JLG TOUCAN 10E Operation And Safety Manual
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JLG TOUCAN 10E Operation And Safety Manual

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Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
AS
®
TOUCAN 10E
TOUCAN 26E
English - Operation and Safety Manual
31210088
May 11, 2010

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Summary of Contents for JLG TOUCAN 10E

  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. TOUCAN 10E TOUCAN 26E 31210088 English - Operation and Safety Manual May 11, 2010 ®...
  • Page 3 The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
  • Page 4 INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO- DECAL WILL HAVE AN ORANGE BACKGROUND. TECTION OF PROPERTY. – JLG Lift – 31210088...
  • Page 5 FOREWORD For: • Accident Reporting • Standards and Regulations THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED Compliance Information • Product Safety Publica- JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- tions •...
  • Page 6 FOREWORD REVISION LOG Original Issue - July 10, 2008 Manual Revised - June 22, 2009 Manual Revised - May 11, 2010 – JLG Lift – 31210088...

  • Page 7: Table Of Contents

    Drive Orientation System (DOS) ... 4-7 Tilt Sensor Check ..... . . 2-8 31210088 – JLG Lift –...
  • Page 8 Wheel and Tire Replacement... . . 6-19 Wheel Installation ..... . 6-19 – JLG Lift – 31210088...
  • Page 9 4-6 Transmission and Drive System ..6-45 6-6 Communication..... 6-46 31210088 – JLG Lift –...
  • Page 10 6-10 Recommended Viscosity Grade ....6-25 Inspection and Repair Log ....7-1 – JLG Lift – 31210088...
  • Page 11 4-10. Lifting the Machine ......4-16 4-11. Lifting the Machine Using a Fork Truck ..4-16 31210088 – JLG Lift –...
  • Page 12 TABLE OF CONTENTS NOTES: – JLG Lift – 31210088...

  • Page 13: Section 1 - Safety Precautions

    • Only authorized and qualified personnel can operate the contact JLG Industries, Inc. (“ JLG”). machine. • Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN and in this manual.

  • Page 14: Workplace Inspection

    • Do not operate or raise the platform while on trucks, trail- ers, railway cars, floating vessels, scaffolds or other equip- ment unless approved in writing by JLG. MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM • Do not operate the machine in hazardous environments SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANU- unless approved for that purpose by JLG.

  • Page 15: Operation

    • Do not carry materials directly on platform railing. Contact JLG for approved material handling accessories. • When two persons are in the platform, the operator shall be responsible for all machine operations.

  • Page 16: Trip And Fall Hazards

    “three point contact” with the machine, using two hands and one foot or two feet and one hand during entry and exit. • Before operating the machine, make sure all gates are closed and fastened in their proper position. – JLG Lift– 31210088...

  • Page 17: Electrocution Hazards

    (exposed or insulated) parts according to the machine. The minimum approach distance shall be Minimum Approach Distance (MAD) as shown in Table 1-1. reduced to a distance within the designed working dimen- • Allow for machine movement and electrical line swaying. 31210088 – JLG Lift –...

  • Page 18: Tipping Hazards

    • Before driving on floors, bridges, trucks, and other sur- faces, check allowable capacity of the surfaces. • Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface. – JLG Lift– 31210088...
  • Page 19 • Do not increase the platform size with unauthorized deck extensions or attachments. • If extending structure assembly or platform is in a position that one or more wheels are off the ground, all persons 31210088 – JLG Lift –...

  • Page 20: Crushing And Collision Hazards

    • Limit travel speed according to conditions of ground sur- emergency, malfunction, power failure, or loading/unload- face, congestion, visibility, slope, location of personnel, ing. Refer to Emergency Towing Procedures Section of this Manual for emergency towing procedures. – JLG Lift– 31210088...

  • Page 21: Additional Hazards / Safety

    • Refer to the Machine Operation Section of this Manual for • Battery fluid is highly corrosive. Avoid contact with skin lifting information. and clothing at all times. • Charge batteries only in a well ventilated area. 31210088 – JLG Lift –...

  • Page 22: Beaufort Scale (For Reference Only)

    32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind. 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road. 47-54 20.8-24.4 Strong gale Light structure damage. 1-10 – JLG Lift– 31210088...

