JLG TOUCAN 861 User manual

Updated:0 4-2006 MA0280-0 1
English -Service
MODELS
TOUCAN861
U.S.A.
JLGINDUSTRIES,INC
1JLGDrive
McConnellsburg
PA172 33-953 3
Tél:[phone]
Fax :[phone]
FRANCE
JLGFrance SAS
Z.I.deFauillet
BP20 -47400 TONNEINS
France
Tel:[phone]
Fax :[phone]
C.E.
JLGIndustries,
KilmartinPlace,
TannochsidePark
Uddingston,ScotlandG715PH
Tel:[phone]
Fax :[phone]

Toucan861 3
Models
Updated04-06
MA0280-01
Models
EnglishVersion
Toucan861
N°___________

Toucan861 Models
Updated04-06
4
TABLEOF CONTENT
INTRODUCTION 1
Foreword
Importantinformation
PLATFORMCHARACTERISTICS 2
Description-------------------------------------------------------------------------------2.1
Characteristics- Dimensions- Performances---------------------------------2.2
Identification ofcomponents-------------------------------------------------------2.3
BREAKDOWN 3
Generalprocedure---------------------------------------------------------------------3.1
Workprincipleofsafetyfeatures-------------------------------------------------3.2
Troubleshooting------------------------------------------------------------------------3.3
Batteries----------------------------------------------------------------------------------------3.3.1
Connectors-----------------------------------------------------------------------------------3.3.2
Circuitbreakersofcontrolcircuit---------------------------------------------------3.3.3
Faultdiagnosis------------------------------------------------------------------------------3.3.4
SETTINGS 4
Adjustmentofalifting chaintension---------------------------------------------4.1
Adjustmentofalignmentand play inthetelescopicmast----------------4.2
Control-Tiltindicatoradjustment------------------------------------------------4.3
Control-Inclinesensoradjustment-----------------------------------------------4.4
Adjustmentofslack chainsensors-----------------------------------------------4.5
Adjustmentofbatterydischargeindicator-------------------------------------4.6
Adjustmentofflashing lightpressureswitches-------------------------------4.7
Hydraulicadjustments----------------------------------------------------------------4.8
Uppercontrolvalve------------------------------------------------------------------------4.8.1
Drivemanifold-------------------------------------------------------------------------------4.8.2
REMOVAL-INSTALLATION 5
Suite--------------------------------------------------------------------------------------------

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TABLEDES MATIERES
REMOVAL-INSTALLATION 5
General------------------------------------------------------------------------------------5.1
Safety-------------------------------------------------------------------------------------------5.1.1
Cleanliness------------------------------------------------------------------------------------5.1.2
Systemmalfunction-----------------------------------------------------------------------5.1.3
Disassembly/Assembly----------------------------------------------------------------5.1.4
Parts replacement--------------------------------------------------------------------------5.1.5
Electricalwiresand cables-------------------------------------------------------------5.1.6
Drychargedbatterry----------------------------------------------------------------------5.1.7
Torquevalues--------------------------------------------------------------------------------5.1.8
Lubrication------------------------------------------------------------------------------------5.1.9
Maintenance and installation ofguiderings-----------------------------------5.2
Mastrollerremoval-------------------------------------------------------------------5.3
Slewing ring-----------------------------------------------------------------------------5.4
Hand pump-------------------------------------------------------------------------------5.5
Hydraulicpower unit------------------------------------------------------------------5.6
Wheelmotors---------------------------------------------------------------------------5.7
Disassembly----------------------------------------------------------------------------------5.7.1
Assembly--------------------------------------------------------------------------------------5.7.2
Upper controlvalve-------------------------------------------------------------------5.8
Lowercontrolvalve-------------------------------------------------------------------5.9
Releasecontrolvalve----------------------------------------------------------------5.10
Drive manifold-------------------------------------------------------------------------5.11
Upperauxillarymanifold------------------------------------------------------------5.12
Cylindersupplymanifolds----------------------------------------------------------5.13
Mast cylinder--------------------------------------------------------------------------------5.13.1
Jibcylinder-----------------------------------------------------------------------------------5.13.2
Safetymanifold----------------------------------------------------------------------------5.13.3
CONTROLS-MAINTENANCE 6

