE ASSEMBLY​

FIGURE 3-32. CARRIAGE ASSEMBLY - DRYWALL CYLINDER​

FIGURE 3-33. CARRIAGE ASSEMBLY - DRYWALL FORKS​

FIGURE 3-34. FORK 2X2X48 / 1940# CAPACITY​

FIGURE 3-35. FORK 2.36X4X48 / 5000# CAPACITY​

FIGURE 3-36. FORK 2.36X4X48 / 5475# CAPACITY​

FIGURE 3-37. FORK 2.00X6X48 / 6005# CAPACITY​

FIGURE 3-38. FORK 2.36X5X48 / 6850# CAPACITY​

FIGURE 3-39. FORK 2.36X4X60 / 5000# CAPACITY​

FIGURE 3-40. FORK 2.36X5X60 / 6850# CAPACITY​

FIGURE 3-41. FORK 2.36X6X60 / 8150# CAPACITY​

FIGURE 3-42. FORK 2.00X6X72 / 6610# CAPACITY​

FIGURE 3-43. FORK 2.36X5X72 / 6850# CAPACITY​

FIGURE 3-44. FORK 40X150X1540​

FIGURE 3-45. FORK 50X180X1540​

FIGURE 3-46. FORK EXTENSION - 90IN​

FIGURE 3-47. FORK CLAMPS INSTALLATION​

FIGURE 3-48. PLATFORM (FORK MOUNTED) (4X9.8)​

FIGURE 3-49. PLATFORM (FORK MOUNTED) (4X8 WITH DOORS)​

FIGURE 3-50. HOOK, COUPLING​

FIGURE 3-51. HOOK, CRANE​

FIGURE 3-52. LIFTING HOOK (6K)​

FIGURE 3-53. MAST, VERTICAL - 8FT (STANDARD)​

FIGURE 3-54. MAST, VERTICAL - 8FT (SIDE TILT ELECTRIC MAST)​

FIGURE 3-55. MAST, VERTICAL - DECAL KIT​

FIGURE 3-56. MAST, VERTICAL - CYLINDER​

FIGURE 3-57. SWEEPER ASSEMBLY​

FIGURE 3-58. SWEEPER ASSEMBLY - BODY​

FIGURE 3-59. SWEEPER ASSEMBLY - CORE​

FIGURE 3-60. SWEEPER ASSEMBLY - HYDRAULIC SINGLE MOTOR ASSEMBLY​

FIGURE 3-61. SWEEPER ASSEMBLY - HOPPER​

FIGURE 3-62. SWEEPER ASSEMBLY - IDLER​

FIGURE 3-63. SWEEPER ASSEMBLY - MOTOR​

FIGURE 3-64. TRASH HOPPER​

SECTION 4 - ENGINE AND ATTACHING PARTS

FIGURE 4-1. ENGINE INSTALLATION, 74HP (ULS)​

FIGURE 4-2. ENGINE COMPONENTS, 74HP (ULS)​

FIGURE 4-3. ENGINE INSTALLATION, 110HP (ULS)​

FIGURE 4-4. ENGINE COMPONENTS, 110HP (ULS)​

FIGURE 4-5. ENGINE INSTALLATION, 110HP (LS)​

FIGURE 4-6. ENGINE COMPONENTS, 110HP (LS)​

FIGURE 4-7. ENGINE MOUNTING INSTALLATION​

FIGURE 4-8. ENGINE PARTS INSTALLATION (NO HEATER)​

FIGURE 4-9. ENGINE PARTS INSTALLATION (HEATER)​

FIGURE 4-10. AIR CLEANER INSTALLATION (ULS)​

FIGURE 4-11. AIR CLEANER INSTALLATION (LS)​

FIGURE 4-12. AIR CLEANER ASSEMBLY, 74HP​

FIGURE 4-13. AIR CLEANER ASSEMBLY, 110HP​

FIGURE 4-14. AIR INTAKE DUCT INSTALLATION​

FIGURE 4-15. AIR CLEANER LINES INSTALLATION (ULS)​

FIGURE 4-16. AIR CLEANER LINES INSTALLATION (LS)​

FIGURE 4-17. AIR INTAKE SHUT OFF VALVE INSTALLATION​

FIGURE 4-18. HEATER BREATHER - 74 HP​

FIGURE 4-19. EXHAUST INSTALLATION, 74HP (ULS)​

FIGURE 4-20. EXHAUST INSTALLATION, 110HP (ULS)​

FIGURE 4-21. EXHAUST INSTALLATION, 110HP (LS)​

FIGURE 4-22. MUFFLER INSTALLATION (LS)​

FIGURE 4-23. DEF TANK INSTALLATION​

FIGURE 4-24. DEF TANK ASSEMBLY​

FIGURE 4-25. DEF BREATHER VALVE​

FIGURE 4-26. DEF PUMP AND CONTROL INSTALLATION​

FIGURE 4-27. UREA PUMP​

FIGURE 4-28. DEF PUMP LINES INSTALLATION​

FIGURE 4-29. DEF TANK LINES INSTALLATION​

FIGURE 4-30. FUEL LINES INSTALLATION (ULS)​

