JLG TOUCAN 8E Service And Maintenance Manual
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JLG TOUCAN 8E Service And Maintenance Manual

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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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Summary of Contents for JLG TOUCAN 8E

  • Page 1 Service and Maintenance Manual Models TOUCAN 8E/20E TOUCAN 10E/26E P/N - 31210090 June 21, 2019 ®...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

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

    It should be noted that the machines hydraulic systems PARTS OR COMPONENTS. operate at extremely high, potentially dangerous pres- sures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system. 31210090 – JLG Lift –...
  • Page 4 SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISON LOG Original Issue - August 28, 2009 Revision - January 27, 2014 Revision - September 17, 2015 Revision - June 08, 2016 Revision - February 16, 2017 Revision - June 21, 2019 – JLG Lift – 31210090...

  • Page 5: Table Of Contents

    Pressure Relief ValVe ............2-8 SECTION 3 - THEORY OF OPERATION 31210090 – JLG Lift –...
  • Page 6 Mast Cylinder Installation ........... 5-26 – JLG Lift –...
  • Page 7 Installation ............. . . 8-17 31210090 – JLG Lift –...
  • Page 8 Upper Control Box - Components Evaluation........8-22 SECTION 9 - JLG CONTROL SYSTEM HAND HELD ANALYZER .
  • Page 9 Hydraulic schematic ............11-20 31210090 – JLG Lift –...
  • Page 10 Bottom Rollers Mast Configuration ..........5-10 5-25. Bottom Rollers Mast Centering (Bottom View - Mast Raised)5-11 – JLG Lift – 31210090...
  • Page 11 Drive Orientation Switch ............8-10 31210090 – JLG Lift –...
  • Page 12 Hydraulic schematic Toucan 8E/Toucan 20E ........
  • Page 13 Machine Personality Adjustment........... 9-13 31210090 – JLG Lift –...
  • Page 14 ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210090...
  • Page 15 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 16: Section 1. Operating Specifications

    SECTION 1 - OPERATING SPECIFICATIONS SECTION 1. OPERATING SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS Table 1-1. Operating Specifications Description Toucan 8E Toucan 8E XL Toucan 20E Toucan 10E Toucan 26E Maximum Work Load 200 kg 500 lbs (227 kg) 200 kg 500 lbs (227 kg)

  • Page 17: Performance Data

    (1) Up to 7.20 m (23.62 ft) - Platform height w / jib stowed (Toucan 10E and Toucan 26E models only) (2) Above 7.20 m (23.62 ft) - Platform height w / jib stowed (Toucan 10E and Toucan 26E models only) – JLG Lift – 31210090...

  • Page 18: Capacities

    9.6 l/mn @ 13 MPa (2.5 gpm@1885 psi) Max. Operating Pressure 18 MPa (2 610 psi) Drive Motor Assembly Table 1-7. Drive Motor Specifications Description Models Toucan 8E - Toucan 20E - Toucan 10E - Toucan 26E Voltage 15 VAC Motor Power 0.85 kW...

  • Page 19: Swing Motor

    50 mm (1.97 in) (Toucan 8E - Toucan 20E) Tires Table 1-10. Tires Specifications Description Model Toucan 8E - Toucan 20E - Toucan 10E - Toucan 26E Size 406 x 125 mm 16 x 4.9 in Max. Allowable Tire Load...

  • Page 20: Major Components Weights

    44 lb Mast Assembly (4 mast sections - Toucan 10E/Toucan 26E) 240 kg 529 lb 390 kg 860 lb (3 mast sections - Toucan 8E/Toucan 20E) Mast Cylinder 48 kg 106 lb 48 kg 106 lb Mast Section #1 135 kg...

  • Page 21: 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. – JLG Lift – 31210090...

  • Page 22: 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. 31210090 – JLG Lift –...

  • Page 23: Lube Specifications

    Torque Values for Hydraulic Fittings TORQUE FOR TORQUE FOR Type Unit STEEL BODY ALUMINUM BODY JIC 9/16"-18 lbf.ft 22.9 BSPP 1/4"-19 lbf.ft 25.8 18.4 BSPP 3/8"-19 lbf.ft 51.6 36.9 Metric M14x150 lbf.ft 33.2 23.6 Metric M18x150 lbf.ft 51.6 36.9 – JLG Lift – 31210090...

