JLG Toucan 12E Operation And Safety Manual Download Page 3 | Manualshive

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FOREWORD

31210162

– 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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Summary of Contents for Toucan 12E

Page 1: ...Operation and Safety Manual Original Instructions Keep this manual with the machine at all times TOUCAN 8E TOUCAN 20E S N A300052840 to present 31210162 February 01 2015 English Operation and Safety...

Page 2: ......

Page 3: ...e 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 improv...

Page 4: ...LL HAVE AN ORANGE BACKGROUND 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...

Page 5: ...S 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 Reliabilit...

Page 6: ...FOREWORD d JLG Lift 31210162 REVISION LOG Original Issue August 03 2010 Manual Revised May 15 2012 Manual Revised May 13 2014 Manual Revised November 03 2014 Manual Revised February 01 2015...

Page 7: ...g 2 1 Training Supervision 2 1 Operator Responsibility 2 1 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Pre Start Inspection 2 4 General 2 6 Function Check 2 7 Tilt Sensor Check 2 8 Overload Sensor...

Page 8: ...DE MSSO IF EQUIPPED 4 13 4 10 SHUT DOWN AND PARK 4 14 4 11 BATTERY CHARGING 4 14 Battery Charger Fault Code 4 16 4 12 TIE DOWN LIFT LUGS 4 17 Tie Down 4 17 Lifting 4 17 4 13 TOWING 4 18 Electric Brake...

Page 9: ...aces 6 25 Lifting Chains 6 26 6 9 OVERLOAD SYSTEM VERIFICATION IF EQUIPPED 6 27 6 10 TILT SENSOR VERIFICATION 6 28 6 11 SUPPLEMENTAL INFORMATION 6 29 6 12 DIAGNOSTIC TROUBLE CODES DTC 6 29 Introductio...

Page 10: ...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 17 4 10 Lifting the Machine 4...

Page 11: ...3 18 4 1 Battery Charger Fault Code 4 16 6 1 Operating Specifications And Dimensions 6 2 6 2 Dimensions 6 6 6 3 Tires Specifications 6 6 6 4 Drive Motors Hydraulic Power Unit 6 7 6 5 Battery Specifica...

Page 12: ...TABLE OF CONTENTS vi JLG Lift 31210162 NOTES...

Page 13: ...ration of the machine has been completed under the supervision of an experi enced and qualified operator If there are any questions with regard to safety training inspection maintenance application an...

Page 14: ...the machine This machine can be operated in temperatures of 0o F to 104o F 20o C to 40o C Consult JLG for operation out side this range This machine must be used in a sufficient ambient light Machine...

Page 15: ...ved 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 ha...

Page 16: ...s 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 addi...

Page 17: ...tional clearance is required for every additional 30 000 volts or less The minimum approach distance may be reduced if insu lating barriers are installed to prevent contact and the bar riers are rated...

Page 18: ...Hazards The user should be familiar with the surface before driv ing Do not exceed the allowable sideslope and grade while driving Never exceed the maximum platform capacity Distribute loads evenly on...

Page 19: ...crease 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 po...

Page 20: ...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 unload ing Refer t...

Page 21: ...breeze Windfeltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperraised Smallbranchesbegintomove 5 19 24 8 0...

Page 22: ...SECTION 1 SAFETY PRECAUTIONS 1 10 JLG Lift 31210162 NOTES...

Page 23: ...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 mal function 6 The s...

Page 24: ...tions 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...

Page 25: ...Inspec tion SeeNote Inservice for3monthsor150hours which evercomesfirst or Outof servicefora periodofmorethan 3 months or Purchasedused Owner DealerorUser QualifiedJLGMechanic ServiceandMaintenanceMan...

Page 26: ...l ANSI markets only and ANSI Manual of Responsibili ties ANSI markets only is enclosed in the weather resistant storage container 5 Walk Around Inspection Refer to Figure 2 1 6 Battery Charge as requi...

Page 27: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 31210162 JLG Lift 2 5 Figure 2 1 Daily Walk Around Inspection...

Page 28: ...soles 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 s...

Page 29: ...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 function...

Page 30: ...arm to ensure proper opera tion 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 rig...

