Oshkosh Corporation JLG TOUCAN 10E Operation And Safety Manual
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Oshkosh Corporation 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
S/N A300036700 to present
TOUCAN 26E
S/N A300052839 to present
31210174
August 28, 2018
English - Operation & Safety

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. TOUCAN 10E S/N A300036700 to present TOUCAN 26E S/N A300052839 to present 31210174 August 28, 2018 English - Operation & Safety ®...
  • Page 2 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.
  • Page 3 FOREWORD FOREWORD This manual is a very important tool! Keep it with the machine at all times. 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.
  • Page 4 FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. INDICATES AN IMMINENTLY HAZARDOUS SITUATION.
  • 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 - November 03, 2014 Manual Revised - February 01, 2015 Manual Revised - August 28, 2018 - Revised Covers, Prop 65 – JLG Lift – 31210174...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS General ......2-6 Function Check .
  • Page 8 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE OPERATION ......4-5 4.13 TOWING .
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Battery Voltage and Electrolyte Specific Gravity . 6-14 Introduction ......6-28 Filling System Maintenance .
  • Page 10 TABLE OF CONTENTS TABLE NO. TITLE PAGE NO. LIST OF TABLES Minimum Approach Distance (M.A.D.) ..1-5 Beaufort Scale (For Reference Only) ..1-10 Inspection and Maintenance Table.
  • Page 11 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE LIST OF FIGURES 4-12. Electric Brake Release ..... 4-18 6-1.
  • Page 12 TABLE OF CONTENTS NOTES: – JLG Lift – 31210174...

  • Page 13: Section 1 - Safety Precautions

    SECTION 1 – SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS GENERAL PRE-OPERATION This section outlines the necessary precautions for proper Operator Training and Knowledge and safe machine operation and maintenance. For proper machine use, it is mandatory that a daily routine is estab- •...

  • Page 14: Workplace Inspection

    SECTION 1 – SAFETY PRECAUTIONS Machine Inspection • All operating personnel must be familiar with the emer- gency controls and emergency operation of the machine • Before machine operation, perform inspections and func- as specified in this manual. tional checks. Refer to Section 2 of this manual for •...

  • Page 15: Operation

    SECTION 1 – SAFETY PRECAUTIONS OPERATION • When driving, always position extending structure over rear axle in line with the direction of travel. Remember, if extending structure is over the front axle, steer and drive General functions will be reversed. •...

  • Page 16: Trip And Fall Hazards

    SECTION 1 – SAFETY PRECAUTIONS Trip and Fall Hazards • Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or similar During operation, occupants in the platform must wear a full items on platform to provide additional reach.

  • Page 17: Electrocution Hazards

    SECTION 1 – SAFETY PRECAUTIONS Electrocution Hazards Table 1-1. Minimum Approach Distance (M.A.D.) Voltage Range MINIMUM APPROACH DISTANCE • This machine is not insulated and does not provide pro- tection from contact or proximity to electrical current. (Phase to Phase) in Meters (Feet) 0 to 50 kV 3 (10)

  • Page 18: Tipping Hazards

    SECTION 1 – SAFETY PRECAUTIONS Tipping Hazards sions of the insulating barrier. This determination shall be made by a qualified person in accordance with employer, • The user should be familiar with the surface before driv- local or governmental requirements for work practices ing.
  • Page 19 SECTION 1 – SAFETY PRECAUTIONS • Do not raise the platform or drive from an elevated posi- • If extending structure assembly or platform is in a position tion unless the machine is on firm, level and smooth sur- that one or more wheels are off the ground, all persons faces.

  • Page 20: Crushing And Collision Hazards

    SECTION 1 – SAFETY PRECAUTIONS Crushing and Collision Hazards and other factors which may cause hazard of collision or injury to personnel. • Approved head gear must be worn by all operating and • Be aware of stopping distances in all drive speeds. When ground personnel.

