JLG SSV Series Mobile Platform Lift Service and Maintenance Manual (Global) - 3121187

-
This service manual PDF download for the SSV Series JLG Electric Mast Lift Personnel has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


TABLE OF CONTENTS :

Section 1. MACHINE specifications
    1.1 Capacities
    1.2 Component Data
    1.3 Performance Data
    1.4 Torque Requirements
    1.5 Lubrication
    1.6 Hydraulic Pressure settings and Adjustment
    1.7 Cylinder Specifications
    1.8 Serial Number Locations
    
Section 2. GENERAL Service Information
    2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
    2.2 Preventive Maintenance and Inspection Schedule
    2.3 Servicing and Maintenance Guidelines
    2.4 Lubrication Information
        
Section 3. BASE COMPONENTS
    3.1 Base Assembly Components
    3.2 Base Frame Covers
    3.3 Drive And Caster Wheels
    3.4 Drive/Elevation Cut-out switch Installation
    3.5 Pump-Motor Assembly - Service Procedure
    3.6 Drive Motor Assembly - Servicing
    3.7 Batteries and Battery Charger - Service Procedures

        
Section 4. CONTROL COMPONENTS
    4.1 CONTROL Components Overview
    4.2 Control Components - Installation
    4.3 Ground Control Module - Service Procedure
    4.4 Ground Control Module - Programming
    4.5 Platform Control Console - Service Procedures
        
SECTION 5. MAST COMPONENTS
    5.1 Mast Components Overview
    5.2 Mast Cover - Install/Remove
    5.3 Platform Assembly - install/ remove
    5.4 Material Tray - Install/Remove
    5.5 Hydraulic Line - Disconnect - Special Tool
    5.6 Mast Assembly Install/REmove
    5.7 MAST DISASSEMBLY PROCEDURE
    5.8 Cylinder Disassembly
    5.9 Mast Assembly
    5.10 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT
        
Section 6. troubleshooting
    6.1 General
    6.2 Troubleshooting Information
    6.3 Hydraulic Circuit Checks
    6.4 ELECTRICAL CIRCUIT CHECKS
    6.5 TROUBLESHOOTING TABLES Index
    6.6 SPECIFICATIONS FOR VARIOUS COMPONENTS
    6.7 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS
    6.8 FAULT CODE TROUBLESHOOTING TABLES
    6.9 MAIN POWER CIRCUIT TROUBLESHOOTING
    6.10 MAST TROUBLESHOOTING
    6.11 HYDRAULIC LEAK TROUBLESHOOTING
    6.12 BASE FRAME COMPONENTS TROUBLESHOOTING
    6.13 DRIVE SYSTEM TROUBLESHOOTING


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3121187
Total Pages : 136


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.


Looking for some other service, repair , workshop , operation & maintenance or parts manual?, please check : 
https://www.sitelux.com

-


Maintenance safety precautions
    a. GENERAL
    b. HYDRAULIC SYSTEM SAFETY
    c. MAINTENANCE
REVISION LOG
TABLE OF CONTENTS

Section 1. MACHINE specifications
    1.1 Capacities
        System Voltage
        Hydraulic System
        Drive Motor GearBox (Gear Oil)
    1.2 Component Data
        Hydraulic Pump/Pump Motor Assembly
        Rear Wheel Drive Motors
        Batteries/Battery Charger
    1.3 Performance Data
        Platform Capacity
        Platform Size
        Material Tray Size
        Platform Height - (Fully Elevated)
        Platform Maximum (Working) Height (Platform fully elevated + Operator height)
        Machine Height
        Machine Overall
        Platform Entry Height (Floor to Platform Floor)
        Machine Underclearance
        Machine Turning Radius (Outside)
    1.4 Torque Requirements
    1.5 Lubrication
        Hydraulic Oil
        Lubrication Specifications
    1.6 Hydraulic Pressure settings and Adjustment
        Hydraulic Pressure Gauge Connection
        After Filter Pressure Check
    1.7 Cylinder Specifications
    1.8 Serial Number Locations
    
