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MODELS TOUCAN 1100

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2. 2 EP Fr Pi N re S NUS E 4 900 1780 E _ 2680 E 4 3 We TU MSS Lee b s il n oed 1900 i 1 es 1 SEES IB Lcd y P d 3 A E i CE Models ALG Toucan 1100 Revision 04 2006 2 2 2 Toucan 1100 B Toucan 1100 C GENERAL DESCRIPTION it l f EN 6 TAA LO 9 1160 1300 1780 3080 Models Revision 04 2006 Toucan 1100 990 2190 3 SAFETY PRECAUTIONS 3 NOTE Illustrations havebeen included in this section to emphasize important points read and follow printed instruction It is impossible to compile a list of safety precautions coveringall situations However there are basic safety precautions that MUST be followed during your daily routine Safety is YOURPRIMARY RESPONSIBILITY since any piece of e
3. ELECTRICAL SCHEMATIC Ref ELE194 11 Z 3103NNOO 0 14 37615526 WAYI SNVS GN Z 3103NNO230 OL 314 318 5N3S 23 4 Ol SLO3NNOO 04 IYA 3WVYS 3AUISN3S 1n0OHLIM e LK OL 1933302510 OL IMM 3AYs3 3ALISN3S HLA 9 nv ara lt lt 114 13 vsf nv aaa 254 714 0 32 1190 3NIVHO 30 NOW 58131492 SIOMI 23 quran rd S 01 SLOINNOD 95 IMA ANY OL SLOSNNOD 29 gt 39 NouJO HOLIMS NIVHD 33HHl HIM lt lt SINL 1 3 30 9 nv 3134 01 Td 3NOvN3TN NOLVTSNvVMI 3arndno2 NOJO OBZN3 NOILVISNVYL 3undnoo NOUdO wa N 0014 OL SIDINNOO Ol SEH OL SLOANNOD 01 3AM NOUdO SNULND INYA NOJO SNTI MaA N N nv 3r 21 14 Vet anyu NOLIVTISNYHI 33 ndn02 e MOZXZ ivNvHI 30 3BVHd MOL TWAVaL 30 OL SLOSNNOD ZL 3AM e LOVI
4. 15 15 20 Preventive maintenance and inspection 15 20 1 Daily preventive maintenance and inspection Daily preventive maintenance inspections should include checking the following items Presence and legibility of the Operator s Safety and Maintenance Handbook Presence and legibility of the decals warning and instructural Good working order of the work platform Good working order of the controls indicators Good working order of the tilt alarm refer to 5 1 3 Good working order of the motion alarm Battery state of charge on the battery discharge indicator refer to 4 1 Condition of heavy duty solid tyres Hydraulic oil level refer to 5 1 2 Condition of jib and attachments Presence of screws and pins Condition of power bridges Mast sensors refer to 5 1 6 Jib sensor refer to 5 1 7 Overload detection refer to 5 1 4 Chain slack and breaking detection refer to 5 1 5 15 20 2 Weekly preventive maintenance and inspection Weekly preventive maintenance inspections should include checking the following items Presence of wheels nuts Hydraulic hoses and fittings leakage Battery electrolyte level refer to 15 5 1 Mast jib cylinders leakage rod lock valve Lubrication refer to 15 21 15 20 3 Monthly preventive maintenance and inspection Monthly preventive maintenance inspections should include checking the following it
5. 15 Trouble shooting CPIV models SIGNALLING SOLUTION CURRENT LEDs INDICATOR Voltage still below 1 7 V per cell 20 4 Battery too discharged contact Product V for batteries after 1 minute of charge Support The first LED flashes Problem with the charger or battery too discharged Switch the charger off Voltage still below 2 05 V per cell 24 6 disconnect the charger from the battery wait V for batteries after 1 hour of charge for approx 15 mn Reconnect the charger to the battery and switch the charger on If the The 2nd LED flashes problem persists the charger is faulty WU Voltage per cell still below the required Battery too discharged Switch the charger gazing voltage after 10 hours of charge off disconnect the charger from the battery wait for approx 15 mn Reconnect the 6 charger to the battery and switch the charger on 3 o0 D A LLI E 2 The 3rd LED flashes oooe Charging safety time exceeded 1 hours The 4th LED flashes Charge interruption due to a power cut Charge will be resumed as soon as the Check power supply power returns Voltage per cell 14096 above the nominal Batt Iready ch d attery already charge Default LED flashes The 4 LEDs flash Trouble shooting HPIII models ERROR CODES CAUSE SOLUTION Voltage still below 1 65 V per cell 19 8 ViBattery too discharged contact Product U LO for batteri
6. DANGER Before operating the machine inspect the entire work site and ground conditions on hich the machine will be dri Do not use the machine if all railing and necessary protection devices are not in place 9 2 2 Shut down procedure Operate the work platform only on firm and level ground Do not drive the machine near 1 Park the machine in a safe and sheltered area holes or other obstacles which could cause 2 Depress the upper EMERGENCY STOP abnormal stresses on the work platform and switch even cause it to tip over 3 Exit the platform 4 Position the key switch ground controls to DANGER de X DANGER 5 Remove the key Do notuse the work platform if wind speeds exceed those recommended in paragraph 5 2 3 Emergency stop 2 3 and during thunderstorms NOTE DANGER Emergency stop is accomplished by unless all controls are functioning properly switches The upper EMERGENCY STOP switch cuts the power from the upper control box The lower EMERGENCY STOP switch cuts all functions from the machine Models Revision 04 2006 Toucan 1100 A 31 5 OPERATING PROCEDURES 5 Death or serious injury could result from falling out of the platform Do not operate the machine if all railing are not in place and secure Close all gates and openings Maintain a firm footing on platform floor at all times Death or serious injury could result from being crushed or from cont
7. MODELS TOUCAN 1100 OPERATOR S AND SAFETY MANUAL U S A C E C E FRANCE JLG Industries Inc JLG Industries JLG Manufacturing Europe JLG France SAS 1 JLG Drive Kilmartin Place Breitwaterstraat 12A Z de Fauillet M cConnellsburg Tannochside Park Oude Bunders 1034 BP 20 47400 TONNEINS PA 17233 9533 Uddingston ScotlandG715PH 3630 Maasmechelen France Tel 171 485 5161 Tel 44 0 1698 811005 Tel 32 0 89 774 974 Tel 33 553848511 Fax 717 485 6417 Fax 44 0 1698 811055 Fax 32 0 89 777 427 Fax 33 553 79 06 87 Updated 04 2006 0138 03 English MODELS TECHNICAL SPECIFICATIONS JLG France Z l de Fauillet B P 20 47400 Tonneins France 200 kg 2 persons 40 kg 230 kg 2 persons 70 kg 200 kg 2 persons 40 kg Maximal load materiel materiel materiel The weighed root mean square acceleration value to which the arms are subjected control levers is inferior to 2 5 m s s Vibration levels The weighed root mean square acceleration value to which the feet are subjected platform floor is inferior to 0 5 m s s The equivelent continuous A weighed sound pressure level at the work station is inferior to 70 dB A Acoustic pressure The measure has been made by placing the sonometer at 1 60 m avobe the platform floor The indicated value does not include the motion alarm Maximum hydraulic 23 Mpa pressure Maximum wind speed 30 km h 0 km h 30 km h
8. Wear safety glasses when servicing batteries Do not disconnect the positive battery clamp first Disconnect the grounded battery clamp first when removing battery and connectit last when installing a battery Charge batteries only in an open well ventilated area free of flame smoking spark and fire Ensure you conform to all particular regulations in force dL 23 4 WORK PLATFORM CONTROLS 4 NOTE Function on the equipment a temporization integrated to the electrical system disconnect 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 emergency control panel must be depressed then turned clockwise to restore the functions of the machine Fig 4 2 Movement control decal a Steering control lever Position the control lever inthe desired direction PUSHto steer the work 4 1 Platfom controls platform to the RIGHT and PULL to steer the work platform to the LEFT b Jiblift lowering control lever PULL the lever
9. Turntable bolts torque refer to Service manual Lifting chains wear refer to 15 16 1 Telescopic mast alignment bronze spacers on roller pins refer to Service manual Relief valve settings refer to Service manual Lubrication refer to 5815 21 NOTE Fire extinguisher optional equipment must be checked according to regulations in force NOTE Turntable attachment bolts have to be retorqued after the first 100 hours operation dL 61 15 15 15 21 Lubncation General Follow designated lubrication procedures to ensure maximum work platform lifetime and use The procedures and lubrication chart in this section provide information on the types of lubricants used the loca tion of lubrication points the frequency intervals for lubrication and other important material When checking for suspected leaks place underneath a piece of cardboard or wood Never modify the setting of a relief valve Lubrication points Regular lubrication must be performed on all lubrication points Normally the frequency for lubrication is based on component operating time The most efficient method for keeping track of lube intervals in to maintain a job log indicating machine usage The log sould include hourmeter readings which can be used to determine which lube points will require attention based on their readings Lubricants or grease types as well as lubrication intervals must be adapted to the
10. b Control levers from left to right Fig 4 6 1 Swing control lever LEFT lift and hold the control lever RIGHT push down and hold the control lever 2 Jib control lever Jib LOWERING push down and hold the control lever Jib RAISING lift and hold the control lever 3 Mastcontrol lever Mast LOWERING push down and hold the control lever Mast RAISING lift and hold the control lever 26 JE WORK PLATFORM CONTROLS AU0660 Fig 4 7 Emergency panel decal c Emergency stop switch Fig 4 8 PUSH the switch in to remove the electrical power from the machine stopping allfunctionsfrom the platform The switch must be pulled out to restore the functions of the machine EMERGENCY Fig 4 8 Lower electrical box d Ignition key Position the ignition key to to startthe machine orto O toremove the electrical power and remove the key e Panel mounted fuse holder Models Toucan 1100 Revision 04 2006 4 WORK PLATFORM CONTROLS 4 Read the safety manual before using the machine This machine can only be usec by a qualified person Maximum rated capacity 200 kg distributed load 2 persons 180Kg equipment 4060 Use on firm level ground free from any obstacle FRIOR TO WORK PLATFORM USE Verify the good working order of the safety emergency and breakdown devices Verify the condition and nature of the ground on which the machine will be driven Veri
11. M z N 2 4 M 1 N tage Sd 1 11100 200 T T1100B 230 kg 11100 200 kg ME 15 19 Venfication of the tit alam setiing 1 Position the selector switch to Ground controls or Platform controls 2 Chock both rear wheels 3 Place a spirit level digital display on the chassis positioned lengthways 4 With a jack of appropriate capacity lift the front of the chassis An acoustic alarm sounds when the chassis is tilted at its max value 2 he corresponding LED lights up on the platform controls 5 Chock both front wheels 6 With a jack of appropriate capacity lift the rear of the chassis An acoustic alarm sounds when the chassis is tilted at its max value 2 Thecorresponding LED lights up on the platform controls T Place a spirit level digital display across the chassis 8 With ajack of appropriate capacity lift the right hand side of the chassis An acoustic alarm sounds when the chassis is tilted atits max value 2 Thecorresponding LED lights up on the platform controls 9 With a jack of appropriate capacity lift the left hand side of the chassis An acoustic alarm sounds when the chassis is tilted at its max value 2 he corresponding LED lights up on the platform controls 10 Remove the blocks Models Toucan 1100 Revision 04 2006 15
12. 19 05 mm Chain stretching cannot be superior to the values indicated in the chart below en L 10 pitches lt T Pitch 5 8 15 875 mm 3 4 19 05 mm 163 5 mm If a chain appears to be faulty or worn both chains of the same stage must be replaced together the con dition of the pulleys and the telescopic mast alignment must be checked 15 16 2 Chains lubrication N CAUTION Do not use grease to lubricate the lifting chains Do not remove lubricant applied at the factory from the chains Do not use acid or detergent to clean the lifting chains Do not pressure wash them Lubrication of the lifting chains can be performed manually with a brush or by spraying Chain lubrication intervals must be established with care depending on the environment in which the work platform is operated or stored dusty or agressive environment The lubricant must be adapted to the machine s operating conditions Generally a non detergent mineral oil is sufficient Its viscosity must be adapted to temperatures according to the chart hereafter Models Revision 04 2006 Toucan 1100 q 9cG 96 96 96 98 9 b Recommended viscosity grades ISO VG 15 to 32 46 to 150 220 to 320 N CAUTION A viscosity too low facilitates draining of the lubricant by gravity A viscosity too high prevents the lubricant from reaching the friction surfaces Lubric