FIGURE 4-31. FUEL LINES INSTALLATION (LS)​

FIGURE 4-32. PRIMARY FUEL FILTER INSTALLATION (ULS)​

FIGURE 4-33. PRIMARY FUEL FILTER INSTALLATION (LS)​

FIGURE 4-34. FUEL TANK ASSEMBLY (Prior to SN 0160134668)​

FIGURE 4-35. FUEL TANK ASSEMBLY (SN 0160134847 to Present)​

FIGURE 4-36. FAN INSTALLATION, 74HP​

FIGURE 4-37. FAN INSTALLATION, 110HP​

FIGURE 4-38. FAN GUARD INSTALLATION​

FIGURE 4-39. COOLING PACKAGE INSTALLATION (ULS)​

FIGURE 4-40. COOLING PACKAGE INSTALLATION (LS)​

FIGURE 4-41. COOLANT LINES INSTALLATION (ULS)​

FIGURE 4-42. COOLANT LINES INSTALLATION (LS)​

FIGURE 4-43. RADIATOR COOLING PACKAGE​

FIGURE 4-44. SURGE TANK INSTALLATION​

FIGURE 4-45. A/C PUMP INSTALLATION (ULS)​

FIGURE 4-46. A/C PUMP INSTALLATION (LS)​

FIGURE 4-47. A/C LINES INSTALLATION​

FIGURE 4-48. ENGINE OIL QUICK DRAIN INSTALLATION​

FIGURE 4-49. CAC LINES INSTALLATION (ULS)​

FIGURE 4-50. CAC LINES INSTALLATION (LS)​

FIGURE 4-51. HOC LINES INSTALLATION​

FIGURE 4-52. TOC LINES INSTALLATION​

SECTION 5 - DRIVE TRAIN

FIGURE 5-1. TRANSMISSION INSTALLATION, 74 HP​

FIGURE 5-2. TRANSMISSION INSTALLATION, 110 HP​

FIGURE 5-3. POWERSHIFT TRANSMISSION​

FIGURE 5-4. TRANSMISION, ENGINE CONNECTION​

FIGURE 5-5. TRANSMISSION, CONVERTER​

FIGURE 5-6. TRANSMISSION, INPUT​

FIGURE 5-7. TRANSMISSION, HOUSING GROUP 1​

FIGURE 5-8. TRANSMISSION, HOUSING GROUP 2​

FIGURE 5-9. TRANSMISSION, CLUTCH GROUP 1​

FIGURE 5-10. TRANSMISSION, CLUTCH GROUP 2​

FIGURE 5-11. TRANSMISSION, COUPLING GROUP 1​

FIGURE 5-12. TRANSMISSION, COUPLING GROUP 2​

FIGURE 5-13. TRANSMISSION, COUPLING GROUP 3​

FIGURE 5-14. TRANSMISSION, COUPLING GROUP 4​

FIGURE 5-15. TRANSMISSION, OUTPUT​

FIGURE 5-16. TRANSMISSION, POWER TAKE-OFF​

FIGURE 5-17. TRANSMISSION, CONTROL UNIT​

FIGURE 5-18. TRANSMISSION, SHIFT SYSTEM​

FIGURE 5-19. TRANSMISSION, PRESSURE REGULATOR​

FIGURE 5-20. TRANSMISSION, PRESSURE OIL PUMP​

FIGURE 5-21. TRANSMISSION, INDUCTIVE TRANSMITTER​

FIGURE 5-22. TRANSMISSION, FILTER​

FIGURE 5-23. TRANSMISSION, OIL DIPSTICK​

FIGURE 5-24. TRANSMISSION, ACCESSORIES​

FIGURE 5-25. TRANSMISSION, TRANSFER BOX HOUSING 1​

FIGURE 5-26. TRANSMISSION, TRANSFER BOX HOUSING 2​

FIGURE 5-27. TRANSMISSION, TRANSFER BOX HOUSING INPUT​

FIGURE 5-28. TRANSMISSION, TRANSFER BOX HOUSING OUTPUT 1​

FIGURE 5-29. TRANSMISSION, TRANSFER BOX HOUSING OUTPUT 2​

FIGURE 5-30. DRIVE SHAFTS INSTALLATION​

FIGURE 5-31. FRONT DRIVE SHAFT INSTALLATION​

FIGURE 5-32. REAR DRIVE SHAFT INSTALLATION​

FIGURE 5-33. DRIVETRAIN INSTALLATION, 74HP​

FIGURE 5-34. DRIVETRAIN INSTALLATION, 110HP​

FIGURE 5-35. FRONT AXLE INSTALLATION, 74HP​

FIGURE 5-36. FRONT AXLE INSTALLATION, 110HP​

FIGURE 5-37. FONT AXLE LINES INSTALLATION​

FIGURE 5-38. FRONT AXLE MOUNTING INSTALLATION, 74HP​

FIGURE 5-39. FRONT AXLE MOUNTING INSTALLATION, 110HP​

