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