JLG TOUCAN 10E Service And Maintenance Manual
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JLG TOUCAN 10E Service And Maintenance Manual

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Service and Maintenance Manual
Model
TOUCAN 10E
P/N - 31210090
August 28, 2009

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Summary of Contents for JLG TOUCAN 10E

  • Page 1 Service and Maintenance Manual Model TOUCAN 10E P/N - 31210090 August 28, 2009...
  • Page 2 NOTES: ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________...

  • Page 3: Section A - Introduction - Maintenance Safety Precautions

    Relieve system pressure by cycling the applicable control several times, to direct any line pressure back into the res- ervoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss. 31210090 – JLG Lift –...
  • Page 4 SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISON LOG Original Issue - August 28, 2009 – JLG Lift – 31210090...

  • Page 5: Table Of Contents

    Pressure Relief Values............2-8 SECTION 3 - THEORY OF OPERATION 31210090 – JLG Lift –...
  • Page 6 PLATFORM ..............6-1 – JLG Lift –...
  • Page 7 Ground Control Station ............8-17 31210090 – JLG Lift –...
  • Page 8 Upper Control Box - Components Evaluation........8-19 SECTION 9 - JLG CONTROL SYSTEM HAND HELD ANALYZER.
  • Page 9 Bevel Washer Lubrication ............6-1 31210090 – JLG Lift –...
  • Page 10 Connector Assembly Figure 4 ........... .11-6 – JLG Lift –...
  • Page 11 Hydraulic schematic ............11-19 31210090 – JLG Lift –...
  • Page 12 ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210090...
  • Page 13 Machine Personality Adjustment...........9-9 31210090 – JLG Lift –...
  • Page 14 ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210090...

  • Page 15: Section 1 - Operating Specifications

    SECTION 1 - OPERATING SPECIFICATIONS SECTION 1. OPERATING SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS Table 1-1. Operating Specifications Description Model Toucan 10E 200 kg 440 lb Maximum Work Load Maximum Persons 400 N 90 Pound Force Maximum Horizontal Side Force 12.5 m/s (45 km/h)

  • Page 16: Performance Data

    SECTION 1 - OPERATING SPECIFICATIONS 1.3 PERFORMANCE DATA Table 1-3. Performances Description Model Toucan 10E 0.37 m 1.21 ft Platform Height - Stowed (Platform floor to ground) 8.10 m 26.5 ft Platform Height - Elevated (Platform floor to ground) 6.60 m 21.6 ft...

  • Page 17: Components Data

    SECTION 1 - OPERATING SPECIFICATIONS 1.5 COMPONENTS DATA Batteries Table 1-5. Battery Specifications Description Model Toucan 10E 12 cells of 2 Volts (traction) Voltage (24V System - Series) 240 Amp Hour @ 5 HR. Rate Amp Hour (Standard battery) 1 200 Cycles...

  • Page 18: Cylinders

    535 mm (21.1 in) 50 mm (1.97 in) Jib Cylinder (Single Action) Tires Table 1-10. Tires Specifications Description Model Toucan 10E 406 x 125 mm 16 x 4.9 in Size 1 815 kg 4 000 lb Max. Allowable Tire Load...

  • Page 19: Lubrication

    NOTE: Hydraulic oils must have anti-wear qualities and sufficient chemical stability for mobile hydraulic system service. It is not advisable to mix oil of different brands or types, as they may not contain the same required additive or be of comparable viscosities. 31210090 – JLG Lift –...

  • Page 20: Lubrication Chart

    NOTE: Lubrication intervals are based on machine operation under normal condition. For machines used in multi shift opera- tions and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly. NOTE: Refer to the corresponding sections in this manual for specific lubrication procedures. – JLG Lift – 31210090...

  • Page 21: Lube Specifications

    81.9 1386 15.7 1095 2200 12.9 lbf.ft 11.6 55.3 95.9 1622 Torque Values for Hydraulic Fittings Type Unit Torque JIC 9/16"-18 lbf.ft 22.1 14.8 BSPP 1/4"-19 lbf.ft BSPP 3/8"-19 lbf.ft 25.1 Metric M18x150 lbf.ft 37.6 31210090 – JLG Lift –...

  • Page 22: Serial Number Locations

    For machines identification, a serial number plate is affixed at the front side of the chassis. If the serial number plate is damaged or missing, the machine serial number is stamped on the frame at location shown following. Figure 1-2. Serial Number – JLG Lift – 31210090...

  • Page 23: Section 2 - General Service Information

    The Annual Machine Inspection must be performed by a This section provides the necessary information needed qualified JLG equipment mechanic on an annual basis, no by those personnel that are responsible to place the later than thirteen (13) months from the date of the prior machine in operation readiness and maintain its safe Annual Machine Inspection.

