JLG TOUCAN 10E, TOUCAN 26E, Toucan 8e, Toucan 12e Operation And Safety Manual

Operation and Safety Manual

®

Original Instructions - Keep this manual with the machine at all times.

TOUCAN 10E
TOUCAN 26E

AS

English - Operation and Safety Manual

31210088

May 11, 2010

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. reserves the right to make specification changes
without prior notification. Contact JLG Industries, Inc. for updated information.

31210088 – JLG Lift – a

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. IF NOT
AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD
DECAL WILL HAVE AN ORANGE BACKGROUND.

RESULT IN SERIOUS INJURY OR DEATH. THIS

INDICATES 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 INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO­TECTION OF PROPERTY.

b – JLG Lift – 31210088

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE­TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED
JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY­RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS
PRODUCT.

For:

• Accident Reporting

• Product Safety Publica­tions

• Current Owner Updates

• Questions Regarding
Product Safety

FOREWORD

• Standards and Regulations
Compliance Information

• Questions Regarding Spe­cial Product Applications

• Questions Regarding Prod­uct Modifications

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 PROP­ERTY 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:

31210088 – JLG Lift – c

Phone: [phone]
Fax: [phone]
E-mail: [e-mail]

FOREWORD

Original Issue - July 10, 2008

Manual Revised - June 22, 2009

Manual Revised - May 11, 2010

REVISION LOG

d – JLG Lift – 31210088

TABLE OF CONTENTS

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. . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . 1-4

Electrocution Hazards. . . . . . . . . . . . . . . . . . . . 1-5

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Crushing and Collision Hazards . . . . . . . . . . . . 1-8

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . 1-8

1.5 ADDITIONAL HAZARDS / SAFETY. . . . . . . . . . . . 1-9

SECTION - 2 - USER RESPONSIBILITIES, MACHINE
PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING. . . . . . . . . . . . . . . . . . . . 2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Responsibility . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . 2-4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Function Check. . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Tilt Sensor Check . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-2

Overload Sensor Check (If Equipped) . . . . . . 2-9

Slack/Broken Chain Sensors Check . . . . . . . 2-10

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . 3-2

Ground Control Station . . . . . . . . . . . . . . . . . . 3-2

Platform Manual Descent Valves. . . . . . . . . . . 3-6

Mast Manual Descent Valve . . . . . . . . . . . . . . 3-6

Jib Manual Descent Valve . . . . . . . . . . . . . . . . 3-7

Manual Swinging Operating Devices . . . . . . . 3-7

Platform Control Station . . . . . . . . . . . . . . . . . 3-8

3.3 DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . 3-14

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 OPERATING SPECIFICATIONS AND LIMITATIONS

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Grade and Side Slope . . . . . . . . . . . . . . . . . . . 4-3

4.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.4 STEERING AND TRAVELLING (DRIVING) . . . . . . 4-5

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Travelling (driving) . . . . . . . . . . . . . . . . . . . . . . 4-6

Drive Orientation System (DOS) . . . . . . . . . . . 4-7

. . 4-1

31210088 – JLG Lift – 1

TABLE OF CONTENTS

4.5 RAISING AND LOWERING THE PLATFORM . . . . 4-7

Raising and lowering the mast . . . . . . . . . . . . 4-8

Raising and lowering the jib . . . . . . . . . . . . . . 4-8

4.6 SWINGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.7 EMERGENCY CONTROL . . . . . . . . . . . . . . . . . . . 4-9

4.8 ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Overload Warning Light/Alarm (If equipped) 4-10

Tilt Warning Light/Alarm . . . . . . . . . . . . . . . . 4-10

Slack Chain Warning Light/Alarm . . . . . . . . 4-11

Soft Touch Warning Light/Alarm (Option) . . 4-12

4.9 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . 4-12

4.10 BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . 4-13

Battery Charger Fault Code. . . . . . . . . . . . . . 4-14

4.11 TIE-DOWN/LIFT LUGS . . . . . . . . . . . . . . . . . . . . 4-15

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.12 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Electric Brake Release. . . . . . . . . . . . . . . . . . 4-17

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . 5-1

5.3 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . 5-1

Operator Unable to Control Machine . . . . . . . 5-1

Platform or Jib Caught Overhead . . . . . . . . . . 5-2

5.4 PLATFORM MANUAL DESCENT. . . . . . . . . . . . . .5-2

5.5 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . .5-2

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE

6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Other Publications Available . . . . . . . . . . . . . . 6-1

