MODELS TOUCAN 1210 TOUCAN 1310 · 2020. 3. 27. · English - Service Manual MODELS TOUCAN 1210 TOUCAN 1310 U.S.A. JLG Industries, Inc. 1 JLG Drive McConnellsburg PA 17233-9533 Tel

Révision: 03 - 2012 MA0295-04English - Service Manual

MODELSTOUCAN 1210TOUCAN 1310

U.S.A.JLG Industries, Inc.1 JLG DriveMcConnellsburgPA 17233-9533Tel : (171) 485-5161Fax : (717) 485-6417

C.E.JLG Manufacturing EuropeBreitwaterstraat 12AOude Bunders 1034B - 3630 MaasmechelenTel : +32(0)89 774 974Fax : +32(0)89 777 427

FRANCEJLG France SASZ.I. de FauilletBP 20 - 47400 TONNEINSFranceTel : +33 553 84 85 11Fax : +33 553 79 06 87

C.E.JLG Industries,Kilmartin Place,Tannochside ParkUddingston, Scotland G71 5PHTel : +44(0)1698 811005Fax : +44(0)1698 811055

3 Models

Revision 03-2012Toucan 1210Toucan 1310

MA0295-04

ModelsEnglish

MACHINE SERIAL NUMBER :

Toucan 1210 _____Toucan 1310 _____

ModelsRevision 03-20124

Toucan 1210Toucan 1310

1 INTRODUCTION

ForewordImportant information

2 WORK PLATFORM CHARACTERISTICS

Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2.1Characteristics - Dimensions - Performances - - - - - - - - - - - - - - - - - - - - - - - - - 2.2

3 HYDRAULIC SYSTEM

Hydraulic power units - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.1Hand pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.2Hydraulic filters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.3Function manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.4Drive manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.5Membrane accumulator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.6Wheel motor distribution manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.7Brake manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.8Differential locking manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.9Wheel motors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.10Steering manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.11Check valves manifold ("Power plus" option) - - - - - - - - - - - - - - - - - - - - - - - - 3.12Release control valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.13Trim correction manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.147-way, 3 position flow diverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.15Cylinders supply manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.16Mast cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.16.1Jib cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.16.2Telescope cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.16.3Assistance cylinder - Master cylinder - Slave cylinder - - - - - - - - - - - - - - - - 3.16.4Rotation cylinder (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.16.5Sequence valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.17Slewing hydraulic motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.18Pressure relief valves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19Brake release circuit pressure check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.1Pressure relief valve setting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2Main pressure [PR1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.1Telescope extension [PR2] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.2Telescope retraction [PR3] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.3Mast elevation [PR4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.4Jib elevation [PR5] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.5Jib lowering [PR6] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.6Brake release maximum pressure [PR7] - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.7Drive at low speed [PR8] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.8Slewing to the left [PR9] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.9Slewing to the right [PR10] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.10Trim correction [PR11] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.11Left steering [PR12] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.12Right steering [PR13] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.13

TABLE OF CONTENTS

5 Models


TABLE OF CONTENT

4 ELECTRICAL SYSTEM

Wiring diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.1Battery wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.1.1Power circuit wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.1.2Components location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.1.3Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2Mast position switch [SW4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.1Jib lower position switch [SW5] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.2Telescope position switch [SW2] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.3Jib higher position switch [SW3] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.4Slack chain sensors [SW34 à 37] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.5Tilt indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.6Strain link (stability control device) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.7Steering sensors (T1310 only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.8Sensor for left steering limitation [SW39] - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.8.1Sensor for right steering limitation [SW40] - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.8.2Steering angle sensors [SW41 & 42] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.8.3Safety features - Movement cut out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.3Adjustment of the battery discharge indicator - - - - - - - - - - - - - - - - - - - - - - - - 4.4Speed electronic controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.5Circuit breakers - Fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.6Circuit breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.6.1Fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.6.2Resetable fuses (Polyswitch®) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.6.3Help with the diagnostic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.7Electronic modules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.8Controls verification module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.8.1Speed control module for the jib (dongle) - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.8.2Time delay module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.9"Power plus" module (option) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.10"Clipper" connector installation procedure - - - - - - - - - - - - - - - - - - - - - - - - - 4.11

5 BATTERIES - CHARGERS

Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5.1Electrolyte specific gravity and battery voltage - - - - - - - - - - - - - - - - - - - - - - 5.1.1Storage at temperatures below -20°C (32°F) - - - - - - - - - - - - - - - - - - - - - - - - 5.1.2Use of a battery in a cold chamber or in cold climate - - - - - - - - - - - - - - - - - 5.1.3Battery not working continuously or inactive battery - - - - - - - - - - - - - - - - - - 5.1.4Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5.1.5Chargers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5.2High frequency charger "Zivan NG3" - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5.2.1Electronic charger "Oldham-Hawker CP IV" - - - - - - - - - - - - - - - - - - - - - - - - 5.2.2



6 TORQUE VALUES

General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6.1Wheel nut torque values - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6.2Torque value of slewing ring attachment bolts - - - - - - - - - - - - - - - - - - - - - - - - 6.3

7 SERVICE - MAINTENANCE

General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1System malfunction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1.1Cleanliness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1.2Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1.3Dissassembly / Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1.4Parts replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1.5Wires and cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1.6Platform cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.2Maintenance and installation of guide rings - - - - - - - - - - - - - - - - - - - - - - - - - - 7.3Steering bracket thrust washers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.4Mast roller removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.5Adjustment of telescopic mast alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.6Lifting chains adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.7Verification and lubrication of the lifting chains - - - - - - - - - - - - - - - - - - - - - - - 7.8Verification of chain wear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.8.1Chain lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.8.2Hydraulic power unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.9Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.10Maintenance of the centralised filling system - - - - - - - - - - - - - - - - - - - - - - - 7.10.1Cleaning - Battery maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.10.2Preventive maintenance and inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.11Daily preventive maintenance and inspection - - - - - - - - - - - - - - - - - - - - - - 7.11.1Weekly preventive maintenance and inspection - - - - - - - - - - - - - - - - - - - - 7.11.2Monthly preventive maintenance and inspection - - - - - - - - - - - - - - - - - - - - 7.11.3Preventive maintenance and inspection every 125 hours - - - - - - - - - - - - - - 7.11.4Preventive maintenance and inspection every 250 hours - - - - - - - - - - - - - - 7.11.5Preventive maintenance and inspection every 500 hours - - - - - - - - - - - - - - 7.11.6Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.12

TABLE OF CONTENT

7 Models


FOREWORD

This manual has been compiled to assist you inproperly operating and maintening your JLG aerialwork platform.

Constant improvement and engineering progress makeit necessary that JLG reserve the right to makespecification and equipment changes without notice.

The definitions of DANGER, CAUTION and NOTE asused in this manual apply as follows :

A DANGER is used to emphasize that if anoperation, procedure or practice is notfollowed exactly, death or serious injury topersonnel may result.

A CAUTION is used to emphasize that if anoperation, procedure, or practice is notfollowed exactly, equipment damage mayresult.

NOTEA NOTE is used to emphasize an importantprocedure or condition

GENERAL WARNINGIt is mandatory that all hydraulic hoses andfittings are correctly tagged and identified beforethey are disconnected to effect repairs or service.Failure to correctly tag and identify hoses andfittings can cause wrong reconnection, which canresult in death or serious injury to personnel.

DANGER

! CAUTION



NOTICE TO OWNER/USER

Should this work platform become involved in a accident, please contact your localJLG distributor immediately and relate details of the incident so he can notify JLG.If the distributor is unknown and/or cannot be reached, please contact :

USA :

JLG Industries, Inc.Product Safety & Reliability Department, 1 JLG DriveMcConnellsburg, PAUSA 17233-9533Toll Free: (877) 554-7233Tel.: (717) 485-5161Fax: (717) 485-6573Email : [email protected]

C.E :

JLG Industries,Kilmartin Place,Tannochside ParkUddingston,Scotland G71 5PHTel : +44(0)1698 811005Fax : +44(0)1698 811055Email : [email protected]

9 Models


The following form is for the use of the Distributor, Customer, Mechanic, and all other person who use this manualand recognize beneficial ways to improve its purpose as a worthy reference. SMCAR's are to be made in regardsto, but not limited to : Safety, Operation Correctness, and Technical Content. All SMCAR's will be reviewed bythe responsible Department at JLG Approved SMCAR's will be distributed in a Service Bulletin immediately andthen incorporated in the next scheduled change to the manual. An answer to the SMCAR, approved ordisapproved, will be sent directly to the one submitting the SMCAR.