  • Page 24: 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 31210090 – JLG Lift –...
  • Page 25 ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210090 1-10...
  • Page 26 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 27: Section 2 - General Service Information

    JLG Service Training maintenance have been completed before placing the School for the subject JLG product model. Reference the machine into service. machine Service and Maintenance Manual and appropri-...

  • Page 28: Preventive Maintenance And Inspection Schedule

    Operator and Safety manual At each Operator change Service and Maintenance Owner, Dealer or Qualified JLG Prior to each sale, lease or Pre-delivery Inspection Manual and applicable JLG User Mechanic rental delivery inspection form In service for 3 months; or Service and Maintenance...
  • Page 29 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 (if welded) Hubs Steering Knuckles Thrust Washers Steer Components Drive Motor Brakes 7-12 Drive Motor Gearbox 31210090 – JLG Lift –...
  • Page 30 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 (ANSI Market) Capacity Decals Installed, Secure, Legible All Decals/Placards installed, Secure, Legi- – JLG Lift – 31210090...

  • Page 31: 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 Footnotes: Maintenance and Inspection Table Codes: : Prior to use each day; or at each operator change. Check for proper and secure installation.

  • Page 32: 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 33: Bolt Usage And Torque Application

    If evidence of NOTICE metal or rubber particles is found, drain and flush the SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND entire system. THREAD DEFORMING LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL. 31210090 – JLG Lift –...

  • Page 34: Welding On Work Platform

    For best performance, JLG recommends the use of ISO vals. When recommended lubricants are not available, VG 32 oil with a viscosity of 32 cSt at 40 °C. Refer to Sec- consult your local supplier for an equivalent that meets or tion 1.7 of this Service Manual for recommended hydraulic...
  • Page 35 In case of noisy operation of the pressure relief valve when cylinders are at end of stroke, bleed the air from the valve. Refer to Sections 7 and 9-8 of this manual for further infor- mation. 31210090 – JLG Lift –...
  • Page 36 ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ ____________________________________ _______________________________________ – JLG Lift – 31210090 2-10...
  • Page 37 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 38: Section 3 - Theory Of Operation

    These resistors are approximately market and model must be set properly for safe and lawful 120 . 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 39 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 40: 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 41: 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 42: 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 43: 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 44: Personality Settings And Calibration

    • Mast Lift Down and Jib Lift Down can be operated at normal speed. If the battery is deeply discharged: • Mast Lift Up and Jib Lift Up are cut out; • The max. driving speed is limited at 0.4 km/h, whatever the platform position is; 31210090 – JLG Lift –...
  • Page 45 ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210090...
  • Page 46 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 47: Section 4 - Chassis Mounted Components

    Blow any accumulated dust in brake compartment. 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 48: Brake Assembly

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

  • Page 49: Drive Motor Assembly Installation

    It can be necessary to give light mallets hits on the stator body to disengage it from the rear casing. Figure 4-7. Motor Disassembly Slide the encoder cable through the rubber cable seal (17) when extracting the stator. Unscrew the 4 screws M8 (1). 31210090 – JLG Lift –...

  • Page 50: Wheel Motor Assembly

    Using a drill Ø 62 mm (2" 7/16) and a mallet, tap on the centering (14b) to the encoder (14) abutment. Install the retaining ring (12). – JLG Lift – 31210090...

  • Page 51: Rotor Assembly

    Screw staggered the 4 screws (1) of the motor (torque value: 16 N.m ± 2.4 N.m). The new encoder should be equipped with contacts Deutsch JLG P/N 4460917. Re-wire the encoder connector (See Fig. 4-8). Brake Assembly: (see procedure on the previous paragraph "Brake Assembly").

  • Page 52: Oil Filling

    Replacement tires must be the same size and rating as the tire being replaced. Use of Prior to 02-2016 Since 02-2016 genuine JLG parts is highly recommended. FILL THROUGH THE FILLING HOLE Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque.

  • Page 53: Steering Linkage

    Link Steer Sensor Right Spindle Pin (Sensor Drive) Left Spindle Pin Cylinder Anchor Pin Right Link Anchor Pin Left Link/Cyl. Anchor Pin Hydraulic Steer Cylinder 10a. Steer Cylinder-Steer Right Port 10b. Steer Cylinder-Steer Left Port 31210090 – JLG Lift –...

  • Page 54: 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.). – JLG Lift – 31210090...

