JLG 642, 742, 943, 1043 Telehandler Parts Manual

Name: JLG 642, 742, 943, 1043 Telehandler Parts Manual
Brand: MidWestTech
SKU: 31211111
Price: 169.97 USD
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1,614 pages · Publication 31211111

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Models: 642, 742, 943, 1043
Serial coverage: 642:SN 0160070489 through 0160080898, 742: Prior to SN 0160084796, 943 & 1043:Prior to SN 0160084858 excluding 0160083719,0160083720 & 0160084650
Manual type: Parts Manual
Pages: 1,614
Publication: 31211111
Condition: Brand new

JLG 642, 742, 943, 1043 Telehandler Parts Manual, publication 31211111

What's inside

From the manual's own table of contents: 272 sections, 564 entries. See sample pages (PDF, 593 KB)

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General47 topics

SECTION 1 - FRAME AND ATTACHING PARTS
FIGURE 1-9. ENGINE ENCLOSURE INSTALLATION
FIGURE 1-10. ENGINE ENCLOSURE COVER INSTALLATION
FIGURE 1-11. HOOD ASSEMBLY
FIGURE 1-12. HOOD ASSEMBLY
FIGURE 1-13. COVER INSTALLATION (NO OUTRIGGERS) (ULS)
FIGURE 1-14. COVER INSTALLATION (OUTRIGGERS) (ULS) (642, 1043)
FIGURE 1-16. COVER INSTALLATION (OUTRIGGERS) (LS) (642, 1043)
FIGURE 1-17. COUNTERWEIGHT INSTALLATION (642) (Prior to SN 0160078403)
FIGURE 1-19. COUNTERWEIGHT INSTALLATION (943, 1043)
FIGURE 1-20. TANK INSTALLATION
FIGURE 1-21. FUEL TANK INSTALLATION
FIGURE 1-22. HYDRAULIC TANK INSTALLATION
FIGURE 1-23. FUEL CAP ASSEMBLY
FIGURE 1-24. OUTRIGGERS INSTALLATION (642, 1043)
FIGURE 1-26. MIRROR INSTALLATION
FIGURE 1-27. BOOM PROP INSTALLATION (ANSI)
FIGURE 1-28. BOOM PROP INSTALLATION (CANADA)
FIGURE 1-29. BOOM PROP BRACKET
SECTION 2 - BOOM
FIGURE 2-3. FIRST BOOM SECTION ASSEMBLY (642, 742)
FIGURE 2-4. FIRST BOOM SECTION ASSEMBLY (943, 1043)
FIGURE 2-5. SECOND BOOM SECTION ASSEMBLY (642, 742)
FIGURE 2-6. SECOND BOOM SECTION ASSEMBLY (943, 1043)
FIGURE 2-8. THIRD BOOM SECTION ASSEMBLY (943, 1043)
FIGURE 2-9. RETRACT CHAIN INSTALLATION
FIGURE 2-10. EXTEND CHAIN INSTALLATION (642, 742)
FIGURE 2-11. EXTEND CHAIN INSTALLATION (943, 1043)
FIGURE 2-14. CHAIN SHEAVE ASSEMBLY
FIGURE 2-15. RETRACT CHAIN SHEAVE
FIGURE 2-16. EXTEND CHAIN ROLLER
FIGURE 2-17. HOSE BRACKET INSTALLATION (642, 742)
FIGURE 2-18. HOSE BRACKET INSTALLATION (943, 1043)
FIGURE 2-19. BOOM PINNING INSTALLATION (642, 742)
FIGURE 2-20. BOOM PINNING INSTALLATION (943, 1043)
FIGURE 2-21. LIFT CYLINDER PINS INSTALLATION (642, 742)
FIGURE 2-22. LIFT CYLINDER PINS INSTALLATION (943, 1043)
FIGURE 2-23. COMPENSATION CYLINDER PINS INSTALLATION (642, 742)
FIGURE 2-24. COMPENSATION CYLINDER PINS INSTALLATION (943, 1043)
FIGURE 2-25. BOOM PIVOT PIN INSTALLATION (642, 742)
FIGURE 2-26. BOOM PIVOT PIN INSTALLATION (943, 1043)
FIGURE 2-27. MANUAL QUICK COUPLER INSTALLATION
FIGURE 2-28. HYDRAULIC QUICK COUPLER INSTALLATION
FIGURE 2-29. BOOM PIN INSTALLATION
FIGURE 2-30. TILT CYLINDER PIN INSTALLATION
FIGURE 2-31. BOOM ANGLE INDICATOR INSTALLATION
FIGURE 2-32. BOOM BRUSHES INSTALLATION (642, 742)

FIGURE 2-33. BOOM BRUSHES INSTALLATION (943, 1043)

FIGURE 2-34. QUICK COUPLER ASSEMBLY

SECTION 3 - ATTACHMENTS

FIGURE 3-2. CARRIAGE ASSEMBLY (50 INCH) (SN 0160075708 to Present)

FIGURE 3-4. CARRIAGE ASSEMBLY (60 INCH) (SN 0160075708 to Present)

FIGURE 3-6. CARRIAGE ASSEMBLY (72 INCH) (SN 0160075708 to Present)

FIGURE 3-7. SIDE TILT CARRIAGE ASSEMBLY (50 INCH)

FIGURE 3-8. SIDE TILT CARRIAGE ASSEMBLY (50 INCH)

FIGURE 3-9. SIDE TILT CARRIAGE ASSEMBLY (60 INCH)

FIGURE 3-10. SIDE TILT CARRIAGE ASSEMBLY (60 INCH)

FIGURE 3-11. SIDE TILT CARRIAGE ASSEMBLY (72 INCH)

FIGURE 3-12. SIDE TILT CARRIAGE ASSEMBLY (72 INCH)

FIGURE 3-13. 90 SWING CARRIAGE ASSEMBLY (72 INCH)

FIGURE 3-14. SIDE SHIFT CARRIAGE ASSEMBLY (50 INCH)

FIGURE 3-15. DUAL FORK POSITIONING CARRIAGE (50 INCH) (Prior to SN 0160082569)

