JLG Boom Lift TOUCAN 12E TOUCAN 12E Plus TOUCAN 32E Service & Maintenance Manual 31210537 2025

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JLG Boom Lift TOUCAN 12E TOUCAN 12E Plus TOUCAN 32E Service & Maintenance Manual 31210537 2025
Size: 14.40 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG TOUCAN 12E, TOUCAN 12E Plus, TOUCAN 32E Boom Lift
Part Number: 31210537
Publication Date: 2025
Number of Pages: 212 Pages

Contents:
Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A General​

B Hydraulic System Safety​

C Maintenance​

Section 1. OPERATING SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS​

1.2 DIMENSIONAL data​

1.3 PERFORMANCE DATA​

1.4 CAPACITIES​

1.5 COMPONENTS DATA​

Batteries​

Electric Pump / Electric Motor Assembly​

Drive Motor Assembly​

Swing Drive​

Platform Rotation Drive​

Cylinders​

Tires​

1.6 MAJOR COMPONENTS WEIGHTS​

1.7 LUBRICATION​

Hydraulic Oil​

Lubrication Chart​

Lube Specifications​

1.8 TORQUE REQUIREMENTS​

1.9 SERIAL NUMBER LOCATIONS​

1.10 CLEARSKY SMART FLEET™ (IF EQUIPPED)​

General​

ClearSky Smart Fleet™ — Access Control​

Section 2. general service information

2.1 Machine preparation, inspection and maintenance​

General​

Preparation, Inspection and Maintenance​

Pre-Start Inspection​

Pre-Delivery Inspection and Frequent Inspection​

Annual Machine Inspection​

Preventative Maintenance​

2.2 preventive maintenance and inspection schedule​

2.3 Servicing and maintenance guidelines​

General​

Safety and Workmanship​

Cleanliness​

Components Removal and Installation​

Component Disassembly and Reassembly​

Pressure-Fit Parts​

Bearings​

Care and Installation of Teflon Coated Bushings​

Bolt Usage and Torque Application​

Hydraulic Lines and Electrical Wiring​

Hydraulic System​

Welding on Work Platform​

Lubrication​

Battery​

2.4 Lubrication Information​

Hydraulic System​

Lubrication Specifications​

Hydraulic Oil​

Changing Hydraulic Oil​

2.5 Pressure Relief ValVe​

2.6 Hydraulic cartridge installation​

Section 3. THEORY OF OPERATION

3.1 OVERVIEW​

3.2 Modes of operation​

Ground Mode​

Platform Mode​

3.3 Can Communications​

3.4 Joysticks​

3.5 Traction​

3.6 Pump/structure movements​

Lift Up/Down​

Swing​

Steer​

Telescope​

Platform Level​

Interlocks​

Personality Settings and Calibration​

Section 4. CHASSIS MOUNTED COMPONENTS

4.1 DRIVE MOTORS​

Brake - Electrical Characteristics​

Brake - Dust Cleaning​

Brake Disassembly​

Brake Disk Wear Checking​

Brake Assembly​

Drive Motor Assembly Removal​

Drive Motor Assembly Installation​

Oil Type & Capacity​

Oil Filling​

4.2 Wheels and Tires​

Tire Wear and Damage​

Wheel and Tire Replacement​

Wheel Installation​

4.3 Steering Linkage​

Steer Cylinder​

Steering Linkage - Spindle/Hub Assembly​

Section 5. TURNTABLE AND VERTICAL MAST

5.1 SWING BEARING​

Swing Bearing Attach Bolts Check​

Swing Bearing Lubrication​

Swing Bearing Wear Tolerance Check​

Replacement of Swing Bearing​

5.2 Swing DRIVE​

Swing Drive Removal​

Swing Drive Disassembly​

Swing Drive Assembly​

Swing Drive Installation​

5.3 Rollers​

Inspection​

Removal and Installation​

5.4 Mast and Rollers Setting​

Introduction​

Procedure​

5.5 Lifting chains​

Safety Accessories and Tooling​

Lubrication​

Lifting Chains Inspection​

Lifting Chains Rotated​

Lifting Chains Removal and Installation​

Chain Tension Adjustment​

5.6 PULLEY - PULLEY SUPPORT​

Pulley Inspection​

Removal and Installation​

5.7 Mast Cylinder​

Mast Cylinder Removal​

Mast Cylinder Disassembly​

Mast Cylinder Installation​

5.8 Counterweight​

Counterweight Removal​

Counterweight Installation​

Section 6. TELESCOPIC BOOM AND PLATFORM

6.1 OVERLOAD SYSTEM​

Overload System Verification​

Overload System Setting​

6.2 PLATFORM​

Platform Removal​

Platform Installation​

6.3 PLATFORM SUPPORTS AND SLAVE CYLINDER​

Platform Supports and Slave Cylinder Removal​

Slave Cylinder Disassembly​

Platform Supports and Slave Cylinder Installation​

6.4 TELESCOPIC BOOM, BOOM AND MASTER CYLINDERS​

Boom and Cylinders Removal​

Boom and Master Cylinders Disassembly​

Boom Disassembly​

Boom and Cylinders Installation​

6.5 TELESCOPE​

6.5.1 Telescope Toucan 12E Plus​

