JLG TOUCAN 1010, Service Manual

Page 1: ...McConnellsburg PA 17233 9533 Tel 171 485 5161 Fax 717 485 6417 C E JLG Manufacturing Europe Breitwaterstraat 12A Oude Bunders 1034 B 3630 Maasmechelen Tel 32 0 89 774 974 Fax 32 0 89 777 427 FRANCE JL...

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Page 3: ...3 Models Edition 04 2006 Toucan 1010 MA0235 02 Models Toucan1010 _____ Toucan1010 I _____...

Page 4: ...b lowering PR6 3 3 6 Brake release maximum pressure PR7 3 3 7 Drive at low speed PR8 3 3 8 Counterbalance valve setting 3 4 BATTERY CHARGER 4 Battery 4 1 Charger 4 2 Fulmen charger 4 2 1 Oldham Hawker...

Page 5: ...8 1 Pin 5 8 2 Bushings and pin 5 8 3 Bushing installation 5 8 4 Mast roller removal 5 9 Upper rollers 5 9 1 Lower rollers 5 9 2 Rollers 5 9 3 Hydraulic system 5 10 Fatigue of welded structures 5 11 L...

Page 6: ...controller 6 6 Help with the diagnosis 6 7 Electronic modules 6 8 Controls verification module 6 8 1 Drive management module 6 9 Clipper connector installation procedure 6 10 PREVENTIVE AND MAINTENAN...

Page 7: ...7 Models Edition 04 2006 Toucan 1010 Foreword Importantinformation TABLE OF CONTENTS 1 INTRODUCTION...

Page 8: ...this manual apply as follows A DANGER is used to emphasize that if an operation procedure or practice is not followed exactly death or serious injury to personnel may result A CAUTION is used to emph...

Page 9: ...________________________________________________ Page s Affected____________________________________________________________________ Reason for submitting SMCAR Useadditional paper or back if necessar...

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Page 11: ...11 Models Edition 04 2006 Toucan 1010 2 1 Description 2 2 Characteristics Dimensions Performances TABLE OF CONTENTS 2 WORK PLATFORM CHARACTERISTICS...

Page 12: ...t steering is located at the top of the main hydraulic tank at the rear of the chassis The turntable rotation movement is accomplished through a moto reducer group located at the base of the turntable...

Page 13: ...Charger Emergencycontrolpanel Counterweight Jib Platform Lateral battery access Steeringwheels Drivingwheels LEFT SIDE Front Rear Counterweight Breakdowncontrol panel Steeringhydraulicunit Steeringwh...

Page 14: ...nous Inner turning radius Machine raised 1 78 m Machine half raised 0 m Outer turning radius Machine raised 3 37 m Machine half raised 1 75 m PLATFORM Length 0 70 m 1 01 m Width 0 90 m Rated load 200...

Page 15: ...y charged battery and working in an ambiant temperature of 20 C Constant product improvement make it necessary that JLG reserve the right to make specification and equipment changes without notice DRI...

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Page 17: ...Circuitreliefvalveadjustment 3 3 1 Main pressure PR1 3 3 2 Right swing PR2 3 3 3 Left swing PR3 3 3 4 Mastelevation PR4 3 3 5 Jib elevation PR5 3 3 6 Jib lowering PR6 3 3 7 Brake release maximumpress...

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Page 19: ...ircuit relief valve pressure settings If the pressure setting of any relief valve is not 5 bar of the setting listed in the table adjust valve as necessary unless otherwise specified Do not overtighte...

Page 20: ...the front Note the maximum reading of the pressure gauge If the reading is not within 5 bar of the relief pressure shown in the table titled Relief Valve Pressure Settings adjust the pressure setting...

Page 21: ...servicing 7 TURN OUT the PR7 relief valve adjustment screw until the pressure drops just under the previously recorded value then turn the adjustment screw 1 4 turn IN 8 Unhook the pump handle and pus...

Page 22: ...latform is driven at its maximum speed 3rd gear it must stop over a 0 8m to 1m distance on flat ground in both forward and reverse when the joystick is returned to neutral When the work platform is dr...

Page 23: ...ng 4 4 Electrolytespecific gravity and battery voltage 4 5 Centralised fillingsystemmaintenance 4 6 Cleaning Battery maintenance 4 7 Storage of a battery at temperatures below 0 C 32 F 4 8 Use of a ba...

