JLG Toucan 800, Toucan 870 Operation And Safety Manual

Operation and Safety Manual

TOUCAN 800
TOUCAN 870

English - Operation and Safety Manual - Original Instructions

31210031

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
AVOIDED, WILL
DECAL WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD
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.

RESULT IN SERIOUS INJURY OR DEATH. THIS

RESULT IN SERIOUS INJURY OR DEATH. THIS

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

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO
THE OWNER OF RECORDS OF THIS MACHINE. CONTACT JLG
INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER
RECORDS ARE UPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN
AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PER­SONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO
PERSONAL PROPERTY OR THE JLG PRODUCT.

For:

• Accident Reporting

• Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Safety

CONTACT:

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Product Modifications

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 : [e-mail]

JLG Industries,
Wright Business Centre,
1 Lonmay Road
Queenslie
Glasgow,
Scotland G33 4EL
Tel : [phone]
Fax : [phone]
Email : [e-mail]

IMPORTANT

IMPORTANT

or Your Local JLG Office
(see adresses on manual rear cover)

b – JLG Lift – 31210031

REVISION LOG

Original Issue - September 14, 2007

Revision - January 01, 2010

FOREWORD

31210031 – JLG Lift – c

FOREWORD

d – JLG Lift – 31210031

TABLE OF CONTENTS

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 PRE-OPERATION. . . . . . . . . . . . . . . . . . . . . 1-1

Operator Training and Knowledge. . . . . 1-1

Workplace Inspection. . . . . . . . . . . . . . . 1-1

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

31210031 – JLG Lift – 1

TABLE OF CONTENTS

2 – JLG Lift – 31210031

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

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

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.

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

o

C to 40oC. Consult JLG for operation outside

-20
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.

• 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.

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

31210031 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

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.

• 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.

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.

• 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)

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.

MINIMUM APPROACH DISTANCE

in Meters

1-2 – JLG Lift – 31210031

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

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

The minimum approach distance may be reduced if
insulating barriers are installed to prevent contact and
the barriers are rated for the voltage of the line being
guarded. These barriers shall not be part of (or
attached to) the machine. The minimum approach
distance shall be reduced to a distance within the
designed working dimensions or the insulating barrier.
This determination shall be made by a qualified person
in accordance with employer, local or governmental
requirements for work practices near energized
equipment.

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

• Do not operate the machine when wind conditions
exceed the rating specified on the manufacturer’s
nameplate.

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

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

• If extending structure assembly or platform is in a
position that one or more wheels are off the ground,
all persons must be removed before attempting to
stabilize the machine. Use appropriate equipment to
stabilize machine and remove personnel.

Tipping Hazards

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

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

• Before driving on floors, bridges, trucks, and other
surfaces, check allowable capacity of the surfaces.
Check the ramp or slope for good adhesion of the
wheels. Ensure that the driving surfaces are free of
moisture, ice, grease or from any other substance
that could affect wheel adhesion.

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

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

• When travelling on slopes (Refer to section 8), the
platform MUST be fully lowered, the machine MUST
travel in second gear. It is recommended to drive up
the slope in FORWARD gear and to REVERSE down
the slope as the machine will perform better.

Crushing and Collision Hazards

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

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

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

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

• Keep non-operating personnel at least 1,8 m away
from machine during all driving and slewing
operations.

• Limit travel speed according to conditions of ground
surface, congestion, visibility, slope, location of
personnel, and other factors which may cause
collision or injury to personnel.

• Be aware of stopping distances in all drive speeds.
When driving in high speed, slow down the machine
using the controller before stopping.

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

31210031 – JLG Lift – 1-3

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.

1-4 – JLG Lift – 31210031

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

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

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

Operator Training

Operator training must cover:

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

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

3. Rules of the employer and government
regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of

the machine to recognize a malfunction or
potential malfunction.

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

2.2 PREPARATION, INSPECTION, AND
MAINTENANCE

The following table covers the periodic machine
inspections and maintenance required by JLG
Industries, Inc. Consult local regulations for further
requirements for aerial work platforms. The frequency
of inspections and maintenance must be increased as
necessary when the machine is used in a harsh or
hostile environment, if the machine is used with
increased frequency, or if the machine is used in a
severe manner.

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.

31210031 – JLG Lift – 2-1

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type Frequency

Pre-Start Inspec­tion

Pre-Delivery
Inspection (See
Note)

Frequent
Inspection
(See Note)

Annual Machine
Inspection
(See Note)

Preventative
Maintenance

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

Before each sale, lease, or rental delivery. O w n er, D e a le r, or

In service for 3 months or 150 hours, which­ever comes first; or

Out of service for a period of more than 3
months; or

Purchased used.

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

At intervals as specified in the Service and
Maintenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Man-

User

Owner, Dealer, or
User

Owner, Dealer, or
User

Owner, Dealer, or
User

Service

Qualification

Qualified JLG
Mechanic

Qualified JLG
Mechanic

Qualified JLG
Mechanic

Qualified JLG
Mechanic

Reference

ual

Service and Maintenance
Manual and applicable
JLG inspection form

Service and Maintenance
Manual and applicable
JLG inspection form

Service and Maintenance
Manual and applicable
JLG inspection form

Service and Maintenance
Manual

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

2-2 – JLG Lift – 31210031

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.

