JLG TOUCAN 1010 User manual

Updated:04-2006 MA0235-02
English-Service
MODELS
TOUCAN1010
U.S.A.
JLGINDUSTRIES,INC
1JLGDrive
McConnellsburg
PA17233-9533
Tel:[phone]
Fax :[phone]
C.E.
JLGManufacturingEurope
Breitwaterstraat12A
OudeBunders1034
B-3630 Maasmechelen
Tel:[phone]
Fax :[phone]
FRANCE
JLGFrance SAS
Z.I.deFauillet
BP20 -47400 TONNEINS
France
Tel:[phone]
Fax :[phone]

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Edition 04-2006 Toucan1010
MA0235-02
Models
Toucan1010 _____
Toucan1010 I_____

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INTRODUCTION 1
Foreword
Importantinformation
WORK PLATFORMCHARACTERISTICS 2
Description-------------------------------------------------------------------------------2.1
Characteristics- Dimensions- Performances---------------------------------2.2
PRESSURESETTINGS 3
Reliefvalve setting--------------------------------------------------------------------3.1
Brake releasecircuitpressurecheck--------------------------------------------3.2
Circuitreliefvalve adjustment-----------------------------------------------------3.3
Mainpressure(PR1)-----------------------------------------------------------------3.3.1
Rightswing (PR2)--------------------------------------------------------------------3.3.2
Left swing (PR3)----------------------------------------------------------------------3.3.3
Mastelevation (PR4)----------------------------------------------------------------3.3.4
Jibelevation (PR5)-------------------------------------------------------------------3.3.5
Jiblowering (PR6)--------------------------------------------------------------------3.3.6
Brake releasemaximum pressure(PR7)--------------------------------------3.3.7
Drive atlowspeed(PR8)----------------------------------------------------------3.3.8
Counterbalance valve setting------------------------------------------------------3.4
BATTERY-CHARGER 4
Battery------------------------------------------------------------------------------------4.1
Charger-----------------------------------------------------------------------------------4.2
Fulmencharger-----------------------------------------------------------------------4.2.1
Oldham-Hawkercharger-----------------------------------------------------------4.2.2
Westinghouse-SGTEcharger-----------------------------------------------------4.2.3
Batteryfilling----------------------------------------------------------------------------4.3
Electrolytespecificgravityand batteryvoltage------------------------------4.4
Centralisedfilling systemmaintenance-----------------------------------------4.5
Cleaning - Batterymaintenance---------------------------------------------------4.6
Storageofabatteryat temperaturebelow0°C(32°F)-------------------4.7
Useofabatteryinacoldchamber orinacoldclimate-------------------4.8
Batterynotworking continuouslyorinactive battery----------------------4.9
Batterytroubleshooting-------------------------------------------------------------4.10
!
TABLEOF CONTENTS

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TABLEOF CONTENTS
MAINTENANCE 5
Systemmalfunctions-----------------------------------------------------------------5.1
Cleanliness-------------------------------------------------------------------------------5.2
Removaland installation-------------------------------------------------------------5.3
Disassemblyand assembly---------------------------------------------------------5.4
Partsreplacement---------------------------------------------------------------------5.5
Wiresand cables-----------------------------------------------------------------------5.6
Gaskets-----------------------------------------------------------------------------------5.7
Careand installation ofteflon-coatedbushings-------------------------------5.8
Bushings--------------------------------------------------------------------------------5.8.1
Pin----------------------------------------------------------------------------------------5.8.2
Bushingsand pin---------------------------------------------------------------------5.8.3
Bushing installation------------------------------------------------------------------5.8.4
Mastrollerremoval-------------------------------------------------------------------5.9
Upperrollers---------------------------------------------------------------------------5.9.1
Lowerrollers--------------------------------------------------------------------------5.9.2
Rollers-----------------------------------------------------------------------------------5.9.3
Hydraulicsystem--------------------------------------------------------------------5.10
Fatigueof weldedstructures-----------------------------------------------------5.11
LOCTITE®-------------------------------------------------------------------------------5.12
Fastenersand torquevalues------------------------------------------------------5.13
Steering switches--------------------------------------------------------------------5.14
Mainhydraulicpowerunit--------------------------------------------------------5.15
Steering bracketthrust washers------------------------------------------------5.16
Mast section alignment------------------------------------------------------------5.17
Lifting chainsadjustment----------------------------------------------------------5.18
Chaincontroland lubrication-----------------------------------------------------5.19
Controlofchainwear-------------------------------------------------------------5.19.1
Chainlubrication-------------------------------------------------------------------5.19.2