Date ______________________________Customer name _____________________Name/first name _____________________Address _____________________________________________________________

Telephone __________________________

Service ManualAffected __________________________________________________________________________

Page(s) Affected____________________________________________________________________

Reason for submitting SMCAR (Use additional paper or back if necessary)

__________________________________________________________________

__________________________________________________________________

__________________________________________________________________

__________________________________________________________________

__________________________________________________________________

__________________________________________________________________

__________________________________________________________________

__________________________________________________________________

__________________________________________________________________

__________________________________________________________________

__________________________________Signature (optional)

Adress SMCAR's to :Supervisor, PublicationsJLG France SASZ.I. de Fauillet,B.P. 2047400 Tonneins, France

CORRECTIVE ACTION REQUEST



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CORRECTIVE ACTION REQUEST

11 Models


WORK PLATFORM CHARACTERISTICS 22

2.1 Description

The Mobile Elevating Work Platform consists of a selfpropelled all welded chassis, of a telescopic mastmounted on a turntable and a telescopic jib. Theplatform is mounted at the end of the jib.

The main hydraulic power unit supplying the functionsof the work platform is located at the rear of the chassison the right hand side. When the "Power Plus" optionis installed, an auxilliary unit is installed on the rearof the chassis on the left hand side.

The drive function is accomplished by two hydraulicmotors propelling the rear axle.The parking brakes integrated to the hydraulic motorswork through lack of pressure.Steering (front axle) is accomplished by a hydrauliccylinder.

The slewing movement is accomplished by a wormgear motor located at the base of the superstructure.

The movements of the telescopic mast, pendular jiband telescope are accomplished by means ofhydraulic cylinders.

The machine may be equipped (optional) with a systemcontrolled by a hydraulic cylinder enabling the rotationof the platform.

The platform is kept horizontal by hydraulic cylindersworking following the "master-slave" principle.

The movements of the machine are controlled fromcontrol panels through solenoid valves. They arelocated at the front of the chassis (for structuremovements) and on the left hand side of the chassis(for drive movements).

The progressivity of movements is obtained by anelectronic controller which controls the rotation speedof the main hydraulic group motor. The electroniccontroller is located near the emergency control panel(ground controls), on the left hand side of thetelescopic mast.

The energy for the control and power circuits of themobile elevating work platform is supplied by a 24VDCbattery.




Steering wheels

FRONT VIEW

REAR

Hand pump

REAR VIEW

Driving wheels

Counterweight

FRONTVIEW LEFT

Counterweight

Telescopic mast

Emergency controlpanel

Charger

Circuit breaker

Platformcontrol panel

Releasevalve

Manual box

Telescopic mast

Workplatform

Breakdowncontrol panel

Telescopic jib

Access to sidebatteries

Access to thefront battery

13 Models



2.2. Characteristics - Dimensions - Performances

(*) Speeds recorded on horizontal and level ground with a person on the platform (approximately 80 kg).(**) Movements durations recorded with the maximum load in the platform (200 kg), the movements being controlledfrom the platform control panel.

Speeds are indicated for a machine with a battery fully charged and operated at ambiant temperature of 20°C.

Constant improvement makes it necessary that JLG France SAS reserve the right to make specification and equipmentchanges without notice.

Toucan 1310DIMENSIONS (LOWERED) Standard Rotation (option) Standard

Length 3,85 m 4,07 m 4,07 mWidth 1,20 m 1,20 m 1,345 mHeight 1,99 m 1,99 m 2,19 mWeight 5 200 kg 5 300 kg 5 600 kgGround clearance 0,08 m 0,08 m 0,09 m

CAPACITY - MANOEUVRABILITY Standard Rotation (option) Standard

Floor height min. 0,40 m 0,40 m 0,57 mFloor height max. 10,00 m 10,00 m 11,00 mMax. outreach (from centerline) 4,93 m 5,16 m 5,16 mFloor height with max. outreach 7,20 m 7,20 m 8,20 mWorking height with max. outreach 9,20 m 9,20 m 10,20 mSlewingRotation (option)

WORK PLATFORM Toucan 1310

LengthWidthRated load

HYDRAULIC CIRCUIT Toucan 1310

Hydraulic tank capacityMain hydraulic pump displacementAuxilliary hydraulic pump displacement (T1210 option)

FILTRATION Toucan 1310

PressureReturn

PRESSURE Toucan 1310

Main hydraulic circuit maximum pressure

ELECTRICAL COMPONENTS Toucan 1310

Power of the main hydraulic power unit motorPower of the auxilliary hydraulic power unit motor (T1210 option)

DRIVE SPEEDS (*) Toucan 13101st gear (low speed) 0,65 to 0,7 km/h 0,45 à 0,7 km/h2nd gear 2,0 km/h 1,5 km/h3rd gear 3,6 km/h 2,6 km/h4th gear 3,6 km/h

MOVEMENT DURATION (**) Toucan 1310Mast elevation movement duration 33 à 40 sMast lowering movement duration 34 à 40 sJib elevation movement duration 20 à 27 sJib lowering movement duration 23 à 30 sTelescope extension movement duration 16 à 22 sTelescope retraction movement duration 14 à 20 sSlewing movement duration (from stop to stop) 75 à 85 s75 à 85 s

20 à 27 s23 à 30 s16 à 22 s14 à 20 s

Toucan 1210

Toucan 121028 to 33 s28 to 33 s

1,10 m200 kg

Toucan 1210

Toucan 1210

0,70 m

345° (2 x 172,5°)120° (2 x 60°)

Toucan 1210

Toucan 1210

4,8 kw / 24 VDC4,8 kw / 24 VDC

24 MPa

10 µm absolute10 µm absolute

Toucan 1210

Toucan 1210

35 l5,2 cm³/t3,5 cm³/t

15 Models


HYDRAULIC SYSTEM 33

3.1. Hydraulic power units

1- Main hydraulic power unit - 4,8 kw - 5,2 cc/tFUNCTION : Supply to the hydraulic circuit of the elevating work platform.

2- Auxilliary hydraulic power unit - 4,8 kw - 3,5 cc/tFUNCTION : Supply of an additional oil flow during a high speed drive to make up for the speed reduction due to theuse of wheel motors of higher displacement.

Do not interchange the pumps from the main and auxilliary power units.Body length of the 5,2 cc/t pump on main power unit : L = 55 mm.Body length of the 3,5 cc/t pump on auxilliary power unit : L = 50 mm.

! DANGER

1 2



HYDRAULIC SYSTEM 33

! CAUTIONDisassembly of the gear pump entails replacement of seals.

1- Remove both screws securing the pump to the motor. Disconnect the pump.

2- Place the pump vertically ona clean work area andremove the four f langeattachment screws. Removethe flange.

3- Extract the pump bodyensuring both pinions andbearings do not getdamaged (beware the twoseals on the upper bearing).

4- Extract the upperbearing, both pinions thenthe lower bearing.

Careful inspection of all pump components allows,depending on parts wear, to diagnose operating faultsor pollution problems in the hydraulic circuit.

L

Electrical motor

Pump bodySeals

Torque value :44 Nm

Torque value : 22 Nm1

2

Seals

Pinions

Bearings

Flange

17 Models


Hydraulic circuit pollution

- ABRASIVE WEAR CAUSED BY ABRASIVE PARTICLES

Such a wear results in a gradual reduction of thepower and speed of the hydraulic circuit.Fine particles may enter the circuit:

• During reservoir filling (clean the area around thefilling neck before opening the cap. Use cleancontainers and funnels during filling procedure).

• Through worn seals, particularly on dirty and poorlymaintained material.

• During maintenance if components are not cappedafter hose disconnection.

HYDRAULIC SYSTEM 33

− ABRASIVE WEAR CAUSED BY METALLIC PARTICLES.Such a wear results in a fairly sudden degradation ofthe performances of the pump. Metallic particles resultgenerally from the degradation of a component or froman abnormal wear of the hydraulic circuit: thecomponent must be identifed and replaced. Everyhydraulic component must be removed and cleaned.The hydraulic circuit must be drained out and flushedand the filters changed.

- AERATION OR CAVITATION

Cavitation and aeration act alike in the system.

Aeration occurs when air mixes with the oil. Air mayenter the system through a small suction leak or byagitation of the oil in the reservoir. Agitation occurswhen the oil returns to the reservoir above the oilsurface. This may occurs when the oil level is toolow. Cavitation is the formation and collapse of vapourbubbles in the oil. This usually results from a restrictedpump suction. Cavitation occurs more readily whenthe oil is cold.

Aeration and cavitation erode and pit the pressureplates and pump housing.

A pump which is either cavitating or operating onaerated fluid is usually noisy and the system operatesin a spongy or jerky manner.

If erosion on the suction side of the pump is evident onthe gear tracks, the cause is either air bubbles in theoil or a restricted suction.

Bearing wear(dull area)

Wear on pinion pressureplates (dull area)

Wear on gear track (dullarea)

Wear on gearing track(grooves)

Bearing wear(grooves)

Wear on pinionpressure plates

(grooves)

Cavitation

Track grooved on suction side = overpressure



- LACK OF OIL

When a failure is due to lack of oil, deteriorations areusually rapid. This type of failure may occur if :

- the oil level is low in the reservoir, or- there is an air leak in the suction line.

