This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or
damage to the equipment. A maintenance program must
be established by a qualified person and must be followed
to ensure that the machine is safe to operate.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST
AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION.
The specific precautions to be observed during machine
maintenance are inserted at the appropriate point in the
manual. These precautions are, for the most part, those
that apply when servicing hydraulic and larger machine
component parts.
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of component weight and never attempt to
move heavy parts without the aid of a mechanical device.
Do not allow heavy objects to rest in an unstable position.
When raising a portion of the equipment, ensure that adequate support is provided.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/
OPERATOR.
C. MAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
• REMOVE ALL RINGS, WATCHES, AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
• OBSERVE AND OBEY ALL DANGER, WARNING, CAUTION AND OTHER INSTRUCTIONS ON MACHINE
AND IN SERVICE MANUAL.
• KEEP STANDING SURFACES AND HAND HOLDS
FREE OF OIL, GREASE, WATER, ETC.
• NEVER WORK UNDER AN ELEVATED PLATFORM
UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED
FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.
•BATTERY SHOULD ALWAYS BE DISCONNECTED
DURING REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
B. HYDRAULIC SYSTEM SAFETY
1. It should be particularly noted that the machines
hydraulic systems operate at extremely high and
potentially dangerous pressures. Every effort should
be made to relieve any system pressure prior to disconnecting or removing any portion of the system.
2. Relieve system pressure by activating the lift DOWN
control with the platform completely lowered to
direct any line pressure back into the return line to
the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid
loss.
NOTE: The batteries on 9MP machines require approxi-
mately five (5) hours to fully charge when drained to
LOW BATTERY VOLTAGE on the Charger’s - Battery
Discharge Indicator.
1.3PERFORMANCE DATA
Platform Capacity
500 lb. (227kg) - Maximum Capacity - (Combined
Platform + Tray Load)
250 lb. (113kg) - Maximum Material Tray Capacity
NOTE: Operator + Material Tray load combined, must not
exceed maximum platform capacity.
Platform and Material Tray Size
Platform - 28.5 in. W x 23 in. L (72cm) x (59cm)
Tray - 25.5 in. W x 23 in. L (65cm) x (59cm)
Machine Height (platform stowed)
77 in. (196cm) height
Base Footprint
34 in.-W x 50 in.-L (86cm) x (127cm)
1.4TORQUE REQUIREMENTS
When maintenance becomes necessary or a fastener has
loosened, refer to the applicable Torque Chart later in this
section of the manual, to determine proper torque values.
1.5LUBRICATION
Hydraulic Oil
Hydraulic oils must have anti-wear qualities at least to API
Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries,
recommends Mobilfluid 424 hydraulic oil, which has an
SAE viscosity of 10W-30 and a viscosity index of 152.
For cold weather applications, i.e. when temperatures
remain consistently below +20°F (–7°C) JLG recom-
mends using Mobil DTE 13 hydraulic oil.
Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is
desired, contact JLG Industries for proper recommendations.
Table 1-2. Hydraulic Oil Operating Range
HYDRAULIC SYSTEM OPERATING
TEMPERATURE RANGE
0 ° F t o +2 3 ° F
(-18° C to -5° C)
SAE VISCOSITY
GRADE
10W
1-2– JLG Lift –3121163
Table 1-2. Hydraulic Oil Operating Range
SECTION 1 - MACHINE SPECIFICATIONS
HYDRAULIC SYSTEM OPERATING
TEMPERATURE RANGE
0° F to +210° F
(-18° C t o + 9 9° C)
50° F to 2 10 ° F
(+10° C to + 21 0 ° C)
SAE VISCOSITY
GRADE
10W-20, 10W-30
20W-20
Lubrication Specifications
Table 1-3. Lubrication Specifications
KEYSPECIFICATIONS
MPG -Multipurpose Grease having a minimum dripping point
of 350° F. Excellent w ater resistance and adhesiv e qualities, and being of extreme pressure type. (Timken OK
40 pounds minimum.)
EPGL -Extreme Pressure Gear Lube (oil) meeting API service
classification GL-5 or MIL-Spec MIL-L-2105.
HO-Hydraulic Oil. ISO-Vg grade 32, 46.
