JLG 742 Telehandler Parts Manual

Name: JLG 742 Telehandler Parts Manual
Brand: MidWestTech
SKU: 31211370
Price: 129.79 USD
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1,298 pages · Publication 31211370

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Models: 742
Manual type: Parts Manual
Pages: 1,298
Publication: 31211370
Condition: Brand new

JLG 742 Telehandler Parts Manual, publication 31211370

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From the manual's own table of contents: 254 sections, 559 entries. See sample pages (PDF, 567 KB)

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General54 topics

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) (PVC 1911)
FIGURE 1-5. COVER INSTALLATION (NO OUTRIGGERS) (ULS) (PVC 2005)
FIGURE 1-6. COVER INSTALLATION (NO OUTRIGGERS) (LS) (PVC 1911)
FIGURE 1-7. COVER INSTALLATION (NO OUTRIGGERS) (LS) (PVC 2005)
FIGURE 1-8. TANK INSTALLATION
FIGURE 1-9. FUEL TANK INSTALLATION
FIGURE 1-10. HYDRAULIC TANK INSTALLATION
FIGURE 1-11. FUEL CAP ASSEMBLY
FIGURE 1-12. MIRROR INSTALLATION
FIGURE 1-13. BOOM PROP INSTALLATION (ANSI)
FIGURE 1-14. BOOM PROP INSTALLATION (CANADA)
FIGURE 1-15. BOOM PROP BRACKET
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) (PVC 1911)
FIGURE 3-6. BOOM - ADJUSTABLE (CARRIAGE MOUNTED) (PVC 2005)
FIGURE 3-7. BOOM - ADJUSTABLE (FORK MOUNTED)
FIGURE 3-8. BOOM - 3FT WITH WINCH
FIGURE 3-9. BOOM - 12FT WITHOUT WINCH (PVC 1911)
FIGURE 3-10. BOOM - 12FT WITHOUT WINCH (PVC 2005)
FIGURE 3-11. BOOM - 12FT WITH WINCH
FIGURE 3-12. BOOM - 15FT WITHOUT WINCH (PVC 1911)
FIGURE 3-13. BOOM - 15FT WITHOUT WINCH (PVC 2005)
FIGURE 3-19. BUCKET - 96IN GRAPPLE
FIGURE 3-21. CARRIAGE ASSEMBLY - 48IN/12000# CAPICITY SIDE SHIFT

FIGURE 3-24. FORK POSITIONING CARRIAGE WITH FORKS (4.5 TON) (PVC1911)

FIGURE 3-25. FORK POSITIONING CARRIAGE WITH FORKS (4.5 TON) (PVC 2005)

FIGURE 3-26. CARRIAGE ASSEMBLY - 50IN/12000# CAPICITY SIDE TILT (PVC 1911)

FIGURE 3-27. CARRIAGE ASSEMBLY - 50IN/12000# CAPICITY SIDE TILT (PVC 2005)

FIGURE 3-30. CARRIAGE ASSEMBLY - 60IN/12000# CAPICITY SIDE TILT (PVC 1911)

FIGURE 3-31. CARRIAGE ASSEMBLY - 60IN/12000# CAPICITY SIDE TILT (PVC 2005)

FIGURE 3-34. 90 SWING CARRIAGE ASSEMBLY (72 INCH) (PVC 1911)

FIGURE 3-35. 90 SWING CARRIAGE ASSEMBLY (72 INCH) (PVC 2005)

FIGURE 3-36. CARRIAGE ASSEMBLY - 72IN/12000# CAPICITY SIDE TILT (PVC 1911)

FIGURE 3-37. CARRIAGE ASSEMBLY - 72IN/12000# CAPICITY SIDE TILT (PVC 2005)

FIGURE 3-38. CARRIAGE ASSEMBLY - DRYWALL (SWING) (PVC 1911)

FIGURE 3-39. CARRIAGE ASSEMBLY - DRYWALL (SWING) (PVC 2005)

