Oshkosh Corporation JLG TOUCAN 10E, Operation And Safety Manual

Page 1: ...Original Instructions Keep this manual with the machine at all times TOUCAN 8E TOUCAN 20E TOUCAN 10E TOUCAN 26E 31210312 September 17 2019 English Operation Safety AS T o o r d e r g o t o D i s c o u...

Page 2: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 3: ...alifornia 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 we...

Page 4: ...s 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 reser...

Page 5: ...DICATES A POTENTIALLY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES THIS DECAL WILL HAVE A YELLOW BACKGROUND INDICATES INFORMATIO...

Page 6: ...DENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP ERTY OR THE JLG PRODUCT Contact Product Safety and Reliability Department JLG Industries Inc...

Page 7: ...FOREWORD d JLG Lift 31210312 REVISION LOG Original Issue September 17 2019 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 8: ...Training Supervision 2 2 Operator Responsibility 2 2 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 2 3 PRE START INSPECTION 2 4 2 4 DAILY WALK AROUND INSPECTION 2 5 2 5 FUNCTION CHECK 2 8 Control St...

Page 9: ...31 Raising and lowering the jib 3 31 3 12 SWINGING 3 32 3 13 ALARMS 3 32 Overload Warning Light Alarm 3 32 Tilt Warning Light Alarm 3 32 Slack Chain Warning Light Alarm 3 33 Gate Opening Warning Light...

Page 10: ...5 9 TIRES WHEELS 5 21 Tire Wear and Damage 5 21 Wheel and Tire Replacement 5 21 Wheel Installation 5 21 5 10 DECAL INSTALLATION 5 23 5 11 LUBRICATION 5 38 Swing Bearing Race 5 39 Swing Bearing Teeth 5...

Page 11: ...ECT PAGE SECTION PARAGRAPH SUBJECT PAGE 8 1 Tilt Sensor 5 67 8 2 Platform Load Sense 5 67 8 6 Steering Axle 5 68 8 7 Safety System Override 5 69 9 9 Hardware 5 69 SECTION 6 INSPECTION AND REPAIR LOG T...

Page 12: ...s 5 9 5 4 Tires Specifications 5 9 5 5 Drive Motors Hydraulic Power Unit 5 10 5 6 Battery Specifications 5 11 5 7 Lubrication Specifications 5 11 5 8 Hydraulic Oil Specifications Standard 5 11 5 9 Hyd...

Page 13: ...3 30 3 20 Machine Tie Down 8E 20E 3 42 3 21 Machine Tie Down 10E 26E 3 43 3 22 Lifting the Machine 3 44 3 23 Lifting the Machine Using a Fork Truck 3 44 3 24 Electric Brake Release 3 46 4 1 Emergency...

Page 14: ...ation 26E ANSI Market 5 34 5 22 Decal Installation 10E AS NZL Market 5 35 5 23 Swing Bearing Race Lubrication 5 39 5 24 Swing Bearing Teeth Lubrication 5 40 5 25 Overload System Verification 5 42 5 26...

Page 15: ...TABLE OF CONTENTS viii JLG Lift 31210312 NOTES T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 16: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 17: ...operation of the machine has been completed under the supervision of an experienced and quali fied operator These sections contain the responsibilities of the owner user operator lessor and lessee co...

Page 18: ...to your utilization and application of the machine Workplace Inspection Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine Do not op...

Page 19: ...Service and Maintenance Manual Ensure all safety devices are operating properly Modifi cation of these devices is a safety violation MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MAD...

Page 20: ...next function Operate controls with slow and even pressure Do not allow personnel to tamper with or operate the machine from the ground with personnel in the plat form except in an emergency Do not c...

Page 21: ...only through gate area Use extreme cau tion when entering or leaving platform Ensure that the platform assembly is fully lowered Face the machine when entering or leaving the platform Always maintain...

Page 22: ...tance may be reduced if insulating barriers are installed to prevent contact and the barriers are rated for the voltage of the line being guarded These barriers shall not be part of or attached to the...

Page 23: ...e platform or drive with platform elevated while on or near a sloping uneven or soft surface Ensure machine is positioned on a firm level and smooth surface before elevating platform or driving with t...

Page 24: ...ndfeltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentle breeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloose paperraised Smallbranchesbegintomove 5 19 24 8 0 10 7 Fr...

