JLG 9MP Service Manual

Service and Maintenance Manual
MODEL
9MP
3121163
May 14, 2003
ANSI
CALIFORNIAN PROPOSITION 65
BATTERY WARNING
terminals and related
accessories contain
lead and lead compounds,
chemical known to the
State of Califormia
to cause cancer and
reproductive harm.
WASH HANDS
AFTER HANDLING!
JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: (61) 2 65 811111 Fax: (61) 2 65 810122
JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil Phone: (55) 19 3295 0407 Fax: (55) 19 3295 1025
JLG Industries (Europe) Kilmartin Place, Tannochside Park Uddingston G71 5PH Scotland Phone: (44) 1 698 811005 Fax: (44) 1 698 811055
JLG Industries (UK) Unit 12, Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone: (44) 870 200 7700 Fax: (44) 870 200 7711
JLG Europe B.V. Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone: (31) 23 565 5665 Fax: (31) 23 557 2493
JLG Industries (Pty) Ltd. Unit 1, 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone: (27) 11 453 1334 Fax: (27) 11 453 1342
JLG Deutschland GmbH Max Planck Strasse 21 D-27721 Ritterhude/lhlpohl Bei Bremen Germany Phone: (49) 421 693 500 Fax: (49) 421 693 5035
JLG Industries (Norge AS) Sofeimyrveien 12 N-1412 Sofienyr Norway Phone: (47) 6682 2000 Fax: (47) 6682 2001
Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755Castellbisbal Spain Phone: (34) 93 77 24700 Fax: (34) 93 77 11762
JLG Industries (Italia) Via Po. 22 20010 Pregnana Milanese - MI Italy Phone: (39) 02 9359 5210 Fax: (39) 02 9359 5845
JLG Polska UI. Krolewska 00-060 Warsawa Poland Phone: (48) 91 4320 245 Fax: (48) 91 4358 200
JLG Industries (Sweden) Enkopingsvagen 150 Box 704 SE - 175 27 Jarfalla Sweden Phone: (46) 8 506 59500 Fax: (46) 8 506 59534
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

MAINTENANCE SAFETY PRECAUTIONS

A. GENERAL

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.
3121163 – JLG Lift – a
INTRODUCTION - REVISION LOG
October 10, 2002 – Original Issue of Manual
October 14, 2002 – Manual Revised
November 12, 2002 – Manual Revised
May 14, 2003 – Manual Revised