- EXCESSIVE HEAT

Excessive heat will harden the seals.

Excessive heat may be caused by a pressure reliefvalve set too low, in which case, the machine will beslow.

- OIL PRESSURE TOO HIGH

There are two possible causes for overpressure :- the pressure relief valve fails to function,producing an extreme surge and immediatefailure.

- The pressure relief valve is set too high,resulting in repeated pressure peaks. Pumpdamage is very similar in both cases.

- INCORRECT ASSEMBLY

This type of failure is self explanatory : components arefaulty, or parts have not been assembled correctly.

Pinching of the O-ring will occur if it is not seatedproperly in its groove. If the O-ring has been fittedincorrectly, the surface of the housing will show adepressed area (especially if the part is made ofaluminium).

5- Remove the seals

NOTEAlign the seals in the order they were removed,mark their position and shape to facilitatelater assembly.

6- Clean the pump components with anappropriate solvent and dry with compressedair. Replace the seals.If components are damaged, replace the pump.

Avoid scratching the grooves and glandsurfaces.

Inspect each groove before assembly.Parts must be free from dust and burrs.Grooves and gland surfaces must be in goodcondition. Worn or damaged parts must bereplaced. Do not stretch seals during theirassembly. Lubricate seals and gland surfaceswith clean hydraulic oil before assembly.

7- Assemble the pump in the reverse order fromdisassembly.

Bolt torque value (Rep. 1) = 22 NmBolt torque value (Rep. 2) = 44 Nm

Respect scrupulously the bolt torque value(Rep. 1) and (Rep. 2). Incorrect torquing willaffect the performance of the pump.

After pump installation, operate the workplatform to bleed the air from the hydrauliccircuit and check the oil level in the mainreservoir (machine fully lowered). Check thegood working order of all the control panels.

HYDRAULIC SYSTEM 33

! CAUTION

! CAUTION

! CAUTION

! CAUTION

19 Models


HYDRAULIC SYSTEM 33

3.2. Hand pump

FUNCTION :- Oil supply to the hydraulic circuit of the work platform when using the breakdown controls : elevation / lowering,telescope extension/retraction, slewing.- Oil supply to the brake pilot circuit (See § 3.13).

Seals

Split pin

Suctioncartridge

Handpump



HYDRAULIC SYSTEM 33

3.3 Hydraulic filters

NOTEThe filter cartridges must be replaced :

- After the first 50 hours of operation.- Every 250 hours of operation.- At each oil change (see chapter 7).

After instal lation, perform severalmovements to bleed the air from thehydraulic circuit, check the oil level in thereservoir (PLATFORM FULLY LOWERED)

The return filter must also be replaced.

3.3.2. Return filterFiltration rating : 10 µm abs

1- Disconnect the battery from the electrical circuitof the work platform.

2- Unscrew the return filter cap and remove thespring.

3- Install a new filter cartridge.4- Check the presence and condition of the O ring,

close the filter cap not forgetting to install thespring.

The pressure filter must also be replaced.

NOTEUsed oils and filter cartridges must bedisposed of in accordance with theregulations in force.

3.3.1. Pressure filterFiltration rating : 10µm abs.

1- Disconnect the battery from the electricalcircuit of the work platform.

2- Position the release control valve lever on to release the pressure in the hydraulic

circuit.3- Unscrew the filter tank

Oil projection on the skin can cause injuriesand burns. Loosen the filter tank very slowlyto allow the oil pressure to dropprogressively.

4- Install a new filter cartridge.5- Check the presence and condition of the O ring.6- Install the filter tank.

Filt

erca

rtri

dge

Cap

Spr

ing

O-R

ing

O r

ing

Filt

erT

ank

å

DANGER

! CAUTION

! CAUTION

cartridgeå

21 Models


HYDRAULIC SYSTEM 33

Manifold schematic :

3.4 Function manifold

FUNCTION : Hydraulic control for the different structure movements of the work platform.

(A) (B) (C)

PR1 : General pressure relief valve

1

2

TORQUE VALUE : 25 to 30 N.m

PR2 : Pressure relief valve : Telescope extensionPR3 : Pressure relief valve : Telescope retractionPR4 : Pressure relief valve : Mast elevationPR5 : Pressure relief valve : Jib elevationPR6 : Pressure relief valve : Jib lowering

Setting range of the pressure relief valves [PR2] to[PR6] : 0 to 25 MPa (0 to 250 bar).

Setting of pressure relief valves : See § 3.19.

1

2

TORQUE VALUE : 12 to 15 N.m

Pressure relief valves [PR2] to [PR6]

1

2

1

2



HYDRAULIC SYSTEM 33

DV1 : Solenoid valve (NO).

FUNCTION :- Dumping of the oil flow supplied by the main

hydraulic power unit (if not actuated).- Divertion of the oil flow to the boosting circuit of the

wheel motors during the stopping phases of the drivemovements.

A. Check valve (0,05 MPa)

FUNCTION : Prevents the oil flow suplied by the handpump from returning to the reservoir during operationusing the breakdown controls.

NOTEThe check valve is kept in position bydeformation of the thread : cannot beremoved.

B. Check valve (0,45 MPa)

FUNCTION : Provides a necessary counter pressure inthe boost circuit. Limits the oil return of the make upflow diverted by the solenoid valve [DV1].

C. Jet Ø 1 mm

FUNCTION : Ensures decompression of the pilot circuitof the counterbalance valve on the mast cylinder(lowering movement).

NOTEThe jet is installed with glue : cannot beremoved.

1 21

2

1

2

1

2

Torque value :4 to 5 N.m

1

2


2

1

DV1

23 Models


HYDRAULIC SYTEM 33

OG/OD : Solenoid valve 4-3 - Slewing movement Left / RightRT/ST : Solenoid valve 4-3 - Telescope extension / retraction movementMM/DM : Solenoid valve 4-3 - Mast elevation / lowering movementMB/DB : Solenoid valve 4-3 - Jib elevation / lowering movement

Face B

P R

BA

DB MB

DB DM RT OD

MB MM ST OGDV1

STRT

A B

RPOD OG

MMDM

A B

RP RP

BA

Spool valve 4-way, 2-position"Restricted floating center spool"

Spool valve 4/3 + sleeveRef. : 952034

Spool valve 4-way, 2-position"Floating center spool"


Spool valve 4-way, 2-position"Floating center spool"

Spool valve 4/3 +sleeveRef. : 952029

Spool valve 4-way, 3-position"Closed center spool"


Exploded view of a solenoid valve 4-way, 3-position :

(B) (P) (A) (R)

Face B

Manu

al co

ntro

l cov

er

Nylon

nut

O-r in

gCo

il 24

VDC

Pole

tube

Sprin

g

Sprin

g gu

ide

Spoo

l

S lee

ve

Mani

fold

Sprin

g gu

ide

Sprin

gPo

letu

be

Coil 2

4 VD

C

Nylon

nut

Manu

al co

ntro

l cov

er



HYDRAULIC SYSTEM 33

Disassembly :

1- Remove the plastic nuts holding the coils.2- Remove the O-rings and the coils.3- Remove the poletubes using adequate tooling

(Ref. 990005), (Torque to unscrew : 13 to 33N.m).

4- Remove the spring guides and drive the spoolout of the sleeve.

Inspection :

1- Clean all parts with an appropriate solvent anddry with compressed air.

2- Check the spool surfaces are not scratched.3- Check the axial and radial holes at each end

of the spool are not blocked.

NOTEIf the spool is scratched or if the holes areblocked, the spool AND the sleeve must bereplaced.

If the spool and the sleeve have to be replaced, drivethe sleeve out of the manifold using an appropriatemandrel in the direction indicated in the drawing below:

Assembly :

Never interchange spools and sleeves. Allcomponents must be clean before assembly.

1- Check for burrs that could damage O-ringsduring the installation of the sleeve.

2- Install the O-rings on the sleeve.

NOTEEnsure the seals are not stretched and thegrooves damaged during assembly.

3- Lubricate the seals before sleeve installation(MILLCOT K320 or equivalent).

4- Insert the sleeve in the manifold using anappropriate mandrel in the direction indicatedin the drawing below :

5- Lubricate the spool with clean hydraulic oil.Slide the spool into the sleeve as indicatedbelow. Ensure the spool slides freely inside thesleeve.

6- Install the spring guide on face B side asindicated in the drawing below. Install the springin the poletube. Install the poletube on themanifold using Loctite® 245. Torque thepoletube to 10 - 12 N.m using adequate tooling(Ref. 990005).

NOTEThe thread on the poletube must be free fromoil or grease before the glue is applied.