  • Page 23: Section 2. User Responsibilities, Machine Preparation, And Inspection

    4. Use of approved fall protection device. or the job site. 5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal- function. 31210088 – JLG Lift –...

  • Page 24: Preparation, Inspection, And Maintenance

    JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL. – JLG Lift – 31210088...

  • Page 25: Inspection And Maintenance Table

    At intervals as specified in the Service and Owner, Dealer or User Qualified JLG Mechanic Service and Maintenance Manual Maintenance Maintenance Manual. NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 31210088 – JLG Lift –...

  • Page 26: Pre-Start Inspection

    4. Operation and Safety Manuals – Make sure a copy of the Operator and Safety manual, AEM Safety manual (ANSI markets only), and ANSI Manual of Responsibility (ANSI markets only) is enclosed in the weather resistant storage container. – JLG Lift – 31210088...
  • Page 27 SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-1. Daily Walk-Around Inspection 31210088 – JLG Lift –...

  • Page 28: General

    (if equipped) are properly secure and legible, control levers and switches return to installed and fastened. See inspection note. neutral and emergency stop switches function properly. 3. Steering Assembly - See inspection note. – JLG Lift – 31210088...

  • Page 29: Function Check

    (Approx.). e. Raise the jib about half a meter (2 ft.), check if the h. Toucan 10E only: With the mast elevated 4.50 m manual descent valve lowers the jib properly (Refer (14.8 ft.), on a smooth, firm and level surface, drive to Figure 3-4).

  • Page 30: Tilt Sensor Check

    Confirm an audible alarm sounds. b. Verify the tilt indicator (red) blinks. c. Check that the following functions are affected : - Drive function disabled. - Mast/Jib lift-up and swinging movements can be performed only in creep mode. – JLG Lift – 31210088...

  • Page 31: Overload Sensor Check (If Equipped)

    Verify the overload indicator (Red) blinks. c. Check that all functions are disabled. 2. From the Ground Control Panel: a. Confirm an audible alarm sounds. b. Verify the overload indicator (Red) blinks. Figure 2-3. Overload Sensor 31210088 – JLG Lift –...

  • Page 32: Slack/Broken Chain Sensors Check

    Confirm an audible alarm sounds. b. Check when the slack chain indicator warning is activated, the following functions are disabled: - Mast/Jib lower - Swing c. Repeat check for each chain sensor. Figure 2-4. Slack/Broken Chain Sensors 2-10 – JLG Lift – 31210088...

  • Page 33: Section 3 - Machine Controls And Indicators

    8- Platform Swinging motor release valve Control valves 9- Platform Control console Manual swinging operating device Counterweight 10- Manual Storage Container 11- Access door to battery/charger Figure 3-1. Basic Nomenclature - Location of Machine Controls 31210088 – JLG Lift –...

  • Page 34: General

    THE EMERGENCY STOP SWITCHES MUST BE POSITIONED TO OFF TO PREVENT DRAINING THE BATTERIES. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON- TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED. – JLG Lift – 31210088...
  • Page 35 5- Battery Charger Status Indicators (depending on equipment) 6- Emergency Stop Switch 7- Function Enable Button 8- Mast Lift/Lower Buttons 9- Jib Lift/Lower Buttons 10- Superstructure Swing Buttons 11- Brake Release Button Figure 3-2. Ground Control Station 31210088 – JLG Lift –...
  • Page 36 The last bar flashes when the level of charge is less than 10%. The bar-graph is not displayed when the batteries are completely discharged. – JLG Lift – 31210088...
  • Page 37 Refer to section 4-12 of this manual for 7. Function Enable Button - A membrane switch that must further information. be pushed in and held to enable the controls of the ground control station. 31210088 – JLG Lift –...

  • Page 38: Platform Manual Descent Valves

    KEEP BODY, HANDS AND ARMS OUT OF THE PATH OF THE MAST, THE JIB AND THE PLATFORM WHILE LOWERING. Figure 3-3. Mast Manual Descent Valve – JLG Lift – 31210088...

  • Page 39: Jib Manual Descent Valve

    - a pinion (2), located below the pump/motor control valves compartment, that can be operated using, depending on equipment, a square 1/2 inch ratchet wrench (a) or the fold- ing lever (b). Figure 3-4. Jib Manual Descent Valve 31210088 – JLG Lift –...