Page 31: ...ST2741 located in the manual storage container to activate the overload sensor and keep it activated Refer to Figure 2 3 1 From the Platform Control Console a Confirm an audible alarm sounds b Verify...

Page 32: ...a slack chain sensor and keep it activated 1 From the Platform Control Console a Confirm an audible alarm sounds b Verify the slack chain indicator Red lights up c Check when the slack chain indicator...

Page 33: ...nly Figure 2 5 XL Basket Check 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 illum...

Page 34: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 12 JLG Lift 31210162 NOTES...

Page 35: ...els 2 SteeringWheels 3 Accessdoorto Pump Motor Control valves 4 Counterweight 5 Jib 6 Ground Control Panel 7 Telescopicmast 8 Platform 9 PlatformControlconsole 10 Manual StorageContainer 11 Accessdoor...

Page 36: ...PRACTICES 3 2 CONTROLS AND INDICATORS TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CON TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELE...

Page 37: ...ator 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 Bu...

Page 38: ...imum drive speed is reduced when the platform is out of transport position The wrench symbol is lit when a DTC Diagno sis Troubleshooting Code is displayed Five Digits Display In normal operating cond...

Page 39: ...chine The switch must be turned clockwise to restore the machine functions 8 Function Enable Button A membrane switch that must be pushed in and held to enable the controls of the ground control stati...

Page 40: ...the actuator when the platform is lowered to the desired level c Return the actuator to the battery storage compart ment after use 2 To lower the jib once the mast is fully retracted push in the manua...

Page 41: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 31210162 JLG Lift 3 7 Jib Manual Descent Valve The jib manual descent button is located on the jib cylinder valve Figure 3 4 Jib Manual Descent Valve...

Page 42: ...s are used in the 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 swin...

Page 43: ...4 Turn the hand wheel clockwise to swing the structure to the right or turn the hand wheel counter clockwise to swing the structure to the left 5 When finished swinging fully close the rotary valve c...

Page 44: ...IndicatorPanel 2 Emergency Stop Switch 3 TriggerSwitch 4 Drive Swing FunctionsController 5 Steer Switch 6 Mast JibFunctionEnableButton 7 MastLiftUp DownJoystickController 8 Jib Lift Up DownJoystick Co...

Page 45: ...rmal operating condition which if not corrected may result in machine interruption or damage This indicator will be yellow Indicates important information regarding the operating condition i e procedu...

Page 46: ...or will illuminate This is a signal for the operator to verify that the drive control is being operated in the proper direction i e drive controls reversed situations e Indicates that the chassis is o...

Page 47: ...the control handle to the left to swing the superstructure to the left or toggle the control handle to the right to swing to the right 5 Steer Switch The thumb operated steer switch on top of the cont...

Page 48: ...riv ing locate the black white orientation arrows on both the chassis and the platform controls Push and release the override switch and within 3 seconds slowly move the Drive Steer control to actuate...

Page 49: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 31210162 JLG Lift 3 15 3 3 DECAL INSTALLATION Figure 3 8 Decal Installation Sheet 1...

Page 50: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 3 16 JLG Lift 31210162 Figure 3 9 Decal Installation Sheet 2...

Page 51: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 31210162 JLG Lift 3 17 Figure 3 10 Decal Installation Sheet 3...

Page 52: ...132 8 1704016 1704016 1704016 1704016 1704016 29 AU2212 AU2212 AU2212 AU2212 AU2212 9 1704277 1704277 1704277 1704277 1704277 30 AU2134 AU2134 AU2134 AU2134 AU2134 10 1705803 1703785 1703785 1703785 1...

Page 53: ...3 19 43 AU2228 AU2228 AU2228 AU2228 45 AU2206 AU2206 AU2206 AU2206 44 AU2229 AU2229 AU2229 AU2229 AU2229 46 Table 3 1 8E 20E Decal Installation Element 8E CE 20E ANSI 20E CSA 20E Spanish 20E Portugues...

Page 54: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 3 20 JLG Lift 31210162 NOTES...

Page 55: ...t and jib lift and swing and are to be used in an emergency to lower the platform to the ground should the operator in the platform be unable to do so The Ground Control is also to be used in Pre Star...

Page 56: ...SECTION 4 MACHINE OPERATION 4 2 JLG Lift 31210162 Figure 4 1 Position of Least BACKWARD stability Figure 4 2 Position of Least FORWARD stability...