6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . .6-2

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-9

6.4 CHASSIS HOOD REMOVAL . . . . . . . . . . . . . . . .6-10

6.5 BATTERY MAINTENANCE. . . . . . . . . . . . . . . . . .6-10

Battery Maintenance and Safety Practices . . 6-10

Filling System Draining . . . . . . . . . . . . . . . . . 6-12

Battery Voltage and Electrolyte Specific Gravity

Filling System Maintenance . . . . . . . . . . . . . . 6-15

Use of a Battery in a Cold Environment. . . . . 6-15

Battery Not Working Continuously or Inactive

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Battery Troubleshooting. . . . . . . . . . . . . . . . . 6-16

6.6 OIL LEVEL/OIL FILTER . . . . . . . . . . . . . . . . . . . .6-17

Hydraulic Oil Check . . . . . . . . . . . . . . . . . . . . 6-17

Hydraulic Filter Replacement. . . . . . . . . . . . . 6-18

6.7 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . .6-19

Tire Wear and Damage . . . . . . . . . . . . . . . . . 6-19

Wheel and Tire Replacement. . . . . . . . . . . . . 6-19

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . 6-19

6-14

2 – JLG Lift – 31210088

TABLE OF CONTENTS

6.8 LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Overload System Spring Washer (If Equipped)

Swing Bearing Race . . . . . . . . . . . . . . . . . . . . 6-22

Swing Bearing Teeth. . . . . . . . . . . . . . . . . . . . 6-23

Mast Profiles Races. . . . . . . . . . . . . . . . . . . . . 6-24

Lifting Chains . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6.9 OVERLOAD SYSTEM VERIFICATION

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6.10 TILT SENSOR VERIFICATION . . . . . . . . . . . . . . 6-27

6.11 SUPPLEMENTAL INFORMATION . . . . . . . . . . . 6-28

6.12 DIAGNOSTIC TROUBLE CODES (DTC) . . . . . . 6-28

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6.13 DTC INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6.14 DTC CHECK TABLES . . . . . . . . . . . . . . . . . . . . . 6-29

0-0 Help Comments . . . . . . . . . . . . . . . . . . . . 6-29

2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

2-2 Platform Controls . . . . . . . . . . . . . . . . . . . 6-31

2-3 Ground Controls . . . . . . . . . . . . . . . . . . . . 6-33

2-5 Function Prevented. . . . . . . . . . . . . . . . . . 6-35

3-1 Line Contactor Open Circuit . . . . . . . . . . . 6-37

3-2 Line Contactor Short Circuit . . . . . . . . . . . 6-37

3-3 Ground Output Driver . . . . . . . . . . . . . . . . 6-38

4-2 Thermal Limit . . . . . . . . . . . . . . . . . . . . . . 6-41

4-4 Battery Supply. . . . . . . . . . . . . . . . . . . . . . 6-43

4-6 Transmission and Drive System . . . . . . . . 6-45

6-6 Communication. . . . . . . . . . . . . . . . . . . . . 6-46

6-21

6-7 Accessory . . . . . . . . . . . . . . . . . . . . . . . . 6-46

7-7 Electric Motor. . . . . . . . . . . . . . . . . . . . . . 6-47

8-1 Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . 6-48

8-2 Platform Load Sense . . . . . . . . . . . . . . . . 6-49

8-6 Steering/Axle . . . . . . . . . . . . . . . . . . . . . . 6-49

9-9 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

SECTION - 7 - INSPECTION AND REPAIR LOG

31210088 – JLG Lift – 3

TABLE OF CONTENTS

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Minimum Approach Distance (M.A.D.) . . . . . . . . . . 1-5

1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10

2-1 Inspection and Maintenance Table. . . . . . . . . . . . . 2-3

3-1 T10E & T26E - Decal Installation. . . . . . . . . . . . . . 3-17

4-1 Battery Charger Fault Code . . . . . . . . . . . . . . . . . 4-14

6-1 Operating Specifications And Dimensions . . . . . . 6-2

6-2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-3 Tires Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-4 Drive Motors - Hydraulic Power Unit. . . . . . . . . . . . 6-6

6-5 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-6 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . 6-7

6-7 Hydraulic Oil Specifications - Standard . . . . . . . . . 6-7

6-8 Hydraulic Oil Specifications - Optional . . . . . . . . . . 6-8

6-9 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-10 Recommended Viscosity Grade . . . . . . . . . . . . . . 6-25

