Operation and Safety Manual

TOUCAN 800
TOUCAN 870

31210031
English - Operation and Safety Manual - Original Instructions
January 01, 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.

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

31210031 – 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 THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BUL-
AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS LETINS, CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHO-
DECAL WILL HAVE A RED BACKGROUND. RIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING
SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED
FOR THIS PRODUCT.

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT

AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS IMPORTANT
DECAL WILL HAVE AN ORANGE BACKGROUND. 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.
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT
AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY
ALSO ALERT AGAINST UNSAFE PRACTICES. IMPORTANT
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INDICATES PROCEDURES ESSENTIAL FOR SAFE OPERATION. INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN
THIS DECAL WILL HAVE A YELLOW BACKGROUND. 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 • Standards and Regulations Compliance Information
• Product Safety Publications • Questions Regarding Special Product Applications
• Current Owner Updates • Questions Regarding Product Modifications
• Questions Regarding Product Safety
CONTACT:
In USA: Outside USA:
JLG Industries, Inc. JLG Industries,
Product Safety & Reliability Department, Wright Business Centre,
13224 Fountain Head Plaza 1 Lonmay Road
Hagerstown, MD Queenslie
USA 21742 Glasgow,
Toll Free :+1 (877) 554-7233 Scotland G33 4EL
Tel. : +1 (240) 420-2661 Tel : +44(0)141 781 6700
Fax : +1 (301) 745-3713 Fax : +44(0)141 773 1907
Email : [email protected] Email : [email protected]
or Your Local JLG Office
(see adresses on manual rear cover)

b – JLG Lift – 31210031

 FOREWORD

REVISION LOG
Original Issue - September 14, 2007
Revision - January 01, 2010

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FOREWORD

d – JLG Lift – 31210031

 TABLE OF CONTENTS

SECTION - 1 - SAFETY PRECAUTIONS 4.5 SHUT DOWN AND PARK . . . . . . . . . . . . . . 4-5

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

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TABLE OF CONTENTS

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 SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL Workplace Inspection
This section outlines the necessary precautions for • The operator is to take safety measures to avoid all
proper and safe machine operation and maintenance. hazards in the work area prior to machine operation.
For proper machine use, it is mandatory that a daily • Do not operate or raise the platform while on trucks,
routine is established based on the content of this trailers, railway cars, floating vessels, scaffolds or
manual. A maintenance program, using the other equipment unless approved in writing by JLG.
information provided in this manual and the Service
• Do not operate the machine in hazardous
and Maintenance Manual, must also be established by
environments unless approved for that purpose by
a qualified person and followed to ensure the machine
JLG.
is safe to operate.
• Be sure that the ground conditions are able to
If there are any questions with regard to safety,
support the maximum load of the machine.
training, inspection, maintenance, application, and
operation, please contact JLG Industries, Inc. (“JLG”). • This machine can be operated in temperatures of
-20oC to 40oC. Consult JLG for operation outside
this range.
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED • This machine must be used in a sufficient ambient
IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, light.
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
Machine Inspection
1.2 PRE-OPERATION • Before machine operation, perform inspections and
functional checks. Refer to Section 2 of this manual
Operator Training and Knowledge for detailed instructions.
• Read and understand this manual before operating • Do not operate this machine until it has been
the machine. 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.
• Do not operate this machine until complete training • Avoid any buildup of debris on the platform floor.
is performed by authorized persons. Keep mud, oil, grease, and other slippery
• Only authorized and qualified personnel can substances from footwear and platform floor.
operate the machine. • Do not clean electrical components with a high
• Read, understand, and obey all DANGERS, pressure cleaner.
WARNINGS, CAUTIONS, and operating instructions
on the machine and in this manual. 1.3 OPERATION
• Use the machine in a manner which is within the General
scope of its intended application set by JLG.
• Do not use the machine for any purpose other than
• All operating personnel must be familiar with the positioning personnel, their tools, and equipment.
emergency controls and emergency operation of
the machine as specified in this manual. • Never operate a machine that is not working
properly. If a malfunction occurs, shut down the
• Read, understand, and obey all applicable machine.
employer, local, and governmental regulations as
they pertain to operation of the machine. • Never slam a control switch or lever through neutral
to an opposite direction. Always return switch to

31210031 – JLG Lift – 1-1

 SECTION 1 - SAFETY PRECAUTIONS

neutral and stop before moving the switch to the • Keep both feet firmly positioned on the platform
next function. Operate controls with slow and even floor at all times. Never use ladders, boxes, steps,
pressure. planks, or similar items on platform to provide
additional reach.
• Park the machine in stowed position when not in
service. • Always enter or leave the platform using the access
gate.
• Do not allow personnel to tamper with or operate
the machine from the ground with personnel in the • Use extreme caution when entering or leaving
platform, except in an emergency. platform. Be sure that the mast assembly is fully
lowered. Face the machine, maintain “three point
• Do not carry materials directly on platform railing
contact” with the machine, using two hands and one
unless approved by JLG.
foot or two feet and one hand during entry and exit.
• When two persons are in the platform, the operator
shall be responsible for all machine operations. Electrocution Hazards
• Always ensure that power tools are properly stowed • This machine is not insulated and does not provide
and never left hanging by their cord from the protection from contact or proximity to electrical
platform work area. current.
• 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
• Maintain distance from electrical lines, apparatus, or
a full body harness with a lanyard attached to an
any energized (exposed or insulated) parts
authorized lanyard anchorage point. For further
according to the Minimum Approach Distance
information regarding fall protection requirements on
(MAD) as shown in Table 1-1.
JLG products, contact JLG Industries, Inc.
• Allow for machine movement and electrical line
swaying.

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

Voltage Range MINIMUM APPROACH DISTANCE

• Before operating the machine, make sure all gates (Phase to Phase) in Meters
are closed and fastened in their proper position.
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.

1-2 – JLG Lift – 31210031

 SECTION 1 - SAFETY PRECAUTIONS

• Keep the chassis of the machine at least 0,6 m from

holes, bumps, drop-offs, obstructions, debris,
DO NOT MANOEUVER MACHINE OR PERSONNEL INSIDE concealed holes, and other potential hazards on the
PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS floor/surface.
AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.
• Do not push or pull any object with the extending
structure.
Maintain a clearance of at least 3 m between any part
of the machine and its occupants, their tools and their • Never attempt to use the machine as a crane. Do
equipment from any electrical line or apparatus not tie-off machine to any adjacent structure.
carrying up to 50 000 volts. A 0,3 m additional • Do not operate the machine when wind conditions
clearance is required for every additional 30 000 volts exceed the rating specified on the manufacturer’s
or less. nameplate.
The minimum approach distance may be reduced if • Do not increase the surface area of the platform or
insulating barriers are installed to prevent contact and the load. Increase of the area exposed to the wind
the barriers are rated for the voltage of the line being will decrease stability.
guarded. These barriers shall not be part of (or
attached to) the machine. The minimum approach • Do not increase the platform size with unauthorized
distance shall be reduced to a distance within the deck extensions or attachments.
designed working dimensions or the insulating barrier. • If extending structure assembly or platform is in a
This determination shall be made by a qualified person position that one or more wheels are off the ground,
in accordance with employer, local or governmental all persons must be removed before attempting to
requirements for work practices near energized stabilize the machine. Use appropriate equipment to
equipment. stabilize machine and remove personnel.
Tipping Hazards Crushing and Collision Hazards
• The user should be familiar with the surface before • Approved head gear must be worn by all operating
driving. Do not exceed the allowable sideslope and and ground personnel.
grade while driving.
• Check work area for clearances overhead, on sides,
and bottom of platform when lifting, slewing or
lowering platform, and driving.

• Never exceed the maximum platform capacity.

Distribute loads evenly on platform floor.
• Before driving on floors, bridges, trucks, and other • During operation, keep all body parts inside
surfaces, check allowable capacity of the surfaces. platform railing.
Check the ramp or slope for good adhesion of the • Always post a lookout when driving in areas where
wheels. Ensure that the driving surfaces are free of vision is obstructed.
moisture, ice, grease or from any other substance
• Keep non-operating personnel at least 1,8 m away
that could affect wheel adhesion.
from machine during all driving and slewing
• Do not elevate platform or drive with platform operations.
elevated while on a sloping, uneven, or soft surface.
• Limit travel speed according to conditions of ground
• Do not raise the platform or drive from an elevated surface, congestion, visibility, slope, location of
position unless the machine is on firm, level personnel, and other factors which may cause
surfaces and evenly supported. collision or injury to personnel.
• When travelling on slopes (Refer to section 8), the • Be aware of stopping distances in all drive speeds.
platform MUST be fully lowered, the machine MUST When driving in high speed, slow down the machine
travel in second gear. It is recommended to drive up using the controller before stopping.
the slope in FORWARD gear and to REVERSE down
• Do not use high speed drive in restricted or close
the slope as the machine will perform better.
quarters or when driving in reverse.

