Grove toucan 1010 User manual

SERVICEMANUAL
Revision 02-2000 MA0235-01
English
Toucan1010 I

3
Models
Revision 02-2000 Toucan 1010
MA0235-01
Models
Toucan1010 _____
Toucan1010 I_____

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INTRODUCTION 1
Foreword
Importantinformation
WORK PLATFORMCHARACTERISTICS 2
Description-------------------------------------------------------------------------------2.1
Characteristics- Dimensions- Performances---------------------------------2.2
PRESSURESETTINGS 3
Reliefvalve setting--------------------------------------------------------------------3.1
Brake releasecircuitpressurecheck---------------------------------------------3.2
Circuitreliefvalve adjustment------------------------------------------------------3.3
Mainpressure(PR1)----------------------------------------------------------------3.3.1
Rightswing (PR2)-------------------------------------------------------------------3.3.2
Left swing (PR3)--------------------------------------------------------------------3.3.3
Mast elevation (PR4)---------------------------------------------------------------3.3.4
Jibelevation (PR5)-----------------------------------------------------------------3.3.5
Jiblowering (PR6)------------------------------------------------------------------3.3.6
Brake releasemaximumpressure(PR7)-------------------------------------3.3.7
Drive atlow speed(PR8)---------------------------------------------------------3.3.8
Counterbalance valve setting-------------------------------------------------------3.4
BATTERY-CHARGER 4
Battery------------------------------------------------------------------------------------4.1
Charger-----------------------------------------------------------------------------------4.2
Fulmencharger----------------------------------------------------------------------4.2.1
Oldham-Hawkercharger----------------------------------------------------------4.2.2
Westinghouse-SGTEcharger-----------------------------------------------------4.2.3
Batteryfilling----------------------------------------------------------------------------4.3
Electrolytespecificgravityand batteryvoltage-------------------------------4.4
Centralisedfilling systemmaintenance------------------------------------------4.5
Cleaning -Batterymaintenance----------------------------------------------------4.6
Storageofabatteryattemperaturebelow0°C(32°F)-------------------4.7
Useofabatteryinacoldchamberorinacoldclimate--------------------4.8
Batterynotworking continuouslyorinactive battery------------------------4.9
Batterytroubleshooting-------------------------------------------------------------4.10
!
TABLEOFCONTENTS

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TABLEOFCONTENTS
MAINTENANCE 5
Systemmalfunctions------------------------------------------------------------------5.1
Cleanliness-------------------------------------------------------------------------------5.2
Removaland installation-------------------------------------------------------------5.3
Disassemblyand assembly----------------------------------------------------------5.4
Partsreplacement----------------------------------------------------------------------5.5
Wiresand cables-----------------------------------------------------------------------5.6
Gaskets-----------------------------------------------------------------------------------5.7
Careand installation ofteflon-coatedbushings-------------------------------5.8
Bushings--------------------------------------------------------------------------------5.8.1
Pin----------------------------------------------------------------------------------------5.8.2
Bushingsand pin---------------------------------------------------------------------5.8.3
Bushing installation------------------------------------------------------------------5.8.4
Mastrollerremoval-------------------------------------------------------------------5.9
Upperrollers---------------------------------------------------------------------------5.9.1
Lowerrollers--------------------------------------------------------------------------5.9.2
Rollers-----------------------------------------------------------------------------------5.9.3
Hydraulicsystem--------------------------------------------------------------------5.10
Fatigueof weldedstructures-----------------------------------------------------5.11
LOCTITE®-------------------------------------------------------------------------------5.12
Fastenersand torquevalues------------------------------------------------------5.13
Steering switches--------------------------------------------------------------------5.14
Mainhydraulicpowerunit---------------------------------------------------------5.15
Steering bracketthrustwashers-------------------------------------------------5.16
Mastsection alignment-------------------------------------------------------------5.17
Lifting chainsadjustment----------------------------------------------------------5.18
Chaincontroland lubrication------------------------------------------------------5.19
Controlofchainwear------------------------------------------------------------5.19.1
Chainlubrication-------------------------------------------------------------------5.19.2
Overloaddetection setting---------------------------------------------------------5.20
Tiltalarm-------------------------------------------------------------------------------5.21
Batterydischargeindicatorsetting----------------------------------------------5.22
Motorspeedcontroller--------------------------------------------------------------5.23
Fuses-------------------------------------------------------------------------------------5.24
Powercircuitmainfuse---------------------------------------------------------5.24.1
Steering powercircuitfuse-----------------------------------------------------5.24.2
Controlcircuitmainfuse--------------------------------------------------------5.24.3
Batteryvoltageindicatorfuse-------------------------------------------------5.24.4
Batteryfilling unitfuse----------------------------------------------------------5.24.5
Electronicallypilotedcircuitsfuses------------------------------------------5.24.6
Drive function sequences-Electronicboardpotentiometerssetting--5.25