FIGURE 5-40. FRONT AXLE, 74HP​

FIGURE 5-41. FRONT AXLE, 74HP - CENTRAL HOUSING​

FIGURE 5-42. FRONT AXLE, 74HP - DIFFERENTIAL​

FIGURE 5-43. FRONT AXLE, 74HP - HUB REDUCTION​

FIGURE 5-44. FRONT AXLE, 74HP - BRAKES​

FIGURE 5-45. FRONT AXLE, 74HP - STEERING​

FIGURE 5-46. FRONT AXLE, 74HP - TRUNION​

FIGURE 5-47. FRONT AXLE, 74HP - PLANET GEAR CARRIER​

FIGURE 5-48. FRONT AXLE, 110HP​

FIGURE 5-49. FRONT AXLE, 110HP - CENTRAL HOUSING​

FIGURE 5-50. FRONT AXLE, 110HP - DIFFERENTIAL​

FIGURE 5-51. FRONT AXLE, 110HP - HUB REDUCTION​

FIGURE 5-52. FRONT AXLE, 110HP - BRAKES​

FIGURE 5-53. FRONT AXLE, 110HP -STEERING​

FIGURE 5-54. FRONT AXLE, 110HP - TRUNION​

FIGURE 5-55. FRONT AXLE, 110HP - DIFFERENTIAL​

FIGURE 5-56. FRONT AXLE, 110HP - REDUCTION BUSHING​

FIGURE 5-57. FRONT AXLE, 110HP - PLANET GEAR CARRIER​

FIGURE 5-58. FRONT AXLE, 110HP - RING GEAR SUPPORT​

FIGURE 5-59. FRONT AXLE, 110HP - PLANET GEAR​

FIGURE 5-60. FRONT AXLE, 110HP - TRUNION KIT​

FIGURE 5-61. REAR AXLE INSTALLATION, 74HP​

FIGURE 5-62. REAR AXLE INSTALLATION, 110HP​

FIGURE 5-63. REAR AXLE LINES INSTALLATION​

FIGURE 5-64. REAR AXLE MOUNTING INSTALLATION, 74HP​

FIGURE 5-65. REAR AXLE MOUNTING INSTALLATION, 110HP​

FIGURE 5-66. REAR AXLE, 74HP​

FIGURE 5-67. REAR AXLE, 74HP - CENTRAL HOUSING​

FIGURE 5-68. REAR AXLE, 74HP - DIFFERENTIAL​

FIGURE 5-69. REAR AXLE, 74HP - HUB REDUCTION​

FIGURE 5-70. REAR AXLE, 74HP - BRAKES​

FIGURE 5-71. REAR AXLE, 74HP - STEERING​

FIGURE 5-72. REAR AXLE, 74HP- TRUNION​

FIGURE 5-73. REAR AXLE, 110HP​

FIGURE 5-74. REAR AXLE, LSI SENSOR INSTALLATION​

FIGURE 5-75. TIRE/WHEEL SET 315/95-28 SOLID CONTINENTAL​

FIGURE 5-76. TIRE/WHEEL SET 370/75-28 PNEUMATIC​

FIGURE 5-77. TIRE/WHEEL SET 370/75-28 PNEUMATIC NON-MARKING​

FIGURE 5-78. TIRE/WHEEL SET 370/75-28 FOAM-FILLED​

FIGURE 5-79. TIRE/WHEEL SET 370/75-28 FOAM-FILLED NON-MARKING​

FIGURE 5-80. TIRE/WHEEL SET 13-24/16PR PNEUMATIC​

FIGURE 5-81. TIRE/WHEEL SET 13-24/16PR FOAM-FILLED​

FIGURE 5-82. TIRE/WHEEL SET 13-24 SOLIDBOSS (DIRECTIONAL)​

FIGURE 5-83. TIRE/WHEEL SET 13-24 SOLIDEAL (DIRECTIONAL)​

FIGURE 5-84. TIRE/WHEEL SET 13-28 SOLIDBOSS (DIRECTIONAL)​

FIGURE 5-85. TIRE/WHEEL SET 13-28 SOLIDBOSS (NON-DIRECTIONAL)​

FIGURE 5-86. TIRE/WHEEL SET 18 X 625 (PNEUMATIC TURF)​

FIGURE 5-87. FENDER INSTALLATION​

FIGURE 5-88. CAB FENDER INSTALLATION​

FIGURE 5-89. CAB FENDER INSTALLATION REAR (LH)​

FIGURE 5-90. WHEEL CHOCK INSTALLATION​

FIGURE 5-91. TOOLBOX INSTALLATION​

SECTION 6 - CAB

FIGURE 6-1. CAB MOUNTING​

FIGURE 6-2. CAB MOUNTS INSTALLATION​

FIGURE 6-3. FRONT CAB OUTRIGGER INSTALLATION​

FIGURE 6-4. OROPS CAB INSTALLATION​

FIGURE 6-5. EROPS CAB INSTALLATION​

FIGURE 6-6. CAB, TRIM KIT​

FIGURE 6-7. CAB, TRIM KIT​

FIGURE 6-8. OPEN CAB ASSEMBLY​