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TABLEOF CONTENTS
ELECTRICALCONTROLSDEVICE 6
Overloaddetection setting----------------------------------------------------------6.1
Tiltalarm---------------------------------------------------------------------------------6.2
Batterydischargeindicator setting-----------------------------------------------6.3
Circuitsprotection---------------------------------------------------------------------6.4
Façadecircuit-breaker-------------------------------------------------------------6.4.1
Resetablefuses-----------------------------------------------------------------------6.4.2
Fuseson board------------------------------------------------------------------------6.4.3
Powercircuit fuses------------------------------------------------------------------6.4.4
Devicesmodifying themachine'sperformance------------------------------6.5
Mastswitch---------------------------------------------------------------------------6.5.1
"5m"mastswitch------------------------------------------------------------------6.5.2
Steering limit switch----------------------------------------------------------------6.5.3
Drive limitswitch--------------------------------------------------------------------6.5.4
Safetyfeatures- Movementcutout-------------------------------------------6.5.5
Speedelectroniccontroller---------------------------------------------------------6.6
Helpwiththediagnosis--------------------------------------------------------------6.7
Electronicmodules--------------------------------------------------------------------6.8
Controls verification module------------------------------------------------------6.8.1
Drive managementmodule---------------------------------------------------------6.9
"Clipper"connectorinstallation procedure-----------------------------------6.10
PREVENTIVE AND MAINTENANCEINSPECTION 7
General------------------------------------------------------------------------------------7.1
Preventive maintenance and inspection required----------------------------7.2
Dailypreventive maintenance and inspection-------------------------------7.2.1
Weeklypreventive maintenance and inspection---------------------------7.2.2
Monthlypreventive maintenance and inspection--------------------------7.2.3
Every125 hoursofoperation preventive maintenance and inspection-7.2.4
Every250 hoursofoperation preventive maintenance and inspection-7.2.5
Every500 hoursofoperation preventive maintenance and inspection-7.2.6
LUBRICATION 8
Lubrication points----------------------------------------------------------------------8.1

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Foreword
Importantinformation
TABLEOF CONTENTS
1
INTRODUCTION

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FOREWORD
Thismanualhasbeen compiled toassistyou in
properlyoperating and maintaining yourJLG Aerial
WorkPlatform.
The Work Platformhasbeen designed formaximum
performancewithminimummaintenance.Withproper
care,yearsoftrouble-free servicecan be expected.
Constantimprovementand engineering progress make
itnecessary thatwereservethe righttomake
specification and equipmentchangeswithoutnotice.
The definitionsofDANGER,CAUTIONand NOTEas
used inthismanualapplyasfollows:
ADANGERisusedtoemphasizethatifan
operation, procedure orpractice isnot
followedexactly, deathorseriousinjuryto
personnelmayresult.
ACAUTIONisusedtoemphasizethatifan
operation, procedure,orpracticeisnot
followedexactly,equipmentdamagemay
result.
NOTE
ANOTEisusedtoemphasizeanimportant
procedure orcondition.
GENERALWARNING
Itismandatory thatall hydraulichosesand
fittingsarecorrectlytaggedand identifiedbefore
theyaredisconnectedtoeffectrepairsorservice.
Failuretocorrectlytagand identifyhoses and
fittingscancausewrong reconnection,whichcan
resultin deathorseriousinjury topersonnel.
!CAUTION
DANGER

