JLG 9MP Parts Manual

Illustrated Parts Manual

Models

9MP

P/N

3121164

March 1, 2011

REVISION LOG

October 1, 2002 - Original Issue Of Manual (Manual edited to B/M 0010589 Revision 3)

June 15, 2003 - Revised Manual (Manual Edited to B/M 0010589 Revision 11)

January 6, 2004 - Revised Manual (Manual Edited to B/M 0010589 Revision 12)

January 11, 2005 - Revised Manual (Manual Edited to B/M 0010589 Revision 12)

November 15, 2006 - Revised Manual (Manual Edited to B/M 0010589 Revision 16)

March 1, 2011 - Revised Manual

3121164 9MP A

REVISION LOG

B 9MP 3121164

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 1 - BASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-1 BASE MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

SECTION 2 - CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 PUMP/MOTOR/GROUND CONTROL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 PUMP/MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 BATTERIES/CHARGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 BATTERY CHARGER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 PLATFORM CABLE AND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 2-12

SECTION 3 - MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 MAST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-1 LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1 HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7-1 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

8-1 DECAL INSTALLATION (ANSI SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 DECAL INSTALLATION (ANSI EXPORT SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8-3 DECAL INSTALLATION (CE SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

3121164 9MP i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

ii 9MP 3121164

SECTION 1

BASE

3121164 9MP 1-1

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

1-2 9MP 3121164

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0272509 Ref. BASE ASSEMBLY (STANDARD) E

1 0630549 12 Screw 3/8”-16NC x 1 1/4” 2Not Used 3 0920114 1 Stop, Floor 4Not Used 5 3760348 2 Ring, Retaining 6 4711600 8 Flatwasher 3/8” Narrow 7 4711800 8 Flatwasher 1/2” Narrow 8 4712200 2 Flatwasher 3/4” Narrow

9 4740456 A/R Washer, Shim 10 4846715 1 Base 11 2 Wheel Assembly (Front) Options:

4860208 Prior to S/N 20797 4860244 S/N 20797 to Present

12 2 Caster Wheel Assembly (Rear) Options:

4860209 Prior to S/N 20797

4860245 S/N 20797 to Present 13 0791812 4 Screw 1/2”-13NC x 1 1/2” 14 3311808 4 Nut, Flanged 1/2”-13NC 15 3539920 1 Plate, Spacer 16 4740415 2 Washer 17 0100011 A/R Loctite #242 (Not Shown) 18 3520195 2 Plug (S/N 19973 to Present) 19 3760365 1 Ring, Tie-Down (S/N 19981 to Present)

0272601 Ref. BASE ASSEMBLY (OPTIONAL ALL CASTER WHEELS) E

101 0630549 20 Screw 3/8”-16NC x 1 1/4” 102 Not Used 103 0920114 1 Stop, Floor

104 to 106 Not Used

107 4846718 1 Base 108 3 Caster Wheel Assembly Options:

4860209 Prior to S/N 20797

4860245 S/N 20797 to Present

109 0791812 4 Screw 1/2”-13NC x 1 1/2” 110 3311808 4 Nut, Flanged 1/2”-13NC 111 3539920 1 Plate, Spacer 112 Not Used 113 0100011 A/R Loctite #242 (Not Shown) 114 3520195 2 Plug (S/N 19973 to Present) 115 3760365 1 Ring, Tie-Down (S/N 19981 to Present) 116 1 Caster Wheel Assembly with Lock (Not Shown - Located on Left

Front Only) Options: 4860242 Prior to S/N 20797 0272943 S/N 20797 to Present

3121164 9MP 1-3

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. MAST SUPPORT INSTALLATIONS 0272641 Ref. Standard Front Wheel C 0272632 Ref. Caster Front Wheel C

201 to 203 Not Used

204 0801358 1 Mast Assembly (See Section 3 for Breakdown) 205 2420140 1 Gage, Level 206 Not Used 207 4568651 2 Brace 208 Not Used 209 4846729 1 Mount, Mast 210 0100011 A/R Loctite #242 (Not Shown) 211 0791610 12 Screw, Flanged 3/8”-16NC x 1 1/4” (Standard Front Wheel)

0791610 10 Screw, Flanged 3/8”-16NC x 1 1/4” (4 Caster Wheels) 0630549 2 Capscrew, Socket 3/8”-16NC x 1 1/4” (4 Caster Wheels)

212 3311608 12 Nut, Flanged 3/8”-16NC

0272650 Ref. STORAGE COMPARTMENT INSTALLATION (OPTIONAL) A

301 0630550 2 Screw 1/4”-20NC x 3/4” 302 1580017 1 Container, Storage 303 3820032 6 Rivet 304 4846749 1 Support

