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V SERVICE MANUAL ' sELF PROPBLLED AERIAL

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1. Suction strainer N Oil reservoir QM EC eM Swivel joint HYDRAULIC CIRCUIT DIAGRAM for Spec 20 Applied to the Serial No 665663 and after Double pilot check valve AMNEM M Platform level solenoid valve gt Platform rotation solenoid valve In line filter Platform rotation motor 1 Preset pressure 8301 14481 140 2 000psi Main control valve No 1 x Rotation Rotation motor Single holding valve lt 210kg cm 3 000psi PC valve Relief valve P1 PKPF1721 C104 In line check valve 4 7 lt Emergency pump Main pump Suction filter reservoir 30 2cc rav Oil cooler 185 Elevation cylinder Double holding valve Extension cylinder 230k 8 f cm 3 270 3 400psi B1 Combination valve gt B2 EE wer leveling cyl Lo GE NC y Main control valve No 2 A 8 CPT172
2. SOLS 9 2 Valye Carty faa eia E a 2 2 M Pei a gt 097774 1 7 3 34 302 02923 g platform level and two ilt up in the hydraulic This valve consists of two Stop valves used for adjustin Relief valves which release excessively high pressure bu circuit of the levelling system 9qquisnfpe jou seA vA JITOA ELON ISd OZZ 0 8 062 SOA VA 401 403 3 35 302 06303 This valve is operated by the platform level switch to adjust the level of the platform TAERE MUS 3 36 302 02909A This valve confines the hydraulic oil to the platform levelling system to maintain the level of platform Valve housing Valve seat Check valve Piston 3 37 4 ELECTRIC SECTION Horn s w Platform swing s w Platform level s w v Accelerator s w Emergency pump s w p d Rotation control lever s Extension control lever yc 5 Elevation control lever b lt Travel L control lever A SZ 4 a Travel R control lever amp els Working light s w Emergency stop s w En
3. FLL FUSIELE LINK 556 STARTER PLETFORM KEY SWITCH T 45a 138 336 80 45 541 198 LiB 1 wW Cem omer SIBI 1 65 LEVEL SOL 7 9 SR 123 ELECTRIC CIRCUIT DIAGRAM for Spec Ab 65 352 0 ES Main control valve NO feo afr CCW Travel L Rev DOWN IN CCW Travel L For UP OUT er te ese a Ya i ta ca OG ddr UT NG CM MIL Extension Remote control box for Travel Lyr Travel Rev Travel For yit Elevation v Main contol valve NO 2 3 5 ic Iz NA CNT sr D Valve control unit VAL 9400 Mis ITI JOY RON D ue WA NCO mein neri mmm H i i 1 H 1 2 2 VI GI E D TT UT A DERI Interface board 1F i 2 SEN Fes 2 2 E 5 5 hov EE ES 3 3 2 z2 Free 5 H
4. X 1st boom Anchor for Retraction wire Tope 2nd boom Extension wire rope G G section _ Anchor pin for Extension wire rope H Detail J Detail 4 Inspection procedures The boom is to be disassembled for a detailed inspection every 4 years 1 Clearance between each boom section 1 Check the clearance between each slider and boom section Specific clearance 2 0mm or less 0 08 or less 2 If the clearance is not adequate adjust the clearance by adding or reducing the spacers installed under the each slider or by adjusting the screws NOTE Check each slider for wear and replace if necessary Apply a thread lock agent to the thread of each set screw for sliders before setting Recommended thread lock agent 3 Bond 1374 2 Bend of boom 1 Set the boom horizontally and extend it fully 2 Visually check the bend of each boom 3 If the bend seems to be excessive stretch a thread over the boom and measure the bend accurately as shown in the figure below NOTE If the bend measured exceeds the serviceable limit 6 0mm replace the boom 0 24 Fig 2 Bend stretched thread 3 Dents scratches Check the each boom for both dents and scratches thoroughly If any dent or scratch which exceeds the serviceable limit Length 50mm or more Depth 2mm more exsists replace the boom 1 97 0 08
5. Bend distortion dent cracks Anchor pins Excessive wear x Wear pads rollers Excessive wear cracks Telescoping function Wire ropes Excessive wear corrosion tension Wire ropes should be inspected in detail when boom is disassembled for inspection every 4 years Hydraulic hoses Oil leakage any damage Sheaves Excessive wear free play Lubrication Extension Elevation cylinders Piston rod cylinder tube Cracks deformation scratches Oil leakage faulty function Anchor pins Wear Lubrication Platform leveling system Function Levelling cylinders Oil leakage Relief valves Oil leakage Stop valves Oil leakage Platform Cracks deformation Anchor bolts Looseness Hook for safety belt Cracks deformation Hydraulic plumbings Oil leakage any damage Auxiliary devices Engine start stop system Function 8 15 damage of the components UNIT ITEM REMARKS Auxiliary devices Emergency pump Function damage of the components Emergency stop Function Hydraulic out lets Oil leakage Pre set pressure Receptacles Any damage Alarm horn Function
6. 2 mo Ban gob 5 3 nee nee 1 on 3 EZ g o un CRIO e 82 ges JB E BK SIC yis CAG GR iA E BBs i Ha Max Fk aar E Won 3 CRB 2 5 CRT 5 TIAE 2 IF USCE 4 SER Set this connector to the following positions depending on the Model 5 123 15 403 and SR123J ISR403J 123 position SRI82 ISR602 182 position 446 2 1 Electric circuit for R 2 N 5 13 foy witout CE MS selector switch c E Ge BM ES 777 lt T een SHL SHH iav su ex R ye Ris 47K Rig ATK RI bia Ria R20 47K A 921 22 47K R23 47K R24 47K 52 A32 Icar Sea OD izk R26 15K CRT SRLS arar SRNR DES RA e 5 16 53 EPP sia 169 1 10 EIN ELI ee 39 100 n Nee rt res BOB AUN poteris ir er rer 5 i5z orr RLS 1640 Sea Run
7. damage of the components Working range controller Moment limitter Function Sensors for any damage Limited working radius Controlled speed Motion alarm buzzer Function Safety switch Function 8 16 The following tests are to be carried out annually Function test TEST ITEM REMARKS Load test Function Natural des Extension cylinder Sevviceable limit cent test Elevation cylinder 2 mm 0 08 10 minutes Operational Elevation speed speed test Extension speed Rotation speed Travel speed Platform swing speed REMARKS 8 17
8. 210ka cm 3 000psi PC valve G PE1 4 P OF 172 Gauge 2 TCPESZ72 uw Swivel joint 7 6 Combination valve Main contro valve NO 2 Main control valve NO 1 Platform level solenoid valve Double pilot check valve View A A 7 7 ELECTRIC CIRCUIT DIAGRAM fe Spec CHW 622512 652348 ROI Sooo 3 aT T mi TEE EN UE CUNT RO BEX rn
9. Upper control box E S 8 8 is operated switched on when Travellin Emergency pump s w Turntable Platform swing Solenoid V Batteries Platform level solenoid valve 5 10 3 teh for Spec ACC AB Interface beard with 5 selector swi for Upper control box Lower control box rpayerado Fl Uo ST 20181510 SIU selectpr sited b ATEA pIOUSJOS 243 ULOJE d Plousjos Suas a Ud z eas saag 5 10 4 gun ONUOO JAVA preoq eoepeju Lower control box amp 2 E 5 E 9 A a 2 VO 1 O O OVO ld ays wog Q A S doys ays 408 4 452319 48341 for Spec Slope sensor 3 gt When the 6 exceeds 39 Slop opened 20 4 91918 5 11 1 Emergency stop s w Y EE 3 D E 8 E i gt 8 s 2 8 3 E 5 11 2 Emergency stop s w Valve control unit Interface board Batteries Opened when the slope exceeds 5 Slope sensor 5 5 11 5 for Spec Ab Yy 652314 45635 Upper contorol box mergency top s w E gt
10. Operate the boom thoroughly and ensure the platform keeps its level position Levelling cylinder Check for oil leakage Relief valve Check for oil leakage Stop valve Check for oil leakage Platform Cracks deformations Check for the items Platform anchor bolts E a Check for looseness Hook for safety belt Check for cracks deformations Hydraulic plumbings Oil leakage any damage Check hydraulic hoses pipes for oil leakage and any other damage 8 9 UNIT ITEM MONTHLY INSPECTION ANNUAL INSPECTION Auxiliary devices Engine start stop system Check the function at both upper and lower controls Check the solenoid and linkages for any damage Emergency pump Stop engine operate the boom using the pump and check that it functions correctly Check the pump for oil leakage Emergency stop Check for the function Slope warning buzzer Tum on main key switch and make sure the warning buzzer sounds for a second just after tuming on the switch Remove slope sensor incline it about 3 and check if the waming buzzer sounds Check slope sensor and buzzer for any damage Hydraulic outlets Check the self seal couplings for oil leakage Using a pressure gauge check the preset pressure Receptacles AC 100 volts Check for any damage 4
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14. Single holding valve is mounted on the Elevation cylinder to prevent any Natural descent of the cylinder caused by the gravities of the boom and the platform NOTE Natural descent This phenomenon causes the hydraulic cylinder to be extended or retracted due to external forces Mr TES S se Z PA gt 176 ZA lt 2 ZAZAN GA an ei 1 1 lt Elevation cylinder Single holding valve 23 5 3 23 Inspection procedures 1 Check the external oil leakage thoroughly 2 Check the internal oil leakage using the following steps Internal oil leakage can be inspected by checking the Natural descent of the elevation cylinder 1 Park the machine on an area of firm level ground 2 Start the machine and position the boom so that the boom angle is set at around 45degrees 3 Stop the engine then put a mark on the piston rod of elevation cylinder as shown in Fig 2 Caution Take care when marking the piston rod so as not to damage it Fig 2 Mark A after 10 minutes Elevation cylinder 4 After marking the rod measure the dimension A as shown in Fig 2 then leave it for 10 minutes 5 After 10 minutes measure the dimension A between the mark made in step 3 and the edge of cylinder tube as shown in Fig 2 A A Natural descent of elevation cylinder Serviceable limit
15. 0404004 ANH TOON Hi 4 ot PIN NN NBM 4 M idi E B 4714 AAR OO HNH YO AND TION DRO NH Y HNM DOO m AAA NNNNMNNNNAMAMIA AAA ANNNN ni 40 O00 N NNM 227 rg METERES 420909 ANN TD Er ONO ANT OG A A A A AA EPI ANH TOTO ANNE VII OQ et Ame Vara ce E POWER CNT LOWER CONTROL BOX TIT TIT 4 7 1 SR 123 for Spec Ab 6E2349 665351 ic circui 1 Electr ejes 82955527 5v 2T SEET PEZT lt n 6 228 emn EADS A 98 s us 301S ME eot T3 s 5 X o a RE a Gr K ijr 38 tuo B f T 51 vedi 19 3 vot V 3 MES uw 212 75215541 5 m Li 325 WSROJZZINTOT n 9 m H NIUH 59 4 TP i N i gt 9S5vt zT n er x veg zie row my 5 ms dH 5 29 n 229 gt 2 asi 9903 1 2522 EUR ENS husz A HIS BETIA E 9 2 15 2 E or m3 et 948 T es gt 25 ae s
16. 13 Wear ring ring 14 U ring 6 9 QQ 49 3 Tightening torque 32kgf m Q3ft Ib 6569 CD Q9 ie e rep 3 26 The Double holding valve is mounted on tbe extension cylinder to prevent Natural descent of the cylinder caused by the gravites of the boom and the platform Valve cartridge 900 15 CX 5209 9 OO 9 lt rang K 18 19 SR io E SES ERES EU aid Po Nic imme SSIS ESSN 18 B TED Lock tight is applied Q3 Q2 921049 Q4 Details of the valve cartridge Details of the valve cartridge _3 27 Inspection procedures 1 Check the external oil leakage thoroughly 2 Check the internal oil leakage using the following steps Internal oil leakage is inspected by checking the Natural descent of the Extension cylinder 1 Park the machine on an area of firm level ground 2 Extend the boom by about 1 meter and raise it fully 3 Stop the engine and put a mark on the 2nd boom as shown in Fig 2 below Fig 2 Mark B after 10 minutes 4 Measure the Dimension B as shown in Fig 2 above then leave it for 10 minutes 5 After 10 minutes measure the Dimension B as shown in Fig 2 B B Natural descent of extension cylinder Serviceable limit 2mm 10min 0 08 10min 6 If the Natural d
17. 2mm 10minutes 0 08 10min 6 If the Natural descent exceeds the limit 2mm 10min check the single holding valve and the elevation cylinder for internal oil leakage NOTE To indentify which has internal oil leakage the single holding valve or the elevation cylinder reter to the following steps 3 24 1 Under the condition that the elevation cylinder is loaded with the gravities of boom and platform disconnect the hydraulic hose connected to port A at the single holding valve 2 If hydraulic oil drips continuously from port A of the single holding valve this indicates internal oil leakage from the single holding valve However if the oil drips stop after a while this indicates that elevation cylinder has internal oil leakage Caution Before disconnecting the hydraulic hose make sure to support the boom using such a crane to prevent the boom from unexpected descent 3 25 Tightening torque 64 94kgf m Lock the set screw by using 460 680ft Ib a center punch after tightening 2 oy eg pert Cylinder tube R12 R4004 Back up ring Piston rod U ring holder Cylinder head O ring Bushing Steel ball U ring Set screw Back up ring Roller Dust seal Pin O ring Snap ring Back up ring O ring Bolt Collar Block Holding valve Piston Holding valve cartridge