REVISION LOG

b JLG Lift – 3121163

TABLE OF CONTENTS

TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION - MAINTENANCE SAFETY PRECAUTIONS
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
B. HYDRAULIC SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
C. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
REVISION LOG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
SECTION 1 - MACHINE SPECIFICATIONS
1.1 CAPACITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.2 COMPONENT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Hydraulic Pump/Pump Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Batteries/Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.3 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Platform Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Platform and Material Tray Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Machine Height (platform stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Base Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.4 TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.6 HYDRAULIC PRESSURE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.7 CYLINDER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.8 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SECTION 2 - GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.3 SERVICING AND MAINTENANCE GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
3121163 JLG Lift i
TABLE OF CONTENTS
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Mast Chain Inspection Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.4 LUBRICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2.5 POSITIONING LIFT FOR ACCESS TO COMPONENTS LOCATED UNDER THE BASE FRAME . . 2-8
SECTION 3 - BASE COMPONENTS
3.1 BASE ASSEMBLY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 PLATFORM DESCENT - BEACON AND ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Descent Beacon - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Descent Alarm - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 WHEEL ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Front Caster Wheel - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Rear Locking Caster Wheel - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Rear Wheel (Straight Axle)- Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 FLOOR STOP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Floor Stop - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Floor Stop Interlock Switch Assembly - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Floor Stop Interlock Switch - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.5 BASE MAST SUPPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Mast Support to Base - Straight Axle Base - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Mast Support to Base - Rear Caster Wheel Base - Remove/Install . . . . . . . . . . . . . . . . . . . 3-5
SECTION 4 - CONTROL COMPONENTS
4.1 CONTROL COMPONENTS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 CONTROL COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Battery/Battery Charger Cover - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Ground Control Station Cover - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 BATTERY AND CHARGER - INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Battery - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Battery Charger - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.4 GROUND STATION - SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.5 PLATFORM STATION - SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.6 PUMP-MOTOR ASSEMBLY - SERVICE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Pump/Motor/Reservoir - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Tank Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Filter Screen Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Pump Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Pressure Adjust Valve Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Pressure Check Valve - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Lift Down Valve - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Motor - Remove/Install - Reference Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Motor Top Cover - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Motor Components - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Brush Carrier - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Brush Housing Final Assembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4.7 BATTERY CHARGER - SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
General Component Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
ii JLG Lift 3121163
Charger Cover - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
DC Circuit Breaker - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
AC Circuit Breaker/Voltage Select Switch - Remove/Install . . . . . . . . . . . . . . . . . . . . . . .4-12
Battery Discharge Indicator - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Printed Circuit Board - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Shunt Assembly and Capacitors - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
SCR Rectifier - Remove/Install (Either Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Transformer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
SECTION 5 - MAST COMPONENTS
5.1 MAST COMPONENTS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Mast Chain Adjustment (See Figure 5-2.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Sequencing Cable Adjustment (See Figure 5-2.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.3 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD . . . . . . . . . . . . . . . . . . . 5-4
Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Lift Cylinder Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4 MAST ASSEMBLY - REMOVE/INSTALL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Mast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5.5 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Mast Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Mast Assembly - 9MP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.6 9MP PLATFORM - REMOVE/INSTALL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
TABLE OF CONTENTS
SECTION 6 - TROUBLESHOOTING
6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 TROUBLESHOOTING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.3 ELECTRICAL AND HYDRAULIC CIRCUIT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.
1-1. Hydraulic Pressure Adjustment - Cap and Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-2. Typical Hydraulic Pressure Gauge Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-3. Torque Chart. (ANSI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-4. Torque Chart. (ANSI to METRIC Conversion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-5. Torque Chart (Metric Class Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
2-1. Accessing Machine Underside Components by Lifting with a Fork Truck. . . . . . . . . . . . . . . . . . .2-8
3-1. 9MP Base Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
4-1. Control Components Location - 9MP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-2. 9MP - SCR Dual Voltage - Battery Charger Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
5-1. Mast Components. (9MP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-2. Mast Chain and Sequence Cable Adjustment Components. (9MP) . . . . . . . . . . . . . . . . . . . . . . .5-3
5-3. Machine Positioned for Cylinder Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5-4. Lift Cylinder Component Cross-Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5-5. Mast Section - Assembly Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-6. Mast Chain Routing Diagram. - 9MP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
5-7. Mast Bottom End - Slide Pad Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-8. Mast Top End - Slide Pad Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
3121163 JLG Lift iii
TABLE OF CONTENTS
5-9. Platform Remove/Install - 9MP.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
6-1. Hydraulic Schematic. (9MP) (2792581-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-2. Electrical Diagram. (9MP) (4933269-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

LIST OF TABLES

TABLE NO. TITLE PAGE NO.
1-1 9MP - Machine Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-2. Hydraulic Oil Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-3. Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-4. Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-5 Lubrication Intervals for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 9MP - Preventive Maintenance & Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-3 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
5-1 9MP Mast Component Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
6-1. 9MP - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
iv JLG Lift 3121163
SECTION 1 - MACHINE SPECIFICATIONS

SECTION 1. MACHINE SPECIFICATIONS

7
6
5
4
3
2
1
Table 1-1. 9MP - Machine Operating Specifications
9MP
Maximum Occupants: 1
Maximum Work Load (Capacity):
(Platform + M aterial Tray)
500 lb. (227 kg)
(250 lb./250 lb.)
8
9
Machine Height (Platform Stowed) 77 in. (196cm)
Maximum Vertical Platform Height: 9 ft. (2.74 m)
M a x . P l a t f o r m S p e e d s (w / M a x . L oa d ) : P l a t f or m U p :
Pl a tf o r m D o wn :
Gross Machine Weight (Platform Empty):
16 sec.
8 - 13 sec.
740 lb. (336kg)
3121163 – JLG Lift – 1-1
SECTION 1 - MACHINE SPECIFICATIONS

1.1 CAPACITIES

System Voltage

12 Volt DC

Hydraulic System

5 qts. U.S. (4.7 L)

1.2 COMPONENT DATA

Hydraulic Pump/Pump Motor Assembly

Pump Motor - 12 Volt DC I-Term Motor
Pump Displacement – 2.1cc/rev.
Pump Output –1.85 GPM (min.) @ 1300 PSI / 185 Amps
(max.) current draw using 200 SSU (43cST) fluid
Reservoir Capacity – 1 Gallon (3.78 L)

Batteries/Battery Charger

Battery – 12 Volt
100 O. A. H.
Leak Proof/Valve Regulated
Type M2 Marine Combination
Battery Charger –
120 - 240 Volt A.C. Selectable -50/60 Hz input
C.E. Approved
12 volt, 20 amp output - with 2 amp finish
Microprocessor Controlled
SCR Circuit Monitor
AC and DC Reset Circuit Breakers
Automatic Charge Circuit
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.