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TABLEOFCONTENTS
PREVENTIVE AND MAINTENANCEINSPECTION 6
General------------------------------------------------------------------------------------6.1
Preventive maintenance and inspection required-----------------------------6.2
Dailypreventive maintenance and inspection-------------------------------6.2.1
Weeklypreventive maintenance and inspection---------------------------6.2.2
Monthlypreventive maintenance and inspection--------------------------6.2.3
Every125 hoursofoperation preventive maintenance and inspection-6.2.4
Every250 hoursofoperation preventive maintenance and inspection-6.2.5
Every500 hoursofoperation preventive maintenance and inspection-6.2.6
LUBRICATION 7
Lubrication points----------------------------------------------------------------------7.1

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Foreword
Importantinformation
TABLEOFCONTENTS
1
INTRODUCTION

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FOREWORD
Thismanualhasbeen compiled toassistyou in
properlyoperatingandmaintainingyourGroveManlift
AerialWork Platform.
The Work Platformhasbeen designed formaximum
performancewithminimummaintenance.Withproper
care,yearsoftrouble-free servicecan be expected.
Constantimprovementand engineering progress make
itnecessary thatwereservethe righttomake
specification and equipmentchangeswithoutnotice.
The definitionsofDANGER,CAUTIONand NOTEas
used inthismanualapplyasfollows:
ADANGERisusedtoemphasizethatifan
operation, procedure orpractice isnotfollowed
exactly,deathorseriousinjurytopersonnel
mayresult.
ACAUTIONisusedtoemphasizethatifan
operation, procedure,orpracticeisnot
followedexactly,equipmentdamagemay
result.
NOTE
ANOTEisusedtoemphasizeanimportant
procedure orcondition.
GENERALWARNING
Itismandatory thatall hydraulichosesand
fittingsarecorrectlytaggedand identifiedbefore
theyaredisconnectedtoeffectrepairsorservice.
Failuretocorrectlytagand identifyhoses and
fittingscancausewrong reconnection,whichcan
resultin deathorseriousinjury topersonnel.
!ATTENTION
DANGER