18. Rated pressure 140 kg cnf 2 000 PSD Constant flow 8 liters min 2 1 gals min at PF port Relief valves P3 Adjustable pressure range 90 140 kg cri 1 280 2 000 PSI Pre set pressure 140 kg cnf 2 000 PSI T Relief valve Lock nut P3 A LE e I2 Adjustment screw Relief valve 11 12 13 14 NOTE Refer to ADJUSTMENT SECTION to adjust the Relief valve 3 13 The swivel joint is installed at the rotation center of the turntable to supply pressurized oil to the Travel motors Fig l Snap ring Fig 2 407 01897 1 Remove snap ring and spacer 2 Press out the shaft 2 from the case D using a hydraulic press or pull the shaft out of the case D using gear puller as shown in Fig 3 9 552 3 Remove the spacer from the shaft 4 Remove all of the O rings from the shaft 1 Check case D and shaft 2 for excessive wear cracks scorings and any other damage 2 Check the clearance between case D and shaft 2 If the clearance exceeds the limit replace the shaft or the case Limit of clearance 0 4mm 0 016 3 Check each groove on case D and shaft for ridges and sharp edges Ridges and sharp edges should be removed before installing O rings as such faults may cause damage to the O rings Assemble in the reverse order of disassembly paying particular attention to the following po
19. 3 17 1 Hydraulic circuit C PE 3 17 2 ae 3 18 TRAVEL MOTOR UNIT for Spec 20 3 19 1 Hydraulic citcitit iz terere este TI d addo 3 19 2 3 D view of gear box 4 4 1 2 3 20 3 3 view of motor eee 3 20 ELEVATION eene nennen 3 21 ELEVATION CYLINDER with descent valve 3 22 SINGLE HOLDING VALVE for Elevation cylinder 3 23 1 Inspection 1 1 1 isandaan 3 24 EXTENSION 222 143 26 DOUBLE HOLDING VALVE for Extension cylinder 3 27 1 Inspection 2222 nene 3 28 PLATFORM LEVELING 5 8 2 2 2 2 3 29 1 on 3 30 2 Inspection 0 3 30 3 Air bleeding 3 31 LOWER LEVELING 2 0 2020 21 3 32 UPPER LEVELING 3 33 DOUBLE PILOT CHECK VALVE for Upper leveling cylinder 3 34 COMBINATION VALVE for Platform leveling system 3 35
20. 4 Note on function NO 1 Input Valve control unit Out put Foot s w 21 3 Potentio meter Upper control Out put signal for Motion alarm buzzer and Automatic accelerator Solenoid gt pr circuit gt Dy LED 7 Red for Boom Travel 37 5Vy AMi interlock Dither Delay Ur l5V Solenoids for va Main control valve A 5 VA ae Sol i vAO c i Delay DOWN i Delay UP 1 Control switch Lower contro Y NULL B B Delay DOWN Emergency X stop switch Q z 1 gt EN G Loue 4 14 5 Note on function NO 2 Foot s w Outputs 24V hen the machine is level Motion alarm buzzer 1 F2 o4 A x stopp ance Rotation CW limit Rotation CCW limit gt 8 Emergenc e Upper Control E 1 Ta Jo 70 1 11 Ko cw 14 Ro cew Jext fr IN 5 m zn leje pown REY Tra 8 For Ta Valve control unit Qi SCOM 12 gt Rotation Main control valve Upper control box Lower control box Extension Elevation Interface board sof lt 2 n zin
21. 4 21 The Engine stop solenoid Safety relay etc are installed as shown in the figure below Engine stop solenoid Safety relay 1 Engine stop solenoid Rated voltage Rated current 10A or less Actuating time 10seconds after Switching off Function chart E 72 y Solenoid 77 DEAS LU 10seconds P The solenoid is switched on for about 10 seconds 02 when the power 24V applied on Signal line 154 is turned off and will switch off automatically after 10 seconds Black 4 22 2 Safety relay M N White White Green Black White Aiternator 3 Glow indicator Rated voltage DC24V Rated current 16 4 Resistance 0 0540 Time reaches to 800 C 20 25seconds 4 23 4 Battery relay Rated voltage DC24V 100A continuously 1 000A 30seconds Battery relay Starter motor 4 24 Rated voltage DC24v Delayed time 5 2 sec The relay contact opens in S 2 sec after 24 1 v are applied to the terminal No 3 Contact load 0 5 Ampere Weight 80 gram Color code Blue red Blue yellow White red Black Black yellow Yellow 0IL PRESSURE SW PUSH ON _ ALTERNATOR 5 ELECTRIC CIRCUIT for INDIVIDUAL SYSTEM SS TEM Foot s w Upper control box Control board M s do
22. 46 4235 6 roni aesjsu rjwajed 4243 7 2 s cT Ab ktz3 9 655351 for Spec Turataple Aa3 ME LA gt Zing HE 451 n 4 ec ong sc 44 64402 232034 174 vay cc 321 124041 1529 9 404 4343 Xad g H1 184841 pow 7073022 TO T 5902104 A EXLAQ 8444 2144574 amp 3 NO m im 1071003 sis gt LEN T6 abunon 4 poquaado st wq iro si Koes SIL addy A dund t E a i Ay iy 3st 73 dei 3 End M 2 m 4225 Kabawa 2 Ab 4553 2 for Spec 224 44 011403 270024 Pavey 4427 13441 a337d riwajed AIAST 217194941 T ON I A z 2 Eu 591427194 c 2 1 qq 5444 2459 5 o FFT BATA 24 2 abunen voq 2749141 1 loq ayp wawa jjo geo poquasdo st bucyarus aa Wo st YL 4 dags afi 4 ME 4235 Qua SN 6523196855351 Ab o
23. F adii T 1 1 gt e t CIE c H H Cure 35 51 2 TIOSLNOD MIMO brand SR 123 1 Electric circuit for Spec Ab Sy 655552 ce E S 00 6 WUN 1023005 9A EA CRUN IBZ 1 O ANH THOR ACO emet DD O ANP J anime ubt e acia act CAI ES AT NIU INR NEAD MA LU d ms FANNIN NORA AMA 1 dmn coo AN ON A Pa NINN FFA MIFTE T nun lbs dem BOX POWER CNT CDM ORO 4 TR LOWER pense 2 Meses 4 i ij T T TET m is 1 Electric circuit for Spec A8 Si DOO ANH YT ORCI NMI OT DNA Vr AAA n AN ANAN OON R12 N5119 614 00580 e io ZIGZXJ3E IEMET EERE EES POWER CNT on 12546579 C2 amp R2 were installed since Dec 1999 Serial No 664636
24. Rotation switch Engine start switch 4 5 6 7 Accelerator switch 8 9 9 Emergency stop switch Emergency stop switch Charge warning lamp 10 Platform swing switch 1 Emergency pump switch Engine water temp lamp Horn switch Engine oil pressure lamp Platform level switch Glow indicator lamp Main key switch Power lamp 7 4 HYDRAULIC CIRCUIT DIAGRAM Platform level sol V Double pilot check valve alc 5 E Y Main control valve NO 1 XL C Platform swing motor Boom Py 2 000PSD Platform swing sol V 140kgf cri P3 In line filter LAFZI Main control valve NO 2 Travel R Pressure A Hydraulic Bauge i lt gt 2 2 e 2 RO bind PSD A PAPE usar 2 Rotation brake sol Shuttle valves Dr A4 B4 Rotation motor applied to the Ser No 662102 665013 Rotation motor Single holding valve Elevation LL E EE Double holding valve Extension DR ien gt Double ue check valve P4 230kgf cni Upper levelling cylinder Lower levelling cylinder 3 270PSI Travel motor x i Haroj Travel motor Right t 1 era H t Dr
25. A2MOT 101 204114 Berg 2 duwag taa s 5 M s njd 4915 6r L 49 ao 4hge24d n AD Lr 9r wn 1248542043 oO 45 M2N 1 121044 151915 Iq Mad 553194 2004 IND 37 u3 4175 SUMS EF s E Aosuas 244 Ss 33 SS 5 z E gt x 7 7 Pr EE m TORN PON SATOR 1943492 zo 104 5 TORIS 4 aliy masg LR x e S N 7 12 NS ER CECI ds pU P Beaded E n 5 53 a lite d SS L tax gt anna E Oj Saul gt gt Sj JS 2 gt 2 gt 5 9 S X FE m 2 gt FI Sov SN JO 5 OJ qa 25 8
26. H TRAVEL L Rev E iL 8 ELEVATION Down E 8 i EXTENSION In ip OE d ROTATION CW 5 uc d H TRAVEL L 1 1 3 ELEVATION Up Em H 2 EXTENSION id EH E 4 i ELE if HUS ES 31 IE TRAVEL Few P RD12 N5113 z nw i TRAVEL A Fwd i Neri eis R18 C1995 2 A ES R12 N5119 3 22 5 Nue isi E 7 E ware 659 1 ia It fit TRAVEL LEFT 624 3 1 MAIN CONT ir LE J sur EPA FLA E VALVE No 2 orgs Ci E i ir E 2s H i 48 2 3 i 2 13 ELE E iB P ROTATION SEIS T i i SEL 5 3 21 21 Iud z 9 2 ees a fd Hae oa a E E 3 MOTION BUZZER case E ap 3 LOP TION CABLE e Exc d HOUR METER Punt Roan P cover sot 45 1 134 DL 3ze 338 a FUSISCR c Y KEY SWITCH a lt SRI z gt at a E pu 71 91 17 69 al Se 2 norm gg ER W TI 7 11 1 23 Xe jet
27. Inadequate adjustment of GAIN voltage Readjust the GAIN voltage at the Valve control unit In case the GAIN voltage is normal press the Manual over ride pin installed on Solenoid EL Actuator is operative Defective solenoid Replace the solenoid Sticked Piston in Pilot valve installed under the Solenoid Clean or replace the Pilot valve is not operative Sticked Main spool or Valves caused by contaminated hydraulic oil Clean the hydraulic system and replace the hydraulic oil PC valve is sticked and the unloading pressure is not obtained Clean or replace the PC valve Sticked Pilot valve installed under the Solenoid Clean or replace the Pilot valve Sticked Main spool Clean or replace the Main control valve Assy Sticked Sectional PC valve Clean or replace the Sectional PC valve Defective Springs Replace the Springs Clogged Orifice Clean or replace the Orifice Distorted Valve body caused by improper mounting Remount or replace the Main control valve Operational speed is too fast when operating control lever slightly Check the NULL voltage at Valve control unit NULL voltage is Inadequate adjustment of NULL voltage Readjust the NULL voltage at the Valve control unit Actuator haunts after overhauling hydraulic system too high Ai
28. sey onuoo Iamo ur papasu yun jOnUOD UO IMA Supmonounj jou ere onuoo Jedd uo uoneiodo dumd pue Sums unope d onuoo 1944 10 1940 JU Surmonoung jou ere suome1edo oAPI pue UOUN UOTPAS H uonisod odd eq 01 qos Kex 19 uonmsod MOT 28 395 ST OHMS Ay 2 awado pue YAMS 1004 55914 passaid jou st OHMS 2004 1 t ASN pue 10J 1dooxo euore1odo uou SI oruoo 1eddn ou pourew esne 191024 7 3 identifications of Control devices and Fuses F4 Emergency stop 10A F5 Main power 20A F6 Spare 10A F6 Engine start 10A FS Working light 5A 2 Working light d F4 Accelerator 3A a Platform swing level amp F3 Emergency pump 10A F2 Engine start 3 dey Fl Hom 104 Fuse hol F3 Limit switch 10A F2 Accelerator motor 5A Fl Engine stop Fuse holder Platform level adjust valves control box Upper control box Working light switch portent switch Hour meter Metal connector for Optional Remote control Rotation control lever Elevation switch Emergency pump switch 1 2 3 4 Extension control lever 5 6 Elevation control lever Travel control lever 7 Power lamp 8 Extension switch
29. 109 lt Elevatipn In Cw cew _ OUT UP _DEWN_ FoR REY KEY Rotation Extension Elevation Travelling Travelling 1 Platform swing is operated is operated hen Travellin hen Boom or 4 15 R12 N5113 witout CE us selector switch The interface board is located in the lower control box to control the electric system 1 OLN tak H C8 2 18 9t ate ue te H 18 1 8 E 3 8 Mori 50 WT LAY E ue qere 25 g x 0 0 S RRE SERS OQ ON Was Walt f s 98890901 39795751 XH HEH 9 sgn EC n JL on Snren 281 oin i i9 T 44 9160 WN en 4 16 1 R12 N5119G with CE US selector switches Set each switch and connector equipped on the board as shown in the figure below depending on the specifications of the machine E d n 8 uw d 3 Ns 5 n d x 5 8 5 256 9 223 8228 p X ES en 9 mu gt Eiin 8 i 25 868 BOP on bn as Ci goo as on aie 2 8 De 8a 8 5 B 2 8 8 9 ges du B36 BAA 2
30. 123456 ETE Sor sus Accu ss 2222 ES 25 1 5 3 gt i 1 Light LL EP 1 H t 1 t LOL RA APonER 3 5 Les 52 01 pz blarcuc FS 106 ST CHAIN t 3 HES 5 2 E RES orn LEL T e EXSZ 1 ry i H J e E gt Sucre 2 acer x SENSOR n a FLATF ORM LEVEL SOL ens LOW ELECTRIC CIRCUIT DIAGRAM for Spec 652349 558351 OWER CONTRO X On for Extension Remote contro box for Travel msn eue Elevation mamn brane 1 P F amp DDR 3 a at ER 5 n ETOP POWER CNT 5 ses H lt to i 34 12 12 12 yid iz a 15 233 is t Shaz 15 i 16 m i i m 2 TEN is is 5 E p Eras Each 2 Zoe 20 5 atz 2i 2 ibn nov 124 22 2z 2 E 3 ge TE B Bz2 ait fi AM
31. Operate the safety switch and check that the engine Stops and that the power lamps turn off range controller Moment limitter Working Function Operate the boom using the lower control and check that it functions correctly 8 2 POWER UNIT UNIT DATE Radiater Cooling water level Battery Electrolyte level Oil pan Engine oil level Fuel tank Fuel level Hydraulic Hydraulic oil level oil reservoir CARRIER Tyre Excessive wear cuts Wheel nuts Looseness Steering linkages Deformation cracks Travel motor unit Oil leakage Carrier frame Deformation cracks Crawler Track link shoes Wear tension TURNTABLE Rotation Function gear box CONTROL SYSTEM Control Function J levers Free play n Switches BOOM Boom Deformation cracks Boom pivot Any damage pin 2 T Extension leakage Elevation cylinder Natural descent PLATFORM Platform level Function ing system Platform amp Deformation cracks swing device wear SAFETY DEVICE UNIT ITEM DATE gt Engine start stop system Function Emergency pump Function Function Slope warn ing buzzer Function Alarm horn Function Motion alarm buzzer
