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SERVICE MANUAL

1. a F 20 1041 NOA aen i AE ree pier RUNDE Adan 91 GROVE V1331E Models Revision 07 2002 1 7 Wiring diagrams Upper control box PC0180 03 SCHEMATICS Il 7
2. LOWER CONTROL BOX BOITIER BAS 535 CRIOU 1 TILT SENSOR RELAY RELAIS DEVERS bisi m o 43 r 445 CR11 15 43 51 36 _ 1 1 Ser en cRE 2 4 a EE 912 24 25 17 4 11 Kos E CR6 15 011 lt gt W ab 2 1 2 cRe 18 4 6 24 p CR6 17 gt y 8 cr10 3 CRE 18 OL ___ wa 1 f m 1 CR10 16 CRE 4 J 4 4 L du EMERGENCY STOP FUSE 5A gt CR11 16 i ARU FUSIBLE cra s 5 36 T 35 39 qa 54 34 eset CR7 5 r2 361 gt 36 27 T L CR cne 2 3 33 GR11 17 KEY SWITCH CLE DE CONTACT CR6 6 6 L CRAB 5 5 37 6 LIFT QOWI 1 BRAKE RELEASE AT fee DEBLOCAGE FREIN CR7 2 214 AD 0 27 ope 456 1 37 1 5 3 44 ras 516 Lo pts 42 pa 39 asl gt N B CR amp 7 CONTROL 217 COMMANDE MUTEURS CRe 5 EN E sa m 9 J 9 Lom dero 7 10 10 asl 43 fom 20 en 1225 CRO SSL erate 45 ms 2 163156 EN 56 17 _ _ 21 46 11 BATTERY DATAS gar 57425198 eu _ INDICATIONS BATTERIE Copt 6 13 15 58_ 88 5 _ 684 10 9
3. UPPER CONTROL BOX BOITIER HAUT 1 MAST RAISING Mila 23 11 112 24 B 50 f 61 1 51 A cga 1 ERS AFFICHAGE E 1 5 CR2 2 i n 2 Jors 2 f u ena 1 1 5 CRA13 5 x i 8 14 fa i 92 2 Per 1 f B 28 29 gern 41594 Y 1 04 1 231 0 13 Jersts OR ayy pee HORN 28 1 E 1 KLAXGN IN T 4 2212421 224 PE i M Wet x PIA 3 EMERGENCY STOP LER 5 A R U HAUT 6242 22 22 T amp lt 8 Jersts EDNNECTEUR CRS j i VERS BOMER BAS l pce EE 1 1 11 s i 1 MANIPLLATEUR cria 2 lt ly EW z lers jensta erst10 11 e 12 68912 lt Lana y E _14 1 44 64 21 12 1 1 1 f 1 1 14 CR2 9 lt al x 1 2 92 CR3 2 CONNECTEUR CRX 3 CR3 4 Bx 1 mm2 VERS CAPTEUR GROVE C Models Revision 07 2002 1 7 Lower controlboxPC0179 03 SCHEMATICS Il 7
4. 44 4 EN 8 Position the mast as indicated below by sliding the top mast sections towards the top of the mast assembly Remove the retaining rings pins securing the chain clevis to the chain equalizer the chain clevis and the chain equalizer fromthe grayed mast section section n 2 U 4 laa EN gt 9 Position the mast assembly as indicated figure 3 3 by sliding the mast sections one by one towards the bottom of the mast assembly Models Revision 07 2002 V1331E GROVE Position the mast assembly and place plastic blocks 3mm thick as indicated above Pull the chains connected to the grayed mast section section n 1 Remove the pulley pin see fig 3 4 fromthe grayed mast section section n 1 Remove the cotter pins and clevis pins securing the chains to the chain clevis and remove the chains Position the assembly as indicated on fig 3 3 Remove the plastic blocks Pulleys Pulley Fig 3 4 53 Il 3 TELESCOPIC MAST Il 3 3 7 Lifting chains installation Before installing a lifting chain check the condition of each link chain link appears to be faulty replace both chains on the mast section with new chains Before installing the lifting chains check the condition of all pulleys and of all pins Check th
5. Mast Cylinder Ne Cylinder Cylinder Ne support plate bracket Fig 3 1 NS Two persons are recommended to handle the cylinder 3 3 Mast cylinder installation 1 Ensure the cylinder support plate is on the cylinder as indicated on fig 3 1 2 Position the cylinder and cylinder brackets assembly on the mast 3 Turn the cylinder barrel to position the cylinder bleeder screw in front of hole on mast section n 2 4 Secure the cylinder brackets to mast section n 1 with bolts and washers 5 Ensure the cylinder is secured properly to the brackets with its bolts Models 50 GROVE V1331E Revision 07 2002 Il 3 TELESCOPIC MAST 1 3 3 4 Slide blocks removal The slide blocks are fitted to the mast sections and slide on the inside wall of the adjacent mast section NOTE is recommended to replace all the slide blocks at the same time The slide blocks fitted on both sides of a mast section are secured by nuts turning automatically to their lock unlock position when screwing unscrewing When removing one of these slide blocks loosen the bolts without removing them fully Slide block We PE Models Revision 07 2002 Removal procedure 1 Remove the mast assembly from the chassis see concerned paragraph 2 Position the mast sections as represented below 3 Totally unscrew the nuts s
6. CRB 6 a i quer 59 CRR 59 10 CRR 7 60 m Lir lt ES cRIQ 11 Ia al ol gl Lal 323338734 _ A 28 3 8 4 203 4 3 _ _ _ _ 88 688 885865 SE 8 9 9 e amp eee a a a a a a 2 n a a L ME 2 u o e a G 0 q EX o o e C Models V1331E Revision 07 2002 GROVE 93 Il 7 SOHOUMS INES 1431 _ HONORI OWLS SHIS DNAS 98 _ 103 19A lt ar TOYINOI SCHEMATICS Control wiring 0173 00 1 7 oy 33M01 o gt ley Sra _ 9 fei 5 is m HOLAS LEWN 3 C um lt lt 1091405 H3ddn C Models Revision 07 2002 V1331E GROVE 94 1 7 1 7 SCHEMATICS Control wiring 0174 02 Power unit Steerin
7. When installing the reducer torque the 8 nuts washers at 23 N m 17 Ibf ft tightening with torque wrench NOTE Each time the reducer is disassembled replace the paper seal with a new seal in perfect condition Each time the reducer is disassembled apply the quantity of grease prescribed refer to chapter and Operator s and Safety Handbook on bearings and the inside diameters Models Revision 07 2002 GROVE 61 11 4 1 Remove the motor reducer flange assembly fromthe chassis ofthe machine see paragraph 2 Remove the motor brake see concerned paragraph 3 Mark the motor body position in relation to the rear flange and in relationto the reducer flange mark with 2 lines going over both parts as represented below 4 Remove the 4 nuts washers and remove the rear flange as represented below 5 Remove the body of the motor by exercising an effort F as indicated below sufficient to overcome the effort of the magnet of the motor During motor assembly ensure the washer located between the motor bearing and the rear flange is present and has been correctly installed During motor assembly ensure the body of the motor is returned to its original position in relation to the rear flange and the reducer flange 62 GROVE DRIVE AND STEER SYSTEM 4 7 Removal Installation of the wheel motor 11 4 4 8 Removal Ins
8. Models Revision 07 2002 1 3 TELESCOPIC MAST 1 3 4 On left hand side of the mast remove the electrical cables fromtheir pulleys 10 Removal of the chains attached to mast section n 2 NOTE L U During removal always start by the top mast ad section and continue in succession U cj c Fig 3 3 WIN 5 Totally unscrew the locknuts from the 2 chain equalizers see fig 3 2 6 Remove the chain equalizer bracket from mast section n 4 7 Position the mast as indicated below by sliding the top mast section towards the top of the mast assembly Remove the retaining rings pins securing the la En EN Position the mastassembly and place plastic blocks 3mm thick as indicated below Pull the chains connectedto the grayed mast section section n 2 Remove the pulley pin see fig 3 4 fromthe grayed mast section section n 2 Remove the cotter pins and the clevis pins securing the chains to the chain clevis and remove the chains Position the assembly as indicated on fig 3 3 Remove the plastic blocks 11 Removal of chains attached to mast section 1 U chain clevis to the chain equalizer the chain clevis and the chain equalizer from the grayed mast section section n 3
9. GROVE 45 46 This page intentionally left blank GROVE V1331E Models Revision 07 2002 CHAPTER il 3 TELESCOPIC MAST Model 1331 GROVE 47 Il 3 TELESCOPIC MAST 1 3 3 1 Lifting chain inspection maintenance Inspect thoroughly each chain in turn over its entire length Chains chain yokes clevis pins and split pins must not be corroded Plate must not be cracked 0 Cracked plate The plate clevis pins must not present excessive play The pins must not be turned in their housing 1 en E M x gt ad 2 a Plates must not present a wear above 5 of the total height refer to chart below a ee ee 5 Chain stretching cannot be superior to the values indicated in the chart below 5 8 15 875 mm 6 437 163 5 mm Pitch L 10 Pitches If a chain appears to be faulty or worn both chains of the same stage must be replaced together the condition of the pulleys and the telescopic mast alignment must be checked C Models Revision 07 2002 V1331E N CAUTION Do not use grease to lubricate the lifting chains Do not remove lubricant applied atthe factory from the chains Do not use acid or detergent to clean the lifting chains Do not pressure wash them Lubrication of the lifting chains can be performed manually
10. If it does occur flush the contacted area with water and consulta doctor immediately Appropriate equipment must be worn gloves goggles rubber apron to prevent electrolyte from contacting the skin or any other part of the body during any servicing operation on the battery New electric vehicle batteries do not have their full capacity until they have been cycled several times somewhere between 5 and 40 cycles Therefore they can be excessively discharged early in their vehicle life thereby shortening their service life Accordingly it is advisable to limit operation of new vehicles or older vehicles with new batteries to well below their advertised range for at least the first five cycles and then gradually increase the range Continuous operation of vehicle with low battery voltage may result in damage to electric motor pump 78 GROVE Battery cleaning amp maintenance During maintenance or any servicing operation on the battery rings watches or any other metallic jewelry must be removed Failure to do so could cause death or serious injury to personnel Itis necessary to clean battery regularly to prevent salt formation and current arcing which could damage the machine Clean battery top with a damp cloth Allow to dry and wipe the battery top with a dry non fluffy rag Ensure the connections are clean and correctly tightened NOTE Coat terminals and connections with an
11. maintaining Before any maintenance onthe work platform you mustread and understand the operating and safety procedures described in the corresponding Operator s and Safety Handbook To perform the procedures described in this manual a basic knowledge in mechanics hydraulics and electricity is necessary Certain procedures require specific competencies tooling andhandling equipment We therefore recommendthat these repair and adjustment procedures are carried out only by authorized and qualified personnel Constantimprovement make itnecessary that GROVE reserve the right to make specification and equipment changes without notice If youhave any questions on operating maintenance procedures contact your authorized GROVE MANLIFT distributor Model den on V1331E GROVE INTRODUCTION Prior to any maintenance or repair procedure it is necessary to Read and understand operating and safety procedures in this manualand inthe Operator s and Safety Handbook m Readeach procedure inthis manual to the end before applying it to the machine m Ensure you have the appropriate tools and equipment necessary for the repair or maintenance to be performed Have all replacement parts ready to performthe repair Workin a clean spacious and well lit area Wear all protection equipment glasses gloves appropriate for the operation to be performed Place the work platform in the following config
12. value of 0 2 mm 0 008 Air gap adjustment See drawing on fig 4 2 Loosen the 3 screws by about 2 turns Turn slightly the 3 threaded sleeve using a spanner When the air gap is too important value higher than 0 5 mm 0 02 screw the threaded sleeve into the stator When the air gap is too small value lower than 0 2 mm 0 008 screw the threaded sleeve out of the stator 1 turn reduces the air gap by about 0 9 mm 0 035 Torque eachone of the 3 screws to 2 8 N m 2 Ibf ft using a torque wrench Check the air gap again near each of the 3 screws 2 If necessary repeat the adjustment procedure Socket head screw Torque wrench Armature plate Stator Threaded sleeve Feeler gauge 4 6 Removal Installation of the reducer on the wheel motor reducer 1 Remove the motor reducer see concerned paragraph 2 Position the motor reducer in such a way the outlet shaft is at the top The motor shaft should not be submitted to any pressure 3 Remove the reducer attachment bolts and open the reducer at the level of the separation seal 4 Remove the cam plate see fig 4 3 Fig 4 3 5 Remove the bearing washer as well as the bearing 6 Remove the eccentric and the bearing When installing the reducer the cam plate must be installed in such a way that the stamped marking is positioned towards the outlet shaft see fig 4 3