1.6HYDRAULIC PRESSURE ADJUSTMENT
Adjust system pressure so that platform will raise with
maximum rated capacity in platform.
The following pressure is a factory recommended (initial)
pressure settings;
2
1
1. Remove Adjust Screw Cap 2. Pressure Adjustment Screw
Note: Ground Control S tation cover has been removed.
Figure 1-1. Hydraulic Pressure Adjustment -
Cap and Screw
MODELPRESSURE SETTING
9MP1300 PSI
Turning adjustment screw clockwise increases system
pressure, turning screw counterclockwise decreases
system pressure.
Perform pressure adjustment with oil at normal operating
temperature. If pressure is set when oil is cold, platform
may not raise rated load after oil has warmed.
OPEN HYDRAULIC SYSTEM LINES ONLY WITH THE MAST FULLY
LOWERED TO RELIEVE PRESSURE IN THE SYSTEM. CAREFULLY
LOOSEN REQUIRED FITTINGS, WEAR SAFETY PROTECTION
EQUIPMENT WHEN WORKING WITH HYDRAULIC SYSTEMS.
Connect pressure gauge as shown in Figure 1-2., Typical
Hydraulic Pressure Gauge Installation. Select a T-Fitting to
exactly match the thread size of the pump pressure line
and gauge fitting as required.
1
2
3
4
1. Pressure Gauge Assembly4. Retu rn Lin e
2. Extend Line5. Pressure Adjust Screw
3. Tee Fitting
Figure 1-2. Typical Hydraulic Pressure Gauge
Installation.
5
3121163– JLG Lift –1-3
SECTION 1 - MACHINE SPECIFICATIONS
1.7CYLINDER SPECIFICATIONS
NOTE: All dimensions are given in inches (in), with the met-
ric equivalent, centimeters (cm), given in parentheses.
Table 1-4. Cylinder Specifications
DESCRIPTION
9MP
Lift Cylinder
BORE
in./(cm)
1.63
(4.10)
STROKE
in./(cm)
47.50
(120.65)
ROD DIA.
in./(cm)
1.375
(3.49)
1.8SERIAL NUMBER LOCATIONS
For machine identification, a serial number plate is affixed
to the machine. The plate is located on the back of the
mast, just above the mast support column.
1-4– JLG Lift –3121163
SECTION 1 - MACHINE SPECIFICATIONS
3
2
1
Lubrication Points
Table 1-5.Lubrication Intervals for Various Components
ITEMCOMPONENT
1Swivel Raceways
2
Hydraulic Oil
3
Mast Chains
Key to Lubricants: MPG - Multipurpose Grease
Notes: 1. Be cer tain to lubricate like items on each side of the machine.
2. Recommended lubricating intervals are based on nor mal use. If machine is subjected to severe operating conditions,
such as a high number of cycles, location, corrosive/dir ty environment, etc., user must adjust lubricating requirements accordingly.
3. Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Failure t o d o s o wi l l
result in incorrect oil level reading on the hydraulic reservoir.
(3)
(2)
HO - Hydrauli c Oil - See Section 1. 5, "Lubrication" in S ervice Manual.
Note: These torque values do not apply to cadmium plated fasteners.
METRIC CLASS 8.8METRIC CLASS 10.
Figure 1-5. Torque Chart (Metric Class Fasteners)
1-8– JLG Lift –3121163
SECTION 2. GENERAL
SECTION 2 - GENERAL
2.1MACHINE PREPARATION, INSPECTION,
AND MAINTENANCE
General
This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and
maintenance have been completed before placing the
machine into service.
Preparation, Inspection, and Maintenance
It is important to establish and conform to a comprehensive inspection and preventive maintenance program.
The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries,
Inc. Consult your national, regional, or local regulations
for further requirements for aerial work platforms. The frequency of inspections and maintenance must be
increased as environment, severity and frequency of
usage requires.
Pre-Start Inspection
It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine prior to use
daily or at each change of operator. Reference the Operator’s and Safety Manual for completion procedures for the
Pre-Start Inspection. The Operator and Safety Manual
must be read in its entirety and understood prior to performing the Pre-Start Inspection.
Pre-Delivery Inspection and Frequent
Inspection
The Pre-Delivery Inspection and Frequent Inspection shall
be performed by a qualified JLG equipment mechanic.
