JLG Toucan 12E Service And Maintenance Manual
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JLG Toucan 12E Service And Maintenance Manual

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Service and Maintenance Manual
Model
TOUCAN 12E
P/N - 31210149
December 18, 2013

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  • Page 1 Service and Maintenance Manual Model TOUCAN 12E P/N - 31210149 December 18, 2013...
  • Page 2  NOTES: ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________...

  • 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. 31210149 – JLG Lift –...
  • Page 4 SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISON LOG Original Issue - December 18, 2013 – JLG Lift – 31210149...

  • Page 5: Table Of Contents

    HYDRAULIC CARTRIDGE INSTALLATION ......... . .2-10 SECTION 3 - THEORY OF OPERATION 31210149 – JLG Lift –...
  • Page 6 Mast Cylinder Disassembly ..........5-20 – JLG Lift –...
  • Page 7 Telescope Toucan 12E / Toucan 32E ........
  • Page 8 Upper Control Box - Components Evaluation........8-21 SECTION 9 - JLG CONTROL SYSTEM HAND HELD ANALYZER.
  • Page 9 HYDRAULIC SCHEMATIC............11-20 31210149 – JLG Lift –...
  • Page 10 Mast Cylinder Removal - 1 of 8 ........... .5-18 – JLG Lift –...
  • Page 11 Mast Elevation Limit Switches........... . .8-6 31210149 – JLG Lift –...
  • Page 12 Hydraulic schematic ............11-20 – JLG Lift –...
  • Page 13 Machine Personality Adjustment...........9-12 31210149 – JLG Lift –...
  • Page 14 _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ – JLG Lift – 31210149...

  • Page 15: Section 1 - Operating Specifications

    4 300 kg 4 900 kg 9 480 lbs Approximate Gross Machine Weight - Global 1.2 DIMENSIONAL DATA Table 1-2. Dimensions Description Models Toucan 12E - Toucan 12E Plus Model Toucan 32E 1.99 m 6.5’ Overall Stowed Machine Height 3.65 m 11.8’...

  • Page 16: Performance Data

    0.75 km/h Mast elevated 1.4 CAPACITIES Table 1-4. Capacities Component Models Toucan 12E - Toucan 32E Model Toucan 12E Plus 15l (11.5 l usable) - 3.96 gal (3.04 gal usable) Hydraulic Tank Approx. 20 l - (5.28 gal) Approx. 21.5 l - (5.3 gal) Hydraulic System (Including Tank) –...

  • Page 17: Components Data

    1.5 COMPONENTS DATA Batteries Table 1-5. Battery Specifications Description Model Toucan 12E - Toucan 12E Plus - Toucan 32E 8 Packs of 6 Volts (semitraction) Voltage (48VSystem - Series) 260 Amp Hour @ 20 HR. Rate Amp Hour (Standard battery) 215 Amp Hour @ 5 HR.

  • Page 18: Swing Drive

    SECTION 1 - OPERATING SPECIFICATIONS Swing Drive Table 1-8. Swing Drive Specifications Description Model Toucan 12E - Toucan 12E Plus - Toucan 32E Orbital Motor Type 20 cc Displacement Wheel and Worm. Ratio 1/50 Gear Reducer Platform Rotation Drive Table 1-9. Platform Rotation Drive Specifications...

  • Page 19: Major Components Weights

    33 lbs Level Correction Support (Option Rotation) 54 kg 119 lbs Boom 28 kg 62 lbs Telescope Mid Section (Toucan 12E Plus) 22 kg 49 lbs Telescope Inner Section (Toucan12E Plus) 32 kg 71 lbs Telescope (Toucan 12E / Toucan 32E)

  • Page 20: Lubrication

    NOTE: Hydraulic oils must have anti-wear qualities and suffi- cient 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 – 31210149...

  • Page 21: 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. 31210149 – JLG Lift –...

  • Page 22: 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 – JLG Lift – 31210149...

  • Page 23: 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 31210149 – JLG Lift –...
  • Page 24 _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ 1-10 – JLG Lift – 31210149...

  • Page 25: Section 2 - General Service Information

    JLG Service Training machine into service. School for the subject JLG product model. Reference the machine Service and Maintenance Manual and appropri- Preparation, Inspection and Maintenance ate JLG inspection form for performance of this inspec- tion.

  • Page 26: 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 27: Inspection And Preventive Maintenance Schedule

    1-2-8-11 1-2-8-11 TURNTABLE Swing Drive System Swing Bearing Bolts Hose, Cables Installation, Power Track 1-2-8-11 1-2-8-11 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 31210149 – JLG Lift –...
  • Page 28 1-2-8 Hydraulic Hoses, Lines and Fittings 1-2-8-11 1-2-8-11 Hydraulic Tank/Hydraulic Fluid Hydraulic Fluid Replacement Electrical Connections Instruments, Switches 7-15 Lights, Horn Electric Motor Brushes (Hyd. Power Unit) 7-12 GENERAL Operation and Safety manuals in Storage – JLG Lift – 31210149...
  • Page 29 Grease and Lubricate to Specifications 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: 21. Verify. 22. Perform. 1. Check for proper and secure installation.

  • Page 30: Servicing And Maintenance Guidelines

    1. Coat inside diameter of bushing with specified lubri- angle, keep in mind that the capacity of an eyebolt or sim- cant prior to pin installation. ilar bracket lessens, as the angle between the supporting – JLG Lift – 31210149...
  • Page 31 2. Properly align pin and bushing so that the coating does not get damaged when installing the pin. 3. Pins have chamfered or rounded end to prevent damage to the coating of the bushing during pin installation. 31210149 – JLG Lift –...

  • Page 32: Bolt Usage And Torque Application

    If evidence of NOTICE metal or rubber particles is found, drain and flush the entire system. SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL. – JLG Lift – 31210149...

  • Page 33: Welding On Work Platform

    Components and assemblies requiring lubrication and servicing are shown in Section 1.7. Service applicable For best performance, JLG recommends the use of ISO components with the amount, type, and grade of lubricant VG 15 oil with a viscosity of 15.1 cSt at 40 °C. Refer to Sec- are recommended in this manual, at the specified inter- tion 1.7 of this Service Manual for recommended hydraulic...

  • Page 34: Hydraulic Cartridge Installation

    If the valve requires two coils, install them separately. Place the washer on top of first coil then install the second coil. Finally, install and tighten the coil nut to the specified torque. 2-10 – JLG Lift – 31210149...