32. SP series SR series Tyre Check for excessive wear and cuts Wheel nuts Track shoe link Check for looseness Tightening torque 25 30kg m 180 220ft Ib Check for tension and wear Drive sprocket Check for excessive wear motor unit Idle wheel and cracks Track roller carrier roller Check for wear and oil leakage Travel Oil leakage external damages Check for the items SSS Gear oil Check oil level Change gear oil Oil change interval 1 200 hours or Annualy j Abnormal noise excessive heat Run the motor and check the motor gear box for the items Bolts nuts Check for looseness 8 6 UNIT ITEM MONTHLY INSPECTION ANNUAL INSPECTION Steering mechanism SP serise Linkages Check for deformation cracks Wheel bearings Jack up the machine and check the wheel bearings for excessive free play and any other damage Steering cylinder Operate the cylinder and check for oil leakage abnormal function Lubrication NS Supply grease to each grease fitting Travel speed limit system Travel speed Perform travelling operation with extended boom or setting boom over the horizontal and make sure the travelling speed is LOW Flow divider valve Check
33. and adjust the pressure to 210 3 0009PSD by turning the Adjustment screw of relief valve P1 6 2 adjust the Preset pressure of Relief valve P2 installed on the Main control valve No 2 take the following steps Preset 2105 3 000 PSI Relief valve P2 210 kgf cnt 3 000 51 Main control valve NO 2 1 Remove the plug from the Pressure test port installed on the out let line of Pump NO 2 and set a Pressure gauge onto the pressure test port 2 Start engine and insert something such as a Steel shaft between Drive sproket and the Track links on the right side travel motor to stop the rotation of travel motor 3 Perform Travelling Right operation and actuate the Relief valve P2 4 Read the pressure gauge while the Relief valve P2 is active and adjust the pressure to 210 kgf cni 3 000 PSI by turning the adjustment screw of Relief valve P2 6 3 To adjust the Preset pressure of Relief valve P3 installed on the Priority valve take the following steps Preset pressure 140 2 000570 PSD Relief valve P3 140kgf cni 2 000 51 Priority valve 1 Remove the plug from the Pressure test port installed on the out let line of Pump NO 2 and set a Pressure gauge onto the pressure test port 2 Start engine swing the Platform fully to the Right and hold the Platform swing switch at Right to actuate the Relief valve P3 3 Read
34. and prevent the introduction of foreign particles When assembling 0 rings or packings apply a little grease or lubricate them with hydraulic oil When installing taper plugs wind seal tape at least one and a half times around the threads 3 2 It should be noted that hydraulic system failures are often caused by defective hydraulic oil which in turn is caused by improper maintenance To insure maximum utilization the followings should be observed 1 Oil temperature should be below 70 and ideally below 60 c 140 as heat causes earlier oxidation On the other hand when the oil is very cold a warm up period is recommended before operation 2 Regularly check for contaminants in the hydraulic oil Contaminants in the may speed up the oxidation process 3 Avoid introduction of water into the hydraulic system as water will cause additives to deteriorate and if the amount of water is sufficiently large it will cause the oil to emulsify 4 As a rule do not mix oils from different maufacturers Furthermore do not mix oils of the same make if they have different product names or viscosity differences Improper mixing will cause the additives to deteriorate 5 Eliminate oil leakage as much as possible from the hydraulic component and its plumbings 6 Make it a habit to check the oil regularly Guidelines for oil change An oil change should be carried out every 1 200 worki
35. lt wag Cua ce 92 oou 5 pue 99399 ON EH9S 666179901 249 oso preoq ooupiojug aae E ONUOD preoq prouajos dois 0 3 Butuuni sums JOIE UIE 2248 spuo22s c u uado sipeioo SUL 8114 O Q Vs onuoo Jaddy A S 1004 q 3141514 xu ATE 5 3 3 TS pA E n N No D lt hi a EE x 5 lt Mys MOI Hf0t3 0303 jaana pd 4243 Jon GAGA 7947007 Atz 2 590421909 zxVL 5341 241584 FUR 914843 BAA Ae P02A 15 abun ve Var q xS 24294 230 A UT OS ERS wer Wout 1o shos put 40 si 4004 244 uo si SOLL 2 4915 Auablauy ADU ab BUF ME 4235 DAL 655252 a x S Platform M s 8917099 10130304 2 0 a 10d 10190308 742407 VV T 7 t 2204 ZX VSI Q Q saul apto amp Aepzoptgad a001 penat 2st MTS 244 oM d put 5paquiado si 241 gatis si M 4915 pee 44
36. pauvado ZE 247 taym pouado 4 Q for Spec AB Turntab e se men FUSE 5 iqabus 494 40 ex izey 242 A240 afia aver 243 4apuyy woog 7 9244 PMA Kng HEZE Hoog puy ME 49 04 22 Lower control box 49 HOS 03 4e paads alia PHF 243422 053 21477 244 UMOYS 0 fusa SHOU G Gl pA 430 wo payogus ovo SDT peo 5 Accelerator N ope 151 i OS E YUEN Emergency O pump Hw d IS ration signal __ Travel operation Boom ope Interface Fusible links UTAX ES Q 5 9 3 Batteries Dc 24 T EL SYSTEM fov Spec Ab Yn 64234 48335 Platform ig is operated Switched on when Travellin Emergency pump s w Interface board selecto Switch Platform swing Solenoid V Platform level solenoid valve Batteries 5 10 1 TAG 65532227 fo 2 Interface board NSE selector Switch for Spec Ag Upper control box Platform swing s w Platform Level s w J 8 x Lower control o mmm g is operated E gt E Travellin EN joo Emergency pump Ww board Platform swing Solenoid V Batteries Platform level solenoid valve 5 10 2
37. 4 Cracks Check each boom thoroughly for cracks For fine cracks use COLOR CHECK or penetrant check Pay special attention when checking each pin boss and welded part 2 5 5 Extension Retraction wire ropes After disassembling the boom inspect extension and retraction wire ropes as follows 1 Measure the diameter of both the extension and retraction wire ropes with slide calipers Replace the rope if the decrease in the diameter is more than 396 of the nominal diameter Fig 3 Nominal diameter Serviceable limit Retraction wire 8mm 0 315 7 76mm 0 306 or less Extension wire rope 12mm 0 472 11 64mm 0 458 or less 2 Check for broken wires 4 Xf any kinks are observed replace If 3 or more wires of a wire rope the wire rope are broken in a twist stroke Also an extremely deformed wire replace the wire rope rope requires replacement Fig 4 Fig 6 3 Check wire ropes for rust 5 Carefully check the end sections If rust is evident around the inside of a wire rope especially sections of the wire rope replace it A and B Replace the wire rope if any defects are found Fig 5 2 6 6 of extension retraction wire ropes Extend retract the boom for a full stroke check for any jerky movements caused by loose or stretched extension retraction wire ropes If the wire ropes are loose adjust their tensions as foll
38. 4215 AMM a bra Ab N 652314 5955 Q 5 S Platform 4918 2494 722209027 WEL zx WLI 99 syay 914174 1222009 BALVA 24724 22 422 Mg dund 426433 9294940 51 Tees 247 UIM 34 shops si 1094 BHR potus c sud dais 4 E 79 A daas 40 1539097109104 3332 bt 401 w23x3 VON 4 1227997 ww EE rp amp 9800 10 SI odor UOISU2 X9 WOO OY suado Jo pue SOYOHMS Z OT pue gy 2eds 101 zx WLI 99 e X EI seq 214574066 5 LST 951 i THF 90423 ajo lt o piroq 220 4217 44 dund hy Ana bawa 6 for Spec 655352 45 dags 1 3 WE UaU A Flatform 2 5 yaqaidorRajod 12751 5 5 2 AMICHI Spec Yy 6523196663561 Elevation 2 Ele yation BRE lt lt esh go Leyer
39. 44 08 E08 GELI LL 0061 p e SPECIFICATIONS Model SR 123 ISR 403 lw eight Overall weight 7 650 kgf 16 865 lbs Max ground contact pressure 0 66 kgf af 9 4 PSI Engine Model ISUZU 4JB1 PA14 i Since Nov 1998 Serial No 6610342 ISUZU AAJBLPAAI S Total displacement 2 771 169 in Output power 55 ps 2 200 rpm 40 5 kw 2 200 rpm Output torque 18 0 kgf m 1 800 rpm 130 ft Ib 1 800 rpm Engine oil capacity 6 6 liters 1 74 gals Cooling water capacity 11 0 liters 2 91 gals Fuel tank capacity 108 liters 28 5 gals Engine speed 1 200 2 300 rpm Battery DC12v 70 AHX2 Platform Rated load 250 kgf or 550158 or 2 persons Tools 90 kgf 2 persons Tools 200 Ibs Max allowable side force 41 kgf 400N 90 165 Inner dimensions 1 800 750X 1 100 mm 5 9X 2 46X 3 6 ft Rotation angle 180 lt Maximum floor height 12 0 meters 39 ft 4 in Maximum working radius 10 6 meters 34 ft 8 in Boom Boom length 5 0 10 9 meters 16 4 35 8 ft Boom angle 20 70 degrees lt lt Rotation angle 360 continuously gt Operational Elevation UP 55 10 seconds stroke Speed DOWN 55 10 seconds stroke Extension
40. 6 6 3 Adjustment procedures of Operational 6 7 4 Trimmer s identification on Valve control 6 14 ADJUSTMENT DATA 5 6 15 APPENDIX 2 4 7 2 1 Identifications of Control devices and 222 7 4 HYDRAULIC CIRCUIT 7 5 HYDRAULIC CIRCUIT DIAGRAM for Spec 20 7 6 IDENTIFICATIONS OF HYDRAULIC 7 7 ELECTRIC CIRCUIT DIAGRAM for Spec A6 S N 652319 652348 7 8 ELECTRIC CIRCUIT DIAGRAM for Spec A6 S N 652349 655351 7 9 ELECTRIC CIRCUIT DIAGRAM for Spec A6 S N 655352 7 10 ELECTRIC CIRCUIT DIAGRAM for 8 7 11 ELECTRIC WIRE 55 2 24 7 12 ELECTRIC WIRING 7 13 IDENTIFICATIONS OF ELECTRIC COMPONENTS 7 14 TIGHTENING TORQUE 58 7 15 MAINTENANCE MANUAL DAILY INSPECTION 8 1 DAILY INSPECTION CHECK 8 3 PERIODICAL INSPECTION PROCEDURES s 8 5 PROCEDURES OF FUNCTION 87 8 11 1 GENERAL INFORMATION 406 0 0559
41. Alarm horn Working range controller Moment limitter Check for function Check for the function Check the switch and horn for any damage Check each sensor for any damage Check each limited working radius Check that the speed control system is functioning correctly Motion alarm buzzer Check for function Safety switch Check for function Foot switch Check for function 8 10 following tests are to be conducted annually All of the tests are to be carried out on firm level ground TEST ITEM DESCRIPTION Load test Function 1 Load platform with the rated load 2 Operate the machine using the lower controls and check that the function is correct Natural descent test Extension 1 Set boom as listed below to check the natural Elevation descent of each cylinder cylinders Boom angle Boom length MAX Extend 1 meter 45 MN Extension cylinder Elevation cylinder 2 Stop engine and leave it for ten minutes 3 Check the elevation and extension cylinders for Natural descent The limit of Natural descent 2 mm 0 08in 10 minutes Operational speed test Elevation speed UP DOWN Raise lower boom to its full stroke with the minimum boom length and measure the UP and DOWN speed se
42. Function Safety switch Working range controller Moment limiter Function Function Carry out both of the descriptions for Monthly and Annual inspections when conducting Annual inspection DESCRIPTION ITEM MONTHLY INSPECTION ANNUAL INSPECTION Water oil leakage Check for water and oil leakage thoroughly E Radiator Check for water level con tamination and replenish or change the water if necessary Check the function of radiator cap and for any damage to the radiator thoroughly Check air filter and clean or replace the element if necessary Water separator Drain water from water separator Disassemble and clean thoroughly Cleaning interval Every 6 months Fuel filter Check filter for fuel leakage Replace the element Replacement interval Every 600 hours Battery Check for the electrolyte level and clean battery terminals Fan belt Check for wear and tension Alternator starter Check the function Valve clearance Remove tappet cover and adjust valve clearance Adjustment interval Every 1 200 hours Engine oil Check oil level and contamination Change engine oil Replacement interval Every 200 hours Oil filter Check filter for oil leakage Replace the element Replace ment interval Every 4