Page 57: ...ity and side slope Refer to Figure 4 3 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 driven across Refer to Table...

Page 58: ...SECTION 4 MACHINE OPERATION 4 4 JLG Lift 31210162 Figure 4 3 Grade and Side Slope...

Page 59: ...PLATFORM MOVE MENT DOES NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED IF THE PLATFORM DOES NOT STOP WHEN CONTROL LEVER OR THE ENABLE BUTTON TRIGGER SWITCH IS RELEASED USE THE EMER GENCY STO...

Page 60: ...in the opposite direction until the wheels are centered Travelling driving 1 With all control levers in neutral position squeeze and hold the trigger switch 1 on front of the joystick 2 Move the joys...

Page 61: ...vate drive or steer 2 Before driving locate the black white directional arrows on both the chassis and the platform controls 3 Move the drive control joystick in a direction matching the directional a...

Page 62: ...stance of travel of the joystick 5 Return the controller to its centered neutral position to stop then release the enable button Raising and lowering the jib 1 With all control levers in neutral posit...

Page 63: ...SURROUNDING WALLS PARTITIONS AND EQUIPMENT Figure 4 7 Swing Control 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...

Page 64: ...ound should the operator in the platform be unable to do so DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSON NEL IN THE PLATFORM EXCEPT IN AN EMERGENCY ENSURE THE AREA BENEATH THE PLATFORM IS FR...

Page 65: ...position and the chassis is out of level an audible alarm will sound IF THE WARNING LIGHT IS ILLUMINATED WHEN THE MAST IS RAISED LOWER THE MAST AND REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE ELEVAT...

Page 66: ...ings does not reveal any pos sible obstacle the alarm may have been triggered by the tele scopic mast jamming which could be due to A foreign body entering the guiding system A lack of lubrication see...

Page 67: ...ANS FOR ACCESS TO AND EGRESS FROM THE PLATFORM Soft Touch Warning Light Alarm If equipped When the bumper under the work platform is against an obsta cle the YELLOW light indicator at platform control...

Page 68: ...ry 4 11 BATTERY CHARGING NOTE Be sure that the machine is parked in a well ventilated area before charging begins ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND GROUNDED OUTLET DO NOT USE GROUND...

Page 69: ...charger light s on the Ground Control Station will flash in sequence for two seconds 3 The batteries are fully charged when the green light on the battery charger status panel Ground Control Sta tion...

Page 70: ...ypack notconnectedtochargerorbatteryvoltspercellisless than0 5VDC Checkthe batterypack and connections 3 Chargetime out Indicatesthebatteriesdidnotchargeintheallowedtime Thiscouldoccurifthebatteriesar...

Page 71: ...wed position Machine must be tied down to the truck bed or trailer deck as shown in Figure 4 9 Figure 4 9 Machine Tie Down Lifting When lifting the machine Platform must be fully lowered in the stowed...

Page 72: ...e 4 11 VERIFY THE CAPACITY OF THE FORK TRUCK AND OF ITS EQUIPMENT FORK LIFT ONLY AT THE DESIGNATED POINTS WHEN DRIVING THE FORK TRUCK KEEP THE WORK PLATFORM AS NEAR TO THE GROUND AS POSSIBLE BUT WITH...

Page 73: ...old the enable push button 2 4 Depress the brake release button 3 for one second to release the brakes Once the brakes are released an acoustic discontinuous sound alarm is triggered 5 When finished t...

Page 74: ...SECTION 4 MACHINE OPERATION 4 20 JLG Lift 31210162 NOTES...

Page 75: ...8 hours of such an occur rence may void any warranty consideration on that particular machine FOLLOWING ANY INCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROL...

Page 76: ...to be used to retrieve an operator that is pinned trapped or unable to operate the machine and the function controls are locked out from the platform due to a platform overload situation NOTE If the M...

Page 77: ...e 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 Maintena...

Page 78: ...aximumStowedTravel Grade Gradeability ReferenceFigure4 3 25 14 25 14 MaximumStowedTravel Grade Sideslope Reference Figure 4 3 8 7 5 8 7 5 MaximumDriveSpeed Stowed MastElevated 5 50km h 0 75km h 3 4mph...