  • Page 55: Hoses And Cables Routing

    Hub should not be noticeably loose when moved parallel with spindle centerline. Install wheel, torque wheel per specification in Sec- tion 4.2. 31210090 – JLG Lift –...
  • Page 56 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 57: Section 5 - Turntable And Vertical Mast

    Swing the structure to the right to gain access to the first grease fitting (2). Lubricate using a grease gun. Swing the structure 180° to the left to gain access to the second grease fitting and lubricate. 31210090 – JLG Lift –...

  • Page 58: Replacement Of Swing Bearing

    Using a brush (2), apply a generous coating of spec- ified lubricant on bearing teeth. Rotate superstruc- ture to reach all the teeth. Install bearing teeth covers. Install chassis hoods. Figure 5-5. Counterweight Removal (T10E/T26E) – JLG Lift – 31210090...

  • Page 59: Counterweight Removal (T8E/T20E)

    Attach suitable sling(s) to mast sections as shown following and draw all slack from sling(s). Remove the locknut, attachment nut and chain slack detec- tion system from chains attachments on mast sec- Figure 5-7. Mast Assembly Lifting 31210090 – JLG Lift –...

  • Page 60: Mast Section #1 Set On Blockings

    SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK and locknuts through inner race of bearing and turn- BETWEEN THE CHASSIS AND TURNTABLE, USE A GENUINE JLG table base plate. Apply a light coating of Loc- PART IS HIGHLY RECOMMENDED.
  • Page 61 Section 5-5). Slack and remove sling(s) from mast sections assembly. Install chain slack detection system and locknut. Secure mast inner power track with hardware (10E/ 26E). Attach chain slack sensor cable to cylinder barrel with plastic straps. 31210090 – JLG Lift –...

  • Page 62: Swing Motor

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

  • Page 63: Mast Profile Lubrication

    Fully lower the mast to remove the upper rollers. Raise the mast as necessary to gain access to the lower rollers. Mast sections alignment must be adjusted after rollers replacement. 31210090 – JLG Lift –...

  • Page 64: Roller Assembly

    Repeat operation for the other pin assemblies. Figure 5-16. Roller Removal Adjust mast transversal play and mast sections alignment. Roller Installation NOTE: If already assembled, use a locknut to free the bronze wear pad, the roller and the washer from the – JLG Lift – 31210090...

  • Page 65: Mast And Rollers Setting

    Models 8E-10E-20E-26E Ensure mast is fully lowered prior to completing top roller setting procedure. Refer to figure 5-21 for mast configuration/terminology. Table 5-1. Influence of roller setting on mast play Figure 5-21. Top Rollers Mast Configuration 31210090 – JLG Lift –...

  • Page 66: Top Rollers Mast Centering

    Slowly tighten the roller so that it comes just in con- Mast 4 tact with the shim. Remove the shim and tighten the rollers as indicated in the Table 5-2. Mast 5 Table 5-3. Bottom Rollers Setting Height – JLG Lift – 31210090 5-10...

  • Page 67: Bottom Rollers Mast Centering

    Figure 5-26. Adjusting Bottom Roller Play Slowly tighten the roller so that it comes just in con- tact with the shim. Remove the shim and tighten the rollers as indicated in the Table 5-4. 31210090 – JLG Lift – 5-11...

  • Page 68: Top And Bottom Rollers

    Bottom Table 5-6. Maximum Tightening Adjustment NOTE: After each tightening operation, it is imperative to ensure that no mast jamming appears. Maximum times for mast lowering are given for a temperature >10°C (50°F). – JLG Lift – 31210090 5-12...

  • Page 69: Lifting Chains

    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 Figure 5-29. Supporting Mast Sections 31210090 – JLG Lift – 5-13...

  • Page 70: Lifting Chains Inspection

    • Plates should not be cracked: Figure 5-31. Cracked Plate • The plate clevis pins should not present excessive play. • Pins should not have turned in their housing (1). Figure 5-32. Turned Pin – JLG Lift – 31210090 5-14...

  • Page 71: Lifting Chains Removal And Installation

    SECTION 5 - TURNTABLE AND VERTICAL MAST Lifting Chains Removal and Installation Figure 5-34. Chains Stages and Attachments Description - T10E/T26E 31210090 – JLG Lift – 5-15...

