00 Front page.p65
SSJ00008
SR12C / SR400C
SR14CJ / SR460CJ
営 業 企 画 部・サ ービ ス 企 画 課
Chapter A
Introduction
Introduction
This manual describes correct adjustment and servicing procedures for Boom
type self- propelled Elevation work platform: SR12C / SR400C and SR14CJ /
SR460CJ in order to ensure safe and reliable operation, the most effective use
of superb performance and excellent features for your satisfaction.
Qualified personnel should read this manual carefully and understand the
descriptions correctly before making any repair or maintenance works.
Always be sure of the following items when conducting repair or maintenance
works.
Use only the spare parts approved by the manufacturer, particularly for loadsupporting components (Structural components including chassis, turntable,
boom section and platform) and safety related components (Scheduled
replacement parts listed in the page 7-6).
Use proper tools, lifting equipment and suitable workshop.
It is strictly forbidden to make modifications to the machine without obtaining
AICHI’s written approval.
Constant improvement of its products is
Constant improvement of its products is AICHI’s policy.
Therefore, specifications of the machine are subject to change without prior
notice.
SSJ00008
a
Chapter A Introduction
Location of Serial number plate
When you contact Aichi / Aichi dealer for Technical support, Parts order / inquiry or Warraty
claim, Inform Commercial name / Model code, Serial number and Date of manufacture
inscribed on the serial number plate.
Commercial name / Model code
Commercial name
Model code
CE model
SR14CJ
SR12C
SR12CSM SR14CJM
ANSI model
SR400C
SR460CJ
SR12CSM SR14CJM
Meaning of model code
S R 1 2 C S M
① ② ③④⑤
① Machine type: SR --- Boom type self propelled with crawler
② Maximum platform height in metric
③ Machine generation
④ Boom type: S --- without Fly jib, J --- with Fly jib
⑤ Machine size: M --- middle
b
SSJ00008
Chapter A Introduction
Safety warnings and safety signal words
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a hazardous situation which, if not avoided, could result in minor /
moderate injury or property damage.
Information not related to personal injury or property damage.
SSJ00008
c
Index
Index
Chapter A
Introduction
Locations of Serial number plate
Safety warnings
-------------------------------------------
a
b
c
Chapter 1 General information
Specifications
Overall dimensions
Work range diagram
Safety devices
---------------------------------------------------------
1-2
1-4
1-8
1-9
Chapter 2 Mechanical components
Chassis
Turntable
Hydraulic pump installation
Turntable bearing
Boom rotation gearbox
Boom
1. Structure
2. Inspection procedures
3. Extension / Retruction wire rope
4. Adjustment of Extension / Retruction wire rope
5. Cable guide
6. Removal and installation of Cable guide
Fly jib
Platform (Adjustment of Overload limit switch)
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
2-2
2-4
2-5
2-6
2-8
2-9
2-9
2-10
2-12
2-13
2-15
2-16
2-36
2-37
Chapter 3 Hydraulic components
Locations of Hydraulic components
HST pump
Gear pump
Emergency pump
Hydraulic oil tank
Filters
Main control valve
Elevation cylinder
Single holding valve for Elevation cylinder
Telescope cylinder
---------------------------------------------------------------------------------------------------------------------------------------------
3-2
3-4
3-6
3-7
3-8
3-9
3-10
3-13
3-14
3-16
i
SSJ00008
Index
Boom rotation motor
Rotary actuator
Platform rotation solenoid valve
Platform rotation / Fly jib solenoid valve
Fly jib cylinder
Double holding valve for Fly jib cylinder
Valve unit for Platform leveling
Platform leveling cylinder, Upper
Double holding valve for
Platform leveling cylinder, Upper
Platform leveling cylinder, Lower
Travel motor
Valve unit for Travel functions
-----------------------------------------------------------------------------------------------------------------
3-18
3-19
3-21
3-22
3-23
3-24
3-25
3-27
---------------------------------------------------------
3-28
3-29
3-30
3-31
Chapter 4 Electric components
Locations of Electric components
Upper control box
CPU board M6
LED board
Joystick controller
Lower control box
CPU board M5-B
Accelerator control unit
Key switch
Engine relay box
Tilt sensor (Longitudinal, Lateral)
Tilt sensor (Omni-directional)
Limit switches
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
4-2
4-3
4-5
4-8
4-9
4-10
4-13
4-16
4-17
4-18
4-19
4-20
4-21
Chapter 5 Trouble shooting
Trouble shooting by LED indication on Upper /
Lower control box
Emergency operations
-----------------------------
5-2
5-7
---------------
6-2
---------------
6-3
Chapter 6 Inspection and Adjustment
Engine speed measurement procedures
Relief valve pre-set pressure measurement
and adjustment procedures
SSJ00008
ii
Index
Chapter 7 Scheduled maintenance
Scheduled inspection table
Lubrication
Scheduled replacement parts
Daily inspection sheet
Periodical inspection sheet
-----------------------------------------------------------------------
7-2
7-4
7-6
7-7
7-8
Chapter 8 Appendix
Hydraulic circuit diagram
Electric circuit diagram, Upper
Electric circuit diagram, Lower
Electric wiring diagram, Upper
Electric wiring diagram, Lower
Electric wiring diagram, Engine
Water proof connector
Color code of Wires
Tightening torque standard
-------------------------------------------------------------------------------------------------------------------------------
8-2
8-3
8-5
8-7
8-8
8-10
8-11
8-13
8-14
Chapter 9 Engine
Safety warnings for Engine maintenance
Component identification
Periodical maintenance procedures
-------------------------------------------
9-2
9-4
9-5
iii
SSJ00008
Chapter 1 General Information
Chapter 1
General Information
SSJ00008
1-1
Chapter 1
General Information
Specifications (CE models)
Commercial name
Performance
Model code
Platform height maximum
Horizontal outreach maximum
Platform capacity (6ft)
Platform capacity (8ft)
Platform rotation
Turntable rotation
Maximum allowable wind speed
Maximum allowable tilt angle
Maximum allowable manual side force
Function Speed
Power
source
Measurements
Gradeability (stowed)
Ground Clearance
Minimum turning radius
Overall length-6ft
Overall length-8ft
Overall width-6ft
Overall width-8ft
Overall height
Inside diameter of Platform -6ft
Inside diameter of Platform -8ft
Vehicle weight
Max. Ground contact pressure
Engine
Auxiliary Power unit
Fuel Tank Capacity
Hydraulic Tank Capacity
Elevation
Up
Down
Telescope
Out
In
Rotation
Jib Elevation
Up
Down
Platform Rotation
Travel speed (High)
Travel speed (Low)
SR12C
SR14CJ
SR12CSM
SR14CJM
11.7 m
13.6 m
10.9 m
12.7 m
250 kg (2 Persons + tools: 90 kg)
227 kg (2 Persons + tools: 67 kg)
+/-90 deg
360 deg (Continuous)
12.5 m/s
5 deg
400 N (41 kg)
58 % (30 deg)
335 mm
0m
6.86 m
7.56 m
7.02 m
7.72 m
2.30 m
2.45 m
1.72 m
1.76x0.72x1.1 m
2.36x0.86x1.1 m
7,675 kg
8,510 kg
60 kPa
65 kPa
YANMAR 4TNV88 (4 Cylinder Diesel 33kW)
DC12V
120 L
190 L
39 - 51 s
39 - 51 s
24 - 36 s
19 - 31 s
120 - 150 s / 360 deg
20 - 30 s
15 - 25 s
10 - 20 s / -90 ∼ +90 deg
1.8 - 3.4 km/h
0.6 - 1.0 km/h
The CE model has been manufactured to conform to European Standard EN280.
1-2
SSJ00008
Chapter 1
General Information
Specifications (ANSI models)
Commercial name
Performance
Model code
Platform height maximum
Horizontal outreach maximum
Platform capacity (6ft)
Platform capacity (8ft)
Platform rotation
Turntable rotation
Maximum allowable wind speed
Maximum allowable manual side force
Function Speed
Power
source
Measurements
Gradeability (stowed)
Ground Clearance
Minimum turning radius
Overall length-6ft
Overall length-8ft
Overall width-6ft
Overall width-8ft
Overall height
Inside diameter of Platform -6ft
Inside diameter of Platform -8ft
Vehicle weight
Max. tire ground contact pressure
Engine
Auxiliary Power unit
Fuel Tank Capacity
Hydraulic Tank Capacity
Elevation
Up
Down
Telescope
Out
In
Rotation
Jib Elevation
Up
Down
Platform Rotation
Travel speed (High)
Travel speed (Low)
SR400C
SR460CJ
SR12CSM
SR14CJM
38 ft 5 in
44 ft 7 in
35 ft 9 in
41 ft 8 in
550 lbs (2 Persons)
500 lbs (2 Persons)
+/-90 deg
360 deg (Continuous)
28 mph
150 lbs
58 % (30 deg)
13 in
0 in
22 ft 6 in
24 ft 10 in
23 ft
25 ft 4 in
7 ft 7 in
8 ft
5 ft 8 in
5 ft 9 in x 2 ft 4 in x 3 ft 7 in
7 ft 9 in x 2 ft 9 in x 3 ft 7 in
16,920 lbs
18,760 lbs
8.7 PSI
9.4 PSI
YANMAR 4TNV88 (4 Cylinder Diesel 33kW)
DC12V
31.7 gallons
50.2 gallons
39 - 51 s
39 - 51 s
24 - 36 s
19 - 31 s
120 - 150 s / 360 deg
20 - 30 s
15 - 25 s
10 - 20 s / -90 ∼ +90 deg
1.1 - 2.1 mph
0.4 - 0.6 mph
The ANSI model has been manufactured to conform to all applicable requirements of
Occupational Safety and Health Administration (OSHA) and
American National Standards Institute (ANSI)
SSJ00008
1-3
Chapter 1 General Information
Overall dimensions (SR12C / SR12CSM) CE model
6 feet platform
8 feet platform
1-4
SSJ00008
Chapter 1 General Information
Overall dimensions (SR14CJ / SR14CJM) CE model
6 feet platform
8 feet platform
SSJ00008
1-5
Chapter 1 General Information
Overall dimensions (SR400C / SR12CSM) ANSI model
6 feet platform
8 feet platform
1-6
SSJ00008
Chapter 1 General Information
Overall dimensions (SR460CJ / SR14CJM) ANSI model
6 feet platform
8 feet platform
SSJ00008
1-7
Chapter 1
General Information
Work range diagram
Rated load 6 feet platform : 250 kg (550 lbs)
8 feet platform : 227 kg (500 lbs)
SR12C / SP12CSM (CE mode)
SR400C / SP12CSM (ANSI model)
SR14CJ / SP14CJM (CE model)
SR460CJ / SP14CJM (ANSI model)
1) The boom deflection is not taken into account in the above working range diagram.
2) The working range shown in the diagram is obtained in any boom rotated directions.
3) It is assumed that the machine is on firm and level surface.
1-8
SSJ00008
Chapter 1
General Information
Safety devices
Name
No
Main function
1
Relief valve
Protect the hydraulic components by relieving abnormally high pressure in the
hydraulic system.
2
Single holding valve on
Boom elevation cylinder
Prevents the boom from natural descent in the event of hydraulic hose
breakage.
3
Double holding valve on
Boom telescope cylinder
Prevents the boom from natural descent in the event of hydraulic hose
breakage.
4
Double holding valve on
Upper leveling cylinder
Maintains the platform level in the event of hydraulic hose breakage.
5
Double holding valve on
Fly- jib cylinder
(SR14CJ / SR460CJ)
Prevents the fly- jib from natural descent in the event of hydraulic hose
breakage.
6
Foot switch
The boom, fly-jib, platform and traveling functions are disabled unless the foot
switch is depressed.
7
This system cancel the foot switch / enable switch if any of the boom, fly-jib,
Foot switch cancel system platform and traveling function is not operated more than 20 seconds.
Release the switch once, then operate again to enable the functions.
8
Enable switch
(Lower control)
The boom, fly-jib and platform functions from the lower control panel are
disabled unless the enable switch is operated.
9
Motion alarm buzzer
The motion alarm buzzer sounds when the machine is in motion to warn the
people nearby.
10 Emergency stop button
Stops all of the movements of the machine when this button is pressed.
11 Tilt alarm buzzer
The tilt alarm buzzer sounds, if the machine tilts more than 5 degrees.
12 Travel speed limit system
The high speed traveling is disabled, unless the boom is fully retracted and
lowered under 15 degrees.
13
Travel function limit
system
This system disables the travel function when the machine is tilted more than
5 degrees, unless the boom is fully retracted and lowered under 15 degrees.
14 Rotation lock pin
Fixes the turntable to the chassis to prevent the turntable from being rotated
when transporting the machine.
15 Emergency pump
Auxiliary hydraulic pump driven by the battery. And used to lower the platform
in the event of engine or main pump failure.
16 Alarm horn
Before moving the machine, sound the alarm horn to warn the personnel
around the machine.
Boom wire rope failure
17 detecting system
(CE model)
This system disables the boom extending functions in the event of the boom
extension wire rope failure.
Overload sensing
system (CE model)
This system disables all of the functions, Overload warning light blinks and
Overload buzzer sounds when the platform is overloaded.
Boom / Travel function
19 interlock system
(CE model)
This system stops all of the functions when the travel and boom operations
are conducted simultaneously.
18
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1-9
Chapter 1
General Information
This page intensionally left blank.
1-10
SSJ00008
Chapter 2 Mechanical Components
Chapter 2
Mechanical Components
SSJ00008
2-1
Chapter 2 Mechanical Components
Chassis
Fig. 2-1 Chassis
2-2
SSJ00008
Chapter 2 Mechanical Components
1. Track tension adjustments
Adjust the track tension as follows periodically to prevent the tracks from detachment.
Adjustment interval: Every 800 hours or 6 months
For new machine, the 1st adjustment should be performed after 10 - 20 hours.
1. Set up the machine on firm and level surface, retract the boom fully, and then rotate the boom to the
right or left side of the chassis.
2. Set the “Boom stand B” and the “Wood block A” under the 1st boom section as shown in the Fig. 2-2
The “Wood block A” should be longer than the width of the 1st boom section, and arrange it so that the
boom comes to the center of the wood block. In the interest of safety, make sure the stand is stable.
3. Lower the boom slowly to press the boom against the wood block, and allow the clearance of 30 - 50
mm (1.2 - 2.0 in) between the track and the ground as shown in the Fig. 2-3.
Fig. 2-2
Fig. 2-3
Be sure to perform the boom operations from the “Lower control.”
Do not lift up the track more than 50 mm (2.0 in) above the ground. If the track is lifted up beyond what is
necessary, the machine may become unstable.
4. Supply grease to the “Grease cylinder” through the “Grease fitting A” installed on the “Lubricator”
shown in the Fig. 2-4 to apply more tension to the track.
Adjust the dimension between the track roller and the track link shown in the Fig. 2-5 to 25 - 40 mm
(1.0 - 1.6 in) to apply the specific tension on the track.
If the track is too tight, unscrew the “Lubricator” part away till the grease exudes.
Fig. 2-4
Fig. 2-5
Do not loosen the grease fitting as it may pops out, resulting in serious injury.
Do not unscrew the “Lubricator” more than one full turn as it may pop out, resulting in serious injury.
5. After adjusting one side, rotate the boom 180°, and adjust the other side in the same manner.
SSJ00008
2-3
Chapter 2 Mechanical Components
Turntable
Tightening torque :
384 +/- 38 N-m
(39.0 +/- 3.9 kg-m)
[283 +/- 28 ft-lbs]
Apply thread lock agent : Loctite 262
Fig. 2-6 Turntable
Wear pads
Swing tray
Turntable
Wear pads [454-0000744] x4
Machine screw [036-30816] x 8
Apply thread lock agent : Loctite 262
Fig. 2-7 Wear pads for swing tray
2-4
SSJ00008
Chapter 2 Mechanical Components
Hydraulic pump installation
Engine flywheel
Coupling boss
Coupling
Tightening torque :
85 - 94 N-m
(8.7 - 9.5 kg-m)
[63 - 69 ft-lbs]
Flange
HST pump
Gear pump
Tightening torque :
22.0 +/- 2.2 N-m
(2.3 +/- 0.2 kg-m)
[16.4 +/- 1.6 ft-lbs]
Tightening torque :
75.2 +/- 7.5 N-m
(7.7 +/- 0.7 kg-m)
[55.5 +/- 5.5 ft-lbs]
Apply grease on the spline shaft
of the pump before installation.
Fig. 2-8 Hydraulic pump installation
SSJ00008
2-5
Chapter 2 Mechanical Components
Turntable bearing (372-0000044)
This turntable bearing is mounted between the chassis and the turntable, and enables the turntable to
rotate freely over the chassis.
Inspection
1. Check the anchor bolts and nuts for looseness, omission and any other damage.
a. Loose bolts should be removed and checked for damaged threads and deformation.
b. When re-installing anchor bolts or nuts, apply thread lock agent to the threads.
* Recommended thread lock agent: Loctite 262.
c. Tighten anchor bolts by the specific tightening torque.
* Specified tightening torque
Anchor bolt for Turntable : 384 +/- 38 N-m (39.0 +/- 3.9 kg-m) [283 +/- 28 ft-lbs]
Anchor bolt for Chassis : 550 +/- 39 N-m (55.0 +/- 4.4 kg-m) [406 +/- 29 ft-lbs]
In case it is hard to loosen anchor bolts due to lock agent, heat them up by using a gas burner to melt
the agent.
The heated or removed bolts and nuts should be replaced with new ones.
2. Check the ring gear for cracks and any other damage.
To make the cracks obvious, use a liquid penetrant test such as a color check.
3. Check the backlash between the ring gear of the turntable bearing and the pinion gear of the rotation
gearbox.
* Standard backlash: 0.2 - 0.3 mm (0.008 - 0.012 in) or less.
To check the backlash, rotate the turntable and insert a lead wire between the ring gear and the
pinion gear of the turntable gearbox to crush the wire, and then measure the thickness of the crushed
lead wire.
If the backlash is inadequate, adjust it by moving the rotation gearbox.
Anchor bolt for Chassis
Tightening torque :
550 +/- 39 N-m
(55.0 +/- 4.4 kg-m)
[406 +/- 29 ft-lbs]
Apply thread lock agent : Loctite 262
Anchor bolt for Turntable
Tightening torque :
384 +/- 38 N-m
(39.0 +/- 3.9 kg-m)
[283 +/- 28 ft-lbs]
Apply thread lock agent : Loctite 262
Turntable
Spacer
Steel ball
Ring gear
Chassis
Fig. 2-9 Turntable bearing
2-6
SSJ00008
Chapter 2 Mechanical Components
4. Check the free-play between inner and outer races of the turntable bearing as follows.
a. Set a dial gauge between the turntable and the chassis as shown in the Fig. 2-10.
b. Retract and raise the boom fully, and set the pointer of the dial gauge at ZERO.
c. Lower the boom, set it horizontally, extend it fully to its maximum outreach and then read the dial
gauge again.
The reading of the gauge is the numerical value of free-play.
* Standard free-play: 0.9 mm (0.035 in).
* Serviceable limit: 3.0 mm (0.118 in).
The turntable bearing should be replaced, if the free-play exceeds the serviceable limit.
50 mm (2 in)
Turntable
Dial gauge
Turntable bearing
Chassis
Fig. 2-10 Checking freeplay
SSJ00008
2-7
Chapter 2 Mechanical Components
Boom rotation gearbox (372-0000082A)
The boom rotation gearbox reduces the rotation speed of the hydraulic motor and increases
the torque to rotate the turntable through the turntable bearing.
Specifications
* Type :
Worm gear
* Reduction ratio :
1/50
* Gear oil :
Shell Spirax EP-90
* Oil change interval : 1,200 hours or annually
Oil drain plug
Oil level gauge
Fig. 2-11 Boom rotation gearbox
Inspection
1. Check the gear oil level and replenish or change the oil,
if necessary.
Recommended gear oil --- Shell Spirax EP- 90
To check the oil level, screw in the oil level gauge (Dipstick)
fully into the gearbox first, then remove the dipstick.
The proper oil level is between the two lines on the dipstick
as shown in the Fig.2-12.
Adjustment
Oil level
Fig. 2-12 Oil level gauge
Stopper
Bolt (1)
1. Check the backlash following instruction in
the page 2-6 and adjust if it is necessary.
1) Screw out the bolt (1)so that the rotation
gearbox touches to the stopper.
