JLG Toucan 12E Manuals

Manuals and User Guides for JLG Toucan 12E. We have 3 JLG Toucan 12E manuals available for free PDF download: Service And Maintenance Manual, Operation And Safety Manual

JLG Toucan 12E Service And Maintenance Manual (205 pages)

Personal lifts

Brand: JLG | Category: Lifting Systems | Size: 10.07 MB

Section a - Introduction - Maintenance Safety Precautions Revison Log

5
- Section a - Introduction - Maintenance Safety Precautions
  
  3
  - Bhydraulic System Safety
    3
  - Cmaintenance
    3
    
    A General
    3
    
    Table of Contents
    5
- Section 1 - Operating Specifications
  
  15
  - Operating Specifications
    15
  - Dimensional Data
    15
  - JLG Lift
    15
  - Performance Data
    16
  - Capacities
    16
  - Components Data
    17
    
    Batteries
    17
    
    Drive Motor Assembly
    17
    
    Electric Pump / Electric Motor Assembly
    17
    
    Cylinders
    18
    
    Platform Rotation Drive
    18
    
    Swing Drive
    18
    
    Tires
    18
  - Major Components Weights
    19
  - Lubrication
    20
    
    Hydraulic Oil
    20
    
    Lubrication Chart
    21
    
    Lube Specifications
    22
  - Torque Requirements
    22
  - Serial Number Locations
    23
- Section 2 - General Service Information
  
  25
  - Machine Preparation, Inspection and Maintenance
    25
    
    Annual Machine Inspection
    25
    
    General
    25
    
    Pre-Delivery Inspection and Frequent Inspection
    25
    
    Pre-Start Inspection
    25
    
    Preparation, Inspection and Maintenance
    25
    
    Preventative Maintenance
    25
  - Preventive Maintenance and Inspection Schedule
    26
  - Inspection and Preventive Maintenance Schedule
    27
    
    Bearings
    30
    
    Care and Installation of Teflon Coated Bushings
    30
    
    Cleanliness
    30
    
    Component Disassembly and Reassembly
    30
    
    Components Removal and Installation
    30
    
    General
    30
    
    Pressure-Fit Parts
    30
    
    Safety and Workmanship
    30
    
    Servicing and Maintenance Guidelines
    30
    
    Bolt Usage and Torque Application
    32
    
    Hydraulic Lines and Electrical Wiring
    32
    
    Hydraulic System
    32
    
    Battery
    33
    
    Changing Hydraulic Oil
    33
    
    Hydraulic Oil
    33
    
    Hydraulic System
    33
    
    Lubrication
    33
    
    Lubrication Information
    33
    
    Lubrication Specifications
    33
    
    Pressure Relief Valve
    33
    
    Welding on Work Platform
    33
    
    Hydraulic Cartridge Installation
    34
- Section 3 - Theory of Operation
  
  35
  - Overview
    35
  - Modes of Operation
    35
    
    Ground Mode
    35
    
    Platform Mode
    35
  - Can Communications
    35
  - Joysticks
    36
  - Traction
    36
  - Pump/Structure Movements
    37
    
    Lift Up/Down
    37
  - Hydraulic Pump Electric Schematic
    37
    
    Swing
    38
    
    Steer
    39
    
    Telescope
    39
  - Telescope System - Basic Schematic
    39
    
    Interlocks
    40
    
    Platform Level
    40
    
    Personality Settings and Calibration
    41
- Section 4 - Chassis Mounted Components
  
  43
  - Drive Motors
    43
    
    Brake - Dust Cleaning
    43
    
    Brake - Electrical Characteristics
    43
    
    Brake Disassembly
    43
    
    Brake Disk Wear Checking
    43
  - Dust Cleaning
    43
    
    Brake Assembly
    44
    
    Drive Motor Assembly Removal
    44
    
    Drive Motor Assembly Installation
    45
    
    Oil Filling
    45
    
    Oil Type & Capacity
    45
  - Drive Motor Installation
    45
    
    Tire Wear and Damage
    46
    
    Wheel and Tire Replacement
    46
    
    Wheel Installation
    46
    
    Wheels and Tires
    46
  - Wheel Lug Nut Tightening Sequence
    46
    
    Steer Cylinder
    47
    
    Steering Linkage
    47
    
    Steering Linkage - Spindle/Hub Assembly
    47
  - Steering Sensor Installation
    48
- Section 5 - Turntable and Vertical Mast
  