FIGURE 3-40. CARRIAGE ASSEMBLY - DRYWALL SWING CARRIAGE

FIGURE 3-41. CARRIAGE ASSEMBLY - DRYWALL BOARD HANDLER

FIGURE 3-42. CARRIAGE ASSEMBLY - DRYWALL PIVOT FRAME

FIGURE 3-43. CARRIAGE ASSEMBLY - DRYWALL CYLINDER

FIGURE 3-44. CARRIAGE ASSEMBLY - DRYWALL HYDRAULICS

FIGURE 3-45. CARRIAGE ASSEMBLY - DRYWALL VALVE ASSEMBLY

FIGURE 3-46. CARRIAGE ASSEMBLY - DRYWALL CYLINDER

FIGURE 3-47. CARRIAGE ASSEMBLY - DRYWALL FORKS

FIGURE 3-61. FORK EXTENSION - 90IN

FIGURE 3-62. FORK CLAMPS INSTALLATION

FIGURE 3-63. HOOK, COUPLING (PVC 1911)

Show all 255 sections

FIGURE 3-64. HOOK, COUPLING (PVC 2005)

FIGURE 3-65. HOOK, CRANE

FIGURE 3-66. MAST, VERTICAL - 8FT (STANDARD)

FIGURE 3-67. MAST, VERTICAL - 8FT (SIDE TILT ELECTRIC MAST)

FIGURE 3-68. MAST, VERTICAL - DECAL KIT

FIGURE 3-69. MAST, VERTICAL - CYLINDER

FIGURE 3-70. SWEEPER ASSEMBLY

FIGURE 3-71. SWEEPER ASSEMBLY - BODY

FIGURE 3-72. SWEEPER ASSEMBLY - CORE

FIGURE 3-73. SWEEPER ASSEMBLY - HYDRAULIC SINGLE MOTOR ASSEMBLY

FIGURE 3-74. SWEEPER ASSEMBLY - HOPPER

FIGURE 3-75. SWEEPER ASSEMBLY - IDLER

FIGURE 3-76. SWEEPER ASSEMBLY - MOTOR

FIGURE 3-77. TRASHER 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)63 topics

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 4-20. EXHAUST INSTALLATION, 74HP (ULS)
FIGURE 4-21. EXHAUST INSTALLATION, 110HP (ULS)
FIGURE 4-22. EXHAUST INSTALLATION, 110HP (LS)
FIGURE 4-23. MUFFLER INSTALLATION (LS)
FIGURE 4-24. DEF TANK INSTALLATION
FIGURE 4-25. DEF TANK ASSEMBLY
FIGURE 4-26. DEF BREATHER VALVE
FIGURE 4-27. DEF PUMP AND CONTROL INSTALLATION
FIGURE 4-28. UREA PUMP
FIGURE 4-29. DEF PUMP LINES INSTALLATION
FIGURE 4-30. DEF TANK LINES INSTALLATION
FIGURE 4-31. FUEL LINES INSTALLATION (ULS)
FIGURE 4-32. FUEL LINES INSTALLATION (LS)
FIGURE 4-33. PRIMARY FUEL FILTER INSTALLATION (ULS)
FIGURE 4-34. PRIMARY FUEL FILTER INSTALLATION (LS)
FIGURE 4-35. FUEL TANK ASSEMBLY
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. CAC LINES INSTALLATION (ULS)
FIGURE 4-49. CAC LINES INSTALLATION (LS)
FIGURE 4-50. HOC LINES INSTALLATION
FIGURE 4-51. TOC LINES INSTALLATION
SECTION 5 - DRIVETRAIN
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, ACCESSORIES GROUP 1

FIGURE 5-24. TRANSMISSION, OIL DIPSTICK

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, 74HP - PLANET GEAR CARRIER KIT