  • Page 72: Chains Stages And Attachments Description (T8E/T20E)

    SECTION 5 - TURNTABLE AND VERTICAL MAST Figure 5-35. Chains Stages and Attachments Description (T8E/T20E) – JLG Lift – 31210090 5-16...
  • Page 73 SECTION 5 - TURNTABLE AND VERTICAL MAST Figure 5-36. First Chain Stage 31210090 – JLG Lift – 5-17...
  • Page 74 SECTION 5 - TURNTABLE AND VERTICAL MAST Figure 5-37. Second Chain Stage (T10E/T26E) – JLG Lift – 31210090 5-18...

  • Page 75: Second Chain Stage (T8E/T20E)5-19

    CHAIN ANCHORS, CLEVIS PINS, BEVEL WASHERS AND NUTS AREA. DO NOT REMOVE THE LUBRICANT FROM THE CHAIN MUST ALSO BE REPLACED. USE ONLY GENUINE JLG PARTS. BEFORE, DURING OR AFTER THEIR INSTALLATION. WHEN REMOVE THE LIFTING CHAINS ONE BY ONE. ALWAYS REPLACE UNROLLING OR INSTALLING CHAINS, AVOID TWISTING THEM.
  • Page 76 Remove the locknut, attachment nut and bevel washers from a chain anchor at attachment #2. If installed, remove the chain slack detection assem- bly from the other end of the chain. If not installed, – JLG Lift – 31210090 5-20...
  • Page 77 Using the ground controls, lower the mast until the mast sections rest on blockings. Secure the block- ings with C-clamps. Remove the locknut, attachment nut and bevel washers from a chain anchor at attachment #4. 31210090 – JLG Lift – 5-21...
  • Page 78 Using the ground controls, lower the mast until the mast section rests on blockings. Secure the block- ings with C-clamps. Remove the locknut, the attachment nut and the bevel washers from a chain anchor at attachment – JLG Lift – 31210090 5-22...

  • Page 79: Chain Tension Adjustment

    Remove the locknut, the attachment nut and the bevel washers from a chain anchor at attachment If installed, remove the chain slack detection system from the other end of the chain. If not installed, 31210090 – JLG Lift – 5-23...

  • Page 80: Pulley - Pulley Support

    Unequal distances sections is kept. indicate a severe pin and pulley assembly wear. Install and tighten the locknut on each anchor. Remove the machine from service until the worn pul- ley assembly has been replaced. – JLG Lift – 31210090 5-24...

  • Page 81: Removal And Installation

    Install a couple of suitable blocking to support mast mast section(s). section #2 as indicated below. Remove the locknut from a long anchor and loosen the attachment nut to slacken the chain. 31210090 – JLG Lift – 5-25...

  • Page 82: Mast Cylinder Disassembly

    From ground controls, perform a few mast raising/ lowering movements to bleed air from the circuit and to check for proper operation. Check hydraulic fluid level and adjust accordingly. Install chassis shield and hoods. – JLG Lift – 31210090 5-26...

  • Page 83: Section 6 - Jib And Platform

    Remove the bearing pins (4). Remove the ball bear- ings (5). Lift and remove the platform assembly (6). 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 84: Overload System Verification

    Secure the cylinder with suitable slings or supports as required. 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 85: Jib Cylinder Disassembly

    Refer to Section 7. Perform a few jib movements from the ground con- trol station to bleed the air from the circuit and to check for proper operation. Check hydraulic fluid level and adjust accordingly. 31210090 – JLG Lift –...
  • Page 86 ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210090...
  • Page 87 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 88: Section 7 - Hydraulics

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

  • Page 89: Tank Filling

    Bleed the proportional pressure relief valve. Refer to Chapter 7-3 of this manual. From platform console, fully steer the wheels to the right. Check hydraulic fluid level and adjust accordingly. – JLG Lift – 31210090...

  • Page 90: Hydraulic Power Unit

    14- Plug - 3/8" BSPP 15- Check Valve 16- Check Valve 17- Swing Motor By-Pass Valve (Needle Valve) 18- Flow Regulator (Jet) 19- Adapter 20- Filler/Breather Cap 21- Return Pipe Figure 7-6. Ports Identification 22- Adapter 23- Suction Pipe 31210090 – JLG Lift –...

  • Page 91: Hydraulic Lines Connections

    (Refer to Figure 7-5.) is controlled by a PWM signal deliv- ered by the master controller. As a function of the electri- Install coil nut (1). cal control signal, the pressure relief value changes. When – JLG Lift – 31210090...

