Document Outline

• Effectivity
• Table of Contents
• Section 1 Safety Practices
  • 1.1 Introduction
  • 1.2 Disclaimer
  • 1.3 Operation & Safety Manual
  • 1.4 Do Not Operate Tags
  • 1.5 Safety Information
    • 1.5.1 Safety Alert System and Signal Words
  • 1.6 Safety Instructions
    • 1.6.1 Personal Hazards
    • 1.6.2 Equipment Hazards
    • 1.6.3 General Hazards
    • 1.6.4 Operational Hazards
  • 1.7 Safety Decals
• Section 2 General Information and Specifications
  • 2.1 Replacement Parts and Warranty Information
  • 2.2 Torque Charts
    • 2.2.1 SAE Fastener Torque Chart
    • 2.2.2 Metric Fastener Torque Chart
    • 2.2.3 Hydraulic Hose Torque Chart
  • 2.3 Specifications
    • 2.3.1 Travel Speeds
    • 2.3.2 Hydraulic Cylinder Performance Specifications
    • 2.3.3 Platform Hydraulic Performance Specifications
    • 2.3.4 Electrical System
    • 2.3.5 Engine Performance Specifications
    • 2.3.6 Tires
  • 2.4 Fluids, Lubricants and Capacities
  • 2.5 Maintenance Schedules
    • 2.5.1 8 & 1st 50 Hour Maintenance Schedule
    • 2.5.2 50, 250 & 500 Hour Maintenance Schedule
    • 2.5.3 1000 & 1500 Hour Maintenance Schedule
  • 2.6 Lubrication Schedules
    • 2.6.1 8 Hour Lubrication Schedule
    • 2.6.2 50 Hour Lubrication Schedule
• Section 3 Boom
  • 3.1 Boom System Component Terminology - Two and Three Section Boom
  • 3.2 Boom System - Two and Three Section Boom
    • 3.2.1 Boom System Description
  • 3.3 Boom Assembly Maintenance - Two and Three Section Boom
    • 3.3.1 Boom Removal
    • 3.3.2 Second Section Boom Removal (12 & 13M)
    • 3.3.3 Third Section Boom Removal (12 & 13M) Second Section Boom Removal (8 & 9M)
    • 3.3.4 Third Section Boom Installation (12 & 13M) Second Section Boom Installation (8 & 9M)
    • 3.3.5 Second Section Boom Installation (12 & 13M)
    • 3.3.6 Boom Installation
  • 3.4 Boom System Component Terminology - Four Section Boom
  • 3.5 Boom System - Four Section Boom
    • 3.5.1 Boom System Operation
  • 3.6 Boom Assembly Maintenance - Four Section Boom
    • 3.6.1 Boom Removal
    • 3.6.2 Second, Third and Fourth Boom Section Removal
    • 3.6.3 Third and Fourth Boom Section Removal
    • 3.6.4 Fourth Boom Section Removal
    • 3.6.5 Hose Carrier Removal
    • 3.6.6 Hose Carrier Installation
    • 3.6.7 Fourth Boom Section Installation
    • 3.6.8 Third and Fourth Boom Section Installation
    • 3.6.9 Second, Third and Fourth Boom Section Installation
    • 3.6.10 Boom Installation
  • 3.7 Boom Extend and Retract Chains Four Section Boom
    • 3.7.1 Boom Chain Inspection
    • 3.7.2 Inspection Guidelines
    • 3.7.3 Expose Chains for Inspection
    • 3.7.4 Chain Lubrication
  • 3.8 Boom Section Separation Adjustment - Four Section Boom
  • 3.9 Hose Carrier Assembly - Four Section Boom
    • 3.9.1 Hose Carrier Assembly Removal
    • 3.9.2 Hose Carrier Assembly Replacement
  • 3.10 Boom Wear Pads
    • 3.10.1 Wear Pad Inspection
    • 3.10.2 Wear Pad Installation and Lubrication
  • 3.11 Quick Switch Assembly
    • 3.11.1 Connecting with a Mechanical Quick Switch Device
    • 3.11.2 Connecting with a Hydraulic Quick Switch Device
    • 3.11.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment
    • 3.11.4 Quick Switch Removal
    • 3.11.5 Quick Switch Installation
  • 3.12 Forks
  • 3.13 Troubleshooting
• Section 4 Cab and Covers
  • 4.1 Operator Cab and Covers Component Terminology
  • 4.2 Operator Cab
    • 4.2.1 Serial Number Decal
  • 4.3 Cab Components
    • 4.3.1 Steering Column and Orbitrol Valve
    • 4.3.2 Service Brake Pedal and Valve
