Grove toucan 1010 Service Manual
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Grove toucan 1010 Service Manual

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Toucan 1010 I
SERVICE MANUAL
English
Revision 02-2000
MA 0235-01

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Summary of Contents for Grove toucan 1010

  • Page 1 Toucan 1010 I SERVICE MANUAL English Revision 02-2000 MA 0235-01...
  • Page 3 Models _____ Toucan 1010 _____ Toucan 1010 I MA0235-01 Models Toucan 1010 Revision 02-2000...

  • Page 4: Table Of Contents

    Storage of a battery at temperature below 0°C (32°F) ------------------- 4.7 Use of a battery in a cold chamber or in a cold climate -------------------- 4.8 Battery not working continuously or inactive battery ------------------------ 4.9 Battery troubleshooting ------------------------------------------------------------- 4.10 Models Toucan 1010 Revision 02-2000...
  • Page 5 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 Models Toucan 1010 Revision 02-2000...
  • Page 6 Every 125 hours of operation preventive maintenance and inspection - 6.2.4 Every 250 hours of operation preventive maintenance and inspection - 6.2.5 Every 500 hours of operation preventive maintenance and inspection - 6.2.6 LUBRICATION Lubrication points ---------------------------------------------------------------------- 7.1 Models Toucan 1010 Revision 02-2000...
  • Page 7 TABLE OF CONTENTS INTRODUCTION Foreword Important information Models Toucan 1010 Revision 02-2000...

  • Page 9: Revision

    FOREWORD This manual has been compiled to assist you in properly operating and maintaining your Grove Manlift Aerial Work Platform. The Work Platform has been designed for maximum performance with minimum maintenance. With proper care, years of trouble-free service can be expected.

  • Page 10: Revision

    Manufacturer shall void this warranty. This warranty covers only the products of Grove Worldwide. The product of other Manufacturers are covered only by such warranties as are made by their Manufacturers."...
  • Page 11 : Safety, Operation Correctness, and Technical Content. All SMCAR's will be reviewed by the responsible Department at Grove. Approved SMCAR's will be distributed in a Service Bulletin immediately and then incorporated in the next scheduled change to the manual. An answer to the SMCAR, approved or disapproved, will be sent directly to the one submitting the SMCAR.
  • Page 12 CORRECTIVE ACTION REQUEST This page intentionally left blank. Models Toucan 1010 Revision 02-2000...

  • Page 13: Work Platform Characteristics

    TABLE OF CONTENTS WORK PLATFORM CHARACTERISTICS 2.1. Description 2.2. Characteristics - Dimensions - Performances Models Toucan 1010 Revision 02-2000...

  • Page 14: Description

    (ground controls), on the left hand side of the telescopic mast. The energy for the control and power circuits of the work platform is supplied by a 24 VDC battery. Models Toucan 1010 Revision 02-2000...
  • Page 15 Counterweight Hand pump Breakdown control panel Steering hydraulic unit Steering wheels LEFT SIDE Front Rear Front battery access Platform controls Manual box Charger Emergency control panel Platform Counterweight Lateral battery access Steering wheels Driving wheels Models Toucan 1010 Revision 02-2000...

  • Page 16: Characteristics - Dimensions - Performances

    Main hydraulic circuit max. pressure 23 M Pa Steering hydraulic circuit max. pressure 12 M Pa ELECTRICA L COMPONENTS Main hydraulic unit motor 3 kw 24 VDC Steering hydraulic unit motor 0,8 kw 24 VDC Models Toucan 1010 Revision 02-2000...
  • Page 17 Speeds are indicated for a machine with a fully 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. Models...

  • Page 19: Pressure Settings

    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 Models Toucan 1010 Revision 02-2000...

  • Page 21: Relief Valve Setting

    NOTE Test plug To adjust a relief valve turn the adjustment screw (in to increase or out to decrease) until the proper setting is reached. Models Toucan 1010 Revision 02-2000...