FIGURE 5-74. REAR AXLE, 110HP

FIGURE 5-75. REAR AXLE, 110HP - CENTRAL HOUSING

FIGURE 5-76. REAR AXLE, 110HP - DIFFERENTIAL

FIGURE 5-77. REAR AXLE, 110HP - HUB REDUCTION

FIGURE 5-78. REAR AXLE, 110HP - BRAKES

FIGURE 5-79. REAR AXLE, 110HP - STEERING

FIGURE 5-80. REAR AXLE, 110HP- TRUNION

FIGURE 5-81. REAR AXLE, 110HP - DIFFERENTIAL KIT

FIGURE 5-82. REAR AXLE, 110HP - REDUCTION BUSHING

FIGURE 5-83. REAR AXLE, 110HP - PLANET GEAR CARRIER KIT

FIGURE 5-84. REAR AXLE, 110HP - RING GEAR SUPPORT KIT

FIGURE 5-85. REAR AXLE, 110HP - PLANET GEAR KIT

FIGURE 5-86. REAR AXLE, 110HP - PISTON KIT

FIGURE 5-87. REAR AXLE, 110HP - SUPPORT KIT

FIGURE 5-88. REAR AXLE, LSI SENSOR INSTALLATION

FIGURE 5-89. TIRE/WHEEL SET 370/75-28 PNEUMATIC64 topics

FIGURE 5-90. TIRE/WHEEL SET 370/75-28 PNEUMATIC NON-MARKING
FIGURE 5-91. TIRE/WHEEL SET 370/75-28 FOAM-FILLED
FIGURE 5-92. TIRE/WHEEL SET 370/75-28 FOAM-FILLED NON-MARKING
FIGURE 5-93. TIRE/WHEEL SET 13-24/16PR PNEUMATIC
FIGURE 5-94. TIRE/WHEEL SET 13-24/16PR FOAM-FILLED
FIGURE 5-95. TIRE/WHEEL SET 315/95-28 FOAM-FILLED
FIGURE 5-97. FENDER INSTALLATION
FIGURE 5-98. CAB FENDER INSTALLATION
FIGURE 5-99. CAB FENDER INSTALLATION REAR (LH)
FIGURE 5-100. WHEEL CHOCK INSTALLATION
FIGURE 5-101. 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 (PVC 1911)
FIGURE 6-9. OPEN CAB ASSEMBLY (PVC 2005)
FIGURE 6-10. OPEN CAB, LSI INSTALLATION
FIGURE 6-11. OPEN CAB PLUG GROUP
FIGURE 6-12. LSI DISPLAY INSTALLATION (OPEN CAB) (PVC 1911)
FIGURE 6-13. LSI DISPLAY INSTALLATION (OPEN CAB) (PVC 2005)
FIGURE 6-14. CAB, EPD CAULK
FIGURE 6-15. ENCLOSED CAB ASSEMBLY (PVC 1911)
FIGURE 6-16. ENCLOSED CAB ASSEMBLY (PVC 2005)
FIGURE 6-17. EMCLOSED CAB, LSI INSTALLATION
FIGURE 6-18. REAR WINDOW INSTALLATION
FIGURE 6-19. REAR WINDOW INSTALLATION (WO/WIPER) (ANSI)
FIGURE 6-20. REAR WINDOW INSTALLATION (WO/WIPER) (ISO)
FIGURE 6-21. REAR WINDOW INSTALLATION (WO/WIPER) (ENG/SPAN)
FIGURE 6-22. REAR WINDOW ASSEMBLY
FIGURE 6-23. DOOR INSTALLATION
FIGURE 6-24. DOOR UPPER GLASS ASSEMBLY
FIGURE 6-25. CAB LATCH ASSEMBLY
FIGURE 6-26. CAB DOOR TRIGGER ASSEMBLY
FIGURE 6-27. DOOR ASSEMBLY
FIGURE 6-28. CAB DOOR
FIGURE 6-29. DOOR STRAP INSTALLATION
FIGURE 6-30. ENCLOSED CAB PLUG GROUP
FIGURE 6-31. ENCLOSED CAB, LSI DISPLAY INSTALLATION
FIGURE 6-32. BASIC MIRROR INSTALLATION
FIGURE 6-33. FRONT COVER INSTALLATION
FIGURE 6-34. FIRE EXTINGUISHER INSTALLATION
FIGURE 6-35. FILTER TRAY PANEL
FIGURE 6-36. FRONT DUCT COVER
FIGURE 6-37. LEVEL INDICATOR INSTALLATION
FIGURE 6-38. SEAT INSTALLATION
FIGURE 6-39. SEAT
FIGURE 6-40. SEAT BELT INSTALLATION (3 INCH) (PVC 1911)
FIGURE 6-41. SEAT BELT INSTALLATION (3 INCH) (PVC 2005)
FIGURE 6-42. HEATER INSTALLATION
FIGURE 6-43. HEATER AND A/C INSTALLATION
FIGURE 6-44. HEATER ASSEMBLY
FIGURE 6-45. HEATER
FIGURE 6-46. HEATER AND A/C ASSEMBLY
FIGURE 6-47. HEATER AND A/C
FIGURE 6-48. HVAC CAB ACTUATOR
FIGURE 6-49. CAB CONDENSER ASSEMBLY
FIGURE 6-50. A/C RECEIVER DRIER
FIGURE 6-51. CONDENSER
FIGURE 6-52. FRONT WIPER INSTALLATION