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 SECTION 1 - SAFETY PRECAUTIONS

• 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 the Emergency
Procedures section of this manual for emergency
towing procedures.
• Ensure extending structure is in the stowed position
prior to towing, lifting or hauling. The platform 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.

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING 2.2 PREPARATION, INSPECTION, AND
The aerial platform is a personnel handling device; so it MAINTENANCE
is necessary that it be operated and maintained only
The following table covers the periodic machine
by trained personnel.
inspections and maintenance required by JLG
Persons under the influence of drugs or alcohol or who Industries, Inc. Consult local regulations for further
are subject to seizures, dizziness or loss of physical requirements for aerial work platforms. The frequency
control must not operate this machine. of inspections and maintenance must be increased as
necessary when the machine is used in a harsh or
Operator Training hostile environment, if the machine is used with
Operator training must cover: increased frequency, or if the machine is used in a
severe manner.
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, drop-offs.
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.

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type Frequency Primary Service Reference

Responsibility Qualification
Pre-Start Inspec- Before using each day; or User or Operator User or Operator Operator and Safety Man-
tion whenever there’s an Operator change. ual
Pre-Delivery Before each sale, lease, or rental delivery. O w n e r, D e a l e r, o r Q u a l i f i e d J L G Service and Maintenance
Inspection (See User Mechanic Manual and applicable
Note) JLG inspection form
Frequent In service for 3 months or 150 hours, which- O w n e r, D e a l e r, o r Q u a l i f i e d J L G Service and Maintenance
Inspection ever comes first; or User Mechanic Manual and applicable
(See Note) JLG inspection form
Out of service for a period of more than 3
months; or
Purchased used.
Annual Machine Annually, no later than 13 months from the O w n e r, D e a l e r, o r Q u a l i f i e d J L G Service and Maintenance
Inspection date of prior inspection. User Mechanic Manual and applicable
(See Note) JLG inspection form
Preventative At intervals as specified in the Service and O w n e r, D e a l e r, o r Q u a l i f i e d J L G Service and Maintenance
Maintenance Maintenance Manual. User Mechanic Manual
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 PRE-START INSPECTION

The Pre-Start Inspection should 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
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 Responsibilities (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.
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 function check
(section 2.3.2) 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.

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Toucan 800

Toucan 800 DI

2-4 – JLG Lift – 31210031

 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Toucan 870

Figure 2-1. Daily Walk-Around Inspection

2.3.1 Walk-Around Inspection 6. Hand Pump - See Inspection Note.

Begin the "Walk-Around Inspection" at Item 1, as noted 7. All Hydraulic Cylinders - No visible damage;
on the diagram. Continue checking each item in pivot pins and hydraulic hoses undamaged, not
sequence for the conditions listed in the following leaking.
checklist. 8. Steering Spindles - See Inspection Note.
9. Lifting Chains, Chain Yokes and Clevis Pins -
Must be installed and in good condition. Chains
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS must be correctly tensioned and lubricated.
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 Guardrails and Gate - Footswitch works
properly, not modified, disabled or blocked. The
gate opens and closes properly.
2. Platform & Ground Control Consoles - Switches
and levers return to neutral, decals/placards
secure and legible, control markings legible.
3. Wheel/Tire Assemblies - Properly secured, no
missing lug nuts.
4. Drive Motor, Brake - No evidence of leakage.
5. Hood Assemblies - See Inspection Note.

31210031 – JLG Lift – 2-5

 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3.2 Function Check Tilt Sensor Check

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

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE

BEEN CORRECTED.

Perform the Function Check as follows:

Check the tilt sensor, located on the left side (Toucan
Control Stations 800), on the right side (Toucan 870) of the chassis, to
1. From the Ground Control Console : ensure proper operation. Wedge a block (P/N :
ST2741, located in the manual storage container) as
• Operate all functions; illustrated above to activate the tilt sensor and keep it
• Ensure that all machine functions are disabled tilted. Raise the mast by approximately 1m.
when the Emergency Stop Button is pushed in; The system is functioning properly if :
• Position the selector switch to Platform Control 1. From the Platform Control Console :
Console ; try to use the Ground Control Console :
• An acoustic alarm sounds.
- No movement shall occur.
• The red tilt indicator lights up on the Platform
2. From the Platform Control Console :
Control Panel.
• Ensure that the platform control console is firmly • The drive function is disabled.
secured;
• The jib raising function is performed at reduced
• Ensure proper operation of horn; speed.
• Ensure proper operation of all functions; • The mast raising function is performed at
• Ensure that all machine functions are disabled reduced speed.
when the Emergency Stop Button is pushed in; • The slewing movements are performed at
• Ensure that no functions can be operated unless reduced speed.
the footswitch is depressed; • All other functions are working normally.
• Activate simultaneously a drive movement and • Prohibited movements are indicated by the
superstructure movement. No movement shall orange light indicator on the platform control
occur. panel.
• Drive the machine on a grade, not to exceed the
2. From the Ground Control Console :
rated gradeability and stop to ensure the brakes
hold. • An acoustic alarm sounds.

2-6 – JLG Lift – 31210031

 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Overload Sensor Check (Toucan 800 & Toucan 800 DI)

Machine manufactured before 2010 Machine manufactured after 2010

Check the overload sensor, located on the platform

support, to ensure proper operation. Wedge a block (P/N :
ST2741) as illustrated above to activate the overload
sensor and keep it activated. The system is functioning
properly if :

1. From the Platform Control Console :

• An acoustic alarm sounds.
• The overload red light indicator flashes on the
platform control panel.
• Each attempt to perform a movement actuates
the orange light indicator on the platform control
panel.
• Every function is disabled from the upper control
panel.
2. From the Ground Control Console :
• An acoustic alarm sounds.
• The overload red indicators on the platform
control panel and on the ground control console
flash.
• Every function is disabled from the ground
control console.

31210031 – JLG Lift – 2-7

 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Slack / Broken Chain Sensors Check Gate sensors check (Toucan 800 DI only)

Check the slack/broken chain sensors to ensure proper

operation :
2 sensors.
Location : one at the top of mast 1 and one at the bottom of
mast 4.
Check the gate sensors to ensure proper operation :
NOTE: The mast 1 is attached to the turntable and mast 4 2 sensors.
supports the jib.
Location : under gate articulation axis.
Wedge a block (P/N : ST2741) as illustrated above to Open the right gate. The system is functioning properly if :
activate the slack chain sensor and keep it activated.
The system is functioning properly if : 1. From the Platform Control Console :

1. From the Platform Control Console : • The orange light indicator is continuously lit.

• An acoustic alarm sounds. • Every function is disabled from the upper control
console.
• The red slack chain indicator lights up on the
Platform Control Panel. 2. From the Ground Control Console :
• The jib and mast lowering functions are • Every function is disabled from the ground con-
disabled. trol console.
• The slewing movements are disabled.
• The driving function is disabled.
• Prohibited movements are indicated by the
orange light indicator on the platform control
panel.
• All other functions work normally.
2. From the Ground Control Console :
• An acoustic alarm sounds.
3. Repeat steps 1 to 2 for each slack chain sensor.

2-8 – JLG Lift – 31210031

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

Toucan 800 - Toucan 800 DI

Toucan 870

1. Driving wheels 9. Platform

2. Steering wheels 10. Platform control station
3. Counterweight 11. Manual storage container
4. Jib 12. Battery cover
5. Ground control station 13. Manual lowering controls
6. Charger 14. Chassis cover
7. Telescopic mast 15. Circuit-breaker (Toucan 800 : ¼ turn - Toucan 870 : Push/Pull)
8. Hand pump

Figure 3-1. Basic Nomenclature

31210031 – JLG Lift – 3-1

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

3.1 GENERAL
This section provides the necessary information
needed to understand control functions.

NOTICE
THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE
APPLICATION AND OPERATION. THE USER AND OPERATOR ARE
RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY
PRACTICES.

3.2 CONTROLS AND INDICATORS

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY

CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING
PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION
WHEN RELEASED.

Ground Control Station

NOTICE
DO NOT OPERATE FROM GROUND CONTROL STATION WITH
PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY.

NOTICE
WHEN THE MACHINE IS SHUT DOWN FOR OVERNIGHT PARKING
OR BATTERY CHARGING, THE PLATFORM/OFF/GROUND
SELECTOR AND THE EMERGENCY STOP SWITCHES MUST BE
POSITIONED TO OFF TO PREVENT DRAINING THE BATTERIES.

