JLG Toucan 800 Use and care manual

Operation and Safety Manual
TOUCAN 800
TOUCAN 870
31210031
January 01, 2010
English - Operation and Safety Manual - Original Instructions

FOREWORD
31210031 – 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.
Other Publications Available:
Service and Maintenance Manual French ........................................... MA0306
Service and Maintenance Manual English .......................................... MA0318
Illustrated Parts Manual Toucan 800..................................................31210056
Illustrated Parts Manual Toucan 870..................................................31210058
Hydraulic schematic Toucan 800.......................................................... FL0147
Hydraulic schematic Toucan 870.......................................................... FL0146
Electrical schematic .............................................................................. ELE240

FOREWORD
b– JLG Lift – 31210031
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 POTENTIALITY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS
DECAL WILL HAVE AN ORANGE BACKGROUND.
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT
AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY
ALSO ALERT AGAINST UNSAFE PRACTICES.
INDICATES PROCEDURES ESSENTIAL FOR SAFE OPERATION.
THIS DECAL WILL HAVE A YELLOW BACKGROUND.
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BUL-
LETINS, CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHO-
RIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING
SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED
FOR THIS PRODUCT.
IMPORTANT
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO
THE OWNER OF RECORDS OF THIS MACHINE. CONTACT JLG
INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER
RECORDS ARE UPDATED AND ACCURATE.
IMPORTANT
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 PER-
SONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO
PERSONAL PROPERTY OR THE JLG PRODUCT.
For:
• Accident Reporting
• Product Safety Publications
• Current Owner Updates
• Questions Regarding Product Safety
• Standards and Regulations Compliance Information
• Questions Regarding Special Product Applications
• Questions Regarding Product Modifications
CONTACT:
In USA: Outside USA:
JLG Industries, Inc.
Product Safety & Reliability Department,
13224 Fountain Head Plaza
Hagerstown, MD
USA 21742
Toll Free :[phone]
Tel. : [phone]
Fax : [phone]
Email : [email protected]
JLG Industries,
Wright Business Centre,
1 Lonmay Road
Queenslie
Glasgow,
Scotland G33 4EL
Tel : [phone]
Fax : [phone]
Email : [email protected]
or Your Local JLG Office
(see adresses on manual rear cover)

FOREWORD
31210031 – JLG Lift – c
REVISION LOG
Original Issue - September 14, 2007
Revision - January 01, 2010