FIGURE 3-16. DUAL FORK POSITIONING CARRIAGE (50 INCH) (SN 0160082569 to Present)

FIGURE 3-17. DUAL FORK CARRIAGE ASSEMBLY (50 INCH)

FIGURE 3-18. DUAL FORK CARRIAGE VALVE ASSEMBLY

FIGURE 3-27. CUBING FORK

FIGURE 3-28. FORK CLAMPS INSTALL

FIGURE 3-29. FORK EXTENSION (90 INCH)

FIGURE 3-30. FORK MOUNTED BUCKET (60 INCH)

FIGURE 3-31. BUCKET (72 INCH)

Show all 273 sections

FIGURE 3-32. BUCKET (96 INCH)

FIGURE 3-34. GRAPPLE BUCKET

FIGURE 3-35. TRUSS BOOM (12 FOOT)

FIGURE 3-36. TRUSS BOOM (15 FOOT)

FIGURE 3-37. ADJUSTABLE TRUSS BOOM

FIGURE 3-38. TRUSS BOOM ASSEMBLY (3 FOOT WITH WINCH)

FIGURE 3-39. TRUSS BOOM (12 FOOT WITH WINCH)

FIGURE 3-40. FORK MOUNTED HOOK

FIGURE 3-41. COUPLER MOUNTED HOOK

FIGURE 3-45. FORK MOUNTED PLATFORM (ASME)

FIGURE 3-46. FORK MOUNTED PLATFORM (ISO)

FIGURE 3-47. FORK MOUNTED PLATFORM (FRENCH)

FIGURE 3-48. FORK MOUNTED PLATFORM ASSEMBLY

FIGURE 3-49. SWEEPER ASSEMBLY

FIGURE 3-50. TRASH HOPPER INSTALLATION

FIGURE 3-51. PO CHECK VALVE

FIGURE 3-52. MAIN LIFT CYLINDER

FIGURE 3-53. KIT DECAL

FIGURE 3-54. ADJUSTABLE TRUSS BOOM INSTALLATION (FORK MOUNTED)

SECTION 4 - ENGINE AND ATTACHING PARTS

FIGURE 4-1. ENGINE INSTALLATION, 110HP (ULS)

FIGURE 4-3. ENGINE INSTALLATION, 110HP (LS)59 topics

FIGURE 4-4. ENGINE MOUNTING INSTALLATION
FIGURE 4-6. ENGINE, 74HP (ULS)
FIGURE 4-8. FAN INSTALLATION
FIGURE 4-9. PRIMARY FUEL FILTER INSTALLATION (ULS)
FIGURE 4-10. PRIMARY FUEL FILTER INSTALLATION (LS)
FIGURE 4-12. AIR CLEANER LINES INSTALLATION (ULS)
FIGURE 4-13. AIR INTAKE LINES INSTALLATION (LS)
FIGURE 4-14. AIR CLEANER INSTALLATION (ULS)
FIGURE 4-15. AIR CLEANER INSTALLATION (LS)
FIGURE 4-16. AIR CLEANER ASSEMBLY (ULS)
FIGURE 4-17. AIR CLEANER ASSEMBLY (LS)
FIGURE 4-18. AIR INTAKE DUCT INSTALLATION
FIGURE 4-19. DEF LINES INSTALLATION
FIGURE 4-20. FUEL LINES INSTALLATION (ULS)
FIGURE 4-21. FUEL LINES INSTALLATION (LS)
FIGURE 4-22. COOLING PACKAGE INSTALLATION (ULS)
FIGURE 4-23. COOLING PACKAGE INSTALLATION (LS)
FIGURE 4-24. RADIATOR COOLING PACKAGE
FIGURE 4-25. HOC LINES INSTALLATION
FIGURE 4-26. COOLANT LINES INSTALLATION (ULS)
FIGURE 4-27. COOLANT LINES INSTALLATION (LS)
FIGURE 4-28. CAC LINES INSTALLATION (ULS)
FIGURE 4-29. CAC LINES INSTALLATION (LS)
FIGURE 4-30. TOC LINES INSTALLATION
FIGURE 4-31. SURGE TANK INSTALLATION
FIGURE 4-32. FAN GUARD INSTALLATION
FIGURE 4-33. EXHAUST INSTALLATION, 110HP (ULS)
FIGURE 4-35. EXHAUST INSTALLATION, 110HP (LS)
FIGURE 4-36. ENGINE PARTS INSTALLATION (NO HEATER)
FIGURE 4-37. ENGINE PARTS INSTALLATION (HEATER)
FIGURE 4-38. A/C PUMP INSTALLATION (ULS)
FIGURE 4-39. A/C PUMP INSTALLATION (LS)
FIGURE 4-40. FUEL TANK ASSEMBLY (Prior to SN 0160075554)
FIGURE 4-41. FUEL TANK ASSEMBLY (SN 0160075554 to Present)
FIGURE 4-42. DEF TANK INSTALLATION
FIGURE 4-43. DEF TANK ASSEMBLY
FIGURE 4-44. DEF PUMP AND CONTROL INSTALLATION
FIGURE 4-45. DEF PUMP LINES INSTALLATION
FIGURE 4-46. MUFFLER INSTALLATION (LS)
FIGURE 4-47. A/C LINES INSTALLATION
FIGURE 4-50. HEATER BREATHER (ULS - 110HP)
FIGURE 4-51. HEATER BREATHER (ULS - 74HP)
FIGURE 4-52. AIR INTAKE SHUT OFF VALVE INSTALLATION
SECTION 5 - DRIVE TRAIN
FIGURE 5-1. DRIVETRAIN INSTALLATION (642, 742)
FIGURE 5-2. DRIVETRAIN INSTALLATION, 74HP (742)
FIGURE 5-3. DRIVETRAIN INSTALLATION, 74HP (943)
FIGURE 5-4. DRIVETRAIN INSTALLATION (943, 1043)
FIGURE 5-5. FRONT AXLE INSTALLATION (642, 742)
FIGURE 5-6. FRONT AXLE INSTALLATION, 74HP (742)
FIGURE 5-7. FRONT AXLE INSTALLATION, 74HP (943)
FIGURE 5-8. FRONT AXLE INSTALLATION (943, 1043)
FIGURE 5-9. REAR AXLE INSTALLATION (642, 742)
FIGURE 5-10. REAR AXLE INSTALLATION, 74HP (742)
FIGURE 5-11. REAR AXLE INSTALLATION, 74HP (943)
FIGURE 5-12. REAR AXLE INSTALLATION (943, 1043)
FIGURE 5-13. DRIVE SHAFTS INSTALLATION (642, 742)
FIGURE 5-14. DRIVE SHAFTS INSTALLATION (943, 1043)
FIGURE 5-15. FRONT AXLE MOUNTING INSTALLATION (642, 742)