  • Page 21: Additional Hazards / Safety

    SECTION 1 – SAFETY PRECAUTIONS ADDITIONAL HAZARDS / SAFETY • Ensure extending structure is in the stowed position prior to towing, lifting or hauling. The platform and the tool tray must be completely empty of tools. • Do not use machine as a ground for welding. •...
  • Page 22 SECTION 1 – SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12,5 M/S OR 45 KM/H). Table 1-2. Beaufort Scale (For Reference Only) Wind Speed Beaufort Description Land Conditions Number 0-0.2 Calm Calm. Smoke rises vertically. 0.3-1.5 Light air Wind motion visible in smoke.

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

    SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where over- head obstructions, other moving equipment, and obsta- The aerial platform is a personnel handling device; so it is cles, depressions, holes or drop-offs exist.

  • Page 24: Preparation, Inspection, And Maintenance

    SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION PREPARATION, INSPECTION, AND MAINTENANCE The following table covers the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms. The frequency of inspections and mainte- nance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a...
  • Page 25 SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Table 2-1.Inspection and Maintenance Table Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Inspec- Before using each day; User or Operator User or Operator Operator and Safety Manual tion or whenever there’s an Operator change. Pre-Delivery Before each sale, lease, or rental delivery.

  • Page 26: Pre-Start Inspection

    SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection 5. “Walk-Around” Inspection – Refer to Figure 2-1. 6. Battery – Charge as required. The Pre-Start Inspection must include each of the following: 7. Hydraulic Oil – Check the hydraulic oil level in the reser- 1.

  • Page 27: Daily Walk-Around Inspection

    SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-1. Daily Walk-Around Inspection 31210174 – JLG Lift –...

  • Page 28: General

    SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION General 4. Wheel/Tire Assemblies - Properly secured, no missing lug nuts. Inspect for worn tread, cuts, tears or other dis- Begin the "Walk-Around Inspection" at Item 1, as noted on crepancies. Inspect wheels for damage and corrosion. the diagram.

  • Page 29: Function Check

    SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check 2. From the Platform Control Console: a. Ensure that the platform control console is firmly Refer to Sections 3 & 4 for description and operation of machine secured. functions. b.

  • Page 30: Tilt Sensor Check

    SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Tilt Sensor Check i. Swing the superstructure either to the left or to the right: when the jib is no longer over the rear axle, the drive orientation system (DOS) indicator lights up (Yellow).

  • Page 31: Overload Sensor Check (If Equipped)

    SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Overload Sensor Check (If Equipped) Check the overload indicator light/alarm to ensure proper operation. Wedge a block (P/N: ST2741 - located in the manual storage container) to activate the overload sensor and keep it activated.

  • Page 32: Slack/Broken Chain Sensors Check

    SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Slack/Broken Chain Sensors Check Check the slack/broken chain indicator light/alarm and interlock to ensure proper operation. Refer to Figure 2-4. for chain sensors location (Qty:3). Wedge a block (P/N: ST2741 - located in the manual storage container) to activate a slack chain sensor and keep it activated.

  • Page 33: Section 3 - Machine Controls And Indicators

    SECTION 3 – MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS Driving wheels 6- Ground Control Panel Mast manual descent valve Steering Wheels 7- Telescopic mast Jib manual descent valve Access door to Pump/Motor 8- Platform Swinging motor release valve Control valves 9- Platform Control console Manual swinging operating device...

  • Page 34: General

    SECTION 3 – MACHINE CONTROLS AND INDICATORS GENERAL Ground Control Station This section provides the necessary information needed to understand controls and their functions. DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSON- NEL IN THE PLATFORM EXCEPT IN AN EMERGENCY. THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION.