3-2 – JLG Lift – 31210031

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Toucan 800

1. Platform /Off/Ground Selector Switch

2. Emergency Stop Switch
3. Function Enable Switch
4. Jib Up / Down Switch
5. Mast Up / Down Switch
6. Turntable Slewing Switch
7. Charger Indicator
8. Circuit Breaker
9. Overload Indicator
10. Battery Filling Pump Switch
11. Main Circuit Breaker

Toucan 870

1. Platform /Off/Ground Selector Switch

2. Emergency Stop Switch
3. Function Enable Switch
4. Jib Up / Down Switch
5. Mast Up / Down Switch
6. Turntable Slewing Switch
7. Charger Indicator (if fitted)
8. Circuit Breaker
10. Battery Filling Pump Switch
11. Main Circuit Breaker

Figure 3-2. Ground Control Stations

31210031 – JLG Lift – 3-3

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Platform / Off / Ground Selector Switch

Movement Control from the Platform Controls

Control Circuit Off Position

Movement Control From The Ground Controls

2. Emergency Stop Switch.

Depress the switch to stop all functions. The
switch must be turned clockwise to restore the
machine’s function.
3. Function Enable Switch.
Must be pushed and held to operate any function.
4. Jib Up / Down Switch.
Move the switch UP to RAISE the jib. Move the
switch DOWN to LOWER the jib.
5. Mast Up / Down Switch.
Move the switch UP to RAISE the mast. Move the
switch DOWN to LOWER the mast.
6. Turntable Slewing Switch.
Move the switch to the RIGHT to slew the turntable
to the RIGHT or to the LEFT to slew the turntable
to the LEFT.
7. Charger Indicator
(Depending on equipment, see § 4-6)
8. Circuit Breaker.
Protection of the control circuit.

9. Overload Indicator
Flashing red light indicator.
10. Battery Filling Pump Switch.
Depress the push button to activate the battery
filling pump.
(See Maintenance section for further instructions).
11. Main Circuit Breaker
T800 : Position the circuit-breaker to its "O" position
(horizontal lever) to insulate the battery "+".
Position the circuit-breaker to its "I" position (vertical
lever) to restore battery supply.
T870 : Push the circuit breaker knob to insulate the
battery.
Pull the circuit breaker knob to restore the battery
supply.

3-4 – JLG Lift – 31210031

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Manual Lowering Controls

Toucan 800 Toucan 870

1. Jib Raising / Lowering Control Valve

2. Mast Raising / Lowering Control Valve
3. Slewing Control Valve
4. Pump Handle
5. Hand Pump
Figure 3-3. Manual Lowering Controls

Electro-Hydraulic Control Valve With Manual Control Push Buttons 4. Pump Handle :
Insert the pump handle in the hand pump to
1. Jib Raising / Lowering Control Valve :
activate a movement.
Depress and keep depressed the top push button
while activating the hand pump to lower the jib. 5. Hand Pump :
Depress and keep depressed the bottom push Operate the hand pump while activating the
button while activating the hand pump to raise the desired movement.
jib.
2. Mast Raising / Lowering Control valve :
Depress and keep depressed the top push button
while activating the hand pump to lower the mast.
Depress and keep depressed the bottom push
button while activating the hand pump to raise the
mast.
3. Slewing Control Valve :
Depress and keep depressed the top push button
while activating the hand pump to slew the
turntable to the right. Depress and keep
depressed the bottom push button while
activating the hand pump to slew the turntable to
the left.

31210031 – JLG Lift – 3-5

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Station

Figure 3-4. Platform Control Console

1. Emergency Stop Switch
2. Footswitch
3. Jib Function Control Switch
4. Mast Function Control Switch
5. Turntable Slewing Control Switch
6. Function Speed Control
7. Battery Discharge Indicator
8. Auxiliary Power Button
9. Drive Control Joystick
10. Drive Speed Selector Switch
11. Horn
12. Steering Control

(See Figure 3-5., Platform Control Indicator Panel) 6. Function Speed Control
When the knob is turned counter-clockwise to the
1. Emergency Stop Switch left ( ), the movements (except the drive
Depress the switch to stop all the functions of the movement) are performed at low speed. Turn the
machine. The switch must be turned clockwise to
knob clockwise to the right ( )to increase the
restore the machine’s functions.
speed of the movements.
2. Footswitch
Must be depressed before any movement is 7. Battery Discharge Indicator
controlled. The controls are enabled for a period As the battery discharges, the bar lit in (1) moves
of 5 seconds. If no function is operated within this from the right to the left (5 green bars followed by
period, the footswitch must be recycled. 3 orange bars).

3. Jib Function Control Switch

Pull the switch to raise the jib.
Push the switch to lower the jib.
4. Mast Function Control Switch
At this point, the LED flashes indicating "energy
Pull the switch to raise the mast.
reserve" (70% discharged).
Push the switch to lower the mast.
The 2 red LEDs most to the left flash indicating
5. Turntable Slewing Control Switch "empty" (80% discharged). At this point, power is
Toggle the switch to the right to slew the turntable cut-off. The battery must be recharged.
to the right.
Toggle the switch to the left to slew the turntable 1 - Discharge Indicator
to the left. 2 - Hourmeter

3-6 – JLG Lift – 31210031

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Auxiliary Power Button Platform Control Indicator Panel.

Once the electrical power is cut due to excessive
battery discharge (80%), the Auxiliary Power
Button can be pressed to use the remaining
battery charge to travel to the charging station.
NOTE: The button must be actuated and held BEFORE the
controls are enabled and the desired movement is
controlled. An intermittent acoustic signal is
actuated when the button is actuated.

IMPORTANT
A TOTAL DISCHARGE WILL RESULT IN IRREVERSIBLE DAMAGE Figure 3-5. Platform Control Indicator Panel
TO THE BATTERY.
1. Tilt Indicator Light and Alarm
9. Drive Control Joystick 2. Slack Chain Indicator Light and Alarm
Move the controller forward to drive forward. 3. Overload Indicator Light and Alarm
Move the controller backward to reverse. 4. Unauthorized Movement Indicator
5. Power Enable Indicator
10. Drive Speed Selector Switch
1st gear or slow speed

1. Tilt Indicator Light and Alarm.

2nd gear or climbing speed (max. 20%)
Excessive tilt. Red light and audible alarm
indicates the rated slope has been exceeded.
3rd gear or high speed
2. Slack Chain Indicator Light and Alarm.
11. Horn Slack lifting chain. Red light and audible alarm
Sounds when the button is depressed. indicates slack chain condition has been detected.
12. Steering control 3. Overload Indicator Light And Alarm
Push the right side of the thumb switch to steer the Flashing red light and audible alarm indicates the
wheels to the right. Push the left side of the thumb platform has been overloaded (Toucan 800 only).
switch to steer the wheels to the left.
4. Unauthorized Movement Indicator.
Orange light which indicates the machine is in a
configuration where the activation of movement is
not permitted.
5. Power Enable Indicator.
Green light indicates that the controls are ready.

31210031 – JLG Lift – 3-7

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-8 – JLG Lift – 31210031

 SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

NOTE: A delay-timer, integrated to the electrical system, 4.2 PLATFORM CONTROLS
disconnects the control boxes approximately 4
hours after the last operation of the machine. This
system preserves the battery should the operator
forget to disconnect the machine. After cut out, the TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY
emergency stop switch on the ground control CONTROL LEVERS OR SWITCHES CONTROLLING THE PLAT-
console must be depressed then turned clockwise FORM MOVEMENT DOES NOT RETURN TO THE OFF OR NEU-
to restore the functions of the machine. TRAL POSITION WHEN RELEASED.
IF THE PLATFORM DOES NOT STOP WHEN CONTROL LEVER OR
• To energize the machine : THE ENABLE SWITCH/TRIGGER IS RELEASED, USE THE EMER-
Toucan 800 : turn the circuit-breaker handle to "I" GENCY STOP SWITCH TO STOP THE MACHINE.
position.
Drive Speed Selector Switch
The DRIVE SPEED selector switch can be positioned
either to 3rd gear ( ), 2nd gear ( ) or 1st ( )
position and that speed will be obtained. When the
mast is raised (and/or the jib is raised for Toucan 800
manufactured before 2010), the high speed drive
(TORQUE or HIGH position) is cutout and only the low
drive speed is attainable.
Toucan 870 : pull the knob of the circuit-breaker Traveling (Driving)
to "I" position.
See Figure 4-1., Grade and Side Slope

NOTE: Refer to the General Specifications (Section 8) for

Gradeability and Side slope ratings.
All ratings for Gradeability and Side slope are based
upon the machine in transport mode with the mast
and jib being in the stowed position, fully lowered,
and retracted.

