SERVICE MANUAL - JLG Industries 1010/1 - SN... · Toucan 1010 Models 4 Revision 02-2000 INTRODUCTION 1 Foreword Important information WORK PLATFORM CHARACTERISTICS 2 Description-----2.1

SERVICE MANUAL

Revision 02-2000 MA 0235-01

English

Toucan 1010 I

3 Models

Revision 02-2000 Toucan 1010

MA0235-01

Models

Toucan 1010 _____

Toucan 1010 I _____

Toucan 1010 Models

Revision 02-20004

INTRODUCTION 1ForewordImportant information

WORK PLATFORM CHARACTERISTICS 2Description ------------------------------------------------------------------------------- 2.1Characteristics - Dimensions - Performances --------------------------------- 2.2

PRESSURE SETTINGS 3Relief valve setting -------------------------------------------------------------------- 3.1Brake release circuit pressure check --------------------------------------------- 3.2Circuit relief valve adjustment ------------------------------------------------------ 3.3Main pressure (PR1)---------------------------------------------------------------- 3.3.1Right swing (PR2) ------------------------------------------------------------------- 3.3.2Left swing (PR3) -------------------------------------------------------------------- 3.3.3Mast elevation (PR4) --------------------------------------------------------------- 3.3.4Jib elevation (PR5) ----------------------------------------------------------------- 3.3.5Jib lowering (PR6) ------------------------------------------------------------------ 3.3.6Brake release maximum pressure (PR7) ------------------------------------- 3.3.7Drive at low speed (PR8) --------------------------------------------------------- 3.3.8Counterbalance valve setting ------------------------------------------------------- 3.4

BATTERY - CHARGER 4Battery ------------------------------------------------------------------------------------ 4.1Charger ----------------------------------------------------------------------------------- 4.2Fulmen charger ---------------------------------------------------------------------- 4.2.1Oldham-Hawker charger ---------------------------------------------------------- 4.2.2Westinghouse-SGTE charger----------------------------------------------------- 4.2.3Battery filling ---------------------------------------------------------------------------- 4.3Electrolyte specific gravity and battery voltage ------------------------------- 4.4Centralised filling system maintenance ------------------------------------------ 4.5Cleaning - Battery maintenance---------------------------------------------------- 4.6Storage of a battery at temperature below 0°C (32°F) ------------------- 4.7Use of a battery in a cold chamber or in a cold climate -------------------- 4.8Battery not working continuously or inactive battery ------------------------ 4.9Battery troubleshooting ------------------------------------------------------------- 4.10

!

TABLE OF CONTENTS

5 Models


TABLE OF CONTENTS

MAINTENANCE 5

System malfunctions ------------------------------------------------------------------ 5.1Cleanliness ------------------------------------------------------------------------------- 5.2Removal and installation ------------------------------------------------------------- 5.3Disassembly and assembly ---------------------------------------------------------- 5.4Parts replacement ---------------------------------------------------------------------- 5.5Wires and cables ----------------------------------------------------------------------- 5.6Gaskets ----------------------------------------------------------------------------------- 5.7Care and installation of teflon-coated bushings------------------------------- 5.8Bushings --------------------------------------------------------------------------------5.8.1Pin ----------------------------------------------------------------------------------------5.8.2Bushings and pin ---------------------------------------------------------------------5.8.3Bushing installation ------------------------------------------------------------------5.8.4Mast roller removal ------------------------------------------------------------------- 5.9Upper rollers ---------------------------------------------------------------------------5.9.1Lower rollers --------------------------------------------------------------------------5.9.2Rollers -----------------------------------------------------------------------------------5.9.3Hydraulic system -------------------------------------------------------------------- 5.10Fatigue of welded structures ----------------------------------------------------- 5.11LOCTITE® ------------------------------------------------------------------------------- 5.12Fasteners and torque values------------------------------------------------------ 5.13Steering switches -------------------------------------------------------------------- 5.14Main hydraulic power unit --------------------------------------------------------- 5.15Steering bracket thrust washers ------------------------------------------------- 5.16Mast section alignment ------------------------------------------------------------- 5.17Lifting chains adjustment ---------------------------------------------------------- 5.18Chain control and lubrication------------------------------------------------------ 5.19Control of chain wear ------------------------------------------------------------ 5.19.1Chain lubrication ------------------------------------------------------------------- 5.19.2Overload detection setting--------------------------------------------------------- 5.20Tilt alarm ------------------------------------------------------------------------------- 5.21Battery discharge indicator setting ---------------------------------------------- 5.22Motor speed controller -------------------------------------------------------------- 5.23Fuses------------------------------------------------------------------------------------- 5.24Power circuit main fuse --------------------------------------------------------- 5.24.1Steering power circuit fuse----------------------------------------------------- 5.24.2Control circuit main fuse -------------------------------------------------------- 5.24.3Battery voltage indicator fuse ------------------------------------------------- 5.24.4Battery filling unit fuse ---------------------------------------------------------- 5.24.5Electronically piloted circuits fuses ------------------------------------------ 5.24.6Drive function sequences - Electronic board potentiometers setting -- 5.25

Toucan 1010 Models

Revision 02-20006

TABLE OF CONTENTS

PREVENTIVE AND MAINTENANCE INSPECTION 6General ------------------------------------------------------------------------------------ 6.1Preventive maintenance and inspection required ----------------------------- 6.2Daily preventive maintenance and inspection------------------------------- 6.2.1Weekly preventive maintenance and inspection --------------------------- 6.2.2Monthly preventive maintenance and inspection -------------------------- 6.2.3Every 125 hours of operation preventive maintenance and inspection - 6.2.4Every 250 hours of operation preventive maintenance and inspection - 6.2.5Every 500 hours of operation preventive maintenance and inspection - 6.2.6

LUBRICATION 7Lubrication points ---------------------------------------------------------------------- 7.1

7 Models


ForewordImportant information

TABLE OF CONTENTS

1INTRODUCTION

9 Models


FOREWORD

This manual has been compiled to assist you inproperly operating and maintaining your Grove ManliftAerial Work Platform.

The Work Platform has been designed for maximumperformance with minimum maintenance. With propercare, years of trouble-free service can be expected.

Constant improvement and engineering progress makeit necessary that we 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 not followedexactly, death or serious injury to personnelmay 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.

! ATTENTION

DANGER

Toucan 1010 Models

Revision 02-200010

WARRANTY

NOTICE TO OWNER/USERShould this work platform become involved in a accident, please contact your localGrove Worldwide distributor immediately and relate details of the incident so he cannotify Grove Worlwide.If the distributor is unknown and/or cannot be reached, please contact :

Delta ManliftZ.I. de Fauillet, BP 20, 47400 Tonneins FRANCE

(33) 553 84 85 11

THERE ARE NO WARRANTY, EXPRESS OR IMPLIED, MADE BY EITHER THE DISTRIBUTOROR THE MANUFACTURER ON NEW GROVE WORLDWILDE EQUIPMENT, EXCEPT THEMANUFACTURER'S WARRANTY AGAINST DEFECTS, IN MATERIAL AND WORKMANSHIPSET OUT BELOW :

NEW EQUIPMENT WARRANTY

"The Manufacturer warrants each new Grove Worldwide product made by theManufacturer to be free from defects in material and workmanship, its obligation andliability under this warranty being limited to repairing or replacing free of charge at itsfactory, any part proving defective under normal use and service, and the reasonablecost of repair and/or replacement of said part or parts, within twelve (12) months fromthe date of initial sale, lease or rental,providing the equipment is on record with theManufacturer as being installed by the distributor. Grove Worldwide further warrantsfor an additional six (6) years the structural components described and identified as themast weldment, turnable, and frame (chassis) weldment to be free from defects inmaterial and workmanship, its obligation and liability under the structural warrantybeing limited to repairing or replacing free of charge at its factory any part provingdefective under normal use and service and does not cover any labor or installationcosts incurred for the repair or replacement of the structural component. If the machineis not on record as being installed by the Distributor, the Manufacturer will consider thedate of shipment from the factory as the date of initial sale, lease or rental. This warrantyis in lieu of all other warranties, express or implied and the obligation and liability of theManufacturer under this warranty shall not include any transportation or other chargesor any liability for direct, indirect or consequential damages or delay resulting from thedefect. Any operation beyond rated capacity or the improper use or application of theproduct or substitution upon it of parts not approved by the Manufacturer shall void thiswarranty. This warranty covers only the products of Grove Worldwide. The product ofother Manufacturers are covered only by such warranties as are made by theirManufacturers."

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS ORIMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESSFOR A PARTICULAR PURPOSE, AND OF ANY OTHER OBLIGATIONS OR LIABILITY ONTHE PART OF THE MANUFACTURER, AND GROVE WORLDWIDE NEITHER ASSUMESNOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR IT ANY OTHER LIABILITY INCONNECTION WITH SUCH EQUIPMENT.

11 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 Grove. Approved SMCAR's will be distributed in a Service Bulletin immediatelyand then 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, PublicationsDelta ManliftZ.I. de Fauillet,B.P. 2047400 Tonneins, France

CORRECTIVE ACTION REQUEST

Toucan 1010 Models

Revision 02-200012

This page intentionally left blank.

CORRECTIVE ACTION REQUEST

13 Models


2.1. Description2.2. Characteristics - Dimensions - Performances

TABLE OF CONTENTS

2WORK PLATFORM CHARACTERISTICS

Toucan 1010 Models

Revision 02-200014

2.1 Description

The work platform consists of a self-propelled allwelded steel frame, a telescopic mast mounted on aturntable and a pendular jib. The platform is mountedat the end of the jib.

The drive function is accomplished by two hydraulicmotors which propel the rear axle.The steering function (front axle) is accomplishedby a hydraulic cylinder supplied with a hydraulic pumpunit located on the chassis between the steeringwheels.The parking brakes integrated to the hydraulic motorswork through lack of pressure.

The main hydraulic power unit supplying the functionsof the work platform (except steering) is located atthe top of the main hydraulic tank, at the rear of thechassis.

The turntable rotation movement is accomplishedthrough a moto-reducer group located at the base ofthe turntable.

The movement of the pendular jib is accomplishedby means of hydraulic cylinder.

The work platform movements are controlled fromthe control boxes through hydraulic control valvescontrolled electrically located at the front of thechassis.

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 box(ground controls), on the left hand side of thetelescopic mast.

The energy for the control and power circuits ofthe work platform is supplied by a 24 VDC battery.

