JLG Toucan 8e Manuals

Manuals and User Guides for JLG Toucan 8e. We have 2 JLG Toucan 8e manuals available for free PDF download: Service And Maintenance Manual, Operation And Safety Manual

JLG Toucan 8e Service And Maintenance Manual (191 pages)

Brand: JLG | Category: Boom Lifts | Size: 15.91 MB

Table of Contents

5
- Section a - Introduction - Maintenance Safety Precautions
  
  3
  - General
    3
  - Bhydraulic System Safety
    3
  - Cmaintenance
    3
  - Table of Contents
    5
- Section 1. Operating Specifications
  
  16
  - Operating Specifications
    16
  - DIMENSIONAL Data
    16
  - Performance Data
    17
  - Capacities
    18
  - Components Data
    18
    
    Batteries
    18
    
    Electric Pump / Electric Motor Assembly
    18
    
    Drive Motor Assembly
    18
    
    Swing Motor
    19
    
    Cylinders
    19
    
    Tires
    19
  - Major Components Weights
    20
  - Lubrication
    21
    
    Hydraulic Oil
    21
    
    Lubrication Chart
    22
    
    Lube Specifications
    23
  - Torque Requirements
    23
  - Serial Number Locations
    24
- Section 2 - General Service Information
  
  27
  - Machine Preparation, Inspection and Maintenance
    27
    
    General
    27
    
    Preparation, Inspection and Maintenance
    27
    
    Pre-Start Inspection
    27
    
    Pre-Delivery Inspection and Frequent Inspection
    27
    
    Annual Machine Inspection
    27
    
    Preventative Maintenance
    27
  - Preventive Maintenance and Inspection Schedule
    28
  - Servicing and Maintenance Guidelines
    31
    
    General
    31
    
    Safety and Workmanship
    31
    
    Cleanliness
    32
    
    Components Removal and Installation
    32
    
    Component Disassembly and Reassembly
    32
    
    Pressure-Fit Parts
    32
    
    Bearings
    32
    
    Care and Installation of Teflon Coated Bushings
    32
    
    Bolt Usage and Torque Application
    33
    
    Hydraulic Lines and Electrical Wiring
    33
    
    Hydraulic System
    33
    
    Welding on Work Platform
    34
    
    Lubrication
    34
    
    Battery
    34
  - Lubrication Information
    34
    
    Hydraulic System
    34
    
    Lubrication Specifications
    34
    
    Hydraulic Oil
    34
    
    Changing Hydraulic Oil
    34
  - Pressure Relief Valve
    34
- Section 3 - Theory of Operation
  
  38
  - Overview
    38
  - Modes of Operation
    38
    
    Ground Mode
    38
    
    Platform Mode
    38
  - Can Communications
    38
  - Joysticks
    40
  - Traction
    40
  - Pump/Structure Movements
    41
    
    Lift Up/Down
    41
  - Hydraulic Pump Electric Schematic
    41
  - Mast Lift System - Basic Schematic
    41
    
    Swing
    42
    
    Steer
    43
    
    Interlocks
    43
  - Steer System - Basic Schematic
    43
    
    Personality Settings and Calibration
    44
- Section 4 - Chassis Mounted Components
  
  47
  - Drive Motors
    47
    
    Brake - Dust Cleaning
    47
    
    Brake Disassembly
    47
    
    Brake Disk Wear Checking
    47
  - Dust Cleaning
    47
    
    Brake Assembly
    48
    
    Drive Motor Assembly Removal
    48
    
    Drive Motor Assembly Installation
    49
    
    Wheel Motor Disassembly
    49
  - Drive Motor Installation
    49
  - Motor Disassembly
    49
    
    Wheel Motor Assembly
    50
  - Rotor Disassembly
    50
  - Encoder Disassembly
    50
  - Encoder Assembly
    50
  - Rotor Assembly
    51
    
    Oil Filling
    52
  - Wheels and Tires
    52
    
    Tire Wear and Damage
    52
    
    Wheel and Tire Replacement
    52
    
    Wheel Installation
    52
  - Steering Linkage
    53
    
    Steer Cylinder
    54
    
    Steering Linkage - Spindle/Hub Assembly
    54
    
    Hoses and Cables Routing
    55
  - Front Wheel Hub
    55
- Section 5 - Turntable and Vertical Mast
  
