Page 1 MODELS TOUCAN 1210 TOUCAN 1310 U.S.A. C.E. C.E. FRANCE JLG Industries, Inc. JLG Industries, JLG Manufacturing Europe JLG France SAS 1 JLG Drive Kilmartin Place, Breitwaterstraat 12A Z.I. de Fauillet McConnellsburg Tannochside Park Oude Bunders 1034 BP 20 - 47400 TONNEINS...
Page 3 Models English MACHINE SERIAL NUMBER : _____ Toucan 1210 _____ Toucan 1310 MA0295-04 Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 4: Table Of Contents
Right steering [PR13] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.13 Toucan 1210...
Page 5 High frequency charger "Zivan NG3" - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5.2.1 Electronic charger "Oldham-Hawker CP IV" - - - - - - - - - - - - - - - - - - - - - - - - 5.2.2 Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 6 Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.12 Toucan 1210...
Page 7 JLG aerial work platform. Constant improvement and engineering progress make it necessary that JLG reserve the right to make specification and equipment changes without notice. The definitions of DANGER, CAUTION and NOTE as used in this manual apply as follows :...
Page 8 NOTICE TO OWNER/USER Should this work platform become involved in a accident, please contact your local JLG distributor immediately and relate details of the incident so he can notify JLG. If the distributor is unknown and/or cannot be reached, please contact : USA : C.E :...
Page 9 Reason for submitting SMCAR (Use additional paper or back if necessary) __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________ Signature (optional) Adress SMCAR's to : Supervisor, Publications JLG France SAS Z.I. de Fauillet, B.P. 20 47400 Tonneins, France Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 10 CORRECTIVE ACTION REQUEST This page intentionally left blank. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 11: Work Platform Characteristics
(ground controls), on the left hand side of the telescopic mast. The energy for the control and power circuits of the mobile elevating work platform is supplied by a 24VDC battery. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 12 Hand pump Manual box Release valve Breakdown control panel VIEW LEFT FRONT REAR Telescopic mast Charger Telescopic jib Emergency control panel Work Counterweight platform Circuit breaker Access to side batteries Steering wheels Driving wheels Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 13: Characteristics - Dimensions - Performances
Speeds are indicated for a machine with a battery fully charged and operated at ambiant temperature of 20°C. Constant improvement makes it necessary that JLG France SAS reserve the right to make specification and equipment changes without notice.
Page 14 This page intentionally left blank. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 15: Hydraulic System
Do not interchange the pumps from the main and auxilliary power units. Body length of the 5,2 cc/t pump on main power unit : L = 55 mm. Body length of the 3,5 cc/t pump on auxilliary power unit : L = 50 mm. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 16 3- Extract the pump body ensuring both pinions and bearings do not get damaged (beware the two seals on the upper bearing). Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 17 If erosion on the suction side of the pump is evident on the gear tracks, the cause is either air bubbles in the oil or a restricted suction. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 18 6- Clean t he pump components with an appropriate solvent and dry with compressed air. Replace the seals. If components are damaged, replace the pump. CAUTION Avoid scratching the grooves and gland surfaces. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 19: Hand Pump
- Oil supply to the hydraulic circuit of the work platform when using the breakdown controls : elevation / lowering, telescope extension/retraction, slewing. - Oil supply to the brake pilot circuit (See § 3.13). Hand pump Split pin Seals Suction cartridge Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 20: Hydraulic Filters
