MODELS TOUCAN 1210 TOUCAN 1310 · 2020. 3. 27. · English - Service Manual MODELS TOUCAN 1210 TOUCAN 1310 U.S.A. JLG Industries, Inc. 1 JLG Drive McConnellsburg PA 17233-9533 Tel
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Révision: 03 - 2012 MA0295-04English - Service Manual
MODELSTOUCAN 1210TOUCAN 1310
U.S.A.JLG Industries, Inc.1 JLG DriveMcConnellsburgPA 17233-9533Tel : (171) 485-5161Fax : (717) 485-6417
C.E.JLG Manufacturing EuropeBreitwaterstraat 12AOude Bunders 1034B - 3630 MaasmechelenTel : +32(0)89 774 974Fax : +32(0)89 777 427
FRANCEJLG France SASZ.I. de FauilletBP 20 - 47400 TONNEINSFranceTel : +33 553 84 85 11Fax : +33 553 79 06 87
C.E.JLG Industries,Kilmartin Place,Tannochside ParkUddingston, Scotland G71 5PHTel : +44(0)1698 811005Fax : +44(0)1698 811055
3 Models
Revision 03-2012Toucan 1210Toucan 1310
MA0295-04
ModelsEnglish
MACHINE SERIAL NUMBER :
Toucan 1210 _____Toucan 1310 _____
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Toucan 1210Toucan 1310
1 INTRODUCTION
ForewordImportant information
2 WORK PLATFORM CHARACTERISTICS
Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2.1Characteristics - Dimensions - Performances - - - - - - - - - - - - - - - - - - - - - - - - - 2.2
3 HYDRAULIC SYSTEM
Hydraulic power units - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.1Hand pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.2Hydraulic filters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.3Function manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.4Drive manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.5Membrane accumulator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.6Wheel motor distribution manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.7Brake manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.8Differential locking manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.9Wheel motors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.10Steering manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.11Check valves manifold ("Power plus" option) - - - - - - - - - - - - - - - - - - - - - - - - 3.12Release control valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.13Trim correction manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.147-way, 3 position flow diverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.15Cylinders supply manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.16Mast cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.16.1Jib cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.16.2Telescope cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.16.3Assistance cylinder - Master cylinder - Slave cylinder - - - - - - - - - - - - - - - - 3.16.4Rotation cylinder (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.16.5Sequence valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.17Slewing hydraulic motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.18Pressure relief valves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19Brake release circuit pressure check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.1Pressure relief valve setting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2Main pressure [PR1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.1Telescope extension [PR2] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.2Telescope retraction [PR3] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.3Mast elevation [PR4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.4Jib elevation [PR5] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.5Jib lowering [PR6] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.6Brake release maximum pressure [PR7] - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.7Drive at low speed [PR8] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.8Slewing to the left [PR9] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.9Slewing to the right [PR10] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.10Trim correction [PR11] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.11Left steering [PR12] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.12Right steering [PR13] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.19.2.13
TABLE OF CONTENTS
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TABLE OF CONTENT
4 ELECTRICAL SYSTEM
Wiring diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.1Battery wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.1.1Power circuit wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.1.2Components location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.1.3Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2Mast position switch [SW4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.1Jib lower position switch [SW5] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.2Telescope position switch [SW2] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.3Jib higher position switch [SW3] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.4Slack chain sensors [SW34 à 37] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.5Tilt indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.6Strain link (stability control device) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.7Steering sensors (T1310 only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.8Sensor for left steering limitation [SW39] - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.8.1Sensor for right steering limitation [SW40] - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.8.2Steering angle sensors [SW41 & 42] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.2.8.3Safety features - Movement cut out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.3Adjustment of the battery discharge indicator - - - - - - - - - - - - - - - - - - - - - - - - 4.4Speed electronic controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.5Circuit breakers - Fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.6Circuit breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.6.1Fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.6.2Resetable fuses (Polyswitch®) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.6.3Help with the diagnostic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.7Electronic modules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.8Controls verification module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.8.1Speed control module for the jib (dongle) - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.8.2Time delay module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.9"Power plus" module (option) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.10"Clipper" connector installation procedure - - - - - - - - - - - - - - - - - - - - - - - - - 4.11
5 BATTERIES - CHARGERS
Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5.1Electrolyte specific gravity and battery voltage - - - - - - - - - - - - - - - - - - - - - - 5.1.1Storage at temperatures below -20°C (32°F) - - - - - - - - - - - - - - - - - - - - - - - - 5.1.2Use of a battery in a cold chamber or in cold climate - - - - - - - - - - - - - - - - - 5.1.3Battery not working continuously or inactive battery - - - - - - - - - - - - - - - - - - 5.1.4Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5.1.5Chargers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5.2High frequency charger "Zivan NG3" - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5.2.1Electronic charger "Oldham-Hawker CP IV" - - - - - - - - - - - - - - - - - - - - - - - - 5.2.2
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6 TORQUE VALUES
General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6.1Wheel nut torque values - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6.2Torque value of slewing ring attachment bolts - - - - - - - - - - - - - - - - - - - - - - - - 6.3
7 SERVICE - MAINTENANCE
General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1System malfunction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1.1Cleanliness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1.2Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1.3Dissassembly / Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1.4Parts replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1.5Wires and cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.1.6Platform cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.2Maintenance and installation of guide rings - - - - - - - - - - - - - - - - - - - - - - - - - - 7.3Steering bracket thrust washers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.4Mast roller removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.5Adjustment of telescopic mast alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.6Lifting chains adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.7Verification and lubrication of the lifting chains - - - - - - - - - - - - - - - - - - - - - - - 7.8Verification of chain wear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.8.1Chain lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.8.2Hydraulic power unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.9Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.10Maintenance of the centralised filling system - - - - - - - - - - - - - - - - - - - - - - - 7.10.1Cleaning - Battery maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.10.2Preventive maintenance and inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.11Daily preventive maintenance and inspection - - - - - - - - - - - - - - - - - - - - - - 7.11.1Weekly preventive maintenance and inspection - - - - - - - - - - - - - - - - - - - - 7.11.2Monthly preventive maintenance and inspection - - - - - - - - - - - - - - - - - - - - 7.11.3Preventive maintenance and inspection every 125 hours - - - - - - - - - - - - - - 7.11.4Preventive maintenance and inspection every 250 hours - - - - - - - - - - - - - - 7.11.5Preventive maintenance and inspection every 500 hours - - - - - - - - - - - - - - 7.11.6Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.12
TABLE OF CONTENT
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FOREWORD
This manual has been compiled to assist you inproperly operating and maintening your JLG aerialwork platform.
Constant improvement and engineering progress makeit necessary that JLG reserve the right to makespecification and equipment changes without notice.
The definitions of DANGER, CAUTION and NOTE asused in this manual apply as follows :
A DANGER is used to emphasize that if anoperation, procedure or practice is notfollowed exactly, death or serious injury topersonnel may result.
A CAUTION is used to emphasize that if anoperation, procedure, or practice is notfollowed exactly, equipment damage mayresult.
NOTEA NOTE is used to emphasize an importantprocedure or condition
GENERAL WARNINGIt is mandatory that all hydraulic hoses andfittings are correctly tagged and identified beforethey are disconnected to effect repairs or service.Failure to correctly tag and identify hoses andfittings can cause wrong reconnection, which canresult in death or serious injury to personnel.
DANGER
! CAUTION
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NOTICE TO OWNER/USER
Should this work platform become involved in a accident, please contact your localJLG distributor immediately and relate details of the incident so he can notify JLG.If the distributor is unknown and/or cannot be reached, please contact :
USA :
JLG Industries, Inc.Product Safety & Reliability Department, 1 JLG DriveMcConnellsburg, PAUSA 17233-9533Toll Free: (877) 554-7233Tel.: (717) 485-5161Fax: (717) 485-6573Email : ProductSafety@JLG.com
C.E :
JLG Industries,Kilmartin Place,Tannochside ParkUddingston,Scotland G71 5PHTel : +44(0)1698 811005Fax : +44(0)1698 811055Email : ProductSafety@JLG.com
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The following form is for the use of the Distributor, Customer, Mechanic, and all other person who use this manualand recognize beneficial ways to improve its purpose as a worthy reference. SMCAR's are to be made in regardsto, but not limited to : Safety, Operation Correctness, and Technical Content. All SMCAR's will be reviewed bythe responsible Department at JLG Approved SMCAR's will be distributed in a Service Bulletin immediately andthen incorporated in the next scheduled change to the manual. An answer to the SMCAR, approved ordisapproved, will be sent directly to the one submitting the SMCAR.
Date ______________________________Customer name _____________________Name/first name _____________________Address _____________________________________________________________
Telephone __________________________
Service ManualAffected __________________________________________________________________________
Page(s) Affected____________________________________________________________________
Reason for submitting SMCAR (Use additional paper or back if necessary)
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__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
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__________________________________Signature (optional)
Adress SMCAR's to :Supervisor, PublicationsJLG France SASZ.I. de Fauillet,B.P. 2047400 Tonneins, France
CORRECTIVE ACTION REQUEST
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WORK PLATFORM CHARACTERISTICS 22
2.1 Description
The Mobile Elevating Work Platform consists of a selfpropelled all welded chassis, of a telescopic mastmounted on a turntable and a telescopic jib. Theplatform is mounted at the end of the jib.