  49
  - Swing Bearing
    49
    
    Swing Bearing Attach Bolts Check
    49
    
    Swing Bearing Lubrication
    49
  - Swing Bearing Race Lubrication
    49
  - Swing Bearing Teeth Lubrication
    49
    
    Replacement of Swing Bearing
    50
  - Swing Bearing Removal - 1 of 6
    50
  - Swing Bearing Removal - 2 of 6
    50
  - Swing Bearing Removal - 3 of 6
    50
  - Swing Bearing Removal - 4 of 6
    50
  - Swing Bearing Removal - 5 of 6
    50
  - Swing Bearing Removal - 6 of 6
    50
    
    Swing Drive
    52
    
    Swing Drive Removal
    52
  - Swing Bearing Installation
    52
    
    Inspection
    53
    
    Removal and Installation
    53
    
    Rollers
    53
    
    Swing Drive Assembly
    53
    
    Swing Drive Disassembly
    53
    
    Swing Drive Installation
    53
  - Roller Assembly
    53
    
    Mast Transversal Play/Mast Sections Alignment
    54
  - Roller Removal
    54
  - Roller Installation
    54
  - Mast Sections Vertical Alignment
    54
    
    Lifting Chains
    55
    
    Lubrication
    55
    
    Safety Accessories and Tooling
    55
    
    Lifting Chains Inspection
    56
    
    Lifting Chains Removal and Installation
    57
  - Chains Stages and Attachments Description
    57
  - First Chain Stage
    58
  - Third Chain Stage
    59
  - First Chains Stage Removal
    60
  - Second Chains Stage Removal
    61
  - Third Chains Stage Removal
    62
  - Fourth Chains Stage Removal
    63
    
    Chain Tension Adjustment
    64
    
    Pulley - Pulley Support
    64
    
    Pulley Inspection
    64
  - Chains Tension Control
    64
    
    Removal and Installation
    65
    
    Mast Cylinder
    66
    
    Mast Cylinder Removal
    66
    
    Mast Cylinder Removal - 4 of 8
    67
    
    Mast Cylinder Disassembly
    68
    
    Mast Cylinder Installation
    68
    
    Counterweight
    69
    
    Counterweight Installation
    69
    
    Counterweight Removal
    69
- Section 6 - Telescopic Boom and Platform
  
  71
- Section 7 - Hydraulics
  
  79
  - Hydraulic Lines Connections
    79
  - Hydraulic Power Unit
    80
    
    Ports Identification
    80
    
    Proportional Pressure Relief Valve
    80
    
    Check Valve 0.5 Bar
    81
    
    Check Valve 4.5 Bar
    81
    
    Electric Motor
    81
  - Dust Cleaning
    81
    
    Adding Oil to the System
    82
    
    Hydraulic Tank
    82
    
    Oil Level
    82
  - Hydraulic Oil Check
    82
    
    Main Manifold
    83
    
    Manifold Schematic
    83
    
    Tank Draining/Cleaning
    83
    
    Tank Filling
    83
    
    Assembly
    84
    
    Disassembly
    84
    
    Inspection
    84
  - Hand Pump
    84
    
    Assembly
    85
    
    Disassembly
    85
    
    Inspection
    85
    
    Manifold Schematic
    85
    
    Secondary Manifold
    85
    
    Cylinders Holding Valves
    86
    
    Jib Cylinder Holding Valve
    86
    
    Mast Cylinder Holding Valve
    86
    
    Jib Cylinder Holding Valve - Schematic/Exploded View
    87
    
    Slave Cylinder Holding Valve
    88
    
    Telescope Cylinder Holding Valve
    88
  - Adjustment Checking
    89
  - Air Bleeding from Rod Side
    89
    
