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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
PA 17233-9533
Tel : (171) 485-5161
Fax : (717) 485-6417
Updated : 06-2015
C.E.
JLG Industries,
Kilmartin Place,
Tannochside Park
Uddingston, Scotland G71 5PH
Tel : +44(0)1698 811005
Fax : +44(0)1698 811055
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
MA0323-05
English - Service Manual

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Questions and answers

arnaud
February 21, 2025

ma nacelle fonctionne bien mes ne veut plus descendre

1 comments:
Mr. Anderson
February 21, 2025

The JLG TOUCAN DUO lift may not descend due to several possible reasons:

1. Shelf Sensor Activation – The shelf elevation movement is interrupted by the shelf sensor, which may be preventing descent.
2. Lifting Chain Tension – If the lifting chains do not have identical tension, the mechanism may not function properly.
3. Back-Up Cables – Cables on the side of the mast prevent chains from slacking, which could cause movement issues if not properly adjusted.
4. Mechanical Obstruction – Misalignment or an obstruction in the shelf or platform components could prevent movement.
5. Alarms or Warnings – The system may have detected a fault, requiring inspection of the alarms and warnings section for troubleshooting.

A qualified technician should inspect these components to determine the exact cause.

This answer is automatically generated

Summary of Contents for JLG TOUCAN DUO

  • Page 1 MODELS MODELS MODELS MODELS MODELS TOUCAN DUO TOUCAN DUO TOUCAN DUO TOUCAN DUO TOUCAN DUO 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...
  • Page 3 Models N° ________________ MA0323-05 Models TOUCAN Duo Updated 06-2015...
  • Page 5: Table Of Contents

    Electronic controller ------------------------------------------------------------------- 3.18 Drive Motors ----------------------------------------------------------------------------- 3.19 Electrical cylinder ---------------------------------------------------------------------- 3.20 Fuses --------------------------------------------------------------------------------------- 3.21 Power circuit fuses ---------------------------------------------------------------------- 3.21.1 Control circuit fuses -------------------------------------------------------------------- 3.21.2 Hydraulic power unit ------------------------------------------------------------------ 3.22 General maintenance ------------------------------------------------------------------- 3.22.1 Troubleshooting -------------------------------------------------------------------------- 3.22.2 Models TOUCAN Duo Updated 06-2015...
  • Page 6 Removal - Installation of the motor reducers ---------------------------------------------------- 6.4.4 Removal - Installation of the wheel motor brakes ---------------------------------------------- 6.4.5 Removal - Installation of the reducer on the wheel motor reducer ------------------------ 6.4.6 Removal - Installation of the speed controller --------------------------------------------------- 6.4.7 models TOUCAN Duo Updated 06-2015...
  • Page 7 Slave controller ----------------------------------------------------------------------------- 7.4.2 Master controller --------------------------------------------------------------------------- 7.4.3 Calibration of the Stering Cylinder Potentiometer ---------------------------- 7.5 Main Parameters ------------------------------------------------------------------------ 7.6 ALARMS AND WARNINGS General ------------------------------------------------------------------------------------- 8.1 Alarms and Warnings ------------------------------------------------------------------ 8.2 Alarms -------------------------------------------------------------------------------------- 8.3 Warnings ----------------------------------------------------------------------------------- 8.4 Models TOUCAN Duo Updated 06-2015...
  • Page 8 This page has been left blank intentionally. models TOUCAN Duo Updated 06-2015...
  • Page 9: Introduction