43. OUT 25 5 seconds stroke IN 255 seconds stroke Rotation C W 11015 seconds 1 turn lt 110 15 seconds 1 turn gt Travelling High Forward 244 2 seconds 10 m 22 2 seconds 10 yards speed Reverse 24 2 seconds 10 m 22 2 seconds 10 yards Low Forward 51 8 seconds 10m 47 X7 seconds 10 yards speed Reverse 51 8 seconds 10m 47 7 seconds 10 yards Platform rotation Right 20 4 seconds stroke gt Left 20 4 seconds stroke Maximum allowable slope 5 degrees lt Gradeability 24 degrees gt Hydraulic Hydraulic oil Tank capacity 170 liters 45 gals system Recommended Shell Tellus oil 32 gt Hydraulic pump Gear pump Double lt Discharge volume 24 5 24 5 rev 1 4941 49 Rated pressure Pump speed Main system Elevation Extension Rotation amp Travelling 1 200 2 300 rpm 210 8 kgf af a 3 000 59 PSI Sub system Platform rotation amp 140 8 kgf af 2 000 8 PSI Fly jib ft m Rated load 250kgf 550165 45 9 14 42 6 13 39 4 12 36 1 1 3 3 0 96 2 FTE o S60 97 r O EZ o 4761 n 4 91 GUET 8 6 a 99 EE a 979 e 8 6 2 MECHANICAL SECTION Front idler Travel motor Lubricator Recoil sp
44. PLATFORM LEVEL SOLENOID 3 36 DOUBLE PILOT CHECK VALVE for Platform leveling system 3 37 ELECTRIC SECTION UPPER CONTROL 204 4 2 1 Sect um rere deed ee ede peo rper eia kl 4 3 JOYSTICK 4 4 CONTROL BOARD radere lo ers 4 5 LOWER CONTROL 00 0 0 4 6 1 Electric Circuit esa eee ee nce sie Tere eben ses ary da Dod E eo dence 4 7 MAIN KEY ee reo arra deae 4 9 External Viewed eee san 4 11 2 Trimmers and their 2 4 0 4 4 12 3 LEDs and their 2 2 4 413 4 Note on function No 1 1002 4 14 5 Note on function No 2 4 15 INTERFACE 2 2 4 16 1 Blectrie cet ve ACCELERATOR esses ene 4 18 1 o 4019 2 Inspection 2 4 42 0 2 0 2 4 19 SLOPE SENSOR tates shee a Ra 4 20 FOOT SWIECH 4 0 ELECTRIC COMPONENTS attached on 4 22 1 Eng
45. Rotate the Turn table with the minimum boom length and the maximum boom angle and measure the turn table rotation speed seconds rev Travelling Travelling speed straight Travel the machine exactly 10 meters 10 yards Forward and REVERSE on firm level ground and measure the travelling speed seconds 10 meters seconds 10yards NOTE Travel the machine with the minimum boom length and with a boom angle which is less than horizontal 6 5 5 Travelling Pivot turn speed Perform Pivot turn to both Right and Left and measure the Pivot turn speed seconds 90 6 Travelling Spin turn speed Perform Spin turn operation C W and C C W and measure the Spin turn speed seconds 90 2 Specific Maximum operational speed Function Direction Upper control Lower control UP 55 7 sec stroke 55 77 sec stroke Elevation 55 7 sec stroke 5527 sec stroke 25 5 sec stroke 25 5 sec stroke Extension 25 5 sec stroke 25 5 sec stroke 1105 sec rev 110 15 sec rev Rotation 1105 sec rev 110415 sec rev i 24 3 sec 10 meters 22 3 sec 10 yards Straight 243 sec 10 meters 22 3 sec 10 yards Travelling 12 t3 sec 909 123 sec 90 12 3 sec 90 12 3 sec 90 6 6 3 Adjustment procedures of Operational speed Each operational speed for Elevation Extension Rotation and Travelling is adjusted by each Trimmer
46. S d 2 veo 7 3 FE H HA f ezz lt 56 4 P8 mx Bick EH il 2 11 os 4121 FF 8 cron rez 2 7 Slep warning b SEE Ei buzzer cse we Facey Ss 9 ge 02 BIL isi 35i 2 pow 5 fers x o 2 3 zoc ES ore 52 8 4 167 2 isv l sns z 65 6 Ens PURP Eus Hd ses 2 EK f ecu ac HE or ieu rz I i5 VeL i9 SHITCH Cee A ji EC START HE Tey E Lo LEVELING Fa ACELE 222 ES ibs 2 5 olz m En Boem length SLOFE o SENSOR nm HE GIO ONIN M DUNE OO VOT B FI Valve control unit VAL 9400 SR 123 CCW Travel L Rev DOWN pom o n Travel L For Travel Rev Travel For Main contro valve NO 2
47. Solenoid Rated voltage DC 24 V Rated current 650 mA Resistance 300 port Acti t Manual over ride pin port Actuator Sectional PC valve for Rotation Main relief V for Elevation Entry Block P port T port for Extension for Travel 3 8 1 Illustrations Main control valve NO 1 R12 R2035 Main control valve NO 2 R12 R2036 3 9 2 Sectional drawings E UE Th E 2 T P q A A section Spring Detail of pilot valve T P Plunger Spring Spring 4 pau SCH ee Ej X X section PC valve B B section Detail of Main relief V 3 10 3 Trouble shooting Trouble Inoperative actuator or Operational speed of the actuator is too slow Check point Check the GAIN voltage at Valve control unit Result No GAIN voltage is obtained Cause Defective Potentio meter or Control switch Remedy Replace the Potenio meter or Control switch Inadequate adjustment of GAIN voltage Readjust the GAIN voltage at the Valve control unit Defective Valve control unit Replace the Valve contro unit Defective electric wirings Repair the electric wirings GAIN voltage is too low Battery voltage is too low Charge or replace the battery
48. as shown in the NOTE table below Function Direction GAIN GAIN trimmer voltage h zs Elevation UP P10 0 53v Extension i 0 50v Rotation 0 47v 0 47v Travelling 0 56v Right 0 56v Left Caution When checking or adjusting NULL voltage for Travelling operate both of the Travel control levers fully in the same direction 5 Adjust each GAIN trimmer listed in the table above so that the each Maximum operational speed becomes a Specific value NOTE To increase the GAIN voltage or Maximum operational speed turn each GAIN trimmer clockwise 6 9 3 Adjustment of Tr trimmers The Tr trimmers are adjusted to vary the Maximum operational speed which is obtained by actuating the Control switches at Lower control Follow the descriptions below to adjust the speed 1 Stop engine and open the Lower control box Then set the Main key switch to the LOWER position 2 Set a Digital voltmeter between each Pin on valve control unit listed below and Body earth Q Function Direction Pin NO Elevation UP DOWN Extension OUT Rotation CW C C W 3 Operate the each Control switch at Lower control box and take the reading from the voltmeter NOTE The reading on the Digital voltmeter is the Out put voltage of valve control unit 4 Turn the each Tr trimmer
49. hours or annually of filter element NOTE The first replacement of the filter element for new machine should be carried out after 300 working hours or 3 months use Tightening torque 14 4kgf m Paper element NOTE Do not reuse Oring and Back up ring when removed once 3 6 TRO 02649 The pump is driven directly by the engine and supplies pressurized oil to hydraulic system Type Gear pump Double Discharge volume 24 5 24 5 1 49 1 49 in rev Rated pressure lt lt 210kgf cai 3 000 PSD Rotating direction Clock wise 3 7 The main control valve is Soleniod Operated Proportional Type and controls the following hydraulic systems 1 Elevation system 2 Extension system 3 Rotation system 4 Travel system When the main control valve is operated by the control levers or Potentio meters located at upper control box the main spools of the valve are shifted proportionally in accordance with the operated value of the control levers Thus the flow which is supplied to the each hydraulic actuator is controlled proportionally On the other hand when the main control valve is operated by the control switches located at the lower control box the valve is operated as a conventional solenoid valve Rated pressure at P A B ports 250 3 555 PSI at T port 10 kg o 140 PSD
50. on the Valve control unit as follows NOTE The locations of each Trimmer on the Valve control unit is shown in the clause of Trimmer identification on valve control unit Adjustment is to be carried out in the following order 1 Minimum Operational speed Maximum Operational speed Adjustment of Tr trimmers Adjustment of Delay trimmers Adjustment of Pivot turn speed Adjustment of Spin turn speed Au bb 6 7 1 Minimum operational speed NOTE The Minimum operational speed is obtained when each Control lever is actuated slightly at the Upper control l Start the machine and lower the platform close to the ground 2 Stop engine and open the Lower control box Then set the Main key switch to the UPPER position 3 Set a Digital voltmeter between each PIN on Valve control unit listed below and Body earth Elevation Extension Rotation Travelling Left Travelling Right 4 Move the Control lever slightly untill the LED indicator Red on Valve control unit turns on and take the reading from the voltmeter NOTE reading on the Digital voltmeter is the NULL voltage Higher NULL voltage causes increased Minimum operational speed The reference value for each NULL voltage is as shwon in the table below Direction UP DOWN Function NULL trimmer NULL voltage P9 0 32V 0 32V Elevatio
51. potentiometer gt ROINA EL Rend LE Main control valve 1 Elevation is switched on when js relay is erated and stays off when the travelling is opera ted Valve control ymt boom 3 d EVO 1 M deas Ko dran huatia 54 Batheries Dc gt t u0119 2 3 T ON 1 1227007 T 224 zx vl QQ sy lt lt O d 5 9 IW m Im 017803 aA oA gt gt Aart pU D x Ome dund i ERY T O o N g Ly E bu M gt FS ER S90 B xj 1 u 8 o x Li Sr 72514940 FT POAT FT Wa Jio slogs peo 4 utaoq an ayn SAUL I 45 AD a 8192 da Wor fl 401 UA 2 3 2233s rjwojed 13 31 p imm Yo for Spec 602319265535 ufi 34041 ZION pes 622995 ing 44229 z XVLI Q Q sp 949980506 jw 4 w m ME 8 qug 19230
52. zi This relay is switched on when Travelling is operated Interface board This Tr is switched on when either the boom or platform swing is Motion alarm buzzer operated Fusble links e 7 2 5 12 fov Spec Ab M 655352 mr Ae ergency top s w mi pper box 15 Fusible links 7 2 202 7 This relay is switched on when Travelling is operated Interface board Emergency pamp Iw This Tr is switched on when either the boom or platform swing is Motion alarm buzzer operated 5 12 2 Spec Ab Sp 6523 9 Upper control box Emergency stop s w Batteries md 5 13 Emergency pump s w Lower control box Interface board 5 13 2 6 ADJUSTMENT SECTION 6 1 To adjust the preset pressure of the relief valve P1 which is installed on the main control valve No 1 take the following steps Preset 210 3 000 9PSD Relief valve P1 OF ts eT 210 kgf cnt 3 000 51 Main control valve NO 1 1 Remove the plug from the Pressure test port installed on the out let line of Pump NO 1 and set a Pressure gauge onto the pressure test port 2 Start engine retract boom fully and hold the Extension switch on IN to actuate the Relief valve 3 Read the pressure gauge while the Relief valve is active
53. 00 hours Fuel tank Check filter for oil leakage Drain fuel and clean the tank Hydraulic oil reservoir Oil leakage Check for oil leakage Anchor bolts Stop valve Check the bolts for looseness Check stop valves for oil leak age and any other damage Oil level contamination viscosity water content oxidation Check oil level 8 5 Stir oil in the reservoir take out sample 60cc and check the following items UNIT MONTHLY INSPECTION ANNUAL INSPECTION Hydraulic oil reservo ir Contamination Within NAS class 12 Viscosity Within 10 Standard Water content Less than 0 5 Oxidation Less than 0 4mgKOR g Oil change interval 1 200 hours orAnnually Hydraulic filter damage Oil leakage any other Check filters for oil leakage element Replacement of filter _ _ 1200 hours or Annualy Replace the element Replacement interval Hydraulic pump Abnormal noise excessive heat Run the pump and check for the items Oil leakage Run the pump with max imum pressure and check for oil leakage anchor bolts Pump bracket Check pump bracket for cracks deformation and anchor bolts for looseness Wheels Crawler
54. 09 BALE RBIS gt E prp zd zd in PC M E i g 3E XOG 124440 0 9 19 941 won 252240849404 4343 goon Ka poig 22042441 I4 M S X lt Parado si woog 943 ous jo sKvjs piwo paquaodo s 24 wall Ko gasastius s1 sULL LN pL on 4n g n dund wU v O 74 294 ral 5 aN w 1 oO 0 1 4 A i e lt 5 a X ge B ES Q 404 ADU faut 3 g 1 4 ni UNC NI 24 4190941 7219827 T AtZIG 59 421 4 514 2 4 nd Z XVL QQ SIA 247003 DAVA 81904 424 A N lt A T 9 amp SUR 9 ala o gt ur EIS gt IS py n op 8 5 e 4 1004 2 2 110 skors peo 1 st 2i Malm payrzims s poa SULL 4935 m E par wn 5 w ES 0 1 XOG 184440 210423 PAL
