JLG TOUCAN DUO User manual

Updated : 06-2015 MA0323-05
English - Service Manual
MODELSMODELS
MODELSMODELS
MODELS
TOUCAN DUOTOUCAN DUO
TOUCAN DUOTOUCAN DUO
TOUCAN DUO
U.S.A.
JLG Industries, Inc.
1 JLG Drive
McConnellsburg
PA 17233-9533
Tel : [phone]
Fax : [phone]
C.E.
JLG Manufacturing Europe
Breitwaterstraat 12A
Oude Bunders 1034
B - 3630 Maasmechelen
Tel : [phone]
Fax : [phone]
FRANCE
JLG France SAS
Z.I. de Fauillet
BP 20 - 47400 TONNEINS
France
Tel : [phone]
Fax : [phone]
C.E.
JLG Industries,
Kilmartin Place,
Tannochside Park
Uddingston, Scotland G71 5PH
Tel : [phone]
Fax : [phone]

3
TOUCAN Duo
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Models
MA0323-05
Models
N° ________________

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TOUCAN Duo
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Models
INTRODUCTION 1
Foreword
Important information
WORK PLATFORM CHARACTERISTICS 2
General Description -------------------------------------------------------------------- 2.1
Characteristics - Dimensions - Performances ---------------------------------- 2.2
GENERAL 3
General procedure ---------------------------------------------------------------------- 3.1
Cleanliness -------------------------------------------------------------------------------- 3.2
Handling ------------------------------------------------------------------------------------ 3.3
Welding from the work platform --------------------------------------------------- 3.4
Assembly - Disassembly -------------------------------------------------------------- 3.5
Bushing installation --------------------------------------------------------------------- 3.6
Bearings ------------------------------------------------------------------------------------ 3.7
Locks ---------------------------------------------------------------------------------------- 3.8
Loctite® ------------------------------------------------------------------------------------- 3.9
Fasteners and torque values-------------------------------------------------------- 3.10
Torque values tables ------------------------------------------------------------------ 3.11
Hydraulic system ----------------------------------------------------------------------- 3.12
Lubricants -------------------------------------------------------------------------------- 3.13
Gasket ------------------------------------------------------------------------------------- 3.14
Electrical wires and cables---------------------------------------------------------- 3.15
Charger ------------------------------------------------------------------------------------ 3.16
Battery discharge indicator --------------------------------------------------------- 3.17
Standard machine------------------------------------------------------------------------ 3.17.1
Machine with battery cut out option + hourmeter ------------------------ 3.17.2
Electronic controller ------------------------------------------------------------------- 3.18
Drive Motors ----------------------------------------------------------------------------- 3.19
Electrical cylinder ---------------------------------------------------------------------- 3.20
Fuses --------------------------------------------------------------------------------------- 3.21
Power circuit fuses ---------------------------------------------------------------------- 3.21.1
Control circuit fuses -------------------------------------------------------------------- 3.21.2
Hydraulic power unit ------------------------------------------------------------------ 3.22
General maintenance ------------------------------------------------------------------- 3.22.1
Troubleshooting -------------------------------------------------------------------------- 3.22.2
TABLE OF CONTENTS
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TABLE OF CONTENTS
ADJUSTMENTS 4
Introduction
Chain attachments inspection ------------------------------------------------------ 4.1
Lifting chains tension adjustment -------------------------------------------------- 4.2
Tension adjustment of the shelf lifting cables --------------------------------- 4.3
Shelf alignment setting ---------------------------------------------------------------- 4.4
Pressure relief valves adjustment-------------------------------------------------- 4.5
Mast power unit pressure relief valve---------------------------------------------- 4.5.1
Mast cylinder pressure relief valve -------------------------------------------------- 4.5.2
Shelf power unit pressure relief valve --------------------------------------------- 4.5.3
Pressure switch adjustment on shelf cylinder --------------------------------- 4.6
Control - Tilt indicator adjustment ------------------------------------------------- 4.7
Control - Wheel motor brake adjustment ---------------------------------------- 4.8
Mast cylinder bleeding----------------------------------------------------------------- 4.9
Steering sensors setting ------------------------------------------------------------- 4.10
Setting of the sensor located above the right hand side wheel ------- 4.10.1
Setting of the sensor located above the left hand side wheel --------- 4.10.2
Gate sensors setting ------------------------------------------------------------------ 4.11
Shelf sensor setting ------------------------------------------------------------------- 4.12
Battery discharge indicator setting (option) ----------------------------------- 4.13
SCHEMATICS 5
Electrical schematics ------------------------------------------------------------------ 5.1
Standard machine -------------------------------------------------------------------------------------- 5.1.1
Battery cut and hourmeter --------------------------------------------------------------------------- 5.1.2
Hydraulic schematic ------------------------------------------------------------------- 5.2
REMOVAL - INSTALLATION PROCEDURES 6
Introduction
Platform and shelf----------------------------------------------------------------------- 6.1
Shelf removal - installation --------------------------------------------------------------------------- 6.1.1
Shelf pre-installation ----------------------------------------------------------------------------------- 6.1.2
Platform removal - installation ---------------------------------------------------------------------- 6.1.3
Mast on chassis-------------------------------------------------------------------------- 6.2
Telescopic mast ------------------------------------------------------------------------- 6.3
Mast cylinder removal -------------------------------------------------------------------------------- 6.3.1
Mast cylinder installation ----------------------------------------------------------------------------- 6.3.2
Slide blocks removal ----------------------------------------------------------------------------------- 6.3.3
Slide blocks installation ------------------------------------------------------------------------------- 6.3.4
Lifting chains removal --------------------------------------------------------------------------------- 6.3.5
Lifting chains installation ----------------------------------------------------------------------------- 6.3.6
Chassis ------------------------------------------------------------------------------------- 6.4
Removal - Installation of the driving wheels (rear wheels) ----------------------------------- 6.4.1
Removal - Installation of the steering wheels (front wheels) ------------------------------- 6.4.2
Removal - Installation of the motor reducer + flange assembly --------------------------- 6.4.3
Removal - Installation of the motor reducers ---------------------------------------------------- 6.4.4
Removal - Installation of the wheel motor brakes ---------------------------------------------- 6.4.5
Removal - Installation of the reducer on the wheel motor reducer ------------------------ 6.4.6
Removal - Installation of the speed controller --------------------------------------------------- 6.4.7