  • Page 35: Section 3 - Theory Of Operation

    Serial Communication Link: Modules on the link send Some faults only show up at power-up when the control messages digitally, bit by bit along the wires where differ- system performs a self-test. All controls should be left 31210149 – JLG Lift –...

  • Page 36: Joysticks

    These resistors are approximately battery status and driving conditions). The default fre- 120 . On a JLG aerial work platform, this is typically in quency range is 0.6Hz to 146 Hz which approximately cor- the platform and in the chassis. These resistors may be in responds to a driving speed of 0km/h to 5.5km/h.

  • Page 37: Pump/Structure Movements

    Lift down is "powered" by gravity. To lift the mast, the pump is run and an appropriate signal is sent to the proportional relief valve. Then, after a short delay, the solenoid energizes and opens the mast valve. 31210149 – JLG Lift –...

  • Page 38: Swing

    Figure 3-5. Swing System - Basic Schematic Figure 3-4. Jib Lift System - Basic Schematic – JLG Lift – 31210149...

  • Page 39: Steer

    When the wheels are straight, it will output approximately 2.5 VDC. Depending on output signal, the speed of the inner drive motor will be reduced to allow machine to take a curve (like a differential system). 31210149 – JLG Lift –...

  • Page 40: Platform Level

    • The switch must be tripped for more than 1s to con- • All the structure movements remain unaffected by the sider the platform overloaded. DOS. • The switch must be released for more than 1s to con- sider the platform not overloaded. – JLG Lift – 31210149...

  • Page 41: Personality Settings And Calibration

    Personality Settings and Calibration Functions performances may be altered by changing the applicable personality settings or calibrating different ele- ments of the control system. Refer to Section 9 of this manual for the applicable proce- dures. 31210149 – JLG Lift –...
  • Page 42 _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ – JLG Lift – 31210149...

  • Page 43: Section 4 - Chassis Mounted Components

    4. Blow any accumulated dust in brake compartment. Check brake disk thickness on several locations. 5. Once complete, correctly reposition the dust protec- Replace the disk if its thickness is below 8.5mm (0.335 tion ring. in.). 31210149 – JLG Lift –...

  • Page 44: Brake Assembly

    7. Loosen hardware securing the motor assembly to slots. the chassis. Remove the drive motor assembly. 9. Install and secure the brake assembly. 10. Correctly position the dust protection ring (6). Install the dust cap (10). – JLG Lift – 31210149...

  • Page 45: Drive Motor Assembly Installation

    The gearbox will need to be filled with 2 liters (0.53 Gal.) of oil. Oil Filling Gearbox oil filling is performed through the filling port as shown in figure 4-6, until oil level is flush with the threads (gearbox in horizontal position). Figure 4-7. Oil filling 31210149 – JLG Lift –...

  • Page 46: Wheels And Tires

    The proper procedure for attaching wheels is as follow: 1. Start all lug nuts by hand to prevent cross thread- ing. DO NOT use a lubricant on threads or nuts. – JLG Lift – 31210149...

  • Page 47: Steering Linkage

    (1) between the two plates of the axle. Insert spindle 6. Check hydraulic fluid level and adjust accordingly. pivot pin (insert right spindle pin (5) so as the blind 31210149 – JLG Lift –...

  • Page 48: Steering Sensor Installation

    7. Install wheels: Refer to Section 4-2. NOTICE IF STEERING SENSOR WAS REMOVED/REPLACED, OR SENSOR DRIVING PIN AND/OR SPINDLE WAS REMOVED/REPLACED, IT IS HIGHLY RECOMMENDED TO PERFORM A STEERING SENSOR CALIBRATION PROCEDURE. REFER TO SECTION 9-5. – JLG Lift – 31210149...

  • Page 49: Section 5 - Turntable And Vertical Mast

    Outer race Figure 5-4. Swing Bearing Teeth Lubrication HEX. HEAD CAPSCREW M12-90 (18mm A/F) HEX. HEAD CAPSCREW M12-70 (18mm A/F) W/LOCKNUTS (19mm A/F) 1. Remove chassis hoods and lateral frame shields. Figure 5-2. Torque Sequence Diagram 31210149 – JLG Lift –...

  • Page 50: Replacement Of Swing Bearing

    Let the machine secured with the lifting device. NOTE: During the lift up operation, the tilt angle will be about 9° for the Toucan 12E and 7° for the Toucan 12E Plus, in the platform direction. Figure 5-7. Swing Bearing Removal - 3 of 6 –...
  • Page 51 (7) with a minimum height of 500 mm NOTE: During the lift up operation, the tilt angle will be (20") and capable of supporting the weight of the about 8° for the Toucan 12E and 7° for the Toucan complete assembly. 12E Plus, in the platform direction.

  • Page 52: Swing Drive

    IS THE ONLY STRUCTURAL LINK BETWEEN THE CHASSIS AND tighten to a final torque of 117 N.m (86 ft.lbs). TURNTABLE, IT IS IMPERATIVE THAT REPLACEMENT HARD- WARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG 9. Repeat all the removal steps in reverse order. HARDWARE IS HIGHLY RECOMMENDED.

  • Page 53: Swing Drive Disassembly

    Figure 5-15. Swing Drive Disassembly - 3 of 3 4. Remove the screw (10) and the pinion (11). 5. Clean and inspect the hydraulic motor and the pin- ion for damage or excessive wear. Replace if necessary. 31210149 – JLG Lift –...

  • Page 54: Mast Transversal Play/Mast Sections Alignment

    4. Once the roller is in line with the pin, tighten the pin so that the roller slides onto the pin. Figure 5-19. Mast Sections Vertical Alignment – JLG Lift – 31210149...

  • Page 55: Lifting Chains

    (or every 3 months) thereafter. THE INITIAL LUBRICATION OF THE CHAINS IS ONLY TO PRO- TECT THEM AGAINST RUST AND TO PROTECT FRICTION SUR- FACES DURING THE FIRST 50 HOURS OF OPERATION. 31210149 – JLG Lift –...

  • Page 56: Lifting Chains Inspection

    Inspect thoroughly each chain over its entire length: • Chains, anchors, clevis pins and splits pins should not be corroded. • Plates should not be cracked: Figure 5-21. Cracked Plate – JLG Lift – 31210149...

