Aichi SV06CNL-SV2032C SV08CNL-SV2632C SERVICE MANUAL SSJ00002 - PDF DOWNLOAD

SERVICE MANUAL

SSJ00002 Rev 2

SV06CNL / SV2032C SV08CNL / SV2632C

AICHI CORPORATION 1152, RYOKE, AGEO, SAITAMA, JAPAN.

Chapter A Introduction

Introduction This manual describes correct adjustment and servicing procedures for Scissors type self- propelled Elevation work platform: SV06CNL / SV2032C and SV08CNL / SV2632C in order to ensure safe and reliable operation, the most effective use of superb performance and excellent features for your satisfaction.

A 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, scissor arms and platform) and safety related components (Schedured replacement parts listed in the page 6-5).

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.

SSJ00002

a

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.

b

SSJ00002

Index

Index Chapter A Introduction Safety warnings

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a b

Chapter 1 General information Specifications (CE model) Specifications (ANSI model) Overall dimensions (CE model) Overall dimensions (ANSI model) Safety devices

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1-2 1-3 1-4 1-5 1-6

Chapter 2 Mechanical components Main structure Chassis Scissor arms Platform Pothole protector

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2-2 2-3 2-7 2-11 2-13

Chapter 3 Hydraulic components Locations of Hydraulic components Power unit Holding valve Lift cylinder Steering solenoid valve Steering cylinder

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3-2 3-3 3-2 3-5 3-6 3-7

Chapter 4 Electric components Locations of Electric components Upper control box Joystick controller Steering dial (for Optional proportional steering) Lower control box Key switch CPU board M6 Inverter unit

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4-2 4-3 4-7 4-8 4-9 4-11 4-12 4-14

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i

Index

Pressure sensor (CE, Japan model) Platform height sensor (ANSI, Japan model) / Steering angle sensor Platform height sensor (CE model) Tilt sensor A (ANSI, Japan model) Tilt sensor A and B (CE model) Tilt sensor C Travel motor Electric magnetic brake Battery charger Battery disconnect switch

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4-16

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4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-25 4-26

Chapter 5 Trouble shooting Trouble shooting by LED indication on Upper / Lower control box Emergency operations

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5-2 5-5

Chapter 6 Scheduled maintenance Scheduled inspection table Lubrication Scheduled replacement parts Daily inspection sheet Periodical inspection sheet

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6-2 6-4 6-5 6-6 6-7

Chapter 7 Appendix Hydraulic circuit diagram Electric circuit diagram Electric wiring diagram Battery cable arrangement Water proof connector Color code of Wires Tightening torque standard

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7-2 7-3 7-4 7-6 7-7 7-9 7-10

ii

SSJ00002

Chapter 1 General Information

Chapter 1 General Information

SSJ00002

1-1

Chapter 1 General Information

Specifications (CE models)

Weight

Measurements

Performance

Name Model Work floor height Rated working load

Max. Min.

Total

Extension deck Maximum allowable tilt angle Traveling speed High Low Platform lift speed Up Down Grade ability Minimum turning radius Overall length (Guardrails folded) Overall width Overall height (Guardrails folded) Wheelbase Tread Platform inner dimensions (length x width x height) Extension length Tires (Diameter x Width) Gross weight

Mobile elevating work platform SV06C NL SV08C NL 6,100 mm 7,770 mm 1,025 mm 1,155 mm 360 kg 230 kg (2 persons + tools: 200 kg) (2 persons + tools: 70 kg) 120 kg (1 person + tools: 40 kg) Front-to-back: 3.0o Left-to-right: 1.5o 3.8 - 5.2 km/h 0.8 - 1.2 km/h 24 - 36 s / 5.1 m 32 - 48 s / 6.8 m 24 - 36 s / 5.1 m 32 - 48 s / 6.8 m 14 o (25 %) 2,240 mm (outside radius) 2,345 mm (2,795 mm) 800 mm 2,125 mm (1,725 mm) 2,255 mm (1,845 mm) 1,815 mm 673 mm 2,210 x 710 x 1,100 mm 1,000 mm 406 x 127 mm 1,810 kg

2,140 kg 800 kg

AC motor power output (Travel) DC motor power output (Platform lift, Steering) Battery model Battery capacity Battery voltage Charger Charging method Input voltage Frequency Max. output current System voltage Rated hydraulic pressure Hydraulic oil tank capacity

0.7 kW

Power source

Maximum tire loading force

2.2 kW Trojan T105 GS Yuasa EB 100 185 Ah 200Ah 6Vx4 12V x 2 ( x 2 Parallel) Fixed current, fixed voltage AC 100–240 V 50 or 60 Hz 25 A DC 24 V 18.1 MPa (185 kg / cm2) 5.3 L

* For the allowance which is not specified otherwise is in accordance with Aichi’s own standards. * Driving speed assumes there is one person on the machine and the battery is fully charged.

The CE model has been manufactured to conform to European Standard EN280.

1-2

Rev 2

SSJ00002

Chapter 1 General Information

Specifications (ANSI models)

Weight

Measurements

Performance

Name Model Work floor height Rated working load

Max. Min.

Total

Extension deck Maximum allowable tilt angle Traveling speed High Low Platform lift speed Up Down Grade ability Minimum turning radius Overall length Overall width Overall height Wheelbase Tread Platform inner dimensions (length x width x height) Extension length Tires (Diameter x Width) Gross weight

Mobile elevating work platform SV2032C SV2632C 20 ft 0.2 in 26 ft 0.6 in 3 ft 4.4 in 3 ft 9.5 in 800 lbs 500 lbs (2 persons + tools: 450 lbs) (2 persons + tools: 150 lbs) 250 lbs (1 person + tools: 75 lbs) 2.0 degrees 2.4 - 3.3 mile/h 0.4 - 0.8 mile/h 24 - 36 s / 16 ft 8.8 in 32 - 48 s / 22 ft 3.7 in 24 - 36 s / 16 ft 8.8 in 32 - 48 s / 22 ft 3.7 in 14 o (25 %) 7 ft 4.2 in (outside radius) 7 ft 6.6 in 2 ft 7.5 in 6 ft 11.7 in 7 ft 4.8 in 5 ft 11.5 in 2 ft 2.5 in 7 ft 2.2 in x 2 ft 4.0 in x 3 ft 7.3 in 3 ft 3.4 in 406 x 127 mm (12.3 x 5.0 in) 3,700 lbs

4,430 lbs 1,764 lbs

AC motor power output (Travel) DC motor power output (Platform lift, Steering) Battery model Battery capacity Battery voltage Charger Charging method Input voltage Frequency Max. output current System voltage Rated hydraulic pressure Hydraulic oil tank capacity

0.7 kW

Power source

Maximum tire loading force

2.2 kW Trojan T105 185 Ah 6Vx4 Fixed current, fixed voltage AC 100–240 V 50 or 60 Hz 25 A DC 24 V 18.1 MPa (185 kg / cm2) [2,630 PSI] 1.4 gallons

* For the allowance which is not specified otherwise is in accordance with Aichi’s own standards. * Driving speed assumes there is one person on the machine and the battery is fully charged.

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) SSJ00002

Rev 2

1-3

Chapter 1 General Information

Overall dimensions : SV06CNL (CE model)

Overall dimensions : SV08CNL (CE model)

1-4

Rev 2

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Chapter 1 General Information

Overall dimensions : SV2032C (ANSI model)

Overall dimensions : SV2632C (ANSI model)

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Rev 2

1-5

Chapter 1 General Information

Safety devices No 1

Name Emergency lowering handle

2

Holding valve

3

Relief valve

4

Motion alarm buzzer

5

6 7

Tilt alarm buzzer

Main function Lower the platform manually by pulling the emergency lowering handle in case of emergency.

Holding valve is attached on the lift cylinder and prevents the platform from natural descent in the event of hydraulic hose breakage.

Protect the hydraulic components by relieving abnormally high pressure in the hydraulic system.

The motion alarm buzzer sounds when the machine is in motion to warn the people nearby.

(CE model) The tilt alarm buzzer sounds, if the machine tilts more than 3 degrees longitudinally and / or 1.5 degrees laterally.