13. Floatdoesnotemerge Floatemerges E Insufficientlevel Correctlevel NOTE Tilt the charger to gain access to the front battery pack Fill the battery cells if necessary after the charge using the centralised filling system N CAUTION Use only distilled or demineralized water to fill the battery cells N CAUTION Battery cells must be filled only after the charge during the charge the electrolyte level increases and can overflow Models Toucan 1100 Revision 04 2006 15 15 15 5 2 Filling the battery with the water pump Fill the can with distilled water Toggle the water pump switch to fill the battery The filling indicator turns quickly and slows down as the battery is filled When the mechanism inside the filling indicator slows down release the pump ignition button FIAMM Oldham Fulmen Check that the level is correct in each battery cells indicator in the center of each filling cap 15 6 Centralised filling system maintenance It is necessary to service the centralised 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 hosesfor flexibility In case of hardening in the connection areas replace the hose Check every fitting for tightness a
14. Maximum ant 150 9001 Cert N FM 40825 MA0138 03 Models Revision 04 2006 Toucan 1100 DANGER ELECTRICAL HAZARD THIS MACHINE IS NOT INSULATED DEATH OR SERIOUS INJURY COULD RESULT FROM CONTACT WITH OR INADEQUATE CLEARANCE FROM ELECTRICAL POWER LINES OR EQUIPMENT DONOT OPERATE ANY PART OF THIS MACHINE IN PROXIMITY TOELECTRICAL POWER LINES OREQUIPMENT MAINTAIN A MINIMUM CLEARANCE OF 6 METRES FROMALL ELECTRICAL POWER LINES OREQUIPMENT KEEP AWAY FROMMACHINEIF BEING OPERATED NEARELECTRICAL POWERLINES OR EQUIPMENT DONOT OPERATE THISMACHINEUNLESS YOU ARE QUALIFIED BY TRAINING EXPERIENCE IN THESAFE OPERATION OF THIS MACHINE TRAININGINCLUDES COMPLETE KNOWLEDGE OF YOUR EMPLOYER S WORK RULES THE OPERATOR S ANDSAFETY HANDBOOK AND ALL GOVERNMENT REGULATIONS RELATIVETO THIS MACHINE AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO DEATH OR SERIOUS INJURY Models ALG Toucan 1100 Revision 04 2006 NOTICE TO OWNER USER Should this work platform become involved in an accident please contact your local JLG distributor immediately and relate details ofthe incident so that he can notify JLG If the distributor is unknown and or cannot be reached please contact USA C E JLG Industries Inc Product Safety amp Reliability Department Ee i Kilmartin Place 1 JLG Drive ADU McConnellsburg PA 2 2 USA 17233 9533 Toll Free 877 554 7233
15. work platform while it is in use Even if a work platform is not affected by an electrical contact others in the area may become seriously injured or killed It is not always necessary to contact a power line or power source to become electrocuted Electricity depending on magnitude can jump or become induced into a work platform Low voltages can also be dangerous ALG 21 3 SAFETY PRECAUTIONS 3 Set up park the work platform in a position such that no part of the machine can be moved to within 6 METRES of power lines and equipment This consideration should include the extremes of the work platform s attainable configurations e g height when the base is in a stationary position A suitable barricade should be erected to physically restrain the work platform and all attachments from entering into an unsafe distance from power lines and equipment Thoroughly READ and UNDERSTAND all applicable regulations in force and operate the work platform in compliance with these regulations The use of proximity devicesor mechanical limit stops does not assure that electrical contact will not occur You must follow the rules and precautions outlined in this handbook at all times regardless of the devices which the work platform may be equipped with Plan ahead and always plan a safe route before travelling under power lines Rider poles should be erected on each side of a crossing to ensure sufficient clearance is maintained Gro
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17. 19 20 21 NO 6 Models 66 ALG Toucan 1100 Revision 04 2006 Models Revision 04 2006 Toucan 1100 NOTES 67
18. CAN BE TOWED NORMALUSE RETURNTHEVALVESTO NORMAL USE THE MACHINE CAN BE OPERATED IN NORMAL USE The work platform must be kept as near to the groundas possible during fork lift operation Lift the forks at the last minute to prevent the machine from tipping over Models 34 ALG Toucan 1100 Revision 04 2006 6 TRANSPORT INSTRUCTIONS 6 6 2 4 Fastening on the bed of a truck Chock the wheels in both directions Figure 6 6 Tie down and chain the machine securely Figure 6 6 Wooden blocks blocks Chains attached to truck bed Strapping of the platform on the ground 4 Fig 6 5 Fork lift truck use decal S 6 2 2 Usingatruckequipped with atail gate Fig 6 6 Transportinstructions N CAUTION Check all the fixations Verify the capacity of the tail gate Place the machine at the centre of the tail gate to distribute the load Nobody must be on the platform of the machine or on the tail gate during loading towing or unloading operations Tie the machine down securely on the bed of the truck See figure 6 6 6 2 3 Using a winch Case of roll back truck Check the capacity of the equipment used Place the machine in towing mode see 6 1 for the loading and unloading procedures Nobody must be in the platform during this
19. Make necessary repairs Recheck to ensure that nothing has been overlooked Functionally test failed part in its system NOTE Your safety and that of others is always the number one consideration when working around machines Safety is a matter of thoroughly understanding the job to be done and the application of good common sense It is not just a matter of do s and don ts Stay clear of all moving parts 15 2 Cleanliness Keep dirt out of working parts to preserve the long life of the machine Enclosed compartments seals and filters keep the supply of air hydraulic oil and lubricants clean Maintain these enclosures properly Whenever hydraulic lines are disconnected clean the adjacent area as well as the point of disconnection As soon as the disconnection is made cap plug or tape each line or opening to prevent entry of foreign material The same recommendations for cleaning and covering apply when access covers or inspection plates are removed Clean and inspect all parts Make sure All passages and holes are open Parts are covered to keep them clean Parts are clean when they are installed Newparts are left in their containers until ready for assembly Rust preventive compound has been removed from all machined surfaces of new parts before they are installed except leaf chains Keep the work platform clean at all times free from mud dirt and grease Dirty equipment wears out faster and ma
20. The red LED on the ON OFF switch lights up to indicate the charger is working Charge intensity is displayed in b during the charge After reaching 2 4 volts per cell the 80 LED lights up to indicate the start of the end of charge sequence the green LED lights up when the batteries are 100 charged Equalisation charge The equalisation charge to be performed periodically enablesthe electrolyte specific gravity to be equalised between the battery cells It follows the normal charge if it has been programmed during the charge by pressing the equalisation charge preselection button a point appears on the right of the number on the display screen When the charger switches to equalisation charge the 100 charge indicator comes off and the 80 charge indicator flashes To cancel the preselection equalisation pressthe STOP and z the point on the display screen disappears Models Revision 04 2006 Toucan 1100 Interruption of the charge cycle A charge cycle should not be interrupted However should it be necessary to stop the charge cycle at anytime the ON OFF switch must be depressed the screen indicates The charge starts where it stopped if the ON OFF switch is pressed again Power cut If a power cut occurs during the charge the charger switches to waiting mode and starts again automatically as soon as the power returns Fault indicator If a problem occurs
21. and by the employer safety rules If the work platform must be towed plan the route and follow proper towing instructions Ensure that the platform is fully lowered Do not allow personnel on the ground to operate service orin any other way tamper with the machine when the platform is occupied except in an emergency situation where platform personnel are unable to fully lower and exit the platform If welding is being performed by an occupant of the platform electrodes and holders must be protected from contact with metal components of the platform Electronic components can be damaged during welding Toavoid damage disconnectall electronic components priorto performing welding from the machine Use the following steps when shutting down the work platform Fully retract mast and jib and exit the platform Place the controls in neutral position Chock the wheels Remove the ignition key In cold weather never allow skin to directly contact metal surfaces Do not park the work platform where the wheels can become frozen to the ground Cold weather requires special starting procedures and ample time for hydraulic oil to warm up Keep the platform free of ice and snow JG 15 3 SAFETY PRECAUTIONS 3 3 2 Machine stability BEWARE OF CONDITIONS THAT COULD ADVERSELY AFFECT MACHINE STABILITY DEATH OR SERIOUS INJURY COULD RESULT FROM TIP OVER PRIORTOANY OPERATION INSPECT THE ENTIRE WORK SITE AND ALL GROUN
22. any serious injury After verification the slack chain is not caused by the platform or the jib resting on an obstacle proceed in the following manner Call competent ground personnel to the rescue Inform the person that the problem is a slack chain and that firstly THE MAST HAS TO BE RAISED to deactivate the alarm and tension the chains using the emergency controls If the alarm is deactivated lower the jib as much as possible and swing the superstructure in the best position to be rescued Try again to lower the mast 4 In case the alarm is reactivated hold on tightly to the guardrail and swing the platform sideways When released the platform will come down suddenly by 10 to 20 cm If the alarm is not activated fully lower the mast A qualified person must inspect the machine before it is returned into service If the mast is still not released or if the alarm is still active an evacuation must be envisaged If the mast is still jammed the following procedures must be respected to prevent any serious injury Ask the ground personnel to raise the mast again until the alarm stops chains tensioned Ask the person to lower the jib as much as possible and swing the superstructure in the best position to be rescued The breakdown control using the hand pump must not be used with the mast jammed except by a qualified person with a good knowledge of the operation of the ve
23. detection system 2f 4 WORK PLATFORM CONTROLS 4 3 1 4 Slack chain detection The detection system for a slack chain prevents dangerous movements in case the work platform or the jib come to rest on an obstacle during a mast or jib lowering movement Each chain stage is fitted with a sensor which upon detection of a slack chain actuates an acoustic alarm and a light indicator on the platform control box All the work platform functions are disabled In normal operation the sensors are not actuated Procedure to follow in case this safety feature is actuated Identify the cause through an examination of the environment Call competent ground personnel to the rescue Inform the person that the problem is a slack chain and that firstly THE MAST AND OR THE JIB HAS TO BE RAISED to release the platform or the jib of the machine As soon as the alarm is no longer actuated the platform control box is operational again perform the necessary movement s to prevent the platform to rest on the obstacle again If the examination of the environment does not reveal any resting possibility the jamming of the telescopic mast may have actuated the alarm This can be due to The presence of a foreign body in the guiding system Alack of lubrication refer to 15 21 An incorrect adjustment refer to the Service Manual If the mast jamming actuates the slack chain alarm the procedure below must be respected to prevent