FIGURE 6-9. OPEN CAB, LSI INSTALLATION​

FIGURE 6-10. OPEN CAB PLUG GROUP​

FIGURE 6-11. LSI DISPLAY INSTALLATION (OPEN CAB)​

FIGURE 6-12. CAB, EPD CAULK​

FIGURE 6-13. ENCLOSED CAB ASSEMBLY​

FIGURE 6-14. ENCLOSED CAB, LSI INSTALLATION​

FIGURE 6-15. REAR WINDOW INSTALLATION​

FIGURE 6-16. REAR WINDOW INSTALLATION (WO/WIPER) (ANSI)​

FIGURE 6-17. REAR WINDOW INSTALLATION (WO/WIPER) (ISO)​

FIGURE 6-18. REAR WINDOW INSTALLATION (WO/WIPER) (ENG/SPAN)​

FIGURE 6-19. REAR WINDOW ASSEMBLY​

FIGURE 6-20. DOOR INSTALLATION​

FIGURE 6-21. DOOR UPPER GLASS ASSEMBLY​

FIGURE 6-22. CAB LATCH ASSEMBLY​

FIGURE 6-23. CAB DOOR TRIGGER ASSEMBLY​

FIGURE 6-24. DOOR ASSEMBLY​

FIGURE 6-25. CAB DOOR​

FIGURE 6-26. DOOR STRAP INSTALLATION​

FIGURE 6-27. ENCLOSED CAB PLUG GROUP​

FIGURE 6-28. ENCLOSED CAB, LSI DISPLAY INSTALLATION​

FIGURE 6-29. BASIC MIRROR INSTALLATION​

FIGURE 6-30. FRONT COVER INSTALLATION (OPEN CAB)​

FIGURE 6-31. FRONT COVER INSTALLATION (ENCLOSED CAB)​

FIGURE 6-32. FIRE EXTINGUISHER INSTALLATION​

FIGURE 6-33. FILTER TRAY PANEL​

FIGURE 6-34. FRONT DUCT COVER​

FIGURE 6-35. LEVEL INDICATOR INSTALLATION​

FIGURE 6-36. SEAT INSTALLATION - CLOTH (ORANGE SEAT BELT)​

FIGURE 6-37. SEAT INSTALLATION - VINYL​

FIGURE 6-38. SEAT ASSEMBLY - CLOTH (ORANGE SEAT BELT)​

FIGURE 6-39. SEAT ASSEMBLY - VINYL​

FIGURE 6-40. SEAT BELT INSTALLATION (3 INCH)​

FIGURE 6-41. HEATER INSTALLATION​

FIGURE 6-42. HEATER AND A/C INSTALLATION​

FIGURE 6-43. HEATER ASSEMBLY​

FIGURE 6-44. HEATER​

FIGURE 6-45. HEATER AND A/C ASSEMBLY​

FIGURE 6-46. HEATER AND A/C​

FIGURE 6-47. CAB CONDENSER ASSEMBLY​

FIGURE 6-48. A/C RECEIVER DRIER​

FIGURE 6-49. CONDENSER​

FIGURE 6-50. FRONT WIPER INSTALLATION​

FIGURE 6-51. REAR WIPER INSTALLATION​

FIGURE 6-52. ROOF WIPER INSTALLATION​

FIGURE 6-53. HEADLINER INSTALLATION​

FIGURE 6-54. TRIM INSTALLATION - OPEN CAB​

FIGURE 6-55. TRIM INSTALLATION - ENCLOSED CAB​

FIGURE 6-56. DASH COVER ASSEMBLY - ENCLOSED CAB​

FIGURE 6-57. ARMREST​

FIGURE 6-58. OPEN CAB FRONT COVER​

FIGURE 6-59. ENCLOSED CAB FRONT COVER​

FIGURE 6-60. ROOF CAP INSTALLATION (A/C)​

FIGURE 6-61. ROOF CAP INSTALLATION (NO A/C)​

FIGURE 6-62. NON SKID TAPE INSTALLATION​

FIGURE 6-63. EXTERNAL WINDOW RELEASE INSTALLATION (CAN & ISO)​

FIGURE 6-64. WASHER TANK INSTALLATION​

FIGURE 6-65. WASHER BOTTLE​

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

FIGURE 6-67. CAB GUARD INSTALLATION (TOP)​

FIGURE 6-68. CAB GUARD INSTALLATION (FRONT)​

FIGURE 6-69. ROOF PIGTAIL CAP INSTALLATION​

FIGURE 6-70. ROOF PIGTAIL INSTALLATION​

FIGURE 6-71. NO SUNSCREEN INSTALLATION​

FIGURE 6-72. RETRACTABLE SUNSCREEN INSTALLATION​

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​

FIGURE 7-5. BRAKE PEDAL PLATE​

FIGURE 7-6. COLUMN CLAMP INSTALLATION​

FIGURE 7-7. HORN BUTTON INSTALLATION​