(ANSI, Japan model) The tilt alarm buzzer sounds, if the machine tilts more than 2 degrees omnidirectionally.

Alarm horn Before moving the machine, sound the alarm horn to warn the people around the (CE, ANSI model) machine.

Emergency stop button Stops all of the movements of the machine when this switch is pressed.

8

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.

(ANSI, Japan model) This system disables Platform lift up function from the platform fully lowered position, Overload warning light blinks and Overload buzzer sounds when the platform is overloaded.

9

Enable switch (Upper control) (ANSI model)

The platform lift, traveling and steering functions from the upper control panel are disabled unless the enable switch is operated.

(CE model) This switch enables the platform lift functions in following conditions.

1). Operate the platform lift function with Lift / Travel select switch is held in "Lift" position.

2). Turn the Lift / Travel select switch to "Lift" position once, and then start the platform lift function within 3 seconds.

This switch enables the traveling and steering functions in following conditions.

1). Operate the traveling or steering function with Lift / Travel select switch is held in "Travel" position.

2). Turn the Lift / Travel select switch to "Travel" position once, and then start the traveling or steering function within 3 seconds.

These functions are disabled in following conditions.

10 Lift / Travel select switch 1). Start these functions 3 seconds after releasing the Lift / Travel select switch.

2). No function is operated more than 3 seconds without holding the Left / Travel select switch.

3). No function is operated more than 20 seconds while the Left / Travel select switch is held.

4). If the Lift / Travel select switch is turned to opposite position while some function is operated.

(ANSI, Japan model) This switch selects the function of Lift / Travel joystick controller.

The joystick controller controls Lift Up / Down functions when the switch is turned in "Lift" position.

The joystick controller controls Travel Fwd / Rev functions when the switch is turned in "Lift" position.

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Rev 2

SSJ00002

Chapter 1 General Information Main function

Name

No

Foot switch 11 (Option)

The platform lift, traveling and steering functions from the upper control panel are disabled unless the foot switch is depressed.

The platform lift functions from the lower control panel are disabled unless the enable switch is operated.

Enable switch (Lower control)

13

This system cancels the foot switch if any of platform lift, travel and steering Foot switch cancel timer function is not operated more than 20 seconds.

(Option) Release the switch once, then operate again to enable the functions.

14

15

Battery charger protection system

12

Excessive input voltage

Prevent the battery charger from damage when the excessive voltage inputs. (more than 276 volts)

Short circuit

Prevent the battery charger from damage when the output line to batteries shortcircuits.

Incorrect connection of batteries

Prevent the battery charger from damage when the battery cables are connected incorrectly.

Battery charge interlock

All function on the machine stops when charging batteries.

Thermal protection

This system stops the battery charging when the temperature of the battery charger exceed specific temperature. (80 degrees C / 176 degrees F)

Charge timer

This system stops the battery charging after 18 hours from starting it.

Platform lift up limit system

(CE model) This system disables Platform lift up function, if the machine tilts more than 3 degrees longitudinally and / or 1.5 degrees laterally.

(ANSI, Japan model) This system disables Platform lift up function, if the machine tilts more than 2 degrees omni-directionally.

Maximum travel speed changes automatically when the platform is raised and/or machine is tilted as shown in the table below.

(CE model) Platform Fully lowered

16

Travel speed limit system

Machine tilt angle

Travel speed

within 3 degrees Longitudinally and 1.5 degrees Laterally.

High (4.5 km/h [2.8 mile/h])

more than 3 degrees Longitudinally and / or 1.5 degrees Laterally.

Slope mode*

within 3 degrees Longitudinally and 1.5 degrees Laterally.

Low (1.0 km/h [0.6 mile/h])

Raised

more than 3 degrees Longitudinally and / or 1.5 degrees Laterally.

(ANSI, Japan model) Platform Fully lowered

Raised

Travel function is disabled

Machine tilt angle

Travel speed

within 2 degrees omni-directionally.

High (4.5 km/h [2.8 mile/h])

more than 2 degrees omni-directionally.

Slope mode*

within 2 degrees omni-directionally.

Low (1.0 km/h [0.6 mile/h])

more than 2 degrees omni-directionally.

Travel function is disabled

* Slope mode : Travel speed changes according to slope angle.

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Rev 2

1-7

Chapter 1 General Information Name

No

Platform lift down limit 17 system (CE model) Pothole protector (CE, ANSI model) Pothole protector 19 interlock system (CE, ANSI model) Travel function limit 20 system select switch (Option) 18

1-8

Rev 2

Main function Platform lift down stops before the platform lowered fully to prevent the people and/or obstacles from being caught between scissors arm.

Release the control lever/switch once, wait 2 seconds and then operate again to lower the platform fully.

Pothole guards automatically come down when the platform is raised to prevent the machine from tip over when one of the tires fall into pothole.

The system disables Travel function, if the pothole guards are not come down despite the platform is raised.

Travel function is disabled when the platform is raised, if the switch is turned in "Limit" position.

SSJ00002

Chapter 2 Mechanical Components

Chapter 2 Mechanical Components

SSJ00002

2-1

Chapter 2 Mechanical Components

Main structure

Platform

Scissor arms

Tire, Wheel

Chassis

Pothole protector (CE, ANSI model)

Fig. 2-1 Main structures

2-2

SSJ00002

Chapter 2 Mechanical Components

Chassis Travel motor Tie rod

Battery box

Steering cylinder

Front wheel

Rear weight SV06CNL (SV2032C) : (130 kg) [287 lb] SV08CNL (SV2632C) : (350 kg) [772 lb]

Power unit box

Center weight (180 kg) [397 lb]

Pothole protector (CE, ANSI model)

Lower control box

Linkage for Pothole protector

Step

Rear wheel

Fig. 2-2 Chassis

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2-3

Chapter 2 Mechanical Components

Travel system

Stopper bolt

Bushing

Busing 341-0000091 Right travel motor bracket

Left travel motor bracket

Apply grease before installing

Stopper bolt Fig. 2-3 Travel system

Stopper bolt installation 1. Screw in the stooper bolt until it touches the shaft ofthe travel motor bracket.

2. Screw it out 1/3 turn, and then tighten the lock nut.

2-4

SSJ00002

Chapter 2 Mechanical Components

Bracket

Bolt : 011-30835 Flat washer : 030-00008 Spring washer : 030-20008 Tightening torque :16.3 +/- 1.6 N-m (1.66 +/- 0.16 kg-m) [12 +/- 1.2 ft-lbs] Apply thread lock agent : Loctite 262

AC travel motor Nut : 020-04212 Washer : 030-10012 Tightening torque : 113 +/- 11 N-m (11.5 +/- 1.1 kg-m) [83.3 +/- 8.3 ft-lbs]

Wheel

Tire

Brake Bolt : 036-10425 Flat washer : 030-20004 Spring washer : 030-00004 Apply thread lock agent : Loctite 262 Bolt : 012-31230 Nut : 020-14212 Washer : 030-10012 Tightening torque : 113 +/- 11 N-m (11.5 +/- 1.1 kg-m) [83.3 +/- 8.3 ft-lbs]

Hub

Gear box

Check the tire for cut, deformation and ware of tread groove.

Replace if any tread groove is worn out.