24. indicating the charger is completing a self test The leds and d will then flash for a short period of time indicating the charger is in automatic starting mode he 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 Models Revision 04 2006 Toucan 1100 Equalization charge When the charger is doing an equalization charge both leds a and c flash slowly Led b is lit fixed Faultindicator Should the transformer overheat the red led d flashes quickly Fr qency 0 2 second If the battery does not reach 2 4V cell after 10 hour charge the charging process stops and the red led d lights up It is advised to have either the charger or the battery checked by a technician Leds signal a b green yellow or or perm Final charge BL ON OFF OFF Automatic starting mode few seconds Charge completed or equalization pon on pause Equalization charge BL ON BL OFF Default safety temporisation __ ON OFF Default thermal protection on transformer OFF the led is off ON the led is lit fixed BL the led flashes T 1sec BV the led f
25. of a slack chain the emergency control panel should only be used after the specific procedure on this safety feature has been read refer to 4 3 1 4 4 3 1 Safety devices and alarms 4 3 1 1 Motion alarm The motion alarm is located inside the front cover This alarm is activated whenever one function is selected Models Revision 04 2006 Toucan 1100 4 3 1 2 Tilt indicator When the chassis is 2 off the horizontal the switch will activate the buzzer and an indicator will light up on the platform upper control box Activation of the alarm indicates that the work platform is at its maximum out of level limit and is nearing an unstable position No function should be performed other than those necessary to return the work platform to a more stable position It is recommended to place the machine in the following configuration Jib retracted Rotation in the position least unfavourable for stability Fig 4 11 Tilt sensor 4 3 1 3 Overload detection The machine is fitted with an overload detection system located at the rear of the platform The platform is articulated on the platform support It rests on an assembly of spring washers A sensor fixed to the platform support detects the overload and stops all movements of the machine when the overload is detected abuzzer sounds Torestore the machine s functions the platform must be unloaded until the buzzer stops Fig 4 12 Overload
26. on the work platform Models Revision 04 2006 Toucan 1100 Working Do not use the work platform for any operation it was not designed for by the manufacturer Itis by definition intended to bring personnel their tools and NECESSARY materials at overhead locations not for handling bulk materials Do not use the work platform in dusty conditions unless it has been protected to this effect Keepall equipment and materials used onthe platform well organized and evenly distributed Neverexceed platform capacity Do notallow ropes electrical cables orhosesto become entangled during operation Never use guardrails to handle materials Operate the work platform slowly and cautiously Always look in the direction of the movement Avoid any dangerous operation Never allow anyone to hitch arideorgetonoroffthe platform while in motion Never operate the work platform outdoors in bad weather thunderstorms violentwinds or if wind speeds exceed those recommended inthe technical characteristics When travelling between work locations on the job site fully lower the mast so that the platform is as close to the ground as possible while maintaining adequate clearance for the terrain The jib may be raised to improve visibility Avoid whenever possible totravel in areas presenting risks of objects falling on the platform occupants Should this be impossible you must wear all individual protections required by the regulations in force
27. the charger stops the LEDs switch themselves off and the screen displays an error code Exx refer to the troubleshooting chart hereafter dL 45 15 15 Protections Transformer inlet terminal block Single pole circuit breaker a on the display pa nel 15A on 24 MO 40A models p n 950172 20A on 24 MO 65A models p n 950064 Output fuse 40A on 24 MO 40A models p n 950029 65A on 24 MO 65A models p n 950022 Adaptation to network voltage Prior to any operation requiring charger cover removal the battery must be disconnected and the charger must be unplugged from the AC outlet Failure to do so could result in death or serious injury to personnel Spare output fuse Connections on transformer inlet terminals block 220 VAC 110 VAC BORE Jumper Troubleshooting chart M the jumper from test ition to propor position on the electronic El RI bus Replace the fuse Check voltage at output and input of the transformer Low intensity Fault on electronic card Contact LG Product Support E3 Electronic card programme erased Contact LG Product Support configuration lost Batteries too discharged Leave the batteries to stand before resuming charge Disconnect and reconnect the batteries Contact J LG Product Support if the fault persists Check the charge If this condition remains for more than 15 mn let the batteries stand befo
28. the machine s nameplate The work platform operations are primarily controlled from the upper control box mounted on the platform The emergency and breakdown panel is located on the left hand side of the machine Ma Toucan 1100 Models Revision 04 2006 2 GENERAL DESCRIPTION 2 2 1 General descnpton Upper control box Telescopic masts ee j REAR FRONT 2 P Manual box Drivingwheels FRONT Counterweight 4 Access to hydraulic unit Emergency and breakdown control panel Models Revision 04 2006 Toucan 1100 A 11 2 GENERAL DESCRIPTION 2 2 2 Dimensions and range diagrammes 221 Toucan 1100 A
29. 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 Models Toucan 1100 Revision 04 2006 AMLE 15 15 15 13 Oil change replacement an filter The first oil change and oil filter replacement must be done after the 50 first 50 hours of operation Thereafter service interval is 250 hours It is recommended to change the oil the oil filter when the oil is warm Change the oil filter when the needle of the clogging indicator reaches the red zone Hydraulic oil recommendations Refer to section 15 21 Lubrication for hydraulic oil specifications The work platform must be FULLY LOWERED when filling the oil tank or when checking the oil level Oil change and flushing N CAUTION The filter must be changed at each oil change 1 Position the ignition key to O 2 Place rags around the oil filter and place a container of 30 liter minimum capacity under the hydraulic tank 3 Remove the breather cap and the draining plug located on the side of the reservoir 4 Remove the oil filter with a filter wrench DANGER Oil projections can cause injuries and burns NOTE Do not spill oil on the work platform or on the ground 5 Clean the oil filter base and the reservo
30. 0 Models Revision 04 2006 3 SAFETY PRECAUTIONS 3 3 5 Electrical power sources ELECTRICAL HAZARD THIS MACHINE IS NOT INSULATED DEATHORSERIOUS INJURY COULD RESULT FROM CONTACT WITH ORINADEQUATE CLEARANCE FROM ELECTRICALPOWER LINES OR EQUIPMENT DONOT OPERATE ANY PART OF THIS MACHINE IN PROXIMIT Y TO ELECTRICAL POWER LINES OREQUIPMENT MAINTAIN A MINIMUM CLEARANCE OF 6 METRES FROM ALL ELECTRICAL POWER LINES OREQUIPMENT KEEP AWAY FROMMACHINEIF BEING OPERATED NEARELECTRICAL POWERLINES OR EQUIPMENT Do not operate any parts of this machine in proximity to electrical power lines or equipment Maintain a minimum clearance of 6 metres from all electrical power lines or equipment at all times Death or serious injury could result from contact with or inadequate clearance from electrical power lines or equipment You must never operate this work platform within any distance of a power source or power line without first notifying the power or utility company Always obtain positive and absolute assurance that the power has beenturned OFF During work platform use assume that every line is energized and take the necessary precautions accordingly Models Revision 04 2006 Toucan 1100 You the operator are responsible for alerting all personnel of dangers associated with electrical power lines and equipment The platform is not insulated Do not allow unnecessary personnel in the vicinity of the
31. 1100 Revision 04 2006 TABLE OF CONTENT 15 20 Preventive maintenance and inspection 15 20 1 Daily preventive maintenance and inspection 15 20 2 Weekly preventive maintenance and inspection 15 20 3 Monthly preventive maintenance and inspection 15 20 4 Preventive maintenance and inspection every 125 hours of operation 15 20 5 Preventive maintenance and inspection every 250 hours of operation 15 20 6 Preventive maintenance and inspection every 500 hours of operation 15 21 Lubrication EXAMPLE OF A LOG BOOK 16 Models Revision 04 2006 Toucan 1100 INTRODUCTION This handbook provides important information for the operation and maintenance of JLG work platform Model Toucan 1100 A Toucan 1100 B and Toucan 1100 C The JLG aerial Elevating Work Platform is aself propelled type with an all welded steel frame The drive is accomplished by two hydraulic motors The steering is accomplished by an hydraulic cylinder The hydraulic power unit is located on the front ofthe chassisand provides hydraulic energy forthe work platform operation The electrical power is provided by a 24 VDC battery In working mode the work platform may be safely drivenonly on firm and level surfaces All four wheels must be in permanent contact with the ground Theload must be distributed in the platform and must not exceed the manufacturer s rated load with the mast and jib in any position The maximum rated load is indicated on
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33. 6 Operation on non level ground AL TABLE OF CONTENT TRANSPORT INSTRUCTIONS 6 6 1 Towing 6 2 Loading and unloading 6 2 1 Using a fork lift truck 6 2 2 Using a truck equipped with a tail gate 6 2 3 Using a winch 6 2 4 Securing on the platform of a truck 6 2 5 Lifting the machine SCHEMATICS 7 OPTIONAL EQUIPMENT 8 8 1 Extinguisher 8 2 220 VAC socket MAINTENANCE 15 15 1 System malfunction 15 2 Cleanliness 15 3 Chargers 15 3 1 Westinghouse SGTE electronic charger 15 3 2 Fulmen electronic charger 15 3 3 Oldham Hawker electronic charger 15 4 Battery 15 5 Centralised filling system 15 5 1 Electronic level 15 5 2 Filling the battery with the water pump 15 6 Centralised filling system maintenance 15 7 Cleaning Battery maintenance 15 8 Electrolyte specific gravity and battery voltage 15 9 Storage of a battery at temperature below 0 32 F 15 10 Use of a battery in a cold chamber or in a cold climate 15 11 Battery not working continuously or inactive battery 15 12 Battery troubleshooting 15 13 Oil change replacement and filter 15 14 Main hdyraulic group motor 15 15 Steering bracket thrust washers 15 16 Chain control and lubrication 15 16 1 Control of chain wear 15 16 2 Chains lubrication 15 17 Lifting chains adjustment 15 18 Verification of the overload detection setting 15 19 Verification of the tilt alarm setting Models 8 ALG Toucan
34. D CONDITIONS WHERE THE PLATFORM WILL TRAVEL DURING OPERATION ENSURE THAT LOAD ON PLATFORM IS SECURE AND EVENLY DISTRIBUTED OPERATE THE WORK PLATFORM ONLY ON FIRMLEVEL SURFACES DO NOT POSITION THE PLATFORM NEAR HOLES OR DROP OFFS DO NOT DRIVE THE PLATFORM INTO HOLES CURBS OR OTHER OBSTACLES ON THE GROUND DO NOT OPERATE THE PLATFORM IF WIND SPEEDS EXCEED THOSE INDICATED IN THE TECHNICAL CHARACTERISTICS Be aware of all conditions that could adversely affect the stability of the work platform Death or serious A DANGER injury could result from the machine tipping over and certain precautions must be taken to avoid such Tue I or Ane possibilities counterweight Substitute this battery for a lighter or heavier battery will cause the machine to tip over Models 16 ALG Toucan 1100 Revision 04 2006 3 SAFETY PRECAUTIONS 3 To preventaccidents while travelling on slopes the platform MUST be fully lowered the drive speed MUST be in second gear and the counterweight MUST always be on the uphill side of the slope PRIOR to any operation you must inspect the ENTIRE work sit
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36. N A FIRM FOOTING ON PLATFORM FLOOR AT ALL TIMES IT IS RECOMMENDED TO WEAR A SAFETY HARNESS You must take every precaution to ensure you do not fall from the platform Falling from any elevation could result in serious injury or death Do not operate the work platform unless the platform railing isin place and secure and all gates or openings are closed While occupying the platform maintain A FIRM FOOTING on the floor of the platform at all times DO NOT LEAN OVER OR SIT ON THE PLATFORM RAILING NEVER CLIMB ONTO THE PLATFORM RAILING OR ONTO ANY OBJECTS ON THE PLATFORM FLOOR TO ATTAIN ADDITIONAL WORKING HEIGHT Ma Keep the platform clean and remove debris from shoes before entering the platform Dirt debris liquids and ice on the platform or access steps could cause a slipping accident Never exit or enter the platform by any other means than the access system provided and when the platform is fully lowered Models Toucan 1100 Revision 04 2006 3 SAFETY PRECAUTIONS 3 3 4 Crushing hazard CRUSHING HAZARD DEATH ORSERIOUS INJURY COULD RESULT FROM CRUSHING OROTHER EXTERNAL CONTACTS AVOID ALL CONTACT WITH OBJECT EXTERNAL TO PLATFORM BEAWARE OF SURROUNDINGS AT ALL TIMES WHILE DRIVING THE MACHINE OR ELEVATINGTHEPLATFORM DONOT POSITION PLATFORM INTO OVERHEAD OBSTRUCTIONS DONOT DRIVE THEPLATFORM IF INTO CONTACTWITH EXTERNAL OBSTACLE DONOTLOWERPLATFORM ONTO OBSTRUCTIONS BELOW Alwa