    CHAPTER 1 INTRODUCTION...
  • Page 10: Foreword

    INTRODUCTION FOREWORD This handbook has been compiled to assist you in properly maintaining your JLG Aerial Work Platform Model TOUCAN Duo. It contains technical information and procedures enabling a qualified personnel to detect possible failures and perform the necessary adjustments or repairs.
  • Page 11 NOTICE TO OWNER / USER Should this work platform become involved in an accident, please contact your local JLG distributor immediately and relate details of the incident so that he can notify JLG. If the distributor is unknown and/or cannot be reached, please contact USA : C.E :...
  • Page 12 APPLY ALSO DURING OPERATING CHECKS, MAINTENANCE AND REPAIRS. THEY DO NOT NOTE REPLACE NATIONAL, STATE OR LOCAL A note is used to emphasize an important WORK REGULATIONS, INDUSTRY procedure or condition. STANDARDS OR EMPLOYER'S WORK RULES. models TOUCAN Duo Updated 06-2015...
  • Page 13 : Safety, Operation Correctness, and Technical Content. All SMCAR's will be reviewed by the responsible Department at JLG. Approved SMCAR's will be distributed in a Service Bulletin immediately and then incorporated in the next scheduled change to the manual. An answer to the SMCAR's, approved or disapproved, will be sent directly to the one submitting the SMCAR.
  • Page 14 This page has been left blank intentionally models TOUCAN Duo Updated 06-2015...
  • Page 15: Work Platform Characteristics

    CHAPTER 2 WORK PLATFORM CHARACTERISTICS...
  • Page 16 CHARACTERISTICS The JLG elevating work platform consists of a self- propelled all-welded steel frame, a telescopic mast and a platform. The platform is fitted with a motorised shelf enabling picking operations. The drive function is accomplished through two electrical motors propelling the rear axle. Steering (front axle) is accomplished by an electrical cylinder located on the chassis between the steering wheels.
  • Page 17: General Description

    II-1 CHARACTERISTICS II-1 2.1 General description REAR FRONT Telescopic mast FRONT REAR Models TOUCAN Duo Updated 06-2015...
  • Page 18: Characteristics - Dimensions - Performances

    Speeds are indicated for a machine with a fully charged battery operating at a 20°C ambient temperature. Constant product improvement make it necessary that JLG France SAS reserve the right to make specification and equipment changes without notice.
  • Page 19: General

    CHAPTER 3 GENERAL...
  • Page 20: General Procedure

    The safety of persons working on and around the work platform must be your prime concern. After repairs, the work platform can only return to service after a thorough functional check. All covers and protections must be installed. models TOUCAN Duo Updated 06-2015...
  • Page 21: Cleanliness

    If a part resists removal, ensure all nuts and bolts have been removed, all electrical or hydraulic connections have been disconnected, and that an adjacent part is not interfering. Models TOUCAN Duo Updated 06-2015...
  • Page 22: Bushing Installation

    Read and follow the instructions on the Flanged bushing packaging. Housing Always follow the instructions on Loctite® packaging. Every type of Loctite® is not suited for every applications. Installation completed models TOUCAN Duo Updated 06-2015...
  • Page 23: Fasteners And Torque Values

    The torque value tables are provided by JLG for Force value readings must be made while the tool is reference when performing maintenance.
  • Page 24: Torque Values Tables

    Torque v alues for hydraulic fittings TORQUE FOR TORQUE FOR Type Unit STEEL BODY ALUMINUM BODY JIC 9/16"-18 22.9 lbf.ft BSPP 1/4"-19 25.8 18.4 lbf.ft BSPP 3/8"-19 51.6 36.9 lbf.ft METRIC M14x150 33.2 23.6 lbf.ft METRIC M18x150 51.6 36.9 lbf.ft models TOUCAN Duo Updated 06-2015...
  • Page 25: Hydraulic System

    Brand and grade indications are given for information When removed, always install the cylinder head and only, JLG Product Support can communicate manifold gasket using recommended gasket equivalences in the leading makes and answer your compound on head gaskets to allow uniform sealing.
  • Page 26: Charger

    Indicates that the battery will not accept charge current, or an internal fault has been Charger Internal Fault detected in the charger. This fault will nearly always be set within the first 30 seconds of operation. Once it has been determined that the batteries and connections models TOUCAN Duo Updated 06-2015...
  • Page 27: Battery Discharge Indicator

    NOTE the battery. A red indicator light is located on the platform control panel and has the same functions as the one located on the battery discharge indicator. Models TOUCAN Duo Updated 06-2015...
  • Page 28: Electronic Controller

