JLG TOUCAN 1210 User manual

Révision:03 -2012 MA0295-04
English -Service Manual
MODELS
TOUCAN1210
TOUCAN1310
U.S.A.
JLGIndustries,Inc.
1JLGDrive
McConnellsburg
PA17233-9533
Tel:[phone]
Fax:[phone]
C.E.
JLGManufacturingEurope
Breitwaterstraat12A
OudeBunders1034
B-3630 Maasmechelen
Tel:[phone]
Fax:[phone]
FRANCE
JLGFranceSAS
Z.I.deFauillet
BP 20 -47400 TONNEINS
France
Tel:[phone]
Fax:[phone]
C.E.
JLGIndustries,
KilmartinPlace,
TannochsidePark
Uddingston,ScotlandG71 5PH
Tel:[phone]
Fax:[phone]

3
Models
Revision 03-2012
Toucan1210
Toucan1310
MA0295-04
Models
English
MACHINESERIALNUMBER:
Toucan1210 _____
Toucan1310 _____

Models
Revision 03-2012
4Toucan1210
Toucan1310
1INTRODUCTION
Foreword
Importantinformation
2WORKPLATFORM CHARACTERISTICS
Description- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2.1
Characteristics-Dimensions-Performances- - - - - - - - - - - - - - - - - - - - - - - - -2.2
3HYDRAULICSYSTEM
Hydraulicpowerunits- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.1
Hand pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.2
Hydraulicfilters- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.3
Function manifold- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.4
Drive manifold- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.5
Membraneaccumulator- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.6
Wheelmotordistribution manifold- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.7
Brake manifold- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.8
Differentiallockingmanifold- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.9
Wheelmotors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.10
Steeringmanifold- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.11
Check valvesmanifold("Powerplus"option)- - - - - - - - - - - - - - - - - - - - - - - -3.12
Releasecontrolvalve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.13
Trimcorrection manifold- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.14
7-way,3position flowdiverter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.15
Cylinders supplymanifold- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.16
Mastcylinder- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.16.1
Jibcylinder- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.16.2
Telescopecylinder- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.16.3
Assistancecylinder-Mastercylinder-Slave cylinder- - - - - - - - - - - - - - - -3.16.4
Rotation cylinder(optional)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.16.5
Sequence valve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.17
Slewinghydraulicmotor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.18
Pressurereliefvalves- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19
Brake releasecircuit pressurecheck- - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.1
Pressurereliefvalve setting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2
Mainpressure[PR1]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.1
Telescopeextension [PR2]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.2
Telescoperetraction [PR3]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.3
Mastelevation [PR4]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.4
Jibelevation [PR5]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.5
Jiblowering[PR6]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.6
Brake releasemaximumpressure[PR7]- - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.7
Drive atlowspeed[PR8]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.8
Slewingtotheleft [PR9]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.9
Slewingtotheright[PR10]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.10
Trimcorrection [PR11]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.11
Left steering[PR12]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.12
Rightsteering[PR13]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3.19.2.13
TABLEOF CONTENTS