  57
  - Swing Bearing
    57
    
    Swing Bearing Attach Bolts Check
    57
    
    Swing Bearing Lubrication
    57
    
    Replacement of Swing Bearing
    58
  - Counterweight Removal (T10E/T26E)
    58
  - Counterweight Removal (T8E/T20E)
    59
  - Mast Assembly Lifting
    59
  - Mast Section #1 Set on Blockings
    60
  - Bearing Alignment T10E/T26E
    60
  - Bearing Alignment T8E/T20E
    60
  - Swing Motor
    62
  - Mast Profile Lubrication
    63
  - Rollers
    63
    
    Inspection
    63
    
    Removal and Installation
    63
  - Mast Profiles Lubrication
    63
  - Roller Assembly
    64
  - Roller Removal
    64
  - Roller Installation
    64
  - Mast and Rollers Setting
    65
    
    Introduction
    65
    
    Procedure
    65
  - Top Rollers Mast Configuration
    65
  - Top Rollers Mast Centering
    66
    
    (Top View-Mast Lowered)5-10
    66
  - Bottom Rollers Mast Configuration
    66
  - Bottom Rollers Mast Centering
    67
    
    (Bottom View - Mast Raised)5-11
    67
  - Mast Vertical Alignment
    67
  - Top and Bottom Rollers
    68
  - Lifting Chains
    69
    
    Safety Accessories and Tooling
    69
    
    Lubrication
    69
    
    Lifting Chains Inspection
    70
    
    Lifting Chains Removal and Installation
    71
  - Chains Stages and Attachments Description - T10E/T26E
    71
  - Chains Stages and Attachments Description (T8E/T20E)
    72
    
    Second Chain Stage (T8E/T20E)5-19
    75
    
    Chain Tension Adjustment
    79
  - Chains Tension Control
    79
  - Pulley - Pulley Support
    80
    
    Pulley Inspection
    80
    
    Removal and Installation
    81
  - Mast Cylinder Removal and Installation
    81
    
    Mast Cylinder Removal
    81
    
    Mast Cylinder Disassembly
    82
    
    Mast Cylinder Installation
    82
- Section 6 - Jib and Platform
  
  83
  - Platform
    83
    
    Platform Removal
    83
    
    Platform Installation
    83
  - Overlaod System
    83
    
    Bevel Washers Lubrication
    83
  - Bevel Washer Lubrication
    83
    
    Overload System Verification
    84
    
    Overload System Setting
    84
  - Jib Cylinder Removal and Installation
    84
    
    Jib Cylinder Removal
    84
    
    Jib Cylinder Removal - Figure 1 of 2
    84
    
    Jib Cylinder Removal - Figure 2 of 2
    84
    
    Jib Cylinder Disassembly
    85
    
    Jib Cylinder Installation
    85
- Section 7 - Hydraulics
  
  88
  - Hydraulic Tank
    88
    
    Oil Level
    88
    
    Oil Level if Decal Is Missing
    88
    
    Adding Oil to the System
    88
    
    Tank Draining/Cleaning
    88
    
    Tank Filling
    89
  - Hydraulic Filter Replacement
    89
  - Oil Filter Replacement
    89
  - Hydraulic Power Unit
    90
    
    Ports Identification
    90
    
    Hydraulic Lines Connections
    91
    
    Proportional Pressure Relief Valve
    91
    
    Air Bleeding
    91
    
    Flow Directional Valve
    92
    
    Steer Valve
    92
    
    Swing Valve
    92
    
    Swing Motor By-Pass Valve
    92
    
    Electric Motor
    92
  - Terminal Tightening
    92
  - Dust Cleaning
    92
  - Swing Motor
    93
    
    Ports Identification
    93
  - Swing Motors
    93
  - Cylinders Holding Valves
    94
    
    Mast Cylinder Holding Valve
    94
    
    Jib Cylinder Holding Valve
    95
  - Mast Cylinder Holding Valve - Schematic/Exploded View
    95
  - Cylinder Repair
    96
    
    Disassembly
    97
    
    Inspection
    97
    
    Assembly
    98
- Section 8 - Control Components
  
  101
  - Control Components Overview
    101
  - Control Components Location - T8E/T20E
    101
  - Control Components Location - T10E/T26E
    102
  - Control Components - Service
    103
    