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The followingformisforthe useofthe Distributor,Customer,Mechanic,and allotherperson who usethismanual
and recognizebeneficialwaystoimproveitspurposeasaworthyreference.SMCAR's aretobe madeinregards
to,butnotlimitedto:Safety,Operation Correctness,andTechnicalContent.AllSMCAR'swillbereviewed by
the responsibleDepartmentatJLG.Approved SMCAR'swillbe distributed inaServiceBulletinimmediatelyand
then incorporated inthenextscheduledchangetothemanual.AnanswertotheSMCAR,approvedor
disapproved,willbe sentdirectlytotheone submitting theSMCAR.
Date______________________________
Customername_____________________
Name/firstname_____________________
Address___________________________
__________________________________
Telephone__________________________
ServiceManual
Affected__________________________________________________________________________
Page(s)Affected____________________________________________________________________
ReasonforsubmittingSMCAR(Useadditional paperorbackifnecessary)
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________
Signature(optional)
Adress SMCAR'sto:
Supervisor,Publications
JLGFrance
Z.I. deFauillet,
B.P.20
47400Tonneins,France
CORRECTIVE ACTIONREQUEST

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2.1.Description
2.2.Characteristics -Dimensions-Performances
TABLEOF CONTENTS
2
WORK PLATFORMCHARACTERISTICS

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2.1Description
Theworkplatformconsistsofaself-propelled all
welded steelframe,atelescopicmastmounted on a
turntable andapendularjib.The platform ismounted
atthe end ofthe jib.
The drivefunctionisaccomplishedbytwo hydraulic
motorswhichpropelthe rearaxle.
The steeringfunction (frontaxle)isaccomplishedby
ahydrauliccylindersupplied withahydraulicpump
unitlocated on the chassisbetweenthesteering
wheels.
Theparkingbrakesintegratedtothehydraulicmotors
work through lack ofpressure.
Themainhydraulicpowerunitsupplyingthefunctions
of the work platform(exceptsteering)islocatedat
thetop ofthemainhydraulictank,attherearofthe
chassis.
Theturntablerotationmovementisaccomplished
through amoto-reducergroup located atthe baseof
the turntable.
Themovementofthependularjib isaccomplishedby
meansofhydrauliccylinder.
Thework platformmovementsarecontrolledfromthe
controlboxesthrough hydrauliccontrol valves
controlledelectricallylocatedatthefrontofthe
chassis.
Theprogressivityof movementsisobtained byan
electroniccontrollerwhichcontrolstherotationspeed
ofthe mainhydraulicgroupmotor.Theelectronic
controllerislocated nearthe emergencycontrolbox
(ground controls),on thelefthandsideofthe
telescopicmast.
The energyforthecontrol and powercircuitsofthe
workplatformissupplied bya24VDC battery.
WORK PLATFORMCHARACTERISTICS 22

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FRONTSIDE
Rightside Leftside
Frontbattery access
Charger
Emergency control panel
Counterweight
Jib
Platform
Lateralbattery access
Steering wheels Driving wheels
LEFTSIDE
Front Rear
Counterweight
Breakdowncontrolpanel
Steering hydraulicunit
Steering wheels
Telescopicmast
Handpump
ManualboxPlatform controls
WORK PLATFORMCHARACTERISTICS 22

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DIMENSIONS(LOWERED) Standardplatform Largeplatform
Length 2,89 m 3,20m
Width 0,99m
Height 1,99m
WeightT1010 3300kg
WeightT1010I 2650kg
Ground Clearance 0,08m
CAPACITY- MANOEUVRABILITY
Platformfloormin. height 0,54m
Platformfloormax.height 8,10m
Max.working height 10,10m
Max.outreach(fromcenterline) 2,62 m 2,93m
Max.working outreach(fromcenterline) 3,12 m 3,43m
Floorheightat max. outreach 6,72m
Working heightat max. outreach 8,72m
Swing 360°non continous
Innerturningradius Machineraised: 1,78m
Machinehalfraised: 0m
Outerturningradius Machineraised: 3,37m
Machinehalfraised: 1,75m
PLATFORM
Length 0,70 m 1,01m
Width 0,90m
Ratedload 200kg
HYDRAULICCIRCUIT
Main hydraulictankcapacity 25,5l
Steering grouptankcapacity 1l
Main hydraulicpumpdisplacement 8cm³/t
Steering hydraulicpumpdisplacement 0,5cm³/t
FILTRATION
Pressure 20µmabsolute
Return 20µmabsolute
PRESSURES
Main hydrauliccircuitmax.pressure 23MPa
Steering hydrauliccircuitmax.pressure 12MPa
ELECTRICALCOMPONENTS
Main hydraulicunitmotor 3kw 24 VDC
Steering hydraulicunitmotor 0,8kw 24 VDC
2.2.Characteristics-Dimensions-Performances
WORK PLATFORMCHARACTERISTICS 22