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Toucan1310
TABLEOF CONTENT
4 ELECTRICALSYSTEM
Wiringdiagrams- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.1
Batterywiring- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.1.1
Powercircuit wiring- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.1.2
Componentslocation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.1.3
Sensors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.2
Mast position switch[SW4]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.2.1
Jiblowerposition switch[SW5]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.2.2
Telescopeposition switch[SW2]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.2.3
Jibhigherposition switch[SW3]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.2.4
Slackchainsensors[SW34 à37]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.2.5
Tilt indicator- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.2.6
Strainlink(stabilitycontroldevice)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.2.7
Steeringsensors(T1310 only)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.2.8
Sensorforleft steeringlimitation [SW39]- - - - - - - - - - - - - - - - - - - - - - - - - -4.2.8.1
Sensorforrightsteeringlimitation [SW40]- - - - - - - - - - - - - - - - - - - - - - - - -4.2.8.2
Steeringanglesensors[SW41 &42]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.2.8.3
Safetyfeatures-Movementcutout- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.3
Adjustmentofthebatterydischarge indicator- - - - - - - - - - - - - - - - - - - - - - - -4.4
Speedelectroniccontroller- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.5
Circuitbreakers -Fuses- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.6
Circuit breakers- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.6.1
Fuses- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.6.2
Resetablefuses(Polyswitch®)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.6.3
Helpwiththediagnostic- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.7
Electronicmodules- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.8
Controlsverification module- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.8.1
Speedcontrolmoduleforthejib(dongle)- - - - - - - - - - - - - - - - - - - - - - - - - - -4.8.2
Timedelay module- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.9
"Powerplus"module(option)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.10
"Clipper"connectorinstallation procedure- - - - - - - - - - - - - - - - - - - - - - - - -4.11
5BATTERIES-CHARGERS
Battery- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5.1
Electrolytespecificgravityand batteryvoltage- - - - - - - - - - - - - - - - - - - - - -5.1.1
Storage attemperaturesbelow-20°C(32°F)- - - - - - - - - - - - - - - - - - - - - - - -5.1.2
Useofabatteryinacoldchamberorincoldclimate- - - - - - - - - - - - - - - - -5.1.3
Batterynotworkingcontinuouslyorinactive battery- - - - - - - - - - - - - - - - - -5.1.4
Troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5.1.5
Chargers- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5.2
Highfrequencycharger"ZivanNG3"- - - - - - - - - - - - - - - - - - - - - - - - - - - - -5.2.1
Electroniccharger"Oldham-HawkerCPIV"- - - - - - - - - - - - - - - - - - - - - - - -5.2.2

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6TORQUEVALUES
General- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6.1
Wheelnuttorquevalues- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6.2
Torquevalueofslewingringattachmentbolts- - - - - - - - - - - - - - - - - - - - - - - -6.3
7SERVICE-MAINTENANCE
General- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.1
Systemmalfunction- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.1.1
Cleanliness- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.1.2
Removaland installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.1.3
Dissassembly/Assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.1.4
Partsreplacement- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.1.5
Wiresand cables- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.1.6
Platformcleaning- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.2
Maintenance and installation ofguiderings- - - - - - - - - - - - - - - - - - - - - - - - - -7.3
Steeringbracketthrustwashers- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.4
Mastrollerremoval- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.5
Adjustmentoftelescopicmastalignment- - - - - - - - - - - - - - - - - - - - - - - - - - - -7.6
Liftingchainsadjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.7
Verification and lubrication oftheliftingchains- - - - - - - - - - - - - - - - - - - - - - -7.8
Verification ofchainwear- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.8.1
Chainlubrication- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.8.2
Hydraulicpowerunit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.9
Battery- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.10
Maintenanceofthecentralisedfillingsystem- - - - - - - - - - - - - - - - - - - - - - -7.10.1
Cleaning-Batterymaintenance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.10.2
Preventive maintenance and inspection- - - - - - - - - - - - - - - - - - - - - - - - - - - -7.11
Dailypreventive maintenanceand inspection- - - - - - - - - - - - - - - - - - - - - -7.11.1
Weeklypreventive maintenanceand inspection- - - - - - - - - - - - - - - - - - - -7.11.2
Monthlypreventive maintenanceand inspection- - - - - - - - - - - - - - - - - - - -7.11.3
Preventive maintenanceand inspection every125 hours- - - - - - - - - - - - - -7.11.4
Preventive maintenanceand inspection every250 hours- - - - - - - - - - - - - -7.11.5
Preventive maintenanceand inspection every500 hours- - - - - - - - - - - - - -7.11.6
Lubrication- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7.12
TABLEOF CONTENT