The main hydraulic power unit supplying the functionsof the work platform is located at the rear of the chassison the right hand side. When the "Power Plus" optionis installed, an auxilliary unit is installed on the rearof the chassis on the left hand side.
The drive function is accomplished by two hydraulicmotors propelling the rear axle.The parking brakes integrated to the hydraulic motorswork through lack of pressure.Steering (front axle) is accomplished by a hydrauliccylinder.
The slewing movement is accomplished by a wormgear motor located at the base of the superstructure.
The movements of the telescopic mast, pendular jiband telescope are accomplished by means ofhydraulic cylinders.
The machine may be equipped (optional) with a systemcontrolled by a hydraulic cylinder enabling the rotationof the platform.
The platform is kept horizontal by hydraulic cylindersworking following the "master-slave" principle.
The movements of the machine are controlled fromcontrol panels through solenoid valves. They arelocated at the front of the chassis (for structuremovements) and on the left hand side of the chassis(for drive movements).
The progressivity of movements is obtained by anelectronic controller which controls the rotation speedof the main hydraulic group motor. The electroniccontroller is located near the emergency control panel(ground controls), on the left hand side of thetelescopic mast.
The energy for the control and power circuits of themobile elevating work platform is supplied by a 24VDCbattery.
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WORK PLATFORM CHARACTERISTICS 22
Steering wheels
FRONT VIEW
REAR
Hand pump
REAR VIEW
Driving wheels
Counterweight
FRONTVIEW LEFT
Counterweight
Telescopic mast
Emergency controlpanel
Charger
Circuit breaker
Platformcontrol panel
Releasevalve
Manual box
Telescopic mast
Workplatform
Breakdowncontrol panel
Telescopic jib
Access to sidebatteries
Access to thefront battery
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WORK PLATFORM CHARACTERISTICS 22
2.2. Characteristics - Dimensions - Performances
(*) Speeds recorded on horizontal and level ground with a person on the platform (approximately 80 kg).(**) Movements durations recorded with the maximum load in the platform (200 kg), the movements being controlledfrom the platform control panel.
Speeds are indicated for a machine with a battery fully charged and operated at ambiant temperature of 20°C.
Constant improvement makes it necessary that JLG France SAS reserve the right to make specification and equipmentchanges without notice.
Toucan 1310DIMENSIONS (LOWERED) Standard Rotation (option) Standard
Length 3,85 m 4,07 m 4,07 mWidth 1,20 m 1,20 m 1,345 mHeight 1,99 m 1,99 m 2,19 mWeight 5 200 kg 5 300 kg 5 600 kgGround clearance 0,08 m 0,08 m 0,09 m
CAPACITY - MANOEUVRABILITY Standard Rotation (option) Standard
Floor height min. 0,40 m 0,40 m 0,57 mFloor height max. 10,00 m 10,00 m 11,00 mMax. outreach (from centerline) 4,93 m 5,16 m 5,16 mFloor height with max. outreach 7,20 m 7,20 m 8,20 mWorking height with max. outreach 9,20 m 9,20 m 10,20 mSlewingRotation (option)
WORK PLATFORM Toucan 1310
LengthWidthRated load
HYDRAULIC CIRCUIT Toucan 1310
Hydraulic tank capacityMain hydraulic pump displacementAuxilliary hydraulic pump displacement (T1210 option)
FILTRATION Toucan 1310
PressureReturn
PRESSURE Toucan 1310
Main hydraulic circuit maximum pressure
ELECTRICAL COMPONENTS Toucan 1310
Power of the main hydraulic power unit motorPower of the auxilliary hydraulic power unit motor (T1210 option)
DRIVE SPEEDS (*) Toucan 13101st gear (low speed) 0,65 to 0,7 km/h 0,45 à 0,7 km/h2nd gear 2,0 km/h 1,5 km/h3rd gear 3,6 km/h 2,6 km/h4th gear 3,6 km/h
MOVEMENT DURATION (**) Toucan 1310Mast elevation movement duration 33 à 40 sMast lowering movement duration 34 à 40 sJib elevation movement duration 20 à 27 sJib lowering movement duration 23 à 30 sTelescope extension movement duration 16 à 22 sTelescope retraction movement duration 14 à 20 sSlewing movement duration (from stop to stop) 75 à 85 s75 à 85 s
20 à 27 s23 à 30 s16 à 22 s14 à 20 s
Toucan 1210
Toucan 121028 to 33 s28 to 33 s
1,10 m200 kg
Toucan 1210
Toucan 1210
0,70 m
345° (2 x 172,5°)120° (2 x 60°)
Toucan 1210
Toucan 1210
4,8 kw / 24 VDC4,8 kw / 24 VDC
24 MPa
10 µm absolute10 µm absolute
Toucan 1210
Toucan 1210
35 l5,2 cm³/t3,5 cm³/t
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HYDRAULIC SYSTEM 33
3.1. Hydraulic power units
1- Main hydraulic power unit - 4,8 kw - 5,2 cc/tFUNCTION : Supply to the hydraulic circuit of the elevating work platform.
2- Auxilliary hydraulic power unit - 4,8 kw - 3,5 cc/tFUNCTION : Supply of an additional oil flow during a high speed drive to make up for the speed reduction due to theuse of wheel motors of higher displacement.
Do not interchange the pumps from the main and auxilliary power units.Body length of the 5,2 cc/t pump on main power unit : L = 55 mm.Body length of the 3,5 cc/t pump on auxilliary power unit : L = 50 mm.
! DANGER
1 2
ModelsRevision 03-201216
Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
! CAUTIONDisassembly of the gear pump entails replacement of seals.
1- Remove both screws securing the pump to the motor. Disconnect the pump.
2- Place the pump vertically ona clean work area andremove the four f langeattachment screws. Removethe flange.
3- Extract the pump bodyensuring both pinions andbearings do not getdamaged (beware the twoseals on the upper bearing).
4- Extract the upperbearing, both pinions thenthe lower bearing.
Careful inspection of all pump components allows,depending on parts wear, to diagnose operating faultsor pollution problems in the hydraulic circuit.
L
Electrical motor
Pump bodySeals
Torque value :44 Nm
Torque value : 22 Nm1
2
Seals
Pinions
Bearings
Flange
17 Models
Revision 03-2012Toucan 1210Toucan 1310
Hydraulic circuit pollution
- ABRASIVE WEAR CAUSED BY ABRASIVE PARTICLES
Such a wear results in a gradual reduction of thepower and speed of the hydraulic circuit.Fine particles may enter the circuit:
• During reservoir filling (clean the area around thefilling neck before opening the cap. Use cleancontainers and funnels during filling procedure).
• Through worn seals, particularly on dirty and poorlymaintained material.
• During maintenance if components are not cappedafter hose disconnection.
HYDRAULIC SYSTEM 33
− ABRASIVE WEAR CAUSED BY METALLIC PARTICLES.Such a wear results in a fairly sudden degradation ofthe performances of the pump. Metallic particles resultgenerally from the degradation of a component or froman abnormal wear of the hydraulic circuit: thecomponent must be identifed and replaced. Everyhydraulic component must be removed and cleaned.The hydraulic circuit must be drained out and flushedand the filters changed.
- AERATION OR CAVITATION
Cavitation and aeration act alike in the system.
Aeration occurs when air mixes with the oil. Air mayenter the system through a small suction leak or byagitation of the oil in the reservoir. Agitation occurswhen the oil returns to the reservoir above the oilsurface. This may occurs when the oil level is toolow. Cavitation is the formation and collapse of vapourbubbles in the oil. This usually results from a restrictedpump suction. Cavitation occurs more readily whenthe oil is cold.
Aeration and cavitation erode and pit the pressureplates and pump housing.
A pump which is either cavitating or operating onaerated fluid is usually noisy and the system operatesin a spongy or jerky manner.
If erosion on the suction side of the pump is evident onthe gear tracks, the cause is either air bubbles in theoil or a restricted suction.
Bearing wear(dull area)
Wear on pinion pressureplates (dull area)
Wear on gear track (dullarea)
Wear on gearing track(grooves)
Bearing wear(grooves)
Wear on pinionpressure plates
(grooves)
Cavitation
Track grooved on suction side = overpressure
ModelsRevision 03-201218
Toucan 1210Toucan 1310
- LACK OF OIL
When a failure is due to lack of oil, deteriorations areusually rapid. This type of failure may occur if :
- the oil level is low in the reservoir, or- there is an air leak in the suction line.
- EXCESSIVE HEAT
Excessive heat will harden the seals.
Excessive heat may be caused by a pressure reliefvalve set too low, in which case, the machine will beslow.
- OIL PRESSURE TOO HIGH
There are two possible causes for overpressure :- the pressure relief valve fails to function,producing an extreme surge and immediatefailure.
- The pressure relief valve is set too high,resulting in repeated pressure peaks. Pumpdamage is very similar in both cases.
- INCORRECT ASSEMBLY
This type of failure is self explanatory : components arefaulty, or parts have not been assembled correctly.
Pinching of the O-ring will occur if it is not seatedproperly in its groove. If the O-ring has been fittedincorrectly, the surface of the housing will show adepressed area (especially if the part is made ofaluminium).
5- Remove the seals
NOTEAlign the seals in the order they were removed,mark their position and shape to facilitatelater assembly.
6- Clean the pump components with anappropriate solvent and dry with compressedair. Replace the seals.If components are damaged, replace the pump.
