JLG SSV10 Parts Manual

Illustrated Parts Manual

Model

SSV-10

P/N

3121188

April 12, 2012

REVISION LOG

June 1, 2004 - Original Issue Of Manual (Edited to B/M 0010611 Revision 1)

September 20, 2004 - Revised Manual (Edited to B/M 0010611 Revision 4)

January 31, 2005 - Revised Manual (Edited to B/M 0010611 Revision 7)

June 2, 2005 - Revised Manual (Edited to B/M 0010611 Revision 8)

December 15, 2005 - Revised Manual (Edited to B/M 0010611 Revision 9)

November 3, 2006 - Revised Manual (Edited to B/M 0010611 Revision 9)

July 29, 2009 - Revised Manual (Edited to B/M 0010611 Revision 10)

April 4, 2012 - Revised Manual

3121188 SSV-10 A

REVISION LOG

B SSV-10 3121188

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

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

1-2 DRIVE MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 COVERS AND TIE-DOWNS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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

2-1 PUMP MOTOR ASSEMBLY AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 CHARGER, HORN AND BATTERIES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 BATTERY CHARGER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-4 GROUND COMPONENTS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-5 PLATFORM CABLES AND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-6 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

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

3-1 MAST ASSEMBLY AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

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

4-2 MATERIAL TRAY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-3 OPTIONAL BICYCLE CARRIERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-4 OPTIONAL RUG CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-5 OPTIONAL FLUORESCENT TUBE CADDY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 4-10

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

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

5-2 LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

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

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

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

7-1 ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 ELECTRICAL COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

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

8-1 DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

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

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

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

3121188 SSV-10 i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

ii SSV-10 3121188

SECTION 1

BASE

3121188 SSV-10 1-1

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

1-2 SSV-10 3121188

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0273784 Ref. BASE ASSEMBLY I

1 0273622 2 Drive Motor and Wheel Assembly (See Items 201-212 for

Breakdown)

2 to 3 Not Used

4 0641612 8 Bolt 3/8”-16NC x 1 1/2” 5 0940132 1 Bumper, Chassis 6Not Used 7 3311605 9 Locknut 3/8”-16NC

8 to 9 Not Used

10 4520342 1 Spindle (Left Side) 11 4520343 1 Spindle (Right Side) 12 4520281 2 Tire & Wheel Assembly 13 0641609 1 Bolt 3/8”-16NC x 1 1/8” 14 4240147 1 Strap, Static

15 to 20 Not Used

21 3760115 2 Ring, Retaining

22 to 29 Not Used

30 0100081 A/R Loctite #454 (Not Shown) 31 0274164 1 Frame Assembly (See Items 101-106 for Breakdown) 32 4711600 1 Flatwasher 3/8” Narrow 33 3760496 2 Ring, Retaining 34 3020039 A/R Lubricant Loctite #51049 35 8882970 A/R Coating, Clear

0274164 Ref. FRAME ASSEMBLY K

101 0440306 2 Bearing, Ball 102 0440307 2 Bearing, Roller 103 0440308 2 Bearing, Race 104 2360697 1 Frame 105 3020029 A/R Grease (Not Shown) 106 3960590 2 Seal

0273622 Ref. DRIVE MOTOR AND WHEEL ASSEMBLY I

Ref. Note: Qty shown is for one side.

201 0100011 A/R Locking Compound (Not Shown) 202 0440258 1 Bearing 203 0651409 4 Bolt 1/4”-28NF x 1” 204 2360665 1 Mount, Motor 205 3160303 1 Motor Assembly (See Figure 1-2 for Breakdown) 206 3312202 1 Nut 3/4”-10NC 207 3450505 1 Pin, Cotter 5/32” x 1/2” 208 4520280 1 Tire & Wheel Assembly 209 2940164 1 Cover, Locking Nut 210 1120579 Plug 211 3020039 A/R Lubricant Loctite #51049 (S/N 0130006558 to Present) 212 4712400 1 Flatwasher 7/8” Narrow

3121188 SSV-10 1-3

SECTION 1 BASE

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0274078 Ref. BUMPERS INSTALLATION (OPTIONAL) B