(B)(P)(A)(R)

Face B

Mandrel

Ø9,

8

(B)(P)(A)(R)

Face B

Mandrel

Face B

Face B

Torque value10 to 12 N.m

LOCTITE 245

Millcot K320or equivalent

0 -0,2

Ø9,

8 0 -0

,2

! CAUTION

25 Models


HYDRAULIC SYSTEM 3

7- Install the spring guide on the other side of thesleeve. Install the spring in the poletube. Installthe poletube in the manifold using glue Loctite®245. Torque the poletube to 5 - 6 N.m usingthe adapted tooling (Réf. 990005).

8- Install the coils and O-rings. Torque the coilnylon nuts to 4 to 5 N.m

3

Face B

Torque value5 to 6 N.m

LOCTITE 245

Play



HYDRAULIC SYSTEM 33

3.5 Drive manifold

1 : Solenoid valve 4-way, 3-position (floating centerspool).FUNCTION : Selection of the drive direction (FWD /REV).

2 : AccumulatorSee § 3.6.

Torque value for the 4 bolts securing the solenoidvalve : 9 N.m

3.6 Membrane accumulator

FUNCTION : Enables storage of a volume of oil destinedto the make up flow for the wheel motors duringreversal of the drive direction.

! DANGER

Technical characteristics :

Never loosen the top seal screw.


REV

Cap

Pressurereservoir

Top sealscrew

Membrane Obturator

Port

Inflating pressure 0,5 MPa (5 bar)Gaz NitrogenMaximum pressure 21 MPa (210 bar)Nominal volume 0,16 litrePort size Ø 1/2" BSPP

FWD

MAV : FWDMAR : REV

27 Models


3.7 Wheel motor distribution manifold

HYDRAULIC SYSTEM 33

1 : Solenoid valveDrive speed change [HI/LO]

2(a) : Counterbalance valveForward drive

2(b) : Counterbalance valveReverse drive

3 : Shuttle valve

4(a).4(b). Make up flow check valves4(c).

Torque value for the 4 bolts securing the solenoid valve[HI/LO] : 9 N.m

1

4c 4a

4b

2b

2a

3




Solenoid valve 4-way, 2-position

FUNCTION : Allows the change in drive speed by placingthe "cyl. B" displacement of the wheel motors in "freewheel".

- When the solenoid valve is not actuated (and ), both motor displacementss (cyl. A +cyl. B) are supplied.

[ HI ] : High displacement Ô slow speed

- When the solenoid valve is actuated ( ), onlythe motor displacement "cyl. A" is supplied,displacement "Cyl. B" is placed in "free wheel".

[ LO] : Low displacement Ô high speed

HYDRAULIC SYSTEM 33

T

P

T

T

P

P

P

P

Cyl. B Cyl. A

FORWARD DRIVE REVERSE DRIVE

P P

P

T

T

TT

Cyl. B Cyl. A

Cyl. B Cyl. A

T P T

TP

T T

T

P

T

T

P

P

P

P

P

Cyl. B Cyl. A

FORWARD DRIVE REVERSE DRIVE

Counterbalance valvesFUNCTION : Allows dynamic braking of the workplatform and the counter pressure necessary for themake up flow to the wheel motors.

Counterbalance valve setting : The tighter thesetting screw is, the sharper is the braking of thework platform.Adjustment must be done with the rated load correctlydistributed in the work platform. Tighten completelythe setting screw, then loosen by 4 1/2 turns to obtainan average setting.

Sharpen the setting if necessary so that :

- When the work platform is driven at maximumspeed, it stops over a distance of 0,8m to 1m onhorizontal ground (in both drive directions) whenthe joystick is returned to its neutral position.

- When the work platform is driven down a 15% slopein 2nd gear, it stops over a distance below 1 mwhen the joystick is returned to its neutral position.

Shuttle valve

FUNCTION : Oil supply to the brake release circuit inboth drive directions of the work platform.

Make up flow check valves

1

2

3 12 3

Torque value : 60 N.m

1 3

2

2 31


1

2

2

1


[H I] [H I]

[LO] [LO]

29 Models


3.8 Brake manifold

HYDRAULIC SYSTEM 33

1 : Pressure reducing valve

2 : Piloted 2-way spool

3 : Check valve

4 : Jet

PR7 : Pressure relief valve(Brake release using the hand pump)

PR8 : Pressure relief valve(Torque limiter at slow speed)

EVF : Decompression solenoid valve for the brakerelease circuit.

EVC : Solenoid valve enabling the relief valve [PR8] tooperate.


13

2

4



Pressure reducing valve

FUNCTION : Reduces the brake release pressurebetween 1,8 and 2,1 MPa (18 and 21 bar).

Piloted 2-way spool

FUNCTION :- Prevents the oil flow delivered to the brake release

circuit from returning to the reservoir when the workplatform is driven.

- Enables decompression of the brake release circuitwhen the drive control is released.

NOTESetting of the pilot pressure of the piloted 2-way spool is factory preset and should notbe modified.

Check valve

FUNCTION : Prevents the oil flow from returning to thetank (via the pressure reducing valve) while using thehand pump to release the brakes.

NOTEThe check valve is kept in position bydeformation of the thread : cannot beremoved.

1

1

23

321

Torque value 15 to 18 N.m

HYDRAULIC SYSTEM 33

Torque value : 25 to 30 N.m

Jet Ø 0,8

FUNCTION : Restricts the oil flow from returning to thetank during decompression of the brake release circuit(delays brake actuation during the dynamic brakingphase performed by the counterbalance valves on thewheel motor distribution manifold).


Pressure relief valve [PR7]

FUNCTION :- Limits the brake release pressure while the handpump is used.

- Protects the brake release circuit against anyoverpressure in case of malfunction of thepressure reducing valve.

- Setting range of the pressure relief valve [PR7]= 0 to 5 MPa (0 to 50 bar).


FUNCTION : Limits the pressure (therefore the wheelmotor torque) in the drive circuit when the machine isdriven at slow speed ( ).

- Setting range of the pressure relief valve [PR8]= 0 to 25 MPa (0 to 250 bar).

The pressure relief valves PR7 and PR8 donot share the same setting range. Do notinterchange the valve springs.

Setting of the relief valves : See § 3.19.

1 21

2

! CAUTION

1

2

Pressure relief valve PR7 - PR8


1

2

1

2

3

12 3

31 Models


HYDRAULIC SYSTEM 33

Decompression solenoid valve [EVF] forthe brake release circuit

FUNCTION :- Quick decompression (therefore immediateactuation of the brakes) of the brake releasecircuit when an emergency stop switch isactivated.

- Automatic decompression of the brake releasecircuit 3 to 4 seconds after the release of thedrive controls.

Solenoid valve [EVC] for operation reliefvalve [PR8]

FUNCTION : When the machine is driven at slow speed( ), supply to the solenoid is cut off and thepressure relief valve [PR8] comes in.

2

1

Solenoid valves [EVC] & [EVF]

Torque value :25 to 30 N.m Torque value :4 to 5 N.m

1

2



HYDRAULIC SYSTEM 33

3a

3b

1 2

A31 A32

A3 G

Differential locking manifold Manifold schematic :

3.9 Differential locking manifold

1 : By-pass solenoid valve

2(a) : Flow divider / Combiner

3(a) :Make up flow check valves

3(b) :

33 Models


13

24

3.10 Wheel motors

Technical characteristics :(Radial piston motors)

- Motor 332 cc/rev. :

Motor identification 332 cc/rev. :

Left motor :

Right motor :

1. Commercial description2. Code = Part number3. Série = Production batch number4. Num = Chronological serial number

PHM S E 0 2 - A - J E 3 - F 0 3 - 1 1 2 0 - D J - 0 0

Code : 0025438-02C Indice

Série : XXX Num : XX

1

2

3 4

PHM S E 0 2 - A - FE03 - 1 1 2 0 - D J - 0 0

Code : 0025438-01B Indice


1

2

3 4

By-pass solenoid valve - 4-way, 2-position

FUNCTION :When the solenoid is not actuated :

- Allows free flow between the motors and thewheel motor distribution manifold.

- When the solenoid valve is actuated ( ) :blocks flow between the motors and thedistribution manifold : the flow divider/combineris operating.

Flow Divider / Combiner

FUNCTION :When the by-pass solenoid valve is actuated ( ) :- Divides equally the oil flow delivered to each wheel

motor (in forward drive).- Combines equally the oil return flow from each wheel

motor (in reverse drive).

Make up flow check valve [3 (a)(b)]

2

1

Torque value :27 N.m maxi

HYDRAULIC SYSTEM 33

2

142 3


1

2

3

1 2 3


Minimum displacement (Cyl. A) 133 cm³/rev.

Maximum displacement (Cyl. A + B) 332 cm³/rev.