    ç A8: EV2 electrovalve control output. Not connected. ç A9: NAUX1 auxiliary output.Not connected. ç A10: Ground of the control card connected to A14. ç A11: DI6 contact input. Not connected. ç A12: DI8 contact input. Drive speed input n°2. models TOUCAN Duo Updated 06-2015...
  • Page 29: Drive Motors

    4 - Reinstall the rear cover. overheating 3- Let the cylinder cool down. 4- Pull on the EMERGENCY STOP switch to reset it. CAUTION Before resuming operations, it is necessary to solve the problem that required the emergency stop. Models TOUCAN Duo Updated 06-2015...
  • Page 30: Fuses

    A dull sandblasted area may appear near the face of the gear. This is caused by contaminated oil flowing through the lubrication grooves. models TOUCAN Duo Updated 06-2015...
  • Page 31 Cavitation is the formation and collapse of vapour bubbles in the oil. This is usually the result of restricted pump suction. Cavitation occurs more readily when the oil is cold. Aeration and cavitation erode and pit the pressure plates and pump housing. Models TOUCAN Duo Updated 06-2015...
  • Page 32: Troubleshooting

    If air in the cylinder, bleed the air. Refer to § f. If a part is worn or damaged inside the pump, 4.9. determine the cause of the failure, repair the parts or replace the pump. models TOUCAN Duo Updated 06-2015...
  • Page 33 If abrasive contaminants in the fluid going through the filter, check the fluid in the reservoir, check the inlet line for any restriction and check the cleanliness of the filter. Models TOUCAN Duo Updated 06-2015...
  • Page 34 This page has been intentionnally left blank. models TOUCAN Duo Updated 06-2015...
  • Page 35 CHAPTER 4 ADJUSTMENTS...
  • Page 36 If you have any queries concerning operating, control or adjustment procedures, please contact your JLG approved distributor. Certain operations require removal of covers or protection housings. All covers or protection housing must be installed before resuming operation.
  • Page 37: Adjustments

    Once checked, move the electrical box back in its original position. = Location of inspection areas Area A x (1) Area B Area A Area B Models TOUCAN Duo Updated 06-2015...
  • Page 38: Lifting Chains Tension Adjustment

    NOTE The shelf elevation movement is interrupted NOTE by the shelf sensor (refer to § 4.12) Back up cables located on the side of the mast prevent the chains from slacking. models TOUCAN Duo Updated 06-2015...
  • Page 39: Shelf Alignment Setting

    . loosen the blocks setting screws. - Check the torque of all setting screws locknuts. Block Do not hesitate to contact you JLG France authorized distributor for further information. Bearing 1- Clean the inside of the platform guide rails to remove the used grease.
  • Page 40: Pressure Relief Valves Adjustment

    To adjust a relief valve, turn the setting screw until the correct setting is reached (pressure increase by tightening the setting screw). CAUTION Do not adjust the pressure of the system above its prescribed value. Increasing the pressure could damage the hydraulic components. models TOUCAN Duo Updated 06-2015...
  • Page 41: Mast Cylinder Pressure Relief Valve

    NOTE The pressure relief valve "A" (shelf elevation) is factory preset and its setting must not be modified. Pressure relief valve Pressure relief valve shelf lowering Pressure relief valve shelf elevation Models TOUCAN Duo Updated 06-2015...
  • Page 42: Pressure Switch Adjustment On Shelf Cylinder

    8- Using a jack of sufficient dimensions, lift the rear of the chassis. - An acoustic alarm sounds when the chassis reaches an inclination of 1.8° ± 0.2°. - The corresponding Led lights up on the platform control panel. 9- Lower the jack. models TOUCAN Duo Updated 06-2015...
  • Page 43: Control-Wheel Motor Brake Adjustment

    - Correct the symetry fault by tightening or loosening the nut C . NOTE When a symetry fault has been corrected, the setting in both directions must be checked again before the work platform is returned to service. Models TOUCAN Duo Updated 06-2015...
  • Page 44: Mast Cylinder Bleeding

    6- The bleeding process is complete once the platform is immobile with the bleeding screw loose. Tighten the bleeding screw (torque value: 5.5 N.m). 7- Clean all parts with a solvent and dry with compressed air. Bleeding screw Access hole Allen Tooling Fig. 4.5 models TOUCAN Duo Updated 06-2015...
  • Page 45: Steering Sensors Setting