  • Page 35: Ground Control Station

    SECTION 3 – MACHINE CONTROLS AND INDICATORS 1- 5 Amp Circuit Breaker 2- Overload Warning Light (If equipped) 3- Multi-Display Indicator (MDI) 4- Platform/Off/Ground Selector Switch 5- Machine Safety System Override (MSSO) (If equipped) 6- Battery Charger Status Indicators (depending on equipment) 7- Emergency Stop Switch 8- Function Enable Button 9- Mast Lift/Lower Buttons...
  • Page 36 SECTION 3 – MACHINE CONTROLS AND INDICATORS 1. 5 Amp. Circuit Breaker - This circuit breaker protects 3. Multi-Display Indicator (MDI) the control circuit in case of a short circuit or other mal- Hourmeter - The hourmeter symbol is lit when function.
  • Page 37 SECTION 3 – MACHINE CONTROLS AND INDICATORS 4. Platform/Off/Ground Selector Switch - A three-posi- 8. Function Enable Button - A membrane switch that must tion, key-operated power select switch supplies power be pushed in and held to enable the controls of the to the platform or ground controls and powers machine ground control station.

  • Page 38: Platform Manual Descent Valves

    SECTION 3 – MACHINE CONTROLS AND INDICATORS Platform Manual Descent Valves Mast Manual Descent Valve and Actuator - The mast manual descent valve actuator is stored behind the The platform manual descent valves are used in the event of access door to the battery. total power failure to lower the platform using gravity.

  • Page 39: Jib Manual Descent Valve

    SECTION 3 – MACHINE CONTROLS AND INDICATORS Jib Manual Descent Valve - The jib manual descent button (2) is located on the jib cyl- inder valve. Figure 3-3. Mast Manual Descent Valve Figure 3-4. Jib Manual Descent Valve 31210174 – JLG Lift –...

  • Page 40: Manual Swinging Operating Devices

    SECTION 3 – MACHINE CONTROLS AND INDICATORS Manual Swinging Operating Devices DO NOT RELEASE THE SWINGING MOTOR UNLESS THE MACHINE IS ON The manual swinging operating devices are used in the event of A LEVEL SURFACE. total power failure to manually swing the superstructure. Those devices are composed of: - a rotary valve (1) located on the pump/motor control valves assembly to release the swinging motor (Refer to Figure 3-...

  • Page 41: Platform Control Station

    SECTION 3 – MACHINE CONTROLS AND INDICATORS Platform Control Station 1. Open the access door to the pump/motor assembly. 2. Fully unscrew the rotary valve. 3. Depending on equipment, engage a square 1/2 inch ratchet wrench in the square hole on top of the pinion or TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON- lift the folding lever.
  • Page 42 SECTION 3 – MACHINE CONTROLS AND INDICATORS 1. Indicator Panel 2. Emergency Stop Switch 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.

  • Page 43: Platform Control Indicator Panel

    SECTION 3 – MACHINE CONTROLS AND INDICATORS 1. Indicator panel NOTE: The indicator panel uses different shaped symbols to alert the operator to different types of operational situations that could arise. The definition of those symbols are explained below. Indicates a potentially hazardous situation, which if not corrected, could result in serious injury or death.
  • Page 44 SECTION 3 – MACHINE CONTROLS AND INDICATORS a. When lit, indicates that the controls are enabled. If e. Indicates that the chassis is out of level (refer to a function is not actuated within seven seconds, or machine specifications for max. allowable slope a seven seconds lapse between ending one func- angle).
  • Page 45 SECTION 3 – MACHINE CONTROLS AND INDICATORS 2. Emergency Stop Switch - A two-position, red, emer- 6. Mast/Jib Function Enable Button - This button is used gency stop switch, when positioned to ON furnishes to enable mast and jib functions. It must be depressed operating power to the platform control station.
  • Page 46 SECTION 3 – MACHINE CONTROLS AND INDICATORS 9. Drive Orientation Override Button - When the jib is swung beyond the rear tires or further in either direction, the Drive Orientation indicator will illuminate. Before driv- ing, locate the black/white orientation arrows on both the chassis and the platform controls.