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Page 25: ...led several times somewhere between five and 40 cycles For at least the first five cycles it is recommended not to discharge the battery above 70 of its capacity To obtain the maximum battery life do...

Page 26: ...xplode NOTE It is not necessary to charge the battery if the electrolyte specific gravity has not dropped under 1 240 kg l Regular charge of a battery when its specific gravity is higher than 1 240 kg...

Page 27: ...40A models 20 Amps on 24 MO 65A models Output fuse 40 Amps on 24 MO 40A models 80 Amps on 24 MO 65A models NOTE A spare output fuse is strapped inside the charger cover Troubleshooting chart BATTERY C...

Page 28: ...z 230VAC 50Hz Adaptation to network voltage Prior to any operation requiring charger cover removal the battery must be disconnected and the charger must be unplugged from the AC outlet Failure to do s...

Page 29: ...ed d lights up It is advised to have either the charger or the battery checked by a technician a b c d e C MT S model Display panel a Battery indicator connected green b Indicator battery in final cha...

Page 30: ...ndicator If a fault occurs during charge switch off the charger and disconnect it from AC outlet c b a d e DANGER Troubleshooting The default LED indicator lights up Pre insulated terminal 220 V 110 V...

Page 31: ...ator stops turning 4 Verify the proper electrolyte level in each battery cell 4 4 Electrolyte specific gravity and battery voltage Specific gravity and voltage measure is the most important check to b...

Page 32: ...sufficient quantity of electrolyte so that the float emerges Ensure the float top does not touch the rubber bulb or that the foat does not stick by capillarity to the glass walls 3 Read the value as i...

Page 33: ...ave become corrosive Do not allow drain water to contact the skin or eyes If it does occur flush the contacted area with water and consult a doctor immediatly Appropriateequipement mustbe worn gloves...

Page 34: ...oose 55 of its autonomy 1 00 1 05 1 10 1 15 1 20 1 25 1 30 1 35 1 40 1 45 1 50 90 80 70 60 50 40 30 20 10 0 1 075 5 Electrolytespecificgravity Temperature in C CAUTION BATTERY CHARGER 4 4 4 9 Battery...

Page 35: ...he electrolyte Fill battery cells after the charge Perform an equalization charge Contact your JLG Distributor Product Support Low voltage in the cells in open circuit Electrolyte specific gravity too...

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Page 37: ...n 5 8 3Bushingsand pin 5 8 4Bushinginstallation 5 9 Mastrollerremoval 5 9 1 Upperrollers 5 9 2 Lowerrollers 5 9 3 Rollers 5 10 Hydraulic system 5 11Fatigueofwelded structures 5 12LOCTITE 5 13Fasteners...

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Page 39: ...been removed from all machined surfacesof newparts before they are installed except leaf chains 5 3 Removal and installation When performing maintenance do not attempt to manually lift heavy parts whe...

Page 40: ...group of wires or cables tag each one to ensure proper identification during assembly 5 7 Gaskets Ensure the holes in the gaskets correspond with the lubricant passages in the mating parts If it is ne...

Page 41: ...pper rollers 1 Lower the mast 2 Unscrew the locknut from the roller to be removed using a polygonal spanner 3 Unscrew the roller pin to release the bronze spacer and free the roller as indicated below...

Page 42: ...s Partly tighten the pin on the mast section and insert the washer on the pin Apply grease to the spacer so that it sticks to the mast and does not fall to the bottom of the mast Press the spacer onto...

Page 43: ...turing methods there is a natural curvature to a hydraulic hose The hose should be installed so any bend is with this curvature Removing air from the hydraulic system Air entering the hydraulic oil wi...

Page 44: ...sis base plate Hydraulic wheel motors attachment plates rear axle Front axle beam connection on chassis plate Steering brackets Mast section 1 connection on turntable plate Hydraulic cylinder end conn...

Page 45: ...t been over torqued the boltsshall be visually inspected for cracks and thread damage and replaced if discontinuities are found Bolts are not to be rethreaded or reworked It ismandatory to replace sys...

Page 46: ...overs all hand tools Grade Tensile strength N mm Unit M4 x70 M5 x80 M6 x100 M8 x125 M10 x150 M12 x175 M14 x200 M16 x200 M18 x250 M20 x250 M22 x250 M24 x300 M27 x300 M30 x350 8 8 785 N m 2 66 5 2 9 1 2...

Page 47: ...alf its course when the limit switch located on the right hand side of the telescopic mast is activated The right hand side lower switch limits the steering to the right when the steering angle of the...