301 0641410 13 Bolt 1/4”-20NC x 1 1/4” 302 0940152 2 Bumper, Side 303 0940153 1 Bumper, Front 304 3311405 13 Locknut 1/4”-20NC 305 4751400 26 Flatwasher 1/4” Wide

0240103 Ref. GUIDE ROLLER ATTACHMENT (OPTIONAL) A

401 0100011 A/R Locking Compound 402 0641606 16 Bolt 3/8”-16NC x 3/4” 403 0641617 4 Bolt 3/8”-16NC x 2 1/8” 404 0903120 4 Bracket, Top Roller 405 0903121 1 Bracket, Bottom Roller 406 3311605 8 Locknut 3/8”-16NC 407 4520352 4 Wheel

1-4 SSV-10 3121188

SECTION 1 BASE

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121188 SSV-10 1-5

SECTION 1 BASE

2324252627

610111213141617181915

FIGURE 1-2. DRIVE MOTOR ASSEMBLY

1-6 SSV-10 3121188

SECTION 1 BASE

FIGURE 1-2. DRIVE MOTOR ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3160303

1 7018059 1 Key

2 7018058 1 Housing, Gear 2A 70000807 1 Primary Gear & Pinion 2B 70000808 1 Secondary Gear & Pinion

2C 70000809 1 Output Gear & Shaft 2D 70001986 A/R Washer, Nylon 2E 70001985 A/R Washer, Steel 2F 70001984 A/R Washer, Nylon 2G 70001989 A/R Washer, Steel 2H 70001983 A/R Washer, Steel

2J 70001988 A/R Washer, Nylon

2K 70001987 A/R Washer, Steel

3 7018028 1 O-Ring

4 Not Available 4 Screw

5 7018057 1 Adapter

6 7018060 1 Armature

7 Not Available 1 Seal

8 Not Available 1 Bearing

9 Not Available 1 Ring, Retaining 10 7018056 1 Ring Assembly 11 Not Available 1 Ring, Retaining 12 Not Available 1 Bearing 13 7018011 1 Washer, Wavy 14 7018000 1 Brush Kit

7018037 2 Cap, Brush 7018061 2 Spring

7018045 2 Cap, Brush 15 Not Available 1 Shield 16 7018055 2 Bolt, Thru 17 Not Available 1 Gear 18 Not Available 1 Screw M5 x 5mm (Part of Item 20) 19 7018059 1 Key 20 7018052 1 Brake Assembly 21 Not Available 3 Screw 22 7018054 1 Boot 23 7018035 1 Clamp 24 7018033 1 Clamp 25 Not Available 1 Harness 26 7018031 1 Housing, Terminal 27 7018030 1 Boot, Housing

Ref. DRIVE MOTOR ASSEMBLY F

3121188 SSV-10 1-7

SECTION 1 BASE

911106851

102

1043103

101

103

104

102

PRIOR TO

S/N 0130008666

TO PRESENT

202122

NOTE: REPLACEMENT DECALS MUST BE ORDERED SEPARATELY - SEE SECTION 8.

FIGURE 1-3. COVERS AND TIE-DOWNS INSTALLATION

1-8 SSV-10 3121188

SECTION 1 BASE

FIGURE 1-3. COVERS AND TIE-DOWNS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0273549 Ref. COVER INSTALLATION K

Ref. Note: Replacement Decals must be ordered separately - See

Section 8.

1 1671141 1 Cover, Battery and Frame 2 1671143 1 Cover, Mast 3 1671146 1 Cover, Rear Bumper 4 1 Cover, Front Hood Options:

1671149 Prior to S/N 0130007502

1671214 S/N 0130007502 to S/N 0130008666

1671298 S/N 0130008666 to Present

5 3300454 9 Nut 1/4”-20NC 6 3900258 22 Screw Button Head 1/4”-20NC x 3/4” 7Not Used 8 4751400 19 Flatwasher 1/4” (Wide)

9 0940049 2 Stopper, Hood 10 3300364 2 Nut 5/16”-18NC (Tinnerman) 11 4751500 4 Flatwasher 5/16” (Wide) 12 Use 2940179 3 (Was P/N 2940166) Latch, Fastener (Prior to S/N 0130007030)

(Use with hood p/n 1671149)