4.1 EMERGENCY CONTROL OPERATION NOTE: When the platform is driven in 3rd gear on a slope
steeper than 5%, the machine switches automati-
The machine has a Ground Control Station which will
cally to 2nd gear. The 3rd gear will be restored only
override the Platform Control Station. Ground Controls
when the platform is driven on a slope below 5%.
operate Lift and Slew, and are to be used in an
Either of the following actions must be done :
emergency to lower the platform to the ground should
- release and activate the enable control again.
the operator in the platform be unable to do so.
- return the joystick to neutral and control the move-
Platform/Off/Ground Selector Switch ment again.
With the switch in the ground position, power is - position the drive speed selector to 2nd gear
supplied to the Ground Control Station. When the ( ) and return it to 3rd gear ( ).
switch is in the platform position, power is supplied to
the Platform Control Station.
Operate the ground controls as follow :
DO NOT DRIVE WITH MAST OUT OF TRANSPORT MODE EXCEPT
1. Position PLATFORM/OFF/GROUND CONTROLS ON A SMOOTH, FIRM AND LEVEL SURFACE.
selector switch to GROUND CONTROLS ( ).
TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT
2. Push and hold the Function Enable Switch. DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED IN
3. Activate slewing, mast or jib function switch. SECTION 8.2 OF THIS MANUAL.

Emergency Stop Switch USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT
This switch, when in the on (out) position, provides ALL TIMES WHEN THE PLATFORM IS ELEVATED.
electrical power to the ground controls or platform
controls, as applicable. In addition, the switch can be BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION
used to turn off power (push the switch IN) to the ARROWS ON BOTH THE CHASSIS AND THE PLATFORM
function controls in the event of an emergency.

31210031 – JLG Lift – 4-1

 SECTION 4 - MACHINE OPERATION

CONTROLS. MOVE THE DRIVE CONTROLS IN A DIRECTION

MATCHING THE DIRECTIONAL ARROWS.

With the machine in transport mode, traveling is limited

by two factors, gradeability and side slope.
Gradeability is the percent of grade of the incline the
machine can climb. Sideslope, is the angle of the slope
the machine can be driven across. Reference section 8
for gradeability and side slope ratings.
W h e n t h e m a s t ( o r t h e j i b f o r To u c a n 8 0 0
manufactured before 2010) is extended, the machine
must not be operated on grades or side slopes that are
greater than that specified in Section 8. The tilt alarm
will sound and tilt indicator will light to alert the
operator when the machine has exceeded the rated
slope. The drive movements are cut and the slewing,
jib and mast raising movements switch automatically
to slow speed.

4-2 – JLG Lift – 31210031

 SECTION 4 - MACHINE OPERATION

Figure 4-1. Grade and Side Slope

Forward

1. Position the DRIVE SPEED selector to 1st gear TO AVOID TIP OVER, LOWER PLATFORM TO GROUND LEVEL.
( ), 2nd gear ( ) or 3rd gear ( ). THEN DRIVE MACHINE TO A LEVEL SURFACE BEFORE RAISING
MAST.
2. Match the black and white direction arrows on
both platform control panel and chassis to TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY
determine the direction the machine will travel. CONTROL LEVER OR TOGGLE SWITCH CONTROLLING
PLATFORM MOVEMENT DOES NOT RETURN TO THE ’OFF’ OR
3. Depress footswitch. NEUTRAL POSITION WHEN RELEASED.
4. Push the controller forward within 5 seconds after
the footswitch has been depressed. IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH
OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH
Stopping OR USE EMERGENCY STOP SWITCH TO STOP THE MACHINE.

Stopping is accomplished by slowly returning the Raising And Lowering The Mast
DRIVE controller to the neutral position. The brakes will
Raising the mast :
apply automatically.
1. Depress footswitch.
Reverse
2. Pull the mast function control switch toward the
Traveling in reverse is accomplished the same way as operator to raise the mast within 5 seconds after
traveling forward except for pulling the DRIVE the footswitch has been depressed.
controller toward the operator to reverse (REV).
3. Adjust the speed movement using the function
Steering speed control.

Steering is accomplished by pressing the left side of Lowering the mast :

the THUMB switch (on top of the controller) to steer to 1. Depress footswitch.
the left or the right side of the THUMB switch (on top
on the controller) to steer to the right. 2. Push the mast function control switch away from
the operator to lower the mast within 5 seconds
after the footswitch has been depressed.
3. Adjust the speed movement using the function
speed control.

31210031 – JLG Lift – 4-3

 SECTION 4 - MACHINE OPERATION

Raising And Lowering The Jib 4.4 ALARMS

Raising the jib : Horn
1. Depress footswitch. Horn is activated when the corresponding push button
located on the Platform Control Console is depressed.
2. Pull the jib function control switch toward the
operator to raise the jib within 5 seconds after the Motion Alarm
footswitch has been depressed. The machine is fitted with 2 lights (beacons) that come
3. Adjust the speed movement using the function on as soon as a function is controlled from the platform
speed control. control panel or from the ground control panel.

Lowering the jib : Tilt Light And Alarm

The alarm is triggered by a tilt sensor located on the
1. Depress footswitch. right hand side (Toucan 870), left hand side (Toucan
2. Push the jib function control switch away from the 800) of the chassis under the chassis cover. This alarm
is active once the mast (and/or the jib for Toucan 800
operator to lower the jib within 5 seconds after the
manufactured before 2010), has left its lowered
footswitch has been depressed. position. It consists of a light on the platform control
3. Adjust the speed movement using the function panel and an alarm. The alarm and light indicate that
speed control. the work platform is at its maximum out of level limit
(refer Table 8.1) and is nearing an unstable position.
Slewing The Turntable Drive function is disabled and the jib, mast and
turntable slewing movements are operable at a
To slew : reduced speed.
When the tilt light or alarm is activated, it is
1. Depress footswitch.
recommended to place the machine in the following
2. Move the turntable slewing control switch to the configuration :
right to slew the turntable to the right. Move the 1. Mast lowered.
turntable slewing control switch to the left to slew
2. Jib in line with the chassis length.
the turntable to the left. The switch has to be
operated within 5 seconds after the footswitch has 3. Jib lowered.
been depressed. The tilt alarm and light are also operational from the
ground control panel.
3. Adjust the speed movement using the function
speed control.

Work Platform Functions Combination DO NOT RAISE MAST OR OPERATE JIB WITH MAST RAISED
A drive movement cannot be combined with a structure WHEN MACHINE IS OUT OF LEVEL.
movement.
Overload Light And Alarm (Toucan 800
If a mast or jib raising movement is activated with a only)
slewing movement, only one function will work and only at
low speed (lower than normal slewing speed) will be A sensor located on the platform support is actuated
attainable. when the maximum rated load is exceeded. In case of
overload, all functions are disabled, the red indicator
4.3 MANUAL LOWERING CONTROLS on the platform control panel and on the emergency
control panel flash and an acoustic alarm is triggered.
The manual lowering controls should be used in The work platform must be unloaded until the flashing
emergency situations or mechanical breakdown. The light and acoustic alarm stop.
manual lowering controls provide an auxiliary means of
lowering and raising the platform and slewing the Slack Chain Light And Alarm
turntable in the event of primary power loss. The slack chain detection system prevents movements
if the platform or the jib come to rest on an obstacle
while lowering the mast or jib.
When a slack chain is detected, the sensor actuates an
acoustic alarm and a red light is lit on the platform
control panel. All functions of the machine, except the
mast and jib raising movements, are disabled.
Procedure to follow in case this feature is activated :

4-4 – JLG Lift – 31210031

 SECTION 4 - MACHINE OPERATION

1. Raise the mast or the jib (generally the reverse 4.5 SHUT DOWN AND PARK
movements to the one that caused the alarm to
sound). To shut down and park the machine, the procedures
are as follow :
2. Identify the cause.
1. Drive machine to a reasonably well protected
3. Perform the movement which will clear the area.
machine and prevent contact with the obstacle.
2. Ensure mast is lowered and jib stowed.
If the examination of the surroundings does not reveal
any possible obstacle, the alarm may have been 3. Push in the Emergency Stop at Platform Control
triggered by the telescopic mast jamming which could Station.
be due to : 4. Push in the Emergency Stop at Ground Control
• A foreign body entering the guiding system. Station. Position Platform/Off/Ground select
switch to center OFF.
• A lack of lubrication.
5. Toucan 800 : Position the circuit-breaker to its "O"
• Incorrect operation.
position.
NOTE: The slack chain and light alarms are also Toucan 870 : Depress the circuit breaker push
operational from the ground control station. button.
6. If necessary, cover Platform Controls to protect
instruction placards, warning decals and
operating controls from hostile environment.
IF THE SLACK CHAIN ALARM HAS BEEN TRIGGERED BY MAST
JAMMING, DISCONTINUE OPERATION IMMEDIATELY. DO NOT 7. Charge the batteries if the LEDs on the discharge
USE THE MANUAL LOWERING CONTROLS. PLATFORM indicator are orange or red.
OCCUPANTS MUST BE RESCUED AND THE MACHINE SERVICED
BY A QUALIFIED TECHNICIAN.