  • Page 22: Brake Release Circuit Pressure Check

    PRESSURE in § 3.3.7. If the maximum 3- Remove the pressure gauge. reading is over 21 bar, consult your local Grove Manlift distributor for servicing. 3.3.4. Mast elevation (PR4) 5- Remove the pressure gauge.

  • Page 23: Jib Lowering (Pr6)

    CAUTION If the pressure reading is lower than 15 bar or higher than 21 bar, consult your local Grove Manlift distributor for 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.

  • Page 24: Counterbalance Valve Setting

    170 bar Function manifold Jib elevation 120 bar Function manifold Jib lowering 50 bar Function manifold Manual brake release 35 bar Brake manifold Max. pressure max. peak pressure Drive at low speed 80 bar Function manifold Models Toucan 1010 Revision 02-2000...

  • Page 25: Battery - Charger

    4.7 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 climate 4.9 Battery not working continuously or inactive battery 4.10 Battery troubleshooting Models Toucan 1010 Revision 02-2000...
  • Page 27 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 wiring T1010I (2 battery packs) Models Toucan 1010 Revision 02-2000...
  • Page 28 (Fulmen and SGTE chargers only). NOTE If a power cut occurs during the charge cycle, the charger switches to a waiting mode and restarts automatically as soon as the power returns. Models Toucan 1010 Revision 02-2000...
  • Page 29 Leave the batteries to rest before resuming Batteries too discharged charge. Disconnect and reconnect the batteries. Contact Electronic safety. Safety time switch faulty Grove Manlift Product Support if the fault persists. Connect the battery from the work platform to Battery incorrect nominal voltage the charger.
  • Page 30 The 4th LED flashes Default LED flashes Charge interruption due to a power cut. Charge will be resumed as soon as the power returns. Voltage per cell 140% above the nominal values. The 4 LEDs flash Models Toucan 1010 Revision 02-2000...
  • Page 31 LUAC No supply voltage (charging horameter has stopped) LHHS Safety time (9 -12 - 14 or 16 hours depending on the charger type) ForC Forced cut by the push button OFFS Periodic mail of control Models Toucan 1010 Revision 02-2000...
  • Page 32 (Soft timer #1). Disconnect the charger from the battery and connect Charging time exceeds 15 hours (Voltage above 2,4V it again. If the problem persists, contact Grove per cell) (Soft timer #2). Manlift® Product Support. Charging time exceeds 16 hours (Hard timer).

  • Page 33: Battery Filling

    1.15 CAUTION 1.10 Battery cells filling must be performed only 100% after charge (during charge, electrolyte level Discharge depth in % increases and can overflow). Filling battery cells : Flow indicator Models Toucan 1010 Revision 02-2000...

  • Page 34: Centralised Filling System Maintenance

    3- Read the value as indicated on the example below : 1.12 1.14 1.16 1.18 1.20 1.23 kg/l 1.22 1.24 1.26 1.28 1.30 Models Toucan 1010 Revision 02-2000...

  • Page 35: Cleaning - Battery Maintenance

    To drain the water : 1- Fill the draining bulb with water (a draining bulb is supplied with the work platform). Models Toucan 1010 Revision 02-2000...

  • Page 36: Use Of A Battery In A Cold Chamber Or In A Cold Climate

    1% of its capacity per Celcius degree below +25°C (77°F) (temperature of the electrolyte). Example : a battery operating with its electrolyte at a temperature of –30°C (-22°F) will loose 55% of its autonomy. Models Toucan 1010 Revision 02-2000...

  • Page 37: Battery Troubleshooting

    Loss of electrolyte due to overflow. Perform an equalization charge. Stratification of the electrolyte. Contact your Grove Manlift Distributor/Product Support. Low voltage in the cells in open Electrolyte specific gravity too low. Refer to "electrolyte specific gravity too circuit.

  • Page 39: Maintenance

    5.24.1 Power circuit main fuse 5.24.2 Steering power circuit fuse 5.24.3 Control csircuit main fuse 5.24.4 Battery voltage indicator fuse 5.24.5 Battery filling unit fuse 5.24.6 Electronically piloted circuits fuses 5.25 Drive function sequences - Electronic board potentiometers setting Models Toucan 1010 Revision 02-2000...