Avoid scratching the grooves and glandsurfaces.
Inspect each groove before assembly.Parts must be free from dust and burrs.Grooves and gland surfaces must be in goodcondition. Worn or damaged parts must bereplaced. Do not stretch seals during theirassembly. Lubricate seals and gland surfaceswith clean hydraulic oil before assembly.
7- Assemble the pump in the reverse order fromdisassembly.
Bolt torque value (Rep. 1) = 22 NmBolt torque value (Rep. 2) = 44 Nm
Respect scrupulously the bolt torque value(Rep. 1) and (Rep. 2). Incorrect torquing willaffect the performance of the pump.
After pump installation, operate the workplatform to bleed the air from the hydrauliccircuit and check the oil level in the mainreservoir (machine fully lowered). Check thegood working order of all the control panels.
HYDRAULIC SYSTEM 33
! CAUTION
! CAUTION
! CAUTION
! CAUTION
19 Models
Revision 03-2012Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.2. Hand pump
FUNCTION :- Oil supply to the hydraulic circuit of the work platform when using the breakdown controls : elevation / lowering,telescope extension/retraction, slewing.- Oil supply to the brake pilot circuit (See § 3.13).
Seals
Split pin
Suctioncartridge
Handpump
ModelsRevision 03-201220
Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.3 Hydraulic filters
NOTEThe filter cartridges must be replaced :
- After the first 50 hours of operation.- Every 250 hours of operation.- At each oil change (see chapter 7).
After instal lation, perform severalmovements to bleed the air from thehydraulic circuit, check the oil level in thereservoir (PLATFORM FULLY LOWERED)
The return filter must also be replaced.
3.3.2. Return filterFiltration rating : 10 µm abs
1- Disconnect the battery from the electrical circuitof the work platform.
2- Unscrew the return filter cap and remove thespring.
3- Install a new filter cartridge.4- Check the presence and condition of the O ring,
close the filter cap not forgetting to install thespring.
The pressure filter must also be replaced.
NOTEUsed oils and filter cartridges must bedisposed of in accordance with theregulations in force.
3.3.1. Pressure filterFiltration rating : 10µm abs.
1- Disconnect the battery from the electricalcircuit of the work platform.
2- Position the release control valve lever on to release the pressure in the hydraulic
circuit.3- Unscrew the filter tank
Oil projection on the skin can cause injuriesand burns. Loosen the filter tank very slowlyto allow the oil pressure to dropprogressively.
4- Install a new filter cartridge.5- Check the presence and condition of the O ring.6- Install the filter tank.
Filt
erca
rtri
dge
Cap
Spr
ing
O-R
ing
O r
ing
Filt
erT
ank
å
DANGER
! CAUTION
! CAUTION
cartridgeå
21 Models
Revision 03-2012Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
Manifold schematic :
3.4 Function manifold
FUNCTION : Hydraulic control for the different structure movements of the work platform.
(A) (B) (C)
PR1 : General pressure relief valve
1
2
TORQUE VALUE : 25 to 30 N.m
PR2 : Pressure relief valve : Telescope extensionPR3 : Pressure relief valve : Telescope retractionPR4 : Pressure relief valve : Mast elevationPR5 : Pressure relief valve : Jib elevationPR6 : Pressure relief valve : Jib lowering
Setting range of the pressure relief valves [PR2] to[PR6] : 0 to 25 MPa (0 to 250 bar).
Setting of pressure relief valves : See § 3.19.
1
2
TORQUE VALUE : 12 to 15 N.m
Pressure relief valves [PR2] to [PR6]
1
2
1
2
ModelsRevision 03-201222
Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
DV1 : Solenoid valve (NO).
FUNCTION :- Dumping of the oil flow supplied by the main
hydraulic power unit (if not actuated).- Divertion of the oil flow to the boosting circuit of the
wheel motors during the stopping phases of the drivemovements.
A. Check valve (0,05 MPa)
FUNCTION : Prevents the oil flow suplied by the handpump from returning to the reservoir during operationusing the breakdown controls.
NOTEThe check valve is kept in position bydeformation of the thread : cannot beremoved.
B. Check valve (0,45 MPa)
FUNCTION : Provides a necessary counter pressure inthe boost circuit. Limits the oil return of the make upflow diverted by the solenoid valve [DV1].
C. Jet Ø 1 mm
FUNCTION : Ensures decompression of the pilot circuitof the counterbalance valve on the mast cylinder(lowering movement).
NOTEThe jet is installed with glue : cannot beremoved.
1 21
2
1
2
1
2
Torque value :4 to 5 N.m
1
2
Torque value :25 to 30 N.m
2
1
DV1
23 Models
Revision 03-2012Toucan 1210Toucan 1310
HYDRAULIC SYTEM 33
OG/OD : Solenoid valve 4-3 - Slewing movement Left / RightRT/ST : Solenoid valve 4-3 - Telescope extension / retraction movementMM/DM : Solenoid valve 4-3 - Mast elevation / lowering movementMB/DB : Solenoid valve 4-3 - Jib elevation / lowering movement
Face B
P R
BA
DB MB
DB DM RT OD
MB MM ST OGDV1
STRT
A B
RPOD OG
MMDM
A B
RP RP
BA
Spool valve 4-way, 2-position"Restricted floating center spool"
Spool valve 4/3 + sleeveRef. : 952034
Spool valve 4-way, 2-position"Floating center spool"
Spool valve 4/3 + sleeveRef. : 952029
Spool valve 4-way, 2-position"Floating center spool"
Spool valve 4/3 +sleeveRef. : 952029
Spool valve 4-way, 3-position"Closed center spool"
Spool valve 4/3 + sleeveRef. : 952033
Exploded view of a solenoid valve 4-way, 3-position :
(B) (P) (A) (R)
Face B
Manu
al co
ntro
l cov
er
Nylon
nut
O-r in
gCo
il 24
VDC
Pole
tube
Sprin
g
Sprin
g gu
ide
Spoo
l
S lee
ve
Mani
fold
Sprin
g gu
ide
Sprin
gPo
letu
be
Coil 2
4 VD
C
Nylon
nut
Manu
al co
ntro
l cov
er
ModelsRevision 03-201224
Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
Disassembly :
1- Remove the plastic nuts holding the coils.2- Remove the O-rings and the coils.3- Remove the poletubes using adequate tooling
(Ref. 990005), (Torque to unscrew : 13 to 33N.m).
4- Remove the spring guides and drive the spoolout of the sleeve.
Inspection :
1- Clean all parts with an appropriate solvent anddry with compressed air.
2- Check the spool surfaces are not scratched.3- Check the axial and radial holes at each end
of the spool are not blocked.
NOTEIf the spool is scratched or if the holes areblocked, the spool AND the sleeve must bereplaced.
If the spool and the sleeve have to be replaced, drivethe sleeve out of the manifold using an appropriatemandrel in the direction indicated in the drawing below:
Assembly :
Never interchange spools and sleeves. Allcomponents must be clean before assembly.
1- Check for burrs that could damage O-ringsduring the installation of the sleeve.
2- Install the O-rings on the sleeve.
NOTEEnsure the seals are not stretched and thegrooves damaged during assembly.
3- Lubricate the seals before sleeve installation(MILLCOT K320 or equivalent).
4- Insert the sleeve in the manifold using anappropriate mandrel in the direction indicatedin the drawing below :
5- Lubricate the spool with clean hydraulic oil.Slide the spool into the sleeve as indicatedbelow. Ensure the spool slides freely inside thesleeve.
6- Install the spring guide on face B side asindicated in the drawing below. Install the springin the poletube. Install the poletube on themanifold using Loctite® 245. Torque thepoletube to 10 - 12 N.m using adequate tooling(Ref. 990005).
NOTEThe thread on the poletube must be free fromoil or grease before the glue is applied.
(B)(P)(A)(R)
Face B
Mandrel
Ø9,
8
(B)(P)(A)(R)
Face B
Mandrel
Face B
Face B
Torque value10 to 12 N.m
LOCTITE 245
Millcot K320or equivalent
0 -0,2
Ø9,
8 0 -0
,2
! CAUTION
25 Models
Revision 03-2012Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 3
7- Install the spring guide on the other side of thesleeve. Install the spring in the poletube. Installthe poletube in the manifold using glue Loctite®245. Torque the poletube to 5 - 6 N.m usingthe adapted tooling (Réf. 990005).
8- Install the coils and O-rings. Torque the coilnylon nuts to 4 to 5 N.m
3
Face B
Torque value5 to 6 N.m
LOCTITE 245
Play
ModelsRevision 03-201226
Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.5 Drive manifold
1 : Solenoid valve 4-way, 3-position (floating centerspool).FUNCTION : Selection of the drive direction (FWD /REV).
2 : AccumulatorSee § 3.6.
Torque value for the 4 bolts securing the solenoidvalve : 9 N.m
3.6 Membrane accumulator
FUNCTION : Enables storage of a volume of oil destinedto the make up flow for the wheel motors duringreversal of the drive direction.
! DANGER
Technical characteristics :
Never loosen the top seal screw.