    Swing Motor
    90
  - Air Bleeding from Piston Side
    90
    
    Cylinder Repair
    91
  - Telescope Plus Cylinder
    94
    
    Assembly
    95
    
    Disassembly
    95
    
    Inspection
    95
- Section 8 - Control Components
  
  97
  - Control Components Overview
    97
  - Control Components Location
    97
    
    Battery Maintenance and Safety Practices
    98
    
    Control Components - Service
    98
  - Draining the Water
    99
  - Battery Troubleshooting
    100
    
    Main Power Contactor Relay
    101
    
    Power Fuse
    101
    
    Jib Elevation Limit Switches
    102
    
    Mast Elevation Limit Switch
    102
  - Mast Elevation Limit Switches
    102
    
    Chain Slack Sensor
    103
    
    Overload Sensor
    104
    
    Overload System Calibration
    104
    
    Drive Orientation Switch
    105
    
    Steering Sensor
    105
    
    Tilt Sensor
    106
    
    Common Traction System Difficulties
    107
    
    Traction System
    107
    
    Power Module
    108
    
    Removal
    108
    
    Installation
    109
    
    Power Module Electrical Evaluation
    110
    
    Ground Control Station
    112
    
    Ground Module
    112
  - Ground Control Station Connectors - 2 of 3
    113
  - Ground Control Station Connectors - 3 of 3
    114
    
    Membrane Panel
    115
    
    Printed Circuit Board (PCB) Replacement
    115
    
    Platform Control Station
    116
    
    Printed Circuit Board (PCB) Replacement
    116
    
    Upper Control Box - Component Replacement
    116
    
    Upper Control Box - Components Evaluation
    117
- Section 9 - Jlg Control System
  
  119
  - Hand Held Analyzer
    119
    
    Analyzer Menu Structure
    119
    
    Hand Analyzer
    120
    
    Using the Analyzer
    120
    
    Changing the Access Level of the Hand Held Analyzer
    121
    
    Adjusting Parameters Using the Hand Held Analyzer
    122
    
    Machine Setup
    123
  - Analyzer Screen Layout
    124
  - Analyzer Flow Chart - Sheet 2 of 2
    125
    
    Machine Setup Programming Information
    126
    
    Calibrating Steering Sensor
    128
    
    Calibrating the Joysticks
    128
    
    Calibrating Tilt Sensor
    128
    
    Calibration Instructions
    128
    
    Calibrating the Pressure Relief Valve
    129
    
    Machine Personality - Adjustment Settings
    130
    
    System Test
    135
Section 10 - Diagnostic Trouble Codes Section 10. Diagnostic Trouble Codes 10.1 Introduction

137
- Section 10 - Diagnostic Trouble Codes
  
  137
  - Introduction
    137
  - Dtc Index
    137
- 10.2 Dtc Index
  
  138
  - Dtc Check Tables
    138
    
    Help Comments
    138
  - Power-Up
    140
  - Platform Controls
    140
  - Ground Controls
    143
  - Function Prevented
    148
  - Line Contactor Open Circuit
    150
  - Line Contactor Short Circuit
    150
  - Ground Output Driver
    152
  - Thermal Limit
    159
  - Battery Supply
    162
  - Transmission and Drive System
    165
  - Communication
    166
  - Accessory
    169
  - Electric Motor
    169
  - Tilt Sensor
    172
  - Platform Load Sense
    173
  - Steering/Axle
    173
  - Safety System Override
    177
  - Hardware
    177
    
    General
    183
  - Resistance Measurement
    184
  - Current Measurement
    185
    
    Automatic Switches
    186
  - Amp Connector
    187
  - Connector Assembly Figure 2
    188
    