Braking torque 250 daN.m

Max. operating pressure 40 MPa (400 bar)

Brake release pressureMini : 1,2 Mpa (12 bar)Maxi : 3,0 Mpa (30 bar)

Studs M14 x 150 (Qty : 5)



HYDRAULIC SYSTEM 33


Left motor :

Right motor :

PHM S E 0 2 - 2- GE 3 - F 0 3 - 1 1 2 0 - D J - 0 0

Code : 0042438-35P Indice


1

2

3 4

PHM S E 0 2 - 2- DE 3 - F 03 - 1 1 2 0 - D J - 0 0

Code : 0042438-34N Indice


1

2

3 4


Left motor :

Right motor :

- Motor 398 cc/rev. : (Option gradeabillity 15%) - Motor 500 cc/rev. : ("Power plus" option)

PHM S E 0 3- 2- GE A- F 0 3 - 1 1 2 0 - D H-J0

Code : 0045438-18D Indice


1

2

3 4

PHM S E 0 3- 2- DEA- F 03 - 1 1 2 0 - D H- J0

Code : 0046438-17C Indice


1

2

3 4




Max. Operating pressure 40 MPa (400 bar)






Max. operating pressure 40 MPa (400 bar)



35 Models


! CAUTION

! CAUTION

! CAUTION

Repeated use of the brakes as emergencybrakes (action on the emergency stop duringa drive movement) will reduce the brakingtorque. The brakes must be tested forefficiency after emergency braking.

NOTEBefore starting a motor, the housing must befilled with hydraulic oil through Port "2".

NOTEDisassembly of the wheel motors requiresspecific competences and tooling. ContactJLG Product Support.

HYDRAULIC SYSTEM 33

! CAUTION

Cyl. B Cyl. AX

A1A2

R

2

Ports identification :

Port A1 :Supply port corresponding to the preferential rotation direction (Cyl. A).Port A2 :Supply port corresponding to the preferential rotation direction (Cyl. B).Port R :Return port corresponding to the preferential rotation direction.Port X :Brake pilot port.Port 2 :Housing drain port.

The brake pilot pressure should not exceed3,0 MPa (30 bar) continuous.

The pressure in the motor housing should notexceed 0,1 MPa (1 bar) after the stabilisationof hydraulic fluid temperature (0,3 MPa (3bar) max. when cold).

Do not operate the motors without any loadand at maximum speed.



Troubleshooting

HYDRAULIC SYSTEM 33

PROBABLE CAUSE SOLUTIONS

Regular rumbling Worn bearing support Replace the bearing support

Vibrations Mounting and/or hydraulic piping becoming loose Tighten to torque

Clattering Boost pressure too low

- Check the pressure setting and condition of the counterbalance valves (Wheel motor distribution manifold)- Check boost pressure. Check for any leak in the drive circuit.

Cavitation Internal leaks too important Replace the cylinder block and the distribution valve assembly : Contact JLG Product Support

No supply to the motor Check the pump drive and pump inlet

The circuit does not reach working pressure

- Check the position of the motor release valve.- Check the condition of the pressure relief valve [PR1]- Check the supply and condition of the solenoid valve [EVC] (Brake manifold).

Excessive internal leaks Replace the cylinder block and the distribution valve assembly : Contact JLG Product Support

The brake stays engaged

- Check the brake pilot circuit. - Check the brakes bleeding screws,- Check the supply and condition of the solenoid valve [EVF] (Brake manifold).

The pump flow is too low- Check the condition of the gear pump.- Check the acceleration input received by the electronic controller.

Excessive internal leaks Check the condition of the cylinder block and of the distribution: Contact JLG Product Support.

- Check setting and condition of the counterbalance valves (wheel motor distribution manifold)- Check the drive circuit for leaks.- Check the supply and condition of the solenoid valve [EVC] (Brake manifold).- Check the condition of the motor release valve.- Check the condition of the piloted 2 way spool (Brake manifold).

Irregular flow - Check the oil level in the reservoir.- Check the pump flow.

Excessive leaks Check the condition of the cylinder block and of the distribution valve assembly : Contact JLG Product Support.

Too high housing pressure Check the drain circuit

Damaged seals Replace the seals : Contact JLG Product Support.

Incorrect assembly Tightening of motor mounting screws, of bleeding screws and hydraulic fittings.

Working pressure is too low

THE MOTOR DOES NOT REVOLVE

THE MOTOR DOES NOT REVOLVE AT ITS NORMAL SPEED UNDER LOAD

THE MOTOR REVOLVES IRREGULARLY

SYMPTOMS

EXTERNAL OIL LEAKS

NOISY MOTOR

Without load

Under load

37 Models


3.11 Steering manifold

HYDRAULIC SYSTEM 33

1 : Solenoid valve, 4-way, 3-position

2 : Pressure relief valve [PR 12] :Steering to the right.

3 : Pressure relief valve [PR 13] :Steering to the left.

4a :Shuttle valve

4b :

5 : Jet Ø 1 mm


See §

3.4

5

1

DG : Steer LEFTDD : Steer RIGHT



HYDDRAULIC SYSTEM 33

Solenoid valve 4-way, 3-position -Steering movement

FUNCTION :- Selection of the steering movement direction.

4-way, 3-position "close center spool".Spool 4/3 + sleeve 06E.Ref. : 952033

Removal / Installation procedure for the4/3 spool

See § 3.4.

Pressure relief valves [PR 12] [PR 13]Setting of the pressure relief valves : See § 3.19.

Shuttle valve

FUNCTION : Directs oil from the highest pressure circuitto the steering cylinder supply circuit.

1

2



1 2

3

Jet Ø 1 mm

FUNCTION : Restricts the oil flow taken for the steeringcylinder supply (limitation of speed reduction of thedrive movement when a steering movement iscontrolled simultaneously).


1

2

39 Models


HYDRAULIC SYSTEM 33

3.12 Check valves manifold ("power plus" option)

DV2 : Solenoid valve (NO).1a : Check valve1b : Check valve2 : Pressure switch

FUNCTION : Combines the flow from both pumps when the "power plus" option is installed.

Manifold schematic

DV2 : Solenoid valve (NO).

Check valve (1a)

FUNCTION : Prevents the return of the oil flow supplied by the main hydraulic power unit through the pump of theauxilliary power unit.

Check valve(1b)

FUNCTION : Prevents the return of the oil flow supplied by the auxilliary hydraulic power unit through the pump ofthe main power unit.

PORT GP :auxilliary pump inletPORT PP :Main pump inlet

Torque value : 30 N.m maxi

FUNCTION : Dumping of the oil flow supplied by thesecondary hydraulic power unit.

2

1b 1a

1

2



1

6

45

8

3

8

27

Spool extractiondirection

Spool assemblydirection

HYDRAULIC SYSTEM 33

2

1

Torque value : 27 N.m max.

2

Check valves (1a) (1b)

Pressure switch

FUNCTION : Cuts automatically the auxilliary hydraulicpower unit as soon as the pressure in the circuitreaches the pressure switch setting : (17 ± 1 MPa /170 ± 10 bar).

Electrical connections : "PDAH" models

Electrical connections : "PSP" models

3

2

5

4

6

1

Gicleur Ø3.2mm

3.13 Release control valve

FUNCTION :- Release of the wheel motors (free wheel).- Diverts the hand pump flow to the brake release

circuit.- Return the oil from the hydraulic power unit(s) to the

tank.

Control valve schematic :

Control valve exploded view :

3 2 1

6 5 4

1- Rear cover attachment screw2- Front cover attachment screw3- Spool4- Index5- Spacer6- Rear cover7- Front cover8- O-ring

NO [3]

NC [2]COM [1]

NO [2]

NC [1]COM [3]

Ô

41 Models


HYDRAULIC SYSTEM 33

3.14 Trim correction manifold

1. Poppet solenoid valve [EVI]2. Pressure relief valve [PR11]

Manifold schematic

FUNCTION : Enables the adjustment of the horizontalityof the work platform :

- When a movement to tilt the platform to the rear iscontrolled :

- The solenoid valve [EVI] is actuated.- The coil [MB] (Jib elevation) on the functionmanifold is supplied.

An additional volume of fluid is admitted in the trimcircuit between the master cylinder (rod side) and theslave cylinder (piston side) : the work platform tiltsrearwards.

- When a movement to tilt the platform to the front iscontrolled :

- The solenoid valve [EVI] is actuated.- The coil [DB] (Jib lowering) on the functionmanifold is supplied.

A volume of fluid is extracted from the trim circuitbetween the master cylinder (rod side) and the slavecylinder (piston side) : the work platform tilts forwards.

Solenoid poppet valve [EVI]


FUNCTION : Protects the trim circuit against excessivepressure during the jib elevation movement.

Setting of the pressure relief valve : see § 3.19.

