Grove toucan 1010 Service Manual Download

Page: 5 / 73

Models

Revision 02-2000

Toucan 1010

TABLE OF CONTENTS

MAINTENANCE

System malfunctions ------------------------------------------------------------------ 5.1

Cleanliness ------------------------------------------------------------------------------- 5.2

Removal and installation ------------------------------------------------------------- 5.3

Disassembly and assembly ---------------------------------------------------------- 5.4

Parts replacement ---------------------------------------------------------------------- 5.5

Wires and cables ----------------------------------------------------------------------- 5.6

Gaskets ----------------------------------------------------------------------------------- 5.7

Care and installation of teflon-coated bushings------------------------------- 5.8

Bushings --------------------------------------------------------------------------------5.8.1

Pin ----------------------------------------------------------------------------------------5.8.2

Bushings and pin ---------------------------------------------------------------------5.8.3

Bushing installation ------------------------------------------------------------------5.8.4

Mast roller removal ------------------------------------------------------------------- 5.9

Upper rollers ---------------------------------------------------------------------------5.9.1

Lower rollers --------------------------------------------------------------------------5.9.2

Rollers -----------------------------------------------------------------------------------5.9.3

Hydraulic system -------------------------------------------------------------------- 5.10

Fatigue of welded structures ----------------------------------------------------- 5.11

LOCTITE® ------------------------------------------------------------------------------- 5.12

Fasteners and torque values------------------------------------------------------ 5.13

Steering switches -------------------------------------------------------------------- 5.14

Main hydraulic power unit --------------------------------------------------------- 5.15

Steering bracket thrust washers ------------------------------------------------- 5.16

Mast section alignment ------------------------------------------------------------- 5.17

Lifting chains adjustment ---------------------------------------------------------- 5.18

Chain control and lubrication------------------------------------------------------ 5.19

Control of chain wear ------------------------------------------------------------ 5.19.1

Chain lubrication ------------------------------------------------------------------- 5.19.2

Overload detection setting --------------------------------------------------------- 5.20

Tilt alarm ------------------------------------------------------------------------------- 5.21

Battery discharge indicator setting ---------------------------------------------- 5.22

Motor speed controller -------------------------------------------------------------- 5.23

Fuses------------------------------------------------------------------------------------- 5.24

Power circuit main fuse --------------------------------------------------------- 5.24.1

Steering power circuit fuse ----------------------------------------------------- 5.24.2

Control circuit main fuse -------------------------------------------------------- 5.24.3

Battery voltage indicator fuse ------------------------------------------------- 5.24.4

Battery filling unit fuse ---------------------------------------------------------- 5.24.5

Electronically piloted circuits fuses ------------------------------------------ 5.24.6

Drive function sequences - Electronic board potentiometers setting -- 5.25

Summary of Contents for toucan 1010

Page 1: ...SERVICE MANUAL Revision 02 2000 MA 0235 01 English Toucan 1010 I...

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Page 3: ...3 Models Revision 02 2000 Toucan 1010 MA0235 01 Models Toucan1010 _____ Toucan1010 I _____...

Page 4: ...ib lowering PR6 3 3 6 Brake release maximum pressure PR7 3 3 7 Drive at low speed PR8 3 3 8 Counterbalance valve setting 3 4 BATTERY CHARGER 4 Battery 4 1 Charger 4 2 Fulmen charger 4 2 1 Oldham Hawke...

Page 5: ...5 12 Fasteners and torque values 5 13 Steering switches 5 14 Main hydraulic power unit 5 15 Steering bracket thrust washers 5 16 Mast section alignment 5 17 Lifting chains adjustment 5 18 Chain contr...

Page 6: ...nce and inspection 6 2 1 Weekly preventive maintenance and inspection 6 2 2 Monthly preventive maintenance and inspection 6 2 3 Every 125 hours of operation preventive maintenance and inspection 6 2 4...

Page 7: ...7 Models Revision 02 2000 Toucan 1010 Foreword Importantinformation TABLE OF CONTENTS 1 INTRODUCTION...

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Page 9: ...ed in this manual apply as follows A DANGER is used to emphasize that if an operation procedureorpracticeisnotfollowed exactly death or serious injury to personnel may result A CAUTION is used to emph...

Page 10: ...is weldment to be free from defects in material and workmanship its obligation and liability under the structural warranty being limited to repairing or replacing free of charge at its factory any par...

Page 11: ..._______________________________________________ Page s Affected ___________________________________________________________________ Reason for submitting SMCAR Use additional paper or back if necessar...

Page 12: ...Toucan 1010 Models Revision 02 2000 12 Thispageintentionallyleftblank CORRECTIVE ACTION REQUEST...

Page 13: ...13 Models Revision 02 2000 Toucan 1010 2 1 Description 2 2 Characteristics Dimensions Performances TABLE OF CONTENTS 2 WORK PLATFORM CHARACTERISTICS...

Page 14: ...t steering is located at the top of the main hydraulic tank at the rear of the chassis The turntable rotation movement is accomplished through a moto reducer group located at the base of the turntable...