2) Screw in the two bolts (2) alternately so that
the backlash between Rotation gearbox and Turntable
bearing become 02 -0.3 mm [0.008- 0.012 in]
3) Tighten the four bolts (3) to fix the rotation
gearbox. Apply thread lock agent before
tightening the bolts.
Bolt (3)
Recommended thread lock agent : Loctite 262
Bolt (2)
Bolt (2)
4) Tighten the bolt (1) and two bolts (2) and
then tighten their lock nuts.
Fig. 2-13 Backlash adjustment
2-8
SSJ00008
Chapter 2 Mechanical Components
Boom
1. Structure
The boom consists of the 1st, 2nd, and 3rd boom sections, Boom telescope cylinder, the Extension/
Retraction wire ropes, Hydraulic hoses, Electric cables and Sheaves.
The 2nd boom section is extended or retracted directly by the Boom telescope cylinder.
However, the 3rd boom section is telescoped by the movement of the 2nd boom section through the
extension and retraction wire ropes.
The 1st and 2nd boom sections are connected by the Boom telescope cylinder, which directly extends and retracts the 2nd boom section.
While, the 3rd boom section is connected to the 2nd boom section by the extension and retraction wire
ropes as shown in the figure below.
The retraction wire ropes are connected to the tail of the 3rd boom section through the tail sheave
installed on the tail of the 2nd boom section.
The extension wire ropes are also connected to the tail of the 3rd boom section through the head
sheave that is installed on the head of the 2nd boom section.
The 2nd boom section is extended by the Boom telescope cylinder together with the head sheave
coming along. As a result, the 3rd boom section is pulled by the extension wire rope and accordingly
goes out of the 2nd boom section.
When retracting the boom, the 2nd boom section is retracted by the Boom telescope cylinder together
with the tail sheave coming along. As a result, the 3rd boom section is pulled by the retraction wire rope
and accordingly goes into the 2nd boom section.
1st boom section
2nd boom tail sheave
Boom telescope cylinder
Retraction wire rope
2nd boom section
3rd boom section
Extension wire rope
2nd boom head sheave
Fig. 2-14 Structure of the boom
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2-9
Chapter 2 Mechanical Components
2. Inspection procedurese
The boom is to be disassembled for a detailed inspection every 5 years.
1. Clearance between each boom section.
1) Check the clearance between each wear pad and boom section.
Lateral direction
Boom head
Vertical direction
Boom tail
Fig. 2-15 Clearance inspection
Vertical direction
Clearance between
1st and 2nd boom
sections
Clearance between
2nd and 3rd boom
sections
boom head
boom tail
boom head
boom tail
0.5 - 1.0 mm
(0.020 - 0.039 in)
0.6 - 1.1 mm
(0.024 - 0.043 in)
0.5 - 1.0 mm
(0.020 - 0.039 in)
0.5 - 0.9 mm
(0.020 - 0.035 in)
Lateral direction,
Sum of Right and Left
0.5 - 0.9 mm
(0.020 - 0.035 in)
0.5 - 1.1 mm
(0.020 - 0.043 in)
0.5 - 0.9 mm
(0.020 - 0.035 in)
0.5 - 0.9 mm
(0.020 - 0.035 in)
2) If the clearance is not adequate, adjust the clearance by adding or reducing
the spacers installed under each wear pad.
Check each wear pad for wear, and replace them if the thickness is thinner than serviceable limit.
Serviceable limit of ware pad
1st boom section Lower
Nominal thickness : 12 mm (0.47 in)
Serviceable limit : 10 mm (0.39 in)
1st boom section Side
Nominal dimension : 15 mm (0.59 in)
Serviceable limit : 13 mm (0.51 in)
2nd boom section Lower
Nominal thickness : 15 mm (0.59 in)
Serviceable limit : 13 mm (0.51 in)
2nd boom section Side
Nominal dimension : 40 mm (1.58 in)
Serviceable limit : 38 mm (1.50 in)
Apply a thread lock agent to the thread of each setscrew for wear pad before setting.
Recommended thread lock agent: Loctite 262
2. Bend of boom section.
1) Set the boom horizontally and extend it fully.
2) Visually check the bend of each boom section and disassemble the boom to measure the
bend, if the excessive bend is observed.
* Serviceable limit
Length
Fig. 2-16 Bend inspection
L
Serviceable Vertical direction A
limit
Lateral direction B
2-10
1st boom section
4,700 mm
(15 ft 5.0 in)
7.1 mm (0.28 in)
4.7 mm (0.19 in)
2nd boom section
4,523 mm
(14 ft 10.1 in)
6.8 mm (0.27 in)
4.5 mm (0.18 in)
3rd boom section
4,748 mm
(15 ft 6.9 in)
7.1 mm (0.28 in)
4.7 mm (0.19 in)
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Chapter 2 Mechanical Components
3. Dents, scratches
Check the each boom section for both dents and scratches thoroughly. If any dent or scratch that exceeds
the serviceable limit is observed, replace the boom section.
* Serviceable limit:
Length = 50 mm [1.97 in], and/or Depth = 2 mm [0.08 in].
Fig. 2-17 Dent inspection
4. Dents on bottom plate of the 2nd and 3rd boom sections
Check the bottom plate of the 2nd and 3rd boom section for dents caused by contact with wear pads.
If any dent that exceeds the serviceable limit is observed, replace the boom section.
* Serviceable limit: 1.6 mm
Wear pad
D : Depth
t : Thickness of the bottom plate 3.2 mm
Fig. 2-18 Dent on the bottom plate of the boom section
5. Cracks.
Check each boom section thoroughly for cracks. For fine cracks, use COLOR CHECK
or penetrant check.
Pay special attention, when checking each pin boss and welded section.
6. Lubrications
Check the grease on the inner surface of each boom section and apply molybdenum grease.
Apply grease
to these area
1st boom
section
3rd boom sec.
2nd boom sec.
2nd boom
section
1st boom sec.
3rd boom
section
* Do not apply grease to the end of each boom section.
Fig. 2-19 Lubrication of the boom section
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2-11
Chapter 2 Mechanical Components
3. Extension / Retraction wire rope
After disassembling the boom, inspect the extension and retraction wire ropes as follows.
1) Measure the diameter of both the extension and retraction wire ropes, using a slide calipers.
Replace the wire rope, if the decrease of the diameter is more than 3 % of the nominal diameter.
Retarction wire rope
Extension wire rope
Nominal diameter
12.0 mm (0.47 in)
12.0 mm (0.47 in)
Serviceable limit
11.7 mm (0.46 in)
11.7 mm (0.46 in)
Fig. 2-20 Wire diameter
2) Check for broken wires.
If you find 3 or more single wires cut in one twist stroke, replace the wire rope.
Fig. 2-21 Broken wires
3) Check wire ropes for rust formation.
If the rust is penetrated into the rope, replace the wire rope.
Fig. 2-22 Rust formation
4) If any kinks are observed, replace the wire rope.
Also, a deformed wire rope requires replacement.
Fig. 2-23 Kink, Deformation
5) Check carefully the end sections of the wire rope, especially sections A and B.
Replace the wire rope, if any defects are found.
Fig. 2-24 Wire rope end
2-12
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Chapter 2 Mechanical Components
4. Adjustment of Extension / Retraction wire rope
Adjust the tension of the Extension/Retraction wire ropes as follows.
Lock nut B
Adjust nut B
L2 :
80 mm
[3.15 in]
L1 : 430 - 450 mm
[1 ft 4.9 in - 1 ft 5.7 in]
Adjust nut A
Extension wire rope
Lock nut A
Retraction wire rope
Fig. 2-25 Wire rope adjustment
1) Set the boom horizontally and retract it fully.
2) Unlock the Lock nuts B, turn the Adjust nuts B and adjust the Dimension L2 to 80 mm [3.15 in].
Do not twist the wire ropes when turning the adjust and lock nuts.
3) Loosen the Lock nuts A and the Adjust nuts A at the terminal end of the retraction wire ropes,
and then make sure that the 6 plate springs, shims, 2 washers and 1 collar are assemble at the
end of the retraction wire rope as shown in the Fig. 2-26.
Set this water drain
to the bottom side.
Washer
Washer
Retraction wire rope
Plate springs (6 pcs)
Collar Shims
Lock nut A
Adjust nut A
Fig. 2-26 Retraction wire end
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2-13
Chapter 2 Mechanical Components
4) Tighten the Adjust nut A until the washers touch the collar as shown in the fig. 2-27.
13.2 mm
(0.52 in)
When brand-new wire ropes are installed,
tighten the Adjust nut A by 13.2 mm (0.52 in) more.
Fig. 2-27 Tighten the adjust nut
5) Measure the Dimension L1 and make sure that it is 430 - 450 mm [1 ft 4.9 in - 1 ft 5.7 in].
6) Adjust the Dimension L1 as follows, if the Dimension L1 is not 430 - 450 mm [1 ft 4.9 in - 1 ft 5.7 in].
* In case the Dimension L1 is shorter than 430 mm [1 ft 4.9 in].
Screw out the Adjust nuts A and screw in the Adjust nuts B to adjust the Dimension L1
to 430 - 450 mm [1 ft 4.9 in - 1 ft 5.7 in].
* In case the Dimension L1 is longer than 450 mm [1 ft 5.7 in].
Screw out the Adjust nuts B and screw in the Adjust nuts A to adjust the Dimension L1
to 430 - 450 mm [1 ft 4.9 in - 1 ft 5.7 in].
7) Repeat the steps 5 and 6, and then tighten the Lock nuts A and B.
8) Telescope the boom several times, retract the boom fully, and then make sure that
Dimension L1 is 430 - 450 mm [1 ft 4.9 in - 1 ft 5.7 ft].
When replacing the Plate springs with the new ones, make sure to insert the correct Shims
by following the next instructions.
Plate springs
Collar
Shims
Fig. 2-28 Plate springs, Collar and Shims
1) Stack the new 6 Plate springs on level surface, and then measure the Overall height (H1)
of the plate springs.
2) Measure the Height (H2) of the Collar.
3) Determine the Thickness (H3) of the Shims using the following formula.
H3 = H1 – H2 – 3.6 mm (0.142 in)
The following shims are provided as service parts.
Part number
443-0000197
443-0000198
2-14
Thickness of Shim
0.5 mm (0.02 in)
0.1 mm (0.004 in)
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Chapter 2 Mechanical Components
5. Cable guide
Plate (5K0-0532400)
Cable guide bracket (Upper)
Attach to the 3rd boom section
Cable guide bracket (Lower)
Attach to the 1st boom section
Plate (5K0-0532400)
Vertical separator
Section B
View A
more than 70 mm
[2.76 in]
View F
Section C
Wrap the hoses and cables by cover
(338-0000020 Water hose, 250 mm [10 in])
Detail H
View G
No.
1
2
3
4
5
Hoses
Hose (P)
Hose (T1)
Hose (T2)
Hose (Platform leveling, Up)
Hose (Platform leveling, Down)
No.
Cables, Wire
6 14 core cable
7 16 core cable with shield wires
8 4 core cable for AC outlet
(CE model and ANSI model)
9 Wire for Boom length limit switch
Fig. 2-29 Cable guide
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2-15
Chapter 2 Mechanical Components
6. Removal and installation of Cable guide
SR12C (SR400C) Removal
1) Set the machine on firm and level surface.
2) Set the boom horizontal, extend the boom about 100
mm [4 in]and then turn off the main key switch.
3) Support the platform by crane or forklift.
4) Take the cover on the platform off. (Fig. 2-30)
5) Disconnect the boom cables (14 cores: Connector
126Gy, 127Gy) and (16 cores: Connector 122Gy,
128Gy, 129Gy). (Fig. 2-31)
[Connector 129Gy is for CE and ANSI model only]
Cover
Fig. 2-30
6) Disconnect the cable (4 cores) for AC outlet from the
receptacle if it is equipped.
7) Tag, Disconnect the T1 hose, P hose and T2 hose
from the platform rotation solenoid valve (Fig. 2-32),
and then plug the fittings on the valve and hose ends.
Platform rotation
solenoid valve
Fig. 2-32
Fig. 2-31
8) Take the 3rd boom front cover and cylinder boot off.
(Fig. 2-33)
Fig. 2-33
2-16
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Chapter 2 Mechanical Components
9) Tag, disconnect the hoses for upper leveling cylinder and then plug the fittings on the hose ends.
(Fig. 2-34)
Fig. 2-34
10) Take the U bolt fixing the boom cable and hoses off. (Fig. 2-35)
Fig. 2-35
11) Cut cable ties fixing the boom cables and then pull out the hoses and boom cables from the guard and
hole at the top of the 3rd boom section. (Fig. 2-36)
Pull out the hoses and boom cables
Fig. 2-36
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2-17
Chapter 2 Mechanical Components
12) Bundle the boom cables and hoses up, and then tie the leading rope to the 4 cores cable for AC outlet
(Fig. 2-37)
Fig. 2-37
Use leading rope longer than 8 meters [26 ft] to pass through the boom section.
13) Open the boom length limit switch cover located under the 1st boom section, and then disconnect the
cable for the boom length limit switch (Connector 572Br) (Fig. 2-38).
Fig. 2-38
14) Wind the disconnected cable and then put it on the cable guide bracket (Lower). (Fig. 2-39)
Fig. 2-39
15) Remove the cable guide fixing bolts. (Fig. 2-40)
Fig. 2-40
2-18
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Chapter 2 Mechanical Components
16) Take the turntable rear cover off. (Fig. 2-41)
Fig. 2-41
17) Open the engine cover, take the key plate and then pull the lower leveling cylinder upper pivot pin out
using slide hummer (Fig. 2-42).
Fig. 2-42
18) Lay down the lower leveling cylinder. (Fig. 2-43)
Fig. 2-43
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2-19
Chapter 2 Mechanical Components
19) Disconnect the cable for the boom wire rope failure limit switches (Connector 530Br, 531Br) and then
cut cable ties fixing the cables (Fig. 2-44) [CE model only]
Fig. 2-44
20) Disconnect the cables listed below. Connectors are located behind the lower control box. (Fig. 2-45)
* Boom cable (14 cores: Connector 518Gy and 546Br)
* Boom cable (16 cores: Connector 516Gy, 517Gy and 521Gy)
[Connector 521Gy is for CE and ANSI model only]
* Cable for Boom length limit switch (Connector 534Gy)
* Cable for Boom wire rope failure limit switches (Connector 503Gy) [CE model only]
* Boom cable (4 cores) for AC outlet (Disconnect from the receptacle if it is equipped)
Horn
F M
546Br, 2p
Boom cable (14 cores)
F M
518Gy, 8p
M F
Boom cable (16 cores)
Lower control box
516Gy, 4p
M F
517Gy, 4p
M F
Cable for
Boom wire rope failure
limit switches
Cable for
Boom length limit switch
Boom cable (4 cores)
for AC outlet
521Gy, 8p (CE and ANSI model only)
F M
503Gy, 2p (CE model only)
M F
534Gy, 2p
Receptacle
Boom angle L/S
Boom rotation angle L/S
M F
504Gy, 4p
Fig. 2-45
2-20
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Chapter 2 Mechanical Components
21) Tag, Disconnect the T1 hose, T2 hose, P hose, Platform leveling Up hose and Down hose from the
adaptor block (Fig. 2-46), and then plug the fittings on the adaptor block and hose ends.
Fig. 2-46
22) Take the guide fixed to the tail end of 3rd boom section off. (Fig. 2-47)
Fig. 2-47
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2-21
Chapter 2 Mechanical Components
23) Remove the cable guide, and then lay it on the stable place. (Fig. 2-48)
Fig. 2-48
2-22
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Chapter 2 Mechanical Components
24) Remove clamps, and then pull out the cables and hoses from the cable guide bracket (Lower).
(Fig. 2-49)
Fig. 2-49
25) Remove the cable guide from the cable guide bracket (Lower). (Fig. 2-50)
26) Open the cable guide by using screw driver (Flat), and then remove the cables and hoses (Fig. 2-51)
Fig. 2-50
Fig. 2-51
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2-23
Chapter 2 Mechanical Components
SR14CJ (SR460CJ) Removal
1) Set the machine on firm and level surface.
2) Set the boom horizontal, Lower the fly-jib to put the
platform on the wooden block and then turn off the
main key switch.
3) Take the cover on the right side of the fly-jib off.
(Fig. 2-52)
4) Disconnect the boom cables (14 cores: Connector
126Gy, 127Gy) and (16 cores: Connector 122Gy,
128Gy, 129Gy). (Fig. 2-53)
[Connector 129Gy is for CE and ANSI model only]
5) Disconnect the cable (4 cores) for AC outlet from the
receptacle if it is equipped.
6) Tag, Disconnect the T1 hose, P hose and T2 hose
and then plug the fittings on the hose ends.
(Fig. 2-54)
Fig. 2-52
7) Follow the SR12C (SR400C) removal instructions
step 8 (Page 2-16) to step 26 (Page 2-23) to remove
the cable guide.
Fig. 2-53
Fig. 2-54
2-24
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Chapter 2 Mechanical Components
SR12C (SR400C) Installation
1) When replacing the boom cables and/or hydraulic hoses with new one, put the designated colored
vinyl tape on them to identify each cable/hose and their specific position as shown in Fig. 2-55 and
Fig. 2-56.
Designated color and detail of Hydraulic hoses
Platform side
Turntable side
2,650 mm [8 ft 8.3 in]
1,900 mm [6 ft 2.8 in]
P hose
Part No: S30997-11
Length: 15,270 mm
[50 ft 4.3 in]
1,150 mm [3 ft 9.3 in]
740 mm [2 ft 5.1 in]
Red
Red x2
2,180 mm [7 ft 1.8 in]
T1 hose
Part No: S30997-12
Length: 14,800 mm
[48 ft 6.7 in]
1,100 mm [3 ft 7.3 in]
1,430 mm [4 ft 8.3 in]
270 mm [10.6 in]
Blue
Blue x2
2,185 mm [7 ft 2.0 in]
T2 hose
Part No: S30997-13
Length: 14,680 mm
[48 ft 2.0 in]
1,100 mm [3 ft 7.3 in]
1,430 mm [4 ft 8.3 in]
270 mm [10.6 in]
Orange
Hose for Platform leveling
(Up)
Part No: S31038-20
Length: 13,400 mm
[43 ft 11.6 in]
Orange x2
2,650 mm [8 ft 8.3 in]
Green
Hose for Platform leveling
(Down)
Part No: S31038-20
Length: 13,400 mm
[43 ft 11.6 in]
1,150 mm [3 ft 9.3 in]
Green x2
2,650 mm [8 ft 8.3 in]
Gray
1,150 mm [3 ft 9.3 in]
Gray x2
Yellow
White
Fig. 2-55
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2-25
Chapter 2 Mechanical Components
Designated color and detail of Boom cables
Boom cable (16 cores)
Part No: 5C1-0465100
Length: 15,350 mm
[50 ft 4.3 in]
Platform side
Connector No:
122
128
129
140 mm
130
[5.5 in]
131
Boom cable (14 cores)
Part No: 5C1-0465000
Length: 15,390 mm
[50 ft 5.9 in]
Platform side
Connector No:
125
150 mm
126
[5.9 in]
127
132
Boom cable (4 cores)
for AC outlet
Part No: 5C1-0468900
Length: 19,960 mm
[65 ft 5.8 in]
14,090 mm [46 ft 2.7 in]
2,615 mm [8 ft 7.0 in]
1,140 mm
[3 ft 8.9 in]
1,850 mm [6 ft 0.8 in]
1,005 mm
[3 ft 3.6 in]
Turntable side
Connector No:
516
517
521
570
740 mm
[2 ft 5.1 in]
680 mm
[2 ft 2.8 in]
14,230 mm [46 ft 8.2 in]
2,600 mm [8 ft 6.4 in]
1,140 mm
[3 ft 8.9 in]
1,850 mm [6 ft 0.8 in]
945 mm
[3 ft 1.2 in]
Turntable side
Connector No:
518
519
546
571
680 mm
[2 ft 2.8 in]
14,230 mm [46 ft 8.2 in]
2,600 mm [8 ft 6.4 in]
1,850 mm [6 ft 0.8 in]
Cable for Boom length limit switch 645 mm
[2 ft 1.4 in]
Part No: 5C1-0466800
Length: 6,110 mm
[20 ft 0.6 in]
Limit switch side Connector No: 572
1,140 mm
[3 ft 8.9 in]
1,955 mm
[6 ft 5.0 in]
1,140 mm 400 mm
[3 ft 8.9 in] [1 ft 3.7 in]
Turntable side Connector No: 534
Yellow
White
Fig. 2-56
2-26
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Chapter 2 Mechanical Components
2) Set the boom cables and hoses in the cable guide as shown in Fig. 2-57
Fig. 2-57
Make sure that all covers are securely closed, or the cable guide may be damaged while extending /
retracting the boom.