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(*)speedsmeasured on horizontalground withone person inthe platform (approximately80 kg).
(**)timesmeasured withthemaximumratedload in theplatform(200 kg),the movementswereperformed from
platformcontrols.
Speedsareindicated foramachine withafullycharged battery and working inan ambianttemperatureof20°C.
ConstantproductimprovementmakeitnecessarythatJLGreservetherighttomakespecificationandequipment
changeswithoutnotice.
DRIVESPEEDS(*)
1stgear(slow speed)
2nd gear
3rdgear
MOVEMENTSPEED(**)
Mastelevation time 24 to 27 s
Mastlowering time 21 to 24 s
Jibelevationtime 16 to 19 s
Jibloweringtime 17 to 20 s
Slewingtime (fromstoptostop) 50 to 55 s
0,65 to0,7 km/h
1,8 km/h
4km/h
WORK PLATFORMCHARACTERISTICS 22

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3.1.Reliefvalvesetting
3.2.Brakereleasecircuitpressurecheck
3.3.Circuitreliefvalveadjustment
3.3.1.Mainpressure(PR1)
3.3.2.Rightswing (PR2)
3.3.3.Left swing (PR3)
3.3.4.Mastelevation (PR4)
3.3.5.Jibelevation (PR5)
3.3.6.Jiblowering (PR6)
3.3.7.Brakereleasemaximumpressure(PR7)
3.3.8.Driveatlowspeed (PR8)
3.4.Counterbalancevalvesetting
TABLEOF CONTENTS
3
PRESSURESETTINGS

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Relief valvesused in the workplatform'shydraulic
systemprotectthesystemfromexcessivepressure
(within the circuitinwhichtheyareused)byreturning
hydraulicoiltothehydraulicreservoirwhenthe
pressuresetting isexceeded.
Youcandeterminethepoint atwhichareliefvalve
opensbyplacing apressuregaugeinthe pressure
testportofthe appropriatevalvemanifold.Theneedle
on the pressuregauge will climbuntil itreachesthe
reliefvalvesetting.Atthatpoint, the needle will stop
climbingandfluctuate-indicatingthatthereliefvalve
isopenand returninghydraulicoiltothe hydraulic
reservoir.
Correctreliefvalveadjustmentismandatoryifany
hydrauliccircuitistofunctionproperly.Reliefpressure
settingsmustalwaysbe within established tolerances.
NOTE
Adjustmentofreliefvalve pressure settings
should onlybeperformed-after theneed
foradjustmenthasbeenestablished-by
qualifiedmechanicsusingthecorrect
equipment.
NOTE
Check pressure settingspriortodeliveryof
workplatform.
The tabletitled ReliefValve PressureSettings lists
main and circuitreliefvalvepressuresettings.Ifthe
pressuresettingofanyreliefvalveisnot±5barofthe
setting listedin the table,adjustvalveasnecessary
(unless otherwisespecified).
Do notovertightentheadjustmentscrewor
locknut.
Donothold thereliefvalve openformore
than oneminute.
Foracorrectreliefvalve pressurecheck,the
locknutofthereliefvalveadjustmentscrew
mustbetightened.
NOTE
Toadjustareliefvalve turntheadjustment
screw(intoincrease orouttodecrease)until
theproper settingisreached.
!CAUTION
!CAUTION
!CAUTION
3.1Reliefvalvesetting
NOTE
Checkthereliefvalveadjustmentswitha
pressuregaugeconnectedtothepressure
testport(M)oftheFUNCTIONMANIFOLD
exceptforthebrake releasereliefvalve
[PR7].Check brake release reliefvalve [PR7]
adjustmentwithapressure gaugeconnected
tothepressure testport(M) oftheBRAKE
MANIFOLD.
Preparation
NOTE
Beforesettingpressures,warmthehydraulic
oiltobetween25°Cto50°C.
NOTE
Usea0to40,0MPa/400 barpressuregauge
whenadjusting thereliefvalves.For
pressures lower than3MPa/30 bar,use a6
MPa/60 bar pressuregauge.
NOTE
Whenadjusting thereliefvalves,operatethe
machinefromtheplatform controlsAT
MAXIMUMSPEED.
Brake manifold
Function manifold
Testplug
PR8
PR7
ä
PR1
PR2
PR6
PR5
PR4 PR3
Testplug
ä
PRESSURESETTINGS 33