  • Page 40: Platform Control Station

    TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON- TROL LEVERS OR SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN Figure 3-5. Manual Swinging Operating Devices RELEASED. – JLG Lift – 31210088...
  • Page 41 3. Trigger Switch 4. Drive/Swing Functions Controller 5. Steer Switch 6. Mast/Jib Function Enable Button 7. Mast Lift Up/Down Joystick Controller 8. Jib Lift Up/Down Joystick Controller 9. Drive Orientation System (DOS) Override Button 10. Horn Button 31210088 – JLG Lift –...
  • Page 42 System Distress Indicator d- Drive Orientation Indicator e- Tilt Indicator Warning Light f- Overload Indicator Warning Light (If equipped) g- Slack Chain Indicator Warning Light h- Battery Discharge Indicator (BDI) i- Soft Touch Indicator (Optional) 3-10 – JLG Lift – 31210088...
  • Page 43 Drive Orientation Creep mode. indicator will illuminate. This is a signal for the oper- ator to verify that the drive control is being operated Yellow in the proper direction (i.e. controls reversed situa- tions). 31210088 – JLG Lift – 3-11...
  • Page 44 5. Steer Switch - The thumb-operated steer switch on top of the control handle activates the steer wheels in the direction activated (right or left). 3-12 – JLG Lift – 31210088...
  • Page 45 10. Horn - This button, when activated, permits the operator to warn job site personnel when the machine is operat- ing in the area. 31210088 – JLG Lift – 3-13...

  • Page 46: Decal Installation

    SECTION 3 – MACHINE CONTROLS AND INDICATORS DECAL INSTALLATION Figure 3-7. Decal Installation - Sheet 1 3-14 – JLG Lift – 31210088...
  • Page 47 SECTION 3 – MACHINE CONTROLS AND INDICATORS Figure 3-8. Decal Installation - Sheet 2 31210088 – JLG Lift – 3-15...
  • Page 48 SECTION 3 – MACHINE CONTROLS AND INDICATORS Figure 3-9. Decal Installation - Sheet 3 3-16 – JLG Lift – 31210088...

  • Page 49: T10E & T26E - Decal Installation

    AU2152 1705514 AU1825 AU1825 AU1825 AU1825 AU1825 AU2141 AU2148 AU2153 AU2095 AU2095 AU2095 AU2095 AU2095 AU2143 AU2149 AU2154 AU2096 AU2096 AU2096 AU2096 AU2096 AU2144 AU2150 AU2155 AU2097 AU2097 AU2097 AU2097 AU2097 AU2145 1704031 1704023 31210088 – JLG Lift – 3-17...
  • Page 50 SECTION 3 – MACHINE CONTROLS AND INDICATORS NOTES: 3-18 – JLG Lift – 31210088...

  • Page 51: Section 4. Machine Operation

    Platform Control Station. Ground Con- trols operate mast and jib lift and swing and are to be used in an 4. Machine is as originally equipped from JLG. emergency to lower the platform to the ground should the oper- Stability ator in the platform be unable to do so.

  • Page 52: Position Of Least Forward Stability

    SECTION 4 – MACHINE OPERATION Figure 4-2. Position of Least FORWARD stability Figure 4-1. Position of Least BACKWARD stability – JLG Lift – 31210088...

  • Page 53: Grade And Side Slope

    Refer to Table 6-1. With the mast out of transport (stowed) position, the machine must not be operated on grade or side slopes greater than that is specified in Table 6-1. 31210088 – JLG Lift –...
  • Page 54 SECTION 4 – MACHINE OPERATION Figure 4-3. Grade and Side Slope – JLG Lift – 31210088...

  • Page 55: Operation

    MENT DOES NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED. IF THE PLATFORM DOES NOT STOP WHEN CONTROL LEVER OR THE ENABLE BUTTON/TRIGGER SWITCH IS RELEASED, USE THE EMER- GENCY STOP SWITCH TO STOP THE MACHINE. 31210088 – JLG Lift –...

  • Page 56: Steering

    3. Return the controller to its centered (neutral) position to stop, then release the trigger. IF THE TILT INDICATOR WARNING LIGHT/ALARM IS ACTIVATED WHILE DRIVING WITH THE MAST RAISED, LOWER THE MAST COMPLETELY AND DRIVE TO A SMOOTH, FIRM AND LEVEL SURFACE. – JLG Lift – 31210088...