31210031 – JLG Lift – 2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Toucan 800

Toucan 800 DI

2-4 – JLG Lift – 31210031

Toucan 870

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Daily Walk-Around Inspection

2.3.1 Walk-Around Inspection

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

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

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

1. Platform 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.

6. Hand Pump - See Inspection Note.

7. All Hydraulic Cylinders - No visible damage;

pivot pins and hydraulic hoses undamaged, not
leaking.

8. Steering Spindles - See Inspection Note.

9. Lifting Chains, Chain Yo k e s an d C l evi s Pins -

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

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

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:

Control Stations

1. From the Ground Control Console :

• Operate all functions;

• Ensure that all machine functions are disabled
when the Emergency Stop Button is pushed in;

• Position the selector switch to Platform Control
Console ; try to use the Ground Control Cons

- No movement shall occur.

2. From the Platform Control Console :

• Ensure that the platform control console is firmly
secured;

• Ensure proper operation of horn;

• Ensure proper operation of all functions;

• Ensure that all machine functions are disabled
when the Emergency Stop Button is pushed in;

• Ensure that no functions can be operated unless
the footswitch is depressed;

• Activate simultaneously a drive movement and
superstructure movement. No movement shall
occur.

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

ole :

Tilt Sensor Check

Check the tilt sensor, located on the left side (Toucan

800), on the right side (Toucan 870) of the chassis, to
ensure proper operation. Wedge a block (P/N :
ST2741, located in the manual storage container) as
illustrated above to activate the tilt sensor and keep it
tilted. Raise the mast by approximately 1m.
The system is functioning properly if :

1. From the Platform Control Console :

• An acoustic alarm sounds.

• The red tilt indicator lights up on the Platform
Control Panel.

• The drive function is disabled.

• The jib raising function is performed at reduced
speed.

• The mast raising function is performed at
reduced speed.

• The slewing movements are performed at
reduced speed.

• All other functions are working normally.

• Prohibited movements are indicated by the
orange light indicator on the platform control
panel.

2. From the Ground Control Console :

• 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.

NOTE: The mast 1 is attached to the turntable and mast 4

Wedge a block (P/N : ST2741) as illustrated above to
activate the slack chain sensor and keep it activated.
The system is functioning properly if :

supports the jib.

1. From the Platform Control Console :

• An acoustic alarm sounds.

• The red slack chain indicator lights up on the
Platform Control Panel.

• The jib and mast lowering functions are
disabled.

• 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.

Check the gate sensors to ensure proper operation :

2 sensors.
Location : under gate articulation axis.

Open the right gate. The system is functioning properly if :

1. From the Platform Control Console :

• The orange light indicator is continuously lit.

• Every function is disabled from the upper control
console.

2. From the Ground Control Console :

• Every function is disabled from the ground con­trol console.

3. Repeat steps 1 to 2 for each slack chain sensor.

2-8 – JLG Lift – 31210031

Toucan 800 - Toucan 800 DI

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

Toucan 870

1. Driving wheels

2. Steering wheels

3. Counter weight

4. Jib
5 . G r o un d co n tr o l st a ti o n

6. Charger

7. Telescopic mast
8 . H a n d p u mp

9 . P l a tf o rm

10. Platform control station

11. Manual storage container

12. Battery cover

13. Manual lowering controls

14. Chassis cover

15. Circuit-breaker (Toucan 800 : ¼ turn - Toucan 870 : Push/Pull)

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

Toucan 800

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Platform /Off/Ground Selector Switch
2 . E m e rg e nc y St o p Sw i tc h

3. Function Enable Switch

4. Jib Up / Down Switch
5 . M as t Up / D o wn Sw i tc h

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 . E m e rg e nc y St o p Sw i tc h

3. Function Enable Switch

4. Jib Up / Down Switch
5 . M as t Up / D o wn Sw i tc h

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

(horizontal lever) to insulate the battery "+".
Position the circuit-breaker to its "I" position (vertical
lever) to restore battery supply.

T870

battery.
Pull the circuit breaker knob to restore the battery
supply.

: Position the circuit-breaker to its "O" position

: Push the circuit breaker knob to insulate the

3-4 – JLG Lift – 31210031

Manual Lowering Controls

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Toucan 800

Toucan 870

1. Jib Raising / Lowering Control Valve

2. Mast Raising / Lowering Control Valve

3. Slewing Control Valve
4 . P u mp H a nd l e
5 . H a n d P u mp

Figure 3-3. Manual Lowering Controls

Electro-Hydraulic Control Valve With Manual Control Push Buttons

1. Jib Raising / Lowering Control Valve :
Depress and keep depressed the top push button
while activating the hand pump to lower the jib.
Depress and keep depressed the bottom push
button while activating the hand pump to raise the
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.

4. Pump Handle :
Insert the pump handle in the hand pump to
activate a movement.

5. Hand Pump :
Operate the hand pump while activating the
desired movement.

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 . J ib Fu n ct i on Co n tr ol S wi t ch

4. Mast Function Control Switch

5. Turntable Slewing Control Switch
6 . F un ct i on S pe ed C on tr o l

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)

1. Emergency Stop Switch
Depress the switch to stop all the functions of the
machine. The switch must be turned clockwise to
restore the machine’s functions.

2. Footswitch
Must be depressed before any movement is
controlled. The controls are enabled for a period
of 5 seconds. If no function is operated within this
period, the footswitch must be recycled.