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Toucan1310
FOREWORD
Thismanualhasbeen compiled toassistyou in
properlyoperating and maintening yourJLGaerial
workplatform.
Constantimprovementandengineering progressmake
itnecessary thatJLGreservethe righttomake
specification and equipmentchangeswithoutnotice.
The definitionsofDANGER,CAUTIONand NOTEas
used inthismanualapplyasfollows:
ADANGERisusedtoemphasizethatifan
operation, procedure orpractice isnot
followedexactly, deathorseriousinjuryto
personnelmayresult.
ACAUTIONisusedtoemphasizethatifan
operation, procedure,orpracticeisnot
followedexactly,equipmentdamagemay
result.
NOTE
ANOTEisusedtoemphasizeanimportant
procedureorcondition
GENERALWARNING
Itismandatory thatall hydraulichosesand
fittingsarecorrectlytaggedand identifiedbefore
theyaredisconnectedtoeffectrepairsorservice.
Failuretocorrectlytagand identifyhoses and
fittingscancausewrong reconnection,whichcan
resultin deathorseriousinjury topersonnel.
DANGER
!CAUTION

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NOTICETOOWNER/USER
Shouldthisworkplatformbecomeinvolvedinaaccident,pleasecontactyourlocal
JLGdistributorimmediatelyand relatedetailsoftheincidentsohecannotifyJLG.
Ifthedistributorisunknownand/orcannotbereached, pleasecontact:
USA:
JLGIndustries,Inc.
ProductSafety&ReliabilityDepartment,
1JLGDrive
McConnellsburg,PA
USA17233-9533
Toll Free:[phone]
Tel.:[phone]
Fax:[phone]
Email : [e-mail]
C.E:
JLGIndustries,
KilmartinPlace,
TannochsidePark
Uddingston,
Scotland G71 5PH
Tel:[phone]
Fax:[phone]
Email : [e-mail]

9
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Toucan1310
ThefollowingformisfortheuseoftheDistributor,Customer,Mechanic,andallotherpersonwhousethismanual
and recognizebeneficialwaystoimproveitspurposeasaworthyreference.SMCAR'saretobemadeinregards
to,butnotlimitedto:Safety,Operation Correctness,andTechnicalContent.AllSMCAR'swillbereviewed by
theresponsibleDepartmentatJLGApproved SMCAR'swill be distributed inaServiceBulletinimmediatelyand
then incorporated inthenextscheduledchangetothemanual.AnanswertotheSMCAR,approvedor
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
JLGFranceSAS
Z.I. deFauillet,
B.P.20
47400Tonneins,France
CORRECTIVE ACTIONREQUEST

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Toucan1310
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CORRECTIVE ACTIONREQUEST

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WORK PLATFORMCHARACTERISTICS 2
2
2.1Description
TheMobileElevatingWorkPlatformconsistsofaself
propelledallwelded chassis,ofatelescopicmast
mounted on aturntable andatelescopicjib.The
platformismountedatthe endofthe jib.
Themainhydraulicpowerunitsupplyingthefunctions
ofthework platformislocated atthe rearofthe chassis
ontherighthand side.When the "PowerPlus"option
isinstalled,an auxilliaryunitisinstalledon the rear
ofthe chassisonthelefthandside.
The drivefunctionisaccomplishedbytwo hydraulic
motorspropelling the rearaxle.
Theparkingbrakesintegratedtothehydraulicmotors
work through lack ofpressure.
Steering(frontaxle)isaccomplished byahydraulic
cylinder.
Theslewing movementisaccomplished byaworm
gearmotorlocated atthe baseofthe superstructure.
The movementsofthe telescopicmast, pendularjib
andtelescopeareaccomplishedbymeansof
hydrauliccylinders.
The machinemaybe equipped (optional)withasystem
controlled byahydrauliccylinderenablingthe rotation
ofthe platform.
Theplatform iskepthorizontalbyhydrauliccylinders
workingfollowingthe"master-slave"principle.
Themovementsofthe machine arecontrolled from
controlpanelsthroughsolenoid valves.Theyare
locatedatthefrontofthechassis(forstructure
movements)and on the left hand side ofthe chassis
(fordrivemovements).
Theprogressivityof movementsisobtained byan
electroniccontrollerwhichcontrolstherotationspeed
ofthe mainhydraulicgroupmotor.Theelectronic
controllerislocated neartheemergencycontrol panel
(ground controls),on thelefthandsideofthe
telescopicmast.
Theenergyforthecontroland powercircuitsofthe
mobileelevating work platformissupplied bya24VDC
battery.