Soft Touch System Light and Alarm (Option)

The soft touch system detects contacts with outside
obstacles under the platform.
When this system is actuated, all the movements of the
platform are disabled, an acoustic alarm sounds and
the movement cut off indicator (orange) lights up on
the platform control panel.
Procedure to follow in case this feature is actuated :
1. Return all controls to neutral.
2. Locate the part of the platform contacting or
interfering with the outside obstacle.
3. Determine the appropriate clearance movement
(generally the opposite movement to the one that
caused the contact).
4. Actuate and keep actuated the auxiliary power
button ( ) BEFORE operating the functions
required to clear the obstacle.
This feature is operational only when the platform is
controlled from the platform control panel.

31210031 – JLG Lift – 4-5

 SECTION 4 - MACHINE OPERATION

4.6 CHARGERS ZIVAN BC1 High Frequency Electronic Charger

The work platform on-board electronic charger is
designed to automatically charge 24 V DC lead-acid
rechargeable batteries.
Several types of chargers can be fitted on the machine
depending on the capacity of the battery.
The covers of the machine must be open during
battery charge.

LEAD-ACID BATTERIES MAY EMIT HIGHLY EXPLOSIVE GASES.

THE EMISSION IS GREATLY INCREASED DURING CHARGING. Charging the battery :
NEVER INTRODUCE FLAMES, SPARKS OR OTHER SOURCES OF
IGNITION TO BATTERY AREA. FAILURE TO COMPLY WITH THIS - Plug the charger into the mains (single phase 2 poles
WARNING COULD RESULT IN DEATH OR INJURY TO + ground).
PERSONNEL. ALWAYS CHARGE BATTERIES IN A WELL- - The charger starts automatically.
VENTILATED AREA.
Remote charge-phase indicator on emergency control
unit :

DO NOT DISCONNECT BATTERY PLUG WHEN THE CHARGER IS Red LED :

ON. THE RESULTING ARCING COULD CAUSE BATTERY TO The charger is in the charge initial phase (phase 1).
EXPLODE AND BURNS TO THE OPERATOR. Flashing Red LED :
At the end of this phase, the battery is 80% charged
NOTE: It is not necessary to charge the battery if the (phase 2).
electrolyte specific gravity has not dropped under Red and Green fixed LED :
1.240 kg/l. Regular charge of a battery when its Battery between 80 and 100% charged.
specific gravity is higher then 1.240 kg/l can greatly Green LED :
reduce the battery life. Battery charge complete, the charging process stops.

Alarms :
NOTE: The charger has an interlock feature which causes
the work platform power circuit to open anytime the A flashing LED and an intermittent acoustic alarm indi-
charger is plugged into a live AC outlet. cate a faulty situation. When the alarm is on, the
charger does no longer deliver any current.
NOTE: If power supply is stopped during the charge cycle,
the charger switches to a waiting mode and restarts Troubleshooting :
automatically as soon as the power returns.
TYPE OF ALARM DESCRIPTION (Action)
Supply Voltage :
Always ensure the voltage selected corresponds to the The charging phase 1 is lasting longer than the
network voltage and the socket protection is sufficient Temporisation maximum authorised (check the capacity of the
battery. Contact JLG Product Support).
to support the charger power.
Incorrect setting of the charger voltage may result in
malfunction or breakdown. Battery current
Loss of control of the output current (fault on
control logic : Contact JLG Product Support).
The chargers are factory preset based upon the plug
type fitted.
Loss of control on output voltage (fault on control
Battery voltage
logic : Contact JLG Product Support).

Overheating of semi-conductors (check for proper

Thermal safety
operation of the fan).

4-6 – JLG Lift – 31210031

 SECTION 4 - MACHINE OPERATION

EMB-MP HAWKER Charger (40 or 70 A) Leds signal :

a. Charge indicator (green)

b. Final charge indicator (yellow)
c. Battery indicator charge completed (green)
d. Fault indicator (red)
e. Circuit breaker

Charging the battery :

OFF = the led is off
- Plug the charger into the mains (single phase 2 poles +
ON = the led is lit fixed
ground).
- Once the charger is connected, all the leds begin to flash BL = the led flashes (T=1 second)
for a short period of time, indicating the charger is com-
BV = the led flashes quickly (T = 0.2 second)
pleting a self-test.
- The leds (c) and (d) will then flash for a short period of * = the led can be on or off, depending on the state of
time, indicating the charger is in "automatic starting" charge of the battery and on the charger’s opera-
mode. tion at that moment.
- The charging phase starts, the green led (a) flashes
slowly (Frequency = 1 second) during the duration of
the charge.
- Once the final charging phase has been reached
(approximately 80%), led (a) still flashes and led (b)
lights up fixed.
- At the end of the charging process, both leds (a) and (c)
are on fixed.
Equalization charge :
- When the charger is doing an equalization charge :
• both leds (a) and (c) flash slowly.
• Led (b) is lit fixed.
Fault indicator :
- Should the transformer overheat, the red led (d) flashes
quickly (Frequency = 0,2 second).
- If the battery does not reach 2.4 V/cell after a 10 hour
charge, the charging process stops and the red led (d)
lights up.
It is advisable to have either the charger or the battery
checked by a technician.

31210031 – JLG Lift – 4-7

 SECTION 4 - MACHINE OPERATION

4.7 EMERGENCY TOWING 4.8 LIFTING AND TIE DOWN

Towing is discouraged and must only be performed as
a last option. IMPORTANT
WHEN TRANSPORTING THE MACHINE, THE MACHINE MUST BE
IMPORTANT STOWED.
VERIFY THE CAPACITY OF THE EQUIPMENT USED TO TOW THE
MACHINE. Lifting
1. The weight of the machine is stamped on the
serial number plate (See § 8.2). If the plate is
missing or illegible, call JLG Industries or weigh
ENSURE THE MACHINE IS ON LEVEL GROUND BEFORE the individual unit to find out the Gross Vehicle
RELEASING THE BRAKES. Weight.
THE MACHINE MUST ALWAYS BE IN STOWED POSITION DURING
TOWING PROCEDURE. 2. Place the machine in the stowed position.
NO PERSONNEL IS ALLOWED ON THE PLATFORM DURING 3. Remove all loose items from the machine.
TOWING PROCEDURE.
4. Attach lifting device and equipment only to the
To tow, release the brakes and the wheel motors as follow: designated lifting points. (See below).

1. Fully lower the platform.

Toucan 800
2. Remove the pump handle from its support.
3. Before releasing the valve, wait 30 seconds after
the end of a drive movement.
4. Pull the lever of the brake release valve (located at
the rear side of the chassis) to "BRAKE
UNLOCKED" position ( ).
5. Insert the handle in the hand pump.
6. Activate the hand pump until the movement gets
harder.
7. Use a winch to tow the machine (if a winch is not
available, use another low speed towing device).

Toucan 870
THERE IS ONE TIE DOWN/EMERGENCY TOW LUG INSTALLED
ON EACH END OF THE CHASSIS OF THE WORK PLATFORM.

8. At the end of the procedure, return the release

valve to NORMAL USE ( ). The machine and
the brakes are operational.

MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST

BE ABLE TO CONTROL MACHINE AT ALL TIMES, ON-HIGHWAY
TOWING NOT PERMITTED, FAILURE TO FOLLOW INSTRUCTIONS
COULD CAUSE SERIOUS INJURY OR DEATH. MAXIMUM TOWING
GRADE 20%.

BEFORE TOWING, THE BRAKES AND THE WHEEL MOTORS

MUST BE RELEASED. TOWING IS LIMITED TO EXTREMELY
SHORT DISTANCES AT A MAXIMUM SPEED OF 1 KM/H. SEVERE
DAMAGE TO THE DRIVE SYSTEM MAY RESULT IF TOWING IS
OTHERWISE ACCOMPLISHED. USE BOTH RINGS TO LIFT THE MACHINE.

5. Properly adjust the rigging to prevent damage to

the machine.

4-8 – JLG Lift – 31210031

 SECTION 4 - MACHINE OPERATION

Tie Down 4.9 LOADING AND UNLOADING

1. Place the machine in the stowed position. Using a fork lift truck
2. Remove all loose items from the machine. Toucan 800
3. Chock wheels in both directions.
4. Secure the chassis using straps or chains of
adequate strength and attached to the designated
tie down points.
Toucan 800

Toucan 870

Toucan 870

Figure 4-2. Position of the forks

VERIFY THE CAPACITY OF THE FORKLIFT TRUCK AND OF ITS

EQUIPMENT. FORK LIFT ONLY AT THE DESIGNATED POINTS. ANY
OTHER POSITION OF THE FORKS WILL CAUSE THE MACHINE TO
TIP OVER. NOBODY MUST BE ON THE PLATFORM OF THE
MACHINE DURING LOADING AND UNLOADING OPERATIONS.