  • Page 24: Preventive Maintenance And Inspection Schedule

    Operator and Safety manual At each Operator change Service and Maintenance Prior to each sale, lease or Owner, Dealer or Qualified JLG Pre-delivery Inspection Manual and applicable JLG rental delivery User Mechanic inspection form In service for 3 months; or Service and Maintenance...
  • Page 25 Swing Bearing Bolts Hoods, Hood Props, Hood Latches 1-2-5 CHASSIS ASSEMBLY Chassis Weldment Tires 1-15 15-16-17 15-16-17 Wheel Bolts Steering Spindles Weldments Hubs Steering Knuckles Thrust Washers Steer Components Drive Motor Brakes 7-12 Drive Motor Gearbox 31210090 – JLG Lift –...
  • Page 26 Electrical Connections Instruments, Switches 7-15 Lights, Horn Electric Motor Brushes (Hyd. Power Unit) 7-12 GENERAL Operation and Safety manuals in Storage ANSI and EMI Manuals/Handbooks Installed Capacity Decals Installed, Secure, Legible All Decals/Placards installed, Secure, Legi- – JLG Lift – 31210090...

  • Page 27: Servicing And Maintenance Guidelines

    Function Test of All Systems 21-22 Paint and Appearance Stamp Inspection Date on Mast Section #1 Notify JLG of Machine Ownership Maintenance and Inspection Table Codes: Footnotes: : Prior to use each day; or at each operator change. 1. Check for proper and secure installation.

  • Page 28: Cleanliness

    Always recheck your work to ensure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval. Pressure-Fit Parts When assembling pressure-fit parts, use an "anti-seize" or molybdenum disulfide base compound to lubricate the mating surface. – JLG Lift – 31210090...

  • Page 29: Bolt Usage And Torque Application

    When welding on the superstructure, connect the nal, or one which is equivalent. welder ground wire to the machine superstructure as close as possible to the area being welded. This is to pre- 31210090 – JLG Lift –...

  • Page 30: Lubrication

    Hydraulic Oil components with the amount, type, and grade of lubricant For best performance, JLG recommends the use of ISO are recommended in this manual, at the specified inter- VG 32 oil with a viscosity of 32 cSt at 40 °C. Refer to Sec- vals.

  • Page 31: Section 3 - Theory Of Operation

    These resistors are approximately market and model must be set properly for safe and lawful . On a JLG aerial work platform, this is typically in operation of the machine. the platform and in the chassis. These resistors may be in the harness or in the module.
  • Page 32 A CAN network also has error detection and han- messages per second. The high bus speed allows all dling for robust communications. modules to be constantly updated around 20 times per Figure 3-1. Basic Electronic Module Connections – JLG Lift – 31210090...

  • Page 33: Joysticks

    Joysticks personalities to define the centered position (where command is 0%), minimum and maximum for- ward, as well as minimum and maximum reverse can be altered by performing a calibration of the joysticks. Figure 3-2. Drive Motor Schematic 31210090 – JLG Lift –...

  • Page 34: Pump/Structure Movements

    The area of the guide that fluid touches on both sides does not provide lift because the forces on both sides cancel each other. Only the area of the rod provides the lifting. Lift down is "powered" by gravity. – JLG Lift – 31210090...

  • Page 35: Swing

    Pressure is applied to one port of the motor and drained from the other, allowing the motor to turn. Figure 3-6. Swing System - Basic Schematic Figure 3-5. Jib Lift System - Basic Schematic 31210090 – JLG Lift –...

  • Page 36: Steer

    This occurs roughly when the jib (like a differential system). is swung past the rear tires. When the drive orientation switch is tripped: – JLG Lift – 31210090...

  • Page 37: Personality Settings And Calibration

    • The max. driving speed is limited at 0.4 km/h, whatever the platform position is; • Max. swing speed is reduced; • Mast Lift Down and Jib Lift Down can be operated at normal speed. 31210090 – JLG Lift –...
  • Page 38 ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210090...

  • Page 39: Section 4 - Chassis Mounted Components

    4. Blow any accumulated dust in brake compartment. 5. Once complete, correctly reposition the dust protec- tion ring. Figure 4-3. Brake Disk Wear Checking Check brake disk thickness on several locations. Replace the disk if its thickness is below 8.5mm (0.335 in.). 31210090 – JLG Lift –...

  • Page 40: Brake Assembly

    8. Reposition the friction plate (7) so as the mounting screws will go through the holes that are nearing the slots. 9. Install and secure the brake assembly. 10. Correctly position the dust protection ring (6). Install the dust cap (10). – JLG Lift – 31210090...

  • Page 41: Drive Motor Assembly Installation

    Oil Filling NOTE: Oil filling procedure requires the removal of the drive motor assembly. Figure 4-7. Oil Filling 1. Position the drive motor assembly vertically, brake upwards, in a stable position (e.g. in a vise). 31210090 – JLG Lift –...

  • Page 42: Wheels And Tires

    Use of Check torque every 3 months or 125 hours of opera- genuine JLG parts is highly recommended. tion. Wheel Installation 4.3 STEERING LINKAGE It is extremely important to apply and maintain proper wheel mounting torque.

  • Page 43: Steer Cylinder

    Check bushings installed on the steering link for damage or excessive wear. Replace if necessary. Check pins condition. Replace if necessary. Check thrust washer thickness. Replace washer if its thickness is less than 3mm (0.12 in.). 31210090 – JLG Lift –...