FIGURE 6-53. REAR WIPER INSTALLATION

FIGURE 6-54. ROOF WIPER INSTALLATION

FIGURE 6-55. HEADLINER INSTALLATION

FIGURE 6-56. OPEN CAB TRIM INSTALLATION

FIGURE 6-57. ENCLOSED CAB TRIM INSTALLATION

FIGURE 6-58. ARMREST

FIGURE 6-59. OPEN CAB FRONT COVER

FIGURE 6-60. ENCLOSED CAB FRONT COVER

FIGURE 6-61. ROOF CAP INSTALLATION (A/C)

FIGURE 6-62. ROOF CAP INSTALLATION (NO A/C)

FIGURE 6-63. NON SKID TAPE INSTALLATION

FIGURE 6-64. EXTERNAL WINDOW RELEASE INSTALLATION (CAN & ISO)

FIGURE 6-65. WASHER TANK INSTALLATION

FIGURE 6-66. WASHER BOTTLE

FIGURE 6-67. CAB GUARD INSTALLATION (TOP AND FRONT)

FIGURE 6-68. CAB GUARD INSTALLATION (TOP)

FIGURE 6-69. CAB GUARD INSTALLATION (FRONT)

FIGURE 6-70. ROOF PIGTAIL CAP INSTALLATION

FIGURE 6-71. ROOF PIGTAIL INSTALLATION

FIGURE 6-72. NO SUNSCREEN INSTALLATION

FIGURE 6-73. 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 (PVC 1911)

FIGURE 7-7. COLUMN CLAMP INSTALLATION (PVC 2005)

FIGURE 7-8. HORN BUTTON INSTALLATION

FIGURE 7-9. JOYSTICK INSTALLATION (2 ROLLER, 0 BUTTON)

FIGURE 7-10. JOYSTICK

FIGURE 7-11. STEERING COLUMN INSTALLATION (PVC 1911)

FIGURE 7-12. STEERING COLUMN INSTALLATION (PVC 2005)

FIGURE 7-13. STEERING COLUMN INSTALLATION (EMERGENCY STEERING) (PVC 1911)

FIGURE 7-14. STEERING COLUMN INSTALLATION (EMERGENCY STEERING) (PVC 2005)

FIGURE 7-15. STEERING WHEEL INSTALLATION

FIGURE 7-16. STEERING WHEEL

FIGURE 7-17. WIPER-TURN SWITCH (PVC 1911)

FIGURE 7-18. WIPER-TURN SWITCH INSTALLATION (PVC 2005)

SECTION 8 - HYDRAULIC CIRCUITS

FIGURE 8-1. MAIN HYDRAULIC INSTALLATION - 74HP (PVC 1911)

FIGURE 8-2. MAIN HYDRAULIC INSTALLATION - 74HP (PVC 2005)

FIGURE 8-3. MAIN HYDRAULIC INSTALLATION - 74HP (EMERGENCY STEERING) (PVC 1911)

FIGURE 8-4. MAIN HYDRAULIC INSTALLATION - 74HP (EMERGENCY STEERING) (PVC 2005)

FIGURE 8-5. MAIN HYDRAULIC INSTALLATION - 110HP

FIGURE 8-6. MAIN HYDRAULIC INSTALLATION - 110HP (EMERGENCY STEERING)