13. 6 6 2 Fuses The fuses usedin the work platformelectricalsystem protect the electrical circuit and the electronic cards from an excessive intensity inside the electrical circuit they are used in Power circuit fuses Fuse 63 A F1 It is located on the chassis above the speed controllers It protects the machine s entire electrical circuit Fuse 16 F3 It is located on the chassis next to the power unit It protects the supply circuit to the electrical cylinder Control circuit fuse Quick acting fuse 5 A F2 It is mounted on the emergency control panel facade It protects the entire control circuit Ensure the charger plug and battery cables are disconnected before performing any maintenance on a fuse Failure to do so may result in death or serious injuries GROVE 77 1 6 ELECTRICAL SYSTEM 1 6 6 3 Batteries The electrical energy of the work platformis provided by a 24 VDC battery The battery is composed of 3 similar 8 VDC packs Each pack contains 4 cells 1 cell 2Volts Because of A hydrogen gas allow no open flames or smoking while servicing the batteries Severe arcing or battery explosion may occur if battery cables are disconnected at random When servicing components use insulated tools and always disconnect and connect batteries according to removal and installation procedures outlined in this section Battery electrolyte must not be allowed to contact the skin or eyes
14. 8 Mast cylinder bleeding 1 Raise the mast until the access hole for the bleeder screw located approximately at 230 mm 9 from the top of the second mast section is 200 mm 7 9 above the first mast section 2 Loosen the bleeder screw by approximately half a turn using the long end of a 4 mmAllen key 3 If necessary tighten the bleeder screw during the operation raise the platform and repeat steps 1 and 2 4 The bleeding is complete once the platform stays immobile with the bleeder screw loose Tighten the bleeder screw 5 Clean all parts with a solvent and dry with compressed air Bleeder screw Access hole C Model den on V1331E GROVE 1 3 55 56 This page intentionally left blank GROVE V1331E Models Revision 07 2002 CHAPTER Il 4 DRIVE AND STEER SYSTEM Model 1331 GROVE 11 4 DRIVE AND STEER SYSTEM 1 4 4 1 Removal Installation of driving wheels rear wheels Removal 1 Fully lower the platform 2 Chock the front wheels lengthways 3 Liftthe chassis ofthe platformandplace a block under the rear of the chassis 4 Remove both bolts securing the wheels as indicated below Attachment bolt Installation 1 Coat the wheels attachment bolts with Loctite 222 over the whole thread 2 Ins
15. If excessive wear the probable could be dirt in the fluid oil viscosity too high or too low pressure above pumprated capacity airleakor restriction ininlet line causing cavitation Solutions are as follows a dirt in the fluid check the cause of contamination Clean the filter and repair or replace the worn parts Replace if necessary with a new pump Replace the fluid with fluid of recommended grade b Iffluid viscosity too high ortoo low replace with recommended fluid c If pressure above pump rated capacity check the reliefvalve for proper functioning d If air leak or restriction in the system causing cavitation repairany leakinthe system check the wear of parts and replace if necessary 8 Ifinternal parts are broken the probable causes could be pressure above pump maximum rated capacity failure due to lack of fluid orabrasive contaminants inthe fluid going through the filter Solutions are as follows a If excessive pressure above pump maximum 70 rated capacity check the good workingorder of the parts and repair b Iffailure due to lack of fluid check the fluid level inthe tank andfor any restrictionin the inletline or for any clogged filter c lfabrasive contaminants inthe fluid going through the filter check the fluid inthe reservoir check the inlet line for any restriction and check the cleanliness of the filter GROVE HYDRAULIC SYSTEM 1 5 5 3 Power unit remo
16. bleed the air Refer to 3 8 chapter Il 3 If the oil is heating up the probable causes could be contamination in the relief valve oil too light or dirty relief valve set too high or too low Solutions are as follows a If contaminationin the relief valve remove and clean it b If oil too light or dirty drain and fill with correct oil c If relief valve set too high or too low use a manometer and adjust the pressure Refer to 4 chapter l 4 Iftheoilis foaming the probable causes could be airleakinthe suction line oil type incorrect orlowoillevel Solutions are as follows a Ifairleakinginthe suctionline tightenthe hose clips or change the pump if necessary b Ifincorrectoiltype drain and fill with proper oil c If low oil level correct level 5 Ifthe pump does not deliver fluid no pressure the probable causes could fluidlevelinthe tank too low pump inlet line clogged airleakin pump inlet line dirt in the pump fluid viscosity too high parts worn or damaged inside the pump or fluid returning to the tank Solutions are as follows a If fluid level reservoirtoo low fill with fluid of correct type and grade and check for any external leaks Refer to 8 3 chapter I C Models Revision 07 2002 1 5 b If pump inlet line is clogged remove and clean it Check the filters and tank for any other possible obstruction If air leak in pump inlet li
17. motor reducer flange assembly from the chassis see concerned paragraph 2 Remove the 8 attachment nuts washers and remove the flange D O Bene When installing the motor reducer on the lt gt flange torque the nuts to 23 N m 17 tightening with a torque wrench 60 GROVE WHE 1 Remove the motor reducers See concerned paragraph 2 Loosen evenly the 3 bolts securing the brakes to the rear flange of the motor as indicated on fig 4 1 and remove the brake 3 Remove the friction disk and the brake spacer as indicated below Friction When installing the brake on the rear flange of the motor see fig 4 1 torque the 3 attachment bolts to 2 8 N m 2 Each time the brake is removed the brake setting must be checked and adjusted if necessary see 4 5 Models Revision 07 2002 11 4 DRIVE AND STEER SYSTEM 1 4 4 5 Control of the wheel motor brake adjustment NOTE Before performing any maintenance on the brake ensure the motor is not running and the brake is not powered Disconnect the battery Air gap control See drawing on fig 4 2 Measure the air gap between the armature plate and the stator using a feeler gauge The air gap value must be the same near each of the 3 screws 2 and range between 0 2 and 0 5 mm 0 008 and 0 02 If necessary adjust the air gap to its nominal
18. o 0 and the steering cylinder is not noisy when fully retracted Top sensor Lower sensor lt gt Sensors direction of movement Models 84 GROVE V1331E Revision 07 2002 1 6 ELECTRICAL SYSTEM 6 10 Control Tilt indicator setting NOTE The control and adjustment of the tilt indicator setting can only be performed by a qualified technician trained for the maintenance of the machine x WD a Q Control 1 Position the control panel selector to Emergency control panel and raise the mast by approximately 15 cm 0 5 ft 2 Chock both rear wheels 3 Positionthe control panel selector to Platform control panel 4 Placea spirit level digital display lengthways on the chassis 5 Using a jack of sufficient dimensions lift the front ofthe chassis An acoustic alarm sounds when the chassis reaches an inclination of 2 0 2 The corresponding Led lights up onthe platform control panel 6 Lowerthe jack 7 Chock both front wheels inline with the chassis 8 Using a jack of sufficient dimensions lift the rear ofthe chassis An acoustic alarm sounds when the chassis reaches an inclination of 2 0 2 The corresponding Led lights up onthe platform control panel 9 Lowerthe jack 10 Place a spirit level
19. of a work platform or a complete work platform securely block the work platform and support the weight of the machine on blocks rather than by lifting equipment When using hoisting equipment Follow hoist manufacturer s recommendations Use lifting devices that will allow you to achieve the proper balance of the assemblies being lifted and ensure safe handling Unless otherwise specified all removals requiring hoisting equipment should be accomplished using an adjustable lifting attachment All supporting members chains and cables should be parallel to each other and as near perpendicular as possible to the top of the object being lifted The capacity of an eyebolt diminishes as the angle between the supporting members and the object becomes less than 90 Eyebolts and brackets should never be bent and should only have stress in tension Some removals require the use of lifting fixtures to obtain proper balance If a part resists removal make sure Allnuts and bolts have been removed Adjacent parts are not interfering 2 5 Disassembly and assembly When assembling or disassembling a component or system complete each step in turn Do not partially assemble one part and then start assembling another part Make all adjustments as recommended Always check the job after it is completed to ensure that nothing has been overlooked Recheck various adjustments by operating the machine before
20. pin on the cylinder brackets turning the cylinder barrel if necessary Lockin place with a new retaining ring Ensure the bleeder screw is opposite the access hole on the 2nd mast section 3 Install both bolts and lock washers 4 Remove the cap from the hydraulic hose and connect the hose 5 Connect the connector 6 Install and secure the base on the mast assembly as indicated 2 chapter Il 7 Bleed the air from the cylinder refer to concerned paragraph Check for proper functioning and any leakage Fillthe reservoir with new hydraulic oil to its proper level with the platform fully retracted 5 9 Removal Installation of the manifold The cylinder manifold is located between the front wheels of the machine It includes a pressure relief valve protection against overpressure due to overheating a pressure compensated flow regulator and a manually controlled solenoid valve Before any maintenance on the manifold disconnect the machine from the electrical power supply disconnect the charger plug and ensure the power unit is shut off Failure to comply could result in death or serious injuries GROVE 73 74 This page intentionally left blank GROVE V1331E Models Revision 07 2002 CHAPTER Il 6 ELECTRICAL SYSTEM Model 1331 GROVE 1 6 ELECTRICAL SYSTEM 6 1 General Electrical system maintenance involves replaceme
21. power unit respectingthe torque values indicated below 10 Install the reservoir on the power unit with the clips 11 Install the power unit on the chassis NOTE Pressure relief valve Breather cap and filter Ensurethe breathercapis positioned opposite the solenoid valve Model den 1331 GROVE 1 Secure the power unit on the chassis of the machine 2 Fill the reservoir with new hydraulic oil to the correct level 3 Connect the hydraulic hose and the electrical cables to the power unit as tagged during removal 4 Set the machine to performsome tests raise the platform several times by 2 m 6 5 ft maximum Bleed the cylinder if necessary refer to concerned paragraph 5 Check for proper functioning and any leakage 6 Install the rear cover 71 1 5 HYDRAULIC SYSTEM 1 5 5 6 Mast cylinder disassembly 1 Remove the mast assembly fromthe chassis as indicated 2 chapter 11 2 Remove the mast cylinder as indicated 8 3 2 3 Remove the bolts and washers securing the cylinder to the cylinder brackets see fig 5 1 4 Remove one of the two retaining rings from the cylinder pin and drive the pin out 5 Remove the cylinder and the cylinder plate CAUTION is recommended that 2 people handle the cylinder Cylinder support plate Cylinder bracket Pin Mast cylinder Fig 5 1 NOTE Any main
22. replaced All rust or masking residue must be cleaned from the pin prior to installation Use emery clothas appropriate Bushings and pin When installing a pin proper care must be taken to ensure the bushing and the pin are properly aligned so that the coating on the bushing does not get damaged Inside diameter of bushing MUST be coated with clean grease before pins are installed at any assembly level Pins have a chamfered or rounded end to prevent the teflon coating on the bushing from being damaged during pin installation Chamfered rounded end gt Direction of installation 24 GROVE Bushing installation Bushings must be inserted in their housing with an appropriate driver with a smooth flat end preferably in soft steel The outside diameter of the bushing must be slightly oiled to facilitate assembly Bushing driver and housing must be correctly aligned during assembly Flange bushing driver 0 2 Bush nominal Dia 0 25 mm Flange Outside Dia 0 25 mm Bush height 20 mm H Driver Flanged bushing Housing Installation completed Models V1331E Revision 07 2002 l 2 GENERAL MAINTENANCE l 2 2 10 Bearings As soonas a bearing is removed cover it to keep dirt and abrasive particles out Clean the bearings in a nonflammable solution and allo