  • Page 44: Hoses And Cables Routing

    Hub should not be noticeably loose when moved parallel with spindle centerline. 6. Install wheel, torque wheel per specification in Sec- tion 4.2. – JLG Lift – 31210090...

  • Page 45: Section 5 - Turntable And Vertical Mast

    (2) in the chassis base plate: 5. Swing the structure 180° to the left to gain access to rotate superstructure using the ground controls (or the second grease fitting and lubricate. 31210090 – JLG Lift –...

  • Page 46: Replacement Of Swing Bearing

    300mm (12") to gain access to the mast cyl- sling (or chain). Remove the hardware securing the inder anchor pin on mast section #2. counterweight. Ensure the electrical cables, battery – JLG Lift – 31210090...

  • Page 47: Mast Assembly Lifting

    Installation SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN THE CHASSIS AND TURNTABLE, USE A GENUINE JLG PART IS HIGHLY RECOMMENDED. 1. Install swing motor assembly if removed. Figure 5-6. Mast Assembly Lifting 2.
  • Page 48 3 hardened washers and locknuts to correctly TURNTABLE, IT IS IMPERATIVE THAT REPLACEMENT HARD- position the assembly. Lower the mast section #1 WARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG assembly onto the chassis. Slightly slack the slings/ HARDWARE IS HIGHLY RECOMMENDED.

  • Page 49: Swing Motor

    21. Install mast cylinder valve and connect hydraulic lines. Install the coil, the O-ring and the manual over- 5. Lift the motor upwards and remove it from its mount- ride device (Refer to Section 7). ing hole. 31210090 – JLG Lift –...

  • Page 50: Mast Profile Lubrication

    HOLD THE BRONZE WEAR PAD, THE ROLLER, THEN THE WASHER TO PREVENT THEM FROM FALLING TO THE BOTTOM OF THE MAST PROFILE. Figure 5-14. Roller Removal Figure 5-12. Mast Profiles Lubrication – JLG Lift – 31210090...

  • Page 51: Mast Transversal Play/Mast Sections Alignment

    THE ALIGNMENT OF THE MAST SECTIONS AND THE ADJUST- MENT OF THE TRANSVERSAL PLAY OF MAST SECTIONS MUST BE PERFORMED BY TRAINED AND QUALIFIED PERSONNEL. 31210090 – JLG Lift –...

  • Page 52: Lifting Chains

    (dusty or aggressive environment). The lubricant must be adapted to the machine's operating condition. In general, a non detergent mineral oil is sufficient. Its viscosity must be adapted to the temperature according to the – JLG Lift – 31210090...

  • Page 53: Lifting Chains Inspection

    • Plates should not be cracked: Figure 5-19. Cracked Plate • The plate clevis pins should not present excessive play. • Pins should not have turned in their housing (1). Figure 5-20. Turned Pin 31210090 – JLG Lift –...

  • Page 54: Lifting Chains Removal And Installation

    SECTION 5 - TURNTABLE AND VERTICAL MAST Lifting Chains Removal and Installation Figure 5-22. Chains Stages and Attachments Description 5-10 – JLG Lift – 31210090...
  • Page 55 SECTION 5 - TURNTABLE AND VERTICAL MAST Figure 5-23. First Chain Stage 31210090 – JLG Lift – 5-11...
  • Page 56 SECTION 5 - TURNTABLE AND VERTICAL MAST Figure 5-24. Second Chain Stage 5-12 – JLG Lift – 31210090...
  • Page 57 CHAIN ANCHORS, CLEVIS PINS, BEVEL WASHERS AND NUTS BEFORE, DURING OR AFTER THEIR INSTALLATION. WHEN MUST ALSO BE REPLACED. USE ONLY GENUINE JLG PARTS. UNROLLING OR INSTALLING CHAINS, AVOID TWISTING THEM. REMOVE THE LIFTING CHAINS ONE BY ONE. ALWAYS REPLACE AND TENSION A CHAIN BEFORE REMOVING ANOTHER ONE.
  • Page 58 8. Adjust lifting chains tension accordingly. Figure 5-26. Supporting Mast Sections (1 of 3) 3. Using the ground controls, lower the mast until the mast sections rest on blockings. Secure the block- ings in place with C-clamps. 5-14 – JLG Lift – 31210090...
  • Page 59 3. Using the ground controls, lower the mast until the mast sections rest on blockings. Secure the block- ings with C-clamps. 4. Remove the locknut, attachment nut and bevel washers from a chain anchor at attachment #4. 31210090 – JLG Lift – 5-15...

  • Page 60: Chain Tension Adjustment

    4. Remove the locknut, the attachment nut and the bevel washers from a chain anchor at attachment 5. If installed, remove the chain slack detection system from the other end of the chain. If not installed, 5-16 – JLG Lift – 31210090...

  • Page 61: Pulley - Pulley Support

    Unequal distances sections is kept. indicate a severe pin and pulley assembly wear. 5. Install and tighten the locknut on each anchor. Shut the machine down till the worn pulley assembly has been replaced. 31210090 – JLG Lift – 5-17...

