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JLG Toucan 12E Service Manual

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

Table of Contents

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Questions and Answers:

JLG Toucan 12E Specifications

General IconGeneral
BrandJLG
ModelToucan 12E
CategoryLifting Systems
LanguageEnglish

Summary

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

C MAINTENANCE SAFETY PRECAUTIONS

Lists specific safety precautions for maintenance, including personal attire, general warnings, and specific procedure guidance.

SECTION 1 - OPERATING SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS

Provides a table detailing key operating specifications for different models, including work load, persons, wind speed, and weight.

1.2 DIMENSIONAL DATA

Presents a table with dimensional data for the machine models, covering height, length, width, and ground clearance.

1.3 PERFORMANCE DATA

Details performance specifications such as platform height, reach, swinging angle, turning radius, and lift/drive times.

1.5 COMPONENTS DATA

Provides specifications for major components including batteries, hydraulic units, drive motors, swing drives, and cylinders.

SECTION 2 - GENERAL SERVICE INFORMATION

2.1 MACHINE PREPARATION, INSPECTION AND MAINTENANCE

Details general information on placing the machine in operation readiness and maintaining safe operating conditions.

2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

Outlines the schedule for periodic machine inspections and maintenance, including types, frequency, and responsibilities.

2.3 SERVICING AND MAINTENANCE GUIDELINES

Provides general information and guidelines for use and application of servicing and maintenance procedures.

SECTION 3 - THEORY OF OPERATION

3.4 JOYSTICKS

Explains the function of joysticks for controlling machine movements and the process of joystick calibration.

3.6 PUMP/STRUCTURE MOVEMENTS

Explains how the hydraulic pump and superstructure movements (lift, swing, steer, telescope, platform level) are actuated.

Interlocks

Details system interlocks that affect functions based on sensors and measurements like overload, tilt, and chain slack.

SECTION 4 - CHASSIS MOUNTED COMPONENTS

4.1 DRIVE MOTORS

Describes the electric wheel drive assemblies, including brake characteristics, dust cleaning, disassembly, and wear checking.

4.3 STEERING LINKAGE

Explains the removal, inspection, and installation procedures for the steer cylinder and steering linkage assembly.

SECTION 5 - TURNTABLE AND VERTICAL MAST

5.1 SWING BEARING

Details checks for swing bearing attach bolts, lubrication procedures for race and teeth, and replacement steps.

Lifting Chains Removal and Installation

Provides detailed steps for removing and installing lifting chains for different stages of the mast.

5.6 MAST CYLINDER

Details the procedure for mast cylinder removal, including safety precautions and component steps.

SECTION 6 - TELESCOPIC BOOM AND PLATFORM

6.1 OVERLAOD SYSTEM

Explains the overload system, including verification procedures and setting adjustments.

6.2 PLATFORM

Details the removal and installation procedures for the platform assembly, including cable and bearing checks.

6.3 PLATFORM SUPPORTS AND SLAVE CYLINDER

Covers the removal and installation of platform supports and the slave cylinder.

6.4 TELESCOPIC BOOM, BOOM AND MASTER CYLINDERS

Provides procedures for removing and installing telescopic boom, boom, and master cylinders.

6.5 TELESCOPE

Details removal and installation procedures for telescope sections and cylinders for different models.

SECTION 7 - HYDRAULICS

7.2 HYDRAULIC POWER UNIT

Describes the hydraulic power unit, its ports, and the proportional pressure relief valve.

7.3 HYDRAULIC TANK

Provides information on hydraulic tank capacity, oil level checks, adding oil, and tank draining/cleaning procedures.

7.6 CYLINDERS HOLDING VALVES

Details the mast, jib, and telescope cylinder holding valves, including removal, installation, and solenoid valve information.

Telescope Cylinder Holding Valve

Covers the telescope cylinder holding valve, including dual over-center valve function and setting procedures.

7.8 CYLINDER REPAIR

Provides general procedures for cylinder repair, covering disassembly, inspection, and assembly of various cylinder types.

Disassembly

General procedures for cylinder disassembly, including safety notices and step-by-step instructions.