Page 25: ...utdoors The addition of such items increases the exposed wind area of the machine Do not increase the platform size with unauthorized deck extensions or attachments If the extending structure assembly...

Page 26: ...tors which may cause hazard of colli sion or injury to personnel Be aware of stopping distances in all drive speeds When driving in high speed slow down the machine using the controller before stoppin...

Page 27: ...y strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property A maintenance program must be established by a qualified person and must be followed...

Page 28: ...nit in any way to affect stability Reference the Service and Maintenance Manual for the weights of critical stability items MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WIT...

Page 29: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 30: ...d safety systems Control labels instructions and warnings on the machine Rules of the employer and government regulations Use of approved fall protection device Enough knowledge of the mechanical oper...

Page 31: ...job site NOTE The Manufacturer or Distributor will provide qualified people for training assistance with the first unit s delivered and from that time forward as requestedbytheuseror his herpersonnel...

Page 32: ...urchasedused Owner DealerorUser QualifiedJLGMechanic ServiceandMaintenanceManualand applicableJLGinspectionform AnnualMachine Inspection SeeNote Annually nolaterthan13monthsfromthedateof priorinspecti...

Page 33: ...Safety Manuals Ensure that a copy of the Operation and Safety manual AEM Safety Man ual ANSI markets only and ANSI Manual of Responsi bility ANSI markets only is enclosed in the weather resistant sto...

Page 34: ...sure that the control console is firmly secured in the proper location Plac ards secure and legible control lever and switches return to neutral position and emergency stop switch functions properly 4...

Page 35: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 6 JLG Lift 31210312 Figure 2 1 Daily Walk Around Inspection 8E 20E T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 36: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 31210312 JLG Lift 2 7 Figure 2 2 Daily Walk Around Inspection 10E 26E T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 37: ...lowers the jib properly 2 From the Platform Control Console a Operate all functions including horn button to ensure proper operation b Ensure that all machine functions are disabled when the emergency...

Page 38: ...t indicator is illuminated to ensure proper operation Tilt Sensor Check Figure 2 3 Tilt Sensor Check the tilt indicator light alarm to ensure proper operation Wedge a block P N ST2741 located in the m...

Page 39: ...container to activate the overload sensor and keep it activated Refer to Figure 2 4 1 From the Platform Control Console a Confirm an audible alarm sounds b Verify the overload indicator Red blinks c C...

Page 40: ...proper operation of the gate opening warning light and interlock Open each gate in turn 1 From the Platform Control Console a Ensure the gate open warning light is illuminated b Check that all functi...

Page 41: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 12 JLG Lift 31210312 NOTES T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 42: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 43: ...STOP SWITCH TO STOP THE MACHINE 3 2 DESCRIPTION This machine is a self propelled hydraulic lift equipped with a work platform on the end of an elevating and rotating mast The primary operator control...

Page 44: ...ns of the machine See foreword for definitions of placard safety signal words Capacities The mast and the jib can be raised above horizontal with or without any load in the platform if 1 Machine is po...

Page 45: ...FORWARD and BACKWARD stability The machine s position of least FORWARD stability is shown in Figure 3 2 and its position of least BACKWARD stability is shown in Fig ure 3 1 TO AVOID FORWARD OR BACKWA...

Page 46: ...NE CONTROLS INDICATORS AND OPERATION 3 4 JLG Lift 31210312 Figure 3 1 Position of Least BACKWARD stability Figure 3 2 Position of Least FORWARD stability T o o r d e r g o t o D i s c o u n t E q u i...

Page 47: ...torControl valves 4 Counterweight 5 Jib 6 GroundControl Panel 7 Telescopic mast 8 Platform 9 Platform Control console 10 ManualStorageContainer 11 Access doorto battery 12 Mast manual descent valve 13...

Page 48: ...Counterweight 5 Jib 6 Ground Control Panel 7 Telescopic mast 8 Platform 9 Platform Control console 10 Manual Storage Container 11 Accessdoortobattery charger 12 Mast manual descent valve 13 Jib manua...

Page 49: ...result in serious injury or death This indicator will be red Indicates an abnormal operating condition which if not corrected may result in machine interruption or damage This indicator will be yellow...

Page 50: ...i 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 Mas...

Page 51: ...n the platform is out of transport position The wrench symbol is lit when a DTC Diagnosis Troubleshooting Code is displayed Five Digits Display In normal operating condition displays the total amount...