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Toucan861 7
Models
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CHAPTER1
INTRODUCTION

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8
INTRODUCTION
FOREWORD
Thishandbookhasbeencompiledtoassistyouinproperlyoperating and
maintaining yourAerialWorkPlatformModel Toucan861.
Itcontainsdetaileddescriptionsofcontrolandmaintenanceprocedurestobe
performed bythe user,including theirperiodicity.
It alsocontainstechnicalinformation and proceduresenabling aqualified
personneltodetectpossiblefailuresand performthenecessaryadjustments
orrepairs.
Verifythatthismanualcorrespondstothe work platformmodelyou will be
maintaining.
Beforeanymaintenanceontheworkplatform,youmustreadand understand
theoperating andsafetyproceduresdescribedin thecorrespondingOperator's
and SafetyHandbook.
Toperformthe maintenanceproceduresdescribed inthismanual,abasic
knowledge inmechanics,hydraulicsand electricy isnecessary.
Certainsproceduresrequirespecificcompetences,tooling,and handling
equipment. Wethereforerecommend that theserepairand maintenance
proceduresarecarried outonlybyauthorized and qualified personnel.
Constantimprovementmakeitnecessary thatJLGreservethe righttomake
specification and equipmentchangeswithoutnotice.
Ifyou haveanyquestionsonoperating,maintenanceprocedures,contactyour
authorized JLGdistributor.

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Models
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INTRODUCTION
Priortoanymaintenanceorrepairprocedure,itis
necessary to:
Read andunderstand theoperating andsafety
proceduresinthismanualandintheOperator's
and SafetyHandbook.
Read eachprocedureinthismanualtothe end
beforeapplying ittothe machine.
Ensureyou haveall the appropriatetoolsand
equipmentnecessaryforthe repairor
maintenancetobe performed.
Haveallreplacementpartsreadytoperformthe
repair.
Work inaclean,spaciousand well litarea.
Wearallprotectionequipment(glasses,
gloves,...)appropriateforthe operation tobe
performed.
Placethework platforminthefollowing
configuration (unlessotherwisespecified):
-on afirm,clean and horizontalfloor.
-wheelschoked inbothdirections.
-inretracted position.
-thecontactkeypositionedto"O"andremoved.
-battery disconnected.
-chargerdisconnected.
-powersocketon theplatform(optional
equipment)disconnected.
-eachcontrolpanelmustbe tagged out.
Failure torespectinstructionsand safety
instructionsdescribedin thismanualand in
Operator'sandSafetyHandbookcould result
in deathorseriousinjuries.
Safetyinstructionscontainedin theoperator's
andsafetyhandbookapplyalsoduring
operatingcontrols,maintenanceandrepairs.
Theydo notreplace national, stateorlocal
work regulations,industrystandardsor
employer'sworkrules.
Donotperformanyoperatingcontrol,
maintenanceorrepair:
1-Ifyou arenotqualified and trainedtothe
maintenanceofTHISparticularworkplatform.
2-Ifyou havenotread and understood the
operatingandsafetyproceduresdescribedin
thismanual and inthe Operator's and Safety
HandbookforTHISparticularwork platform.
3-If you arenot familiarwithregulationsand
standardsgoverningaerialwork platforms
and theiroperation.
4-Ifyou do nothavenecessary toolsand
equipments.
Yoursafetyand thatofpersonsworkingon
andaround theworkplatformmustbeyour
prime concern. Allsafetycomponentson the
workplatformmustbemaintainedin perfect
workingorder.
Youwillfind in thismanualblocksor
paragraphescontainingthefollowing
mentions:
DANGER,CAUTIONand NOTE.These
mentionsaredefined as follows:
ADANGERisusedtoemphasizethatifan
operation, procedure orpractice isnot
followedexactly,deathorseriousinjury to
personnelmay result.
ACAUTIONisusedtoemphasizethatifan
operation,procedure,orpractice isnot
followedexactly,equipmentdamagemay
result.
NOTE
Anoteisusedto emphasizeanimportant
procedure orcondition.
DANGER
DANGER
DANGER
!CAUTION