3) Fix the boom cables and hoses to the cable guide bracket (Upper) by clamp. (Fig. 2-58)
Fig. 2-58
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2-27
Chapter 2 Mechanical Components
4) Wrap the hoses and cables by cover. (Fig. 2-59)
Fig. 2-59
5) Fix the hoses for platform leveling to the top of the cable guide bracket (Upper). (Fig. 2-60)
Fig. 2-60
6) Install the cable guide to the cable guide bracket (Lower). (Fig. 2-61)
Fig. 2-61
2-28
SSJ00008
Chapter 2 Mechanical Components
7) Set the boom cables and hoses in the cable guide bracket (Lower) as shown in Fig. 2-62
Fig. 2-62
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2-29
Chapter 2 Mechanical Components
8) Wind the cable for the boom length limit switch and then put it on the cable guide bracket (Lower).
(Fig. 2-63)
Fig. 2-63
9) Bundle the boom cables and hoses up, and then tie the leading rope to the 4 cores cable for AC outlet
(Fig. 2-64)
Fig. 2-64
10) Insert the cable guide into the boom section. (Fig. 2-65)
Fig. 2-65
11) Fix the cable guide bracket (Lower) to the 1st boom section and cable guide bracket (Upper) to the 3rd
boom section. (Fig. 2-66)
Fig. 2-66
2-30
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Chapter 2 Mechanical Components
12) Install the guide. (Fig. 2-67)
Fig. 2-67
13) Connect the cable for Boom length limit switch (Connector 572Br) ,Set the cable as shown in Fig. 2-68
to prevent the cable from interference with bottom of 2nd boom section and then install the boom
length limit switch cover
Fig. 2-68
14) Insert the T1 hose, T2 hose, P hose, Platform leveling Up hose and Down hose to the cover (Fig. 2-69),
and then connect them to the adaptor block. (Page. 2-21, Fig. 2-46)
Fig. 2-69
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2-31
Chapter 2 Mechanical Components
15) Connect the cables listed below. (Page. 2-20, Fig. 2-45)
* Boom cable (14 cores: Connector 518Gy and 546Br)
* Boom cable (16 cores: Connector 516Gy, 517Gy and 521Gy)
[Connector 521Gy is for CE and ANSI model only]
* Cable for Boom length limit switch (Connector 534Gy)
* Cable for Boom wire rope failure limit switches (Connector 503Gy) [CE model only]
* Boom cable (4 cores) for AC outlet (Disconnect from the receptacle if it is equipped)
16) Connect the cable for the boom wire rope failure limit switches (Connector 530Br, 531Br) and then fix
them by cable tie. (Page. 2-20, Fig. 2-44) [CE model only]
17) Fix the lower leveling cylinder to the boom. (Fig. 2-70)
Fig. 2-70
18) Install the turntable rear cover. (Page. 2-19, Fig. 2-41)
19) Fix the cables and hoses with cover to the left side of the 3rd boom section by U-bolt. Apply thread lock
agent (Loctite 262) to the U-bolt before tightening (Page. 2-17, Fig. 2-35)
20) Connect the hoses for upper leveling cylinder. (Page. 2-17, Fig. 2-34)
21) Install the 3rd boom front cover. Apply thread lock agent (Loctite 262) to the fixing bolts before
tightening. (Page. 2-16, Fig. 2-33)
2-32
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Chapter 2 Mechanical Components
22) Arrange the hoses and cables as shown in the Fig. 2-71.
Fig. 2-71
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2-33
Chapter 2 Mechanical Components
23) Connect the T1 hose, P hose and T2 hose to the platform rotation solenoid valve. (Page. 2-16,
Fig. 2-32)
24) Connect the boom cables (14 cores: Connector 126Gy, 127Gy) and (16 cores: Connector 122Gy,
128Gy, 129Gy). (Page. 2-16, Fig. 2-31)
[Connector 129Gy is for CE and ANSI model only]
25) Connect the cable (4 cores) for AC outlet from the receptacle if it is equipped.
26) Install the cover on the platform. (Page. 2-16, Fig. 2-30)
2-34
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Chapter 2 Mechanical Components
SR14CJ (SR460CJ) Installation
1) Follow the SR12C (SR400C) Installation instructions step 1 (Page 2-25) to step 21 (Page 2-32) to install
the cable guide.
2) Arrange the hoses and cables as shown in the Fig. 2-72.
Fig. 2-72
3) Connect the T1 hose, P hose and T2 hose.
4) Connect the boom cables (14 cores: Connector 126Gy, 127Gy) and (16 cores: Connector 122Gy, 128Gy,
129Gy).
[Connector 129Gy is for CE and ANSI model only]
5) Connect the cable (4 cores) for AC outlet from the receptacle if it is equipped.
6) Install the cover on the right side of the fly jib. (Page. 2-24, Fig. 2-52).
SSJ00008
2-35
Chapter 2 Mechanical Components
Fly jib (for SR14CJ/SR460CJ)
Upper jib
Fly jib cylinder
Lower jib
No.
1 Hose (P)
2 Hose (T1)
3 Hose (T2)
Hoses
Marking (White)
Fly jib bracket
No.
Cables, Wire
6 14 core cable
7 16 core cable with shield wires
8 4 core cable for AC outlet
(CE model and ANSI model)
Fig. 2-73 Fly jib
2-36
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Chapter 2 Mechanical Components
Platform (Adjustment of Overload limit switch) (CE model)
Test weight position 1
Z
Y
Y
Center of the
rotary actuator
Test weight position 2
G
Lock nut for adjust bolt
Limit switch bracket
Overload limit switch
X + 5 mm (0.2 in)
X
82 mm (3.2 in)
Spring bolt
Spring
Spring bolt
Lock nut for
spring bolt
Adjust bolt
Stopper bolt
Lock nut for stopper bolt
Detail G
Fig. 2-74 Platform (Overload limit switch)
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2-37
Chapter 2 Mechanical Components
Adjustment procedures of Overload limit switch
1. Adjust the spring length to 82 mm (3.2 in) by tightening the spring bolt, and then lock the lock nut.
2. Load the platform with the test weight shown in the table below at the Test weight position 1, and then
shake the platform several times.
3. Move the weight to the Test weight position 2, and then shake the platform several times.
4. Perform the above steps 2 and 3 five times to settle the spring and the linkages.
5. Load the platform with the test weight at the Test weight position 1, and then turn the Adjust bolt so that
the limit switch is switched on.
6. Move the weight to the Test weight position 2, and then make sure that the limit switch switches on.
If the limit switch does not switch on, perform the followings.
1) Turn the Adjust bolt again until the limit switch switches on.
2) Move the test weight to the Test weight position 1 again, and then make sure that the limit switch
switches on.
3) If the limit switch does not switch on, repeat the steps 2 to 6.
7. Lock the lock nut.
X” between the Roller of the overload limit switch and the Adjust bolt.
8. Measure the clearance “X
Adjust the clearance between the limit switch bracket and the stopper bolts to X + 5 mm (X + 0.2 in)
and then lock the lock nut to prevent the limit switch from breakage that is caused by overloading.
Platform
size
6 feet
8 feet
2-38
Platform
capacity
Dimension
Y
Dimension
Z
Test
waight
250 kg
[550 lbs]
227 kg
[500 lbs]
590 mm
[1 ft 11 in]
870 mm
[2 ft 10 in]
890 mm
[3 ft 11 in]
1,040 mm
[3 ft 5 in]
285 kg
[630 lbs]
260 kg
[570 lbs]
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Chapter 3 Hydraulic Components
Chapter 3
Hydraulic Components
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3-1
Chapter 3 Hydraulic Components
Locations of Hydraulic components
Fly jib cylinder
(for SR14CJ/SR460CJ)
[303-0037200]
Double holding valve
[302-0034000]
Platform leveling cylinder (Upper)
[303-0037100A]
Double holding valve
[302-05847A]
Boom telescope cylinder
[303-0037000C]
B view
C view
A view
Platform leveling
cylinder (Lower)
[303-0037500C]
Rotary actuator
[407-0000505C]
Platform rotation solenoid valve
[SR12C/SR400C : 302-0034300]
Platform rotation / Fly jib
solenoid valve
[SR14CJ/SR460CJ : 302-0034400]
Boom elevation cylinder
[303-0037400B]
Single holding valve
[302-0011702]
Travel motor
Swivel joint
A view
Fig. 3-1 Location of Hydraulic components 1
3-2
SSJ00008
Chapter 3 Hydraulic Components
Valve unit (for Travel functions)
[302-0034700A]
Charge filter
[305-0000073]
High-pressure filter
[305-0000017]
HST pump
[300-0000110B]
Gear pump
[300-0000115]
Hydraulic oil tank
[378-0000695C]
Suction filter
[305-06597]
Emergency pump
[300-0000065]
B view
Main control valve
[302-0034200A]
Valve unit
(for Platform leveling)
[302-0034600]
Boom rotation motor
[301-0000022]
C view
Fig. 3-2 Location of Hydraulic components 2
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3-3
Chapter 3 Hydraulic Components
HST pump (300-0000110B)
Plunger pump
(for Travel HST system)
Charge pump
Solenoid
Displacement
Rated pressure
Displacement
Rated pressure
0 - 28 cm3/rev [0 - 1.7 in3/rev]
22.5 MPa (230 kgf/cm2) [3,300 PSI]
15.6 cm3/rev [0.95 in3/rev]
2.4 +/- 0.07 MPa (24 +/- 0.7 kgf/cm2) [350 +/- 10 PSI]
Rated voltage
Rated current
Coil resistance
DC12V
1.6 A
5.0 ohms (at 20 degrees C)
Port (B1)
Port (M22)
Travel (Right) Rev
Travel by-pass (Left) Fwd
Gauge port for Travel (Left) Fwd
Port (M21)
Travel by-pass (Right) Rev
Port (B2)
Gauge port for Travel (Right) Rev
Travel (Left) Fwd
Port (A2)
Travel (Left) Rev
Case drain port (L21)
Case drain port (L22)
Port (M12)
Travel by-pass (Left) Rev
Gauge port for Travel (Left) Rev
Outlet port (D)
to Charge filter
Port (A1)
Travel (Right) Fwd
Inlet port (E2)
from Charge filter
Inlet port (E1)
from Charge filter
Inlet port (S)
for Charge pump
Port (M11)
Travel by-pass (Right) Fwd
Gauge port for Travel (Right) Fwd
Relief valve (R4)
Relief valve (R1)
Relief valve (R3)
Relief valve (R2)
Fig. 3-3 HST pump
3-4
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Chapter 3 Hydraulic Components
From Charge filter
To Charge filter
From Hydraulic oil tank
Travel
(Left) REV
Travel
(Left) FWD
To Valve unit
(Travel by-pass)
Travel
(Right) FWD
Travel
(Right) REV
To Valve unit
(Travel by-pass)
Fig. 3-4 Hydraulic diagram
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3-5
Chapter 3 Hydraulic Components
Gear pump (300-0000115)
Displacement
Rated pressure
Gear pump 1
for Boom function
16.2 cm3/rev [0.99 in3/rev]
20.6 MPa (210 kgf/cm2) [3,000 PSI]
Gear pump 2
for Platform and
Fly jib function
11.6 cm3/rev [0.71 in3/rev]
20.6 MPa (210 kgf/cm2) [3,000 PSI]
Outlet port
Gear pump 2
Outlet port
Gear pump 1
View A
Hydraulic circuit diagram
Suction port
Fig. 3-5 Gear pump
3-6
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Chapter 3 Hydraulic Components
Emergency pump (300-0000065)
DC motor
Rated pressure
Displacement
DC 12 Volts
17.2 MPa (175 kgf/cm2) [2,500 PSI]
1.66 cm3/rev [0.10 in3/rev]
Contactor
Suction port
Outlet port
Fig. 3-6 Emergency pump
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3-7
Chapter 3 Hydraulic Components
Hydraulic oil tank (3780000695C)
Oil capacity
Recommended hydraulic oil
Oil change interval
190 liters [50.2 gal]
Shell Tellus T22
Every 1,200 working hours or annually
Level gauge
Oil filler
Suction filter
305-06597
Drain plug
Fig. 3-7 Hydraulic oil tank
3-8
SSJ00008
Chapter 3 Hydraulic Components
Filters
High-pressure filter (305-0000017)
Rated pressure
Rated flow volume
Filteration accuracy
20.6 MPa (210 kgf/cm2) [3,000 PSI]
50 litters / min [13.2 gal / min]
30 microns
By-pass valve
cracking pressure
0.5 MPa (5.0 kgf/cm2) [73 PSI]
Replacement interval Every 1,200 working hours or annually
Element part number G319050014
Fig. 3-8 High-pressure filter
Charge filter (305-0000073)
Rated pressure
Rated flow volume
Filteration accuracy
7 MPa (70 kgf/cm2) [1,000 PSI]
50 litters / min [13.2 gal / min]
30 microns
By-pass valve
cracking pressure
0.1 MPa (1.0 kgf/cm2) [15 PSI]
Replacement interval Every 1,200 working hours or annually
Element part number G319050032
Suction filter (305-06597)
Rated flow volume
200 liters / min [52.8 gal / min]
Filteration accuracy
105 microns
Replacement interval Every 1,200 working hours or annually
Fig. 3-9 Charge filter
Fig. 3-10 Suction filter
SSJ00008
3-9
Chapter 3 Hydraulic Components
Main control valve (302-0034200A)
Rated pressure
Rated flow
Relief valve
pre-set
pressure
Solenoid
Main relief valve
Port reliaf valve (Telescope, In)
Port reliaf valve (Elevation, Down)
Rated voltage
Rated current
Coil resistance
20.6 MPa (210 kgf/cm2) [3,000 PSI]
80 litters/min [21.1 gal/min]
20.6 MPa (210 kgf/cm2) [3,000 PSI]
17.6 MPa (180 kgf/cm2) [2,550 PSI]
14.7 MPa (150 kgf/cm2) [2,150 PSI]
DC 12 V
1.6 A
3.2 ohms (at 20 degrees C)
Telescope
Out
Elevation
Up
Rotation
C.W.
Gauge port (P’)
P port
T port
Main
reliaf
valve
Port reliaf valve
(Elevation, Down)
Manual control lever
Port reliaf valve
(Telescope, In)
Telescope Elevation
In
Down
Rotation
C.C.W.
Fig. 3-11 Main control valve
3-10
SSJ00008
Chapter 3 Hydraulic Components
Sectional drawings
D - D Section
B - B Section
C - C Section
A - A Section
Fig. 3-12 Sectional drawings
SSJ00008
3-11
Chapter 3 Hydraulic Components
Hydraulic circuit
Gauge port
Telescope
Out
In
Elevation
Up Down
Rotation
C.W. C.C.W
P port
T port
Main reliaf valve
Port reliaf valve
(Telescope, In)
Port reliaf valve
(Elevation, Down)
Fig. 3-13 Hydraulic circuit
3-12
SSJ00008
Chapter 3 Hydraulic Components
Elevation cylinder (303-0037400B)
Dr port
B port
A port
Lock the Spherical bearing (6) at
4 points using a center punch
after being press- fitted.
Tightening torque : 1060 +/- 235 Nm
(108 +/- 24 Kg-m)
[782 +/- 173 ft-lbs]
1
2
3
4
5
6
7
8
9
10
11
12
Cylinder tube
Piston rod
Cylinder head
Piston
Single holding valve
Spherical bushing
Bushing
Dust seal
U-ring
Backup ring
O-ring
Backup ring
13
14
15
16
17
18
19
20
21
22
23
24
Tightening torque : 16.7 +/- 3 Nm
(1.7 +/- 0.3 Kg-m)
[12.3 +/- 2.2 ft-lbs]
Tightening torque : 1830 +/- 180 Nm
(187 +/- 18 Kg-m)
[1350 +/- 130 ft-lbs]
O-ring
Wear ring
U-ring
Backup ring
O-ring
Bushing
Grease nipple
Bolt (M8 x 60)
Flat washer
Set screw (M8 x 25)
Cap screw (M8 x 30)
O-ring
Hydraulic circuit
Fig. 3-14 Elevation cylinder
SSJ00008
3-13
Chapter 3 Hydraulic Components
Single holding valve for Elevation cylinder (302-0011702)
The Single holding valve is mounted on the Boom elevation cylinder to prevent the cylinder
from natural retraction.
Rated pressure
Rated flow
24.5 MPa (250 kgf/cm2) [3,550 PSI]
30 liters/min [7.9 gal/min]
1
2
3
4
5
6
7
8
9
10
Body
Holding valve
Check valve
Cap
O-ring
O-ring
O-ring
O-ring
Spring
Piston
11
12
13
14
15
16
17
Plug
O-ring
Orifice
Plug
Flange
Cap screw
O-ring
Fig. 3-15 Single holding valve
3-14
SSJ00008
Chapter 3 Hydraulic Components
Inspection procedures
Measure the natural descent of the boom elevation cylinder as follows to check the internal oil leakage of
the boom elevation cylinder.
1. Set up the machine on firm and level surface.
2. Raise the boom and set the boom at the boom angle of about 45 degrees, then shut down the engine.
3. Apply the mark on the piston rod of the boom elevation cylinder, then measure the Dimension A as
shown in Fig. 3-16.
Fig. 3-16 Inspection procedures of natural descent
Do not damage the piston rod when applying the mark.
4. Leave the machine for 10 minutes, and then measure the Dimension A’.
A - A’ = Natural descent
Serviceable limit of natural descent —— 2 mm (0.08 in) / 10 minutes.
5. If the natural descent exceeds the serviceable limit, check the single holding valve and the boom
elevation cylinder for internal oil leakage.
Follow the next procedures to identify which has internal oil leakage, the single holding valve or the
boom elevation cylinder.
1) Support the boom using a crane to prevent the boom from sudden descent.
2) Disconnect the hydraulic hoses that are connected to the single holding valve.
Loosen the hydraulic hose fittings slowly when disconnecting the hydraulic hoses.
3) Lower the hoisting hook of the crane to load the boom elevation cylinder with the gravity of the boom,
and then check if the hydraulic oil leaks from the single holding valve.
If the hydraulic oil leaks from the single holding valve, it indicates that the internal oil leakage is in the
single holding valve.
No oil leakage indicates that the internal oil leakage is in the boom elevation cylinder.
Do not remove the single holding valve without supporting the boom.
If the single holding valve is removed or loosened, the boom will fall, resulting in death or
serious injury.
SSJ00008
3-15
Chapter 3 Hydraulic Components
Telescope cylinder (303-0037000C)
Tightening torque :
1177 +/- 98 Nm
(120 +/- 10 Kg-m)
[870 +/- 70 ft-lbs]
Tightening torque :
15.7 +/- 2.94 Nm
(1.6 +/- 0.3 Kg-m)
[11.6 +/- 2.1 ft-lbs]
Tightening torque : 530 +/- 122 Nm
(54 +/- 12 Kg-m)
[390 +/- 90 ft-lbs]
Tightening torque : 22.5 +/- 0.98 Nm
(2.3 +/- 0.1 Kg-m)
[16.6 +/- 0.7 ft-lbs]
Tightening torque : 166.7 +/- 8.33 Nm
(17 +/- 0.85 Kg-m)
[123 +/- 6 ft-lbs]
Tightening torque : 17.2 +/- 2.5 Nm
(1.75 +/- 0.25 Kg-m)
[12.7 +/- 1.8 ft-lbs]
Hydraulic circuit
Tightening torque :
3.77 +/- 0.19 Nm
(0.38 +/- 0.02 Kg-m)
[2.78 +/- 0.14 ft-lbs]
Tightening torque : 108 +/- 10 Nm
(11 +/- 1.0 Kg-m)
[80 +/- 7 ft-lbs]
1
2
3
4
5
6
7
8
9
10
Cylinder tube
Piston rod
Cylinder head
Bushing
U-ring
Backup ring
Wiper ring
O-ring
O-ring
Lock washer
11
12
13
14
15
16
17
18
19
20
Spacer
Piston
Wear ring
U-ring
Backup ring
O-ring
Backup ring
Set screw
Holding valve
Plug
21
22
23
24
25
26
27
Holding valve
Valve body
O-ring
Cap screw
Plug
O-ring
Name plate
Fig. 3-17 Telescope cylinder
3-16
SSJ00008
Chapter 3 Hydraulic Components
Inspection procedures
Measure the natural descent of the boom telescope cylinder as follows to check the internal oil leakage
of the holding valve.