Page 52: ...LLOW Charging in process RED Charging abnormal 7 Emergency Stop Switch Depress the switch to stop all functions of the machine The switch must be turned clockwise to restore the machine functions 8 Ma...

Page 53: ...ES WHEN USING THE MANUAL DESCENT CONTROL ENSURE THE MAST ELE MENTS ARE LOWERING SYNCHRONOUSLY 1 To lower the mast a Install the actuator on the remote pull bar b Pull on the actuator Release the actua...

Page 54: ...Actuator 8E 20E The mast manual descent valve actuator 1 is stored behind the access door to the battery The mast manual descent remote pull bar 2 is located on the right side of the platform Figure...

Page 55: ...lve 8E 20E Jib ManualLift Up Valve 20E only The jib manual lift up operating device is used in the event of total power failure to manually lift up the jib 1 Push and hold the jib lift membrane switch...

Page 56: ...e event of 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 Figur...

Page 57: ...the rotary valve 1 3 Open the access cover to the operating hand wheel 4 Turn the hand wheel 2 clockwise to swing the struc ture to the right or turn the hand wheel counter clock wise to swing the st...

Page 58: ...DURE WHEN USING THE MANUAL DESCENT CONTROL ENSURE THE MAST ELE MENTS ARE LOWERING SYNCHRONOUSLY 1 To lower the mast a Install the actuator on the remote push bar b Push on the actuator Release the ac...

Page 59: ...0E 26E The mast manual descent valve actuator 1 is stored behind the access door to the battery The mast manual descent valve remote push bar 2 is located behind the access door to the pump motor asse...

Page 60: ...alve 10E 26E Jib ManualLift Up Valve 26E only The jib manual lift up operating device is used in the event of total power failure to manually lift up the jib 1 Push and hold the jib lift membrane swit...

Page 61: ...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 14 a pinion 2 located below the pump motor control valves com...

Page 62: ...ngage it in the turntable bearing teeth Turn the lever clockwise to swing the structure to the right or turn the lever counter clockwise to swing the structure to the left 4 When finished swinging fol...

Page 63: ...TURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED Figure 3 15 Platform Control Station 1 Indicator Panel 2 Emergency Stop Switch 3 Trigger Switch 4 Drive Swing Functions Controller 5 Steer Switch 6 Fu...

Page 64: ...gure 3 16 Platform Control Indicator Panel a Control EnableIndicator b Creep SpeedIndicator c System DistressIndicator d DriveOrientation Indicator e Tilt Indicator WarningLight f OverloadIndicator Wa...

Page 65: ...s is a signal for the operator to verify that the drive control is being operated in the proper direction i e controls reversed situations e Indicates that the chassis is out of level refer to machine...

Page 66: ...ine back ward Swing Engage the trigger switch lever 3 with the joystick in neutral position then toggle the control handle to the left to swing the superstructure to the left or toggle the control han...

Page 67: ...or further in either direc tion the Drive Orientation indicator will illuminate Before driving locate the black white orientation arrows on both the chassis and the platform controls Push and release...

Page 68: ...ode travelling is limited by two factors gradeability and side slope Gradeability is the percent of grade of the incline the machine can climb Side slope is the angle of the surface the machine can be...

Page 69: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 31210312 JLG Lift 3 27 Figure 3 17 Grade and Side Slope T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 70: ...N 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 EMERGENCY STOP SWITCH TO STOP THE MACHINE 3 10 S...

Page 71: ...s to the straightened position the switch must be acti vated in the opposite direction until the wheels are centered Travelling driving 1 With all control levers in neutral position squeeze and hold t...

Page 72: ...er direction the drive orientation indicator 1 will illuminate and drive will be disabled 1 Push and release the override button 2 and within 3 seconds move the drive steer controls to activate drive...

Page 73: ...t move the mast controller in the desired movement direction The speed of the movement is proportionally controlled by the dis tance of travel of the joystick 3 Return the controller to its centered n...

Page 74: ...MS Overload Warning Light Alarm When the maximum rated load in the platform is exceeded RED light indicators at both the ground and the platform con trol stations will blink and an audible alarm will...

Page 75: ...tem detects a slack chain condition the RED light indicator at platform control station will illuminate and an audible alarm will sound Slack chain condition is generally caused by the platform or the...