Loosen the filter tank very slowly to allo w the oil pressure to d rop progressively. 4- Install a new filter cartridge. 5- Check the presence and condition of the O ring. 6- Install the filter tank. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 21: Function Manifold
PR6 : Pressure relief valve : Jib lowering Setting range of the pressure relief valves [PR2] to [PR6] : 0 to 25 MPa (0 to 250 bar). Setting of pressure relief valves : See § 3.19. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 22 C. Jet Ø 1 mm : Ensures decompression of the pilot circuit UNCTION of the counterbalance valve on the mast cylinder (lowering movement). NOTE The jet is installed with glue : cannot be removed. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 23 Spool valve 4-way, 2-position "Floating center spool" "Floating center spool" Spool valve 4/3 +sleeve Spool valve 4/3 + sleeve Ref. : 952029 Ref. : 952029 Exploded view of a solenoid valve 4-way, 3-position : Face B Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 24 Torque value LOCTITE 245 2- Install the O-rings on the sleeve. 10 to 12 N.m NOTE The thread on the poletube must be free from oil or grease before the glue is applied. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 25 245. Torque the poletube to 5 - 6 N.m using the adapted tooling (Réf. 990005). Play Face B LOCTITE 245 Torque value 5 to 6 N.m 8- Install the coils and O-rings. Torque the coil nylon nuts to 4 to 5 N.m Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 26: Drive Manifold
Top seal screw Pressure reservoir : Enables storage of a volume of oil destined UNCTION to the make up flow for the wheel motors during reversal of the drive direction. Membrane Obturator Port Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 27: Wheel Motor Distribution Manifold
Forward drive 2(b) : Counterbalance valve Reverse drive 3 : Shuttle valve 4(a). 4(b). Make up flow check valves 4(c). Torque value for the 4 bolts securing the solenoid valve [HI/LO] : 9 N.m Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 28 ORWARD DRIVE EVERSE DRIVE [ LO] : Low displacement Ô high speed Torque value : 27 N.m Make up flow check valves Torque value : 34 N.m Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 29: Brake Manifold
(Brake release using the hand pump) PR8 : Pressure relief valve (Torque limiter at slow speed) EVF : Decompression solenoid valve for the brake release circuit. EVC : Solenoid valve enabling the relief valve [PR8] to operate. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 30 NOTE Torque value : 12 to 15 N.m The check valve is kept in position by deformation of the thread : cannot be Setting of the relief valves : See § 3.19. removed. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 31 Solenoid valve [EVC] for operation relief valve [PR8] : When the machine is driven at slow speed UNCTION ), supply to the solenoid is cut off and the pressure relief valve [PR8] comes in. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 32: Differential Locking Manifold
HYDRAULIC SYSTEM 3.9 Differential locking manifold Manifold schematic : Differential locking manifold 1 : By-pass solenoid valve 2(a) : Flow divider / Combiner 3(a) : Make up flow check valves 3(b) : Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 33: Wheel Motors
Make up flow check valve [3 (a)(b)] 1. Commercial description 2. Code = Part number 3. Série = Production batch number 4. Num = Chronological serial number Torque value : 27 N.m maxi Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 34 M S E 0 3- 2- DEA- F 03 - 1 1 2 0 - D H- J0 Code : 0042438-34N Indice Code : 0046438-17C Indice Série : XXX Num : XX Série : XXX Num : XX Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 35 Port "2". CAUTION NOTE Disassembly of the wheel motors requires Do not operate the motors without any load specific competences and tooling. Contact and at maximum speed. JLG Product Support. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 36 Excessive leaks valve assembly : Contact JLG Product Support. Too high housing pressure Check the drain circuit Damaged seals Replace the seals : Contact JLG Product Support. EXTERNAL OIL LEAKS Tightening of motor mounting screws, of bleeding screws and Incorrect assembly hydraulic fittings.