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WARRANTY
NOTICETOOWNER/USER
Shouldthisworkplatformbecomeinvolvedinaaccident,pleasecontactyourlocal
GroveWorldwidedistributorimmediatelyand relatedetailsoftheincidentsohecan
notifyGroveWorlwide.
Ifthedistributorisunknownand/orcannotbereached,pleasecontact:
Delta Manlift
Z.I.deFauillet,BP20,47400 TonneinsFRANCE
(33)553 84 85 11
THEREARENOWARRANTY,EXPRESS ORIMPLIED,MADEBYEITHERTHEDISTRIBUTOR
ORTHEMANUFACTURERONNEWGROVE WORLDWILDEEQUIPMENT,EXCEPTTHE
MANUFACTURER'SWARRANTYAGAINSTDEFECTS,INMATERIALAND WORKMANSHIP
SETOUTBELOW:
NEWEQUIPMENTWARRANTY
"TheManufacturerwarrantseachnewGroveWorldwideproductmadebythe
Manufacturertobefree fromdefectsinmaterialand workmanship,itsobligation and
liabilityunderthiswarrantybeing limitedtorepairing orreplacing free ofchargeatits
factory,anypartproving defectiveundernormal useand service,and thereasonable
costofrepairand/orreplacementofsaidpartorparts,withintwelve(12)monthsfrom
thedateofinitialsale,leaseorrental,providing theequipmentison recordwiththe
Manufacturerasbeing installedbythedistributor.GroveWorldwidefurtherwarrants
foranadditionalsix(6)yearsthestructuralcomponentsdescribedand identifiedasthe
mastweldment,turnable,and frame(chassis)weldmenttobefree fromdefectsin
materialand workmanship,itsobligation and liabilityunderthestructuralwarranty
being limitedtorepairing orreplacing free ofchargeatitsfactoryanypartproving
defectiveundernormaluseand service and doesnotcoveranylabororinstallation
costsincurredfortherepairorreplacementofthestructuralcomponent.Ifthemachine
isnoton recordasbeing installedbytheDistributor,theManufacturerwill considerthe
dateofshipmentfromthefactoryasthedateofinitialsale,leaseorrental.Thiswarranty
isinlieuofall otherwarranties,express orimpliedand theobligation and liabilityofthe
Manufacturerunderthiswarrantyshall notincludeanytransportation orothercharges
oranyliabilityfordirect,indirectorconsequentialdamagesordelayresulting fromthe
defect.Anyoperation beyond ratedcapacityortheimproperuseorapplication ofthe
productorsubstitution upon itofpartsnotapprovedbytheManufacturershall voidthis
warranty.ThiswarrantycoversonlytheproductsofGroveWorldwide.Theproductof
otherManufacturersarecoveredonlybysuchwarrantiesasaremadebytheir
Manufacturers."
THISWARRANTYISEXPRESSLYINLIEUOFANYOTHERWARRANTIES,EXPRESS OR
IMPLIED,INCLUDINGANYIMPLIEDWARRANTYOFMERCHANTABILITYORFITNESS
FORAPARTICULARPURPOSE,ANDOFANYOTHEROBLIGATIONSORLIABILITYON
THEPARTOFTHEMANUFACTURER,ANDGROVE WORLDWIDENEITHERASSUMES
NORAUTHORIZES ANYOTHERPERSONTOASSUMEFORITANYOTHERLIABILITYIN
CONNECTIONWITHSUCHEQUIPMENT.

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The followingformisforthe useofthe Distributor,Customer,Mechanic,and allotherperson who usethismanual
and recognizebeneficialwaystoimproveitspurposeasaworthyreference.SMCAR's aretobe madeinregards
to,butnotlimitedto:Safety,Operation Correctness,andTechnicalContent.AllSMCAR'swillbereviewed by
theresponsible DepartmentatGrove.ApprovedSMCAR'swill be distributedinaServiceBulletinimmediately
andthenincorporatedinthe next scheduledchange tothemanual.Ananswertothe SMCAR,approved or
disapproved,willbe sentdirectlytotheone submitting theSMCAR.
Date______________________________
Customername_____________________
Name/firstname_____________________
Address___________________________
__________________________________
Telephone__________________________
ServiceManual
Affected__________________________________________________________________________
Page(s)Affected___________________________________________________________________
ReasonforsubmittingSMCAR(Useadditional paperorbackifnecessary)
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________
Signature(optional)
Adress SMCAR'sto:
Supervisor,Publications
DeltaManlift
Z.I. deFauillet,
B.P. 20
47400Tonneins,France
CORRECTIVE ACTIONREQUEST

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Thispageintentionallyleftblank.
CORRECTIVE ACTIONREQUEST

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2.1.Description
2.2.Characteristics -Dimensions-Performances
TABLEOFCONTENTS
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WORK PLATFORMCHARACTERISTICS

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2.1Description
Theworkplatformconsistsofaself-propelled all
welded steelframe,atelescopicmastmounted on a
turntable andapendularjib.The platform ismounted
atthe end ofthe jib.
The drivefunctionisaccomplishedbytwo hydraulic
motorswhichpropelthe rearaxle.
Thesteering function (frontaxle)isaccomplished
byahydrauliccylindersuppliedwithahydraulicpump
unitlocated on the chassisbetweenthesteering
wheels.
Theparkingbrakesintegratedtothehydraulicmotors
work through lack ofpressure.
Themainhydraulicpowerunitsupplyingthefunctions
of the work platform(exceptsteering)islocatedat
thetop ofthemainhydraulictank,attherearofthe
chassis.
Theturntablerotationmovementisaccomplished
through amoto-reducergroup located atthe baseof
theturntable.
Themovementofthe pendularjibisaccomplished
bymeansofhydrauliccylinder.
Theworkplatformmovementsarecontrolled from
thecontrolboxesthrough hydrauliccontrol valves
controlledelectricallylocatedatthefrontofthe
chassis.
Theprogressivityof movementsisobtained byan
electroniccontrollerwhichcontrolstherotationspeed
ofthe mainhydraulicgroupmotor.Theelectronic
controllerislocated nearthe emergencycontrolbox
(ground controls),on thelefthandsideofthe
telescopicmast.
Theenergyforthe control andpowercircuitsof
theworkplatformissupplied bya24VDC battery.
WORK PLATFORMCHARACTERISTICS 22