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Toucan861 11
Models
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Thefollowingform isforthe useofthe Distributor,Customer,Mechanic,and allotherpersonwho usethis
manualand recognizebeneficialways toimproveitspurposeasaworthyreference.SMCAR'saretobe
made inregardsto,butnotlimited to:Safety,Operation Correctness,and TechnicalContent. All SMCAR's
will bereviewed bythe responsibleDepartmentatJLG. ApprovedSMCAR'swillbe distributed inaService
Bulletin immediatelyand then incorporatedinthe nextscheduled changetothe manual.Ananswertothe
SMCAR's,approvedordisapproved,willbe sentdirectlytotheonesubmitting theSMCAR.
Date_____________________
Customername_____________
Name/Firstname____________
Address__________________
__________________________
Telephone__________________
ServiceManual
Affected______________________________________________________________________
Page(s)Affected________________________________________________________________
Reason forsubmittingSMCAR(useadditinalpaperorbackifnecessary)_____________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
_______________________________
Signature(optional)
AddressSMCAR's to:
JLGFranceSAS
ProductSupport
Z.I. de Fauillet, BP 20
47400TonneinsFRANCE
CORRECTIVE ACTIONREQUEST

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Toucan861 13
Models
Updated04-06
CHAPTER2
WORK PLATFORMCHARACTERISTICS

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Models
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II-1 CHARACTERISTICS II-1
2.1Description
Theworkplatformconsistsofaselfpropelled all
welded steelframe,atelescopicmastmounted on a
turntable andapendularjib.The platform ismounted
atthe end ofthe jib.
The drivefunctionisaccomplishedbytwo hydraulic
motorsthat propeltherearaxle.Boththesemotors
integratetheparking brakeoperating through lack of
pressure.Steeringisaccomplished bymeansofa
hydrauliccylinder.
Thehydraulicpowerunitsupplying the functionsof
the work platformislocatedon the baseoftheturntable
on the righthand side ofthetelescopicmast.
Theturntablerotationmovementisaccomplished
throughawormgearreducerlocatedatthe baseof
the turntable.
Themovementsofthetelescopicmastand pendular
jibareaccomplishedbymeansofhydrauliccylinders.
Thework platformmovementsarecontrolledfromthe
control panelsthrough hydrauliccontrolvalves
controlled electricallylocated on therighthand side
ofthe telescopicmast.
Forhydrauliccontrolvalvewithmanualcontrol,the
maincontrolvalve(located inthe platform)issupplied
bythe hydraulicpowerunit.The emergency and
breakdowncontrol valve,located underthe oil tank
(left hand side ofthemast)issuppliedbythe hand
pump.
The energyforthecontrol and powercircuitsofthe
workplatformissupplied bya24Vdcbattery.

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16
2.2Characteristics-Dimensions-Performances
II-2 CHARACTERISTICS II-2
Length
Width
Height
Weight
Groundclearance
Min. floorheight
Max. floorheight
Max. w orkingheight
Maxoutreach (centerline)
Maxworkingoutreach (centerline)
Floorheightatmax. outreach
Working heightatmax. outreach
Slewing
Innersteering radius
Outersteering radius
Length
Width
Ratedload
Oiltankcapacity
Hydrauliccircuitcapacity(tankincluded)
Hydraulicpumpcylindriccapacity
Pressure
Return
PRESSURES OverallSteering Mast
raising
Jib
raising Slewing
Hydrauliccircuitmax.pressure(MPa) 23 12 16 14 8
20 µmabsolute
HYDRAULICCIRCUIT
PLATFORM
0,70 m 1,01m
0,90m
Standard platform
Largeplatform
ACCESSIBILITY
FILTRATION
3kW - 24Vdc
ELECTRICALCOMPONENTS
Powerofpowerunitmotor
220kg 200 kg
10 µmabsolute
Standard platform
Largeplatform
0,40m
6,72m
2,68 m 2,99
0,99m
1,99m
Largeplatform
Standard platform
DIMENSIONS(LOWERED)
5,5cm³/t
20l
25l
8,72m
2,64 m
2980kg
0,10m
2,96m
3,14 m 3,46m
2,40m
5,42m
7,42m
180°
1,02m