Page 79: ...31210162 JLG Lift 6 3 Model TOUCAN 8E CE TOUCAN 8EXL CE TOUCAN 20E ANSI MaximumHydraulicPressure 16MPa 2320psi 16Mpa MaximumGroundBearing Pressure 18 2kg cm 270psi 19kg cm Electrical SystemVoltage 24...

Page 80: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 6 4 JLG Lift 31210162 1 0 2 3 4 5 6 7 0 1 2 Figure 6 1 Range Diagram 8E 20E...

Page 81: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 31210162 JLG Lift 6 5 Figure 6 2 Range Diagram 8E XL...

Page 82: ...ght Elevated 6 15m 20 21 6 16m Working Height 8 15m 26 77 8 16m OverallStowedMachine Height 1 99m 6 59 2 01m OverallMachine Width 0 99m 3 25 0 99m OverallMachine Length 2 09m 2 35 m 6 85 2 09m Platfor...

Page 83: ...Drive Motors Hydraulic Power Unit DESCRIPTION All Models DriveMotor Voltage 15VAC Power 0 85kW HydraulicPower Unit Motor Voltage 24VDC Power 3kW Pump Displacement 3 1cc rev 0 19 ci rev FlowRate 9 6l m...

Page 84: ...kg Table 6 6 Lubrication Specifications KEY SPECIFICATIONS e g A Extreme Pressure MultiPurposeGrease MOBILUX EP2 COMPLEX EP2 B OpenGearLube MOBILTAC81 C NonDetergent MineralOil MOBIL DTE16M D Syntheti...

Page 85: ...ype SyntheticBiodegradable Low Temperature Synthetic FoodCompatible ISOViscosityGrade 32cSt 32cSt 32cSt CinematicViscosity 20 C 4 F 1150cSt 428cSt 795cSt CinematicViscosity 0 C 32 F 280 cSt 127cSt 198...

Page 86: ...igure 6 3 Operator Maintenance Lubrication Diagram 1 Battery 2 Oil Level Oil Filter 3 Tires Wheels 4 Overload System Spring Washer if equipped 5 Turntable Bearing Lubrication 6 Telescopic Mast Lubrica...

Page 87: ...OOD REMOVAL Unscrew the four 4 retaining screws a 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 cover to remove it completely Remov...

Page 88: ...LLS WITH BAKING SODA AND WATER BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARGING ALLOW NO OPEN FAMES SPARKS OR LIGHTED TOBACCO PRODUCTS IN THE AREA WHILE CHARGING BATTERIES CHARGE BATTERIES ONLY I...

Page 89: ...ation Button 3 Flow Indicator filter Regularly Clean and dry the battery top Ensure the connections are clean and tight Drain the water that can accumulate at the bottom of the container electrolyte o...

Page 90: ...once the charger has been unplugged and after the battery has been standing for at least 15 minutes Open the filling cap of the battery on which the red cable is connected B Using the hydrometer supp...

Page 91: ...10162 JLG Lift 6 15 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...

Page 92: ...e cap Use of a Battery in a Cold Environment Low temperatures decrease battery capacity The battery must be fully charged when the machine is operated in a cold envi ronment Battery Not Working Contin...

Page 93: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 31210162 JLG Lift 6 17 Battery Troubleshooting...

Page 94: ...heck Daily NOTE Check oil level with the wheels fully steered to the left 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 m...

Page 95: ...r unit 1 3 Wipe 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 filter and extract the filter 4 Use a container to collec...

Page 96: ...s extremely important to apply and maintain proper mounting torque WHEEL LUG NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS BROKEN LUG NUTS AND POSSIBLE SEPARATION...

Page 97: ...of operation 6 8 LUBRICATION NOTE Recommended lubricating intervals are based on machine operation under normal conditions For machines used in multi shift operations and or exposed to hostile enviro...

Page 98: ...ped 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...

Page 99: ...move chassis hoods 2 From ground 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 acces...

Page 100: ...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 3 Remove...

Page 101: ...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 Clean the inside walls of the mast profiles to remove the old grease...

Page 102: ...peration and every 125 hours of operation or every 30 days thereafter Lubricant can be applied manually with a brush or by spraying Apply lubricant longitudinally and transversally for the lubricant t...