  • Page 57: Lifting Chains Removal And Installation

    SECTION 5 - TURNTABLE AND VERTICAL MAST Lifting Chains Removal and Installation Figure 5-24. Chains Stages and Attachments Description 31210149 – JLG Lift –...

  • Page 58: First Chain Stage

    SECTION 5 - TURNTABLE AND VERTICAL MAST Figure 5-25. First Chain Stage Figure 5-26. Second Chain Stage 5-10 – JLG Lift – 31210149...

  • Page 59: Third Chain Stage

    SECTION 5 - TURNTABLE AND VERTICAL MAST Figure 5-27. Third Chain Stage Figure 5-28. Fourth Chain Stage 31210149 – JLG Lift – 5-11...

  • Page 60: First Chains Stage Removal

    REPLACE SYSTEMATICALLY BOTH CHAINS OF A SAME STAGE. CHAIN ANCHORS, CLEVIS PINS, BEVEL WASHERS AND NUTS MUST ALSO BE REPLACED. USE ONLY GENUINE JLG PARTS. REMOVE THE LIFTING CHAINS ONE BY ONE. ALWAYS REPLACE AND TENSION A CHAIN BEFORE REMOVING ANOTHER ONE. IN ADDITION, LIFTING EQUIPMENT SUCH AS CHAINS OR SLINGS SHOULD BE INSTALLED AS REQUIRED TO SUPPORT MAST SECTIONS DURING CHAIN REMOVAL.

  • Page 61: Second Chains Stage Removal

    If not installed, remove the locknut and the attach- ment nut from the other end of the chain. 5. Remove the chain from the pulley groove. 6. Install and tension a new chain before removing the other one. 31210149 – JLG Lift – 5-13...

  • Page 62: Third Chains Stage Removal

    5. Remove one of the chain anchors so that the chain can be removed from the pulley groove. 6. Install and tension a new chain before removing the other one. 5-14 – JLG Lift – 31210149...

  • Page 63: Fourth Chains Stage Removal

    If not installed, remove the locknut and the attach- ment nut from the other end of the chain. 5. Remove the chain from the pulley. 6. Install and tension a new chain before removing the other one. 31210149 – JLG Lift – 5-15...

  • Page 64: Chain Tension Adjustment

    5. Install and tighten the locknut on each anchor. 5-16 – JLG Lift – 31210149...

  • Page 65: Removal And Installation

    Pulley Removal 1. Follow the lifting chains removal and installation pro- cedure to secure the appropriate mast section(s). 2. Remove the locknut from a long anchor and loosen the attachment nut to slacken the chain. 31210149 – JLG Lift – 5-17...

  • Page 66: Mast Cylinder

    The blocking must rest on turntable circular base plate. Secure the blocking with C-clamps (3). 4. Using the ground controls, lower the mast until mast section #2 rollers (4) rest on blockings. Figure 5-40. Mast Cylinder Removal - 3 of 8 5-18 – JLG Lift – 31210149...

  • Page 67: Mast Cylinder Removal - 4 Of 8

    8. Control the mast lowering by pushing on mast lowering lever (9) until the cylinder rod (10) is fully retracted. Figure 5-44. Mast Cylinder Removal - 7 of 8 Figure 5-42. Mast Cylinder Removal - 5 of 8 31210149 – JLG Lift – 5-19...

  • Page 68: Mast Cylinder Disassembly

    6. From the ground controls, perform a few mast rais- ing/lowering movements to bleed the air from the circuit and to check for proper operation. 7. Check hydraulic fluid level and adjust accordingly. Install hoods and frame shields. 5-20 – JLG Lift – 31210149...

  • Page 69: Counterweight

    (4) (it will help for the installation). Lift up the counterweight and remove it from the turnta- ble (5). Counterweight Installation 1. Repeat all removal steps in reverse order. 2. Torque the retaining bolts to 350 N.m (260 ft.lbs). 31210149 – JLG Lift – 5-21...
  • Page 70 _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ 5-22 – JLG Lift – 31210149...

  • Page 71: Section 6 - Telescopic Boom And Platform

    (3) and the 4 lateral ball bearings (4). 6. Lift and remove the platform assembly (5). 7. Check the ball bearings (4 lateral and 2 front) for cracks or hard points. Replace bearings if neces- sary. 31210149 – JLG Lift –...

  • Page 72: Platform Installation

    3. Remove all the clamps (1), channel (2) and power track (3). Figure 6-3. Platform Rotation Option (If Equipped) 4. Remove electrical cylinder pin (4) and retaining washers (5). 5. Lift and remove platform support (6). – JLG Lift – 31210149...
  • Page 73 10 and Figure 6-5. Platform Support and Slave Cylinder Removal - 3 of 4 8. Tilt the support to gain access and to remove the slave cylinder rod pin (10). 31210149 – JLG Lift –...

  • Page 74: Slave Cylinder Disassembly

    NOTE: It is not required to remove platform and platform supports to remove the boom and master cylinders. To remove boom and master cylinders, support the boom with a sling and remove the cylinders pins (2), (4), (6) and (7). – JLG Lift – 31210149...

  • Page 75: Boom And Master Cylinders Disassembly

    SECTION 6 - TELESCOPIC BOOM AND PLATFORM 6.5 TELESCOPE 6.5.1 Telescope Toucan 12E Plus Telescope Sections and Cylinder Removal 1. Remove the telescopic boom. Refer to Section 6-4. Figure 6-9. Telescope and Cylinder Removal - 1of 5 2. Remove the holding valve block (1) from the tele- scope dual cylinder (2).

  • Page 76: Telescope Dual Cylinder Disassembly

    3. Perform a few telescope movements from the ground control to check for proper operation. 4. Check hydraulic level and adjust accordingly. 6.5.2 Telescope Toucan 12E / Toucan 32E Telescope Sections and Cylinder Removal 1. Remove telescopic boom. Refer to section 6-4.

  • Page 77: Telescope Cylinder Disassembly

    Secure wear pads retaining bolt with thread locking compound Loctite 243. Torque the retaining bolts to 7.5 N.m (5.5 ft.lbs). 3. Perform a few telescope movements from the ground control to check for proper operation. 4. Check hydraulic level and adjust accordingly. 31210149 – JLG Lift –...
  • Page 78 ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ ____________________________________ ______________________________________ – JLG Lift – 31210149...