FIGURE 7-8. JOYSTICK INSTALLATION (ELOBAU BRAND)​

FIGURE 7-9. JOYSTICK INSTALLATION (BOSCH/REXROTH BRAND)​

FIGURE 7-10. JOYSTICK ASSEMBLY (ELOBAU BRAND)​

FIGURE 7-11. JOYSTICK ASSEMBLY (BOSCH/REXROTH BRAND)​

FIGURE 7-12. STEERING COLUMN INSTALLATION​

FIGURE 7-13. STEERING COLUMN INSTALLATION (EMERGENCY STEERING)​

FIGURE 7-14. STEERING WHEEL INSTALLATION​

FIGURE 7-15. STEERING WHEEL​

FIGURE 7-16. WIPER-TURN SWITCH INSTALLATION​

SECTION 8 - HYDRAULIC CIRCUITS

FIGURE 8-1. MAIN HYDRAULIC INSTALLATION - 74HP​

FIGURE 8-2. MAIN HYDRAULIC INSTALLATION - 74HP (EMERGENCY STEERING)​

FIGURE 8-3. MAIN HYDRAULIC INSTALLATION - 110HP​

FIGURE 8-4. MAIN HYDRAULIC INSTALLATION - 110HP (EMERGENCY STEERING)​

FIGURE 8-5. BOOM HYDRAULICS INSTALLATION - 74HP​

FIGURE 8-6. BOOM HYDRAULICS INSTALLATION - 110HP​

FIGURE 8-7. BOOM AUXILIARY HYDRAULICS INSTALLATION​

FIGURE 8-8. BOOM AUXILIARY HYDRAULICS INSTALLATION (SIDE MOUNTED)​

FIGURE 8-9. BOOM AUXILIARY HYDRAULICS INSTALLATION (HYDRAULIC COUPLER)​

FIGURE 8-10. BOOM AUXILIARY VALVE & FITTINGS ASSEMBLY (HYDRAULIC COUPLER)​

FIGURE 8-11. BOOM TUBES INSTALLATION​

FIGURE 8-12. CAB HYDRAULICS INSTALLATION - 74HP​

FIGURE 8-13. CAB HYDRAULICS INSTALLATION - 74HP (EMERGENCY STEERING)​

FIGURE 8-14. CAB HYDRAULICS INSTALLATION - 110HP​

FIGURE 8-15. CAB HYDRAULICS INSTALLATION - 110HP (EMERGENCY STEERING)​

FIGURE 8-16. COUNTERBALANCE VALVE INSTALLATION (LIFT - NO RIDE CONTROL) (74HP)​

FIGURE 8-17. COUNTERBALANCE VALVE INSTALLATION (LIFT - NO RIDE CONTROL) (110HP)​

FIGURE 8-18. COUNTERBALANCE VALVE HYDRAULIC LINES (LIFT - RIDE CONTROL) (74HP)​

FIGURE 8-19. COUNTERBALANCE VALVE HYDRAULIC LINES (LIFT - RIDE CONTROL) (110HP)​

FIGURE 8-20. EMERGENCY STEERING MANIFOLD & FITTINGS ASSEMBLY​

FIGURE 8-21. FRAME HYDRAULICS INSTALLATION - 74HP​

FIGURE 8-22. FRAME HYDRAULICS INSTALLATION 110HP​

FIGURE 8-23. FRAME LEVEL INSTALLATION​

FIGURE 8-24. FRAME LEVEL HYDRAULICS INSTALLATION (NO OUTRIGGERS)​

FIGURE 8-25. FRAME LEVEL HYDRAULICS INSTALLATION (NO OUTRIGGERS) (EMERGENCY STEERING)​

FIGURE 8-26. PISTON PUMP INSTALLATION - 74HP​

FIGURE 8-27. PISTON PUMP INSTALLATION - 110HP​

FIGURE 8-28. PISTON PUMP ASSEMBLY - 74HP​

FIGURE 8-29. PISTON PUMP ASSEMBLY - 110HP​

FIGURE 8-30. REAR AXLE STABILIZER INSTALLATION​

FIGURE 8-31. VALVES INSTALLATION - 74HP​

FIGURE 8-32. VALVES INSTALLATION - 110HP​

FIGURE 8-33. VALVES INSTALLATION - FRAME LEVEL​

FIGURE 8-34. VALVE & FITTINGS ASSEMBLY- FRAME LEVEL​

FIGURE 8-35. VALVES INSTALLATION - MAIN & PRIORITY- 74HP​

FIGURE 8-36. VALVES INSTALLATION - MAIN & PRIORITY- 110HP​

FIGURE 8-37. VALVE INSTALLATION - MAIN - 74HP​

FIGURE 8-38. VALVE INSTALLATION - MAIN - 110HP​

FIGURE 8-39. VALVE & FITTINGS ASSEMBLY- MAIN - 74HP​

FIGURE 8-40. VALVE INSTALLATION - PRIORITY - 74HP​