Section 2. GENERAL Service Information
    2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
        General
        Preparation, Inspection, and Maintenance
        Pre-Start Inspection
        Pre-Delivery Inspection and Frequent Inspection
        Annual Machine Inspection
        Preventative Maintenance
    2.2 Preventive Maintenance and Inspection Schedule
        Maintenance and Inspection Table Codes:
        Footnotes:
    2.3 Servicing and Maintenance Guidelines
        General
        Safety and Workmanship
        Cleanliness
        Components Removal and Installation
        Component Disassembly and Reassembly
        Pressure-Fit Parts
        Bearings
        Gaskets
        Bolt Usage and Torque Application
        Hydraulic Lines and Electrical Wiring
        Hydraulic System
        Lubrication and Servicing
        Batteries
        Mast Chain Inspection Procedure
    2.4 Lubrication Information
        Hydraulic System
        Hydraulic Oil
        Changing Hydraulic Oil
        Lubrication Specifications
        
Section 3. BASE COMPONENTS
    3.1 Base Assembly Components
    3.2 Base Frame Covers
        Front Cover - Installation (Original)
        Front Cover - Installation (Carry Deck Version)
        Carry Deck Support Frame - Installation
        Rear Bumper Cover - Installation
        Drive Motor Cover - Installation
    3.3 Drive And Caster Wheels
        (Rear) Drive Motor Wheel - Removal
        Drive Motor Wheel Hub - Installation
        (Rear) Drive Motor Wheel - Installation
        (Front) Caster Wheel - Installation
    3.4 Drive/Elevation Cut-out switch Installation
    3.5 Pump-Motor Assembly - Service Procedure
        General
        Pump-Motor Assembly - Remove/Install
        Motor - Remove/Install - Reference Marks
        Motor/Brush Cover - Remove/Install
        Brush Carrier Assembly - Remove/Install
        Brush Assembly - Remove/Install
        Tank Remove/Install
        Filter Screen Remove/Install
        Pump Remove/Install
        Pressure Adjust Valve Remove/Install
        Pressure Check Valve - Remove/Install
    3.6 Drive Motor Assembly - Servicing
        Drive Motor Assembly - Removal
        Drive Motor Assembly - Components
        Drive Motor - Boot Installation
        Drive Motor - Brake Location
        Brake Assembly Removal From Motor
        Brake Operation
        Checking/Adjusting Armature Plate Gap Setting
        Brake Assembly Installation
        Drive Motor Brush Replacement
        Brush Removal
        Brush Reassembly
    3.7 bATTEries and Battery Charger - Service Procedures
        Battery Condition Testing
        Battery Replacement
        Battery - Installation
        Battery Charge LED Indicator on Platform Control Console
        Battery Low Voltage Warning Indicators
        Battery Charger General Information
        Battery Charging Status Indicators
        Wet/VRLA Battery - Charging Profile Switch
        Battery Charger Installation
        Battery Charger Cover Installation
        General Component Installation Notes
        AC Line Fuse Installation
        Interlock Relay Installation
        Wet/VRLA Switch Installation
        Shunt Assembly Installation
        SCR Rectifier Installation (Either Side)
        Transformer Installation
        Printed Circuit Board Installation
        DC Breaker/Voltage Select Switch Installation
        
Section 4. CONTROL COMPONENTS
    4.1 CONTROL Components Overview
    4.2 Control Components - Installation
        Ground Control Module
        Traction Control Module
        Platform Control Console Installation
        Platform Junction Box - Install/Remove
        Junction Box to Ground Control Harness - Remove/Install
        Platform Interlock Switch Circuit
    4.3 Ground Control Module - Service Procedure
        Cover Removal/Installation
        Power Selector/EStop Switch Installation
    4.4 Ground Control Module - Programming
        General
        Programming Levels
        Activating Programming Mode
        Entering Password
        Programming Mode Selection
        Selecting Programmable Item to Adjust
        Adjusting Programmable Setting
        Service Programming Mode - (Level-2)
        Operator Programming Mode - (Level-3)
    4.5 Platform Control Console - Service Procedures
        General
        Remove Platform Control Console
        Display/Controller Module Electrical Connections
        Mounting Bracket - Install/Remove
        Rear Cover - Install/Remove
        Display/Controller Module - Install/Remove
        Drive/Lift Mode Switch - Install/Remove
        Horn Button Switch - Install/Remove
        Key Switch - Install/Remove
        E-Stop/ShutDown Switch - Install/Remove
        Joystick Assembly - Install/Remove
        