  • Page 79: Section 7 - Hydraulics

    SECTION 7 - HYDRAULICS SECTION 7. HYDRAULICS 7.1 HYDRAULIC LINES CONNECTIONS Figure 7-1. Hydraulic Lines Connections 31210149 – JLG Lift –...

  • Page 80: Hydraulic Power Unit

    18. Plug - 1/2" BSPP NOTICE AFTER REPLACEMENT OF THE PROPORTIONAL RELIEF VALVE AND/OR THE PROPORTIONAL COIL, ALL PRESSURE RELIEF VALUES MUST BE CHECKED AND ADJUSTED ACCORDINGLY. Refer to Section 9-7 for proper proportional relief valve adjustment procedure. – JLG Lift – 31210149...

  • Page 81: Check Valve 0.5 Bar

    Brush Removal NOTE: No hydraulic power unit connections or hydraulic need to be disconnected. 1. Disconnect battery plug. 2. Disconnect both power unit motor cables (+ and -). 31210149 – JLG Lift –...

  • Page 82: Hydraulic Tank

    2. Attach the brush terminal end to the terminal post Toucan 12E: approximately 20 liters (5.28 gallons) using the terminal screw (1). Toucan 12E Plus: approximately 21 liters (5.55 gallons) 3. Repeat previous steps for each brush. Oil Level 4. Install the protection cover.

  • Page 83: Tank Draining/Cleaning

    3. From platform console, fully steer the wheels to the right. 4. Check hydraulic fluid level and adjust accordingly. 31210149 – JLG Lift –...

  • Page 84: Disassembly

    A solenoid-operated, 4 way, 3 positions, direct-act- ing, spool-type, closed center, screw-in hydraulic cartridge valve. Coil Nominal Voltage: 12 VDC Coil Resistance Value: 9.8  Tightening torque for the cartridge: 27 N.m Tightening torque for the coil of the cartridge: 6.8 – JLG Lift – 31210149...

  • Page 85: Secondary Manifold

    Prevents draining of platform levelling lines after a jib or a platform level movement. This dual pilot operated check valve has a 3:1 pilot ratio and the check is spring-biased at 1.7 bar to assure hold- ing. Tightening torque for the cartridge: 27 N.m 31210149 – JLG Lift –...

  • Page 86: Cylinders Holding Valves

    4. Perform a few mast raising/lowering movements to Figure 7-16. Jib Cylinder Holding Valve bleed air from the circuit and to check for proper - Removal/Installation operation. 5. Check the mast manual descent for proper opera- tion. – JLG Lift – 31210149...

  • Page 87: Jib Cylinder Holding Valve - Schematic/Exploded View

    (full stroke) and repeat this step until all Ensures a constant and limited lowering speed in the air is bled from the circuit. event of hydraulic failure (valves, hoses...). 8. Check hydraulic fluid level and adjust accordingly. 31210149 – JLG Lift –...

  • Page 88: Telescope Cylinder Holding Valve

    Raise the mast and install suitable blockings to support the end of the telescope. Lower the mast until the end of the telescope rests on blockings. Turn power off at ground controls. Disconnect bat- tery plug. 7-10 – JLG Lift – 31210149...

  • Page 89: Adjustment Checking

    4. Perform a few jib raising/lowering movements to check for proper operation then bleed air from the circuit (on the cylinder sides). 5. Check hydraulic fluid level and adjust accordingly. 31210149 – JLG Lift – 7-11...

  • Page 90: Swing Motor

    4. Clean all parts with a solvant and dry with com- pressed air. 5. Perform a few platform level up/down movements to check for proper operation. 6. Check hydraulic fluid level and adjust accordingly. 7-12 – JLG Lift – 31210149...

  • Page 91: Cylinder Repair

    14. Draining Screw 9. Wiper Seal 4. Piston 15. Drawing Screw Seal 10. Rod Guide 5. O-Ring 16. Flange Bushing 11. Split Back Up Ring 6. Split Back Up Ring Figure 7-25. Master Cylinder 31210149 – JLG Lift – 7-13...
  • Page 92 8. O-Ring 2. Rod 5. Rod Guide 9. O-Ring + Back Up Ring 3. Gland (Tightening 6. Wiper Seal 10. O-Ring torque: 300 N.m) 7. Rod Guide 11. Flange Bushing Figure 7-27. Jib Cylinder 7-14 – JLG Lift – 31210149...
  • Page 93 3. Gland (Tightening torque: 300 8. Rod Guide 13. Back Up Ring N.m) 9. O-Ring 14. O-Ring 4. Piston 10. Lock Screw (Tightening 15. O-Ring 5. Spacer torque: 130 N.m) 16. Flange Bushing Figure 7-29. Telescope Cylinder 31210149 – JLG Lift – 7-15...

  • Page 94: Telescope Plus Cylinder

    6. Piston Rod #1 14. Wiper Seal 23. O-Ring 7. Piston Rod #2 (Tightening 15. Rod Guide 24. Flange Bushing torque: 120 N.m) 16. Back Up Ring 8. Spacer 17. O-Ring Figure 7-30. Telescope Plus Cylinder 7-16 – JLG Lift – 31210149...

  • Page 95: Disassembly

    NOTE: Prior to cylinder assembly, ensure that the proper 5. All cylinder but mast and jib cylinders: place the rod cylinder seal kit is used. See your JLG Parts manual. assembly into a suitable holding fixture. Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 96 9. Secure the cylinder head gland. 10. After the cylinder has been reassembled, the rod should be pushed all the way (fully retracted). 7-18 – JLG Lift – 31210149...

  • Page 97: Section 8 - Control Components

    SECTION 8 - CONTROL COMPONENTS SECTION 8. CONTROL COMPONENTS 8.1 CONTROL COMPONENTS OVERVIEW Figure 8-1. Control Components Location 31210149 – JLG Lift –...

  • Page 98: Control Components - Service

    ADD ONLY DISTILLED WATER TO BATTERIES. ADD WATER TO BATTERIES AFTER CHARGING TO AVOID ELECTROLYTE OVER- Battery Cleaning: FLOW. • Regularly clean and dry battery top. • Ensure all connections are clean and correctly tight. • Coat terminals with a silicone dielectric compound. – JLG Lift – 31210149...

  • Page 99: Draining The Water

    (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. 31210149 – JLG Lift –...