  • Page 62: Removal And Installation

    3. Install a couple of suitable blocking to support mast mast section(s). section #2 as indicated below. 2. Remove the locknut from a long anchor and loosen the attachment nut to slacken the chain. 5-18 – JLG Lift – 31210090...

  • Page 63: Mast Cylinder Disassembly

    5. From ground controls, perform a few mast raising/ lowering movements to bleed air from the circuit and to check for proper operation. 6. Check hydraulic fluid level and adjust accordingly. Install chassis shield and hoods. 31210090 – JLG Lift – 5-19...
  • Page 64 ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ 5-20 – JLG Lift – 31210090...

  • Page 65: Section 6 - Jib And Platform

    Remove the bearing pins (4). Remove the ball bear- ings (5). 7. Lift and remove the platform assembly (6). 8. Check the ball bearings (Qty:6) for cracks or hard points. Replace bearings if necessary. Figure 6-2. Bevel Washer Lubrication 31210090 – JLG Lift –...

  • Page 66: Overload System Verification

    3. Secure the cylinder with suitable slings or supports as required. 4. Remove the hardware securing the cylinder anchor pin (1) to the upper jib (2). Using a suitable brass drift, drive the pin out. – JLG Lift – 31210090...

  • Page 67: Jib Cylinder Disassembly

    Refer to Section 7. 5. Perform a few jib movements from the ground con- trol station to bleed the air from the circuit and to check for proper operation. 6. Check hydraulic fluid level and adjust accordingly. 31210090 – JLG Lift –...
  • Page 68 ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210090...

  • Page 69: Section 7 - Hydraulics

    6. Disconnect hydraulic line from port 1. Place the hose in the collecting tank. Fully lower the jib using the breakdown controls. 7. Cap/Plug hydraulic line and valve body port. 31210090 – JLG Lift –...

  • Page 70: Tank Filling

    SECTION 7 - HYDRAULICS 8. Loosen the two bolts securing the hydraulic power 7.2 HYDRAULIC FILTER REPLACEMENT unit. Lube Point: Replaceable Element (JLG P/N: 930134) Interval: After first 50 hours of operation and every 250 hours thereafter. Figure 7-4. Oil Filter Replacement Figure 7-3.

  • Page 71: Hydraulic Power Unit

    26- Check Valve (Built-in) 10- Flow DIrectional Valve 11- Steer Valve 12- Swing Valve 13- Check Valve 14- Plug - 3/8" BSPP 15- Check Valve 16- Check Valve 17- Swing Motor By-Pass Valve (Needle Valve) 31210090 – JLG Lift –...

  • Page 72: Ports Identification

    COIL. THE VOLTAGE INDICATION ON THE PROPORTIONAL COIL LEFT Swinging movement is controlled. IS 24 "VADC" AND ITS RESISTANCE VALUE IS 8.8 OHMS. Steer Valve This 4-Way, 2-Position Solenoid Valve (11) is supplied each time a Steering movement is controlled. – JLG Lift – 31210090...

  • Page 73: Swing Valve

    4. Install the protection cover (1). Brush Removal: 5. Secure the hydraulic power unit to the machine, as NOTE: No hydraulic power unit connections, hydraulic or originally installed. electrical need to be disconnected. 31210090 – JLG Lift –...

  • Page 74: Swing Motor

    3. Remove the spring ring (7) from the elbow adapter. 4. Unscrew coil nut (2), remove the manual override device (3), the O-ring (4) and the coil (5). 5. Unscrew the valve mounting screw (6) and plug the cylinder port (3/8" BSPP). – JLG Lift – 31210090...

  • Page 75: Mast Cylinder Holding Valve - Schematic/Exploded View

    Exploded View 1. Ported Body 2. Banjo Bolt w/ Built-in Flow Regulator 3. BS Ring 4. Mast Solenoid Valve 5. Coil - 24 VDC 6. O-Ring 7. Manual Override Device 8. Coil Nut 9. Elbow Adapter 31210090 – JLG Lift –...

  • Page 76: Jib Cylinder Holding Valve

    4. Install the coil onto the solenoid valve. Install the O- 13. Elbow Adapter ring and tighten the coil nut 4 to 5 Nm (2.8 to 3.7 ft lbs). 5. Remove port plug and hydraulic line cap. Correctly connect line to valve port. – JLG Lift – 31210090...

  • Page 77: Cylinder Repair

    13. Wiper Seal 14. Flange Bushing Figure 7-18. Mast Cylinder 1. Barrel 2. Rod 3. Gland 4. Rod Guide 5. Rod Seal 6. Guide Band 7. Snap Ring 8. O-Ring + Back-up Ring 9. Wiper Seal 31210090 – JLG Lift –...

  • Page 78: Disassembly

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts manual. 5. Steer cylinder only: place the rod assembly into a Apply a light film of hydraulic oil to all components suitable holding fixture.
  • Page 79 9. Secure the cylinder head gland. 10. After the cylinder has been reassembled, the rod should be pushed all the way (fully retracted). 31210090 – JLG Lift – 7-11...
  • Page 80 ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ 7-12 – JLG Lift – 31210090...