23. temperature 33 LUBRICATION V1331E LUBRICATION CHART LOCATION LUBE TYPE LUBE INTERNAL LUBE AMOUNT APPLICATION MOBILUX EP2 1 Mast profiles or MOBILITH SHC 220 Low temperature MOBIL DTE 16M 2 Viscosity 68 cSt at 40 C Lifting chains Viscosity index 142 Pour point 45 C 3 Wheel bearings MOBILUX 2 non drive Lithium base grease hubs 4 13 Main hydraulic Viscosity index 155 reservoir Pour point 48 C 5 MOBILUX EP2 Steering bar Lithium base grease 6 Bearing on rear wheel motor reducers SHELL Alvania RA 34 Lithium base grease Viscosity 32 cSt at 40 C Every 125 hours of operation or after each cleaning or more often if the work platform is used or stored in a very dusty or corrosive environment Every 125 hours or once every 30 days of operation or more often if the platform is used or stored in a very dusty or corrosive environment Every 250 hours of operation Check daily Drain after 1000 51 hours of operation or at 1 3 gallons least every 2 years Every 250 hours of operation Every 250 hours of operation GROVE 1 Clean the inside wall of mast to remove the old grease 2 Lubricate the mast as indicated 3 Cycle the mast and relubricate Lubricant can be applied manually with a brush or by spraying Apply lubricant Longitudinally in areas where joints are under small load t
24. the 1 2 Platform removal forklift truck or the overheadcrane as indicated below N CAUTION Ensure the electrical cables do not get mM pinched or crushed during platform removal RK 1 Unscrew the 8 platform attachment bolts on the last mast section Direction 1 59 94 4 2 bolts to unscrew Sy 5 ih h overheadcraneas perdirection2 asindicated below us 4 Remove the platform withthe forklift truck orthe Direction 2 The platform can fallifnot correctly supported The platform mustbe unoccupied and empty during this procedure 2 Support the platform with s forklift truck or an Zu overhead crane IN CAUTION without lifting it i Ensure joystick upper control box FR does not get damaged during platform prevent damage to oval the platform N 77 IT 1 C Models 42 GROVE V1331E Revision 07 2002 CHAPTER Il 2 MAST ON CHASSIS Model 1331 GROVE 1 2 MAST ON CHASSIS 1 2 The platform must fully lowered before removing the mast assembly from the chassis 1 Ensure the mast is fully lowered depress both emergency stop switc
25. the fitting to the terminal block assembly then install the gland Lock the bent gland if fitted Push the cable inside the connector and tighten the gland nut Orientation of the mating keys if the connector is fitted with a bent gland Dummy studs Mating keys Polarization keys GROVE 87 1 6 ELECTRICAL SYSTEM 1 6 6 12 Connectors and cables from lower control box UCB connector 18 conductors core section 0 75 mm E Y Hooo Jat ame N MC 09 e a b O ROWE AU13B6 ARS 2 18 conductors 18 conductors core section 0 75 mm core section 0 75 mm Charger L Sevcon motors controllers Power unit Motors brakes Tilt indicator Motors relay Steering cylinder relay Motion alarm Steering limit switches Models 88 GROVE V1331E Revision 07 2002 CHAPTER Il 7 SCHEMATICS Model 1331 GROVE Il 7 SCHEMATICS Ref Ele229 05 1 7 A am E Ur dr un 4 ri 1 ae sarao rg ejes i i A manvi 1 L waag Gen lt I i i j pel I
26. the most frequent cause of pump failure Its symptomis usually a gradual decrease in power and speed of the hydraulic system Fine particles or other foreign bodies circulating through the system cause wear on all components and is noticeable of pressure plates housing bores and inthe shaft bearing area Dirt can enter the system through worn seals especially on dirty equipment Always cleantank caps funnels and other areas around the filler neck before opening the tank Immediately cover all disconnected lines fitting and various openings The fine particles that cause abrasive wear are usually not visible to the eye The size of these particles is about 125 microns Oil containing particles of this size can actually look clean while having enough abrasive particles to cause failure Adull sandblasted area may appear near the face of the gear This is caused by contaminated oil flowing through the lubrication grooves Models Revision 07 2002 1 5 2 Abrasive wear caused metal particles Metal contaminants usually results from components wear in the hydraulic system which was insufficiently flushed after a previous failure Metal particle damage may be gradual or fairly sudden depending on the quantity and size of the particles Metal particle damage is indicated by surface scratches on the pressure plates A pressure plate will have several circular scratches if particles of more than 125 microns are present I
27. with a brush or by spraying Chain lubrication intervals must be established with care depending onthe environment in whichthe work platform is operated or stored dusty or aggressive environment The lubricant must be adapted to the machine s operating conditions Generally a non detergent mineral oilis sufficient lts viscosity must be adapted to temperatures according to the chart hereafter Temperature Recommended viscosity TF grades iso vG IN CAUTION A viscosity too lowfacilitates draining of the lubricant by gravity A viscosity too high prevents the lubricant from reaching the friction surfaces Lubricant must be applied Longitudinally in areas where joints are under small load to facilitate penetration of the lubricant Transversely between the plates to enable the lubricant to reach the joint and between the internal plates and the rollers refer to 3 chapter Lubrication GROVE 49 Il 3 TELESCOPIC MAST 1 3 3 2 Mast cylinder removal is necessary to remove mast assembly from the chassis before the mast cylinder can be removed see concerned paragraph 1 Position the mast horizontally as indicated below 2 Remove the bolts and washers securing the cylinder brackets to the mast see fig 3 1 3 To facilitate cylinder removal loosen the bolts securing the cylinder to the cylinder brackets 4 Remove the cylinder and cylinder brackets
28. 300 80 non marking 11 8x3 15 Max Ground Bearing Pressure 14 kg cm 200 psi of Tire Contact Patch ELECTRICAL SYSTEM System Voltage 24 VDC Number of Batteries 4 four battery packs 6 VDC Battery pack Battery Capacity 180 Ah 5h On Board Electronic Charger Charger supply 110 220 VAC 50 60 Hz Charger capacity 15 Amps Drive Motors 24 VDC 0 3 kW 0 4 HP Power Unit Motor 24 VDC 1 kW 1 3 HP Steering cylinder motor 24 VDC 0 4 kW 0 5 HP Models 16 GROVE V1331E Revision 07 2002 1 Weight Working Height Platform Height Overall Length Overall Width Overall Height stowed Ground Clearance Wheel base Platform Size aluminum made Safety Rail Height Kick Plate Height Toe Board Entry Gradeability Turning Radius Inside Outside chassis Maximum wheel load Maximum Drive Speed Rated slope Rated Horizontal Force GENERAL DESCRIPTION 1 CONFIGURATION 850 kg 1874 lbs 5 8 19 4 00 13 1 1 5 4 11 0 78 m 31 1 79 m 5 10 0 08 3 1 1 20 3 11 0 75x1 01 m 30 x40 1 10 m 3 7 0 15 m 6 0 10 m 4 PERFORMANCE 2096 11 3 degrees 0m 1 64 m 5 5 540 kg 1235 Ibs 4 00 km h 2 5 mph 0 degree 445N VIBRATIONLEVELS The weighed root mean square acceleration value to which the arms are subjected control level is inferior to 2 5 ms s The weighed root mean square acceleration value to which the feet are subjected plat
29. GROVE mu VIS3STE SERVICE MANUAL Revision 07 2002 GROVE USA Models GROVE 5 CHAPTER 1 GENERAL DESCRIPTION 1 1 1 2 1 3 Description List of specifications Basic nomenclature 2 GENERAL MAINTENANCE General procedure System malfunctions Cleanliness Removal and Installation Disassembly and Assembly Parts replacement Wires and cables Gaskets Care and installation of teflon coated bushings Bearings Hydraulic system Fatigue of welded structures Welding from on work platform Loctite Fasteners and torque values Steering bracket thrust washers Lifting chains tension adjustment 3 LUBRICATION 4 PRESSURE SETTINGS 4 1 4 2 4 3 Models Revision 07 2002 Pressure relief valves adjustment Main pressure relief valve Mast cylinder relief valve GROVE 5 CHAPTER Il PLATFORM 1 1 1 2 Access gate Platform removal MAST ON CHASSIS TELESCOPIC MAST Lift chain inspection and maintenance Mast cylinder removal Mast cylinder installation Slide blocks removal Slide blocks installation Lifting chains removal Lifting chains installation Mast cylinder bleeding DRIVE AND STEER SYSTEM Removal Installation of the driving wheels rear wheels Removal Installation of the motor reducer flange assembly Removal Installation of the motor reducer Removal Installation of the motor
30. IPPER P N 168 GL3 crimping pliers or similar Crimp the cores in part the female pin Crimp the insulation in part B of the female pin 86 GROVE V1331E Inserting the pins into the terminal block assembly 1 Slide the gland and then the fitting onto the cable Bend the gland opening if fitted Cores Insulation 2 Strap the cable to the terminal block assembly as indicated below Plastic strap 3 Finger squeeze both side locking clips and pull out the red terminal block A 2 Models Revision 07 2002 1 6 ELECTRICAL SYSTEM 1 6 4 Insert the pins housing inthe following order Wire number 18 Housing number 18 Wire number 17 Housing number 17 Wire number 1 Housing number 1 The pin is correctly inserted once it has gone througha notch l 5 Push inthe red terminal block while squeezing the locking clips on both sides Red terminal block locking must be done without any effort Forcing the red terminal locking will damage the connector 2 If the terminal blockis hard or impossible to push in check the correct insertion of the pins in their housing using crimping pliers Models Revision 07 2002 V1331E If the terminal block is still impossible to push in then remove the red terminal block and check for broken sprockets Replace the connector if pin sprockets are broken broken sprocket 6 Screw and tighten
31. Publications Department 530 Product Support 1086 Wayne Avenue Chambersburg Pennsylvania 17201 C Models Revision 07 2002 V1331E GROVE 11 This page intentionally left blank GROVE V1331E Models Revision 07 2002 1 1 GENERAL DESCRIPTION Model 1331 GROVE 1 GENERAL DESCRIPTION 1 1 Description This manual provides important information for personnal performing maintenance on the Grove Manlift self propelled aerial work platform V1331E model US model The work platform consists of a self propelled all welded steel frame and a telescopic mast at the end of which a platformis mounted The drive function is accomplished through two electrical motors propelling the rear axle Steering front axle is accomplished by an electrical cylinder located on chassis between the steering wheels Both electrical motors are fitted with an electromagnetic brake working through lack of current ensuring the parking brake function The parking brakes lock the driving wheels The hydraulic power unit supplying the lifting functions of the work platform is located in the centre of the chassis behind the telescopic mast The telescopic mast movements are performed through a hydraulic cylinder The work platform functions are primarily controlled from the platform controls Some work platform functions can als
32. Remove the plastic blocks installed during slide block removal 5 Install new nuts on the equalizers to adjust the lifting chains tension 6 Grease the sliding surfaces the mast sections see Operator s and Safety Handbook and 8 3 chapter in this manual 52 GROVE V1331E 3 6 Lifting chains removal The mastsections are connected together with lifting chains There are two lifting chains per mast section The lifting chains are always under tension The tensions forces are equalized by a chain equalizer located at the chain end The chains ride on pulleys mounted on top the mast sections When the lifting function is actuated the lifting chain pulls the mast sections up Chain Chainclevis Cotter pin NOTE The mastassembly is made of4 mastsections For ease of description a number will be attributed to each mast section starting from the bottom mast section to thetop section NOTE Beware the removal of the lifting chains is a delicate operation requiring certain precautions The platform must be fully lowered and empty The machine must be parked in an open area Check the capacity of the work bench and ensure bench is level Removal procedure 1 Remove the mast assembly fromthe chassis 2 Remove the mast cylinder 3 On the lower end of each mast section mark the position of the mounting plate of the back up cable Remove the 2 mounting plates
