Document Outline

• 31200206_C_8, 9, 12, 13, 17M PS, 40.8, 40.9_JLG_Service
  • 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