Page 76: ...rm is no longer actuated fully lower the mast and get qualified personnel to inspect the machine before it is used again If the mast has not released itself or if the alarm is still actu ated appropri...

Page 77: ...lows 1 Drive the machine to a reasonably well protected and well ventilated area 2 Ensure the platform is fully lowered 3 Turn the platform ground selector switch to off and remove the key to disable...

Page 78: ...IN ANY WAY ALWAYS DISCONNECT THE AC SUPPLY BEFORE MAKING OR BREAKING THE POS NEG CONNECTIONS TO THE BATTERY DO NOT OPEN OR DISASSEMBLE CHARGER The battery charger AC input plug 1 is located in the ba...

Page 79: ...eanthat the charger programming modeisactive The E F and P codesarefollowedbythreenum bersand aperiodto indicate different conditions e g E 0 0 4 Seethe Charger FaultCodes or ChargerError Codes sectio...

Page 80: ...edFault Error USB Indicator Readfaultcode e g F 0 0 1 number ontheChargeProfile ErrorDisplayandreferto the fault codetablebelow Flashingamber Fault Error USB Indicator Readerrorcode e g E 0 0 1 number...

Page 81: ...poorbatteryhealth very deeplydischarged battery and orpoorlyconnectedbattery Possiblesolutions Operateat lowerambient temperature Replacebatterypack CheckDC connections This errorwill automaticallycl...

Page 82: ...onditionhasbeencorrected E 0 1 6 E 0 1 8 E 0 2 6 USB operationfailed Softwareupgradefailureor scriptoperationfailure Ensurethe USB flash driveisproperly formattedandretryinserting theUSB flash drivein...

Page 83: ...tionpersists tryusing adifferent USB flashdrive E 0 2 8 Chargeprofileincompatibility Theselected chargeprofile isincompatiblewiththecharger ssoftware Updatecharger softwareor select adifferent chargep...

Page 84: ...ting the machine Platform must be fully lowered in the stowed position Remove all loose items from the machine Machine must be tied down to the truck bed or trailer deck as shown in Figure 3 20 8E 20E...

Page 85: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 31210312 JLG Lift 3 43 Figure 3 21 MachineTie Down 10E 26E T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 86: ...d using a fork truck Fully lower the mast and the jib Position the platform in line with the chassis with the jib over the rear axle Fork lift as shown in Figure 3 23 VERIFY THE CAPACITY OF THE FORK T...

Page 87: ...OWING It is not recommended that this machine be towed except in the event of an emergency or a machine power failure THE ALLOWABLE TOWING SPEED IS 3 KM H 1 9 MPH THE MAXIMUM ALLOWABLE TOWING DISTANCE...

Page 88: ...tion 1 3 Depress the brake release button 2 for one second to release the brakes Once the brakes are released an acoustic discontinuous sound alarm is triggered 4 When finished towing depress and hol...

Page 89: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 90: ...plat form occupant s Cranes and forklift can be used to stabilize motion of the machine Platform orJib CaughtOverhead If the platform or the jib becomes jammed or snagged in over head structures or e...

Page 91: ...2 1 Position the key select switch 1 to GROUND 2 Actuate the appropriate function button 2 until the desired elevation or position of the platform is achieved Figure 4 1 Emergency Controls T o o r d e...

Page 92: ...OPE 44 1 698 811005 AUSTRALIA 61 2 65 811111 E mail ProductSafety JLG com Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may...

Page 93: ...d thefault indicator will flash and a fault code is setintheJLGControlSystemwhichmustberesetbyaqualifiedJLGServiceTechni cian NOTE No functional checks of the MSSO system are necessary The JLG Control...

Page 94: ...is section is intended as infor mation to assist the machine operator to perform daily main tenance tasks only and does not replace the more thorough Preventive Maintenance and Inspection Schedule inc...

Page 95: ...adeabilityandSideslope 4 4 2 5 MaximumStowedTravelGrade Gradeability ReferenceFig 3 15 25 14 MaximumStowedTravelGrade Sideslope ReferenceFig 3 15 8 7 5 MaximumDriveSpeed Stowed 5 5km h MastElevated 0...