A Tread groove

Fig. 2-4 Installation of wheel / Travel motor SSJ00002

Detail A

2-5

Chapter 2 Mechanical Components

Steering system Steering angle sensor (for Optional Proportional steering)

Steering lock pin Lock pin : 5E0-0814100 Set bolt : 017-30816

Tie rod Steering cylinder

Fig. 2-5 Steering system

2-6

SSJ00002

Chapter 2 Mechanical Components

Scissor arms (SV06CNL / SV2032C) Wear pad

Cable guide

Wear pad

3rd arm (Outer) 3rd arm (Inner)

2nd arm (Outer) 2nd arm (Inner) Safety prop

1st arm (Outer) 1st arm (Inner) Lift cylinder

Wear pad Pothole protector actuator

Fig. 2-6 Scissor arms (SV06C / SV2032C)

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2-7

Chapter 2 Mechanical Components

Scissor arms (SV08CNL / SV2632C) Wear pad

4th arm (Outer) 4th arm (Inner)

Wear pad

3rd arm (Outer) 3rd arm (Inner) Cable guide

2nd arm (Outer) 2nd arm (Inner) Safety prop

1st arm (Outer) 1st arm (Inner) Lift cylinder

Wear pad Pothole protector actuator

Fig. 2-7 Scissor arms (SV08C / SV2632C)

2-8

SSJ00002

Chapter 2 Mechanical Components

A

D

C

E

B

Pivot pin (445-0000546)

Self lock nut (028-70208)

Wear pad (5K0-0522100)

Wear pad (5K0-0522000)

4th inner arm Bolt (011-30875)

4th outer arm

View A 1st inner arm

View D Self lock nut (028-70208)

Pivot pin (445-0000543)

Wear pad (5K0-0522100)

Bolt (011-30875) 1st outer arm View E

View B Bushing (341-0000051) Cap (5K0-0358500)

Self lock nut (028-70208)

Bolt (017-30816)

F Retaining ring (041-30040)

Bolt (011-30875)

Washer (443-04868)

Outer arm

Inner arm Pivot pin (445-0000544)

View C Bolt (011-30875)

Self lock nut (028-70208)

0.5 - 1.0 mm View F Fig. 2-8 Detail of the Scissor arms Do not tighten the self lock nut fully.

Make a clearance of 0.5 - 1.0 mm between self lock nut and arms.

Do not reuse the self lock nuts.

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2-9

Chapter 2 Mechanical Components

Wear pad (5K0-05220-00A, 5K0-05221-00A ) 4th arm Outer (Front) : 5K0-05220-00A

4th arm Inner (Rear) 1st arm Outer (Rear) : 5K0-05221-00A

Fig. 2-9 Wear pad Check the height of the wear pads.

Replace them if the height is shorter than serviceable limit.

Nominal : 105 mm [4.13 in] Serviceable limit : 103.3 mm [4.07 in]

Install the wear pads in the direction shown in the Fig.2-10.

4th arm Outer (5K0-05220-00A) Long side (Upper)

Short side (Lower)

4th arm Inner (5K0-05221-00A)

Inside Outside

Cut

Long side (Upper)

Short side (Lower)

1st arm Outer (5K0-05221-00A)

Inside Outside

Cut

Short side (Upper)

Long side (Lower)

Inside Outside

Cut

Fig. 2-10 Installation of wear pads

2-10 Rev 2

SSJ00002

Chapter 2 Mechanical Components

Platform with Fold down guardrail SV06CNL, SV08CNL (CE model) SV2632C (ANSI model)

Upper control box

Extension deck release handle

Manual holder

E

Extension deck

C

F

D

B Foot switch (Option) Door

A

Roller

Pin

Bolt

Apply thread lock agent : Loctite 262 Detail B

Detail A

Insert the bolt from inside of the platform.

Do not tighten the bolt too mach so that the guard rail could be smoothly folded.

Detail C

Lock pin

Pipe

Extension deck release handle

Bushing Lock Insert the lock pin from inside of the platform.

Detail D SSJ00002

Detail E

Set the lock of the bushing at bottom of the pipe when installing it.

Fig. 2-11 Platform with Fold down guardrail

Detail F Rev 2

2-11

Chapter 2 Mechanical Components

Platform with fixed guardrail SV2032C (ANSI model)

Upper control box

Extension deck release handle

Manual holder

C

Extension deck

D

B E A

Slide bar

Roller

Pin

Apply thread lock agent : Loctite 262 Detail B

Detail A Extension deck release handle Pipe

Slide bar Bushing Lock Detail C

Detail E

Set the lock of the bushing at bottom of the pipe when installing it.

Detail D Fig. 2-12 Platform with fixed guardrail

2-12 Rev 2

SSJ00002

Chapter 2 Mechanical Components

Pothole protector (CE, ANSI model) The pothole protector consists of two guards, two arm and actuator.

The two guards automatically come down when the platform is raised to prevent the machine from tip-over.

019-31016 Bolt with washer x3 39.0 - 47.6 N-m Chassis (4.0 - 4.8 kgf-m) [29.0 - 35.0 ft-lb]

019-31016 Bolt with washer x4 39.0 - 47.6 N-m (4.0 - 4.8 kgf-m) [29.0 - 35.0 ft-lb]

1st inner arm

Pothole actuator

445-0000551 341-0000089 031-00020 041-30020

Pothole link (LH) Pothole guard (LH)

Pin Bushing Flat washer Retaining ring

x2 x2 x2 x2

Pothole link (RH) Pothole guard (RH) Spring

042-12050 Pin x6 5E0-07975-00 Collar x6 031-00020 Flat washer x6 043-05030 Split pin x6

Pothole limit switches x2 320-0002600 (CE model) 171-20005 (ANSI model)

Fig. 2-13 Pothole protector

SSJ00002

2-13

Chapter 2 Mechanical Components Function of the Pothole protector Stowed position

Pothole actuator

Pothole actuator

Pothole guard

Operating position

Pothole link

When the platform is lowered fully, The pothole actuator installed on the 1st scissor arm inner depress two pothole links connected to each pothole guard hold them in stowed position.

Pothole guard

Pothole link

When the platform is raised, the pothole guards come down.

Fig. 2-14 Function of the Pothole protector

2-14

SSJ00002

Chapter 2 Mechanical Components Pothole limit switches The pothole limit switches detect the stowed position of the pothole guards and disable the travel function when the pothole guards are stowed despite the platform is raised.

Stowed position

Limit switches

Operating position

Limit switches

Relay CR-10 is energized, when the key switch on lower control box is in Upper or Lower position and emergency stop button on upper and lower control box are pulled.

Limit switches are opend when the pothole guards are stowed.

Fig. 2-15 Pothole limit switches

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Chapter 2 Mechanical Components

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2-16

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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

Fig. 3-1 Location of Hydraulic components

3-2

SSJ00002

Chapter 3 Hydraulic Components

Power unit (300-0000107C) The power unit consists of DC motor, Gear pump, Solenoid valve, Relief valve and Oil reservoir to supply pressurized oil to Sissors lift circuit and Steering circuit.

Specifications

Oil reservoir DC motor Gear pump Relief valve Solenoid valve

Oil capacity Rated voltage Power consumption Displacement Preset pressure Rated voltage

5.7 liters [1.4 gal] DC24V 2.2 kw 3.07 cm3/rev [0.19 in3/rev] 18.1 +/- 0.5 MPa (185 +/- 5 kg/cm2) [2630 +/- 70 PSI] DC24V

Coil resistance

25 ohms

Tightening torque : 5.9 - 7.9 N-m (0.6 - 0.8 kg-m) [4.4 - 5.8 ft-lb]

Solenoid valve (302-0033900)

C port

G port (Gauge port) B port

D port

Terminal

Relief valve

Tightening torque : 24.5 - 27.5 N-m (2.5 - 2.8 kg-m) [18 - 20 ft-lb]

A port

Oil filler (Air bleeder) Level gauge

DC motor

Oil reservoir Drain port

Gear pump Tightening torque : 14.7 - 17.7 N-m (1.5 - 1.8 kg-m) [11 - 13 ft-lb]

Hydraulic schematic

G A B

C D

Solenoid valve Relief valve Gear pump DC motor Oil reservoir Suction strainer Fig. 3-2 Power unit SSJ00002

Rev 2

3-3

Chapter 3 Hydraulic Components

Holding valve (302-0031900 for SV06CNL / SV2032C, 302-0031901 for SV08CNL / SV2632C) The holding valve is attached on the lift cylinder to prevent it from natural discent.

Platform lift down solenoid valve is attached on the holding valve to control platform lift down.

Specifications

Rated voltage

DC24V

Coil resistance

35.8 ohms

Preset pressure Rated flow volume

20.6 MPa (210 kg/cm2) [3,000 PSI] 15 liters / min [4.0 gal / min]

This shaft is connected to the emergency lowering handle.