13 Use 2940179 3 (Was P/N 2940167) Latch, Clip (Prior to S/N 0130007030)

(Use with hood p/n 1671149) 14 Not Used 15 0100011 A/R Locking Compound (Not Shown) 16 Use 2940179 3 (Was P/N 2940168) Latch, Retainer (Prior to S/N

0130007030)(Use with hood p/n 1671149)

17 0903222 1 Brace

18 to 19 Not Used

20 4341067 1 Support, Hood (S/N 0130008666 to Present) 21 0641616 4 Bolt 3/8”-16NC x 2”(S/N 0130008666 to Present) 22 4711600 4 Flatwasher 3/8” (Narrow) (S/N 0130008666 to Present) 23 1380169 1 Clip, Receptacle (S/N 0130008666 to Present)

(Use with hood p/n 1671298) 24 3760308 1 Retainer (S/N 0130008666 to Present)

(Use with hood p/n 1671298) 25 3900174 1 Screw, Thumb (S/N 0130008666 to Present)

(Use with hood p/n 1671298)

0240114 Ref. TIE-DOWNS INSTALLATION A

101 0811610 4 Screw 3/8”-16NC x 1 1/4” 102 3311605 4 Locknut 3/8”-16NC 103 3760365 2 Tie-Ring 104 4711600 4 Flatwasher 3/8” Narrow

3121188 SSV-10 1-9

SECTION 1 BASE

FIGURE 1-3. COVERS AND TIE-DOWNS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-10 SSV-10 3121188

SECTION 2

CONTROLS

3121188 SSV-10 2-1

SECTION 2 CONTROLS

102

1B 1D

107

4A 4D

108

FIGURE 2-1. PUMP MOTOR ASSEMBLY AND INSTALLATION

2-2 SSV-10 3121188

SECTION 2 CONTROLS

FIGURE 2-1. PUMP MOTOR ASSEMBLY AND INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3600392 1 PUMP/MOTOR ASSEMBLY D

1 7027943 Ref. Pump Components Kit 1A Not Available 1 Pump 1B Not Available 1 Seal 1C 7011021 1 Seal 1D Not Available 1 Seal 1E 7010928 4 Screw 1F 7011033 1 Screw 1G Not Available 1 Lockwasher 1H Not Available 1 Retainer

1J 7011016 1 Coupler

2 7027944 Ref. Adaptor Components Kit 2A 7011025 1 Seal 2B 7011011 2 Screw 2C Not Available 1 Plug 2D Not Available 1 Adaptor 2E 7011013 1 Retainer 2F Not Available 1 Plug, Plastic (Not Shown) 2G Not Available 1 Plug, Steel 2H Not Available 1 Seat Assembly

2J Not Available 1 Plug

3 7027945 Ref. Relief Valve Components Kit 3A 7011008 1 Spring 3B 7011017 1 Spring 3C 7011009 1 Screw, Adjustment 3D Not Available 1 Gasket 3E 7011004 1 Cap 3F Not Available 1 Ball

4 7027946 Ref. Tube Components Kit 4A 7011024 1 Seal 4B Not Available 1 Seal 4C Not Available 1 Washer 4D 7011031 1 Ring, Retaining 4E 7011032 1 Ring, Retaining 4F Not Used 4G Not Available 1 Tube 4H Not Available 1 Tube

4J Not Available 1 Tube

4K 7011029 1 Strainer

4L 7011034 1 Spacer

5 7027947 Ref. Tank Components Kit 5A Not Available 1 Tank 5B Not Available 4 Screw 5C 7011027 1 Magnet 5D Not Available 1 Label 5E 7011069 1 Breather/Dipstick

6 Not Available 1 Label (Not Shown)

3121188 SSV-10 2-3

SECTION 2 CONTROLS

FIGURE 2-1. PUMP MOTOR ASSEMBLY AND INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

7 7027948 1 Motor Assembly

70000041 1 Brush Kit

8 7027949 Ref. Return Port Components Kit 8A Not Available 1 Seal 8B Not Available 1 Seal 8C Not Available 1 Washer 8D Not Available 1 Body, Return Port

9 2221185 1 Fitting, 90° 10 2110606 1 Fitting, Straight

PUMP/MOTOR INSTALLATIONS

0273546 Ref. Standard Hydraulic Oil E 0274181 Ref. Fire Resistant Hydraulic Oil A

101 0100011 A/R Locking Compound (Not Shown) 102 0641606 2 Bolt 3/8”-16NC x 3/4”