    Disassembly
    189
  - Connector Installation
    190
    
    Deutsch Connectors
    191
    
    HD30/HDP20 Series Assembly
    192
    
    Connectors Identification
    193
  - Wiring Harness and Connectors - Sheet 2 of 3
    194
  - Wiring Harness and Connectors - Sheet 3 of 3
    195
  - Electrical Schematic
    196
  - Electrical Schematic - Turntable
    197
  - Electrical Schematic - Lower Control Board
    198
  - Electrical Schematic - Mast
    199
  - Electrical Schematic - Platform Box
    200
  - Electrical Schematic - Batteries
    201
  - Hydraulic Schematic
    202

JLG Toucan 12E Operation And Safety Manual (136 pages)

Brand: JLG | Category: Boom Lifts | Size: 4.33 MB

Table of Contents
7
Section 1 - Safety Precautions
13
General
13
Pre-Operation
13
Operator Training and Knowledge
13
Workplace Inspection
14
Machine Inspection
14
Operation
15
General
15
Trip and Fall Hazards
16
Electrocution Hazards
17
Minimum Approach Distance (M.A.D.)
17
Tipping Hazards
18
Crushing and Collision Hazards
19
Towing, Lifting, and Hauling
20
Additional Hazards / Safety
20
Beaufort Scale (for Reference Only)
21
Section 2. User Responsibilities, Machine Preparation, and Inspection
23
Personnel Training
23
Operator Training
23
Training Supervision
23
Operator Responsibility
23
Preparation, Inspection, and Maintenance
24
Inspection and Maintenance Table
25
Pre-Start Inspection
26
General
28
Function Check
29
Tilt Sensor Check
30
Tilt Sensor
30
Overload Sensor Check (if Equipped)
31
Overload Sensor
31
Slack/Broken Chain Sensors Check
32
Slack/Broken Chain Sensors
32
Gate Sensors Check (XL Basket Only)
33
XL Basket
33
Section 3 - Machine Controls and Indicators
35
Basic Nomenclature - Location of Machine Controls
35
General
36
Controls and Indicators
36
Ground Control Station
36
Ground Control Station
37
Platform Manual Descent Valves
40
Mast Manual Descent Valve and Actuator
40
Mast Manual Descent Valve
40
Jib Manual Descent Valve
41
Manual Swinging Operating Devices
42
Rotary Valve
42
Platform Control Station
43
Platform Control Indicator Panel
45
Decal Installation
49
Decal Installation - Sheet 1
49
Section 4. Machine Operation
55
Description
55
Operating Specifications and Limitations
55
Capacities
55
Stability
55
Position of Least BACKWARD Stability
56
Position of Least FORWARD Stability
56
Grade and Side Slope
57
Grade and Side Slope
58
Operation
59
Steering and Travelling (Driving)
59
Steering
60
Travelling (Driving)
60
Drive Orientation System (DOS)
61
Raising and Lowering the Platform
61
Lift Controls
61
Raising and Lowering the Mast
62
Raising and Lowering the Jib
62
Swinging
63
Swing Control
63
Emergency Control
64
Emergency Controls
64
Alarms
65
Overload Warning Light/Alarm (if Equipped)
65