3. Jib Function Control Switch
Pull the switch to raise the jib.
Push the switch to lower the jib.

4. Mast Function Control Switch
Pull the switch to raise the mast.
Push the switch to lower the mast.

5. Turntable Slewing Control Switch
Toggle the switch to the right to slew the turntable
to the right.
Toggle the switch to the left to slew the turntable
to the left.

6. Function Speed Control
When the knob is turned counter-clockwise to the
left (

movement) are performed at low speed. Turn the
knob clockwise to the right (

speed of the movements.

7. Battery Discharge Indicator
As the battery discharges, the bar lit in (1) moves
from the right to the left (5 green bars followed by
3 orange bars).

At this point, the LED flashes indicating "energy
reserve" (70% discharged).
The 2 red LEDs most to the left flash indicating
"empty" (80% discharged). At this point, power is
cut-off. The battery must be recharged.

1 - Discharge Indicator
2 - Hourmeter

), the movements (except the drive

)to increase the

3-6 – JLG Lift – 31210031

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Auxiliary Power Button
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
TO THE BATTERY.

9. Drive Control Joystick
Move the controller forward to drive forward.
Move the controller backward to reverse.

10. Drive Speed Selector Switch

1st gear or slow speed

2nd gear or climbing speed (max. 20%)

3rd gear or high speed

11. Horn
Sounds when the button is depressed.

12. Steering control
Push the right side of the thumb switch to steer the
wheels to the right. Push the left side of the thumb
switch to steer the wheels to the left.

Platform Control Indicator Panel.

Figure 3-5. Platform Control Indicator Panel

1. Tilt Indicator Light and Alarm

2. Slack Chain Indicator Light and Alarm

3. Overload Indicator Light and Alarm

4. Unauthorized Movement Indicator

5. Power Enable Indicator

1. Tilt Indicator Light and Alarm.
Excessive tilt. Red light and audible alarm
indicates the rated slope has been exceeded.

2. Slack Chain Indicator Light and Alarm.
Slack lifting chain. Red light and audible alarm
indicates slack chain condition has been detected.

3. Overload Indicator Light And Alarm
Flashing red light and audible alarm indicates the
platform has been overloaded (Toucan 800 only).

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,

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
emergency stop switch on the ground control
console must be depressed then turned clockwise
to restore the functions of the machine.

• To energize the machine :
Toucan 800 : turn the circuit-breaker handle to "I"
position.

Toucan 870 : pull the knob of the circuit-breaker
to "I" position.

4.2 PLATFORM CONTROLS

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY
CONTROL LEVERS OR SWITCHES CONTROLLING THE PLAT
FORM MOVEMENT DOES NOT RETURN TO THE OFF OR NEU­TRAL POSITION WHEN RELEASED.
IF THE PLATFORM DOES NOT STOP WHEN CONTROL LEVER OR
THE ENABLE SWITCH/TRIGGER IS RELEASED, USE THE EMER
GENCY STOP SWITCH TO STOP THE MACHINE.

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.

Trav eli ng ( Dri v ing )

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

The machine has a Ground Control Station which will
override the Platform Control Station. Ground Controls
operate Lift and Slew, and are to be used in an
emergency to lower the platform to the ground should
the operator in the platform be unable to do so.

Platform/Off/Ground Selector Switch

With the switch in the ground position, power is
supplied to the Ground Control Station. When the
switch is in the platform position, power is supplied to
the Platform Control Station.

Operate the ground controls as follow :

1. Position PLATFORM/OFF/GROUND CONTROLS

selector switch to GROUND CONTROLS (

2. Push and hold the Function Enable Switch.

3. Activate slewing, mast or jib function switch.

Emergency Stop Switch

This switch, when in the on (out) position, provides
electrical power to the ground controls or platform
controls, as applicable. In addition, the switch can be
used to turn off power (push the switch IN) to the
function controls in the event of an emergency.

rd

NOTE: When the platform is driven in 3

steeper than 5%, the machine switches automati-

cally to 2
when the platform is driven on a slope below 5%.
Either of the following actions must be done :

- release and activate the enable control again.

- return the joystick to neutral and control the move­ment again.

- position the drive speed selector to 2nd gear

( ) and return it to 3

DO NOT DRIVE WITH MAST OUT OF TRANSPORT MODE EXCEPT
ON A SMOOTH, FIRM AND LEVEL SURFACE.

).

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT
DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED IN
SECTION 8.2 OF THIS MANUAL.

USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT
ALL TIMES WHEN THE PLATFORM IS ELEVATED.

BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION
ARROWS ON BOTH THE CHASSIS AND THE PLATFORM

nd

gear. The 3rd gear will be restored only

rd

gear ( ).

gear on a slope

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.

When the mast (or the jib for Toucan 800
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

Figure 4-1. Grade and Side Slope

SECTION 4 - MACHINE OPERATION

Forward

1. Position the DRIVE SPEED selector to 1st gear

), 2nd gear ( ) or 3rd gear ( ).

(

2. Match the black and white direction arrows on
both platform control panel and chassis to
determine the direction the machine will travel.

3. Depress footswitch.

4. Push the controller forward within 5 seconds after

the footswitch has been depressed.

Stopping

Stopping is accomplished by slowly returning the
DRIVE controller to the neutral position. The brakes will
apply automatically.