The shaft is pulled by the emergency lowering handle to lower the platform manually in case of emergency.

Tightening torque : 3.4 - 4.9 Nm (0.35 - 0.50 kg-m) [2.5 - 3.6 ft-lb]

Solenoid coil Solenoid valve

Tightening torque : 41.2 - 43.2 Nm (4.2 - 4.4 kg-m) [30.4 - 31.9 ft-lb] Tightening torque : 31.4 - 34.8 Nm (3.2 - 3.6 kgf-m) [23.1 - 25.7 ft-lb]

C port

A port (G 3/8)

B port D port

Orifice : SV06CNL / SV2032C d=1.4 mm SV08CNL / SV2632C d=1.2 mm Solenoid valve Check valve

Fig. 3-3 Holding valve Use safety prop properly to support the Scissor arms when remove the Holding valve.

The scissor arms will fall down when remove the Holding valve if it was not supported, result in Death or serious injury.

3-4

Rev 2

SSJ00002

Chapter 3 Hydraulic Components

Lift cylinder (303-0043400 for SV06CNL / SV2032C 303-0043500 for SV08CNL / SV2632C) Holding valve SV06CNL / SV2032C : 302-0031900 SV08CNL / SV2632C : 302-0031901

Serial number

Tightening torque : 16.7 +/- 3 Nm (1.7 +/- 0.3kg-m) [12.3 +/- 2.2 ft-lb]

Tightening torque : 392 - 490 Nm (40.0 - 40.0 kgf-m) [290 - 360 ft-lb] Apply thread lock agent : Loctite 222

Tightening torque : 294 - 392 Nm (30.0 - 40.0 kgf-m) [220 - 290 ft-lb] Fig. 3-4 Lift cylinder

No. Descriptions 1 Cylinder tube 2 Piston rod 3 Cylinder head 4 Piston 5 Holding valve 6 Dust seal 7 Rod packing 8 O-ring 9 Backup ring 10 O-ring

No. Descriptions 11 Piston packing 12 Backup ring 13 Wear ring 14 U-nut 15 Bushing 16 Bushing 17 Bolt 18 Flat washer 19 O-ring

Use safety prop properly to support the Scissor arms when remove the Lift cylinder.

The scissor arms will fall down when remove the Lift cylinder if it was not supported, result in Death or serious injury.

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Rev 2

3-5

Chapter 3 Hydraulic Components

Steering solenoid valve (302-0033700) The unit valve is located in the power unit box to control steering.

Specifications Rated voltage Solenoid coil resistance Rated pressure Rated flow

DC24V 35.8 ohms 20.6 MPa (210 kg/cm2) [3,000 PSI] 30 liters/min [7.9 gal/min]

P port

A port Yellow (-) Pink (+)

B port

T port

Fig. 3-5 Steering solenoid valve

3-6

Rev 2

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Chapter 3 Hydraulic Components

Steering cylinder (303-0036600B)

Tightening torque : 167 +/- 16 Nm (17.0 +/- 1.6kg-m) [123 +/- 11 ft-lb]

Tightening torque : 56 +/- 5 Nm (5.7 +/- 0.5kg-m) [41 +/- 3 ft-lb]

Fig. 3-6 Steering cylinder

No. Descriptions 1 Cylinder tube 2 Piston rod 3 Cylinder head 4 Piston 5 Nut 6 Bushing 7 Dust seal 8 Rod packing 9 Backup ring 10 O-ring 11 Backup ring 12 O-ring 13 Bushing

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Chapter 3 Hydraulic Components

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3-8

SSJ00002

Chapter 4 Electric Components

Chapter 4 Electric Components

SSJ00002

4-1

Chapter 4 Electric Components

Locations of Electric components

Fig. 4-1 Locations of Electric components

4-2

SSJ00002

Chapter 4 Electric Components

Upper control box (Standard)

Female

Male

Male

Female

Male

Female

Fig. 4-2 Upper control box (Standard)

No. Descriptions 1 Enable switch (ANSI, Japan model) 2 Lift / Travel select switch 3 Power indicator light Overload warning light (CE, Japan model) 4 / Error indicator light 5 Horn switch 6 Steering switch 7 Emergency stop button 8 Lift / Travel joystick controller 9 Lever guard 10 Overload / Tilt alarm buzzer

SSJ00002

Part number 320-05325 173-01101 (ANSI, Japan model) 320-05325 (CE model) 321-03433

Switch cover 173-40000 173-40000 173-40000

321-02222 173-51100 320-05325 320-0007201 324-0000012 462-0000072, 5N5-0113200 324-0008000

173-70000 173-40000 320-0001900

Rev 1

4-3

Chapter 4 Electric Components Electric schematic

Fig. 4-3 Electric schematic (Standard)

4-4

Rev 1

SSJ00002

Chapter 4 Electric Components

Upper control box (for the machine with optional proportional steering)

Female

Male

Male

Male

Female

Female

Fig. 4-4 Upper control box (with Proportional steering)

No. Descriptions 1 Enable switch (ANSI, Japan model) 2 Lift / Travel select switch 3 Power indicator light Overload warning light (CE, Japan model) 4 / Error indicator light 5 Horn switch 6 Steering dial 7 Emergency stop button 8 Lift / Travel joystick controller 9 Lever guard 10 Overload / Tilt alarm buzzer

SSJ00002

Part number 320-05325 173-01101 (ANSI, Japan model) 320-05325 (CE model) 321-03433

Switch cover 173-40000 173-40000 173-40000

321-02222 173-51100 324-0011900 320-0007201 324-0000012 462-0000072, 5N5-0113200 324-0008000

173-70000 320-0001900

Rev 1

4-5

Chapter 4 Electric Components Electric schematic

Fig. 4-5 Electric schematic (with Proportional steering)

4-6

Rev 1

SSJ00002

Chapter 4 Electric Components

Lift / Travel joystick controller (324-0000012) Joystick controller is installed on the upper control box to control the Platform lift and Travel functions.

Direction selector switch

Potentiometer Neutral 3 deg.

Direction selector switch Blue

3 deg.

ON Yellow Green OFF Red 5 deg.

5 deg.

Brown

White Potentiometer

Black OFF 21 deg.

21 deg.

Fig. 4-6 Joystick controller SSJ00002

4-7

Chapter 4 Electric Components

Steering dial (for Optional Proportional steering) (324-0011900A)

Red 60 deg.

60 deg.

White

Brown

Potentiometer Blue Direction selector switch

Yellow Green

Output

Neutral

Fig. 4-7 Steering dial

4-8

SSJ00002

Chapter 4 Electric Components

Lower control box (5N5-0111200A)

Male,White

Male, White

Male, Gray

Fig. 4-8 Lower control box No. Descriptions 1 Battery level indicator / Hourmeter 2 Battery charger failure indicator light (Red) 3 Battery charger indicator light (Green) 4 Enable switch / Pre-start check switch 5 Lift switch 6 Key switch 7 Emergency stop button 8 Overload warning light / Error indicator light 9 Override switch

SSJ00002

Part number 381-0000011 321-02222 321-03433 173-01212 173-01212 378-0000701 320-0007201 321-02222 173-01102

Switch cover

173-40000 173-40000 320-0001900 173-40000

4-9

Chapter 4 Electric Components

Electric schematic Lower control box

Emergency stop button Battery charger indicator light (Green)

Key switch Upper Lower

Battery charger failure indicator light (Red)

Upper Lower

Battery level indicator / Hourmeter

Overload warning / Error indicator light

Override switch Limit

Enable

Release Enable switch / Pre-start check switch Pre-start check

Lift switch

Up

Down

Fig. 4-9 Electric schematic Refer to page 4-24 for the LED status of the battery charger indicator light “Green” and “Red”

4-10

SSJ00002

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

SSJ00002

Control position OFF Upper control Lower control

Connection ---------B - 1, B1 - 2 B - 3, B1 - 4

4-11

Chapter 4 Electric Components

CPU board “M6” (G309290018) J4

J5

J1 J2

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. 4-10 CPU board “M6”

4-12 Rev 2

SSJ00002

Chapter 4 Electric Components Input / Output characteristics

SSJ00002

Rev 2

4-13

Chapter 4 Electric Components

Inverter unit (329-0086400A)

P

B‑

M3

B+

M2

M1

LED

Connector

Connector Pin No.