Page 37: Steering Manifold
Steering to the right. 3 : Pressure relief valve [PR 13] : Steering to the left. DG : Steer LEFT DD : Steer RIGHT 4a : Shuttle valve 4b : 5 : Jet Ø 1 mm Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 38 Setting of the pressure relief valves : See § 3.19. Torque value : 25 to 30 N.m Shuttle valve : Directs oil from the highest pressure circuit UNCTION to the steering cylinder supply circuit. Torque value : 15 to 18 N.m Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 39: Check Valves Manifold ("Power Plus" Option)
: Prevents the return of the oil flow supplied by the main hydraulic power unit through the pump of the UNCTION auxilliary power unit. Check valve(1b) : Prevents the return of the oil flow supplied by the auxilliary hydraulic power unit through the pump of UNCTION the main power unit. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 40: Release Control Valve
NO [2] direction COM [3] NC [1] Spool assembly direction 1- Rear cover attachment screw 2- Front cover attachment screw 3- Spool 4- Index 5- Spacer 6- Rear cover 7- Front cover 8- O-ring Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 41: Trim Correction Manifold
Pressure relief valve [PR1] : Protects the trim circuit against excessive UNCTION pressure during the jib elevation movement. Torque value : 25 to 30 N.m Setting of the pressure relief valve : see § 3.19. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 42: 7-Way, 3 Position Flow Diverter
Use a screwdriver of appropriate dimensio n to prevent d amag e to the regulator recess. Diverter 7-way, 2-position 7-way, 2-position flow diverter Jet Ø 0.6 mm on port B2 Jet Ø 1.0 mm on port A2 Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 43: Jib Cylinder
The locknut must be tight to prevent any external leak. Regulated flow CAUTION Respect the assembly direction of the flow regulator. Use a screwdriver of appropriate dimensio n to prevent d amag e to the regulator recess. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 44: Telescope Cylinder
- Fully raise the jib. Extend the telescope by approximately 50 cm. - Slowly loosen the valve setting screw until the telescope starts to retract, then tighten the screw by a turn ½. Tighten the locknut. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 45: Assistance Cylinder - Master Cylinder - Slave Cylinder
Use a screwdriver of appropriate dimensio n to prevent d amag e to the regulator recess. Couple de serrage : 45 N.m. Pilot ratio : 2,5:1 NOTE The locknut must be tightened to prevent any external leak. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 46: Rotation Cylinder (Optional)
- With one person only in the platform, perform a trim correction movement towards the rear. - The platform must recline to the rear and the jib not rise. Otherwise, loosen the setting screw turn. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 47: Sequence Valve
- Position the speed adjustment potentiometer on minimum and lower the jib. The jib should start to lower only when a pressure of 12 ± 0,5 MPa (120 ± 5 bar) is reached. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 48: Pressure Relief Valves
Function manifold Trim correction 18 Mpa (180 bar) PR11 Trim correction manifold Steering to the right 14 Mpa (140 bar) PR12 Function manifold Steering to the left 14 Mpa (140 bar) PR13 Function manifold Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 49: Brake Release Circuit Pressure Check
"M" on the FUNCTION MANIFOLD. maximum pressure is higher than 21 bar, 2- RAISE THE MAST until the mast cylinder is at consult your local JLG distributor. the end of its course. Adjust the pressure relief 5- Disconnect the pressure gauge.
Page 50: Brake Release Maximum Pressure [Pr7]
CAUTION 3.19.2.10 Slewing to the right [PR10] If the pressure is below 15 bar or higher than 21 bar, consult your JLG distributor. 1- Connect the pressure gauge to the pressure plug "M" on the FUNCTION MANIFOLD. 7- LOOSEN the setting screw on the pressure 2- SLEW fully the structure to the RIGHT.