  • Page 81: Section 8 - Control Components

    SECTION 8 - CONTROL COMPONENTS SECTION 8. CONTROL COMPONENTS 8.1 CONTROL COMPONENTS OVERVIEW Figure 8-1. Control Components Location 31210090 – JLG Lift –...

  • Page 82: Control Components - Service

    ADD ONLY DISTILLED WATER TO BATTERIES. ADD WATER TO BATTERIES AFTER CHARGING TO AVOID ELECTROLYTE OVER- • Regularly clean and dry battery top. FLOW. • Ensure all connections are clean and correctly tight. • Coat terminals with a silicone dielectric compound. – JLG Lift – 31210090...
  • Page 83 (EVEN IF THE ELECTROLYTE SPECIFIC GRAVITY MEASURES ARE HIGH). BEFORE RETURNING TO SERVICE A BATTERY THAT REMAINS INACTIVE FOR A LONG PERIOD OF TIME, CHARGE THE BAT- TERY AND CHECK ELECTROLYTE LEVEL IN THE CELLS. 31210090 – JLG Lift –...
  • Page 84 Loss of electrolyte due to overflow. Perform an equalization charge. electrolyte specific gravity too low. Stratification of the electrolyte. Contact your JLG Distributor/Product Support. Electrolyte specific gravity too low. Refer to "electrolyte specific gravity too low". Low voltage in the cells in open circuit.

  • Page 85: Main Power Contactor Relay

    Amp. Rating: 325 Amps Nominal voltage: 24V Type: C20 (DIN 43560) Coil resistance: 52 See Figure 8-21 for electrical wiring connections. See Figure 8-21 for electrical wiring connections. Figure 8-5. Main Power Contactor Relay Figure 8-6. Power Fuse 31210090 – JLG Lift –...

  • Page 86: Mast Elevation Limit Switches

    The main mast limit switch (1) is the first to be actuated (at the beginning of mast travel). The secondary mast limit switch (2) is actuated about 0.9 meter (2.95 ft) before mast full elevation. Figure 8-8. Actuators Setting – JLG Lift – 31210090...

  • Page 87: Chain Slack Sensor

    - More rarely caused by a mast jamming. This can be due to a lack of lubrication (Refer to Section 5-3), an incor- rect adjustment (Refer to Section 5-4) or a foreign body entering the guiding system. 31210090 – JLG Lift –...

  • Page 88: Overload Sensor

    Power (+) +Vbatt +Vbatt Output +Vbatt Open Power (-) -Vbatt -Vbatt Figure 8-10. Overload Sensor The sensor is calibrated mechanically as shown following. Refer to § 9-6 for Overload System Calibration. Figure 8-11. Drive Orientation Switch – JLG Lift – 31210090...

  • Page 89: Steering Sensor

    Wheels Leff Stop Stop Straight Output +Vbatt Open Power (+) A or 1 4.2V - 4.4V Output B or 2 0.5V - 1.0V 2.2V - 2.8V 3.4V - 3.9V Power (-) C or 3 -Vbatt 31210090 – JLG Lift –...

  • Page 90: Tilt Sensor Check

    The LED at the bottom of the sensor body will blink, indicating the new 0 degree position has been defined. Figure 8-17. Tilt Sensor Calibration Verification Figure 8-16. Tilt Sensor Calibration 8-10 – JLG Lift – 31210090...

  • Page 91: Ground Alarm

    The warning beacon is located at the top of the mast, Acoustic alarm personalities to define operating mode can above the battery compartment door. be access via analyzer menu: refer to § 9 JLG CONTROL SYSTEM. Figure 8-19. Warning Beacon 31210090 –...

  • Page 92: Traction System

    Before investigating Traction System Issues, examine the JLG Analyser’s HELP Menu while attempting to Drive from Platform Mode. Refer to the Sec- tion 9 for explanation of the JLG Analyzer Help Messages. 1. Battery Pack 2. Battery Power Quick-Disconnect 3.

  • Page 93: Power Module

    1. From ground controls, swing the turntable 90° from chassis center line. Shut machine down and discon- nect battery plug. 2. Actuate the battery filling pump button: the pump will run for a few seconds till the capacitors are dis- charged. 31210090 – JLG Lift – 8-13...

  • Page 94: Installation

    THE UNIT COULD OCCUR. 7. Proceed with a system setup and calibration (Refer to Section 9.3). 4. After all connections to the power module are made and verified, the battery can be reconnected. 8-14 – JLG Lift – 31210090...

  • Page 95: Power Module Electrical Evaluation

    Input Overload Switch (N.C.) Digital Input Steer Angle Sensor Analog Input Unused Digital Output Charger Interlock Digital Input Unused Digital Output Manual Brake Release Digital Input Chain Slack Switch Digital Input Unused Digital Input 31210090 – JLG Lift – 8-15...
  • Page 96 Analog Inputs: PWM Outputs: • Acceptable signal range: 0 - 10V • PWM controlled (Adjustable voltage) • Toucan 10E signal range: 0.5 - 4.5V • Drive to -Vbatt Power Inputs: • Max. output current: 2.5A • 24V input, taken after the voting relay.