Reverse

Traveling in reverse is accomplished the same way as
traveling forward except for pulling the DRIVE
controller toward the operator to reverse (REV).

Steering

Steering is accomplished by pressing the left side of
the THUMB switch (on top of the controller) to steer to
the left or the right side of the THUMB switch (on top
on the controller) to steer to the right.

TO AVOID TIP OVER, LOWER PLATFORM TO GROUND LEVEL.
THEN DRIVE MACHINE TO A LEVEL SURFACE BEFORE RAISING
MAST.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY
CONTROL LEVER OR TOGGLE SWITCH CONTROLLING
PLATFORM MOVEMENT DOES NOT RETURN TO THE ’OFF’ OR
NEUTRAL POSITION WHEN RELEASED.

IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH
OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH
OR USE EMERGENCY STOP SWITCH TO STOP THE MACHINE.

Raising And Lowering The Mast

Raising the mast :

1. Depress footswitch.

2. Pull the mast function control switch toward the

operator to raise the mast within 5 seconds after
the footswitch has been depressed.

3. Adjust the speed movement using the function
speed control.

Lowering the mast :

1. Depress footswitch.

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

Raising the jib :

1. Depress footswitch.

2. Pull the jib function control switch toward the

operator to raise the jib within 5 seconds after the
footswitch has been depressed.

3. Adjust the speed movement using the function
speed control.

Lowering the jib :

1. Depress footswitch.

2. Push the jib function control switch away from the

operator to lower the jib within 5 seconds after the
footswitch has been depressed.

3. Adjust the speed movement using the function
speed control.

Slewing The Turntable

To s l e w :

1. Depress footswitch.

2. Move the turntable slewing control switch to the

right to slew the turntable to the right. Move the
turntable slewing control switch to the left to slew
the turntable to the left. The switch has to be
operated within 5 seconds after the footswitch has
been depressed.

3. Adjust the speed movement using the function
speed control.

4.4 ALARMS

Horn

Horn is activated when the corresponding push button
located on the Platform Control Console is depressed.

Motion Alarm

The machine is fitted with 2 lights (beacons) that come
on as soon as a function is controlled from the platform
control panel or from the ground control panel.

Tilt Light And Alarm

The alarm is triggered by a tilt sensor located on the
right hand side (Toucan 870), left hand side (Toucan

800) of the chassis under the chassis cover. This alarm
is active once the mast (and/or the jib for Toucan 800
manufactured before 2010), has left its lowered
position. It consists of a light on the platform control
panel and an alarm. The alarm and light indicate that
the work platform is at its maximum out of level limit
(refer Table 8.1) and is nearing an unstable position.
Drive function is disabled and the jib, mast and
turntable slewing movements are operable at a
reduced speed.

When the tilt light or alarm is activated, it is
recommended to place the machine in the following
configuration :

1. Mast lowered.

2. Jib in line with the chassis length.

3. Jib lowered.

The tilt alarm and light are also operational from the
ground control panel.

Work Platform Functions Combination

A drive movement cannot be combined with a structure
movement.

If a mast or jib raising movement is activated with a
slewing movement, only one function will work and only at
low speed (lower than normal slewing speed) will be
attainable.

4.3 MANUAL LOWERING CONTROLS

The manual lowering controls should be used in
emergency situations or mechanical breakdown. The
manual lowering controls provide an auxiliary means of
lowering and raising the platform and slewing the
turntable in the event of primary power loss.

DO NOT RAISE MAST OR OPERATE JIB WITH MAST RAISED
WHEN MACHINE IS OUT OF LEVEL.

Overload Light And Alarm (Toucan 800
only)

A sensor located on the platform support is actuated
when the maximum rated load is exceeded. In case of
overload, all functions are disabled, the red indicator
on the platform control panel and on the emergency
control panel flash and an acoustic alarm is triggered.
The work platform must be unloaded until the flashing
light and acoustic alarm stop.

Slack Chain Light And Alarm

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
movements to the one that caused the alarm to
sound).

2. Identify the cause.

3. Perform the movement which will clear the

machine and prevent contact with the obstacle.

If the examination of the surroundings does not reveal
any possible obstacle, the alarm may have been
triggered by the telescopic mast jamming which could
be due to :

• A foreign body entering the guiding system.

• A lack of lubrication.

• Incorrect operation.

NOTE: The slack chain and light alarms are also

operational from the ground control station.

IF THE SLACK CHAIN ALARM HAS BEEN TRIGGERED BY MAST
JAMMING, DISCONTINUE OPERATION IMMEDIATELY. DO NOT
USE THE MANUAL LOWERING CONTROLS. PLATFORM
OCCUPANTS MUST BE RESCUED AND THE MACHINE SERVICED
BY A QUALIFIED TECHNICIAN.

4.5 SHUT DOWN AND PARK

To shut down and park the machine, the procedures
are as follow :

1. Drive machine to a reasonably well protected
area.

2. Ensure mast is lowered and jib stowed.

3. Push in the Emergency Stop at Platform Control

Station.

4. Push in the Emergency Stop at Ground Control
Station. Position Platform/Off/Ground select
switch to center OFF.

5. Toucan 800 : Position the circuit-breaker to its "O"
position.
Toucan 870 : Depress the circuit breaker push
button.

6. If necessary, cover Platform Controls to protect
instruction placards, warning decals and
operating controls from hostile environment.