    5- Tighten the sensor on the chassis. 6- Straighten the wheels and fully steer to the left to check the angle a = 0 and the steering cylinder is not noisy when fully extended. Sensor ↔ Sensor's direction of movement Models TOUCAN Duo Updated 06-2015...
  • Page 46: Gate Sensors Setting

    If one of the two gates is open: - Only the shelf elevation and lowering movements are availble from the upper control panels. - The mast movements from the ground control box are not allowed. models TOUCAN Duo Updated 06-2015...
  • Page 47: Battery Discharge Indicator Setting (Option)

    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 Duo Updated 06-2015...
  • Page 48 This page has been intentionnally left blank. models TOUCAN Duo Updated 06-2015...
  • Page 49: Schematics

    CHAPTER 5 SCHEMATICS...
  • Page 50 This page has been intentionnally left blank. models TOUCAN Duo Updated 06-2015...
  • Page 51 TABLE POWER UNIT MOTOR MOTEUR CENTRALE TABLETTE TABLE PRESSURE PRESSION TABLETTE TABLE RAISING MONTEE TABLETTE TABLE RAISING RELAY RELAIS MONTEE TABLETTE TILT SENSOR DEVERS TILT SENSOR RELAY RELAIS DEVERS TRIGGER GACHETTE TRIGGER RELAY RELAIS GACHETTE Models TOUCAN Duo Updated 06-2015...
  • Page 52: Electrical Schematics

    SCHEMATICS 5.1 Electrical schematics 5.1.1 Standard machine - Functional diagramme Réf. : ELE258 half left models TOUCAN Duo Updated 06-2015...
  • Page 53 SCHEMATICS Réf. : ELE258 half right Models TOUCAN Duo Updated 06-2015...
  • Page 54 SCHEMATICS Wiring diagramme. Power models TOUCAN Duo Updated 06-2015...
  • Page 55 SCHEMATICS Wiring diagramme. Controls Models TOUCAN Duo Updated 06-2015...
  • Page 56 SCHEMATICS Upper control box models TOUCAN Duo Updated 06-2015...
  • Page 57 SCHEMATICS Shelf box Models TOUCAN Duo Updated 06-2015...
  • Page 58 SCHEMATICS Card box models TOUCAN Duo Updated 06-2015...
  • Page 59 SCHEMATICS Lower control box Models TOUCAN Duo Updated 06-2015...
  • Page 60 SCHEMATICS 5.1.2 - Machine with battery cut out and hourmeter option Functional diagramme Ref. : ELE258 models TOUCAN Duo Updated 06-2015...
  • Page 61: Hydraulic Schematic

    SCHEMATICS 5.2 Hydraulic schématic Ref : FL0148_04 Models TOUCAN Duo Updated 06-2015...
  • Page 62 This page has been intentionnally left blank. models TOUCAN Duo Updated 06-2015...
  • Page 63: Removal - Installation Procedures

    CHAPTER 6 REMOVAL - INSTALLATION PROCEDURES...
  • Page 64: Introduction

    We recommend that these operations are performed by qualified and authorized personnel only. Contact your JLG distributor for any question on removal - installation procedure or for any query you may have. Certain operations require removal of covers or protection housings.
  • Page 65: Platform And Shelf

    Models TOUCAN Duo Updated 06-2015...
  • Page 66: Shelf Removal - Installation

    CAUTION Check the condition of all pulleys and pins before installing the shelf lifting and back up cables. Check they turn freely on the pins and replace them if necessary. models TOUCAN Duo Updated 06-2015...
  • Page 67: Shelf Pre-Installation

    CAUTION Ensure a certain thickness of the slide blocks, which is out of its housing is equal on either side. As indicated on the drawing above, thickness 1 must be similar to thickness 2. Models TOUCAN Duo Updated 06-2015...
  • Page 68: Platform Removal - Installation

    CAUTION Ensure the electrical cables do not get pinched or crushed during platform removal. DANGER The platform may fall if it is not correctly supported. It must be empty and inoccupied during this operation. models TOUCAN Duo Updated 06-2015...
  • Page 69: Mast On Chassis

