JLG Toucan 12E Plus Service Manual

Service and Maintenance Manual
Model
TOUCAN 12E
P/N - 31210149
December 18, 2013

JLG Toucan 12E Plus Specifications

General

Platform Capacity	250 kg
Drive Type	Electric
Turning Radius	3.05 m
Machine Weight	2, 700 kg
Platform Width	0.76 m
Gradeability	25%
Battery Voltage	48 V

Summary

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A GENERAL

Provides general safety precautions for aerial platform maintenance.

B HYDRAULIC SYSTEM SAFETY

Details safety precautions for high-pressure hydraulic systems.

C MAINTENANCE

Lists crucial safety warnings and general maintenance guidelines.

SECTION 2 - GENERAL SERVICE INFORMATION

2.1 MACHINE PREPARATION, INSPECTION AND MAINTENANCE

2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

Outlines inspection and maintenance requirements and intervals.

2.3 SERVICING AND MAINTENANCE GUIDELINES

SECTION 5 - TURNTABLE AND VERTICAL MAST

5.1 SWING BEARING

Covers swing bearing checks, lubrication, and replacement.

5.2 SWING DRIVE

5.4 LIFTING CHAINS

5.6 MAST CYLINDER

SECTION 6 - TELESCOPIC BOOM AND PLATFORM

6.1 OVERLAOD SYSTEM

Details overload system verification and setting procedures.

6.2 PLATFORM

6.3 PLATFORM SUPPORTS AND SLAVE CYLINDER

6.4 TELESCOPIC BOOM, BOOM AND MASTER CYLINDERS

6.5 TELESCOPE

Covers telescope sections and cylinder removal/installation for different models.

SECTION 7 - HYDRAULICS

7.2 HYDRAULIC POWER UNIT

7.6 CYLINDERS HOLDING VALVES

7.8 CYLINDER REPAIR

Outlines general procedures for cylinder disassembly and assembly.

SECTION 8 - CONTROL COMPONENTS

8.2 CONTROL COMPONENTS - SERVICE

Covers battery maintenance, troubleshooting, and electrical component service.

8.3 TRACTION SYSTEM

8.4 POWER MODULE

Details power module removal, installation, and electrical evaluation.

8.5 GROUND CONTROL STATION

8.6 PLATFORM CONTROL STATION

Covers PCB replacement and joystick components for the platform control.

SECTION 9 - JLG CONTROL SYSTEM

9.1 HAND HELD ANALYZER

Explains the analyzer's menu structure and basic operation.

9.3 MACHINE SETUP PROGRAMMING INFORMATION

Details machine configuration settings and options.

9.4 CALIBRATION INSTRUCTIONS

Lists required calibrations and reasons for re-calibration.

9.5 CALIBRATING STEERING SENSOR

Provides step-by-step instructions for steering sensor calibration.

9.6 CALIBRATING TILT SENSOR

Explains the procedure for calibrating the tilt sensor.

9.7 CALIBRATING THE JOYSTICKS

Details the process for calibrating machine joysticks.

9.8 CALIBRATING THE PRESSURE RELIEF VALVE

Describes how to set and adjust pressure relief valve personalities.

9.9 MACHINE PERSONALITY - ADJUSTMENT SETTINGS

Lists personality settings for drive, steer, and swing functions.

9.10 SYSTEM TEST

Explains how to perform system tests using the analyzer.

SECTION 10 - DIAGNOSTIC TROUBLE CODES

10.1 INTRODUCTION

10.3 DTC CHECK TABLES

Lists DTCs, conditions, and corrective actions for troubleshooting.

2-2 Platform Controls

2-3 Ground Controls

2-5 Function Prevented

Lists DTCs indicating prevented functions due to specific conditions.

3-3 Ground Output Driver

4-2 Thermal Limit

4-4 Battery Supply

Lists DTCs related to battery voltage issues.

4-6 Transmission and Drive System

6-6 Communication

Lists DTCs related to CAN bus communication errors.

7-7 Electric Motor

Lists DTCs related to electric motors, including drive and pump motors.

8-1 Tilt Sensor

Lists DTCs related to the tilt sensor and its calibration.

8-2 Platform Load Sense

Lists DTCs related to platform overload detection.

8-6 Steering/Axle