FIGURE 5-16. FRONT AXLE MOUNTING INSTALLATION, 74HP (742)

FIGURE 5-17. FRONT AXLE MOUNTING INSTALLATION, 74HP (943)

FIGURE 5-18. FRONT AXLE MOUNTING INSTALLATION (943, 1043)

FIGURE 5-19. FONT AXLE LINES INSTALLATION (642, 742)

FIGURE 5-20. FONT AXLE LINES INSTALLATION (943, 1043)

FIGURE 5-21. REAR AXLE MOUNTING INSTALLATION (642, 742)

FIGURE 5-22. REAR AXLE MOUNTING INSTALLATION, 74HP (742)

FIGURE 5-23. REAR AXLE MOUNTING INSTALLATION, 74HP (943)

FIGURE 5-24. REAR AXLE MOUNTING INSTALLATION (943, 1043)

FIGURE 5-25. REAR AXLE LINES INSTALLATION (642, 742)

FIGURE 5-26. REAR AXLE LINES INSTALLATION (943, 1043)

FIGURE 5-27. FRONT DRIVE SHAFT INSTALLATION (642, 742)

FIGURE 5-28. FRONT DRIVE SHAFT INSTALLATION (943, 1043)

FIGURE 5-29. REAR DRIVE SHAFT INSTALLATION

FIGURE 5-31. FRONT AXLE, CENTRAL HOUSING (642, 742)

FIGURE 5-32. FRONT AXLE, DIFFERENTIAL (642, 742)

FIGURE 5-33. FRONT AXLE, HUB REDUCTION (642, 742)

FIGURE 5-37. FRONT AXLE, DIFFERENTIAL (642, 742)

FIGURE 5-38. FRONT AXLE, REDUCTION BUSHING (642, 742)

FIGURE 5-39. FRONT AXLE, PLANET GEAR CARRIER (642, 742)

FIGURE 5-40. FRONT AXLE, RING GEAR SUPPORT (642, 742)

FIGURE 5-44. FRONT AXLE, CENTRAL HOUSING 74HP (742)

FIGURE 5-45. FRONT AXLE, DIFFERENTIAL 74HP (742)

FIGURE 5-46. FRONT AXLE, HUB REDUCTION 74HP (742)

FIGURE 5-48. FRONT AXLE, STEERING 74HP (742)

FIGURE 5-49. FRONT AXLE, TRUNION 74HP (742)

FIGURE 5-51. FRONT AXLE, CENTRAL HOUSING 74HP (943)

FIGURE 5-52. FRONT AXLE, DIFFERENTIAL 74HP (943)

FIGURE 5-53. FRONT AXLE, HUB REDUCTION 74HP (943)

FIGURE 5-55. FRONT AXLE, STEERING 74HP (943)

FIGURE 5-56. FRONT AXLE, TRUNION 74HP (943)

FIGURE 5-59. FRONT AXLE, CENTRAL HOUSING (943, 1043)

FIGURE 5-60. FRONT AXLE, DIFFERENTIAL (943, 1043)

FIGURE 5-64. FRONT AXLE, DIFFERENTIAL KIT (943, 1043)

FIGURE 5-65. FRONT AXLE, PLANET GEAR CARRIER (943, 1043)

FIGURE 5-66. FRONT AXLE, RING GEAR SUPPORT (943, 1043)

FIGURE 5-67. FRONT AXLE, PLANET GEAR CARRIER (943, 1043)

FIGURE 5-70. REAR AXLE, CENTRAL HOUSING (642, 742)

FIGURE 5-71. REAR AXLE, DIFFERENTIAL (642, 742)

FIGURE 5-76. REAR AXLE, DIFFERENTIAL KIT (642, 742)

FIGURE 5-77. REAR AXLE, REDUCTION BUSHING (642, 742)

FIGURE 5-78. REAR AXLE, PLANET GEAR CARRIER KIT (642, 742)