37. NOD ON AOLXZ ONO MOL LHOIT ONDINOM NOUdO ONINO Wad lt lt gt AMBLIVE gt m aa fae oe np 1 T tes 7 T w 6 6 c 1 ms BINS i mE ZL 1 1 1 pcc OD eo i AOZZ MOL 1 1 T uy S9 0v lt ME o Alins ANYA aa 1 3 MNFONVHI SIvT34 NOlldO M3ONVHD M3NOd HOLIMS AVIS Wey 3NIVH2 30 NOW i 09 244 NOWdO AVTIH N393NHO as HOLMS XIVS S pe E S 1 1 MT Y pz or PU ari le sl ie a PE u i K 4 i 5 i 5 l WHOLLY l NS oS 5 vel g 661 Hi be 8 6 Eel mc i Se a ee a ee ees eae 7 4 1 9 yor 4 l vO 36504 1 1 x eta os SS cp Is iniri E eS See eee Si x 1 1 P atarsna 96 yO 3S04 1 m a H 4 9 4 rer ee EM 1 b qisna 56 66 166 3504 i Z z i i 4 X e gt lt SN 9 gt vs 3181514 yso
38. OCEDURE ORPRACTICE IS NOT FOLLOWED EXACTLY EQUIPMENT DAMAGE MAY RESULT NOTE A note is used to emphasize an important procedure or condition Models ALG Toucan 1100 Revision 04 2006 TABLE OF CONTENT INTRODUCTION 1 GENERAL DESCRIPTION 2 2 1 General description 2 2 Dimensions and range diagrammes 2 2 1 Toucan 1100 A 2 2 2 Toucan 1100 B and Toucan 1100 C SAFETY PRECAUTIONS 3 3 1 General 3 1 1 Operator sinformations 3 1 2 Operator squalification 3 1 3 Work practice 3 2 Machine stability 3 3 Falling hazard 3 4 Crushing hazard 3 5 Electrical power sources 3 6 Maintenance WORK PLATFORM CONTROLS 4 4 1 Platform controls 4 2 Emergency and breakdown controls 4 3 Breakdown 4 3 1 Safety devices and alarms 4 3 1 1 Motion alarm 4 3 2 2 Tiltalarm 4 3 1 3 Overload detection 4 3 1 4 Chain slack detection OPERATING PROCEDURES 5 5 1 Pre starting checks Models Revision 04 2006 5 1 1 Batteries 5 1 2 Hydraulic reservoir andfilter 5 1 3 Tilt alarm 5 1 4 Overloaddetection 5 1 5 Chain slack detection 5 1 6 Mast sensor operation test 5 1 7 Jib sensor operation test 5 1 8 Wheels 5 1 9 Control operation 5 2 Work platform operating tips Toucan 1100 5 2 1 Starting procedure 5 2 2 Shutdown procedure 5 2 3 Emergency stop 5 2 4 Operation from the platform 5 2 5 Operation from the ground emergency and breakdown 5 2
39. Tel 44 0 1698 811005 Tel 717 485 5161 Fax 717 485 6573 Fax 44 0 1698 811055 Email ProductSafety JLG com Email ProductSafety JLG com DISTRIBUTOR S STAMP Models Revision 04 2006 Toucan 1100 FOREWORD This handbook has been compiled to assist you in properly operating and maintaining your Self Propelled Work Platform Before placingthe work platform in service take time to thoroughly familiarize yourself with the content of this manual After all sections have been read and understood retain this manual in the manual box provided tothis effect for future reference The work platform has been designed for maximum performance with minimum maintenance With proper care years of trouble free service can be expected Constant improvementand engineering progress make it necessary that we reserve the right to make specification and equipment changes without notice Routine maintenance procedures are supplied atthe end of this handbook and can be consulted for more detailed information Information in this manual does not replace Community state or local regulations safety codes or insurance requirements Thedefinitions of DANGER CAUTION and NOTE as used in this manual apply as follows A DANGER IS USED TO EMPHASIZE THAT IF AN OPERATION PROCEDURE ORPRACTICE IS NOT FOLLOWED EXACTLY DEATH OR SERIOUS INJURY TO PERSONNEL MAY RESULT ACAUTIONIS USED TO EMPHASIZE THAT IF AN OPERATION PR
40. Telescope Tunrtable Lifting chains owing bearing race moOU Models 64 ALG Toucan 1100 Revision 04 2006 16 Example of a log book EXAMPLE OF A LOG BOOK 16 Verification interval WEEKLY 14 15 20 21 22 23 24 OPERATIONS TO BE DONE Verification interval MONTHLY Date Absence of hydraulic leaks check Mechanical check Electrolyte density measure per battery cell Electrical motor cleaning Battery tray cleaning OPERATIONS TO BE DONE Date Verification interval BI YEARLY Swing ring lubrication Safety mechanisms check Check of motor brushes Lift cylinder check Hydraulic circuit general pressure check Check of electrical safety devices Verification intervals 18 MONTHS OPERATIONS TO BE DONE Date Hydraulic circuit oil change Oil filter cartridge change VISA Models Revision 04 2006 Toucan 1100 16 EXAMPLE OF A LOG BOOK 16 Example of a log book Cont d Verification interval WEEKLY 37 38 39 40 41 42 43 44 45 46 47 48 49 50 34 35 36 Verification interval MONTHLY 25 26 27 28 29 30 31 32 33 co 10 11 Verification interval BI YEARLY Verification interval 18 MONTHS
41. a long period of time you must recharge the battery and check the electrolyte level in the cells 55 15 15 15 12 Battery troubleshooting Serious accidents resulting in complete destruction of a traction battery are relatively rare If small problems encountered on a battery in use are rapidly and correctly determined battery life and operation can be improved PREVENTION AUTONOMY ANDLONGLIFE Symptoms Probable causes 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 45 Battery incapable of supporting regular operation Filing done before the charge Cells overfilled Overcharge Filing 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 I Fill battery cells after the charge Perform an equalization charge Contact your JLG Distributor Product Refer to electrolyte specific gravity too technician Open access doors
42. act with other external obstacles Be aware at all times of your surroundings while elevating and clear all personnel and obstacles from the platform while lowering the mast and or jib Do not position platform into overhead obstructions and do not lower the platform onto obstructions below Do not operate the machine in an atmosphere presenting risks of explosion volatile gazes fine dust etc To activate a function Depress the foot switch to enable controls Activate slowly the control lever corresponding to the desired function To stop a function Slowly return the control lever to neutral Release the enable pedal 5 2 5 Operation from the ground emergency and breakdown NOTE When the platform is occupied use of the lower controls is restricted to emergency cases NOTE The emergency and breakdown controls should be checked every day prior to work platform operation Operate the ground controls only if the platform is unoccupied or if the occupant is unable to use the upper controls Failure to do so may result in death or serious injury JLG Use extreme caution when operating the work platform from the ground controls If possible obtain permission from the operator in the platform before using the ground controls Death or serious injury could result from being crushed or from contact with other external obstacles Be aware at all times of your surroundings while elevatin
43. ant must be applied 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 refer to S lubrication 15 17 Lifting chains adjustment The lifting chains of a same stage must have an identical tension The chains must always be tensioned so that the mast sections are slightly offset towards the top 4to6 mm 4to6mm A to 6 mm 4 to 6 mm S JL 5o 15 15 15 18 of the detection setting 1 Place a X kg load evenly distributed on the platform floor 2 Position the Ground controls Platform controls selector switch to Platform controls Ensure the lower emergency stop is not activated 3 Apply a slight pressure F1 on the platform An acoustic alarm sounds The corresponding LED lights up Every function is disabled from the platform controls 4 Position the Ground controls Platform controls selector switch to Ground controls An acoustic alarm sounds AEvery function is disabled from the ground controls 5 Apply aslighttraction force F2 onthe platform The acoustic alarm stops PC 1 2 N 1 M 1 1 d 25 1 N 1 x Ny
44. assist NOT direct the operation Warning devices can be mechanical electrical or electronic or a combination thereof There are subject to failure or misuse You the operator are the only one whocan be relied upon to assure the safety of yourself and those around you Bea PROFESSIONAL and follow the RULES of safety Remember failure to follow just one safety precaution can cause that accidentto people and equipment You are responsible for the safety of yourself and those around you IMMEDIATELY report all accidents malfunctions and equipment damage to your employer and the local authorised JLG distributor Following any accident or damage to equipment the JLG distributor must be immediately advised of the incident and consulted on necessary inspections and repairs Should the distributor not be immediately available contact should be made directly with JLG Product Support The work platform must not be returned to service until it is thoroughly inspected for any evidence of damage and all damaged parts are repaired or replaced 3 1 1 Operator s information You must READ and UNDERSTAND the Operator s and Safety Handbook before operating the work platform This manual must be readily available at all times and remain with the work platform in the manual box provided to this effect Ensure that all personnel occupying the platform and also ground personnel are thoroughly familiar with safe operating practices Yo
45. conditions and operating and storage environments of the work platform temperature dusty atmosphere corrosive atmosphere humidity Check oil levels and perform lubrication only when the work platform is parked on a level surface in the transport position and while the oil is at ambient temperature unless otherwise specified All grease fittings are SAE STANDARD unless otherwise indicated Grease non sealed fittings until grease extrudes from the fitting Excessive lubrication on non sealed fittings will not harm the fittings or components but too little lubrication can lead to shorter component life Grease fittings that are worn and will not hold the grease gun or those that have a stuck check ball must be replaced JLG The following chart titted Lubrication Chart describes lubrication points and gives the lube type lube interval lube amount and application of each Use the following lubrication intervals as a guideline only Formulate actual lubrication intervals to correspond to conditions such as continuous operating cycles and or hazardous environments Unless otherwise indicated items not described Such as linkages pins levers etc should be lubricated Motor or hydraulic oil applied sparingly will provide the necessary lubrication and help prevent the forma tion of rust An anti seize compound may be used if rust has not formed If rust or corrosion is present the component must be thoro
46. e dL 53 15 15 15 8 Electrolyte specific gravity and battery voltage Specific gravity and voltage measures are the most important checks to be performed on a battery A hydrometer is supplied with the work platform Specific gravity and voltage readings must be performed at least once a month and recorded ina battery service log The state of charge of the battery can be checked by measuring the specific gravity of the electrolyte This value decreases as the battery discharges When the battery is fully charged the specific gravity is 1 280 kg l When the battery is 80 discharged the specific gravity is 1 150 kg I The following chart shows the correspondence between specific gravity and battery discharge Electrolyte specific gravity Discharge depth in Checking electrolyte specific gravity 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 During maintenance or any servicing operation on the battery rings watches or any other jewellery must be removed MLE NOTE Specific gravity measure must not be performed after battery cells have been filled 1 Open the batte