    (located under the platform on the last mast section) does not 5- Disconnect both connectors for the flashing hit the chassis of the machine. lights located on each side of the first mast section. Models TOUCAN Duo Updated 06-2015...
  • Page 70: Telescopic Mast

    (see fig. 4.5, § 4.8). 4- Secure the cylinder brackets on mast section n°1 with screws and washers. 5- Ensure the screws securing the cylinder to the brackets are tight. models TOUCAN Duo Updated 06-2015...
  • Page 71: Slide Blocks Installation

    Before removing the slide blocks, note their 6.3). marking and location and give this 5- Install new nuts on the chain equalizers to information to your JLG distributor when adjust the tension of the lifting chains (see § ordering. 4.2).
  • Page 72: Lifting Chains Removal

    (see § 6.2) 2- Remove the mast cylinder (see § 6.3.1) 3- On the lower part of each mast section, mark the position of the mounting plate for the back up cable. Remove both plates. models TOUCAN Duo Updated 06-2015...
  • Page 73: Lifting Chains Installation

    NOTE During assembly of the chain clevis and double strand chains, insert a shim 14,5 mm thick between the clevis and the chain (as indicated above), to prevent deformation of the links during pin installation. Models TOUCAN Duo Updated 06-2015...
  • Page 74 4- Adjust the tension of the chains (refer to the procedure for chain tension adjustment, § 4.2). NOTE Ensure the backup cables and electrical cables are correctly installed in the grooves of the pulleys. models TOUCAN Duo Updated 06-2015...
  • Page 75: Chassis

    3- Remove the blocks from the machine. CAUTION Clean and grease the motor reducer shaft before installing the wheels. CAUTION When installing the rear wheels, torque the bolts to 21 N.m (torque with a torque wrench). Models TOUCAN Duo Updated 06-2015...
  • Page 76: Removal - Installation Of The Motor Reducer + Flange Assembly

    23 N.m (tightening with torque wrench). 10- Lift the chassis of the machine and place a block under the rear of the chassis. 11- Remove the flange attachment screw on the chassis. models TOUCAN Duo Updated 06-2015...
  • Page 77: Removal - Installation Of The Wheel Motor Brakes

    4- Remove the brake disc (3) from its housing (4). Remove the friction disc (5). Figure 6.7 CAUTION After each brake removal, it is necessary to check the air gap value (see § 4.8). Figure 6.8 Models TOUCAN Duo Updated 06-2015...
  • Page 78: Removal - Installation Of The Reducer On The Wheel Motor Reducer

    - After each disassembly, replace the paper seal with a new seal in perfect condition. - After each disassembly, apply the prescribed quantity of grease (see § 3.13 and the Operator's Manual) on the bearing and inner periphery. models TOUCAN Duo Updated 06-2015...
  • Page 79: Removal - Installation Of The Speed Controller

    2- Install the power module with the Molex Figure 6.9. connectors down and secure to the chassis. NOTE Power module shown as installed on the machine (Molex connectors downwards). Models TOUCAN Duo Updated 06-2015...
  • Page 80 7- Proceed with a system setup and calibration seals. (refer to section 7). 6- Drain all the hydraulic oil from the cylinder. 7- Using a spanner, unscrew the cylinder head until it clears the barrel (see fig. 6.8). models TOUCAN Duo Updated 06-2015...
  • Page 81 9- Remove the guide ring and the stop ring from the rod. 10- Remove the cylinder head. 11- Remove the seals, wiper ring from the cylinder head. Models TOUCAN Duo Updated 06-2015...
  • Page 82 Before any maintenance on the manifold, disconnect the machine from the electrical power supply, disconnect the charger plug, and ensure the power unit is off. Failure to comply could result in death or serious injuries. models TOUCAN Duo Updated 06-2015...
  • Page 83 10- Install the reservoir on the power unit with the maximum). Bleed the cylinder if necessary clips. (refer to § 4.8). 11- Install the power unit on the chassis. 5- Check for proper functionning and any leakage. 6- Install the rear cover. Models TOUCAN Duo Updated 06-2015 Fig. 6.18.
  • Page 84 NOTES models TOUCAN Duo Updated 06-2015...
  • Page 85: Eco Smart Display