WORK PLATFORM CHARACTERISTICS 22

15 Models


FRONT SIDERight side Left side

Front battery access

Charger

Emergency control panel

Counterweight

Jib

Platform

Lateral battery access

Steering wheels Driving wheels

LEFT SIDEFront Rear

Counterweight

Breakdown control panelSteering hydraulic unit

Steering wheels

Telescopic mast

Hand pump

Manual boxPlatform controls


Toucan 1010 Models

Revision 02-200016

DIMENSIONS (LOWERED) Standard platform Large platform

Length 2,89 m 3,20 mWidth 0,99 mHeight 1,99 mWeight T 1010 3300 kgWeight T 1010 I 2650 kgGround Clearance 0,08 m

CAPACITY - MANOEUVRABILITY

Platform floor min. height 0,54 mPlatform floor max. height 8,10 mMax. working height 10,10 mMax. outreach (from centerline) 2,62 m 2,93 mMax. working outreach (from centerline) 3,12 m 3,43 mFloor height at max. outreach 6,72 mWorking height at max. outreach 8,72 mSwing 360° non continousInner turning radius Machine raised : 1,78 m

Machine half raised : 0 mOuter turning radius Machine raised : 3,37 m

Machine half raised : 1,75 m

PLATFORM

Length 0,70 m 1,01 mWidth 0,90 mRated load 200 kg

HYDRAULIC CIRCUIT

Main hydraulic tank capacity 25,5 lSteering group tank capacity 1 lMain hydraulic pump displacement 8 cm³/tSteering hydraulic pump displacement 0,5 cm³/t

FILTRATION

Pressure 20 µm absoluteReturn 20 µm absolute

PRESSURES

Main hydraulic circuit max. pressure 23 MPaSteering hydraulic circuit max. pressure 12 MPa

ELECTRICAL COMPONENTS

Main hydraulic unit motor 3 kw 24 VDCSteering hydraulic unit motor 0,8 kw 24 VDC

2.2. Characteristics - Dimensions - Performances


17 Models


(*) speeds measured on horizontal ground with one person in the platform (approximately 80 kg).(**) times measured with the maximum rated load in the platform (200 kg), the movements were performed fromplatform controls.

Speeds are indicated for a machine with a fully charged battery and working in an ambiant temperature of20°C.

Constant product improvement make it necessary that GROVE reserve the right to make specification andequipment changes without notice.

DRIVE SPEEDS (*)

1st gear (slow speed)

2nd gear

3rd gear

MOVEMENT SPEED (**)

Mast elevation time 24 to 27 s

Mast lowering time 21 to 24 s

Jib elevation time 16 to 19 s

Jib lowering time 17 to 20 s

Slewing time (from stop to stop) 50 to 55 s

0,65 to 0,7 km/h

1,8 km/h

4 km/h


19 Models


3.1. Relief valve setting3.2. Brake release circuit pressure check3.3. Circuit relief valve adjustment

3.3.1. Main pressure (PR1)3.3.2. Right swing (PR2)3.3.3. Left swing (PR3)3.3.4. Mast elevation (PR4)3.3.5. Jib elevation (PR5)3.3.6. Jib lowering (PR6)3.3.7. Brake release maximum pressure (PR7)3.3.8. Drive at low speed (PR8)

3.4. Counterbalance valve setting

TABLE OF CONTENTS

3PRESSURE SETTINGS

21 Models


Relief valves used in the work platform's hydraulicsystem protect the system from excessive pressure(within the circuit in which they are used) by returninghydraulic oil to the hydraulic reservoir when thepressure setting is exceeded.

You can determine the point at which a relief valveopens by placing a pressure gauge in the pressuretest port of the appropriate valve manifold. The needleon the pressure gauge will climb until it reaches therelief valve setting. At that point, the needle will stopclimbing and fluctuate - indicating that the relief valveis open and returning hydraulic oil to the hydraulicreservoir.

Correct relief valve adjustment is mandatory if anyhydraulic circuit is to function properly. Reliefpressure settings must always be within establishedtolerances.

NOTEAdjustment of relief valve pressure settingsshould only be performed - after the need foradjustment has been established - by qualifiedmechanics using the correct equipment.

NOTECheck pressure settings prior to delivery ofwork platform.

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

Do not overtighten the adjustment screw orlocknut.

Do not hold the relief valve open for morethan one minute.

For a correct relief valve pressure check, thelocknut of the relief valve adjustment screwmust be tightened.

NOTETo adjust a relief valve turn the adjustmentscrew (in to increase or out to decrease) untilthe proper setting is reached.

! CAUTION

! CAUTION

! CAUTION

3.1 Relief valve setting

NOTECheck the relief valve adjustments with apressure gauge connected to the pressuretest port (M) of the FUNCTION MANIFOLDexcept for the brake release relief valve [PR7].Check brake release relief valve [PR7]adjustment with a pressure gauge connectedto the pressure test port (M) of the BRAKEMANIFOLD.

Preparation

NOTEBefore setting pressures, warm the hydraulicoil to between 25°C to 50°C.

NOTEUse a 0 to 40,0 MPa/400 bar pressure gaugewhen adjusting the relief valves. Forpressures lower than 3 MPa/30 bar, use a 6MPa/60 bar pressure gauge.

NOTEWhen adjusting the relief valves, operate themachine from the platform controls ATMAXIMUM SPEED.

Brake manifold

Function manifold

Test plugPR8

PR7

ä

PR1

PR2

PR6

PR5

PR4 PR3

Test plug

ä

PRESSURE SETTINGS 33

Toucan 1010 Models

Revision 02-200022

3.2 Brake release circuit pressurecheck

1- Chock both front wheels as indicated below :

2- Connect the pressure gauge to the pressuretest plug at port "M" on BRAKE MANIFOLD.

3- Position the DRIVE SPEED selector switch to

HIGH ( ).4- Activate a DRIVE FORWARD function by

pushing the controller forward (away from theoperator). If the maximum reading on thepressure gauge is not between 15 and 21 bar,refer to BRAKE RELEASE MAXIMUMPRESSURE in § 3.3.7. If the maximumreading is over 21 bar, consult your local GroveManlift distributor for servicing.

5- Remove the pressure gauge.

3.3 Circuit relief valve adjustment

3.3.1. Main pressure (PR1)

1- Chock both rear wheels as indicated below :

2- Connect the pressure gauge to the pressuretest plug at port "M" on FUNCTIONMANIFOLD.

3- Position the DRIVE SPEED SELECTOR switch

to HIGH ( ).4- Activate a DRIVE REVERSE function by

FULLY pulling the controller to the rear(towards the operator). Note the maximumreading on the pressure gauge. If the readingis not within ± 5 bar of the relief pressureshown in the table titled Relief Valve PressureSettings, adjust the pressure setting asnecessary.


3.3.2. Right swing (PR2)


2- SWING the superstructure fully to the RIGHT(jib over the front). Note the maximum readingof the pressure gauge. If the reading is notwithin ± 5 bar of the relief pressure shown inthe table titled Relief Valve Pressure Settings,adjust the pressure setting as necessary.


3.3.3. Left swing (PR3)1- Connect the pressure gauge to the pressure test

plug at port "M" on FUNCTION MANIFOLD.2- SWING the superstructure fully to the LEFT

(jib over the front). Note the maximum readingof the pressure gauge. If the reading is notwithin ± 5 bar of the relief pressure show inthe table titled Relief Valve Pressure Settings,adjust the pressure setting as necessary.


3.3.4. Mast elevation (PR4)1- Connect the pressure gauge to the pressure

test plug at port «M» on FUNCTION MANIFOLD.2- Perform a MAST RAISING function until the

the mast cylinder reaches the end of itscourse. Note the maximum reading of thepressure gauge. If the reading is not within ±5 bar of the relief pressure shown in the tabletitled Relief Valve Pressure Settings, adjustthe pressure setting as necessary.


3.3.5. Jib elevation (PR5)

1- Connect the pressure gauge to the pressure testplug at port «M» on FUNCTION MANIFOLD.

2- Perform a JIB RAISING function until the jibcylinder reaches the end of its course. Notethe maximum reading of the pressure gauge.If the reading is not within ± 5 bar of the reliefpressure shown in the table titled Relief ValvePressure Settings, adjust the pressure settingas necessary.



23 Models


3.3.6. Jib lowering (PR6)


2- Perform a JIB LOWERING function until thejib cylinder reaches the end of its course. Notethe maximum reading of the pressure gauge.If the reading is not within ± 5 bar of the reliefpressure shown in the table titled Relief ValvePressure Settings, adjust the pressure settingas necessary.


3.3.7. Brake release maximum pressure(PR7)

1- Chock both front wheels as indicated below :

2- Disconnect and cap the hydraulic lines to thebrakes.

3- Connect the pressure gauge to the pressuretest plug at port «M» on BRAKE MANIFOLD.

4- TURN FULLY IN the PR7 relief valve adjustmentscrew.

5- Position the DRIVE SPEED SELECTOR switch

to HIGH ( ) speed.6- Activate a DRIVE FORWARD function by

pushing the controller forward (away from theoperator). The maximum reading on thepressure gauge must be between 15 and 21bar corresponding to the pressure reducersetting. Note the exact reading on the pressuregauge.

If the pressure reading is lower than 15 baror higher than 21 bar, consult your localGrove Manlift distributor for servicing.

7- TURN OUT the PR7 relief valve adjustmentscrew until the pressure drops just under thepreviously recorded value, then turn theadjustment screw 1/4 turn IN.

8- Unhook the pump handle and push the brakerelease lever towards the chassis to BRAKEUNLOCKED position ( ). Refer to the Towingprocedure in the Operator's and Safetyhandbook.

! CAUTION

( P )

9- Insert the handle in the hand pump and activatethe handle energetically. Note the peakpressure on the pressure gauge. If the peak-pressure exceeds 35 bars, turn out the PR7relief valve adjustment screw 1/8 turn andcheck the peak pressure again.

10- Remove the pressure gauge.11- Connect the hydraulic lines to the brakes.

Brakes maximum working pressure = 30 bar.Maximum admissible peak-pressure whenusing the hand pump to release the brakes =35 bar.

3.3.8 Drive at low speed (PR8)

1- Chock both wheels as indicated below :


3- Position the DRIVE SPEED SELECTOR switchto LOW ( ) speed.

4- Activate a DRIVE FORWARD function byFULLY pushing the controller forward (awayfrom the operator). Note the maximum readingon the pressure gauge. If the reading is notwithin 0/-5 bar of the relief pressure shown inthe table titled Relief Valve Pressure Settings,adjust the pressure setting as necessary.


! CAUTION


Toucan 1010 Models

Revision 02-200024

3.4 Counterbalance valves setting

- Mast/jib cylinder counterbalance valve.

The valve opening pressure is factory pre-set at 210bars at 4 l/mn. This setting must not be modified.

- Drive manifold counterbalance valve.

Counterbalance valvedrive forward

Counterbalancevalve

drive reverse

The counterbalance valves on the drive manifoldensure dynamic braking for the work platform.The more the setting screw is tightened, the sharperthe braking is.

Setting must be performed with the rated load (200 kg)evenly distributed in the platform.

The counterbalance valves must be set so that :

- When the work platform is driven at itsmaximum speed (3rd gear), it must stop overa 0.8m to 1m distance on flat ground (in bothforward and reverse) when the joystick isreturned to neutral.

- When the work platform is driven directly up ordown a 15% slope in 2nd gear, it must stopover a distance inferior to 1m when the joystickis returned to neutral.

Function Relief Pressure Relief Valve Check Port "M" on

Main pressure 230 bar PR1 Function manifold

Right swing 60 bar PR2 Function manifold

Left swing 60 bar PR3 Function manifold

Mast elevation 170 bar PR4 Function manifold

Jib elevation 120 bar PR5 Function manifold

Jib lowering 50 bar PR6 Function manifold

Manual brake release Max. pressure

35 barmax. peak pressure PR7 Brake manifold

Drive at low speed 80 bar PR8 Function manifold

RELIEF VALVE PRESSURE SETTINGS


25 Models


4.1 Battery4.2 Charger

4.2.1 "Fulmen" charger4.2.2 "Oldham-Hawker" charger4.2.3 "Westinghouse-SGTE" charger

4.3 Battery filling4.4 Electrolyte specific gravity and battery voltage4.5 Centralised filling system maintenance4.6 Cleaning - Battery maintenance4.7 Storage of a battery at temperatures below 0°C (32°F)4.8 Use of a battery in a cold chamber or in a cold climate4.9 Battery not working continuously or inactive battery4.10 Battery troubleshooting

TABLE OF CONTENTS

BATTERY - CHARGER 4

27 Models


4.1. Battery

The electrical energy of the work platform is providedby a 24 VDC battery. The battery is composed of 12cells (1 cell Þ 2 volts).