Manifold schematic :
REV
Cap
Pressurereservoir
Top sealscrew
Membrane Obturator
Port
Inflating pressure 0,5 MPa (5 bar)Gaz NitrogenMaximum pressure 21 MPa (210 bar)Nominal volume 0,16 litrePort size Ø 1/2" BSPP
FWD
MAV : FWDMAR : REV
27 Models
Revision 03-2012Toucan 1210Toucan 1310
3.7 Wheel motor distribution manifold
HYDRAULIC SYSTEM 33
1 : Solenoid valveDrive speed change [HI/LO]
2(a) : Counterbalance valveForward drive
2(b) : Counterbalance valveReverse drive
3 : Shuttle valve
4(a).4(b). Make up flow check valves4(c).
Torque value for the 4 bolts securing the solenoid valve[HI/LO] : 9 N.m
1
4c 4a
4b
2b
2a
3
Manifold schematic :
ModelsRevision 03-201228
Toucan 1210Toucan 1310
Solenoid valve 4-way, 2-position
FUNCTION : Allows the change in drive speed by placingthe "cyl. B" displacement of the wheel motors in "freewheel".
- When the solenoid valve is not actuated (and ), both motor displacementss (cyl. A +cyl. B) are supplied.
[ HI ] : High displacement Ô slow speed
- When the solenoid valve is actuated ( ), onlythe motor displacement "cyl. A" is supplied,displacement "Cyl. B" is placed in "free wheel".
[ LO] : Low displacement Ô high speed
HYDRAULIC SYSTEM 33
T
P
T
T
P
P
P
P
Cyl. B Cyl. A
FORWARD DRIVE REVERSE DRIVE
P P
P
T
T
TT
Cyl. B Cyl. A
Cyl. B Cyl. A
T P T
TP
T T
T
P
T
T
P
P
P
P
P
Cyl. B Cyl. A
FORWARD DRIVE REVERSE DRIVE
Counterbalance valvesFUNCTION : Allows dynamic braking of the workplatform and the counter pressure necessary for themake up flow to the wheel motors.
Counterbalance valve setting : The tighter thesetting screw is, the sharper is the braking of thework platform.Adjustment must be done with the rated load correctlydistributed in the work platform. Tighten completelythe setting screw, then loosen by 4 1/2 turns to obtainan average setting.
Sharpen the setting if necessary so that :
- When the work platform is driven at maximumspeed, it stops over a distance of 0,8m to 1m onhorizontal ground (in both drive directions) whenthe joystick is returned to its neutral position.
- When the work platform is driven down a 15% slopein 2nd gear, it stops over a distance below 1 mwhen the joystick is returned to its neutral position.
Shuttle valve
FUNCTION : Oil supply to the brake release circuit inboth drive directions of the work platform.
Make up flow check valves
1
2
3 12 3
Torque value : 60 N.m
1 3
2
2 31
Torque value : 27 N.m
1
2
2
1
Torque value : 34 N.m
[H I] [H I]
[LO] [LO]
29 Models
Revision 03-2012Toucan 1210Toucan 1310
3.8 Brake manifold
HYDRAULIC SYSTEM 33
1 : Pressure reducing valve
2 : Piloted 2-way spool
3 : Check valve
4 : Jet
PR7 : Pressure relief valve(Brake release using the hand pump)
PR8 : Pressure relief valve(Torque limiter at slow speed)
EVF : Decompression solenoid valve for the brakerelease circuit.
EVC : Solenoid valve enabling the relief valve [PR8] tooperate.
Manifold schematic :
13
2
4
ModelsRevision 03-201230
Toucan 1210Toucan 1310
Pressure reducing valve
FUNCTION : Reduces the brake release pressurebetween 1,8 and 2,1 MPa (18 and 21 bar).
Piloted 2-way spool
FUNCTION :- Prevents the oil flow delivered to the brake release
circuit from returning to the reservoir when the workplatform is driven.
- Enables decompression of the brake release circuitwhen the drive control is released.
NOTESetting of the pilot pressure of the piloted 2-way spool is factory preset and should notbe modified.
Check valve
FUNCTION : Prevents the oil flow from returning to thetank (via the pressure reducing valve) while using thehand pump to release the brakes.
NOTEThe check valve is kept in position bydeformation of the thread : cannot beremoved.
1
1
23
321
Torque value 15 to 18 N.m
HYDRAULIC SYSTEM 33
Torque value : 25 to 30 N.m
Jet Ø 0,8
FUNCTION : Restricts the oil flow from returning to thetank during decompression of the brake release circuit(delays brake actuation during the dynamic brakingphase performed by the counterbalance valves on thewheel motor distribution manifold).
NOTEThe jet is installed with glue : cannot beremoved.
Pressure relief valve [PR7]
FUNCTION :- Limits the brake release pressure while the handpump is used.
- Protects the brake release circuit against anyoverpressure in case of malfunction of thepressure reducing valve.
- Setting range of the pressure relief valve [PR7]= 0 to 5 MPa (0 to 50 bar).
Pressure relief valve [PR8]
FUNCTION : Limits the pressure (therefore the wheelmotor torque) in the drive circuit when the machine isdriven at slow speed ( ).
- Setting range of the pressure relief valve [PR8]= 0 to 25 MPa (0 to 250 bar).
The pressure relief valves PR7 and PR8 donot share the same setting range. Do notinterchange the valve springs.
Setting of the relief valves : See § 3.19.
1 21
2
! CAUTION
1
2
Pressure relief valve PR7 - PR8
Torque value : 12 to 15 N.m
1
2
1
2
3
12 3
31 Models
Revision 03-2012Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
Decompression solenoid valve [EVF] forthe brake release circuit
FUNCTION :- Quick decompression (therefore immediateactuation of the brakes) of the brake releasecircuit when an emergency stop switch isactivated.
- Automatic decompression of the brake releasecircuit 3 to 4 seconds after the release of thedrive controls.
Solenoid valve [EVC] for operation reliefvalve [PR8]
FUNCTION : When the machine is driven at slow speed( ), supply to the solenoid is cut off and thepressure relief valve [PR8] comes in.
2
1
Solenoid valves [EVC] & [EVF]
Torque value :25 to 30 N.m Torque value :4 to 5 N.m
1
2
ModelsRevision 03-201232
Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3a
3b
1 2
A31 A32
A3 G
Differential locking manifold Manifold schematic :
3.9 Differential locking manifold
1 : By-pass solenoid valve
2(a) : Flow divider / Combiner
3(a) :Make up flow check valves
3(b) :
33 Models
Revision 03-2012Toucan 1210Toucan 1310
13
24
3.10 Wheel motors
Technical characteristics :(Radial piston motors)
- Motor 332 cc/rev. :
Motor identification 332 cc/rev. :
Left motor :
Right motor :
1. Commercial description2. Code = Part number3. Série = Production batch number4. Num = Chronological serial number
PHM S E 0 2 - A - J E 3 - F 0 3 - 1 1 2 0 - D J - 0 0
Code : 0025438-02C Indice
Série : XXX Num : XX
1
2
3 4
PHM S E 0 2 - A - FE03 - 1 1 2 0 - D J - 0 0
Code : 0025438-01B Indice
Série : XXX Num : XX
1
2
3 4
By-pass solenoid valve - 4-way, 2-position
FUNCTION :When the solenoid is not actuated :
- Allows free flow between the motors and thewheel motor distribution manifold.
- When the solenoid valve is actuated ( ) :blocks flow between the motors and thedistribution manifold : the flow divider/combineris operating.
Flow Divider / Combiner
FUNCTION :When the by-pass solenoid valve is actuated ( ) :- Divides equally the oil flow delivered to each wheel
motor (in forward drive).- Combines equally the oil return flow from each wheel
motor (in reverse drive).
Make up flow check valve [3 (a)(b)]
2
1
Torque value :27 N.m maxi
HYDRAULIC SYSTEM 33
2
142 3
Torque value :34 N.m maxi
1
2
3
1 2 3
Torque value :34 N.m maxi
Minimum displacement (Cyl. A) 133 cm³/rev.
Maximum displacement (Cyl. A + B) 332 cm³/rev.
Braking torque 250 daN.m
Max. operating pressure 40 MPa (400 bar)
Brake release pressureMini : 1,2 Mpa (12 bar)Maxi : 3,0 Mpa (30 bar)
Studs M14 x 150 (Qty : 5)
ModelsRevision 03-201234
Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
Motor identification 398 cc/rev. :
Left motor :
Right motor :
PHM S E 0 2 - 2- GE 3 - F 0 3 - 1 1 2 0 - D J - 0 0
Code : 0042438-35P Indice
Série : XXX Num : XX
1
2
3 4
PHM S E 0 2 - 2- DE 3 - F 03 - 1 1 2 0 - D J - 0 0
Code : 0042438-34N Indice
Série : XXX Num : XX
1
2
3 4
Motor identification 500 cc/rev. :
Left motor :
Right motor :
- Motor 398 cc/rev. : (Option gradeabillity 15%) - Motor 500 cc/rev. : ("Power plus" option)
PHM S E 0 3- 2- GE A- F 0 3 - 1 1 2 0 - D H-J0
Code : 0045438-18D Indice
Série : XXX Num : XX
1
2
3 4
PHM S E 0 3- 2- DEA- F 03 - 1 1 2 0 - D H- J0
Code : 0046438-17C Indice
Série : XXX Num : XX
1
2
3 4
Minimum displacement (Cyl. A) 199 cm³/rev.
Maximum displacement (Cyl. A + B) 398 cm³/rev.