Page 103: ...ight on platform additional load not to exceed 30kg until the overload warning is activated RED light indicators at both the ground and the plat form control stations blink An audible alarm sounds All...

Page 104: ...4 Using a jack of appropriate capacity lift the front on the chassis The tilt alarm must be activated within 0 2 below the value in Table 6 1 5 Place the spirit level perpendicular to the chassis and...

Page 105: ...MDI For more information on the MDI refer to Section 3 For informa tion on the locations of any limit switches sensors refer to Sec tion 2 DTC s are sorted in groups by the first two digits which is...

Page 106: ...ationshould resume after a powercycle Referproblemto aqualifiedJLGmechanic 0010 RUNNINGATCUTBACK OUT OFTRANSPORTPOSITION Drivespeedislimitedwhile themast iselevated Displaysontheanalyzeronly Fullystow...

Page 107: ...lat form andreposition themachine toalevelsurface Fullystowthe platform Checkthatthetilt sensorissecurelymounted and its wireconnected ReferproblemtoaqualifiedJLGmechanic 0029 RUNNINGATCREEP MAX ELEVA...

Page 108: ...TPERMANENTLY SELECTED The Steer RightSwitchwas closedduringpower upinplatformmode Checkifthesteerrightswitchisobstructedorjammed Referproblemto aqualifiedJLGmechanic 226 ACCELERATOR FAULTY WIPER OUTOF...

Page 109: ...switchisobstructedor jammed ReferproblemtoaqualifiedJLGmechanic 2241 LIFTENABLESWITCH PERMANENTLY SELECTED The Lift Enable Switchwasclosedduringpower upinplatformmode Checkif theliftenable switchisobs...

Page 110: ...NENTLY SELECTED The MastLift Up Switchwasclosedduring power upingroundmode Checkiftheconcernedswitchisdamaged obstructed orjammed Referproblemto aqualifiedJLGmechanic 2369 FUNCTIONPROBLEM MAST LIFTDOW...

Page 111: ...witches is damaged obstructed orjammed ReferproblemtoaqualifiedJLGmechanic 2375 JIBSWITCH FAULTY The Jib Lift Up andDown Switchesareactive simultaneously Checkif one oftheconcerned switches is damaged...

Page 112: ...problemhasbeen detected in this function Referproblemto aqualifiedJLGmechanic 2382 FUNCTIONPREVENTED OVERSWINGDETECTED The structure isswungbeyond thereartiresor furtherineither direction Ifthe struct...

Page 113: ...his damaged obstructed orjammed ReferproblemtoaqualifiedJLGmechanic 2543 FUNCTIONPREVENTED CHAINSLACKDETECTED Slack wasdetectedinthemastchain Referto section4forthe requiredoperationsto clear thefault...

Page 114: ...RMANENTLY OFF Thereisaproblem with thepower moduleline contactor control Referproblemto aqualifiedJLGmechanic DTC FAULT MESSAGE DESCRIPTION CHECK 321 LINE CONTACTORMISWIRED ONORWELDED Thereisaproblem...

Page 115: ...TBRAKE OPEN CIRCUIT A problemhas been detectedin this function ReferproblemtoaqualifiedJLGmechanic 33100 JIBLIFTUPVALVE SHORTTO GROUND Aproblemhas been detectedin this function Referproblemtoaqualifie...

Page 116: ...c 33356 STEERVALVE OPENCIRCUIT A problemhasbeendetected in this function Referproblemto aqualifiedJLGmechanic 33358 FLOWDIRECTIONVALVE SHORTTOGROUND Aproblemhasbeen detected in this function Referprob...

Page 117: ...lemhas been detectedin this function ReferproblemtoaqualifiedJLGmechanic 33381 MASTERMODULEOUTPUTS SHORTTOBATTERY Aproblemhas been detectedin this function ReferproblemtoaqualifiedJLGmechanic 33382 SL...

Page 118: ...blemto aqualifiedJLGmechanic 33390 LEFTBRAKERETURN SHORT TOGROUND Aproblemhasbeen detected in this function Referproblemto aqualifiedJLGmechanic 33391 RIGHTBRAKE RETURN SHORTTOBATTERY Aproblemhasbeen...