The batteries are integral part of the machinecounterweight. Substitution of the batteriesfor a lighter or a heavier one will affect workplatform stability and will cause the machineto tip over.

New electrical vehicles batteries do not havetheir full capacity until they have been cycledseveral times (somewhere between five and40 cycles). For at least the first five cycles, itis recommended not to discharge the batteryabove 70% of its capacity. To obtain themaximum battery life, do not discharge thebattery above 80% of its capacity.

DANGER

! CAUTION

Batteries location

BATTERY - CHARGER 44

Charger

Batteries

- T1010 (3 packs) :1 pack at the front,1 pack on both sides of the mast

- T1010 (2 packs) :1 pack on both sides of the mast,1 additional counterweight at the front

- T1010 I :1 pack at the front,1 pack on the left hand side of the mast

Batteries wiringT1010I

(2 battery packs)

Batteries wiringT1010

(2 battery packs)

Batteries wiringT1010

(3 battery packs)

Toucan 1010 Models

Revision 02-200028

4.2 Charger

The work platform on-board electronic charger isdesigned to automatically charge 24 VDC (wet) lead-acid rechargeable batteries.

Lead-acid batteries may emit highly explosivegases. The emission is greatly increasedduring charging. Never introduce flames,sparks, or other sources of ignition to batteryarea. Failure to comply with this warningcould result in death or injury to personnel.Always charge batteries in a well-ventilatedarea.

Do not disconnect battery plug when thecharger is ON. The resulting arcing andburning could cause battery to explode.

NOTEIt is not necessary to charge the battery ifthe electrolyte specific gravity has notdropped under 1.240 kg/l. Regular charge ofa battery when its specific gravity is higherthan 1.240 kg/l can greatly reduce the batterylife time.

NOTEThe charger has an interlock feature whichcauses the work platform power circuit toopen anytime the charger is plugged into alive AC outlet.

NOTEIt is important to perform an equalisationcharge regularly to equalise electrolytespecific gravity in all battery cells. Theequalisation charge takes place at the end ofthe charge cycle (Fulmen and SGTE chargersonly).

NOTEIf a power cut occurs during the charge cycle,the charger switches to a waiting mode andrestarts automatically as soon as the powerreturns.

DANGER

DANGER


29 Models


4.2.1 "Fulmen" charger.

Charger panel

a. Circuit breaker.b. Display.c. Equalisation function button.d. 100% charged LED indicator.e. Charger ON LED indicator.f. 80% charged LED indicator.g. ON/OFF button.

Power supply : 110VAC - 60Hz / 220VAC - 50Hz

- Adaptation to network voltage :

a

b

d

fg

e

c

DANGER

+ 0 1 2 3 4

Jumper

+ 0 1 2 3 4

Jumpers

Prior to any operation requiring chargercover removal, the battery must bedisconnected and the charger must beunplugged from the AC outlet. Failure to doso could result in death or serious injury topersonnel.

Connections on transformer inlet terminals block :

220 VAC - 50 Hz 110 VAC - 60 Hz

- Protections :

Single pole circuit breaker :- 15 Amps on 24 MO 40A models- 20 Amps on 24 MO 65A models

Output fuse :- 40 Amps on 24 MO 40A models- 80 Amps on 24 MO 65A models

NOTEA spare output fuse is strapped inside thecharger cover.

Troubleshooting chart :

Display Probable cause Solution

EO Charger in test modeMove the jumper from "test" position to "propor." position on the electronic card.

E1Output fuse faultyLow intensity

Replace the fuse. Check voltage at output and input of the transformer.

E2 Fault on electronic card Contact Grove Manlift Product Support.

E3Electronic card programme erased (configuration lost)

Contact Grove Manlift Product Support.

E4 Batteries too dischargedLeave the batteries to rest before resuming charge.

E5 Electronic safety. Safety time switch faultyDisconnect and reconnect the batteries. Contact Grove Manlift Product Support if the fault persists.

E6 Battery incorrect nominal voltageConnect the battery from the work platform to the charger.


Toucan 1010 Models

Revision 02-200030

DEFAULT LED CURRENT LEDs INDICATOR

The first LED flashes

Voltage still below 1,7 V per cell after 1 minute of charge

The 2nd LED flashes

Voltage still below 2,05 V per cell after 1 hour of charge

The 3rd LED flashes

Voltage per cell still below the required gazing voltage after 10 hours of charge.

The 4th LED flashesCharging safety time exceeded.

Default LED flashesCharge interruption due to a power cut. Charge will be resumed as soon as the power returns.

The 4 LEDs flashVoltage per cell 140% above the nominal values.

SIGNALLINGCAUSE

Default LED lights up

4.2.2 "Oldham-Hawker" charger




Connections on transformer inlet terminals block :

- Protections :

- Single pole circuit breaker : 32 Amps.

- Output fuse : 100 Amps.

FAULT SIGNALLING CHART (CPIV models)

?

?

NOTEA spare output fuse is strapped inside thecharger cover.

- CP IV models

CP IV models panel

a. Charger ON LED indicator (green).b. Second charging rate LED indicator (yellow).c. End of charge LED indicator (green).d. Ah applied into the battery : 4 LEDs (from the right

to the left : 100% - 75% - 50% - 25%).e. ON/OFF switch.f. Default led indicator (red).g. Circuit breaker.

230 VAC - 50 Hz 110 VAC - 60 Hz

Jumpers

brown

blue

brown

blue

DANGER

a

fb

e

cg

a


31 Models


- HP III model

HP III models panel

a- Charger ON LED indicator (green)b- Second charging rate LED indicator (yellow)c- Compensation charge LED indicator (green)d- End of charge LED indicator (yellow flashing)e- Fault LED indicator (red)f- ON/OFF switchg- Circuit breaker

- Fault signalling :If a problem occurs, the charger stops. The led " "lights up and the screen displays an error code.

- Screen display :

AxxxCharging supplyUx.xxVoltage per elementcxxx or CxxxAh reinjected into the battery(cxxx = <999 Ah - Cxxx>999Ah)Hxx.x Charging time from the begining of the charge(hour and tenth)L000O.KU L0Voltage below 1.65V/cellL205Voltage below 2.05V/cell after 30 mm chargingL09HVoltage below 2.4V/cell after 9 H chargingLIL0Supply = 0LUACNo supply voltage (charging horameter has stopped)LHHSSafety time (9 -12 - 14 or 16 hours depending onthe charger type)ForCForced cut by the push button

OFFSPeriodic mail of control

f

abcde

g

?


Toucan 1010 Models

Revision 02-200032

4.2.3 "Westinghouse-SGTE" charger.

a. Default LED indicator (red).b. Charger ON LED indicator (orange).c. End of charge LED indicator (orange).d. Stop switch.e. Equalisation function button (green).



Charger panel


- Connections on auto-transformer and transfor-mer inlet terminals block :

220 VAC - 50 Hz :Auto-transformer Transformer terminal block

110 VAC - 60 Hz :Auto-transformer Transformer terminal block

- Protections :

Single pole thermal circuit breaker 20 Amps.

Output fuse : 100 AmpsAC auxiliaries : 2 Amps

Default LED indicator

If a fault occurs during charge, switch off thecharger and disconnect it from AC outlet.

c

b

a d

e

DANGER

Troubleshooting

The default LED indicator lights up :

Pre-insulatedterminal

é

220 V

110 V0 V

Pre-insulatedterminal

220 V

110 V0 V

é

! CAUTION

PROBABLE CAUSE SOLUTION

Voltage above 3V per cell (corroded plates)Depress the equalising function button to resume charge. (The default LED indicator flashes).

Voltage below 1,8V per cell after 5 minutes charge.Note : If the voltage is below 1,5V per cell, the charger will not detect the battery.

Depress the equalising function button to resume charge. (The default LED indicator flashes).

Voltage does not reach 2,4V per cell after 11 hours charge (Soft timer #1).Charging time exceeds 15 hours (Voltage above 2,4V per cell) (Soft timer #2).

Charging time exceeds 16 hours (Hard timer).

Check condition of battery - connections and charger. Disconnect the charger from the battery and connect it again. If the problem persists, contact Grove Manlift® Product Support.


33 Models


4.3. Battery filling

Verify the electrolyte level using the floats in the centerof each filling cap.

NOTETilt the charger to gain access to the frontbattery pack.

If necessary, fill the battery cells after the chargeusing the centralised water filling system.

Use only distilled or demineralised water tofill the battery cells.

Battery cells filling must be performed onlyafter charge (during charge, electrolyte levelincreases and can overflow).

Filling battery cells :

1- Ensure that the water can of the filling unit isfilled sufficiently with distilled water.

2- Position and hold the ELECTRICALBATTERY FILLING switch either to the left orto the right to activate the filling unit.

3- Release the ELECTRICAL BATTERY FILLINGswitch when the flow indicator stops turning.

4- Verify the proper electrolyte level in eachbattery cell.

4.4. Electrolyte specific gravityand battery voltage

Specific gravity and voltage measure is the mostimportant check to be performed on a battery. Ahydrometer is supplied with the work platform.Specific gravity and voltage readings must beperformed at least once a month and recorded in abattery service log.The state of charge of the battery can be checkedby measuring the specific gravity of the electrolyte.This value decreases as the battery discharges.When the battery is fully charged, the specificgravity is 1.280 kg/l.When the battery is 80% discharged, the specificgravity is 1.150 kg/l.The following graphic shows the correspondencebetween specific gravity and battery discharge.

0%

1.15

1.10

1.20

1.25

1.30

20% 40% 60% 80% 100%

Elec

trol

yte

spec

ific

grav

ity

Discharge depth in %

! CAUTION

! CAUTION

Flow indicator

Float doesn't emergeè Insuffisant level

Float emergesè Correct level


Toucan 1010 Models

Revision 02-200034

- Check the hoses for flexibility. In case ofhardening in the connection areas, replacethe hose.

- Check every fitting for tightness and leakage.- Check the cell caps individually. Ensure theperfect mobility of the floats. In case ofexcessive clogging, replace the cap.


During maintenance or any servicingoperation on the battery, rings, watches orany other jewellery must be removed.

NOTESpecific gravity measure must not beperformed after battery cell filling.

1- Open the battery cell filling cap.2- Using the hydrometer, take a sufficient quantity

of electrolyte so that the float emerges. Ensurethe float top does not touch the rubber bulb orthat the foat does not stick by capillarity to theglass walls.

3- Read the value as indicated on the examplebelow :

DANGER

1.121.141.161.181.201.221.241.261.281.30

1.23 kg/l

Checking electrolyte specific gravity :

Battery electrolyte must not be allowed tocontact the skin or eyes. If it does occur, flushthe contacted area with water and consulta doctor immediately. Appropiateequipment must be worn (GLOVES,GOGGLES, RUBBER APRON) to prevent theelectrolyte from contacting the skin or anyother part of the body during any servicingoperation on the battery.

DANGER

4- Return the electrolyte in the cell and recordcell electrolyte specific gravity on the batteryservice log.

5- Repeat operation for each battery cell.

4.5. Centralised filling systemmaintenance

It is necessary to service the centralised filling systemat least once a year. Cleaning frequency must beincreased in case of premature clogging of the filteror a reduction of water flow.