SECTION 5. MAST COMPONENTS
    5.1 Mast Components Overview
    5.2 Mast Cover - Install/Remove
    5.3 Platform Assembly - install/ remove
    5.4 Material Tray - Install/Remove
    5.5 Hydraulic Line - Disconnect - Special Tool
        Tool Use
    5.6 Mast Assembly Install/REmove
        Mast Removal
        Mast Installation
    5.7 MAST DISASSEMBLY PROCEDURE
        Mast Disassembly Procedure
    5.8 Cylinder Disassembly
        Lift Cylinder Component Inspection
        Cylinder Assembly
    5.9 Mast Assembly
    5.10 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT
        Mast Chain/Cable Adjustment
        Sequencing Cable Adjustment
        
Section 6. troubleshooting
    6.1 General
    6.2 Troubleshooting Information
    6.3 Hydraulic Circuit Checks
    6.4 ELECTRICAL CIRCUIT CHECKS
        General
        Ground Control Module LCD Display
    6.5 TROUBLESHOOTING TABLES Index
        SPECIFICATIONS FOR VARIOUS COMPONENTS PAGE
        SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS
        FAULT CODE TROUBLESHOOTING TABLES
        MAIN POWER CIRCUIT TROUBLESHOOTING
        MAST TROUBLESHOOTING
        HYDRAULIC LEAK TROUBLESHOOTING
        BASE FRAME COMPONENTS TROUBLESHOOTING
        DRIVE SYSTEM TROUBLESHOOTING
    6.6 SPECIFICATIONS FOR VARIOUS COMPONENTS
    6.7 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS
    6.8 FAULT CODE TROUBLESHOOTING TABLES
        Machine in Drive Speed Cut-Back (Turtle) Mode All The Time
        Code 01 - Low Battery Voltage
        Code 02 - RESERVED
        Code 03 - RESERVED
        Code 04 - Tilt Condition
        Code 05 - RESERVED
        Code 06 - RESERVED
        Code 07- Left Drive Motor - Disconnected
        Code 08 - Right Drive Motor - Disconnected
        Code 09 - Left Brake - Disconnected
        Code 10 - Right Brake - Disconnected
        Code 11 - Left Drive Motor - Short Circuit
        Code 12 - Right Drive Motor - Short Circuit
        Code 13 - Traction Module - In Fold Back
        Code 14 - Pump Motor - Disconnected
        Code 15 - Lift Down Valve - Disconnected
        Code 16 - Lift Down Valve - Short Circuit
        Code 17 - Ground Control Module - In Fold Back
        Code 18 - Alarm - Short Circuit
        Code 19 - Alarm - Disconnected
        Code 20 - Beacon - Short Circuit
        Code 21 - Beacon - Disconnected
        Code 22 - Horn - Short Circuit
        Code 23 - Horn - Disconnected
        Code 24 - Auxiliary #1 Circuit - Short Circuit
        Code 25 - Auxiliary #1 Circuit - Disconnected
        Code 26 - Auxiliary #2 - Short Circuit
        Code 27 - Auxiliary #2 - Disconnected
        Code 28 - RESERVED
        Code 29 - RESERVED
        Code 30 - Traction Module - No Communication with Ground Control Module
        Code 31 - Platform Control Console - No Communication with Ground Control Module
        Code 32 - Pump Motor - Over Current
        Code 33 - RESERVED
        Code 34 - Auxiliary #2 - Inhibit
        Code 35 - Auxiliary #2 - Tie Down
        Code 36 - RESERVED
        Code 37 - RESERVED
        Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) LED/LCDs lit
        Code 39 - Battery Voltage Low - Warning Level 3 - One (1) LED/LCDs lit
        Code 40 - RESERVED
        Codes 41 thru 46 - RESERVED
        Codes (100 - 199) Ground Control Module - Fault Condition
        Codes (200 - 299) Platform Control Console - Fault Condition
        Codes (300 - 399) Traction Control Module - Fault Condition
    6.9 MAIN POWER CIRCUIT TROUBLESHOOTING
        Machine Will Not Power Up
    6.10 MAST TROUBLESHOOTING
        Platform Will Not Lower Manually
        Platform Lift Up And Down Jerky
        Mast Noisy When Lifting And Lowering
        Platform (Mast) Won’t Stay Elevated
        Platform (Mast) Descends Too Slowly
    6.11 HYDRAULIC LEAK TROUBLESHOOTING
        Miscellaneous Hydraulic Leak Troubleshooting
    6.12 BASE FRAME COMPONENTS TROUBLESHOOTING
        Caster Wheels Not Operating Freely
    6.13 DRIVE SYSTEM TROUBLESHOOTING
        Won’t Climb Grade
        Machine Drives in Opposite Direction
        Machine Won’t Drive Straight
        Noise From Drive Assembly
        
-