FIGURE 8-41. VALVE ASSEMBLY - PRIORITY FUNCTION MANIFOLD​

FIGURE 8-42. PARK BRAKE INSTALLATION​

FIGURE 8-43. VALVE INSTALLATION - PARKING BRAKE​

FIGURE 8-44. VALVE INSTALLATION - SAHR BRAKE​

FIGURE 8-45. VALVE ASSEMBLY - SAHR BRAKE​

FIGURE 8-46. VALVES INSTALLATION - STEER SELECT​

FIGURE 8-47. VALVE MOUNTING INSTALLATION - STEER SELECT​

FIGURE 8-48. VALVE INSTALLATION - STEER SELECT​

FIGURE 8-49. VALVE & FITTINGS ASSEMBLY- STEER SELECT​

SECTION 9 - HYDRAULIC COMPONENTS

FIGURE 9-1. COUPLER - HYDRAULIC COUPLER​

FIGURE 9-2. CYLINDER GROUP INSTALLATION (74HP)​

FIGURE 9-3. CYLINDER GROUP INSTALLATION (110HP)​

FIGURE 9-4. CYLINDER - CARRIAGE SIDE TILT​

FIGURE 9-5. CYLINDER - CARRIAGE SWING​

FIGURE 9-6. CYLINDER - COMPENSATION (74HP)​

FIGURE 9-7. CYLINDER - COMPENSATION (110HP)​

FIGURE 9-8. CYLINDER & VALVE SUB-ASSEMBLY - EXTEND/RETRACT (74HP)​

FIGURE 9-9. CYLINDER & VALVE SUB-ASSEMBLY - EXTEND/RETRACT (110HP)​

FIGURE 9-10. CYLINDER ASSEMBLY - EXTEND/RETRACT​

FIGURE 9-11. CYLINDER - FORK POSITIONING​

FIGURE 9-12. CYLINDER - FORK POSITIONING​

FIGURE 9-13. CYLINDER INSTALLATION - FRAME LEVEL​

FIGURE 9-14. CYLINDER - FRAME LEVEL​

FIGURE 9-15. CYLINDER ASSEMBLY - GRAPPLE BUCKET​

FIGURE 9-16. CYLINDER ASSEMBLY - LIFT​

FIGURE 9-17. CYLINDER SUB-ASSEMBLY - QUICK COUPLER​

FIGURE 9-18. CYLINDER - QUICK COUPLER​

FIGURE 9-19. CYLINDER & VALVE INSTALLATION - STABILIZER (REAR AXLE) (Prior to SN 0160134213)​

FIGURE 9-20. CYLINDER & VALVE INSTALLATION - STABILIZER (REAR AXLE) (SN 0160134214 to Present)​

FIGURE 9-21. CYLINDER - STABILIZER (REAR AXLE)​

FIGURE 9-22. CYLINDER & FITTINGS SUB-ASSEMBLY - TILT​

FIGURE 9-23. CYLINDER ASSEMBLY - TILT​

FIGURE 9-24. PUMP - GEAR​

FIGURE 9-25. PUMP - PISTON​

FIGURE 9-26. TANK - HYDRAULIC​

FIGURE 9-27. TANK - HYDRAULIC FILTER ASSEMBLY​

FIGURE 9-28. VALVE - AIR SHUT OFF​

FIGURE 9-29. VALVE & FITTINGS - CARRIAGE (DUAL FORK)​

FIGURE 9-30. VALVE - CARRIAGE DUAL FORK FLOW DIVIDER​

FIGURE 9-31. VALVE ASSEMBLY - FRAME LEVEL​

FIGURE 9-32. VALVE ASSEMBLY - MAIN CONTROL (74HP)​

FIGURE 9-33. VALVE ASSEMBLY - MAIN CONTROL (110HP)​

FIGURE 9-34. VALVE - PARKING BRAKE​

FIGURE 9-35. VALVE ASSEMBLY - PRIORITY​

FIGURE 9-36. VALVE ASSEMBLY - PRIORITY​

FIGURE 9-37. VALVE - QUICK COUPLER​

FIGURE 9-38. VALVE ASSEMBLY - SAHR BRAKE​

FIGURE 9-39. VALVE ASSEMBLY - STABILIZER (REAR AXLE) (Prior to SN 0160134213)​

FIGURE 9-40. VALVE ASSEMBLY - STABILIZER (REAR AXLE) (SN 0160134214 to Present)​

FIGURE 9-41. VALVE ASSEMBLY - STEERING ORBITAL​

FIGURE 9-42. VALVE ASSEMBLY - STEERING SELECT​

SECTION 10 - ELECTRICAL

FIGURE 10-1. MAIN ELECTRICAL INSTALLATION - 74HP (ULS)​

FIGURE 10-2. MAIN ELECTRICAL INSTALLATION - 110HP (ULS)​

FIGURE 10-3. MAIN ELECTRICAL INSTALLATION - 110HP (LS)​

FIGURE 10-4. A/C OPTION HARNESS​