Pin No.

drive feed drive Key SW 13 feed CAN 24 Key SW Term 1

Key SW

CAN High CAN Low

therm1

D11

An2 Vin An1 Vin

D12

therm2 (An2+)

An1+

D13

Vdrive1

12

D15

D17

23 D18

D14

Idrive1

35

Fig. 4-11 Sevcon control box

4-14

SSJ00002

Chapter 4 Electric Components Input / Output characteristics

SSJ00002

Rev 1

4-15

Chapter 4 Electric Components

Pressure sensor (312-0000035) CE, Japan mpdel The pressure sensor is installed on the holding valve on the lift cylinder.

It senses the pressure imposed in the bottom room of the cylinder to detect the platform load.

Output characteristics

Output voltage

Pressure

Connector Power supply (+24 volts) Output (+1 - 5 volts)

R B

W Shielded

GND Shielded

Fig. 4-12 Pressure sensor

Specifications Rated voltage : +24 volts Output voltage : +1 - 5 volts Pressure range : 0 - 20 MPa (0 - 200 kgf/cm2) [0 - 2,900 PSI]

4-16

SSJ00002

Chapter 4 Electric Components

Platform height sensor for ANSI, Japan model Steering angle sensor for proportional steering (Option) (382-0006400A) The platform height sensor is located on the chassis and its arm is connected with the scissors arm (1st Inner) as shown in fig 4-14 to detect the platform height. (for CE model, see page 4-18 : 382-0006600) The steering angle sensor is located under the chassis and its arm is connected with the tie rod as shown in fig 4-15 to detect the steer angle. (for the machine with optional proportional steering only)

Specifications Resistance : 2.0 k ohm Detectable angle : 110 degrees

Output characteristics Connector

Resistance between R and W

5 degrees

R VCC

W OUT

B GND

55 degrees 110 degrees 120 degrees Angle Fig. 4-13 Platform height sensor, Steering angle sensor Platform height sensor

Steering angle sensor

Scissors arm (1st Inner)

Arm

Fig. 4-14 Platform height sensor SSJ00002

Tie rod Arm Fig. 4-15 Steering angle sensor

4-17

Chapter 4 Electric Components

Platform height sensor for CE model (382-0006600) The platform height sensor is located on the chassis and its arm is connected with the scissor arm (1st Inner) as shown in fig 4-14 to detect the platform height.

Specifications Resistance : 2.0 k ohm Detectable angle : 120 degrees

Wiring White : GND Blue : OUT Red : Vcc Blue/Red : Vcc Blue/Yellow : OUT Black : GND Output characteristics POT 1 (Resistance between Black and Blue/Yellow)

Resistance

60 degrees 15 degrees

POT 2 (Resistance between Red and Blue)

120 degrees 150 degrees Angle

Fig. 4-16 Platform height sensor (for CE model)

4-18

SSJ00002

Chapter 4 Electric Components

Tilt sensor A (ANSI, Japan model) (324-06220A) The tilt sensor A is installed on the chassis (behind the lower control box) to detect the omnidirectional machine’s tilt angle of 2 degrees.

It outputs the signal (+24volts) to CPU “M6” when the machine is in level and stop the output when the machine is tilted more than 2 degrees omnidirectionally.

This LED goes on when the tilt angle is within 2 degrees.

Connector

Diagram Power supply (White) Main switch circuit

Output (Red) (Black)

Fig. 4-18 Tilt sensor A (ANSI, Japan model)

Specifications Rated voltage : DC24 volts (DC10 - 32volts) Pre-set angle 2 +/- 0.5 degrees Output characteristics : The sensor ceases its output when the tilt angle exceeds 2 degrees omnidirectionally.

SSJ00002

4-19

Chapter 4 Electric Components

Tilt sensor A and B (CE model) (324-0012300) The tilt sensor A and B are installed on the chassis (behind the lower control box) to detect the machine’s longitudinal tilt angle of 3 degrees and lateral tilt angle of 1.5 degrees.

They outputs the signal (+24volts) to CPU “M6” when the machine is in level and stop the output when the machine is tilted more than 3 degrees longitudinally and/or 1.5 degrees laterally.

Lateral direction

Longitudinal direction

Connector

Diagram Power supply (White)

Main switch circuit

Output (Red) GND (Black)

Fig. 4-17 Tilt sensor A and B (CE model)

Specifications Rated voltage : DC24 volts (DC8 - 32volts) Output current : 10 -100 mA Pre-set angle Longitudinal : 3 +/- 0.5 degrees Lateral : 1.5 +/- 0.5 degrees Output characteristics : The sensor ceases its output when the tilt angle exceeds 3 degrees longitudinally and/or 1.5 degrees laterally.

4-20

SSJ00002

Chapter 4 Electric Components

Tilt sensor C (382-0001600) The tilt sensor C is installed under the chassis to detect the machine’s longitudinal tilt angle.

Output characteristics

Output voltage

Tilt angle Fig. 4-19 Tilt sensor C

Specifications Rated voltage : DC 5 +/- 0.5 volts Output voltage : 0.1 V/1 degree [2.5 volts when the machine is in level]

SSJ00002

Rev 1

4-21

Chapter 4 Electric Components

Travel motor (AC induction motor) (322-0007100A) The Travel motor is installed on each front wheel bracket to drive machine.

Tightening torque of the upper nut Max : 8 N-m (0.8 kg-m) [5.9 ft-lb] U

V

W

d7 hole 462-0000069 : Grommet 304-0000048 : O ring

5E0-0758600 : Brake cover

322-0007100 : Travel motor

036-10406 : Screw 030-20004 : Spring washer 030-00004 : Flat washer 370-0000079A : Electric magnetic brake 5E0-0790300 : Washer 346-0000002 : Key 036-00616 : Screw

036-10425 : Screw 030-20004 : Spring washer 030-00004 : Flat washer Tightening torque of the screw Max : 3.5 N-m (0.36 kg-m) [2.6 ft-lb]

Fig. 4-20 Travel motor (AC induction motor)

Specifications Rated voltage Rated output power Rated operation time Maximum output torque Weight

4-22

: AC 15 volts : 0.7 kw : 30 min : 18 N-m (1.84 kg-m) [13.3 ft-lb] : 16.5 kg [36.4 lb]

SSJ00002

Chapter 4 Electric Components

Electric magnetic brake (370-0000079A) The Electric magnetic brake is installed behind the travel motor to prevent the machine from runaway when the travel function is not operated.

Specifications

Rated voltage Rated output power Minimum brake release voltage Weight

DC 24 volts 0.7 kw 16 volts 1.5 kg [36.4 lbs]

Fig. 4-21 Electric magnetic brake Refer to page 5-7 for brake release by brake release connector.

Disassemble and reassemble the electric magnetic brake

Do not disassemble the brake when the machine is on the slope or the machine may run away result in death or serious injury.

Set up the wheel chocks in front and/or rear of all tires to prevent the machine from uncontrolled movement.

When disassemble the electric magnetic brake on the machine with proportional steering.

Steer angle stays when turn off the enable switch while operating steering dial.

It automatically return to neutral when enable switch is operated.

Do not operate the enable switch during disassembling/reassembling the electric magnetic brake and Do not put your body or any obstacle around the wheels when turn on the enable switch or may result serious injury or property damage.

1) Disassemble 1. Set the machine on firm and level surface.

2. Steer right or left fully so that the electric magnetic brake is accessible. and then turn off the main key switch.

3. Set up the wheel chocks in front and/or rear of all tires.

4. Take the connector cover off. (Fig.4-22) 5. Unscrew the three screws (M4 x 6 mm) that secure the brake cover. (Fig.4-22) 6. Take the brake cover off.