Page 51: Trim Correction [Pr11]
7- Disconnect the direct supply from the coil and reconnect the connector to the solenoid. 8- Adjust the relief valve [PR5] : see § 3.19.2.5. 9- Disconnect the pressure gauge. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 52 This page intentionally left blank. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 53: Wiring Diagrams
ELECTRICAL SYSTEM 4.1 Wiring diagrams 4.1.1. Battery wiring Battery plug Right Side battery pack FU LMEN Front battery pack Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 54: Power Circuit Wiring
ELECTRICAL SYSTEM 4.1.2 Power circuit wiring PC0338 Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 55: Components Location
ELECTRICAL SYSTEM 4.1.3 Components location Linked to the platform control box Toucan 1210 and Toucan 1310 Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 56 ELECTRICAL SYSTEM Linked to the emergency control panel Toucan 1210 Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 57 ELECTRICAL SYSTEM Linked to the emergency control panel Toucan 1310 HF Charger Chargeur HF LF Charger Chargeur BF Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 58 ELECTRICAL SYSTEM Linked to the chassis box Toucan 1210 Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 59 ELECTRICAL SYSTEM Linked to the chassis box Toucan 1310 Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 60: Sensors
(See § 4.2.6). - The automatic switch to slow drive speed (parameter "Test 3" on controller =CL when a drive movement is controlled - see § 4.5). Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 61: Jib Higher Position Switch [Sw3]
- Actuation of the "Pump Inhibit" function of released. the controller when a non authorized movement is controlled (parameter "Test 10 of the controller = CL - see § 4.5). Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 62: Tilt Indicator
ç Stop upon extinction of the indicator: value (c). 9- Using a jack of sufficient capacity, lift the left hand side of the chassis in (4) . ç Stop upon extinction of the indicator: value (d). Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 63: Strain Link (Stability Control Device)
= CL - see § 4.5). NOTE Actuation of this safety feature occurs only when the enable pedal is released. The structure must be retracted until the alarm stops for all the work platform functions to be restored. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 64 1. Read this procedure completely before applying 2. Connect the sensor to the electronic card (machine switched off). 3. Switch the machine on. 4. Place the sensor flat on the steering bar (no stresses) as indicated opposite: Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 65 - Retract the telescope. - Lower the mast. - Lower the jib. 9. Position the machine in t he f ollowing configuration: - Jib horizontal. - Telescope fully extended. - Mast fully raised. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 66 9. Suspend the 100 kg load and wait for the complete stabilisation of the structure. ç the red led [D20] should not light up. ç the alarm should not be triggered. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 67 Should the sensor shift, it is possible to recalibrate the system automatically and to restore the initial work window by determinating a new zero for the sensor: refer to the autocalibration procedure below. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 68 The card errors are indicated by led [D21] flashing: Number of Meaning flashes No error Card error : contact JLG Product Support Card error : contact JLG Product Support J4 connector wiring incorrect J4 connector wiring incorrect Replace the card Meaning of the green led [D3] : card supplied.
Page 69 ELECTRICAL SYSTEM Configuration of the Windows Hyper Terminal ® Start ä Programs ä Accessories ä Communications ä Hyper Terminal NOTE If COM1 corresponds to the computor serial port. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 70 ELECTRICAL SYSTEM Record the configuration once all the parameters are installed. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 71: Steering Sensors (T1310 Only)
When the right wheel reaches a steering angle of 45° to the right, the cam installed on the steering bracket pin actuates the sensor and causes the supply (+) cut to the coil [DD] on the steering manifold. SW40 Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 72: Steering Angle Sensors [Sw41 & 42]
ç relay(s) supplied, corresponding Led lit. Additional relay (k6) : supplied when a non authorized movement is controlled. : cuts the supply to the coil [DV1]. UNCTION Relay k9 : authorizes static detection of the stability control. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 73: Adjustment Of The Battery Discharge Indicator
This cut off threshold can be adjusted with the potentiometer at the back of the indicator, where a K to U scale allows a precise adjustment. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 74: Speed Electronic Controller
- Press on the arrow to display 1000's of lights up opposite the next parameter, the value of this operating hours. parameter is displayed on the screen and can be modified with the buttons. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 75 ELECTRICAL SYSTEM Description and values of parameters for models Toucan 1210 and Toucan 1310. Values Parameter Description Unit Pitch Observations Toucan 1210 / 1310 Mast lowering movement. Make up flow to the wheel motors. Speed 1 Speed n°1 (variable) Platform inclination movements.