  • Page 97: Ground Control Station

    • Insert the ribbon cable into the plate slot. Figure 8-25. Ground Control Box Circuit Board - Installation 1. Door 2. Control Box Panel Assembly 3. Panel Attach Screws 4. Panel Plastic Washers 5. Circuit Board Assembly 6. Circuit Board Attach Screws 31210090 – JLG Lift – 8-17...

  • Page 98: Platform Control Station

    2. Drive/Swing Joystick Assembly 3. Drive/Steer Joystick Attach Screws 4. Mast/Jib Joysticks Assembly 5. Mast/Jib Joystick Attach Screws 6. Guard 7. Guard Attach Screws Figure 8-26. Upper Control Box Circuit Board - Installa- tion 8-18 – JLG Lift – 31210090...

  • Page 99: Upper Control Box - Components Evaluation

    3. If the switch requires removal, pull the switch release lever out with the blade of a screwdriver and remove Yellow Rocker: Steer Left the switch. Violet 4. Reverse steps to install. Rocker: Steer Right Brown Trigger + Rocker Power (+24V) 31210090 – JLG Lift – 8-19...
  • Page 100 / swing left position (-100%) 3. Membrane Switches The DOS and Horn switches are made of membrane switches: Each push button is a SPST switch; switch ON = 15 to 25 (circuit impedance, measured on the ribbon connector). 8-20 – JLG Lift – 31210090...

  • Page 101: Section 9 - Jlg Control System

    SECTION 9 - JLG CONTROL SYSTEM SECTION 9. JLG CONTROL SYSTEM The top level menus are as follow: 9.1 HAND HELD ANALYZER (Also see § 9-2 Analyzer Screen Layout). To Connect the Hand Analyzer 1. Connect the four pin end of cable supplied with the...

  • Page 102: Changing The Access Level Of The Hand Held Analyzer

    SECTION 9 - JLG CONTROL SYSTEM Changing the Access Level of the Hand Held If ENTER is pressed again, the display moves to the fol- lowing display: Analyzer When the analyzer is first connected, you will be in access level 2 which enables you to only view most configuration settings which cannot be changed until you enter a pass- word to advance to a lower level.

  • Page 103: Machine Setup

    SECTION 9 - JLG CONTROL SYSTEM Machine Setup Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- When a machine digit item is selected, press the UP or word was entered correctly: DOWN arrow keys to adjust its value.

  • Page 104: Analyzer Screen Layout

    SECTION 9 - JLG CONTROL SYSTEM 9.2 ANALYZER SCREEN LAYOUT – JLG Lift – 31210090...

  • Page 105: Machine Setup Programming Information

    SECTION 9 - JLG CONTROL SYSTEM 9.3 MACHINE SETUP PROGRAMMING INFORMATION In case of complete system reset (Controller change, Per- sonality settings reset), the following logic shall be fol- lowed: Shaded entries are not available for the selected market. Configuration Digit...

  • Page 106: Calibration Instructions

    All calibration procedures are menu driven through the use of the standard JLG analyzer (connected to the con- trol system on the bottom of the platform control box). The user is prompted to exercise the machine in a specific...

  • Page 107: Calibrating The Joysticks

    SECTION 9 - JLG CONTROL SYSTEM 7. Remove the cap screw (1). 8. The screen will indicate 'CENTER'. 8. Loosen the locknut of the setting screw (2). 9. Release the joystick and allow it to center. 9. Screw the setting screw (3) until the sensor is acti- 10.

  • Page 108: Machine Personality - Adjustment Settings

    SECTION 9 - JLG CONTROL SYSTEM will calculate overwrite MAXP 9.9 MACHINE PERSONALITY - personalities). ADJUSTMENT SETTINGS 12. After completing the Relief Valve calibration, hit ESC Personality settings adjustments shall be done when the twice to go back to CALIBRATIONS.
  • Page 109 SECTION 9 - JLG CONTROL SYSTEM Table 9-3. Machine Personality Adjustment Submenu Parameter Adjustment Default Values Description (Displayed on (Displayed on Range Analyzer 1st line) Analyzer 2nd line) DRIVE ACCEL Displays/adjusts drive acceleration 0.5 - 5.0 sec DECEL Displays/adjusts drive deceleration 0.5 - 5.0 sec...
  • Page 110 SECTION 9 - JLG CONTROL SYSTEM Table 9-3. Machine Personality Adjustment Submenu Parameter Adjustment Default Values Description (Displayed on (Displayed on Range Analyzer 1st line) Analyzer 2nd line) ACCEL DN Displays/adjusts jib lift down acceleration 0.1 - 5.0 sec DECEL DN Displays/adjusts jib lift down deceleration 0.1 - 5.0 sec...