47. e and all ground conditions for bumps holes drop offs obstructions and personnel where the work platform will travel during operation Ensure that the surfaces where the machine will travel in elevated position are horizontal and will support aload greater thatthe work platform s weight Check the tilt alarm for proper functioning Models Revision 04 2006 Toucan 1100 Operate the work platform only on firm level surfaces Do not position the work platform near holes or drop offs Never drive the machine into holes curbs or other obstacles on the ground Before drivingthe work platform the operator must be thoroughly familiar with the machine s driving steering and stopping characteristics Avoid sudden starts and stops which can produce motion swaying and an increased loading effect Reduce operating speed whenin close quarters Never apply excessiveforce to the work platform controls NEVER EXCEED THE PLATFORM S RATED CAPACITY printed on the capacity plate on the machine and ensure that any load on the platform is secure and evenly distributed Neveroperate the work platform if wind speeds exceed those indicated in the technical characteristics 17 3 SAFETY PRECAUTIONS 3 3 3 Falling hazard DANGER ACXOOOOOOO XX XN FALLING HAZARD DEATH OR SERIOUS INJURY COULD RESULT FROM FALLING OUT OF PLATFORM DONOT OPERATE PLATFORM UNLESS ALL PLATFORM RAILING IS INPLACE AND SECURE MAINTAI
48. e brushes Brushes installation 1 Lift the spiral spring and install the brushes 2 Install the brushes connection screws 3 Install the protection covers MLE 15 15 Steenng bracket thrust washers Check thickness of thrust washers on both steering brackets Replace the washers if their thickness is below 2 5 mm Refer to Service Manual for further information 2 5mm mini 15 16 Chain control and lubnc aton The service life of a lifting chain depends on the work platform operating conditions and on the environment in which the machine is used or stored Service life is reduced if the chains are exposed to significant temperature fluctuations acid or corrosive products or vapours or abrasive dust cation Due to the high resistance level of their components chains can be weakened through contact with a corrosive product 15 16 1 Control of chain wear Inspect thorougly each chain in turn over its entire length AChains chain yokes clevis pins and split pins must not be corroded APlate must not be cracked cracked plate AThe plate clevis pins must not present excessive play The pins must not be turned in their housing 1 CIC IES Models Revision 04 2006 Toucan 1100 15 15 APlates must not present a wear above 5 of the total height refer to chart below Pitch 5 8 15 875 mm 3 4
49. ed to reach the charging station after the battery discharge indicator has cut the electrical supply d Battery discharge indicator hour meter 0 1 2 1 7 RS s IL i Thebarislitwhenthe battery is charged correctly As the battery discharges the bars light up in succession from top to bottom one after theother 5 green bars followed by 3 orange bars The barflashes when the battery is 7096 discharged At this point the bottom 2 bars red flash in alternance the electrical power is cut off indicating that the battery is 80 discharged and that it must be recharged Models Revision 04 2006 Toucan 1100 WORK PLATFORM CONTROLS 4 e Indicator showing an excessive tilt or a chain slack refer to 4 3 1 2 and 4 3 1 4 Fig 4 4 Enable pedal 25 4 2 Emergency and breakdown contol panel It is possible to operate the work platform from the ground controls with the exception of the drive and steering functions The ground controls are located on the left hand side of the machine They are used to operate the emergency and breakdown functions Fig 4 5 Hand pump a Hand pump Fig 4 5 Insert the pump handle inthe hand pump activate the pump handle to supply the necessary power while activating the control lever corresponding to the desired function Fig 4 6 Control levers
50. ems Mast lifting chains lubrication refer to 815 21 Batteries electrolyte specific gravity refer to 815 8 Lubrication refer to 815 21 Models Revision 04 2006 Toucan 1100 15 20 4 Preventive maintenance and inspection every 125 hours of operation Preventive maintenance inspections should include checking the following items Oylinders leakage rod holding valve Condition of lifting chains refer to 15 16 Condition of the batteries refer to 815 6 to 15 9 Check the wheel nut torque refer to the Service manual Overload sensor setting refer to 15 18 Tilt indicator setting refer to 815 19 Motor brushes of main hydraulic group refer to 15 14 Motor ventilation holes cleaning refer to 15 14 Steering brakets thrust washers refer to 15 15 Condition of bushes on jib and steering system Lubrication refer to 815 21 15 20 5 Preventive maintenance and inspection every 250 hours of operation Preventive maintenance inspections should include checking the following items Hydraulic filter replacement refer to 815 13 Motor brushes of main hydraulic group refer to 815 14 Turntable bearing greasing Lubrication refer to 815 21 15 20 6 Preventive maintenance and inspection every 500 hours of operation Preventive maintenance inspection should include checking the following items and must be performed by a technician approved by JLG
51. ergency stop switches are not activated On the upper control panel An accoustic alarm sounds The corresponding red indicator lights up functions are working normally dL 29 5 OPERATING PROCEDURES 5 5 1 4 Overload detector You must test the overload detection system each day by activating the sensor with a screwdriver Each month you must check the overload detection setting with an overload test Refer to S 15 Fig 5 8 Overload detection test 5 1 5 Chain slack detector NOTE This safety device is operational when the work platform is controlled from the upper control panel or from the ground control panel 1 Position a wedge between the sensor and the actuator to keep the sensor activated wedge supplied Ref 572053 2 Position the ignition key to I Ensure that the emergency stop switches are notactivated On the upper control panel An accoustic alarm sounds The red indicator lights up functions are disabled 3 Repeat stages 1 to 2 for each chain slack sensor 7 ME 5 1 6 Mast sensor operation test Verification of the mast sensor s good working order is essential to ensure safe operation of the work platform when driving in elevated position A malfunction of this sensor can lead to a serious or lethal accident 1 Position the ignition key to I 2 Ensure the emergency stop switch
52. es after 1 minute of charge Support Problem with the charger or battery too discharged Switch the charger off disconnect Voltage still below 2 05 V per cell 24 6 V the charger from the battery wait for approx 15 for batteries after 1 hour of charge mn Reconnect the charger to the battery and switch the charger on If the problem persists the charger is faulty LOH Voltage still below 2 4 V per cell after 9 hours of charge Battery too discharged Switch the off disconnect the charger from the battery wait for approx 15 mn Reconnect the charger to the LHHS Charging safety time exceeded battery and switch the charger on Charge interruption due to a power cut LUAC Charge will be resumed as soon as power supply power returns Charge interruption due to a power cut or Check the circuit breaker on the display screen LILO circuit breaker default Charge will befis in good working order resumed as soon as the power returns Check power supply Models 50 ALG Toucan 1100 Revision 04 2006 8 B HAWKER models Display panel a Charge indicator green b Final charge indicator yellow c Battery indicator charge completed green d Fault indicator rouge e Circuit breaker Battery charge Connect the charger plug to the power supply Once the charger is connected all the leds begin to flash for a short period of time
53. es are not actuated Enterthe platform and close the gate Raise the mast by approximately 1 50 m Perform each movement one by one in both directions The work platform travels at slow speed 6 Return the mast to its retracted position 5 1 7 Jib sensor operation test Verification of the jib sensor s good working order is essential to ensure safe operation of the work platform when driving in elevated position A malfunction of this sensor can lead to a serious or lethal accident 1 Position the ignition key to I 2 Ensure the emergency stop switches are not actuated Enterthe platform and close the gate Raise the jib by approximately 1 50 m Perform each movement one by one in both directions The work platform travels at slow speed 6 Return the jib to its retracted position 5 1 8 Wheels 1 Check for severe cuts and foreign objects imbedded in the threads 2 Ensure the wheels nuts and bolts are tight 3 Ensure the locking pins are in place driving wheel shaft 5 1 9 Control operation 1 Verify the good working order of the upper control box 2 Verify the good working order of the emergency and breakdown control panel Models Toucan 1100 Revision 04 2006 5 OPERATING PROCEDURES 5 1 Push f the EMERGENCY STOP 5 2 Work platform operating tps ird 2 Eliminate the problem 1 The rated capacity of the machine includes the 3 P
54. f the charger remains connected to the battery for more than 9 hours after the charge is completed the charger will charge automatically for 15 mn The compensation charge will be renewed automatically every 9 hours Interruption of the charge cycle A charge cycle should not be interrupted However should it be necessary to stop the charge cycle at any time the STOP switch must be depressed The charge starts where it had stopped if the STOP switch is pressed again Fault indicator Thefaultindicator lights up when a fault inthe charger has been detected If a fault occurs during charge switch off the charger and disconnect it from AC outlet 43 15 15 Protections oingle pole thermal circuit breaker 20 A Output fuse 100A P N 950105 AC auxiliaries 2 P N 950150 Adaptation to network voltage DANGER Prior to any operation requiring charger cover removal the battery must be disconnected and the charger must be unplugged from the AC outlet Failure to do so could result in death or serious injury to personnel Transformer terminal block Auto transformer Connections on auto transformer and transformer inlet terminals block 220 VAC 50 Hz Transformer terminal block Auto transformer Pre insulated terminal 110 VAC 60 Hz Transformer terminal block Auto transformer A O Pre insulated terminal Troubleshooting The de
55. fault LED indicator lights PROBABLE CAUSE SOLUTION Depress the equalising function button to resume charge The default LED indicator flashes Voltage above 3V per cell 36V for batteries corroded plates Voltage below 1 8V per cell 21 6V for batteries after 5 minutes of charge Note If the voltage is below 1 5V per cell 18V for batteries the charger will not detect the battery Depress the equalizing function button to resume charge The default LED indicator flashes o 9 o ac Voltage does not reach 2 4V 28 8V for batteries per u cell after 11 hours of charge Soft timer 1 Check condition of battery connections and charger Disconnect the charger from the battery and reconnect it If the problem persists contact LG Product Support Charging time exceeds 15 hours Voltage above 2 4V per cell Soft timer 72 Charging time exceeds 16 hours Hard timer Models 44 1100 Revision 04 2006 15 15 15 3 2 Fulmen electronic charger Display panel a Circuitbreaker b Display c Equalisationfunction button d 100 charged LED indicator e Charger ON LED indicator f 80 charged LED indicator ON OFF button Battery charge Power supply 220 or 110VAC 2 poles earth monophase Connect the charger s plug to the power supply After a few seconds the electronic card verifies the system
56. g and clear all personnel and obstacles from the platform be lowering the mast and or jib Do not position platform into overhead obstructions and do not lower the platform onto obstructions below To lower the platform from the ground controls with the hand pump refer to paragraph 4 2 1 Push on the emergency stop switch 2 Insert the pump handle in the hand pump 3 Hold the control lever corresponding to the desired function 4 Activate the hand pump with the handle 5 2 6 Operation on non level ground The work platforms are designed and manufactured to be operated exclusively on firm and level surfaces Nevertheless the work platform can be driven in stowed position on a sloped surface not exceeding 10 and following the conditions set out below Failure to comply with the following recommendations could result in death or serious injury To prevent accidents while travelling on a slope the platform MUST be fully lowered the drive speed must be in second gear and the counterweight MUST always be on the uphill side of the slope NOTE To drive the work platform on a slope the battery discharge must not exceed 50 NOTE In cold weathers the hydraulic fluid is thicker Warm up the hydraulic fluid before attempting to drive on a slope Models Toucan 1100 Revision 04 2006 6 TRANSPORT INSTRUCTIONS 6 The release valves enable the machine to be towed without damaging the drive train They are l