FIGURE 5-79. REAR AXLE, RING GEAR SUPPORT KIT (642, 742)41 topics

FIGURE 5-84. REAR AXLE, CENTRAL HOUSING 74HP (742)
FIGURE 5-85. REAR AXLE, DIFFERENTIAL 74HP (742)
FIGURE 5-86. REAR AXLE, HUB REDUCTION 74HP (742)
FIGURE 5-88. REAR AXLE, STEERING 74HP (742)
FIGURE 5-91. REAR AXLE, CENTRAL HOUSING 74HP (943)
FIGURE 5-92. REAR AXLE, DIFFERENTIAL 74HP (943)
FIGURE 5-93. REAR AXLE, HUB REDUCTION 74HP (943)
FIGURE 5-95. REAR AXLE, STEERING 74HP (943)
FIGURE 5-105. REAR AXLE, PLANET GEAR CARRIER (943, 1043)
FIGURE 5-106. REAR AXLE, PLANET GEAR CARRIER (943, 1043)
FIGURE 5-109. TRANSMISSION INSTALLATION, (LS)
FIGURE 5-110. TRANSMISSION INSTALLATION, (ULS)
FIGURE 5-111. POWERSHIFT TRANSMISSION
FIGURE 5-112. TRANSMISION, ENGINE CONNECTION
FIGURE 5-113. TRANSMISSION, CONVERTER
FIGURE 5-114. TRANSMISSION, INPUT
FIGURE 5-115. TRANSMISSION, HOUSING GROUP 1
FIGURE 5-116. TRANSMISSION, HOUSING GROUP 2
FIGURE 5-117. TRANSMISSION, CLUTCH GROUP 1
FIGURE 5-118. TRANSMISSION, CLUTCH GROUP 2
FIGURE 5-119. TRANSMISSION, COUPLING GROUP 1
FIGURE 5-120. TRANSMISSION, COUPLING GROUP 2
FIGURE 5-121. TRANSMISSION, COUPLING GROUP 3
FIGURE 5-122. TRANSMISSION, COUPLING GROUP 4
FIGURE 5-123. TRANSMISSION, OUTPUT
FIGURE 5-124. TRANSMISSION, POWER TAKE-OFF
FIGURE 5-125. TRANSMISSION, CONTROL UNIT
FIGURE 5-126. TRANSMISSION, SHIFT SYSTEM
FIGURE 5-127. TRANSMISSION, PRESSURE REGULATOR
FIGURE 5-128. TRANSMISSION, PRESSURE OIL PUMP
FIGURE 5-129. TRANSMISSION, INDUCTIVE TRANSMITTER
FIGURE 5-130. TRANSMISSION, FILTER
FIGURE 5-131. TRANSMISSION, ACCESSORIES GROUP 1
FIGURE 5-132. TRANSMISSION, PERIPHERALS GROUP 1
FIGURE 5-133. TRANSMISSION, ACCESSORIES GROUP 2
FIGURE 5-134. TRANSMISSION, TRANSFER BOX
FIGURE 5-135. TRANSMISSION, TRANSFER BOX HOUSING 1
FIGURE 5-136. TRANSMISSION, TRANSFER BOX HOUSING 2
FIGURE 5-137. TRANSMISSION, TRANSFER BOX HOUSING INPUT
FIGURE 5-138. TRANSMISSION, TRANSFER BOX HOUSING OUTPUT 1
FIGURE 5-139. TRANSMISSION, TRANSFER BOX HOUSING OUTPUT 2

FIGURE 5-166. FENDER INSTALLATION

FIGURE 5-169. WHEEL CHOCK INSTALLATION

FIGURE 5-170. TOOLBOX INSTALLATION

SECTION 6 - CAB

FIGURE 6-1. CAB MOUNTING

FIGURE 6-2. CAB MOUNT INSTALLATION

FIGURE 6-3. FRONT CAB OUTRIGGER INSTALLATION

FIGURE 6-4. CAB FENDER INSTALLATION

FIGURE 6-5. CAB FENDER INSTALLATION (742) (IF EQUIPPED)

FIGURE 6-6. OROPS CAB INSTALLATION

FIGURE 6-7. EROPS CAB INSTALLATION

FIGURE 6-8. OPEN CAB INSTALLATION

FIGURE 6-9. ENCLOSED CAB INSTALLATION (SN 0160079247 to Present)

FIGURE 6-10. OPEN CAB ASSEMBLY

FIGURE 6-11. OPEN CAB PLUG GROUP

FIGURE 6-13. ENCLOSED CAB ASSEMBLY

FIGURE 6-14. REAR WINDOW INSTALLATION

FIGURE 6-15. REAR WINDOW INSTALLATION (WO/WIPER) (ANSI)

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

FIGURE 6-17. REAR WINDOW INSTALLATION (WO/WIPER) (ENG/SPAN)

FIGURE 6-18. REAR WINDOW ASSEMBLY

FIGURE 6-19. DOOR INSTALLATION

to Present)

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. MIRROR INSTALLATION

FIGURE 6-29. FRONT COVER INSTALLATION

FIGURE 6-30. FILTER TRAY PANEL

FIGURE 6-31. FRONT DUCT COVER

FIGURE 6-32. LEVEL INDICATOR INSTALLATION

FIGURE 6-33. SEAT INSTALLATION

FIGURE 6-34. SEAT

FIGURE 6-37. HEATER INSTALLATION59 topics

FIGURE 6-39. HEATER ASSEMBLY (SN 0160077679 to Present)
FIGURE 6-40. HEATER
FIGURE 6-41. HEATER
FIGURE 6-42. HEATER AND A/C INSTALLATION
FIGURE 6-43. HEATER AND A/C ASSEMBLY (Prior to SN 0160077679)
FIGURE 6-44. HEATER AND A/C ASSEMBLY (SN 0160077679 to Present)
FIGURE 6-45. HEATER AND A/C
FIGURE 6-46. HEATER AND A/C
FIGURE 6-47. HVAC CAB ACTUATOR
FIGURE 6-48. CAB CONDENSER ASSEMBLY
FIGURE 6-49. A/C RECEIVER DRIER
FIGURE 6-50. CONDENSER
FIGURE 6-51. FRONT WIPER INSTALLATION
FIGURE 6-52. REAR WIPER INSTALLATION
FIGURE 6-53. ROOF WIPER INSTALLATION
FIGURE 6-54. HEADLINER INSTALLATION
FIGURE 6-55. OPEN CAB TRIM INSTALLATION (Prior to SN 0160081650)
FIGURE 6-56. OPEN CAB TRIM INSTALLATION (SN 0160081650 to Present)
FIGURE 6-57. ENCLOSED CAB TRIM INSTALLATION (Prior to SN 0160081650)
FIGURE 6-58. ENCLOSED CAB TRIM INSTALLATION (SN 0160081650 to Present)
FIGURE 6-59. LONG CAB ROOF CAPPING INSTALLATION
FIGURE 6-60. SHORT CAB ROOF CAPPNG INSTALLATION
FIGURE 6-61. OPEN CAB FRONT COVER INSTALLATION
FIGURE 6-62. ENCLOSED CAB FRONT COVER INSTALLATION
FIGURE 6-63. NON SKID TAPE INSTALLATION
FIGURE 6-64. EXTERNAL WINDOW RELEASE INSTALLATION
FIGURE 6-65. WASHER TANK INSTALLATION
FIGURE 6-66. SCREEN GUARDS INSTALLATION
FIGURE 6-67. TOP SCREEN GUARD INSTALLATION
FIGURE 6-68. FRONT SCREEN GUARD INSTALLATION
FIGURE 6-69. ROOF PIGTAIL CAP INSTALLATION
FIGURE 6-70. ROOF PIGTAIL INSTALLATION
FIGURE 6-71. RETRACTABLE SUNSCREEN INSTALLATION
FIGURE 6-72. NO SUNBLIND INSTALLATION
SECTION 7 - CONTROLS
FIGURE 7-1. BRAKE PEDAL INSTALLATION (642, 742)
FIGURE 7-2. BRAKE PEDAL INSTALLATION (943, 1043)
FIGURE 7-5. BRAKE PEDAL PLATE
FIGURE 7-6. ACCELERATOR PEDAL INSTALLATION
FIGURE 7-7. ACCELERATOR PEDAL
FIGURE 7-8. STEERING COLUMN INSTALLATION (642, 742)
FIGURE 7-9. STEERING COLUMN INSTALLATION (EMERGENCY STEERING) (642, 742)
FIGURE 7-10. STEERING COLUMN INSTALLATION (943, 1043)
FIGURE 7-11. STEERING COLUMN INSTALLATION (EMERGENCY STEERING) (943, 1043)
FIGURE 7-12. STEERING WHEEL INSTALLATION
FIGURE 7-13. STEERING WHEEL
FIGURE 7-14. HORN BUTTON INSTALLATION
FIGURE 7-15. JOYSTICK INSTALLATION (AUX, DECLUTCH)
FIGURE 7-16. COLUMN CLAMP INSTALLATION
FIGURE 7-17. WIPER-TURN SWITCH
FIGURE 7-18. OUTRIGGER SWITCHES INSTALLATION
FIGURE 7-19. JOYSTICK
SECTION 8 - HYDRAULIC CIRCUITS
FIGURE 8-1. MAIN HYDRAULIC INSTALLATION (NO OUTRIGGERS) (642,742)
FIGURE 8-2. MAIN HYDRAULIC INSTALLATION (NO OUTRIGGERS) (110HP) (742) (SN 0160084432 to Present)
FIGURE 8-3. MAIN HYDRAULIC INSTALLATION (OUTRIGGERS) (642)
FIGURE 8-4. MAIN HYDRAULIC INSTALLATION (OUTRIGGERS 74HP) (742)
FIGURE 8-5. MAIN HYDRAULIC INSTALLATION (NO OUTRIGGERS) (943) (Prior to SN 0160081535)
FIGURE 8-6. MAIN HYDRAULIC INSTALLATION (NO OUTRIGGERS) (943) (SN 0160081535 to Present)