Page 48: ...ion 1 Lift the spiral spring and install the brushes 2 Install the brushes connection screws 3 Install the protection covers Areas to blow air through Cover Spring 10 mm mini Brush 5 16 Steering brack...

Page 49: ...information CAUTION 5 18 Lifting chains adjustment The lifting chains of a same stage must have an identical tension Thechainsmust alwaysbetensionedsothat themast sections are slightly offset towards...

Page 50: ...sely between the plates to enable the lubricant to reach the joint and between the internal platesand the rollers lubricant type refer to 8 1 s Temperature C Recommended viscosity grades ISO VG 15 T 0...

Page 51: ...s 6 4 2Fusesonboard 6 4 4 Powercircuitfuses 6 5Devicesmodifyingthemachine sperformance 6 5 1Mastswitch 6 5 2 5 m mast switch 6 5 3 Steeringlimitswitch 6 5 4 Drive limitswitch 6 5 5Safetyfeatures Movem...

Page 52: ...m sounds Everyfunctionisdisabledfrom theground controls 5 Applyaslight tractionforceF2on theplatform The acoustic alarm stops Setting 1 Place a 200 kg load evenly distributed on the platformfloor 2 Lo...

Page 53: ...rm sounds when the chassis is tilted at 2 ThecorrespondingLEDalarmlightsupon platformcontrols 7 Placeaspiritlevel digitaldisplay acrossthe chassis from 8 With a jack of appropriate capacity lift the r...

Page 54: ...es Trying to increase the battery capacity by exceeding the 80 discharge threshhold will lead to 1 malfunctions of the electrical system due to lack of energy 2 damage to the batteries at short or med...

Page 55: ...LE OF OPERATION These componants present a variable resistance depending on the current This resistance is almost null for a current equal to the value noted on the componant value also notified on th...

Page 56: ...1010 Model R vision 04 2006 ELECTRICAL CONTROLS DEVICE 6 6 LOCATION Electronic card a Main board 1 Platform control box 2 Emergency control box Refer to the electrical schematic to locate the protect...

Page 57: ...E REARWARD F2 MAR DUMP valve F3 DV HI LO F4 HI LO BRAKE F5 EVF MAST F7 DM JIB LOWERING F6 DB Types F1 F2 F3 F5 F6 F7 Quick fuse ATO 1 A F4 Quick fuse ATO 2 A F1 F2 F3 F4 F5 F6 F7 6 4 4 Fuses of the po...

Page 58: ...22 Elements in italic Depending of the position of the drive speed selector 6 5 2 5m mast switch Situation Mast n 3 Right side Top of the mast Detection Platform height over 5m Actions Cancellation of...

Page 59: ...nd chain slack continuous detection Overload static detection NOTE The safety features operate the same way on the various control box for available movements Prohibited movement R Slower movement 3 M...

Page 60: ...on the screen Press on the arrow to display the operating hours Press on the arrow to display 1000 s of operating hours To battery To battery To power unit motor Insulatedfrom and battery Diagnostic...

Page 61: ...e motor enables the determination of the current limit value to which the controller must be set when themachine isdrivenon a ramp TEMP C Themeasureofthetemperatureenablestheanalysisof the controller...

Page 62: ...ocated near the calibrator socket At connection the LED must light up and stay lit If thegreenLEDisoff The controller is out of order The controller circuit is faulty Controller supply fault fuses fau...

Page 63: ...orm control panel marking Componant or function Input State Output LK1 Relay K1 LK2 Relay K2 P Dead man pedal trigger MM Mast elevation DM Mast lowering MB Jib elevation DB Jib lowering OD Structure s...

Page 64: ...y K8 LK9 Relay K9 LK10 Relay K10 LK11 Relay K11 LK12 Relay K12 MM1 Mast elevation DM1 Mast lowering MB1 Jib elevation DB1 Jib lowering OD1 Structure slewing Right OG1 Structure slewing Left MM Mast el...

Page 65: ...RICAL CONTROLS DEVICE 6 6 LOCATION Controls verification module Led 1 Movement authorization Led 2 Drivemovements Led 3 Inverse of Led 2 Led 4 Structure movement Led 5 Pump Inhibit Led 6 platform incl...

Page 66: ...R Chain Slack R R Norm Overload R R Tilt R Chain Slack R Norm Overload R R Tilt R Chain Slack R R Norm Overload R R Tilt R Chain Slack R R Steering Right Left R Mast UP R Tilt Over Steering R Over Ste...