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3.2Brakereleasecircuitpressure
check
1-Chock bothfrontwheelsasindicatedbelow:
2-Connect the pressuregaugetothe pressure
testplugatport"M"on BRAKE MANIFOLD.
3-Position the DRIVE SPEEDselectorswitchto
HIGH( ).
4-ActivateaDRIVE FORWARD function by
pushingthe controllerforward(awayfromthe
operator).Ifthemaximumreadingonthe
pressuregaugeisnotbetween 15and 21bar,
referto BRAKE RELEASEMAXIMUM
PRESSURE in§3.3.7.Ifthemaximumreading
isover21bar,consultyourlocalJLGdistributor
forservicing.
5-Removethe pressuregauge.
3.3Circuitrelief valve adjustment
3.3.1.Mainpressure(PR1)
1-Chock bothrearwheelsasindicated below:
2-Connect the pressuregaugetothe pressure
testplug atport"M" on FUNCTIONMANIFOLD.
3-Positionthe DRIVE SPEEDSELECTORswitch
toHIGH( ).
4-ActivateaDRIVE REVERSEfunction byFULLY
pullingthe controllertothe rear(towardsthe
operator).Notethe maximumreadingon the
pressuregauge.If the readingisnotwithin±5
barofthe reliefpressureshowninthe table
titled ReliefValvePressureSettings,adjustthe
pressuresetting asnecessary.
5-Removethe pressuregauge.
3.3.2.Rightswing(PR2)
1-Connect the pressuregaugetothe pressure
testplug atport"M" on FUNCTIONMANIFOLD.
2-SWINGthe superstructurefullytotheRIGHT
(jiboverthefront).Notethemaximumreading
ofthe pressuregauge.Ifthe readingisnot
within±5barofthe reliefpressureshownin
the tabletitled ReliefValvePressureSettings,
adjustthe pressuresetting asnecessary.
3-Removethe pressuregauge.
3.3.3.Left swing(PR3)
1-Connectthe pressuregauge tothe pressuretest
plug atport"M" onFUNCTIONMANIFOLD.
2-SWINGthe superstructurefullytothe LEFT
(jiboverthefront).Notethemaximumreading
ofthe pressuregauge.Ifthe readingisnot
within±5barofthe reliefpressureshowinthe
tabletitled ReliefValvePressureSettings,
adjustthe pressuresetting asnecessary.
3-Removethe pressuregauge.
3.3.4.Mastelevation(PR4)
1-Connectthe pressuregaugetothe pressuretest
plug atport«M»on FUNCTIONMANIFOLD.
2-PerformaMASTRAISINGfunction until the
themastcylinderreachestheendofitscourse.
Notethemaximumreading ofthe pressure
gauge.Ifthe readingisnotwithin±5barofthe
reliefpressureshowninthe tabletitled Relief
ValvePressureSettings,adjustthe pressure
setting asnecessary.
3-Removethe pressuregauge.
3.3.5.Jibelevation(PR5)
1-Connectthe pressuregauge tothe pressuretest
plug atport«M»on FUNCTIONMANIFOLD.
2-PerformaJIBRAISING function untilthe jib
cylinderreachesthe end of itscourse.Note
themaximumreadingofthepressuregauge.If
thereading isnotwithin±5barof therelief
pressureshowninthe tabletitled ReliefValve
PressureSettings,adjustthe pressuresetting
asnecessary.
3-Removethe pressuregauge.
PRESSURESETTINGS 33