Present)

FIGURE 8-9. MAIN HYDRAULIC INSTALLATION (OUTRIGGERS) (1043) (Prior to SN 0160081535)

FIGURE 8-10. MAIN HYDRAULIC INSTALLATION (OUTRIGGERS) (1043) (SN 0160081535 to Present)

FIGURE 8-11. MAIN HYDRAULIC INSTALLATION (EMERGENCY STEERING NO OUTRIGGERS) (642, 742)

FIGURE 8-12. MAIN HYDRAULIC INSTALLATION (EMERGENCY STEERING WITH OUTRIGGERS) (642)

FIGURE 8-15. MAIN HYDRAULIC INSTALLATION - 74HP (EMERGENCY STEERING NO OUTRIGGERS) (742)

FIGURE 8-16. VALVE INSTALLATION (NO OUTRIGGERS) (642, 742)

FIGURE 8-17. VALVE INSTALLATION (OUTRIGGERS) (642)

FIGURE 8-18. VALVE INSTALLATION (NO OUTRIGGERS) (943) (Prior to SN 0160081535)

FIGURE 8-20. VALVE INSTALLATION (OUTRIGGERS) (1043) (Prior to SN 0160081535)

FIGURE 8-21. VALVE INSTALLATION (OUTRIGGERS) (1043) (SN 0160081535 to Present)

FIGURE 8-22. PISTON PUMP INSTALLATION (642, 742)

FIGURE 8-24. HYDRAULIC LINES INSTALLATION (110HP) (642, 742)

FIGURE 8-25. HYDRAULIC LINES INSTALLATION (74HP) (742)

FIGURE 8-28. FRAME LEVEL HYDRAULICS INSTALLATION (NO OUTRIGGERS) (642, 742)

FIGURE 8-29. FRAME LEVEL HYDRAULICS INSTALLATION (OUTRIGGERS) (642)

FIGURE 8-30. FRAME LEVEL HYDRAULICS INSTALLATION (NO OUTRIGGERS) (742, 943)

FIGURE 8-31. FRAME LEVEL HYDRAULICS INSTALLATION (OUTRIGGERS) (943, 1043)

FIGURE 8-32. CAB HYDRAULIC INSTALLATION (OUTRIGGERS) (642)

FIGURE 8-33. CAB HYDRAULIC INSTALLATION (OUTRIGGERS) (742)

FIGURE 8-34. CAB HYDRAULIC INSTALLATION (NO OUTRIGGERS) (642, 742)

FIGURE 8-35. CAB HYDRAULIC INSTALLATION (943, 1043)

FIGURE 8-36. CAB HYDRAULIC INSTALLATION EMERGENCY STEERING (642, 742)

FIGURE 8-37. CAB HYDRAULIC INSTALLATION, EMERGENCY STEERING (943, 1043)

FIGURE 8-38. BOOM HYDRAULIC INSTALLATION (642, 742)

FIGURE 8-39. BOOM HYDRAULIC INSTALLATION, EMERGENCY STEERING (742, 943, 1043)

FIGURE 8-41. MAIN HYDRAULIC VALVES INSTALLATION (742, 943, 1043)

FIGURE 8-42. MAIN CONTROL VALVE INSTALLATION (642, 742)

FIGURE 8-44. MAIN CONTROL VALVE INSTALLATION (742, 943, 1043)

FIGURE 8-45. MAIN CONTROL VALVE ASSEMBLY (642)

FIGURE 8-48. STEERING SELECT AND FRAME LEVEL VALVE INSTALLATION

FIGURE 8-49. PARK BRAKE INSTALLATION

FIGURE 8-50. PARK BRAKE VALVE ASSEMBLY

FIGURE 8-53. FRAME LEVEL INSTALLATION (642, 742)

FIGURE 8-54. FRAME LEVEL INSTALLATION (943, 1043)