  • Page 100: Battery Troubleshooting

    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 101: Main Power Contactor Relay

    Amp. Rating: 250 Amps Nominal voltage: 48V DC Type: C20 (DIN 43560) Coil resistance: 195  Pull in voltage: 32 V DC Hold voltage: 13.9 V DC Figure 8-5. Main Power Contactor Relay Figure 8-6. Power Fuse 31210149 – JLG Lift –...

  • Page 102: Mast Elevation Limit Switch

    Down End Of Stroke Contact NC +V Supply Contact NC + V Supply + V Supply +V Supply = 12 to 14 VDC Contact NC + V Supply +V Supply = 12 to 14 VDC – JLG Lift – 31210149...

  • Page 103: Chain Slack Sensor

    SECTION 8 - CONTROL COMPONENTS Chain Slack Sensor One chain of each lifting chain stage is fitted with a slack detection device. Those 4 switches are wired in series. Figure 8-12. Chain Slack Sensors 31210149 – JLG Lift –...

  • Page 104: Overload Sensor

    Calibrating the overload system is a mechanical opera- tion. 1. Position the Platform/Ground select switch to the Platform position. 2. Pull out both Platform and Ground Emergency Stop switches. Figure 8-15. Overload System 3. Position the machine on a flat level ground. – JLG Lift – 31210149...

  • Page 105: Drive Orientation Switch

    B or 2 0.5V - 1.0V 2.2V - 2.8V 3.4V - 3.9V Power (-) C or 3 -Vbatt If the sensor is dismounted, the output voltage is: 0.1x (Sensor Power Voltage) = 0.42V - 0.44V). 31210149 – JLG Lift –...

  • Page 106: Tilt Sensor

    White Power Yellow Ground Brown Output X 0.5 V to 4.5 V Green Output Y 0.5 V to 4.5 V Refer to Section 9-3 for Tilt Sensor Calibration Figure 8-20. Tilt Sensor Calibration Verification 8-10 – JLG Lift – 31210149...

  • Page 107: 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 6. Drive Motor - Right 2.

  • Page 108: Power Module

    7. 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 8-22. Power Module Removal - Installation 8-12 – JLG Lift – 31210149...

  • Page 109: Installation

    5. Install chassis rear shield and chassis covers. 6. Check software version (Refer to Section 9), if nec- essary proceed with a software update. 7. Proceed with a steer sensor calibration (Refer to Section 9.3). 31210149 – JLG Lift – 8-13...

  • Page 110: Power Module Electrical Evaluation

    Right Wheel Encoder Pin B Digital Input Unused Digital Input Steer Angle Sensor Analog Input Unused Digital Output Charger Interlock Digital Input Unused Digital Output Unused Digital Input Unused Digital Input Unused Digital Input 8-14 – JLG Lift – 31210149...
  • Page 111 • Max. output current: 2.5A • V Batt input Proportional Outputs (Prop): • PWM controlled with current sensing • Drive to -Vbatt Power Outputs: • +5V power supply for the motor encoder (exact value: 4.3V) 31210149 – JLG Lift – 8-15...

  • Page 112: Ground Control Station

    SECTION 8 - CONTROL COMPONENTS 8.5 GROUND CONTROL STATION Ground Module Figure 8-25. Ground Control Station Connectors - 1 of 3 8-16 – JLG Lift – 31210149...

  • Page 113: Ground Control Station Connectors - 2 Of 3

    SECTION 8 - CONTROL COMPONENTS Figure 8-26. Ground Control Station Connectors - 2 of 3 31210149 – JLG Lift – 8-17...

  • Page 114: Ground Control Station Connectors - 3 Of 3

    SECTION 8 - CONTROL COMPONENTS Figure 8-27. Ground Control Station Connectors - 3 of 3 8-18 – JLG Lift – 31210149...

  • Page 115: Membrane Panel

    • Insert the ribbon cable into the plate slot. Figure 8-28. 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 31210149 – JLG Lift – 8-19...

  • Page 116: Platform Control Station

    Figure 8-30. Joystick Controls - Installation 1. Face Plate 2. Drive/Swing Joystick Assembly 3. Drive/Steer Joystick Attach Screws 4. Mast/Jib/Telescope Joysticks Assembly 5. Mast/Jib/Telescope Joystick Attach Screws Figure 8-29. Upper Control Box Circuit Board - Installa- tion 8-20 – JLG Lift – 31210149...

  • Page 117: 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 the switch. 4. Reverse steps to install. 31210149 – JLG Lift – 8-21...
  • Page 118 _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ 8-22 – JLG Lift – 31210149...

  • Page 119: Section 9 - Jlg Control System

    Powering down returns the (fault) message. This is intended to quickly guide Analyzer to Operator Access. the technician in the event of a fault in the JLG Con- 5. PERSONALITIES trol System. This menu also displays functional inter- This menu contains performance settings specific to locks.

  • Page 120: Hand Analyzer

    SECTION 9 - JLG CONTROL SYSTEM Using the Analyzer 7. CALIBRATIONS This menu allows the operator to interact with the With the machine power on and the analyzer connected sensors on the machine. These settings can be properly, the analyzer will display the following: modified in the Service access level.

  • Page 121: Changing The Access Level Of The Hand Held Analyzer

    SECTION 9 - JLG CONTROL SYSTEM The top level menus are as follows: When a top level menu is selected, a new set of menu items may be offered: for example: HELP: DRIVE DIAGNOSTICS STEER SYSTEM TEST SWING OPERATOR ACCESS...

  • Page 122: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 9 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Press ENTER to select the ACCESS LEVEL menu. Analyzer Using the UP or DOWN arrow keys, enter the first digit of the password, 3. Once you have gained Service Access, and a personality...

  • Page 123: Machine Setup

    SECTION 9 - JLG CONTROL SYSTEM Machine Setup When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value. For example: GROUND ALARM: 2=DRIVE The effect of the machine digit value is displayed along with its value.

  • Page 124: Analyzer Screen Layout

    SECTION 9 - JLG CONTROL SYSTEM 9.2 ANALYZER SCREEN LAYOUT Figure 9-3. Analyzer Flow Chart - Sheet 1 of 2 NOTE: - Service only.  – JLG Lift – 31210149...

  • Page 125: Analyzer Flow Chart - Sheet 2 Of 2

    SECTION 9 - JLG CONTROL SYSTEM Figure 9-4. Analyzer Flow Chart - Sheet 2 of 2 NOTE: - Service only.  31210149 – JLG Lift –...

