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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 !!!!
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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
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JLG SSV Series Mobile Platform Lift Service and Maintenance Manual (Global) – 3121187.pdf