FIGURE 8-7. BOOM HYDRAULICS INSTALLATION - 74HP

FIGURE 8-8. BOOM HYDRAULICS INSTALLATION - 110HP

FIGURE 8-9. BOOM AUXILIARY HYDRAULICS INSTALLATION

FIGURE 8-10. BOOM AUXILIARY HYDRAULICS INSTALLATION (SIDE MOUNTED)

FIGURE 8-11. BOOM AUXILIARY HYDRAULICS INSTALLATION (HYDRAULIC COUPLER)

FIGURE 8-12. BOOM AUXILIARY VALVE & FITTINGS ASSEMBLY (HYDRAULIC COUPLER)

FIGURE 8-13. BOOM TUBES INSTALLATION

FIGURE 8-14. CAB HYDRAULICS INSTALLATION - 74HP (PVC 1911)

FIGURE 8-15. CAB HYDRAULICS INSTALLATION - 74HP (PVC 2005)

FIGURE 8-16. CAB HYDRAULICS INSTALLATION - 74HP (EMERGENCY STEERING) (PVC 1911)

FIGURE 8-17. CAB HYDRAULICS INSTALLATION - 74HP (EMERGENCY STEERING) (PVC 2005)

FIGURE 8-18. CAB HYDRAULICS INSTALLATION - 110HP

FIGURE 8-19. CAB HYDRAULICS INSTALLATION - 110HP (EMERGENCY STEERING)

FIGURE 8-20. COUNTERBALANCE VALVE INSTALLATION (LIFT - NO RIDE CONTROL) (74HP)

FIGURE 8-21. COUNTERBALANCE VALVE INSTALLATION (LIFT - NO RIDE CONTROL) (110HP)

FIGURE 8-22. COUNTERBALANCE VALVE HYDRAULIC LINES (LIFT - RIDE CONTROL) (74HP)63 topics

FIGURE 8-23. COUNTERBALANCE VALVE HYDRAULIC LINES (LIFT - RIDE CONTROL) (110HP)
FIGURE 8-24. EMERGENCY STEERING MANIFOLD & FITTINGS ASSEMBLY
FIGURE 8-25. FRAME HYDRAULICS INSTALLATION - 74HP (PVC 1911)
FIGURE 8-26. FRAME HYDRAULICS INSTALLATION - 74HP (PVC 2005)
FIGURE 8-27. FRAME HYDRAULICS INSTALLATION 110HP
FIGURE 8-28. FRAME LEVEL INSTALLATION
FIGURE 8-29. FRAME LEVEL HYDRAULICS INSTALLATION (NO OUTRIGGERS)
FIGURE 8-32. PISTON PUMP INSTALLATION - 74HP
FIGURE 8-33. PISTON PUMP INSTALLATION - 110HP
FIGURE 8-34. PISTON PUMP ASSEMBLY - 74HP (PVC 1911)
FIGURE 8-35. PISTON PUMP ASSEMBLY - 74HP (PVC 2005)
FIGURE 8-36. PISTON PUMP ASSEMBLY - 110HP
FIGURE 8-37. STABILIZER INSTALLATION - REAR AXLE (PVC 1911)
FIGURE 8-38. REAR AXLE STABILIZER INSTALLATION (PVC 2005)
FIGURE 8-39. VALVES INSTALLATION - 74HP
FIGURE 8-40. VALVES INSTALLATION - 110HP
FIGURE 8-41. VALVES INSTALLATION - FRAME LEVEL
FIGURE 8-42. VALVE & FITTINGS ASSEMBLY- FRAME LEVEL
FIGURE 8-43. VALVES INSTALLATION - MAIN & PRIORITY- 74HP (PVC 1911)
FIGURE 8-44. VALVES INSTALLATION - MAIN & PRIORITY- 74HP (PVC 2005)
FIGURE 8-45. VALVES INSTALLATION - MAIN & PRIORITY- 110HP
FIGURE 8-46. VALVE INSTALLATION - MAIN - 74HP
FIGURE 8-47. VALVE INSTALLATION - MAIN - 110HP
FIGURE 8-48. VALVE & FITTINGS ASSEMBLY- MAIN - 74HP
FIGURE 8-49. VALVE INSTALLATION - PRIORITY - 74HP (PVC 1911)
FIGURE 8-50. VALVE INSTALLATION - PRIORITY - 74HP (PVC 2005)
FIGURE 8-51. VALVE ASSEMBLY - PRIORITY FUNCTION MANIFOLD (PVC 1911)
FIGURE 8-52. VALVE ASSEMBLY - PRIORITY FUNCTION MANIFOLD (PVC 2005)
FIGURE 8-53. VALVE INSTALLATION - PARKING BRAKE - 110HP
FIGURE 8-54. VALVES INSTALLATION - PARKING BRAKE - 110HP
FIGURE 8-55. VALVE INSTALLATION - SAHR BRAKE (PVC 2005)
FIGURE 8-56. VALVE ASSEMBLY - SAHR BRAKE (PVC 2005)
FIGURE 8-57. VALVES INSTALLATION - STEER SELECT
FIGURE 8-58. VALVE MOUNTING INSTALLATION - STEER SELECT
FIGURE 8-59. VALVE INSTALLATION - STEER SELECT
FIGURE 8-60. 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 - EXTEND/RETRACT (74HP)
FIGURE 9-9. CYLINDER & VALVE - 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 (PVC 1911)
FIGURE 9-14. CYLINDER INSTALLATION - FRAME LEVEL (PVC 2005)
FIGURE 9-15. CYLINDER - FRAME LEVEL
FIGURE 9-16. CYLINDER ASSEMBLY - GRAPPLE BUCKET
FIGURE 9-17. CYLINDER ASSEMBLY - LIFT
FIGURE 9-18. CYLINDER SUB-ASSEMBLY - QUICK COUPLER
FIGURE 9-19. CYLINDER - QUICK COUPLER
FIGURE 9-20. CYLINDER & VALVE INSTALLATION - STABILIZER (REAR AXLE)
FIGURE 9-21. CYLINDER - STABILIZER (REAR AXLE)
FIGURE 9-22. CYLINDER & FITTINGS - 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. VALVE - AIR SHUT OFF