FIGURE 10-5. AIR SHUT OFF VALVE HARNESS - CAB​

FIGURE 10-6. AIR SHUT OFF VALVE HARNESS - ENGINE​

FIGURE 10-7. ALARM INSTALLATION - BACK UP (97DB)​

FIGURE 10-8. ALARM INSTALLATION - BACK UP (120DB)​

FIGURE 10-9. ALARM INSTALLATION - BACK UP (WHITE NOISE)​

FIGURE 10-10. ARCTIC COLD WEATHER PACKAGE INSTALLATION (74HP) (ULS)​

FIGURE 10-11. ARCTIC COLD WEATHER PACKAGE INSTALLATION (110HP) (ULS)​

FIGURE 10-12. ARCTIC COLD WEATHER PACKAGE INSTALLATION (110HP) (LS)​

FIGURE 10-13. BATTERY INSTALLATION​

FIGURE 10-14. BATTERY INSTALLATION​

FIGURE 10-15. BATTERY INSTALLATION - ARCTIC PACKAGE​

FIGURE 10-16. BOOM ANGLE SENSOR INSTALLATION (LSI)​

FIGURE 10-17. BOOM ELECTRIC HARNESS INSTALLATION​

FIGURE 10-18. BOOM ELECTRIC HARNESS​

FIGURE 10-19. BOOM AUXILIARY ELECTRIC INSTALLATION​

FIGURE 10-20. BOOM AUXILIARY ELECTRIC HARNESS INSTALLATION​

FIGURE 10-21. CAB DASH ELECTRICAL (ULS)​

FIGURE 10-22. CAB DASH ELECTRICAL (LS)​

FIGURE 10-23. CAB ELECTRICAL INSTALLATION​

FIGURE 10-24. CAB ELECTRICAL BOARD ASSEMBLY​

FIGURE 10-25. CAB ELECTRICAL COMMUNICATION CABLE​

FIGURE 10-26. CAB HARNESS​

FIGURE 10-27. CAB ELECTRICAL INSTALLATION - ENCLOSED​

FIGURE 10-28. CAB ELECTRICAL INSTALLATION - OPEN​

FIGURE 10-29. CAB OPTION 1 ELECTRICAL BOARD​

FIGURE 10-30. CAB OPTION 2 ELECTRICAL BOARD​

FIGURE 10-31. CAB OPTION HARNESS​

FIGURE 10-32. CAB OPTION 1 HARNESS​

FIGURE 10-33. CAB OPTION 2 HARNESS​

FIGURE 10-34. CAB - KEY HARNESS​

FIGURE 10-35. CAB MULTIFUNCTION DISPLAY INSTALLATION​

FIGURE 10-36. CAB SEAT BELT ALARM HARNESS​

FIGURE 10-37. CLEARSKY CS550 BEACON INSTALLATION​

FIGURE 10-38. CLEARSKY HARNESS - CS550 BEACON​

FIGURE 10-39. DEF PURGE LIGHT HARNESS (110HP) (ULS)​

FIGURE 10-40. ENGINE - WIRING INSTALLATION (74HP) (ULS)​

FIGURE 10-41. ENGINE - WIRING INSTALLATION (110HP) (ULS)​

FIGURE 10-42. ENGINE - WIRING INSTALLATION (110HP) (LS)​

FIGURE 10-43. ENGINE HARNESS (74HP) (ULS)​

FIGURE 10-44. ENGINE HARNESS (110HP) (ULS)​

FIGURE 10-45. ENGINE HARNESS (110HP) (LS)​

FIGURE 10-46. ENGINE BAY - ELECTRICAL INSTALLATION (74HP) (ULS)​

FIGURE 10-47. ENGINE BAY - ELECTRICAL INSTALLATION (110HP) (ULS)​

FIGURE 10-48. ENGINE BAY - ELECTRICAL INSTALLATION (110HP) (LS)​

FIGURE 10-49. ENGINE BAY - WIRING INSTALLATION (74HP) (ULS)​

FIGURE 10-50. ENGINE BAY - WIRING INSTALLATION (110HP) (ULS)​

FIGURE 10-51. ENGINE BAY - WIRING INSTALLATION (110HP) (LS)​

FIGURE 10-52. ENGINE/CHASSIS HARNESS (110HP) (ULS)​

FIGURE 10-53. ENGINE - ECU INSTALLATION (ULS)​

FIGURE 10-54. ENGINE - ECU INSTALLATION (LS)​

FIGURE 10-55. ENGINE TBAP HARNESS​

FIGURE 10-56. FRAME - ELECTRICAL INSTALLATION​

FIGURE 10-57. FRAME - POWER DISTRIBUTION BOX​

FIGURE 10-58. FRAME - WIRING INSTALLATION (74HP) (ULS)​

FIGURE 10-59. FRAME - WIRING INSTALLATION (110HP) (ULS)​