THE WORK PLATFORM MUST BE KEPT AS NEAR TO THE

GROUND AS POSSIBLE DURING FORK LIFT OPERATION.

Using a winch for loading

If the work platform cannot be loaded safely using the
work platform controls, use a winch (release brakes
prior to the operation).

CHECK THE CAPACITY OF THE EQUIPMENT USED. PLACE THE

MACHINE IN TOWING MODE (SEE § 4.7) FOR THE LOADING AND
UNLOADING PROCEDURES. NOBODY MUST BE IN THE
PLATFORM DURING THIS OPERATION.

31210031 – JLG Lift – 4-9

 SECTION 4 - MACHINE OPERATION

4-10 – JLG Lift – 31210031

 SECTION 5 - DECALS

SECTION 5. DECALS
Toucan 800

Instructions AU1743
Loads AU1095

31210031 – JLG Lift – 5-1

 SECTION 5 - DECALS

5-2 – JLG Lift – 31210031

 SECTION 5 - DECALS

Toucan 800 DI

Instructions AU1743
Loads AU1755
Load Transfer AU1387

31210031 – JLG Lift – 5-3

 SECTION 5 - DECALS

5-4 – JLG Lift – 31210031

 SECTION 5 - DECALS

Toucan 870

Standard Platform
Instructions AU1757
Loads AU1756
Large Platform
Instructions AU1757
Loads AU1758

31210031 – JLG Lift – 5-5

 SECTION 5 - DECALS

5-6 – JLG Lift – 31210031

 SECTION 6 - EMERGENCY PROCEDURES

SECTION 6. EMERGENCY PROCEDURES

6.1 GENERAL 6.4 EMERGENCY LOWERING
This section explains the steps to be taken in case of If primary power is lost, the platform may be lowered
an emergency situation while operating. manually. Reference section 3 for Manual Lowering
Control procedures.
6.2 INCIDENT NOTIFICATION
JLG Industries, Inc. must be notified immediately of 6.5 EMERGENCY TOWING PROCEDURES
any incident involving a JLG product. Even if no injury
or property damage is evident, the factory should be Towing this machine is discouraged. However,
contacted by tel ephone and pr ovided with all provisions for towing the machine in emergency
necessary details. situations have been incorporated. For specific
procedures, refer to Section 4.
In USA : 877-JLG-SAFE (Toll free)

Outside USA: +44 (0) 141 781 6700

E-mail:[email protected]
Failure to notify the manufacturer of an incident
involving a JLG Industries product within 48 hours of
such an occurrence may void any warranty
consideration on that particular machine.

IMPORTANT
FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE
MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND
CONTROLS, THEN FROM THE PLATFORM CONTROLS. DO NOT
LIFT ABOVE 3 M UNTIL YOU ARE SURE THAT ALL DAMAGE HAS
BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE
OPERATING CORRECTLY.

6.3 EMERGENCY OPERATION

Operator Unable to Control Machine
IF THE PLATFORM OPERATOR IS PINNED, TRAPPED
OR UNABLE TO OPERATE OR CONTROL MACHINE:
1. Other personnel should operate the machine from
ground controls only as required.
2. Other qualified personnel on the platform may use
the platform controls. DO NOT CONTINUE
OPERATION IF CONTROLS DO NOT FUNCTION
PROPERLY.
3. Appropriate equipment can be used to remove
platform occupants and stabilize motion of the
machine.

Platform or Mast Caught Overhead

If the platform or mast becomes jammed or snagged in
overhead structures or equipment, rescue platform
occupants prior to freeing the machine.

31210031 – JLG Lift – 6-1

 SECTION 7 - INSPECTION AND REPAIR LOG

SECTION 7. INSPECTION AND REPAIR LOG

Type of machine :_______________________________________ Machine Serial Number :__________________________________

Table 7-1. Inspection and Repair Log

Date Comments

Name :______________________________________

Signature :____________________________________

31210031 – JLG Lift – 7-1

 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 8. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

8.1 INTRODUCTION
This section of the manual provides additional
necessary information to the operator for proper
operation and maintenance of this machine.
The maintenance portion of this section is intended as
information to assist the machine operator to perform
daily maintenance tasks only, and does not replace the
more thorough Preventive Maintenance and Inspection
Schedule included in the Service and Maintenance
Manual.

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

31210031 – JLG Lift – 8-1

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

8.2 OPERATING SPECIFICATIONS

Table 8-1. Operating Specifications And Dimensions

TOUCAN 800 A TOUCAN 800 A TOUCAN 800 DI TOUCAN 870 TOUCAN 870
Platform Size 700 x 900 1010 x 900 1300 x 900 700 x 900 1010 x 900
220 kg 200 kg
Maximum Work Load 200 kg (2 persons + 40 kg material) (2 persons + 60 kg (2 persons + 40 kg
material) material)
Slewing 360° non-continuous 180°
Max. Platform Height 6.10 m 6.72 m
Horizontal Reach
(from centerline of machine) 1.89 m 2.19 m 2.40 m 2.64 m 2.96 m
(from rear wheel edge) 1.10 m 1.40 m 1.60 m 1.84 m 2.15 m
(from side wheel edge) 1.40 m 1.70 m 1.90 m 2.15 m 2.46 m
Up and Over Clearance 5.35 m 5.42 m
Max. Hydraulic System Pressure 23 MPa
Maximum Operating Wind Speed 45 km/h (12.5 m/s) 0 km/h 45 km/h (12.5 m/s)
Maximum Horizontal Manual Force 400 N
Electrical System Voltage 24V
Gross Machine Weight (Platform Empty) before 2010 1950 kg 2000 kg 2980 kg
Gross Machine Weight (Platform Empty) since 2010 2100 kg 2200 kg 2980 kg
Overall Length before 2010 1.90 m 2.20 m 2.50 m 2.67 m 2.99 m
Overall Length since 2010 1.94 m 2.25 m 2.53 m 2.67 m 2.99 m
Overall Height 1.99 m
Overall Width 0.99 m
Maximum Wheel Load 1400 kg 1500 kg 1950 kg
Maximum Travel Grade (Gradeability)
20% (11°) 15% (8.5°)
With mast in stowed position and jib below horizontal
Maximum Travel Grade (Side slope)
5°
With mast in stowed position and jib below horizontal
Tilt Sensor Setting 2°
Turning Radius
Inside : 1.05 m
Outside : 2.40 m
The weighed root mean square acceleration value to which the arms are subjected (control levers)
is inferior to 2,5m/s/s.
Vibration levels
The weighed root mean square acceleration value to which the feet are subjected (platform floor)
is inferior to 0,5m/s/s/.
The equivalent continuous ’A’ weighed sound pressure level at the work station is <to 70 dB(A).
Acoustic pressure
The measure has been taken by placing the sonometer at 1,60 m above the platform floor.

8-2 – JLG Lift – 31210031

 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Fluid Capacities
Table 8-2. Capacities

Main Hydraulic Tank 19 l

Hydraulic Power Unit

Table 8-3. Hydraulic Power Unit Specifications

Maximum 24 MPa
Power 4.8 kW
Main Motor
Voltage 24 VDC
Power
Unit Flow Rate 9.1 l/mn
Pump
Displacement 3.5 cm³/t
Maximum 12 MPa
Power 0.8 kW
Steering Motor
Voltage 24 VDC
Unit
Pump Displacement 0.5 cm³/t

Batteries
Table 8-4. Battery Specifications

Voltage 24 Volt
Toucan 800 240 Ah (5h rate)
Amp Hour Rating
Toucan 870 620 Ah (5h rate)
Life Cycle Rating 1200 Cycles

31210031 – JLG Lift – 8-3

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Toucan 800

Toucan 870

Figure 8-1. Operator Maintenance & Lubrication Diagram

1- Batteries 7- Hydraulic Oil Reservoir

2- Hydraulic Filters 8- Steering Hydraulic Unit Reservoir
3- Turntable Lubrication 9- Tires & Wheels
4- Lifting Chains Lubrication 10- Verification of the Overload Detection Setting (if fitted)
5- Mast Section Lubrication 11- Verification of the Tilt Alarm Setting
6- Wheel Bearing & Steering Knuckles Lubrication

8-4 – JLG Lift – 31210031

 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

8.3 OPERATOR MAINTENANCE • Fill the can with distilled water.

1. Batteries

DRAINED WATER MAY HAVE BEEN IN CONTACT WITH ACID AND

MAY HAVE BECOME CORROSIVE. DO NOT ALLOW DRAIN
WATER TO CONTACT THE SKIN OR EYES. IF IT OCCURS, FLUSH
THE CONTACTED AREA WITH WATER AND CONSULT A DOCTOR
IMMEDIATELY. APPROPRIATE EQUIPMENT MUST BE WORN
(GLOVES, GOGGLES, RUBBER APRON) TO PREVENT THE
DRAINED WATER FROM CONTACTING THE SKIN OR ANY PART
OF THE BODY.