  • Page 47: Decal Installation

    SECTION 3 – MACHINE CONTROLS AND INDICATORS DECAL INSTALLATION Figure 3-7. Decal Installation - Sheet 1 31210174 – JLG Lift – 3-15...
  • Page 48 SECTION 3 – MACHINE CONTROLS AND INDICATORS Figure 3-8. Decal Installation - Sheet 2 3-16 – JLG Lift – 31210174...
  • Page 49 SECTION 3 – MACHINE CONTROLS AND INDICATORS Figure 3-9. Decal Installation - Sheet 3 31210174 – JLG Lift – 3-17...
  • Page 50 SECTION 3 – MACHINE CONTROLS AND INDICATORS Table 3-1. 10E & 26E - Decal Installation Item # Item # ANSI Spanish Portuguese ANSI Spanish Portuguese 1705781 1705781 1705781 1705781 1705781 1705803 1703785 1703785 1703785 1704031 AU1825 AU1825 AU1825 AU1825 AU1825 AU2104 AU2104 AU2104...

  • Page 51: Section 4. Machine Operation

    SECTION 4 – MACHINE OPERATION SECTION 4. MACHINE OPERATION DESCRIPTION OPERATING SPECIFICATIONS AND LIMITATIONS Capacities This machine is a self-propelled hydraulic lift equipped with a work platform on the end of an elevating and rotating mast. The mast and the jib can be raised above horizontal with or The primary operator control station is in the platform and shall without any load in the platform if: only be accessed with the extending structure fully stowed.

  • Page 52: Position Of Least Backward Stability

    SECTION 4 – MACHINE OPERATION Figure 4-2. Position of Least FORWARD stability Figure 4-1. Position of Least BACKWARD stability – JLG Lift – 31210174...

  • Page 53: Grade And Side Slope

    SECTION 4 – MACHINE OPERATION Grade and Side Slope With the machine in transport mode, travelling is limited by two factors: gradeability and side slope (Refer to Figure 4-3.). Gradeability is the percent of grade of the incline the machine can climb.

  • Page 54: Grade And Side Slope

    SECTION 4 – MACHINE OPERATION Figure 4-3. Grade and Side Slope – JLG Lift – 31210174...

  • Page 55: Operation

    SECTION 4 – MACHINE OPERATION OPERATION STEERING AND TRAVELLING (DRIVING) 1. At ground control station, position the key-select switch to PLATFORM. DO NOT DRIVE WITH MAST OUT OF TRANSPORT (STOWED) POSITION 2. Position the emergency stop switch to the on (out) posi- EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE FREE OF tion by turning it clockwise.

  • Page 56: Steering

    SECTION 4 – MACHINE OPERATION Steering 1. Squeeze and hold the trigger switch (1) on front of the joystick. 2. Activate the thumb switch on top of the joystick to right (2) for travelling right or to left (3) for travelling left. When released, the thumb switch will return to the cen- ter-off position and the wheels will remain in the previ- ously selected position.

  • Page 57: Drive Orientation System (Dos)

    SECTION 4 – MACHINE OPERATION Drive Orientation System (DOS) RAISING AND LOWERING THE PLATFORM When the structure is swung beyond the rear wheels or further in either direction, the drive orientation indicator (1) will illumi- DO NOT RAISE THE PLATFORM EXCEPT ON A SMOOTH, FIRM AND nate and drive will be disabled.

  • Page 58: Raising And Lowering The Mast

    SECTION 4 – MACHINE OPERATION Raising and lowering the mast Raising and lowering the jib 1. With all control levers in neutral position, push in and 1. With all control levers in neutral position, push in and hold the green enable button (1) on the left hand side hold the green enable button (1) on the left hand side of the console.

  • Page 59: Swinging

    SECTION 4 – MACHINE OPERATION SWINGING 1. With all control levers in neutral position, squeeze and hold the trigger switch (1) on front of the joystick. 2. Move the joystick to the desired direction: right (2) or left (3). The speed of the movement is proportionally DO NOT SWING THE SUPERSTRUCTURE EXCEPT ON A SMOOTH, FIRM controlled by the distance of travel of the joystick.