  • Page 92: Flow Directional Valve

    Disconnect the battery plug. Remove the protection cover from the motor. Blow any accumulated brush dust around the brushes and armature commutator. Check brushes for wear, replace if necessary. Figure 7-11. Moving Hydraulic Power Unit 31210090 – JLG Lift –...

  • Page 93: Swing Motor

    Connect battery plug and check for proper opera- tion of the machine. Figure 7-13. Swing Motors Ports Identification Toucan 8E/Toucan 20E Port 1: Swing Right Port 2: Swing Left Toucan 10E/Toucan 26E Port A: Swing Left Port B: Swing Right Port DR: Drain Port - Plugged –...

  • Page 94: Cylinders Holding Valves

    PORTED) BEFORE DISMOUNTING THE VALVE. DISCONNECT BATTERY PLUG UNTIL THE REPAIRS ARE COMPLETED. Remove chassis hoods. Swing the structure 90° to the right. Fully raise the mast and install suitable blockings to support mast section #2 (Refer to Sec- 31210090 – JLG Lift –...

  • Page 95: Jib Cylinder Holding Valve

    Manual Override Device Unscrew the hardware (3) securing the valve protec- Coil Nut tor (4) and remove the protector. Elbow Adapter Unscrew the valve banjo bolt (5) and plug the cylin- der port (3/8" BSPP). – JLG Lift – 31210090...

  • Page 96: Cylinder Repair

    Figure 7-18. Steer Cylinder Barrel Gland Piston (a-b) O-Ring Piston Angled guide Split Back-up Ring O-Ring Locknut O-Ring + Back-up Ring O-Ring Rod Seal Wiper Seal Figure 7-17. Jib Cylinder Holding Valve - Schematic/ Flange Bushing Exploded View 31210090 – JLG Lift –...

  • Page 97: Disassembly

    Check inside diameter Rod Seal for tapering or ovality. Replace cylinder if necessary. Guide Band Inspect threaded portion of the barrel for damage. Snap Ring Dress threads as necessary. O-Ring + Back-up Ring Wiper Seal – JLG Lift – 31210090 7-10...

  • Page 98: Assembly

    Repair as necessary. Assembly NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts manual. Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 99 ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210090 7-12...
  • Page 100 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 101: Section 8 - Control Components

    SECTION 8 - CONTROL COMPONENTS SECTION 8. CONTROL COMPONENTS 8.1 CONTROL COMPONENTS OVERVIEW Figure 8-1. Control Components Location - T8E/T20E 31210090 – JLG Lift –...

  • Page 102: Control Components Location - T10E/T26E

    SECTION 8 - CONTROL COMPONENTS Figure 8-2. Control Components Location - T10E/T26E – JLG Lift – 31210090...

  • Page 103: Control Components - Service

    ADD ONLY DISTILLED WATER TO BATTERIES. ADD WATER TO Check for proper level in each cell (float on each BATTERIES AFTER CHARGING TO AVOID ELECTROLYTE OVER- cell’s cap). Actuate the filling pump again if some FLOW. cells show improper level. 31210090 – JLG Lift –...
  • Page 104 Never remove this check valve. • Keep the top of the battery clean and dry to prevent Doing so will cause excessive electrolyte level in the self-discharge. cells and electrolyte overflow. – JLG Lift – 31210090...
  • Page 105 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 106: Main Power Contactor Relay

    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 8-6. Main Power Contactor Relay Figure 8-7. Power Fuse – JLG Lift – 31210090...

  • Page 107: 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. 31210090 – JLG Lift –...

  • Page 108: Chain Slack Sensor

    Chain Slack Sensor One chain of each lifting chain stage is fitted with a slack detection device. Those 3 (T10E/T26E) / 2 (T8E/T20E) switches are wired in series. Figure 8-10. Chain Slack Sensors - T8E/T20E – JLG Lift – 31210090...
  • Page 109 - 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 110: Overload Sensor (If Equipped)

    Power (+) Output +Vbatt Open -Vbatt -Vbatt Power (-) The sensor is calibrated mechanically as shown following. Figure 8-12. Overload Sensor Refer to Section 9-6 for Overload System Calibration. Figure 8-13. Drive Orientation Switch – JLG Lift – 31210090 8-10...

