Aichi SV06ENS SV06ENL SV08ENL SV08EWL SV10EWL SERVICE MANUAL SSJ00066 - PDF DOWNLOAD

SERVICE MANUAL

SSJ00066

SV06ENS SV06ENL SV08ENL SV08EWL SV10EWL CE models

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: SV06ENS, SV06ENL, SV08ENL, SV08EWL and SV10EWL 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 (Scheduled replacement parts listed in the page 6-9 and 6-10).

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 AICHI’s policy.

Therefore, specifications of the machine are subject to change without prior notice.

This machine has been manufactured to conform to European Machinery Directive 2006/42/EC and European Standard EN280.

SSJ00066

a

Chapter A Introduction

Location of Serial number plate

Serial number plate

View A

A

Model code

Serial number

Date of manufacture

When you contact AICHI / AICHI Dealer, for technical support, parts order/inquiry, or questions related to warranty, please provide the model code, serial number, and date of manufacture.

b

SSJ00066

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.

SSJ00066

c

Index

Index Chapter A Introduction Location of Serial number plate Safety warnings

----------------------------------

a b c

Chapter 1 General information Specifications : SV06ENS Specifications : SV06ENL, SV08ENL Specifications : SV08EWL, SV10EWL Overall dimensions : SV06ENS Overall dimensions : SV06ENL, SV08ENL Overall dimensions : SV08EWL, SV10EWL Safety devices

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1-2 1-3 1-4 1-5 1-6 1-7 1-8

Chapter 2 Mechanical components Chassis Traveling and Steering system Travel gearbox Tire Scissor arms Wear pad Platform Pothole protector

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2-2 2-4 2-6 2-7 2-8 2-16 2-17 2-19

Chapter 3 Hydraulic components Locations of Hydraulic components Power unit Valve unit Holding valve (Platform lift down solenoid valve) Steering cylinder Lift cylinder

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3-2 3-3 3-4 3-6 3-7 3-8

i

SSJ00066

Index

Chapter 4 Electric components Locations of Electric components Upper control box Lift / Travel joystick controller Sub CPU board Lower control box Key switch Multi-function indicator Main CPU board “M6” Inverter unit Platform height sensor Steering angle sensors Travel motor (AC induction motor) Electric magnetic brake Battery charger Contactor Pressure sensors

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4-2 4-4 4-7 4-8 4-10 4-12 4-13 4-14 4-16 4-19 4-20 4-21 4-23 4-26 4-31 4-32

Chapter 5 Troubleshooting Troubleshooting by diagnostic code Troubleshooting by monitor Emergency operations Override switch Emergency lowering handle Brake release connector Manual release screw

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5-2 5-14 5-26 5-26 5-27 5-28 5-29

Chapter 6 Inspection and Maintenance Daily inspection procedures Periodical inspection procedures Lubrication Scheduled replacement parts Daily inspection sheet Periodical inspection check sheet Major alterations and repairs

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6-2 6-4 6-8 6-9 6-11 6-12 6-14

SSJ00066

ii

Index

Chapter 7 Appendix Hydraulic circuit diagram Electric circuit diagram (SV06ENS, SV06ENL, SV08ENL) Electric circuit diagram (SV08EWL, SV10EWL) Electric circuit diagram (Option) Electric wiring diagram (SV06ENS, SV06ENL, SV08ENL) Electric wiring diagram (SV08EWL, SV10EWL) Electric wiring diagram (Option) Water proof connector (Sumitomo) Water proof connector (Deutsch DT) Color code of Wires Tightening torque standard

iii

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7-2 7-3 7-6 7-9 7-10 7-14 7-18 7-19 7-21 7-23 7-24

SSJ00066

Chapter 1 General Information

Chapter 1 General Information

SSJ00066

1-1

Chapter 1 General Information

Specifications : SV06ENS Commercial Name / Model Code

Weight *3

Measurements

Performance

Platform Floor Height Rated Working Load

Max Min Total Extension Deck

Indoor (No Wind) Outdoor Total (Max. Wind Speed: Extension Deck 12.5 m/s)

SV06ENS / SV06E1NS 5,720 mm 880 mm 230 kg (2 persons + tools : 70 kg) 120 kg (1 person + tools : 40 kg) 230 kg (1 persons + tools : 150 kg) 120 kg (1 person + tools : 40 kg)

Maximum Allowable Tilt Angle Stowed Maximum Travel Speed *2 Elevated (Level Surface) Up Platform Lift Speed *1 Down Gradeability *1 *2 (Stowed) Inside Minimum Turning Radius Outside Standard Guardrail Overall Fold Down Raised Length Guardrail Folded Overall Width Standard Guardrail Overall Raised Fold Down Height Folded Guardrail Ground Stowed Pothole Protector Clearance Deployed Wheelbase Tread (Front, Rear) Platform Inner Standard Guardrail Dimensions (L x W x H) Fold Down Guardrail Extension Length Tires (Diameter x Width)