33. TTINGS l 4 4 3 Mast cylinder relief valve The mast cylinder pressure relief valve protection against overpressure due to ambient temperature increase is factory preset at 18 MPa and cannot be adjusted on the machine Models 38 GROVE V1331E Revision 07 2002 CHAPTER Il DETAILLED REMOVAL INSTALLATION AND MAINTENANCE PROCEDURES Model 1331 GROVE 1 1 PLATFORM 1 1 Introduction The removal installation procedures described in this chapter require specific competencies tooling handling equipment and equipment We recommend that these operations are performed by qualified and authorized personnel only Contact your Grove Manlift distributor for any question on removal installation procedure or for any query you may have Certain operations require removal of covers or protection housings All covers housings and protection must be installed before the work platform is returned to operation Models Revision 07 2002 1 1 Access gate 1 Remove the nuts securing the ring inthe tube and remove bolts at each end of the gate 2 Slide the gate tube fully on one of the rings 3 Remove the ring at the opposite end ofthe gate tube 4 Pull the tube to release the second ring 5 Bend the rings to release them fromthe platform posts V1331E GROVE 41 1 1 1 1 3 Lift the platform slightly in direction 1 with
34. a fine crocus cloth except on surfaces rectified and polished 3 Clean with a solvent and dry with compressed air any parts that have been rectified and polished 4 Inspect the barrel carefully for scoring 5 8 Mast cylinder assembly N CAUTION When installing seals avoid damaging grooves and seals NOTE Lubricate new seals with new hydraulic oil Avoid stretching the seal ensure the seals and rings are installed in correct order Ensure all components are clean prior to and during assembly 1 Install the wiper ring in the cylinder head 2 Install the seals and rings in the cylinder head 3 Install the cylinder head on the cylinder rod 4 Install the stop ring and the rings onto the rod When installing the stop ring onto the rod see fig 5 2 ensure to fix it to the adequate groove farest from the cylinder manifold 5 Lubricate the rod with new hydraulic oil 6 Remove the cover from the cylinder barrel Ensure the barrelis clean 7 Lubricate the wear ring with new hydraulic oil and install the rod assembly in the cylinder barrel with a slight twisting motion Models Revision 07 2002 V1331E Donotuse compressed airtotest or pressurize the cylinder 8 Lubricate and test the cylinder Check for proper operation and any leakage Installation 1 Ensure the cylinder support plate is properly installed see fig 3 1 3 2 chapter II 2 Install the cylinder its plate and
35. anticorrosion compound or grease Keep the metallic containers clean In case of corrosion clean neutralize corrosion and apply antiacid painton the affected area Drain the water which can accumulate at the bottom of the container electrolyte overflow leak in the centralized filling circuit battery cleaning C Models Revision 07 2002 1 6 Storage of a battery at temperature below 0 C 32 F Prior to battery storage at temperatures below 0 C 32 F electrolyte specific gravity must be verified in each cell Refer to ELECTROLYTE SPECIFIC GRAVITY AND BATTERY VOLTAGE in this section for electrolyte specific gravity measures operating mode Density measure enables to determine the electrolyte freezing point using the chart below 0 ELECTRICAL SYSTEM 5 10 CN i 20 30 50 Temperature A 5 7 a 70 1 80 1 075 90 1 15 1 20 1 25 1 30 1 35 Electrolyte density NOTE When the battery is fully charged specific gravity 1 280kg the electrolyte freezing point is 85 121 F Freezing point of battery 80 discharged specific gravity 1 150 kg l is 12 C 10 F Use of a battery in a cold chamber or in a cold climate The battery must be fully charged when the work platform is operating in a cold chamber or in cold weather conditions Temperature has an effect o
36. ature dusty corrosive atmosphere humidity Check oil level and perform lubrication only when the work platformis parked on a level surface in transport position and while the oil is cold unless otherwise specified All grease fittings are SAE STANDARD unless otherwise indicated Grease non sealed fittings until grease extrudes fromthe fitting Excessive lubrication on non sealed fittings will not harm the fittings or components but too little lubrication can lead to shorter component life Unless otherwise indicated items not equipped with grease fittings such as linkages pins levers etc should be lubricated with oil once a week If rust or corrosion is present the component must be thoroughly cleaned before applying lubricant Grease fittings that are worn and will not hold the grease gun or those that have a stuck check ball must be replaced Where wear pads are used cycle the component and relubricate to ensure complete lubrication of the entire wearing surface The following chart titted V1331E Lubrication Chart describes lubrication points and gives the lube type lube interval lube amount and application of each Models Revision 07 2002 GROVE Use the following lubrication intervals as a guideline only Formulate actual lubrication intervals to correspond to conditions such as continuous duty cycles and or hazardous environments NOTE Check all fluid levels at ambient
37. ctions and or repair procedures may request same by contacting your local Grove Worldwide servicing distributor for assistance 26 GROVE 2 13 Welding from on work platform When welding from on work platform follow these precautions When welding from the platform always run the welder ground wire directly to the structure that is being welded Do not allow any part of the work platform to contact welding rods holders ground terminals or the structure being welded Do not ground the welder through the machine as this can cause arcing inside the mast assembly orinside the hydraulic cylinder When welding on the work platform disconnect all electronic components When welding on the frame on all work platforms connect the welder ground wire to the machine frame as close to area being welded as possible 2 14 LOCTITE Loctite type adhesives contain chemicals that may be harmful if misused Read and follow the instructions on the container Always follow the directions on the Loctite container Notall Loctite types are suitable for all applications The following types of Loctite brand adhesives are available from Grove Worldwide Lifetime Customer Support LOCTITE ADHESIVES Loctite Number Grove Worldwide Part Number 587 9999 100804 Models V1331E Revision 07 2002 l 2 GENERAL MAINTENANCE l 2 2 15 Fasteners and torque values Use bolts of the correct length In a bl
38. d to ensure correct assembly This tightening can be achieved by applying a measured torque When untreated self locking nuts such as the plastic patch or dimpled types are coated with a light oil the run down torque that would normally be added to the wrench setting need not be added Run down torque is the force necessary to the nut ona free thread When referring to the applicable torque charts use values as close as possible tothe torque values shown to allow for wrench calibration tolerance An erratic or jerking motion of the wrench can easily result in excessive torque Always use a slow wrench movement and stop when the predetermined value has been reached Torque wrenches are precision instruments and are to be handled with care to ensure calibrated accuracy Calibration checks should be made on a scheduled basis Whenever the wrench might be either overstressed or damaged it should immediately be removed from service and recalibrated Know your torque wrench Flexible beam type wrenches even though they might have a preset feature must be pulled at right angles and the force must be applied at the exact center of the handle Force value readings must be made while the tool is in motion Rigid beam type wrenches are available with a limited and preset torque feature but values are not displayed NOTE When multipliers and or special tools are used to reach hard to get at spots ensure torque readings are precise
39. d to automatically charge the 24VDC battery Batteries produce highly explosive gazes This emission increases greatly during charge Do not allow open flames sparks or incandescent bodies near the battery Failure to do so may result in death or serious injuries Always charge the batteries in a well ventilated area NOTE It is not necessary to charge the battery if the electrolyte density is superior to 1 240 kg l The service life of a battery can be greatly reduced if it is charged regularly when the electrolyte density is superior to 1 240 kg l NOTE When connected to the electrical power supply the charger cuts automatically the supply to the control and power circuits of the machine NOTE In case of a power cut during the charge cycle the charger switches to waiting mode and starts again automatically as soon as the power returns High frequency charger HI TEC 24V 15A Three LEDs displaying the condition the charging process are located on the emergency control box Red Led Fault High frequency charger display Leds Led flashing excessive temperature of the charger the charger stops if the temperature exceeds 100 C 212 F Led fixed deep discharge of the battery Ubatt lt 18 V If the voltage remains below 18 V for more than 5 minutes the charger stops automatically To resume operation unplug it from the electrical power supply wait for approximately 10 minutes before returning it to
40. digital display across the chassis C Models Revision 07 2002 V1331E 1 6 11 Using a jack of sufficient dimension lift the right hand side of the chassis An acoustic alarm sounds when the chassis reaches an inclination of 2 0 2 The corresponding Led lights up onthe platform control panel 12 Lower the jack 13 Using a jack of sufficient dimensions lift the left hand side of the chassis An acoustic alarm sounds when the chassis reaches an inclination of 2 0 2 The corresponding Led lights up onthe platform control panel 14 Lower the jack 15 Remove all blocks from around the machine Setting If the tilt indicator does not work symmetrically in the O O direction Correct the symmetry fault by tightening or loosening the nuts A or If the tilt indicator does not work symmetrically in the direction Correct the symmetry fault by tightening or loosening the NOTE When a symmetry fault has been corrected the setting in both directions mustbe checked again before the work platform is returned to service GROVE 85 1 6 ELECTRICAL SYSTEM 1 6 connector installation procedure 6 11 Clipper Cable preparation 1 Strip the cable outer sheath over the length indicated in the table below V 18 45 1 77 2 Strip each wire insulation over 5 0 19 Wire number Pins crimping Using CL
41. e free rotation of the pulley on its pin If necessary replace the bushes pulleys or their pins 1 Install the clevis chain on the chains as indicated below Chain 10 44 Shim Hh During assembly of the chain clevis and double strand chains inserta shim 14 5 mm 10 57 thick between the clevis and the chain as indicated above to prevent deformation of the links during pin installation 2 Lubricate all the chains NOTE During chains installation ensure that two lifting chains are separated on both sides of the chains separator located at the bottom and centre of the mast and that the chains are not twisted before installing the equalizers NOTE Once removed use only new clevis pins cotter pins and retaining rings during chains installation 54 GROVE V1331E 3 Installthe lifting chains inreverse orderfromthe removal and disassembly procedure see concerned paragraph NOTE Use Loctite 243 to install the equalizer brackets and the nuts securing the pulley pins NOTE Install and tighten all equalizers on the mast sections with new locknuts 4 Adjust the tension of the chains refer to the procedure for chaintension adjustment NOTE Ensure the backup cables and electrical cables are correctly installed in the grooves of the pulleys C Models Revision 07 2002 1 3 TELESCOPIC MAST 3