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Toucan1310
WORK PLATFORMCHARACTERISTICS 2
2
Steeringwheels
FRONTVIEW
REAR
Handpump
REARVIEW
Drivingwheels
Counterweight
FRONT
VIEWLEFT
Counterweight
Telescopicmast
Emergency control
panel
Charger
Circuitbreaker
Platform
controlpanel
Release
valve
Manualbox
Telescopicmast
Work
platform
Breakdown
controlpanel
Telescopicjib
Access toside
batteries
Access tothe
frontbattery

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WORK PLATFORMCHARACTERISTICS 2
2
2.2.Characteristics-Dimensions-Performances
(*)Speedsrecordedon horizontalandlevelgroundwithapersonontheplatform(approximately80kg).
(**)Movementsdurations recordedwiththe maximumloadinthe platform(200kg), themovementsbeing controlled
fromthe platformcontrolpanel.
Speeds areindicated foramachinewithabatteryfullycharged andoperatedatambianttemperatureof20°C.
Constantimprovementmakesit necessarythat JLGFranceSAS reservethe righttomakespecificationandequipment
changeswithoutnotice.
Toucan1310
DIMENSIONS (LOWERED) Standard Rotation(option) Standard
Length
3,85 m
4,07 m
4,07 m
Width
1,20 m
1,20 m
1,345m
Height
1,99 m
1,99 m
2,19 m
Weight
5200 kg
5300 kg
5600 kg
Groundclearance
0,08 m
0,08 m
0,09 m
CAPACITY- MANOEUVRABILITY Standard Rotation(option) Standard
Floorheightmin.
0,40 m
0,40 m
0,57 m
Floorheightmax.
10,00 m
10,00 m
11,00m
Max. outreach(fromcenterline)
4,93 m
5,16 m
5,16 m
Floorheightwithmax. outreach
7,20 m
7,20 m
8,20 m
Workingheightwithmax. outreach
9,20 m
9,20 m
10,20m
Slewing
Rotation(option)
WORKPLATFORM Toucan1310
Length
Width
Ratedload
HYDRAULICCIRCUIT Toucan1310
Hydraulictankcapacity
Mainhydraulicpumpdisplacement
Auxilliaryhydraulicpumpdisplacement(T1210 option)
FILTRATION Toucan1310
Pressure
Return
PRESSURE Toucan1310
Mainhydrauliccircuitmaximumpressure
ELECTRICALCOMPONENTS Toucan1310
Powerofthemainhydraulicpower unitmotor
Poweroftheauxilliaryhydraulicpowerunitmotor(T1210 option)
DRIVESPEEDS(*) Toucan1310
1stgear(lowspeed) 0,65 to0,7km/h 0,45à0,7km/h
2ndgear 2,0km/h 1,5km/h
3rdgear 3,6km/h 2,6km/h
4thgear 3,6km/h
MOVEMENT DURATION(**) Toucan1310
Mastelevationmovementduration 33à40s
Mastloweringmovementduration 34à40s
Jibelevationmovementduration 20à27s
Jibloweringmovementduration 23à30s
Telescopeextensionmovementduration 16à22s
Telescoperetractionmovementduration 14à20s
Slewingmovementduration(fromstoptostop) 75à85s
75 à85 s
20 à27 s
23 à30 s
16 à22 s
14 à20 s
Toucan1210
Toucan1210
28 to33 s
28 to33 s
1,10 m
200 kg
Toucan1210
Toucan1210
0,70 m
345° (2x172,5°)
120° (2x60°)
Toucan1210
Toucan1210
4,8kw/ 24VDC
4,8kw/ 24VDC
24MPa
10 µmabsolute
10 µmabsolute
Toucan1210
Toucan1210
35l
5,2cm³/t
3,5cm³/t