    Battery Maintenance and Safety Practices
    103
    
    Main Power Contactor Relay
    106
    
    Power Fuse
    106
    
    Mast Elevation Limit Switches
    107
    
    Chain Slack Sensor
    108
    
    Overload Sensor (if Equipped)
    110
    
    Drive Orientation Switch
    110
  - Overload Sensor
    110
    
    Steering Sensor
    111
    
    Tilt Sensor
    111
    
    Ground Alarm
    113
    
    Warning Beacon
    113
    
    Descent/Motion Alarm (Optional)
    114
  - Traction System
    115
    
    Common Traction System Difficulties
    115
  - Power Module
    116
    
    Removal
    116
    
    Installation
    117
    
    Power Module Electrical Evaluation
    118
  - Ground Control Station
    120
    
    Membrane Panel
    120
    
    Printed Circuit Board (PCB) Replacement
    120
  - Platform Control Station
    121
    
    Printed Circuit Board (PCB) Replacement
    121
    
    Upper Control Box - Component Replacement
    121
    
    Upper Control Box - Components Evaluation
    122
- Section 9 - Jlg Control System
  
  126
  - Hand Held Analyzer
    126
    
    To Connect the Hand Analyzer
    126
    
    Using the Analyzer
    126
    
    Changing the Access Level of the Hand Held Analyzer
    127
    
    Machine Setup
    128
  - Analyzer Screen Layout
    129
  - Machine Setup Programming Information
    134
  - Calibration Instructions
    135
  - Calibrating Steering Sensor
    135
  - Calibrating Overload System
    135
  - Calibrating the Joysticks
    136
  - Calibrating the Pressure Relief Valve
    136
  - Machine Personality - Adjustment Settings
    137
  - System Test
    140
Section 10 - Diagnostic Trouble Codes Section 10. Diagnostic Trouble Codes 10.1 Introduction

143
- Section 10 - Diagnostic Trouble Codes
  
  143
  - Introduction
    143
  - Dtc Index
    143
  - Dtc Check Tables
    144
    
    Help Comments
    144
  - Power-Up
    145
  - Platform Controls
    145
  - Ground Controls
    146
  - Function Prevented
    150
  - Line Contactor Open Circuit
    150
  - Line Contactor Short Circuit
    151
  - Ground Output Driver
    151
  - Thermal Limit
    155
  - Battery Supply
    156
  - Transmission and Drive System
    157
  - Communication
    158
  - Accessory
    159
  - Electric Motor
    159
  - Tilt Sensor
    160
  - Platform Load Sense
    161
  - Steering/Axle
    161
    
    Safety System Override
    162
    
    Hardware
    162
- Section 11 - General Electrical Information & Schematics
  
  168
  - General
    168
  - Multimeter Basics
    168
    
    Grounding
    168
    
    Backprobing
    168
    
    Min/Max
    168
    
    Polarity
    168
    
    Scale
    168
    
    Voltage Measurement
    168
    
    Resistance Measurement
    169
    
    Continuity Measurement
    169
    
    Current Measurement
    170
  - Checking Switches
    170
    
    Basic Check
    170
    
    Limit Switches
    170
    
    Automatic Switches
    171
    
    Switch Wiring - Low Side, High Side
    171
  - Applying Silicone Dielectric Compound to Electrical Connections
    171
  - AMP Connector
    172
    
    Applying Silicone Dielectric Compound to AMP Connectors
    172
    
    Assembly
    172
    
    Disassembly
    174
    
    Wedge Lock
    174
    
    Service - Voltage Reading
    174
  - Deutsch Connectors
    176
    
    DT/DTP Series Assembly
    176
    
    DT/DTP Series Disassembly
    176
    
    HD30/HDP20 Series Assembly
    177
    
    HD30/HDP20 Series Disassembly
    177

JLG Toucan 8e 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

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JLG Toucan 8e Manuals

JLG Toucan 8e Service And Maintenance Manual (191 pages)

Table of Contents

Table of Contents

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 - Jib 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

Section 11 - General Electrical Information & Schematics

JLG Toucan 8e Operation And Safety Manual (136 pages)

Table of Contents

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