Braking torque 250 daN.m
Max. Operating pressure 40 MPa (400 bar)
Brake release pressureMini : 1,2 Mpa (12 bar)Maxi : 3,0 Mpa (30 bar)
Studs M14 x 150 (Qty : 5)
Minimum displacement (Cyl. A) 250 cm³/rev.
Maximum displacement (Cyl. A + B) 500 cm³/rev.
Braking torque 250 daN.m
Max. operating pressure 40 MPa (400 bar)
Brake release pressureMini : 1,2 Mpa (12 bar)Maxi : 3,0 Mpa (30 bar)
Studs M14 x 150 (Qty : 5)
35 Models
Revision 03-2012Toucan 1210Toucan 1310
! CAUTION
! CAUTION
! CAUTION
Repeated use of the brakes as emergencybrakes (action on the emergency stop duringa drive movement) will reduce the brakingtorque. The brakes must be tested forefficiency after emergency braking.
NOTEBefore starting a motor, the housing must befilled with hydraulic oil through Port "2".
NOTEDisassembly of the wheel motors requiresspecific competences and tooling. ContactJLG Product Support.
HYDRAULIC SYSTEM 33
! CAUTION
Cyl. B Cyl. AX
A1A2
R
2
Ports identification :
Port A1 :Supply port corresponding to the preferential rotation direction (Cyl. A).Port A2 :Supply port corresponding to the preferential rotation direction (Cyl. B).Port R :Return port corresponding to the preferential rotation direction.Port X :Brake pilot port.Port 2 :Housing drain port.
The brake pilot pressure should not exceed3,0 MPa (30 bar) continuous.
The pressure in the motor housing should notexceed 0,1 MPa (1 bar) after the stabilisationof hydraulic fluid temperature (0,3 MPa (3bar) max. when cold).
Do not operate the motors without any loadand at maximum speed.
ModelsRevision 03-201236
Toucan 1210Toucan 1310
Troubleshooting
HYDRAULIC SYSTEM 33
PROBABLE CAUSE SOLUTIONS
Regular rumbling Worn bearing support Replace the bearing support
Vibrations Mounting and/or hydraulic piping becoming loose Tighten to torque
Clattering Boost pressure too low
- Check the pressure setting and condition of the counterbalance valves (Wheel motor distribution manifold)- Check boost pressure. Check for any leak in the drive circuit.
Cavitation Internal leaks too important Replace the cylinder block and the distribution valve assembly : Contact JLG Product Support
No supply to the motor Check the pump drive and pump inlet
The circuit does not reach working pressure
- Check the position of the motor release valve.- Check the condition of the pressure relief valve [PR1]- Check the supply and condition of the solenoid valve [EVC] (Brake manifold).
Excessive internal leaks Replace the cylinder block and the distribution valve assembly : Contact JLG Product Support
The brake stays engaged
- Check the brake pilot circuit. - Check the brakes bleeding screws,- Check the supply and condition of the solenoid valve [EVF] (Brake manifold).
The pump flow is too low- Check the condition of the gear pump.- Check the acceleration input received by the electronic controller.
Excessive internal leaks Check the condition of the cylinder block and of the distribution: Contact JLG Product Support.
- Check setting and condition of the counterbalance valves (wheel motor distribution manifold)- Check the drive circuit for leaks.- Check the supply and condition of the solenoid valve [EVC] (Brake manifold).- Check the condition of the motor release valve.- Check the condition of the piloted 2 way spool (Brake manifold).
Irregular flow - Check the oil level in the reservoir.- Check the pump flow.
Excessive leaks Check the condition of the cylinder block and of the distribution valve assembly : Contact JLG Product Support.
Too high housing pressure Check the drain circuit
Damaged seals Replace the seals : Contact JLG Product Support.
Incorrect assembly Tightening of motor mounting screws, of bleeding screws and hydraulic fittings.
Working pressure is too low
THE MOTOR DOES NOT REVOLVE
THE MOTOR DOES NOT REVOLVE AT ITS NORMAL SPEED UNDER LOAD
THE MOTOR REVOLVES IRREGULARLY
SYMPTOMS
EXTERNAL OIL LEAKS
NOISY MOTOR
Without load
Under load
37 Models
Revision 03-2012Toucan 1210Toucan 1310
3.11 Steering manifold
HYDRAULIC SYSTEM 33
1 : Solenoid valve, 4-way, 3-position
2 : Pressure relief valve [PR 12] :Steering to the right.
3 : Pressure relief valve [PR 13] :Steering to the left.
4a :Shuttle valve
4b :
5 : Jet Ø 1 mm
Manifold schematic :
See §
3.4
5
1
DG : Steer LEFTDD : Steer RIGHT
ModelsRevision 03-201238
Toucan 1210Toucan 1310
HYDDRAULIC SYSTEM 33
Solenoid valve 4-way, 3-position -Steering movement
FUNCTION :- Selection of the steering movement direction.
4-way, 3-position "close center spool".Spool 4/3 + sleeve 06E.Ref. : 952033
Removal / Installation procedure for the4/3 spool
See § 3.4.
Pressure relief valves [PR 12] [PR 13]Setting of the pressure relief valves : See § 3.19.
Shuttle valve
FUNCTION : Directs oil from the highest pressure circuitto the steering cylinder supply circuit.
1
2
Torque value : 25 to 30 N.m
Torque value : 15 to 18 N.m
1 2
3
Jet Ø 1 mm
FUNCTION : Restricts the oil flow taken for the steeringcylinder supply (limitation of speed reduction of thedrive movement when a steering movement iscontrolled simultaneously).
NOTEThe jet is installed with glue : cannot beremoved.
1
2
39 Models
Revision 03-2012Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.12 Check valves manifold ("power plus" option)
DV2 : Solenoid valve (NO).1a : Check valve1b : Check valve2 : Pressure switch
FUNCTION : Combines the flow from both pumps when the "power plus" option is installed.
Manifold schematic
DV2 : Solenoid valve (NO).
Check valve (1a)
FUNCTION : Prevents the return of the oil flow supplied by the main hydraulic power unit through the pump of theauxilliary power unit.
Check valve(1b)
FUNCTION : Prevents the return of the oil flow supplied by the auxilliary hydraulic power unit through the pump ofthe main power unit.
PORT GP :auxilliary pump inletPORT PP :Main pump inlet
Torque value : 30 N.m maxi
FUNCTION : Dumping of the oil flow supplied by thesecondary hydraulic power unit.
2
1b 1a
1
2
ModelsRevision 03-201240
Toucan 1210Toucan 1310
1
6
45
8
3
8
27
Spool extractiondirection
Spool assemblydirection
HYDRAULIC SYSTEM 33
2
1
Torque value : 27 N.m max.
2
Check valves (1a) (1b)
Pressure switch
FUNCTION : Cuts automatically the auxilliary hydraulicpower unit as soon as the pressure in the circuitreaches the pressure switch setting : (17 ± 1 MPa /170 ± 10 bar).
Electrical connections : "PDAH" models
Electrical connections : "PSP" models
3
2
5
4
6
1
Gicleur Ø3.2mm
3.13 Release control valve
FUNCTION :- Release of the wheel motors (free wheel).- Diverts the hand pump flow to the brake release
circuit.- Return the oil from the hydraulic power unit(s) to the
tank.
Control valve schematic :
Control valve exploded view :
3 2 1
6 5 4
1- Rear cover attachment screw2- Front cover attachment screw3- Spool4- Index5- Spacer6- Rear cover7- Front cover8- O-ring
NO [3]
NC [2]COM [1]
NO [2]
NC [1]COM [3]
Ô
41 Models
Revision 03-2012Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.14 Trim correction manifold
1. Poppet solenoid valve [EVI]2. Pressure relief valve [PR11]
Manifold schematic
FUNCTION : Enables the adjustment of the horizontalityof the work platform :
- When a movement to tilt the platform to the rear iscontrolled :
- The solenoid valve [EVI] is actuated.- The coil [MB] (Jib elevation) on the functionmanifold is supplied.
An additional volume of fluid is admitted in the trimcircuit between the master cylinder (rod side) and theslave cylinder (piston side) : the work platform tiltsrearwards.
- When a movement to tilt the platform to the front iscontrolled :
- The solenoid valve [EVI] is actuated.- The coil [DB] (Jib lowering) on the functionmanifold is supplied.
A volume of fluid is extracted from the trim circuitbetween the master cylinder (rod side) and the slavecylinder (piston side) : the work platform tilts forwards.
Solenoid poppet valve [EVI]
Pressure relief valve [PR1]
FUNCTION : Protects the trim circuit against excessivepressure during the jib elevation movement.
Setting of the pressure relief valve : see § 3.19.
1
2
Torque value : 25 to 30 N.m
1 2
1
2
Torque value :25 to 30 N.m
ModelsRevision 03-201242
Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.15 7-way, 3-position flowdiverter (option)
FUNCTION : Diverts the supply circuit for the telescopecylinder to the cylinder ensuring the work platformrotation. The diverter coil [EVR] is supplied when arotation movement is controlled. The direction of therotation movement is determined by the solenoid valveST/RT on the function manifold (see § 3.4). Port "T"enables the decompression of the cylinder circuit thatis not used.
