JLG TOUCAN 1100 Operator's And Safety Manual
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JLG TOUCAN 1100 Operator's And Safety Manual

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MODELS
TOUCAN 1100
U.S.A.
JLG Industries, Inc.
1 JLG Drive
McConnellsburg
PA 17233-9533
Tel : (171) 485-5161
Fax : (717) 485-6417
Updated : 04.2006
C.E.
JLG Industries,
Kilmartin Place,
Tannochside Park
Uddingston, Scotland G71 5PH
Tel : +44(0)1698 811005
Fax : +44(0)1698 811055
C.E.
JLG Manufacturing Europe
Breitwaterstraat 12A
Oude Bunders 1034
B - 3630 Maasmechelen
Tel : +32(0)89 774 974
Fax : +32(0)89 777 427
FRANCE
JLG France SAS
Z.I. de Fauillet
BP 20 - 47400 TONNEINS
France
Tel : +33 553 84 85 11
Fax : +33 553 79 06 87
MA0138-03
English

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  • Page 1 MODELS TOUCAN 1100 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.I. de Fauillet McConnellsburg Tannochside Park Oude Bunders 1034 BP 20 - 47400 TONNEINS PA 17233-9533...
  • Page 3 MODELS TECHNICAL SPECIFICATIONS Serial number T 1100 A : T 1100 B : T 1100 C : JLG France, Z.I. de Fauillet, B.P. 20 Made in 47400 Tonneins, France Weight 3500 kg 3540 kg 3500 kg 200 kg (2 persons + 40 kg...

  • Page 4: Electrical Hazard

    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 GOVERNMENT REGULATIONS RELATIVE TO THIS MACHINE. AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO DEATH OR SERIOUS INJURY. Models Toucan 1100 Revision 04-2006...
  • Page 5 Should this work platform become involved in an accident, please contact your local JLG distributor immediately and relate details of the incident so that he can notify JLG. If the distributor is unknown and/or cannot be reached, please contact : USA : C.E :...
  • Page 6 Routine maintenance procedures are supplied at the 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. Models Toucan 1100 Revision 04-2006...

  • Page 7: Table Of Contents

    TABLE OF CONTENT INTRODUCTION GENERAL DESCRIPTION 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 3.1. General. 3.1.1. Operator's informations. 3.1.2. Operator's qualification. 3.1.3. Work practice. 3.2. Machine stability.
  • Page 8 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 Toucan 1100 Revision 04-2006...
  • Page 9 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 Models Toucan 1100 Revision 04-2006...
  • Page 10 This handbook prov ides important inf ormation f or 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 a self-propelled type with an all welded steel frame.

  • Page 11: General Description

    2.1. General description. Upper control box Telescopic masts Charger Battery Platform REAR FRONT Manual box Steering wheels Driving wheels Access door to battery and charger FRONT REAR Counterweight Access to hydraulic unit Emergency and breakdown control panel Models Toucan 1100 Revision 04-2006...

  • Page 12: Dimensions And Range Diagrammes

    GENERAL DESCRIPTION 2.2. Dimensions and range diagrammes. 2.2.1. Toucan 1100 A. 1160 1780 2680 1900 2750 Models Toucan 1100 Revision 04-2006...

  • Page 13: Toucan 1100 B And Toucan 1100 C

    GENERAL DESCRIPTION 2.2.2 Toucan 1100 B, Toucan 1100 C. 1160 1300 1780 3080 2300 3150 -1 -2 Models Toucan 1100 Revision 04-2006...

  • Page 14: Safety Precautions

    JLG Product Support. The work If you have any questions on operating procedures, platform must not be returned to service until it is...

  • Page 15: Operator's Qualification

    Anyone entering the platform must first clean weather requires special starting procedures and his shoes. Do not store flammable materials on the ample time for hydraulic oil to warm up. Keep the work platform. platform free of ice and snow. Models Toucan 1100 Revision 04-2006...

  • Page 16: Machine Stability

    The battery is an integral part of the certain precautions must be taken to avoid such counterweight. Substitute this battery for a possibilities. lighter or heavier battery will cause the machine to tip over. Models Toucan 1100 Revision 04-2006...
  • Page 17 Ensure that the surfaces where the machine will travel in elevated position are horizontal and will support a load greater that the work platform's weight. Check the tilt alarm for proper functioning. Models Toucan 1100 Revision 04-2006...

  • Page 18: Falling Hazard

    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. Models Toucan 1100 Revision 04-2006...

  • Page 19: Crushing Hazard

    If you are unable to clearly see in the direction of motion, you must post a look-out or signal person before operating the work platform. Models Toucan 1100 Revision 04-2006...
  • Page 20 BEFORE LOWERING THE JIB AND/OR MAST OR ROTATING 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. Models Toucan 1100 Revision 04-2006...

  • Page 21: Electrical Power Sources

    Low voltages can also be positive and absolute assurance that the power has been turned OFF. dangerous. During work platform use, assume that every line is energized and take the necessary precautions accordingly. Models Toucan 1100 Revision 04-2006...