  • Page 126: Machine Setup Programming Information

    SECTION 9 - JLG CONTROL SYSTEM 9.3 MACHINE SETUP PROGRAMMING INFORMATION The following logic shall be followed: WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON- TROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS.
  • Page 127 SECTION 9 - JLG CONTROL SYSTEM Configuration Digit Setting Range Description Default Number DISPLAY UNITS METRIC IMPERIAL PLATFORM ROTATE Table 9-1. Machine Setup Programming Information 31210149 – JLG Lift –...

  • Page 128: Calibration Instructions

    All calibration procedures are menu driven through the use of the standard JLG analyzer. The user is prompted to exercise the machine in a specific order to use the machines physical properties to consistently establish sensor response and the interaction of valves, pump and motors.

  • Page 129: Calibrating The Pressure Relief Valve

    SECTION 9 - JLG CONTROL SYSTEM 6. The screen will indicate 'FWD TO MAX' (or 'LEFT TO 11. Repeat steps 6 to 10 for each movement in order to MAX') : Tilt and maintain the Joystick fully forward set all pressures. Other personalities to be adjusted (or fully to the left).

  • Page 130: Machine Personality - Adjustment Settings

    SECTION 9 - JLG CONTROL SYSTEM 9.9 MACHINE PERSONALITY - ADJUSTMENT SETTINGS Personality settings adjustments shall be done when the system is idle (none of the power components, drive or pump motor, is running). Table 9-4. Machine Personality Adjustment MODEL NUMBER DEFAULT VALUES...
  • Page 131 SECTION 9 - JLG CONTROL SYSTEM Table 9-4. Machine Personality Adjustment MODEL NUMBER DEFAULT VALUES ADJUSTMENT ADJUSTMENT RANGES TOUCAN 12E TOUCAN 12E PLUS TOUCAN 32E MAST UP ACCEL 0-5.0s UP DECEL 0-2.0s UP MIN 5-30% UP MAX 50-100% UP REDUCED MAX...
  • Page 132 SECTION 9 - JLG CONTROL SYSTEM Table 9-4. Machine Personality Adjustment MODEL NUMBER DEFAULT VALUES ADJUSTMENT ADJUSTMENT RANGES TOUCAN 12E TOUCAN 12E PLUS TOUCAN 32E JIB LIFT UP ACCEL 0-5.0s UP DECEL 0-2.0s UP MIN 5-30% UP MAX 40-80% UP REDUCED MAX...
  • Page 133 SECTION 9 - JLG CONTROL SYSTEM Table 9-4. Machine Personality Adjustment MODEL NUMBER DEFAULT VALUES ADJUSTMENT ADJUSTMENT RANGES TOUCAN 12E TOUCAN 12E PLUS TOUCAN 32E JOYSTICKS DRIVE JOY FWD 500-600 MIN COUNTS DRIVE JOY FWD 850-950 MAX COUNTS DRIVE JOY REV...
  • Page 134 SECTION 9 - JLG CONTROL SYSTEM Table 9-4. Machine Personality Adjustment MODEL NUMBER DEFAULT VALUES ADJUSTMENT ADJUSTMENT RANGES TOUCAN 12E TOUCAN 12E PLUS TOUCAN 32E TELE JOY OUT 75-175 MAX COUNTS JIB JOY DN 500-575 MIN COUNTS JIB JOY DN...

  • Page 135: System Test

    SECTION 9 - JLG CONTROL SYSTEM 3. Plug the analyzer. 9.10 SYSTEM TEST 4. Enter Service Access and scroll to the SYSTEM The Control System incorporates a built-in system test to TEST screen. check the system components and functions. To use this 5.
  • Page 136 SECTION 9 - JLG CONTROL SYSTEM 9-18 – JLG Lift – 31210149...

  • Page 137: Section 10 - Diagnostic Trouble Codes

    9-9 Hardware ........10-41 31210149 – JLG Lift – 10-1...

  • Page 138: Dtc Check Tables

    LOCKED OUT - System enters a low-power state to preserve • Check battery charge, con- Refer problem to a qualified JLG SYSTEM POW- battery charge. Displays on the analyzer dition, etc. mechanic.
  • Page 139 • Proceed with a joystick cali- • Check if the enable switch is bration. damaged. • Check Joystick voltages Refer problem to a qualified JLG (refer to Section 8-6). mechanic. • Check if the enable switch is damaged. • Check the enable switch out- put : J1(18).

  • Page 140: Power-Up

    Displays on the ana- necessary. essary. lyzer only. KEYSWITCH Both Platform and Ground modes are • Check key switch function. Refer problem to a qualified JLG FAULTY selected simultaneously. Defaults to • Replace key switch. mechanic. Ground Mode. 2-2 Platform Controls...
  • Page 141 TOO LONG stick • Check lift enable switch out- Refer problem to a qualified JLG WHILE IN NEU- was centered. put voltage: J1(18). mechanic. TRAL...
  • Page 142 DOS switch is sending a continual over- obstructed or jammed. obstructed or jammed. OVERRIDE PER- ride signal. • Check the DOS switch out- Refer problem to a qualified JLG MANENTLY put: J4(2). mechanic. SELECTED DRIVE/SWING The Drive/Swing joystick wiper signal •...

  • Page 143: Ground Controls

    RELEASE PERMA- jammed. jammed. NENTLY • Disconnect the membrane Refer problem to a qualified JLG SELECTED panel ribbon cable : replace mechanic. the membrane panel if DTC is no longer present. • Check the switch line voltage : C0170-J3(3), C0170-J1(4) and C084-J4(4).
  • Page 144 DOWN PERMA- jammed. jammed. NENTLY • Disconnect the membrane Refer problem to a qualified JLG SELECTED panel ribbon cable : replace mechanic. the membrane panel if DTC is no longer present. • Check the switch line voltage : C0170-J3(8), C0170-J1(8) and C084-J4(8).
  • Page 145 • Disconnect the membrane Refer problem to a qualified JLG panel ribbon cable : replace mechanic. the membrane panel if DTC is no longer present. • Check both switch lines volt-...
  • Page 146 Movement and/or to Clear Fault MAIN MAST LIMIT N.O. and N.C. contacts show the same Check if the Main Mast limit Refer problem to a qualified JLG 2380 SWITCH - FAULTY electrical status for more than 1 second. switch is mechanic damaged;...
  • Page 147 Machine Condition Movement and/or to Clear Fault 23121 JIB LIMIT SWITCH The jib limit switch outputs are reading • Check if the Jib limit switch is Refer problem to a qualified JLG - FAULTY high or low simultaneously damaged; mechanic.

