JLG TOUCAN 1010 Bedienungsanleitung

Updated:04-2006 MA0235-02

English-Service

MODELS

TOUCAN1010

U.S.A.

JLGINDUSTRIES,INC

1JLGDrive

McConnellsburg

PA17233-9533

Tel:(171)485-5161

Fax :(717)485-6417

C.E.

JLGManufacturingEurope

Breitwaterstraat12A

OudeBunders1034

B-3630 Maasmechelen

Tel:+32(0)89 774974

Fax :+32(0)89 777 427

FRANCE

JLGFrance SAS

Z.I.deFauillet

BP20 -47400 TONNEINS

France

Tel:+33 553 84 85 11

Fax :+33 553 79 06 87

Models

Edition 04-2006 Toucan1010

MA0235-02

Models

Toucan1010 _____

Toucan1010 I_____

4Toucan1010 Model

Révision 04-2006

INTRODUCTION 1

Foreword

Importantinformation

WORK PLATFORMCHARACTERISTICS 2

Description-------------------------------------------------------------------------------2.1

Characteristics- Dimensions- Performances---------------------------------2.2

PRESSURESETTINGS 3

Reliefvalve setting--------------------------------------------------------------------3.1

Brake releasecircuitpressurecheck--------------------------------------------3.2

Circuitreliefvalve adjustment-----------------------------------------------------3.3

Mainpressure(PR1)-----------------------------------------------------------------3.3.1

Rightswing (PR2)--------------------------------------------------------------------3.3.2

Left swing (PR3)----------------------------------------------------------------------3.3.3

Mastelevation (PR4)----------------------------------------------------------------3.3.4

Jibelevation (PR5)-------------------------------------------------------------------3.3.5

Jiblowering (PR6)--------------------------------------------------------------------3.3.6

Brake releasemaximum pressure(PR7)--------------------------------------3.3.7

Drive atlowspeed(PR8)----------------------------------------------------------3.3.8

Counterbalance valve setting------------------------------------------------------3.4

BATTERY-CHARGER 4

Battery------------------------------------------------------------------------------------4.1

Charger-----------------------------------------------------------------------------------4.2

Fulmencharger-----------------------------------------------------------------------4.2.1

Oldham-Hawkercharger-----------------------------------------------------------4.2.2

Westinghouse-SGTEcharger-----------------------------------------------------4.2.3

Batteryfilling----------------------------------------------------------------------------4.3

Electrolytespecificgravityand batteryvoltage------------------------------4.4

Centralisedfilling systemmaintenance-----------------------------------------4.5

Cleaning - Batterymaintenance---------------------------------------------------4.6

Storageofabatteryat temperaturebelow0°C(32°F)-------------------4.7

Useofabatteryinacoldchamber orinacoldclimate-------------------4.8

Batterynotworking continuouslyorinactive battery----------------------4.9

Batterytroubleshooting-------------------------------------------------------------4.10

TABLEOF CONTENTS

Models

Edition 04-2006 Toucan1010

TABLEOF CONTENTS

MAINTENANCE 5

Systemmalfunctions-----------------------------------------------------------------5.1

Cleanliness-------------------------------------------------------------------------------5.2

Removaland installation-------------------------------------------------------------5.3

Disassemblyand assembly---------------------------------------------------------5.4

Partsreplacement---------------------------------------------------------------------5.5

Wiresand cables-----------------------------------------------------------------------5.6

Gaskets-----------------------------------------------------------------------------------5.7

Careand installation ofteflon-coatedbushings-------------------------------5.8

Bushings--------------------------------------------------------------------------------5.8.1

Pin----------------------------------------------------------------------------------------5.8.2

Bushingsand pin---------------------------------------------------------------------5.8.3

Bushing installation------------------------------------------------------------------5.8.4

Mastrollerremoval-------------------------------------------------------------------5.9

Upperrollers---------------------------------------------------------------------------5.9.1

Lowerrollers--------------------------------------------------------------------------5.9.2

Rollers-----------------------------------------------------------------------------------5.9.3

Hydraulicsystem--------------------------------------------------------------------5.10

Fatigueof weldedstructures-----------------------------------------------------5.11

LOCTITE®-------------------------------------------------------------------------------5.12

Fastenersand torquevalues------------------------------------------------------5.13

Steering switches--------------------------------------------------------------------5.14

Mainhydraulicpowerunit--------------------------------------------------------5.15

Steering bracketthrust washers------------------------------------------------5.16

Mast section alignment------------------------------------------------------------5.17

Lifting chainsadjustment----------------------------------------------------------5.18

Chaincontroland lubrication-----------------------------------------------------5.19

Controlofchainwear-------------------------------------------------------------5.19.1

Chainlubrication-------------------------------------------------------------------5.19.2