Page 96: ...e jib fully raised Model 8E 8E L 8EXL 10E 10E L MaximumTireLoad perwheel 1170kg 1020kg 1160kg 1660kg 1450kg MaximumHydraulicPressure 16MPa 18MPa MaximumGroundBearingPressure 17 2kg cm 15 9kg cm 17 1kg...

Page 97: ...5m s 41ft s 0 0ft s MaximumElevatedTravelGrade GradeabilityandSideslope 4 4 2 5 MaximumStowedTravelGrade Gradeability ReferenceFig 3 15 25 14 MaximumStowedTravelGrade Sideslope ReferenceFig 3 15 8 7...

Page 98: ...30kg 6900lbs 2750kg 6060lbs MaximumTireLoad perwheel 1250kg 2755lbs 1100kg 2425lbs 1760kg 3880lbs 1590kg 3510lbs MaximumHydraulicPressure 16MPa 18MPa MaximumGroundBearingPressure 17 9kg cm 255psi 16 6...

Page 99: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 5 6 JLG Lift 31210312 Figure 5 1 Range Diagram 8E 8E L 20E 20E L T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 100: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 31210312 JLG Lift 5 7 Figure 5 2 Range Diagram 8E XL T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 101: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 5 8 JLG Lift 31210312 Figure 5 3 Range Diagram 10E 10E L 26E 26E L T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 102: ...hineHeight 1 99m 6 2 OverallMachineWidth 0 99m 3 3 OverallMachineLength Dropbar Swinggates 2 10m 6 9 2 09m 6 8 2 35m 2 82m 9 3 2 77m 9 1 PlatformSize Length 0 85m 2 8 1 06m 0 70m 2 3 PlatformSize Widt...

Page 103: ...PTION All Models DriveMotor Voltage 15VAC Power 0 85kW Hydraulic Power Unit Motor Voltage 24VDC Power 3kW Pump Displacement 3 1cc rev 0 19cu in rev FlowRate 9 6l mn 13MPa 2 54gal min 1900psi Capacity...

Page 104: ...ns KEY SPECIFICATIONS e g A ExtremePressure MultiPurposeGrease MOBILUXEP2 COMPLEXEP2 B OpenGearLube MOBILTAC81 C NonDetergentMineralOil MOBILDTE10XL68 D SyntheticChainOil FuchsVT800 Tobeadaptedtothema...

Page 105: ...mperature SyntheticFoodCompatible ISOViscosityGrade 32cSt 32cSt 32cSt CinematicViscosity 20 C 4 F 1150cSt 428cSt 795cSt CinematicViscosity 0 C 32 F 280cSt 127cSt 198cSt CinematicViscosity 40 C 104 F 3...

Page 106: ...NCE Figure 5 4 Operator Maintenance Lubrication Diagram 8E 20E 1 Battery 2 Oil Level Oil Filter 3 Tires Wheels 4 Turntable Bearing Lubrication 5 Lifting Chains Lubrication 6 Overload System Verificati...

Page 107: ...5 Operator Maintenance Lubrication Diagram 10E 26E 1 Battery 2 Oil Level Oil Filter 3 Tires Wheels 4 Turntable Bearing Lubrication 5 Lifting Chains Lubrication 6 Overload System Verification 7 Tilt S...

Page 108: ...AINTENANCE Battery Maintenanceand SafetyPractices ENSURE THAT BATTERY ACID DOES NOT COMES INTO CONTACT WITH SKIN OR CLOTHING WEAR PROTECTIVE CLOTHING AND EYEWEAR WHEN WORKING WITH BATTERIES NEUTRALIZE...

Page 109: ...pacity The battery must be fully charged when the machine is operated in a cold environment Battery Not Working Continuously or InactiveBattery A battery that is not used or used intermittently must b...

Page 110: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 31210312 JLG Lift 5 17 Battery Troubleshooting T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 111: ...hthewheelsfullysteeredto theleft 1 Locate the decal 1 on the tank 2 through the left mast hood a hole is intended to this purpose 2 The oil level in the tank must be within the MIN mini mum and Max ma...

Page 112: ...Checkoil levelwiththewheelsfullysteeredto theleft 1 Open the access door to the hydraulic power unit 1 2 Locate the decal 2 on the tank 3 3 The oil level in the tank must be within the MIN mini mum a...

Page 113: ...e all dirt and debris from the filter plug 2 area 4 Unscrew the filter plug 2 5 Install a screw M6 in the threaded hole 3 of the fil ter and extract the filter 4 Use a container to collect oil that ca...