    • 4.3.3 Throttle Pedal Replacement
    • 4.3.4 Joystick Assembly Replacement
    • 4.3.5 Parking Brake (8, 9, 12 & 13M)
    • 4.3.6 Parking Brake (17M)
    • 4.3.7 Windshield Wiper Assembly
    • 4.3.8 Windshield Washer Assembly
    • 4.3.9 Heater/Defroster System
    • 4.3.10 Cab Heater/Air Conditioning Controls
  • 4.4 Cab Removal
  • 4.5 Cab Installation
• Section 5 Axles, Drive Shafts, Wheels and Tires
  • 5.1 Axle, Drive Shaft and Wheel Component Terminology
  • 5.2 General Information
  • 5.3 Axle Assemblies
    • 5.3.1 Axle Serial Number Plate
    • 5.3.2 Axle Specifications
    • 5.3.3 Axle Internal Service
    • 5.3.4 Axle Maintenance
    • 5.3.5 Axle Removal
    • 5.3.6 Axle Installation
    • 5.3.7 Axle Assembly and Drive Shaft Troubleshooting
  • 5.4 Drive Shafts
    • 5.4.1 Drive Shaft Inspection and Service
    • 5.4.2 Drive Shaft Maintenance
    • 5.4.3 Drive Shaft Removal
    • 5.4.4 Drive Shaft Cleaning and Drying
    • 5.4.5 Drive Shaft Installation
  • 5.5 Wheels and Tires
    • 5.5.1 Removing Wheel and Tire Assembly from Machine
    • 5.5.2 Installing Wheel and Tire Assembly onto Machine
  • 5.6 Brakes
    • 5.6.1 Brake Disk Inspection.
  • 5.7 Towing A Disabled Machine
    • 5.7.1 Towing (8, 9, 12 & 13M)
    • 5.7.2 Manually Releasing the Park Brake (17M)
    • 5.7.3 Manually Resetting the Park Brake (17M)
• Section 6 Transmission:
  • 6.1 Transmission Assembly Component Terminology
  • 6.2 Transmission Description
  • 6.3 Transmission Serial Number
  • 6.4 Transmission Specifications
    • 6.4.1 Transmission Maintenance
    • 6.4.2 Transmission Maintenance Schedule
  • 6.5 Transmission Replacement
    • 6.5.1 Transmission Removal
    • 6.5.2 Transmission Inspection and Internal Repair
    • 6.5.3 Transmission Installation
    • 6.5.4 After Transmission Service or Replacement
  • 6.6 Troubleshooting
• Section 7 Engine: Perkins 1104-42 & 1104-42T
  • 7.1 Introduction
    • 7.1.1 Disclaimer and Scope
    • 7.1.2 Component Terminology
  • 7.2 Engine Serial Number
  • 7.3 Specifications and Maintenance Information
  • 7.4 Engine Cooling System
    • 7.4.1 Radiator Pressure Cap
    • 7.4.2 Thermostat Replacement
    • 7.4.3 Radiator/Oil Cooler and Coolant Heater Replacement
  • 7.5 Engine Electrical System
  • 7.6 Fuel System
    • 7.6.1 Diesel Fuel
    • 7.6.2 Fuel Tank
    • 7.6.3 After Fuel System Service
  • 7.7 Engine Exhaust System
    • 7.7.1 Exhaust System Removal
    • 7.7.2 Exhaust System Installation
  • 7.8 Air Cleaner Assembly
    • 7.8.1 Air Cleaner Assembly Removal
    • 7.8.2 Air Cleaner Assembly Installation
  • 7.9 Engine Replacement
    • 7.9.1 Engine Removal
    • 7.9.2 Engine Disassembly, Inspection and Service
    • 7.9.3 Engine Installation
  • 7.10 Engine Drive Plate
    • 7.10.1 Drive Plate Removal
    • 7.10.2 Drive Plate Installation
  • 7.11 Troubleshooting
• Section 8 Hydraulic System
  • 8.1 Hydraulic Component Terminology
  • 8.2 Safety Information
  • 8.3 Hydraulic Pressure Diagnosis
  • 8.4 Hydraulic Circuits
    • 8.4.1 Hydraulic Pressures
  • 8.5 Hydraulic Schematics
    • 8.5.1 8M, 9M, 12M & 13M (w/o trailer brakes)
    • 8.5.2 8M, 9M, 12M & 13M (w/ trailer brakes)
    • 8.5.3 8M, 9M, 12M & 13M - Frame Level (if equipped)
    • 8.5.4 17M
    • 8.5.5 13M (if equipped for platform)
    • 8.5.6 17M (if equipped for platform)
  • 8.6 Hydraulic Reservoir
    • 8.6.1 Hydraulic Oil Reservoir Draining
    • 8.6.2 Hydraulic Oil Reservoir Filling
    • 8.6.3 Hydraulic Oil Reservoir Removal/ Installation
  • 8.7 Hydraulic System Pump
    • 8.7.1 Pump Description
    • 8.7.2 Pump Failure Analysis