SSJ00002

Connector cover

Screws (M4 x 6 mm)

Brake cover Fig. 4-22 Rev 2

4-23

Chapter 4 Electric Components 7. Disconnect the gray connector. (Fig.4-23) 8. Cut the two Yellow wires between brake and connector (Gray). (Fig.4-23) 9. Take the tube and grommet off from the wires. (Fig.4-24) 10. Unscrew the three screws (M4 x 25 mm) that secure the brake. (Fig.4-24) 11. Take the brake off.

Two wires (Yellow)

Tube Tube

Brake

Connector (Gray)

Screws (M4 x 25 mm)

Fig. 4-23

Grommet

Fig. 4-24

1) Reassemble 1. Thread two wires from the electric magnetic brake through the hole on the travel motor. (Fig.4-25) 2. Thread the grommet and tube on the wires.

3. Install the brake.

4. Secure the brake with three screws.

Apply thread lock agent (Loctite 262) Tightening torque : Max : 3.5 N-m (0.36 kgf-m) [2.6 ft-lb] 5. Insert the grommet threaded on the wires into the hole on the travel motor.

6. Install the brake cover.

Do not damage the o-ring when install the brake cover.

7. Secure the brake cover with three screws.

8. Connect the wires using copper connecting sleeves or soldering.

9. Make water proof treatment to the wires using heat shrink tube.

Hole

Brake O-ring Fig. 4-25

4-24

SSJ00002

Chapter 4 Electric Components

Battery charger (322-0008100A) The battery charger is located in the battery box to charge the batteries.

Cable for CN53

CN51

Connector for AC power source

LED CN50 Connector

CN50 NO NC

COM Mode 1

Mode 2 LED (R) M COM LED (G)

CN51 Charge

Fig. 4-26 Battery charger Specifications Rated input voltage Input voltage range Maximum input current Output voltage Output current Battery

: Single phase AC 100 - 240 volts (50Hz / 60Hz) : AC 90 - 260 volts : 15 A : DC 24 volts : 25 A : GS Yusasa EB100 or Trojan T105

LED status Status Charging Finished Error Error

Description LED (Green) The battery charger is charging batteries.

Blink Charging is finished.

On AC Power supply is higher than 276 volts AC Power supply is lower than 80 volts Wrong connection of batteries.

Batteries are not connected.

Charging is not finished within specific time.

LED (Red)

Blink On

The battery charger indicator lights on the lower control box go on and blink as same as this table.

SSJ00002

4-25

Chapter 4 Electric Components

Battery disconnect switch (320-0013100) The battery disconnect switch contains a push-pull switch and a relay.

It supplies power supply for the travel AC motor and DC motor on power unit through the sevcon controller only when the push-pull switch is pulled and relay is energized.

It stops to supply when the push-pull switch is pushed and/or relay is not energized.

Specifications Rated voltage : DC 24 volts Rated current : 250 A

Electric schematic

(1)

(2)

(3)

(4)

Fig. 4-27 Battery disconnect switch

(1) (2) (3) (4)

4-26

Push-pull switch Pulled Pushed Pulled Pushed

Relay Off Off On On

Contact Open Open Close Open

SSJ00002

Chapter 5 Scheduled maintenance

Chapter 5 Trouble shooting

SSJ00002

5-1

Chapter 5 Trouble shooting

Trouble shooting by LED indication on Upper / Lower control box Overload warning light / Error indicator light on the Upper and Lower control boxes blink as shown in the table below to indicate the system error.

Overload warning light / Error indicator light

Upper control box Lower control box Fig. 5-1 Locations of Overload warning light / Error indicator light Error descriptions Overload alarm

LED Causes status Platform is overloaded.

Blinks continu -ously Inverter unit error Blinks Power supply to the Inverter unit is out of (Power, Temp) twice specific range.

1. Faulty electric lines between batteries and Inverter unit.

2. Dead batteries.

3. Incorrect batteries.

Temperature problem 4. Temperature of the Inverter unit is too cold.

5. Temperature of the Inverter unit and / or Travel motor is too hot.

6. Faulty Inverter unit.

Countermeasures Unload the platform.

1. Rectify the electric lines between Batteries and Inverter unit.

2. Charge the batteries.

3. Replace the batteries.

4. Move the machine into warmer place.

5. Turn off the key switch and leave the machine until the Inverter unit / Travel motor get cool.

6. Replace the Inverter unit.

Inverter unit error Blinks (Input) 3 times

Travel Forward and Reverse signal input at the same time.

Analog signal input from the Joystick controller is out of specific range.

1. Rectify the electric lines between 1. Faulty electric line between Joystick controller and Inverter unit.

Joystick controller and Inverter unit.

2. Faulty Joystick controller.

2. Replace the Joystick controller.

3. Faulty Inverter unit.

3. Replace the Inverter unit.

Inverter unit error (System 1) Inverter unit error (System 2)

Internal system error of the Inverter unit.

1. Faulty Inverter unit.

Incorrect or corrupted parameters.

1. Incorrect parameters are memorized in the Inverter unit.

2. Incorrect parameters are tried to write into the Inverter unit during adjustment using handy tool.

3. Parameters memorized in the Inverter unit is corrupted.

Blinks 4 times Blinks 5 times

1. Replace the Inverter unit.

1. Write the correct parameters into the Inverter unit, using the handy tool.

2. Write the correct parameters into the Inverter unit, using the handy tool.

3. Replace the Inverter unit.

Battery disconnect switch problem.

4. Short circuit or cut on the electric lines 4. Rectify the electric lines between between Inverter unit and Battery Inverter unit and Battery disconnect disconnect switch. switch.

5. Faulty battery disconnect switch.

5. Replace the battery disconnect switch.

6. Faulty Inverter unit.

6. Replace the Inverter unit.

5-2

SSJ00002

Chapter 5 Trouble shooting Error LED Causes descriptions status Inverter unit error Blinks Short circuit between terminals (Output) 6 times (B+ or B-) and (M1, M2 or M3).

1. Faulty electric lines between Inverter unit and Travel motor.

2. Faulty Inverter unit.

Pothole Error Blinks CPU board M6 does not receive the 7 times signal from pothole limit switches despite the platform is raised.

1. Pothole protectors are stuck and do not come down.

2. Incorrect adjustment of limit switch installation.

3. Faulty electric lines between Limit switches and CPU board M6.

4. Faulty limit switches.

Pre-start check error

Countermeasures

1. Rectify the electric lines between Inverter unit and Travel motor.

2. Replace the Inverter unit.

1. Check the pothole protectors for stuck.

2. Adjust the limit switches so that the limit switches are released when the pothole protectors come down.

3. Rectify the electric lines between Limit switches and CPU board M6.

4. Replace the limit switches.

Blinks Input from Pressure sensor and / or 8 times Tilt sensor C is out of specific range when the platform is stopped during pre-start check.

1. Platform is loaded.

1. Unload the platform and perform the Pre-start check.

2. Machine is tilted.

2. Set the machine horizontal and perform the Pre-start check.

3. Incorrect Pressure sensor calibration. 3. Perform the Pressure sensor calibration using handy tool.

4. Incorrect Tilt sensor C calibration.

4. Perform the Tilt sensor C calibration using handy tool.

5. Faulty Pressure sensor.

5. Replace the Pressure sensor.

6. Faulty Tilt sensor C. 6. Replace the Tilt sensor C.

Lift / Travel select switch error

Blinks Both Lift and Travel select signals input 9 times at the same time.

1. Faulty electric lines between Lift / Travel select switch and Inverter unit.

(CE model) Faulty electric lines between Lift / Travel select switch and CPU board M6 or Electric lines between CPU board M6 and Inverter unit.

2. Faulty Lift / Travel select switch.

Tilt sensor C error

Blinks Input from Tilt sensor C is out of specific 10 times range.

1. Incorrect calibration of the Tilt sensor 1. Perform the Tilt sensor C calibration C. using handy tool.

2. Faulty electric lines between Tilt 2. Rectify the electric lines between Tilt sensor C and CPU board M6. sensor C and CPU board M6.

3. Faulty Tilt sensor C. 3. Replace the Tilt sensor C.

1. Rectify the electric lines between Lift / Travel select switch and Inverter unit.

(CE model) Rectify the electric lines between Lift / Travel select switch and CPU board M6 Rectify the electric lines between CPU board M6 and Inverter unit.