  • Page 60: Alarms

    SECTION 4 – MACHINE OPERATION 1. Position the key-select switch (1) to GROUND. 2. Push and hold the enable button (2). 3. Actuate the appropriate function button (3) until the desired elevation or position of the platform is achieved. ALARMS Overload Warning Light/Alarm (If equipped) When the maximum rated load in the platform is exceeded, RED light indicators at both the ground and the platform control sta-...

  • Page 61: Slack Chain Warning Light/Alarm

    SECTION 4 – MACHINE OPERATION Slack Chain Warning Light/Alarm When the tilt indicator warning is activated, the following func- tions are affected: -The Drive function is disabled out of stowed position. When the system detects a slack chain condition, the RED light -Mast/Jib Lift and Swinging movements switch to Creep indicator at platform control station will illuminate and an audible mode.

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

    SECTION 4 – MACHINE OPERATION IF THE SLACK CHAIN ALARM HAS BEEN TRIGGERED BY THE MAST IF THE SELF RESCUE PROCEDURE FAILED, DISCONTINUE OPERATION JAMMING, FAILURE TO RESPECT THE PROCEDURES BELOW CAN IMMEDIATELY. CAUSE SERIOUS INJURIES. DO NOT USE MANUAL DESCENT CONTROLS. DO NOT USE MANUAL DESCENT CONTROLS.

  • Page 63: Shut Down And Park

    SECTION 4 – MACHINE OPERATION 4.10 SHUT DOWN AND PARK 4.11 BATTERY CHARGING Shut down and park the machine as follows: NOTE: Be sure that the machine is parked in a well-ventilated area before charging begins. 1. Drive the machine to a reasonably well-protected and well-ventilated area.

  • Page 64: Battery Charger Fault Code

    SECTION 4 – MACHINE OPERATION Battery Charger Fault Code 1. Connect the AC input plug (1) to a grounded outlet. If a fault occured during charging, the red (Fault LED located on the Ground Control Station panel) will flash with a code corre- sponding to the error.
  • Page 65 SECTION 4 – MACHINE OPERATION Table 4-1. Battery Charger Fault Code Flash(s) Fault Remedy Battery voltage high Auto-recover - Indicates a high battery pack voltage. Auto-recover - Indicates either a battery pack failure, battery pack not connected to charger or battery volts per cell is less Battery voltage low than 0.5 VDC.

  • Page 66: Tie-Down/Lift Lugs

    SECTION 4 – MACHINE OPERATION 4.12 TIE-DOWN/LIFT LUGS Tie Down 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.

  • Page 67: Lifting

    SECTION 4 – MACHINE OPERATION Lifting The machine may also be lifted using a fork truck: - Fully lower the mast and the jib. When lifting the machine: - Position the platform in line with the chassis with the jib over the rear axle.

  • Page 68: Electric Brake Release

    SECTION 4 – MACHINE OPERATION Electric Brake Release 1. Chock wheels or secure machine with tow vehicle. 2. Position the key-select-switch to ground control station NOTE: Electrical release of the brakes requires enough battery (1). power to hold the brakes in released mode until destina- tion is reached.

  • Page 69: Section 5 - Emergency Procedures

    SECTION 5 – EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES GENERAL FOLLOWING ANY INCIDENT, THOROUGHLY INSPECT THE MACHINE This section explains the steps to be taken in case of an AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS, emergency situation during operation. THEN FROM THE PLATFORM CONTROLS.

  • Page 70: Platform Or Jib Caught Overhead

    SECTION 5 – EMERGENCY PROCEDURES Platform or Jib Caught Overhead NOTE: If the MSSO functionality is used, the fault indicator will flash and a fault code is set in the JLG Control System If the platform or the jib become jammed or snagged in over- which must be reset by a qualified JLG Service Techni- head structures or equipment, rescue platform occupants cian.

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

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION This section of the manual provides additional necessary infor- mation to the operator for proper operation and maintenance of this machine. The maintenance portion of this section is intended as informa- tion to assist the machine operator to perform daily mainte- nance tasks only, and does not replace the more thorough Preventive Maintenance and Inspection Schedule included in...

