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TOUCAN DUO
JLG TOUCAN DUO Service Manual
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Updated : 06-2015
MA0323-05
English - Service Manual
MODELS
MODELS
MODELS
MODELS
MODELS
TOUCAN DUO
TOUCAN DUO
TOUCAN DUO
TOUCAN DUO
TOUCAN DUO
U.S.A.
JLG Industries, Inc.
1 JLG Drive
McConnellsburg
P
A 1
7233-9533
T
el : (1
7
1) 485-5
161
F
ax : (7
1
7) 485-6
41
7
C.E.
JLG Manufacturing Europe
Breitwaterstraat 12A
Oude Bunders 1034
B - 3630 Maasmechelen
T
el : +32(0)89 7
7
4 9
7
4
Fax : +32(0)89 777 427
FRANCE
JLG France SAS
Z.I. de Fauillet
BP 20 - 4
7
400 TONNEINS
France
T
el : +33 553 84 85 1
1
Fax : +33 553 79 06 87
C.E.
JLG Industries,
Kilmartin Place,
T
annochside Par
k
Uddingston, Scotland G71 5PH
T
el : +4
4(0)1
698 8
11
005
Fax : +44(0)1698 811055
2
Table of Contents
Default Chapter
5
Table of Contents
5
Introduction
9
Foreword
10
Work Platform Characteristics
15
General Description
17
Characteristics - Dimensions - Performances
18
General
19
General Procedure
20
Cleanliness
21
Handling
21
Welding from the Work Platform
21
Assembly - Disassembly
21
Bushing Installation
22
Bearings
22
Locks
22
Loctite
22
Fasteners and Torque Values
23
Torque Values Tables
24
Hydraulic System
25
Lubricants
25
Gasket
25
Electrical Wires and Cables
25
Charger
26
Battery Discharge Indicator
27
Standard Machine
27
Machine with Battery Cut out Option + Hourmeter
27
Electronic Controller
28
Drive Motors
29
Electrical Cylinder
29
Fuses
30
Power Circuit Fuses
30
Control Circuit Fuses
30
Hydraulic Power Unit
30
General Maintenance
30
Troubleshooting
32
Adjustments
37
Chain Attachments Inspection
37
Lifting Chains Tension Adjustment
38
Tension Adjustment of the Shelf Lifting Cables
38
Shelf Alignment Setting
39
Pressure Relief Valves Adjustment
40
Mast Power Unit Pressure Relief Valve
40
Mast Cylinder Pressure Relief Valve
41
Shelf Power Unit Pressure Relief Valve
41
Pressure Switch Adjustment on Shelf Cylinder
42
Control-Wheel Motor Brake Adjustment
43
Mast Cylinder Bleeding
44
Steering Sensors Setting
45
Setting of the Sensor Located above the Right Hand Side Wheel
45
Setting of the Sensor Located above the Left Hand Side Wheel
45
Gate Sensors Setting
46
Shelf Sensor Setting
46
Battery Discharge Indicator Setting (Option)
47
Schematics
49
Electrical Schematics
52
Standard Machine
52
Hydraulic Schematic
61
Removal - Installation Procedures
63
Introduction
64
Platform and Shelf
65
Shelf Removal - Installation
66
Shelf Pre-Installation
67
Platform Removal - Installation
68
Mast on Chassis
69
Telescopic Mast
70
Mast Cylinder Removal
70
Mast Cylinder Installation
70
Slide Blocks Removal
70
Slide Blocks Installation
71
Lifting Chains Removal
72
Lifting Chains Installation
73
Chassis
75
Removal - Installation of the Driving Wheels (Rear Wheels)
75
Removal - Installation of the Steering Wheels (Front Wheels)
75
Removal - Installation of the Motor Reducer + Flange Assembly
76
Removal - Installation of the Motor Reducers
76
Removal - Installation of the Wheel Motor Brakes
77
Removal - Installation of the Reducer on the Wheel Motor Reducer
78
Removal - Installation of the Speed Controller
79
Eco Smart Display
85
General Description
87
Screen Operation
87
Connection
88
Menus Displays
89
Display
89
Slave Controller
90
Master Controller
93
Calibration of the Stering Cylinder Potentiometer
97
Main Parameters
98
Alarms and Warnings
101
General
101
Alarms
102
Warnings
105
4
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JLG TOUCAN DUO Specifications
General
Platform Capacity
200 kg
Weight
1350 kg
Drive Speed
4.5 km/h
Turning Radius
1.80 m (Inside) / 2.95 m (Outside)
Power Source
24 V DC
Platform Height
4.10 m
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