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Toucan 8e
Service and maintenance manual
JLG TOUCAN 8E Service And Maintenance Manual
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Also See for TOUCAN 8E
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Operation and safety manual
(136 pages)
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
Section a - Introduction - Maintenance Safety Precautions
General
Bhydraulic System Safety
Cmaintenance
Table of Contents
Section 1. Operating Specifications
Operating Specifications
DIMENSIONAL Data
Performance Data
Capacities
Components Data
Batteries
Electric Pump / Electric Motor Assembly
Drive Motor Assembly
Swing Motor
Cylinders
Tires
Major Components Weights
Lubrication
Hydraulic Oil
Lubrication Chart
Lube Specifications
Torque Requirements
Serial Number Locations
Section 2 - General Service Information
Machine Preparation, Inspection and Maintenance
General
Preparation, Inspection and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
Preventive Maintenance and Inspection Schedule
Servicing and Maintenance Guidelines
General
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Care and Installation of Teflon Coated Bushings
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Welding on Work Platform
Lubrication
Battery
Lubrication Information
Hydraulic System
Lubrication Specifications
Hydraulic Oil
Changing Hydraulic Oil
Pressure Relief Valve
Section 3 - Theory of Operation
Overview
Modes of Operation
Ground Mode
Platform Mode
Can Communications
Joysticks
Traction
Pump/Structure Movements
Lift Up/Down
Hydraulic Pump Electric Schematic
Mast Lift System - Basic Schematic
Swing
Steer
Interlocks
Steer System - Basic Schematic
Personality Settings and Calibration
Section 4 - Chassis Mounted Components
Drive Motors
Brake - Dust Cleaning
Brake Disassembly
Brake Disk Wear Checking
Dust Cleaning
Brake Assembly
Drive Motor Assembly Removal
Drive Motor Assembly Installation
Wheel Motor Disassembly
Drive Motor Installation
Motor Disassembly
Wheel Motor Assembly
Rotor Disassembly
Encoder Disassembly
Encoder Assembly
Rotor Assembly
Oil Filling
Wheels and Tires
Tire Wear and Damage
Wheel and Tire Replacement
Wheel Installation
Steering Linkage
Steer Cylinder
Steering Linkage - Spindle/Hub Assembly
Hoses and Cables Routing
Front Wheel Hub
Section 5 - Turntable and Vertical Mast
Swing Bearing
Swing Bearing Attach Bolts Check
Swing Bearing Lubrication
Replacement of Swing Bearing
Counterweight Removal (T10E/T26E)
Counterweight Removal (T8E/T20E)
Mast Assembly Lifting
Mast Section #1 Set on Blockings
Bearing Alignment T10E/T26E
Bearing Alignment T8E/T20E
Swing Motor
Mast Profile Lubrication
Rollers
Inspection
Removal and Installation
Mast Profiles Lubrication
Roller Assembly
Roller Removal
Roller Installation
Mast and Rollers Setting
Introduction
Procedure
Top Rollers Mast Configuration
Top Rollers Mast Centering
(Top View-Mast Lowered)5-10
Bottom Rollers Mast Configuration
Bottom Rollers Mast Centering
(Bottom View - Mast Raised)5-11
Mast Vertical Alignment
Top and Bottom Rollers
Lifting Chains
Safety Accessories and Tooling
Lubrication
Lifting Chains Inspection
Lifting Chains Removal and Installation
Chains Stages and Attachments Description - T10E/T26E
Chains Stages and Attachments Description (T8E/T20E)
Second Chain Stage (T8E/T20E)5-19
Chain Tension Adjustment
Chains Tension Control
Pulley - Pulley Support
Pulley Inspection
Removal and Installation
Mast Cylinder Removal and Installation
Mast Cylinder Removal
Mast Cylinder Disassembly
Mast Cylinder Installation
Section 6 - Jib and Platform
Platform
Platform Removal
Platform Installation
Overlaod System
Bevel Washers Lubrication
Bevel Washer Lubrication
Overload System Verification
Overload System Setting
Jib Cylinder Removal and Installation
Jib Cylinder Removal
Jib Cylinder Removal - Figure 1 of 2
Jib Cylinder Removal - Figure 2 of 2
Jib Cylinder Disassembly
Jib Cylinder Installation
Section 7 - Hydraulics
Hydraulic Tank
Oil Level
Oil Level if Decal Is Missing
Adding Oil to the System
Tank Draining/Cleaning
Tank Filling
Hydraulic Filter Replacement
Oil Filter Replacement
Hydraulic Power Unit
Ports Identification
Hydraulic Lines Connections
Proportional Pressure Relief Valve
Air Bleeding
Flow Directional Valve
Steer Valve
Swing Valve
Swing Motor By-Pass Valve
Electric Motor
Terminal Tightening
Dust Cleaning
Swing Motor
Ports Identification
Swing Motors
Cylinders Holding Valves
Mast Cylinder Holding Valve
Jib Cylinder Holding Valve
Mast Cylinder Holding Valve - Schematic/Exploded View
Cylinder Repair
Disassembly
Inspection
Assembly
Section 8 - Control Components
Control Components Overview
Control Components Location - T8E/T20E
Control Components Location - T10E/T26E
Control Components - Service
Battery Maintenance and Safety Practices
Main Power Contactor Relay
Power Fuse
Mast Elevation Limit Switches
Chain Slack Sensor
Overload Sensor (if Equipped)
Drive Orientation Switch
Overload Sensor
Steering Sensor
Tilt Sensor
Ground Alarm
Warning Beacon
Descent/Motion Alarm (Optional)
Traction System
Common Traction System Difficulties
Power Module
Removal
Installation
Power Module Electrical Evaluation
Ground Control Station
Membrane Panel
Printed Circuit Board (PCB) Replacement
Platform Control Station
Printed Circuit Board (PCB) Replacement
Upper Control Box - Component Replacement
Upper Control Box - Components Evaluation
Section 9 - Jlg Control System
Hand Held Analyzer
To Connect the Hand Analyzer
Using the Analyzer
Changing the Access Level of the Hand Held Analyzer
Machine Setup
Analyzer Screen Layout
Machine Setup Programming Information
Calibration Instructions
Calibrating Steering Sensor
Calibrating Overload System
Calibrating the Joysticks
Calibrating the Pressure Relief Valve
Machine Personality - Adjustment Settings
System Test
Section 10 - Diagnostic Trouble Codes Section 10. Diagnostic Trouble Codes 10.1 Introduction
Section 10 - Diagnostic Trouble Codes
Introduction
Dtc Index
Dtc Check Tables
Help Comments
Power-Up
Platform Controls
Ground Controls
Function Prevented
Line Contactor Open Circuit
Line Contactor Short Circuit
Ground Output Driver
Thermal Limit
Battery Supply
Transmission and Drive System
Communication
Accessory
Electric Motor
Tilt Sensor
Platform Load Sense
Steering/Axle
Safety System Override
Hardware
Section 11 - General Electrical Information & Schematics
General
Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement
Checking Switches
Basic Check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side
Applying Silicone Dielectric Compound to Electrical Connections
AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Assembly
Disassembly
Wedge Lock
Service - Voltage Reading
Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
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Section 10 - Diagnostic Trouble Codes
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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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Section 10 - Diagnostic Trouble Codes Section 10. Diagnostic Trouble Codes 10.1 Introduction
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This manual is also suitable for:
Toucan 20e
Toucan 10e
Toucan 26e
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