FIGURE 9-28. VALVE & FITTINGS - CARRIAGE (DUAL FORK)

FIGURE 9-29. VALVE - CARRIAGE DUAL FORK FLOW DIVIDER

FIGURE 9-30. VALVE ASSEMBLY - FRAME LEVEL

FIGURE 9-31. VALVE ASSEMBLY - MAIN CONTROL (74HP)

FIGURE 9-32. VALVE ASSEMBLY - MAIN CONTROL (110HP)

FIGURE 9-33. VALVE - PARKING BRAKE

FIGURE 9-34. VALVE ASSEMBLY - PRIORITY (PVC 1911)

FIGURE 9-35. VALVE ASSEMBLY - PRIORITY

FIGURE 9-36. VALVE - QUICK COUPLER

FIGURE 9-37. VALVE ASSEMBLY - SAHR BRAKE

FIGURE 9-38. VALVE ASSEMBLY - STABILIZER (REAR AXLE)

FIGURE 9-39. VALVE ASSEMBLY - STEERING ORBITAL

FIGURE 9-40. 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 (STANDARD)

FIGURE 10-17. BOOM ANGLE SENSOR INSTALLATION (LSI)

FIGURE 10-18. BOOM ELECTRIC HARNESS INSTALLATION

FIGURE 10-19. BOOM ELECTRIC HARNESS

FIGURE 10-20. BOOM AUXILIARY ELECTRIC INSTALLATION

FIGURE 10-21. BOOM AUXILIARY ELECTRIC HARNESS INSTALLATION

FIGURE 10-22. CAB DASH ELECTRICAL (ULS) (PVC 1911)

FIGURE 10-23. CAB DASH ELECTRICAL (ULS) (PVC 2005)

FIGURE 10-24. CAB DASH ELECTRICAL (LS) (PVC 1911)

FIGURE 10-25. CAB DASH ELECTRICAL (LS) (PVC 2005)

FIGURE 10-26. CAB ELECTRICAL INSTALLATION (PVC 1911)

FIGURE 10-27. CAB ELECTRICAL INSTALLATION (PVC 2005)