1. Set up the machine on firm and level surface.
2. Raise the boom fully and extend the boom about 1 meter (3 feet), then shut down the engine.
3. Apply the mark on the 2nd boom section, and then measure the Dimension A as shown in Fig. 3-18.
Fig. 3-18 Inspection procedures of natural descent
4. Leave the machine for 10 minutes, and then measure the Dimension A’.
A - A’ = Natural descent
Serviceable limit of natural descent —— 2 mm (0.08 in) / 10 minutes.
5. If the natural descent exceeds the serviceable limit, check the holding valve and the boom telescope
cylinder for internal oil leakage.
Follow the next procedures to identify which has internal oil leakage, the holding valve or the boom
telescope cylinder.
1) Raise the boom fully and extend the boom about 1 meter (3 feet).
2) Disconnect the hydraulic hoses that are connected to the holding valve, and then check if the hydraulic
oil leaks from the holding valve.
Loosen the hydraulic hose fittings slowly when disconnecting the hydraulic hoses.
If the hydraulic oil leaks from the holding valve, it indicates that the internal oil leakage is in the holding
valve.
No oil leakage indicates that the internal oil leakage is in the boom telescope cylinder.
Retract the boom fully and set it about 5 degrees when removing the holding valve.
If the holding valve is removed or loosened while the boom is not retracted fully or set below horizontal, the
2nd boom section will retract or extend suddenly, may result in death or serious injury.
SSJ00008
3-17
Chapter 3 Hydraulic Components
Boom rotation motor (301-0000022)
The boom rotation motor is installed on the rotation gearbox to rotate the turntable
O-ring
Cover
Tightening torque
: 49 - 59 Nm
(5.0 - 6.0Kg-m)
[37 - 43 ft-lbs]
Oil seal
B-B section
A-A section
A port
Drain port
B port
Hydraulic circuit
B port
Drain port
A port
Fig. 3-19 Boom rotation motor
3-18
SSJ00008
Chapter 3 Hydraulic Components
Rotary actuator (407-0000505C)
The Platform rotary actuator is installed between the platform and the top of 3rd boom or
Fly- jib to rotate the platform.
Punch
C.W.
Tightening torque :
18.6 Nm +/- 30%
(1.9 Kg-m +/- 30%)
[13.7 ft-lbs +/- 30%]
C.C.W.
Apply grease :
Shell Alvania EP2
Apply grease :
Shell Alvania EP2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Air bleed plug
Steel ball
Shaft
O-ring
Ball bearing
Wear ring
Backup ring
Packing
Set screw
Head
Backup ring
O-ring
Body
Piston
Backup ring
Packing
O-ring
O-ring
Apply grease :
Shell Alvania EP2
2.5 mm
[0.1 in]
Tightening torque :
50 Nm +/- 10%
(5.1 Kg-m +/- 10%)
[37 ft-lbs +/- 10%]
Lock the Set screw (9) at
2 points using a center punch
View A
Fig. 3-20 Rotary actuator
SSJ00008
3-19
Chapter 3 Hydraulic Components
Function of Rotary actuator
1. Clockwise
1) Pressurized oil comes in to the lower room of the rotary actuator
and push up the piston as shown in the fig 3-21..
2) The piston and the shaft are threaded and mesh each other.
3) The piston rotates the shaft clockwise while it goes up.
Threaded section
2. Counter clockwise
1) Pressurized oil comes in to the upper room of
the rotary actuator and push down the piston as
shown in the fig 3-21..
2) The piston rotates the shaft counter clockwise
while it goes down.
Fig. 3-21 Function of Rotary actuator
3-20
SSJ00008
Chapter 3 Hydraulic Components
Platform rotation solenoid valve (302-0034300) for SR12C/SR400C
This valve is mounted on the Rotary actuator for Platform rotation to control the platform rotation functions.
Solenoid coil resistance 11.3 ohms
Relief valve (P8)
Relief valve (P7)
Throttle
check valve
Solenoid coil
Double pilot
check valve
Hydraulic circuit
Solenoid valve cartridge
Solenoid valve
Fig. 3-22 Platform rotation solenoid valve
Solenoid valve installation procedures
Follow the instructions below to install the Solenoid valve onto the manifold.
1. Insert the Solenoid valve cartridge (7) into the manifold, and then tighten the cartridge by the
tightening torque of 41 - 43 Nm (4.2 - 4.4 kg-m) [30 - 32 ft-lbs].
2. Install the 2 pieces of the Solenoid coils (1) onto the valve cartridge, and then tighten the Nut (17)
by the tightening torque of 4.0 - 5.0 Nm (0.4 - 0.5 kg-m) [3.0 - 3.7 ft-lbs].
3. Turn the Adjust screw (31) counter-clockwise to screw it out fully.
4. Install the Cap nut (32), and tighten it by the tightening torque of 5.0 - 6.0 Nm (0.5 - 0.6 kg-m)
[3.6 - 4.4 ft-lbs].
Do not allow the Adjust screw (31) to be turned when tightening the Cap nut (32).
SSJ00008
3-21
Chapter 3 Hydraulic Components
Platform rotation / Fly jib solenoid valve (302-0034400) for SR14CJ/SR460CJ
This valve is mounted on the Rotary actuator to control the platform rotation and Fly jib articulation
functions.
Relief valve (P7)
Relief valve (P8)
Throttle
check valve
Solenoid coil
Double pilot
check valve
Solenoid valve cartridge
Hydraulic circuit
Solenoid coil resistance 11.3 ohms
Solenoid valve
Fig. 3-23 Platform rotation / Fly jib solenoid valve
Solenoid valve installation procedures
Follow the instructions below to install the Solenoid valve onto the manifold.
1. Insert the Solenoid valve cartridge (7) into the manifold, and then tighten the cartridge by the
tightening torque of 41 - 43 Nm (4.2 - 4.4 kg-m) [30 - 32 ft-lbs].
2. Install the 2 pieces of the Solenoid coils (1) onto the valve cartridge, and then tighten the Nut (17)
by the tightening torque of 4.0 - 5.0 Nm (0.4 - 0.5 kg-m) [3.0 - 3.7 ft-lbs].
3. Turn the Adjust screw (31) counter-clockwise to screw it out fully.
4. Install the Cap nut (32), and tighten it by the tightening torque of 5.0 - 6.0 Nm (0.5 - 0.6 kg-m)
[3.6 - 4.4 ft-lbs].
Do not allow the Adjust screw (31) to be turned when tightening the Cap nut (32).
3-22
SSJ00008
Chapter 3 Hydraulic Components
Fly-jib cylinder (303-0037200) for SR14CJ/SR460CJ
Tightening torque : 16.7 +/- 3 Nm
(1.7 +/- 0.3 Kg-m)
[12.3 +/- 2.2 ft-lbs]
Tightening torque : 7 +/- 1.25 Nm
(0.7 +/- 0.1 Kg-m)
[5.2 +/- 0.9 ft-lbs]
Tightening torque : 510 +/- 50 Nm
(52 +/- 5 Kg-m)
[376 +/- 36 ft-lbs]
Tightening torque : 422 +/- 96 Nm
(43 +/- 9 Kg-m)
[311 +/- 70 ft-lbs]
Tightening torque : 16.7 +/- 3 Nm
(1.7 +/- 0.3 Kg-m)
[12.3 +/- 2.2 ft-lbs]
1
2
3
4
5
6
7
8
9
10
Cylinder tube
Piston rod
Cylinder head
Piston
Holding valve
Bushing
Dust seal
U-ring
Backup ring
O-ring
11
12
13
14
15
16
17
18
19
20
Backup ring
O-ring
Wear ring
U-ring
Backup ring
O-ring
Bushing
Grease nipple
Grease nipple
Cap screw
21
22
23
24
25
Steel ball
Bolt
Flat washer
Cap screw
O-ring
Fig. 3-24 Fly-jib cylinder
SSJ00008
3-23
Chapter 3 Hydraulic Components
Double holding valve for Fly-jib cylinder (302-0034000) for SR14CJ/SR460CJ
The Double holding valve is equipped on the Fly- jib cylinder to prevent the cylinder from natural
retraction and extension.
Hydraulic circuit
Fig. 3-25 Double holding valve
3-24
SSJ00008
Chapter 3 Hydraulic Components
Valve unit for Platform leveling (302-0034600)
The valve unit consists of the four solenoid valves and three relief valves to supply pressurized oil to
the Main control valve and Platform rotation solenoid valve (SR12C/SR400C) or Platform rotation /
Fly jib solenoid valve (SR14CJ/SR460CJ).
The valve also controls Platform leveling functions.
1
2
Solenoid coil resistance
1
4.8 ohms
2
6.25 ohms
3
6.25 ohms
4
8.8 ohms
3
4
A port
P3 port
M2 port
E port
10
12
11
14
13
15
5
6
7
8
9
G port
F port
T1 port
M1 port
P2 port
D port
T port
P1 port
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Unloading solenoid valve (for Platform, Fly jib)
Emergency solenoid valve
Unloading solenoid valve (for Boom functions)
Platform leveling solenoid valve
Relief valve 22.5 MPa (230 kgf/cm2) [3,300 PSI]
Check valve
Orifice (0.8 mm)
Relief valve 22.5 MPa (230 kgf/cm2) [3,300 PSI]
Relief valve 22.5 MPa (230 kgf/cm2) [3,300 PSI]
Pilot check valve
Pilot check valve
Check valve
Check valve
Check valve
Check valve
Port
A To Main control valve
From Platform rotation solenoid valve or
D
Platform rotation / Fly-jib solenoid valve
To Platform rotation solenoid valve or
E
Platform rotation / Fly-jib solenoid valve
F To Platform leveling cylinders (Down)
G To Platform leveling cylinders (Up)
P1 From Gear pump P1
P2 From Gear pump P2
P3 From Emergency pump
T To Hydraulic oil tank
T1 Pluged
M1 Gauge port
M2 Gauge port
Fig. 3-26 Valve unit
SSJ00008
3-25
Chapter 3 Hydraulic Components
Hydraulic circuit
Platform rotation / Fly-jib
T
P
Platform leveling
Down Up
Main
control
valve
Fig. 3-27 Hydraulic circuit
3-26
SSJ00008
Chapter 3 Hydraulic Components
Platform leveling cylinder, Upper (303-0037100A)
Tightening torque : 16.7 +/- 3 Nm
(1.7 +/- 0.3 Kg-m)
[12.3 +/- 2.2 ft-lbs]
Tightening torque : 690 +/- 70 Nm
(70 +/- 7 Kg-m)
[510 +/- 52 ft-lbs]
Tightening torque : 530 +/- 122 Nm
(54 +/- 12 Kg-m)
[390 +/- 90 ft-lbs]
Tightening torque : 16.7 +/- 3 Nm
(1.7 +/- 0.3 Kg-m)
[12.3 +/- 2.2 ft-lbs]
1
2
3
4
5
6
7
8
9
10
Cylinder tube
Piston rod
Cylinder head
Piston
Holding valve
Bushing
Dust seal
U-ring
Backup ring
O-ring
11
12
13
14
15
16
17
18
19
20
Backup ring
O-ring
Wear ring
U-ring
Backup ring
O-ring
Bushing
Grease nipple
Cap screw
Steel ball
21 Cap screw
22 Cap screw
23 O-ring
Fig. 3-28 Platform leveling cylinder (Upper)
SSJ00008
3-27
Chapter 3 Hydraulic Components
Double holding valve for Platform leveling cylinder, Upper (302-05847A)
The Double holding valve is mounted on the Upper leveling cylinder to maintain the platform level in
the event of hydraulic hose breakage
Rated pressure
Rated flow
22.5 MPa (230 kgf/cm2) [3,300 PSI]
10 liters/min (2.64 gal/mi n)
Double holding valve
Upper leveling cylinder
1
2
3
4
5
Body
Valve seat
Valve spool
Cap
Spring
6
7
8
9
10
Cap
Orifice
Check valve
O-ring
O-ring
11
12
13
14
O-ring
O-ring
O-ring
Plug
Fig. 3-29 Double holding valve
3-28
SSJ00008
Chapter 3 Hydraulic Components
Platform leveling cylinder, Lower (303-0037500C)
Tightening torque : 690 +/- 70 Nm
(70 +/- 7 Kg-m)
[510 +/- 52 ft-lbs]
Tightening torque : 530 +/- 122 Nm
(54 +/- 12 Kg-m)
[390 +/- 90 ft-lbs]
Tightening torque : 16.7 +/- 3 Nm
(1.7 +/- 0.3 Kg-m)
[12.3 +/- 2.2 ft-lbs]
1
2
3
4
5
6
7
8
9
10
Cylinder tube
Piston rod
Cylinder head
Piston
Bushing
Bushing
Dust seal
U-ring
Backup ring
O-ring
11
12
13
14
15
16
17
18
19
20
Backup ring
O-ring
Wear ring
U-ring
Backup ring
O-ring
Bushing
Grease nipple
Grease nipple
Cap screw
21 Steel ball
Fig. 3-30 Platform leveling cylinder (Lower)
SSJ00008
3-29
Chapter 3 Hydraulic Components
Travel motor
Hydraulic motor
Motor type
Rated pressure
Displacement
Gear box
Parking brake
Low
High
Gear type
Reduction ratio
Recommended gear oil
Gear ol capacity
Braking torque
Brake releaseing pressure
Plunger motor
27.4MPa (280 kgf/cm2) [4,000 PSI]
27.5 cm3 [1.68 in3]
16.3 cm3 [0.99 in3]
Planetary gear
1 : 79.3
Shell Spirax EP90
1.0 litter [0.26 gallons]
64.7 Nm (6.6 kg-m) [47.7 ft-lbs]
0.89 MPa (9.1 kg/cm2) [129 PSI]
Drain port (D1)
Main port (A)
A
Pilot port for
parking brake release (E)
Main port (B)
Pilot port for
Hi-Lo select
(P)
Drain port (D2)
Hydraulic circuit
View : A
Level check port
Gear oil fill port
Drain port
Fig. 3-31 Travel motor
3-30
SSJ00008
Chapter 3 Hydraulic Components
Valve unit for Travel functions (302-0034700A)
The valve unit consists of three solenoid valves to release the Parking brake, select Hi-Lo speed of
the travel motor and by-pass left and right travel circuit when travel straight.
P, A1, A2
A3, A4, B3, B4
P, A3, A4, B3, B4
Rated flow volume
A1, A2
Rated voltage
Solenoid coil resistance
Rated pressure
Parking brake release sol.V
4.9 MPa (50 kg/cm2) [710 PSI]
34.3 MPa (350 kg/cm2) [5,000 PSI]
10 L/min [2.64 gal/min]
3 L/min [0.79 gal/min]
DC12V
11.8 ohms
Travel speed select sol.V
Travel by-pass sol.V
Fig. 3-32 Valve unit
SSJ00008
3-31
Chapter 3 Hydraulic Components
Hydraulic circuit
Parking brake release sol.V
Travel speed select sol.V
Travel by-pass sol.V
Fig. 3-33 Hydraulic circuit
3-32
SSJ00008
Chapter 4 Electric Components
Chapter 4
Electric Components
SSJ00008
4-1
Chapter 4 Electric Components
Locations of Electric components
View A
Upper control box
Overload
limit switch
[320-0002600]
Battery
[GS Yuasa 130E41R:
322-0008300]
View B
Engine relay box
[5N5-0114100B]
Boom wire rope failure
limit switches
(CE model)
[320-0005800]
Boom angle
limit switch
[320-0005800]
Alarm buzzer
[324-0008001]
Foot switch
[320-04017C]
Fuel sensor
[382-0000024]
Tilt sensor
(Lateral)
[382-0001600]
Boom length limit switch
[320-0005800]
Horn
[324-00821]
View B
Motion alarm buzzer
[324-00832A]
Lower control box
Tilt sensor
(Longitudinal)
[382-0001600]
Alarm buzzer
[324-0008001]
Tilt sensor
(Omni-directional: CE model)
[382-0000019]
View A
Fig. 4-1 Locations of Electric components
4-2
SSJ00008
Chapter 4 Electric Components
Upper control box
1 Platform leveling s/w
173-01212
16 Joystick controller for Boom elevation 324-0008100
2 Travel speed select s/w
173-01111
17 Joystick controller for Travel (Left)
324-0008100
3 Horn s/w
173-51100
18 Joystick controller for Travel (Right)
324-0008100
5 Rotating beacon s/w (Option)
173-00100
20 System failure light
6 Work light s/w (Option)
173-00100
21 Fuel level light
7 Head light s/w (Option)
173-00100
22 Engine failure light
8 Hydraulic generator s/w (Option)
173-00100
23 Power indicator light
4
19
9
24
329-0091300
10 Engine start / Emergency pump s/w
173-02212
11 Emergency stop button
320-0007201 26
25 Overload warning light (CE model)
12 Platform rotation s/w
320-05325
27 Tilt warning light
13 Fly-jib s/w (for SR14CJ/SR460CJ)
320-05325
28 Hydraulic generator light (Option)
14 Joystick controller for Boom rotation
324-0008100 29 CPU board M6 : Sub1
G309290016
15 Joystick controller for Boom telescope 324-0008100 30 CPU board M6 : Sub2
G309290017
Fig. 4-2 Upper control box
SSJ00008
4-3
Chapter 4 Electric Components
Electric circuit diagram
Connector
(SR14CJ / (CE model)
SR460CJ)
Fig. 4-3 Electric circuit diagram
4-4
SSJ00008
Chapter 4 Electric Components
CPU board “M6” (Sub 1: G309290016, Sub 2: G309290017)
J4
J1
J2
J5
J3
J7
J8
J6
J9
Connectors
J1
J2
Vbac
FG
OT7
OT6
OT5
OT4
OT3
OT2
OT1
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
KA6
KA5
KG6
KG5
KV4
KV3
KA4
KA3
KG4
KG3
KV2
S5V
KA2
KA1
J6
485_H
485_H
486_L
486_L
485_TM
FG
J7
CAN_H
CAN_H
CAN_L
CAN_L
CAN_TM
CAN_TM
FG
FG
J8
Vcc
/Vpp_EN
FG
/EXRES
/WDT
J9
PTX
PRX
PSG
FG
/WE1
Vp
Vp
GND
L4
L3
L2
L1
OT8
D1
D2
D3
D4
J5
KV6
KV5
GND
J3
J4
KG2
KG1
PSG
Fig. 4-4 CPU board “M6”
SSJ00008
4-5
Chapter 4 Electric Components
Input / Output characteristics (CPU board M6 : Sub1)
4-6
SSJ00008
Chapter 4 Electric Components
Input / Output characteristics (CPU board M6 : Sub2)
SSJ00008
4-7
Chapter 4 Electric Components
LED board (329-0091300)
Connector
Electric diagram
1
2
3
4
5
6
7
8
9
10
System failure light
Fuel level light
Engine failure light
Power indicator light
Overload warning light (CE model)
Tilt warning light
Hydraulic generator light (Option)
Fig. 4-5 LED board
4-8
SSJ00008
Chapter 4 Electric Components
Joystick controller (324-0008100)
Electric diagram
Direction selector switch
Potentiometer
1
2
3
4
5
6
7
Brown
Red
White
Black
Yellow
Green
Blue
Fig. 4-6 Joystick controller
SSJ00008
4-9
Chapter 4 Electric Components
Lower control box
Detail A
1 Emergency stop button
320-0007201
21 Pre-heat light
2 Boom rotation s/w
173-01212
22 Engine oil pressure light
3 Platform rotation s/w
173-01212
23 Water temp. light
4 Boom elevation s/w
173-01212
24 Charge light
5 Boom telescope s/w
173-01212
25 Air cleaner clog light
6 Fly-jib s/w ( SR14CJ/SR460CJ)
173-01212
26
7 Platform leveling s/w
173-01212
27
8 Engine start / Emergency pump s/w
173-02212
28 Relay CR-3
329-0091300
320-05306
9 Travel speed select s/w
173-00100
29 Relay CR-4
320-05306
10 Pre-start check s/w
173-02102
30 Relay CR-5
320-05306
11
12 Rotating beacon s/w (Option)
173-00100
31 Relay CR-11 (Option)
32 CPU board M5-B
320-05306
G309290023
13 Enable s/w
173-01102
33 Accelerator control unit
329-0079701
14 Key s/w
378-0000701
34 Relay CR-12
320-05306
15 Hour meter
381-00112
35 Relay CR-10
320-05781
16 Fuel level light
36 Fuse box
320-0003900
17 Overload warning light (CE model)
37 Emergency s/w
173-02102
18
329-0091300
19 Tilt warning light
20 System failure light
Fig. 4-7 Lower Control box
4-10
SSJ00008
Chapter 4 Electric Components
Electric circuit diagram
Fig. 4-8 Electric circuit diagram
SSJ00008
4-11
Chapter 4 Electric Components
Electric circuit diagram
Connector
Fig. 4-9 Electric circuit diagram
4-12
SSJ00008
Chapter 4 Electric Components
CPU board “M5-B” (G309290023)
J2
J3
J5
J8
J9
J4
J1
J6
J7
Connectors
Fig. 4-10 CPU board “M5-B”
SSJ00008
4-13
Chapter 4 Electric Components
Input / Output characteristics (CPU board M5-B)
4-14
SSJ00008
Chapter 4 Electric Components
SSJ00008
4-15
Chapter 4 Electric Components
Accelerator control unit (329-0079701)
Accelerator control unit is installed in the lower control box to send the signal to ECU to change the
engine speed.