Tilt Warning Light/Alarm
65
Slack Chain Warning Light/Alarm
66
Gate Opening Warning Light (XL Basket Only)
67
Soft Touch Warning Light/Alarm (if Equipped)
67
Machine Safety System Override (Msso) (if Equipped)
67
Shut down and Park
68
Battery Charging
68
Battery Charger Fault Code
70
Tie-Down/Lift Lugs
71
Tie down
71
Lifting
71
Machine Tie-Down
71
Lifting the Machine
71
Towing
72
Lifting the Machine Using a Fork Truck
72
Electric Brake Release
73
Section 5 - Emergency Procedures
75
General
75
Incident Notification
75
Emergency Operation
75
Operator Unable to Control Machine
75
Platform or Jib Caught Overhead
76
Platform Manual Descent
76
Emergency Towing
76
Machine Safety System Override (Msso) (if Equipped)
76
Section 6. General Specifications & Operator Maintenance
77
Introduction
77
Other Publications Available
77
Operating Specifications
78
Operating Specifications and Dimensions
78
Tires Specifications
82
Drive Motors - Hydraulic Power Unit
83
Battery Specifications
84
Lubrication Specifications
84
Hydraulic Oil Specifications - Standard
84
Hydraulic Oil Specifications - Optional
85
Operator Maintenance
86
Operator Maintenance & Lubrication Diagram
86
Chassis Hood Removal
87
Battery Maintenance
88
Battery Maintenance and Safety Practices
88
Level Indicators
88
Adding Water to Batteries
89
Battery Voltage and Electrolyte Specific Gravity
90
Draining the Water
90
Measuring Electrolyte Specific Gravity
91
Filling System Maintenance
92
Use of a Battery in a Cold Environment
92
Battery Not Working Continuously or Inactive Battery
92
Battery Troubleshooting
93
Oil Level/Oil Filter
94
Hydraulic Oil Check
94
Hydraulic Filter Replacement
95
Tires & Wheels
96
Tire Wear and Damage
96
Wheel and Tire Replacement
96
Wheel Installation
96
Wheel Lug Nut Tightening Sequence
96
Lubrication
97
Wheel Torque Chart
97
Overload System Spring Washer (if Equipped)
98
Overload System Spring Washer Lubrication
98
Swing Bearing Race
99
Swing Bearing Race Lubrication
99
Swing Bearing Teeth
100
Swing Bearing Teeth Lubrication
100
Mast Profiles Races
101
Mast Profiles Races Lubrication
101
Lifting Chains
102
Overload System Verification (if Equipped)
103
Overload System Verification
103
Tilt Sensor Verification
104
Jacking Points
104
Dtc Index
105
Dtc Check Tables
106
Help Comments
106
Power-Up
107
Platform Controls
108
Ground Controls
110
Function Prevented
112
Line Contactor Open Circuit
114
Line Contactor Short Circuit
114
Ground Output Driver
115
Thermal Limit
118
Battery Supply
120
Transmission and Drive System
122
Communication
123
Accessory
123
Electric Motor
124
Tilt Sensor
125
Platform Load Sense
126
Steering/Axle
126
Safety System Override
127
Hardware
128
Section 7 - Inspection and Repair Log
133
Inspection and Repair Log
134