55. 2 11 3 HYDRAULIC SECTION When repairing servcing or overhauling the hydraulic system take the following into consideration 1 When disconnecting plumbing a b Prepare a suitable container to catch the draining oil Put MATCH MARKS on each part before disconnecting This will make recoginition on the time of reconnection easier Use double spanners as not to damage the plumbing and components Clean the plumbing or components out before disconnection to prevent foreign particles from entering into the hydraulic system Install proper plugs to the disconnected plumbing or components to prevent foreign particles from entering into the hydraulic system 2 When connecting the plumbing a d Check the MATCH MARKS made on disconnection to avoid incorrect connections Clean the connecting plumbing tz prevent foreign particles from entering into the hydraulic system When connecting the TP adaptors wind seal tape at least one and a half times around the threads Use double spanners when tightening the connectors 3 When assembling or disassembling hydraulic components a b Put proper plugs onto the openings of passages to prevent foreign particles entering into the components Before disassembling clean the component thoroughly with a solvent and compressed air Clean each disassembled part with solvent thoroughly This will ensure easier check up procedures
56. 4 s f ANH THOR anma SN Jo cand UU OUE RELL Hs 227 Ad i dues dd fy Y eem were z 4 5 415 44344997654321 FLL i7TA 2 TNI T UNO 5 Nm alos solenoid valve level C 34 c9 SWING LIFT RUN R bd t z 5 2 2 9 NP IO Bem y Les tc 1 3 olo i 055 JANI OJD 055 DAVI ACM TINO 0 em TE 955 Duns CONTROL CAG UPPER BOX Wo l g Pues ig ine En FUSIBLE LINK Z BT2 BT d amp Sak RBS a M v BR Battery rela Emergence SAFETY RELAY 7 13 Boom angle limit s w 1 5 2 Wire rope slack limit s w LS 6 amp LS 7 Boom cable Batteries v Emergency pump Boom length limit s w 15 1 Upper control box Lower control box Motion alarm buzzer Slope sensor Working light Hom Foot s w 7 14 1 Hexagon Bolts and Nuts 8 8T Material S45C kgf m Tensile strength 80 kgf mi Yield point 64 Brinell hardness 225 300 0 68 0 92 1 63 2 21 3 22 4 36 5 60 7 57 8 92 12 1 13 7 1
57. 5 114 SERVICE MANUAL SELF PROPELLED AERIAL PLATFORM SR 123 ISR403 Applied to Specification 20 BD MCHI CORPORATION 1152 RYOKE AGEO SAITAMA JAPAN INTRODUCTION This manual describes the correct adjustment and maintenance procedures for SR 123 self propelled aerial platform These procedures will ensure the most effective use of the operation features and will ensure satisfaction through excellent performance Read this manual carefully and ensure you understand each descriptions correctly When carrying out any maintenance or repair work please cafully note the following Use only the spare parts approved by the manufacturer particularly for load supporting and safety related components Do not carry out any modification to the machine without obtaining the manufacturer s approval Please note that the numerical values in this manual may be subject to change due to engineering improvement Customer Service Division Aichi Corporation GENERAL INFORMATION OVERALL 6 24 1 2 SPECIFICATION Snie vene eaae ELE De COE UY 1 3 WORKING RANGE 1 1 5 MECHANICAL SECTION CRAWLERS s ione too 2 2 BOOM seeds ener ROM e e eere 2 3 1 Note on functions ve urere reta re EE NOR AUR Ee E EY Fe ER ER 2 3 2 M MT IR 2 3 3 Sectional drawings e
58. 8 5 18 1 24 5 25 3 34 2 34 2 46 2 43 7 59 2 63 4 85 8 86 3 116 8 116 5 157 6 150 2 203 3 1086 1471 193 1 261 2 1397 1889 214 5 290 2 1552 2099 266 2 360 2 1926 2605 321 4 434 8 2325 3145 412 7 558 4 2985 4039 2 Hexagon Socket Head Cap Screws 10 9T Material SCM435 Tensile strength 100 Yield point 90kgf mt Brinell hardness 280 365 Color Black Tightening torque kgf m 1 22 1 65 2 94 3 98 5 80 7 84 10 1 13 6 16 1 21 7 24 6 33 2 32 6 44 1 45 6 61 6 61 5 83 2 78 7 106 5 114 1 154 4 155 4 210 2 209 6 283 6 270 4 365 9 347 5 470 2 386 1 522 4 479 2 648 3 578 5 782 7 742 6 1011 7 16 SME 906 INSPECTION MANUAL SELF PROPELLED AERIAL PLATFORM SP SR SERIES AMICHI CORPORATION 1152 RYOKE AGEO SAITAMA JAPAN X Procedures of Daily inspection entente 8 1 Daily inspection check sheet gt 44400 041 1 4408 0 4 40 00 ttntnttntn tuc 8 3 Procedures of Periodical inspection s 8 5 Procedures of Function test 8 11 Periodical inspection check sheet eerte 8 12 8 0 1 The inspection is to be carried out on firm level ground POWER UNIT UNIT ITEM DESCRIPTION Radiater Cooling water level R
59. 9A ZIA OIA ON 40 4 104 MOO MO uj ino 1 UuoneloH uoisSua1x3 uoneAo 3 uonounJ 00 ea ON TEES laq3aHS Viva LNSWLSNrav 6 15 7 APPENDIX 8 31915 pue Ne idu sr ong Z Uurede jmjs jou seop pue A e meu peddois oursuq UAO qQ sey asny eu Id onuoo ur VOE doys eurgug 1 jou seop ouiSug EN 8 pejs pue s8njd ooo sr eurduq vs jou urua yes pue Tony III st jon 1 guru Mq SUNI 0j0ur 1912015 1 asny onuoo reddy U esnj ues 2 UMO Q Seu nyomas 3235 oui ssaid pue yams 100 ISLAMIA pesseid SI A S 2009 Jonuoo Jedd ie Uni 30 1OjOUI 1931 yum 19151 osny eoejdow esnj esny eoe dow uo um sdum 10201000 19AO UI VOT 94 sn res ouiSug olojuoo 19AOT U WOT SH osnj 6 JO um sdure Jomog 10203009 IOMOT VOI p 98 4015 AoueS1ourg U o q seq WOE 91418041 6 UMO Q Seq go um
60. EDs are turned off q Normal ON 1 case the solenoids e Yellow m eus Outpu lines to Extension solenoids jan Output lines to Elevation solenoids Yellow Faulty OFF or electric lines to sole Normal gt noids get short circuit Faulty OFF Normal Faulty O aulty FF Output lines to Travelling Right solenoids Output lines to Travelling Left solenoids LEDs for Output Yellow Yellow Yellow OFF when Emergency stop is Operated OFF when Rotation C W limitation is applied OFF when Rotation C C W limitation is applied Red ON when Rotation C W selector input signal exists ON when Rotation C C W selector input signal exists Red ON when Extension OUT selector input signal exists ON when Extension IN selector input LDi2 Red Green LEDs for Limitatin Green LD10 Red signal exists ON when Elevation UP selector input signal exists TON when Elevation DOWN selector input Signal exists ON when Travelling Right FWD selector input signal exists ON when Travelling Right REV selector input signal exists ON when Travelling Left FWD selector input _ signal exists ON when Travelling Left REV selector input signal exists LD13 ee LEDs for selector input signals Red Red Red 4 13
61. G2VH 234PH 24 G2VH 234PH G2VH 234PH 1621 1222 D VAZ ZA R17 OY Bi mu T0 2003 VA 2 MR72C 24US Ah i 424 415 9 Gy qi o oe Te FPS RS OUT COM DC DC 1 2 CAL 68 1134 perv TPS e Enit VOCE m 54214 55500 C4 CS gir ARD12 1 W 50A F2134A1 Fitio 7815 IC14 1 15 7810 NS RY ci oa E 01 4 A8 Re R16 DIO AG ATI St n cus 54 4 H Ria H4 cali LIN 2 2405 Y3 12 Q C C E 44 44 44 o O vs v6 7 V0 D 0 vio vii vi 07 1 V2 y4 02 vi3Yicvi vie 08 vir vie vio 20 Fuse F2 SA Fuse F1 10A 32 so 98 7 LL ee 4 11 2 Trimmers and their functions Operation Extension Elevation Travelling Right Travelling Left Travelling Travelling Right Left Trimmer for adjusting Input voltage to Valve control unit when conducting Pivot turn Vise RM Trimmer for adjusting Input voltage to Valve control unit MIN VR 38 VR 40 when conducting Spin turn 4 12 3 LEDs and their functions The LEDs and their functions installed on the Valve control unit are as shown in the table below Color ON OFF conditions amp functions Remarks Output lines to Yar prn ON Rotation solenoids Faulty OFF e Normal ON Faulty OFF L
62. HL 6 EE 2x 5 H EN 2 26 28 1 E RUNDBZA n ast Slop warring H Dori buzzer ONDE UNI ON OY REFER 1 zic H 7 2 5 nr H Ld i 25 1 HE Pee 92 2 32 SHITCH ZB 4 LL sue i ba 5 Ey 2 38 EFE SLOPE le SENSOR PLATFORM LEVEL SoL FUSIPLE LINK Fur tot Ste Je 7 10 ELECTRIC CIRCUIT DIAGRAM for Spec 8 602 14372 cete Fi T cus Ri2 NS115 seen RT OAN SERO MAIN CONT VALVE No 1 R12 N5118 i A y 3 E ROTATION
63. O Surgsng Sun dn yorg peonoydg Uojsid 8 O 9195 jog Ieddoig feos isuq meq 1996 2120895 SUI surysng Jeppog Sun N dn xoeg pesy uompsnj 0 3u O uojstd leurejoi Supr uoTYsND eqn 2 Lt re BEL NEN NL t OO ICOMOS Ds SEC OOD 8 De yound usn M S 19 eui 207 41 0861 LOSE L Uu Dxp 2 28 Bu ua1U6 L 3 21 Cylinder tube ergue Piston red 27 kaf adex head 43 56 m tbs U ving Dust seal O rnn3 Back up xing Q ring Cylinder head O 4 2 Back up rim 3 Cushion Yin 741 Stopper me 751 za P 4 ud iergue 7 Wear ring 7 kgf n 12 ft lbs Emergency descent Valye 8 U ring 11 Back up ring Tightening 2114 ring holder 22 0 ri 230 kaf mn 0440 ft lbs E 23 Steel al 24 Sel strew i E Cushion Collar Grease fitting 26 Manifold Piston Detail Cylinder head Detail Emergency descent valve Detail 3 22
64. a crs 3 SSSA SUNS Nan Lug 4 1 n 1 t va 1 1 2 DINRIN O0 CORRES SS 155554 EA i AN 2 qU 44 8 Ha gg 0 RES us E n us SSE Pl 9 33 a Se TRS R siui 9 Bd LAC ed dB EADS RADIOS A DB oe re A 417 1 1 Electric circuit for RIZA 719 foy with CE us selector switch uenit EC 4 n Pe 93 ha 4 pA us Le wa RiB dm E ICS R19 347 us 819 L cogit 4062 d 21 47K a R22 e p AAA reve Na 1 NS 5 mu 2 RATE quaj 1092 2 Ac pm F sig 1 3 Ho reso a 1661 Toes _ JZ E 4 es
65. and after 04 0102 The main key switch is located on the Lower control box This supplies power to the Upper or Lower control Key position 4 9 R12 N5112 The Valve control unit is installed within the electric circuit between the Potentio meters or control switches and the Solenoids of the main control valve When the Valve control unit inputs Voltage variation sent from Potentiometer it converts this Voltage variation into the Ampare variation and outputs it to the Solenoids of the main control valve Thus the proportional operation of main control valve is achieved when the poten tio meter is operated at the upper control However in case the Control switch is operated at the lower control the main control valve is actuated as a conventional solenoid valve since the control switch does not output Voltage variation which is necessary for proportional operation Rated voltage De 24v Input voltage DCO 10V Output current Delay Ramp 0 7seconds when input voltage is 10V sonz NULL MAX NULL MIN mA GAIN MAX GAIN MAX o GAIN MID 800 700 600 Output current Input voltage 0 2 4 6 8 10 0 4 10 1 External view 4 TAS TAS a Li 4 sas T o G2VM 234PH DC24vV G2VH 234PH DC24v G2VN 234PH DC24w
66. boom is pulled by the extension wire rope and accordingly goes out of the second boom When retracting the boom the second boom is retracted by the extension cylinder together with tbe tail sheave As a result the third boom is pulled by the retraction wire rope and accordingly goes into second boom 7KO 01022 2 Illustraction oa 141 142 140139 8 3 LESS 58 que 975 ae M i 1 i 146147 2 3 3 Sectional drawings 2nd boom 1st boom 3rd boom 6105 mm Ist boom 1st boom TH ene Extension CYL Hose separator 2nd boom mi dokis 2nd boom 2nd boom Pin 3rd boom 2nd boom 1 Hose separator Anchor pin 3rd boom H 1 for Extension wire rope Anchor pin 1 Anchor pin i W for Retraction wire rope for Upper levelling CYL Anchor pin 2 or Extension CYL gt H NS 4 in T be 2nd boom iu 2nd b Sp Anchor pin mec ist boom Head sheave for Extension CYL St boom for Extension wire section B B section C C section D D section Retraction wire rope Extension wire rope Tail sheave Head sheave 2nd boom for Extension wire rope 3rd boom Hose separators
67. conds stroke Extension speed IN OUT Extend retract boom to its full stroke with the maxi mum boom angle and measure the OUT and IN speed seconds stroke Rotation speed Rotate turntable 360 with the maximum boom angle C W C C W and minimum boom length and measure the C W and C C W speed seconds 360 Travel speed FOR REV Retract boom fully set it at an angle less than horizontal perform travel operation and measure the FWD and REV speed seconds 10 meter Swing platform to its full stroke and measure the RIGHT and LEFT motion speed seconds stroke Platform swing speed RIGHT LEFT 8 11 CUSTMER ADDRESS PHONE NO MODEL SERIAL NO HOUR METER INSPECTOR The marks are the items to be inspected only on the annual inspection ITEM CHECK MARKS REMARKS Water oil leakage Radiator Water level contamination any damage Air filter Cleaning Water separator Fuel filter Oil leakage Replacement Draining water Cleaning Cleaning interval Every 6 months Replacement interval Every 600 hours Battery Electrolyte level Battery terminals Fan belt Tension wear Alternator starter _ Function Valve clearance X Adjustment Adjuatment interval Every 1 200 hour