FIGURE 10-60. FRAME - WIRING INSTALLATION (110HP) (LS)​

FIGURE 10-61. FRAME HARNESS - FRONT​

FIGURE 10-62. FRAME HARNESS - REAR (74HP)​

FIGURE 10-63. FRAME HARNESS - REAR (110HP)​

FIGURE 10-64. HEATER HARNESS - CUMMINS BREATHER (74HP) (ULS)​

FIGURE 10-65. HEATER HARNESS - CUMMINS BREATHER (110HP) (ULS)​

FIGURE 10-66. HEATER HARNESS - FUEL FILTER​

FIGURE 10-67. HEATER HARNESS - HYDRAULIC TANK​

FIGURE 10-68. HVAC ACTUATOR HARNESS​

FIGURE 10-69. JOYSTICK HARNESS​

FIGURE 10-70. LIGHTS - BOOM WORK LIGHTS SWITCH/HARNESS INSTALLATION (LED)​

FIGURE 10-71. LIGHTS - BOOM WORK LIGHTS INSTALLATION (LED)​

FIGURE 10-72. LIGHTS - BOOM WORK LIGHTS HARNESS​

FIGURE 10-73. LIGHTS - CAB WORK LIGHTS INSTALLATION (NO A/C) (LED)​

FIGURE 10-74. LIGHTS - CAB WORK LIGHTS INSTALLATION (A/C) (LED)​

FIGURE 10-75. LIGHTS - ROADLIGHTS INSTALLATION​

FIGURE 10-76. LIGHTS - ROADLIGHTS HEADLIGHT HARNESS​

FIGURE 10-77. LIGHTS - ROADLIGHTS TAILLIGHTS HARNESS​

FIGURE 10-78. LIGHTS - SWITCH INSTALLATION​

FIGURE 10-79. LSI HARNESS - BOOM RETRACT​

FIGURE 10-80. PLATFORM HARNESS​

FIGURE 10-81. REVERSE CAMERA INSTALLATION​

FIGURE 10-82. MULTI VIEW CAMERA INSTALLATION​

FIGURE 10-83. REVERSE SENSOR INSTALLATION​

FIGURE 10-84. REVERSE SENSOR HARNESS​

FIGURE 10-85. RIDE CONTROL VALVE HARNESS INSTALLATION​

FIGURE 10-86. RIDE CONTROL VALVE HARNESS​

FIGURE 10-87. ROOF PIGTAIL HARNESS​

FIGURE 10-88. TELEMATICS READY INSTALLATION​

FIGURE 10-89. TELEMATICS READY HARNESS​

FIGURE 10-90. USB CHARGER INSTALLATION​

SECTION 11 - DECALS

FIGURE 11-1. DECAL INSTALLATION (ANSI) (74 HP)​

FIGURE 11-2. DECAL INSTALLATION (ANSI) (110 HP)​

FIGURE 11-3. DECAL INSTALLATION (CSA ENGLISH/FRENCH) (74 HP)​

FIGURE 11-4. DECAL INSTALLATION (CSA ENGLISH/FRENCH) (110 HP)​

FIGURE 11-5. DECAL INSTALLATION (ISO) (74 HP)​

FIGURE 11-6. DECAL INSTALLATION (ISO) (110 HP)​

FIGURE 11-7. DECAL INSTALLATION (HRC)(110HP)​

FIGURE 11-8. DECAL INSTALLATION (HRC)(74HP)​

FIGURE 11-9. DECAL INSTALLATION (LATIN AMERICAN ENGLISH/SPANISH) (74HP)​

FIGURE 11-10. DECAL INSTALLATION (LATIN AMERICAN ENGLISH/SPANISH) (110HP)​

FIGURE 11-11. DECAL INSTALLATION - CLEARSKY CS550 BEACON​

FIGURE 11-12. BRAND AND MODEL DECAL INSTALLATION​

FIGURE 11-13. CAPACITY CHART BOOKLET (ANSI)​

FIGURE 11-14. CAPACITY CHART BOOKLET (ISO)​

FIGURE 11-15. CAPACITY CHART HOLDER INSTALLATION​

FIGURE 11-16. REVERSE SENSING SYSTEM DECAL (ANSI)​

FIGURE 11-17. REVERSE SENSING SYSTEM DECAL (CSA)​

FIGURE 11-18. REVERSE SENSOR SYSTEM DECAL (ENGLISH/SPANISH)​

FIGURE 11-19. REVERSE SENSING SYSTEM DECAL (ISO)​

SECTION 12 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 12-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 13 - SPECIAL OPTIONS/ACCESSORIES/KITS

FIGURE 13-1. SPECIAL OPTIONS/ACCESSORIES/KITS​

PART NUMBER INDEX