7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

4 – JLG Lift – 31210088

TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

2-1. Daily Walk-Around Inspection . . . . . . . . . . . . . . . . 2-5

2-2. Tilt Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-3. Overload Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-4. Slack/Broken Chain Sensors . . . . . . . . . . . . . . . . 2-10

3-1. Basic Nomenclature - Location of Machine Controls

3-2. Ground Control Station . . . . . . . . . . . . . . . . . . . . . 3-3

3-3. Mast Manual Descent Valve . . . . . . . . . . . . . . . . . . 3-6

3-4. Jib Manual Descent Valve . . . . . . . . . . . . . . . . . . . 3-7

3-5. Manual Swinging Operating Devices. . . . . . . . . . . 3-8

3-6. Platform Control Indicator Panel . . . . . . . . . . . . . 3-10

3-7. Decal Installation - Sheet 1. . . . . . . . . . . . . . . . . . 3-14

3-8. Decal Installation - Sheet 2. . . . . . . . . . . . . . . . . . 3-15

3-9. Decal Installation - Sheet 3. . . . . . . . . . . . . . . . . . 3-16

4-1. Position of Least BACKWARD stability. . . . . . . . . . 4-2

4-2. Position of Least FORWARD stability. . . . . . . . . . . 4-2

4-3. Grade and Side Slope . . . . . . . . . . . . . . . . . . . . . . 4-4

4-4. Steer/Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-5. Drive Orientation System (DOS) . . . . . . . . . . . . . . 4-7

4-6. Lift Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-7. Swing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4-8. Emergency Controls. . . . . . . . . . . . . . . . . . . . . . . 4-10

4-9. Machine Tie-Down . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-10. Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-11. Lifting the Machine Using a Fork Truck . . . . . . . . 4-16

. . 3-1

4-12. Electric Brake Release . . . . . . . . . . . . . . . . . . . . . 4-17

6-1. Range Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-2. Operator Maintenance & Lubrication Diagram . . . . 6-9

6-3. Chassis Hood Removal. . . . . . . . . . . . . . . . . . . . . 6-10

6-4. Level Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-5. Adding Water to Batteries . . . . . . . . . . . . . . . . . . . 6-11

6-6. Filling System Draining . . . . . . . . . . . . . . . . . . . . . 6-12

6-7. Draining the Water . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-8. Measuring Electrolyte Specific Gravity . . . . . . . . . 6-14

6-9. Hydraulic Oil Check . . . . . . . . . . . . . . . . . . . . . . . 6-17

6-10. Hydraulic Filter Replacement . . . . . . . . . . . . . . . . 6-18

6-11. Wheel Lug Nut Tightening Sequence. . . . . . . . . . 6-19

6-12. Overload System Spring Washer Lubrication . . . 6-21

6-13. Swing Bearing Race Lubrication. . . . . . . . . . . . . . 6-22

6-14. Swing Bearing Teeth lubrication. . . . . . . . . . . . . . 6-23

6-15. Mast Profiles Races Lubrication . . . . . . . . . . . . . . 6-24

6-16. Overload System Verification . . . . . . . . . . . . . . . . 6-26

6-17. Jacking Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

31210088 – JLG Lift – 5

TABLE OF CONTENTS

NOTES:

6 – JLG Lift – 31210088

SECTION 1 – SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section outlines the necessary precautions for proper
and safe machine operation and maintenance. For proper
machine use, it is mandatory that a daily routine is estab­lished based on the content of this manual. A maintenance
program, using the information provided in this manual and
the Service and Maintenance Manual, must also be estab­lished by a qualified person and followed to ensure the
machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine
should not operate the machine until this manual has been
read, training is accomplished, and operation of the machine
has been completed under the supervision of an experi­enced and qualified operator.

If there are any questions with regard to safety, training,
inspection, maintenance, application, and operation, please
contact JLG Industries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN
THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAM­AGE, PERSONAL INJURY OR DEATH.

1.2 PRE-OPERATION

Operator Training and Knowledge

• Read and understand this manual before operating the
machine.

• Do not operate this machine until complete training is per­formed by authorized persons.

• Only authorized and qualified personnel can operate the
machine.

• Read, understand, and obey all DANGERS, WARNINGS,
CAUTIONS, and operating instructions on the machine
and in this manual.

