Jlg 9MP Service Manual Instrukcja Użytkownika

Service and Maintenance ManualMODEL9MP3121163May 14, 2003ANSI

SECTION 1 - MACHINE SPECIFICATIONS1-2 – JLG Lift – 31211631.1 CAPACITIESSystem Voltage12 Volt DCHydraulic System5 qts. U.S. (4.7 L)1.2 COMPONENT DATAH

SECTION 1 - MACHINE SPECIFICATIONS3121163 – JLG Lift – 1-3Lubrication Specifications1.6 HYDRAULIC PRESSURE ADJUSTMENTAdjust system pressure so that pl

SECTION 1 - MACHINE SPECIFICATIONS1-4 – JLG Lift – 31211631.7 CYLINDER SPECIFICATIONSNOTE: All dimensions are given in inches (in), with the met-ric e

SECTION 1 - MACHINE SPECIFICATIONS3121163 – JLG Lift – 1-5Lubrication Points132Table 1-5.Lubrication Intervals for Various ComponentsITEM COMPONENTNO/

SECTION 1 - MACHINE SPECIFICATIONS1-6 – JLG Lift – 3121163 Figure 1-3. Torque Chart. (ANSI)

SECTION 1 - MACHINE SPECIFICATIONS3121163 – JLG Lift – 1-7 Figure 1-4. Torque Chart. (ANSI to METRIC Conversion)SAE GRADE 5SAE GRADE 8Note:

SECTION 1 - MACHINE SPECIFICATIONS1-8 – JLG Lift – 3121163VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLYCLASS 8.8 METRIC BOLTS &CLASS 8 M

SECTION 2 - GENERAL3121163 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 2 - GENERAL2-2 – JLG Lift – 31211632.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE(See Table 2-2.)The preventive maintenance and inspection

SECTION 2 - GENERAL3121163 – JLG Lift – 2-3Table 2-2. 9MP - Preventive Maintenance & Inspection Schedule.AREA ON MACHINEINTERVALPRE-START (1)INSP

CALIFORNIAN PROPOSITION 65BATTERY WARNINGBattery posts,terminals and relatedaccessories containlead and lead compounds,chemical known to theState of C

SECTION 2 - GENERAL2-4 – JLG Lift – 3121163Footnotes:(1) Prior to use each day; or at each Operator change(2) Prior to each sale, lease, or delivery

SECTION 2 - GENERAL3121163 – JLG Lift – 2-52.3 SERVICING AND MAINTENANCE GUIDELINESGeneralThe following information is provided to assist you in theus

SECTION 2 - GENERAL2-6 – JLG Lift – 3121163Hydraulic Lines and Electrical WiringClearly mark or tag hydraulic lines and electrical wiring, aswell as t

SECTION 2 - GENERAL3121163 – JLG Lift – 2-7Chain Anchors and Sheaves: An inspection of the chainmust include a close examination of chain anchors ands

SECTION 2 - GENERAL2-8 – JLG Lift – 31211632.5 POSITIONING LIFT FOR ACCESS TO COMPONENTS LOCATED UNDER THE BASE FRAMEAccess to the underside of the 9M

SECTION 3 - BASE COMPONENTS3121163 – JLG Lift – 3-1SECTION 3. BASE COMPONENTS3.1 BASE ASSEMBLY COMPONENTS 1. Base Frame 4. Front Swivel Caster

SECTION 3 - BASE COMPONENTS3-2 – JLG Lift – 31211633.2 PLATFORM DESCENT - BEACON AND ALARMDescent Beacon - Remove/Install Descent Alarm - Remove/

SECTION 3 - BASE COMPONENTS3121163 – JLG Lift – 3-3Rear Wheel (Straight Axle)- Remove/Install 3.4 FLOOR STOP ASSEMBLY Floor Stop - Remove/Instal

SECTION 3 - BASE COMPONENTS3-4 – JLG Lift – 3121163Floor Stop Interlock Switch Assembly - Remove/Install Floor Stop Interlock Switch - Remove/Inst

SECTION 3 - BASE COMPONENTS3121163 – JLG Lift – 3-53.5 BASE MAST SUPPORTS Mast Support to Base - Straight Axle Base - Remove/Install Mast Suppo

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3121163 – JLG Lift – aMAINTENANCE SAFETY PRECAUTIONSA. GENERALThis section contains the general safety pr

SECTION 3 - BASE COMPONENTS3-6 – JLG Lift – 3121163This page intentionally left blank.