7. Charge the batteries if the LEDs on the discharge
indicator are orange or red.

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 (
required to clear the obstacle.

This feature is operational only when the platform is
controlled from the platform control panel.

) BEFORE operating the functions

31210031 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

4.6 CHARGERS

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.
NEVER INTRODUCE FLAMES, SPARKS OR OTHER SOURCES OF
IGNITION TO BATTERY AREA. FAILURE TO COMPLY WITH THIS
WARNING COULD RESULT IN DEATH OR INJURY TO
PERSONNEL. ALWAYS CHARGE BATTERIES IN A WELL­VENTILATED AREA.

DO NOT DISCONNECT BATTERY PLUG WHEN THE CHARGER IS
ON. THE RESULTING ARCING COULD CAUSE BATTERY TO
EXPLODE AND BURNS TO THE OPERATOR.

NOTE: It is not necessary to charge the battery if the

electrolyte specific gravity has not dropped under

1.240 kg/l. Regular charge of a battery when its
specific gravity is higher then 1.240 kg/l can greatly
reduce the battery life.

NOTE: The charger has an interlock feature which causes

the work platform power circuit to open anytime the
charger is plugged into a live AC outlet.

NOTE: If power supply is stopped during the charge cycle,

the charger switches to a waiting mode and restarts
automatically as soon as the power returns.

Supply Voltage :

Always ensure the voltage selected corresponds to the
network voltage and the socket protection is sufficient
to support the charger power.
Incorrect setting of the charger voltage may result in
malfunction or breakdown.
The chargers are factory preset based upon the plug
type fitted.

ZIVAN BC1 High Frequency Electronic Charger

Charging the battery :

- Plug the charger into the mains (single phase 2 poles
+ ground).

- The charger starts automatically.

Remote charge-phase indicator on emergency control
unit :

Red LED :
The charger is in the charge initial phase (phase 1).
Flashing Red LED :
At the end of this phase, the battery is 80% charged
(phase 2).
Red and Green fixed LED :
Battery between 80 and 100% charged.
Green LED :
Battery charge complete, the charging process stops.

Alarms :

A flashing LED and an intermittent acoustic alarm indi­cate a faulty situation. When the alarm is on, the
charger does no longer deliver any current.

Troubleshooting :

TYPE OF ALARM DESCRIPTION (Action)

Temporisation

Battery current

Battery voltage

The charging phase 1 is lasting longer than the
maximum authorised (check the capacity of the
battery. Contact JLG Product Support).

Loss of control of the output current (fault on
control logic : Contact JLG Product Support).

Loss of control on output voltage (fault on control
logic : Contact JLG Product Support).

Thermal safety

Overheating of semi-conductors (check for proper
operation of the fan).

4-6 – JLG Lift – 31210031

SECTION 4 - MACHINE OPERATION

EMB-MP HAWKER Charger (40 or 70 A)

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 :

- Plug the charger into the mains (single phase 2 poles +
ground).

- Once the charger is connected, all the leds begin to flash
for a short period of time, indicating the charger is com­pleting a self-test.

- The leds (c) and (d) will then flash for a short period of
time, indicating the charger is in "automatic starting"
mode.

- 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.

Leds signal :

OFF = the led is off

ON = the led is lit fixed

BL = the led flashes (T=1 second)

BV = the led flashes quickly (T = 0.2 second)

* = the led can be on or off, depending on the state of

charge of the battery and on the charger’s opera­tion at that moment.

31210031 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

4.7 EMERGENCY TOWING

Towing is discouraged and must only be performed as
a last option.

IMPORTANT

VERIFY THE CAPACITY OF THE EQUIPMENT USED TO TOW THE
MACHINE.

ENSURE THE MACHINE IS ON LEVEL GROUND BEFORE
RELEASING THE BRAKES.
THE MACHINE MUST ALWAYS BE IN STOWED POSITION DURING
TOWING PROCEDURE.
NO PERSONNEL IS ALLOWED ON THE PLATFORM DURING
TOWING PROCEDURE.

To tow, release the brakes and the wheel motors as follow:

1. Fully lower the platform.

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.

).

4.8 LIFTING AND TIE DOWN

IMPORTANT

WHEN TRANSPORTING THE MACHINE, THE MACHINE MUST BE
STOWED.

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
the individual unit to find out the Gross Vehicle
Weight.

2. Place the machine in the stowed position.

3. Remove all loose items from the machine.

4. Attach lifting device and equipment only to the

designated lifting points. (See below).

To uc an 80 0

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).

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.

Toucan 870

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

1. Place the machine in the stowed position.

2. Remove all loose items from the machine.

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

4.9 LOADING AND UNLOADING

Using a fork lift truck

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

Tou ca n 8 00

SECTION 5 - DECALS

SECTION 5. DECALS

Instructions AU1743

Loads AU1095

31210031 – JLG Lift – 5-1

SECTION 5 - DECALS

5-2 – JLG Lift – 31210031

Toucan 800 DI

SECTION 5 - DECALS

Instructions AU1743

Loads AU1755

Load Transfer AU1387

31210031 – JLG Lift – 5-3

SECTION 5 - DECALS

5-4 – JLG Lift – 31210031

Toucan 870

SECTION 5 - DECALS

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

This section explains the steps to be taken in case of
an emergency situation while operating.