  • Page 111: Steering Sensor

    Leff Stop Stop Straight Output +Vbatt Open A or 1 4.2V - 4.4V Power (+) B or 2 0.5V - 1.0V 2.2V - 2.8V 3.4V - 3.9V Output C or 3 Power (-) -Vbatt 31210090 – JLG Lift – 8-11...
  • Page 112 The LED at the bottom of the sensor body will blink, indicating the new 0 degree position has been defined. Figure 8-19. Tilt Sensor Calibration Verification Figure 8-18. Tilt Sensor Calibration – JLG Lift – 31210090 8-12...

  • Page 113: Ground Alarm

    The ground alarm is located at the left side of the power The warning beacon is located at the top of the mast, modules, on the chassis. above the battery compartment door. Figure 8-20. Ground Alarm Figure 8-21. Warning Beacons 31210090 – JLG Lift – 8-13...

  • Page 114: Descent/Motion Alarm (Optional)

    An optional acoustic alarm can be installed on the chassis at the left side of the power modules. Figure 8-22. Descent/Motion Alarm Acoustic alarm personalities to define operating mode can be access via analyzer menu: refer to Section 9 JLG CON- TROL SYSTEM. – JLG Lift – 31210090...

  • Page 115: 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. Battery Pack Battery Power Quick-Disconnect Power Fuse...

  • Page 116: Power Module

    Remove the four screws securing the power mod- ule. Use a ratchet wrench with appropriate exten- sions and a universal joint (3) to remove the bottom screws. Remove the power module. Figure 8-24. Power Module Removal - Installation – JLG Lift – 31210090 8-16...

  • Page 117: Installation

    Install chassis rear shield and chassis covers. Check software version (Refer to Section 9), if nec- essary proceed with a software update. Proceed with a system setup and calibration (Refer to Section 9.3). 31210090 – JLG Lift – 8-17...

  • Page 118: Power Module Electrical Evaluation

    Input Right Wheel Encoder Pin B Steer Angle Sensor Analog Input Unused Digital Output Digital Input Unused Digital Output Charger Interlock Digital Input Chain Slack Switch Digital Input Manual Brake Release Digital Input Unused – JLG Lift – 31210090 8-18...
  • Page 119 • 24V input, taken after the voting relay. Proportional Outputs (Prop): • PWM controlled with current sensing • Drive to -Vbatt Power Outputs: • +5V power supply for the motor encoder (exact value: 4.3V) 31210090 – JLG Lift – 8-19...

  • Page 120: Ground Control Station

    • Insert the ribbon cable into the plate slot. Figure 8-27. Ground Control Box Circuit Board - Installation Door Control Box Panel Assembly Panel Attach Screws Panel Plastic Washers Circuit Board Assembly Circuit Board Attach Screws – JLG Lift – 31210090 8-20...

  • Page 121: Platform Control Station

    Figure 8-29. Joystick Controls - Installation Face Plate Drive/Swing Joystick Assembly Drive/Steer Joystick Attach Screws Mast/Jib Joysticks Assembly Mast/Jib Joystick Attach Screws Guard Guard Attach Screws Figure 8-28. Upper Control Box Circuit Board - Installa- tion 31210090 – JLG Lift – 8-21...

  • Page 122: Upper Control Box - Components Evaluation

    If the switch requires removal, pull the switch release lever out with the blade of a screwdriver and remove Rocker: Steer Left Yellow the switch. Rocker: Steer Right Violet Reverse steps to install. Trigger + Rocker Power (+24V) Brown – JLG Lift – 31210090 8-22...
  • Page 123 / swing left position (-100%) 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). 31210090 – JLG Lift – 8-23...
  • Page 124 ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210090 8-24...
  • Page 125 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 126: 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 Connect the four pin end of cable supplied with the...

  • Page 127: 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 128: 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 129: Analyzer Screen Layout

    SECTION 9 - JLG CONTROL SYSTEM 9.2 ANALYZER SCREEN LAYOUT Figure 9-2. Analyzer Flow Chart - Sheet 1 of 5 NOTE:  - Only available in access level 1. – JLG Lift – 31210090...
  • Page 130 SECTION 9 - JLG CONTROL SYSTEM Figure 9-3. Analyzer Flow Chart - Sheet 2 of 5 NOTE:  - Only available in access level 1. 31210090 – JLG Lift –...
  • Page 131 SECTION 9 - JLG CONTROL SYSTEM Figure 9-4. Analyzer Flow Chart - Sheet 3 of 5 NOTE:  - Only available in access level 1. – JLG Lift – 31210090...
  • Page 132 SECTION 9 - JLG CONTROL SYSTEM Figure 9-5. Analyzer Flow Chart - Sheet 4 of 5 NOTE:  - Only available in access level 1. 31210090 – JLG Lift –...
  • Page 133 SECTION 9 - JLG CONTROL SYSTEM Figure 9-6. Analyzer Flow Chart - Sheet 5 of 5 NOTE:  - Only available in access level 1. – JLG Lift – 31210090...