FIGURE 10-28. CAB ELECTRICAL BOARD ASSEMBLY

FIGURE 10-29. CAB ELECTRICAL COMMUNICATION CABLE

FIGURE 10-32. CAB ELECTRICAL INSTALLATION - ENCLOSED

FIGURE 10-33. CAB ELECTRICAL INSTALLATION - OPEN

FIGURE 10-34. CAB OPTION 1 ELECTRICAL BOARD

FIGURE 10-35. CAB OPTION 2 ELECTRICAL BOARD

FIGURE 10-36. CAB OPTION HARNESS

FIGURE 10-37. CAB OPTION 1 HARNESS

FIGURE 10-38. CAB OPTION 2 HARNESS

FIGURE 10-39. CAB MULTIFUNCTION DISPLAY INSTALLATION

FIGURE 10-40. CLEARSKY TELEMATICS CANBUS INSTALLATION (CLEARSKY 2) (ANSI)

FIGURE 10-41. CLEARSKY TELEMATICS CANBUS INSTALLATION (CLEARSKY 2) (CE)

FIGURE 10-42. CLEARSKY TELEMATICS CANBUS HARNESS (CLEARSKY 2)

FIGURE 10-43. CLEARSKY TELEMATICS ADAPTER HARNESS

FIGURE 10-44. CLEARSKY TELEMATICS 3-WIRE INSTALLATION (ANSI)

FIGURE 10-45. CLEARSKY TELEMATICS 3-WIRE INSTALLATION (CE)

FIGURE 10-46. CLEARSKY TELEMATICS 3-WIRE HARNESS

FIGURE 10-47. CLEARSKY TELEMATICS READY INSTALLATION

FIGURE 10-48. CLEARSKY TELEMATICS READY HARNESS

FIGURE 10-49. DEF PURGE LIGHT HARNESS (110HP) (ULS)