Ref. STATIC STRAP INSTALLATION (ANSI OPTION ONLY) (NOT

SHOWN)

401 0220007 1 Lanyard, Static

Ref. ALARM AND STROBE INSTALLATIONS 0272513 Ref. Standard System C 0272685 Ref. Keyless System (Optional) B

501 Not Used 502 0140033 1 Alarm 503 0630550 4 Screw 1/4”-20NC x 3/4”

504 to 510 Not Used

510 1320224 2 Clamp, Cable 511 2920155 1 Light, Strobe

7026196 1 Bulb, Flash Tube 7026195 1 Lens 4460320 1 Plug, Male 2 Position 4460226 2 Socket, Female

512 to 513 Not Used

514 3820032 2 Rivet

515 to 519 Not Used

520 4922828 1 Harness, Frame (See Items 601 to 615 for Breakdown)

521 to 524 Not Used

525 4240033 A/R Tie-Strap (Not Shown) 526 4460234 A/R Base, Tie-Strap (Not Shown)

1-4 9MP 3121164

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

4922828 Ref. FRAME HARNESS ASSEMBLY 2/A

601 to 606

607 4460662 1 Connector, Strain Relief 608 4360456 1 Limit Switch 609 3911024 2 Screw #10-24NC x 1 1/2” 610 3311001 2 Nut #10-24NC 611 4751000 2 Flatwasher #10 612 4761000 2 Lockwasher #10 613 0902523 1 Bracket, Limit Switch 614 4460424 1 Receptacle - 2 Position 615 4460227 2 Pin, Male

0272671 Ref. CORD REEL INSTALLATION (ANSI OPTION ONLY) B

701 3680054 1 Cord Reel Assembly

3311508 1 Nut, Flanged 5/16”-18NC 0100011 A/R Loctite #242 (Not Shown)

3121164 9MP 1-5

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-6 9MP 3121164

SECTION 2

CONTROLS

3121164 9MP 2-1

SECTION 2 CONTROLS

409

407

410

121

302

121

415

416

414

408

413

106

123

10 11

405

115

301

201

107C

17B0

107A

107

402

113

110

121

109 122

119

125

126

119A

108

501

618

617

616

615

FIGURE 2-1. PUMP/MOTOR/GROUND CONTROL INSTALLATIONS

2-2 9MP 3121164

SECTION 2 CONTROLS

FIGURE 2-1. PUMP/MOTOR/GROUND CONTROL INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. PUMP/MOTOR/TANK INSTALLATION 0272512 Ref. Pump/Motor/Tank with Poly Tank B 0272958 Ref. Pump/Motor/Tank with Steel Tank A

1 0100011 A/R Loctite

#242 (Not Shown) 2Not Used 3 0741605 2 Screw, Flathead 3/8”-16NC x 5/8” 4 3311605 4 Locknut 3/8”-16NC 5 1 Pump/Motor/Tank Assembly (See Figure 2-2 for Breakdown)

3600364 Pump/Motor/Tank with Poly Tank 3600378 Pump/Motor/Tank with Steel Tank

6 to 8 Not Used

9 4845714 1 Mount, Pump

10 0791610 4 Screw 3/8”-16NC x 1 1/4” 11 3311608 4 Nut, Flanged 3/8”-16NC

Ref. GROUND CONTROLS INSTALLATION 0272513 Ref. Standard C 0272685 Ref. Keyless B

101 0100051 A/R Grease (Not Shown)

102 to 105 Not Used

106 0721006 1 Screw #10-24NC x 3/4” 107 1 Ground Control Box Assembly

0861305 1 Standard D 0861536 1 Keyless A 3910804 4 Screw #8-32NC x 1/4”

107A 7020078 1 Switch, Push-Pull (Stop)

7020096 1 Legend Plate, “Stop”

107B 1 Switch, Key

7024411 Keyless 4360467 Keyed Switch 2860030 1 Key, Replacement 7020097 1 Legend Plate, “Power/Off/On”

107C Use 7027299 1 Connector, Strain Relief (Prior to S/N 23600 was p/n

4460633) 108 1060994 1 Cable, Electrical (Pump + to Starter Relay) 109 1060995 1 Cable, Electrical (Pump – to Starter Housing) 110 1320224 1 Clamp

111 to 112 Not Used

113 3740049 1 Relay 114 Not Used 115 4061024 1 Cover

116 to 118 Not Used

119 4922740 1 Harness, Pump

2400006 1 Fuse 4460044 1 Fuseholder 4460424 1 Receptacle - 2 Position

3121164 9MP 2-3

SECTION 2 CONTROLS

FIGURE 2-1. PUMP/MOTOR/GROUND CONTROL INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