  • Page 148: Function Prevented

    (Refer to Section 8-2) is aged, obstructed, or jammed. damaged, obstructed or • Check the Jib limit switch and jammed. Jib EOS limit switch wiring : Refer problem to a qualified JLG Jib stowed : mechanic. @ +VSupply: X253A(2), X704B(2), C084-J7(21), X761A(2), X638A(H).
  • Page 149 DRIVE CUTOUT set to 1 (YES), and the • Fully stow the platform. • Fully stow the platform. 2516 VENTED - ABOVE mast is elevated. Refer problem to a qualified JLG ELEVATION mechanic. FUNCTIONS Constant Data is not compatible with • Cycle power to clear the •...

  • Page 150: Line Contactor Open Circuit

    • Cycle power to clear the • Cycle power to clear the fault. 2565 VENTED – RIGHT release drivers are damaged. fault. Refer problem to a qualified JLG BRAKE NOT • If the fault is not cleared: mechanic. RELEASING Replace the Master control- ler.
  • Page 151 Machine Condition Movement and/or to Clear Fault CONTACTOR The line contactor driver output is shorted • Check contactor wiring for a Refer problem to a qualified JLG DRIVER PERMA- or open circuit. short circuit with -Vbatt or mechanic. NENTLY ON open circuit.

  • Page 152: Ground Output Driver

    Movement and/or to Clear Fault GROUND ALARM The Ground Module detects a short to • Check the UGM driver output Refer problem to a qualified JLG 3311 – SHORT TO BAT- +VSupply at the Ground Alarm Output. C084-J2(7) for a short circuit mechanic.
  • Page 153 Movement and/or to Clear Fault 33119 SWING RIGHT The Ground Module detects an open circuit • Check the valve harness for Refer problem to a qualified JLG VALVE – OPEN at the Swing Right Valve output. signs of damage mechanic.
  • Page 154 Movement and/or to Clear Fault 33295 SWING LEFT The Ground Module detects an open circuit • Check the valve harness for Refer problem to a qualified JLG VALVE – OPEN at the Swing Left Valve output. signs of damage mechanic.
  • Page 155 Movement and/or to Clear Fault 33316 FLOW CONTROL The Ground Module detects a short -VSup- • Check the valve driver output Refer problem to a qualified JLG VALVE – SHORT ply at the Flow Control Valve output. C084-J2(31) and C084- mechanic.
  • Page 156 Requirement for Function Machine Condition Movement and/or to Clear Fault 33368 PROPORTIONAL The Proportional Relief valve coil is faulty • Check the valve harness for Refer problem to a qualified JLG RELIEF VALVE - or disconnected. signs of damage mechanic. OPEN CIRCUIT •...
  • Page 157 Movement and/or to Clear Fault 33470 MAST VALVE – The mast valve current measures less than • Check the valve harness for Refer problem to a qualified JLG CURRENT FEED- 225 mA while commanding the valve at signs of damage mechanic.
  • Page 158 Movement and/or to Clear Fault 33475 JIB VALVE – The Jib valve driver output is detected • Check the UGM driver output Refer problem to a qualified JLG SHORT TO BAT- short to power supply 12 Volts. C084-J2(12) for a short cir- mechanic.

  • Page 159: Thermal Limit

    33481 LEFT BRAKE - The Slave Power Module detects a short to • Check the harness for signs of Refer problem to a qualified JLG SHORT TO -Vbatt or open circuit at the left brake out- damage between the Power mechanic.
  • Page 160 Requirement for Function Machine Condition Movement and/or to Clear Fault MASTER MOD- The Master Module (right controller) has • Power down and allow to Refer problem to a qualified JLG ULE TOO HOT - reached thermal cutout. cool. mechanic. PLEASE WAIT •...
  • Page 161 Requirement for Function Machine Condition Movement and/or to Clear Fault RIGHT DRIVE The right drive motor temperature is too • Power down and allow to Refer problem to a qualified JLG 4210 MOTOR TOO high. cool. mechanic. HOT - PLEASE •...

  • Page 162: Battery Supply

    Requirement for Function Machine Condition Movement and/or to Clear Fault RIGHT DRIVE The right drive motor sensor is damaged • Check the sensor wiring and Refer problem to a qualified JLG 4212 MOTOR TEM- or disconnected. connections. mechanic. PERATURE - OUT •...
  • Page 163 • indicators for at least 30 sec- approved options on the onds. machine. Refer problem to a qualified JLG • If no voltage transient is mechanic. detected on the supply line and the fault appears every...
  • Page 164 • indicators for at least 30 sec- approved options on the onds. machine. Refer problem to a qualified JLG • If no voltage transient is mechanic. detected on the supply line and the fault appears every time the key is switched ON : Replace the Slave controller.

  • Page 165: Transmission And Drive System

    Machine Condition Movement and/or to Clear Fault RIGHT SPEED A problem has been detected with the • Check the right motor Refer problem to a qualified JLG 4610 SENSOR - NOT right drive motor speed sensor encoder wiring and connec- mechanic.

  • Page 166: Communication

    Machine Condition Movement and/or to Clear Fault CANBUS FAIL- The UGM determines that CAN communi- • Check if platform is powered Refer problem to a qualified JLG URE – PLAT- cation from the Platform Module is lost. mechanic. FORM MODULE •...
  • Page 167 Movement and/or to Clear Fault CANBUS FAIL- The control system failed to receive mes- • Check the Can Bus connec- Refer problem to a qualified JLG 6632 URE - MASTER sages from the Master Module (right con- tions on the Master power mechanic.
  • Page 168 Movement and/or to Clear Fault THE PLATFORM The platform module failed to receive • Check the Can Bus connec- Refer problem to a qualified JLG 6634 MODULE FAILED messages from both the master and the tions on the Slave power mechanic.

  • Page 169: Accessory

    An obstacle has been detected by the soft • Clear the obstacle. • Clear the obstacle. CUTOUT - SOFT touch device (if equipped). • Ensure ANALYZER- Refer problem to a qualified JLG TOUCH >MACHINE SETUP->SOFT mechanic. DETECTED TOUCH is set to 0 if not installed.
  • Page 170 Machine Condition Movement and/or to Clear Fault SLAVE MODULE The power capacitor bank of the power • Ensure that no external Refer problem to a qualified JLG 7722 CAPACITOR module is not charging properly at device is connected to the mechanic.
  • Page 171 Movement and/or to Clear Fault PUMP MOTOR The pump motor voltage output is higher • Check the pump motor Refer problem to a qualified JLG 7730 OUTPUT - OUT than expected (driven by the Master Mod- power wiring and connec- mechanic.