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(*)speedsmeasuredonhorizontalgroundwithonepersoninthe platform(approximately80kg).
(**)timesmeasuredwiththe maximumratedloadin theplatform(200 kg),themovementswereperformedfromthe
controlpanelintheplatform.
Constantproductimprovementmakeitnecessary thatJLGreservethe righttomakespecification and equipment
changeswithoutnotice.
II-2 CHARACTERISTICS II-2
DRIVESPEEDS(* )
1stgear(lowspeed) 0,5to0,75km/hie24to36sover5m
2ndgear(climbingspeed) 1,65 to2,1km/hie17to22sover5m
3rdgear(highspeed) 3,2to4,1km/hie13to17sover10m
MOVEMENTSPEEDS(** )
Mastelevationtime 20 to26 s
Mastlowering time 27 to35 s
Jibelevationtime 15 to20 s
Jibloweringtime 19 to23 s
Slewingtime(fromstoptostop) 25 to33 s

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18
II-3 CHARACTERISTICS II-3
REAR
ARRIERE
AVANT
FRONT
Q
A
C
H
G
S
R
PD
E
O
I
W
X
B
N
L
U
V
J
M
F
T
K
2.3Identificationof components
MarkDescription See § MarkDescription See§
AUppercontrolvalve 4-8-1/5-8 L Returnfilter OP
BLowercontrolvalve 5-9 M Handpump 5-5
CAuxillaryuppermanifold 5-12 N Wheelmotor 5-7
DReleasemanifold 5-10 O Tank OP
EDrivemanifold 4-8-2/5-11 P Upperelectricalbox OP
Safetymanifold Q Lowerelectricalbox OP
Dumpvalvemanifold R Circuitbreaker OP
GMastcylinder 5-13-1 S Tilt sensor 3-2
HJibcylinder 5-13-2 T Mast switch 4-3
ISteeringcylinder U Inclinesensor 4-4
JPowerunit 5-6 V Drivingwheel
KPressurefilter OP W Steeringwheel
SeeOP=seeOperator'sandsafetyhandbook
F 4-7/5-13-3

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II-3 CHARACTERISTICS II-3
LCB
BATTERY
GHARGER
DISCON-
BATTERY
CON1
[D4]
M1
PUMP
MOTOR
M
3kW
24V DC
5,5cc/rev
7
6
321
[SW14][SW12]
[SW11]
54 8
SLACK
CHAIN [SW13]
(+)
24V
COM
(-)
5
(+)
2
(+)
3
BATTIGN
(-)
4
N.O.
FOOTSWITCH
BOITIER HAUT
(+)
7 6
HRM
H2 HORN
UCB
MASTSW
FlashingLights
M2
DESCENTENABLES
JDE
MDE
TILT
SLOPESENSORS
SENSOR
+
-
[D14]
PRESSURESW
[D13]
-
+
BATTERY PACK
325A
FUSE
24V DC
-
Supply
[D18]
[D17]
Lo Speed Disable
HiSpeed Enable
115/230V50/60Hz
BatteryFillingPump
BOITIER BAS
1
Left
Gauche
Pmax=23MPa
Po=2MPa
ACCUMULATOR
ACCUMULATEUR
Moteurs Translation
DRIVE MOTORS
A
Right
Droite
A
DIRECTION
STEERING
DEØ50-25
H21 H3 1
D
Ø0 .5
HighSpeed
Vitesse
Grande
Enable
DRIVEMANIFOLD
BLOCTRANSLATION
Ø1,8
ptevitesse
Coupure
Disable
Low SP
SE Ø60
MAST
MAT
A
B
DEØ60-40
JIB
BRAS
ø0,6 ø0,6
Orientation
SWING
O
-NECTION
P
J
S
R
F
T
U
J
K
D
E
I
A
C
GH
F
B
M L
N
Q
Hydraulicschematic/ Schémahydraulique
Electrical schematic/ Schémaelectrique

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