Low speed (VR2)
High speed (VR4)
Idling speed (VR5)
Mid speed (VR3)
Trimmer turning direction
Decrease
Increase
Engine speed for optional
Hydraulic generator (VR1)
Electric diagram
Fig. 4-11 Accelerator control unit
Engine speed Adjustment procedures
1. Warm up the engine.
2. Turn the trimmer VR5 to adjust the Idling speed to 1,050 rpm.
3. Turn the trimmer VR2 to adjust the Low speed to 1,800 rpm.
4. Turn the trimmer VR3 to adjust the High speed to 2,200 rpm.
5. Turn the trimmer VR1 to adjust the engine speed for hydraulic generator to 1,400 rpm if it is equipped.
See page 6-2 for engine speed measurement procedures.
4-16
SSJ00008
Chapter 4 Electric Components
Key switch (378-0000701)
Key switch is installed on the lower control box to select the upper or lower control.
Upper control
Lower control
Upper control
Lower control
Position
OFF
P1
P2
Control position
OFF
Upper control
Lower control
Connection
---------B - 1, B1 - 2
B - 3, B1 - 4
Fig. 4-12 Key switch
SSJ00008
4-17
Chapter 4 Electric Components
Engine relay box (5N5-0114100B)
1
2
3
4
5
6
7
8
9
10
Key switch ON relay
Engine start relay
Engine stop relay
Glow light relay
Charge relay
Starter relay
Glow relay
Rack actuator relay
Main relay
Fuse box
320-05306
320-05306
320-05306
320-05306
320-05306
G031780002
G031780002
G031780003
G031780003
----------
Fig. 4-13 Engine relay box
4-18
SSJ00008
Chapter 4 Electric Components
Tilt sensor (Longitudinal, Lateral) (382-0001600)
Two analog tilt sensors are installed on the turntable to sense the tilt angle of the machine in
longitudinal direction and lateral direction.
Tilt alarm buzzer sounds when the actual machine tilt angle (calculated from longitudinal and
lateral tilt angle) is more than 5 degrees.
Output characteristics
Output
voltage
Tilt angle
Fig. 4-14 Tilt sensor (Longitudinal, Rateral)
Specifications
Rated voltage : DC 5 +/- 0.5 volts
Output voltage : 0.1 V/1 degree [2.5 volts when the machine is in level]
SSJ00008
4-19
Chapter 4 Electric Components
Tilt sensor (Omni-directional) (382-0000019) CE model
The tilt sensor (Omni-directional) is installed on the turntable to detect the machine tilt angle of 5 degrees.
This LED goes on when the tilt angle is
within 5 degrees.
Power
Switch
Out
GND
Fig. 4-15 Tilt sensor (Omni-directional)
4-20
SSJ00008
Chapter 4 Electric Components
Limit switches (320-0002600, 320-0005800)
Boom angle
limit switch
Boom length
limit switch
Overload limit switch
Boom wire rope failure limit
switches
320-0002600
320-0005800
Fig. 4-16 Limit switches
Descriptions
Opening conditions
Boom angle limit switch
Opens when the boom angle Travel speed is limited
is higher than 5 +/- 4 degrees. at Low speed.
320-00005800
Boom length limit switch
Opens when the boom is
Travel speed is limited
extended more than 600 mm. at Low speed.
320-00005800
Boom wire rope failure
limit switches (CE model)
Open when the boom
Boom telescope Out
extension wire is cut or loose. function is disabled.
320-00005800
Overload limit switch
(CE model)
Opens when the platform is
overloaded.
320-00002600
SSJ00008
Functions
All of the functions are
disabled.
Part number
4-21
Chapter 4 Electric Components
This page intensionally left blank.
4-22
SSJ00008
Chapter 5 Trouble shooting
Chapter 5
Trouble shooting
SSJ00008
5-1
Chapter 5
Trouble shooting
Trouble shooting by LED indication on Upper / Lower control box
LEDs on the Upper and Lower control panel goes on or blink as shown in the table below to indicate
the system error.
Upper control box
Lower control box
Fig. 5-1 Locations of LEDs
No. Locations
LED status
Descriptions
1 Upper control panel System failure light
Off LED stays off
2 Upper control panel Fuel level light
On LED goes on
B9 LED blinks 9 times
5 Upper control panel Tilt warning light
B1 LED blinks 10 times
0
BC LED blinks continuously B1
LED blinks 11 times
1
B2 LED blinks twice
B1 LED blinks 12 times
2
B3 LED blinks 3 times
B1
LED blinks 13 times
6 Lower control panel System failure light
B4 LED blinks 4 times
3 Upper control panel Engine failure light
4 Upper control panel Power indicator light
B5 LED blinks 5 times
B6 LED blinks 6 times
B7 LED blinks 7 times
B8 LED blinks 8 times
Error
descriptions
Foot switch
time out
1
2
LED status
3
4 5
6
Causes
No function is operated for more
Off Off Off BC Off Off than 20 seconds in spite of the foot
switch is pressed.
3
B1
LED blinks 14 times
4
B1
LED blinks 15 times
5
B1 LED blinks 16 times
6
B1
LED blinks 17 times
7
Countermeasures
Release the foot switch.
CPU board M5-B and M6 (Sub1) fail
to communicate each other.
Communication
1. Faulty communication line
1. Rectify the communication line.
error
BC Off Off Off Off B2
between CPU board M5-B
(M5B and M6 (Sub1).
2. Replace the CPU board M6
M6 Sub1)
2. Faulty CPU board M6 (Sub1).
(Sub2).
3. Faulty CPU board M5-B.
3. Replace the CPU board M5-B.
CPU board M5-B and M6 (Sub2) fail
Communication
to communicate each other.
1. Faulty communication line
1. Rectify the communication line.
error
On Off Off B4 Off B2
between CPU board M6 (Sub1)
(M5B M6 Sub2)
and M6 (Sub2).
2. Replace the CPU board M6
2. Faulty CPU board M6 (Sub2).
(Sub2).
CPU board M5-B and M6 (Sub2) fail
Communication
to communicate each other.
error
1. Faulty communication line
1. Rectify the communication line.
On Off Off B5 Off B2
(M5B between CPU board M6 (Sub2)
M6 Sub3)
and M6 (Sub3).
2. Replace the CPU board M6
2. Faulty CPU board M6 (Sub3).
(Sub3).
5-2
SSJ00008
Chapter 5
Error
descriptions
1
2
LED status
3
4 5
6
Causes
Trouble shooting
Countermeasures
CPU board M5-B and M6 (Sub4) fail
to communicate each other.
Communication
1. Faulty communication line
1. Rectify the communication line.
error
On Off Off B6 Off B2
between CPU board M5-B
(M5B and M6 (Sub4).
2. Replace the CPU board M6
M6 Sub4)
2. Faulty CPU board M6 (Sub4).
(Sub4).
3. Faulty CPU board M5-B.
3. Replace the CPU board M5-B.
EEPROM error
1. Incorrect or damaged parameters 1. Write the correct parameters
are memorized in the CPU board
into the CPU board M5-B,
On B3 Off Off Off B15
M5-B.
using the Handy tool.
2. Faulty CPU board M5-B.
2. Replace the CPU board M5-B.
PWM error
The CPU board M5-B has output to
the solenoids for Boom elevation,
Boom telescope, Boom rotation
and/or Travel in spite of no
On B4 Off Off Off B15 command.
1. Short circuit in the output lines to
the solenoid(s).
2. Faulty solenoid(s).
3. Faulty CPU board M5-B.
1. Rectify the output lines to
the solenoid(s).
2. Replace the faulty solenoid(s).
3. Replace the CPU board M5-B.
ET error
The CPU board M5-B has output to
the Relays for unloading solenoid
valves, Travel speed select solenoid
and/or Parking brake release
solenoid in spite of no command.
On B5 Off Off Off B15
1. Short circuit in the output lines to
the Relay(s) and/or solenoid(s).
2. Faulty relay(s)
3. Faulty solenoid(s).
4. Faulty CPU board M5-B.
1. Rectify the output lines to
the Relay(s) and/or solenoid(s).
2. Replace the faulty relay(s).
3. Replace the faulty solenoid(s).
4. Replace the CPU board M5-B.
CPU error
On Off Off Off Off B15 Faulty CPU board M5-B
Replace the CPU board M5-B.
Water temp.
error
On Off B2 Off Off B10
1. Water (Coolant) temperature is
higher 110 degrees C.
1. Stop the engine and wait to
cool down the engine.
Water temp sensor signal is more
than 4.8 volts or less than 0.2 volts.
2. Faulty electric lines between
Water temp sensor and ECU.
3. Faulty water temp sensor.
2. Rectify the electric lines.
3. Replace the Water temp
sensor.
Engine oil
pressure error
Oil pressure switch in not turned on
while engine is stopped.
Oil pressure switch is not turned on
On Off B3 Off Off B10 while engine is running.
1. Faulty electric lines to Oil
pressure switch.
2. Faulty Oil pressure switch.
Turn off the key switch once, and
then turn on it.
If the error still occurs, check
followings.
1. Rectify the electric lines.
2. Replace the Oil pressure
switch.
Charge error
Battery charging switch in not turned
on while engine is stopped.
Battery charging switch is not turned
On Off B4 Off Off B10 on while engine is running.
1. Faulty electric lines between
Alternator and ECU.
2. Faulty Alternator.
Turn off the key switch once, and
then turn on it.
If the error still occurs, check
followings.
1. Rectify the electric lines.
SSJ00008
2. Replace the Alternator.
5-3
Chapter 5
Trouble shooting
Error
descriptions
1
2
LED status
3
4 5
6
Causes
1. Air cleaner is clogged.
Air cleaner error On Off B5 Off Off B10 2. Faulty electric lines between Air
cleaner sensor and ECU.
3. Faulty Air cleaner sensor.
Countermeasures
1. Clean or replace the air cleaner
element.
2. Rectify the electric lines.
3. Replace the Air cleaner sensor.
Accelerator
sensor error
Input from Accelerator control unit is
more than 4.6 volts or less than 0.2
volts.
1. Incorrect adjustment of
1. Adjust the accelerator control
On Off B6 Off Off B10
accelerator control unit.
unit.
2. Faulty electric lines between
2. Rectify the electric lines.
Accelerator control unit and ECU. 3. Replace the accelerator control
3. Faulty Accelerator control unit.
unit.
Engine speed
sensor error
Turn off the key switch once, and
then turn on it again.
If the error still occurs, check
Faulty electric lines between Engine
On Off B7 Off Off B10
and rectify electric lines if
speed sensor and ECU.
necessary.
Ask Yanmar distributor to detail
check.
Rack position
sensor error
Faulty electric lines between Rack
position sensor and ECU.
Turn off the key switch once, and
then turn on it again.
If the error still occurs, check
and rectify electric lines if
necessary.
Ask Yanmar distributor to detail
check.
Faulty electric lines between Rack
actuator and ECU.
Turn off the key switch once, and
then turn on it again.
If the error still occurs, check
and rectify electric lines if
necessary.
Ask Yanmar distributor to detail
check.
Rack actuator
error
CAN error
On Off B8 Off Off B10
On Off B9 Off Off B10
On Off B10 Off Off B10 Faulty CAN communication lines.
EGR valve error On Off B11 Off Off B10
CSD solenoid
valve error
5-4
On Off B12 Off Off B10
Check and rectify electric lines if
necessary.
Ask Yanmar distributor to detail
check.
Faulty electric lines between EGR
valve and ECU.
Turn off the key switch once, and
then turn on it again.
If the error still occurs, check
and rectify electric lines if
necessary.
Ask Yanmar distributor to detail
check.
Faulty electric lines between CSD
solenoid valve and ECU.
Turn off the key switch once, and
then turn on it again.
If the error still occurs, check
and rectify electric lines if
necessary.
Ask Yanmar distributor to detail
check.
SSJ00008
Chapter 5
Error
descriptions
1
2
LED status
3
4 5
6
Causes
Trouble shooting
Countermeasures
Turn off the key switch once, and
then turn on it again.
If the error still occurs, check
and rectify electric lines if
necessary.
Ask Yanmar distributor to detail
check.
Relay error
1. Faulty electric lines between
Main relay and ECU,
2. Faulty electric lines between
On Off B13 Off Off B10 Rack actuator relay and ECU
3. Faulty electric lines between
Glow relay (Starting aid relay)
and ECU
Power supply
voltage error
Power supply to ECU is higher than
16 volts or lower than 10 volts.
Power supply to sensors are higher
than 5.5 volts or lower than 4.5 volts.
1. Faulty electric lines between
1. Rectify the electric lines.
On Off B15 Off Off B10
Battery and ECU.
2. Charge the battery.
2. Faulty Battery.
Replace the battery
if necessary.
3. Faulty ECU.
3. Ask Yanmar distributor to detail
check.
ECU error
On Off B17 Off Off B10 Faulty ECU.
Turn off the key switch once, and
then turn on it.
If the error still occurs, ask
Yanmar
distributor to detail check.
Input from Tilt sensors (Longitudinal)
and/or (Lateral) are out of specific
range during pre-start check.
Pre-start check
1. Pre-start check switch is operated 1. Release the pre-start check
On Off Off Off B2 B3
error
when the machine is tilted .
switch.
2. Incorrect calibration of the
2. Perform the Tilt sensor
Tilt sensors.
calibration using handy tool.
3. Faulty Tilt sensors.
3. Replace the Tilt sensors.
Input from Tilt sensor (Longitudinal)
is out of specific range.
1. Incorrect calibration of the Tilt
1. Perform the Tilt sensor
sensor.
calibration using handy tool.
Tilt sensor error
2. Faulty electric lines between
2. Rectify the electric lines
On Off Off Off B3 B4
(Longitudinal)
Tilt sensor (Longitudinal) and
between Tilt sensor
CPU board M5-B.
(Longitudinal) and CPU board
M5-B.
3. Faulty Tilt sensor (Longitudinal). 3. Replace the Tilt sensor
(Longitudinal)
Input from Tilt sensor (Lateral) is out
of specific range.
1. Incorrect calibration of the Tilt
1. Perform the Tilt sensor
sensor.
calibration using handy tool.
Tilt sensor error
On Off Off Off B4 B4 2. Faulty electric lines between
2. Rectify the electric lines
(Lateral)
Tilt sensor (Lateral) and
between Tilt sensor (Lateral)
CPU board M5-B.
and CPU board M5-B.
3. Replace the Tilt sensor
3. Faulty Tilt sensor (Lateral).
(Lateral)
SSJ00008
5-5
Chapter 5
Trouble shooting
Error
descriptions
1
2
LED status
3 4 5
6
Causes
Countermeasures
The difference of detected angle
between Tilt sensors
(Longitudinal/Lateral) and Tilt sensor
(Omni directional) exceed specific
angle.
1. Perform the Tilt sensor
1. Incorrect calibration of the
calibration using handy tool.
Tilt sensors.
Tilt sensor
2. Rectify the electric lines
On Off Off Off B5 B4 2. Faulty electric lines between
duplication error
between Tilt sensor
Tilt sensors (Longitudinal, Lateral
(Longitudinal, Lateral and/or
and/or Omni directional) and
Omni directional) and
CPU board M5-B.
CPU board M5-B.
3. Faulty Tilt sensors (Longitudinal, 3. Replace the Tilt sensor
(Longitudinal, Lateral and/or
Lateral and/or Omni directional).
Omni directional)
Emergency
switch error
Both Limit and Release signal input
at the same time.
1. Faulty electric lines between
On Off Off Off B6 B5
Emergency switch and
CPU board M5-B.
2. Faulty Emergency switch.
1. Rectify the electric lines
between Emergency switch
and CPU board M5-B.
2. Replace the Emergency switch.
No input from the Boom wire rope
failure L/S.
1. Rectify the electrical lines
1. Faulty electric lines between
Boom wire rope
between Boom wire rope failure
On Off Off Off B7 B6
Boom wire rope L/S and
failure error
L/S and CPU board M5-B.
CPU board M5-B.
2. Faulty Boom wire rope failure L/S. 2. Replace the Boom wire rope
failure L/S.
5-6
SSJ00008
Chapter 5
Trouble shooting
Emergency operations
When the Boom, Fly-jib, Platform and/or Travel functions are disabled because of any problem,
operate the machine following the instruction described in this clause to escape from working site.
Do not perform Emergency operations described in this clause unless in case of emergency.
These operations disable the safety devices described in each item and allow unsafe movement of the
machine, may cause the death or serious injury.
Emergency pump
1. Lower the platform using emergency pump in case of engine or hydraulic system failure
If the machine does not work due to the engine or main pump failure, use the emergency pump to
lower the platform. It is not necessary to turning on the enable switch when operating the boom
from the lower control with using the emergency pump.
Emergency pump switch
Fig. 5-2 Emergency pump switch
The emergency pump can only be used for only 30 seconds or less at a time, with a rest period
over 30 seconds between uses.
Do not use the emergency pump for normal work because it puts a great load on the pump.
SSJ00008
5-7
Chapter 5
Trouble shooting
Override switch
1. Lower the platform using override switch when the System failure occurs.
When the system failure occurs, System failure light on upper and lower control box blinks and some
functions may be disabled.
If the boom function is disabled due to system failure, use the override switch to lower the platform as
follows.
1) Take the cover on the lower control panel off.
2) Hold the override switch and make sure that the warning buzzer sounds.
3) Operate the boom telescope switch with holding override switch to retract the boom.
4) Operate the boom elevation switch with holding override switch to lower the boom.
System failure light
Override switch
Fig. 5-3 Override switch
Platform overload sensing system is disabled when the override switch is operated.
Do not put more weight on the platform or the machine may tip over result in death or serious injury.
Retract the boom first and then lower the boom to keep the working radius in minimum.
5-8
SSJ00008
Chapter 5
Trouble shooting
Manual control lever
1. Lower the platform using manual control lever in case of electric system failure
If the boom function is disabled due to electric system failure, use the manual control lever to lower
the platform as follows.
1) Start the engine.
2) Open the turntable cover (Left, Rear).
3) Take the lever from the lever holder, and then put it into the hole under the solenoid valve .
4) Push the red button on unloading valve.
5) Operate the lever to control the boom function.
Main control valve
Boom rotation
C.W. -- C.C.W.
Boom elevation
Up ------ Down
Boom telescope
Out ------- In
Hole
Valve unit
Unloading valve
Fig. 5-4 Manual control lever
Platform overload sensing system does not disable the manual control lever operation.
Retract the boom first and then lower the boom to keep the working radius in minimum.
SSJ00008
5-9
Chapter 5
Trouble shooting
This page intensionally left blank.
5-10
SSJ00008
Chapter 6 Inspection and Adjustment
Chapter 6
Inspection and Adjustment
SSJ00008
6-1
Chapter 6
Inspection and Adjustment
Engine speed measurement procedures
Specific engine speed
Engine speed (rpm)
Idling speed
1,050 +50/-0
Low speed
1,800 +50/-0
High speed
2,200 +50/-0
for Hydraulic generator (Option)
1,400 +50/-0
Engine speed measurement procedures
See page 4-16 for engine speed adjustment procedures.
1. Set the machine on firm and level surface.
2. Warm up the engine and operate the machine to raise the hydraulic oil temperature to
50 +/- 10 degrees C (104-140 degrees F).