- Disconnect and clean the filter by reversingthe water flow from the normal direction.

35 Models



4.6. Cleaning - Batterymaintenance

It is necessary to clean the battery regularly to preventsalt formation and current arcing which could damagethe machine.

- Clean battery top with a damp cloth.- Allow to dry and wipe the battery top with adry non-fluffy cloth.

- Ensure the connections are clean and correctlytighten.

NOTECoat terminals and connections with an anti-corrosion compound or grease.

- Keep the metallic containers clean. In case ofcorrosion, clean, neutralize corrosion andapply anti-acid paint on the affected area.

- Drain the water which can accumulate at thebottom of the container (electrolyte overflow,leak in the centrals and filling circuit, batterycleaning…).

Drained water may have been in contact withacid and may have become corrosive. Do notallow drain water to contact the skin or eyes.If it does occur, flush the contacted area withwater and consult a doctor immediatly.Appropriate equipement must be worn (gloves,goggles, rubber apron) to prevent the drainedwater from contacting the skin or any part ofthe body.

To drain the water :1- Fill the draining bulb with water (a draining

bulb is supplied with the work platform).

DANGER

2- Connect the hose to the pipe located in thebattery container.

3- Connect the other end of the hose to the bulband press the bulb to fill the hose and the pipewith water.

4- Once the hose and the pipe are filled, removethe bulb and place the hose in a container onthe ground to recuperate the drainage water.The battery container drains itself automaticallyby siphoning.

NOTETo drain the water, it is necessary that theend of the hose is kept below the bottom ofthe container.

5- Repeat operation for each container.

4.7. Storage of a battery attemperatures below 0°C (32 °F)

Toucan 1010 Models

Revision 02-200036

4.7. Storage of a battery attemperatures below 0°C (32 °F)

Prior to battery storage at temperatures below 0°C (32 °F), electrolyte specific gravity must be verifiedin each cell. Refer to ELECTROLYTE SPECIFICGRAVITY AND BATTERY VOLTAGE in this sectionfor electrolyte specific gravity measurement operatingmode.Electrolyte specific gravity measures enable todetermine the electrolyte freezing point using thechart below :

NOTEWhen the battery is fully charged (1.280 kg/l),the electrolyte freezing point is –85°C (-121°F).The freezing point of a battery 80% discharged(1.150 kg/l) is –12°C (10°F).

4.8. Use of a battery in a coldchamber or in a cold climate

The battery must be fully charged when thework platform is operated in a cold chamberor in cold weather conditions.

Temperature has an effect on battery autonomy : thebattery looses 1% of its capacity per Celcius degreebelow +25°C (77°F) (temperature of the electrolyte).Example : a battery operating with its electrolyte ata temperature of –30°C (-22°F) will loose 55% ofits autonomy.

1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.35 1.40 1.45 1.50

-90

-80

-70

-60

-50

-40

-30

-20

-10

0

1.075

-5

Electrolyte specific gravity

Tem

pera

ture

in °

C

! CAUTION


4.9. Battery not workingcontinuously or inactive battery

A battery which is not used or used by intermittencemust be stored charged in a dry area away fromfreezing temperatures. An equalization charge mustbe performed once a month.(In these conditionsbattery storage is possible at temperature of 30°C(86°F) for a 12 months period.

Storing a discharged battery will result inirreversible 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 inactivityperiods, bat teries loose their chargeprogressively (self-discharge). Self-dischargecauses battery plates corrosion, whichincreases with time, resulting in batterymalfunction.

If the battery is not used continously, it mustbe recharged at least once a month, even ifthe electrolyte specific gravity measures arehigh.

Before placing in service a battery whichremained inactive for a long period of timeyou must recharge the battery and check theelectrolyte level in the cells.

! CAUTION

! CAUTION

! CAUTION

37 Models


4.10. Battery troubleshootingSerious accidents resulting in complete destruction of a traction battery are relatively rare. If small problemsencountered on a battery in use are rapidly and correctly determined, battery life and operation can be improved.

PREVENTION = AUTONOMY AND LONG LIFE

Symptoms Probable causes SolutionsElectrolyte overflow. Filling done before the charge.

Cells overfilled.

Overcharge.

Fill battery cells after the charge.

Never charge battery if electrolyte specific gravity is above 1,240 kg/l.

Inequal electrolyte specific gravity or electrolyte specific gravity too low.

Filling done before the charge.

Loss of electrolyte due to overflow.

Stratification of the electrolyte.

Fill battery cells after the charge.

Perform an equalization charge.

Contact your Grove Manlift Distributor/Product Support.

Low voltage in the cells in open circuit.

Electrolyte specific gravity too low.

Short-circuit.

Refer to "electrolyte specific gravity too low".

Battery cells temperature too high.

Problem with the charger.

Bad air circulation during charge.

Cell weak or faulty Cells shorted.

Get the charger checked by a technician.

Open access doors to batteries during charge.Leave the battery to cool down when disconnected before charge.Reduce temperature of the area where the battery is charged (artificial ventilation).

Change battery cell

Battery not able of supporting regular operation.

Battery under charged.

Cell faulty.

Faulty cable or connection.

Battery at the end of its service life.

Perform an equalization charge.

Replace faulty cell.

Check wires condition and connections.

Replace the battery.


39 Models


5.1 System malfunctions5.2 Cleanliness5.3 Removal and installation5.4 Disassembly and assembly5.5 Parts replacement5.6 Wires and cables5.7 Gaskets5.8 Care and installation of teflon-coated bushings

5.8.1 Bushings5.8.2 Pin5.8.3 Bushings and pin5.8.4 Bushing installation

5.9 Mast roller removal5.9.1. Upper rollers5.9.2. Lower rollers5.9.3. Rollers

5.10 Hydraulic system5.11 Fatigue of welded structures5.12 LOCTITE®5.13 Fasteners and torque values5.14 Steering switches5.15 Main hydraulic power unit5.16 Steering bracket thrust washers5.17 Mast section alignment5.18 Lifting chain adjustment5.19 Chain control and lubrication

5.19.1 Control of chain wear5.19.2 Chain lubrication

5.20 Overload detection setting5.21 Tilt alarm5.22 Battery discharge indicator setting5.23 Motor speed controller5.24 Fuses

5.24.1 Power circuit main fuse5.24.2 Steering power circuit fuse5.24.3 Control csircuit main fuse5.24.4 Battery voltage indicator fuse5.24.5 Battery filling unit fuse5.24.6 Electronically piloted circuits fuses

5.25 Drive function sequences - Electronic board potentiometers setting

5MAINTENANCE

TABLE OF CONTENTS

41 Models


5.1. System malfunctions

When analysing a system malfunction, use a systematicprocedure to locate and correct problems :

- Determine problem.- List possible causes.- Plan checks.- Conduct checks in a logical order to determinethe cause.

- Consider remaining service life of componentsagainst cost of parts and labour necessary toreplace them.

- Make necessary repairs.- Recheck to ensure that nothing has beenoverlooked.

- Functionally test failed part in its system.

NOTEYour safety and that of others is always thenumber one consideration when workingaround machines. Safety is a matter ofthoroughly understanding the job to be doneand the application of good common sense.It is not just a matter of do's and don'ts. Stayclear of all moving parts.

5.2. Cleanliness

Keep dirt out of working parts to preserve the longlife of the machine. Enclosed compartments, sealsand filters keep the supply of air, hydraulic oil andlubricants clean. Maintain these enclosures properly.Whenever hydraulic lines are disconnected, cleanthe adjacent area as well as the point ofdisconnection. As soon as the disconnection is made,cap, plug or tape each line or opening to prevententry of foreign material. The same recommendationsfor cleaning and covering apply when access coversor 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.- New parts are left in their containers until readyfor assembly.

- Rust preventive compound has been removedfrom all machined surfaces of new parts beforethey are installed (except leaf chains).

5.3. Removal and installation

When performing maintenance, do not attempt tomanually lift heavy parts when hoisting equipmentshould be used. Never locate or leave heavy parts inan unstable position. When raising a portion of awork platform - or a complete work platform - securelyblock the work platform and support the weight of themachine on blocks (rather than by lifting equipment).

When using hoisting equipement :

- Follow hoist manufacturer's recommendations.- Use lifting devices that will allow you to achievethe proper balance of the assemblies beinglifted and ensure safe handling.

Unless otherwise specified, all removals requiringhoisting equipment should be accomplished usingan adjustable lifting attachment. All supportingmembers (chains and cables) should be parallel toeach other and as near perpendicular as possible tothe top of the object being lifted.

The capacity of an eyebolt diminishes as theangle between the supporting members andthe object becomes less than 90°. Eyeboltsand brackets should never be bent andshould only have stress in tension.

Some removals require the use of lifting fixtures toobtain proper balance.

If a part resists removal, make sure :

- All nuts and bolts have been removed.- Adjacent parts are not interfering.

5.4. Disassembly and assembly

When assembling or disassembling a component orsystem, complete each step in turn :

- Do not partially assemble one part and thenstart assembling another part.

- Make all adjustments as recommended.- Always check the job after it is completed toensure that nothing has been overlooked.

- Recheck various adjustments by operating themachine before returning it to the job.

! CAUTION

MAINTENANCE 55

Toucan 1010 Models

Revision 02-200042

5.8.3. Bushings and pin

- When installing pin, proper care must be takento ensure bushing and pin are properly alignedso that bushing coating is not damaged.

- I.D. of bushing MUST be coated with cleangrease before pins are instal led at anyassembly level.

- Pins have a chamfered or rounded end toprevent the teflon coating on the bushing frombeing damaged during pin installation.

5.8.4. Bushing installation

Bushings must be inserted in their housing with anappropriate driver with a smooth flat end (preferablyin soft steel).The O.D. of the bushing must be slightly oiled tofacilitate assembly.Bushing, driver and housing must be correctly alignedduring assembly.

Bushing driver

Flange Outside Dia. ± 0.25 mm

5.5. Parts replacementParts found damaged or out of tolerance duringmaintenance should be replaced. Refer to thecorresponding Spare Parts Manual for properreplacement parts.

5.6. Wires and cables

Always disconnect batteries prior to working on theelectrical system.

When removing or disconnecting a group of wiresor cables, tag each one to ensure proper identificationduring assembly.

5.7. Gaskets

Ensure the holes in the gaskets correspond with thelubricant passages in the mating parts. If it isnecessary to make gaskets, select material of theproper type and thickness. Ensure holes are cut inthe right places. Blank gaskets can cause seriousdamage.

When removed, always install new cylinder head andmanifold gaskets using recommended gasketcompound on head gaskets to allow uniform sealing.

5.8. Care and installation of teflon-coated bushings

The following instructions must be followed whenworking with teflon-coated bushing :

5.8.1. Bushings

- No jiffy wheels or reaming of any kind can beused on coated bushings.

- Once the coating on the bushing is damagedit cannot be used and must be replaced.

- Coat bushing, pin and interior of housings withgrease before assembling.

5.8.2. Pin

- Any rough or damaged surface on pin willdamage the teflon coating on the bushing ;the bushing therefore must be replaced.

- All rust or masking residue must be cleanedfrom pin prior to installation. Use emery clothas appropriate.

Bush nominal Dia. -0.2 mm-0.25 mm

Bush height +1 mm+0 mm

Bushing Housing

Direction of installation

Pin

ð

MAINTENANCE 55

43 Models


Blocking must be used on parts that will receive twobushings to prevent damage to the flange of the lowerbushing.