42. e rod end while inserting the bracket Install the cams as tagged during disassembly the washers and the screws 6 Connectthe battery plug Actuate the steering system and steer the wheels in both directions 7 Install the wheels onto the hubs and secure them with lug nuts 8 Torque the front wheel lug nuts at 119 N m 88 Ibf ft 9 Check the proper operation of the drive speed limitation device cams Referto 6 9 chapter Il in this service manual Models 64 GROVE 1331 Revision 07 2002 CHAPTER Il 5 HDYRAULIC SYSTEM Model 1331 GROVE 1 5 HYDRAULIC SYSTEM 5 1 Power unit maintenance An independent power unit consisting of a pump section and driven by a 24 VDC motor is installed on the chassis behind the mast The power unit supplies the hydraulic power to activate the raising of the machine Gear type hydraulic pumps can be relied on to deliver reliable performance over a long period of time if operating in a properly maintained system This includes using clean oil of the correct grade regular filter cleaning and frequent inspections of the system components However if a pump fails itis important to determine all the causes and to eliminate them to prevent repeated failures There are several causes for gear pump failure The following are the most common causes of pump failures 1 Abrasive wear caused by fine particles Abrasive wear caused by fine particles is
43. ecuring the 2 chains equalizers fromthe mast sections see 5 3 6 3 2 4 Remove the 2 equalizers brackets from the mast sections see 8 3 6 fig 3 2 5 Position the mast sections as represented below Plastic blocks 6 Place plastic blocks 3 mm 0 12 thick between the mast sections on which the slide blocks must be replaced as represented above 7 Remove the pulleys located the top of the mast sections supporting the electrical cables NOTE Before removing the slide blocks note their marking and location and give this information to your Grove distributor when ordering 8 Remove the slide blocks and their shims GROVE 51 1 3 TELESCOPIC MAST 1 3 3 5 Slide blocks installation 1 Install new slide blocks with shims as previously installed respecting the information recorded during removal and tighten the bolts Use Loctite 243 on the bolts securing the slide blocks and torque to 7 5 N m 5 5 Ibf ft 2 Using gauges check the play between the mast sections is comprised between 0 2 mm 0 008 and0 3 mm 0 012 as indicated below If it is not replace the shims El Shims Contact Block Ensure an equal thickness of shims is placed on both sides of a mast section as indicated above Thickness 1 must be nearthickness 2 3 Install the equalizer brackets on the mast using Loctite 243 on the bolt thread 4
44. edin accordance with local regulations and V manufacturer s specifications and works perfectly Return to operation The safety of persons working on and around the work platform must be your prime concern After repairs the work platform can only return to service after a thorough functional check All covers and protections must be installed CE Model den on V1331E GROVE 21 l 2 GENERAL MAINTENANCE l 2 2 2 System malfunctions When analyzing a system malfunction use a systematic procedure to locate and correct problems Determine problem List possible causes Devise checks Conduct checks in a logical order to determine the cause Consider remaining service life of components against costof parts and labor necessary to replace them Make necessary repairs Recheck to ensure that nothing has been overlooked Functionally test failed part in its system NOTE Your safety and that of others is always the number one consideration when working around machines Safety is a matter of thoroughly understanding the job to be done and the application of good common sense It is not just a matter of do s and don ts Stay clear of all moving parts 22 GROVE 2 3 Cleanliness Keep dirt out of working parts to preserve the long life of the machine Enclosed compartments seals and filters keep the supply of air hydraulic oil and lubricants clean Maintain these enclosures properly Whenever h
45. equipment within tolerances and only after the need for adjustment has been established Setting values of the relief valves are indicated in chapters 4 2 and 4 3 If the setting of a relief valve is not within 5 of the indicated setting adjust it to its correct value A X DANGER Do notexceed indicated torque values A X DANGER Do not leave the relief valve open for more than one minute NOTE To adjust a relief valve turn the setting screw until the correct setting is reached pressure increase by tightening the setting screw Do not adjust the pressure of the system above its prescribed value Increasing the pressure could damage the hydraulic components Do notattempt to loosen hydraulic fittings in pressurized lines or when the pump motor assembly is running Failure to do so may result in death or serious injuries 1 Place the rated load increased by 1096 in the platform approximately 250 kg 550 lbs 2 Connect a 0 400 bar pressure gauge on the pressure plug mini mess type of the power unit 3 Remove the plug 4 Loosenthe locknut 5 Fromthe ground controls fully raise the mast 6 Adjustthe settingto 15 MPa usingthe setting screw 7 Tighten the locknut while holding the setting screw to preserve the setting Torque to 16 1 N m 11 8 0 74 lbf ft 8 Installthe seal 9 Torque the plug to 11 1 N m 8 11 0 74 CE Model den on V1331E GROVE 37 l 4 PRESSURE SE
46. f exposed to particles of this size long enough the entire surface will be rough and heavily grooved With abrasive wear from metal particles the shaft bearing area will have many small grooves The severity of damage will depend on the amount of contamination in the system and on operating pressure worn housing will have grooves in the gear track caused by large particles being caught between tips of the gear teeth and body This usually results from the failure of another component 3 Incorrectinstallation Incorrect installation can create external loads on the pump which can result in various types of failures 4 Aeration orcavitation Cavitation and aeration act very much alike in the system This type of failure 1 rare and careful investigation is required to pinpoint it Aeration occurs when air mixes with the oil Air may enter the system through a small suction leak or by agitation of the surface of the the tank Surface agitation occurs when return oilis dumped back above the surface of the oil This can occur when the oil level is too low Cavitation is the formation and collapse of vapor bubbles in the oil This is usually the result of restricted pump suction Cavitation occurs more readily when the oil is cold GROVE 67 1 5 HYDRAULIC SYSTEM 1 5 Aeration and cavitation erode pit the pressure plates and pump housing A pump that is either cavitating or operating on aerated fl
47. form floor is inferior to 0 5 m s s ACOUSTIC PRESSURE The equivalent continuous weighed sound pressure level at the work station is inferior to 70 dB A The measure has been made by placing the sonometer at 1 60 mabove the floor of the platform The indicated value does not include the motion alarm C Models Revision 07 2002 V1331E GROVE 17 1 GENERAL DESCRIPTION 1 1 3 Basic nomenclature Platformcontrols Telescopic mast REAR m FRONT Lift and tie Platform down ring a Mast back up system Manual box Towingrings Drivingwheels Batteries Steering wheels Ale fh FRONT x EN REAR Kr Ground controls Manual lowering Lm NY Power unit control not shown not shown 9 po f Charger not shown Batteries C Models 18 GROVE V1331E Revision 07 2002 CHAPTER Il 2 GENERAL MAINTENANCE Model 1331 GROVE l 2 GENERAL MAINTENANCE l 2 2 1 General procedure General procedure to follow when performing a repair Service required Identification of symptoms Identification of causes V Repairs V Malfunction subsists Verification Operating test The work platform is checked and test
48. g cylinder Steering cylinder relay Battery cell Steering cylinder fuse O Battery cell Battery cell O O Battery Motors fuse Motors relay 71 Left motor EA hh Ed V1331E Speed controllers Right motor Models Revision 07 2002 GROVE 95 1 7 SCHEMATICS Il 7 R f FL0128 00 E U gt D O 0 E CNW We a oa DI o gt Ea lt gt No y 150 Bors Models 96 GROVE V1331E Revision 07 2002 This page intentionally left blank Model 1331 GROVE 98 GROVE V1331E Models Revision 07 2002
49. h or serious injury to personnel may result A CAUTION is used to emphasize that if an operation procedure or practice is not followed exactly equipment damage may result SAFETY INSTRUCTIONS CONTAINED IN THE OPERATOR S AND SAFETY HANDBOOK APPLY ALSO DURING OPERATING CHECKS MAINTENANCE AND REPAIRS THEY DO NOT REPLACE NATIONAL STATE OR LOCAL WORK REGULATIONS INDUSTRY STANDARDS OREMPLOYER S WORK RULES NOTE A note is used to emphasize an important procedure or condition Models 10 GROVE V1331E Revision 07 2002 CORRECTIVE ACTION REQUEST The following formis forthe use of the Distributor Customer Mechanic andallother personwho use this manual andrecognize beneficial ways to improve its purpose as a worthy reference SMCAR s are to be made inregards to but notlimited to Safety Operation Correctness and Technical Content All SMCAR s willbe reviewed by the responsible Department at Grove Approved SMCAR s will be distributedin a Service Bulletin immediately and then incorporated in the next scheduled change to the manual An answer to the SMCAR s approved or disapproved will be sent directly to the one submitting the SMCAR Date Customer name Name First name Address Telephone Service Manual Affected Page s Affected Reason for submitting SMCAR use additional paper or back if necessary Signature optional Address SMCAR s Supervisor
50. hes on the control boxes and disconnect the battery quick release plug 2 Remove the 2 front covers 3 Attach a strap on the mast assembly lifting ring and support the assembly with a forklift truck or an overhead crane without lifting it 4 Disconnect both cables located at the bottom of the emergency control box by unscrewing both 18 pinconnectors as indicated below Connectors to disconnect 5 Remove both cable clamps holding the cables which were disconnected during step 4 stuck to mast section n 1 so that these 2 cables do not contact the mast any longer Models Revision 07 2002 6 Disconnect the coil and its connector from the solenoid breakdown control valve located on the lifting cylinder manifold 7 Disconnect and cap the hydraulic line from the lifting cylinder 8 Remove the solenoid cartridge NOTE Cap the hydraulic line and the cylinder ports to prevent any pollution 9 Tension the strap ensuring the 4 wheels stay in firm contact with the ground 10 Remove both nuts and bolts securing the struts to the chassis 11 Remove the 4 bolts and washers securing the mast assembly to the chassis and release the mast sections using appropriate lifting equipment During its removal from the chassis the mast assembly will tilt to reach its balance position as represented above
51. ind hole a bolt too long may bottom before the head is tight against the part it is to hold If a bolt is too short there may not be enough threads engaged to hold the part securely Thread can be damaged Inspect them at each disassembly and replace fasteners as necessary Torque values should correspond to the type of bolts studs and nuts used unless otherwise noted The torque value tables are provided by Grove Worldwide for reference when performing maintenance Use of proper torque values is extremely important Improper torquing can seriously affect performance and reliability NOTE Some special applications require variation from the standard torque values Reference should always be made to component overhaul procedures for recommendations Special attention should be given to the existence of lubricants plating or other factors that might require variation from standard torque values When maximum recommended torque values have been exceeded the fastener should be replaced If installation is in a tapped hole the thread shall be checked witha gauge and the bolt replaced If reusing previously installed bolts that have not been over torqued the bolts shall be visually inspected for cracks and thread damage and replaced if discontinuities are found Bolts are not to be rethreaded rewelded or reworked Models Revision 07 2002 V1331E All lower grade fasteners must be properly tightene