Page 15: ...harger Emergency control panel Counterweight Jib Platform Lateral battery access Steeringwheels Drivingwheels LEFT SIDE Front Rear Counterweight Breakdowncontrol panel Steering hydraulic unit Steering...

Page 16: ...inous Inner turning radius Machine raised 1 78 m Machine half raised 0 m Outer turning radius Machine raised 3 37 m Machine half raised 1 75 m PLATFORM Length 0 70 m 1 01 m Width 0 90 m Rated load 200...

Page 17: ...charged battery and working in an ambiant temperature of 20 C Constant product improvement make it necessary that GROVE reserve the right to make specification and equipment changes without notice DR...

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Page 19: ...Circuitreliefvalveadjustment 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 maximumpres...

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Page 21: ...circuit relief valve pressure settings If the pressure setting of any relief valve is not 5 bar of the setting listed in the table adjust valve as necessary unless otherwise specified Do not overtigh...

Page 22: ...ib over the front Note the maximum reading of the pressure gauge If the reading is not within 5 bar of the relief pressure shown in the table titled Relief Valve Pressure Settings adjust the pressure...

Page 23: ...servicing 7 TURN OUT the PR7 relief valve adjustment screw until the pressure drops just under the previously recorded value then turn the adjustment screw 1 4 turn IN 8 Unhook the pump handle and pu...

Page 24: ...rk platform is driven at its maximum speed 3rd gear it must stop over a 0 8m to 1m distance on flat ground in both forward and reverse when the joystick is returned to neutral When the work platform i...

Page 25: ...4 Electrolyte specific gravity and battery voltage 4 5 Centralised filling system maintenance 4 6 Cleaning Battery maintenance 4 7 Storage of a battery at temperatures below 0 C 32 F 4 8 Use of a bat...

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Page 27: ...cled several times somewhere between five and 40 cycles For at least the first five cycles it is recommended not to discharge the battery above 70 of its capacity To obtain the maximum battery life do...

Page 28: ...xplode NOTE It is not necessary to charge the battery if the electrolyte specific gravity has not dropped under 1 240 kg l Regular charge of a battery when its specific gravity is higher than 1 240 kg...

Page 29: ...Amps on 24 MO 65A models Output fuse 40 Amps on 24 MO 40A models 80 Amps on 24 MO 65A models NOTE A spare output fuse is strapped inside the charger cover Troubleshootingchart Display Probable cause S...

Page 30: ...0Hz 230VAC 50Hz Adaptation to network voltage Prior to any operation requiring charger cover removal the battery must be disconnected and the charger must be unplugged from the AC outlet Failure to do...

Page 31: ...reen displays an error code Screen display Axxx Charging supply Ux xx Voltageperelement cxxx or Cxxx Ah reinjected into the battery cxxx 999 Ah Cxxx 999Ah Hxx xChargingtime from thebeginingof thecharg...

Page 32: ...cator If a fault occurs during charge switch off the charger and disconnect it from AC outlet c b a d e DANGER Troubleshooting The default LED indicator lights up Pre insulated terminal 220 V 110 V 0...

Page 33: ...icator stops turning 4 Verify the proper electrolyte level in each battery cell 4 4 Electrolyte specific gravity and battery voltage Specific gravity and voltage measure is the most important check to...

Page 34: ...he value as indicated on the example below DANGER 1 12 1 14 1 16 1 18 1 20 1 22 1 24 1 26 1 28 1 30 1 23 kg l Checking electrolyte specific gravity Battery electrolyte must not be allowed to contact t...

Page 35: ...have become corrosive Do not allow drain water to contact the skin or eyes If it does occur flush the contacted area with water and consult a doctor immediatly Appropriateequipement mustbe worn gloves...

Page 36: ...loose 55 of its 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 Electrolytespecificgravity Temperature in C CAUTION BATTERY CHARGER 4 4 4 9 Battery...

Page 37: ...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...

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Page 39: ...rsandtorquevalues 5 14 Steering switches 5 15Mainhydraulicpowerunit 5 16Steeringbracketthrustwashers 5 17Mast sectionalignment 5 18Liftingchainadjustment 5 19Chaincontrol andlubrication 5 19 1 Control...

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Page 41: ...been removed from all machined surfacesof newparts before they are installed except leaf chains 5 3 Removal and installation When performing maintenance do not attempt to manually lift heavy parts whe...

Page 42: ...ng a group of wires or cables tag each one to ensure proper identification during assembly 5 7 Gaskets Ensure the holes in the gaskets correspond with the lubricant passages in the mating parts If it...

Page 43: ...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 belo...

Page 44: ...ps Partly tighten the pin on the mast section and insert the washer on the pin Apply grease to the spacer so that it sticks to the mast and does not fall to the bottom of the mast Press the spacer ont...

Page 45: ...cturing methods there is a natural curvature to a hydraulic hose The hose should be installed so any bend is with this curvature Removing air from the hydraulic system Air entering the hydraulic oil w...

Page 46: ...sis base plate Hydraulic wheel motors attachment plates rear axle Front axle beam connection on chassis plate Steering brackets Mast section 1 connection on turntable plate Hydraulic cylinder end conn...