  • Page 57: Drive Orientation System (Dos)

    (3). Move the drive control joystick in a direction matching the directional arrow, for the intended direction of travel. Figure 4-6. Lift Controls Figure 4-5. Drive Orientation System (DOS) 31210088 – JLG Lift –...

  • Page 58: Raising And Lowering The Mast

    5. Return the controller to its centered (neutral) position to 5. Return the controller to its centered (neutral) position to stop, then release the enable button. stop, then release the enable button. – JLG Lift – 31210088...

  • Page 59: Swinging

    DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY. ENSURE THE AREA BENEATH THE PLATFORM IS FREE OF PERSONNEL OR OBSTACLES PRIOR TO LOWERING. Figure 4-7. Swing Control 31210088 – JLG Lift –...

  • Page 60: Alarms

    IF THE WARNING LIGHT IS ILLUMINATED WHEN THE MAST IS RAISED, LOWER THE MAST AND REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE ELEVATING THE MAST. Figure 4-8. Emergency Controls 4-10 – JLG Lift – 31210088...

  • Page 61: Slack Chain Warning Light/Alarm

    IF THE EXAMINATION OF THE SURROUNDINGS DOES NOT REVEAL ANY POSSIBLE OBSTACLE, DISCONTINUE OPERATION IMMEDIATELY. DO NOT USE MANUAL DESCENT CONTROLS. PLATFORM OCCUPANTS MUST BE RESCUED AND THE MAST MECHA- NISM SERVICED BY A QUALIFIED TECHNICIAN. 31210088 – JLG Lift – 4-11...

  • Page 62: Soft Touch Warning Light/Alarm (Option)

    (pushed in) position. 5. If necessary, cover the platform console, the instruction placards, caution and warning decals so that they will be protected from hostile environment. 6. If necessary, charge the battery. 4-12 – JLG Lift – 31210088...

  • Page 63: Battery Charging

    30 days has elapsed. The battery charger AC input plug (1) is located on the battery compartment. 31210088 – JLG Lift – 4-13...

  • Page 64: Battery Charger Fault Code

    30 seconds of operation. Once it has been determined that the batteries and connections Fault are not faulty and fault 6 is again displayed after interrupting AC power for at least 10 seconds, the charger must be brought to a qualified service depot. 4-14 – JLG Lift – 31210088...

  • Page 65: Tie-Down/Lift Lugs

    When transporting the machine: - Platform must be fully lowered in the stowed position. - Machine must be tied down to the truck bed or trailer deck as shown in Figure 4-9. Figure 4-9. Machine Tie-Down 31210088 – JLG Lift – 4-15...

  • Page 66: Lifting

    Figure 4-11. Lifting the Machine Using a Fork Truck 4.12 TOWING It is not recommended that this machine be towed, except in the Figure 4-10. Lifting the Machine event of an emergency or a machine power failure. 4-16 – JLG Lift – 31210088...

  • Page 67: Electric Brake Release

    NOTE: Any action to remove electrical power from the brakes such as, depressing the ground control emergency stop switch, or switching the key switch to OFF or PLATFORM MODE will re-engage the brakes. Figure 4-12. Electric Brake Release 31210088 – JLG Lift – 4-17...
  • Page 68 SECTION 4 – MACHINE OPERATION NOTES: 4-18 – JLG Lift – 31210088...

  • Page 69: Section 5 - Emergency Procedures

    REQUIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY. JLG Industries, Inc. must be notified immediately of any inci- dent involving a JLG product. Even if no injury or property EMERGENCY OPERATION damage is evident, the factory should be contacted by tele- phone and provided with all necessary details.

  • Page 70: Platform Or Jib Caught Overhead

    Refer to Section 3-2 PLATFORM MANUAL DESCENT AND SWING. EMERGENCY TOWING Towing this machine is discouraged. However provisions for towing the machine in emergency situations have been incorpo- rated. Refer to Section 4-12 TOWING. – JLG Lift – 31210088...

  • Page 71: Section 6 - General Specifications & Operator Maintenance

    Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual. Other Publications Available Service and Maintenance Manual....31210090 Illustrated Parts Manual........31210091 Hydraulic Schematic .......... FL0153 Electrical Schematic...........ELE251 31210088 – JLG Lift –...