57. ge c Endof charge LED indicator orange d Stop switch e Equalisation function button green Battery charge Power supply 220 or 110VAC 2 poles earth monophase Connect the charger s plug to the power supply The charger stops automatically at the end of the charge cycle The Normal charge indicator Rep b goes off the charge completed indicator Rep c lights up NOTE No indicator lights are on as long as the battery is not connected to the charger even if the charger is connected to the power supply Models Revision 04 2006 Toucan 1100 Equalisation charge Theequalisation charge to be performed periodically enablesthe electrolyte specific gravity between the battery cells to be equalised It follows the normal charge if ithas been programmed during the charge by pressing the equalisation charge preselection button The corresponding indicator lights up When the charger switches to equalisation charge the normal charge indicator light goes off Tocancel the preselection equalisation press at the same time on the STOP The equalisation charge preselection light goes off After 12 hours the charger stops and the equalisation charge light stays on NOTE The equalisation charge can also follow a normal charge after the charger has stopped Press on the equalisation charge selection switch the charger starts again Compensation charge I
58. inspections and maintenance specified by the manufacturer and government agencies Allow only authorized service and repairs to be performed on this machine Do not modify substitute parts or change any hydraulic electrical or operators aid setting without obtaining written approval from JLG Do notremove any decal or the Operator s and Safety Handbook from this machine NEVER operate a damaged or poorly maintained work platform Before work platform use Conduct a visual inspection for cracked welds leaks damaged controls or cables and loose wire connections Any item or component that is found to be damaged broken leaking cracked worn etc must be repaired or replaced Inspect tyres for nicks cuts imbedded stones and abnormal wear Ensure all bolts and lug nuts are properly torqued Keep the work platform clean at all times free from mud dirt and grease Dirty equipment wears out faster and makes good maintenance difficult Cleaning solutions used should be appropriate for thejob and nonflammable Avoid spraying cleaning solutions directly onto electrical components Do not clean electrical components boxes motor controller etc with a high pressure cleaner Failure to respect this precaution can result in serious damages to components Models Toucan 1100 Revision 04 2006 3 SAFETY PRECAUTIONS 3 ROUTINE MAINTENANCE and INSPECTION of this work platform mustbe performed b
59. ir Avoid fluffy rags If necessary blow the reservoir with compressed air Models Revision 04 2006 Toucan 1100 a Oil level indicator b Breather cap c Funnel d Clogging indicator e Oil filter f Draining plug 6 Clean and install the draining plug on the reservoir and replace the oil filter T Fill the reservoir with new hydraulic oil to the level shown on the oil level indicator 8 Actuate the enable pedal for a few minutes to bleed the air from the hydraulic circuit 9 Add hydraulic oil if necessary without exceeding the maximum level on the oil level indicator Reservoir capacity is 14 liters Circuit capacity is 30 liters 10 Install the breather cap 11 Check the machine for proper functioning and any leakage 57 15 15 15 14 Main hydraulic group motor Main hydraulic group motor brushes Qty 4 have to be regularily checked Motor ventilation holes have to be regularly cleaned by blowing compressed air through the holes as indicated below Areas to blow air through Cover m ud Brush Brushes removal 1 Disconnect the battery plug 2 Remove the covers from the motor 3 Remove brushes connection screws 4 Lift the spiral springs and remove the brushes from their housing carton If the length of one of the brushes is below 10 mm all 4 brushes must be replaced During removal installation do not interchange or reverse th
60. kes good maintenance difficult Cleaning solutions used should be appropriate for the job and nonflammable Avoid spraying cleaning solutions directly onto electrical components Models Revision 04 2006 Toucan 1100 Do not clean electrical components boxes motor controller etc with a high pressure cleaner Failure to respect this precaution can result in serious damages to components 15 3 Chargers The work platform on board electronic charger is designed to automatically charge 24 VDC wet lead acid rechargeable batteries Several types of chargers can be fitted onthe machine depending on the capacity of the battery Charge batteries only in an open well ventilated area free of flame smoking spark and fire Ensure you conform to all particular regulations in force DANGER 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 well ventilated area DANGER 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 gra
61. lashes quickly T 0 2 sec the led can be or off depending on the state of charge of the battery and on the charger s operation at that moment 51 15 15 15 4 Battery The electrical energy of the work platform is provided by a 24 VDC battery The battery is composed of 12 battery cells DANGER The batteries are integral part of the machine s counterweight Substitute the batteries for lighter or heavier ones will affect work platform stability and will cause the machine to tip over New traction batteries do not have their full capacity until they have been cycled several times somewhere between 5 and 40 cycles For at least the first five cycles it is recommended not to discharge the battery above 70 of its capacity To obtain the maximum battery life do not discharge the battery above 80 of its capacity DANGER Before performing any maintenance on the machine the batteries and the charger plug must be disconnected Do not disconnect the positive battery clamp first Disconnect the grounded battery clamp firstwhen removing a battery and connectitlast when installing a battery Do not short across the battery posts to check charge Spark or flame could cause battery explosion AMLE 15 5 Centralised filing system 15 5 1 Electrolyte level Verify the electrolyte level after the charge using the floats in the center of each filling cap
62. lectrical power supply in the platform A differential circuit breaker located on the lower part of the machine protects the circuits If the circuit breaker trips the reason must be found and the problem corrected before resetting the circuit breaker Fig 8 2 220V electrical power socket and circuit breaker Fig 8 1 Extinguisher location Models Revision 04 2006 Toucan 1100 39 15 40 General This section contains information on daily checks weekly maintenance servicing based on operating time as well as inspection required on JLG aerial work platforms NOTE This material does not replace any pre operational checks required by the owner or a local or state safety board NOTE Community regulations require that written dated and signed inspection records are maintained NOTE Perform lubrication as outlined in this Operator s Safety and Maintenance Handbook or in the machine specific Service Manual ALG Toucan 1100 15 Models Revision 04 2006 15 15 15 1 System malfunctions When analyzing a system malfunction use a systematic procedure to locate and correct problems Determine the problem List the possible causes Devise checks Conduct checks in a logical order to determine the cause Consider remaining service life of components against the cost of parts and labour necessary to replace them
63. led lights up and the charge begins At the end of the charge LEDs come off Indication Lon A appears during 8 mn The LED flashes and the display visualizes the last memorized values Compensation charge It takes place at the end of the charge cycle This compensation charge occurs 5 mn hour for 48 hours The led nm lights up The led ex lights up at the end of the charge Interruption of the charge cycle A charge cycle should not be interrupted However should it be necessary to stop the charge cycle at any time the ON OFF switch must be depressed Fault signalling If a problem occurs the charger stops The LED lights up and the screen displays an error code Refer to the trouble shooting chart hereafter Models Revision 04 2006 Toucan 1100 Display screen Charging supply Ux xx Voltage per element or Cxxx Ah reinjected into the battery 999 Ah Cxxx gt 999Ah Hxx x Charging time from the begining of the charge hour and tenth L000 O K ULO Voltage below 1 65V cell L205 Voltage below 2 05V cell after 30 mm of charge L09H Voltage below 2 4V cell after 9 H of charge LILO Supply 0 LUAC No supply voltage charging horameterhas stopped LHHS oafety time 9 12 14 or 16 hours depending on the chargertype ForC Forced cut by the push button OFFS Periodic mail of control dL 49 15
64. ly Ihe absence of abslacles on Ihe route of Ihe work plalfarm during Manoeuvres USE Energize by turning the contact key on the lower contro box to position I Remove the contact key In case of overload an alarm will sound and all movements will be stopped The platform must then be partially unloaded After use cut the power off from the machine position 0 and emove the contact key EMERGENCY AND BREAKDOWN CONTROLS Press on the emergency stop switch Give instructions to the operator on the ground for breakdown Activate and hold the selected lever in the direction of the desired movement Activate the hand pump with the pump handle CHAIN SLACK SECURITY LED Ask the ground personnel clear the machine from the obstacle using the breakdown control pans until the indicator ligth switches cff Strictly follow the procedure descr bed in the manual in case of the mast jamming DO NOT USE THE MACHINE f you are not authorized If the safety devices have been neutralized or if their settings have been changed In close proximity to electrical power lines or equipment lf wind speed exceeds 8 am s 30 Km h If solid ar openwork panels have been added on the machine or the platform AUT1374 Fig 4 9 Use and safety instructions 4 3 Breakdown In case of a breakdown Ground personnel must obtain authorization from the operator before performing a manoeuvre In the case
65. ly disengaged Replace the handle in its holder Use a winch to pull the machine f a winch is not available use another low speed towing device For towing use the towing ring located at the front of the machine e The machine can also be pushed by two persons Fig 6 1 Towing ring 33 6 TRANSPORT INSTRUCTIONS 6 6 2 Loading unloading 6 2 1 Using a fork lift truck Fig 6 2 Release valves a Wheel motors release valve b Brake cylinderrelease valve e Reset the automatic brake and the wheel motors FORKS INSERT Returnthe valve leversto normal use Activate the enable pedal he machine is operational CONTROL VALVES MOTORS RELEASED CYLINDERS Fig 6 4 Positioning of the forks RELEASED of the fork lift truck Verify the capacity of the fork lift truck and of its equipment 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 Fig 6 3 Release valve decal Do not remain in the evolution zone of the forklift truck during the manoeuvre OPERATING PROCEDURES TOWING POSITION THE VALVES TO RELEASED INSERT THE PUMP HANDLE INTO THEHAND PUMP ACTIVATE THE HAND PUMP THE CYLINDERS ARE FULLY RETRACTED THE MACHINE
66. n the gas emission voltage has been reached the yellow led Gaz lights up the 2nd charge regime starts Its duration will be proportional to the time spent to reach the gaz point At the end of the charging process the green LED DISPO will light up Interruption of the charge cycle A charge cycle should not be interrupted However should it be necessary to stop the charge cycle at any time the ON OFF switch must be depressed the OFF LED switches itself off ALG Fault indicator If a problem occurs the charger stops The LED lights up and the leds e flash refer to the Troubleshooting chart hereafter Power cut In case of a power cut the charging process will be temporarily interrupted and the DEFAUT LED will flash The charging process will be resumed as soon as the power returns Models Toucan 1100 Revision 04 2006 15 15 B HP Ill model Display panel am C e a Charger ONLED indicator green b Secondcharging rate LED indicator yellow c Compensation charge LED indicator green d Endofcharge LED indicator yellow flashing e FaultLED indicator red f ON OFF switch g Circuit breaker h Display screen Battery charge Power supply 220 or 110VAC 2 poles earth monophase Connect the charger plug to an electrical power supply Each led will light up for a lighting test The