FOREWORD
d– JLG Lift – 31210031

TABLE OF CONTENTS
31210031 – JLG Lift – 1
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 PRE-OPERATION. . . . . . . . . . . . . . . . . . . . . 1-1
Operator Training and Knowledge. . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . 1-1
Machine Inspection . . . . . . . . . . . . . . . . 1-1
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Trip and Fall Hazards . . . . . . . . . . . . . . . 1-2
Electrocution Hazards . . . . . . . . . . . . . . 1-2
Tipping Hazards . . . . . . . . . . . . . . . . . . . 1-3
Crushing and Collision Hazards . . . . . . 1-3
1.4 TOWING, LIFTING, AND HAULING . . . . . . . 1-4
1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . 1-4
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 MAINTE-
NANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 PRE-START INSPECTION . . . . . . . . . . . . . . 2-3
2.3.1 Walk-Around Inspection. . . . . . . . . . . . . . . . 2-5
2.3.2 Function Check . . . . . . . . . . . . . . . . . . . . . . 2-6
Control Stations . . . . . . . . . . . . . . . . . . . 2-6
Tilt Sensor Check . . . . . . . . . . . . . . . . . . 2-6
Overload Sensor Check (Toucan 800 & Toucan
800 DI) 2-7
Slack / Broken Chain Sensors Check . . 2-8
Gate sensors check (Toucan 800 DI only) 2-8
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 CONTROLS AND INDICATORS. . . . . . . . . . 3-2
Ground Control Station . . . . . . . . . . . . . 3-3
Manual Lowering Controls . . . . . . . . . . . 3-5
Platform Control Station . . . . . . . . . . . . . 3-6
Platform Control Indicator Panel. . . . . . . 3-7
SECTION - 4 - MACHINE OPERATION
4.1 EMERGENCY CONTROL OPERATION . . . . 4-1
Platform/Off/Ground Selector Switch. . . 4-1
Emergency Stop Switch. . . . . . . . . . . . . 4-1
4.2 PLATFORM CONTROLS . . . . . . . . . . . . . . . 4-1
Drive Speed Selector Switch . . . . . . . . . 4-1
Traveling (Driving) . . . . . . . . . . . . . . . . . 4-1
Raising And Lowering The Mast . . . . . . 4-3
Raising And Lowering The Jib . . . . . . . . 4-4
Slewing The Turntable . . . . . . . . . . . . . . 4-4
Work Platform Functions Combination . 4-4
4.3 MANUAL LOWERING CONTROLS . . . . . . . 4-4
4.4 ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Motion Alarm . . . . . . . . . . . . . . . . . . . . . 4-4
Tilt Light And Alarm . . . . . . . . . . . . . . . . 4-4
Overload Light And Alarm (Toucan 800 only)4-4
Slack Chain Light And Alarm . . . . . . . . 4-4
Soft Touch System Light and Alarm (Option)4-5
4.5 SHUT DOWN AND PARK . . . . . . . . . . . . . . 4-5
4.6 CHARGERS . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
ZIVAN BC1 High Frequency Electronic Charger4-6
EMB-MP HAWKER Charger (40 or 70 A) 4-7
4.7 EMERGENCY TOWING. . . . . . . . . . . . . . . . 4-8
4.8 LIFTING AND TIE DOWN . . . . . . . . . . . . . . 4-8
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.9 LOADING AND UNLOADING . . . . . . . . . . . 4-9
Using a fork lift truck . . . . . . . . . . . . . . . . 4-9
Using a winch for loading . . . . . . . . . . . . 4-9
SECTION - 5 - DECALS
SECTION - 6 - EMERGENCY PROCEDURES
6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . 6-1
6.3 EMERGENCY OPERATION. . . . . . . . . . . . . 6-1
Operator Unable to Control Machine . . . 6-1
Platform or Mast Caught Overhead. . . . . 6-1
6.4 EMERGENCY LOWERING . . . . . . . . . . . . . 6-1
6.5 EMERGENCY TOWING PROCEDURES . . . 6-1
SECTION - 7 - INSPECTION AND REPAIR LOG
SECTION - 8 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE
8.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 OPERATING SPECIFICATIONS . . . . . . . . . 8-2
Fluid Capacities . . . . . . . . . . . . . . . . . . . . 8-3
Hydraulic Power Unit . . . . . . . . . . . . . . . . 8-3
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 OPERATOR MAINTENANCE. . . . . . . . . . . . 8-5
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Hydraulic filters . . . . . . . . . . . . . . . . . . . . 8-8
Turntable Lubrication. . . . . . . . . . . . . . . . 8-9
Lifting chains lubrication . . . . . . . . . . . . . 8-9
Mast Section Lubrication . . . . . . . . . . . . . 8-9
Wheel Bearing & Steering Knuckle Lubrication8-9
Hydraulic Oil Reservoir . . . . . . . . . . . . . 8-10
Steering hydraulic unit reservoir . . . . . . 8-11
Tires And Wheels. . . . . . . . . . . . . . . . . . 8-11
Verification Of The Overload Detection Setting
(Toucan 800 only) . . . . . . . . . . . . . . . . . 8-12
Verification Of The Tilt Alarm Setting. . . 8-12

TABLE OF CONTENTS
2– JLG Lift – 31210031

SECTION 1 - SAFETY PRECAUTIONS
31210031 – JLG Lift – 1-1
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.
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.
• 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 of the machine.
• This machine can be operated in temperatures of
-20oC to 40oC. Consult JLG for operation outside
this range.
• This machine must be used in a sufficient ambient
light.
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 footswitch 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.
• Do not clean electrical components with a high
pressure cleaner.
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

SECTION 1 - SAFETY PRECAUTIONS
1-2 – JLG Lift – 31210031
neutral and stop before moving the switch to the
next function. Operate controls with slow and even
pressure.
• Park the machine in stowed position when not in
service.
• 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
unless approved by JLG.
• 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 towing points
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.
Trip and Fall Hazards
JLG recommends that occupants of the platform wear
a full body harness with a lanyard attached to an
authorized lanyard anchorage point. For further
information regarding fall protection requirements on
JLG products, contact JLG Industries, Inc.
• 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.
• Always enter or leave the platform using the access
gate.
• Use extreme caution when entering or leaving
platform. Be sure that the mast assembly 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.
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 Distances (M.A.D.)
Voltage Range
(Phase to Phase)
MINIMUM APPROACH DISTANCE
in Meters
0 to 50 kV 3
Over 50 kV to 200 kV 5
Over 200 kV to 350 kV 6
Over 350 kV to 500 kV 8
Over 500 kV to 750 kV 11
Over 750 kV to 1000 kV 14
NOTE: This requirement shall apply except where
employer, local or governmental regulations
are more stringent.