-
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
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3 Models
Revision 03-2012Toucan 1210Toucan 1310
MA0295-04
ModelsEnglish
MACHINE SERIAL NUMBER :
Toucan 1210 _____Toucan 1310 _____
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ModelsRevision 03-20124
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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7 Models
Revision 03-2012Toucan 1210Toucan 1310
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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Toucan 1210Toucan 1310
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 :
[email protected]
C.E :
JLG Industries,Kilmartin Place,Tannochside
ParkUddingston,Scotland G71 5PHTel : +44(0)1698 811005Fax :
+44(0)1698 811055Email : [email protected]
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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)
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________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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This page intentionally left blank.
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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Toucan 1210Toucan 1310
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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15 Models
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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
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ModelsRevision 03-201216
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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
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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
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- 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
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19 Models
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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
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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
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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
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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
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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
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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
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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
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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
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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 :
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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]
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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
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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
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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
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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)
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ModelsRevision 03-201234
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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)
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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
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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
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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
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ModelsRevision 03-201242
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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
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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
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ModelsRevision 03-201244
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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
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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
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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
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ModelsRevision 03-201248
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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
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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.
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ModelsRevision 03-201250
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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
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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.
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53 Models
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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
61
CR
64
Det
ecte
ur d
e dé
vers
Tilt
sens
or
CR
59
LCB
- Boî
tier d
e co
mm
ande
bas
DG
MM
MB
STD
V1
OG
EVF
DLC
K
Diff
lock
man
ifold
Seco
ndar
y co
ntac
tor
Con
tact
eur s
econ
daire
DV2KM
2
SW38
SW
41 MAV
MA
R
Blo
c cl
apet
sC
heck
val
ves
man
ifold
HI/L
OS
teer
man
ifold
Blo
c di
rect
ion
Bloc
dis
tribu
tion
mot
eurs
de
roue
sD
rive
mot
ors
dist
ribut
ion
man
ifold
K14
K15
SW
42
CR
34
Bloc
blo
cage
diff
éren
tiel
Brak
e m
anifo
ldBl
oc fr
eina
ge
EVC
-
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