Blocks

5.9 Mast roller removal

NOTEThe mast rollers (Qty 16) can be removedone by one without removing the telescopicmast.

5.9.1. Upper rollers.

1- Lower the mast.2- Unscrew the locknut from the roller to be

removed using a polygonal spanner.3- Unscrew the roller pin to release the bronze

spacer and free the roller as indicated below.

Hold the bronze spacer, roller and washerto prevent any of them from falling to thebottom of the mast.

Install the roller before removing anotherone (refer to § 5.9.3).

LocknutSpacer Roller

Flange bushings

Roller pin

Roller pin washer

55

! CAUTION

10

! CAUTION

MAINTENANCE 55

Toucan 1010 Models

Revision 02-200044

5.9.2. Lower rollers.

NOTEBefore removing the lower rollers, ensure theupper rollers are installed.

Using ground controls :

1- Raise the telescopic mast to gain access tothe roller to be removed.

2- Unscrew the locknut from the roller to beremoved using a polygonal spanner.

3- Unscrew the roller pin to release the bronzespacer and free the roller as indicatedpreviously.

Install the roller before removing another one(§ 5.9.3.).

5.9.3. Rollers

The bronze spacer must be replaced if itsthickness is below 3,5 mm. Check thecondition of roller pin, bushings and rollerprior to installation. Replace damaged partswith original parts. Grease bushings beforeinstallation.

Roller installation tips :

- Partly tighten the pin on the mast section andinsert the washer on the pin.

- Apply grease to the spacer so that it "sticks"to the mast and does not fall to the bottom ofthe mast.

- Press the spacer onto the mast and slide it.The roller and spacer must be in line with thepin.

! CAUTION

3,5 mm.

Bronze spacerminimum thickness.

- Tighten the pin so that the roller slides onto thepin.

- Reposition the spacer in line with the pin. Tightenthe pin fully until the bronze spacer is fullyinserted.

- Once the spacer is properly in place, unscrewthe pin by one turn to prevent the mast fromjamming during adjustment. Install the locknutwithout tightening it (tightening of locknut afteradjustment of mast alignment).

Clean and grease the faces of the bronzespacers on the mast. Refer to § 7.1 Lubricationpoints.

After maintenance operation on the roller, themast alignment must be adjusted. Refer to §5.17.

Grease

! CAUTION

! CAUTION

! CAUTION

MAINTENANCE 55

45 Models


5.10 Hydraulic system

Exercise extreme care around pressurizedhydraulic systems. Do not work on a hydraulicsystem while it is in operation or until allpressure is released.

CleanlinessContaminants in a hydraulic system affect operationand will result in serious damage to the systemcomponents. Dirty hydraulic systems are a majorcause of component failures.

Keep the system cleanWhen removing components of a hydraulic system,cover all openings on both the component and thework platform.

If evidence of foreign particles is found in the hydraulicsystem, flush the system.

Disassemble and assemble hydraulic components ona clean surface.

Clean all metal parts in a non-flammable cleaning fluid.Then lubricate all components to aid in assembly.

Hydraulic filters location

Pressure filterPressure filter is locatedon the front left handside of the chassis.

Return filterThe top in-tank return filteris located at the rear of thechassis.

Sealing elements

Inspect all sealing elements (O-rings, gaskets, etc,...)when disassembling and assembling hydraulic systemcomponents. Installation of new elements is alwaysrecommended.

Hydraulic lines

When installing metal tubes, tighten all bolts finger-tight. Then, in order, tighten the bolts at the rigidend, the adjustable end and the mounting brackets.After tubes are mounted, install the hoses. Connectboth ends of the hose with all bolts finger-tight.Position the hose so that it does not rub on themachine and can bend and twist. Tighten bolts inboth couplings.

Due to manufacturing methods there is a naturalcurvature to a hydraulic hose. The hose should beinstalled so any bend is with this curvature.

Removing air from the hydraulic system

Air entering the hydraulic oil will normally be removedautomatically with the hydraullic oil passing in thereservoir. However, if a component has been replacedor the reservoir level is too low, air can enter thesystem. If air becomes entrapped in the hydraulicoil, it may be detected by noisy operation of the pump/motor-operated components. Should this occur,check the level of the hydraulic reservoir andreplenish as necessary.

Minute leaks may be difficult to locate. Should youencounter a leak that is not readily detectable, usethe following method when checking for leaks :

- Seal all normal openings in the hydraulicsystem and the hydraulic reservoir.

- Using a positive means to control the pressure(i.e. a regulator), pressurize the hydraulicsystem to 13.8 kPa/0.14 bar - 27.5 kPa/0.28bar.

- Inspect all joints and fittings for evidence ofleaks. A soap solution - may also prove helpfulin detecting minute leaks when the system ispressurized.

- Remove the pressure, repair any leaks foundand reopen any openings (vents, etc...) closedfor inspection.

- Refill the hydraulic reservoir after completingany repairs or service.

- Operate all hydraulics circuits several timesin both directions. This action should returnany entrapped air to the hydraulic reservoirwhere it can be removed from the hydraulicoil by the hydraulic reservoir vent.

Use extreme care when removing any plugsor restrictions from a hydraulic systemsuspected to have entrapped air that may bepressurized. Failure to comply could resultin death or injury to personnel.

DANGER

Pressure filter

Return filter

DANGER

MAINTENANCE 55

Toucan 1010 Models

Revision 02-200046

Entrapped air may be removed from cylinders (havingwet rods) by cycling. On certain cylinders, a pluggedport is provided on the barrel end to bleed off entrappedair.

Do not attempt to loosen fittings inpressurized lines or while the hydraulic pumpis in operation. Failure to comply could resultin death or injury to personnel.

If air entrapment should persist, it may becomenecessary to bleed air by loosening various clamp-and screw-type fittings. If the above procedures failsto eliminate air entrapment, contact your GroveWorldwide distributor.

NOTEWhen servicing the hydraulic system, use acontainer to collect the oil from the hydrauliclines or components and prevent it fromspilling on the work platform or on theground.

5.11. Fatigue of welded structures

Experience has shown that highly stressed weldedstructures - when repeatedly subjected to varyingstresses caused by twisting, shock, bending andintentional and/or unintentional overloads - oftenbecome subject to weld cracking which may beattributed to fatigue of the welded joint. This condi-tion is not uncommon in construction equipment.

Equipment should be periodically inspected forevidence of weld fatigue. The frequency of these ins-pections should be commensurate with the :

- Age of equipment.- Severity of application.- Experience of operators and maintenancepersonnel.

A visual inspection of the following high-stress areasshould be made part of the owner's planned preventivemaintenance program :

- Welded joint of the plates making up thechassis base plate.

- Hydraulic wheel motors attachment plates (rearaxle).

- Front axle beam connection on chassis plate.- Steering brackets.- Mast section #1 connection on turntable plate.- Hydraulic cylinder end connections.- Tie rods end connections.

- Roller pins, tie rods, hydraulic cylindersattachment points.

The items listed above are provided as a guide. Donot limit your inspection plan to the areas listed. Athorough visual inspection of all weldments is goodpractice.

If you require more detailed inspection instructionsand/or repair procedures, contact your local GroveWorldwide distributor for assistance.

Welding from/on work platform

When welding from/on work platforms, follow theseprecautions :

- When welding from the platform, always runthe welder ground wire directly to the structurethat is being welded. Do not allow any part ofthe work platform to contact welding rods,holders, ground terminals or the structure beingwelded. Do not ground the welder through themachine as this can cause arcing inside theturntable bearing or inside hydraulic cylinders.

- When welding on the work platform, disconnectall electronic components. When welding onthe frame on all work platforms, connect thewelder ground wire to the machine frame - asclose to the area being welded as possible.When welding on the superstructure, connectthe welder ground wire to the machinesuperstructure - as close to the area beingwelded as possible. This is to prevent arcinginside the turntable bearing.

5.12. LOCTITE®

Loctite®-type adhesives contain chemicalsthat may be harmful if misused. Read andfollow the instructions on the container.

Always follow the directions on the Loctite® contai-ner. Not all Loctite® types are suitable for all applica-tions.

DANGER

DANGER

MAINTENANCE 55

47 Models


5.13. Fasteners and torque values

Use bolts of the correct length. A bolt that is too longmay bottom before the head is tight against the partit is to hold. If a bolt is too short, there may not beenough threads engaged to hold the part securely.Threads can be damaged. Inspect them and replacefasteners as necessary.

Torque values should correspond to the type of bolts,studs and nuts being used unless otherwise noted.

Torque tables are provided by Grove Worldwide forreference when preforming maintenance.

Use of proper torque values is extremely important.Improper torquing can seriously affect performanceand reliability.

NOTESome special applications require variationfrom standard torque values. Referenceshould always be made to componentoverhaul procedures for recommendations.

Special attention should be given to the existence oflubricant, plating or other factors that might requirevariation from standard torque values.

When maximum recommended torque values havebeen exceeded, the fastener should be replaced. Ifinstallation is in a tapped hole, check the thread witha gauge and then replace the bolt.

If reusing previously installed grade 10.9 bolts thathave not been over torqued, the bolts shall be visuallyinspected for cracks and thread damage and replacedif discontinuities are found. Bolts are not to berethreaded or reworked.

It is mandatory to replace systematically ALL washers,bolts and nuts of turntable bearing if they were removed(even if bolts have not been over torqued).

All lower grade fasteners must also be properlytightened to assure a good assembly. This tighteningcan be achieved by using a procedure (such as theturn-of-the-nut) or by applying the measured torque.

When unfinished self-locking nuts (such as the plas-tic patch or dimpled types) are coated with a light oil,the run down torque that would normally be added tothe wrench setting need not be added. Run downtorque is the force necessary to turn the nut on a freethread.

When referring to applicable torque charts, use va-lues as close as possible to the torque values shownto allow for wrench calibration tolerance. An erraticor jerking motion of the wrench can easily result inexcessive torque. ALWAYS use a slow wrenchmovement and STOP when the predetermined valuehas been reached.

Torque wrenches are precision instruments and areto be handled with care to ensure calibratedaccuracy. Calibration checks should be made on ascheduled basis. Whenever the wrench might beeither overstressed or damaged, it should immediatelybe removed from service until recalibrated.

MAINTENANCE 55

Toucan 1010 Models

Revision 02-200048

Nut identification :

8 10 12

8.8 10.9 12.9

Grade 8.8 Grade 10.9 Grade 12.9

Bolt identification :

Grade 8.8 Grade 10.9 Grade 12.9

HEX. HEAD BOLT

SOCKET HEAD BOLT

8.8 10.9 12.9

STUDGrade 8.8

QUALITYTENSILE

STRENGTHN/mm²

M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30

Maxi 2.5 5.2 8.8 15.2 21.6 42.4 75 119 184 255 358 487 620 908 1230mini 2.28 4.7 8 13.6 20 39.2 68 109 170 235 330 450 572 837 1136Maxi 3.6 7.4 12.8 20.8 30.4 60 104 170 258 364 503 685 872 1273 1730mini 3.3 6.8 11.2 19.2 28 55.2 96 156 238 334 465 632 804 1175 1598Maxi 4.3 8.8 15.2 24.8 36 71.2 125 199 310 426 605 823 1045 1528 2076mini 3.9 8 13.6 22.4 33.6 66.4 115 182 286 392 559 760 965 1410 1916

TORQUE VALUES FOR PLATED NUTS AND BOLTSFOR TORQUING WITH TORQUE WRENCH

(COARSE THREAD)

N.m

UNIT

8.8 785

10.9 981 N.m

N.m12.9 1177

MIN. MAXN.m. N.m.