JLG Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or
experience, has successfully demonstrated the ability and
proficiency to service, repair, and maintain the subject
JLG product model.
The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-Delivery Inspection shall be performed
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in service for 3 months; out of service for a period of more than
3 months; or when purchased used. The frequency of this
inspection must be increased as environment, severity
and frequency of usage requires.
Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
Schedule for items requiring inspection during the performance of these inspections. Reference the appropriate
areas of this manual for servicing and maintenance procedures.
Annual Machine Inspection
JLG recommends that an Annual Machine Inspection be
performed by a Factory-Certified Service Technician on an
annual basis, no later than thirteen (13) months from the
date of the prior Annual Machine Inspection. JLG Industries, Inc. recognizes a Factory-Certified Service Technician as a person who has successfully completed the JLG
Service Training School for the subject JLG product
model. Reference the machine Service and Maintenance
Manual and appropriate JLG inspection form for performance of this inspection.
Reference the JLG Annual Machine Inspection Form and
the Inspection and Preventative Maintenance Schedule for
items requiring inspection during the performance of this
inspection. Reference the appropriate areas of this manual for servicing and maintenance procedures.
For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
information for each machine. When performing each
Annual Machine Inspection, notify JLG Industries, Inc. of
the current machine ownership.
Preventative Maintenance
In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment
mechanic. JLG Industries, Inc. recognizes a qualified JLG
equipment mechanic as a person who, by possession of a
recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the
ability and proficiency to service, repair, and maintain the
subject JLG product model.
Reference Table 2-2, 9MP - Preventive Maintenance &
Inspection Schedule., and the appropriate areas of this
manual for servicing and maintenance procedures. The
frequency of service and maintenance must be increased
as environment, severity and frequency of usage requires.
3121163– JLG Lift –2-1
SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
TypeFrequency
Pre-Start
Inspection
Pre-Delivery
Inspection
Frequent
Inspection
Annual
Machine
Inspection
Preventative
Maintenance
Prior to use each day; or
At each Operator change .
Prior to each sale, lease, or
rental delivery.
In service for 3 months; o r Out of service for
a period of more than 3 months; or Purchased used.
Annually, no later than 13 months from the
date of the prior inspe ction.
At intervals as specifi ed in the Service and
Maintenance Manual.
Primary
Responsibility
User or OperatorUs er or OperatorOperator and Safety M anual
Owner, Dealer, or User Qualified JLG
Owner, Dealer, or UserQualified JLG
Owner, Dealer, or UserQualified JLG
Owner, Dealer, or UserQualified JLG
Service
Qualification
Mechanic
Mechanic
Mechanic
Mechanic
Reference
Service and Maintenance Man ual
and applicable JLG in spection
form.
Service and Maintenance Man ual
and applicable JLG in spection
form.
Service and Maintenance Man ual
and applicable JLG in spection
form.
Service and Mai ntenance Manual
2.2PREVENTIVE MAINTENANCE AND
INSPECTION SCHEDULE
(See Table 2-2.)
The preventive maintenance and inspection checks are
listed and defined in the following table. This table is
divided into two basic parts, the “AREA” to be inspected
and the “INTERVAL” at which the inspection is to take
place. Under the “AREA” portion of the table, the various
systems along with the components that make up that
system are listed. The “INTERVAL” portion of the table is
divided into five columns representing the various inspection time periods. The numbers listed within the interval
column represent the applicable inspection code for
which that component is to be checked.
The checks and services listed in this schedule are not
intended to replace any local or regional regulations that
may pertain to this type of equipment nor should the lists
be considered as all inclusive. Variances in interval times
may occur due to climate and/or conditions and depending on the location and use of the machine.
All Decals/Placards Installed, Secure, Legible212121
"Walk-Around" Inspection Performe d22
Annual Machine Inspecti on Due21
No Unauthorized Modificatio ns or Additions2121
All Relevant Safety Publ ications Incorporated2121, 22
General Structural C ondition and Welds2, 42, 4
All Fasteners, Pins , Shields, and Covers1, 2
Grease and Lubricate to Specificat ions2222
Function Test of All Systems2222
Paint and Appearance77
Stamp Inspection Da te on Frame22
Notify JLG of Machine Ownershi p22
* Drain and Refill w ith fresh hydraulic fluid every two years.