  • Page 41: Cleanliness

    - Rust preventive compound has been removed ensure that nothing has been overlooked. from all machined surfaces of new parts before - Recheck various adjustments by operating the they are installed (except leaf chains). machine before returning it to the job. Models Toucan 1010 Revision 02-2000...

  • Page 42: Parts Replacement

    - All rust or masking residue must be cleaned from pin prior to installation. Use emery cloth as appropriate. +1 mm Bush height Flange Outside Dia. ± 0.25 mm +0 mm Models Toucan 1010 Revision 02-2000...

  • Page 43: Mast Roller Removal

    Flange bushings CAUTION Hold the bronze spacer, roller and washer to prevent any of them from falling to the bottom of the mast. CAUTION Install the roller before removing another one (refer to § 5.9.3). Models Toucan 1010 Revision 02-2000...

  • Page 44: Lower Rollers

    - Press the spacer onto the mast and slide it. The roller and spacer must be in line with the After maintenance operation on the roller, the pin. mast alignment must be adjusted. Refer to § 5.17. Models Toucan 1010 Revision 02-2000...

  • Page 45: Hydraulic System

    Installation of new elements is always Use extreme care when removing any plugs recommended. or restrictions from a hydraulic system suspected to have entrapped air that may be pressurized. Failure to comply could result in death or injury to personnel. Models Toucan 1010 Revision 02-2000...

  • Page 46: Fatigue Of Welded Structures

    If you require more detailed inspection instructions is in operation. Failure to comply could result and/or repair procedures, contact your local Grove in death or injury to personnel. Worldwide distributor for assistance. If air entrapment should persist, it may become...

  • Page 47: Fasteners And Torque Values

    Torque tables are provided by Grove Worldwide for reference when preforming maintenance. Use of proper torque values is extremely important.
  • Page 48 FOR TORQUING WITH TORQUE WRENCH MIN. UNIT N.m. N.m. JIC 7/16 JIC 9/16 JIC 3/4 TORQUE VALUES FOR BSPP FITTINGS FOR TORQUING WITH TORQUE WRENCH UNIT N.m. BSPP 1/4 BSPP 3/8 BSPP 1/2 BSPP 3/4 Models Toucan 1010 Revision 02-2000...

  • Page 49: Steering Switches

    45°. The left hand side lower switch limits the steering to the left when the steering angle of the left steering wheel reaches 45°. Models Toucan 1010 Revision 02-2000...

  • Page 50: Main Hydraulic Power Unit

    Do not suppress the play completely : for the Brushes installation : mechanism to work, a minimum play is necessary. 1- Lift the spiral spring and install the brushes. 2 Install the brushes connection screws. 3- Install the protection covers. Models Toucan 1010 Revision 02-2000...

  • Page 51: Lifting Chains Adjustment

    - Check the torque value of all roller pin locknuts. Deflection mast sections is kept. Do not hesitate to contact your approved Grove Manlift distributor for more information. 6- Check the presence and correct tightening of the locknut on each chain anchor.

  • Page 52: Chain Control And Lubrication

    (lubricant type Pitch refer to § 7.1).s L = 10 pitches Pitch 5/8" (15,875 mm) 3/4" (19,05 mm) L max. 163,5 mm 196 mm Models Toucan 1010 Revision 02-2000...

  • Page 53: Overload Detection Setting

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

  • Page 54: Tilt Alarm

    4- With a jack of appropriate capacity, lift the À front of the chassis in - An acoustic alarm sounds when the chassis is tilted at 2°. - The corresponding LED alarm lights up on platform controls. Models Toucan 1010 Revision 02-2000...

  • Page 55: Battery Discharge Indicator Setting

    - Specific gravity will be 1,190 kg/l on the next The potentionmeter is set depending on the capacity of the battery for "normal" discharge conditions. discharge cycle if the setting is modified to number 3. Models Toucan 1010 Revision 02-2000...