Diverter 7-way, 2-position
1. 7-way, 2-position flow diverter2. Jet Ø 0.6 mm on port B2
3. Jet Ø 1.0 mm on port A2
1
23
3.16 Cylinders supply manifold
3.16.1 Mast cylinder
1. Single effect cylinder wet rod Ø80 - stroke 1005mm(T1210) and 1175mm (T1310).2. Pressure compensated flow regulator : 9 l/mn.3. Counterbalance valve : pilot ratio : 10:1.
Pressure compensated flow regulator
FUNCTION : Ensures a constant lowering speedwhatever the load in the work platform.
Respect the assembly direction of the flowregulator. Use a screwdriver of appropriatedimension to prevent damage to theregulator recess.
! CAUTION
Regulated flow
1 2
2 1
1 32Assembly direction
43 Models
Revision 03-2012Toucan 1210Toucan 1310
Counterbalance valve
FUNCTION :- Load holding in the event of hose failure.- Allows pressure relief in case of overload.- Allows thermal expansion relief of the hydraulicfluid.
Pilot ratio : 10:1.Setting : 21MPa (210 bar) at 4 l/mn (factory setting).
NOTEThe locknut must be tight to prevent anyexternal leak.
1
2
3
1
2 3
3.16.2 Jib cylinder
1. Double effect cylinder Ø80-60 - stroke 783 mm2. Pressure compensated flow regulator : 9 l/mn3. Counterbalance valve : pilot ratio : 2,5:14. Male cap Ø3/8" BSPP
Pressure compensated flow regulator
FUNCTION :- Ensures a constant lowering speed whateverthe load in the work platform.
Respect the assembly direction of the flowregulator. Use a screwdriver of appropriatedimension to prevent damage to theregulator recess.
HYDRAULIC SYSTEM 33
Torque value : 45 N.m
! CAUTION
1
3
4
2
Assembly direction
Supply
Regulated flow
1 2
2 1
ModelsRevision 03-201244
Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.16.3 Telescope cylinder
1. Double effect cylinder Ø70-45 - stroke 1205 mm2. Dual overcenter valves
2a. Counterbalance valve rod side2b. Counterbalance valve piston side.
Dual overcenter valvesFUNCTION :
- Load holding in the event of hose failure.- Allows pressure relief in case of overload.- Allows thermal expansion relief of the hydraulicfluid.
Pilot ratio : 6,5:1.
Setting of the counterbalance valve (2a) rod side
- Lower the jib, telescope retracted.- Fully tighten the valve setting screw.- Place a 250 kg load evenly distributed on thework platform floor.
- Slowly loosen the valve setting screw until thetelescope starts to extend, then tighten thescrew again by a 1 turn ½. Tighten the locknut.
Setting of the counterbalance valve (2b) pistonside
- Place a 250 kg load evenly distributed on thework platform floor.
- Fully tighten the valve setting screw.- Fully raise the jib. Extend the telescope byapproximately 50 cm.
- Slowly loosen the valve setting screw until thetelescope starts to retract, then tighten thescrew by a turn ½. Tighten the locknut.
1
2
3
1
2 3
Counterbalance valve
FUNCTION :- Load holding in the event of hose failure.- Allows pressure relief in case of overload.- Allows thermal expansion relief of the hydraulicfluid.
Pilot ratio : 2,5:1Setting : 21MPa (210 bar) at 4 l/mn (Factory setting)
NOTEThe locknut must be tight to prevent anyexternal leak.
2a
2b
Torque value : 45 N.m
45 Models
Revision 03-2012Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
1. Assistance cylinder :double effect Ø60-30 - stroke 319 mm.
2. Counterbalance valve3. Slave cylinder :
double effect Ø60-30 - stroke 319 mm.4. Dual overcenter valves
4a. Counterbalance valve rod side.4b. Counterbalance valve piston side.
5. Pressure compensated flow regulator : 3 l/mn.6. Male cap Ø 3/8" BSPP.7. Master cylinder :
double effect Ø 70-35 - stroke 323 mm.8. Bleeding screws.
Counterbalance valve
Pilot ratio : 2,5:1
NOTEThe locknut must be tightened to prevent anyexternal leak.
Regulated flow
1 2
2 1
Respect assembly direction of the flowregulator. Use a screwdriver of appropriatedimension to prevent damage to theregulator recess.
3.16.4. Assistance cylinder - Mastercylinder - Slave cylinder
! CAUTION
1 3
2 4
Pressure compensated flow regulator
FUNCTION : Ensures a constant extension speed ofthe cylinder whatever the load in the work platform.
Pilot ratio : 2,5:1
1
2
3
1
2 3
Couple de serrage : 45 N.m.
67
7
3
3b
3a
4
52
ModelsRevision 03-201246
Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.16.5 Rotation cylinder (optional)
1. Double effect cylinder Ø 50-30 - stroke : 130 mm.2. Dual overcenter valves
2a. Counterbalance valve rod side2b. Counterbalance valve piston side
Dual overcenter valvesFUNCTION :
- Keep the cylinder in position in the event ofhose failure.
- Allow pressure relief in case of overload.- Allow thermal expansion relief of the hydraulicfluid.
Pilot ratio : 6,5:1.
Setting of the counterbalance valves (2a & 2b) :
- Loosen the valve setting screw.- Tighten the setting screw until it contacts thevalve springs, then tighten the screw by 1 turn.Tighten the locknut.
1
2
2b
2a2m
m
Dual overcenter valvesFUNCTION :
- Load holding in the event of hose failure.- Allows pressure relief in case of overload.- Allows thermal expansion relief of the hydraulicfluid.
Pilot ratio : 6,5:1.
Setting of the counterbalance valve (4a) rod side
- Lower the jib with the work platform floorhorizontal.
- Fully tighten the valve setting screw (4a).Loosen without removing it the counterbalancevalve (2) setting screw and tighten the locknut.
- Place a 250 kg load evenly distributed on thework platform floor.
- Loosen slowly the setting screw until theplatform starts to tilt rearwards, then tightenthe screw again by 1 turn. Tighten the locknut.
Setting of the counterbalance valve (4b)piston side :
- Loosen the valve setting screw (4b).- Tighten the valve setting screw until it contactsthe valve spring, then tighten the screw by 2turns. Tighten the locknut.
Setting of the counterbalance valve (2) :
- Tighten the setting screw and the locknut untilthe screw juts out over the locknut by 2mm.
- Lower the jib. Position the speed adjustmentpotentiometer for the structure movements onmaximum speed ( ).
- With one person only in the platform, performa trim correction movement towards the rear.
- The platform must recline to the rear and thejib not rise. Otherwise, loosen the setting screwby 1/8 turn.
47 Models
Revision 03-2012Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.17 Sequence valve
FUNCTION : Authorizes the counterbalance valve on thejib cylinder (jib lowering) to be piloted only once thenecessary pressure in the chambers of the slave andassistance cylinders has been reached (necessarypressure to keep the work platform with its loadhorizontal during the jib lowering movement).Decompression of the counterbalance valve pilotcircuit is performed through the check valveincorporated to the valve.
Control of the sequence valve setting
- Connect a pressure gauge on the pressure plug"M" on the function manifold (see § 3.4).
- Fully raise the jib, telescope retracted.- Position the speed adjustment potentiometeron minimum and lower the jib. The jib shouldstart to lower only when a pressure of 12 ± 0,5MPa (120 ± 5 bar) is reached.
3.18 Slewing hydraulic motor
1. Hydraulic motor 32 cc/rev.2. Pressure relief valve [PR9] (slewing to the right)3. Pressure relief valve [PR10] (slewing to the left)
Pressure relief valves setting : see § 3.19.
1
2
ModelsRevision 03-201248
Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.19 Pressure relief valves
The pressure relief valves are used to protect thehydraulic system against excessive pressures (withinthe circuit in which they are used) by returning thehydraulic oil to the reservoir when the setting pressureis reached.
NOTEAdjustement of a pressure relief valve settingshould only be performed by qualifiedmechanics using the correct equipment - onlyafter the need for adjustment has beenestablished.
The table titled Relief Valve Pressure Settings listsmain and circuit relief valve pressure settings. If thepressure setting of any relief valve is not ± 5 bars ofthe setting listed in the table, adjust valve as necessary(unless otherwise specified).
Identification of the pressure relief valves on thefunction manifold : see § 3.4.Identification of the pressure relief valves on thebrake manifold : see § 3.6.Identification of the pressure relief valves on thesteering manifold : see § 3.11.Identification of the pressure relief valves for theslewing movement : see § 3.18.
For the adjustment of the pressure reliefvalves, the movements must be performedat MAXIMUM SPEED.
NOTEFor a correct verification of a relief pressure,the locknut of the relief valve adjustmentscrew must be tightened.To adjust a pressure relief valve, turn theadjustment screw until the correct setting isreached (tighten to increase the pressure).
Preparation
Before performing any adjustment on relief valves,warm the oil between 25°C and 50°C.Use a pressure gauge from 0 to 40,0 MPa (400 bar)to adjust pressure relief valves. For pressures below3 MPa (30 bar), use a pressure gauge from 0 to 6MPa (60 bar).
