Related Manuals for JLG Toucan 800
Summary of Contents for JLG Toucan 800
- Page 1 Operation and Safety Manual TOUCAN 800 TOUCAN 870 31210031 English - Operation and Safety Manual - Original Instructions January 01, 2010...
- Page 3 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.
- Page 4 INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BUL- AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS LETINS, CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHO- DECAL WILL HAVE A RED BACKGROUND. RIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.
- Page 5 FOREWORD REVISION LOG Original Issue - September 14, 2007 Revision - January 01, 2010 31210031 – JLG Lift –...
- Page 6 FOREWORD – JLG Lift – 31210031...
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Page 7: Table Of Contents
Verification Of The Overload Detection Setting EMERGENCY CONTROL OPERATION ..4-1 (Toucan 800 only) ....8-12 Platform/Off/Ground Selector Switch. . . 4-1 Verification Of The Tilt Alarm Setting. - Page 8 TABLE OF CONTENTS – JLG Lift – 31210031...
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Page 9: Section 1. Safety Precautions
. A m a i n t e n a n c e p r o g r a m , u s i n g t h e other equipment unless approved in writing by JLG. -
Page 10: Trip And Fall Hazards
• Stow extending structure and shut off all power before leaving machine. Trip and Fall Hazards JLG recommends that occupants of the platform wear • Maintain distance from electrical lines, apparatus, or a full body harness with a lanyard attached to an... -
Page 11: Tipping Hazards
FORWARD gear and to REVERSE down • Do not use high speed drive in restricted or close the slope as the machine will perform better. quarters or when driving in reverse. 31210031 – JLG Lift –... -
Page 12: Towing, Lifting, And Hauling
• Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times. • Charge batteries only in a well ventilated area. – JLG Lift – 31210031... -
Page 13: Section - 2 - User Responsibilities, Machine
The following table covers the periodic machine by trained personnel. inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further Persons under the influence of drugs or alcohol or who requirements for aerial work platforms. - Page 14 Q u a l i f i e d J L G Service and Maintenance Maintenance Maintenance Manual. User Mechanic Manual NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. – JLG Lift – 31210031...
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Page 15: Pre-Start Inspection
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 –... - Page 16 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Toucan 800 Toucan 800 DI – JLG Lift – 31210031...
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Page 17: Walk-Around Inspection
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 –... -
Page 18: Function Check
• Drive the machine on a grade, not to exceed the 2. From the Ground Control Console : rated gradeability and stop to ensure the brakes hold. • An acoustic alarm sounds. – JLG Lift – 31210031... -
Page 19: Overload Sensor Check
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Overload Sensor Check (Toucan 800 & Toucan 800 DI) Machine manufactured after 2010 Machine manufactured before 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. -
Page 20: Slack / Broken Chain Sensors Check
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. -
Page 21: Section 3 - Machine Controls And Indicators
5. Ground control station 13. Manual lowering controls 6. Charger 14. Chassis cover 7. Telescopic mast 15. Circuit-breaker (Toucan 800 : ¼ turn - Toucan 870 : Push/Pull) 8. Hand pump Figure 3-1. Basic Nomenclature 31210031 – JLG Lift –... -
Page 22: General
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. – JLG Lift – 31210031... - Page 23 4. Jib Up / Down Switch 5. Mast Up / Down Switch 6. Turntable Slewing Switch 7. Charger Indicator (if fitted) 8. Circuit Breaker 10. Battery Filling Pump Switch 11. Main Circuit Breaker Figure 3-2. Ground Control Stations 31210031 – JLG Lift –...
- Page 24 (horizontal lever) to insulate the battery "+". Position the circuit-breaker to its "I" position (vertical lever) to restore battery supply. T870 : Push the circuit breaker knob to insulate the battery. Pull the circuit breaker knob to restore the battery supply. – JLG Lift – 31210031...
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Page 25: Manual Lowering Controls
Depress and keep depressed the top push button while activating the hand pump to slew the turntable right. Depress keep depressed bottom push button while activating the hand pump to slew the turntable to the left. 31210031 – JLG Lift –... -
Page 26: Platform Control Station
Toggle the switch to the right to slew the turntable cut-off. The battery must be recharged. to the right. Toggle the switch to the left to slew the turntable 1 - Discharge Indicator to the left. 2 - Hourmeter – JLG Lift – 31210031... -
Page 27: Platform Control Indicator Panel
Push the right side of the thumb switch to steer the Flashing red light and audible alarm indicates the wheels to the right. Push the left side of the thumb platform has been overloaded (Toucan 800 only). switch to steer the wheels to the left. 4. Unauthorized Movement Indicator. - Page 28 SECTION 3 - MACHINE CONTROLS AND INDICATORS – JLG Lift – 31210031...
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Page 29: Section 4. Machine Operation
) 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. - Page 30 The drive movements are cut and the slewing, jib and mast raising movements switch automatically to slow speed. – JLG Lift – 31210031...
