Troubleshooting - JLG TOUCAN DUO Service Manual

III-21

3.22.2 Troubleshooting

NOTE
Use a pressure gauge on the quick release
fitting near the pump to isolate the problem.
1- If the pump is noisy (cavitation), the probable
causes could be : low oil level, heavy oil, wrong
oil type, suction filter dirty, relief valve open,
restriction in suction line, air in the system,
pump stuck, or parts worn or broken.
Solutions are as follows :
a. If the oil level is low, fill to correct level. (refer to
the Operator's Manual).
b. If the oil is too heavy, replace with proper oil.
Refer to § 3.13.
c. If incorrect oil type, replace with proper oil.
(Refer to § 3.13).
d. If the suction filter is dirty, clean the filter.
e. If the relief valve is open, adjust it. Refer to § 4.5.
f. If restriction in the suction line, remove and
replace the line.
g. If air in the system, bleed the air from the
system. Refer to § 4.9.
h. If the pump is stuck, inspect all parts for burrs
or check if the pump is contaminated. If burrs
are found on parts, replace parts. If
contamination, flush the system and fill with
correct fluid.
i. If the pump is worn or broken, replace the pump.
2. If the pump is too long to respond or fails to
respond, the probable causes could be : low oil
level, relief valve set too low, pump worn or damaged,
or air in the cylinder.
Solutions are as follows :
a. If low oil level, fill to the correct level. (refer to
Operator's Manual).
b. If relief valve set too low, use a pressure gauge
to adjust pressure. Refer to § 4.5.
c. If the pump is worn or damaged, replace the
pump.
d. If air in the cylinder, bleed the air. Refer to §
4.9.
32
GENERAL
3. If the oil is heating up, the probable causes could
be : contamination in the relief valve, oil too light or
dirty, relief valve set too high or too low.
Solutions are as follows :
a. If contamination in the relief valve, remove and
clean it. (refer to § 6.5.6).
b. If oil too light or dirty, drain and fill with correct
oil (refer to § 3.13).
c. If relief valve set too high or too low, use a
pressure gauge and adjust the pressure. Refer
to § 4.5.
4. If the oil is foaming, the probable causes could be:
air leak in the suction line, oil type incorrect, or low
oil level.
Solutions are as follows :
a. If air leaking in the suction line, tighten the hose
clips or change the pump if necessary.
b. If incorrect oil type, drain and fill with proper oil.
(refer to § 3.13).
c. If low oil level, fill to correct level. (refer to the
Operator's Manual).
5. If the pump does not deliver fluid (no pressure), the
probable causes could be : fluid level in the tank too
low, pump inlet line clogged, air leak in pump inlet
line, dirt in the pump, fluid viscosity too high, parts
worn or damaged inside the pump, or fluid returning
to the tank.
Solutions are as follows :
a. If fluid level in reservoir too low, fill with fluid of
correct type and grade and check for any
external leaks. Refer to § 3.13.
b. If pump inlet line is clogged, remove and clean
it. Check the filters and tank for any other
possible obstruction.
c. If air leak in pump inlet line, locate and repair
leak.
d. If dirt in the pump, remove and clean the pump.
Check the system and fill with proper fluid.
e. If fluid viscosity too high, check the
manufacturer's recommendations and fill with
correct fluid. (refer to § 3.13).
f. If a part is worn or damaged inside the pump,
determine the cause of the failure, repair the
parts or replace the pump.
TOUCAN Duo
Updated 06-2015
III-21
models