Hydraulic System - JLG TOUCAN 1010 Service Manual

5

5.10 Hydraulic system

DANGER
Exercise extreme care around pressurized
hydraulic systems. Do not work on a hydraulic
system while it is in operation or until all
pressure is released.
Cleanliness
Contaminants in a hydraulic system affect operation
and will result in serious damage to the system
components. Dirty hydraulic systems are a major
cause of component failures.
Keep the system clean
When removing components of a hydraulic system,
cover all openings on both the component and the
work platform.
If evidence of foreign particles is found in the hydraulic
system, flush the system.
Disassemble and assemble hydraulic components on
a clean surface.
Clean all metal parts in a non-flammable cleaning fluid.
Then lubricate all components to aid in assembly.
Hydraulic filters location
Pressure filter
Pressure filter is located
on the front left hand
side of the chassis.
Return filter
The top in-tank return filter
is located at the rear of the
chassis.
Sealing elements
Inspect all sealing elements (O-rings, gaskets, etc,...)
when disassembling and assembling hydraulic system
components. Installation of new elements is always
recommended.
Models
Toucan 1010
Edition 04-2006
MAINTENANCE
Hydraulic lines
When installing metal tubes, tighten all bolts finger-
tight. Then, in order, tighten the bolts at the rigid end,
the adjustable end and the mounting brackets. After
tubes are mounted, install the hoses. Connect both
ends of the hose with all bolts finger-tight. Position
the hose so that it does not rub on the machine and
can bend and twist. Tighten bolts in both couplings.
Due to manufacturing 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 will normally be removed
automatically with the hydraullic oil passing in the
reservoir. However, if a component has been replaced
or the reservoir level is too low, air can enter the
system. If air becomes entrapped in the hydraulic oil,
it may be detected by noisy operation of the pump/
motor-operated components. Should this occur, check
the level of the hydraulic reservoir and replenish as
necessary.
Minute leaks may be difficult to locate. Should you
encounter a leak that is not readily detectable, use
the following method when checking for leaks :
Pressure filter
Return filter
Use extreme care when removing any plugs
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.
- Seal all normal openings in the hydraulic
system and the hydraulic reservoir.
- Using a positive means to control the pressure
(i.e. a regulator), pressurize the hydraulic
system to 13.8 kPa/0.14 bar - 27.5 kPa/0.28
bar.
- Inspect all joints and fittings for evidence of
leaks. A soap solution - may also prove helpful
in detecting minute leaks when the system is
pressurized.
- Remove the pressure, repair any leaks found
and reopen any openings (vents, etc...) closed
for inspection.
- Refill the hydraulic reservoir after completing
any repairs or service.
- Operate all hydraulics circuits several times in
both directions. This action should return any
entrapped air to the hydraulic reservoir where
it can be removed from the hydraulic oil by the
hydraulic reservoir vent.
DANGER
5
43