1

2


1 2

1

2




HYDRAULIC SYSTEM 33

3.15 7-way, 3-position flowdiverter (option)

FUNCTION : Diverts the supply circuit for the telescopecylinder to the cylinder ensuring the work platformrotation. The diverter coil [EVR] is supplied when arotation movement is controlled. The direction of therotation movement is determined by the solenoid valveST/RT on the function manifold (see § 3.4). Port "T"enables the decompression of the cylinder circuit thatis not used.

Diverter 7-way, 2-position

1. 7-way, 2-position flow diverter2. Jet Ø 0.6 mm on port B2

3. Jet Ø 1.0 mm on port A2

1

23

3.16 Cylinders supply manifold

3.16.1 Mast cylinder

1. Single effect cylinder wet rod Ø80 - stroke 1005mm(T1210) and 1175mm (T1310).2. Pressure compensated flow regulator : 9 l/mn.3. Counterbalance valve : pilot ratio : 10:1.

Pressure compensated flow regulator

FUNCTION : Ensures a constant lowering speedwhatever the load in the work platform.

Respect the assembly direction of the flowregulator. Use a screwdriver of appropriatedimension to prevent damage to theregulator recess.

! CAUTION

Regulated flow

1 2

2 1

1 32Assembly direction

43 Models


Counterbalance valve

FUNCTION :- Load holding in the event of hose failure.- Allows pressure relief in case of overload.- Allows thermal expansion relief of the hydraulicfluid.

Pilot ratio : 10:1.Setting : 21MPa (210 bar) at 4 l/mn (factory setting).

NOTEThe locknut must be tight to prevent anyexternal leak.

1

2

3

1

2 3

3.16.2 Jib cylinder

1. Double effect cylinder Ø80-60 - stroke 783 mm2. Pressure compensated flow regulator : 9 l/mn3. Counterbalance valve : pilot ratio : 2,5:14. Male cap Ø3/8" BSPP


FUNCTION :- Ensures a constant lowering speed whateverthe load in the work platform.

Respect the assembly direction of the flowregulator. Use a screwdriver of appropriatedimension to prevent damage to theregulator recess.

HYDRAULIC SYSTEM 33


! CAUTION

1

3

4

2

Assembly direction

Supply

Regulated flow

1 2

2 1



HYDRAULIC SYSTEM 33

3.16.3 Telescope cylinder

1. Double effect cylinder Ø70-45 - stroke 1205 mm2. Dual overcenter valves

2a. Counterbalance valve rod side2b. Counterbalance valve piston side.

Dual overcenter valvesFUNCTION :

- Load holding in the event of hose failure.- Allows pressure relief in case of overload.- Allows thermal expansion relief of the hydraulicfluid.

Pilot ratio : 6,5:1.

Setting of the counterbalance valve (2a) rod side

- Lower the jib, telescope retracted.- Fully tighten the valve setting screw.- Place a 250 kg load evenly distributed on thework platform floor.

- Slowly loosen the valve setting screw until thetelescope starts to extend, then tighten thescrew again by a 1 turn ½. Tighten the locknut.

Setting of the counterbalance valve (2b) pistonside

- Place a 250 kg load evenly distributed on thework platform floor.

- Fully tighten the valve setting screw.- Fully raise the jib. Extend the telescope byapproximately 50 cm.

- Slowly loosen the valve setting screw until thetelescope starts to retract, then tighten thescrew by a turn ½. Tighten the locknut.

1

2

3

1

2 3


FUNCTION :- Load holding in the event of hose failure.- Allows pressure relief in case of overload.- Allows thermal expansion relief of the hydraulicfluid.

Pilot ratio : 2,5:1Setting : 21MPa (210 bar) at 4 l/mn (Factory setting)

NOTEThe locknut must be tight to prevent anyexternal leak.

2a

2b


45 Models


HYDRAULIC SYSTEM 33

1. Assistance cylinder :double effect Ø60-30 - stroke 319 mm.

2. Counterbalance valve3. Slave cylinder :

double effect Ø60-30 - stroke 319 mm.4. Dual overcenter valves

4a. Counterbalance valve rod side.4b. Counterbalance valve piston side.

5. Pressure compensated flow regulator : 3 l/mn.6. Male cap Ø 3/8" BSPP.7. Master cylinder :

double effect Ø 70-35 - stroke 323 mm.8. Bleeding screws.


Pilot ratio : 2,5:1

NOTEThe locknut must be tightened to prevent anyexternal leak.

Regulated flow

1 2

2 1

Respect assembly direction of the flowregulator. Use a screwdriver of appropriatedimension to prevent damage to theregulator recess.

3.16.4. Assistance cylinder - Mastercylinder - Slave cylinder

! CAUTION

1 3

2 4


FUNCTION : Ensures a constant extension speed ofthe cylinder whatever the load in the work platform.

Pilot ratio : 2,5:1

1

2

3

1

2 3

Couple de serrage : 45 N.m.

67

7

3

3b

3a

4

52



HYDRAULIC SYSTEM 33

3.16.5 Rotation cylinder (optional)

1. Double effect cylinder Ø 50-30 - stroke : 130 mm.2. Dual overcenter valves

2a. Counterbalance valve rod side2b. Counterbalance valve piston side


- Keep the cylinder in position in the event ofhose failure.

- Allow pressure relief in case of overload.- Allow thermal expansion relief of the hydraulicfluid.


Setting of the counterbalance valves (2a & 2b) :

- Loosen the valve setting screw.- Tighten the setting screw until it contacts thevalve springs, then tighten the screw by 1 turn.Tighten the locknut.

1

2

2b

2a2m

m


- Load holding in the event of hose failure.- Allows pressure relief in case of overload.- Allows thermal expansion relief of the hydraulicfluid.


Setting of the counterbalance valve (4a) rod side

- Lower the jib with the work platform floorhorizontal.

- Fully tighten the valve setting screw (4a).Loosen without removing it the counterbalancevalve (2) setting screw and tighten the locknut.

- Place a 250 kg load evenly distributed on thework platform floor.

- Loosen slowly the setting screw until theplatform starts to tilt rearwards, then tightenthe screw again by 1 turn. Tighten the locknut.

Setting of the counterbalance valve (4b)piston side :

- Loosen the valve setting screw (4b).- Tighten the valve setting screw until it contactsthe valve spring, then tighten the screw by 2turns. Tighten the locknut.

Setting of the counterbalance valve (2) :

- Tighten the setting screw and the locknut untilthe screw juts out over the locknut by 2mm.

- Lower the jib. Position the speed adjustmentpotentiometer for the structure movements onmaximum speed ( ).

- With one person only in the platform, performa trim correction movement towards the rear.

- The platform must recline to the rear and thejib not rise. Otherwise, loosen the setting screwby 1/8 turn.

47 Models


HYDRAULIC SYSTEM 33

3.17 Sequence valve

FUNCTION : Authorizes the counterbalance valve on thejib cylinder (jib lowering) to be piloted only once thenecessary pressure in the chambers of the slave andassistance cylinders has been reached (necessarypressure to keep the work platform with its loadhorizontal during the jib lowering movement).Decompression of the counterbalance valve pilotcircuit is performed through the check valveincorporated to the valve.

Control of the sequence valve setting

- Connect a pressure gauge on the pressure plug"M" on the function manifold (see § 3.4).

- Fully raise the jib, telescope retracted.- Position the speed adjustment potentiometeron minimum and lower the jib. The jib shouldstart to lower only when a pressure of 12 ± 0,5MPa (120 ± 5 bar) is reached.

3.18 Slewing hydraulic motor

1. Hydraulic motor 32 cc/rev.2. Pressure relief valve [PR9] (slewing to the right)3. Pressure relief valve [PR10] (slewing to the left)

Pressure relief valves setting : see § 3.19.

1

2



HYDRAULIC SYSTEM 33

3.19 Pressure relief valves

The pressure relief valves are used to protect thehydraulic system against excessive pressures (withinthe circuit in which they are used) by returning thehydraulic oil to the reservoir when the setting pressureis reached.

NOTEAdjustement of a pressure relief valve settingshould only be performed by qualifiedmechanics using the correct equipment - onlyafter the need for adjustment has beenestablished.

The table titled Relief Valve Pressure Settings listsmain and circuit relief valve pressure settings. If thepressure setting of any relief valve is not ± 5 bars ofthe setting listed in the table, adjust valve as necessary(unless otherwise specified).

Identification of the pressure relief valves on thefunction manifold : see § 3.4.Identification of the pressure relief valves on thebrake manifold : see § 3.6.Identification of the pressure relief valves on thesteering manifold : see § 3.11.Identification of the pressure relief valves for theslewing movement : see § 3.18.

For the adjustment of the pressure reliefvalves, the movements must be performedat MAXIMUM SPEED.

NOTEFor a correct verification of a relief pressure,the locknut of the relief valve adjustmentscrew must be tightened.To adjust a pressure relief valve, turn theadjustment screw until the correct setting isreached (tighten to increase the pressure).