6.2 INCIDENT NOTIFICATION

JLG Industries, Inc. must be notified immediately of
any incident involving a JLG product. Even if no injury
or property damage is evident, the factory should be
contacted by telephone and provided with all
necessary details.

In USA : 877-JLG-SAFE (Toll free)

Outside USA: [phone]

E-mail:[e-mail]

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.

6.4 EMERGENCY LOWERING

If primary power is lost, the platform may be lowered
manually. Reference section 3 for Manual Lowering
Control procedures.

6.5 EMERGENCY TOWING PROCEDURES

Towing this machine is discouraged. However,
provisions for towing the machine in emergency
situations have been incorporated. For specific
procedures, refer to Section 4.

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

Maximum Work Load 200 kg (2 persons + 40 kg material)

Slewing 360° non-continuous 180°

Max. Platform Height 6.10 m 6.72 m

Horizontal Reach
( fr o m ce n te r li n e of m ac h in e )
( fr o m re a r w h ee l e dg e )
( fr o m s i de w he e l e d ge )

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

Gross Machine Weight

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)
With mast in stowed position and jib below horizontal

Maximum Travel Grade (Side slope)
With mast in stowed position and jib below horizontal

Tilt Sensor Setting 2°

Tu rn in g R ad iu s
Inside :
Outside :

Vibration levels

Acoustic pressure

(Platform Empty) before 2010 1950 kg 2000 kg 2980 kg

(Platform Empty) since 2010 2100 kg 2200 kg 2980 kg

1.89 m

1.10 m

1.40 m

The weighed root mean square acceleration value to which the arms are subjected (control levers)
is inferior to 2,5m/s/s.

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).

The measure has been taken by placing the sonometer at 1,60 m above the platform floor.

2.19 m

1.40 m

1.70 m

20% (11°) 15% (8.5°)

2.40 m

1.60 m

1.90 m

1.05 m

2.40 m

(2 persons + 60 kg

material)

2.64 m

1.84 m

2.15 m

5°

200 kg

(2 persons + 40 kg

material)

2.96 m

2.15 m

2.46 m

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

Powe r 4.8 k W

Vol tage 24 V DC

Flow Rate 9.1 l/mn

Displacement 3.5 cm³/t

Powe r 0.8 k W

Vol tage 24 V DC

Main

Power

Unit

Steering

Unit

Motor

Pump

Maximum 12 MPa

Motor

Pump Displacement 0.5 cm³/t

Batteries

Table 8-4. Battery Specifications

Voltage 24 Volt

Amp Hour Rating

Life Cycle Rating 1200 Cycles

Toucan 800 240 Ah (5h rate)

Toucan 870 620 Ah (5h rate)

31210031 – JLG Lift – 8-3

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

To uc a n 8 00

To uc a n 8 70

Figure 8-1. Operator Maintenance & Lubrication Diagram

1 - B a t te r ie s
2- Hydraulic Filters
3- Turntable Lubrication
4- Lifting Chains Lubrication
5 - M a s t S e ct i on L u br i ca t io n
6 - W h ee l B ea r in g & S t eering Knuckles Lubrication

7- Hydraulic Oil Reser voir
8- Steering Hydraulic Unit Reservoir
9- Tires & Wheels
10- Verification of the Overload Detection Setting (if fitted)
11- Verification of the Tilt Alarm Setting

8-4 – JLG Lift – 31210031

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

8.3 OPERATOR MAINTENANCE

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.

BATTERY ELECTROLYTE MUST NOT BE ALLOWED TO CONTACT
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.

• Fill the can with distilled water.

• Depress and hold the push button to activate the
battery filling pump until the flow indicator slows
down.

DURING MAINTENANCE OR ANY SERVICING OPERATION ON
THE BATTERY, RINGS, WATCHES OR ANY OTHER JEWELLERY
MUST BE REMOVED.

Daily maintenance

Electrolyte level

Verify the electrolyte level after the charge using the floats in
the center of each filling cap.

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.

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

Weekly maintenance

Cleaning - Battery maintenance

It is necessary to clean the battery regularly to prevent
salt formation and current arcing which could damage
the machine.

• Clean and dry the battery top.

• 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 :

IMPORTANT

USE ONLY DISTILLED OR DEMINERALIZED WATER TO FILL THE
BATTERY CELLS. BATTERY CELLS MUST BE FILLED ONLY
AFTER THE CHARGE (DURING THE CHARGE, THE
ELECTROLYTE LEVEL INCREASES AND CAN OVERFLOW).

31210031 – JLG Lift – 8-5

• A draining bulb is supplied with the work platform

NOTE: The water that contacted a battery is classified as

industrial waste, it must be disposed of according
to regulations in force.

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Monthly maintenance

Checking voltage and electrolyte specific gravity

NOTE: Voltage and specific gravity measures should not

be performed after battery cells have been filled.
These measures must be done after a complete
charge once the charger has been unplugged and
the machine has been standing for 15 mn.

• Open the battery cell filling cap.

• Using the hydrometer, take a quantity of electrolyte
sufficient so that the float emerges. Ensure the float
top does not touch the rubber bulb or that the float
does not stick by capillarity to the glass wall.

• Read the value as indicated on the example below :

Various recommendations

Use of a battery in a cold chamber or in a cold climate

Low temperatures decrease battery capacity. The
battery must be fully charged when the work platform
is operated in a cold chamber or in cold weather
condition.