Page 47: ...have not been over torqued the boltsshall be visually inspected for cracks and thread damage and replaced if discontinuities are found Bolts are not to be rethreaded or reworked It ismandatory to repl...

Page 48: ...20 8 30 4 60 104 170 258 364 503 685 872 1273 1730 mini 3 3 6 8 11 2 19 2 28 55 2 96 156 238 334 465 632 804 1175 1598 Maxi 4 3 8 8 15 2 24 8 36 71 2 125 199 310 426 605 823 1045 1528 2076 mini 3 9 8...

Page 49: ...f its course when the limit switch located on the right hand side of the telescopic mast is activated The right hand side lower switch limits the steering to the right when the steering angle of the r...

Page 50: ...1 Lift the spiral spring and install the brushes 2 Install the brushes connection screws 3 Install the protection covers Areas to blow air through Cover Spring 10 mm mini Brush 5 16 Steering bracket t...

Page 51: ...more information CAUTION 5 18 Lifting chains adjustment The lifting chains of a same stage must have an identical tension Thechainsmust alwaysbetensionedsothat themast sections are slightly offset tow...

Page 52: ...rsely between the plates to enable the lubricant to reach the joint and between the internal platesand the rollers lubricant type refer to 7 1 s Temperature C Recommended viscosity grades ISO VG 15 T...

Page 53: ...tic alarm sounds Everyfunctionisdisabledfrom theground controls 5 Applyaslight tractionforceF2on theplatform The acoustic alarm stops Setting 1 Place a 200 kg load evenly distributed on the platform f...

Page 54: ...ustic alarm sounds when the chassis is tilted at 2 ThecorrespondingLEDalarmlightsupon platformcontrols 7 Placeaspiritlevel digitaldisplay acrossthe chassis from 8 With a jack of appropriate capacity l...

Page 55: ...arged thus protecting the battery The power cut threshold depends from the battery capacity and from the discharge conditions to which thebatteryissubmitted Thisthresholdcanbeadjusted using the potent...

Page 56: ...layed on the screen Press on the arrow to display the operating hours Press on the arrow to display 1000 s of operating hours To battery To battery To power unit motor Insulated from and battery Diagn...

Page 57: ...1010 Comments Speed 1 Speed n 1 variable 1 45 First gear drive speed Mast and jib lowering function speed Swing movement speed from platform controls Speed 2 Speed n 2 variable 1 50 Jib raising functi...

Page 58: ...t thespeed isnot selected or is notactive DiagnosticLed The controller is equipped with a diagnostic system using a green LED located near the calibrator socket At connection the LED must light up and...

Page 59: ...43560 63 Amps 5 24 3 Control circuit main fuse The CONTROL CIRCUIT MAIN FUSE F3 panel mounted on the Lower Control Box protectsthe whole control circuit Cartridge fuse link 5 x 20 mm quick acting fus...

Page 60: ...sequence When the controller is activated to perform a drive function DRIVE SPEED selector positioned on HIGH speed the work platform starts driving in TORQUE speed and switches automatically to HIGH...

Page 61: ...w head indicators NOTE A smooth jerk occurs when the machine switches from TORQUE speed to HI speed or from HI speed to TORQUE speed Potentiometer P1 setting 1 Position the DRIVE SPEED selector switch...

Page 62: ...ches to HI speed with an accelerator input value too high slightly turn by 1 32 turn the potentiometer P2 wiper screw clockwise Potentiometer P3 setting 1 Position the DRIVE SPEED selector switch to H...

Page 63: ...ivemaintenanceandinspection 6 2 2Weeklypreventivemaintenanceandinspection 6 2 3Monthlypreventivemaintenanceandinspection 6 2 4 Every 125 hours of operation preventive maintenance and inspection 6 2 5...

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Page 65: ...s outlined in section 7 The control and maintenance procedures described in this chapter require specific competences We recommendthat theseoperationsareperformedonly by authorised and qualifed person...

Page 66: ...2 2 Weekly preventive maintenance and inspection Weekly preventive maintenance inspections should include verification of the following items Wheels nuts Hydraulic hoses and fittings Battery electrol...

Page 67: ...ar Telescopic mast alignment bronze spacers on roller pins Relief valve settings Lubrication NOTE The work platform must be controlled by a notified body according to the regulation in force NOTE Fire...

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Page 69: ...69 Models Revision 02 2000 Toucan 1010 LUBRICATION 7 7 1 Lubrication points TABLE OF CONTENTS...

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Page 71: ...tems not equipped with grease fittings such as linkages pins levers etc should be lubricated with oil once a week Motor oil applied sparingly will provide the necessary lubrication and help prevent th...

Page 72: ...te 5 Main hydraulic reservoir MOBIL DTE 13M Viscosity 32 cSt at 40 C Viscosity index 155 Pour point 48 C Check daily Drain after 1000 hours of operation or at least every 2 years 21 5 l Fill through t...

Page 73: ...73 Models Revision 02 2000 Toucan 1010 NOTES...

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