Page 114: ...ine into service If a cut tear chunk or other discrepancy exceeds any one or more of the following dimensions the tire must be replaced 76 mm long 19 mm wide 19 mm deep If the metal wheel is visible a...

Page 115: ...per wheel torque 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 opera tion Table 5 10 Wheel Torque Ch...

Page 116: ...GENERAL SPECIFICATIONS AND MAINTENANCE 31210312 JLG Lift 5 23 5 10 DECAL INSTALLATION Figure 5 10 Decal Installation 8E 20E All Markets Sheet 1 3 T o o r d e r g o t o D i s c o u n t E q u i p m e n...

Page 117: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 5 24 JLG Lift 31210312 Figure 5 11 Decal Installation 8E 20E All Markets Sheet 2 3 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 118: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 31210312 JLG Lift 5 25 Figure 5 12 Decal Installation 8E 20E All Markets Sheet 3 3 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 119: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 5 26 JLG Lift 31210312 Figure 5 13 Decal Installation 8E CE Market T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 120: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 31210312 JLG Lift 5 27 Figure 5 14 Decal Installation 20E ANSI Market Sheet 1 2 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 121: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 5 28 JLG Lift 31210312 Figure 5 15 Decal Installation 20E ANSI Market Sheet 2 2 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 122: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 31210312 JLG Lift 5 29 Figure 5 16 Decal Installation 8E AS NZL Market T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 123: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 5 30 JLG Lift 31210312 Figure 5 17 Decal Installation 10E 26E All Markets Sheet 1 3 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 124: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 31210312 JLG Lift 5 31 Figure 5 18 Decal Installation 10E 26E All Markets Sheet 2 3 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 125: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 5 32 JLG Lift 31210312 Figure 5 19 Decal Installation 10E 26E All Markets Sheet 3 3 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 126: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 31210312 JLG Lift 5 33 Figure 5 20 Decal Installation 10E CE Market T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 127: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 5 34 JLG Lift 31210312 Figure 5 21 Decal Installation 26E ANSI Market T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 128: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 31210312 JLG Lift 5 35 Figure 5 22 Decal Installation 10E AS NZL Market T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 129: ...4313 AU2108 AU2108 26 AU2107 AU2107 AU2107 1001245244 1001245244 9 1001227848 1001227848 1001227848 1703814 1703814 27 AU2108 AU2108 AU2108 1706740 1706740 10 1703811 1703811 1703811 AU2107 AU2107 28...

Page 130: ...1223858 1001223855 1001223856 100122385 1001223860 8 1001223861 1001223862 1001223861 1001223862 1001223861 1001223862 1001223861 1001223862 Item 26E ENG 26E L ENG 26E SPA POR 26E L SPA POR 26E ENG SP...

Page 131: ...ommended lubricating intervals are based on machine operation under normal conditions For machines used in multi shift operations and or exposed to hostile environments or conditions lubrication frequ...

Page 132: ...control station raise the mast to gain access to the turntable plate 3 Locate the access hole 1 on the turntable plate 4 Swing the structure to the right to gain access to the first grease fitting 2 5...

Page 133: ...ee Table 5 7 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 3 Remove bearing teeth covers 1 4 Apply gr...

Page 134: ...125 hours of operation or every 30 days thereafter Lubricant can be applied manually with a brush or by spray ing Apply lubricant longitudinally and transversally for the lubricant to reach the joints...

Page 135: ...5 Add an additional weight of 15 kg 33 lbs to the load L 6 Lift the platform with your hands to apply a small upwards force F then remove the force to let the platform fall RED light indicators at bo...

Page 136: ...the front on the chassis The tilt alarm must be activated within 0 2 below the value in Table 5 1 5 Place the spirit level perpendicular to the chassis and lift either the left or the right side of t...

Page 137: ...tom of mast 5 Wedge a block P N ST2741 as illustrated opposite to activate the slack chain sensor and keep it activated The system is functioning properly if 1 From the Platform Control Console An aco...

Page 138: ...leration to which the whole body is subjected does not exceed 0 5 m s 5 16 DIAGNOSTIC TROUBLE CODES DTC Introduction This sub section provides a reference for Diagnostic Trouble Codes DTC read from th...