• Use the machine in a manner which is within the scope of
its intended application set by JLG.

31210088 – JLG Lift – 1-1

SECTION 1 – SAFETY PRECAUTIONS

• All operating personnel must be familiar with the emer­gency controls and emergency operation of the machine
as specified in this manual.

• Read, understand, and obey all applicable employer,
local, and governmental regulations as they pertain to
operation of the machine.

Workplace Inspection

• The operator is to take safety measures to avoid all haz­ards in the work area prior to machine operation.

• Do not operate or raise the platform while on trucks, trail­ers, railway cars, floating vessels, scaffolds or other equip­ment unless approved in writing by JLG.

• Do not operate the machine in hazardous environments
unless approved for that purpose by JLG.

• Be sure that the ground conditions are able to support the
maximum load shown on the decals located on the
machine.

• This machine can be operated in temperatures of 0

o

F (-20o C to 40o C). Consult JLG for operation out-

104
side this range.

• This machine must be used in a sufficient ambient light.

o

F to

Machine Inspection

• Before machine operation, perform inspections and func­tional checks. Refer to Section 2 of this manual for
detailed instructions.

• Do not operate this machine until it has been serviced and
maintained according to requirements specified in the
Service and Maintenance Manual.

• Be sure the trigger control, platform enable button and all
other safety devices are operating properly. Modification
of these devices is a safety violation.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANU­FACTURER.

• Do not operate any machine on which safety or instruction
placards or decals are missing or illegible.

• Avoid any buildup of debris on the platform floor. Keep
mud, oil, grease, and other slippery substances from foot­wear and platform floor.

1-2 – JLG Lift– 31210088

SECTION 1 – SAFETY PRECAUTIONS

1.3 OPERATION

General

• Do not use the machine for any purpose other than posi­tioning personnel, their tools and equipment.

• Never operate a machine that is not working properly. If a
malfunction occurs, shut down the machine.

• Never slam a control switch or lever through neutral to an
opposite direction. Always return switch to neutral and
stop before moving the switch to the 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 platform,
except in an emergency.

• Do not carry materials directly on platform railing. Contact
JLG for approved material handling accessories.

• When two persons are in the platform, the operator shall
be responsible for all machine operations.

• Always ensure that power tools are properly stowed and
never left hanging by their cord from the platform work
area.

• Supplies or tools which extend outside the platform are
prohibited unless approved by JLG.

• 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
functions will be reversed.

• Do not assist a stuck or disabled machine by pushing,
pulling, or by using extending structure functions. Only
pull the unit from the tie-down lugs on the chassis.

• Do not place extending structure or platform against any
structure to steady the platform or to support the struc­ture.

• Stow extending structure and shut off all power before
leaving machine.

31210088 – JLG Lift – 1-3

SECTION 1 – SAFETY PRECAUTIONS

Trip and Fall Hazards

During operation, occupants in the platform must wear a full
body harness with a lanyard attached to an authorized lan­yard anchorage point. Attach only one (1) lanyard per lan­yard anchorage point.

• Before operating the machine, make sure all gates are
closed and fastened in their proper position.

• Keep both feet firmly positioned on the platform floor at all
times. Never use ladders, boxes, steps, planks, or similar
items on platform to provide additional reach.

• Never use the extending structure to enter or leave the
platform.

• Use extreme caution when entering or leaving platform.
Be sure that the platform is fully lowered. Face the
machine, maintain “three point contact” with the machine,
using two hands and one foot or two feet and one hand
during entry and exit.

1-4 – JLG Lift– 31210088

SECTION 1 – SAFETY PRECAUTIONS

Electrocution Hazards

• This machine is not insulated and does not provide pro­tection from contact or proximity to electrical current.

• Maintain distance from electrical lines, apparatus, or any
energized (exposed or insulated) parts according to the
Minimum Approach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

Table 1-1. Minimum Approach Distance (M.A.D.)

Voltag e Ran ge

(Phase to Phase)

0 to 50 kV 3 (10)

Over 50 kV to 200 kV 5 (15)

Over 200kV to 350 kV 6 (20)

Over 350 kV to 500 KV 8 (25)

Over 500 kV to 750 kV 11 (35)

Over 750 kV to 1000 kV 14 (45)

NOTE: This requirement shall apply except where

employer, local or governmental regulations are
more stringent.