Page 76 A 3,5 V voltage on pin 14 of the controller connector not active. corresponds to a 0% input (speed null). A 0 V voltage on pin 14 of the controller connector corresponds to a 100% input (max. speed). Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 77: Circuit Breakers - Fuses
(inside the box). 1- Circuit breaker 3,15A : Protection of the centralized filling pump UNCTION circuit (push to reset). 2- Circuit breaker 0,63A : Protection of the battery discharge indicator UNCTION circuit (push to reset). Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 78: Resetable Fuses (Polyswitch®)
F1, F2, F3, F5, F6, F7 : Quick acting pluggable fuses type ATO 1A. F4 : Quick acting pluggable fuse type ATO 2A. Toucan 1210 Equiped with resetable fuses. See § 4.6.3. 1. PolySwitch® 0,25A : Protection of the supply circuit to the UNCTION controls module.
Page 79 Coil [HI / LO] supply (-) (drive speed circuit) 1.1 A Coil [EVF] supply (-) (brake circuit quick release) 1.1 A Coil [DB] supply (jib lift down circuit) 1.1 A Coil [DM] supply (mast lift down circuit) Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 80 1,1A Coil [MM] (Mast elevation) 1,1A Coil [DB] (Jib lowering) 1,1A Coil [HI/LO] (Gear change) 1,1A Coil [EVC] (Torque limitation) 1,1A Pressure switch 1,1A Tilt indicator 1,85A Coil [DV2] and contactor [KM2] (Option) Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 81: Help With The Diagnostic
Platform rotation - left û Drive - Forward û Drive - Reverse û Steering left û Steering right û Selection Drive speed 1 û Selection Drive speed 2 û Selection Drive speed 3 û Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 82 Steering right û Decompression of braking circuit off û Torque limiter off û Gear change (high speed) û DLCK Differential locking û Hydraulic power units oil return û Auxillary power unit oil return û Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 83 Led 1 : Selection 3 gear Led 2 : Drive movements Led 3 : Led condition of pressure switch Led 4 : Selection 4 gear Led 5 : Led condition of module output Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 84 : W ork position ( out o f travel po sition ) information only (they can vary slightly from : T ele sco pe In ( fully retra cted ) : T ele sco pe Out ( e xtented ) one machine to another). Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 85 - R - ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® { R } R { R } ® ® ® ® Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 86: Electronic Modules
1 2 3 4 5 6 7 8 9 10 11 12 13 Led 4 : Structure movement Led 5 : Pump Inhibit 14 15 16 17 18 19 20 21 22 23 24 25 Led 6 : Platform levelling Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 87 ç Inputs [N5] and [N6] are in the same state - 0 to 4 V if the control has not been authorized- Led [LD1] off. - 24 V if the control has been authorized- Led [LD1] on. ç LED [LD6] lights up. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 88: Speed Control Module For The Jib (Dongle)
- Reduction of the maximum speed if the potentiometer is on maximum. During a jib lowering movement from its higher position, the release of the switch [SW3] restore the movement normal speed. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 89: Time Delay Module
The delay for the platform to restart in the opposite direction can be adjusted using the potentiometer (P3). During this delay, the hydraulic power unit turns at low speed, supplying the make up flow to the wheel motors. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 90 Forced supply to overload relay Not used Input auxiliary sensor for authorization of simultaneous lowering Connected to 0V Input Jib lowering control Input Mast lowering control Supply to coil [DB] Supply to coil [DM] Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 91 : Following typical values of the analogical input [E10] can be measured between battery negative terminal and pin #14 of the motor speed controller connector (connector must still plugged to the controller socket). Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 92 = 1s t = 2s mini [E13] [E8] or [E9] [E15] [E19] and [E20] 2 t = 4s [E17] 4 x t = 4s t = 2s [E11] 100% Fixed value approx.30% 30° 0° Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 93 = 1s t = 2s mini [E13] [E8] or [E9] [E15] [E19] and [E20] 2 x t = 4s [E17] t = 2s 4 x t = 4s [E11] 100% 30° 0° Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 94 = 1s t = 2s mini [E13] [E8] t =1s [E9] [E15] [E19] and [E20] [E17] 4 x t = 4s 4 x t = 4s [E11] 100% 30° 0° Neutral zone -30° Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 95 Potentiometer P3 : Temporisation for make up flow and braking [t2] NOTE A small jerk occurs when the machine switches from ( ) gear to ( ) gear or from ( ) gear to ( ) gear. . Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 96 P2 setting screw (by a 1/32 turn) anti clockwise. - If the platform switches to ( ) gear with an acceleration signal value too high (important jerk), turn slightly the potentiometer P2 setting screw (by a 1/32 turn) clockwise. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 97: Power Plus" Module (Option)
Coil [HI / LO] supply detection Input Pressure switch (+) Input 4th gear selection (+) Input acceleration order Analogic entry Contactor [KM2] - Coil [DV2] supply — — Not used Drive movement detection Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 98 The voltage on input [X5] is lower than 450 mV. - When the pressure in the hydraulic circuit is inferior to the pressure switch setting pressure : Input [X4] is supplied. Led [LD3] lights up. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 99 Temporisation Hysteresis 0,3 s 0,7 s 1,0 s 1,3 s 1,6 s 2,0 s 2,3 s 2,6 s 3,0 s 3,3 s 3,7 s 3,9 s 4,2 s 4,6 s – 4,9 s Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 100 - When the potentiometer is turned clockwise : ç the threshold is lowered = voltage increases - W hen the pot enti omet er is turned anticlockwise : ç The threshold is raised = voltage decreases. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 101 - crimp the copper in part A - crimp copper + insulation in part B 2. Crimp with tooling CLIPPER ref. Y16SCM-GL3 or similar Insulation Cores 3. Insert the contacts in their housing Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 102 : locating sprockets should not - check the contacts are correctly inserted in be broken. their housing with rounded pliers. (see below) b r o k e n sprocket Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 103 70% of its capacity. To obtain maximum service life, do not discharge the battery beyond 80% of its capacity. Location of batteries Front pack Side right pack Side left pack Battery wiring : see § 4.1.1. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 104: Battery
DANGER During maintenance or any servicing operation on the battery, rings, watches or any other jewellery must be removed. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 105: Storage At Temperatures Below -20°C (32°F)
Temperature affects battery autonomy : the battery looses 1% of its capacity per Celcius degree below +25°C (temperature of the electrolyte). C° 20°C 10C° 0C° -10C° -20C° -30C° F° 68°F 50°F 32°F 14°F -4°F -22°F % lost Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 106: Troubleshooting
Loss of electrolyte due to overflow. Perform an equalization charge. Stratification of the electrolyte. Contact your JLG Distributor/Product Support. Low voltage in the cells in Electrolyte specific gravity too low. Refer to "electrolyte specific gravity open circuit.
Page 107: Chargers
Prior to any operation requiring charger cover removal, th e charger must be disconnected from the battery and from the AC source. Failure to do so could result in death or serious injury to personnel. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 108 Led indicator 100% Red Led : The charger is in the initial phase (T1 + T2) Yellow Led : The battery 80% charged (T3) Green Led : The battery is 100% charged Start Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 109 Contact JLG Product Support). - Loss of output voltage control (check the battery connections. RED / GREEN Battery voltage Fault of the control logic : Contact JLG Product Support). RED / Overheating of the semi conductors (check the fan's YELLOW / Thermal safety operation).