52. ly calculated Identification of fastener grade is always necessary When marked as a high strength bolt i e grade 8 8 12 9 etc the mechanic must be aware that he is working with highly stressed component and the fastener should be torqued accordingly GROVE 27 l 2 GENERAL MAINTENANCE l 2 Nut identification Bolt identification PR SN 8 8 HEAD BOLD Grade8 8 Grade10 9 Grade 12 9 Stud identification CHC BOLT y 8 8 Grade8 8 gt Grade10 9 Grade 12 9 Grade 8 8 TORQUE VALUES FOR PLATED NUTS AND BOLTS FOR TORQUING WITH TORQUE WRENCH COARSE THREAD 4 7 8 68 170 450 572 837 A ee 6 8 19 2 28 96 156 238 632 804 1175 1598 ee ee ee eee 8 22 4 66 4 182 286 760 965 1410 1916 TORQUE VALUES FOR HYDRAULIC FITTINGS FOR TORQUING WITH TORQUE WRENCH Models 28 GROVE V1331E Revision 07 2002 l 2 GENERAL MAINTENANCE l 2 2 16 Steering brackets thrust 2 17 Lifting chains tension washers adjustment Check thickness of thrust washers on both steering The lifting chains must be tensioned so thatthe mast brackets sections are slightly offset towards the top as Replace the washers if their thickness is below 2 5 indicated on the drawings below mm 0 1 ed e nea NOTE Referto Service Man
53. ments is always recommended NOTE When Servicing the hydraulic system use a container to collect the oil from the hydraulic lines or components and prevent it from spilling on the work platform or on the ground GROVE 25 l 2 GENERAL MAINTENANCE l 2 2 12 Fatigue of welded structures Experience has shown that highly stressed welded structures when repeatedly subjected to varying stresses caused by twisting shock bending and intentional and or unintentional overloads often become subject to weld cracking which may be attributed to fatigue of the welded joint This condition is not uncommon in the all welded construction Equipment should be periodically inspected for evidence of weld fatigue The frequency of these inspections should commensurate with the age of the equipment the severity of the application and the experience of the operators and maintenance personnel The following points are known high stress areas and a visual inspection should be made as part of a preventive maintenance program HASSIS 1 Inspect the strut mounting bracket 2 Inspect the mast mounting frame 3 Inspect the steering cylinder fixation pin PLATFORM Inspect all weldments The information in this paragraph is provided only as a guide and your inspection program should not be limited to the areas listed Athorough visual inspection of all weldments is good practice Anyone requiring more detailed inspection instru
54. n Get the charger checked by a technician Change battery cell Check connections cables and quick connection plugs Replace the battery Models V1331E Revision 07 2002 1 6 ELECTRICAL SYSTEM 6 4 Battery discharge indicator Failure to correctly maintain battery charge or a battery discharge exceeding 80 of its capacity will damage the battery and the electrical motors The indicator is made of 3 colored lights located on the top left hand side of the emergency control box It indicates the state of charge of the battery refer to picture below Green light The battery is between full charge and 7096 discharge Orange light The battery is between 70 and 80 discharged It must be recharged before resumingoperation Red light The battery discharge exceeds 80 of its capacity The battery must imperatively be charged Continuing to use the machine will 1 6 6 5 Hourmeter The hourmeter indicates hours of work platform operation Hours are displayed in 1 10hsteps During work platform operation from platform controls the hour glass sign flashes in about 4 second interval Use the hourmeter as a guide for determining your work platform maintenance inspection and overhaul schedules CURTIS p damage the battery C Models Revision 07 2002 V1331E GROVE 81 1 6 ELECTRICAL SYSTEM 6 6 On board electronic charger The electronic charger on board the work platform is designe
55. n battery autonomy the battery looses 1 of its capacity per degree Celsius below 25 77 F Temperature ofthe electrolyte Example a battery operating withits electrolyte at a temperature of 30 C 22 F will loose 55 of its autonomy C Models Revision 07 2002 V1331E GROVE 1 6 Battery not working continuously inactive battery A battery which is not used or used by intermittence must be stored charged in a dry area away from freezing temperatures An equalization charge must be performed once a month In these conditions battery storage is possible at a 30 C 86 F temperature for a 12 months period Storing a discharged battery will result in irreversible damage Unplug the battery to insulate it electrically Keep the top of the battery clean and dry to prevent self discharge during inactivity periods batteries loose their charge progressively auto discharge Auto discharge causes battery plate corrosion which increases with time resulting in battery malfunction Ifthe battery is not used continuously it must be recharged at least once a month even if density measures are high Before placing in service a battery which remained inactive for a long period of time you must recharge the battery and check the electrolyte level in the cells 79 1 6 Troubleshooting ELECTRICAL SYSTEM 1 6 Serious accidents resulting in complete destruction of a traction ba
56. n it should be null a noise characteristic of the steering cylinder when the steering control is kept depressed Setting of the sensors located above the right hand side wheel 1 Positionthe control panel selector to Platform control panel 2 Steer the wheels fully to the left 3 Loosen both nuts and bolts securing the top right hand side sensor until it can be moved in the direction indicated on the drawing below 4 Move the top sensor until the angle 0 when the wheels are steered to the left refer to drawing below 5 Tighten the sensor on the chassis 6 Straighten the wheels and steer them fully to the left again to ensure the angle 0 and the steering cylinder is not noisy when fully extended Top sensor Lower sensor lt gt Sensors direction of movement Setting of the sensors located above the left hand side wheel 1 Positionthe control panel selector to Platform control panel 2 Steer the wheels fully to the right 3 Loosen both nuts and bolts securing the top right hand side sensor until it can be moved in the direction indicated on the drawing below 4 Move the top sensor until the angle 0 when the wheels are steered to the right refer to drawing below 5 Tighten the sensor onthe chassis 6 Straighten the wheels and steer them fully to the right again to ensure the angle
57. ne locate and repair leak d If dirt inthe pump remove and cleanthe pump Check the system and fill with proper fluid e If fluid viscosity too high check the manufacturer s recommendations and fill with correct fluid f Ifa part is worn or damaged inside the pump determine the cause of the failure repair the parts or replace the pump g If fluid returns to the tank check the voltage at the coil s terminals If no voltage check the right solenoid wiring refer to S 7 chapter II Otherwise replace the solenoidorthe assembly if necessary Check also the pressure relief valves for contamination If contaminated clean and check the fluid in the system 6 If pressure is low or erratic the probable causes could be incorrect fluid viscosity air leak or restriction in inlet line pump internal parts stuck distance between parts increased due to wear Solutions are as follows a If incorrect fluid viscosity replace with oil of manufacturer s recommended grade b If air leak or clogged inlet line repair or clean c Ifpumpinternal parts stuck check the parts for any burrs or check the fluid for metal particles Clean and fill with the correct fluid d If distance between internal parts increased due to wear replace the pump assembly e Check the power unit relief valve for contamination If contaminated clean it check its setting and check the fluid in the system V1331E GROVE 69 1 5 T
58. nt of damaged or malfunctioning components Most components require limited maintenance however standard wiring practices should be observed when any replacement is necessary Should it become necessary to perform electrical maintenance on live or hot circuits remove allrings watches and other jewelry before performing maintenance Failure to comply could result in death or injury Never replace original wiring with wiring of a smaller gauge Troubleshooting Use a multimeter to isolate electrical troubles A multimeter when used properly provides readings you can use to determine Continuity in the electrical system Voltage in the electrical system When troubleshooting the electrical system look for loose or corroded pin type connectors Make sure the connectors wire pins are properly seated and in the receptacle If male and female pin show signs of corrosion use a good quality electrical contact cleaner or fine sandpaper to clean them Replace wire pins showing sign of arcing NOTE Backfill all female fastons with Nyogel 759G in accordance with the following procedure Clean the electrical contacts and connectors of all foreign material such as grease oil and dirt before applying lubricant Apply a generous amount of lubricant on the electrical contacts and connectors before mating After mating contacts and connectors clean off excess squeezed out Models Revision 07 2002 V1331E 1
59. o facilitate penetration of the lubricant Transversally between the plates to enable the lubricant to reach the joint and internal plates and the rollers Grease nipple on each hub Check level with the decal on the chassis Grease cap on each reducer Grease cap Models V1331E Revision 07 2002 1 4 PRESSURE SETTINGS Model 1331 GROVE l 4 PRESSURE SETTINGS l 4 4 1 Pressure relief valves adjustment Pressure relief valves are used to protect the hydraulic system fromexcessive pressures They return the oil to the reservoir when the pressure setting is reached relieving pressure within the circuit in which they used The pressure relief valves are checked and adjusted by bringing the circuit to reach its prescribed pressure limit Atthis point the relief valve opens returning oil to the reservoir The cylinder circuit can be adjusted by extending the cylinder to its limit of travel The values indicated correspond to the settings to be obtained with the pressure gauge connected to the pressure point on the pump motor assembly Connecting the gauge to another point of the circuit presents risks of setting the relief valve too high and could result in serious injuries and equipment damage Acorrect setting of the relief valve is mandatory for the hydraulic circuit to function correctly Settings must be performed by qualified technicians only using correct
60. o be controlled from the ground controls located on the left hand side of the machine or from the manual override control located at the front of the machine underneath the electrical steering cylinder The progressivity of movements is accomplished through electronic controllers managing the rotation speed of the electrical motors and ensuring the dynamic braking function The electronic controllers are located in front of the electrical motors on the chassis V1331E The energy for the control circuits and power for the work platform is supplied by 24 VDC battery The work platform may be used safely on hard firm and horizontal surfaces exclusively indoors All four wheels must be in permanent contact with the ground The work platform may be used with a load equal to but not exceeding the rated work load evenly distributed on the platform The rated load is indicated on the manufacturer s plate Model den on V1331E GROVE 1 GENERAL DESCRIPTION 1 1 2 List of specifications GENERAL Model V1331E Platform Capacity 227 kg 500 pounds Compliance ANSI A92 6 CSA CAN3 B354 2 M82 HYDRAULIC CIRCUIT Gear Pump 1 Maximum Operating Pressure 15 MPa 2175 Psi Hydraulic Reservoir 5 1 1 3 gallons DRIVE MOTORS Type Permanent magnets Gear Ratio 1 43 BRAKES Type Electromagnetic electrically released integral to wheel motors WHEELS AND TIRES Tire Size Heavy duty solid tires
61. product or substitution upon it of parts not approved bythe Manufacturer shall void this warranty This warranty covers only the products of Grove Worldwide The product of other Manufacturers are covered only by such warranties as are made by their Manufacturers THISWARRANTY IS EXPRESSLY IN LIEU OF ANY OTHERWARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR APARTICULAR PURPOSE AND OF ANY OTHER OBLIGATIONS OR LIABILITY ON THE PART OF THE MANUFACTURER AND GROVE WORLDWIDE NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR IT ANY OTHER LIABILITY IN CONNECTION WITH SUCH EQUIPMENT NOTICE TO OWNER USER Should this work platform become involved in an accident please contact your local GROVE distributorimmediatelyand relate details ofthe incidentsothathe can notify GROVE If the distributor is unknown and or cannot be reached please contact Grove Worldwide Manlift 1086 Wayne Avenue Chambersburg Pennsylvania 17201 USA Tel 717 263 5100 Fax 717 267 0404 C Models 8 GROVE V1331E Revision 07 2002 INTRODUCTION FOREWORD This handbookhas been compiledto assist you in properly maintaining your Grove Manlift Aerial Work Platform Model V1331E It contains technical information and procedures enablinga qualified personnel to detect possible failures and performthe necessary adjustments or repairs Verify that this manual corresponds to the model of work platform you will be