Battery not working continuously or inactive battery

A battery that is not used or used intermittently must be
stored charged in a dry area away from freezing
temperatures. A charge must be performed once a
month.

• Unplug the battery to insulate it electrically.

• 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

Electrolyte overflow.

Inequal electrolyte specific gravity or
electrolyte specific gravity too low.

Low voltage in the cells in open circuit.

Battery cells temperature too high (over 113°F
(45°C)).

Battery incapable of supporting regular
operation.

Filling done before the charge.
Cells overfilled.

Overcharge.

Filling done before the charge.

Loss of electrolyte due to overflow.

Stratification of the electrolyte.
Electrolyte specific gravity too low.

Short-circuit.
Problem with the charger.

Bad air circulation during charge.

Cell weak or faulty
Cells shorted.
Battery under charged.

Cell faulty.

Faulty cable or connection.

Battery at the end of its service life.

Fill battery cells after the charge.

Never charge battery if electrolyte specific gravity is above 1,240 kg/l.

Fill battery cells after the charge.

Perform an equalization charge.

Contact your JLG Distributor/Product Support.
Refer to "electrolyte specific gravity too low".

Clean battery top.
Get the charger checked by a technician.

Open access doors to batteries during charge.
Reduce temperature of the area where the battery is charged (artificial ventilation).

Change battery cell.

Perform an equalization charge.

Replace faulty cell.

Check wire condition and connection.

Replace the battery.

31210031 – JLG Lift – 8-7

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Lubrication Specification

ST ANDA RD

NERVOFLU ID VG 32 NERVO L - EQUI VIS XV 32 MOBI LTAC 81

NE R VO F L UI D DVG 3 2 NE R VO L - HY DR AL F XV 32

A

B

MOBIL DTE 13M

FO OD C OM PATI BL E

NERVOL - AGROFLUID DVG 32 NERVOL - AGROFLUID MOBIL DTE 16M

MOBIL - DTE FM 32 CHAINE FILANTE HYDRELF XV 32

ST ANDA RD

COMPLEX EP 2 NERVO L - CRYOGREASE MOBILUX EP2

MOBILUX EP2 MOBILITH SHC 220 COMPLEX EP2

2. Hydraulic filters

LOW TEMPERATURE

DOWN -35°C

FO OD COM P ATIB LE

LOW TEMPERATURE

LOW TEMPERATURE

DOWN -35°C

C

D

E

• Install a new filter cartridge.

• Install the filter container.

IMPORTANT

ALWAYS REPLACE BOTH FILTERS AT THE SAME TIME.

Pressure Filter

To uc an 8 00

Toucan 870

Return Filter

Interval - After first 50 hours of operation and
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.

STANDARD

STANDARD

STANDARD

LOW TEMPERATURE

DO WN -3 5°C

Interval - After first 50 hours of operation and
every 250 hours thereafter.
.

• Position the Platform/Off/Ground
Selector Switch to "O" position.

• Activate the release valve (located at
the rear side of the chassis) to release
the pressure in the hydraulic circuit
(position the release valve lever to

"release position" ( ).

• Unscrew the filter container.

HIGH PRESSURE OIL COULD PENETRATE SKIN AND CAUSE
INJURIES OR BURNS.
LOOSEN THE FILTER TANK VERY SLOWLY TO ALLOW THE OIL
PRESSURE TO DROP GRADUALLY.

NOTE: Use a container to collect the oil from the hydraulic

lines or from the filter and prevent it from spilling on
the work platform or on the ground.

IMPORTANT

AFTER INSTALLATION, PERFORM A FEW MOVEMENTS TO
BLEED THE AIR FROM THE HYDRAULIC CIRCUIT, CHECK THE
OIL LEVEL IN THE TANK (PLATFORM IN RETRACTED POSITION).

NOTE: Used oils and cartridges must be disposed of

according to regulations in force.

NOTE: Aside from JLG recommendations, it is not

advisable to mix oils of different brands or types, as
they may not contain the same required additives or
be of comparable viscosities. If use of hydraulic oil
or grease other than recommended in the previous
chart, contact JLG Industries for proper
recommendations.

IMPORTANT

LUBRICATION INTERVALS ARE BASED ON MACHINE
OPERATION UNDER NORMAL CONDITIONS. FOR MACHINES
USED IN MULTI-SHIFT OPERATIONS AND/OR SEVERE
ENVIRONMENTS, LUBRICATION FREQUENCY MUST BE
INCREASED ACCORDINGLY.

8-8 – JLG Lift – 31210031

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

3. Turntable Lubrication

Bearing Track :

Lube Point - Grease Fitting
Lube - TYPE E
Interval - Every 250 hours of operation.

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.

5. Mast Section Lubrication

Lube - TYPE B
Interval - every 125 hours of operation or after each
cleaning.
Comments - Clean the inside wall of mast to remove
the old grease. Lubricate the mast inside wall using a
brush.

6. Wheel Bearing & Steering Knuckle Lubrication

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
Interval - every 125 hours or once every 30 days of
operation.
Comments - Lubricant can be applied manually with a
brush or by spraying. Apply lubricant :

- 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.

Lube point(s) - 2 Grease Fittings
Lube - TYPE E
Interval - every 125 hours of operation.
Comments - One fitting on each hub and one fitting
on each knuckle.