  • Page 72: Operating Specifications

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OPERATING SPECIFICATIONS Table 6-1. Operating Specifications And Dimensions Model TOUCAN 10E (CE) TOUCAN 26E (ANSI) 200 kg Maximum Work Load (2 persons 500 lbs (227 kg) + 40 kg material) Maximum Manual Force...
  • Page 73 285 psi Electrical System Voltage (1) Up to 7.20 m (23.6’) - Platform height with the jib fully raised (2) Above 7.20 m (23,6’) - Platform height with the jib fully raised - Toucan 10E only. 31210088 – JLG Lift –...
  • Page 74 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE – JLG Lift – 31210088...
  • Page 75 78.5” (1.99 m) Overall Machine Width 0.99 m 45” (1.14 m) Overall Machine Length 2.82 m 109” (2.77 m) Platform Size - Length 0.70 m 27.5” (0.70 m) Platform Size - Width 0.90 m 35.4” (0.90 m) 31210088 – JLG Lift –...
  • Page 76 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-4. Drive Motors - Hydraulic Power Unit DESCRIPTION Model TOUCAN 10E - TOUCAN 26E Voltage 15 VAC Drive Motor Power 0.85 kW Voltage 24 VDC Motor Power 3 kW Hydraulic Displacement 3.1 cc/rev - (0.19 cu.in/rev)
  • Page 77 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not con- Table 6-5. Battery Specifications tain the same required additives or be of comparable vis- cosities.
  • Page 78 (32°F) Cinematic Viscosity @ +40°C 30.6 cSt 32.3 cSt 31 cSt (104°F) Pour Point, Max. -58°C (-72.4°F) -39°C (-38.2°F) -60°C (-76°F) Flash Point, Min. 240°C (464°F) 208°C (406.4°F) 230°C (446°F) Viscosity Index ISO 6743-4 Classification – JLG Lift – 31210088...

  • Page 79: Operator Maintenance

    4. Overload System Spring Washers (If Equipped) 5. Turntable Bearing Lubrication 6. Telescopic Mast Lubrication 7. Lifting Chains Lubrication 8. Overload System Verification (If Equipped) 9. Tilt Sensor Verification Figure 6-2. Operator Maintenance & Lubrication Diagram 31210088 – JLG Lift –...

  • Page 80: Chassis Hood Removal

    BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARGING, ALLOW NO OPEN FAMES, SPARKS OR LIGHTED TOBACCO PRODUCTS IN THE AREA WHILE CHARGING BATTERIES. CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA. Figure 6-3. Chassis Hood Removal 6-10 – JLG Lift – 31210088...
  • Page 81 - Depress and hold the filling pump activation button (2). 3. Flow Indicator - Release the button when the flow indicator (3) slows down. 4. Filter - Ensure the level is correct in each cell. 31210088 – JLG Lift – 6-11...

  • Page 82: Filling System Draining

    - Press on the battery filling system button until the can is empty. - Disconnect the pipe (b) from the can (c). Figure 6-6. Filling System Draining 3. Reconnect the can (c) on the battery filling network (1). 6-12 – JLG Lift – 31210088...
  • Page 83 NOT COME INTO CONTACT WITH SKIN OR CLOTHING. WEAR PROTEC- TIVE CLOTHING AND EYEWEAR WHEN WORKING WITH BATTERIES. NEUTRALIZE ANY BATTERY ACID SPILLS WITH BAKING SODA AND WATER. Figure 6-7. Draining the Water 1. Battery Container 2. Plunger 3. Bulb 31210088 – JLG Lift – 6-13...

  • Page 84: Battery Voltage And Electrolyte Specific Gravity

    Battery Voltage and Electrolyte Specific Gravity NOTE: If important disparities are noticed between gravity/volt- age of different cells or if the gravity values are lower than 1.240kg/l (after a complete charge) contact JLG Product NOTE: Voltage and specific gravity measures should not be per- Support.

  • Page 85: Filling System Maintenance

    FOR A LONG PERIOD OF TIME, CHARGE THE BATTERY AND CHECK ELECTROLYTE LEVEL IN THE CELLS. Low temperatures decrease battery capacity. The battery must be fully charged when the machine is operated in a cold envi- ronment. 31210088 – JLG Lift – 6-15...