6Toucan1010 Model

Révision 04-2006

TABLEOF CONTENTS

ELECTRICALCONTROLSDEVICE 6

Overloaddetection setting----------------------------------------------------------6.1

Tiltalarm---------------------------------------------------------------------------------6.2

Batterydischargeindicator setting-----------------------------------------------6.3

Circuitsprotection---------------------------------------------------------------------6.4

Façadecircuit-breaker-------------------------------------------------------------6.4.1

Resetablefuses-----------------------------------------------------------------------6.4.2

Fuseson board------------------------------------------------------------------------6.4.3

Powercircuit fuses------------------------------------------------------------------6.4.4

Devicesmodifying themachine'sperformance------------------------------6.5

Mastswitch---------------------------------------------------------------------------6.5.1

"5m"mastswitch------------------------------------------------------------------6.5.2

Steering limit switch----------------------------------------------------------------6.5.3

Drive limitswitch--------------------------------------------------------------------6.5.4

Safetyfeatures- Movementcutout-------------------------------------------6.5.5

Speedelectroniccontroller---------------------------------------------------------6.6

Helpwiththediagnosis--------------------------------------------------------------6.7

Electronicmodules--------------------------------------------------------------------6.8

Controls verification module------------------------------------------------------6.8.1

Drive managementmodule---------------------------------------------------------6.9

"Clipper"connectorinstallation procedure-----------------------------------6.10

PREVENTIVE AND MAINTENANCEINSPECTION 7

General------------------------------------------------------------------------------------7.1

Preventive maintenance and inspection required----------------------------7.2

Dailypreventive maintenance and inspection-------------------------------7.2.1

Weeklypreventive maintenance and inspection---------------------------7.2.2

Monthlypreventive maintenance and inspection--------------------------7.2.3

Every125 hoursofoperation preventive maintenance and inspection-7.2.4

Every250 hoursofoperation preventive maintenance and inspection-7.2.5

Every500 hoursofoperation preventive maintenance and inspection-7.2.6

LUBRICATION 8

Lubrication points----------------------------------------------------------------------8.1

Models

Edition 04-2006 Toucan1010

Foreword

Importantinformation

TABLEOF CONTENTS

INTRODUCTION

8Toucan1010 Model

Révision 04-2006

FOREWORD

Thismanualhasbeen compiled toassistyou in

properlyoperating and maintaining yourJLG Aerial

WorkPlatform.

The Work Platformhasbeen designed formaximum

performancewithminimummaintenance.Withproper

care,yearsoftrouble-free servicecan be expected.

Constantimprovementand engineering progress make

itnecessary thatwereservethe righttomake

specification and equipmentchangeswithoutnotice.

The definitionsofDANGER,CAUTIONand NOTEas

used inthismanualapplyasfollows:

ADANGERisusedtoemphasizethatifan

operation, procedure orpractice isnot

followedexactly, deathorseriousinjuryto

personnelmayresult.

ACAUTIONisusedtoemphasizethatifan

operation, procedure,orpracticeisnot

followedexactly,equipmentdamagemay

result.

NOTE

ANOTEisusedtoemphasizeanimportant

procedure orcondition.

GENERALWARNING

Itismandatory thatall hydraulichosesand

fittingsarecorrectlytaggedand identifiedbefore

theyaredisconnectedtoeffectrepairsorservice.

Failuretocorrectlytagand identifyhoses and

fittingscancausewrong reconnection,whichcan

resultin deathorseriousinjury topersonnel.

!CAUTION

DANGER

Models

Edition 04-2006 Toucan1010

The followingformisforthe useofthe Distributor,Customer,Mechanic,and allotherperson who usethismanual

and recognizebeneficialwaystoimproveitspurposeasaworthyreference.SMCAR's aretobe madeinregards

to,butnotlimitedto:Safety,Operation Correctness,andTechnicalContent.AllSMCAR'swillbereviewed by

the responsibleDepartmentatJLG.Approved SMCAR'swillbe distributed inaServiceBulletinimmediatelyand

then incorporated inthenextscheduledchangetothemanual.AnanswertotheSMCAR,approvedor

disapproved,willbe sentdirectlytotheone submitting theSMCAR.

Date______________________________

Customername_____________________

Name/firstname_____________________

Address___________________________

__________________________________

Telephone__________________________

ServiceManual

Affected__________________________________________________________________________

Page(s)Affected____________________________________________________________________

ReasonforsubmittingSMCAR(Useadditional paperorbackifnecessary)

__________________________________________________________________

__________________________________

Signature(optional)

Adress SMCAR'sto:

Supervisor,Publications

JLGFrance

Z.I. deFauillet,

B.P.20

47400Tonneins,France

CORRECTIVE ACTIONREQUEST

10 Toucan1010 Model

Révision 04-2006

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CORRECTIVE ACTIONREQUEST

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