67. nd 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 Models Revision 04 2006 Toucan 1100 15 7 Cleaning Battery maintenance It is necessary to clean the battery regularly to prevent salt formation and current arcing which could damage the machine Clean battery top with a damp cloth Allow to dry and wipe the battery top with a dry non fluffy rag Ensure connections are clean and tight NOTE Coat the terminals and connections with anti corrosion compound or grease 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 centralised filling circuit battery cleaning 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 does occur flush the contacted area with water and consult a doctor immediately Appropriate equipement must be worn gloves goggles rubber apron to prevent the drained water from contacting the skin or any part of the body NOTE The water that contacted a battery is classified as industrial waste it must be disposed of according to regulations in forc
68. ns and capabilities Do not operate this machine unless you are qualified by training experience in the safe operation of this machine Training includes complete knowledge of your employer s work rules the operator s and safety handbook and all governmental regulations relative to this machine An untrained operator subjects himself and others to death or serious injury 3 1 3 Work practice Job preparation You mustinspect the work platform priorto your work shift checking for cracked welds other damaged components You must ensure that the work platform is fully and properly equipped including plaform railing access steps covers gates guards and controls You must also check that this manual is inits box and the good condition of the decals on the machine Wear properclothing and personal protective equipment as required by local job regulations It is recommended to wear a safety harness Two harness attachment rings are fitted on the work platform Before entering the platform you must be THOROUGHLY familiar with the planned route of travel andareaof operation including surface conditions i e debris drop offs holes etc and the presence of overhead obstructions and power lines Be familiar with the location and use ofthe nearestfire extinguisher Always keep the platform clean free of dirt debris and grease Anyone entering the platform mustfirst clean his shoes Do not store flammable materials
69. ocated at the front of the machine Toucan 1100A C 3500 Kg Toucan 1100 B 3540 Kg Ifthe machine gets stuck in mud or otherwise becomes bogged down use an appropriate tractor to pull it out Never try to drive the machine out of such asituation underits own power Such an attempt may result in major damage to the drive axle The machine should only be towed for extremely short distances and at a speed not exceeding 2km h Towing at high speeds or over long distances may result in major damage to the drive train Use the towing ring on the chassis provided for this purpose NOTE Before towing the machine the brakes and wheel motors must be released by means of the release valves located at the front of the machine Ensure the machine is on firm and level ground before releasing the brakes and wheel motors Failure to observe the operating instructions may result in death or serious injury Uri te Never leave the machine unattended Models Revision 04 2006 Toucan 1100 The machine must always be in stowed position during towing procedure DANGER No personnel is allowed on the platform during towing procedure Procedure to follow Disengage the parking brake and release the wheel motors Bring the valve levers to position release at the front of the machine Insert the pump handle in the hand pump Activate the hand pump until the brake cylinders are ful
70. operation Models Revision 04 2006 Toucan 1100 35 6 TRANSPORT INSTRUCTIONS 6 6 2 5 Lifting the machine N CAUTION Verify the capacity of the equipment used to lift the machine DANGER Do not remain near the machine during manoeuvre Fig 6 7 Lifting rings Lifting Use the rings against the mast Fastening Use the hooks Models 36 ALG Toucan 1100 Revision 04 2006 N S3S0H S3 18IX314 Sddld lxx S3di9iH XNVANL p NOILVISNVYL 30 SYHNALOW SYOLOW SANG 39V 31 SNISIVM ED ED jo ai I L LI i L N I N a I w i NIJH4 A HYDRAULIC SCHEMATIC FL 0151 01 Ref
71. ports 4 Perform afunction check of operating controls to ensure proper operation Load test must be performed when a structural or lifting memberis involvedinrepair Models Revision 04 2006 Toucan 1100 LUBRICATION The work platform must be lubricated according tothe factory recommendations for lubrication points time intervals andtypes Exercise care when servicing the hydraulic system of the work platform Pressurized hydraulicoil can cause serious injury Thefollowing precautions mustbe taken when servicing the hydraulic system 1 Follow the manufacturer s recommendations when adding oil to the system 2 Becertainalllines components and fittings are tight before resuming operation 3 When checking for suspected leaks place underneath a piece of cardboard or wood 4 Never modify the setting of a relief valve BATTERIES Before performing any maintenance on the machine the batteries and the charger plug must be disconnected Battery electrolyte must not be allowed to contact the skin or eyes If this does occur flush the affected area with water and consult a doctor immediately When checking and maintaining batteries follow the following proper procedures and precautions Do not short across the battery posts to check charge Spark or flame could cause battery explosion Check electrolyte levels in the battery by using the generally yellowfloats in the centre of each filler cap
72. quipment is only as safe AS THE PERSONAT THE CONTROLS With this thought in mind this information has been providedtoassist you the operator in promoting a safe working atmosphere for yourself and those around you Itisnotmeantto coverevery conceivable circumstance which could arise Itisintendedto present basic safety precautions that should be followed in daily operation If you have any questions on operating procedures work platform usage or any other applications contact your local authorized JLG distributor Definitions Work platform Elevating Work Platform A self propelled integral frame machine with a platform supported by a telescopic mast to position personnel along with their tools and materials at overhead work locations Platform The portion ofthe work platform intended to be occupied by personnel tools and materials Upper Control Box console in the platform containing operating controlsfor the work platform Emergency and Breakdown Panel ground level console containing the levers and hand pump enabling the platform manual lowering from the ground in emergency or breakdown cases Because you the operator arethe only part of the work platform that canthink and reason your responsibility is not lessened by the addition of warning devices or operational aids Infact you must guard against a false sense of security when using the machine Warning devices and operational aids are there to
73. re resuming the charge If the fault persists contact the J LG Product Support Models 46 ALG Toucan 1100 Revision 04 2006 15 15 15 3 3 Oldham Hawker electronic charger Adaptation to network voltage DANGER Prior to any operation requiring charger cover removal the battery must be disconnected and the charger must be unplugged from the AC outlet Failure to do so could result in death or serious injury to personnel Connections on transformer inlet terminals block 110 VAC 50 60 Hz 230 VAC 50 Hz Protections Single pole circuit breaker 32 A g on the display panel Output fuse 100A inside the charger NOTE A spare output fuse is strapped inside the charger cover Models Revision 04 2006 Toucan 1100 47 15 15 CP IV models Display panel Charger ONLED indicator green Second charging rate LED indicator yellow End of charge LED indicator green Default led indicator red Ah appliedtothe battery 4 LEDs from the right to the left 100 75 50 25 ON OFF switch g Circuit breaker h Battery charge Power supply 220 or 110VAC 2 poles earth monophase Connect the charger plug to a AC outlet socket Each LEDs will light up during a starting up test The green LED ON lights up and the charging process starts Whe
74. ries can cause damage to both the batteries and the electrical motor New batteries do not have the full capacity until approximately 30 cycles have been made Nevertheless to obtain maximum battery life do not discharge the battery below 80 of its capacity Check the state of charge of the battery ensure the cables and clamps are tight and not corroded For storage at temperatures below 0 C check electrolyte density to prevent freezing point refer to 15 Models Revision 04 2006 Toucan 1100 Battery charge Several types of chargers can be fitted on the machine depending on the capacity of the battery For further information refer to 15 5 1 2 Hydraulic reservoir and filter Check the level of hydraulic fluid in the reservoir with the machine in retracted position Check the clogging indicator with the machine warm If the needle is in the red zone when the motor 22 pump is functionning change the filter cartridge Ref 310013 5 1 3 Tilt sensor NOTE This safety device is operational when the work platform is controlled from the upper control panel or from the ground control panel when the platform has left its stowed position 1 Raise the mast and or jib in order to activate the mast and or jib sensors 2 Press on the edge of the tilt sensor and wedge a block to keep it tilted wedge supplied Ref 512053 3 Position the ignition key to I Ensure that the em
75. rtical mast Any mast lowering movement controlled from the breakdown controls by a person induce not qualified unsynchronised movement of the mast sections and cause serious injuries due to the sudden lowering of the platform Wait for rescue personnel Qualified personnel must inspect the machine before it is returned into service Models Toucan 1100 Revision 04 2006 MLE 5 OPERATING PROCEDURES 5 5 1 Pre starting checks complete walk around visual inspection of the work platform should always be made with special attention to structural damage loose equipment leaks or other conditions that would require immediate correction for safety of operation The following check list items are suggested specially for the operator s benefit to ensure the work platform is prepared for starting the day s work 5 1 1 Batteries Battery electrolyte may cause painful burns if allowed to contact the skin Use extreme caution when filling a battery cell or when checking the charge Batteries must be charged only in a clean and well ventilated area conform to any particular regulation in force Do not charge the batteries near fire flame or other source of heat During charge batteries produce highly explosive hydrogen gazes Before performing any maintenance of the machine the batteries and the charger plug must be disconnected Operating the machine with insufficiently charged batte
76. ry 80 discharged 1 150 is 12 C 10 F 15 10 Use of a battery in a cold chamber cold climate The battery must be fully charged when the work platform is operated in a cold chamber or in cold weather condition Temperature has an effect on battery capacity the battery looses 1 of its capacity per 1 C 1 8 F below 25 C 77 F 0 oce 10 14 F 4 F 22 F 5 15 25 35 45 55 P Models Revision 04 2006 Toucan 1100 15 11 Battery not working continuoudy or inactive battery A battery that is not used or used by intermittence must be stored charged in a dry area away from freezing temperatures A charge must be performed once a month In these conditions battery storage is possible at temperatures of 30 C 86 F fora 12 month period Storing a discharged battery will result in irreversible damage to the battery Unplug the battery to insulate it electrically Keep the top of the battery clean and dry to prevent self discharge during inactivity periods batteries loose their charge progressively auto discharge Auto discharge causes battery plates corrosion which increases with time resulting in battery malfunction If the battery is not used continously it must be recharged at least once a month even if the electrolyte specific gravity measures are high Before placing in service a battery which remained inactive for
77. ry cell filling cap 2 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 walls 3 Read the value as indicated on the example below 1 23 4 Return the electrolyte in the cell and record cell electrolyte specific gravity i n the battery service log 5 Repeat operation for each battery cell Models Toucan 1100 Revision 04 2006 15 15 15 9 Storage of a battery at temperatures below 0 C 32 F Prior to battery storage at temperature below 0 C 32 F the electrolyte specific gravity must be verified in each cell Refer to ELECTROLYTE DENSITY AND BATTERY VOLTAGE in this section for the operating mode of electrolyte specific gravity measure Measure of the electrolyte specific gravity enables the determination of the electrolyte freezing point using the chart below 0 C 32 F 5 C 23 F 10 C 14 F 20 C 4 30 22 40 40 50 58 1 075 90 130 1 00 1 05 1 10 1 15 1 20 1 25 1 30 1 35 1 40 1 45 1 50 Electrolyte specific gravity NOTE When the battery is fully charged 1 280 kg l the electrolyte freezing point is 85 C 121 F Freezing point of a batte