FIGURE 8-55. FRAME LEVEL AND OUTRIGGER VALVE INSTALLATION

FIGURE 8-56. FRAME LEVEL AND OUTRIGGER VALVE ASSEMBLY

FIGURE 8-57. FRAME LEVEL VALVE ASSEMBLY

FIGURE 8-58. STEERING SELECT VALVE MOUNTING INSTALLATION

FIGURE 8-59. STEERING SELECT VALVE INSTALLATION

FIGURE 8-60. STEERING SELECT VALVE ASSEMBLY

FIGURE 8-61. REAR AXLE STABILIZER INSTALLATION (642, 742)

FIGURE 8-62. REAR AXLE STABILIZER INSTALLATION (943, 1043)

FIGURE 8-63. COUNTERBALANCE VALVE INSTALLATION (LIFT - NON PGLS NO RIDE CONTROL) (642, 943, 1043)

FIGURE 8-64. COUNTERBALANCE VALVE INSTALLATION (LIFT - PGLS NO RIDE CONTROL) (742 (74HP), 943, 1043)

FIGURE 8-65. COUNTERBALANCE VALVE INSTALLATION (LIFT - PGLS NO RIDE CONTROL 110HP) (742)

FIGURE 8-66. COUNTERBALANCE VALVE INSTALLATION (LIFT - PGLS RIDE CONTROL 74HP) (742)

FIGURE 8-67. COUNTERBALANCE VALVE INSTALLATION (LIFT - PGLS RIDE CONTROL 110HP) (742)

FIGURE 8-68. COUNTERBALANCE VALVE HYDRAULIC LINES (LIFT - RIDE CONTROL) (742, 943, 1043)

FIGURE 8-69. COUNTERBALANCE VALVE INSTALLATION (LIFT- RIDE CONTROL) (642)43 topics

FIGURE 8-72. COUNTERBALANCE VALVE HYDRAULIC LINES (LIFT - RIDE CONTROL) (943, 1043)
FIGURE 8-73. COUNTERBALANCE VALVE HYDRAULIC LINES (LIFT - RIDE CONTROL) (642)
FIGURE 8-74. BOOM HYDRAULIC TUBES INSTALLATION (642, 742)
FIGURE 8-75. BOOM HYDRAULIC TUBES INSTALLATION (943, 1043)
FIGURE 8-76. BOOM AUXILIARY HYDRAULICS INSTALLATION (642, 742)
FIGURE 8-77. BOOM AUXILIARY HYDRAULICS INSTALLATION (943, 1043)
FIGURE 8-78. BOOM AUXILIARY HYDRAULICS (HYDRAULIC COUPLER) (642, 742)
FIGURE 8-79. BOOM AUXILIARY HYDRAULICS (HYDRAULIC COUPLER) (943, 1043)
FIGURE 8-80. BOOM AUXILIARY HYDRAULICS (SIDE MOUNTED) (742)
FIGURE 8-81. BOOM AUXILIARY HYDRAULICS (SIDE MOUNTED) (943, 1043)
FIGURE 8-82. QUICK COUPLER VALVE ASSEMBLY (642, 742)
FIGURE 8-83. QUICK COUPLER VALVE ASSEMBLY (943, 1043)
FIGURE 8-84. HYDRAULIC QUICK COUPLER ASSEMBLY
FIGURE 8-85. QUICK COUPLER CYLINDER ASSEMBLY (Prior to SN 0160073806)
FIGURE 8-86. QUICK COUPLER CYLINDER ASSEMBLY (SN 0160073806 to Present)
FIGURE 8-87. BOOM ANGLE SENSOR INSTALLATION
FIGURE 8-88. PRIORITY FUNCTION MANIFOLD INSTALLATION
FIGURE 8-89. PRIORITY FUNCTION MANIFOLD VALVE ASSEMBLY
FIGURE 8-90. EMERGENCY STEERING MANIFOLD
FIGURE 8-91. INTGRATED RECOVERY VALVE (LIFT - RIDE CONTROL) (742)
SECTION 9 - HYDRAULIC COMPONENTS
FIGURE 9-1. CYLINDER GROUP INSTALLATION (642, 742)
FIGURE 9-2. CYLINDER GROUP INSTALLATION - 74HP (742)
FIGURE 9-10. TILT CYLINDER ASSEMBLY (642, 742)
FIGURE 9-11. TILT CYLINDER ASSEMBLY (943, 1043)
FIGURE 9-16. COMPENSATION CYLINDER (642, 742)
FIGURE 9-17. COMPENSATION CYLINDER (742)
FIGURE 9-18. COMPENSATION CYLINDER (943, 1043)
FIGURE 9-19. FRAME LEVEL CYLINDER INSTALLATION
FIGURE 9-20. FRAME LEVEL CYLINDER
FIGURE 9-21. EXTEND/RETRACT CYLINDER ASSEMBLY (642) (Prior to SN 0160080899)
FIGURE 9-22. EXTEND/RETRACT CYLINDER ASSEMBLY (642, 742) (SN 0160080899 to Present)
FIGURE 9-27. EXTEND/RETRACT CYLINDER (742)
FIGURE 9-28. EXTEND/RETRACT CYLINDER (943, 1043)
FIGURE 9-29. REAR AXLE STABILIZER CYLINDER INSTALLATION
FIGURE 9-30. REAR AXLE STABILITY CYLINDER
FIGURE 9-33. SIDE TILT CYLINDER
FIGURE 9-34. REAR AXLE STABILIZER VALVE (Prior to SN 0160080899)
FIGURE 9-35. REAR AXLE STABILIZER VALVE (SN 0160080899 to Present)
FIGURE 9-36. MAIN CONTROL VALVE (642)
FIGURE 9-38. MAIN CONTROL VALVE - INLET SECTION (943, 1043)
FIGURE 9-39. MAIN CONTROL VALVE - SPOOL SECTION (943, 1043)
FIGURE 9-40. MAIN CONTROL VALVE - SPOOL SECTION (943, 1043)

FIGURE 9-41. MAIN CONTROL VALVE - SPOOL SECTION (943, 1043)