68. d check that the platform always stays level If the platform does not stay level check the levelling system as follows 1 Thoroughly check the system for external oil leakage 2 Bleed air from the platform levelling system refer to the Air bleeding procedures on the next page 3 Check the internal oil leakage of the Combination valve Make sure the two stop valves on the combination valve are closed firmly 4 Check the internal oil leakage of the Double pilot check valve 5 Check the internal oil leakage of the Upper and Lower levelling cylinders 2 Natural descent Load the platform with its maximum load 250kg then visually check for any sign of the platform tilting downward 550165 If the platform descends naturally thoroughly check the levelling system for external oil leakage Then check for internal oil leakage in the components listed below Double pilot check valve Combination valve Upper and lower levelling cylinders 3 30 S Air bleeding procedures Caution When bleeding air always operate the machine from the lower control panel Always unload the platform completely before carrying out these procedures 1 Retract the boom fully and position it horizontally 2 Fully open the two stop valves installed on the combination valve 3 Switch the Extension switch to IN and tilt the platform fully upward 4 Now switch the Extension switch to OUT and tilt the platform fully down
69. de and from there the resistance 250 is varied as the control lever is inclined Yellow Green Blue 49 4 4 4 g The parts in not equipped 4 5 With resistance The board is installed in the Upper control box Toro 7 4 5 2 12 3511 Limit switch F3 10A F4 10A Emergency stop UJS 074 193 Un Un 2 u9 010051452 ur u2 us u4 lez 08 09 03 0405 o 5 0530541055 00 05 06 u7 us oso 3 2 106 four jo12 Gray Green White Gray Green Valve control unit R12 N5112 010 6 BE F3 s a zs 3 z E 111417 151152 BZ G 5 9 LM RM 5 5 8 Gray Green White Green Interface board 12 VJ14 EJ7 EJ9 R12 N5119 8 B 3 4 6 11 4 v viojvii vi2 viz vis vis v2o Bi Bi 12 15 16 17 White Green Gray Gray White Terminal base Identifications of Connectors Varister Main Relay CR 7 Interface board Glow Relay CR 3 Relay CR 8 Terminal base Condenser view SR 123 1 Electric circuit for Spec 5 652270 652348 i denn oem fa DORON CANNY Mor ANDY URN
70. e E Rotation a agp eom qum zi CCW Travel L Rev MR lt qui DOWN i N mee Er COW i9 PN ES P Travel L For ERES 9 Remote contro Extension i H 5 E yr for Travel 15 32 Bee A i Ii OUT gom N 2 2 35 2 E 7 c 2 lt 12 Im i E 7 7 ue te gt oos amp Travel Rev 2 Travel R For Elevation o E 2 S tee H E DEE t i UG I Main control valve NO 2 2 12 2 H 1 5 uj 2 B i Um 4 5 E 9 2 105 vi E 5 Es 27 i E PONER ENT 2 NI H 5 lt fee ds HH T Spe 116 11 AZ 25 8 14 m m 1s e 36 16 g m ibe 1 is 18 2 2 L 20 20 15V 3 2 21 21 ibn 4 be 22 2 i E ji Be 2 H RUN 3 3 ES Te ij Bu mur v os 41 PF crunzezs 2 z Ig E acu m i Slope warning res iov sure 2 burg ey cm PR iv 1 2 02 pir 20 _ m AE 3 n TEE a CE fine i 2 si 2 VaLa SCH 3 X EN i E 2 SER 12 12 EG H cue 1 Em PURE f pec al n pe ac i Tren gap Rl ib ESSE x 2 SML 2 2 EL s Ee s1 po T e 4 7 E L Sorevertne pa m
71. emove radiator cap and check the cooling water level Battery Electrolyte level Remove filler cap and check the electrolyte level Oil pan Engine oil level Check oil level Fuel tank Fuel level Check fuel level Hydraulic Hydraulic oil level Lower platform to its lowest position retract jacks oil reservoir i fully and check oil level CARRIER Excessive wear cuts Check tyres for excessive wear and cuts Wheel nuts Looseness Check wheel nuts for looseness Steering linkages Deformation cracks Check steering linkages for deformation and cracks Travel motor unit Oil leakage Check the unit for oil leakage Carrier frame Deformation cracks Check carrier frame for deformation and cracks Crawler Track link shoes Excessive wear tension abnormal tension OUTRIGGERS Outrigger arm Cracks deformation jack post and check for cracks deformation Check track link and shoes for excessive wear and Extend all of the outriggers and jacks fully Jack cylinder Oil leakage Check each jack cylinder for oil leakage Natural descent l Extend all jacks and ground them the weight of machine CONTROL SYSTEM Control levers Function 2 Check each jack cylinder if it is retracted due to Operate all of the control levers switches and check that their func
72. ere eee y ve Eo ete ee dnt abra E TIER 2 4 4 Inspection ade e AUI TSS 2 5 5 Extension Retraction wire 3 2 6 6 Tension of Extension Retraction wire 2 7 7 Tension of Electric cable 2 5i 2 8 TURNTABLE 1 2 9 I Inspection procedures eee esas se esee ORES E TESA 2 9 PLATFORM ROTATION 2 11 HYDRAULIC SECTION NOTE ON OVERHAULING THE HYDRAULIC SYSTEM 3 2 HYDRAULIC A 3 3 QUE RESBERVOTR seuss ASRS 3 5 INLINE EILTEBR SSE 3 6 HYDRAULIC PUMP ooi edese e 3 7 MAIN CONTROL VALVE No 1 and 2 3 8 1 0 8 52522 nin eia ra sly ahve re deta e e 3 9 2 Sectional 4 2 2 nne 3 10 3 Trouble shooting 3 see e reno seats ove nea ee taxed RR Ice rac 3 11 PLATFORM ROTATION SOLENOID VALVE 3 12 PRIORITY VALVES esa ven ae en 3 13 SWIVELJIOINT 3 14 ROTATION MOTOR UNIT for 8 3 15 ROTATION MOTOR UNIT for 20 3 16 TRAVEL MOTOR UNIT for Spec 8
73. escent exceeds the Serviceable limit further check the internal oil leakage of the Double holding valve or Extension cylinder by to the clause of SINGLE HOLDING VALVE for Elevation cylinder Yefeving 3 28 The system maintains the platform at its level position automatically boom s vertical movements It consists of Upper and lower levelling cylinders Double pilot check valve Platform level solenoid valve and Combination valve as shown in the figure below regardless of Platform Down ward level sol V from Main control valve to Extension cylinder Combination valve 3 270PSD Lower levelling cylinder 3 29 1 Note on function Two levelling cylinders are in place as shown in Fig 1 When the boom is lowered the Lower levelling cylinder is retracted and the hydraulic oil in the bottom room of the cylinder flows into the bottom room of Upper levelling cylinder The sizes of the both levelling cylinders are exactly same Therefore the Upper levelling cylinder extends simultaneously with the retraction of the Lower levelling cylinder Thus the platform is balanced by the Levelling cylinders to maintain its level as the boom is lowered When the boom is raised the levelling cylinders work in an exactly opposite fashion to that described above 2 Inspection procedures 1 Tilt of platform Perform elevation and extension operations several times an
74. gine start s w F6 Spare 10A FS Working light 5A F4 Accelerator 3A Platform swing level amp F3 Emergency pump 10A D B Engine start 3 F1 10 Fuse holder Detail Fuse holder Slope warning buzzer Lever potentiometer P 8 Connectors Connectors Inside view of control panel Control board E Inside view of back panel circui 1 Electr 228 14 T nime POND JOjelo oooV 925 Luyis 93 Li T THE we 23 ni NIHE HHO4IWd 192714 8 aan Be ET 8 oue N1347 EnS Pa E lt Ma GPT Hanes 2628 mti Pi FIL Ei IiM 222 2 mT ION CO4 UODPAO H USUA kepy 4 3 The lever potentiometer consists of two parts One which functions as a switch and one which controls variations of resistance These two parts are operated simultaneously by tbe control lever The OFF section of the switch extends 4 to either side of the lever s central position The switch will be turned ON when the lever is inclined in excess of 4 to either side The OFF section of the resistance control extends 5 to either si
75. gth Horizontally 0 1 of the boom length Pivot pin Check boom pivot pin for excessive wear and any other damage The limit of clearance between pin and bushing 0 6 mm 0 024in 8 8 MONTHLY INSPECTION ANNUAL INSPECTION Extension Elevation Platform swing cylinders Wear pads rollers Check each wear pad and roller for wear cracks Check the clearance between each boom section and wear pad Telescoping function Extend retract the boom several times and check for any abnormal function Wire ropes Check wire ropes for exces sive wear breakage corrosion Check turn buckles and wire end fittings for any damage Check the tension of wire Wire Topes should be checked in detail when boom is disassembled for inspection every 4 years Hydraulic hoses Check hydraulic hoses for oil leakage and any damage Sheaves Check sheaves for excessive wear free play PUER Lubrication Piston rod cylinder tube Lubricate the sliding parts with grease Check for cracks deformations scratches Oil leakage faulty function Extend retract the cylinders and check for oil leakage any faulty function Anchor pins Check anchor pins for wear Lubrication Supply grease to each grease fitting Platform leveling System Function
76. hown in the figures Hydraulic motor UE Axial plunger type Rated pressure ess 210kgf cni 3 000 51 Discharge volume 62 9cc rev 3 84in rev Allowable drain pressure 2kgf cnf 28 51 Reduction gear box Planetary gear 1 50 579 SAE 90 1 7liters 0 45gals Reduction gear box Hydraulic motor Counter balance valve z ETSI L 3 17 2 lilustrations 4950 lt ae AM Vg f ey SS TRAVEL MOTOR UNIT for Spec 20 Applied to Serial No 665663 and after This unit consists of such major components as a hydraulic motor a parking brake and a reduction gear box as shown in the figure Hydraulic motor Type uen Axial plunger type Rated pressure 210 kgf 3 000 PSI Discharge volume 51 1 rev 3 12403 Gear box Planetary gear Reduction ratio 1 624 Gear oil SAE 90 X 1 7 liter 0 45 gallon Parking brake Brake torque 14 8 kgf m 107 ft lb Release pressure 6 94 kgf 98 7 PSI 1 Hydraulic circuit Drain Pilot i H E C1 tee T WE 5 i ed i i poe i f 1 1 M 3 19 i 3 3 D view of Motor Section 12 4003 Sum 958240 FUN
77. ine stop 2 6 4 22 2 Safety relay i e or eth IIo sae eee PRESTA Adde Va des conven 4 23 3 Glow indicator cvi rst eer vs Ea eo ve Lesbo reis 4 23 4 Battery relay mE 4 24 5 THM eR 4 25 ELECTRIC CIRCUIT FOR INDIVIDUAL SYSTEM ENGINE CONTROL SYSTEM for Spec A6 S N 652319 652348 5 2 ENGINE CONTROL SYSTEM for Spec A6 S N 652349 A8 20 5 3 ROTATION 5 58 5 4 EXTENSION 5 8 1024 5 5 ELEVATION 5 8 5 6 TRAVEL RIGHT 5 8 000 5 7 TRAVEL LEFT 5 8 0 5 8 ACCELERATOR 5 5 9 PLATFORM ROTATION PLATFORM LEVEL SYSTEM 5 10 SLOPE WARNING HORN and WORKING LIGHT SYSTEM 5 11 MOTION ALARM SYSTEM ER ed AA 5 12 EMERGENCY 5 5 5 13 ADJUSTMENT SECTION RELIEF VALVE 6 2 2 6 3 22 0 ee rer eR 6 4 OPERATIONAL 2 11 6 5 1 Measurement procedures of Maximum operational speed 6 5 2 Specific Maximum operational
78. ints Do not reuse O rings Apply a slight amount of grease to O rings before installation 3 14 301 05015 unit consists of such major components as the Hydraulic motor the Brake valve and the Reduction gear box as shown in the figure below Hydraulic pump Orbit type Discharge volume 195cc rev 11 9 in rev Brake valve Preset pressure 60kgf ci 850 PSD Reduction gear box E elec ipee Planetary gear 1 16 6 Seated oi ew cen Shell Omala oil 460 1 1 liters 0 3 gals A port PF 3 8 Brake valve Hydraulic motor Reduction gear box Reduction gear tox Brake valve Hydraulic motor 3 15 370 0000023 ROTATION MOTOR UNIT for Spec 20 Applied to Serial No 665663 and after This unit consists of such major components as a hydraulic motor and a reducer as shown in the figure below Hydraulic motor EYP sive eese Plunger type Gear box gt Worm gear Reduction ratio 1 50 Gear oil Shell Spirax EP90 X 1 7 liter Pinion gear 301 0000022 A port 3 8 3 D view Oillevel gauge Zn CENE t 3 16 301 05014 einen pore to Ser No 665013 This unit consists of such major components as the Hydraulic motor the Counter balance valve the Parking brake and the Reduction gear box as s
79. ircuit above 2 Operate the switch to L side and ensure the output shaft rotates counter clock wise then stops at L position 3 Operate the switch to R side and ensure the output shaft rotates clock wise then stops at R position Output shaft 4 19 The sensor installed on the turntable detects the tilt angle of the machine caused by a slope for Spec 6 d ree The sensor stops out put power DC24V and activates the slope warning buzzer in case the machine is inclined 3 or more DC24V DC10 32V Rated voltage Preset angle 3 2 5 3 5 Output current 200mA Black NLS White ri 1 NOTE The wire color of the slope sensor may be changed follows Red Brown White J3 Black Black Blue for A8 5 de gree s e n s o The sensor stops its out put power DC24V and activates the slope warning buzzer in case the machine is inclined 5 or more Rated voltage DC24V DC10 32V Preset angle 55557 47 Output current f00mA IR B 1 2 OUT LS OG 4 20 The foot switch is installed on the platform floor to stop the functions of Upper control levers and switches This will happen when the switch is not pressed down a 2
