Oshkosh Corporation JLG TOUCAN 8E Use and care manual

Operation and Safety Manual
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
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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. For more
information go to www.P65Warnings.ca.gov.
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FOREWORD
31210312 – JLG Lift – a
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. reserves the right to make specification changes without
prior notification. Contact JLG Industries, Inc. for updated information.
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FOREWORD
b– JLG Lift – 31210312
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT
AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE A RED BACKGROUND.
INDI CATES A POTENTIALLY HAZARDOUS SI TUATION. IF NOT
AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE AN ORANGE BACKGROUND.
INDIC ATES A POTEN TIALLY HA ZARDOUS 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 INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-
TECTION OF PROPERTY.
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.
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FOREWORD
31210312 – JLG Lift – c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-
TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED
JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-
RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS
PRODUCT.
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE
OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,
INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED
AND ACCURATE.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN
ACCIDENT 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.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
For:
• Accident Reporting
• Product Safety Publica-
tions
• Current Owner Updates
• Questions Regarding
Product Safety
• Standards and Regulations
Compliance Information
• Questions Regarding Special
Product Applications
• Questions Regarding Prod-
uct Modifications
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FOREWORD
d– JLG Lift – 31210312
REVISION LOG
Original Issue - September 17, 2019
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TABLE OF CONTENTS
31210312 – JLG Lift – i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1
Workplace Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Tipping Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . . 1-10
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . 1-11
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION,
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
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 Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Tilt Sensor Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Overload Sensor Check. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Gate sensors check (8E XL basket only). . . . . . . . . . . . 2-11
SECTION - 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
3.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . .3-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Stability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 MACHINE CONTROL LOCATIONS. . . . . . . . . . . . . . . . . . . . . .3-5
3.6 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3.7 GROUND CONTROL STATION . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Platform Manual Descent Valves - 8E/20E . . . . . . . . . 3-11
Mast Manual Descent Valve and Actuator - 8E/20E . . 3-12
Jib Manual Descent Valve - 8E/20E . . . . . . . . . . . . . . . . 3-13
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TABLE OF CONTENTS
ii – JLG Lift – 31210312
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Jib Manual Lift Up Valve (20E only) . . . . . . . . . . . . . . . 3-13
Manual Swinging Operating Devices - 8E/20E. . . . . 3-14
Platform Manual Descent Valves - 10E/26E. . . . . . . . 3-16
Mast Manual Descent Valve and Actuator - 10E/26E . 3-17
Jib Manual Descent Valve - 10E/26E . . . . . . . . . . . . . . 3-18
Jib Manual Lift Up Valve (26E only) . . . . . . . . . . . . . . . 3-18
Manual Swinging Operating Devices - 10E/26E . . . 3-19
3.8 PLATFORM CONTROL STATION . . . . . . . . . . . . . . . . . . . . . .3-21
Grade and Side Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
3.10 STEERING AND TRAVELLING (DRIVING). . . . . . . . . . . . . . .3-28
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Travelling (driving). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Drive Orientation System (DOS) . . . . . . . . . . . . . . . . . . 3-30
3.11 RAISING AND LOWERING THE PLATFORM . . . . . . . . . . . .3-31
Raising and lowering the mast . . . . . . . . . . . . . . . . . . . 3-31
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 (8E XL Basket Only) . 3-34
3.14 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3.15 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3.16 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
Charger Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.17 TIE-DOWN/LIFT LUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
3.18 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
Electric Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
SECTION - 4 - EMERGENCY PROCEDURES
4.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operator Unable to Control Machine . . . . . . . . . . . . . . 4-1
Platform or Jib Caught Overhead. . . . . . . . . . . . . . . . . . 4-1
4.3 EMERGENCY CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.4 PLATFORM MANUAL DESCENT . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.6 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.7 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
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TABLE OF CONTENTS
31210312 – JLG Lift – iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Other Publications Available Specific to this machine . 5-1
5.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 OPERATOR MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.4 CHASSIS HOOD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.5 BATTERY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Battery Maintenance and Safety Practices. . . . . . . . . 5-15
Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Use of a Battery in a Cold Environment. . . . . . . . . . . . 5-16
Battery Not Working Continuously or Inactive Battery 5-16
Battery Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.6 OIL LEVEL/OIL FILTER - 8E/20E. . . . . . . . . . . . . . . . . . . . . . . 5-18
Hydraulic Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.7 OIL LEVEL/OIL FILTER - 10E/26E . . . . . . . . . . . . . . . . . . . . . 5-19
Hydraulic Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.8 HYDRAULIC FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . 5-20
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Lifting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5.12 OVERLOAD SYSTEM VERIFICATION . . . . . . . . . . . . . . . . . . 5-42
5.13 TILT SENSOR VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.14 SLACK CHAIN SENSORS CHECK. . . . . . . . . . . . . . . . . . . . . . 5-44
5.15 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 5-45
5.16 DIAGNOSTIC TROUBLE CODES (DTC) . . . . . . . . . . . . . . . . 5-45
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5.17 DTC INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5.18 DTC CHECK TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
0-0 Help Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
2-2 Platform Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
2-3 Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
2-5 Function Prevented . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
3-1 Line Contactor Open Circuit . . . . . . . . . . . . . . . . . . 5-56
3-2 Line Contactor Short Circuit. . . . . . . . . . . . . . . . . . . 5-56
3-3 Ground Output Driver . . . . . . . . . . . . . . . . . . . . . . . . 5-57
4-2 Thermal Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
4-4 Battery Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
4-6 Transmission and Drive System . . . . . . . . . . . . . . . 5-64
6-6 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
6-7 Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
7-7 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
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