103 to 106 Not Used

107 3600392 1 Pump/Motor Assembly (See Items 1-9 for Breakdown) 108 1704412 1 Decal - Hydraulic Oil (Stamp Appropriately) 109

1.2 gals

2300021 Standard Hydraulic Oil 2300014 Fire Resistant Hydraulic Oil

Oil, Hydraulic Options (Not Shown):

2-4 SSV-10 3121188

SECTION 2 CONTROLS

FIGURE 2-1. PUMP MOTOR ASSEMBLY AND INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121188 SSV-10 2-5

SECTION 2 CONTROLS

111

115

103

127

128

105

108

109

123

127

125

126

123

112

113

114

124

104

102

14615

161217

FIGURE 2-2. CHARGER, HORN AND BATTERIES INSTALLATION

2-6 SSV-10 3121188

SECTION 2 CONTROLS

FIGURE 2-2. CHARGER, HORN AND BATTERIES INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. BATTERY CHARGER INSTALLATIONS 0273559 Ref. Charger with ANSI Plug C 0274169 Ref. Charger with Australian Plug A 0274168 Ref. Charger without Plug A 0274259 Ref. Charger with Plug/Cord Reel A

1 0400208 1 Battery Charger Assembly (See Figure 2-3 for Breakdown) 2 0610131 1 LED Board 3 0641404 4 Bolt 1/4”-20NC 1/2”

4 to 5 Not Used

6 3911016 4 Screw #10-24NC x 1” 7 A/R Cover, Terminal Options:

4460802 1 Charger with Plug 4460802 1 Charger without Plug

Not Required 0 Charger with Plug/Cord Reel

8 A/R Terminal, Inlet Options:

4460803 1 Charger with ANSI Plug 4460940 1 Charger with Australian Plug

Not Required 0 Charger without Plug

4120046 1 Socket, Cord Reel Stop (Charger with Plug/Cord Reel Only)

9 to10 Not Used

11 0100011 A/R Locking Compound (Not Shown)

Note: Items 12 - 16 used with Charger with Plug/Cord Reel only.

12 3680056 1 Reel, Charger 13 0791406 1 Screw 1/4”-20NC x 3/4” 14 3311001 4 Nut #10-24NC 15 3311501 1 Nut 5/16”-18NC 16 3575423 1 Plate 17 0791506 1 Bolt 5/16”-18NC x 3/4”

0273548 Ref. HORN AND BATTERIES INSTALLATION L

101 0100051 A/R Grease, Battery Terminal (Not Shown) 102 0140022 1 Horn 103 0400209 2 Battery 104 0641404 1 Bolt 1/4”-20NC x 1/2” 105 0741005 2 Capscrew, Flat Head #10-24NC x 1/2”

106 to 107 Not Used

108 2400044 1 Block, Fuse Mounting 109 2400069 1 Fuse 175Amp 110 3020038 A/R Grease, Electrical Contact (Not Shown) 111 3311501 4 Nut 5/16”-18NC 112 3911016 4 Screw #10-24NC x 1” 113 4071084 2 Shim 114 4360514 2 Switch, Proximity 115 4761500 4 Lockwasher 5/16”

116 to 122 Not Used

123 0791003 4 Screw #10-24NC x 3/8”

3121188 SSV-10 2-7

SECTION 2 CONTROLS

FIGURE 2-2. CHARGER, HORN AND BATTERIES INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

124 3380541 1 Shield, Wire 125 0791406 2 Screw 1/4”-20NC x 3/4” 126 3575423 2 Plate, Battery Hold-down 127 2920178 2 Light, Strobe B

7027733 2 Bulb, Replacement (1 Per Assembly) 128 3820032 2 Rivet 129 0100011 A/R Locking Compound (Not Shown)

2-8 SSV-10 3121188

SECTION 2 CONTROLS

FIGURE 2-2. CHARGER, HORN AND BATTERIES INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121188 SSV-10 2-9

SECTION 2 CONTROLS

3126

1415161718

FIGURE 2-3. BATTERY CHARGER ASSEMBLY

2-10 SSV-10 3121188

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