  • Page 86: Battery Troubleshooting

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Battery Troubleshooting 6-16 – JLG Lift – 31210088...

  • Page 87: Oil Level/Oil Filter

    4. If additional oil is required, wipe all dirt and debris from the filler/breather cap (5) area, add proper grade of oil by using a funnel. Fill until oil level is between the MIN and MAX markings (4). Figure 6-9. Hydraulic Oil Check 31210088 – JLG Lift – 6-17...

  • Page 88: Hydraulic Filter Replacement

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Filter Replacement Lube Point - Replaceable Element (JLG P/N: 930134) Interval - After first 50 hours of operation and every 250 hours thereafter. 1. Turn machine power off at ground control station.

  • Page 89: Tires & Wheels

    PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN LUG NUTS, AND POSSIBLE SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO Figure 6-11. Wheel Lug Nut Tightening Sequence USE ONLY THE LUG NUTS THAT MATCHED TO THE CONE ANGLE OF THE WHEEL. 31210088 – JLG Lift – 6-19...

  • Page 90: Lubrication

    (18-25 ft.lbs) (51-62 ft.lbs) (88-103 ft.lbs) 4. Wheel lug nuts should be torqued after the first 50 hours of operation and after each wheel removal. Check torque every 3 month or 125 hours of operation. 6-20 – JLG Lift – 31210088...

  • Page 91: Overload System Spring Washer (If Equipped)

    Coat the spring washers using a brush or by spraying. Lube Points - Spring Washers Capacity: A/R Lube - D (See Table 6-6) Interval - Every 125 hours of operation or after each cleaning. Figure 6-12. Overload System Spring Washer Lubrication 31210088 – JLG Lift – 6-21...

  • Page 92: Swing Bearing Race

    4. Swing the structure to the right to gain access to the first grease fitting (2). 5. Lubricate using a grease gun. 6. Swing the structure 180° to the left to gain access to the second grease fitting and lubricate. Figure 6-13. Swing Bearing Race Lubrication 6-22 – JLG Lift – 31210088...

  • Page 93: Swing Bearing Teeth

    2. From ground control station, raise the mast to gain access to the turntable plate. 3. Remove bearing teeth covers (1). 4. Apply grease on teeth using a brush (2). Figure 6-14. Swing Bearing Teeth lubrication 31210088 – JLG Lift – 6-23...

  • Page 94: Mast Profiles Races

    2. Clean the inside walls of the mast profiles to remove the old grease. 3. Using a brush, lubricate the bronze spacer track. 4. Cycle the mast and complete lubrication as necessary. Figure 6-15. Mast Profiles Races Lubrication 6-24 – JLG Lift – 31210088...

  • Page 95: Lifting Chains

    Table 6-10. Recommended Viscosity Grade TEMPERATURE ISO VISCOSITY GRADE -15°C to 0°C (5°F to 32°F) 15 to 32 mm²/s (cSt) 0°C to 50°C (32°F to 122°F) 46 to 150 mm²/s (cSt) 31210088 – JLG Lift – 6-25...

  • Page 96: Overload System Verification (If Equipped)

    - Alarms stop. 5. If the overload warning is not activated after the addition of 30kg, have the overload system calibrated by a quali- fied technician before replacing machine into service. Figure 6-16. Overload System Verification 6-26 – JLG Lift – 31210088...

  • Page 97: Tilt Sensor Verification

    Table 6-1. 6. If the tilt warning is not activated within the indicated angle values, the tilt sensor must be recalibrated by a qualified technician before replacing machine into ser- vice. Figure 6-17. Jacking Points 31210088 – JLG Lift – 6-27...

  • Page 98: Dtc Index

    9-9 Hardware ........6-50 6-28 – JLG Lift – 31210088...

  • Page 99: Dtc Check Tables

    • Normal operation should resume after a power cycle. SYSTEM POWERED DOWN enters a low-power state to preserve battery Refer problem to a qualified JLG mechanic. charge. Displays on the analyzer only; the MDI’s LED is blinking with the display Off.