  • 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 400 N 100 lbf (445 N) Maximum Operating Wind Speed...
  • Page 73 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-1. Operating Specifications And Dimensions Approximate Gross Machine Weight 2990 kg 6834 lbs (3100 kg) Maximum Tire Load (per wheel) 1680 kg 3485 lbs (1580 kg) Maximum Hydraulic Pressure 18 MPa 2600 psi Maximum Ground Bearing Pressure 21 kg/cm²...
  • Page 74 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE – JLG Lift – 31210174...
  • Page 75 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-2. Dimensions Table 6-3. Tires Specifications Model Model Model Model DESCRIPTION DESCRIPTION TOUCAN 10E TOUCAN 26E TOUCAN 10E TOUCAN 26E Platform Height - Stowed 0.35 m 14” (0.35 m) Size Ø406 x 125 mm Ø406 x 125 mm Platform Height - Elevated 8.10 m...
  • 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) Power Pump...
  • 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 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-8. Hydraulic Oil Specifications - Optional SPECIFICATIONS PANOLIN HLP SYNTH 3504 NERVOL EQUIVIS XV32 NERVOL AGROFLUID 32 Oil Type Synthetic Biodegradable Low Temperature Synthetic Food Compatible ISO Viscosity Grade 32 cSt 32 cSt 32 cSt Cinematic Viscosity @...

  • Page 79: Operator Maintenance

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OPERATOR MAINTENANCE 1. Battery 2. Oil Level / Oil Filter 3. Tires & Wheels 4. Overload System Spring Washers (If Equipped) 5. Turntable Bearing Lubrication 6. Telescopic Mast Lubrication 7. Lifting Chains Lubrication 8.

  • Page 80: Chassis Hood Removal

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE CHASSIS HOOD REMOVAL BATTERY MAINTENANCE - Unscrew the four (4) retaining screws (a); Battery Maintenance and Safety Practices - Remove first the left chassis cover (b) : Slide the cover to the rear of the machine (1) by approx. 20 mm (1”), then lift the covers to remove it completely;...

  • Page 81: Level Indicators

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE As with any wet cell battery, check the electrolyte level of the batteries often, using the floats in the center of each cell filling. Figure 6-4. Level Indicators 1. Float does not emerge - Insufficient Level 2.

  • Page 82: Filling System Draining (If Equipped)

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Filling System Draining (If equipped) Frequency - Prior to extended use in cold chamber or outdoor storage when temperatures could fall below freezing. 1. Battery Filling Network Draining - Disconnect the can (c) from the battery filling network (1). - Connect the pipe (b) on the battery filling network outlet (2).

  • Page 83: Draining The Water

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Regularly: NOTE: The water that contacted a battery is classified as indus- trial waste and must be disposed of according to regula- - Clean and dry the battery top. tions in force. - Ensure the connections are clean and tight.

  • Page 84: Battery Voltage And Electrolyte Specific Gravity

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Filling System Maintenance Battery Not Working Continuously or Inactive Battery Batteries filling circuit must be serviced once a year. Cleaning frequency must be increased in case of premature clogging of A battery that is not used or used intermittently must be stored the filter or a reduction of water flow.

  • Page 86: Battery Troubleshooting

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Battery Troubleshooting 6-16 – JLG Lift – 31210174...

  • Page 87: Oil Level/Oil Filter

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OIL LEVEL/OIL FILTER NOTE: Care should be taken not to introduce any impurities (dirt, water etc.) while cap or plug is removed. Hydraulic Oil Check Lube Point - Hydraulic Tank Reservoir Capacity: 6 liters Lube - Hydraulic Oil (See Table 6-7) Interval - Check Daily NOTE: Check oil level with the wheels fully steered to the left.

  • 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. 2.