FIGURE 10-50. ENGINE - WIRING INSTALLATION (74HP) (ULS)61 topics

FIGURE 10-51. ENGINE - WIRING INSTALLATION (110HP) (ULS)
FIGURE 10-52. ENGINE - WIRING INSTALLATION (110HP) (LS)
FIGURE 10-53. ENGINE HARNESS (74HP) (ULS)
FIGURE 10-54. ENGINE HARNESS (110HP) (ULS)
FIGURE 10-55. ENGINE HARNESS (110HP) (LS)
FIGURE 10-56. ENGINE BAY - ELECTRICAL INSTALLATION (74HP) (ULS)
FIGURE 10-57. ENGINE BAY - ELECTRICAL INSTALLATION (110HP) (ULS)
FIGURE 10-58. ENGINE BAY - ELECTRICAL INSTALLATION (110HP) (LS)
FIGURE 10-59. ENGINE BAY - WIRING INSTALLATION (74HP) (ULS)
FIGURE 10-60. ENGINE BAY - WIRING INSTALLATION (110HP) (ULS)
FIGURE 10-61. ENGINE BAY - WIRING INSTALLATION (110HP) (LS)
FIGURE 10-62. ENGINE/CHASSIS HARNESS (110HP) (ULS)
FIGURE 10-63. ENGINE - ECU INSTALLATION (ULS)
FIGURE 10-64. ENGINE - ECU INSTALLATION (LS)
FIGURE 10-65. ENGINE TBAP HARNESS
FIGURE 10-66. FRAME - ELECTRICAL INSTALLATION
FIGURE 10-67. FRAME - POWER DISTRIBUTION BOX
FIGURE 10-68. FRAME - WIRING INSTALLATION (74HP) (ULS) (PVC 1911)
FIGURE 10-69. FRAME - WIRING INSTALLATION (74HP) (ULS) (PVC 2005)
FIGURE 10-70. FRAME - WIRING INSTALLATION (110HP) (ULS) (PVC 1911)
FIGURE 10-71. FRAME - WIRING INSTALLATION (110HP) (ULS) (PVC 2005)
FIGURE 10-72. FRAME - WIRING INSTALLATION (110HP) (LS) (PVC 1911)
FIGURE 10-73. FRAME - WIRING INSTALLATION (110HP) (LS) (PVC 2005)
FIGURE 10-74. FRAME HARNESS - FRONT (PVC 1911)
FIGURE 10-75. FRAME HARNESS – FRONT (PVC 2005)
FIGURE 10-80. HEATER HARNESS - CUMMINS BREATHER (74HP) (ULS)
FIGURE 10-81. HEATER HARNESS - CUMMINS BREATHER (110HP) (ULS) (PVC 1911)
FIGURE 10-82. HEATER HARNESS - CUMMINS BREATHER (110HP) (ULS) (PVC 2005)
FIGURE 10-83. HEATER HARNESS - FUEL FILTER
FIGURE 10-84. HEATER HARNESS - HYDRAULIC TANK
FIGURE 10-85. HVAC ACTUATOR HARNESS
FIGURE 10-86. LIGHTS - BEACON INSTALLATION (LED)
FIGURE 10-87. LIGHTS - BOOM WORK LIGHTS SWITCH/HARNESS INSTALLATION (LED)
FIGURE 10-88. LIGHTS - BOOM WORK LIGHTS HARNESS INSTALLATION (LED)
FIGURE 10-89. LIGHTS - BOOM WORK LIGHTS HARNESS
FIGURE 10-90. LIGHTS - CAB WORK LIGHTS INSTALLATION (NO A/C) (LED)
FIGURE 10-91. LIGHTS - CAB WORK LIGHTS INSTALLATION (A/C) (LED)
FIGURE 10-92. LIGHTS - ROADLIGHTS INSTALLATION
FIGURE 10-93. LIGHTS - ROADLIGHTS HEADLIGHT HARNESS
FIGURE 10-94. LIGHTS - ROADLIGHTS TAILLIGHTS HARNESS
FIGURE 10-95. LIGHTS - SWITCH INSTALLATION
FIGURE 10-96. LSI HARNESS - BOOM RETRACT
FIGURE 10-97. PLATFORM HARNESS
FIGURE 10-98. REVERSE CAMERA INSTALLATION
FIGURE 10-99. REVERSE CAMERA INSTALLATION - NO HED
FIGURE 10-100. REVERSE CAMERA OPTION HARNESS - NO HED
FIGURE 10-101. REVERSE SENSOR INSTALLATION
FIGURE 10-102. REVERSE SENSOR HARNESS
FIGURE 10-103. RIDE CONTROL VALVE HARNESS INSTALLATION
FIGURE 10-104. RIDE CONTROL VALVE HARNESS
FIGURE 10-105. ROOF PIGTAIL HARNESS
FIGURE 10-106. 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 (LATIN AMERICAN ENGLISH/SPANISH) (74HP)
FIGURE 11-8. DECAL INSTALLATION (LATIN AMERICAN ENGLISH/SPANISH) (110HP)

FIGURE 11-9. BRAND AND MODEL DECAL INSTALLATION

FIGURE 11-10. CAPACITY CHART BOOKLET (ANSI)

FIGURE 11-11. CAPACITY CHART BOOKLET (ISO)

FIGURE 11-12. CAPACITY CHART HOLDER INSTALLATION

FIGURE 11-13. CLEARSKY DECAL INSTALLATION

FIGURE 11-14. REVERSE SENSING SYSTEM DECAL (ANSI)

FIGURE 11-15. REVERSE SENSING SYSTEM DECAL (CSA)

FIGURE 11-16. REVERSE SENSOR SYSTEM DECAL (ENGLISH/SPANISH)

FIGURE 11-17. REVERSE SENSING SYSTEM DECAL (ISO)

SECTION 12 - RECOMMENDED SPARE PARTS

FIGURE 12-1. RECOMMENDED SERVICE PARTS STOCK

SECTION 13 - SPECIAL OPTIONS

FIGURE 13-1. SPECIAL OPTIONS

PART NUMBER INDEX

Inside this manual

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Sample pages from the JLG 742 Telehandler Parts Manual: Parts illustration, Parts illustration

Parts illustration, page 814: SECTION 8 - HYDRAULIC CIRCUITS
Parts illustration, page 1,054: SECTION 10 - ELECTRICAL

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