Telescope Sections and Cylinder Removal​

Telescope Dual Cylinder Disassembly​

Telescope Sections and Cylinder Installation​

6.5.2 Telescope Toucan 12E / Toucan 32E​

Telescope Sections and Cylinder Removal​

Telescope Cylinder Disassembly​

Telescope Sections and Cylinder Installation​

Section 7. HYDRAULICS

7.1 Hydraulic lines Connections​

7.2 Hydraulic Power Unit​

Ports Identification​

Proportional Pressure Relief Valve​

Air bleeding​

Hand Pump​

Proportional Flow Control Valve​

Solenoid Valve 4-3​

Check Valve 0.5 bar​

Electric Motor​

7.3 HYDRAULIC TANK​

Oil Level​

Adding Oil to the System​

Tank Draining/Cleaning​

Tank Filling​

7.4 SECONDARY MANIFOLD​

Manifold Schematic​

A, B: Counterbalance Valve​

C: Check Valve 3 bar​

RT-ST/CAV-CAR: Solenoid Valve 4-3​

Disassembly​

Inspection​

Assembly​

7.5 cylinders holding valves​

Mast Cylinder Holding Valve​

Jib Cylinder Holding Valve​

Telescope Cylinder Holding Valve​

Slave Cylinder Holding Valve​

7.6 SWING MOTOR​

7.7 CYLINDER REPAIR​

Disassembly​

Inspection​

Assembly​

Section 8. CONTROL COMPONENTS

8.1 Control components overview​

8.2 Control Components - Service​

Battery Maintenance and Safety Practices​

Main Power Contactor Relay​

Power Fuse​

Mast Elevation Limit Switch​

Jib Elevation Limit Switches​

Chain Slack Sensor​

Overload Sensor​

Overload System Setting​

Drive Orientation Switch​

Skyguard Switch​

Steering Sensor​

Tilt Sensor​

8.3 CLEARSKY® LED MOTION / AMBER BEACON (CS550) (IF EQUIPPED)​

ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

8.4 Traction System​

Common Traction System Difficulties​

8.5 Power Module​

Removal​

Installation​

Power Module Electrical Evaluation​

8.6 Ground Control Station​

Ground Module​

Membrane Panel​

Printed Circuit Board (PCB) Replacement​

8.7 Platform Control Station​

Printed Circuit Board (PCB) Replacement​

Upper Control Box - Component Replacement​

Upper Control Box - Components Evaluation​

Section 9. JLG CONTROL SYSTEM

9.1 HAND HELD ANALYZER​

Analyzer Menu Structure​

Hand Analyzer​

Using the Analyzer​

Changing the Access Level of the Hand Held Analyzer​

Adjusting Parameters Using the Hand Held Analyzer​

Machine Setup​

9.2 Analyzer screen layout​

9.3 MACHINE SETUP PROGRAMMING INFORMATION​

9.4 CALIBRATION INSTRUCTIONS​

9.5 CALIBRATING STEERING SENSOR​

9.6 Calibrating Tilt Sensor​

9.7 CALIBRATING OVERLOAD SYSTEM​

9.8 CALIBRATING THE JOYSTICKS​

9.9 Calibrating the pressure relief valve​

9.10 Calibrating the drive motor temperature sensor​

9.11 Calibrating the charger​

9.12 MACHINE PERSONALITY - ADJUSTMENT SETTINGS​

9.13 SYSTEM TEST​

9.14 CLEARSKY CS550 CONFIGURATION AND TROUBLESHOOTING​

ClearSky Smart FleetTM CS550 Configuration​

Troubleshooting​

Section 10. DIAGNOSTIC TROUBLE CODES

10.1 INTRODUCTION​

10.2 DTC INDEX​

10.3 DTC CHECK TABLES​

0-0 Help Comments​

2-1 Power-Up​

2-2 Platform Controls​

2-3 Ground Controls​

2-5 Function Prevented​

3-1 Line Contactor Open Circuit​

3-2 Line Contactor Short Circuit​

3-3 Ground Output Driver​

4-2 Thermal Limit​

4-4 Battery Supply​

4-6 Transmission and Drive System​

6-6 Communication​

6-7 Accessory​

6-8 Functions in Creep or Locked​

7-7 Electric Motor​

8-1 Tilt Sensor​

8-2 Platform Load Sense​

8-6 Steering/Axle​

8-7 Safety System Override​

9-9 Hardware​

10.4 ClearSky CSV3 Smart Fleet DTC Fault Codes​

Section 11. GENERAL ELECTRICAL INFORMATION & SCHEMATICS

11.1 GENERAL​

11.2 Multimeter Basics​

Grounding​

Backprobing​

Min/Max​

Polarity​

Scale​

Voltage Measurement​

Resistance Measurement​

Continuity Measurement​

Current Measurement​

11.3 Checking Switches​

Basic Check​

Limit Switches​

Automatic Switches​

Switch Wiring - Low Side, High Side​

11.4 Applying Silicone Dielectric Compound to Electrical Connections​

11.5 AMP Connector​

Applying Silicone Dielectric Compound to AMP Connectors​

Assembly​

Disassembly​

Wedge Lock​

Service - Voltage Reading​

11.6 Deutsch Connectors​

DT/DTP Series Assembly​

DT/DTP Series Disassembly​

HD30/HDP20 Series Assembly​

HD30/HDP20 Series Disassembly​

11.7 CONNECTORS IDENTIFICATION​

11.8 ELECTRICAL SCHEMATIC​

11.9 Hydraulic schematic​