• Maintain a clearance of at least 3 m (10 ft.) between any
part of the machine and its occupants, their tools and their
equipment from any electrical line or apparatus carrying
up to 50 000 volts. A 0,3 m (1 ft.) additional clearance is
required for every additional 30 000 volts or less.

• The minimum approach distance 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
machine. The minimum approach distance shall be
reduced to a distance within the designed working dimen-

MINIMUM APPROACH DISTANCE

in Meters (Feet)

31210088 – JLG Lift – 1-5

SECTION 1 – SAFETY PRECAUTIONS

sions of the insulating barrier. This determination shall be
made by a qualified person in accordance with employer,
local or governmental requirements for work practices
near energized equipment.

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED
ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE
ENERGIZED UNLESS KNOWN OTHERWISE.

Tipping Hazards

• The user should be familiar with the surface before driv­ing. Do not exceed the allowable sideslope and grade
while driving.

• Never exceed the maximum platform capacity. Distribute
loads evenly on platform floor.

• Before driving on floors, bridges, trucks, and other sur­faces, check allowable capacity of the surfaces.

• Do not elevate platform or drive with platform elevated
while on a sloping, uneven, or soft surface.

1-6 – JLG Lift– 31210088

SECTION 1 – SAFETY PRECAUTIONS

• Do not raise the platform or drive from an elevated posi­tion unless the machine is on firm, level and smooth sur­faces.

• When travelling on grades (Refer to Section 4), the plat­form MUST be fully lowered. It is recommended to drive
up the grade in FORWARD gear and to REVERSE down
the slope.

• Keep the chassis of the machine at least 0,6 m (2 ft.) from
holes, bumps, drop-offs, obstructions, debris, concealed
holes, and other potential hazards on the floor/surface.

• Do not push or pull any object with the extending struc­ture.

• Never attempt to use the machine as a crane. Do not tie­off machine to any adjacent structure.

• Do not operate the machine when wind conditions exceed

12.5 m/s (28 mph). Refer to Table 1-2, Beaufort Scale (For
Reference Only).

• Do not increase the surface area of the platform or the
load. Increase of the area exposed to the wind will
decrease stability.

• Do not increase the platform size with unauthorized deck
extensions or attachments.

• If extending structure assembly or platform is in a position
that one or more wheels are off the ground, all persons

must be removed before attempting to stabilize the
machine. Use cranes, forklift trucks, or other appropriate
equipment to stabilize machine.

31210088 – JLG Lift – 1-7

SECTION 1 – SAFETY PRECAUTIONS

Crushing and Collision Hazards

• Approved head gear must be worn by all operating and
ground personnel.

• Check work area for clearances overhead, on sides, and
bottom of platform when lifting, swinging or lowering plat­form, and driving.

• During operation, keep all body parts inside platform rail­ing.

• Always post a lookout when driving in areas where vision
is obstructed.

• Keep non-operating personnel at least 2m (6 ft.) away
from machine during all driving and swinging operations.

• Limit travel speed according to conditions of ground sur­face, congestion, visibility, slope, location of personnel,

and other factors which may cause hazard of collision 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 stopping.

• Do not use high speed drive in restricted or close quarters
or when driving in reverse.

• Exercise extreme caution at all times to prevent obstacles
from striking or interfering with operating controls and per­sons in the platform.

• Be sure that operators of other overhead and floor level
machines are aware of the aerial work platform’s pres­ence. Disconnect power to overhead cranes.

• Warn personnel not to work, stand, or walk under a raised
extending structure or platform. Position barricades on
floor if necessary.

1.4 TOWING, LIFTING, AND HAULING

• Never allow personnel in platform while towing, lifting, or
hauling.

• This machine should not be towed, except in the event of
emergency, malfunction, power failure, or loading/unload­ing. Refer to Emergency Towing Procedures Section of
this Manual for emergency towing procedures.

1-8 – JLG Lift– 31210088

SECTION 1 – SAFETY PRECAUTIONS

• 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.

• When lifting machine, lift only at designated areas of the
machine. Lift the unit with equipment of adequate capac­ity.

• Refer to the Machine Operation Section of this Manual for
lifting information.

1.5 ADDITIONAL HAZARDS / SAFETY

• Do not use machine as a ground for welding.

• When performing welding or metal cutting operations,
precautions must be taken to protect the chassis from
direct exposure to weld and metal cutting spatter.

• Battery fluid is highly corrosive. Avoid contact with skin
and clothing at all times.