  • Page 100: Power-Up

    • Check if the joystick is obstructed or jammed. • Check if the enable switch is damaged. Refer problem to a qualified JLG mechanic. DRIVE PREVENTED - TILTED & Drive is prevented while the platform is not in •...

  • Page 101: Platform Controls

    • Check if the horn switch is damaged, obstructed or PERMANENTLY SELECTED platform mode. jammed. Refer problem to a qualified JLG mechanic. FUNCTION PROBLEM - STEER The Steer Left Switch was closed during power- • Check if the steer left switch is obstructed or jammed.
  • Page 102 • Check if the joystick is not obstructed or jammed. Refer problem to a qualified JLG mechanic. GATE LIMIT SWITCH - FAULTY This DTC does not apply to the Toucan 10E. Refer problem to a qualified JLG mechanic. 2244 6-32 –...

  • Page 103: Ground Controls

    • Check if the concerned switch is damaged, obstructed RELEASE PERMANENTLY power-up in ground mode. or jammed. SELECTED Refer problem to a qualified JLG mechanic. FUNCTION PROBLEM - The Ground Enable Switch was closed during • Check if the concerned switch is damaged, obstructed 2310 GROUND ENABLE power-up in ground mode.
  • Page 104 2372 LEFT PERMANENTLY up in ground mode. or jammed. SELECTED Refer problem to a qualified JLG mechanic. FUNCTION PROBLEM - SWING The Swing Right Switch was closed during • Check if the concerned switch is damaged, obstructed 2373 RIGHT PERMANENTLY power-up in ground mode.

  • Page 105: Function Prevented

    2379 NOT RESPONDING change while raising the mast. aged, obstructed or jammed. Refer problem to a qualified JLG mechanic. MAIN MAST LIMIT SWITCH - A problem has been detected in this function. Refer problem to a qualified JLG mechanic. 2380...
  • Page 106 • Check if the charger is connected to off board power 2538 CHARGER CONNECTED charging. source and disconnect if desired. Refer problem to a qualified JLG mechanic. FUNCTION PREVENTED - Manual brake release mode is activated. Drive or • Push manual brake release switch again or cycle 2542 BRAKES ELECTRONICALLY lift is not possible.

  • Page 107: Line Contactor Open Circuit

    FAULT MESSAGE DESCRIPTION CHECK OPEN CIRCUIT LINE There is a problem with the line contactor. Refer problem to a qualified JLG mechanic. CONTACTOR CONTACTOR DRIVER There is a problem with the power module line Refer problem to a qualified JLG mechanic.

  • Page 108: Ground Output Driver

    FAULT MESSAGE DESCRIPTION CHECK LEFT BRAKE - SHORT TO A problem has been detected in this function. Refer problem to a qualified JLG mechanic. 3312 BATTERY RIGHT BRAKE - SHORT TO A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
  • Page 109 FAULT MESSAGE DESCRIPTION CHECK JIB LIFT DOWN VALVE - SHORT A problem has been detected in this function. Refer problem to a qualified JLG mechanic. 33105 TO BATTERY LEFT BRAKE - SHORT TO A problem has been detected in this function.
  • Page 110 FAULT MESSAGE DESCRIPTION CHECK PROPORTIONAL RELIEF A problem has been detected in this function. Refer problem to a qualified JLG mechanic. 33367 VALVE - SHORT TO GROUND PROPORTIONAL RELIEF A problem has been detected in this function. Refer problem to a qualified JLG mechanic.

  • Page 111: Thermal Limit

    FAULT MESSAGE DESCRIPTION CHECK OVERLOAD LIGHT - SHORT TO A problem has been detected in this function. Refer problem to a qualified JLG mechanic. 33387 GROUND OVERLOAD LIGHT - OPEN A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
  • Page 112 FAULT MESSAGE DESCRIPTION CHECK SLAVE MODULE The Slave Module (left controller) temperature Refer problem to a qualified JLG mechanic. TEMPERATURE - OUT OF sensor is out of the permitted range. RANGE MASTER MODULE TOO HOT - The Master Module (right controller) has reached •...

  • Page 113: Battery Supply

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK LEFT DRIVE MOTOR A problem has been detected in this function. Refer problem to a qualified JLG mechanic. 4213 TEMPERATURE - OUT OF RANGE 4-4 Battery Supply FAULT MESSAGE...
  • Page 114 • Check for damaged batteries, battery cables or con- nections. • Check battery charger function. Be sure to observe indicators for at least 30 seconds. Refer problem to a qualified JLG mechanic. MASTER MODULE VOLTAGE A problem has been detected with the batteries or • Recharge batteries.