4460268 2 Socket, Female (Used with p/n 4460424)

119A 4460741 1 Plug - 4 Position (To Relay)

4460420 4 Terminal (Used with p/n 4460741) 120 Not Used 121 0791404 6 Screw 1/4”-20NC x 1/2” 122 0791504 1 Screw 5/16”-18NC x 1/2” 123 3311001 2 Nut #10-24NC 124 0100011 A/R Loctite #242 (Not Shown) 125 4240033 A/R Tie-Strap 126 4460234 A/R Base, Tie-Strap Mounting

0259450 Ref. AUXILIARY LOWERING INSTALLATION (OPTIONAL) A

201 0861213 1 Box, Power down

4420064

4420065

4in/10cm

Velcro, Loop Velcro, Hook

0272686 Ref. PROGRAMMABLE SECURITY LOCK INSTALLATION

(OPTIONAL)

301 2940132 1 Lock, Electronic 302 0791003 2 Screw #10-24NC x 3/8”

0272670 Ref. FLOOR BRAKE ALARM INSTALLATION B

401 0100011 A/R Loctite #242 (Not Shown) 402 0140022 1 Horn

403 to 404 Not Used

405 3311001 2 Nut #10-24 406 Not Used 407 3520166 1 Plug 408 3740080 1 Relay 409 3911024 2 Screw #10-24NC x 3” 410 4360437 1 Switch, Limit

411 to 412 Not Used

413 4922583 1 Harness, Brake Alarm 414 0791406 1 Screw 1/4”-20NC x 3/8” 415 0791507 1 Screw 5/16”-18NC x 7/8” 416 3311508 1 Nut, Flanged 5/16”-18NC

0273365 Ref. HOURMETER INSTALLATION (OPTIONAL) C

501 2420172 1 Hourmeter

3311001 2 Nut #10-24NC

3572158 1 Plate, Mounting

3911010 2 Screw #10-24NC x 5/8”

4761000 2 Lockwasher #10

4922935 1 Harness, Hourmeter

2-4 9MP 3121164

SECTION 2 CONTROLS

FIGURE 2-1. PUMP/MOTOR/GROUND CONTROL INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. ACCESSORY OUTLET INSTALLATION (OPTIONAL) 0273943 Ref. 110V/120V (ANSI Spec) B 0272516 Ref. 220V/240V (ANSI Spec) B 0272518 Ref. 220V/240V (ANSI Export Spec) B

601 to 614 Not Used

615 0641614 4 Bolt 3/8”-16NC x 1 3/4” 616 3311605 4 Locknut 3/8”-16NC 617 4070984 2 Shim, Pump Spacer 618 4711600 8 Flatwasher 3/8” Narrow

3121164 9MP 2-5

SECTION 2 CONTROLS

FIGURE 2-2. PUMP/MOTOR ASSEMBLY

2-6 9MP 3121164

SECTION 2 CONTROLS

FIGURE 2-2. PUMP/MOTOR ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. PUMP/MOTOR/TANK ASSEMBLY 3600364 Ref. Pump/Motor/Tank with Poly Tank B 3600378 Ref. Pump/Motor/Tank with Steel Tank B

1 7011003 1 Motor - 12VDC (Includes Item 12) 2 7011051 1 Start Relay Kit (Includes Hardware and Lead Wire & Boots) 3 7011052 1 Pump Kit (Includes Mounting Hardware & 2 O-Rings) 4 Not Available 1 Nameplate 5 7011054 1 Valve, Release Less Coil 6 7011000 1 Coil, Solenoid 7 7011055 1 Valve, Relief 8 7011056 1 Adapter

9 7011053 1 Decal - Full (Not Shown - Poly Tank Only) 10 7010950 1 Valve, Check 11 1 Cap Options:

7011057 Filler Cap/Breather (Poly Tank)

Not Serviced Filler Cap/Dipstick (Steel Tank) (Note: Part of Tank - Not Sold

Separately) 12 7011058 1 Brush Kit (Part of Item 1) 13 7011025 1 O-Ring (Part of Item 15) 14 7011016 1 Coupling 15 7011059 1 Tank Kit Options (Includes Hardware, Tubes, O-Rings & Retain-

ers, Strainer and Steel Tank):

Use 7011068 Poly Tank (Note: Use Steel Tank as Replacement)

15A 7011068 Steel Tank Kit

16 7011060 1 Fitting, 90° 17 7011061 1 Fitting, 90°

3121164 9MP 2-7

SECTION 2 CONTROLS

FIGURE 2-3. BATTERIES/CHARGER INSTALLATION

2-8 9MP 3121164

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