FIGURE 9-42. MAIN CONTROL VALVE - SPOOL SECTION (943, 1043)

FIGURE 9-46. STEERING ORBITAL VALVE (642, 742)

FIGURE 9-47. STEERING ORBITAL VALVE (943, 1043)

FIGURE 9-48. STEER SELECT VALVE

FIGURE 9-49. PARK BRAKE VALVE

FIGURE 9-50. FRAME LEVEL VALVE

FIGURE 9-51. FRAME LEVEL AND OUTRIGGER VALVE

FIGURE 9-52. QUICK COUPLER VALVE

FIGURE 9-53. HYDRAULIC TANK

FIGURE 9-54. PRIORITY MANIFOLD VALVE

FIGURE 9-55. QUICK COUPLER CYLINDER

FIGURE 9-56. SWING CARRIAGE CYLINDER

FIGURE 9-57. GRAPPLE BUCKET CYLINDER

FIGURE 9-58. SIDE SHIFT CARRIAGE CYLINDER

FIGURE 9-59. AIR SHUT OFF VALVE

SECTION 10 - ELECTRICAL

FIGURE 10-1. MAIN ELECTRICAL INSTALLATION (ULS) (642, 742)

FIGURE 10-2. MAIN ELECTRICAL INSTALLATION (ULS) (943, 1043)

FIGURE 10-4. MAIN ELECTRICAL INSTALLATION (LS) (642, 742)

FIGURE 10-5. MAIN ELECTRICAL INSTALLATION (LS) (943, 1043)

FIGURE 10-6. ELECTRICAL FRAME INSTALLATION

FIGURE 10-7. POWER DISTRIBUTION ELECTRICAL BOX

FIGURE 10-8. ENGINE BAY WIRING INSTALLATION (ULS)

FIGURE 10-9. ENGINE BAY WIRING INSTALLATION (74HP) (ULS)

FIGURE 10-10. ENGINE BAY WIRING INSTALLATION (LS)

FIGURE 10-11. FRAME WIRING INSTALLATION (ULS) (642, 742)

FIGURE 10-13. FRAME WIRING INSTALLATION (ULS) (943, 1043)

FIGURE 10-14. FRAME WIRING INSTALLATION (LS) (642, 742)

FIGURE 10-15. FRAME WIRING INSTALLATION (LS) (943, 1043)

FIGURE 10-18. ENGINE WIRING INSTALLATION (ULS)

FIGURE 10-19. ENGINE WIRING INSTALLATION, 74HP (ULS) (742, 943)

FIGURE 10-20. ENGINE WIRING INSTALLATION (LS)

FIGURE 10-21. ENGINE ECU INSTALLATION

FIGURE 10-22. ENGINE ECM INSTALLATION (LS)

FIGURE 10-23. BOOM AUXILIARY ELECTRIC INSTALLATION

FIGURE 10-24. BOOM AUXILIARY ELECTRIC HARNESS INSTALLATION

FIGURE 10-25. BATTERY INSTALLATION (642, 742)

FIGURE 10-27. ARCTIC COLD WEATHER PACKAGE INSTALLATION (ULS - 110HP)

FIGURE 10-28. ARCTIC COLD WEATHER PACKAGE INSTALLATION (ULS - 74HP)

FIGURE 10-29. ARCTIC COLD WEATHER PACKAGE INSTALLATION (LS)

FIGURE 10-30. FUEL FILTER HEATER INSTALLATION

FIGURE 10-31. ARCTIC BATTERIES INSTALLATION

FIGURE 10-32. HYDRAULIC TANK HEATER INSTALLATION

FIGURE 10-33. BACKUP ALARM INSTALLATION (120 DB)

FIGURE 10-34. BACKUP ALARM INSTALLATION (97 DB)

FIGURE 10-35. WHITE NOISE BACKUP ALARM INSTALLATION

FIGURE 10-36. CAB ELECTRICAL INSTALLATION

FIGURE 10-37. DASH ELECTRICAL INSTALLATION (ULS)

FIGURE 10-38. DASH ELECTRICAL INSTALLATION (LS)