78. the wheel to gain access to the grease nipple Grease nipple s on turntable base Every 250 hours of operation Check daily Drain after 1000 hours of Fill through top in tank return filter Check about 22 level through the reservoir Biodegradable For the sight gauge on MAX machine s life the reservoir 6 Return filter Filter change interval After first 50 hours of operation and every 250 hours thereafter Internal gear bearing 1 Remove swing gear box 2 Apply a thick coat of grease with a brush through the gear box centering hole Manually rotate the turntable to reach every teeth T bearing internal C Every 1000 hours of operation Coat each tooth gear Models Revision 04 2006 Toucan 1100 63 NOTES TYPE OF LUBRICANT LOW TEMPERATURE FOOD COMPATIBLE STANDARD TILL 35 C FOOD COMPATIBLE LOW TEMPERATURE BIO DEGRADABLE OIL oO NERVOFLUID VG 32 NERVOL EQUIVIS XV 32 ERVOL AGROFLUID DVG 32 NERVOL AGROFLUID PANOLIN 3504 HLP SYNTHESE 32 NERVOFLUID DVG 32 NERVOL HYDRELF XV 32 MOBIL DTE FM 32 MOBIL DTE 13M MOBIL DTE 13M COMPLEX EP2 NERVOL CRYOGREASE MOBILUX EP2 MOBILITH SHC 220 C STANDARD MOBILTAC 81 BASSE TEMPERATURE JUSQU A 35 C MOBIL DTE 16M HYDRELF XV 32 CHAINE FILANTE BASSE TEMPERATURE ALIMENTAIRE e SEARDARD JUSQU A 35 C duds AGAR BASSE TEMPERATURE HEN STANDARD MOBILUX EP2 COMPLEX EP2 Reservoir Masts Wheel hub
79. to RAISE the jib and PUSH the lever to LOWER the jib c Mastlift lowering control lever PULL the lever to RAISE the mast and PUSH the lever to LOWER the mast d Swingcontrollever PULL theleverto swingthe platform to the RIGHT and PUSH the lever to swing the platform to the LEFT e Drive control lever PUSH the lever to drivethe machine FORWARD and PULL the lever to REVERSE the machine The work platform can be operated from the platform The upper control box is located on the platform They ensure hydraulic functions in normal operation NOTE Depress the enable pedal before activating a movement control lever Fig 4 1 Upper control box controls A DANGER Injuries to the occupants of the platform and damage to the machine could result from a a Movement control levers brusqueinversion ofthe drive direction when the machine is being driven in retracted position b Electrical control box Models 24 ALG Toucan 1100 Revision 04 2006 a Emergency stop switch Push on the switch to cut the electrical supply from the hydraulic unit stopping all functions from the platform The switch must be pulled out to restore the functions of the machine b Drive speed selector 1 Slow speed oM 2 Slope climbing speed 3 Fast speed NOTE As soon as the platform is raised the machine switches automatically to slow speed c Double function push button Horn Reset button us
80. u must be thoroughly familiar with the location and content of all placards and decals on the work platform Decals provide important instructions and warnings and must be read prior to any operational or maintenance function You must be familiar with the regulations and standards governing work platforms and their operation Work practice requirements may vary slightly between governement regulations industry standards and employer policies so a thorough knowledge of all such relevant work rules is necessary The machine must be used with sufficient ambiant light Models Toucan 1100 Revision 04 2006 3 SAFETY PRECAUTIONS 3 3 1 2 Operator s qualification Do not attempt to operate the work platform unless you are trained and thoroughly familiar with all operational functions Controls features and operating procedures may vary from work platform to work platform so it is ESSENTIAL that you have specific training given by competent authorized personnel for the particular machine you will be using Never jeopardize your well being or that of others by attempting to operate a work platform on which you have not been trained Training is ESSENTIAL to proper operation and safe work practices depend on proper operation You must be mentally and physically fit to operate the work platform and not be under the influence of medication narcotics or alcohol ANY type of drug could impair physical visual and mental reactio
81. ughly cleaned before applying lubricant Turntable greasing 1 Grease the bearing track using a grease pump 2 Remove the swing reducer b Handling must be imperatively performed on flat and horizontal ground in an area large enough to allow complete rotation of the superstructure 3 Using a brush apply new grease on all the turntable teeth through the reducer centering hole Rotate the superstructure manually to access all the teeth Models Revision 04 2006 Toucan 1100 15 15 LUBRICATION CHART LOCATION LUBE TYPE LUBE INTERNAL LUBE AMOUNT APPLICATION 1 Clean the inside wall of mast to remove the old grease 2 Lubricate the mast inside wall using a brush Every 125 hours of operation or after each cleaning or more 1 Mast profiles often if the work platform is used or stored in a very dusty or corrosive environment 3 Cycle the mast and relubricate Lubricant can be applied manually with a brush or by spraying Every 125 hours or once every Apply lubricant 30 days of operation or more Longitudinally in areas where often if the platform is used or joints are under small load to facilitate stored in a very dusty or penetration of the lubricant transversally between the plates to enable the lubricant to reach the joints 1 Grease nipple on each hub 3 Wheel bearings Every 250 hours of operation Remove
82. ull the EMERGENCY STOP switch to reset weight of the work platform occupants and the required tools to perform a desired task Do N CAUTION not exceed this capacity 2 When the work platform is in working mode Before restarting you must eliminate the release the enable pedal problem which caused the emergency stop 3 Do notletthe work platform remain idle for long periods of time At least once a week turn on NOTE the ignition and activate all the functions of the To reactivate the dead man device the work platform enable pedal must be released during re 4 The work platform is only stable on firm and energizing level ground Ensure the machine is positioned on firm and level ground before raising the mast 5 2 4 Operation from the platform 5 In cold climates a function must be activated to circulate and warm the oil 5 minutes General maximum DANGER 5 2 1 Starting procedure Beware of all conditions that could affect machine stability Death or serious injury Position the key switch ground control to I could result from machine tip over 1 2 Remove the ignition key 3 Ensure that the lower EMERGENCY STOP DANGER switch is pulled out distributed and secure 4 Enter the platform and close the gate 5 Ensure that the EMERGENCY STOP switch heure he Iosd amshe plattonmisieveniy on the upper control box is pulled out 6 E the desired function refer to paragraph DANGER
83. unding of a work platform affords little or no protection from electrical hazards DO NOT depend on grounding Overhead lines tend to blowin the wind so allowforthis when determining safe operating distances If the work platform should come in contact with an energized power source you must immediately warn those in the vicinity to stay away Allow no one to use the lower controls at ground level in this situation You the operator onthe platform should attempt to move the work platform away from the power source Should the operator become incapacitated or the work platform loose functional capability the power company should be contactedto de energize the electrical source NO ONE must attempt to use the lower work platform controls until the power has been turned off Following a contact with an energized electrical source thelocal JLG distributor mustbe immediately advised ofthe incident and consulted on necessary inspections andrepairs Should the distributor not be immediately available contact should be made directly with JLG Product Support The work platform must not be returned to service until it is thoroughly inspected for any evidence of damage and until all damaged parts are repaired or replaced MLE 3 6 Maintenance X DANGER Failure to properly maintain and inspect this machine could result in death or serious injury This machine must not be used unless itis operating properly Perform all periodic
84. vity is higher than 1 240 kg I 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 It is important to perform an equalisation charge regularly to equalise electrolyte specific gravity between all battery cells The equalisation charge takes place at the end of the charge cycle Fulmen and SGTE chargers only ALG 41 15 If a power cut occurs during the charge cycle the charger switches to a waiting mode and restarts automatically as soon as the power returns Charger voltage f a charger set on 110V is used with 220V power supply the input fuse or the transformer will be damaged f a charger set on 220V is used with a 110V power supply the charger will indicate a fault during the charge safety time exeeded Supply voltage Always ensure the voltage selected corresponds to the network voltage and the socket protection is sufficient to support the charger power The chargers are factory preset function of the plug fitted USA Plug Yellow CEI60309 Plug IP67 Plug NF220VN 16A K Toucan 1100 15 Models Revision 04 2006 15 15 15 3 1 Westinghouse SGTE electronic charger Charger panel Display panel a Default LED indicator red b Charger ONLED indicator oran
85. y a qualified person s and in accordance with the recommendations in this manual Any question regarding procedures and specifications should be directedto the local authorized JLG distributor or JLG Product Support Service andrepairstothe work platform must only be performed by a qualified person All service and repairs must be performed in accordance with manufacturer s recommendations and the handbook for this machine All replacement part must be JLG approved Unless authorized and approved by JLG do not make any modification alterations or changes to a work platform which in any way affects it original design Such action invalidates all warranties and makes the owner user liable for any resultant accident Before performing any maintenance service or repairs on the work platform 1 The mast and jib must be fully lowered or lowered until resting on suitable blocking or support 2 Controls should be properly tagged Never operate the work platform if itis TAGGED OUT norattemptto do so until itis restored to proper operating condition and all tags are removed 3 Thebatteries as well asthe charger plug should be disconnected and the ignition key removed 4 Recognize and avoid pinch points while performing maintenance After performing maintenance service or repairs on the work platform 1 Replace all guards and covers that were removed 2 Reconnectthe batteries and remove tags 3 Remove blocking and or sup
86. ys be aware of your working environment during operation of the work platform Always avoid contacting the work platform and its occupants with external objects during operation Should contact occur lower the platform and inspect for damage before continuing operation You must always be aware of what is below above beside before and behindthe work platform during any elevating lowering swinging or driving function If you are unable to clearly see in the direction of motion you must posta look out or signal person before operating the work platform Models Revision 04 2006 Toucan 1100 Never position the platform into any obstructions or put yourself in a position of interference between the platform and another object Take extreme caution to avoid such situation Never drive any part of the work platform into obstructions or personnel Always look inthe direction of travel dL 19 SAFETY PRECAUTIONS PLATFORMLOWERING MAST LOWERING SUPERSTRUCTURE ROTATION CRUSHING HAZARD DEATH OR SERIOUS INJURY COULD RESULT FROM BEING CRUSHED BY MOVING MACHINERY CLEARALL PERSONNEL FROM THE COUNTERWEIGHT AND SUPERSTRUCTURE AREA BEFORE LOWERING THE JIB AND OR MAST ORROTATING THE SUPERSTRUCTURE Exercise caution when lowering the platform to avoid descending onto objects or personnel below Clear all personnel from the platform before lowering the mast and or jib or rotating the platform 20 ALG Toucan 110

MODELS TOUCAN 1100

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