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HYDRAULICSYSTEM 3
3
3.1.Hydraulicpowerunits
1- Mainhydraulicpowerunit-4,8kw-5,2cc/t
FUNCTION :Supplytothe hydrauliccircuitoftheelevating workplatform.
2- Auxilliaryhydraulicpowerunit-4,8kw-3,5cc/t
FUNCTION :Supplyofanadditionaloil flowduringahigh speeddrivetomakeup forthe speedreduction due tothe
useofwheelmotorsofhigherdisplacement.
Do notinterchangethepumpsfromthemainand auxilliarypowerunits.
Bodylengthofthe5,2cc/tpumpon main power unit:L =55 mm.
Bodylengthofthe3,5cc/tpump on auxilliary powerunit:L =50 mm.
!DANGER
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HYDRAULICSYSTEM 3
3
!CAUTION
Disassemblyofthegearpumpentailsreplacementofseals.
1-Removebothscrewssecuring the pumptothemotor.Disconnectthe pump.
2-Placethepumpverticallyon
aclean work area and
removethefourflange
attachmentscrews.Remove
theflange.
3-Extractthepumpbody
ensuringbothpinionsand
bearingsdo notget
damaged(bewarethe two
sealson theupperbearing).
4-Extractthe upper
bearing,bothpinionsthen
thelowerbearing.
Carefulinspectionofall pumpcomponentsallows,
dependingon partswear,todiagnoseoperatingfaults
orpollution problemsinthe hydrauliccircuit.
L
Electricalmotor
Pumpbody
Seals
Torquevalue:
44 Nm
Torquevalue:22 Nm
1
2
Seals
Pinions
Bearings
Flange

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Hydrauliccircuitpollution
-ABRASIVE WEAR CAUSED BY ABRASIVE PARTICLES
Suchawearresultsin agradualreductionofthe
powerand speed ofthe hydrauliccircuit.
Fineparticlesmayenterthe circuit:
•Duringreservoirfilling (clean theareaaround the
fillingneckbeforeopening thecap.Useclean
containersandfunnelsduringfillingprocedure).
•Through wornseals,particularlyon dirtyand poorly
maintainedmaterial.
•During maintenanceifcomponentsarenotcapped
afterhosedisconnection.
HYDRAULICSYSTEM 3
3
-ABRASIVE WEAR CAUSED BY METALLIC PARTICLES.
Suchawearresultsinafairlysudden degradation of
the performancesofthepump.Metallicparticlesresult
generallyfromthe degradation ofacomponentorfrom
anabnormal wearofthehydrauliccircuit:the
componentmustbeidentifedandreplaced.Every
hydrauliccomponentmustbe removedandcleaned.
Thehydrauliccircuitmustbedrained outandflushed
and thefilterschanged.
-AERATION OR CAVITATION
Cavitation and aerationactalikein thesystem.
Aerationoccurswhen airmixeswiththe oil.Airmay
enterthe systemthrough asmall suctionleakorby
agitationof the oil in the reservoir.Agitationoccurs
whentheoilreturnstothereservoirabovethe oil
surface.Thismayoccurswhen theoillevel istoo
low.Cavitation istheformation andcollapseofvapour
bubblesinthe oil.Thisusuallyresultsfromarestricted
pumpsuction.Cavitation occursmorereadilywhen
theoil iscold.
Aerationand cavitationerode andpit the pressure
platesand pumphousing.
Apumpwhichiseithercavitatingoroperatingon
aerated fluidisusuallynoisyand the systemoperates
inaspongyorjerky manner.
Iferosion onthe suction side ofthe pumpisevidenton
thegeartracks,the causeiseitherairbubblesinthe
oilorarestricted suction.
Bearing wear
(dull area)
Wear on pinion pressure
plates (dull area)
Wear on gear track (dull
area)
Wear on gearing track
(grooves)
Bearing wear
(grooves)
Wear on pinion
pressureplates
(grooves)
Cavitation
Trackgroovedonsuctionside=overpressure