Page 67: ...R 3 5 3 5 0 R R R R R R R R R R 1 3 0 R R R R R R R R R R R R R R R R R R R R R R R 1 95 0 R Outputs MM DM MB DB OD OG MAv MAr DD DG EVF EVC LO DLCK DV R R R R R R R R R R R R R R R R R R R R R R R R...

Page 68: ...ol of a structure drive platform levelling movement Authorization of restarting a drive movement without having to return the joystick to neutral once the enable pedal has been released at the conditi...

Page 69: ...ler actuated see 4 5 and orange indicator on Led LD5 lights up indicates the state of the output E8 Detection of discharge indicator power cut When the power is cut out by the discharge indicator the...

Page 70: ...g in the opposite direction as described in the start sequence The delay for the platform to restart in the opposite direction can be adjusted using the potentiometer P3 During this delay the hydrauli...

Page 71: ...ut Acceleratiorn order Analogic entry E11 12 Supply to coil HI LO E12 8 Input Differential lock control E13 36 Supply Speed 1 controller acceleration order at 100 E14 3 Input fast drive speed control...

Page 72: ...TROLS DEVICE 6 6 Progressive start stop sequence mini STARTING SEQUENCE PROGRESSIVE STOPS E8 or E9 2 t 4s 2 4 x t 4s 1 t 2s 2 Fixed value approx 30 signal Accelerator incline Joystick 0 40 E3 or E4 E1...

Page 73: ...2006 Toucan 1010 ELECTRICAL CONTROLS DEVICE 6 6 Starting sequence Sudden stop t 2s 2 4 x t 4s 1 signal 0 Joystick Incline 30 0 E15 Accelerator 100 E11 E19 and E20 E17 1 t 2s E13 t 1s 1 mini E3 or E4...

Page 74: ...6 ELECTRICAL CONTROLS DEVICE 6 6 Starting sequence sudden reversal of drive direction signal Incline Joystick Accelerator 0 30 0 100 E11 E19 and E20 1 t 1s E15 E17 E13 4 x t 4s 1 t 2s E4 E3 E8 E9 30 m...

Page 75: ...nearing 100 on the calibrator see 4 5 0 75 V Voltage 1 10 V Voltage threshold for the automatic switch to 3rd gear after temporisation t1 is over A 0 75 V voltage corresponds to a signal near 80 on t...

Page 76: ...he acceleration signal value goes under 40 and before the movement stops If the movement stops before the platform switches to gear the machine stops s and cannot start again turn slightly the potenti...

Page 77: ...or installation procedure Cable preparation Strip the cable outer sheath over the length indicated in the table below Strip each wire insulation over 5 mm Contact crimping Place the bare wire on the t...

Page 78: ...l is hard or impossible to push in check the contacts are correctly inserted in their housing with rounded pliers screw in the rear part of the connector while holding the red terminal block in place...

Page 79: ...1Dailypreventivemaintenanceandinspection 7 2 2Weeklypreventivemaintenanceandinspection 7 2 3Monthlypreventivemaintenanceandinspection 7 2 4Every125hoursofoperationpreventivemaintenanceandinspection 7...

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Page 81: ...n as outlined in section 8 Thecontrol andmaintenanceproceduresdescribedin this chapter require specific competences We recommendthat theseoperationsareperformedonly byauthorisedandqualifed personnel I...

Page 82: ...2 2 Weekly preventive maintenance and inspection Weekly preventive maintenance inspections should include verification of the following items Wheels nuts Hydraulic hoses and fittings Battery electroly...

Page 83: ...ar Telescopic mast alignment bronze spacers on roller pins Relief valve settings Lubrication NOTE The work platform must be controlled by a notified body according to the regulation in force NOTE Fire...

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Page 85: ...85 Models Edition 04 2006 Toucan 1010 LUBRICATION 8 8 1 Lubrication points TABLE OF CONTENTS...

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Page 87: ...ems not equipped with grease fittings such as linkages pins levers etc should be lubricated with oil once a week Motor oil applied sparingly will provide the necessary lubrication and help prevent the...

Page 88: ...te 5 Main hydraulic reservoir MOBIL DTE 13M Viscosity 32 cSt at 40 C Viscosity index 155 Pour point 48 C Check daily Drain after 1000 hours of operation or at least every 2 years 21 5 l Fill through t...

Page 89: ...89 Models Edition 04 2006 Toucan 1010 NOTES...