2. Replace the Lift / Travel select switch.

Pressure sensor Blinks Input from Pressure sensor is out of error 11 times specific range.

1. Incorrect calibration of the Pressure 1. Perform the Pressure sensor sensor. calibration using handy tool.

2. Faulty electric lines between Pressure 2. Rectify the electric lines between sensor and CPU board M6.

Pressure sensor and CPU board M6.

3. Faulty Pressure sensor.

3. Replace the Pressure sensor.

SSJ00002

Rev 1

5-3

Chapter 5 Trouble shooting Error descriptions Platform height sensor error

LED Causes Countermeasures status Blinks Input from Platform height sensor is out 12 times of specific range.

1. Incorrect calibration of the Platform 1. Perform the Platform height sensor height sensor. calibration using handy tool.

2. Faulty electric lines between Platform 2. Rectify the electric lines between height sensor and CPU board M6.

Platform height sensor and CPU board M6.

3. Faulty Platform height sensor.

3. Replace the Platform height sensor.

Steering angle Blinks sensor error 13 times (for the machine equipped with optional steering dial only)

Input from Steering angle sensor is out of specific range.

1. Incorrect calibration of the Steering 1. Perform the Steering angle sensor angle sensor. calibration using handy tool.

2. Faulty electric lines between Steering 2. Rectify the electric lines between angle sensor and CPU board M6.

Steering angle sensor and CPU board 3. Faulty Steering angle sensor.

M6.

3. Replace the Steering angle sensor.

Override switch error

Blinks Both Limit and Release signals input 14 times at the same time.

1. Faulty electric lines between Override 1. Rectify the electric lines between switch and CPU board M6.

Override switch and CPU board M6.

2. Faulty Override switch.

2. Replace the Override switch.

Communication error

Blinks CPU board M6 and Inverter unit fail to 15 times communicate each other.

1. Faulty communication line between CPU board M6 and Inverter unit.

2. No power supply to Inverter unit.

3. Faulty Inverter unit 4. Faulty CPU board M6.

5-4

Rev 1

1. Rectify the communication line.

2. Check the terminal 1, 13, 24 (Key sw) of the Inverter unit for power supply.

3. Replace the Inverter unit.

4. Replace the CPU board M6.

SSJ00002

Chapter 5 Trouble shooting

Emergency operations When the Platform lift, Travel and Steering functions are disabled because of any problem, operate the machine following the instruction desclibed 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 result in death or serious injury.

Lower the platform and unload it before towing the machine.

Towing the machine with the platform lifted and / or loaded makes the machine unstable and may tip over result in death or serious injury.

Platform lift function 1. Lower the platform when the system error is occured Platform lift Up/Down function will be disabled when the system error occured.

In this case, Hold the Override switch in its “Release” position and operate the Lift switch at Lower control box to lower the platform.

Platform lift down limit system (CE model) will be disabled when using the Override switch.

Do not put your body or any object between scissor arms or may result serious injury or property damage.

Override switch

Fig. 5-2 Override switch

SSJ00002

5-5

Chapter 5 Trouble shooting 2. Lower the platform using emergency lowering handle When the Platform lift Down function is disabled even using emergency switch, lower the platform using emergency lowering handle that connected to the holding valve on lift cylinder.

Pull the emergency lowering handle shown in fig.5-2, so that the platform start lowering.

Do not put your body or any object between scissor arms or may result serious injury or property damage.

Fig. 5-2 Emergency lowering handle

5-6

SSJ00002

Chapter 5 Trouble shooting

Travel / Steering functions Free the parking brake and steering linkage and then tow the machine to escape the machine from working site, when the travel function is disabled.

Lower the platform and unload it before towing the machine.

Towing the machine with the platform lifted and/or loaded makes the machine unstable and may tip over result in death or serious injury.

Do not free the parking brake and/or steering linkage when the machine is on the slope, or the machine may run away result in death or serious injury.

1. Free the steering linkage 1) Remove the steering lock pin.

Steering lock pin

Steering cylinder

Tie rod

Fig. 5-3 Steering lock pin 2. Free the parking brake by Brake release connector 2) Set up the wheel chocks in front and/or rear of all tires.

3) Open the power unit box.

4) Disconnect the connector 12W, and then connect the Male side of 12W and Female side of 13W which is free.

5) Disconnect the connector 15W, and then connect the Male side of 15W and Female side of 16W which is free.

Connector 13W

Connector 12W Power unit box

SSJ00002

Connectors

Connector 15W

Connector 16W

Fig. 5-4 Connector

5-7

Chapter 5 Trouble shooting 6) Attach the sling chain or wire rope to the front or rear of hoisting rings.

7) Remove the wheel chocks carefully and then tow the machine slowly.

8) After towing the machine, Disconnect the connector 12W and 13W, and then connect Male and Female of the 12W. Disconnect the connector 15W and 16W, and then connect Male and Female of the 15W.

Hoisting ring

Hoisting ring Fig. 5-5 Hoisting ring

Make sure that the parking brakes work correctly after reconnect the connectors 12W and 15W, or the machine may run away result in death or serious injuly.

3. Free the parking brake by removing Electric magnetic brake 9) When the parking brakes are not freed by changing Brake release connectors because of dead battery or faulty electric magnetic brakes, remove the electric magnetic brakes from the travel motors.

See the page 4-23,24 “Electric magnetic brake” to remove and re-install the electric magnetic brakes.

5-8

SSJ00002

Chapter 6 Scheduled maintenance

Chapter 6 Scheduled maintenance

SSJ00002

6-1

Chapter 6 Scheduled maintenance

Scheduled inspection table Ｉｔｅｍｓ Battery Battery box

Power unit

Daily inspection Battery charge level, Battery fluid level

Monthly inspection Annual inspection Damage, Corrosion Specific gravity on terminals

Battery disconnect switch

Damage, Function

Battery charger

Damage, Function

Hydraulic oil tank

Oil leakage, Hydraulic oil level

Pump, Valves

Oil leakage

DC motor

Abnormal noise

Chassis frame

← ← Vibration, Excessive heat ←

← Damage on battery cables Replace hydraulic oil every two years or 2,400 hours ← ←

Cracks, Deformations ← Wear, Cut, Deformations Tire, Wheel ← ← (See page 2-5) Wheel nuts Looseness ← ← Abnormal noise, Looseness of nuts / Travel motor, Gearbox ← Damage bolts Chassis Electric magnetic brake Function ← ← Looseness of Steering linkage Cracks, Deformations ← stopper bolt Steering cylinder Oil leakage, Damage ← ← Wire harnesses, Hoses Oil leakage, Damage ← ← Lubrication Pothole protector Cracks, Deformations ← (See page 6-4) Scissor arms Cracks, Deformations ← ← Cracks, Safety prop ← Deformations pivot pins Damage ← ← Scissor Damage, Oil leakage, Lift cylinder ← ← arms Natural descent Holding valve Oil leakage, Function ← ← Lubrication Wear (Thickness) Wear pads (See page 6-4) (See page 2-10) Wire harnesses, Hoses Oil leakage, Damage ← ← Platform Cracks, Deformations ← ← Extension deck Cracks, Deformations ← ← Platform Hand rail Cracks, Deformations ← ← Wire harnesses Damage ← ← Damage, Function, Switches ← ← Smoothness Function, Abnormal Platform lift function ← ← noise, Vibration Lower Emergency stop button Damage, Function ← ← control Battery level indicator / Damage, Legibility ← ← hour meter LEDs Damage, Legibility ← ← Decals Legibility ← ←

6-2

SSJ00002

Chapter 6 Scheduled maintenance

Ｉｔｅｍｓ Switches, Joystick controller Platform lift function Upper control

Travel function Steering function

Emergency stop button LEDs Decals Motion alarm buzzer Tilt alarm buzzer Overload sensing system Platform lift up limit Safety system devices Travel speed limit system Platform lift down limit system Pothole protector interlock system Pre-start check Decals

Daily inspection Damage, Function, Smoothness Function, Abnormal noise, Vibration Function, Abnormal noise, Vibration Function, Abnormal noise, Vibration Damage, Function Damage, Legibility Legibility Sound Sound

Monthly inspection Annual inspection ←

←

←

←

←

←

←

←

← ← ← ← ←

← ← ← ← ←

Function

←

Function

←

←

Function

←

←

Function

←

←

Function

←

←

←

←

←

←

←

←

Platform stops at specific height Error indicator light is not blinking Legibility

Only trained and qualified people may conduct “Monthly” and / or “Annual” inspection.