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-LACK OF OIL
Whenafailureisduetolack ofoil,deteriorationsare
usuallyrapid.Thistypeoffailuremayoccurif:
-the oil levelislowinthe reservoir,or
-thereisanairleakin thesuctionline.
-EXCESSIVE HEAT
Excessiveheatwill hardentheseals.
Excessiveheatmaybe causedbyapressurerelief
valvesettoo low,inwhichcase,themachine willbe
slow.
-OIL PRESSURE TOO HIGH
Therearetwo possible causesforoverpressure:
-thepressurereliefvalvefailstofunction,
producingan extremesurge and immediate
failure.
-The pressurereliefvalveissettoo high,
resulting in repeatedpressurepeaks.Pump
damage isvery similarinbothcases.
-INCORRECT ASSEMBLY
Thistypeoffailureisselfexplanatory:componentsare
faulty,orpartshavenotbeen assembled correctly.
Pinching ofthe O-ring will occurifitisnotseated
properlyinitsgroove.Ifthe O-ring hasbeen fitted
incorrectly,the surfaceofthe housing will showa
depressed area (especiallyifthe partismade of
aluminium).
5-Removethe seals
NOTE
Alignthesealsintheordertheywereremoved,
mark theirposition and shapetofacilitate
later assembly.
6-Clean the pumpcomponentswithan
appropriatesolventanddrywithcompressed
air.Replacethe seals.
If componentsaredamaged,replacethepump.
Avoidscratching thegroovesand gland
surfaces.
Inspecteachgroovebefore assembly.
Partsmustbefree fromdustand burrs.
Groovesand glandsurfacesmustbein good
condition. Wornordamagedpartsmustbe
replaced.Donotstretchsealsduringtheir
assembly.Lubricatesealsandglandsurfaces
with cleanhydraulicoilbefore assembly.
7-Assemblethe pumpinthe reverseorderfrom
disassembly.
Bolttorque value (Rep.1)=22 Nm
Bolttorque value (Rep.2)=44 Nm
Respectscrupulouslythebolttorquevalue
(Rep. 1)and (Rep.2). Incorrecttorquing will
affecttheperformanceofthepump.
Afterpumpinstallation, operatethework
platformtobleed theairfromthehydraulic
circuitand checktheoil levelin themain
reservoir(machinefullylowered).Checkthe
good working order ofall thecontrol panels.
HYDRAULICSYSTEM 3
3
!CAUTION
!CAUTION
!CAUTION
!CAUTION

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HYDRAULICSYSTEM 3
3
3.2.Handpump
FUNCTION :
-Oil supplytothe hydrauliccircuitofthe work platform whenusingthe breakdowncontrols:elevation /lowering,
telescope extension/retraction,slewing.
-Oil supplytothe brakepilotcircuit(See §3.13).
Seals
Splitpin
Suction
cartridge
Hand
pump

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HYDRAULICSYSTEM 3
3
3.3Hydraulicfilters
NOTE
Thefilter cartridges mustbereplaced:
-After thefirst50 hours ofoperation.
-Every 250 hours ofoperation.
-Ateachoil change(seechapter 7).
After installation, performseveral
movementstobleedtheairfromthe
hydrauliccircuit,check theoil levelin the
reservoir(PLATFORMFULLYLOWERED)
Thereturn filter mustalsobereplaced.
3.3.2.Returnfilter
Filtration rating : 10µmabs
1-Disconnectthebatteryfromtheelectrical circuit
ofthe work platform.
2-Unscrewthe returnfiltercap andremovethe
spring.
3-Install anew filtercartridge.
4-CheckthepresenceandconditionoftheOring,
closethe filtercap notforgettingtoinstall the
spring.
Thepressurefilter mustalso bereplaced.
NOTE
Usedoilsandfiltercartridgesmustbe
disposedofin accordance withthe
regulationsin force.
3.3.1.Pressurefilter
Filtration rating :10µmabs.
1-Disconnectthe battery fromthe electrical
circuitofthe work platform.
2-Positionthereleasecontrolvalveleveron
toreleasethepressureinthehydraulic
circuit.
3-Unscrew the filtertank
Oil projection ontheskin cancause injuries
andburns.Loosenthefiltertankvery slowly
toallowtheoil pressure todrop
progressively.
4-Installanew filtercartridge.
5-Checkthe presenceandconditionofthe Oring.
6-Installthe filtertank.
Filter
cartridge
Cap
Spring
O-Ring
O ring
Filter
Tank
å
DANGER
!CAUTION
!CAUTION
cartridge
å