  • Page 115: Transmission And Drive System

    • Check for damaged batteries, battery cables or con- nections. • Check battery charger function. Be sure to observe indicators for at least 30 seconds. Refer problem to a qualified JLG mechanic. 4-6 Transmission and Drive System FAULT MESSAGE DESCRIPTION...

  • Page 116: Communication

    • Clear the obstacle. TOUCH DETECTED device (if equipped). Refer problem to a qualified JLG mechanic. FUNCTIONS CUTOUT - GATE This DTC does not apply to the Toucan 10E. Refer problem to a qualified JLG mechanic. OPEN DETECTED 6-46 – JLG Lift –...

  • Page 117: Electric Motor

    7-7 Electric Motor FAULT MESSAGE DESCRIPTION CHECK MASTER MODULE CAPACITOR There is a problem with the Master Module (right Refer problem to a qualified JLG mechanic. 7721 BANK FAULT controller). SLAVE MODULE CAPACITOR There is a problem with the Slave Module (left Refer problem to a qualified JLG mechanic.

  • Page 118: Tilt Sensor

    FAULT MESSAGE DESCRIPTION CHECK LEFT MOTOR OUTPUT-OUT OF The left motor voltage output is lower than Refer problem to a qualified JLG mechanic. 7729 RANGE LOW expected (Slave Module). PUMP MOTOR OUTPUT-OUT The pump motor voltage output is higher than Refer problem to a qualified JLG mechanic.

  • Page 119: Platform Load Sense

    8-2 Platform Load Sense FAULT MESSAGE DESCRIPTION CHECK LLS HAS NOT BEEN The Load Sensing System has not been cali- Refer problem to a qualified JLG mechanic. CALIBRATED brated. FUNCTIONS CUTOUT - The platform is overloaded and functions are • Unload the platform.

  • Page 120: Hardware

    • Check the steer sensor for damage. 8666 • Check that the steer sensor is securely mounted. Refer problem to a qualified JLG mechanic. STEER SENSOR - NOT Invalid signal from the steer sensor. • Check the steer sensor for damage.
  • Page 121 There is an internal error in the Slave Module (left • Cycle power to clear the fault. 9995 FAILURE controller). Refer problem to a qualified JLG mechanic. MASTER MODULE MEMORY There is an internal error in the Master Module • Cycle power to clear the fault. 9996 FAILURE (right controller).
  • Page 122 There is an internal error in the Slave Module (left • Cycle power to clear the fault. 99103 RESET controller). Refer problem to a qualified JLG mechanic. MASTER MODULE There is an internal error in the Master Module • Cycle power to clear the fault. 99104 WATCHDOG2 RESET (right controller).
  • Page 123 There is an internal error in the Master Module • Cycle power to clear the fault. 99112 ERROR (right controller). Refer problem to a qualified JLG mechanic. MASTER MODULE - INTERNAL There is an internal error in the Master Module • Cycle power to clear the fault. 99114 ERROR (right controller).
  • Page 124 • Cycle power to clear the fault. 99122 ERROR (right controller). Refer problem to a qualified JLG mechanic. SLAVE MODULE - INTERNAL There is an internal error in the Slave Module (left • Cycle power to clear the fault. 99123 ERROR controller).
  • Page 125 There is an internal error in the Master Module • Cycle power to clear the fault. 99131 ERROR (right controller). Refer problem to a qualified JLG mechanic. MASTER MODULE - INTERNAL There is an internal error in the Master Module • Cycle power to clear the fault. 99132 ERROR (right controller).
  • Page 126 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6-56 – JLG Lift – 31210088...

  • Page 127: Inspection And Repair Log

    SECTION 7 – INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Type of machine: ________________________________________ Machine Serial Number: __________________________________ Table 7-1. Inspection and Repair Log Date Comments 31210088 – JLG Lift –...
  • Page 128 SECTION 7 – INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments Name: ______________________________________________ Signature: _____________________________________________ – JLG Lift – 31210088...
  • Page 130 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. Guillaume mon Amy...

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