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JLG Toucan 8e Service Manual

JLG Toucan 8e
191 pages
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Service and Maintenance Manual
Models
TOUCAN 8E/20E
TOUCAN 10E/26E
P/N - 31210090
June 21, 2019
®
AS
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Table of Contents

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JLG Toucan 8e Specifications

General IconGeneral
Max Working Height8.15 m
Max Platform Height6.15 m
Platform Capacity200 kg
Overall Width / Machine Width / Stowed Width0.99 m
Overall Height / Stowed Height1.99 m
Power SourceElectric
Gradeability25%

Summary

Section A: Introduction - Maintenance Safety Precautions

General Safety Precautions

General safety precautions for machine maintenance, emphasizing importance and owner responsibility.

Hydraulic System Safety

Safety precautions for hydraulic systems, highlighting high pressures and potential hazards.

Maintenance Safety

Key safety rules for maintenance, including personal safety and equipment protection.

Section 1: Operating Specifications

Operating Specifications Overview

Details on operating specifications for Toucan models, including load, persons, and wind speed.

Dimensional Data

Provides dimensional measurements for Toucan models, such as height, length, and width.

Performance Data

Lists performance metrics like platform height, reach, swing angle, and lift times.

Component Data and Weights

Specifications for batteries, hydraulic units, drive motors, swing motors, and cylinders.

Lubrication Specifications

Details hydraulic oil specifications and lubrication chart for machine components.

Torque Requirements

Provides torque values for bolts, nuts, studs, and hydraulic fittings.

Section 2: General Service Information

Machine Preparation, Inspection and Maintenance

Information on establishing a comprehensive inspection and preventive maintenance program.

Preventive Maintenance and Inspection Schedule

Details the inspection schedule, outlining areas and intervals for checks.

Servicing and Maintenance Guidelines

General guidelines for servicing, including safety, cleanliness, and component handling.

Lubrication Information

Guidance on hydraulic system contamination and lubrication best practices.

Section 3: Theory of Operation

System Overview and Modules

Explains the master and slave controller functions and platform module communication.

Modes of Operation

Describes Ground Mode and Platform Mode operations.

CAN Communications

Details the Controller Area Network (CAN) communication system used in the machine.

Joysticks and Traction

Explains joystick operation and the electric drive system for traction.

Pump/Structure Movements

Describes how hydraulic pump and structure movements are actuated.

Interlocks and System Functions

Explains system interlocks like overload, tilt, chain slack, and drive orientation switches.

Section 4: Chassis Mounted Components

Drive Motors and Brake System

Details drive motor assembly, brake dust cleaning, disassembly, and wear checking.

Wheels and Tires

Covers tire wear, damage, replacement, and proper wheel installation torque.

Steering Linkage and Front Wheel Hub

Procedures for steering linkage assembly and front wheel hub installation.

Section 5: Turntable and Vertical Mast

Swing Bearing Maintenance

Covers swing bearing attach bolt checks, lubrication, and replacement procedures.

Mast Cylinder Removal and Installation

Step-by-step guide for removing and installing the mast cylinder assembly.

Lifting Chains Service

Procedures for lifting chains removal, installation, inspection, and tension adjustment.

Mast and Rollers Setting

Instructions for setting top and bottom rollers for mast alignment and play.

Section 6: Jib and Platform

Platform Removal and Installation

Procedures for removing and installing the platform assembly, including bearings.

Overload System Verification and Setting

Steps to verify and set the overload system for safety.

Jib Cylinder Removal and Installation

Detailed instructions for removing and installing the jib cylinder.

Section 7: Hydraulics

Hydraulic Tank Service

Procedures for checking oil level, adding oil, draining, cleaning, and filling the hydraulic tank.

Hydraulic Filter Replacement

Instructions for replacing the hydraulic filter element.

Hydraulic Power Unit Components

Identification and explanation of components within the hydraulic power unit.

Hydraulic Lines and Valves

Description of hydraulic lines, proportional relief valve, and air bleeding.

Cylinders Holding Valves

Procedures for removal and installation of mast and jib cylinder holding valves.

Cylinder Repair Procedures

General procedures for cylinder disassembly, inspection, and assembly.

Section 8: Control Components

Control Components Overview

Diagram showing the location of control components on the machine.

Battery Maintenance and Safety

Guidelines for battery maintenance, safety practices, and electrolyte level checks.

Power Module Service

Procedures for removing and installing power modules, including electrical evaluation.

Ground and Platform Control Stations

Maintenance and replacement of ground control panel and platform control station components.

Joystick and Switch Evaluation

Evaluation of mast, jib, and drive joysticks, as well as membrane switches.

Section 9: JLG Control System

Hand Held Analyzer Operation

Instructions for connecting and using the hand-held analyzer for system diagnostics.

Machine Setup Programming

Information on programming machine setup parameters for optimal performance.

Calibration Procedures

Guides for calibrating steering sensor, overload system, joysticks, and pressure relief valve.

System Test

Procedures for performing a built-in system test to check components and functions.

Section 10: Diagnostic Trouble Codes

Introduction to Diagnostic Trouble Codes

Overview of DTCs, their display, and troubleshooting methodology.

DTC Check Tables

Comprehensive tables listing fault messages, descriptions, and check procedures.

Platform Control System Codes

Diagnostic Trouble Codes related to platform controls and functions.

Ground Control System Codes

Diagnostic Trouble Codes related to ground controls and system functions.

Line Contactor and Drive System Codes

DTCs for line contactor issues and ground output driver problems.

Thermal Limit and Battery Supply Codes

Troubleshooting codes for thermal limits and battery voltage issues.

Communication and Accessory Codes

DTCs related to CANbus communication failures and accessory functions.

Section 11: General Electrical Information & Schematics

General Electrical Information

Basic electrical information and schematics for troubleshooting equipment problems.

Multimeter Basics and Usage

Guidance on using multimeters for voltage, resistance, and continuity measurements.

Checking Switches and Connectors

Procedures for testing switches, applying dielectric compound, and handling AMP/Deutsch connectors.

Electrical and Hydraulic Schematics

Wiring diagrams and hydraulic schematics for Toucan models.

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