  • Page 22: Maintenance

    Cleaning solutions used should be appropriate for Following a contact with an energized electrical source, the job and non flammable. Avoid spraying cleaning the local JLG distributor must be immediately advised solutions directly onto electrical components. of the incident and consulted on necessary inspections and repairs.
  • Page 23 The following precautions must be taken when servicing for this machine. All replacement part must be JLG the hydraulic system : approved. 1. Follow the manufacturer's recommendations Unless authorized and approved by JLG do not make when adding oil to the system.

  • Page 24: Work Platform Controls

    Injuries to the occupants of the platform and a- Movement control levers. damage to the machine could result from a brusque inversion of the drive direction, when b- Electrical control box. the machine is being driven in retracted position. Models Toucan 1100 Revision 04-2006...
  • Page 25 The bar flashes when the battery is 70% 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 Toucan 1100 Revision 04-2006...

  • Page 26: Emergency And Breakdown Controls

    "0" to remove the electrical power and remove the key. 3. Mast control lever Mast LOWERING : push down and hold the e. Panel mounted fuse holder. control lever. Mast RAISING : lift and hold the control lever. Models Toucan 1100 Revision 04-2006...

  • Page 27: Breakdown

    4.3.1. Safety devices and alarms. buzzer stops. 4.3.1.1. Motion alarm. The motion alarm is located inside the front cover. This alarm is activated whenever one function is selected. Fig. 4.12 - Overload detection system. Models Toucan 1100 Revision 04-2006...
  • Page 28 - 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. Models Toucan 1100 Revision 04-2006...

  • Page 29: Operating Procedures

    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 Toucan 1100 Revision 04-2006...

  • Page 30: Overload Detection

    3. Repeat stages 1 to 2 for each chain slack 1. Verify the good working order of the upper sensor. control box. 2. Verify the good working order of the emergency and breakdown control panel. Models Toucan 1100 Revision 04-2006...

  • Page 31: Work Platform Operating Tips

    EMERGENCY STOP 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 Toucan 1100 Revision 04-2006...

  • Page 32: Operation From The Ground (Emergency And Breakdown)

    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...

  • Page 33: Transport Instructions

    DANGER No personnel is allowed on the platform WEIGHT during towing procedure. Toucan 1100 A / C 3500 Kg. Toucan 1100 B 3540 Kg. Procedure to follow CAUTION • Disengage the parking brake and release the wheel motors.

  • Page 34: Loading And Unloading

    DANGER The work platform must be kept as near to the ground as possible during fork lift operation. Lift the forks at the last minute to prevent the machine from tipping over. Models Toucan 1100 Revision 04-2006...

  • Page 35: Using A Truck Equipped With A Tail Gate

    (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 operation. Models Toucan 1100 Revision 04-2006...

  • Page 36: Lifting The Machine

    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 Toucan 1100 Revision 04-2006...

  • Page 37: Hydraulic Schematic

    HYDRAULIC SCHEMATIC Ref. : FL 0151-01 Models Toucan 1100 Revision 04-2006...

  • Page 38: Electrical Schematic

    ELECTRICAL SCHEMATIC Ref. : ELE194-11 Models Toucan 1100 Revision 04-2006...

  • Page 39: Optional Equipment

    DANGER 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 Toucan 1100 Revision 04-2006...

  • Page 40: Maintenance

    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.

  • Page 41: System Malfunctions

    (Fulmen and SGTE chargers Cleaning solutions used should be appropriate for only). the job and non flammable. Avoid spraying cleaning solutions directly onto electrical components. Models Toucan 1100 Revision 04-2006...
  • Page 42 The chargers are factory preset function of the plug fitted. - 110 V : USA Plug Yellow CEI60309 Plug - IP67 - 220 V : German and French United Kingdom Plug Plug (NF220VN - 16A) Blue CEI60309 Plug - IP44 Models Toucan 1100 Revision 04-2006...
  • Page 43 Rep b goes of f , 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 Toucan 1100 Revision 04-2006...

  • Page 44: Troubleshooting

    Disconnect the charger from the Charging time exceeds 15 hours (Voltage above 2,4V per battery and reconnect it . If the problem cell) (Soft timer #2). persists, contact JLG Product Support. Charging time exceeds 16 hours (Hard timer). Models Toucan 1100...
  • Page 45 When the charger switches to equalisation charge, the "100%" charge indicator comes off and the "80%" charge indicator flashes. To cancel the preselection "equalisation", press the "STOP" and " = " (the point on the display screen disappears). Models Toucan 1100 Revision 04-2006...

  • Page 46: Troubleshooting Chart

    Contact JLG Product Support. (configuration lost) Batteries too discharged Leave the batteries to stand before resuming charge. Disconnect and reconnect the batteries. Contact JLG Product Support if the Electronic safety. Safety time switch faulty fault persists. Battery incorrect nominal voltage Connect the battery from the work platform to the charger.