JLG Toucan 12E Operation And Safety Manual (115 pages)

Brand: JLG | Category: Lifting Systems | Size: 8.07 MB

Table of Contents
8
Section 1. Safety Precautions
15
- General
  15
- Pre-Operation
  15
  - Operator Training and Knowledge
    15
  - Workplace Inspection
    16
  - Machine Inspection
    17
- Operation
  18
  - General
    18
  - Trip and Fall Hazards
    19
  - Electrocution Hazards
    20
Minimum Approach Distance (M.A.D.)
20
- Tipping Hazards
  21
Beaufort Scale (for Reference Only)
22
- Crushing and Collision Hazards
  24
- Towing, Lifting, and Hauling
  25
- Maintenance
  25
  - Maintenance Hazards
    25
  - Battery Hazards
    26
Section 2. User Responsibilities, Machine Preparation, and Inspection
28
- 2.1 Personnel Training
  28
  - Operator Training
    28
  - Training Supervision
    29
  - Operator Responsibility
    29
- Preparation, Inspection, and Maintenance
  29
Inspection and Maintenance Table
30
Pre-Start Inspection
31
Daily Walk-Around Inspection
32
Daily Walk-Around Inspection
34
Function Check
35
- Overload Sensor Check
  37
Overload Sensor
37
Section 3. Machine Controls, Indicators and Operation
39
General
39
Description
39
Operating Characteristics and Limitations
40
- General
  40
- Placards
  40
- Capacities
  40
Platform Loading
40
- Stability
  41
Position of Least BACKWARD Stability
42
Position of Least FORWARD Stability
42
Basic Nomenclature - Machine Control Locations
43
Machine Control Locations
43
Controls and Indicators
44
Ground Control Station
44
Ground Control Station
45
Mast Manual Descent Actuator Installation
50
Platform Control Station
54
Platform Control Indicator Panel
55
- Grade and Side Slope
  59
Grade and Side Slope
60
Operation
61
Steering and Traveling (Driving)
61
- Steering
  62
- Traveling (Driving)
  62
- Drive Orientation System (DOS)
  63
3.11 Platform
64
- Platform Level Adjustment
  64
- Platform Rotation (if Equipped)
  64
3.12 Raising and Lowering the Platform
65
3.13 Swinging
66
3.14 Alarms
66
Machine Safety System Override (Msso)
68
3.16 Shut down and Park
69
3.17 Battery Charging
70
- Battery Charger Fault Code
  71
- 3.18 Tie-Down/Lift Lugs
  72
  - Tie down
    72
Machine Tie-Down
72
- Lifting
  73
- 3.19 Towing
  73
Lifting the Machine
73
- Electric Brake Release
  74
Section 4. Emergency Procedures
76
- General Information
  76
- Emergency Operation
  76
  - Operator Unable to Control Machine
    76
  - Platform or Boom Caught Overhead
    76
- Emergency Control
  77
Emergency Controls
77
- Platform Manual Descent
  78
- Incident Notification
  78
- Emergency Towing
  78
- Machine Safety System Override (Msso)
  79
Section 5. General Specifications and Maintenance
80
- Introduction
  80
  - Other Publications Available Specific to this Machine
    80
Operating Specifications
81
Operating Specifications and Dimensions
81
Tires Specifications
85
Drive Motors - Hydraulic Power Unit
86
Battery Specifications
87
Lubrication Specifications
87
Hydraulic Oil Specifications - Standard
87
Hydraulic Oil Specifications - Optional
88
Operator Maintenance
89
Operator Maintenance & Lubrication Diagram
89
Overload System Verification
89
Tilt Sensor Verification
89
Chassis Hood Removal
90
Battery Maintenance
90
- Battery Maintenance and Safety Practices
  90
Level Indicators
91
Adding Water to Batteries
91
Draining the Water
92
- Battery Voltage and Electrolyte Specific Gravity
  93
Measuring Electrolyte Specific Gravity
93
Oil Level / Oil Filter
96
- Hydraulic Oil Check
  96
- Hydraulic Oil Replacement
  96
- Hydraulic Filter Replacement
  97
Tires & Wheels
98
- Tire Wear and Damage
  98
- Wheel and Tire Replacement
  98
- Wheel Installation
  98
Wheel Torque Chart
99
Wheel Lug Nut Tightening Sequence
99
Decal Installation
100
Decal Installation - All Market
100
Decal Installation - CE Market
101
Machine Decal Installation Chart
103
Lubrication
104
- Swing Bearing Race
  104
Swing Bearing Race Lubrication
104
- Swing Bearing Teeth
  105
Swing Bearing Teeth Lubrication
105
- Lifting Chains
  106
Recommended Viscosity Grade
106
Overload System Verification
107
Jacking Points
108
Inspection and Repair Log
113

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JLG Toucan 12E Manuals

JLG Toucan 12E Service And Maintenance Manual (205 pages)

Table of Contents

Section a - Introduction - Maintenance Safety Precautions Revison Log

Section a - Introduction - Maintenance Safety Precautions

Section 1 - Operating Specifications

Section 2 - General Service Information

Section 3 - Theory of Operation

Section 4 - Chassis Mounted Components

Section 5 - Turntable and Vertical Mast

Section 6 - Telescopic Boom and Platform

Section 7 - Hydraulics

Section 8 - Control Components

Section 9 - Jlg Control System

Section 10 - Diagnostic Trouble Codes Section 10. Diagnostic Trouble Codes 10.1 Introduction

Section 10 - Diagnostic Trouble Codes

10.2 Dtc Index

JLG Toucan 12E Operation And Safety Manual (136 pages)

Table of Contents

JLG Toucan 12E Operation And Safety Manual (115 pages)

Table of Contents

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