• Depress and hold the push button to activate the

battery filling pump until the flow indicator slows
BATTERY ELECTROLYTE MUST NOT BE ALLOWED TO CONTACT down.
THE SKIN OR EYES. IF IT DOES OCCUR, FLUSH THE
CONTACTED AREA WITH WATER AND CONSULT A DOCTOR
IMMEDIATELY. APPROPRIATE EQUIPMENT MUST BE WORN
(GLOVES, GOGGLES, RUBBER APRON) TO PREVENT THE
ELECTROLYTE FROM CONTACTING THE SKIN OR ANY OTHER
PART OF THE BODY DURING ANY SERVICING OPERATION ON
THE BATTERY.

• Check that the level is correct in each battery cell.

DURING MAINTENANCE OR ANY SERVICING OPERATION ON
THE BATTERY, RINGS, WATCHES OR ANY OTHER JEWELLERY Weekly maintenance
MUST BE REMOVED.
Cleaning - Battery maintenance
Daily maintenance It is necessary to clean the battery regularly to prevent
salt formation and current arcing which could damage
Electrolyte level
the machine.
Verify the electrolyte level after the charge using the floats in
• Clean and dry the battery top.
the center of each filling cap.
• Ensure the connections are clean and tight.
• Keep the metallic containers clean. In case of
corrosion, clean, neutralize corrosion and apply
anti-acid paint on the affected area.
• Drain the water that can accumulate at the bottom of
the container (electrolyte overflow, leak in the
centralized filling circuit, battery cleaning...).
To drain the water :

NOTE: Tilt the charger to gain access to the front battery

pack.

Fill the battery cells, if necessary, after the charge

using the filling system.

IMPORTANT
USE ONLY DISTILLED OR DEMINERALIZED WATER TO FILL THE • A draining bulb is supplied with the work platform
BATTERY CELLS. BATTERY CELLS MUST BE FILLED ONLY
AFTER THE CHARGE (DURING THE CHARGE, THE NOTE: The water that contacted a battery is classified as
ELECTROLYTE LEVEL INCREASES AND CAN OVERFLOW). industrial waste, it must be disposed of according
to regulations in force.

31210031 – JLG Lift – 8-5

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Monthly maintenance Various recommendations

Checking voltage and electrolyte specific gravity Use of a battery in a cold chamber or in a cold climate

NOTE: Voltage and specific gravity measures should not Low temperatures decrease battery capacity. The
be performed after battery cells have been filled. battery must be fully charged when the work platform
These measures must be done after a complete is operated in a cold chamber or in cold weather
charge once the charger has been unplugged and condition.
the machine has been standing for 15 mn.
Battery not working continuously or inactive battery
• Open the battery cell filling cap. A battery that is not used or used intermittently must be
stored charged in a dry area away from freezing
• Using the hydrometer, take a quantity of electrolyte
temperatures. A charge must be performed once a
sufficient so that the float emerges. Ensure the float
month.
top does not touch the rubber bulb or that the float
does not stick by capillarity to the glass wall. • Unplug the battery to insulate it electrically.
• Read the value as indicated on the example below : • Keep the top of the battery clean and dry to prevent
self discharge.

IMPORTANT
IF THE BATTERY IS NOT USED CONTINUOUSLY, IT MUST BE
RECHARGED BEFORE USE AND AT LEAST ONCE A MONTH, EVEN
IF THE ELECTROLYTE SPECIFIC GRAVITY MEASURES ARE HIGH.
BEFORE PLACING IN SERVICE A BATTERY WHICH REMAINED
INACTIVE FOR A LONG PERIOD OF TIME, YOU MUST RECHARGE
THE BATTERY AND CHECK THE ELECTROLYTE LEVEL IN THE
CELLS

• Return the electrolyte in the cell and record cell

electrolyte specific gravity in the battery service log.
• Repeat operation for each battery cell.
• Contact JLG Industries if important disparities are
noticed between the gravity of the different cells and
if the values are lower than 1.24.
• Check each cell voltage.
• Contact JLG Industries if important disparities are
noticed between the voltage of the different cells.
Annual maintenance
Filling system maintenance
It is necessary to service the centralized filling system
at least once a year. Cleaning frequency must be
increased in case of premature clogging of the filter or
a reduction in water flow.
• Disconnect and clean the filter by reversing the
water flow from the normal direction.
• Check the hoses for flexibility. In case of hardening
in the connection areas, replace the hose.
• Check every fitting for tightness and leakage.
• Check the cell caps individually. Ensure the perfect
mobility of the floats. In case of excessive clogging,
replace the cap. In any case, it is recommended to
replace the caps every 2 to 3 years.

8-6 – JLG Lift – 31210031

 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Battery troubleshooting

Symptoms Probable causes Solutions

Filling done before the charge. Fill battery cells after the charge.
Cells overfilled.
Electrolyte overflow.
Overcharge. Never charge battery if electrolyte specific gravity is above 1,240 kg/l.
Filling done before the charge. Fill battery cells after the charge.
Inequal electrolyte specific gravity or
Loss of electrolyte due to overflow. Perform an equalization charge.
electrolyte specific gravity too low.
Stratification of the electrolyte. Contact your JLG Distributor/Product Support.
Electrolyte specific gravity too low. Refer to "electrolyte specific gravity too low".
Low voltage in the cells in open circuit.
Short-circuit. Clean battery top.
Problem with the charger. Get the charger checked by a technician.

Bad air circulation during charge. Open access doors to batteries during charge.
Battery cells temperature too high (over 113°F
Reduce temperature of the area where the battery is charged (artificial ventilation).
(45°C)).
Cell weak or faulty Change battery cell.
Cells shorted.
Battery under charged. Perform an equalization charge.

Cell faulty. Replace faulty cell.

Battery incapable of supporting regular
operation.
Faulty cable or connection. Check wire condition and connection.

Battery at the end of its service life. Replace the battery.

31210031 – JLG Lift – 8-7

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Lubrication Specification

LOW TEMPE RATURE

STANDARD S TANDARD
DOWN - 35°C
C
NERVOFLUID VG 32 NERVO L - EQUIVIS XV 32 MOBILTAC 81
NE RVOFLUID DVG 3 2 NERVO L - HY DRALF XV 32
A MOBIL DTE 1 3M
FO OD COMP ATIBLE LOW TEMPERATURE
FO OD COMP ATIBLE S TANDARD
LOW TEMPE RATURE DO WN -3 5°C
D
NERVOL - AGROFLUID DVG 32 NERVOL - AGROFLUID MOBIL DTE 16M
MOBIL - DTE FM 3 2 CHAINE FILANTE HY DRELF XV 32

LOW TEMPE RATURE

STANDARD S TANDARD
DOWN - 35°C
B E
CO MPLEX EP 2 NERVO L - CRYO GREAS E MOBILUX EP 2
MO BILUX E P2 MOBILITH S HC 220 CO MPLEX EP2

2. Hydraulic filters • Install a new filter cartridge.

• Install the filter container.
IMPORTANT
ALWAYS REPLACE BOTH FILTERS AT THE SAME TIME. Return Filter

Pressure Filter Interval - After first 50 hours of operation and

Toucan 800 Toucan 870 every 250 hours thereafter.
• Position the Platform/Off/Ground
Selector Switch to "O" position.
• Remove the return filter cap and remove
the spring.
• Replace the filter cartridge with a new
one.
• Check the presence and condition of the
O ring, close the filter cover. Do not
forget to install the spring.

IMPORTANT
Interval - After first 50 hours of operation and
AFTER INSTALLATION, PERFORM A FEW MOVEMENTS TO
every 250 hours thereafter.
BLEED THE AIR FROM THE HYDRAULIC CIRCUIT, CHECK THE
.
OIL LEVEL IN THE TANK (PLATFORM IN RETRACTED POSITION).
• Position the Platform/Off/Ground
Selector Switch to "O" position. NOTE: Used oils and cartridges must be disposed of
according to regulations in force.
• Activate the release valve (located at
the rear side of the chassis) to release
NOTE: Aside from JLG recommendations, it is not
the pressure in the hydraulic circuit
advisable to mix oils of different brands or types, as
(position the release valve lever to
they may not contain the same required additives or
"release position" ( ). be of comparable viscosities. If use of hydraulic oil
• Unscrew the filter container. or grease other than recommended in the previous
chart, contact JLG Industries for proper
recommendations.
HIGH PRESSURE OIL COULD PENETRATE SKIN AND CAUSE
INJURIES OR BURNS. IMPORTANT
LOOSEN THE FILTER TANK VERY SLOWLY TO ALLOW THE OIL L U B R I C AT I O N I N T E R VA L S A R E B A S E D O N M A C H I N E
PRESSURE TO DROP GRADUALLY. OPERATION UNDER NORMAL CONDITIONS. FOR MACHINES
U S E D I N M U L T I - S H I F T O P E R AT I O N S A N D / O R S E V E R E
NOTE: Use a container to collect the oil from the hydraulic ENVIRONMENTS, LUBRICATION FREQUENCY MUST BE
lines or from the filter and prevent it from spilling on
the work platform or on the ground. INCREASED ACCORDINGLY.