  • Page 56: Motor Speed Controller

    Each time the "select" button is depressed, a red LED lights up opposite the next parameter, the value of this parameter is displayed on the screen and can be modified with the buttons. Models Toucan 1010 Revision 02-2000...
  • Page 57 MAINTENANCE Description and parameters values for Toucan 1010 models. Values Parameter Description Unit Step Comments Toucan 1010 First gear drive speed. Mast and jib lowering function speed Speed 1 Speed n°1 (variable) Swing movement speed from platform controls. Jib raising function speed from platform controls.
  • Page 58 Not used - The 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. Models Toucan 1010 Revision 02-2000...

  • Page 59: Fuses

    The STEERING POWER CIRCUIT FUSE (F2) located on the front axle beam of the chassis protects the power supply circuit of the electrical steering unit motor (DIN 43560 - 63 Amps). Steering power circuit fuse 5.24.3. Control circuit main fuse Models Toucan 1010 Revision 02-2000...

  • Page 60: Electronically Piloted Circuits Fuses

    40% when slowly returning the controller to neutral. The speed change threshold can be adjusted by means of the potentiometer (P2). NOTE The differential acceleration input value for speed changing (from HI to TORQUE speed) is a fixed value (about 30%). Models Toucan 1010 Revision 02-2000...
  • Page 61 - If the work platform switches too quickly to HI speed, the work platform may not be able to go forward or backwards, increase the delay by slightly turning (by 1/32 turn) the potentiometer P1 wiper screw clockwise. Potentiometers without arrow head indicators : Models Toucan 1010 Revision 02-2000...
  • Page 62 (P3) wiper screw clockwise. -If the time during which the pump motor runs at low speed (make-up flow) exceeds 1 second, reduce the delay by turning slightly (by 1/32 turn) the potentiometer (P3) wiper screw anticlockwise. Models Toucan 1010 Revision 02-2000...
  • Page 63 6.2.3 Monthly preventive maintenance and inspection 6.2.4 Every 125 hours of operation preventive maintenance and inspection 6.2.5 Every 250 hours of operation preventive maintenance and inspection 6.2.6 Every 500 hours of operation preventive maintenance and inspection Models Toucan 1010 Revision 02-2000...

  • Page 65: General

    If you have any queries concerning control and maintenance procedures, please contact your Grove Manlift distributor. Certain operations require removal of covers or protection housings. All covers or protection housings must be installed before returning the work platform to service.

  • Page 66: Preventive Maintenance And Inspection Required

    6.2.5. Every 250 hours of operation - Lubrication preventive maintenance and inspection Preventive maintenance/inspections should include the previous preventive and maintenance inspections and verification of the following items : - Hydraulic filters (replacement) - Turntable bearing (greasing) - Lubrication Models Toucan 1010 Revision 02-2000...

  • Page 67: Every 500 Hours Of Operation Preventive Maintenance And Inspection

    NOTE Turntable attachment caps screws have to be retorqued after the first 100 hours operation. NOTE Hydraulic filters have to be replaced after the first 50 hours operation. Models Toucan 1010 Revision 02-2000...
  • Page 69 TABLE OF CONTENTS LUBRICATION 7.1 Lubrication points Models Toucan 1010 Revision 02-2000...

  • Page 71: Lubrication Points

    (Lithium base grease) cleaning or more often 1. Mast profiles if the work platform is MOBILITH SHC 220 used or stored in a very (Low temperature) dusty or corrosive environment. 3. Cycle the mast and relubricate. Models Toucan 1010 Revision 02-2000...
  • Page 72 MOBILTAC 81 9.Swing bearing Every 1000 hours of with a brush through the gear box Coat all teeth. internal gear operation. centering hole. Manually rotate MOBILITH SHC 1500 the turntable to reach the whole teeth. Models Toucan 1010 Revision 02-2000...
  • Page 73 NOTES Models Toucan 1010 Revision 02-2000...

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