  • Page 111: System Test

    SECTION 9 - JLG CONTROL SYSTEM 5. Hit ENTER. The analyzer will prompt you asking if 9.10 SYSTEM TEST you want to activate the system test; hit ENTER again to activate. The Control System incorporates a built-in system test to check the system components and functions.
  • Page 112 SECTION 9 - JLG CONTROL SYSTEM NOTES: ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________...

  • Page 113: Section 10 - Diagnostic Trouble Codes

    9-9 Hardware ........10-18 31210090 – JLG Lift – 10-1...

  • Page 114: Dtc Check Tables

    • Check that the mast switches are securely mounted. Displays on the analyzer only. • Check the mast switches wiring : @ +Vbatt : CR4(A), CR23(1), CR23(4), CR23(3), CR23(6), CR5(3), CR5(5), CR2(31), CR2(20). @ -Vbatt : CR4(B), CR4(C), CR23(2), CR23(5). 10-2 – JLG Lift – 31210090...

  • Page 115: Power-Up

    The Lift Enable switch was closed during • Check if the lift enable switch is obstructed or 2240 MANENTLY SELECTED power-up in platform mode. jammed. • Check lift enable switch output voltage : J1(18). 31210090 – JLG Lift – 10-3...

  • Page 116: Ground Controls

    SELECTED • Disconnect the membrane panel ribbon cable : replace the membrane panel if DTC is no longer present. • Check the switch line voltage : J3(7), CR1(22) and CR3(32). 10-4 – JLG Lift – 31210090...
  • Page 117 CHAIN SLACK SWITCH DIS- Chain slack switch controllers' inputs are • Check the wiring between the two controllers 2377 AGREEMENT not the same for more than 1 second. CR2(35) to CR3(35) ) and the connections. 31210090 – JLG Lift – 10-5...
  • Page 118 • Check the Main Mast limit switch wiring : Mast stowed : @ +Vbatt : CR4(A), CR23(4), CR23(6), CR5(5), CR2(20). @ -Vbatt : CR4(C), CR23(5). Mast elevated : @ +Vbatt : CR4(A), CR4(C), CR23(4), CR23(5). @ -Vbatt : CR23(6), CR5(5), CR2(20). 10-6 – JLG Lift – 31210090...

  • Page 119: Function Prevented

    +Vbatt when one of the control console is energized. ENABLE operated from the Slave controller. (SYSTEM TEST MODE) The system is in test mode. • Cycle power to clear test mode. 2548 SYSTEM TEST MODE ACTIVE 31210090 – JLG Lift – 10-7...

  • Page 120: Line Contactor Open Circuit

    • Check the right brake positive driver output CR2(2) 3315 CUIT brake while a drive function is active. for a short circuit with -Vbatt. • If the wiring is correct, the driver circuit is damaged : replace the Slave controller. 10-8 – JLG Lift – 31210090...
  • Page 121 -Vbatt. • Check the brake coil for correct impedance (refer to Section 8). • If the wiring and the coil are correct, the driver cir- cuit is damaged : replace the Master controller. 31210090 – JLG Lift – 10-9...
  • Page 122 • Check the valve driver output CR3(23) for a short 33367 VALVE - SHORT TO GROUND is shorted. circuit with -Vbatt. • If the wiring is correct, the driver circuit is damaged : replace the Slave controller. 10-10 – JLG Lift – 31210090...
  • Page 123 • Check the valve driver output CR2(4) for a short cir- 33389 SHORT TO GROUND driver is shorted to -Vbatt. cuit with -Vbatt. • If the wiring is correct, the driver circuit is damaged : replace the Master controller. 31210090 – JLG Lift – 10-11...

  • Page 124: Thermal Limit

    (over 120A). • Check the Slave module for proprer installation (refer to § 8-4). • If the module is cold when the fault appears : replace the module. 10-12 – JLG Lift – 31210090...

  • Page 125: Battery Supply

    BATTERY VOLTAGE TOO A problem has been detected with the bat- • May be due to improper battery charging or incor- HIGH - SYSTEM SHUTDOWN teries or power module. rect voltage batteries being used. 31210090 – JLG Lift – 10-13...

  • Page 126: Transmission And Drive System

    35V, undervoltage threshold batteries, creating down-going pulses. Refer to a is 9,5V . qualified JLG mechanic to know the approved options on the machine. • If no voltage transient is detected on the supply line and the fault appears every time the key is switched ON : Replace the Master controller.

  • Page 127: Communication

    • Ensure that all the connectors pins are properly in place and the connectors are free of moisture or oxidation. • Measure the resistance between J1(3) and J1(4) of the platform board : if it is not 120 ±5%, replace the board. 31210090 – JLG Lift – 10-15...

  • Page 128: Accessory

    • Ensure ANALYZER->MACHINE SETUP->SOFT TOUCH is set to 0 if not installed. FUNCTIONS CUTOUT - GATE This DTC does not apply to the Toucan • Ensure ANALYZER->MACHINE SETUP->GATE is OPEN DETECTED 10E. set to 0 (Not Installed). 10-16 – JLG Lift – 31210090...