80. listed in the table below to adjust the speed NOTE An increase to the output voltage causes an increase to the speed To increase the Out put voltage turn each Tr trimmer clockwise Function Direction Tr trimmer Ne Output voltage Elevation E Tr5 0 53 v DOWN Tr6 0 55 v Extension OUT Tr3 0 49 v IN Tr4 0 50 v Rotation 1 0 47 C C W 2 0 47 v 6 10 4 Adjustment of DELAY trimmers The DELAY trimmers can be adjusted to start or stop each operation more gradually or quickly Function Delay trimmer Elevation UP VR 13 DOWN VR 14 Extension Rotation Travelling Left Travelling Right Adjustment of DITHER trimmers NOTE To start each function more gradually turn the each Delay trimmer UP clockwise To stop each function more gradually turn the each Delay trimmer DOWN clockwise The DITHER trimmers are adjusted to give the correct Vibration to the Output power of Valve control unit NOTE Do not adjust the Dither trimmers as they have been precisely adjusted by the manufacturer Function Elevation Extension Rotation Travelling Left Travelling Right Dither trimmer VR 33 VR 32 VR 31 6 11 5 Adjustment of Pivot turn speed The Pivot turn speed is adjusted by the trimmers installed o
81. n Extension Rotation Travelling Left REV Travelling Right Caution When checking or adjusting NULL voltage for Travelling operate both of the Travel control levers Right and Left slightly in the same direction 5 Adjust each NULL trimmer listed above so that each hydraulic actuator is about to move when each Control lever is actuated slightly NOTE To increase the NULL voltage or Minimum operational speed turn each NULL trimmer clockwise 2 Maximum operational speed NOTE The Maximum operational speed is obtained when each Control lever is actuated fully at the Upper control 1 Start the machine and lower the platform close to the ground 2 Stop the engine and open the Lower control box Then set the Main key switch to the UPPER position 3 Set a Digital voltmeter between each PIN on Valve control unit listed below and Body earth Elevation UP Function Direction DOWN OUT Extension IN C W Rotati otation ECW Travelling FWD Left REV Travelling Right 4 Operate the Control lever fully and take the reading from the voltmeter The reading on the Digital voltmeter is the GAIN voltage Higher GAIN voltage causes increased Maximum operational speed The reference value for each GAIN voltage is
82. n Retraction wire ropes as follows It is advisable to apply the tension on each electric cable every 6 months or 600 working hours 1 Position the boom horizontally retract it fully and check the tension of the Extension Retraction wire ropes Adjust the tension if necessary 2 Loosen the cable clamps at the top of the 3rd boom 3 Pull each electric cable by applying 30 40kgf and lock the cable with the cable clamp 66 88lbs 3rd boom 30 40kgf 66 88Ibs Electric cables Cable clamps Note Apply tension to the cables every 6 months 2 8 The is mounted between the carrier frame and the turn table it enables the turn table to rotate freely over the carrier frame 35 9 48 5kg m Quo 250 Ring gear Carrier frame 1 Inspection procedures l Check anchor bolts and nuts for any looseness omissions or any other damage Loose bolts should be removed and checked for damaged threads and deformation b When resetting anchor bolts or nuts apply thread lock agent to the threads Recommended thread lock agent 3 Bond 1374 c Tighten anchor bolts and nuts to the specified tightening torque Specified tightening torque 35 9 48 5 kg m 260 350 ft lb 2 9 NOTE Before removing anchor bolts or nuts use gas bunner to heat them until they are red hot This will remove the thread lock agent applied on the thread of each bolt and nut 2 Check ring gea
83. n the Valve control unit s follows Caution The Pivot turn speed should be adjusted after having adjusted Straight travelling speed The main key switch is to be set at its UPPER position when adjusting the pivot turn speed 1 Pivot Turn Right Adjustment procedures Remarks Set a Digital volt meter between the Check TP D on Valve control unit and GND O Operate the Travel lever Left fully to FWD and read the voltmeter Voltage reference 6 2V 2 Piv Adjust the voltage by Trimmer VR37 The higher voltage causes the faster pivot turn speed Specific pivot turn speed 12 3 sec 90 ot Turn Left Adjustment procedures Pivot turn Right Set a Digital volt meter between the Check pin on Valve control unit and GND O Operate the Travel lever Right fully to FWD and read the voltmeter Voltage reference Adjust the voltage by Trimmer VR36 The higher voltage causes the faster pivot turn speed Specific pivot turn speed 12 3 sec 90 6 12 Pivot tum Left 6 Adjustment of Spin turn speed The Spin turn speed is adjusted by the trimmers installed on the Valve control unit as follows Caution The Spin turn speed should be adjusted after having adjusted Straight travelling speed The main key switch is to be set at its UPPER position when adjusting the spin turn speed Adj
84. ng hours or on an annual basis For new Machine After 300 working hours or 3 months use In the meantime take a small amount of oil from the oil reservoir and conduct the following inspections and tests 1 Visually compare the sample taken from the oil reservoir and a fresh unused sample Color As the oil deteriorates the color becomes darker and less clear If the oil is milky let it settle for about 10 hours then observe a If there is little or no change to the milky oil the cause is water mixed into the oil In this case a complete oil change is necessary 3 3 b If the and water seperate this indicates that the water has been introduced to the hydraulic system a short time ago It can be reused after taking out water c If the oil becomes clear with no water at the bottom of the container it is an indication that air has been mixed into the oil Access the cause of the air Smell If the oil has a strong pungent odor it is an indication that the deterioration has progressed to a point where an oil change is needed Contaminants If suspended contaminants are introduced to the hydraulic oil leave the sample for 1 to 2 days and gather sediments for further tests of the development of contaminants 2 Analytical tests Test the hydraulic oil for viscosity water content oxidation contaminants etc Test for Shell Tellus 32 Shell Tellus T15 Contamination Within NAS Class 12 Water content 96 Le
85. ows 1 Retract boom fully and set it horizontally 2 Loosen both the lock nuts and the Adjustment nuts NO 1 which are located on both sides of the top part of the ist boom 3 Lubricate the Adjustment nuts NO 1 with machine oil and make sure that the nuts turn smoothly on the threads 4 Tighten both of the Adjustment nuts NO 1 Do this alternatly using a torque wrench until the specified tightening torque is reached Specified tightening torque of Adjustment nuts NO 1 1 0 1 5kgf m 7 2 10 8ft 1b 5 Check dimension A shown in the figure below and make sure that it is 610 mm 24004 If the mesurement of dimension A is less than 610mm 24 0 Screw out Adjustment nuts NO 1 2 and screw in Adjustment nuts NO 2 D until the specified dimension A is obtained If the mesurement of dimension A is more than 620mm 24 4 Screw out Adjustment nuts NO 2 D and screw in Adjustment nuts NO 1 until the specified dimension A is obtained 6 Extend retract boom several times for a full stroke and recheck the tightening torque of Adjustment nuts NO 1 and dimension A then secure the Adjustment nuts with lock nuts Adjustment nuts NO 1 2 4 Lock nut 1 0 1 5kgf m 7 2 10 8ft Ib Retraction wire rope Extension wire rope 6102 mm Q4 0 22 Note Adjust the tension of wire ropes every 6 months T Tension of Electric cable 3 Apply tension on the each electric cable after adjusting the tension of Extensio
86. r 2 1069 EU n 19 1 9 AO ZR remo E i T ETES 7 2 i y 2 2K Pen 2 E 406 n pe en Iv 8 amp 7597 E 1 2 SS 2 _ E 3 5 2 2 lz M 15 i 4 z 29 21 2 25 4 ic F FS mo _ are i 3 j BM 17 2 2K ov M 1 i P eis ich ig i a 30 Hopf pa i p cri E 16 EH 17 3 E 15 RISS 2 2k 21 4 T Ri ae 1623 nac n 4 53 1 Sr tee X E ALCOA N 3 RUN STOP AUR UEN i BRL es J 4c dena 4 17 2 322 00913 The Accelerator motor is installed on the turn table It is used to increase or decrease the engine speed Rated voltage DC24V DC20 30V Out put BS0kgf cm Rated 250mA Structure O 5 Oupar sat 5 4 18 1 Electric circuit Accelerator motor DC24V 2 Inspection procedures Follow the steps listed below to check that the accelerator motor is functioning correctly 1 Connect battery amp switch as shown in the electric c
87. r for cracks scorings and any other damage For any fine cracks use a penetrant check such as a color check 3 Check the back lash between ring gear of T T B and the drive pinion of Rota ton gear box sne Standerd back lash 0 6mm 0 024 or less NOTE To measure the value of back lash rotate turn table and crush a lead wire between the ring gear and the drive pinion then measure the thick ness of the crushed lead wire When the back lash is not within the the tolerance adjust it by moving the position of rotation gear box 4 Check the free play between inner and outer races of T T B To check the free play use the following steps 50mm 2 Dial gauge T T B Carrier frame a Set a dial gauge between the turn table and the carrier frame as shown in Fig 2 b Retract and raise the boom fully with minimum boom length and maximum boom angle and set the pointer of the dial gauge at ZERO c Lower the boom set it horizontally and extend it fully then re check the dial gauge The reading of the dial gauge is the value of free play Standard free play 0 9mm 0 035 Limit of free play 3 0mm 0 118 NOTE The T T B with free play in excess of the limit 3 0mm 0 118 should be replaced 2 10 7L1 00920 Apply grease on worm gear mm Tightening torque 10 13 5kgf m 72 98 ft Ib Tightening torque 10 13 5kgf m 72 98 ft Ib Apply Lock tight
88. r is in the hydraulic system Bleed air by operating actuator several times Loosen the Air bleed screw installed on Solenoid and bleed air Actuator is powerless Check the MAX pressure MAX pressure is too low Improper adjustment of Relief valve Readjust the Relief valve PC valve is loose Tighten the PC valve Erratic hydraulic pressure or higher pressure is not achieved Disassemble the Relief amp PC valves Defective spring Replace the spring Wom out Poppet or Poppet seat Replace the Relief or PC valve Sticked Plunger Clean or replace the Relief or PC valve 302 06303A PLATFORM ROTATION SOLENOID VALVE This valve is controlled electrically by the platform rotation switch located at the upper control box WWE IS The priority valve maintains the flow Which comes out of the PF port at the constant level regardless of any variation to the volume of pump discharge While the rest of the pump discharge volume is by passed through the EF port The relief valve incorporated in the valve is for limiting the maximum hydraulic pressure for the PF port For SR 182 the flow and the maximum hydraulic pressure of the Platform swing System are both limited by the priority valve This is because the System is supplied with hydraulic power through the PF port
89. r oil Oil change interval 1 200 hours or Annually Control System Swivel joint Oil leakage Apply the maximum pressure and check for oil leakage Anchor bolts stopper Check for looseness 4 _ _ ____ Slip rings carbon brushes Remove the cover or carbon brush holder and check for excessive wear corrosion Lubrication Control levers switches cables linkages Supply grease to grease fitting Test all of the control levers switches and check the correct function and any excessive free play Instruments Check for the function Relief valve Actuate relief valve and check for abnormal noise oil leakage Set a pressure gauge measure the preset pressure of relief valve Control valves Operate control valves and check for oil leakage any other fault Accelerator Name plates Decals Check for legibility and any damage Operate accelerator switch either at lower or upper control and check for the function Check accelerator motor limit switches cams wires for any damage Boom crack scratch Bend distortion dent Extend boom fully and check for the items The limit of bend Vertically 0 15 of the boom len