  • Page 47: Chargers

    - Protections : - Single pole circuit breaker : 32 A ("g" on the display panel). - Output fuse : 100 A (inside the charger) NOTE A spare output fuse is strapped inside the charger cover. Models Toucan 1100 Revision 04-2006...
  • Page 48 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 "ON / OFF" LED switches itself off). Models Toucan 1100 Revision 04-2006...
  • Page 49 If a problem occurs, the charger stops. The LED " " lights up and the screen displays an error code. Ref er t o t he t r oubl e shoot i ng chart hereafter). Models Toucan 1100 Revision 04-2006...
  • Page 50 Charge interruption due to a power cut or Check the circuit breaker on the display screen LILO circuit breaker default. Charge will be is in good working order. resumed as soon as the power returns. Check power supply. Models Toucan 1100 Revision 04-2006...
  • Page 51 (a) and (c) are on fixed. = the led flashes quickly (T=0.2 sec) = the led can be on or off, depending on the state of charge of the battery and on the charger’s operation at that moment. Models Toucan 1100 Revision 04-2006...

  • Page 52: Battery

    (during the charge, the electrolyte when installing a battery. level increases and can overflow). - Do not short across the battery posts to check charge. Spark or flame could cause battery explosion. Models Toucan 1100 Revision 04-2006...

  • Page 53: Filling The Battery With The Water Pump

    In case of classified as industrial waste, it must be excessive clogging, replace the cap. in any disposed of according to regulations in force. case, it is recommended to replace the caps every 2 to 3 years. Models Toucan 1100 Revision 04-2006...

  • Page 54: Electrolyte Specific Gravity And Battery Voltage

    DANGER During maintenance or any servicing operation on the battery, rings, watches or any other jewellery must be removed. Models Toucan 1100 Revision 04-2006...

  • Page 55: Storage Of A Battery At Temperature Below 0°C (32°F)

    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). 20°C 10C° 0C° -10C° -20C° -30C° C° F° 68°F 50°F 32°F 14°F -4°F -22°F % Lost Models Toucan 1100 Revision 04-2006...

  • Page 56: Battery Troubleshooting

    Loss of electrolyte due to overflow. Perform an equalization charge. Stratification of the electrolyte. Contact your JLG Distributor/Product Support. Low voltage in the cells in open Electrolyte specific gravity too low. Refer to "electrolyte specific gravity too circuit.

  • Page 57: Oil Change Replacement And Filter

    Do not spill oil on the work platform or on and any leakage. the ground. 5- Clean the oil filter base and the reservoir. Avoid fluffy rags. If necessary, blow the reservoir with compressed air. Models Toucan 1100 Revision 04-2006...

  • Page 58: Main Hdyraulic Group Motor

    3- Install the protection covers. ç Plate must not be cracked. cracked plate ç The plate clevis pins must not present excessive play. The pins must not be turned in their housing.(1) : Models Toucan 1100 Revision 04-2006...

  • Page 59: Chains Lubrication

    (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 Toucan 1100 Revision 04-2006...

  • Page 60: Verification Of The Overload Detection Setting

    - An acoustic alarm sounds when the chassis is tilted at its max value (2°). - The corresponding LED lights up on the platform controls. X kg 10- Remove the blocks. Model T1100A 200 kg T1100B 230 kg T1100C 200 kg Models Toucan 1100 Revision 04-2006...

  • Page 61: Preventive Maintenance And Inspection

    - Hydraulic hoses and fittings (leakage) checking the following items and must be performed - Battery electrolyte level (refer to §15-5-1) by a technician approved by JLG : - Mast/jib cylinders (leakage, rod, lock valve) - Lubrication (refer to §15-21) - Turntable bolts torque (refer to Service manual) - Lifting chains wear (refer to §15-16-1)
  • Page 62 Grease fittings that are worn and will not hold the grease gun (or those that have a stuck check ball) must be replaced. Models Toucan 1100 Revision 04-2006...
  • Page 63 2- Apply a thick coat of grease with a bearing internal Every 1000 hours of operation Coat each tooth brush through the gear box centering gear hole. Manually rotate the turntable to reach every teeth. Models Toucan 1100 Revision 04-2006...
  • Page 64 MOBILITH SHC 220 STANDARD MOBILTAC 81 BASSE TEMPERATURE STANDARD JUSQU'A -35°C MOBIL DTE 16M HYDRELF XV 32 CHAÏNE FILANTE STANDARD MOBILUX EP2 COMPLEX EP2 Reservoir Masts / Wheel hub / Telescope Tunrtable Lifting chains Swing bearing race Models Toucan 1100 Revision 04-2006...
  • Page 65 Check of motor brushes Lift cylinder check Hydraulic circuit general pressure check Check of electrical safety devices VISA Verification intervals 18 MONTHS OPERATIONS TO BE DONE Date Hydraulic circuit oil change Oil filter cartridge change VISA Models Toucan 1100 Revision 04-2006...
  • Page 66 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Verification interval MONTHLY Verification interval BI-YEARLY Verification interval 18 MONTHS Models Toucan 1100 Revision 04-2006...
  • Page 67 NOTES Models Toucan 1100 Revision 04-2006...

This manual is also suitable for:

Toucan 1100 aToucan 1100 bToucan 1100 cT 1100 aT 1100 bT 1100 c

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