  • Page 129: Electric Motor

    • Ensure that no external device is connected to the 7721 TOR BANK FAULT module is not charging properly at star- batteries. Refer to a qualified JLG mechanic to tup. know the approved options on the machine. • Check battery, power cables and connections.

  • Page 130: Tilt Sensor

    STEER SENSOR - OUT OF Invalid signal from the steer sensor. • Check the steer sensor for damage. 8664 RANGE HIGH • Check the steer sensor installation. • Check the steer sensor connections voltages (refer to Section 8). 10-18 – JLG Lift – 31210090...
  • Page 131 • If the sensor can not be calibrated : -Check the steer connection voltages (refer to Sec- tion 8). -If the sensor power is correct but its output improper: Replace the sensor and proceed with a calibrations (refer to § 9-3). 31210090 – JLG Lift – 10-19...

  • Page 132: Hardware

    MASTER MODULE RAM FAIL- There is an internal error in the Master • Cycle power to clear the fault. 99106 Module (right controller). • If the fault is not cleared : Replace the Master con- troller. 10-20 – JLG Lift – 31210090...
  • Page 133 There is an internal error in the Slave Mod- • Cycle power to clear the fault. 99123 ERROR ule (left controller). • If the fault is not cleared : Replace the Slave control- ler. 31210090 – JLG Lift – 10-21...
  • Page 134 MASTER KO - SWING VALVE There is an internal error in the Master • Cycle power to clear the fault. 99133 Module (right controller). • If the fault is not cleared : Replace the Master con- troller. 10-22 – JLG Lift – 31210090...

  • Page 135: Section 11 - General Electrical Information & Schematics

    Also check that the lead on the "COM" port goes to the Ground or negative side of the 31210090 – JLG Lift – 11-1...

  • Page 136: Resistance Measurement

    • Circuit power must be turned OFF before testing resis- continuity. tance. • Disconnect component from circuit before testing. • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual). • Use firm contacts with meter leads. 11-2 – JLG Lift – 31210090...

  • Page 137: Current Measurement

    These switches can be tested the same way as a standard switch by manually operating the sensing arm. Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Induc- tive proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch.

  • Page 138: Automatic Switches

    Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. This procedure applies to all plug connections not enclosed in a box. Sili- cone grease should not be applied to connectors with external seals. 11-4 – JLG Lift – 31210090...

  • Page 139: Amp Connector

    3. Install a hole plug into this and/or any unused wire contact (See Figure 11-7). seal that has silicone dielectric compound escaping from it. Figure 11-6. AMP Connector 31210090 – JLG Lift – 11-5...
  • Page 140 (See Figure 11-9). Release the locking latches by squeezing them inward (See Figure 11-8). Figure 11-9. Connector Assembly Figure 4 Figure 11-8. Connector Assembly Figure 3 11-6 – JLG Lift – 31210090...

  • Page 141: Disassembly

    The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick. 31210090 – JLG Lift – 11-7...
  • Page 142 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-11. Connector Installation 11-8 – JLG Lift – 31210090...

  • Page 143: Deutsch Connectors

    The wedgelock will snap into place. Rectangular wedges are not oriented. Thy may go in either way. NOTE: The receptacle is shown - use the same procedure for plug. 31210090 – JLG Lift – 11-9...

  • Page 144: Hd30/Hdp20 Series Assembly

    Figure 11-15. HD/HDP Locking Contacts Into Position Figure 11-17. HD/HDP Unlocking Contacts NOTE: For unused wire cavities, insert sealing plugs for full NOTE: Do not twist or insert tool at an angle. environmental sealing. 11-10 – JLG Lift – 31210090...

  • Page 145: Connectors Identification

    SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 11.7 CONNECTORS IDENTIFICATION Figure 11-18. Wiring Harness and Connectors - Sheet 1 of 3 31210090 – JLG Lift – 11-11...
  • Page 146 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-19. Wiring Harness and Connectors - Sheet 2 of 3 11-12 – JLG Lift – 31210090...
  • Page 147 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-20. Wiring harness and Connectors - Sheet 3 of 3 31210090 – JLG Lift – 11-13...
  • Page 148 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-21. Ground Controls Connectors 11-14 – JLG Lift – 31210090...
  • Page 149 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-22. Platform Controls Connectors Figure 11-23. Turntable Connectors 31210090 – JLG Lift – 11-15...

  • Page 150: Electrical Schematic

    SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 11.8 ELECTRICAL SCHEMATIC Figure 11-24. Electrical schematic caption 11-16 – JLG Lift – 31210090...
  • Page 151 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-25. Electrical Schematic - Sheet 1 of 2 31210090 – JLG Lift – 11-17...
  • Page 152 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-26. Electrical Schematic - Sheet 2 of 2 11-18 – JLG Lift – 31210090...

  • Page 153: Hydraulic Schematic

    SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 11.9 HYDRAULIC SCHEMATIC Figure 11-27. Hydraulic schematic 31210090 – JLG Lift – 11-19...
  • Page 154 ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ 11-20 – JLG Lift – 31210090...
  • Page 156 1 JLG Drive McConnellsburg PA. 17233-9533 Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. Guillaume mon Amy...

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