JIC 7/16 10 15JIC 9/16 23 35JIC 3/4 32 48

UNIT

TORQUE VALUES FOR JIC FITTINGS

FOR TORQUING WITH TORQUE WRENCH

TORQUE VALUES FOR BSPP FITTINGS

FOR TORQUING WITH TORQUE WRENCH

UNIT N.m.BSPP 1/4 50BSPP 3/8 80BSPP 1/2 105BSPP 3/4 220

MAINTENANCE 55

49 Models


KNOW YOUR TORQUE WRENCH ! Flexible beamtype-wrenches - even though they might have a presetfeature - must be pulled at right angles and the forcemust be applied at the exact center of the handle.Force value readings must be made while the tool isin motion.

Rigid handle-type torque wrenches are available withtorque limiting devices that can be preset to requiredvalues and which eliminate dial readings.

NOTEWhen multipliers and/or special tools areused to reach hard-to-get-at spots, ensuretorque readings are precisely calculated.Identification of fastener grade is alwaysnecessary. When marked as a high-strengthbolt (grade 10.9, 12.9 etc.), the mechanic mustbe aware that he is working with a highlystressed component and the fastener shouldbe torqued accordingly.

5.14 Steering switches

Lower switches :

The lower switches limit the steering angle of thewheels when the mast is raised at more than half itscourse (when the limit switch located on the righthand side of the telescopic mast is activated).The right hand side lower switch limits the steering tothe right when the steering angle of the right steeringwheel reaches 45°.The left hand side lower switch limits the steering tothe left when the steering angle of the left steeringwheel reaches 45°.

Upper switches :

The upper switches cut off the drive function whenthe mast has been raised at more than half its course(when the limit switch located on the right hand sideof the telescopic mast is activated) with the steeringwheels initially steered at an angle above 45°. Thewheels need to be straightened to restore the drivefunction.

When the mast is fully lowered and the machine isdriven at HIGH speed ( ) the machine switchesautomatically to TORQUE speed when one of thelower switches is activated (drive speed limitationwhen the wheels are steered at an angle above 45°).

NOTEWhen steering the wheels, the lowerswitches must be activated before the upperswitches so as the steering limitation occursbefore the drive function cut-off.

Upperswitches

Lowerswitches

MAINTENANCE 55

Toucan 1010 Models

Revision 02-200050

5.15 Main hydraulic power unit

Main hydraulic power unit motor brushes (Qty = 4)have to be regularily checked. Motor ventilation holeshave to be regularily cleaned by blowing compressedair through the holes as indicated below :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.

If the length of one of the brushes is below10 mm, all 4 brushes must be replaced.During removal/installation, do notinterchange the brushes.

Brushes installation :

1- Lift the spiral spring and install the brushes.2 Install the brushes connection screws.3- Install the protection covers.

Areas to blowair through

Cover

Spring

10 m

mm

ini.Brush

5.16 Steering bracket thrustwashers

Check thickness of thrust washers on both steeringbrackets.Replace the washers if their thickness is below 2,5mm.

5.17 Mast section alignment

Mast sections alignment and adjustment ofthe transversal play between the mastsections must be performed by trained andqualified personnel.

1- Clean the inside walls of the mast sections toremove old grease.

2- Loosen the locknuts of the roller pins.3- Reduce the transversal play by tightening the

roller pins in succession.

Do not suppress the play completely : for themechanism to work, a minimum play isnecessary.

! CAUTION

! CAUTION

DANGER

MAINTENANCE 55

51 Models


4- Use a plumb line to ensure the verticalalignment of the mast sections is kept :

5- Tighten the roller pin locknuts.Torque value : 1000 N.m approximately.

If during adjustment one of the mast sectionsjams, stop the lowering movement and raisethe mast to retension the chains. Loosenslightly the roller pins of the jammed mast.

Controls after adjustment

- Fully raise and lower the telescopic mast twoor three times with the rated load (200 kg)evenly distributed in the platform.

- If no jamming occurs, fully raise and lowerthe telescopic mast with one person in theplatform.

- If jamming occurs during lowering, loosenslightly the roller pins of the jammed mastsection.

- Check the torque value of all roller pin locknuts.

Do not hesitate to contact your approved GroveManlift distributor for more information.

! CAUTION

5.18 Lifting chains adjustment

The lifting chains of a same stage must have anidentical tension.The chains must always be tensioned so that the mastsections are slightly offset towards the top :

Control of tension :

1- Fully raise the telescopic mast.2- Lower the mast by approximately 50 cm.3- Press on each chain between the pulley and

chain yoke. Each chain of a same stage musthave the same deflection.

4- Fully lower the mast.5- Raise the mast by approximately 50 cm.

Ensure the deflection is the same for eachchain of a same stage :

Tighten the nut on the anchorof the chain which is too slackor loosen the nut on the anchorof the chain which is too tight,ensuring the final offset of themast sections is kept.

6- Check the presence and correct tightening ofthe locknut on each chain anchor.

NOTERefer to Section 7. LUBRICATION for chainlubrication procedure and lubricantspecification.

4 to

6 m

m

4 to

6 m

m

4 to

6 m

m

4 to

6 m

m

Deflection

INCORRECT

Plumbline

CORRECT

Plumbline

Plumbline

MAINTENANCE 55

Toucan 1010 Models

Revision 02-200052

If a chain appears to be faulty or worn, it must bereplaced ; the condition of the pulleys and thetelescopic mast alignment must be checked.

5.19.2 Chains lubrication.

Do not use grease to lubricate the liftingchains.

Do not remove lubricant applied at the factoryfrom the chains. Do not use acid or detergentto clean the lifting chains.

Lubrication of the lifting chains can be performedmanually with a brush, or by spraying.Chain lubrication intervals must be established withcare, depending on the environment in which thework platform is operated or stored (dusty or agres-sive environment).The lubricant must be adapted to the machine'soperating conditions.In general, a non detergent mineral oil is sufficient.Its viscosity must be adapted to temperaturesaccording to the chart below :

A viscosity too low facilitates draining of thelubricant by gravity. A viscosity too highprevents the lubricant from reaching thefriction surfaces.

Lubricant must be applied :

- Longitudinally : in areas where joints are undersmall load to facilitate penetration of thelubricant.

- Transversely : between the plates to enablethe lubricant to reach the joint and betweenthe internal plates and the rollers (lubricant typerefer to § 7.1).s

Temperature (C°)Recommended viscosity

grades ISO - VG-15 < T <= 0 15 to 320 < T <= 50 46 to 15050 < T < 80 220 to 320

cracked plate

5.19 Chain control and lubrication

The service life of a lifting chain depends on thework platform operating conditions and on theenvironment in which the machine is used or stored.Service life is reduced if the chains are exposed tosignificant temperature fluctuations, acid or corrosiveproducts or vapours, or abrasive dust.

Due to the high resistance level of theircomponents, chains can be weakened byhydrogen.

5.19.1 Control of chain wear.

Inspect thorougly each chain in turn over its entirelength :

ç Chains, chain yokes, clevis pins and splitpins must not be corroded.

ç Plate must not be cracked.

ç The plate clevis pins must not presentexcessive play. The pins must not beturned in their housing.(1) :

ç Plates must not present a wear above 5%of the total height (refer to chart below).

ç Chain stretching cannot be superior to thevalues indicated in the chart below :

! CAUTION

! CAUTION

! CAUTION

! CAUTION

Pitch 5/8" (15,875 mm) 3/4" (19,05 mm)L max. 163,5 mm 196 mm

Pitch 5/8" (15,875 mm) 3/4" (19,05 mm)A min. 11,5 mm 13,6 mm

MAINTENANCE 55

5% of A max.

A

L = 10 pitches Pitch

A

(1)

53 Models


5.20 Overload detection setting

Check :

1- Place a 200 kg load evenly distributed on theplatform floor.

2- Position the Ground controls/Platform controlsselector switch to "Platform controls". Ensurethe lower emergency stop is not activated.

3- Apply a slight pressure F1 on the platform.ç An acoustic alarm sounds.ç The corresponding LED alarm lights up.ç Every function is disabled from the platform

controls.4- Position the "Ground controls"/"Platform

controls" selector switch to "Ground controls".

ç An acoustic alarm sounds.ç Every function is disabled from the ground

controls.

5- Apply a slight traction force F2 on the platform.

ç The acoustic alarm stops.

Setting :

1- Place a 200 kg load evenly distributed on theplatform floor.

2- Loosen the locknut of the setting screw.3- Loosen the setting screw until the sensor is

activated and the acoustic alarm sounds.4- Apply a slight traction force F2 on the platform.

The acoustic alarm should stop. If the acousticalarm does not stop, tighten slightly the settingscrew.

5- When the correct setting has been found,tighten the locknut.

6- Follow steps 3 and 4 of the checking procedureto verify the setting is correct.

Platform floor

Lock nut

Setting screw

Overload sensor

Platformsupport

200 kg

F1

F2

MAINTENANCE 55

Toucan 1010 Models

Revision 02-200054

5.21 Tilt alarm

General

This machine is fitted with a tilt sensor. The device islocated on the front of the frame.

Tilt sensor

Check :

1- Position the selector switch to "Groundcontrols" or "Platform controls"

2- Chock the rear wheels.3- Place a spirit level (digital display) on the

chassis positioned lengthways from À - Á.4- With a jack of appropriate capacity, lift the

front of the chassis in À :

- An acoustic alarm sounds when the chassisis tilted at 2°.

- The corresponding LED alarm lights up onplatform controls.

5- Chock the front wheels.6- With a jack of appropriate capacity, lift the

rear of the chassis in Á.

- An acoustic alarm sounds when thechassis is tilted at 2°.


7- Place a spirit level (digital display) across thechassis from Â - Ã.

8- With a jack of appropriate capacity, lift theright hand side of the chassis in Â.

- An acoustic alarm sounds when thechassis is tilted at 2°.


9- With a jack of appropriate capacity, lift the lefthand side of the chassis in Ã.

- An acoustic alarm sounds when the chassisis tilted at 2°.


Setting :

If the tilt sensor does not work symetrically in thedirection À - Á :

- Correct the symetry fault by tightening orloosening the nut C .

If the tilt sensor does not work symetrically in thedirection Â - Ã :

- Correct the symetry fault by tightening orloosening nuts A or B .

1

2

34

BA

C

MAINTENANCE 55

55 Models


5.22 Battery discharge indicatorsetting

A battery discharge indicator and hourmeter isfitted on the upper control box.

A serie of 10 coloured LEDs provides information onbattery discharge.As the battery discharges, the green LEDs (5) followedby the yellow LEDs (3) light up in succession from theright to the left.When a red LED flashes, the battery has reached a70% discharge depth : the machine must be driven toa charging station to recharge the battery.When both red LEDs flash in alternance, the batteryis discharged at 80% of its capacity and power supplyto the work platform is automatically cut off : thebattery must imperatively be recharged (a push buttonresets the power supply to enable to machine to reachthe charging station).The state of discharge of the battery is determined bycomparison of the battery voltage when the workplatform is operating at a pre-determined referencevoltage, then by integration of the period of time duringwhich the battery voltage is below the referencevoltage.The most significant function of the discharge indicatoris to cut off the electrical circuit when the battery is80% discharged, thus protecting the battery.The power cut threshold depends from the batterycapacity and from the discharge conditions to whichthe battery is submitted. This threshold can be adjustedusing the potentiometer at the back of the indicator,where a scale from 1 to 9 allows precise setting.The potentionmeter is set depending on the capacityof the battery for "normal" discharge conditions.