1.3 PERFORMANCE 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)

1.4 TORQUE 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.

1.5 LUBRICATION

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
KEY SPECIFICATIONS
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.

1.6 HYDRAULIC 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
MODEL PRESSURE SETTING
9MP 1300 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 Assembly 4. Retu rn Lin e
2. Extend Line 5. Pressure Adjust Screw
3. Tee Fitting
Figure 1-2. Typical Hydraulic Pressure Gauge
Installation.
5
3121163 – JLG Lift – 1-3
SECTION 1 - MACHINE SPECIFICATIONS

1.7 CYLINDER 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)

1.8 SERIAL 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
ITEM COMPONENT
1 Swivel 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.
NO/TYPE
LUBE POINTS
2 - Front Casters 2 - Rear Casters -
(if equipped)
F il l To Li n e o n Reservoir 4 Qt. Reservoir
2 - Per Section
LUBE/METHOD
MONTHS6MONTHS1YEAR2YEARS
MPG - Pressure Gun
HO - Check Hyd. Oil L e ve l HO - Change Hyd. Oil
Chain Lube - Brush or Spray
INTERVAL HOURS
3
COMMENTS
Check Hydraulic Oil level daily. Change Hydr aulic Oil every 2
years.
Inspect, lubricate if dry or rusting.
3121163 – JLG Lift – 1-5
SECTION 1 - MACHINE SPECIFICATIONS
Figure 1-3. Torque Chart. (ANSI)
1-6 JLG Lift 3121163
SECTION 1 - MACHINE SPECIFICATIONS
S
G
5S
G
8
RADE
UNPLATED
CAP SCREWS
AE
RADE
AE
VALUES FOR ZINC PLATED BOLTS ONLY
Note: These torque values do not apply to cadium plated fasteners.
Figure 1-4. Torque Chart. (ANSI to METRIC Conversion)
3121163 – JLG Lift – 1-7
SECTION 1 - MACHINE SPECIFICATIONS
9
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY
CLASS 8.8 METRIC BOLTS &
CLASS 8 METRIC NUTS
TORQUE
LUB
LOCTITE
262
LOCTITE
242 OR
271
SIZE PITCH
TENSILE
STRESS
AREA
CLAMP
LOAD
DRY OR
LOCTITE
263
sq. mm KN N, m N, m N, m N, m KN N, m N, m N, m N, m
3 .5 5.03 2.19 1.3 1.0 1.2 1.4 3.13 1.9 1.4 1.5 2.1
3.5 .6 6.78 2.95 2.1 1.6 1.9 2.3 4.22 3.0 2.2 2.4 3.3
4 .7 8.78 3.82 3.1 2.3 2.8 3.4 5.47 4.4 3.3 3.5 4.8
5 .8 14.2 6.18 6.2 4.6 5.6 6.8 8.85 8.9 6.6 7.1 9.7
6 1 20.1 8.74 11 7.9 9.4 12 12.5 15 11 12 17
7 1 28.9 12.6 18 13 16 19 18 25 19 20 28
81.2536.615.92519232822.837272940
10 1.5 58.0 25.2 50 38 45 55 36.1 72 54 58 79
12 1.75 84.3 36.7 88 66 79 97 52.5 126 95 101 139
14 2 115 50.0 140 105 126 154 71.6 200 150 160 220
16 2 157 68.3 219 164 197 241 97.8 313 235 250 344
18 2.5 192 83.5 301 226 271 331 119.5 430 323 344 473
20 2.5 245 106.5 426 320 383 469 152.5 610 458 488 671
22 2.5 303 132.0 581 436 523 639 189.0 832 624 665 915
24 3 353 153.5 737 553 663 811 220.0 1060 792 845 1170
27 3 459 199.5 1080 810 970 1130 286.0 1540 1160 1240 1690
30 3.5 561 244.0 1460 1100 1320 1530 349.5 2100 1570 1680 2310
33 3.5 694 302.0 1990 1490 1790 2090 432.5 2600 2140 2280 2860
36 4 817 355.0 2560 1920 2300 2690 509.0 3660 2750 2930 4020
42 4.5 1120 487.0 4090 3070 3680 4290 698.0 5860 4400 4690 6440
CLASS 10.9 METRIC BOLTS &
CLASS 10 METRIC NUTS
CLAMP
LOAD
DRY OR
LOCTITE
263
TORQUE
LUB
LOCTITE
262
LOCTITE
242 OR
271
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