• Charge batteries only in a well ventilated area.

31210088 – JLG Lift – 1-9

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)

Beaufort

Number

0 0 0-0.2 Calm Calm. Smoke rises vertically.

1 1-3 0.3-1.5 Light air Wind motion visible in smoke.

2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle.

3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion.

4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.

5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.

6 25-31 10.8-13.8 Strong breeze Large branches in motion. Whistling heard in overh ead wires.

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.

8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.

9 47-54 20.8-24.4 Strong gale Light structure damage.

Wind Speed

mph m/s

Description Land Conditions

Umbrella use becomes difficult.

1-10 – JLG Lift– 31210088

SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

The aerial platform is a personnel handling device; so it is
necessary that it be operated and maintained only by trained
personnel.

Persons under the influence of drugs or alcohol or who are
subject to seizures, dizziness or loss of physical control must
not operate this machine.

Operator Training

Operator training must cover:

1. Use and limitations of the controls in the platform and at
the ground, emergency controls and safety systems.

2. Control labels, instructions, and warnings on the
machine.

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of the

machine to recognize a malfunction or potential mal­function.

6. The safest means to operate the machine where over­head obstructions, other moving equipment, and obsta­cles, depressions, holes or drop-offs exist.

7. Means to avoid the hazards of unprotected electrical
conductors.

8. Specific job requirements or machine application.

Training Supervision

Training must be done under the supervision of a qualified
person in an open area free of obstructions until the trainee
has developed the ability to safely control and operate the
machine.

Operator Responsibility

The operator must be instructed that he/she has the respon­sibility and authority to shut down the machine in case of a
malfunction or other unsafe condition of either the machine
or the job site.

31210088 – JLG Lift – 2-1

SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 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 mainte­nance 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
severe manner.

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

2-2 – JLG Lift – 31210088

SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type Frequency

Pre-Start Inspec­tion

Pre-Delivery
Inspection
(See Note)

Freque nt Inspec ­tion
(See Note)

Annual Machine
Inspection
(See Note)

Preventative
Maintenance

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

Before using each day;
or whenever there’s an Operator change.

Before each sale, lease, or rental delivery. Owner, Dealer or User Qualified JLG Mechanic Service and Maintenance Manual

In service for 3 months or 150 hours, which­ever comes first; or
Out of service for a period of more than 3
months; or
Purchased used.

Annually, no later than 13 months from the
date of prior inspection.

At intervals as specified in the Service and
Maintenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer or User Qualified JLG Mechanic Service and Maintenance Manual

Owner, Dealer or User Factory-Trained Service

Owner, Dealer or User Qualified JLG Mechanic Service and Maintenance Manual

Service

Qualification

Technician (Recom­mended)

Reference

and applicable JLG inspection form

and applicable JLG inspection form

Service and Maintenance Manual
and applicable JLG inspection form

31210088 – JLG Lift – 2-3

SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Pre-Start Inspection

The Pre-Start Inspection must include each of the following:

1. Cleanliness – Check all surfaces for leakage (oil or bat­tery fluid) or foreign objects. Report any leakage to the
proper maintenance personnel.

2. Structure – Inspect the machine structure for dents,
damage, weld or parent metal cracks or other discrep­ancies.

3. Decals and Placards – Check all for cleanliness and
legibility. Make sure none of the decals and placards are
missing. Make sure all illegible and missing decals and
placards are cleaned or replaced.

4. Operation and Safety Manuals – Make sure a copy of
the Operator and Safety manual, AEM Safety manual
(ANSI markets only), and ANSI Manual of Responsibility
(ANSI markets only) is enclosed in the weather resistant
storage container.

5. “Walk-Around” Inspection – Refer to Figure 2-1.

6. Battery – Charge as required.

7. Hydraulic Oil – Check the hydraulic oil level in the reser-

voir. Ensure hydraulic oil is added as required.

8. Accessories/Attachments - Reference the Operator
and Safety Manual of each attachment or accessory
installed upon the machine for specific inspection, oper­ation, and maintenance instructions.

9. Function Check – Once the “Walk-Around” Inspection
is complete, perform a functional check of all systems in
an area free of overhead and ground level obstructions.
Refer to Section 4 for more specific operating instruc­tions.

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE
MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER
MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT
IS DECLARED SAFE FOR OPERATION.