62. r cursor 10 Input 10 5 V potentiometer 11 Not used 12 Output motor relay OMANOABRWN The controller is fitted with two fixed speed limitations 1st speed limitation reduces the maximum rotation speed of the right left wheel motor when the steering wheels are steered to the right left 2nd speed limitation reduces the maximum rotation speed of both wheel motors as soon as the mast leaves its transport position 6 8 Electrical cylinder The electrical cylinder enables steering of the work platform steering wheels It consists of an electrical motor a reducer and a nut and worm mechanism The electrical motor is fitted with a thermal protection cutting automatically the cylinder supply in case of overheating If the electrical cylinder overheats 1 Depress one ofthe EMERGENCY STOP switch to cut the electrical supply 2 Eliminate the problem which caused the overheat 3 Letthe cylinder cool down 4 Pull out the EMERGENCY STOP switch to reset Before restarting it is necessary to eliminate the problem which caused the emergency stop GROVE 83 1 6 ELECTRICAL SYSTEM 1 6 6 9 Steering sensors setting The steering sensors are factory preset and locked in such a way that the steering wheels can be steered at an angle of 90 maximum However these sensors may become maladjusted which results when the steering wheels are fully steered in aninner steering radius too important whe
63. r the pump to isolate the problem 1 If the pump is noisy cavitation the probable causes could be low oil level heavy oil wrong oil type suction filter dirty relief valve open restriction in suction line air in the system pump stuck or parts worn or broken Solutions are as follows a If low oil level fill to correct level b Ifoiltoo heavy replace with proper oil Referto 8 3 chapter If incorrect oil type replace with proper oil d If suction filter dirty clean the filter e Ifreliefvalve open adjust it Referto 4 chapter l f If restriction in the suction line remove and replace the line g If air in the system bleed the air from the system Refer to S 3 8 chapter Il h If the pump is stuck inspect all parts for burrs or check if the pump is contaminated If burrs are found on parts replace parts If contamination flush the system and fill with correctfluid i If pump is worn or broken replace the pump 2 If the pump is too long to respond or fails to respond the probable causes could be low oil level relief valve set too low pump worn or damaged or air in the cylinder Solutions are as follows If low oil level fill to the correct level Models Revision 07 2002 1 5 HYDRAULIC SYSTEM b If relief valve set too low use a manometer to adjust pressure Refer to 4 chapter I c If pump worn or damaged replace the pump d Ifairinthe cylinder
64. reducer brake Control of the wheel motor brake adjustment Removal Installation of the reducer on the wheel motor reducer Removal Installation of the wheel motor Removal Installation of the steering wheels front wheels Steering brackets Steering cylinder HYDRAULIC SYSTEM Power unit maintenance Power unit troubleshooting Power unit removal Power unit disassembly assembly Power unit installation Mast cylinder disassembly Mast cylinder inspection Mast cylinder assembly Removal Installation of the manifold Models GROVE V1331E Revision 07 2002 Models 07 2002 5 CHAPTER Il ELECTRICAL SYSTEM 6 1 General 6 2 Fuses 6 3 Batteries 6 4 Battery discharge indicator 6 5 Hourmeter 6 6 On board electronic charger 6 7 Motor speed controller 6 8 Electrical cylinder 6 9 Steering sensors setting 6 10 Control Tilt indicator setting 6 11 Clipper connector installation procedure 6 12 Connectors and cables from lower control box SCHEMATICS V1331E GROVE THERE ARE WARRANTY EXPRESS OR IMPLIED MADE BY EITHER THE DISTRIBUTOR OR THE MANUFACTURER ON NEW GROVE WORLDWIDE EQUIPMENT EXCEPT THE MANUFACTURER S WARRANTY AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP SET OUT BELOW NEW EQUIPMENT WARRANTY The Manufacturer warrants each new Grove Worldwide product made by the Manufacturer to be free from defects in material and wo
65. returning it to the job Models Revision 07 2002 V1331E 2 6 Parts replacement Parts found damaged or out of tolerance during maintenance should be replaced Refer to the corresponding Spare Parts Manual for proper replacement parts 2 7 Wires and cables Always disconnect batteries prior to working on the electrical system When removing or disconnecting a group of wires or cables tag each one to ensure proper identification during assembly 2 8 Gaskets Be sure the holes in the gaskets correspond with the lubricant passages in the mating parts If it is necessary to make gaskets select material of the proper type and thickness Ensure holes are cut in the right places Blank gaskets can cause serious damage When removed always install new cylinder head and manifold gaskets using recommended gasket compound on head gaskets to allow uniform sealing GROVE 23 l 2 GENERAL MAINTENANCE l 2 2 9 Care and installation of teflon coated bushings The following instructions must be followed when working with teflon coated bushing Bushings No jiffy wheels or reaming of any kind can be used on coated bushings Once the coating on the bushing is damaged it cannot be used and must be replaced Coat bushing pin and interior of housings with grease before assembly Pin Any rough or damaged surface on a pin will cause the teflon coating on the bushing to be damaged therefore bushing must be
66. rkmanship its obligation and liability under this warranty being limited to repairing or replacing free of charge atits factory any part proving defective under normal use and service and the reasonable cost of repair and or replacement of said part or parts within twelve 12 months from the date of initial sale lease or rental providing the equipment is on record with the Manufacturer as being installed by the distributor Grove Worldwide further warrants for an additional six 6 years the structural components described and identified as mast and frame chassis weldment to be free from defects in materialand workmanship its obligation and liabilityunderthe structural warranty being limited to repairing orreplacing free of charge at its factory anypart proving defective under normal use and service and does not cover any labor or installation costs incurredforthe repair or replacement of the structural component Ifthe machine is noton recordas beinginstalled bythe Distributor the Manufacturer will consider the date of shipment fromthe factory as the date of initial sale lease orrental This warrantyis in lieu of all other warranties express orimplied andthe obligation andliability of the Manufacturer under this warrantyshall notincludeany transportation or other charges oranyliabilityfor direct indirect or consequential damages or delay resulting from the defect Any operation beyond rated capacity orthe improper use or application of the
67. service 82 GROVE 1 6 Yellow Led Charge This Led remains lit as long as the battery is not fully charged Green Led 100 This Led lights up when the battery is charged Safety devices Electronic protection against Short circuitat output fuse 10A fitted on power card Battery discharge in case of electrical power failure Circuit breaker protection against Battery overvoltage and undervoltage Excessive increase of battery or charger temperature Fuse protection against Overvoltage of power supply input Battery polarity reversal Ventilation The fan comes on whenthe temperature of the internal probe exceeds 60 C 140 F Fan Fuse 25A Fuse 10A N Disconnect the charger from the battery and from the electrical power supply before removing the charger cover NOTE It is recommended from time to time to remove dust from the charger depending of work platform operating conditions remove the charger cover and remove dust especially at fan level C Models V1331E Revision 07 2002 1 6 ELECTRICAL SYSTEM 1 6 6 7 Motor speed controller The electronic controller is a high frequency microprocessor controller It enables variation of the rotation speed of the wheel motor reducers therefore of the drive speed of the work platform NOTE Use of this machine in an environment with electromagnetic interferences may result in fluctuations in speed of certain mo
68. tall the wheels on the motor reducer shaft and secure them with both bolts without forget the washer 3 Remove the blocks fromthe machine N CAUTION Clean and grease the motor reducer shaft before installing the wheels When installing the rear wheels torque the bolts to 21 N m 15 5 tightening with a torque wrench Models Revision 07 2002 V1331E 4 2 Removal Installation of the motor reducer flange assembly 1 Fully lowerthe platform 2 Depress the emergency stop switches on both control panels and disconnect the battery quick connecting plug 3 Remove the rear cover 4 Chock the front wheels lengthways 5 Remove the rear wheels 6 Tag and disconnect both supply wires to each motor red and blue wires 7 Discomectthe 2 wire connector fromthe brake on each motor 8 Remove the step and the motor protection plate secured by 4 bolts and washers Flange attachment bolts 9 Lift the platform chassis and place a block under the rear ofthe chassis 10 Remove the bolts securing the flanges on the chassis Motor reducer flange assembly When installing the motor reducer flange assembly on the chassis torque the attachment bolts to 78 N m 57 5 Ibf ft tightening with a torque wrench GROVE 59 11 4 DRIVE AND STEER SYSTEM 1 4 4 4 Removal Installation of the motor reducer brake 4 3 Removal installation of the motor reducer 1 Remove the
69. tallation of the steering wheels front wheels 1 Fully lower the platform 2 Chock the rear wheels lengthways 3 Loosen the 4 nuts without removing them 4 Lift the front of the work platform chassis place a block under the chassis 5 Remove the 4 nuts and remove the wheel When installing the front wheels torque the attachment nuts to 119 N m 88 Ibf ft tightening with torque wrench Wheel attachment nuts Models V1331E Revision 07 2002 11 4 DRIVE AND STEER SYSTEM 11 4 4 9 Steering bracket Steering cylinder Steering cylinder Right rod Steering bar Pillow blocks The steering system is made of several articulated parts wich may cause pinching during servicing NOTE The steering system assembly uses teflon coated bushing Refer to section 2 9 chapter I in this service manual Removal 1 Fully lower the mast Disconnect the battery plug 2 Loosen the wheels lug nuts by a quarter turn while the wheels are still on the ground 3 Using a forklift truck or an adequate lifting device attached to the ring on mast section 1 lift the work platform until cribbing of a minimum height of 200 mm 8 capable of handling the weight of the work platform can be placed under the chassis for support Refer to OPERATOR S amp SAFETY HANDBOOK for lifting instructions Models Revision 07 2002 Steering cams 4 Remove the wheel l
70. tenance requiring cylinder disassembly must include replacement ofall seals 6 Drain allthe hydraulic oil from the cylinder 7 Using a unscrew the cylinder head until it clears the barrel see fig 5 2 72 GROVE V1331E Guide ring Do not use compressed air to remove the cylinder rod Use only a source of controlled hydraulic oil pressure if the rod assembly is hard to remove 8 Withdraw the rod assembly from the cylinder barrel and move it to a clean work area Exercise extreme care when handling or setting down the cylinder rod Do not damage the chrome surface NOTE It is recommended to coverthe cylinder barrel opening to prevent contamination When installing new seals avoid stretching seals and damaging the grooved surfaces NOTE Aligning discarded seals in the order of disassembly will facilitate installation of new seals and rings 9 Remove the guide ring and the stop ring from the rod 10 Remove the cylinder head 11 Remove the seals wiper ring fromthe cylinder head C Models Revision 07 2002 1 5 HYDRAULIC SYSTEM 1 5 5 7 Mast cylinder inspection 1 Clean all parts with a solventand dry them with compressed air Inspect all parts for serviceability Before installing new seals and rings clean all surfaces and carefully remove burrs and nicks Parts displaying excessive wear or damaged should be replaced 2 Stone out minor blemishes and polish with