8-8 – JLG Lift – 31210031

 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

3. Turntable Lubrication 5. Mast Section Lubrication

Bearing Track :

Lube - TYPE B
Interval - every 125 hours of operation or after each
cleaning.
Comments - Clean the inside wall of mast to remove
Lube Point - Grease Fitting the old grease. Lubricate the mast inside wall using a
Lube - TYPE E brush.
Interval - Every 250 hours of operation.
6. Wheel Bearing & Steering Knuckle Lubrication
Grease the bearing track using a grease pump.
Turntable Teeth :
Lube Point(s) - Coat each tooth.
Lube - TYPE C
Interval - Every 1000 hours of operation
• Remove the protection covers.

OPERATION MUST BE PERFORMED ON FLAT AND HORIZONTAL

GROUND, IN AN AREA ALLOWING FULL ROTATION OF THE
STRUCTURE.

• Apply new grease with a brush on the turntable

teeth. Rotate the structure to ensure all the teeth
have been greased.
4. Lifting chains lubrication
Lube - TYPE D Lube point(s) - 2 Grease Fittings
Interval - every 125 hours or once every 30 days of Lube - TYPE E
operation. Interval - every 125 hours of operation.
Comments - Lubricant can be applied manually with a Comments - One fitting on each hub and one fitting
brush or by spraying. Apply lubricant : on each knuckle.
- Longitudinally : in areas where joints are under small
load to facilitate penetration of the lubricant.
- Transversally : between the plates to enable the
lubricant to reach the joint and between the internal
plates and the rollers.

31210031 – JLG Lift – 8-9

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7. Hydraulic Oil Reservoir b. Place a container with a minimum capacity of 25

liters under the oil reservoir plug.
Toucan 800
Toucan 800

Toucan 870
Toucan 870

Lube point(s) - Return filters c. Unscrew the drain plug.

Capacity : 19 liters NOTE: Do not let the oil spill on the work platform or on the
Lube - TYPE A ground.
Interval - Check oil daily. Change after every 1000
d. Tighten the drain plug once all the oil has been
hours of operation or at least every 2 years.
drained.
Reservoir Draining : e. Used oils must be disposed of according to
regulations in force.
IMPORTANT Reservoir Filling :
THE FILTERS MUST BE REPLACED WHEN THE OIL IS CHANGED
f. Replace the pressure filter cartridge (refer to
IN THE MAIN RESERVOIR.
"Hydraulic Filters section").
a. Position the Platform/Off/Ground Selector g. Unscrew the return filter cover and remove the
Switch to "O" position. spring.
h. Remove the filter cartridge.
i. Fill the tank with new oil to the maximum level.
j. Install a new filter cartridge, check the presence
of the O-ring and close the filter lid.
k. Perform a few movements to bleed the air from
the hydraulic circuit.
l. Check oil level in the tank through sight gauge
on the reservoir and add oil if necessary, with
T H E W O R K P L AT F O R M I N R E T R A C T E D
POSITION, without exceeding maximum level.

8-10 – JLG Lift – 31210031

 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

8. Steering hydraulic unit reservoir 9. Tires And Wheels

Tire wear and damage :
Inspect tires periodically for wear or damage. Tires with
worn edges or distorted profiles require replacement.
Tires with significant damage in the tread area or side
wall, require immediate evaluation before placing the
machine into service.
Wheel installation :
Lube Point(s) - Breather Cap It is extremely important to apply and maintain proper
Capacity - 1 liter wheel mounting torque.
Lube - TYPE A
Interval - Check after every 125 hours of operation.
Drain after 1000 hours of operation or at least every 2
years. WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE
PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN
Reservoir Draining : STUDS AND POSSIBLE SEPARATION OF WHEEL FROM THE
a. Disconnect the battery form the work platform. AXLE. BE SURE THAT THE LUG NUTS ARE SEATED PROPERLY
TO THE WHEEL.
b. Tag and disconnect electrical cables from the
hydraulic unit motor.
Use a torque wrench to tighten the fasteners. If you do
c. Tag and disconnect the hydraulic lines from the not have a torque wrench, tighten the fasteners with a
hydraulic unit output. Cap the hydraulic lines lug wrench, then immediately have a service garage or
and the unit port holes. dealer tighten the lug nuts to the proper torque. Over-
tightening wi ll res ult in br eakin g the s tuds or
permanently deforming the mounting stud holes in the
HIGH PRESSURE OIL COULD PENETRATE SKIN AND CAUSE wheels. The proper procedure for attaching wheels is
INJURIES OR BURNS. LOOSEN THE HYDRAULIC CONNECTIONS as follows :
VERY SLOWLY TO ALLOW THE PRESSURE TO DROP GRADUALLY. • Start all nuts by hand to prevent cross threading.
DO NOT use a lubricant on threads or nuts.
NOTE: Use a container to collect the oil from the hydraulic
lines or from the hydraulic group and prevent it from • Tighten nuts in the following sequence :
spilling on the work platform or on the ground.

d. Remove the hydraulic unit.

e. Place the hydraulic unit above a container, open
the filling hole and turn the group upside down
to drain the oil from the reservoir.
f. Wipe the outside of the group with a non fluffy
rag.
g. Install the hydraulic unit, reconnect the hydraulic Figure 8-2. Wheel Torque Chart
lines and the electrical cables.
Torque Values (Nm) 150
h. Used oils must be disposed of according to
regulations in force. • Tightening of the nuts should be done in stages.
Reservoir Filling : Following the recommended sequence, tighten nuts
as follow :
i. Unscrew the filling cap and fill the tank with new
oil until the oil level is visible through the filling Torque Stages (Nm)
hole. 1st stage 2nd stage 3rd stage
j. Install the cap and perform a few steering 50 100 150
movements to bleed the air from the hydraulic
circuit. • Wheel nuts should be torqued after first 50 hours or
after each wheel removal. Check and torque every 3
NOTE: Tighten the hydraulic lines as soon as the oil starts months or 150 hours of operation.
flowing out.

k. Add oil in the tank if necessary, with the steering

IMPORTANT
cylinder in retracted position. TIGHTEN THE NUTS USING A TORQUE WRENCH. DO NOT USE
IMPACT WRENCH.

31210031 – JLG Lift – 8-11

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

10. Verification Of The Overload Detection

Setting (Toucan 800 only) Machine manufactured before 2010

Interval - Check after every 6 months of operation.

a. Place a 200 kg load evenly distributed on the

platform floor.
b. Position the Platform/Off/Ground selector switch
to "Platform Con trols". ensure the lower
emergency stop is not activated.
c. Apply a slight pressure F1 on the platform and
ensure that :
• An acoustic alarm sounds.
• The corresponding LED lights up.
• Every function is disabled from the platform con-
trols.
d. Position the Platform/Off/Ground selector switch
to "Ground Controls" and ensure that :
• An acoustic alarm sounds.
• The corresponding LED lights up. Machine manufactured after 2010
• Every function disabled from the ground con-
trols.
e. Apply a slight traction F2 on the platform and
ensure that the acoustic alarm stops.

8-12 – JLG Lift – 31210031

 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

11. Verification Of The Tilt Alarm Setting

Interval - Check after every 6 months of operation.

a. Place machine on a known level surface.

b. Position the selector switch to "Ground controls".
c. Chock both rear wheels.
d. Place a spirit level (digital display) on the chassis
positioned lengthways.
e. With a jack of appropriate capacity, lift the front
of the chassis to tilt level specified in Table 8.1
and ensure that :
• An acoustic alarm sounds when the chassis is
tilted at its max value.
• The corresponding LED lights up on the
platform controls.
f. Repeat steps (d) to (e) with the front wheels
chocked and lift at the rear.
g. Place a spirit level (digital display) across the
chassis.
h. With a jack of appropriate capacity, lift the right
hand side of the chassis to tilt level specified in
Table 8.1 and ensure that :
• An acoustic alarm sounds when the chassis is
tilted at its max value.
• The corresponding LED lights up on the
platform controls
i. Repeat steps (g) and (h) with the left side of the
chassis lifted.
j. Remove the blocks.

31210031 – JLG Lift – 8-13

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

8-14 – JLG Lift – 31210031

 Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Fax: (717) 485-6417

JLG Worldwide Locations

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www.jlg.com