  • Page 134: 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 135: 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 136: Calibrating The Joysticks

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

  • Page 137: Machine Personality - Adjustment Settings

    SECTION 9 - JLG CONTROL SYSTEM will calculate overwrite MAXP 9.9 MACHINE PERSONALITY - personalities). ADJUSTMENT SETTINGS After completing the Relief Valve calibration, hit ESC Personality settings adjustments shall be done when the twice to go back to CALIBRATIONS. system is idle (none of the power components, drive or Control the different pressures and adjust the per- pump motor, is running).
  • Page 138 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 139 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 140: System Test

    SECTION 9 - JLG CONTROL SYSTEM 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. To use this Follow the flow path in Figure 9-9., System Test Flow...
  • Page 141 SECTION 9 - JLG CONTROL SYSTEM  NOTES: _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________...
  • Page 142 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 143: Section 10 - Diagnostic Trouble Codes

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

  • Page 144: Dtc Check Tables

    • Check that the tilt sensor is securely mounted and its wire connected. • Check the tilt sensor wiring : @+Vbatt : CR9(B), CR9(C), CR2(7), CR3(7). @ -Vbatt : CR9(A). • Check the tilt sensor setting; if necessary, proceed with a sensor calibration. – JLG Lift – 31210090 10-2...

  • Page 145: Power-Up

    The trigger switch was closed for more • Check if the trigger switch is obstructed or jammed. WHILE IN NEUTRAL than seven seconds while the joystick • Check trigger switch output voltage : J2(5). was centered. 31210090 – JLG Lift – 10-3...

  • Page 146: Ground Controls

    NENTLY SELECTED • Disconnect the membrane panel ribbon cable : replace the membrane panel if DTC is no longer present. • Check the switch line voltage : J3(12), CR1(34) and CR2(17). – JLG Lift – 31210090 10-4...
  • Page 147 NENTLY SELECTED • Disconnect the membrane panel ribbon cable : replace the membrane panel if DTC is no longer present. • Check the switch line voltage : J3(10), CR1(32) and CR3(31). 31210090 – JLG Lift – 10-5...
  • Page 148 CR23(4), CR23(6), CR5(5), CR2(20). @ -Vbatt : CR4(C), CR23(3), CR23(5), CR5(3), CR2(31). Mast fully elevated : @ +Vbatt : CR4(A), CR4(B), CR4(C), CR23(1), CR23(2), CR23(4), CR23(5). @ -Vbatt : CR23(3), CR23(6), CR5(3), CR5(5), CR2(20), CR2(31). – JLG Lift – 31210090 10-6...
  • Page 149 • Check the switch wiring : Structure in line with the chassis : @+Vbatt : CR21(1), CR21(2); @ -Vbatt : CR21(3). Structure swung : @+Vbatt : CR21(1); @ -Vbatt : CR21(3); Insulated : CR21(2). 31210090 – JLG Lift – 10-7...

  • Page 150: Function Prevented

    @+Vbatt : CR19(1), CR17(8), CR1(25). • Check the line contactor coil. • Replace the line contactor. CONTACTOR DRIVER PER- The line contactor driver is out of order. • Replace the Master controller. MANENTLY OFF – JLG Lift – 31210090 10-8...

  • Page 151: Line Contactor Short Circuit

    The Jib Lift Up valve coil driver output is • Check the valve coil connections and wiring for BATTERY shorted to +Vbatt. short to +Vbatt. • Check the valve coil for correct impedance (refer to Section 8). 31210090 – JLG Lift – 10-9...
  • Page 152 • Check the valve coil for correct impedance (refer to Section 8). • Replace the Slave controller if the coil and its har- ness are correct. – JLG Lift – 31210090 10-10...
  • Page 153 • Check the line contactor coil for correct impedance (refer to Section 8). • If the harness and the devices are correct and if the fault appears at start up : Replace the Master con- troller. 31210090 – JLG Lift – 10-11...
  • Page 154 +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. – JLG Lift – 31210090 10-12...