Assembly

Details the general assembly procedures for cylinders, including seal installation and component alignment.

SECTION 8 - CONTROL COMPONENTS

8.2 CONTROL COMPONENTS - SERVICE

Covers service procedures for control components, focusing on battery maintenance, filling circuits, and container care.

Battery Troubleshooting

Presents a troubleshooting table for common battery issues, their probable causes, and corrective actions.

Mast Elevation Limit Switch

Describes the mast elevation limit switch, its actuation, and conditions for mast limit switch operation.

Jib Elevation Limit Switches

Explains the jib limit switches, their actuation points, and conditions for main and end-of-stroke switches.

Chain Slack Sensor

Details the chain slack detection device, its location on each lifting chain stage, and wiring.

Overload Sensor

Describes the overload sensor, its function, and conditions that trigger it.

Overload System Calibration

Provides a mechanical calibration procedure for the overload system, including load placement and setting adjustments.

Steering Sensor

Details the steering sensor's location, operation, and connection conditions.

Tilt Sensor

Describes the tilt sensor's location and function in determining machine tilt.

8.4 POWER MODULE

Details the location, function, removal, and installation of the power modules.

8.5 GROUND CONTROL STATION

Details the ground control station components, including connector pin assignments for the ground module.

8.6 PLATFORM CONTROL STATION

Details procedures for replacing the printed circuit board and components in the upper control box.

SECTION 9 - JLG CONTROL SYSTEM

9.1 HAND HELD ANALYZER

Introduces the hand-held analyzer for accessing the control system, including its menu structure and basic operation.

Hand Analyzer

Details the connection and usage of the hand analyzer, including navigating menus and changing access levels.

Adjusting Parameters Using the Hand Held Analyzer

Explains how to adjust personality settings using the analyzer once Service Access is gained.

Machine Setup

Describes how to adjust machine digit items and configure settings like ground alarm and model selection.

9.3 MACHINE SETUP PROGRAMMING INFORMATION

Provides guidance on programming new power module controllers for proper machine configuration and options.

9.4 CALIBRATION INSTRUCTIONS

Lists required calibrations for sensors and valves, and reasons for re-calibration.

9.5 CALIBRATING STEERING SENSOR

Details the step-by-step procedure for calibrating the steering sensor, including wheel alignment.

9.6 CALIBRATING TILT SENSOR

Explains how to calibrate the tilt sensor, including verification steps and acceptable angle tolerances.

9.7 CALIBRATING THE JOYSTICKS

Provides instructions for calibrating joysticks for various machine functions like drive, swing, mast, jib, and telescope.

9.8 CALIBRATING THE PRESSURE RELIEF VALVE

Describes the procedure for calibrating pressure relief valves for all machine movements, setting personalities.

9.9 MACHINE PERSONALITY - ADJUSTMENT SETTINGS

Lists personality settings for drive, steer, swing, mast, telescope, and platform functions with adjustment ranges.

9.10 SYSTEM TEST

Explains how to perform a built-in system test to check machine components and functions using the analyzer.

SECTION 10 - DIAGNOSTIC TROUBLE CODES

10.1 INTRODUCTION

Provides a reference for Diagnostic Trouble Codes (DTCs) displayed on analyzer, MDI, and platform console.

10.3 DTC CHECK TABLES

Contains tables detailing DTCs, help messages, conditions, system response, and corrective actions for troubleshooting.

8-1 Tilt Sensor

Covers DTCs related to the tilt sensor, including calibration status, out-of-range signals, and stagnant sensor faults.

8-2 Platform Load Sense

Details DTCs related to platform load sensing, including overload conditions and sensor information inconsistencies.

8-6 Steering/Axle

Lists DTCs related to steering valve circuits and the steer sensor, covering open circuits, shorts, and out-of-range signals.

SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

11.8 ELECTRICAL SCHEMATIC

Presents electrical schematics for the drive system, turntable, lower control board, mast, platform box, and batteries.

11.9 HYDRAULIC SCHEMATIC

Includes the hydraulic schematic illustrating the system's components and flow paths.

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