  • Page 89: Tires & Wheels

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE TIRES & WHEELS Tighten the lug nuts to the proper torque to prevent wheels from coming loose. Use a torque wrench to tighten the fasteners. Over-tightening will result in breaking the lug nuts or perma- Tire Wear and Damage nently deforming the mounting holes in the wheels.

  • Page 90: Lubrication

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE LUBRICATION 3. The tightening of the lug nuts should be done in stages. Following the recommended sequence, tighten lug nut NOTE: Recommended lubricating intervals are based on per wheel torque. machine operation under normal conditions.

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

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Overload System Spring Washer (If Equipped) Spring washer stack lubrication is important to maintain over- load system accuracy. 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.

  • Page 92: Swing Bearing Race

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Swing Bearing Race Lube Points - 2 grease fittings Capacity: A/R Lube - A (See Table 6-6) Interval - Every 250 hours of operation 1. Remove chassis hoods. 2. From ground control station, raise the mast to gain access to the turntable plate.

  • Page 93: Swing Bearing Teeth

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Swing Bearing Teeth Lube Points - Coat each tooth Capacity: A/R Lube - B (See Table 6-6) Interval - Every 1000 hours of operation 1. Remove chassis hoods. 2. From ground control station, raise the mast to gain access to the turntable plate.

  • Page 94: Mast Profiles Races

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Mast Profiles Races Lube Points - Bronze spacers tracks Capacity: A/R Lube - A (See Table 6-6) Interval - Every 125 hours of operation or after each cleaning 1. From ground control station, fully raise the mast. 2.

  • Page 95: Lifting Chains

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Lifting Chains Lube Points - 6 chains Capacity: A/R Lube - C (See Table 6-6) Interval - After the first 50 hours of operation and every 125 hours of operation (or every 30 days) thereafter. Lubricant can be applied manually with a brush or by spraying.

  • Page 96: Overload System Verification (If Equipped)

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OVERLOAD SYSTEM VERIFICATION (IF EQUIPPED) Interval - At least every 6 month of operation. 1. Turn machine power on at ground control station. 2. Place a 200kg load evenly distributed on platform floor: - No alarm should be triggered.

  • Page 97: Tilt Sensor Verification

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.10 TILT SENSOR VERIFICATION Interval - At least every 6 month of operation. 1. Drive the machine on a known level surface. 2. Chock both rear wheels. 3. Remove chassis hoods and place a spirit level (digital display) on the chassis positioned in line w/chassis.

  • Page 98: Dtc Index

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.11 SUPPLEMENTAL INFORMATION 6.13 DTC INDEX The following information is provided in accordance with the DTC TABLE PAGE requirements of the European Machinery Directive 2006/42/EC 0-0 Help Comments....... 6-29 and is only applicable to CE machines.

  • Page 99: Dtc Check Tables

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.14 DTC CHECK TABLES 0-0 Help Comments FAULT MESSAGE DESCRIPTION CHECK EVERYTHING OK The normal help message in Platform Mode. Dis- plays on the analyzer only. GROUND MODE OK The normal help message in Ground Mode. Dis- plays on the analyzer only.

  • Page 100: Power-Up

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK FUNCTION SELECTED BUT LIFT The Mast or the Jib joystick was activated, but the • Release joystick and allow to center. 0027 ENABLE SWITCH OPEN enable switch was not. •...

  • Page 101: Platform Controls

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2-2 Platform Controls FAULT MESSAGE DESCRIPTION CHECK FUNCTION PROBLEM - HORN The horn switch was closed during power-up in • Check if the horn switch is damaged, obstructed or PERMANENTLY SELECTED platform mode. jammed.
  • Page 102 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK FUNCTION PROBLEM - The trigger switch was closed during power-up in • Check if the trigger switch is obstructed or jammed. TRIGGER PERMANENTLY platform mode. Refer problem to a qualified JLG mechanic. CLOSED TRIGGER CLOSED TOO LONG The trigger switch was closed for more than...