! CAUTION
Function Opening pressure Pressure relief valve Check at port "M" onGeneral pressure 23 Mpa (230 bar) PR1 Function manifoldTelescope extension 15 Mpa (150 bar) PR2 Function manifoldTelescope retraction 18 Mpa (180 bar) PR3 Function manifoldMast elevation 18 Mpa (180 bar) PR4 Function manifoldJib elevation 16 Mpa (160 bar) PR5 Function manifoldJib lowering 18 Mpa (180 bar) PR6 Function manifold
Brake piloting max pressure35 bar
Max. peak pressurePR7 Brake manifold
Drive at low speed 11 Mpa (110 bar) PR8 Function manifoldSlewing to the left 11 Mpa (110 bar) PR9 Function manifoldSlewing to the right 11 Mpa (110 bar) PR10 Function manifoldTrim correction 18 Mpa (180 bar) PR11 Trim correction manifoldSteering to the right 14 Mpa (140 bar) PR12 Function manifoldSteering to the left 14 Mpa (140 bar) PR13 Function manifold
PRESSURE RELIEF VALVE SETTINGS T1210 - T1310
49 Models
Revision 03-2012Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.19.2.2. Telescope extension [PR2]
1- Connect the pressure gauge to the pressureplug "M" on the FUNCTION MANIFOLD.
2- EXTEND THE TELESCOPE until the cylinderis at the end of its course. Adjust the pressurerelief valve setting if necessary.
3- Disconnect the pressure gauge.
3.19.2.3. Telescope retraction [PR3]
1- Connect the pressure gauge to the pressureplug "M" on the FUNCTION MANIFOLD.
2- RETRACT THE TELESCOPE until the cylinderis at the end of its course. Adjust the pressurerelief valve setting if necessary.
3- Disconnect the pressure gauge.
3.19.2.4. Mast elevation [PR4]
1- Connect the pressure gauge to the pressureplug "M" on the FUNCTION MANIFOLD.
2- RAISE THE MAST until the mast cylinder is atthe end of its course. Adjust the pressure reliefvalve setting if necessary.
3- Disconnect the pressure gauge.
3.19.2.5. Jib elevation [PR5]
1- Connect the pressure gauge to the pressureplug "M" on the FUNCTION MANIFOLD.
2- RAISE THE JIB until the jib cylinder is at theend of its course. Adjust the pressure relief valvesetting if necessary.
3- Disconnect the pressure gauge.
3.19.2.6. Jib lowering [PR6]
1- Connect the pressure gauge to the pressureplug "M" on the FUNCTION MANIFOLD.
2- LOWER THE JIB until the jib cylinder is atthe end of its course. Adjust the pressure reliefvalve setting if necessary.
3- Disconnect the pressure gauge.
3.19.1. Brake release circuit pressurecheck
1- Chock both front wheels as indicated below :
2- Connect the pressure gauge to the pressureplug "M" on the BRAKE MANIFOLD;
3- Position the DRIVE SPEED selector to ( ).4- Actuate a FORWARD drive movement by
pushing the joystick forward. If the pressureindicated by the pressure gauge is not between15 and 21 bar, refer to BRAKE RELEASEMAXIMUM PRESSURE § 3.19.2.7. If themaximum pressure is higher than 21 bar,consult your local JLG distributor.
5- Disconnect the pressure gauge.
3.19.2. Pressure relief valve setting
Setting values : See table § 3.19.
3.19.2.1. Main pressure [PR1]
1- Chock both rear wheels as indicated below :
2- Connect the pressure gauge to the pressureplug "M" on the FUNCTION MANIFOLD.
3- Position the DRIVE SPEED selector to ( ).4- Actuate a REVERSE DRIVE movement by
pulling the joystick rearwards. Adjust thepressure relief valve setting if necessary.
5- Disconnect the pressure gauge.
ModelsRevision 03-201250
Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.19.2.8 Drive at low speed [PR8]
1- Chock both wheels as indicated below :
2- Connect the pressure gauge to the pressureplug "M" on the FUNCTION MANIFOLD.
3- Position the speed selector to ( ).4- Push the joystick forward to actuate a
FORWARD DRIVE movement. Adjust thepressure relief valve setting if necessary.
5- Disconnect the pressure gauge.
3.19.2.9 Slewing to the left [PR9]
1- Connect the pressure gauge to the pressureplug "M" on the FUNCTION MANIFOLD.
2- SLEW fully the structure to the LEFT. Adjustthe pressure relief valve setting if necessary.
3- Disconnect the pressure gauge.
3.19.2.10 Slewing to the right [PR10]
1- Connect the pressure gauge to the pressureplug "M" on the FUNCTION MANIFOLD.
2- SLEW fully the structure to the RIGHT. Adjustthe pressure relief valve setting if necessary.
3- Disconnect the pressure gauge.
! CAUTION
3.19.2.7. Brake release maximum pressure[PR7]
1- Chock both wheels as indicated below :
2- Disconnect and cap the brake supply hoses(see §3.10).
3- Connect a pressure gauge to the pressure plug"M" on the BRAKE MANIFOLD.
4- TIGHTEN FULLY the setting screw for thepressure relief valve [PR7].
5- Position the DRIVE SPEED selector on ( ).6- Push the joystick forward to actuate a
FORWARD DRIVE movement. The maximumpressure reading on the pressure gauge mustbe between 15 and 21 bar corresponding tothe setting of the pressure reducing valve.Record the exact value indicated by thepressure gauge.
If the pressure is below 15 bar or higher than21 bar, consult your JLG distributor.
7- LOOSEN the setting screw on the pressurerelief valve [PR7] until the pressure drops justunder the value recorded previously, thenTIGHTEN the setting screw by ¼ turn.
8- Remove the pump handle and push the lever ofthe release control valve to the released position
.9- Insert the handle in the hand pump and actuate
the handle vigorously. Note the pressure peakon the pressure gauge. If the pressure peakexceeds 35 bars, loosen the setting screw onthe pressure relief valve PR7 by 1/8 of a turnand check the pressure peak again.
10- Disconnect the pressure gauge.11- Reconnect the brake supply hoses.
Maximum brake supply pressure = 30 bar.Maximum admissible pressure peak duringuse of the hand pump to release the brakes= 35 bar.
! CAUTION
51 Models
Revision 03-2012Toucan 1210Toucan 1310
HYDRAULIC SYSTEM 33
3.19.2.11. Trim correction [PR11]
1- Connect the pressure gauge to the pressureplug "M" on the trim correction manifold.
2- Fully raise the jib.3- Fully tighten the pressure relief valve, [PR5] on
the function manifold.4- Disconnect the [EVI] solenoid connector on
the trim correction manifold (see § 3.14).5- Connect a direct 24 VDC supply to the coil
[EVI].
Connect a direct supply to [EVI] only whenthe jib is at the end of its high course andwhen no movement is performed.
6- Control a JIB ELEVATION movement. Adjustthe pressure relief valve setting if necessary.
Do not control any other movement than thejib elevation movement as long as the coil[EVI] is supplied directly and only when thejib is at the end of its high course.
7- Disconnect the direct supply from the coil andreconnect the connector to the solenoid.
8- Adjust the relief valve [PR5] : see § 3.19.2.5.9- Disconnect the pressure gauge.
DANGER
DANGER
3.19.2.12. Left steering
1- Connect the pressure gauge to the pressureplug "M" on the function manifold.
2- STEER the wheels fully to the LEFT. Adjustthe pressure relief valve in necessary.
3- Disconnect the pressure gauge.
3.19.2.13. Right steering
1- Connect the pressure gauge to the pressureplug "M" on the function manifold.
2- STEER the wheels fully to the RIGHT. Adjustthe pressure relief valve in necessary.
3- Disconnect the pressure gauge.
ModelsRevision 03-201252
Toucan 1210Toucan 1310
This page intentionally left blank.
