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_____

Toucan1010
Models
Revision 02-2000
4
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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Revision 02-2000 Toucan 1010
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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Models
Revision 02-2000
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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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Revision 02-2000 Toucan 1010
Foreword
Importantinformation
TABLEOFCONTENTS
1
INTRODUCTION

9
Models
Revision 02-2000 Toucan 1010
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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Models
Revision 02-2000
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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.