  • Page 155: Thermal Limit

    • Check the sensor wiring and connections. • Check the sensor for correct impedance (refer to Section 8). • If the motor is cold and the fault is still present : replace the Master controller. 31210090 – JLG Lift – 10-13...

  • Page 156: Battery Supply

    BATTERY POWER LOW The batteries are discharged. • Recharge batteries. • Check for damaged battery, battery cables or con- nections. • Check battery charger function. Be sure to observe indicators for at least 30 seconds. – JLG Lift – 31210090 10-14...

  • Page 157: Transmission And Drive System

    9,5V . check that no external device is connected to the batteries, creating down-going pulses. Refer to a 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 158: 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. – JLG Lift – 31210090 10-16...

  • Page 159: Accessory

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

  • Page 160: Tilt Sensor

    DESCRIPTION CHECK CHASSIS TILT SENSOR DIS- Tilt sensor inputs to the control system • Check the wiring between the two controllers and AGREEMENT are not the same state. the connections : CR2(7) to CR3(7). – JLG Lift – 31210090 10-18...

  • Page 161: Platform Load Sense

    (refer to § 9-3). • If the sensor power is correct but its output improper : Replace the sensor and proceed with a calibration (refer to § 4-3 & 9-3). 31210090 – JLG Lift – 10-19...

  • Page 162: Safety System Override

    SLAVE MODULE EEPROM There is an internal error in the Slave Mod- • Cycle power to clear the fault. FAILURE ule (left controller). • If the fault is not cleared : Replace the Slave control- ler. – JLG Lift – 31210090 10-20...
  • Page 163 SLAVE MODULE - INTERNAL There is an internal error in the Slave Mod- • Cycle power to clear the fault. ERROR ule (left controller). • If the fault is not cleared : Replace the Slave control- ler. 31210090 – JLG Lift – 10-21...
  • Page 164 MASTER KO - MAST LIMIT2 There is an internal error in the Master • Cycle power to clear the fault. Module (right controller). • If the fault is not cleared : Replace the Master con- troller. – JLG Lift – 31210090 10-22...
  • Page 165 MASTER KO - SWING VALVE There is an internal error in the Master • Cycle power to clear the fault. Module (right controller). • If the fault is not cleared : Replace the Master con- troller. 31210090 – JLG Lift – 10-23...
  • Page 166 ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210090 10-24...
  • Page 167 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 168: Section 11 - General Electrical Information & Schematics

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

  • Page 169: 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. – JLG Lift – 31210090 11-2...

  • Page 170: 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 171: 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. – JLG Lift – 31210090 11-4...

  • Page 172: Amp Connector

    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 173 (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 – JLG Lift – 31210090 11-6...

  • Page 174: 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 175 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-11. Connector Installation – JLG Lift – 31210090 11-8...

  • Page 176: 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 177: 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. – JLG Lift – 31210090 11-10...
  • Page 178 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 179 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-19. Wiring Harness and Connectors - Sheet 2 of 3 – JLG Lift – 31210090 11-12...
  • Page 180 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-20. Wiring harness and Connectors - Sheet 3 of 3 31210090 – JLG Lift – 11-13...
  • Page 181 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 11.8 ELECTRICAL SCHEMATIC Figure 11-21. Electrical schematic caption – JLG Lift – 31210090 11-14...
  • Page 182 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS This page has been left blank intentionally 31210090 – JLG Lift – 11-15...
  • Page 183 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ELE251 - Sans MSSO Figure 11-22. Electrical Schematic ELE251 - Sheet 1 of 2 – JLG Lift – 31210090 11-16...
  • Page 184 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-23. Electrical Schematic Toucan ELE251 - Sheet 2 of 2 31210090 – JLG Lift – 11-17...
  • Page 185 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ELE259 - Avec MSSO Figure 11-24. Electrical Schematic ELE259 - Sheet 1 of 2 – JLG Lift – 31210090 11-18...
  • Page 186 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-25. Electrical Schematic ELE259 - Sheet 2 of 2 31210090 – JLG Lift – 11-19...
  • Page 187 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 11.9 HYDRAULIC SCHEMATIC Figure 11-26. Hydraulic schematic Toucan 10E/Toucan 26E – JLG Lift – 31210090 11-20...
  • Page 188 SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-27. Hydraulic schematic Toucan 8E/Toucan 20E 31210090 – JLG Lift – 11-21...
  • Page 189 ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210090 11-22...
  • Page 191 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

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