3. Measure the engine Idling speed without loading the engine.
4. Measure the engine Low speed as follows.
1) Retract the boom fully.
2) Measure the engine Low speed while operating Boom telescope In to activate the relief valve.
5. Measure the engine High speed as follows.
1) Retract the boom fully and raise the boom fully.
2) Measure the engine Mid speed while operating Boom telescope In and Boom elevation Up
simultaneously to activate the relief valve.
6. Measure the engine speed for Hydraulic generator as follows if it is equipped.
1) Turn on the Hydraulic generator switch.
2) Measure the engine speed while using electric tool to load the hydraulic generator.
6-2
SSJ00008
Chapter 6
Inspection and Adjustment
Relief valve pre-set pressure measurement and adjustment procedures
Specific pre-set pressure
Relief valve
R1
R2
R3
R4
R9
R12
PR1
PR2
SSJ00008
Pre-set pressure
Relief valve
locations
22.5 - 23.0 MPa
HST pump
(230 - 235 kg/cm2)
[3,270 - 3,340 PSI]
22.5 - 23.0 MPa
HST pump
(230 - 235 kg/cm2)
[3,270 - 3,340 PSI]
22.5 - 23.0 MPa
HST pump
(230 - 235 kg/cm2)
[3,270 - 3,340 PSI]
22.5 - 23.0 MPa
HST pump
(230 - 235 kg/cm2)
[3,270 - 3,340 PSI]
17.2 - 17.7 MPa
Valve unit for
(175 - 180 kg/cm2)
Platform leveling
[2,500 - 2,570 PSI]
20.6 - 21.1 MPa
Main control
(210 - 215 kg/cm2)
valve
[2,990 - 3,060 PSI]
17.6 - 18.1 MPa
Main control
(180 - 185 kg/cm2)
valve
[2,550 - 2,620 PSI]
14.7 - 15.2 MPa
Main control
(150 - 155 kg/cm2)
valve
[2,130 - 2,200 PSI]
Gauge port
(Size)
Pump speed
Functions
M11
(9/16-18 UNF)
High
(2,200 rpm)
Travel (Right) FWD
M21
(9/16-18 UNF)
High
(2,200 rpm)
Travel (Right) REV
M12
(9/16-18 UNF)
High
(2,200 rpm)
Travel (Left) REV
M22
(9/16-18 UNF)
High
(2,200 rpm)
Travel (Left) FWD
M2
(1/4)
Low
(1,800 rpm)
Platform rotation
Platform leveling
Fly-jib
P'
(1/4)
High
(2,200 rpm)
Boom elevation Up
Boom telescope In
Boom rotation
P'
(1/4)
High
(2,200 rpm)
Boom telescope Out
P'
(1/4)
Low
Boom elevation Down
(1,800 rpm)
6-3
Chapter 6
Inspection and Adjustment
Pre-set pressure measurement procedures
Before measuring each pre- set pressure, set the machine on firm and level surface, start the engine,
and then operate the machine to warm up the hydraulic system.
1. Pre-set pressure of the Relief valve R1, R2, R3 and R4
1) Rotate the boom 90 degrees to C.W. or C.C.W. direction, and then set the machine so that the track
shoes on the front (Idler wheel side) touch to the stopper as shown in Fig. 6-1.
Stopper
(Big block, Wall, etc)
Fig. 6-1
Idler wheel
2) Stop the engine, Disconnect the hoses from port “M11
M11
M22
M11” and “M22
M22” of the HST pump, plug end of the
M11
M22
disconnected hoses and then connect the pressure gauges to the port “M11
M11” and “M22
M22”.
(See page 3-3 for location of the HST pump)
Port (M22)
Travel by-pass (Left) Fwd
Gauge port for Travel (Left) Fwd
Port (M21)
Relief valve (R2)
Travel by-pass (Right) Rev
Gauge port for Travel (Right) Rev
Relief valve (R4)
Port (M12)
Travel by-pass (Left) Rev
Gauge port for Travel (Left) Rev
Port (M11)
Relief valve (R1)
Travel by-pass (Right) Fwd
Gauge port for Travel (Right) Fwd
Relief valve (R3)
Fig. 6-2 HST pump
3) Start the engine.
4) Retract the boom fully and lower it under the horizontal.
5) Set the travel speed select switch to its High- speed position.
6) Operate both Right and Left travel joystick controller to Forward direction to activate the relief valve
(R1) and (R4).
M11
M22
7) Read the Pressure gauge connected to the gauge port “M11
M11” and “M22
M22” and make sure that the
pre- set pressure of the relief valve (R1) and (R4) are within the specific value.
z Specific pre-set pressure: 22.5 - 23.0 MPa (230 - 235 kg/cm2) [3,270 - 3,340 PSI]
6-4
SSJ00008
Chapter 6
Inspection and Adjustment
M11
M22
8) Stop the engine, disconnect the pressure gauges from the port “M11
M11” and “M22
M22” of the HST pump,
and then connect the hoses disconnected at the step 2.
9) Set the machine so that the track shoes on the Rear (Travel motor side) touch to the stopper as
shown in Fig. 6-3.
Stopper
(Big block, Wall, etc)
Travel motor
Fig. 6-3
10) Stop the engine, Disconnect the hoses from port “M21
M21
M12
M21” and “M12
M12” of the HST pump, plug end of the
M21
M12
disconnected hoses and then connect the pressure gauges to the port “M21
M21” and “M12
M12”.
11) Start the engine.
12) Retract the boom fully and lower it under the horizontal.
13) Set the travel speed select switch to its High- speed position.
14) Operate both Right and Left travel joystick controller to Reverse direction to activate the relief valve
(R2) and (R3).
M21
M12
15) Read the Pressure gauge connected to the gauge port “M21
M21” and “M12
M12” and make sure that the
pre- set pressure of the relief valve (R2) and (R3) are within the specific value.
z Specific pre-set pressure: 22.5 - 23.0 MPa (230 - 235 kg/cm2) [3,270 - 3,340 PSI]
M21
M12
16) Stop the engine, disconnect the pressure gauges from the port “M21
M21” and “M12
M12” of the HST pump,
and then connect the hoses disconnected at the step 10.
SSJ00008
6-5
Chapter 6
Inspection and Adjustment
2. Pre-set pressure of the Relief valve R9
M2
1) Stop the engine, connect the pressure gauge to gauge port “M2
M2” of the Valve unit for Platform
leveling.
(See page 3-3 for location of the Valve unit for Platform leveling)
M2
Gauge port “M2
M2”
Relief valve (R9)
Fig. 6-4 Valve unit for Platform leveling
2) Start the engine.
3) Rotate the platform C.W. or C.C.W. to its end to activate the relief valve (R9).
4) Read the Pressure gauge and make sure that the pre- set pressure of the relief valve (R9) is within
the specific value.
z Specific pre-set pressure: 17.2 - 17.7 MPa (175 - 180 kg/cm2) [2,500 - 2,570 PSI]
6-6
SSJ00008
Chapter 6
Inspection and Adjustment
3. Pre-set pressure of the Relief valve R12
P’
1) Stop the engine, connect the pressure gauge to gauge port “P’
P’” of the Main control valve.
(See page 3-3 for location of the Main control valve.)
P’
Gauge port “P’
P’”
Relief valve (PR2)
Relief valve (R12)
Relief valve (PR1)
Fig. 6-5 Main control valve
2) Start the engine.
3) Retract the boom fully and then raise it fully.
4) Operate the Boom elevation Up and Boom telescope In simultaneously to activate the relief valve
(R12).
5) Read the Pressure gauge and make sure that the pre- set pressure of the relief valve (R12) is within
the specific value.
z Specific pre-set pressure: 20.6 - 21.1 MPa (210 - 215 kg/cm2) [2,990 - 3,060 PSI]
4. Pre-set pressure of the Relief valve PR1
P’
1) Stop the engine, connect the pressure gauge to gauge port “P’
P’” of the Main control valve.
(See page 3-3 for location of the Main control valve.)
2) Start the engine.
3) Raise the boom fully and then extend it fully.
4) Operate the Boom telescope Out to activate the relief valve (PR1).
5) Read the Pressure gauge and make sure that the pre- set pressure of the relief valve (PR1) is within
the specific value.
z Specific pre-set pressure: 17.6 - 18.1 MPa (180 - 185 kg/cm2) [2,550 - 2,620 PSI]
SSJ00008
6-7
Chapter 6
Inspection and Adjustment
5. Pre-set pressure of the Relief valve PR2
P’
1) Stop the engine, connect the pressure gauge to gauge port “P’
P’” of the Main control valve.
(See page 3-3 for location of the Main control valve.)
2) Start the engine.
3) Retract the boom fully and then lower it fully.
4) Operate the Boom elevation Down to activate the relief valve (PR2).
5) Read the Pressure gauge and make sure that the pre- set pressure of the relief valve (PR2) is within
the specific value.
z Specific pre-set pressure: 14.7 - 15.2 MPa (150 - 155 kg/cm2) [2,130 - 2,200 PSI]
Pre-set pressure adjustment procedures
Adjust the relief valve as follows, if the pre- set pressure is not within the specific value.
1. Loosen the lock nut.
2. Adjust the pre- set pressure by turning the adjusting screw.
To increase the pressure, turn the adjusting screw clockwise.
To decrease the pressure, turn the adjusting screw counter- clockwise.
3. Lock the adjusting screw by the lock nut, and then check the pre- set pressure again and make sure
that the pressure is within the specific value.
Fig. 6-6 Adjustment of relief valve
6-8
SSJ00008
Chapter 7 Scheduled maintenance
Chapter 7
Scheduled maintenance
SSJ00008
7-1
Chapter 7 Scheduled maintenance
Scheduled inspection table
1. Engine maintenance
Every
Every
Every
Every Every Every
2,000 hrs
1,000 hrs
Items
1,500
Daily 50
250 500
or every
or
hrs
hrs
hrs
hrs
2 years
annually
Coolant Level, Replenish
1
Coolant
Replacement
1
Cooling
Radiator fin
Check, Clean
1
system
Fan belt
Tension
1*
1
Radiator hoses Replacement
1#
Oil level
1
Engine Engine oil
Replacement
1*
1
oil
Oil filter
Replacement
1*
1
Fuel
Fuel level, Replenish
1
Fuel filter
Replacement
1
Fuel hoses
Replacement
1#
Fuel
Fuel tank
Drain
1
Check
1
Water
Drain
1
sedimentor
Clean
1
Air
Clean
1
Element
cleaner
Replacement
1
Cylinder Adjust Intake / Exhaust valve clearance
1#
head
Lap Intake / Exhaust valve seats
1#
Emission Inspect, clean and test Fuel injectors
1#
control Inspect Crankcase breather system
1#
1* For new machine, Perform these maintenance after 50 working hours for first time.
1# Ask your authorized Yanmar industrial engine dealer or distributor to perform these maintenance.
See Chapter 9 "Engine" for the detail.
2. Other maintenance
Items
Battery
box
Chassis frame
Daily inspection
Battery charge level,
Battery fluid level
Oil level,
Oil leakage
Oil leakage
Abnormal noise, Oil
leakage
Cracks, Deformations
Track links, Shoes
Wear, Tension
Travel motor, Gearbox
Abnormal noise, Damage
Parking brake
Wire harnesses, Hoses
Function
Oil leakage, Damage
Battery
Hydraulic oil tank
Hydraulic
Hydraulic filters
system
Hydraulic pump
Chassis
7-2
Monthly inspection
Damage, Corrosion
on terminals
←
←
Looseness of bolts
and nuts
←
←
Oil leakage,
Looseness of nuts
←
←
Annual inspection
Specific gravity
Replacement of
hydraulic oil
Replacement
←
←
Adjust track tension
every 6 months
Replacement of gear oil
←
←
SSJ00008
Chapter 7 Scheduled maintenance
Items
Daily inspection
Turntable bearing
Wear, Crack
Boom rotation gearbox
Abnormal noise
Turntable
Cracks, Deformations
Swivel joint
Oil leakage
Elevation, Telescope,
Fly jib cylinders
Damage, Oil leakage,
Natural descent
Cracks, Deformations,
Abnormal noise,
Movement
Turntable
Cylinder
Boom
Fly jib
Boom
Pivot pins
Extension /retraction
wire ropes
Cable guide
Platform
Wear pads
Platform
Hand rail
Rotary actuator
Platform
Leveling cylinder
leveling
system
Functions
Switches
Lower
control
Upper
control
Safety
devices
Functions
Emergency stop button
LEDs
Decals
Switches,
Joystick controllers
Functions
Emergency stop button
LEDs
Decals
Foot switch
Motion alarm buzzer
Tilt alarm buzzer
Emergency pump
Alarm horn
Overload sensing system
Decals
SSJ00008
Cracks, Deformations,
Abnormal noise,
Movement
Damage
Abnormal noise
Monthly inspection Annual inspection
Looseness of bolts
←
and nuts, Lubrication
Oil leakage,
Backlash
Looseness of nuts
Replacement of gear oil
Looseness of bolts
←
and nuts
Looseness of bolts
←
and nuts, Lubrication
←
←
←
Disassemble the boom
for detailed inspection
every 5 years
←
←
←
Damage, Corrosion,
Tension
Movements,
Damage
←
←
←
Wear
Cracks, Deformations
Cracks, Deformations
Oil leakage, Abnormal
noise, Movement
←
←
←
←
←
←
Oil leakage
←
←
Functions
Damage, Function,
Smoothness
Function, Abnormal
noise, Vibration
Damage, Function
Damage, Legibility
Legibility
Damage, Function,
Smoothness
Function, Abnormal
noise, Vibration
Damage, Function
Damage, Legibility
Legibility
Function
Sound
Sound
Function
Sound
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
Function
Legibility
←
7-3
Chapter 7 Scheduled maintenance
Lubrications
Lubrication intervals
Location
Lubricating point
Interval
Lubricant
Chassis
Hydraulic oil tank
1,200 working hours
or annually.
Hydraulic oil
(ISO VG22)
Travel motor
gear box
Turntable
Boom rotation
gear box
1
Refer
"Greasing point" 2 to 14
Gear oil
For new machine
(SAE 90)
(Initial replacement)
After 300 working hours Gear oil
or 3 months
(SAE 90)
100 hours
Quantity
190 litters
[1.4 gal]
1.0 litter x2
[0.26 gallons x2]
1.0 litter
[0.26 gallons]
Molybdenum grease
---------------
General grease
---------------
Recommended lubricant
Manufacturers
Shell oil
Mobil oil
Hydraulic oil
Tellus oil T22
DTE 22
Gear oil
Spirax EP 90
Pegasus gear oil 90
Molybdenum grease
General grease
Alvania HDX 2
Alvania EP grease 2
Mobilgrease special
Mobilux EP2
Greasing point
2nd and 3rd boom section upper tail ware pads
1 (Take off the grommet on the 1st boom section upper surface to lubricate the
3rd boom section ware pads.)
2
3
4
5
6
7
8
9
10
11
12
13
14
7-4
Turntable bearing
Elevation cylinder - 1st boom section pivot pin
Jib bracket - Upper jib pivot pin (SR14CJ / SR460CJ)
Upper jib - Platform base pivot pin (SR14CJ / SR460CJ)
Elevation cylinder - Turntable pivot pin
1st boom section pivot pin
Lower leveling cylinder - 1st boom section pivot pin
Lower leveling cylinder - Turntable pivot pin
Oscillation track roller bracket pivot pins
3rd boom section - Platform base / Jib bracket pivot pin
Leveling cylinder - Platform base / Jib bracket pivot pin
Fly-jib cylinder - Upper jib pivot pin (SR14CJ / SR460CJR)
Lower jib - Platform base pivot pin (SR14CJ / SR460CJ)
Fly-jib cylinder - Jib bracket pivot pin (SR14CJ / SR460CJ)
Jib bracket - Lower jib pivot pin (SR14CJ / SR460CJ)
SSJ00008
Chapter 7 Scheduled maintenance
Greasing point
Fig. 7-1 Greasing point
SSJ00008
7-5
Chapter 7 Scheduled maintenance
Scheduled replacement parts
The parts listed in the table below are related to safety devices and must be replaced at
designated intervals.
Location
Items
High pressure filter
Charge filter
Suction filter
Turntable
Tilt angle sensor
Longitudinal, Lateral
Tilt angle sensor
Omni-directional (CE model)
Boom angle limit switch
Boom
Boom length limit switch
Platform
Overload limit switch (CE model)
base
Lower
Emergency stop button
control box
Upper
Emergency stop button
control box
Interval
Every 1 year or
1,200 working hours
Every 1 year or
1,200 working hours
Every 1 year or
1,200 working hours
Every 8 years or
9,600 working hours
Every 8 years or
9,600 working hours
Every 4 years or
4,800 working hours
Every 4 years or
4,800 working hours
Every 4 years or
4,800 working hours
Every 4 years or
4,800 working hours
Every 4 years or
4,800 working hours
Part number
305-0000017
(G319050014)
305-0000073
(G319050032)
Quantity
1
1
305-06597
1
382-0001500
2
382-0000019
1
320-0005800
1
320-0005800
1
320-0002600
1
320--0007201
1
320--0007201
1
( ) : Element
The parts listed in the table below are important for machine’s main function and highly recommended
to replace at designated intervals.
Location
Platform
Items
Foot switch
Enable switch
Engine start /Emergency pump switch
Boom elevation switch
Lower
Boom telescope switch
control box Boom rotation switch
Platform rotation switch
Platform leveling switch
Fly-jib switch (SR14C/SR460CJ)
Engine start /Emergency pump switch
Platform rotation switch
Platform leveling switch
Upper
Fly-jib switch (SR14C/SR460CJ)
control box Boom elevation joystick controller
Boom telescope joystick controller
Boom rotation joystick controller
Travel joystick controller
7-6
Interval
Every 4 years or
4,800 working hours
Every 4 years or
4,800 working hours
Every 4 years or
4,800 working hours
Every 5 years or
6,000 working hours
Part number
Quantity
320-04017
1
173-01102
173-02212
173-01212
173-01212
173-01212
173-01212
173-01212
173-01212
173-02212
320-05325
173-01212
320-05325
324-0008100
324-0008100
324-0008100
324-0008100
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
SSJ00008
Chapter 7 Scheduled maintenance
SSJ00008
7-7
Chapter 7 Scheduled maintenance
Periodical inspection check sheet
Page 1/2
Model
Spec No.
Serial No.
Hour meter
Date
The items marked (*) should be inspected only on the annual inspections.
Items
Monthly inspection
Coolant
Coolant level
Fan belt
Check tension every 250 hours
Engine
Oil level
Water sedimentor
Air cleaner element
Battery
Battery
Hydraulic oil tank
Hydraulic
system
Hydraulic filters
Hydraulic pump
Chassis frame
Track links, Shoes
Chassis
Travel motor, Gearbox
Parking brake
Wire harnesses, Hoses
7-8
Remarks
Replacement interval
Every 1,000 hours or annually
Replacement interval
Every 250 hours
Replacement interval
Every 500 hours
Fuel filter
Fuel tank
Result
Replacement interval
Every 2 years or 2,000 hours
Radiator hoses
Engine oil
Oil filter
Inspector
Drain every 250 hours
Drain every 50 hours
Clean every 500 hours
Clean every 250 hours
Battery charge level
Battery fluid level
Damage
Corrosion on terminals
Specific gravity *
Oil leakage
Hydraulic oil level
Oil leakage
Abnormal noise, Oil leakage
looseness of bolts and nuts
Cracks, Deformations
Wear, Tension
Abnormal noise
Damage
Oil leakage
Looseness of nuts
Function
Oil leakage
Damage
Replacement interval
Every 500 hours
1.28 at 20 degrees C
Replacement interval
Every 1,200 hours or annually
See page 2-3
Replacement interval of
gear oil
Every 1,200 hours or annually
SSJ00008
Chapter 7 Scheduled maintenance
Page 2/E
The items marked (*) should be inspected only on the annual inspections.