6 MONTH
PREVENTATIVE
MAINTENANCE
PRE-DELIVERY (2)
OR FREQUENT (3)
INSPECTION
ANNUAL (4)
(YEARLY)
INSPECTION
Footnotes:
(1) Prior to use each day; or at each Operator change
(2) Prior to each sale, lease, or delivery
(3) In service for 3 months; or Out of service for 3 months
or more; or Purchased used
(4) Annually, no later than 13 months from the date of the
prior inspection
Inspection and Maintenance Codes:
1. Check for proper and secure installation.
2. Visual inspection for damage, cracks, distortion, or
excessive wear.
3. Check for proper adjustment.
4. Check for cracked or broken welds.
5. Operates properly.
6. Returns to neutral or "off" position when released.
7. Clean and free of debris.
8. Interlocks function properly.
9. Check for signs of leakage.
10. Decals installed and legible.
11. Check for proper fluid level.
12. Check for chafing and proper routing.
13. Check for proper tolerances.
14. Properly lubricated.
15. Torqued to proper specification.
16. No gouges, excessive wear, or cords showing.
17. Properly inflated and seated around rim.
18. Proper and authorized components.
19. Fully charged.
20. No loose connections, corrosion, or abrasions.
21. Verify.
22. Perform.
23. Sealed properly.
24. Overrides Platform controls.
25. Inspected per Service and Maintenance Manual.
2-4– JLG Lift –3121163
SECTION 2 - GENERAL
2.3SERVICING AND MAINTENANCE
GUIDELINES
General
The following information is provided to assist you in the
use and application of servicing and maintenance procedures contained in this chapter.
Safety and Workmanship
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of component weight. Never attempt to
move heavy parts without the aid of a mechanical device.
Do not allow heavy objects to rest in an unstable position.
When raising a portion of the equipment, ensure that adequate support is provided.
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT
BY BLOCKING OR OVERHEAD SLING.
Cleanliness
The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials
out of the vital components. Precautions have been taken
to safeguard against this. Shields, covers, seals, and filters are provided to keep the wheel bearings, mast sections and oil supply clean; however, these items must be
maintained on a scheduled basis in order to function
properly.
At any time when oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected,
cap or cover all openings to prevent entry of foreign matter.
Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are
unobstructed. Cover all parts to keep them clean. Be sure
all parts are clean before they are installed. New parts
should remain in their containers until they are ready to be
used.
Components Removal and Installation
Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,cables, etc.) should be parallel to each other and as near
perpendicular as possible to top of part being lifted.
Should it be necessary to remove a component on an
angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting
structure and the component becomes less than 90
degrees.
If a part resists removal, check to see whether all nuts,
bolts, cables, brackets, wiring, etc., have been removed
and that no adjacent parts are interfering.
Component Disassembly and Reassembly
When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially
disassemble or assemble one part, then start on another.
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper approval.
Pressure-Fit Parts
When assembling pressure-fit parts, use an “anti-seize” or
molybdenum disulfide base compound to lubricate the
mating surface.
Bearings
When a bearing is removed, cover it to keep out dirt and
abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used
but do not spin the bearing.
Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.
If bearing is found to be serviceable, apply a light coat of
oil and wrap it in clean (waxed) paper. Do not unwrap
reusable or new bearings until they are ready to install.
Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore,
apply pressure to the outer race. If the bearing is to be
installed on a shaft, apply pressure to the inner race.
Gaskets
Check that holes in gaskets align with openings in the
mating parts. If it becomes necessary to hand-fabricate a
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as
blank gaskets can cause serious system damage.
Bolt Usage and Torque Application
Use bolts of proper length. A bolt which is too long will
bottom before the head is tight against its related part. If a
bolt is too short, there will not be enough thread area to
engage and hold the part properly. When replacing bolts,
use only those having the same specifications of the original, or one which is equivalent.
Unless specific torque requirements are given within the
text, standard torque values should be used on heattreated bolts, studs, and steel nuts, in accordance with
recommended shop practices. (See Torque Charts in Sec-
tion-1.)
3121163– JLG Lift –2-5
Loading...
+ 49 hidden pages
You need points to download manuals.
1 point = 1 manual.
You can buy points or you can get point for every manual you upload.