In certain operating cases, these discharge conditionsare not respected, therefore making it necessary toadjust the potentiometer.For example, in quick discharge conditions, the powercut will occur when the battery is still charged. Toadjust power cut threshold, proceed as follows :

- Measure battery electrolyte specific gravitywhen the power cut occurs (both red LEDs flashin alternance).

- Set the power cut threshold using thepotentiometer knowing that each numbercorrects the battery specific gravity by 0.020points.

For example, if the potentiometer is set onnumber 2 and electrolyte specific gravity is1,170 kg/l when the power was cut off :

- Specific gravity will be 1,150 kg/l on the nextdischarge cycle if the setting is modified tonumber 1.

- Specific gravity will be 1,190 kg/l on the nextdischarge cycle if the setting is modified tonumber 3.

"LED" batterydischarge indicator

Hourmeter Potentiometer

Battery 280 Ah :

Battery 560 Ah :

MAINTENANCE 55

Toucan 1010 Models

Revision 02-200056

5.23 Motor speed controller

The motor speed controller fitted to the work platformenables fluctuation of the rotation speed of the mainhydraulic unit motor, therefore modifying the speedof the work platform movements.The controller presents eight programmable speeds :

- Six variable speeds (four are used).- Two fixed speeds.

The controller variables can only be set with anappropriate SEVCON calibrator (P/N : 920021).

No variable or parameter can be modifiedwithout prior written approval from themanufacturer.

Controller variable setting :

1- Position the control panel selector either to"platform controls" or "ground controls". Ensurethe lower emergency stop switch is notactivated.

2- Connect the calibrator to the controller.

When the calibrator is connected to the controller,the operating time is displayed on the screen.

- Press on the arrow to display the operatinghours.

- Press on the arrow to display 1000's ofoperating hours.

To (-) battery

To (+) battery

To (-) power unit motorInsulated from (+) and (-)battery

Diagnosticled

Calibrator

Example :For an operating time of 1436 hours 27 minutes and20 seconds, the screen will display :

- Display on connection to the calibrator : 27.2(meaning 27 minutes and 20 seconds).

- Button depressed, display : 436 (meaning436 hours).

- Button depressed, display : 1 (meaning 1000hours).

NOTEThe meter rolls over to 0 after 65500 hours ofoperation.

3- Press on the "select" button. A red LED lightsup opposite the first parameter : "speed1". Theparameter value is displayed on the screen.Press on the arrow to increase the value ofthis parameter.Press on the arrow to decrease the value ofthis parameter.

Each time the "select" button is depressed, a red LEDlights up opposite the next parameter, the value of thisparameter is displayed on the screen and can bemodified with the and buttons.

DANGER

Available parameters for "pump" controller

MAINTENANCE 55

57 Models


Description and parameters values for Toucan 1010 models.

Calibrator use as measuring instrument :

BATT V :The measure of battery voltage can be done at any time,even when the work platform is in operation, thusenabling analysis, if necessary, of the battery voltagefluctuations.

MOTOR V :The measure of the motor voltage in operation enablesthe determination, for a chosen speed, of the voltage tobe applied at the motor terminals. The value of this voltagecalculated in percentage of the battery voltage determinesthe speed setting.

MOTOR AMP. :The measure of the current at the motor enables thedetermination of the current limit value to which thecontroller must be set when the machine is driven on aramp.

TEMP °C :The measure of the temperature enables the analysis ofthe controller temperature increases, therefore theoperating conditions of the work platform.

Parameter Description Unit StepValuesToucan

1010Comments

Speed 1 Speed n°1 (variable) % 1% 45

First gear drive speed.Mast and jib lowering function speedSwing movement speed from platform controls.

Speed 2 Speed n°2 (variable) % 1% 50

Jib raising function speed from platform controls.Mast raising function speed from ground controls.

Speed 3 Speed n°3 (variable) % 1% 80 Mast raising function speed from platform controls.

Speed 4 Speed n°4 (variable) % 1% 100 Drive speed in 2nd and 3rd gear.Speed 5 Speed n°5 (variable) % 1% 0 Not used.Speed 6 Speed n°6 (variable) % 1% 0 Not used.

Speed 7 Speed n°7 (fixed) % 1% 45 Speed of movements from the emergency control panel (Ground controls).

Speed 8 Speed n°8 (fixed) % 1% 30Pump speed for make-up flow to hydraulic wheel motors.

Creep%VB Starting threshold % 1% 10Ramp sec Ramp shape sec. 0,1 1 1 second max.Extra % Additional speed % 1% 0 Not used.

Imax Amp. Current limit Amp. 10 400Batt V Battery voltage Volt

Motor V Motor voltage VoltMotor Amp. Motor current Amp.

Temp °C Temperature of mosfet radiator

°C

Test Test Mode - Refer to "Calibrator use as operating control instrument"

Refer to "Calibrator use as measuring instrument"

MAINTENANCE 55

Toucan 1010 Models

Revision 02-200058

Calibrator use as operating control instrument (testmode) :

- Position the control panel selector either to"platform controls" or "ground controls".

- Ensure the lower emergency stop switch is notactivated.

- Connect the calibrator to the controller anddepress the "select" button until "TEST" isdisplayed.

NOTEWhen "TEST" is selected, the work platformcan operate normally.

The value displayed on the screen corresponds to thevalue of the accelaration input received by the motorspeed controller.

- When the joystick controller is activated atplatform controls, the acceleration input variesfrom 0 to 100%.

- When controlling a superstructure function andusing the rotary potentiometer, theacceleration input varies from 40/45% to100%.

- The or buttons step through the other tests.

- CL : (closed) means that the selected speed is active.- OP : (open) means that the speed is not selected or is

not active.

Diagnostic Led :

The controller is equipped with a diagnostic systemusing a green LED located near the calibrator socket.At connection the LED must light up and stay lit.If the green LED is off :

- The controller is out of order.- The controller circuit is faulty.- Controller supply fault (fuses faulty in thecontrol circuit).

The green led may also flash a certain number oftimes at connection :

- 2 flashes : "Pump inhibit" function active. (Pumpinhibit function is active when the telescopicmast is raised above its middle course with thewheels steered over 45°).

- 3 flashes : Short circuit across mosfets or motoropen circuit.

- 7 flashes : Battery discharged. (Voltage less than13V).

- 8 flashes : Activation of thermal cutback (overheat).

Connections on 17 pin connector "SEVCON - MOS"90 - "PUMP" controller :

Test sequence Function Display

- Accelerator 0 to 100%1 Speed n°1 CL or OP2 Speed n°2 CL or OP3 Speed n°3 CL or OP4 Speed n°4 CL or OP5 Speed n°5 CL or OP6 Speed n°6 CL or OP7 Speed n°7 CL or OP8 Speed n°8 CL or OP9 Not used10 Not used

MAINTENANCE 55

59 Models


5.24 Fuses

Fuses used in the work platform electrical systemprotect the electrical circuit and electronic boardsfrom excessive intensity (within the electrical circuitin which they are used).

5.24.1. Power circuit main fuseThe POWER CIRCUIT MAIN FUSE (F1) located onthe right hand side of the lower control box, protectsthe power supply circuit (DIN 43560 - 325 Amps).

5.24.2. Steering power circuit fuseThe STEERING POWER CIRCUIT FUSE (F2) locatedon the front axle beam of the chassis protects thepower supply circuit of the electrical steering unitmotor (DIN 43560 - 63 Amps).

5.24.3. Control circuit main fuse

The CONTROL CIRCUIT MAIN FUSE (F3) panelmounted on the Lower Control Box protects the wholecontrol circuit. Cartridge fuse link : 5 x 20 mm quickacting fuse - 5 Amps.

5.24.4. Battery voltage indicator fuseThe BATTERY VOLTAGE INDICATOR FUSE (F4)panel mounted on the Lower Control Box protectsthe circuit between the battery (+) and the batteryvoltage input on the battery discharge indicator.Cartridge fuse link : 5 x 20 mm quick acting fuse -0.5 Amp.

5.24.5. Battery filling unit fuseThe BATTERY FILLING UNIT FUSE (F5) locatedinside the Lower Control Box protects the powersupply circuit of the battery filling unit motor. Cartridgefuse link : 5 x 20 quick acting fuse - 3 Amps.

Power circuit main fuse

F1

F5

F2

Steering power circuit fuse

F3 F4

MAINTENANCE 55

Toucan 1010 Models

Revision 02-200060

5.24.6. Electronically piloted circuitsfuses

The ELECTRONIC PILOTED CIRCUIT FUSES(Qty : 7) mounted on the electronic board inside the LowerControl Box protect the coil supply circuit of :

- The DRIVE FWD valve (F1) [MAV]- The DRIVE REV valve (F2) [MAR]- The DUMP valve (F3) [DV]- The DRIVEHI/LO valve (F4) [HI/LO]- The DRIVE BRAKE valve (F5) [EVF]- The MAST valve (F7) [DM]- The JIB LOWERING valve (F6) [DB]

F1,F2,F3,F5,F6 & F7 : ATO quick acting fuses 1 A.F4 : ATO quick acting fuse 2 A.

5.25 Drive function sequences.Electronic board potentiometerssetting.

The potentiometers used on the electronicboard are single turn trimmers. Do notattempt to turn the wiper setting screw morethan the allowed mechanical rotation. Use ascrew driver of proper dimension.

Description

The potentiometers (P1) (P2) (P3) enable theadjustments of the correct sequencing delays for aproper operation of the drive function.

Start sequence : When the controller is activated toperform a drive function (DRIVE SPEED selectorpositioned on HIGH speed ( )), the work platformstarts driving in TORQUE speed and switchesautomatically to HIGH speed. The time delay for thework platform to switch to HI speed can be adjustedby means of the potentiometer (P1).

Soft start / Stop Sequence : When the controller isslowly activated to perform a drive function (DRIVESPEED selector positioned on HIGH speed ( )),the work platform starts in TORQUE speed and shouldonly switch to HI speed when the acceleration inputvalue (from the controller potentiometer) has reachedabout 70% of its maximum course. With the platformdriving in HI speed, the platform should switch toTORQUE speed when the acceleration input value(from the controller potentiometer) falls just under40% when slowly returning the controller to neutral.The speed change threshold can be adjusted bymeans of the potentiometer (P2).

NOTEThe differential acceleration input value forspeed changing (from HI to TORQUE speed)is a fixed value (about 30%).

! CAUTION

MAINTENANCE 55

F1

F2

F3

F4 F5

F6

F7

61 Models


Stopping sequence - Brusque drive directioninversion sequence :In case of brusque drive direction inversion, the workplatform first slows down and then stops before re-starting in the opposite direction (as described inthe Start Sequence). The time delay for the workplatform to re-start in the opposite direction can beadjusted by means of the potentiometer (P3). Duringthis time delay, the pump motor is running at lowspeed, providing make-up flow to the hydraulic wheelmotors.

SettingNOTE

The potentiometers arrow head indicatorpositions shown on the figures belowcorrespond to an approximate setting.

Potentiometers with arrow head indicators :

Potentiometers without arrow head indicators :

NOTEA smooth jerk occurs when the machineswitches from TORQUE speed to HI speed orfrom HI speed to TORQUE speed.