SECTION 4 - CONTROL COMPONENTS3121163 – JLG Lift – 4-1SECTION 4. CONTROL COMPONENTS4.1 CONTROL COMPONENTS OVERVIEW 1. Rear Cover 4. Ground Con

SECTION 4 - CONTROL COMPONENTS4-2 – JLG Lift – 31211634.2 CONTROL COVER INSTALLATIONBattery/Battery Charger Cover - Remove/Install Ground Control S

SECTION 4 - CONTROL COMPONENTS3121163 – JLG Lift – 4-34.3 BATTERY AND CHARGER - INSTALLATIONIMPORTANTBEFORE REMOVING ANY COMPONENT FROM THE ELECTRICAL

SECTION 4 - CONTROL COMPONENTS4-4 – JLG Lift – 31211634.4 GROUND STATION - SERVICING Ground Control Box - Removal/Installation• Remove the ground

SECTION 4 - CONTROL COMPONENTS3121163 – JLG Lift – 4-54.5 PLATFORM STATION - SERVICING Platform Control Station - Removal/Installation1. Platfor

SECTION 4 - CONTROL COMPONENTS4-6 – JLG Lift – 31211634.6 PUMP-MOTOR ASSEMBLY -SERVICE PROCEDUREGeneralThe following is a complete tear-down/re-assemb

SECTION 4 - CONTROL COMPONENTS3121163 – JLG Lift – 4-7Tank Removal/InstallationFilter Screen Removal/InstallationPump Removal/InstallationPressure Adj

SECTION 4 - CONTROL COMPONENTS4-8 – JLG Lift – 3121163Pressure Check Valve - Removal/InstallationLift Down Valve - Removal/InstallationMotor - Remove/

SECTION 4 - CONTROL COMPONENTS3121163 – JLG Lift – 4-9Motor Top Cover - Removal/InstallationMotor Components - Removal/InstallationMotor Top Cover - R

INTRODUCTION - REVISION LOGb – JLG Lift – 3121163REVISION LOG October 10, 2002 – Original Issue of ManualOctober 14, 2002 – Manual RevisedNovemb

SECTION 4 - CONTROL COMPONENTS4-10 – JLG Lift – 3121163Brush Carrier - Removal/InstallationOnce brush carrier assembly has been removed, inspectthe ro

SECTION 4 - CONTROL COMPONENTS3121163 – JLG Lift – 4-114.7 BATTERY CHARGER -SERVICE PROCEDURESGeneral InformationIMPORTANTDO NOT ATTEMPT TO DISASSEMBL

SECTION 4 - CONTROL COMPONENTS4-12 – JLG Lift – 3121163AC Circuit Breaker/Voltage Select Switch - Remove/Install Battery Discharge Indicator - Rem

SECTION 4 - CONTROL COMPONENTS3121163 – JLG Lift – 4-13Shunt Assembly and Capacitors -Remove/Install SCR Rectifier - Remove/Install (Either Side)

SECTION 4 - CONTROL COMPONENTS4-14 – JLG Lift – 3121163Figure 4-2. 9MP - SCR Dual Voltage - Battery Charger Wiring Diagram.2134151743BUTTSPLICEGREENP

SECTION 5 - MAST COMPONENTS3121163 – JLG Lift – 5-1SECTION 5. MAST COMPONENTS5.1 MAST COMPONENTS OVERVIEW 1. Mast Section - 1 4. Lift Cylinder

SECTION 5 - MAST COMPONENTS5-2 – JLG Lift – 31211635.2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENTMast Chain Adjustment (See Figure 5-2.)The intentio

SECTION 5 - MAST COMPONENTS3121163 – JLG Lift – 5-31. Sequence Cable Adjust Nut 4. Mast Section - 3 (c) 7. Chain Anchor Plate 10. Threaded Chain E

SECTION 5 - MAST COMPONENTS5-4 – JLG Lift – 31211635.3 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILDHYDRAULIC CYLINDERS ARE DESIGNED TO HO

SECTION 5 - MAST COMPONENTS3121163 – JLG Lift – 5-57. Remove the cylinder rod anchor block attach screwfrom the back of the anchor block at the top of

3121163 – JLG Lift – iTABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION - MAINTENANCE SAFETY PRECAUTIONSA. GENERAL . . .