2.1 MACHINE 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 Users or Operators primary responsibility to per­form a Pre-Start Inspection of the machine prior to use daily or at each change of operator. Reference the Opera­tors 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
Type Frequency
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 Operator Us er or Operator Operator and Safety M anual
Owner, Dealer, or User Qualified JLG
Owner, Dealer, or User Qualified JLG
Owner, Dealer, or User Qualified JLG
Owner, Dealer, or User Qualified 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

2.2 PREVENTIVE 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.
2-2 JLG Lift 3121163
SECTION 2 - GENERAL
Table 2-2. 9MP - Preventive Maintenance & Inspection Schedule.
INTERVAL
AREA ON MACHINE
PRE-START (1)
INSPECTION
3 MONTH
PREVENTATIVE
MAINTENANCE
MAST ASSEMBLY 7
Mast Sections 2, 5 2, 5
Chain Systems 14 3, 14 14, 25
Sequence Cable Systems 31, 2, 3
Covers or Shields 1
Sheave Systems 1, 2 1, 2
Bearings 1, 2
Slide Pads 1, 2
PLATFORM ASSEMBLY 7
Platform and Material Tray 11
Guard Rails 1, 2, 4 1, 2, 4
Gate 1, 5 1, 5
Floor 1, 2 1, 2
Lanyard Anchorage Point 1, 4 1, 4
CHASSIS ASSE MBLY 7
Front (and Rear, if equipped) Ca ster Wheels 1, 2 14 1, 2 1, 2
Rear Wheel Assembl y 22
Bubble Level 1, 7 1, 7
Floor Stop Assembly 1, 3, 7
FUNCTIONS/CONTROLS 7
Platform Cont rols 5, 6, 7 5, 6, 7
Ground Controls 5, 6 5, 6, 14
Function Control Locks, Guards, or Detents 5 5
Function Enable Syste m
Emergency Stop Swit ches (Ground & Platform) 5
Function Limit or C utout Switch Systems 5
Manual Descent or Aux iliary Power 5 5
POWER SYSTEM
Battery 19 9 18
Battery Charger 5
HYDRAULIC/ELECTRIC SYS TEM 9
Hydraulic Pump 1, 2, 9 1, 2, 5, 9
Hydraulic Cylind er 2, 7, 9 2, 9
Cylinder Attachment Pins and Pin Retainers 1, 2 1, 2
Hydraulic Hoses, Li nes, and Fittings 1, 9 1, 9
Hydraulic Reservoir, Cap, and Breather 5, 7 5, 7
Hydraulic Filter
Hydraulic Fluid * 11 11 11
Electrical Connections 20 20
Instruments, Gauges, S witches, Lights, Horn 5
6 MONTH PREVENTATIVE MAINTENANCE
PRE-DELIVERY (2) OR FREQUENT (3)
INSPECTION
ANNUAL (4)
(YEARLY)
INSPECTION
3121163 – JLG Lift – 2-3
SECTION 2 - GENERAL
Table 2-2. 9MP - Preventive Maintenance & Inspection Schedule.
INTERVAL
AREA ON MACHINE
PRE-START (1)
INSPECTION
3 MONTH PREVENTATIVE MAINTENANCE
GENERAL
Operator and Safety Manua ls in Storage Box 21 21 21
ANSI and EMI Manuals/Handbooks Install ed 21 21 21
Capacity Decals Ins talled, Secure, Legible 21 21 21
All Decals/Placards Installed, Secure, Legible 21 21 21
"Walk-Around" Inspection Performe d 22
Annual Machine Inspecti on Due 21
No Unauthorized Modificatio ns or Additions 21 21
All Relevant Safety Publ ications Incorporated 21 21, 22
General Structural C ondition and Welds 2, 4 2, 4
All Fasteners, Pins , Shields, and Covers 1, 2
Grease and Lubricate to Specificat ions 22 22
Function Test of All Systems 22 22
Paint and Appearance 77
Stamp Inspection Da te on Frame 22
Notify JLG of Machine Ownershi p 22
* 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

2.3 SERVICING 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
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