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JLG TOUCAN DUO Service Manual

JLG TOUCAN DUO
108 pages
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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 : (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
JLG France SAS
Z.I. de Fauillet
BP 20 - 47400 TONNEINS
France
Tel : +33 553 84 85 11
Fax : +33 553 79 06 87
C.E.
JLG Industries,
Kilmartin Place,
Tannochside Park
Uddingston, Scotland G71 5PH
Tel : +44(0)1698 811005
Fax : +44(0)1698 811055

Table of Contents

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JLG TOUCAN DUO Specifications

General IconGeneral
Platform Capacity200 kg
Weight1350 kg
Drive Speed4.5 km/h
Turning Radius1.80 m (Inside) / 2.95 m (Outside)
Power Source24 V DC
Platform Height4.10 m

Summary

Introduction

Foreword

Introduction to the service manual, its purpose and scope.

Introduction to Maintenance

General guidelines and precautions before performing maintenance.

Work Platform Characteristics

General Description of the Work Platform

Overview of the work platform's main components and their functions.

Specifications and Performance

Detailed specifications including dimensions, capacity, and performance metrics.

General Procedures and Maintenance

General Repair Procedure

Step-by-step process for performing repairs and maintenance.

Cleanliness Guidelines

Importance of cleanliness for machine longevity and maintenance.

Handling and Assembly

Guidelines for safe handling, assembly, and disassembly of components.

Fasteners and Torque Values

Importance of correct fasteners and applying specified torque values.

Torque Value Tables

Tables listing torque values for various fasteners and fittings.

Hydraulic System and Lubricants

Safety, maintenance for hydraulic system, and recommended lubricants.

Electrical Components and Charger

Handling electrical wires, cables, and information on the battery charger.

Battery Discharge Indicator

Explanation of the battery discharge indicator lights and settings.

Electronic Controllers and Drive Motors

Description of controllers, drive motors, and electrical cylinders.

Hydraulic Power Unit Troubleshooting

Description of the hydraulic power unit and troubleshooting guide.

Adjustments and Settings

Chain Attachment Inspection

Procedure for inspecting lifting chains and attachments.

Lifting Chain Tension Adjustment

How to adjust the tension of the mast lifting chains.

Shelf Lifting Cable Tension

Procedure for adjusting shelf lifting cable tension.

Shelf Alignment Setting

Steps to align the shelf and adjust transversal play.

Pressure Relief Valve Adjustments

General and specific procedures for adjusting pressure relief valves.

Pressure Switch and Tilt Indicator Settings

Adjusting the pressure switch and setting the tilt indicator.

Mast Cylinder Bleeding

Procedure for bleeding the mast cylinder.

Steering Sensor Calibration

Procedures for setting steering sensors on both sides.

Gate and Shelf Sensor Settings

How to set gate and shelf sensors for proper operation.

Battery Discharge Indicator Setting

How to set the battery discharge indicator and potentiometer.

Schematics and Diagrams

Electrical Schematics

Functional diagram and wiring details for electrical systems.

Hydraulic Schematic

Diagram illustrating the hydraulic system components and flow.

Removal and Installation Procedures

Platform and Shelf Procedures

Diagram and procedures for platform and shelf removal/installation.

Mast Assembly Removal and Installation

Steps for removing and installing the mast assembly from the chassis.

Telescopic Mast Cylinder Procedures

Procedures for removing, installing, and disassembling the mast cylinder.

Slide Block Procedures

How to remove and install slide blocks on mast sections.

Lifting Chain Procedures

Detailed steps for removing and installing lifting chains.

Chassis Component Procedures

Removal and installation of wheels, motor reducers, and brakes.

Speed Controller Removal and Installation

Procedure for removing and installing the speed controller.

Mast Cylinder Disassembly and Assembly

Steps to disassemble, inspect, and assemble the mast cylinder.

Hydraulic Manifold Procedures

Steps for removing and installing the hydraulic manifold.

Mast Power Unit Procedures

Procedures for removal, disassembly, assembly, and installation of the mast power unit.

Eco Smart Display

General Description and Screen Operation

Introduction to the Eco Smart Display, its indicators, and screen functions.

Display Connection and Menu Structure

Connector pinout and overview of the display menu structure.

Controller Menu Options

Detailed menu options for slave and master controllers.

Steering Cylinder Potentiometer Calibration

Procedure to calibrate the steering cylinder potentiometer.

Main Operational Parameters

Table of main operational parameters and their values.

Alarms and Warnings

General Alarm and Warning Recording

How alarms and warnings are recorded in the logbook.

System Alarms and Warnings

Distinction between system alarms (stop operation) and warnings (impair performance).

List of System Alarms

List of system alarms, error codes, descriptions, and checks.

List of System Warnings

List of system warnings, error codes, descriptions, and checks.

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