Page 139: ...Contactor Open Circuit 5 55 3 2 Line Contactor Short Circuit 5 56 3 3 Ground Output Driver 5 56 4 2 Thermal Limit 5 60 4 4 Battery Supply 5 62 4 6 Transmission and Drive System 5 64 6 6 Communication...

Page 140: ...ervebattery charge Displayson the analyzer only theMDI s LED isblinkingwiththedisplay Off Normaloperationshouldresumeafterapowercycle Referproblemtoa qualified JLG mechanic 0010 RUNNING AT CUTBACK OUT...

Page 141: ...eckiftheenableswitchisdamaged Referproblemtoa qualified JLG mechanic 0028 DRIVEPREVENTED TILTED ELEVATED Driveispreventedwhiletheplatform is not in transport positionandthechassisisnot level Checkthat...

Page 142: ...UNCTIONPROBLEM HORN PERMANENTLY SELECTED Thehornswitchwasclosedduringpower up in platformmode Checkifthehornswitchisdamaged obstructedorjammed Referproblemtoa qualified JLG mechanic 224 FUNCTIONPROBLE...

Page 143: ...asclosedduringpower upin platformmode Checkifthetriggerswitchisobstructedorjammed Referproblemtoa qualified JLG mechanic 2210 TRIGGER CLOSEDTOO LONG WHILEINNEUTRAL Thetriggerswitchwas closed formoreth...

Page 144: ...44 GATELIMIT SWITCH FAULTY If equipped Aproblem hasbeendetected inthis function CheckiftheGateLimitSwitchesaredamaged obstructedor jammed Referproblemtoa qualified JLG mechanic DTC FAULT MESSAGE DESCR...

Page 145: ...heckiftheconcernedswitchisdamaged obstructedor jammed Referproblemtoa qualified JLG mechanic 2371 FUNCTIONPROBLEM JIB LIFT DOWN PERMANENTLY SELECTED TheJib Lift Down Switch was closed during power up...

Page 146: ...problemtoa qualified JLG mechanic 2377 CHAINSLACK SWITCH DISAGREEMENT Aproblemhasbeendetectedinthisfunction Referproblemtoa qualified JLG mechanic 2378 MAIN MAST LIMIT SWITCH DECOUPLED Theinformationf...

Page 147: ...qualified JLG mechanic DTC FAULT MESSAGE DESCRIPTION CHECK DTC FAULT MESSAGE DESCRIPTION CHECK 259 MODELCHANGED HYDRAULICSSUSPENDED CYCLEEMS Themodel selectionhasbeenchanged Referproblemtoa qualified...

Page 148: ...t chain Refertosection4fortherequiredoperationstoclearthefault CheckiftheChainSlackLimitSwitchesaredamaged obstructedorjammed Referproblemtoa qualified JLG mechanic 2544 ALL FUNCTIONSPREVENTED FAULTY...

Page 149: ...epower moduleline contactor control Referproblemtoa qualified JLG mechanic DTC FAULT MESSAGE DESCRIPTION CHECK 321 LINECONTACTORMISWIRED ONOR WELDED Thereisaproblemwiththelinecontactor Referproblemtoa...

Page 150: ...etectedinthisfunction Referproblemtoa qualified JLG mechanic 33100 JIB LIFT UP VALVE SHORT TO GROUND Aproblemhasbeendetectedinthisfunction Referproblemtoa qualified JLG mechanic 33101 JIB LIFT UP VALV...

Page 151: ...IT Aproblemhasbeendetectedinthisfunction Referproblemtoa qualified JLG mechanic 33358 FLOWDIRECTIONVALVE SHORT TOGROUND Aproblemhasbeendetectedinthisfunction Referproblemtoa qualified JLG mechanic 333...

Page 152: ...Referproblemtoa qualified JLG mechanic 33381 MASTERMODULE OUTPUTS SHORT TOBATTERY Aproblemhasbeendetectedinthisfunction Referproblemtoa qualified JLG mechanic 33382 SLAVEMODULEOUTPUTS SHORT TOBATTERY...

Page 153: ...EFT BRAKERETURN SHORT TO GROUND Aproblemhasbeendetectedinthisfunction Referproblemtoa qualified JLG mechanic 33391 RIGHT BRAKERETURN SHORT TOBATTERY Aproblemhasbeendetectedinthisfunction Referproblemt...