  • Page 172: Tilt Sensor

    Requirement for Function Machine Condition Movement and/or to Clear Fault PLATFORM The Platform Rotate Controller has deter- • Check harnesses for signs Refer problem to a qualified JLG 7746 ROTATE MOTOR mined that the positive motor terminal is of damage mechanic.

  • Page 173: Platform Load Sense

    • Check if the overload switch FORM OVER- is obstructed or jammed. is obstructed or jammed. LOADED • Check harnesses for signs Refer problem to a qualified JLG of damage mechanic. When Platform is not over- loaded: @ +VSupply: X261(4),...
  • Page 174 Movement and/or to Clear Fault FRONT LEFT The Ground Module detects a short to • Check the UGM driver output Refer problem to a qualified JLG 8640 STEER VALVE – +VSupply at the Front Left Steer Valve C084-J2(19) for a short cir- mechanic.
  • Page 175 Machine Condition Movement and/or to Clear Fault STEER SENSOR - Invalid signal from the steer sensor. • Check the steer sensor for Refer problem to a qualified JLG 8665 OUT OF RANGE damage. mechanic. • Check that the steer sensor is securely mounted.
  • Page 176 • Check that the steer sensor is unchanged for more than 1 second. - Pump not running : check securely mounted. the voltage applied to Refer problem to a qualified JLG the pump motor; mechanic. - Pump running : check the oil level; check the...

  • Page 177: Safety System Override

    Machine Condition Movement and/or to Clear Fault MACHINE Machine Safety System Override has • Go into the analyzer under Refer problem to a qualified JLG SAFETY SYSTEM Been used to override a Safety System or CALIBRATIONS > MSSO > mechanic.
  • Page 178 • Cycle power to clear the fault. • Cycle power to clear the fault. SOR REF VOLTAGE Sensor Reference Voltage Output is out of • Check harnesses for signs of Refer problem to a qualified JLG OUT OF RANGE range damage mechanic.
  • Page 179 • Cycle power to clear the fault. EEPROM FAILURE ule (left controller). • If the fault is not cleared : Refer problem to a qualified JLG Replace the Slave controller. mechanic. 9998 MASTER MODULE There is an internal error in the Master •...
  • Page 180 • Cycle power to clear the fault. INTERNAL ERROR ule (left controller). • If the fault is not cleared : Refer problem to a qualified JLG Replace the Slave controller. mechanic. 99112 MASTER MODULE There is an internal error in the Master •...
  • Page 181 • Cycle power to clear the fault. • Cycle power to clear the fault. ERROR sistent Pump command messages • Reinstall the most current Refer problem to a qualified JLG Production software for the mechanic. UGM and Power Modules. • Replace UGM •...
  • Page 182 _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ 10-46 – JLG Lift – 31210149...

  • Page 183: General

    Also check that the lead on the "COM" port goes to the Ground or negative side of the sig- 31210149 – JLG Lift – 11-1...

  • Page 184: 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 – 31210149...

  • Page 185: 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 186: 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 – 31210149...

  • Page 187: 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 31210149 – JLG Lift – 11-5...

  • Page 188: Connector Assembly Figure 2

    (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 – 31210149...

  • Page 189: 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. 31210149 – JLG Lift – 11-7...

  • Page 190: Connector Installation

    SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-11. Connector Installation 11-8 – JLG Lift – 31210149...

  • Page 191: 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. 31210149 – JLG Lift – 11-9...

  • Page 192: 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 – 31210149...

  • Page 193: Connectors Identification

    MANIFOLD MS743 X261 HV179 HV319 HV321 HV320 MAST SWITCHES SWITCH JIB CYL. X761 VALVE HV398 X627 X695 X253 X704 X688 X628 X297 X298 Figure 11-18. Wiring Harness and Connectors - Sheet 1 of 3 31210149 – JLG Lift – 11-11...

  • Page 194: Wiring Harness And Connectors - Sheet 2 Of 3

    X295 HV185 HV186 HYD. POWER HV180 HV188 UNIT BATTERY CHARGER 48V-12V CONVERTER SN568 CO107-J3 D.O.S. SENSOR X279 CO107-J2 CO107-J4 IP240 X524 X263 X262 Figure 11-19. Wiring Harness and Connectors - Sheet 2 of 3 11-12 – JLG Lift – 31210149...

  • Page 195: Wiring Harness And Connectors - Sheet 3 Of 3

    STEERING SENSOR X273 IP67 CO173-J1 CO172-J1 RIGHT CONTROLLER LEFT (MASTER) CONTROLLER (SLAVE) LEFT DRIVE MOTOR RIGHT DRIVE MOTOR MS658 BRAKE BRAKE MS123-J1 MS97-J1 Figure 11-20. Wiring harness and Connectors - Sheet 3 of 3 31210149 – JLG Lift – 11-13...

  • Page 196: Electrical Schematic

    SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 11.8 ELECTRICAL SCHEMATIC Figure 11-21. Electrical schematic - Drive System 11-14 – JLG Lift – 31210149...

  • Page 197: Electrical Schematic - Turntable

    SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-22. Electrical Schematic - Turntable 31210149 – JLG Lift – 11-15...

  • Page 198: Electrical Schematic - Lower Control Board

    SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-23. Electrical Schematic - Lower Control Board 11-16 – JLG Lift – 31210149...

  • Page 199: Electrical Schematic - Mast

    SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-24. Electrical Schematic - Mast 31210149 – JLG Lift – 11-17...

  • Page 200: Electrical Schematic - Platform Box

    SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-25. Electrical Schematic - Platform Box 11-18 – JLG Lift – 31210149...

  • Page 201: Electrical Schematic - Batteries

    SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 11-26. Electrical Schematic - Batteries 31210149 – JLG Lift – 11-19...

  • Page 202: Hydraulic Schematic

    SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 11.9 HYDRAULIC SCHEMATIC Figure 11-27. Hydraulic schematic 11-20 – JLG Lift – 31210149...
  • Page 204 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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