Preparation

Before performing any adjustment on relief valves,warm the oil between 25°C and 50°C.Use a pressure gauge from 0 to 40,0 MPa (400 bar)to adjust pressure relief valves. For pressures below3 MPa (30 bar), use a pressure gauge from 0 to 6MPa (60 bar).

! CAUTION

Function Opening pressure Pressure relief valve Check at port "M" onGeneral pressure 23 Mpa (230 bar) PR1 Function manifoldTelescope extension 15 Mpa (150 bar) PR2 Function manifoldTelescope retraction 18 Mpa (180 bar) PR3 Function manifoldMast elevation 18 Mpa (180 bar) PR4 Function manifoldJib elevation 16 Mpa (160 bar) PR5 Function manifoldJib lowering 18 Mpa (180 bar) PR6 Function manifold

Brake piloting max pressure35 bar

Max. peak pressurePR7 Brake manifold

Drive at low speed 11 Mpa (110 bar) PR8 Function manifoldSlewing to the left 11 Mpa (110 bar) PR9 Function manifoldSlewing to the right 11 Mpa (110 bar) PR10 Function manifoldTrim correction 18 Mpa (180 bar) PR11 Trim correction manifoldSteering to the right 14 Mpa (140 bar) PR12 Function manifoldSteering to the left 14 Mpa (140 bar) PR13 Function manifold

PRESSURE RELIEF VALVE SETTINGS T1210 - T1310

49 Models


HYDRAULIC SYSTEM 33

3.19.2.2. Telescope extension [PR2]

1- Connect the pressure gauge to the pressureplug "M" on the FUNCTION MANIFOLD.

2- EXTEND THE TELESCOPE until the cylinderis at the end of its course. Adjust the pressurerelief valve setting if necessary.

3- Disconnect the pressure gauge.

3.19.2.3. Telescope retraction [PR3]


2- RETRACT THE TELESCOPE until the cylinderis at the end of its course. Adjust the pressurerelief valve setting if necessary.


3.19.2.4. Mast elevation [PR4]


2- RAISE THE MAST until the mast cylinder is atthe end of its course. Adjust the pressure reliefvalve setting if necessary.


3.19.2.5. Jib elevation [PR5]


2- RAISE THE JIB until the jib cylinder is at theend of its course. Adjust the pressure relief valvesetting if necessary.


3.19.2.6. Jib lowering [PR6]


2- LOWER THE JIB until the jib cylinder is atthe end of its course. Adjust the pressure reliefvalve setting if necessary.


3.19.1. Brake release circuit pressurecheck

1- Chock both front wheels as indicated below :

2- Connect the pressure gauge to the pressureplug "M" on the BRAKE MANIFOLD;

3- Position the DRIVE SPEED selector to ( ).4- Actuate a FORWARD drive movement by

pushing the joystick forward. If the pressureindicated by the pressure gauge is not between15 and 21 bar, refer to BRAKE RELEASEMAXIMUM PRESSURE § 3.19.2.7. If themaximum pressure is higher than 21 bar,consult your local JLG distributor.


3.19.2. Pressure relief valve setting

Setting values : See table § 3.19.

3.19.2.1. Main pressure [PR1]

1- Chock both rear wheels as indicated below :


3- Position the DRIVE SPEED selector to ( ).4- Actuate a REVERSE DRIVE movement by

pulling the joystick rearwards. Adjust thepressure relief valve setting if necessary.




HYDRAULIC SYSTEM 33

3.19.2.8 Drive at low speed [PR8]

1- Chock both wheels as indicated below :


3- Position the speed selector to ( ).4- Push the joystick forward to actuate a

FORWARD DRIVE movement. Adjust thepressure relief valve setting if necessary.


3.19.2.9 Slewing to the left [PR9]


2- SLEW fully the structure to the LEFT. Adjustthe pressure relief valve setting if necessary.


3.19.2.10 Slewing to the right [PR10]


2- SLEW fully the structure to the RIGHT. Adjustthe pressure relief valve setting if necessary.


! CAUTION

3.19.2.7. Brake release maximum pressure[PR7]

1- Chock both wheels as indicated below :

2- Disconnect and cap the brake supply hoses(see §3.10).

3- Connect a pressure gauge to the pressure plug"M" on the BRAKE MANIFOLD.

4- TIGHTEN FULLY the setting screw for thepressure relief valve [PR7].

5- Position the DRIVE SPEED selector on ( ).6- Push the joystick forward to actuate a

FORWARD DRIVE movement. The maximumpressure reading on the pressure gauge mustbe between 15 and 21 bar corresponding tothe setting of the pressure reducing valve.Record the exact value indicated by thepressure gauge.

If the pressure is below 15 bar or higher than21 bar, consult your JLG distributor.

7- LOOSEN the setting screw on the pressurerelief valve [PR7] until the pressure drops justunder the value recorded previously, thenTIGHTEN the setting screw by ¼ turn.

8- Remove the pump handle and push the lever ofthe release control valve to the released position

.9- Insert the handle in the hand pump and actuate

the handle vigorously. Note the pressure peakon the pressure gauge. If the pressure peakexceeds 35 bars, loosen the setting screw onthe pressure relief valve PR7 by 1/8 of a turnand check the pressure peak again.

10- Disconnect the pressure gauge.11- Reconnect the brake supply hoses.

Maximum brake supply pressure = 30 bar.Maximum admissible pressure peak duringuse of the hand pump to release the brakes= 35 bar.

! CAUTION

51 Models


HYDRAULIC SYSTEM 33

3.19.2.11. Trim correction [PR11]

1- Connect the pressure gauge to the pressureplug "M" on the trim correction manifold.

2- Fully raise the jib.3- Fully tighten the pressure relief valve, [PR5] on

the function manifold.4- Disconnect the [EVI] solenoid connector on

the trim correction manifold (see § 3.14).5- Connect a direct 24 VDC supply to the coil

[EVI].

Connect a direct supply to [EVI] only whenthe jib is at the end of its high course andwhen no movement is performed.

6- Control a JIB ELEVATION movement. Adjustthe pressure relief valve setting if necessary.

Do not control any other movement than thejib elevation movement as long as the coil[EVI] is supplied directly and only when thejib is at the end of its high course.

7- Disconnect the direct supply from the coil andreconnect the connector to the solenoid.

8- Adjust the relief valve [PR5] : see § 3.19.2.5.9- Disconnect the pressure gauge.

DANGER

DANGER

3.19.2.12. Left steering

1- Connect the pressure gauge to the pressureplug "M" on the function manifold.

2- STEER the wheels fully to the LEFT. Adjustthe pressure relief valve in necessary.


3.19.2.13. Right steering

1- Connect the pressure gauge to the pressureplug "M" on the function manifold.

2- STEER the wheels fully to the RIGHT. Adjustthe pressure relief valve in necessary.