Page 110: Electronic Charger "Oldham-Hawker Cp Iv
Charge interruption due to a power cut. The charge will be Check power supply. resumed as soon as the power returns. Voltage per cell 140% above the nominal values. Battery already charged. The 4 LEDs flash Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 111: Torque Values
936 1386 1880 12.9 1177 4,57 15,7 875 1095 1622 2200 Torque values for fittings BSPP Metric JIC 7/16 BSPP 1/4 M14x150 JIC 9/16 BSPP 3/8 M18x150 JIC 3/4 BSPP 1/2 JIC 7/8 BSPP 3/4 Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 112: Wheel Nut Torque Values
(Qty : 8) • Locknuts M12 Grade 10-9 (Qty : 8) - First torque all the bolts alternately to 80 N.m - Torque all the bolts alternately to a final torque of 117 N.m Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 113: Service - Maintenance
- Make all adjustments as recommended. - Always check the job after it is completed to ensure that nothing has been overlooked. - Recheck various adjustments by operating the machine before returning it to the job. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 114: Parts Replacement
Dry carefully the platform (compressed air, cloths...) oiled to facilitate assembly. and lubricate the machine as indicated in paragraph Bushing, driver and housing must be correctly aligned 7.12 prior to returning it to service. during assembly. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 115: Steering Bracket Thrust Washers
2- Unscrew the locknut from the roller pin using a polygonal spanner. 3- Unscrew the roller pin to release the bronze spacer as indicated below. Blocks Spacer Roller Locknut Roller pin Roller pin washer Flange bushings Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 116 5 mm Minimum thickness of the bronze spacer The rollers pins are generally delivered fitted. To remove the bronze spacer, screw a locknut on the pin until the roller and the spacer are separated. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 117: Adjustment Of Telescopic Mast Alignment
Torque value : 1000 N.m approximately. CAUTION If during adjustement one of the mast sections jams, stop the lowering movement and raise the mast to retension the chains. Loosen slightly the roller pins of the jammed section. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 118: Verification And Lubrication Of The Lifting Chains
In general, a non detergent mineral oil is sufficient. excessive play. Pins should not have turned Its viscosity must be adapted to the temperature in their housing.(1) : according to the chart below : Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 119 - Transversally : between the plates to enable the lubricant to reach the joint and between the internal plates and rollers (lubricant type see § 7.12). Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 120: Hydraulic Power Unit
- Drain the water that can accumulate at the bottom of the container (electrolyte overflow, leak of the centralised filling system, battery cleaning...). Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 121 NOTE Water that contacted a battery is classified industrial waste and must be disposed of in accordance with regulations in force. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 122: Preventive Maintenance And Inspection
- Hydraulic hoses and fittings (leaks) - Electrolyte level in the battery (see § 5.1.1) - Cylinders - Verification / water drainage from the battery container (see § 7.10) - Lubrication (see § 7.12) Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 123: Preventive Maintenance And Inspection Every 500 Hours
500 hours Preventive maintenance / inspection must include verification of the following points and must be performed by a technician approved by JLG : - Turntable bolt torque(§ 6.3) - Lifting chain wear (see § 7.8.1) - Telescopic mast alignment / bronze spacers on the roller pins (see §...
Page 124 Turntable attachment bolts Telescopic mast alignment / Bronze spacers on roller pins Pressure relief valves ¢ : Operator n : Maintenance technician (n) : Depending on the frequency of the operation of the machine Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 125: Lubrication
CAUTION Use lubrication intervals as a guideline only. Intervals must correspond to operating conditions such as continuous duty cycles and/or aggressive environments. NOTE Check all fluid levels at ambiant temperature. Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 126 Coat the teeth bearing teeth operation 1- Remove the cover plate 2- Apply a thick coat of grease with a brush through the grease inspection hole. Turn the turntable to reach all the teeth. Toucan 1210 Models Revision 03-2012 Toucan 1310...
Page 127 LOW TEMPERATURE STANDARD UP TO -35°C MOBIL DTE 16M HYDRELF XV 32 CHAÎNE FILANTE STANDARD MOBILUX EP2 COMPLEX EP2 Reservoir Mast / Wheel hub / Telescope Turntable teeth Lifting chains Turntable bearing track Models Toucan 1210 Revision 03-2012 Toucan 1310...
Page 128 NOTES Toucan 1210 Models Revision 03-2012 Toucan 1310...

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Toucan 1310

JLG TOUCAN 1210 Service Manual

2 Work Platform Characteristics

3 Hydraulic System

4 Electrical System

5 Batteries - Chargers

6 Torque Values

7 Service - Maintenance

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