71. ttery relatively rare small problems encountered on a battery in use are rapidly and correctly determined battery life and operation can be improved PREVENTION AUTONOMY AND LONG LIFE Symptoms Probable causes Electrolyte overflow Inequal densities or densities too low Low voltage in the cells in open circuit Battery cells temperature too high Battery incapable of supporting regular operation 80 Filling done before the charge Cells overfilled Overcharge Filling done before the charge Loss of electrolyte due to overflow Stratification of the electrolyte Densities too low Short circuit Problem with the charger Bad air circulation during charge Cell weak or faulty Cells shorted Battery undersized Battery under charged Cell faulty Faulty cable or connection Battery at the end of its service life GROVE Fill battery cells after the charge Never charge battery if density is above 1 230 kg l Fill battery cells after the charge Contact your Grove Manlift Distributor Product Support Refer to densities too low Clean battery top Get the charger checked by a technician Remove battery cap during charge Leave the battery to cool down when disconnected before charge Reduce temperature of the area where the battery is charged artificial ventilation Change battery cell Install battery of a higher capacity Perform complete charge cycles without any interruptio
72. ual for further information Inspect the lifting chains for cleanliness during tension control NOTE Both lifting chains ofeach assembly have an equal tension because of the chain equalizer NOTE Backup cables located on the right side of the mast prevent the lifting chains from slackening CE Model den on V1331E GROVE 29 30 This page intentionally left blank GROVE V1331E Models Revision 07 2002 1 3 LUBRICATION Model 1331 GROVE 3 LUBRICATION 3 Follow designated lubrication procedures to ensure maximum work platform lifetime and use The procedures and lubrication chart in this section provide information on the types of lubricants used the location of lubrication points the frequency intervals for lubrication and other important material Lubrication points Regular lubrication must be performed on all lubrication points Normally the frequency for lubrication is based on component operating time The most efficient method for keeping track of lube intervals in to maintain a job log indicating machine usage The log should include hourmeter readings which can be used to determine which lube points will require attention based on the readings Lubricants or grease types as well as lubrication intervals must be adapted to the conditions and operating and storage environments of the work platform temper
73. ug nuts and slide the wheel out of the hub 5 Tag the steering cams left right 6 While holding the bracket remove the attatchment screw and washer Remove the bracket NOTE Check the bracket thrust washers The washers must be replaced if their thickness is less than 2 5 mm 0 1 7 While holding the cylinder steering bar assembly remove the 4 attachments screws of the pillow blocks on the steering bar 8 Remove the locking pin from the cylinder knuckle pinand remove the cylinder steering bar rod assembly Exercise extreme caution to prevent damage to the chromed rods during these operations V1331E GROVE 63 1 4 DRIVE AND STEER SYSTEM 1 4 9 Remove the locking pins from rods Remove the pins and rods 10 Remove the steering bar locking pin from the cylinder and remove the pin 11 Remove the steering bar by sliding the pillow blocks Installation NOTE This assembly uses teflon coated bushings Refer to section 2 9 chapter I inthis service manual 1 Install the locking pin and the steering bar pin onthe cylinder 2 Place both pillow blocks on the steering bar 3 Install the split pins and rod pins onthe steering bar 4 Install the assembly on the chassis 4 attachment screws on the pillow blocks NOTE Before tightening the cylinder assembly attachment screws make sure the cylinder is parallel to the front axle beam 5 Drive the tie rod pin welded on the bracket into the ti
74. uid is usually noisy and the system operates ina jerky manner If erosion onthe suction side of the pump is evident of the gear track the cause was due either to air bubbles in the oil or starved suction 5 Lack of oil When a failure is due to lack of oil deterioration is usually rapid This type of failure can occur fromeither ortwo condition a Oil level is low in the tank or b There is an air leak inthe suction line 6 Excessive heat Excessive heat willharden O rings and seals Excessive heat usually results froma relief valve set too low Ifa relief valve is set too low partof the oil will be dumped across the relief valve at each cycle In this case the machine will be very slow 7 Oil pressure too high There aretwo reasons for overpressure a The relief valve fails to function producing an extreme surge and immediate failure b The relief valve setting is too high resulting in repeated pressure peaks Damage to the pump looks very similar in both cases 8 Incorrectassembly This type of failure is self explanatory either components are faulty or parts were not assembled correctly Pinching of the O ring will occur if not properly placed inits groove If the O ring is installed incorrectly the housing surface willshowa depressedarea especially if the part is made of aluminium 68 GROVE V1331E 5 2 Power unit troubleshooting NOTE Use a manometer on the quick release fitting nea
75. uration unless otherwise specified ona firm clean and horizontal floor wheels choked in both directions inretracted position thecontactkey positioned to O and removed battery plug disconnected chargerdisconnected power socket on the platform optional equipment disconnected eachcontrol panel must be tagged out Failure to respect instructions and safety instructions described in this manual and Operator s and Safety Handbook could result in death or serious injuries Do not perform any operating control maintenance or repair 1 If you are not qualified and trained to the maintenance of THIS particular work platform 2 If you have not read and understood the operating and safety procedures describedin this manual and the Operator s and Safety Handbook for THIS particular work platform 3 If you are not familiar with regulations and standards governing aerial work platforms and their operation 4 If you do not have necessary tools and equipments YOUR SAFETY AND THAT OF PERSONS WORKING ON AND AROUND THE WORK PLATFORM MUST BE YOUR PRIME CONCERN ALL SAFETY COMPONENTS ON THE WORK PLATFORM MUST BE MAINTAINED INPERFECT WORKING ORDER You will find in this manual paragraphs containing the following mentions DANGER ATTENTION and NOTE These mentions are defined as follows A DANGER is used to emphasize that if an operation procedure or practice is not followed exactly deat
76. val Before any maintenance of the power unit disconnectthe battery and the charger plug and ensure power unit is shut off Failure to comply could result in death or serious injuries 1 Remove the rear cover fromthe machine 2 Disconnect the charger from the electrical power supply as well as the battery quick release plug 3 Tag and disconnect the electrical cables and the connector from the power unit 4 Disconnect and cap the hydraulic line from the power unit 5 Drain the oil from the reservoir refer to the Operator s and Safety Handbook 6 Remove the power unit and move it to a clean work area It is not necessary to remove the hydraulic fittings if there is no leakage Models V1331E Revision 07 2002 1 5 HYDRAULIC SYSTEM 1 5 5 4 Power unit disassembly Assembly 5 5 Power unit installation Check valve 1 Remove the power unit fromthe chassis 2 Remove the clips securing the reservoir and remove the reservoir 3 Remove the bolt securing the pump and remove the pump 4 Remove the pressure relief valve 5 Remove the filter check valve torque value 20 0 2 N m 14 75 0 15 Ibf ft 6 Remove the solenoid torque value 30 0 5 N m 122 12 0 37 Ibf ft 7 Loosen the nut securing the solenoid to the solenoid valve and removethe solenoid torque value 5 N m 3 69 Ibf ft 8 Cleanall parts that were removed 9 Replace the seals clean the filters and reassemble the
77. vements slowing down and the setting off of acoustic and light alarms All functions and safety devices of the machine remain operational Diagnostic Led The controller is fitted with an automatic diagnostic system which includes a green led visible on top of the controller cover see photo below e C Green led 2 When contact is made the led must light up and stay lit If the green led does not light up The controller is faulty The controller circuit is faulty Controller supply faulty control circuit fuse faulty The green led may also flash intermittently a certain number of times when contact is first made 2 flashes starting procedure the emergency stop switches must be pulled out first before the joystick is actuated 3 flashes terminal B of the controller connected to the battery terminal or controller faulty 5 flashes circuit open between battery terminal and terminal B of the controller 6 flashes accelerator faulty joystick potentiometer faulty 7 flashes battery discharged 8 flashes actuation ofthe thermal protection controller overheating Models Revision 07 2002 V1331E Connections on 12 pin connector of controller SEVCON MICROMOS Supply 24V Input forward drive Input reverse drive 1 limitation 2 speed limitation Output motor relay Not used Not used Input potentiomete
78. w them to dry Bearings can be dried with compressed air but do not spin the bearing Discard the bearings if the races and balls or rollers are pitted scored or burned If the bearing is serviceable coat itwith oil and wrap it in clean waxed paper Do not unwrap new bearings until time of installation The life of a bearing will be shortened if not properly lubricated Dirt in antifriction bearing can cause the bearing to lock resulting in the shaft turning with the cage Models Revision 07 2002 2 11 Hydraulic system Exercise extreme care around pressurized hydraulic systems Do not work on a hydraulic system while it is in operation or until all pressure is released Cleanliness Contaminants in a hydraulic system affect operation and will result in serious damage to the system components Dirty hydraulic systems are a major cause of component failures Keep the system clean When removing components of a hydraulic system cover all openings on both the component and the work platform If evidence of foreign particles is found in the hydraulic system flush the system Disassemble and assemble hydraulic components on a clean surface Clean all metal parts ina nonflammable cleaning fluid Then lubricate all components to aid in assembly Sealing elements Inspect all sealing elements O rings gaskets etc when disassembling and assembling hydraulic system components Installation of new ele
79. ydraulic line is disconnected clean the adjacent area as wellas the point of disconnection As soon as the disconnection is made plug or tape each line or opening to prevent entry of foreign material The same recommendations for cleaning and covering apply when access covers or inspection plates are removed Clean and inspect all parts Make sure All passages and holes are open Parts are coveredto keep them clean Parts are clean when they are installed New parts are left in their containers until ready for assembly Rust preventive compound has been removed from all machined surfaces of new parts before they are installed except leaf chains WORK PLATFORM CLEANING During cleaning the battery must be disconnected from the work platform circuit the charger must be disconnected from the electrical power supply and the 110 VAC supply in the platform optional equipment must be off EXTERNAL CLEANING Cleanthe work platform with chemicals diluted in water water spray sponge cloths High pressure cleaning can only be done with a maximum pressure of 50 bars and a maximum temperature of 70 C C Models V1331E Revision 07 2002 l 2 GENERAL MAINTENANCE l 2 2 4 Removal and installation When performing maintenance do not attempt to manually lift heavy parts when hoisting equipment should be used Neverlocate or leave heavy parts in an unstable position When raising a portion

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