Page 154: ...ed thermal cutout Powerdownandallowtocool Donotoperateinambientsover60 C 140 F Referproblemtoa qualified JLG mechanic 4210 RIGHTDRIVEMOTORTOOHOT PLEASEWAIT Theright drivemotor temperatureis too high P...

Page 155: ...sorconnections Checkbatterychargerfunction Besuretoobserveindicators foratleast30seconds Referproblemtoa qualified JLG mechanic 442 BATTERY VOLTAGETOO HIGH SYSTEM SHUTDOWN Aproblemhas beendetectedwith...

Page 156: ...Aproblemhasbeendetectedwith thebatteriesor power module Rechargebatteries Checkfordamagedbatteries batterycablesorconnections Checkbatterychargerfunction Besuretoobserveindicators foratleast30seconds...

Page 157: ...chineoverspeed hasbeendetected onthe right motor Themachineshouldbedrivenatlimitedspeedinramps Referproblemtoa qualified JLG mechanic 4613 LEFT SPEEDSENSOR RPM HIGH Machineoverspeed hasbeendetected on...

Page 158: ...ifequipped Cleartheobstacle Referproblemtoa qualified JLG mechanic 673 FUNCTIONSCUTOUT GATE OPENDETECTED If equipped Platform entrygateis detected open CheckiftheGateLimitSwitchesaredamaged obstructed...

Page 159: ...mechanic 7727 LEFT MOTOROUTPUT OUTOF RANGEHIGH Theleftmotorvoltageoutputishigher than expected SlaveModule Referproblemtoa qualified JLG mechanic 7728 RIGHT MOTOROUTPUT OUT OF RANGELOW Theright motor...

Page 160: ...talled Ensurevehicleisnotstuckonsomethingpreventingmove ment Referproblemtoa qualified JLG mechanic DTC FAULT MESSAGE DESCRIPTION CHECK DTC FAULT MESSAGE DESCRIPTION CHECK 815 CHASSIS TILT SENSOR DISA...

Page 161: ...echanic DTC FAULT MESSAGE DESCRIPTION CHECK DTC FAULT MESSAGE DESCRIPTION CHECK 8664 STEERSENSOR OUTOF RANGEHIGH Invalid signal fromthesteersensor Checkthesteersensorfordamage Referproblemtoa qualifie...

Page 162: ...mtoa qualified JLG mechanic DTC FAULT MESSAGE DESCRIPTION CHECK DTC FAULT MESSAGE DESCRIPTION CHECK 873 MACHINESAFETYSYSTEM OVERRIDE OCCURED MachineSafetySystemOverridehasbeen used to overrideaSafetyS...

Page 163: ...rthefault Referproblemtoa qualified JLG mechanic 9997 SLAVEMODULEMEMORY FAILURE Thereisaninternal error intheSlaveModule left controller Cyclepowertoclearthefault Referproblemtoa qualified JLG mechani...

Page 164: ...reisaninternal error intheMasterModule right controller Cyclepowertoclearthefault Referproblemtoa qualified JLG mechanic 99105 SLAVEMODULEWATCHDOG2 RESET Thereisaninternal error intheSlaveModule left...

Page 165: ...echanic 99114 MASTERMODULE INTERNAL ERROR Thereisaninternal error intheMasterModule right controller Cyclepowertoclearthefault Referproblemtoa qualified JLG mechanic 99115 SLAVEMODULE INTERNAL ERROR T...

Page 166: ...chanic 99123 SLAVEMODULE INTERNAL ERROR Thereisaninternal error intheSlaveModule left controller Cyclepowertoclearthefault Referproblemtoa qualified JLG mechanic 99124 MASTERMODULE INTERNAL ERROR Ther...

Page 167: ...dule right controller Cyclepowertoclearthefault Referproblemtoa qualified JLG mechanic 99131 MASTERMODULE INTERNAL ERROR Thereisaninternal error intheMasterModule right controller Cyclepowertoclearthe...

Page 168: ...SECTION 6 INSPECTION AND REPAIR LOG Typeofmachine ________________________________________ MachineSerial Number __________________________________ Table 6 1 Inspection and Repair Log Date Comments T o...

Page 169: ...JLG Lift 31210312 Name ______________________________________________ Signature _____________________________________________ Table 6 1 Inspection and Repair Log Date Comments T o o r d e r g o t o D...

Page 170: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 171: ...T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...