FIGURE 10-39. SWITCH LIGHT INSTALLATION

FIGURE 10-40. USB CHARGER INSTALLATION

FIGURE 10-41. OPEN CAB ELECTRICAL INSTALLATION WITH OPTIONS

FIGURE 10-42. HIGH END DISPLAY INSTALLATION

FIGURE 10-43. ENCLOSED CAB ELECTRICAL INSTALLATION WITH OPTIONS

FIGURE 10-44. REVERSE CAMERA INSTALLATION

FIGURE 10-45. REVERSE SENSOR INSTALLATION43 topics

FIGURE 10-48. TELEMATICS READY INSTALLATION
FIGURE 10-50. ROAD LIGHTS INSTALLATION (NO OUTRIGGERS) (Prior to SN 0160079247)
FIGURE 10-51. ROAD LIGHTS INSTALLATION (NO OUTRIGGERS) (SN 0160079247 to Present)
FIGURE 10-52. ROAD LIGHTS INSTALLATION (OUTRIGGERS) (Prior to SN 0160079247)
FIGURE 10-53. ROAD LIGHTS INSTALLATION (OUTRIGGERS) (SN 0160079247 to Present)
FIGURE 10-54. CAB WORKLIGHTS INSTALLATION (NO A/C)
FIGURE 10-55. CAB LED WORK LIGHTS INSTALLATION (NO A/C)
FIGURE 10-56. CAB WORKLIGHTS INSTALLATION (A/C)
FIGURE 10-57. CAB LED WORK LIGHTS INSTALLATION (A/C)
FIGURE 10-58. BOOM WORK LIGHTS INSTALLATION
FIGURE 10-59. BOOM WORK LIGHTS INSTALLATION (LED)
FIGURE 10-60. BOOM LIGHTS INSTALLATION
FIGURE 10-61. BOOM LED LIGHTS INSTALLATION
FIGURE 10-62. A/C OPTION HARNESS
FIGURE 10-63. BEACON INSTALLATION
FIGURE 10-64. LED BEACON INSTALLATION
FIGURE 10-65. OUTRIGGER HARNESS
FIGURE 10-66. RIDE CONTROL CB VALVE HARNESS INSTALLATION (LIFT) (642, 742)
FIGURE 10-67. RIDE CONTROL CB VALVE HARNESS INSTALLATION (LIFT) (943, 1043)
FIGURE 10-68. RIDE CONTROL CB VALVE HARNESS (LIFT)
FIGURE 10-69. FRONT FRAME HARNESS (Prior to SN 0160080782)
FIGURE 10-73. ENGINE CHASSIS HARNESS (ULS)
FIGURE 10-79. TBAP HARNESS
FIGURE 10-80. BOOM ELECTRICAL HARNESS INSTALLATION
FIGURE 10-81. BOOM HARNESS
FIGURE 10-82. PLATFORM HARNESS
FIGURE 10-83. CAB HARNESS
FIGURE 10-84. FRONT FRAME HEADLIGHT HARNESS
FIGURE 10-85. HBP TAIL LIGHTS HARNESS
FIGURE 10-89. REVERSE SENSOR HARNESS
FIGURE 10-90. TELEMATICS INSTALLATION, UNITED RENTALS
FIGURE 10-91. OPTION 1 CAB HARNESS
FIGURE 10-92. ROOF PIGTAIL HARNESS
FIGURE 10-93. OPTION 2 CAB HARNESS
FIGURE 10-94. OPTION 2 ELECTRICAL BOARD ASSEMBLY
FIGURE 10-95. CAB OPTION HARNESS
FIGURE 10-96. TELEMATICS READY HARNESS
FIGURE 10-97. STANDARD ELECTRICAL BOARD ASSEMBLY
FIGURE 10-98. OPTION 1 ELECTRICAL BOARD ASSEMBLY
FIGURE 10-99. CUMMUNICATION ANALYZER CABLE
FIGURE 10-100. TELEMATICS HARNESS
FIGURE 10-103. TELEMATICS INSTALLATION, UNITED RENTALS
FIGURE 10-104. GATEWAY CONTROLLER

FIGURE 10-105. TELEMATICS CANBUS INSTALLATION (CLEARSKY 2) (ANSI)

FIGURE 10-106. TELEMATICS CANBUS INSTALLATION (CLEARSKY 2) (CE)

FIGURE 10-107. TELEMATICS HARNESS (CLEARSKY 2)

FIGURE 10-108. CLEARSKY INSTALLATION 3-WIRE (ANSI)

FIGURE 10-109. CLEARSKY INSTALLATION 3-WIRE (CE)

FIGURE 10-110. CONTROL ACCESSORY

FIGURE 10-111. CAB AIR SHUT OFF VALVE HARNESS

FIGURE 10-112. ENGINE AIR SHUT OFF VALVE HARNESS

SECTION 11 - DECALS

FIGURE 11-1. CAPACITY CHART HOLDER

FIGURE 11-2. BRAND AND MODEL DECAL INSTALLATION (642)

FIGURE 11-3. BRAND AND MODEL DECAL INSTALLATION (742)

FIGURE 11-4. BRAND AND MODEL DECAL INSTALLATION (943)

FIGURE 11-5. BRAND AND MODEL DECAL INSTALLATION (1043)

FIGURE 11-6. DECAL INSTALLATION (ANSI)

FIGURE 11-7. DECAL INSTALLATION (ANSI) (742, 943)

FIGURE 11-8. DECAL INSTALLATION (ISO)

FIGURE 11-10. DECAL INSTALLATION (CSA ENGLISH/FRENCH) (642, 742)

FIGURE 11-11. DECAL INSTALLATION (CSA ENGLISH/FRENCH) (742, 943)

FIGURE 11-12. DECAL INSTALLATION (ENGLISH/SPANISH)

FIGURE 11-13. CAPACITY CHART BOOKLET (ANSI) (NO OUTRIGGERS) (642) (Prior to SN 0160075708)

FIGURE 11-14. CAPACITY CHART BOOKLET (ANSI) (NO OUTRIGGERS) (642) (SN 0160075708 to Present)

FIGURE 11-15. CAPACITY CHART BOOKLET (ANSI) (OUTRIGGERS) (642) (SN 0160075708 to Present)

FIGURE 11-16. CAPACITY CHART BOOKLET (ISO) (NO OUTRIGGERS) (642) (SN 0160075708 to Present)

FIGURE 11-17. CAPACITY CHART BOOKLET (ISO) (OUTRIGGERS) (642) (SN 0160075708 to Present)

FIGURE 11-18. CAPACITY CHART BOOKLET (ANSI) (742)

FIGURE 11-19. CAPACITY CHART BOOKLET (ISO) (742)

FIGURE 11-25. CAPACITY CHART BOOKLET (ANSI) (OUTRIGGERS) (1043) (Prior to SN 0160075708)

FIGURE 11-27. CAPACITY CHART BOOKLET (ANSI) (OUTRIGGERS) (1043) (SN 0160081272 to Present)

FIGURE 11-29. CAPACITY CHART BOOKLET (ISO) (OUTRIGGERS) (1043) (SN 0160081272 to Present)

FIGURE 11-30. REVERSE SENSOR SYSTEM DECAL (ENGLISH)

FIGURE 11-31. REVERSE SENSOR SYSTEM DECAL (ISO)

FIGURE 11-32. REVERSE SENSOR SYSTEM DECAL (ENGLISH/FRENCH)

FIGURE 11-33. REVERSE SENSOR SYSTEM DECAL (ENGLISH/SPANISH)

FIGURE 11-34. DECAL INSTALLATION (642)

FIGURE 11-36. CLEARSKY DECAL INSTALLATION

FIGURE 11-38. DECAL INSTALLATION (742, 943) (74 HP - ENGLISH/SPANISH

SECTION 12 - RECOMMENDED SPARE PARTS

FIGURE 12-1. RECOMMENDED SPARE PARTS

PART NUMBER INDEX

Inside this manual

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Parts illustration, page 547: SECTION 5 - DRIVE TRAIN
Parts illustration, page 955: SECTION 8 - HYDRAULIC CIRCUITS
Parts illustration, page 1,075: SECTION 8 - HYDRAULIC CIRCUITS

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