  • Page 103: Ground Controls

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2-3 Ground Controls FAULT MESSAGE DESCRIPTION CHECK FUNCTION PROBLEM - BRAKE The Brake Release Switch was closed during • Check if the concerned switch is damaged, obstructed RELEASE PERMANENTLY power-up in ground mode. or jammed.
  • Page 104 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK FUNCTION PROBLEM - SWING The Swing Left Switch was closed during power- • Check if the concerned switch is damaged, obstructed 2372 LEFT PERMANENTLY up in ground mode. or jammed.

  • Page 105: Function Prevented

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK MAIN MAST LIMIT SWITCH - The status of the Main Mast Limit Switch does not • Check if the Main Mast limit switch (left switch) is dam- 2379 NOT RESPONDING change while raising the mast.
  • Page 106 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK FUNCTION PREVENTED - Functions are prevented while the vehicle is • 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.

  • Page 107: Line Contactor Open Circuit

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3-1 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

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3-3 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.
  • Page 109 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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 DESCRIPTION CHECK BATTERY VOLTAGE TOO LOW -...
  • Page 114 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK BATTERY POWER LOW The batteries are discharged. • Recharge batteries. 4417 • Check for damaged batteries, battery cables or con- nections. • Check battery charger function. Be sure to observe indicators for at least 30 seconds.

  • Page 115: Transmission And Drive System

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK BATTERY DEEPLY The batteries are deeply discharged. • Recharge batteries. 4420 DISCHARGED • Check for damaged batteries, battery cables or con- nections. • Check battery charger function. Be sure to observe indicators for at least 30 seconds.

  • Page 116: Communication

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6-6 Communication FAULT MESSAGE DESCRIPTION CHECK CANBUS FAILURE - MASTER The control system failed to receive messages Refer problem to a qualified JLG mechanic. 6632 MODULE from the Master Module (right controller). CANBUS FAILURE - SLAVE The control system failed to receive messages Refer problem to a qualified JLG mechanic.

  • Page 117: Electric Motor

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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 •...

  • Page 120: Safety System Override

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK STEER SENSOR - DECOUPLED Invalid signal from the steer sensor. • 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.

  • Page 121: Hardware

    SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 9-9 Hardware FAULT MESSAGE DESCRIPTION CHECK MASTER MODULE A/D There is an internal error in the Master Module • Cycle power to clear the fault. 9992 FAILURE (right controller). Refer problem to a qualified JLG mechanic. SLAVE MODULE A/D FAILURE There is an internal error in the Slave Module (left •...
  • Page 122 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK MASTER MODULE FAILURE - A short circuit on the power outputs of the Master • Cycle power to clear the fault. 99100 CHECK POWER CIRCUITS OR Module (right controller) has been detected. Refer problem to a qualified JLG mechanic.
  • Page 123 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK MASTER MODULE - INTERNAL There is an internal error in the Master Module • Cycle power to clear the fault. 99108 ERROR (right controller). Refer problem to a qualified JLG mechanic. SLAVE MODULE - INTERNAL There is an internal error in the Slave Module (left •...
  • Page 124 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK MASTER MODULE - INTERNAL There is an internal error in the Master Module • Cycle power to clear the fault. 99118 ERROR (right controller). Refer problem to a qualified JLG mechanic. SLAVE MODULE - INTERNAL There is an internal error in the Slave Module (left •...
  • Page 125 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE FAULT MESSAGE DESCRIPTION CHECK MASTER MODULE - INTERNAL There is an internal error in the Master Module • Cycle power to clear the fault. 99127 ERROR (right controller). Refer problem to a qualified JLG mechanic. MASTER MODULE - INTERNAL There is an internal error in the Master Module •...
  • Page 126 SECTION 6 – GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTES: 6-56 – JLG Lift – 31210174...

  • Page 127: Section 7. 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 31210174 – JLG Lift –...
  • Page 128 SECTION 7 – INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments Name: ______________________________________________ Signature: _____________________________________________ – JLG Lift – 31210174...
  • Page 130 31210174 Corporate O ce JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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