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FRONTSIDE
Rightside Left side
Frontbattery access
Charger
Emergency controlpanel
Counterweight
Jib
Platform
Lateralbattery access
Steering wheels Driving wheels
LEFTSIDE
Front Rear
Counterweight
Breakdowncontrolpanel
Steering hydraulicunit
Steering wheels
Telescopicmast
Hand pump
Manual boxPlatformcontrols
WORK PLATFORMCHARACTERISTICS 22

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DIMENSIONS(LOWERED) Standardplatform Largeplatform
Length 2,89 m 3,20m
Width 0,99m
Height 1,99m
WeightT1010 3300kg
WeightT1010I 2650kg
Ground Clearance 0,08m
CAPACITY- MANOEUVRABILITY
Platformfloormin. height 0,54m
Platformfloormax.height 8,10m
Max.working height 10,10m
Max.outreach(fromcenterline) 2,62 m 2,93m
Max.working outreach(fromcenterline) 3,12 m 3,43m
Floorheightat max. outreach 6,72m
Working heightat max. outreach 8,72m
Swing 360°non continous
Innerturningradius Machineraised: 1,78m
Machinehalfraised: 0m
Outerturningradius Machineraised: 3,37m
Machinehalfraised: 1,75m
PLATFORM
Length 0,70 m 1,01m
Width 0,90m
Ratedload 200kg
HYDRAULICCIRCUIT
Main hydraulictankcapacity 25,5l
Steering grouptankcapacity 1l
Main hydraulicpumpdisplacement 8cm³/t
Steering hydraulicpumpdisplacement 0,5cm³/t
FILTRATION
Pressure 20µmabsolute
Return 20µmabsolute
PRESSURES
Main hydrauliccircuitmax.pressure 23MPa
Steering hydrauliccircuitmax.pressure 12MPa
ELECTRICALCOMPONENTS
Main hydraulicunitmotor 3kw 24 VDC
Steering hydraulicunitmotor 0,8kw 24 VDC
2.2. Characteristics-Dimensions-Performances
WORK PLATFORMCHARACTERISTICS 22

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(*)speedsmeasured onhorizontalgroundwithone personin the platform(approximately80 kg).
(**)timesmeasured withthemaximumratedload in theplatform(200 kg),the movementswereperformed from
platform controls.
Speedsareindicated foramachine withafullychargedbattery and working in an ambianttemperatureof
20°C.
Constant productimprovementmakeit necessarythat GROVE reservethe righttomakespecification and
equipmentchangeswithoutnotice.
DRIVESPEEDS(*)
1stgear(slow speed)
2nd gear
3rdgear
MOVEMENTSPEED(**)
Mastelevation time 24 to 27 s
Mastlowering time 21 to 24 s
Jibelevationtime 16 to 19 s
Jibloweringtime 17 to 20 s
Slewingtime (fromstoptostop) 50 to 55 s
0,65 to0,7 km/h
1,8 km/h
4km/h
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3.1.Reliefvalvesetting
3.2.Brakereleasecircuitpressurecheck
3.3.Circuitreliefvalveadjustment
3.3.1.Mainpressure(PR1)
3.3.2.Rightswing (PR2)
3.3.3.Left swing (PR3)
3.3.4.Mastelevation (PR4)
3.3.5.Jibelevation (PR5)
3.3.6.Jiblowering (PR6)
3.3.7.Brakereleasemaximumpressure(PR7)
3.3.8. Driveatlowspeed (PR8)
3.4.Counterbalancevalvesetting
TABLEOFCONTENTS
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PRESSURESETTINGS