Daily inspection
Items
Wear, Crack
looseness of bolts and nuts
Turntable bearing
Lubrication
Abnormal noise
Oil leakage
Boom rotation gearbox
Turntable
Looseness of nuts
Backlash *
Cracks, Deformations
Turntable
looseness of bolts and nuts
Oil leakage
Swivel joint
looseness of bolts and nuts
Cracks, Deformations
Boom
Abnormal noise, Movement
Cracks, Deformations
Fly jib
Abnormal noise, Movement
Damage
Pivot pins
Boom
Damage, Corrosion
Extension/retraction wire
ropes
Tension
Abnormal noise
Cable guide
Movement, Damage
Wear (Thickness) *
Wear pads
Cracks, Deformations
Platform
Cracks, Deformations
Hand rail
Oil leakage
Platform
Rotary actuator
Abnormal noise, Movement
Switches
Lower control
Functions
Emergency stop button
LEDs
Decals
Switches,
Joystick controller
Upper control
Safety
devices
Decals
SSJ00008
Functions
Emergency stop button
LEDs
Decals
Foot switch
Motion alarm buzzer
Tilt alarm buzzer
Emergency pump
Alarm horn
Overload sensing system
Result
Remarks
Replacement interval of
gear oil
Every 1,200 hours or annually
(See page 2-6)
See page 2-13
See page 2-10
Damage, Function, Smoothness
Function
Abnormal noise, Vibration
Damage, Function
Damage, Legibility
Legibility
Damage, Function, Smoothness
Function
Abnormal noise, Vibration
Damage, Function
Damage, Legibility
Legibility
Function
Sound
Sound
Function
Sound
Function
Legibility
7-9
Chapter 7 Scheduled maintenance
This page intensionally left blank.
7-10
SSJ00008
Chapter 8 Appendix
Chapter 8
Appendix
SSJ00008
8-1
SSJ00008
[2,550 PSI]
[2,150 PSI]
[3,000 PSI]
[2,500 PSI]
PR1
PR2
R13, R14
R15, R16
Swivel joint
Gear pump
1st pump
2nd pump
Emergency
pump
Adaptor
filter
Emergency
sol.V
Adaptor filter
Boom telescope
Boom Elevation
Boom rotation
Rev
A2
Left
Fwd
B2 M12
High-pressure
filter
M22
{3,000 PSI]
R12
E2
Adaptor filter
Unloading
sol.V
(Platform/
Fly jib)
Out
In
Down
Up
CCW
CW
--------
--------
Low
High
High
L22
Fwd
A1
Right
Rev
B1 M11
M21
E1
Hydraulic oil tank
Suction filter
L21
Oil cooler
HST pump
Plunger pump
Charge pump
Holding valve
Double holding valve
Platform rotation/
Fly jib sol.V
Platform rotation sol.V
SR12C / SR400C
High
(Right)
(Left)
S
Charge filter
Travel motor
Valve unit
Adaptor filter
Adaptor filter
Platform
leveling
sol.V
Down
[3,300 PSI]
R10, R11
Up
Low
[2,500 PSI]
R9
Unloading
sol.V
(Boom)
Idling
--------
[260 PSI]
R7, R8
Main control valve
Low
Low
[350 PSI]
--------
High
High
[3,300 PSI]
R5, R6
Pump speed
Pump speed
R1 - R4
Pre-set pressure
Relief valve pre-set pressure
Pump speed: Specified in the table below
Hydraulic oil temperature:
Travel
by-pass
sol.V
Travel speed
select sol.V
Parking brake
release sol.V
Valve unit
Platform leveling
cylinder (Lower)
Boom elevation cylinder
Boom rotation motor
Boom telescope cylinder
Double holding valve
Platform leveling
cylinder (Upper)
Fly jib cylinder
Rotary actuator
Rotary actuator
Hydraulic circuit diagram (601-0015200)
Chapter 8 Appendix
Low
High
Low
8-2
Chapter 8 Appendix
Electric circuit diagram, Upper (602-0080100) 1/2
Upper control box
C.W.
Up
Boom elevation
Down
Platform rotation sol.V
C.C.W.
Out
Boom telescope
In
16 cores cable
with shield wire
To Fly jib sol.V
(SR14CJ/SR460CJ)
14 cores cable
To Turntable
To Turntable
C.W.
Boom rotation
C.C.W.
Fwd
Travel (Right)
Rev
Alarm buzzer
LED board
Fwd
Travel (Left)
Rev
System failuer light
Platform C.W.
rotation C.C.W.
To Work light s/w (Option)
To Fly jib s/w
(SR14CJ/SR460CJ)
Fuel level light
To Head light (Option)
To Head light s/w (Option)
Head light
Backup (Vbac)
Power for Upper CPU
To Platform
leveling s/w
(CE/ANSI model)
Engine failure light
Work light GND
Power for Work light
Upper CPU GND
For Adjustment cable
Power indicator light
Power supply for Adjustment tool
For Hydraulic generator (Option)
Horn s/w
Hydraulic generator
Power for Horn
Horn GND
To overload
warning light
(CE model)
Overload warning light
(CE model)
To Hydraulic
generator light
(Option)
Tilt warning light
To Touch s/w buzzer relay (Option)
High
Travel speed
Low
select s/w
Slope
To Hydraulic generator relay (Option)
Hydraulic generator
light (Option)
To Panel light s/w (Option)
For Rotating beacon (Option)
To Rotating beacon relay (Option)
To Overload
L/S
(CE model)
To Rotating
beacon
(Option)
To Hydraulic
generator
(Option)
Rotating beacon
To Touch s/w (Option)
Emergency stop
Emergency stop button
Power for Emergency stop
Engine start / Emergency pump s/w
Engine start
Engine start
Engine start
Emergency pump
Foot s/w
Power for Upper control
SSJ00008
8-3
Chapter 8 Appendix
Electric circuit diagram, Upper (602-0080100) 2/2
Fly jib (SR14CJ/SR460CJ)
16 cores cable
with shield wire
14 cores cable
Touch switch (Option)
Upper control box
Rotating beacon with switch (Option)
Upper control box
16 cores cable
with shield wire
Upper control box
Platform
rotation s/w
CW
CCW
C.W.
Platform rotation sol.
C.C.W.
Up
Down
Travel speed
select s/w
Up
Fly jib sol.
Down
Fly-jib s/w
Rotating beacon s/w
Touch s/w
Emergency stop button
14 cores cable
Work light (Option)
Upper control box
Engine start with Foot switch pressed (Option)
Overload limit switch (CE model)
LED board
Overload
warning light
Upper control box
Upper control box
Platform rotation s/w
CW
CCW
Overload
L/S
Up
Down
Work light (Single)
Work light s/w
Platform leveling switch (CE/ANSI model)
14 cores cable
Upper control box
Engine start/
Emergency pump s/w
Eng.start
Work light (Double)
Foot s/w
Emergency pump
Platform leveling s/w
Head light (Option)
AC outlet (Option)
Hydraulic generator (Option)
Upper control box
16 cores cable
with shield wire
Upper control box
4 cores cable
4 cores cable
Hydraulic
generator light
Head light s/w
Panel light (Option)
LED board
Travel speed select s/w
Upper control box
16 cores cable
with shield wire
Panel light
Hydraulic
generator s/w
SSJ00008
8-4
Chapter 8 Appendix
Electric circuit diagram, Lower (602-0080200) 1/2
14 cores cable
LED board
Fuel
level
Alarm buzzer
To
Platform
System
failure
Preheat
Engine
oil
pressure
Water
temp.
Charge
Air
cleaner
crog
Horn
GND
Engine start
Engine start
Power for Upper control
Backup (Vbac)
Power for Upper CPU
Power for Work light
Power for Horn
Tilt
worning
To Overload warning light
(CE model)
Work light (Op)
Power for Adjustment tool
Work light (Op)
Emergency stop
Work light GND
Power for Emergency stop
Rotating beacon
Head light (Op)
Hydraulic generator (Op)
Rotating beacon (Op)
Head light
Hydraulic generator
16 cores cable with shield wire
Overload
warning
(CE model)
Horn
Main control valve
Tilt sensor (Longitudinal)
Up
Boom elevation
Down
Lower control box
Tilt sensor (Lateral)
Key switch
Out
Boom telescope
In
Terminal
To Boom wire rope failure L/S
(CE model)
Position
Upper
Main relay
Boom elevation s/w
Fuse box
Up
Down
Engine start/
Emergency pump s/w
Engine
start
Lower
Boom telescope s/w
Out
In
Boom rotation s/w
Key switch
CW
Emergency
pump
CCW
To Tilt sensor
(Omni-directional : CE model)
Boom angle L/S
Boom length L/S
C.W.
Boom rotation
C.C.W.
HST pump
Fwd
Travel (Right)
Rev
Fwd
Travel (Left)
Rev
Platform rotation s/w
CW
Emergency
stop button
CCW
Fly jib
(SR14CJ/SR460CJ)
Platform leveling s/w
Enable s/w
Pre-start
check s/w
Unload sol.V
(Boom)
Up
Down
Hour meter
Unload sol.V
(Platform
/Fly-jib)
Override s/w
Enable
Emergency sol.V
Limit
Release
Emergency pump
Accelerator Mid
Accelerator High
Engine stop
Stand-by
Up
Platform
leveling sol.V
Down
Fuel level sensor
Engine failure
Travel
Travel
Travel
Travel
Accelerator control unit
Right/Fwd
Right/Rev
Left/Fwd
Left/Rev
Travel speed
select sol.V
Parking brake
release sol.V
Travel by-pass
sol.V
Engine
SSJ00008
signal
Right/Fwd
Right/Rev
Left/Fwd
Left/Rev
Enable
Travel
Travel
Travel
Travel
Emergency stop
Power for
Remote controller
Remote controller
relay
Remote controller
relay
Emergency stop
Engine stop
Stand-by
Fuel level sensor
GND
Engine failure
Key s/w ON
Engine start
Glow LED
Emergency pump
Accelerator Power
Accelerator Signal
Accelerator GND
+12V
+12V
Mortion alarm buzzer
Remote controller (Option)
8-5
Chapter 8 Appendix
Electric circuit diagram, Lower (602-0080200) 2/2
Fly jib (SR14CJ/SR460CJ)
Boom wire rope failure limit switch (CE model)
Lower control box
Platform
rotation s/w
Overload warning light (CE model)
Fuse box
CW
CCW
Fly jib s/w
Rotating beacon with switch (Option)
Head light (Option)
Lower control box
LED board
Lower control box
16 cores cable with shield wire
Overload
warning
light
Boom wire rope failure L/Ss
16 cores cable with shield wire
Lower control box
Fuse box
Up
Down
Lower control box
Fuse box
Duplicated tilt sensor (CE model)
Tilt sensor
(Omni-directional)
Lower control box
Head light (45W x2)
Fuse box
Fuse box
Head light (25W x4)
Battery
Rotating beacon
Hydraulic generator (Option)
4 cores cable
AC outlet (Option)
4 cores cable
16 cores cable
with shield wire
Battery
Accelerator control unit
Lower control box
Fuse box
Automatic rotating beacon (Option)
Lower control box
Fuse box
Remote controller (Option)
Hydraulic generator sol.V
Touch switch (Option)
Lower control box
16 cores cable
with shield wire
Work light
(Option)
14 cores cable
SSJ00008
Rev
Main relay
Left
Fuse box
Right
Fwd
Left and Right
Emergency
stop
Remote controller
Rotating beacon
Lower control box
Fuse box
Battery
Battery
Lower control box
8-6
Chapter 8 Appendix
Electric Wiring diagram, Upper (602-0080300)
16 cores cable
with shield wire
To Turntable
Fly jib (SR14CJ/SR460CJ)
14 cores cable
C.W.
Platform
rotation sol.V
C.C.W.
To Turntable
C.W.
Platform rotation
sol.V
C.C.W.
Upper control box
Upper control box
Overload limit switch (CE model)
Up
Fly jib sol.V
Down
Overload L/S
Alarm buzzer
Upper control box
AC outlet (Option)
Hydraulic generator (Option)
For Adjustment tool
4 cores cable
4 cores cable
Work light GND
Power for Work light
Power for CPU
GND
Power for Horn
Horn
Emergency stop
Power for Emergency stop
Power for Upper control
Backup (Vbac)
Engine start
Engine start
To head light s/w (Option)
For Hydraulic generator (Option)
For Rotating beacon (Option)
Upper control box
To Work light s/w (Option)
16 cores cable
with shield wire
Panel light (Option)
Upper control box
Panel light
Work light (Option)
Touch switch (Option)
14 cores cable
16 cores cable
with shield wire
Head light
Hydraulic generator
Rotating beacon
Upper control box
Work light (Single)
Upper control box
Work light
(Double)
Touch s/w
Head light (Option)
Rotating beacon (Option)
Upper control box
16 cores cable
with shield wire
Upper control box
16 cores cable
with shield wire
Foot s/w
SSJ00008
8-7
Chapter 8 Appendix
Electric circuit diagram, Lower (602-0080400) 1/2
To Platform
14 cores cable
Main control valve
16 cores cable
(with Shield wire)
Power for Back up (Vbac)
Engine start
Engine start
Power for Emergency stop
Emergency stop
Power for Upper control
Power for Upper CPU
GND
Horn
GND
Work light
Head light
Hydraulic generator
Rotating beacon
Horn
Tilt sensor (Longitudinal)
Up
Boom elevation
Down
Alarm buzzer
For Adjustment tool
Out
Boom telescope
In
C.W.
Boom rotation
C.C.W.
Tilt sensor (Lateral)
HST pump
Fwd
Travel (Left)
Rev
Work light
Head light
Hydraulic generator
Rotating beacon
AC outlet
Boom angle L/S
Fwd
Travel (Right)
Rev
Boom length L/S
Unload sol.V
(Boom)
Unload sol.V
(Platform/Fly-jib)
Lower control box
Emergency sol.V
Up
Platform
leveling sol.V
(SR14CJ/
SR460CJ)
Down
Travel speed
select sol.V
Parking brake
Release sol.V
Travel by-pass
sol.V
Horn
To Battery
SSJ00008
Stand-by
Engine failure
Engine stop
Fuel level sensor
GND
Key s/w ON
Engine start
Glow light
Emergency pump
Accelerator Power
Accelerator Signal
Accelerator GND
+12V
+12V
To Remote controller (Option)
Motion alarm buzzer
To Engine
8-8
Chapter 8 Appendix
Electric circuit diagram, Lower (602-0080400) 2/2
Lower control box
Lower control box
Head light (Option)
Touch switch (Option)
Boom wire rope failure limit switch (CE model)
16 cores cable
with shield wire
Boom wire rope failure L/S
Lower control box
Head light (45W x2)
16 cores cable
with shield wire
Head light (25W x4)
Fusible link
AC outlet (Option)
Duplicated tilt sensor (CE model)
4 cores cable
Power
Output
Lower control box
Tilt sensor
(Omni-directional)
Battery
Remote controller (Option)
Lower control box
Remote
controller
Rotating beacon (Option)
Lower control box
Install on Turntable
16 cores cable
with shield wire
Rotating beacon
Install on Top of the
1st boom section
Rotating beacon
Hydraulic generator (Option)
Lower control box
Fusible link
Hydraulic generator sol.V
16 cores cable
with shield wire
Fusible link
Battery
Work light (Option)
4 cores cable
14 cores cable
Lower control box
Battery
SSJ00008
8-9
Chapter 8 Appendix
Engine stop
Key s/w ON
Engine start
Glow light
Emergency pump
Accelerator Power
Accelerator Signal
Accelerator GND
+12V
+12V
Fuel level sensor
GND
Lower control box
Stand-by
Engine failure
Electric wiring diagram, Engine (602-0076800B)
Engine relay box
Engine stop relay
Key switch ON relay
Starter relay
Glow relay
Main relay
Engine start relay
Rack actuator relay
Glow light ralay
Charge relay
Engine failure
Fuse box
Engine oil pressure
Engine speed
sensor
Emergency pump
Contactor
Fusible link
Fuel level sensor
Rack
actuator
ECU
Fusible link
Fusible link
GND
(Engine
mount
frame)
CSD coil
GND
(Engine
block)
Fusible link
Water temp.
sensor
Fusible link
Oil pressure
s/w
Battery
Fusible link
GND
(Engine
block)
Air cleaner sensor
Glow plug
GND(Turntable)
GND
(Engine block)
GND
(Engine mount frame)
SSJ00008
Starter B Starter S
Alternator B Alternator
GND(Engine block)
Feed pump
GND(Engine block)
8-10
Chapter 8 Appendix
Water proof connector
A view
A view
B view
Fig. 7-1 Water proof connector
SSJ00008
8-11
Chapter 8 Appendix
Pin arrangements of Water proof connector
12 poles
8 poles
6 poles
4 poles
3 poles
2 poles
See the table below to specify the pin arrangements of water proof connectors when reading
“electric wiring diagram”.
8-12
SSJ00008
Chapter 8
Appendix
Color code of wires
See the table below to specify the colors of wires from the “Color codes”.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
SSJ00008
Color
codes
R
Y
W
G
L
B
V
P
O
Br
Lg
Lb
Gy
RY
RW
RG
RL
RB
YR
YW
YG
YL
YB
WR
WY
WG
WL
WB
WBr
GR
Color
No.
Red
Yellow
White
Green
Blue
Black
Violet
Pink
Orange
Brown
Light green
Light blue
Gray
Red/ Yellow
Red/ White
Red/ Green
Red/ Blue
Red/ Black
Yellow/ Red
Yellow/ White
Yellow/ Green
Yellow/ Blue
Yellow/ Black
White/ Red
White/ Yellow
White/ Green
White/ Blue
White/ Black
White/ Brown
Green/ Red
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
Color
codes
GY
GW
GB
GO
LR
LY
LW
LG
LB
LO
BR
BY
BW
BG
BL
PY
PL
PB
OW
OB
BrR
BrY
BrW
BrB
LgR
LgW
LgB
GyR
GyB
Color
Green/ Yellow
Green/ White
Green/ Black
Green/ Orange
Blue/ Red
Blue/ Yellow
Blue/ White
Blue/ Green
Blue/ Black
Blue/ Orange
Black/ Red
Black/ Yellow
Black/ White
Black/ Green
Black/ Blue
Pink/ Yellow
Pink/ Blue
Pink/ Black
Orange/ White
Orange/ Black
Brown/ Red
Brown/ Yellow
Brown/ White
Brown/ Black
Light green/ Red
Light green/ White
Light green/ Black
Gray/ Red
Gray/ Black
8-13
Chapter 8
Appendix
Tightening torque standard
Hexagon headed bolts (8T or 8.8T) and nuts (6T)
Strength grade
Material
Tensile strength
Size
(mm)
5
6
8
10
12
14
16
18
20
22
24
Bolt
8T or 8.8T
S45C
80 kg/cm2
Pitch
(mm)
0.8
1.0
1.25
1.5
1.75
2.0
2.0
2.5
2.5
2.5
3.0
Nut
6T
S45C
80 kg/cm2
N-m
3.71 - 5.87
5.42 - 10.0
13.0 - 24.2
25.7 - 47.6
44.6 - 82.7
71.2 - 132
109 - 201
157 - 291
220 - 407
296 - 549
379 - 703
Tightening torque
kg-m
0.32 - 0.60
0.56 - 1.04
1.33 - 2.47
2.59 - 4.81
4.55 - 8.45
7.00 - 13.00
11.2 - 20.8
16.1 - 29.9
22.4 - 41.6
30.1 - 55.9
38.5 - 71.5
ft-lbs
2.31 - 4.34
4.05 - 7.52
9.62 - 17.9
18.7 - 34.8
32.9 - 61.1
50.6 - 94.0
81.0 - 150
116 - 216
162 - 301
218 - 404
278 - 517
Tightening torque
kg-m
0.73 - 0.90
1.26 - 1.54
3.06 - 3.74
5.94 - 7.26
9.90 - 12.10
16.2 - 19.8
25.2 - 30.8
35.1 - 42.9
49.5 - 60.5
66.6 - 81.4
84.6 - 103
ft-lbs
5.28 - 6.51
9.11 - 11.1
22.1 - 27.1
43.0 - 52.5
71.6 - 87.5
117 - 143
182 - 223
254 - 310
358 - 438
482 - 589
612 - 745
Hexagon headed bolts (10.9T) and nuts (8T)
Strength grade
Material
Tensile strength
Size
(mm)
5
6
8
10
12
14
16
18
20
22
24
8-14
Bolt
10.9T
SCM435
2
100 kg/cm
Pitch
(mm)
0.8
1.0
1.25
1.5
1.75
2.0
2.0
2.5
2.5
2.5
3.0
Nut
8T
SCM435
2
100 kg/cm
N-m
7.21 - 8.79
12.3 - 15.1
29.7 - 36.2
58.5 - 71.3
102 - 124
162 - 197
247 - 302
364 - 422
483 - 589
652 - 795
835 - 1018
SSJ00008
Chapter 8
Appendix
Hexagon socket headed cap screws (10.9T)
Bolt
10.9T
SCM435
100 kg/cm2
Strength grade
Material
Tensile strength
Size
(mm)
5
6
8
10
12
14
16
18
20
22
24
SSJ00008
Pitch
(mm)
0.8
1.0
1.25
1.5
1.75
2.0
2.0
2.5
2.5
2.5
3.0
N-m
4.81 - 5.87
8.24 - 10.0
19.8 - 24.2
39.0 - 47.6
67.8 - 82.7
108 - 132
165 - 201
239 - 291
333 - 407
450 - 549
576 - 703
Tightening torque
kg-m
0.49 - 0.60
0.81 - 0.99
2.07 - 2.53
3.96 - 4.84
6.93 - 8.47
10.8 - 13.2
17.1 - 20.9
24.3 - 29.7
34.2 - 41.8
45.9 - 56.1
58.5 - 71.5
ft-lbs
3.54 - 4.34
5.86 - 7.16
15.0 - 18.3
28.6 - 35.0
50.1 - 61.3
78.1 - 95.5
124 - 151
176 - 215
247 - 302
332 - 406
423 - 517
8-15
Chapter 8
Appendix
This page intensionally left blank.