31210031 – JLG Lift – 8-9

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7. Hydraulic Oil Reservoir

To uc an 8 00

To uc a n 8 70

b. Place a container with a minimum capacity of 25

liters under the oil reservoir plug.

Toucan 800

Toucan 870

Lube point(s) - Return filters
Capacity : 19 liters
Lube - TYPE A
Interval - Check oil daily. Change after every 1000
hours of operation or at least every 2 years.

Reservoir Draining :

IMPORTANT

THE FILTERS MUST BE REPLACED WHEN THE OIL IS CHANGED
IN THE MAIN RESERVOIR.

a. Position the Platform/Off/Ground Selector

Switch to "O" position.

c. Unscrew the drain plug.

NOTE: Do not let the oil spill on the work platform or on the

ground.

d. Tighten the drain plug once all the oil has been

drained.

e. Used oils must be disposed of according to

regulations in force.

Reservoir Filling :

f. Replace the pressure filter cartridge (refer to

"Hydraulic Filters section").

g. Unscrew the return filter cover and remove the

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
THE WORK PLATFORM IN RETRACTED
POSITION, without exceeding maximum level.

8-10 – JLG Lift – 31210031

SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

8. Steering hydraulic unit reservoir

Lube Point(s) - Breather Cap
Capacity - 1 liter
Lube - TYPE A
Interval - Check after every 125 hours of operation.
Drain after 1000 hours of operation or at least every 2
years.

Reservoir Draining :

a. Disconnect the battery form the work platform.

b. Tag and disconnect electrical cables from the

hydraulic unit motor.

c. Tag and disconnect the hydraulic lines from the

hydraulic unit output. Cap the hydraulic lines
and the unit port holes.

HIGH PRESSURE OIL COULD PENETRATE SKIN AND CAUSE
INJURIES OR BURNS. LOOSEN THE HYDRAULIC CONNECTIONS
VERY SLOWLY TO ALLOW THE PRESSURE TO DROP GRADUALLY

NOTE: Use a container to collect the oil from the hydraulic

lines or from the hydraulic group and prevent it from
spilling on the work platform or on the ground.

.

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 :

It is extremely important to apply and maintain proper
wheel mounting torque.

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE
PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN
STUDS AND POSSIBLE SEPARATION OF WHEEL FROM THE
AXLE. BE SURE THAT THE LUG NUTS ARE SEATED PROPERLY
TO THE WHEEL.

Use a torque wrench to tighten the fasteners. If you do
not have a torque wrench, tighten the fasteners with a
lug wrench, then immediately have a service garage or
dealer tighten the lug nuts to the proper torque. Over­tightening will result in breaking the studs or
permanently deforming the mounting stud holes in the
wheels. The proper procedure for attaching wheels is
as follows :

• Start all nuts by hand to prevent cross threading.
DO NOT use a lubricant on threads or nuts.

• Tighten nuts in the following sequence :

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

lines and the electrical cables.

h. Used oils must be disposed of according to

regulations in force.

Reservoir Filling :

i. Unscrew the filling cap and fill the tank with new

oil until the oil level is visible through the filling
hole.

j. Install the cap and perform a few steering

movements to bleed the air from the hydraulic
circuit.

NOTE: Tighten the hydraulic lines as soon as the oil starts

flowing out.

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

cylinder in retracted position.

Figure 8-2. Wheel Torque Chart

To rq u e V al ue s (N m ) 15 0

• Tightening of the nuts should be done in stages.
Following the recommended sequence, tighten nuts

as follow :

To rq u e S ta g es ( Nm )

1st stage 2nd stage 3rd stage

50 100 150

• Wheel nuts should be torqued after first 50 hours or
after each wheel removal. Check and torque every 3
months or 150 hours of operation.

IMPORTANT

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)

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 Controls". 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 con­trols.

d. Position the Platform/Off/Ground selector switch

to "Ground Controls" and ensure that :

• An acoustic alarm sounds.

• The corresponding LED lights up.

• Every function disabled from the ground con­trols.

e. Apply a slight traction F2 on the platform and

ensure that the acoustic alarm stops.

Machine manufactured before 2010

Machine manufactured after 2010

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

JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

Phone: [phone]

Fax: [phone]

JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: [phone]
Fax: [phone]

JLG Deutschland GmbH
Max Planck Strasse 21
D-27721 Ritterhude/lhlpohl
Germany
Phone: [phone] - 20
Fax: [phone] - 45

JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: [phone]
Fax: [phone]

JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
Phone: [phone]
Fax: [phone]

JLG Equipment Services Ltd
Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N.T.
Hong Kong
Phone: [phone]
Fax: [phone]

JLG Industries (Scotland)
Wright Business Centre,
1 Lonmay Road
Queenslie
Glasgow G33 4EL
Scotland
Phone: [phone]
Fax: [phone]

JLG Industries (UK) Ltd
Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP
England
Phone: [phone]
Fax: [phone]

JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: [phone]
Fax: [phone]

Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal
Spain
Phone: [phone]
Fax: [phone]

JLG France SAS
Z.I. Guillaume mon Amy
BP 20
47400 Fauillet
France
Phone: [phone]
Fax: [phone]

JLG Europe B.V.
Polaris Avenue 63
2132 HJ Foofddorp
The Netherlands
Phone: [phone]
Fax: [phone]

JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
Phone: [phone]
Fax: [phone]

www.jlg.com