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TABLE OF CONTENTS
ECO SMART DISPLAY7
General Description -------------------------------------------------------------------- 7.1
Screen Operation ------------------------------------------------------------------------ 7.2
Connection -------------------------------------------------------------------------------- 7.3
Menus Displays -------------------------------------------------------------------------- 7.4
Display ----------------------------------------------------------------------------------------- 7.4.1
Slave controller ----------------------------------------------------------------------------- 7.4.2
Master controller --------------------------------------------------------------------------- 7.4.3
Calibration of the Stering Cylinder Potentiometer ---------------------------- 7.5
Main Parameters ------------------------------------------------------------------------ 7.6
ALARMS AND WARNINGS 8
General ------------------------------------------------------------------------------------- 8.1
Alarms and Warnings ------------------------------------------------------------------ 8.2
Alarms -------------------------------------------------------------------------------------- 8.3
Warnings ----------------------------------------------------------------------------------- 8.4

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CHAPTER 1
INTRODUCTION

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This handbook has been compiled to assist you in properly maintaining your JLG
Aerial Work Platform Model TOUCAN Duo.
It contains technical information and procedures enabling a qualified personnel to
detect possible failures and perform the necessary adjustments or repairs.
Check that this manual corresponds to the model of work platform you will be
maintaining.
Before any maintenance on the work platform, you must read and understand the
operating and safety procedures described in the corresponding Operator's and
Safety Handbook.
To perform the procedures described in this manual, a basic knowledge in
mechanics, hydraulics and electricy is necessary.
Certainsprocedures require specificcompetences,tooling, and handlingequipment.
We therefore recommend that these repair and adjustment procedures are carried
out only by authorized and qualified personnel.
Constant improvement make it necessary that JLG reserve the right to make
specification and equipment changes without notice.
If you have any questions on operating, maintenance procedures, contact your
authorized JLG distributor.
FOREWORD
INTRODUCTION