8-16
SSJ00008
Chapter 9 Engine
Chapter 9
Engine
SSJ00008
9-1
Chapter 9 Engine
Safety warnings for Engine maintenance
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive under certain conditions.
• When you remove any fuel system component to perform maintenance (such as
changing the fuel filter) place an approved container under the opening to catch
the fuel.
• NEVER use a shop rag to catch the fuel. Vapors from the rag are flammable and
explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system is under pressure and fuel could spray out
when you remove any fuel system component.
• NEVER use diesel fuel as a cleaning agent.
• Failure to comply will result in death or serious injury.
SCALD HAZARD!
• NEVER remove the radiator cap if the engine is hot. Steam and hot engine coolant
will spurt out and seriously burn you. Allow the engine to cool down before you
attempt to remove the radiator cap.
• Tighten the radiator cap securely after you check the radiator. Steam can spurt out
during engine operation if the cap is loose.
• ALWAYS check the level of the engine coolant by observing the reserve tank.
• Failure to comply will result in death or serious injury.
BURN HAZARD!
• If you must drain the engine oil while it is still hot, stay clear of the hot engine oil to avoid being burned.
• ALWAYS wear eye protection.
• Failure to comply could result in death or serious injury.
BURN HAZARD!
• Wait until the engine cools before you drain the engine coolant.
Hot engine coolant may splash and burn you.
• Failure to comply could result in death or serious injury.
9-2
SSJ00008
Chapter 9 Engine
FLYING OBJECT HAZARD!
• ALWAYS wear eye protection when servicing the engine and when using compressed air or
high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor or moderate injury.
COOLANT HAZARD!
• Wear eye protection and rubber gloves when you handle long life or extended life engine coolant.
If contact with the eyes or skin should occur, flush eyes and wash immediately with clean water.
• Failure to comply may result in minor or moderate injury.
SSJ00008
9-3
Chapter 9 Engine
Component Identification
Fig.9-1
1 – Lifting Eye (Flywheel End)
3 – Lifting Eye (Engine Cooling Fan End)
4 – Engine Coolant Pump
5 – Engine Cooling Fan
6 – Crankshaft V-Pulley
7 –V-Belt
8 – Side Filler Port (Engine Oil)
9 – Drain Plug (Engine Oil)
10 – Fuel Injection Pump
12 –Engine Oil Filter
13 – Dipstick (Engine Oil)
14 –Governor Lever
15 – Intake Manifold
16 – Fuel Filter
17 – Fuel Inlet
18 – Fuel Return to Fuel Tank
19 – Top Filler Port (Engine Oil)
20 –Rocker Arm Cover
21 –Air Intake Port (From Air Cleaner)
22 – Flywheel
23 – Starter Motor
24 –Exhaust Manifold
25–Alternator
For detailed engine information, see Yanmar engine Operation manual / Service manual
Yanmar TNV series Operation Manual: Part number 0ATNV-G00101
Yanmar TNV series Service Manual: Part number 0BTNV-G00101
9-4
SSJ00008
Chapter 9 Engine
Periodical maintenance procedures
After initial 50 hours of operation
1) Replace Engine Oil and Engine Oil Filter
The engine oil on a new engine becomes
contaminated from the initial break-in of internal parts.
It is very important that the initial oil change is performed
as scheduled.
Note: The oil drain plug may be in another
location if an optional oil pan is used.
Drain the engine oil as follows:
1. Make sure the engine is level.
2. Start the engine and bring it up to operating temperature.
3. Stop the engine.
4. Remove one of the oil filler caps (Fig.9-2, (1))
to vent the engine crankcase and allow the
engine oil to drain more easily.
5. Position a container under the engine to collect
waste oil.6. Remove the oil drain plug (Fig.9-3, (1))
from the engine oil pan. Allow oil to drain.
7. After all oil has been drained from the engine,
reinstall the oil drain plug (Fig.9-3, (1)) and
tighten to 40-47 ft-lb (53.9-63.7 N·m, 5.5-6.5 kgf/m).
8. Dispose of used oil properly.
Fig.9-2
Remove the engine oil filter as follows:
1. Turn the engine oil filter (Fig.9-3, (2))
counterclockwise (Fig.9-3, (3)) using an oil
filter wrench.
2. Clean the engine oil filter mounting face.
3. Lightly coat the gasket on the new oil filter with
engine oil. Install the new engine oil filter
manually by turning it clockwise (Fig.9-3, (4))
until it contacts the mounting surface. Tighten to
14-17 ft-lb (19.6-23.5 N·m, 2.0-2.4 kgf/m) or
one additional turn using the oil filter wrench.
Engine oil filter part number:
129150-35153
Fig.9-3
SSJ00008
9-5
Chapter 9 Engine
4. Add new engine oil to the engine through either
of the oil filler ports as specified in Fig.9-4.
5. Warm up the engine by running it for 5 minutes
and check for any engine oil leaks.6.
After engine is warm, shut it off and let it sit for
10 minutes.
7. Recheck the engine oil level.
8. Add engine oil to engine oil filler port
(Fig.9-5, (5)) as needed until the level is
between the upper (Fig.9-5, (2)) and lower
lines (Fig.9-5, (3)) shown on the dipstick
(1)).
(Fig.9-5, (1))
9. Reinstall the oil filler cap (Fig.9-5, (4))
(4)). If any
Fig.9-4
engine oil is spilled, wipe it away with a clean cloth.
Fig.9-5
• Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal
engine components to seize and / or shorten engine life.
• Prevent dirt and debris from contaminating the engine oil. Carefully clean the oil cap / dipstick and
the surrounding area before you remove the cap.
• NEVER mix different types of engine oil. This may adversely affect the lubricating properties of the
engine oil.
• NEVER overfill. Overfilling may result in white exhaust smoke, engine overspeed or internal damage.
9-6
SSJ00008
Chapter 9 Engine
2) Check and Adjust Cooling Fan V-Belt
The V-belt will slip if it does not have the proper
tension. This will prevent the alternator from
generating sufficient power. Also, the engine will
overheat due to the engine coolant pump pulley
slipping.
Check and adjust the V-belt tension (deflection) as
follows:
1. Press the V-belt down with your thumb with a
force of approximately 22 ft-lb (98 N·m, 10 kgf/m)
to check the deflection.
There are three positions to check for V-belt
tension (Fig.9-6, (A), (B) and (C)).
(C)) You can
check the tension at whichever position is the
most accessible. The proper deflection of a
used V-belt at each position is:
(A) 10-14 mm [3/8 - 1/2 in]
(B) 7-10 mm [1/4-3/8 in]
(C) 9-13 mm [5/16-1/2 in]
2. If necessary, adjust the V-belt tension. Loosen
the adjusting bolt (Fig.9-7, (1)) and move the
alternator (Fig.9-7, (2)) with a pry bar
(Fig.9-7, (3)) to tighten the V-belt to the
desired tension. Then tighten the adjusting bolt.
3. Tighten the V-belt to the proper tension. There
must be clearance (Fig.9-8, (1)) between the
V-belt and the bottom of the pulley groove. If
there is no clearance (Fig.9-8, (2)) between
the V-belt and the bottom of the pulley groove,
replace the V-belt.
4. Check the V-belt for cracks, oil or wear. If any of
these conditions exist, replace the V-belt.
5. Install the new V-belt and adjust the proper
deflection.
The proper deflection of a new V-belt at each
position is:
(A) 8-12 mm [5/16 - 7/16 in]
(B) 5-8 mm [3/16-5/16 in]
(C) 7-11 mm [1/4-7/16 in]
6. After adjusting, run the engine for 5 minutes or
more. Check the tension again using the
specifications for a used V-belt.
SSJ00008
Fig.9-6
Fig.9-7
Fig.9-8
9-7
Chapter 9 Engine
Every 50 hours of operation
1) Drain Fuel Filter / Water Separator
Drain the fuel filter / water separator whenever there are contaminants, such as water, collected in the
bottom of the cup.
NEVER wait until the scheduled periodic maintenance if contaminants are discovered.
The separator cup is made from semi-transparent material. In the cup is a red-colored float ring.
The float ring will rise to the surface of the water to show how much needs to be drained.
Also, some optional fuel filter / water separators are equipped with a sensor to detect the amount of
contaminants. This sensor sends a signal to an indicator to alert the operator.
Drain the fuel filter / water separator as follows:
1. Position an approved container under the fuel
filter / water separator (Fig.9-9, (1)) to collect
the contaminants.
2. Close (Fig.9-9, (2)) the fuel cock (Fig.9-9, (3))
(3)).
3. Loosen the drain cock (Fig.9-9, (4)) at the
bottom of the fuel filter / water separator. Drain
any water collected inside.
4. Hand-tighten the drain cock.
5. Open the fuel cock (Fig.9-9, (3))
(3)).
6. Turn the key to the ON position for 10 to 15 seconds
to prime the diesel fuel system by the electric fuel pump
when you are done.
7. Check for fuel leaks.
Fig.9-9
NEVER use the starter motor to crank the engine in order to prime the fuel system.
This may cause the starter motor to overheat and damage the coils, pinion and / or ring gear.
If no water drips when the fuel filter / water separator drain cock is opened, loosen the air vent screw
on the top of the fuel filter / water separator by using a screwdriver to turn it counterclockwise 2-3 turns.
This may occur if the fuel filter / water separator is positioned higher than the fuel level in the fuel tank.
After draining the fuel filter / water separator, be sure to tighten the air vent screw.
9-8
SSJ00008
Chapter 9 Engine
Every 250 hours of operation
1) Drain Fuel tank
1. Position an approved container under the diesel fuel tank (Fig.9-10, (1)) to collect the
contaminants.
2. Take the drain hose (Fig.9-10, (2)) from the clamp (Fig.9-10, (3)), and then put the end of the
hose into the container.
3. Remove the fuel cap (Fig.9-10, (4))
(4)).
4. Remove the drain plug (Fig.9-10, (5)) from the hose end to drain the contaminants (water, dirt, etc.)
from the bottom of the tank.
5. Drain the tank until clean diesel fuel with no water or dirt flows out. Reinstall and tighten the drain plug
firmly.
6. Reinstall the fuel cap.
7. Fix the drain hose by clamp.
8. Check for leaks.
(4)
(2)
(1)
(5)
(3)
Fig.9-10
2) Replace Engine Oil and Engine Oil Filter
Change the engine oil every 250 hours of operation after the initial change at 50 hours.
Replace the engine oil filter at the same time.
See Replace Engine Oil and Engine Oil Filter on page 9-5.
SSJ00008
9-9
Chapter 9 Engine
3) Check and Clean Radiator Fins
Dirt and dust adhering to the radiator fins reduce
the cooling performance, causing overheating.
Make it a rule to check the radiator fins daily and
clean as needed.
Blow off dirt and dust from fins and radiator with
28 psi (0.19 MPa, 2 kgf/cm2) or less of
compressed air (Fig.9-11, (1)).
(1)) Be careful not to
damage the fins with the compressed air.
If there is a large amount of contamination on the
fins, apply detergent, thoroughly clean and rinse
with tap water.
Fig.9-11
NEVER use high-pressure water or compressed air at greater than 28 psi (193 kPa; 19 686 mmAq) or a
wire brush to clean the radiator fins. Radiator fins damage easily.
4) Check and Adjust Cooling Fan V-Belt
Check and adjust the cooling fan V-belt every 250 hours of operation after the initial 50 hour V-belt
maintenance.
See Check and Adjust Cooling Fan V-Belt on page 9-7.
9-10
SSJ00008
Chapter 9 Engine
5) Clean Air Cleaner Element
Note that a typical air cleaner is shown in Fig.9-12
and Fig.9-13 for illustrative purposes only.
The engine performance is adversely affected
when the air cleaner element is clogged with dust.
Be sure to clean the air filter element periodically.
1. Unlatch and remove the air cleaner cover
(1)).
(Fig.9-12, (1))
2. Remove the element (Fig.9-12, (2)) (outer
element if equipped with two elements).
3. Blow air (Fig.9-12, (3)) through the element
from the inside out using 42-71 psi
(0.29-0.49 MPa, 3.0-5.0 kgf/cm2) compressed
air to remove the particulates. Use the lowest
possible air pressure to remove the dust without
damaging the element.
4. If the air cleaner is equipped with a double
element, only remove and replace the inner
element (Fig.9-13,
ig.9-13, (1)) if the engine lacks
power or the dust indicator actuates (if
equipped).
Fig.9-12
Fig.9-13
Note:
The inner element should not be removed when cleaning or replacing the outer element.
The inner element is used to prevent dust from entering the engine while servicing the outer element.
5. Replace the element with a new one if the element is damaged, excessively dirty or oily.
6. Clean inside of the air cleaner cover.
7. Reinstall the element into the air cleaner case (Fig.9-12, (4))
(4)).
8. Reinstall the air cleaner cover making sure you match the arrow (Fig.9-12, (5)) on the cover
with the arrow on the case (Fig.9-12, (6))
(6)).
9. Latch the air cleaner cover to the case.
• When the engine is operated in dusty conditions, clean the air cleaner element more frequently.
• NEVER operate the engine with the air cleaner element(s) removed.
This may allow foreign material to enter the engine and damage it.
SSJ00008
9-11
Chapter 9 Engine
Every 500 hours of operation
1) Replace Air Cleaner Element
Replace the air cleaner element (Fig.9-12, (2)) every 500 hours even if it is not damaged or dirty.
When replacing the element, clean the inside of the air cleaner case (Fig.9-12, (4))
(4)).
If the air cleaner is equipped with a double element, only remove and replace the inner element
(Fig.9-13, (1)) if the engine lacks power or the dust indicator actuates (if equipped).
This is in addition to replacing the outer element.
Air cleaner element part number:
119005-12571
2) Replace Fuel Filter
Replace the fuel filter at specified intervals
to prevent contaminants from adversely
affecting the diesel fuel flow.
1. Stop the engine and allow it to cool.
2. Close the fuel cock of the fuel filter / water
separator.
3. Remove the fuel filter using a filter wrench to
turn it to the left (Fig.9-14, (1))
(1)). When
removing the fuel filter, carefully hold it to
prevent the fuel from spilling. Wipe up all spilled
fuel.
Fig.9-14
4. Clean the filter mounting surface and apply a small
amount of diesel fuel to the gasket of the new fuel filter.
5. Install the new fuel filter. Hand-tighten it to the right (Fig.9-14, (2)) until it comes in contact
with the mounting surface. Use a filter wrench and tighten to 14-17 ft-lb (19.6-23.5 N•m, 2.0-2.4 kgf/m)
or one additional turn using the filter wrench.
6. Open the fuel cock of the fuel filter / water separator.
7. Turn the key to the ON position for 10 to 15 seconds to prime the diesel fuel system by the electric
fuel pump.
8. Check for fuel leaks.
Engine oil filter part number:
119802-55801
9-12
SSJ00008
Chapter 9 Engine
3) Clean Fuel Filter / Water Separator
Periodically clean the fuel filter / water
separator element and inside the cup.
1. Position an approved container under the cup
(Fig.9-15, (1)) of the fuel filter / water
separator to collect the contaminants.
2. Close (Fig.9-15, (2)) the fuel cock
(3)).
(Fig.9-15, (3))
3. Loosen the drain cock (Fig.9-15, (4)) and
drain the contaminants. See Drain Fuel Filter /
Separator on page 9-5.
4. Turn the retaining ring (Fig.9-15, (5)) to the
left (Fig.9-15, (10)) and remove the cup
(Fig.9-15, (1)).
(1)) If equipped, disconnect the
sensor wire (Fig.9-15, (7)) from the cup
before removing the cup.
5. Carefully hold the cup to prevent fuel from
spilling. If you spill any fuel, clean up the spill
completely.
6. Remove the float ring (Fig.9-15, (8)) from the
cup. Pour the contaminants into the container
and dispose of it properly.
7. Clean the element (Fig.9-15, (9)) and inside
cup. Replace the element if it is damaged.
Element part number
119802-55710
Fig.9-15
8. Install the element and O-ring in the bracket.
9. Position the float ring in the cup.
10. Check the condition of the O-ring. Replace if necessary.
11. Install the cup to the bracket by tightening the retaining ring to the right (Fig.9-15, (6)) to
11-15 ft-lb (15-20 N·m, 1.5-2.0 kfg/m).
12. Close the drain cock. Reconnect the sensor wire if equipped.
13. Open the fuel cock (Fig.9-15, (3))
(3)).
14. Turn the key to the ON position for 10 to 15 seconds to prime the diesel fuel system by the electric
fuel pump.
15. Check for leaks.
SSJ00008
9-13
Chapter 9 Engine
Every 1,000 hours of operation
1) Drain, Flush and Refill Cooling System With New Coolant
Engine coolant contaminated with rust or water
scale reduces the cooling effect. Even when
extended life engine coolant is properly mixed,
the engine coolant gets contaminated as its
ingredients deteriorate. Drain, flush and refill the
cooling system with new coolant every 1000 hours
or once a year, whichever comes first.
1. Allow engine and coolant to cool.
2. Remove the radiator cap (Fig.9-16, (1))
(1)).
3. Remove the drain plug or open the drain cock
(Fig.9-16, (2)) at the bottom of the radiator
and drain the engine coolant.
4. Drain the coolant from the engine block.
remove the coolant drain plug (Fig.9-17, (1))
Fig.9-16
from the engine block.
5. After draining the engine coolant, flush the
radiator and engine block to remove any rust,
scale and contaminants. Then reinstall and
tighten the drain plug or close the drain cock in
the radiator. Reinstall and tighten the engine
block drain plug or reconnect the coolant hose
at the oil cooler.
6. Fill radiator and engine with engine coolant.
Fig.9-17
2) Adjust Intake / Exhaust Valve Clearance
Proper adjustment is necessary to maintain the correct timing for opening and closing the valves.
Improper adjustment will cause the engine to run noisily, resulting in poor engine performance and
engine damage. Ask your authorized Yanmar industrial engine dealer or distributor to adjust the
intake / exhaust valve clearance.
9-14
SSJ00008
Chapter 9 Engine
Every 1,500 hours of operation
1) Inspect, Clean and Test Fuel Injectors
Proper operation of the fuel injectors is required to obtain the optimum injection pattern for full engine
performance. The EPA / ARB requires that you have the injectors inspected, cleaned and tested
every 1500 hours. Ask your authorized Yanmar industrial engine dealer or distributor for this service.
2) Inspect Crankcase Breather System
Proper operation of the crankcase breather system is required to maintain the emission requirements
of the engine. The EPA / ARB requires that you have the crankcase breather system inspected
every 1500 hours. Ask your authorized Yanmar industrial engine dealer or distributor for this service.
Every 2,000 hours of operation
1) Check and Replace Fuel Hoses and Engine Coolant Hoses
Regularly check the fuel system and engine coolant system hoses. If they are cracked or degraded,
replace them. Replace the hoses at least every two years. Ask your authorized Yanmar industrial
engine dealer or distributor to replace fuel hoses and engine coolant system hoses.
2) Lap the Intake and Exhaust Valves
Adjustment is necessary to maintain proper contact of the valves and seats. Ask your authorized
Yanmar industrial engine dealer or distributor to lap the valve seats.
SSJ00008
9-15
Chapter 9 Engine
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9-16
SSJ00008
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