    CHAPTER 7 ECO SMART DISPLAY Models TOUCAN Duo Updated 06-2015...
  • Page 86 This page has been intentionnally left blank. models TOUCAN Duo Updated 06-2015...
  • Page 87: General Description

    The arrow point is up when the machine is in forward drive; the arrow point is down when the machine is in reverse. If the machine is not running a dot is displayed instead of the arrow. Models TOUCAN Duo Updated 06-2015...
  • Page 88: Connection

    Pin n°1 - Supply negative reference Pin n°2 - Supply negative reference Pin n°3 - CAN - signal high Pin n°4 - CAN - signal low Pin n°5 - not used Pin n°6 - Supply positive reference models TOUCAN Duo Updated 06-2015...
  • Page 89: Menus Displays

    VII-4 ECO SMART DISPLAY VII-4 7.4 Menus display 7.4.1 Display Models TOUCAN Duo Updated 06-2015...
  • Page 90: Slave Controller

    VII-4 ECO SMART DISPLAY VII-4 7.4.2 Slave Controller models TOUCAN Duo Updated 06-2015...
  • Page 91 VII-4 ECO SMART DISPLAY VII-4 Models TOUCAN Duo Updated 06-2015...
  • Page 92 VII-4 ECO SMART DISPLAY VII-4 models TOUCAN Duo Updated 06-2015...
  • Page 93: Master Controller

    VII-4 ECO SMART DISPLAY VII-4 7.4.3 Master Controller Models TOUCAN Duo Updated 06-2015...
  • Page 94 VII-4 ECO SMART DISPLAY VII-4 models TOUCAN Duo Updated 06-2015...
  • Page 95 VII-4 ECO SMART DISPLAY VII-4 Models TOUCAN Duo Updated 06-2015...
  • Page 96 VII-4 ECO SMART DISPLAY VII-4 models TOUCAN Duo Updated 06-2015...
  • Page 97: Calibration Of The Stering Cylinder Potentiometer

    Push on the central button again. 8- Push once on the arrow UP then twice on the central button. 9- Install the steering switches in their original position and the front covers. Models TOUCAN Duo Updated 06-2015...
  • Page 98: Main Parameters

    VII-6 ECO SMART DISPLAY VII-6 7.6 Main Parameters NOTE When the machine has left its lowered position (mast raised), the maximum travel speeds are reduced to 20% of the maximum speed in lowered position. models TOUCAN Duo Updated 06-2015...
  • Page 99 CHAPTER 8 ALARMS AND WARNINGS Models TOUCAN Duo Updated 06-2015...
  • Page 100 This page has been intentionnally left blank. models TOUCAN Duo Updated 06-2015...
  • Page 101: Alarms And Warnings

    These errors open the machine power circuit et most of the time, maintain the motors braked. Machine operation is stopped. - Warnings : These errors do not stop machine operation. The controllers continue to operate but some performances have been impaired. Models TOUCAN Duo Updated 06-2015...
  • Page 102: Alarms

    VIII-3 ALARMS AND WARNINGS VIII-3 8.3 Alarms models TOUCAN Duo Updated 06-2015...
  • Page 103 VIII-3 ALARMS AND WARNINGS VIII-3 Models TOUCAN Duo Updated 06-2015...
  • Page 104 VIII-3 ALARMS AND WARNINGS VIII-3 models TOUCAN Duo Updated 06-2015...
  • Page 105: Warnings

    VIII-4 ALARMS AND WARNINGS VIII-4 8.4 Warnings Models TOUCAN Duo Updated 06-2015...
  • Page 106 VIII-4 ALARMS AND WARNINGS VIII-4 models TOUCAN Duo Updated 06-2015...
  • Page 107 VIII-4 ALARMS AND WARNINGS VIII-4 Models TOUCAN Duo Updated 06-2015...
  • Page 108 This page has been intentionnaly left blank. models TOUCAN Duo Updated 06-2015...

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