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Page 31: Raising And Lowering The Mast
2. Push the mast function control switch away from on the controller) to steer to the right. 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 –... -
Page 32: Raising And Lowering The Jib
800) of the chassis under the chassis cover. This alarm 2. Push the jib function control switch away from the is active once the mast (and/or the jib for Toucan 800 operator to lower the jib within 5 seconds after the manufactured before 2010), has left its lowered footswitch has been depressed. -
Page 33: Soft Touch System Light And Alarm (Option)4-5
Station. Position Platform/Off/Ground select • A foreign body entering the guiding system. switch to center OFF. • A lack of lubrication. 5. Toucan 800 : Position the circuit-breaker to its "O" • Incorrect operation. position. Toucan 870 : Depress the circuit breaker push NOTE: The slack chain and light alarms are also button. -
Page 34: Chargers
Loss of control of the output current (fault on Battery current control logic : Contact JLG Product Support). The chargers are factory preset based upon the plug type fitted. Loss of control on output voltage (fault on control Battery voltage logic : Contact JLG Product Support). -
Page 35: Emb-Mp Hawker Charger (40 Or 70 A)
- If the battery does not reach 2.4 V/cell after a 10 hour charge, the charging process stops and the red led (d) lights up. It is advisable to have either the charger or the battery checked by a technician. 31210031 – JLG Lift –... -
Page 36: Emergency Towing
1. The weight of the machine is stamped on the serial number plate (See § 8.2). If the plate is missing or illegible, call JLG Industries or weigh ENSURE THE MACHINE IS ON LEVEL GROUND BEFORE the individual unit to find out the Gross Vehicle RELEASING THE BRAKES. -
Page 37: Tie Down
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 –... - Page 38 SECTION 4 - MACHINE OPERATION 4-10 – JLG Lift – 31210031...
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Page 39: Section 5 - Decals
SECTION 5 - DECALS SECTION 5. DECALS Toucan 800 Instructions AU1743 Loads AU1095 31210031 – JLG Lift –... - Page 40 SECTION 5 - DECALS – JLG Lift – 31210031...
- Page 41 SECTION 5 - DECALS Toucan 800 DI Instructions AU1743 Loads AU1755 Load Transfer AU1387 31210031 – JLG Lift –...
- Page 42 SECTION 5 - DECALS – JLG Lift – 31210031...
- Page 43 SECTION 5 - DECALS Toucan 870 Standard Platform Instructions AU1757 Loads AU1756 Large Platform Instructions AU1757 Loads AU1758 31210031 – JLG Lift –...
- Page 44 SECTION 5 - DECALS – JLG Lift – 31210031...
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Page 45: Section 6 - Emergency Procedures
INCIDENT NOTIFICATION EMERGENCY TOWING PROCEDURES 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 Towing this machine is discouraged. However, contacted by tel ephone and pr ovided with all provisions for towing the machine in emergency necessary details. -
Page 46: Section 7 - Inspection And Repair Log
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 –... -
Page 47: Section 8 - General Specifications & Operator 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........... -
Page 48: Operating Specifications
SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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... -
Page 49: Fluid Capacities
24 VDC Unit Pump Displacement 0.5 cm³/t Batteries Table 8-4. Battery Specifications Voltage 24 Volt Toucan 800 240 Ah (5h rate) Amp Hour Rating Toucan 870 620 Ah (5h rate) Life Cycle Rating 1200 Cycles 31210031 – JLG Lift –... - Page 50 9- Tires & Wheels 4- Lifting Chains Lubrication 10- Verification of the Overload Detection Setting (if fitted) 5- Mast Section Lubrication 11- Verification of the Tilt Alarm Setting 6- Wheel Bearing & Steering Knuckles Lubrication – JLG Lift – 31210031...
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Page 51: Operator Maintenance
A F T E R T H E C H A R G E ( D U R I N G T H E C H A R G E , T H E industrial waste, it must be disposed of according ELECTROLYTE LEVEL INCREASES AND CAN OVERFLOW). to regulations in force. 31210031 – JLG Lift –... - Page 52 • 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.
- Page 53 Loss of electrolyte due to overflow. Perform an equalization charge. electrolyte specific gravity too low. Stratification of the electrolyte. Contact your JLG Distributor/Product Support. Electrolyte specific gravity too low. Refer to "electrolyte specific gravity too low". Low voltage in the cells in open circuit.
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Page 54: Hydraulic Filters
• Activate the release valve (located at the rear side of the chassis) to release NOTE: Aside from JLG recommendations, it is not the pressure in the hydraulic circuit advisable to mix oils of different brands or types, as... -
Page 55: Turntable Lubrication
- Longitudinally : in areas where joints are under small load to facilitate penetration of the lubricant. - Transversally : between the plates to enable the lubricant to reach the joint and between the internal plates and the rollers. 31210031 – JLG Lift –... -
Page 56: Hydraulic Oil Reservoir
T H E W O R K P L AT F O R M I N R E T R A C T E D POSITION, without exceeding maximum level. 8-10 – JLG Lift – 31210031... -
Page 57: Steering Hydraulic Unit Reservoir
150 hours of operation. flowing out. IMPORTANT Add oil in the tank if necessary, with the steering cylinder in retracted position. TIGHTEN THE NUTS USING A TORQUE WRENCH. DO NOT USE IMPACT WRENCH. 31210031 – JLG Lift – 8-11... -
Page 58: Verification Of The Overload Detection Setting (Toucan 800 Only)
SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 10. Verification Of The Overload Detection Setting (Toucan 800 only) Machine manufactured before 2010 Interval - Check after every 6 months of operation. Place a 200 kg load evenly distributed on the platform floor. -
Page 59: Verification Of The Tilt Alarm Setting
An acoustic alarm sounds when the chassis is tilted at its max value. • The corresponding LED lights up on the platform controls Repeat steps (g) and (h) with the left side of the chassis lifted. Remove the blocks. 31210031 – JLG Lift – 8-13... - Page 60 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8-14 – JLG Lift – 31210031...
- Page 62 1 JLG Drive McConnellsburg PA. 17233-9533 Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. Guillaume mon Amy...