SECTION 5 - MAST COMPONENTS5-6 – JLG Lift – 3121163Cylinder Disassembly(See Figure 5-4.)1. Before disassembling the cylinder, clean away alldirt and f

SECTION 5 - MAST COMPONENTS3121163 – JLG Lift – 5-7Cylinder Assembly(See Figure 5-4.)1. Rinse the inside of the tube with hydraulic fluid andallow to

SECTION 5 - MAST COMPONENTS5-8 – JLG Lift – 3121163Cylinder InstallationTo install the lift cylinder reverse the Lift Cylinder Removalinstructions at

SECTION 5 - MAST COMPONENTS3121163 – JLG Lift – 5-95.4 MAST ASSEMBLY - REMOVE/INSTALLNOTE: The mast may be completely disassembled while onthe machine

SECTION 5 - MAST COMPONENTS5-10 – JLG Lift – 31211635.5 MAST ASSEMBLY AND DISASSEMBLYPROCEDURESThe model 9MP lift mast sections are constructed ofextr

SECTION 5 - MAST COMPONENTS3121163 – JLG Lift – 5-11Mast Disassembly Procedure 1. After the mast assembly has been removed from themachine, lay the ma

SECTION 5 - MAST COMPONENTS5-12 – JLG Lift – 3121163Mast Assembly - 9MP(See Figure 2-2.)MAST SECTION 1 - ASSEMBLY1. Place mast section-1, rail (open)

SECTION 5 - MAST COMPONENTS3121163 – JLG Lift – 5-13MAST SECTION 2 - ASSEMBLYIMPORTANTSPRAY THE SLIDE PAD CHANNELS WITH KRYTOX LUBRICANT ATROOM TEMPER

SECTION 5 - MAST COMPONENTS5-14 – JLG Lift – 312116311. At the bottom of mast section-2, slide the lift cylinderassembly into mast section-2, with the

SECTION 5 - MAST COMPONENTS3121163 – JLG Lift – 5-1515. Assemble chain sheaves on cylinder anchor block(attached to cylinder rod end) and attach to ma

ii – JLG Lift – 3121163TABLE OF CONTENTSBatteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 - MAST COMPONENTS5-16 – JLG Lift – 3121163 e. Begin sliding top of mast section-3 with closedrail down engaging the slide pads into slide

SECTION 5 - MAST COMPONENTS3121163 – JLG Lift – 5-17Sequence Cable Bracket Installation)(Bottom End)1. Cable End Bracket 3. Sheave Wheel Screw (a)2.

SECTION 5 - MAST COMPONENTS5-18 – JLG Lift – 31211635.6 9MP PLATFORM - REMOVE/INSTALL1. Mast Platform Header Section 2. Nut (Qty.-6) 3. Washers (Qt

SECTION 6 - TROUBLESHOOTING3121163 – JLG Lift – 6-1SECTION 6. TROUBLESHOOTING6.1 GENERALThis section contains troubleshooting information to beused f

SECTION 6 - TROUBLESHOOTING6-2 – JLG Lift – 3121163Table 6-1. 9MP - TROUBLESHOOTINGTROUBLE PROBABLE CAUSE REMEDYPlatform does not rise.Power source

SECTION 6 - TROUBLESHOOTING3121163 – JLG Lift – 6-3Figure 6-1. Hydraulic Schematic. (9MP) (2792581-A)2792581_A

SECTION 6 - TROUBLESHOOTING6-4 – JLG Lift – 3121163Figure 6-2. Electrical Diagram. (9MP - 12 Volt) (4933269-A)4933269_A

SECTION 6 - TROUBLESHOOTING3121163 – JLG Lift – 6-5Figure 3-2. Electrical Diagram. (9MP - 12 Volt) (4933269-A)4933269_A

SECTION 6 - TROUBLESHOOTING6-6 – JLG Lift – 3121163This page left intentionally blank.

3121163 – JLG Lift – iiiTABLE OF CONTENTSCharger Cover - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Customer Support Toll Free:

iv – JLG Lift – 3121163TABLE OF CONTENTS5-9. Platform Remove/Install - 9MP.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 - MACHINE SPECIFICATIONS3121163 – JLG Lift – 1-1SECTION 1. MACHINE SPECIFICATIONS 123456789Table 1-1. 9MP - Machine Operating Sp