53 Models
Revision 03-2012Toucan 1210Toucan 1310
ELECTRICAL SYSTEM 44
4.1 Wiring diagrams
4.1.1. Battery wiring
Filli
ng h
ose
Filli
ng h
ose
Bat
tery
cab
leL=
1500
-
FULMEN
L=15
00
+
Bat
tery
cab
le
Bat
tery
cab
leL=
1500
L=40
00
L=15
00
+-
Bat
tery
cab
le
FULMEN
-+L=
2000
Left
side
bat
tery
pac
k
Front battery pack
Flow
Indi
cato
r
Filte
rRight Side battery pack
Battery plug
ModelsRevision 03-201254
Toucan 1210Toucan 1310
ELECTRICAL SYSTEM 44
4.1.2 Power circuit wiring
PC0338
55 Models
Revision 03-2012Toucan 1210Toucan 1310
ELECTRICAL SYSTEM 44
4.1.3 Components locationLinked to the platform control box Toucan 1210 and Toucan 1310
Foot
sw
itch
Péda
le
Dév
iate
ur 7
voi
es7-
way
val
ve
EVRCR
52 CR
53
CR
51B
oîtie
r de
com
man
de
UC
B plat
e-fo
rme
T131
0
LCB
- B
oîtie
r de
com
man
de b
as
LCB
- B
oîtie
r de
com
man
de b
as
CR
1C
R2
CR
14
SW
1
CR
9
SW 2
Cap
teur
téle
scop
eTé
leco
pe s
witc
h
Cap
teur
bra
s fd
cJi
b sw
itch SW
3C
apte
ur b
ras
Jib
switc
h
SW 5
Cap
teur
mât
Mas
t sw
itchS
W 4
Blo
c in
clin
aiso
nIn
clin
atio
n m
anifo
ld
CR
8
PC
023
8
PC
024
0
PC 0
260
PC 0
252
PC
026
1
ModelsRevision 03-201256
Toucan 1210Toucan 1310
CR
30
Cha
rger
M3
Cha
rgeu
r
Aux
1nc
cno
Rem
plis
sage
bat
tery
Bat
tery
filli
ng u
nit
Con
trolle
r
B-
Varia
teur
SW
34SW
35
SW36
Flas
hing
ligt
hsLa
mpe
s cl
igno
tant
es
CR
60C
R58
CR
54
CR
55
CR
57C
R56
CR
27
CR
24
LCB
- P
oste
de
seco
urs
CR
26
-+
CO
N1
CR
16
CR
18C
R17
UC
B -
Boî
tier d
e co
mm
ande
pla
te-fo
rme
Cha
ssis
Box
- B
oîtie
r cha
ssis
UC
B -
Boî
tier d
e co
mm
ande
pla
te-fo
rme
Con
trolle
r 17
pins
con
nect
orS
lack
cha
in d
etec
tion
swC
apte
urs
mou
de
chaî
ne
CR
25
Cap
teur
de
défo
rmat
ion
Stra
in li
nk
Hor
nA
verti
sseu
r
+
+ - Tou
can
1210
13
2
6
45 10
Linked to the emergency control panel Toucan 1210
ELECTRICAL SYSTEM 44
57 Models
Revision 03-2012Toucan 1210Toucan 1310
+
+
M3
KM
1-
+-
CR
56
Aux
1
Chargeur HF nccHF Charger
no
Ave
rtiss
eur
Hor
n
Feux
à é
clat
sFl
ashi
ng li
gths
SW
36C
ontro
ller 1
7 pi
ns c
onne
ctor
CR
55
CR
54
CR
58
Varia
teur
Con
trolle
r
Cap
teur
s m
ou d
e ch
aîne
Cha
in s
lack
det
ectio
n sw
CR
60
SW
35
CR
17C
R18
Rem
plis
sage
bat
tery
CR
25
CR
26
LCB
- Boî
tier d
e co
mm
ande
bas
CR
24
CR
27
CR
16
B-
SW
34
UC
B - B
oîtie
r de
com
man
de p
late
-form
e
Cha
ssis
éle
ctric
al c
onne
ctio
n bo
x
UC
B - B
oîtie
r de
com
man
de p
late
-form
e
CR
57
Stra
in li
nkC
apte
ur d
e dé
form
atio
n
Chargeur BFLF Charger
SW37
Boîti
er c
onne
xion
s ch
assi
s
CR
63
CR
30CR
19
Batte
ry fi
lling
unit C
R62
Linked to the emergency control panel Toucan 1310
ELECTRICAL SYSTEM 44
ModelsRevision 03-201258
Toucan 1210Toucan 1310
Linked to the chassis box Toucan 1210
ELECTRICAL SYSTEM 44
DG
CR
19
LCB
- P
oste
de
seco
urs
CR
59
SW38
DLC
K
EVF
EVC
MA
R
MA
V
KM2
Tilt
sens
orD
etec
teur
de
déve
rs
Driv
e m
anifo
ldB
loc
trans
latio
n
Blo
c bl
ocag
e di
ffére
ntie
lD
ifflo
ck m
anifo
ld
Bloc
frei
nage
Brak
e m
anifo
ld
Driv
e m
otor
s m
anifo
ld
HI/L
OD
V2
Che
ck v
alve
s m
anifo
ldB
loc
clap
ets
Con
tact
eur s
econ
daire
Seco
ndar
y co
ntac
tor
Cha
ssis
Box
Boî
tier c
hass
is
(Opt
ion)
(Opt
ion)
CR
26
DD
DB
DM
RT
OD
MB
MM
STO
GD
V1
+-CR
26
Blo
c di
strib
utio
n m
oteu
rs d
e ro
ues
59 Models
Revision 03-2012Toucan 1210Toucan 1310
Linked to the chassis box Toucan 1310
ELECTRICAL SYSTEM 44
CR
32CR
33
CR
31
CR
35
CR
36
DD
Driv
e m
anifo
ld
SW39
OD
Blo
c tra
nsla
tion
SW40
DM
DB
RT
CR
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CR
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ModelsRevision 03-201260
Toucan 1210Toucan 1310
4.2. Sensors
4.2.1 Mast position switch [SW4]
When the telescopic mast leaves its lowered position,the switch is actuated and provides :
- Supply cut (+) to the coil [HI/LO] of thedistribution manifold for the wheel motors.
- Supply cut (+) to the coil [EVC] of the brakemanifold.
- Actuation of the selective cut of movementswhen the aerial work platform is tilting (See §4.1.6).
- The automatic switch to slow drive speed(parameter "Test 3" on controller =CL when adrive movement is controlled - see § 4.5).
4.2.2. Jib lower position switch [SW5]
When the jib is raised, the switch is actuated andcauses :
- The supply cut (+) to the coil [HI/LO] of thedistribution manifold for the wheel motors.
- The supply cut (+) to the coil [EVC] of the brakemanifold.
- Actuation of the selective cut of movementswhen the aerial work platform is tilting (See §4.2.6).
- The automatic switch to slow drive speed(parameter "Test 3" on controller =CL when adrive movement is controlled - see § 4.5).
ELECTRICAL SYSTEM 44
4.2.3. Telescope position switch [SW2]
When the telescope is extended, the switch isactuated and causes :
- The supply cut (+) to the coil [HI/LO] of thedistribution manifold for the wheel motors.
- The supply cut (+) to the coil [EVC] of the brakemanifold.
- Actuation of the selective cut of movementswhen the aerial work platform is tilting (See §4.2.6).
- The automatic switch to slow drive speed(parameter "Test 3" on controller =CL when adrive movement is controlled - see § 4.5).
Jib lower position switch
61 Models
Revision 03-2012Toucan 1210Toucan 1310
ELECTRICAL SYSTEM 44
4.2.4. Jib higher position switch [SW3]
During an elevation movement of the jib, the switch isactuated before the jib reaches the end of its highercourse and causes a reduction in the speed of themovement (Reduction of the acceleration inputdelivered to the controller). When the switch has beenactuated, and a jib lowering movement is controlled,it will be performed also at low speed till the switch isreleased.
Jib higher position switch
4.2.5. Slack chain sensors [SW34 to 37]
The 4 slack chain sensors are wired in series. Whena slack chain appears, one (or several) sensor isactuated and causes :
- Actuation of an alarm.- Cut off all movements except jib and mastraising movements :
- Supply cut (+) to the coil [DV1] on thefunction manifold.
- Actuation of the "Pump Inhibit" function ofthe controller when a non authorizedmovement is controlled (parameter "Test 10of the controller = CL - see § 4.5).
ModelsRevision 03-201262
Toucan 1210Toucan 1310
ELECTRICAL SYSTEM 44
4.2.6. Control-Adjustment of the tiltindicator
Control :
Ensure the detector rests correctly on the supportcapnuts.
1- Position the control panel selector on ( ).2- Chock the rear wheels.3- Place a spirit level (digital display) on the
chassis in the direction (1) - (2).4- Using a jack of sufficient capacity, lift the front
of the chassis in (1) :ç Stop as soon as the green light indicator
on the sensor switches off (jerks linked tothe manoeuvre stopped). Read the chassisangle : value (a).
5- Chock the front wheels.6- Using a jack of sufficient capacity, lift the rear
of the chassis in (2).ç Stop upon extinction of the indicator: value (b).
7- Place the spirit level on the chassis in thedirection (3) - (4) .
8- Using a jack of sufficient capacity, lift the righthand side of the chassis in (3).ç Stop upon extinction of the indicator: value
(c).9- Using a jack of sufficient capacity, lift the left
hand side of the chassis in (4) .ç Stop upon extinction of the indicator: value
(d).
PB1 : Tilt indicator to replace.PB2 : Tilt indicator to replace.PB3 : Adjust
Adjustment:
- Position the machine with chassis horizontalin all directions (1) (2) & (3) (4) (Blocks underthe wheels) : installation tolerance : ± 0,1°.
- Remove the protection on the calibraion wire.Link the latter to the - on the battery until thedetector green indicator flashes.ç The detector is set. Install the protection.
NOTEIf a symetry fault is corrected, the setting mustbe checked again in both directions beforethe machine is returned to service.
1
2
34
Spirit level
Niveauélectronique
Recordings Values admitted Otherwise see
a + b (c+d) ± 0.2° PB1a + bc + d
abcd
3.6° to 4.4° PB2
1.8 to 2.2° PB3
63 Models
Revision 03-2012Toucan 1210Toucan 1310
ELECTRICAL SYSTEM 44
4.2.7. Strain link (Stability control device)
The factors acting upon the work platform stability(tilt, overload, wind, outside forces....) induce in thestructure mechanical stresses that are expressed byan elastic deformation measured by theextensiometric sensor. The sensor output signal istreated by an electronic box equipped with a relayoutput that opens the circuit when the signal reachesa predetermined value. Opening of the circuit causes:
- Actuation of an alarm.- Reduction in speed of the mast and jib elevationmovements (parameter Test 4 of the controller= CL - see § 4.5).
- The cut off of the following movements :- drive- slewing- telescope extension- jib lowering as long as the telescope isnot retracted [SW2]
Movement cut off is obtained by :
- Supply cut (+) to the coil [DV1] on the functionmanifold.
- Actuation of the "Pump Inhibit" function of thecontroller when a non authorized movement incontrolled (p
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