2-4 – JLG Lift – 31210088

SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Daily Walk-Around Inspection

31210088 – JLG Lift – 2-5

SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

General

Begin the "Walk-Around Inspection" at Item 1, as noted on
the diagram. Continue checking each item in sequence for
the conditions listed in the following checklist.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.
DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN
CORRECTED.

INSPECTION NOTE: On all components, make sure there
are no loose or missing parts, that they are securely fastened,
and no visible damage, leaks or excessive wear exists in
addition to any other criteria mentioned.

1. Platform Assembly and Gate - Gate opens and closes
properly, manual in storage container. See inspection
note.

2. Platform & Ground Control Consoles - Placards
secure and legible, control levers and switches return to
neutral and emergency stop switches function properly.

3. Steering Assembly - See inspection note.

4. Wheel/Tire Assemblies - Properly secured, no missing

lug nuts. Inspect for worn tread, cuts, tears or other dis­crepancies. Inspect wheels for damage and corrosion.
See inspection note.

5. Hood Assemblies - See Inspection Note.

6. Hydraulic Cylinders- No visible damage, pivot pins and

hydraulic hoses undamaged, no leakage (hose connec­tions - valve block).

7. Manual Descent - See Inspection Note.

8. Lifting Chains, Chain Yokes and Clevis Pins - Must be

installed and in good condition. Chains must be cor­rectly tensioned and lubricated.

9. Hydraulic Pump/Motor Control Valves Installation/Oil
Level in Reservoir - Swing needle valve fully closed.

See Inspection Note.

10. Limit Switches - Mast limit switch(es), chain slack limit
switches and overload sensor (if equipped) are properly
installed and fastened. See inspection note.

2-6 – JLG Lift – 31210088

SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Function Check

Refer to Sections 3 & 4 for description and operation of machine
functions.

Control Stations

1. From the Ground Control Console with no load in the

platform:

a. Operate all functions to ensure proper operation.

b. While operating a mast lift-up movement, push in all

other function buttons. Mast lift-up movement
should continue and no other movement should
occur.

c. Ensure that all machine functions are disabled

when the emergency stop button is depressed.

d. Raise the mast about one meter (3 ft.), check if the

manual descent valve lowers the mast properly
(refer to Figure 3-3. for mast manual descent valve
location).

e. Raise the jib about half a meter (2 ft.), check if the

manual descent valve lowers the jib properly (Refer
to Figure 3-4).

2. From the Platform Control Console:

a. Ensure that the platform control console is firmly

secured.

b. Check that all guards protecting the switches are

securely in place.

c. Operate all functions including horn button to

ensure proper operation.

d. Ensure that all machine functions are disabled

when the emergency stop button is depressed.

e. Ensure all mast and jib functions stop when the

function enable button is released.

f. Ensure all drive functions stop when joystick trigger

is released.

g. With the mast elevated half a meter (2 ft.), on a

smooth, firm and level surface, drive the machine to
check if the high drive cutout speed-limit is
engaged. Drive speed will be reduced from a top
speed of 5.5 km/h to 0.75 km/h (3.40 mph to 0.45
mph) (Approx.).

h. Toucan 10E only: With the mast elevated 4.50 m

(14.8 ft.), on a smooth, firm and level surface, drive
the machine to check if the extra drive cutout
speed-limit is engaged. Drive speed will be reduced
to 0.40 km/h (0.25 mph) (Approx.).

31210088 – JLG Lift – 2-7

SECTION 2 – USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-2. Tilt Sensor

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).
Actuate a drive function: the drive function is dis­abled. The DOS indicator blinks, and the DOS over­ride button must be used for the drive function to
operate.

j. With the machine in transport (stowed) position,

drive the machine on a grade, not to exceed the
rated gradeability and stop to ensure the brakes
hold.

Tilt Sensor Check

Check the tilt indicator light/alarm to ensure proper opera­tion. Wedge a block (P/N: ST2741 - located in the manual
storage container) to activate the tilt sensor and keep it tilted.
The tilt sensor is located on the chassis behind the right rear
wheel. Refer to Figure 2-2.

1. From the platform console :

- Raise the mast by approximately 1m (3 ft.).

a. Confirm an audible alarm sounds.

b. Verify the tilt indicator (red) blinks.

c. Check that the following functions are affected :

- Drive function disabled.

- Mast/Jib lift-up and swinging movements can be
performed only in creep mode.

2-8 – JLG Lift – 31210088