    • 8.7.3 Pump Replacement
  • 8.8 Auxiliary Pump (Platform Equipped Models Only)
    • 8.8.1 Auxiliary Pump Description
    • 8.8.2 Auxiliary Pump Replacement
  • 8.9 Valves and Manifolds
    • 8.9.1 Main Control Valve
    • 8.9.2 Service Brake Valve
    • 8.9.3 Brake Test
    • 8.9.4 Steering Orbitrol Valve
    • 8.9.5 Steer Select Valve
    • 8.9.6 Leveling Valve
  • 8.10 Hydraulic Cylinders
    • 8.10.1 General Cylinder Removal Instructions
    • 8.10.2 General Cylinder Disassembly
    • 8.10.3 Cylinder Cleaning Instructions
    • 8.10.4 Cylinder Inspection
    • 8.10.5 General Cylinder Assembly
    • 8.10.6 General Cylinder Installation
    • 8.10.7 Cylinder Pressure Checking
    • 8.10.8 Steering Cylinders
    • 8.10.9 Hydraulic Cylinder Torque Specifications
• Section 9 Electrical System
  • 9.1 Electrical Component Terminology
  • 9.2 Specifications
  • 9.3 Platform Interlock Checks
  • 9.4 Software Level 2 Accessibility
    • 9.4.1 Operator Tools
    • 9.4.2 Personalities
    • 9.4.3 Calibrations
  • 9.5 Operator Tools
    • 9.5.1 Resetting the Anti Theft Code
    • 9.5.2 Hardware Exchange
    • 9.5.3 Confirm Machine Service
    • 9.5.4 Review Service History
    • 9.5.5 Set Service Interval
    • 9.5.6 Cabin Joystick Telescope: X-Axis/ Roller
  • 9.6 Fuses and Relays
    • 9.6.1 Cab
    • 9.6.2 Engine Compartment
    • 9.6.3 Power Distribution Board
  • 9.7 Electrical System Schematics
    • 9.7.1 Cab Harness Electrical Schematic
    • 9.7.2 Cabin Roof Harness Electrical Schematic
    • 9.7.3 Power Distribution Electrical Schematic
    • 9.7.4 Chassis and Boom Harness Electrical Schematic
    • 9.7.5 Engine Harness Electrical Schematic
    • 9.7.6 Platform Electrical Schematic
    • 9.7.7 Platform Cab Harness Schematic (if equipped)
  • 9.8 Circuit Breakdowns
    • 9.8.1 Constant Power Circuit from Battery
    • 9.8.2 Start Circuit
  • 9.9 Engine Start Circuit
    • 9.9.1 Starter
  • 9.10 Charging Circuit
    • 9.10.1 Alternator
  • 9.11 Electrical System Components
    • 9.11.1 Back-up Alarm
  • 9.12 Window Wiper/Washer
    • 9.12.1 Windshield Wiper Motor
    • 9.12.2 Rear Window Wiper Motor
    • 9.12.3 Windshield Washer Reservoir and Pump
  • 9.13 Cab Heater and Fan
    • 9.13.1 Cab Heater Controls
  • 9.14 Switches, Solenoids, Sensors and Senders
    • 9.14.1 Transmission Solenoid Valves
    • 9.14.2 Transmission Temperature Switch
    • 9.14.3 Transmission Mounted Speed Sensor (if equipped)
    • 9.14.4 Engine Coolant Temperature Sender/ Switch
    • 9.14.5 Ignition Key Switch
    • 9.14.6 Fuel Level Indicator and Fuel Level Sender
    • 9.14.7 Boom Angle Sensor
    • 9.14.8 Boom Retracted Sensor
  • 9.15 Load Stability Indicator (LSI) - 8, 9, 12 & 13M Before S/N 1160005993 excluding 1160005949 & 1160005950 17M Before S/N 1160005937 including 1160005952, 1160005960, 1160005963, 1160005966 & 1160005978
    • 9.15.1 Load Stability Indicator
    • 9.15.2 LSI Sensor
    • 9.15.3 LSI System Calibration
  • 9.16 Load Stability Indicator (LSI) - 8, 9, 12 & 13M S/N 1160005993 & After including 1160005949 & 1160005950 17M S/N 1160005937 & After excluding 1160005952, 1160005960, 1160005963, 1160005966 & 1160005978
    • 9.16.1 Load Stability Indicator
    • 9.16.2 LSI Sensor
    • 9.16.3 LSI System Calibration
    • 9.16.4 LSI - CAN CHECK PT
    • 9.16.5 500 Hour - LSI UGM Calibration Check
  • 9.17 Hand Held Analyzer
    • 9.17.1 Analyzer Usage
    • 9.17.2 Analyzer Software Version 3.5 (Sheet 1 of 2)
  • 9.18 Fault Codes
    • 9.18.1 Indicator Cross Reference Table
    • 9.18.2 Fault Code Table