53 Models


ELECTRICAL SYSTEM 44

4.1 Wiring diagrams

4.1.1. Battery wiring

Filli

ng h

ose

Filli

ng h

ose

Bat

tery

cab

leL=

1500

-

FULMEN

L=15

00

+

Bat

tery

cab

le

Bat

tery

cab

leL=

1500

L=40

00

L=15

00

+-

Bat

tery

cab

le

FULMEN

-+L=

2000

Left

side

bat

tery

pac

k

Front battery pack

Flow

Indi

cato

r

Filte

rRight Side battery pack

Battery plug




4.1.2 Power circuit wiring

PC0338

55 Models



4.1.3 Components locationLinked to the platform control box Toucan 1210 and Toucan 1310

Foot

sw

itch

Péda

le

Dév

iate

ur 7

voi

es7-

way

val

ve

EVRCR

52 CR

53

CR

51B

oîtie

r de

com

man

de

UC

B plat

e-fo

rme

T131

0

LCB

- B

oîtie

r de

com

man

de b

as

LCB

- B

oîtie

r de

com

man

de b

as

CR

1C

R2

CR

14

SW

1

CR

9

SW 2

Cap

teur

téle

scop

eTé

leco

pe s

witc

h

Cap

teur

bra

s fd

cJi

b sw

itch SW

3C

apte

ur b

ras

Jib

switc

h

SW 5

Cap

teur

mât

Mas

t sw

itchS

W 4

Blo

c in

clin

aiso

nIn

clin

atio

n m

anifo

ld

CR

8

PC

023

8

PC

024

0

PC 0

260

PC 0

252

PC

026

1



CR

30

Cha

rger

M3

Cha

rgeu

r

Aux

1nc

cno

Rem

plis

sage

bat

tery

Bat

tery

filli

ng u

nit

Con

trolle

r

B-

Varia

teur

SW

34SW

35

SW36

Flas

hing

ligt

hsLa

mpe

s cl

igno

tant

es

CR

60C

R58

CR

54

CR

55

CR

57C

R56

CR

27

CR

24

LCB

- P

oste

de

seco

urs

CR

26

-+

CO

N1

CR

16

CR

18C

R17

UC

B -

Boî

tier d

e co

mm

ande

pla

te-fo

rme

Cha

ssis

Box

- B

oîtie

r cha

ssis

UC

B -

Boî

tier d

e co

mm

ande

pla

te-fo

rme

Con

trolle

r 17

pins

con

nect

orS

lack

cha

in d

etec

tion

swC

apte

urs

mou

de

chaî

ne

CR

25

Cap

teur

de

défo

rmat

ion

Stra

in li

nk

Hor

nA

verti

sseu

r

+

+ - Tou

can

1210

13

2

6

45 10

Linked to the emergency control panel Toucan 1210


57 Models


+

+

M3

KM

1-

+-

CR

56

Aux

1

Chargeur HF nccHF Charger

no

Ave

rtiss

eur

Hor

n

Feux

à é

clat

sFl

ashi

ng li

gths

SW

36C

ontro

ller 1

7 pi

ns c

onne

ctor

CR

55

CR

54

CR

58

Varia

teur

Con

trolle

r

Cap

teur

s m

ou d

e ch

aîne

Cha

in s

lack

det

ectio

n sw

CR

60

SW

35

CR

17C

R18

Rem

plis

sage

bat

tery

CR

25

CR

26

LCB

- Boî

tier d

e co

mm

ande

bas

CR

24

CR

27

CR

16

B-

SW

34

UC

B - B

oîtie

r de

com

man

de p

late

-form

e

Cha

ssis

éle

ctric

al c

onne

ctio

n bo

x

UC

B - B

oîtie

r de

com

man

de p

late

-form

e

CR

57

Stra

in li

nkC

apte

ur d

e dé

form

atio

n

Chargeur BFLF Charger

SW37

Boîti

er c

onne

xion

s ch

assi

s

CR

63

CR

30CR

19

Batte

ry fi

lling

unit C

R62

Linked to the emergency control panel Toucan 1310




Linked to the chassis box Toucan 1210


DG

CR

19

LCB

- P

oste

de

seco

urs

CR

59

SW38

DLC

K

EVF

EVC

MA

R

MA

V

KM2

Tilt

sens

orD

etec

teur

de

déve

rs

Driv

e m

anifo

ldB

loc

trans

latio

n

Blo

c bl

ocag

e di

ffére

ntie

lD

ifflo

ck m

anifo

ld

Bloc

frei

nage

Brak

e m

anifo

ld

Driv

e m

otor

s m

anifo

ld

HI/L

OD

V2

Che

ck v

alve

s m

anifo

ldB

loc

clap

ets

Con

tact

eur s

econ

daire

Seco

ndar

y co

ntac

tor

Cha

ssis

Box

Boî

tier c

hass

is

(Opt

ion)

(Opt

ion)

CR

26

DD

DB

DM

RT

OD

MB

MM

STO

GD

V1

+-CR

26

Blo

c di

strib

utio

n m

oteu

rs d

e ro

ues

59 Models


Linked to the chassis box Toucan 1310


CR

32CR

33

CR

31

CR

35

CR

36

DD

Driv

e m

anifo

ld

SW39

OD

Blo

c tra

nsla

tion

SW40

DM

DB

RT

CR

61

CR

64

Det

ecte

ur d

e dé

vers

Tilt

sens

or

CR

59

LCB

- Boî

tier d

e co

mm

ande

bas

DG

MM

MB

STD

V1

OG

EVF

DLC

K

Diff

lock

man

ifold

Seco

ndar

y co

ntac

tor

Con

tact

eur s

econ

daire

DV2KM

2

SW38

SW

41 MAV

MA

R

Blo

c cl

apet

sC

heck

val

ves

man

ifold

HI/L

OS

teer

man

ifold

Blo

c di

rect

ion

Bloc

dis

tribu

tion

mot

eurs

de

roue

sD

rive

mot

ors

dist

ribut

ion

man

ifold

K14

K15

SW

42

CR

34

Bloc

blo

cage

diff

éren

tiel

Brak

e m

anifo

ldBl

oc fr

eina

ge

EVC



4.2. Sensors

4.2.1 Mast position switch [SW4]

When the telescopic mast leaves its lowered position,the switch is actuated and provides :

- Supply cut (+) to the coil [HI/LO] of thedistribution manifold for the wheel motors.

- Supply cut (+) to the coil [EVC] of the brakemanifold.

- Actuation of the selective cut of movementswhen the aerial work platform is tilting (See §4.1.6).

- The automatic switch to slow drive speed(parameter "Test 3" on controller =CL when adrive movement is controlled - see § 4.5).

4.2.2. Jib lower position switch [SW5]

When the jib is raised, the switch is actuated andcauses :

- The supply cut (+) to the coil [HI/LO] of thedistribution manifold for the wheel motors.

- The supply cut (+) to the coil [EVC] of the brakemanifold.




4.2.3. Telescope position switch [SW2]

When the telescope is extended, the switch isactuated and causes :

- The supply cut (+) to the coil [HI/LO] of thedistribution manifold for the wheel motors.

- The supply cut (+) to the coil [EVC] of the brakemanifold.



Jib lower position switch

61 Models



4.2.4. Jib higher position switch [SW3]

During an elevation movement of the jib, the switch isactuated before the jib reaches the end of its highercourse and causes a reduction in the speed of themovement (Reduction of the acceleration inputdelivered to the controller). When the switch has beenactuated, and a jib lowering movement is controlled,it will be performed also at low speed till the switch isreleased.

Jib higher position switch

4.2.5. Slack chain sensors [SW34 to 37]

The 4 slack chain sensors are wired in series. Whena slack chain appears, one (or several) sensor isactuated and causes :

- Actuation of an alarm.- Cut off all movements except jib and mastraising movements :

- Supply cut (+) to the coil [DV1] on thefunction manifold.

- Actuation of the "Pump Inhibit" function ofthe controller when a non authorizedmovement is controlled (parameter "Test 10of the controller = CL - see § 4.5).




4.2.6. Control-Adjustment of the tiltindicator

Control :

Ensure the detector rests correctly on the supportcapnuts.

1- Position the control panel selector on ( ).2- Chock the rear wheels.3- Place a spirit level (digital display) on the

chassis in the direction (1) - (2).4- Using a jack of sufficient capacity, lift the front

of the chassis in (1) :ç Stop as soon as the green light indicator

on the sensor switches off (jerks linked tothe manoeuvre stopped). Read the chassisangle : value (a).

5- Chock the front wheels.6- Using a jack of sufficient capacity, lift the rear

of the chassis in (2).ç Stop upon extinction of the indicator: value (b).

7- Place the spirit level on the chassis in thedirection (3) - (4) .

8- Using a jack of sufficient capacity, lift the righthand side of the chassis in (3).ç Stop upon extinction of the indicator: value

(c).9- Using a jack of sufficient capacity, lift the left

hand side of the chassis in (4) .ç Stop upon extinction of the indicator: value

(d).

PB1 : Tilt indicator to replace.PB2 : Tilt indicator to replace.PB3 : Adjust

Adjustment:

- Position the machine with chassis horizontalin all directions (1) (2) & (3) (4) (Blocks underthe wheels) : installation tolerance : ± 0,1°.

- Remove the protection on the calibraion wire.Link the latter to the - on the battery until thedetector green indicator flashes.ç The detector is set. Install the protection.

NOTEIf a symetry fault is corrected, the setting mustbe checked again in both directions beforethe machine is returned to service.

1

2

34

Spirit level

Niveauélectronique

Recordings Values admitted Otherwise see

a + b (c+d) ± 0.2° PB1a + bc + d

abcd

3.6° to 4.4° PB2

1.8 to 2.2° PB3

63 Models



4.2.7. Strain link (Stability control device)

The factors acting upon the work platform stability(tilt, overload, wind, outside forces....) induce in thestructure mechanical stresses that are expressed byan elastic deformation measured by theextensiometric sensor. The sensor output signal istreated by an electronic box equipped with a relayoutput that opens the circuit when the signal reachesa predetermined value. Opening of the circuit causes:

- Actuation of an alarm.- Reduction in speed of the mast and jib elevationmovements (parameter Test 4 of the controller= CL - see § 4.5).

- The cut off of the following movements :- drive- slewing- telescope extension- jib lowering as long as the telescope isnot retracted [SW2]

Movement cut off is obtained by :

- Supply cut (+) to the coil [DV1] on the functionmanifold.

- Actuation of the "Pump Inhibit" function of thecontroller when a non authorized movement incontrolled (p

Documents

MODELS TOUCAN 1210 TOUCAN 1310 · 2020. 3. 27. · English - Service Manual MODELS TOUCAN 1210 TOUCAN 1310 U.S.A. JLG Industries, Inc. 1 JLG Drive McConnellsburg PA 17233-9533 Tel