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

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Révision 04-2006
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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Edition 04-2006 Toucan1010
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)
__________________________________________________________________
__________________________________________________________________
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Signature(optional)
Adress SMCAR'sto:
Supervisor,Publications
JLGFrance
Z.I. deFauillet,
B.P.20
47400Tonneins,France
CORRECTIVE ACTIONREQUEST

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Révision 04-2006
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CORRECTIVE ACTIONREQUEST