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6-3

Chapter 6 Scheduled maintenance

Lubrications Lubrication intervals

Location

Lubricating point

Interval Every 2 years or 2,400 working ours

Hydraulic oil tank Chassis

Platform

Pothole actuator, 100 hours Pothole links Wear pad sliding surface 100 hours (CE, Japan model) Wear pad sliding surface 100 hours (CE, Japan model)

Lubricant Hydraulic oil (ISO VG22)

Quantity 5.3 litters [1.4 gal]

Grease (General)

--------

Grease (Molybdenum)

--------

Grease (Molybdenum)

--------

Greasing point

Pothole actuator

1,350 mm (4 ft 5 in) Pothole links

1,200 mm (3 ft 11 in)

Contacting surface between Pothole actuator and Pothole links

Wear pad sliding surface (CE, Japan model)

Fig. 6-1 Greasing point Recommended lubricant Manufacturers Shell oil Mobil oil

6-4

Rev 2

Hydraulic oil Tellus oil T22 DTE 22

Grease (General) Alvania EP grease 2 Mobilux EP2

Grease (Molybdenum) Alvania HDX 2 Mobilgrease special

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Chapter 6 Scheduled maintenance

Scheduled replacement parts The parts listed in the table below are related to safety devices. Faulty these parts may cause tip over and/or malfunction of safety devices result in death or serious injury.

It is very difficult to check inner deterioration of these parts by usual inspection therefore the parts must be replaced at desinated intervals.

Location

Items Platform height sensor

Chassis

Interval Every 8 years or 9,600 working hours

Tilt sensor A (for ANSI, Japan models) Every 8 years or 9,600 working hours Tilt sensor A and B (for CE model) Limit switches for pothole protector

Scissor Pressure sensor arms Lower Emergency stop button control box Upper Emergency stop button control box

Every 4 years or 4,800 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

Part number For ANSI, Japan models 382-0006400A for CE model 382-0006600

Quantity 1

324-06220A

1

324-0012300

2

For ANSI, Japan models 171-20005 for CE model 320-0002600

2 2

312-0000035A

1

320-0007201

1

320-0007201

1

The parts listed in the table below are important for machine’s main function and highly recommended to replace at designated intervals.

Location

Interval Every 8 years or Tilt sensor C 9,600 working hours Chassis Every 5 years or Battery disconnect switch 6,000 working hours Every 4 years or Platform Foot switch (Option) 4,800 working hours Every 4 years or Enable switch 4,800 working hours Lower control box Every 4 years or Lift switch 4,800 working hours Enable switch Every 4 years or (ANSI / Japan model) 4,800 working hours Lift / Travel select switch Every 4 years or (CE model) 4,800 working hours Upper Lift / Travel Every 5 years or control box joystick controller 6,000 working hours Every 4 years or Steering switch 4,800 working hours Every 5 years or Steering dial (Option) 6,000 working hours SSJ00002

Items

Part number

Quantity

382-0001600

1

320-0013100

1

320-04017

1

173-01212

1

173-01212

1

320-05325

1

320-05325

1

324-0000012

1

320-05325

1

324-0011900

1 Rev 1

6-5

Chapter 6 Scheduled maintenance

6-6

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Chapter 6 Scheduled maintenance

Periodical inspection check sheet Model

Spec No.

Serial No.

Hour meter

Date

The items marked (*) should be inspected only on the annual inspections.

Items Battery charge level Battery fluid level Battery Damage Corrosion on terminals Battery box Specific gravity * Battery disconnect switch Damage, Function Damage, Function Battery charger Damage on battery cables * Hydraulic oil tank Power unit

Pump, Valves DC motor Chassis frame Tire, Wheel Wheel nuts Travel motor, Gearbox

Chassis

Electric magnetic brake Steering linkage Steering cylinder Wire harnesses, Hoses Pothole protector Scissor arms Safety prop Pivot pins Lift cylinder

Scissor arms Holding valve Wear pads

Platform

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Wire harnesses, Hoses Platform Extension deck Hand rail Wire harnesses

Oil leakage Hydraulic oil level Oil leakage Abnormal noise, Vibration Excessive heat Cracks, Deformations Wear, Cut, Deformations Looseness Abnormal noise Damage Looseness of nuts / bolts Function Cracks, Deformations Looseness of stopper bolt Damage, Oil leakage Damage, Oil leakage Cracks, Deformations Lubrication Cracks, Deformations Cracks, Deformations Damage Damage, Oil leakage Natural descent Oil leakage Function Lubrication Wear (Thickness) * Damage, Oil leakage Cracks, Deformations Cracks, Deformations Cracks, Deformations Damage

Page 1/2 Inspector

Result

Remarks

Replacement interval Every 2 years or 2,400 hours

Serviceable limit : 103.3 mm (4.07 in)

6-7

Chapter 6 Scheduled maintenance Items Switches Platform lift function Lower control Emergency stop button

LEDs Decals

Damage, Legibility Legibility

Switches, Joystick controller

Damage, Function, Smoothness

Steering function Emergency stop button LEDs Decals Motion alarm buzzer Tilt alarm buzzer Overload sensing system Safety devices

6-8

Function Abnormal noise, Vibration Function Abnormal noise, Vibration Function Abnormal noise, Vibration Damage, Function Damage, Legibility Legibility Sound Sound Function

Platform lift up limit system Function Travel speed limit system

Function

Platform lift down limit system

Function

Pothole protector interlock system

Function

Pre-start check

Decals

Function Abnormal noise, Vibration Damage, Function Damage, Legibility

Travel function

Page 2/E Remarks

Damage, Function, Smoothness

Battery level indicator / hour meter

Platform lift function Upper control

Result

Platform stops at specific height Error indicator light is not blinking Legibility

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Chapter 7 Appendix

Chapter 7 Appendix

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7-1

Chapter 7 Appendix

Hydraulic circuit diagram (601-0014800)

7-2

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Electric circuit diagram (602-0070300)

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Chapter 7 Appendix

Rev 1

7-3

Electric wiring diagram (602-0070400) (1/2)

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Chapter 7 Appendix

Rev 1

7-4

Electric wiring diagram (602-0070400) (2/2)

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Chapter 7 Appendix

Rev 1

7-5

Chapter 7 Appendix

Battery cable arrangement Trojan T105 (CE, ANSI model) Cable 3

Battery (Trojan T105) x4

Cable 2

Cable 1

Fuse (200A)

Cable 5

Cable 4

Battery disconnect switch

GS Yuasa EB100 (CE, Japan model) Cable 5

Cable 2

Cable 3

Cable 4

Battery (GS Yuasa EB100) x4

Discriptions Cable 1 Cable 2 Cable 3 Cable 4 Cable 5 Cable 6 Fuse (200A)

Fuse (200A) Cable 1

Cable 6 Battery disconnect switch

Part number 327-0017900

Cable length 700 mm (2 ft 3.6 in)

327-0017800A

530 mm (1 ft 8.9 in)

320-02079

Fig. 7-1 Battery cable arrangement

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Rev 2

7-6

Chapter 7 Appendix

Water proof connector

A view

A view

B view Fig. 7-2 Water proof connector

7-7

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Chapter 7 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”.

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7-8

Chapter 7 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

7-9

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

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Chapter 7 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 0.38 ~ 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 2.74 ~ 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

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Bolt 10.9T SCM435 100 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 8T SCM435 100 kg/cm2

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

7-10

Chapter 7 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

7-11

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

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Chapter 7 Appendix

This page intensionally left blank.

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7-12