90. ring Drive sprocket SESS Track roller Grease cylinder Note 1 For the details the Travel motor refer to the Hydraulic section 2 For the adjustment procedures of the Track tension efer to the Adjustment section 2 2 The boom Assy consists of 1st boom 2nd boom 3rd boom extension cylinder extension retraction wire ropes hydraulic plumbings electric cables and their sheaves The 2nd boom is extended or retracted directly by the Extension cylinder However the 3rd boom is telescoped by the movement of 2nd boom through extension retraction wire ropes 1 Note on function 2nd boom head sheave Retraction wire rope 2nd boom tail sheave 3rd boom 2nd boom 15 boom Extension wire rope 3rd boom tail Extension cylinder The first and second booms are connected by the extension cylinder which directry extends and retracts the second boom The third boom is connected by two pairs of wire ropes one is the retraction wire This is connected to the tail of the third boom through the tail sheave installed on the tail of the second boom The other is the extension wire rope this is also connected to the tail of the third boom through the head sheave which is installed on the bead of the second boom During the extension of the boom the second boom is extended by the extension cylinder together with the head sheave As a result the third
91. s Engine oil Oil level contamination change Oil change interval Every 200 hours Oil filter Oil leakage Replacement Replacement interval Every 400 hours Fuel tank Cracks deformation _ G Cleaning Hydraulic oil reservoir Oil leakage Anchor bolts Looseness Stop valve Oil leakage Oil level contamination water content oxidation 8 12 Oil change interval 1 200 hours or Annually UNIT ITEM REMARKS Hydraulic Oil leakage fillter 9 Repllacement of filter element Replacement interval 1 200 hours or Annually Hydraulic Abnormal noise excessive heat pump Oil leakage Pump bracket anchor bolts Cracks deformation looseness Wheels Tyre SP series Wear cuts Wheel nuts Looseness Crawler Track shoe link SR series Tension wear Drive sprocket idle wheel Wear Cracks Track roller carrier roller Wear Oil leakage Travel Oil leakage Oil level motor unit Change gear oil Oil change interval 1 200 hours or Annually Abnormal noise excessive heat Bolts nuts Looseness Steering Linkages mechanism Deformation Cracks SP series Wheel bearing Excessive free play any damage Steering cylinder Oil leakage abnormal function Lubrication Travel speed limit s
92. s Koued1ourg Interface board for AL Fh 652319 452540 Turntable 532 2 ta 8 E 5 0 W Iaou VOT SA gt Safety rela Starter motor sand Engine stop solenoid VOS Apt Alternator dr XUH 919514 souoneg 5 2 for Spec Ab Sy 642347 655351 Turntable Starter motor ATE Sa QUU La UAZ 93 ANN C3472 ed Power LED Control board Interface board Lower control box Alternator m s dois Kouog1ounq Engine stop solenoid Foot s w O 91138 Upper control box WLI 5 3 1 for Spec Ab 9 652352 Platform 191815 A S was 8 ayes M S eisSeld D A A S e lt 364045 710 O 2142174 Quote ba 4 x 8 TR T PER prouopos 4018 oursuq sqrsnd o ue lt a jones Um MS 100g 5 3 2 for Spec 8 amp 20 ENGINE CONTROL SYSTEM 22 M S UES ourduq 960809 ON EHS 6661 D Q eouts sem 010 Jojo 25819 IMMA was 2101890 19 95 2 dd
93. ss than 0 596 Oxidation mgKOH g 0 4mgKOH g Viscosity cst 32 cst 15 cst at 40 c Suction strainer Be sure to clean suction strainer at the time of an oil change Wash and clean the strainer in kerosene or a similar solvent then air blast it from the inside Oil filters Regulary replace the filter element If the machine is new replace the element after 300 working hours or 3 months use Thereafter replace it every 1 200 working hours or on an annual basis The element should also be replaced at the time of an oil change 3 4 750 02740 The oil reservoir consists of such components as shown in the figure below and supplies hydraulic oil to the whole hydraulic system Capacity 170 liters 45 gals Recommended oil Shell Tellus oil 32 Oil filler cap Oil level gauge Oil return pipe Suction strainer Oil out let port Oil drain plug Oil change interval Every 1 200 hours or annually For a new machine the first oil change should be carried out after 300 hours or 3 months use Note When checking oil level retract and lower the boom fully Clean Suction strainer and replace In line filter when changing the hydraulic oil 3 5 R12 R5014 The in line filter is installed at the outlet line of the hydraulic pump to eliminate the contaminants contained in the hydraulic oil Replacement interval Every 1 200 working
94. tension Elevation Travelling Right Travelling Left LDI 192 Extension 0 Elevation Right Travelling Left Travelling R Travelling L Pivot Turn VR 36 VR 37 VR 38 VR 39 Spin Tum DC DC convertor our DC DC convertor F21341 1110 A 2 Fuse 5A c m VAL 9400A 2 Y va VS v8 v7 V D vg 12 13 14 15 vag vit viv VID GEHA EHA LEHA cEHA SEHA 1OUHGQ m wa SFE stog 01566 O17 emo roid pa os eye es aa ven 602 9 92 01455 01558 9194 zi uw om JOU AL 9 ESHA OCHA SHA 8HA ViHA umoq SCHA SCHA 6 OLHA ZHA SIHA SIHA dn Jawu Aejaq d c o cR RI Jeyv 9S 0 98 0 99 0 960 azro azro azro nos o nos o happened td 8d Old Ure weusnp Jeyv 260 ACEO AZEO 260 AZ 0 260 azeo S eDeyoA JINN 61 LZld d 4d 6d IMN OCA SIA SIA VIA vA ZA 8
95. the Pressure gauge while Relief valve P3 is active and adjust the pressure to 140 3kgf cri 2 000770 PSI by turning the Adjustment screw of Relief valve P3 6 4 The following conditions must be strictly kept when measuring or adjusting the operational speed Hydraulic pump speed 2 300 rpm Without load Maximum hydraulic pressure for Main control system 210 kg c 3 000 PSD for Sub control system 140 kg cnf 2 000 PSI Pump discharge volume More than 18 liters min 4 76gals min At pump speed 1 000 rpm Hydraulic oil temperature 40 60 Platform No load condition 1 Measurement procedures of Maximum operational speed Take the following items into consideration when measuring each Maximum operational speed Measure each operational speed at least 3 times for the purpose of obtaining accurate data Operate the control levers fully up to the stroke ends when measuring the operational speed by functioning the upper control Elevation Boom raising Up lowering DOWN speed Raise lower the boom to its full stroke with the minimum boom length and measure the boom raising UP and lowering DOWN speeds seconds stroke Extension Boom extending OUT retracting IN speed Extend retract the boom to its full stroke with the maximum boom angle and measure the the boom extention OUT and retraction IN speeds seconds stroke Rotation Turn table rotation speed
96. the valves for oil leakage solenoid valve Travel speed select Check the solenoid valve for oil leakage Limit switch Check the limit switches for any damage Carrier frame Deformation cracks Check the frame for the items Turntable Deformation cracks Check turntable for the items Anchor bolts T T B Turn Table Bearing Ring gear Check ring gear for excessive wear cracks Check anchor bolts for looseness Bearings Rotate T T B and check for abnormal noise and any other fault Check the T T B for free play serviceable limit 3 mm 0 12 in Anchor bolts Check bolts for looseness Lubrication Supply grease to each grease fitting Rotation motor gear box Oil leakage Check gear box and motor for oil leakage Abnormal noise excessive heat Run the motor and check for the items Bolts nuts Check bolts and nuts for looseness 8 7 UNIT ITEM MONTHLY INSPECTION ANNUAL INSPECTION Rotation box motor gear te Pinion gear Check pinion gear for wear and cracks _ ___ Back lash between pinion amp T T B Check the back lash between the pinion and ring gear of T T B Standard back lash 0 6 mm 0 02in or less Gear oil Check oil level Change gea
97. tions are operating correctly Switches Excessive free play check for excessive free play 8 1 Operate all of the control levers switches and UNIT DESCRIPTION ing system Platform level Function Operate the boom by the lower control and check that the platform always keeps its level position SAFETY DEVICE Engine start stop system Platform Deformation cracks Swing device wear Function Check platform swing device for deformation cracks and wear Test the engine start stop switches at upper control and check they function correctly pump Emergency Function Stop engine operate boom by emergency pump and check it functions correctly Foot switch Function Operate the machine using the upper control release foot Switch and check if all of the function stops immediately ing buzzer Slope warn Function Turn on main key switch and make sure the slope warning buzzer sounds for a second just after turning on Alarm horn Motion alarm buzzer Function Function Press horn switch at upper control and check it functions correctly Operate the control levers and switches then check that the motion alarm buzzer sounds switch Safety Function
98. ustment procedures Remarks Set a Digital volt meter between the Check pin on Valve control unit and GND O Operate Travel Left lever to REV slightly and Travel Right lever to FWD fully Hold the Travel levers at the above positions and adjust the voltage Vi to 6 2V by Trimmer VR 38 Operate Travel Left lever to REV fully and Travel Right lever to FWD fully Hold the Travel levers at the above positions and adjust the voltage V2 to 3 8V by Trimmer VR 39 Set a Digital voltmeter between the Check pin 0 Valve control unit and GND O Operate Travel Right lever to REV slightly and Travel Left lever to FWD fully Hold the Travel levers at the above positions and adjust the voltage V3 to 6 2V by Trimmer VR 40 Operate Travel Right lever to REV fully 1 and Travel Lef lever to FWD fully 5 C C W Hold the Travel levers at the above positions and adjust the voltage V4 to 3 8V by Trimmer VR 41 Specific spin turn speed C W 1213sec 909 Adjust the Spin turn speed CW amp CCW C C W 1233sec 90 by varing the voltage V2 amp V4 The higher voltage causes the faster Spin turn speed 6 13 4 Trimmer s Identification on Valve control unit 101 10 00010 LO14 1016 L018 Check pins 90 6 610 33 e Rotation Ex
99. ward 5 Perform the above steps 3 and 4 several times 3 4times 6 Return the platform to its level position and firmly close the two Stop valves 3 31 Cylinder tube Piston Piston rod 12 Wear ring Cylinder head 13 U ring Bushing 14 Back up ring an U ring 15 ring holder Back up ring 16 O ring Dust seal Steel ball O ring 18 Set screw Back up ring 19 Bushing O ring Grease fitting R12 R4005 302 02902 1 Cylinder tube Piston 2 Piston rod U ring 3 Cylinder head 13 Back up ring 4 Bushing 14 Wear ring 5 U ring 15 Steel ball Dust seal 16 E Set screw O ring 17 Bushing Back up ring 18 Grease fitting O ring 19 Bushing Lock plate Double pilot check valve Tightening torque Tightening torque 43 10kgf m 65 1Okgf m 310 72ft Ib 47077 72ft Ib B ES 3 33 This valve is mounted on the Upper levelling cylinder It confines the hydraulic oil into tbe Upper levelling cylinder to keep the platform level in an emergency situation such as hydraulic line failure Valve cartridge 7 Tightening borg o Te fm
100. ystem Function Flow divider valve Oil leakage Travel speed select solenoid valve Oil leakage Limit switch Any damage L Carrier frame Deformation cracks 8 13 UNIT ITEM Turn table Deformation cracks T T B Anchor bolts Looseness Turn Table Ring gear Excessive wear cracks Bearing Bearings Abnormal noise play Anchor bolts Loosensee Lubrication Rotation motor gear box Oil leakage Abnormal noise excessive heat Bolts nuts Looseness Pinion gear Excessive wear cracks Back lash between pinion and ring gear Gear oil Oil level change Oil change interval 1 200 hours or Annually Swivel Oil leakage joint Anchor bolts stopper Looseness Slip rings carbon brushes Excessive wear corrosion Lubrication Control system Control lever switch cable linkage Function excessive free play Control valves Oil leakage Instruments Function Relief valves Noise Oil leakage Pre set pressure Name plates Decals Legibility any damage Accelerator Function damage of the components 8 14

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