Page 119: ...le leftcontroller hasreached thermalcutout Powerdownandallow to cool Do not operate inambientsover60 C 140 F ReferproblemtoaqualifiedJLGmechanic 4210 RIGHTDRIVEMOTORTOOHOT PLEASEWAIT The rightdrive mo...

Page 120: ...441 BATTERYVOLTAGETOOLOW SYSTEMSHUTDOWN Aproblemhasbeendetectedwiththebatteriesor powermodule Recharge batteries Checkfordamagedbatteries batterycables orcon nections Checkbatterychargerfunction Be s...

Page 121: ...Aproblemhasbeendetectedwiththebatteriesor powermodule Recharge batteries Checkfordamagedbatteries batterycables orcon nections Checkbatterychargerfunction Be suretoobserve indicatorsforatleast 30secon...

Page 122: ...RIGHTSPEED SENSOR NOT RESPONDINGPROPERLY Aproblemhasbeen detected withtherightdrive motor speed sensor encoder Referproblemto aqualifiedJLGmechanic 4611 LEFTSPEED SENSOR NOT RESPONDINGPROPERLY Aprobl...

Page 123: ...mtheSlaveModule leftcontroller ReferproblemtoaqualifiedJLGmechanic 6634 CANBUS COMM LOST The platformmodulefailedtoreceive messages fromboththe masterandthe slave modules ReferproblemtoaqualifiedJLGme...

Page 124: ...LGmechanic 7724 LEFTMOTOR FEEDBACK FAILURE The left motorvoltage feedbackcircuitsaredam aged SlaveModule Referproblemto aqualifiedJLGmechanic 7725 PUMP MOTOR NOT RESPONDING The pump motorfeedbackisnot...

Page 125: ...e pumpmotorvoltage outputislowerthan expected drivenby theMaster Module ReferproblemtoaqualifiedJLGmechanic 7732 STALLED RIGHTMOTOR The rightmotorhasbeen detectedstalled Ensurevehicle is not stuckonso...

Page 126: ...atform Checkif theoverload switch isobstructed orjammed Referproblemto aqualifiedJLGmechanic 8210 OVERLOADSENSOR ERROR Inconsistencyintheoverloadsensorinformation Checkif theoverload switch isdamaged...

Page 127: ...from thesteersensor Checkthesteersensor fordamage Checkthatthesteersensoris securelymounted ReferproblemtoaqualifiedJLGmechanic 8668 STEER SENSOR NOT CALIBRATED The steeringsensorhasnotbeencalibrated...

Page 128: ...ic 9995 SLAVEMODULEEEPROM FAILURE Thereisan internalerrorin theSlaveModule left controller Cyclepower toclearthe fault Referproblemto aqualifiedJLGmechanic 9996 MASTERMODULEMEMORY FAILURE Thereisan in...

Page 129: ...rproblemtoaqualifiedJLGmechanic 99103 SLAVEMODULEWATCHDOG RESET Thereisan internalerrorin theSlaveModule left controller Cyclepower toclearthefault ReferproblemtoaqualifiedJLGmechanic 99104 MASTERMODU...

Page 130: ...ault Referproblemto aqualifiedJLGmechanic 99112 MASTERMODULE INTERNAL ERROR Thereisan internalerrorin theMaster Module rightcontroller Cyclepower toclearthe fault Referproblemto aqualifiedJLGmechanic...

Page 131: ...fault ReferproblemtoaqualifiedJLGmechanic 99122 MASTERMODULE INTERNAL ERROR Thereisan internalerrorin theMasterModule rightcontroller Cyclepower toclearthefault ReferproblemtoaqualifiedJLGmechanic 991...

Page 132: ...ault Referproblemto aqualifiedJLGmechanic 99130 MASTERMODULE INTERNAL ERROR Thereisan internalerrorin theMaster Module rightcontroller Cyclepower toclearthe fault Referproblemto aqualifiedJLGmechanic...

Page 133: ...PAIR LOG 31210162 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG Typeof machine ________________________________________ MachineSerialNumber __________________________________ Table 7 1 Inspection a...

Page 134: ...7 INSPECTION AND REPAIR LOG 7 2 JLG Lift 31210162 Name ______________________________________________ Signature _____________________________________________ Table 7 1 Inspection and Repair Log Date C...

Page 135: ......

Page 136: ...pohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia s r...

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