Potentiometer (P1) setting :

1. Position the DRIVE SPEED selector switch toHI speed ( ).

2. Perform a DRIVE REVERSE movement byfully pulling the controller towards the operatoras quickly as possible.

3. The work platform should start in TORQUEspeed then should switch to HI speed withinan approximate 2 seconds time delay.

- If the time delay for the work platform to switchto HI speed is longer than 2 seconds, reducethe delay by turning slightly (by 1/32 turn) thepotentiometer P1 wiper screw anticlockwise.

- If the work platform switches too quickly to HIspeed, the work platform may not be able togo forward or backwards, increase the delayby sl ightly turning (by 1/32 turn) thepotentiometer P1 wiper screw clockwise.

Lower Control Box Electronic Board

P1 -

+

P2 +

-

P3 -

+

-

+

+

-

-

+

P1 P2 P3

MAINTENANCE 55

Toucan 1010 Models

Revision 02-200062


1. Connect the cal ibrator to the SEVCONcontroller. Using the "SELECT" button selectthe ACCELERATOR INPUT TEST SEQUENCE.Refer to MOTOR SPEED CONTROLLER in thissection for further information.


3. Perform a drive function by acting slowly onthe controller. The work platform should switchto HI speed when the accelerator input value(displayed by the calibrator) reaches about70%.

4. Reduce the work platform speed by letting thecontroller slowly return to neutral. The workplatform should return to TORQUE speed whenthe accelerator input value falls under 40%and before the movement stops.

- If the drive movement stops before the workplatform switches to TORQUE speed turnslightly (by 1/32 turn) the potentiometer P2wiper screw anticlockwise.

- If the work platform switches to HI speed withan accelerator input value too high , slightlyturn (by 1/32 turn) the potentiometer (P2)wiper screw clockwise.



2. Drive the work platform forward at full speed(controller fully pushed away from the operator).

3. Release the pedal. The work platform shouldstop smoothly. The work platform should stopbefore the pump motor stops running (thepump motor runs at low speed to provide make-up flow to the wheel motors).

4. Drive the work platform forward at full speedthen quickly reverse the movement. The workplatform should stop smoothly BEFOREstarting in the reverse direction :-If the work platform re-starts in reversedirection before stopping completely and / orthe wheels motors clatter, increase the delayby turning sl ightly (by 1/32 turn) thepotentiometer (P3) wiper screw clockwise.-If the time during which the pump motor runsat low speed (make-up flow) exceeds 1second, reduce the delay by turning slightly(by 1/32 turn) the potentiometer (P3) wiperscrew anticlockwise.

MAINTENANCE 55

63 Models


PREVENTIVE MAINTENANCE AND INSPECTION 6

6.1 General6.2 Preventive maintenance and inspection required

6.2.1 Daily preventive maintenance and inspection6.2.2 Weekly preventive maintenance and inspection6.2.3 Monthly preventive maintenance and inspection6.2.4 Every 125 hours of operation preventive maintenance and inspection6.2.5 Every 250 hours of operation preventive maintenance and inspection6.2.6 Every 500 hours of operation preventive maintenance and inspection

TABLE OF CONTENTS

65 Models


Do not spray directly on :- Electrical boxes and components,- The electronic controller,- The battery,- The charger,- The hydraulic unit motors,- Cylinder rods and seals,- Lifting chains.

Dry thoroughly the work platform (compressed air,cloths...) and lubricate as indicated (§ 7) before thework platform is returned to service.

! CAUTION6.1. General

The information in this section point out the items tobe checked when performing daily, weekly and timebased maintenance and inspections required onGrove Manlift aerial work platforms.

NOTEThis material does not replace any pre-operational checks required by the owner ora local or state safety board.

NOTEState regulations require that written, datedand signed inspection records aremaintained.

NOTEPerform lubrication as outlined in section 7.

The control and maintenance procedures describedin this chapter require specific competences. Werecommend that these operations are performed onlyby authorised and qualifed personnel.

If you have any queries concerning control andmaintenance procedures, please contact your GroveManlift distributor.

Certain operations require removal of covers orprotection housings. All covers or protection housingsmust be installed before returning the work platform toservice.

Work platform cleaning :

During cleaning, the battery must bedisconnected from the work platform circuit,the charger must be disconnected from thepower supply, the 220 V power socket on theplatform (option) must be disconnected.

External cleaning :

Clean the work platform with an appropriate cleaningchemical mixed with water (water spray, sponge,cloths)

High pressure cleaning can only be used witha maximum pressure of 50 bar and a maximumtemperature of 70°C.

! CAUTION

! CAUTION


Toucan 1010 Models

Revision 02-200066

6.2. Preventive maintenance andinspection required

Control and maintenance intervals must berespected to ensure safe operation of thework platform. The work platform must not beused if it is not operating PERFECTLY : it mustbe repaired and checked by a qualified andtrained personnel before the machine isreturned to service.

NOTEIf the work platform has been left idle for along period of time, all the control, cleaningand lubrication procedures described belowmust be performed before the work platformis used again.

6.2.1. Daily preventive maintenance andinspection

Daily preventive maintenance/inspections shouldinclude verification of the following items :

- Operator's and Safety Handbook- Decals - warning and instruction- Work platform- Controls / indicators- Tilt alarm- Motion alarm- Mast limit switches- Steering limitation switches- Overload detection- Chain slack/breaking detection- Battery state of charge- Electrolyte level in battery cells- Tyres condition- Hydraulic oil level in reservoir- Jib and attachments- Screw and cotter pins for clevis pins- Power track- Lubrication

! CAUTION

6.2.2. Weekly preventive maintenanceand inspection

Weekly preventive maintenance/inspections shouldinclude verification of the following items :

- Wheels nuts- Hydraulic hoses and fittings- Battery (electrolyte level)- Mast/jib cylinders- Lubrication

6.2.3. Monthly preventive maintenanceand inspection

Monthly preventive maintenance/inspections shouldinclude verification of the following items :

- Mast lifting chains (lubrication)- Batteries (electrolyte specific gravity - cellsvoltage)

- Lubrication

6.2.4. Every 125 hours of operationpreventive maintenance and inspection

Preventive maintenance/inspections should includethe previous preventive and maintenance inspectionsand verification of the following items :

- Cylinders- Mast lifting chains/pulleys- Batteries- Wheel nuts (torque value)- Tilt indicator (setting)- Overload detection (setting)- Motor brushes of main hydraulic unit- Motor ventilation holes (cleaning)- Steering brakets thrust washers- Brake release pressure- Bushes (jib/steering system)- Lubrication



- Hydraulic filters (replacement)- Turntable bearing (greasing)- Lubrication


67 Models




- Swing bearing bolts (torque)- Lifting chains (wear)- Telescopic mast alignment/bronze spacers onroller pins

- Relief valve settings- Lubrication

NOTEThe work platform must be controlled by anotified body according to the regulation inforce.

NOTEFire extinguisher (optional equipment) mustbe checked according to regulations in force.

NOTETurntable attachment caps screws have to beretorqued after the first 100 hours operation.

NOTEHydraulic filters have to be replaced after thefirst 50 hours operation.


69 Models


LUBRICATION 7

7.1 Lubrication points

TABLE OF CONTENTS

71 Models


Follow designated lubrication procedures to ensuremaximum work platform lifetime and use. Theprocedures and lubrication chart in this sectionprovide information on the types of lubricants used,the location of lubrication points, the lubricationintervals and other important material.

7.1. Lubrication points

Regular lubrication must be performed on alllubrication points. Normally, the frequency forlubrication is based on component operating time.The most efficient method for keeping track oflubrification intervals is to maintain a job log indicatingmachine usage. The log should include hourmeterreadings which can be used to determine whichlubrification points will require attention.

Lubricants or grease types as well as lubricationintervals must be adapted to the conditions, operatingand storage environments of the work platform(temperature, dusty atmosphere, corrosiveatmosphere, humidity...)

Check oil levels and perform lubrication only whenthe work platform is parked on a level surface in thetransport position - and while the oil is cold (unlessotherwise specified).

Excessive lubrication on non-sealed fittings will notharm the fittings or components, but too littlelubrication can lead to shorter component life.

Unless otherwise indicated, items not equipped withgrease fittings (such as linkages, pins, levers, etc...)should be lubricated with oil once a week. Motor oilapplied sparingly will prov ide the necessarylubrication and help prevent the formation of rust.An anti-seize compound may be used if rust has notformed.

If rust or corrosion is present, the component mustbe thoroughly cleaned before applying lubricant.

Grease fittings that are worn and will not hold thegrease gun (or those that have a stuck check ball)must be replaced.

Where wear pads are used, cycle the componentand relubricate to ensure complete lubrication of theentire wearing surface.

The following chart titled Lubrication Chart describeslubrication points and gives the lubricant type,lubrication interval, lubricant amount and applicationof each.

Use the following lubrication intervals as aguideline only. Formulate actual lubricationintervals to correspond to conditions suchas continuous duty cycles and/or hazardousenvironments.

NOTECheck all fluid levels at ambient temperature.

! CAUTION

LUBRICATION 77

LOCATION LUBE TYPE LUBE INTERNAL LUBE AMOUNT APPLICATION

1. Mast profiles

MOBILUX EP2(Lithium base grease)

orMOBILITH SHC 220(Low temperature)

Every 125 hours of operation or after each cleaning or more often if the work platform is used or stored in a very dusty or corrosive environment.

N/A

1. Clean the inside wall of mast to remove the old grease2. Lubricate the mast inside wall using a brush

3. Cycle the mast and relubricate.

LUBRICATION CHART

Toucan 1010 Models

Revision 02-200072

MINMAX

LOCATION LUBE TYPE LUBE INTERNAL LUBE AMOUNT APPLICATION

2. Lifting chains

MOBIL DTE 16MViscosity : 68 cSt at 40°CViscosity index : 142Pour point : -45°C

Every 125 hours or once every 30 days of operation or more often if the platform is used or stored in a very dusty or corrosive environment.

N/A

Lubricant can be applied manually with a brush or by spraying.Apply lubricant :- Longitudinally = in areas where joints are under small load to facilitate penetration of the lubricant.- Transversally = between the plates to enable the lubricant to reac

3. Wheel bearings (non-drive hubs)


Every 250 hours of operation. N/A

1 Grease nippleon each hub

4. Swing bearing race


Every 250 hours of operation. N/A

1 Grease nipple on turntable base plate

5. Main hydraulic reservoir


- Check daily.- Drain after 1000 hours of operation or at least every 2 years.

21,5 l

Fill through top in-tank return filter.Checklevel through thesight gauge onthe reservoir.

6. Return filter

7. Pressure filter

8. Steering unit reservoir


- Check every 125 hours of operation.- Drain after 1000 hours of operation or at least every 2 years.

1l Check level/fill through reservoir breather cap.

9.Swing bearing internal gear

MOBILTAC 81orMOBILITH SHC 1500

Every 1000 hours of operation. Coat all teeth.

1- Remove swing gear box2- Apply a thick coat of grease with a brush through the gear box centering hole. Manually rotate the turntable to reach the whole teeth.

Element replacement interval : After first 50 hours of operation and every 250 hours thereafter.

Element replacement interval : After first 50 hours of operation and every 250 hours thereafter.

LUBRICATION 77

73 Models


NOTES

Documents

SERVICE MANUAL - JLG Industries 1010/1 - SN... · Toucan 1010 Models 4 Revision 02-2000 INTRODUCTION 1 Foreword Important information WORK PLATFORM CHARACTERISTICS 2 Description-----2.1