Front to Back: 3.0 degrees, Left to Right: 1.5 degrees 4.8 km/h 0.8 km/h 21 - 31 s / 4.8 m 24 - 36 s / 4.8 m 25 % (14 deg) 0 mm 1,880 mm 1,870 mm 1,870 mm 2,060 mm 810 mm 1,990 mm 1,990 mm 1,650 mm 130 mm 20 mm 1,510 mm 710 mm 1,770 x 680 x 1,110 mm 1,770 x 680 x 1,110 mm 900 mm 323 x 100 mm

Gross Weight

1,540 kg

Maximum Tire Loading Force

700 kg

Power source

AC Motor Power Output (Travel) 1.0 kW DC Motor Power Output (Platform Lift, Steering) 2.0 kW Battery Model Trojan T105 Battery Capacity 185 Ah Battery Voltage 6V x 4 Fixed Current, Fixed Voltage Charging Method AC 100 - 240 V Input Voltage Charger 45 - 65 Hz Frequency Maximum Output Current 25 A System Voltage DC 24 V Rated Hydraulic Pressure 17.2 Mpa (175 kg/cm2) 3.5 L Hydraulic Oil Tank Capacity This machine is intended for both indoor and outdoor use.

Advisable atmospheric temperature range: -20 to +40 deg C *1 Function speeds and gradeability assume there is 1 person on the platform and the battery is fully charged. *2 Travel speed and gradeability are subject to surface conditions and sufficient traction. *3 Weight informations are approximate and do not incorporate different option configurations.

1-2

SSJ00066

Chapter 1 General Information

Specifications : SV06ENL, SV08ENL

Weight *3

Measurements

Performance

Commercial Name / Model Code

SV06ENL / SV06E1NL SV08ENL / SV08E1NL Max 6,100 mm 7,770 mm Platform Floor Height Min 1,095 mm 1,215 mm Platform to 6.10 m 360 kg (2 persons + tools : 200 kg) Total Indoor 230 kg Platform to 7.77 m ----(No Wind) (2 persons + tools : 70 kg) Rated Extension Deck 120 kg (1 person + tools : 40 kg) Working 230 kg Platform to 6.00 m (Indoor use only) Outdoor Total Load (1 persons + tools : 150 kg) (Max. Wind Platform to 7.77 m ----(Indoor use only) Speed: 120 kg (Indoor use only) 12.5 m/s) Extension Deck (1 person + tools : 40 kg) Front to Back: 3.0 degrees, Left to Right: 1.5 degrees Maximum Allowable Tilt Angle 4.5 km/h Maximum Travel Speed *2 Stowed 0.8 km/h (Level Surface) Elevated Up 22 - 34 s / 5.0 m 26 - 40 s / 6.6 m Platform Lift Speed *1 Down 32 - 48 s / 5.0 m 29 - 45 s / 6.6 m 25 % (14 deg) Gradeability *1 *2 (Stowed) 0 mm Inside Minimum Turning Radius 2,250 mm Outside 2,300 mm Raised Overall Fold Down 2,485 mm Folded Length Guardrail 810 mm Overall Width Raised 2,205 mm 2,325 mm Overall Fold Down Folded 1,865 mm 1,990 mm Height Guardrail 130 mm Stowed Ground Pothole Protector 20 mm Deployed Clearance 1,880 mm Wheelbase Tread (Front, Rear) 685 mm 2,205 x 680 x 1,110 mm Platform Inner Dimensions (L x W x H) Extension Length 900 mm 406 x 125 mm Tires (Diameter x Width) Gross Weight

1,965 kg

Maximum Tire Loading Force

830 kg

2,100 kg

Power source

1.0 kW AC Motor Power Output (Travel) DC Motor Power Output (Platform Lift, Steering) 2.0 kW Battery Model Trojan T105 185 Ah Battery Capacity 6V x 4 Battery Voltage Charging Method Fixed Current, Fixed Voltage Input Voltage AC 100 - 240 V Charger Frequency 45 - 65 Hz 25 A Maximum Output Current DC 24 V System Voltage Rated Hydraulic Pressure 17.2 Mpa (175 kg/cm2) Hydraulic Oil Tank Capacity 5.7 L SV06ENL is intended for both indoor and outdoor use. SV08ENL is intended for indoor use only.

Advisable atmospheric temperature range: -20 to +40 deg C *1 Function speeds and gradeability assume there is 1 person on the platform and the battery is fully charged. *2 Travel speed and gradeability are subject to surface conditions and sufficient traction. *3 Weight informations are approximate and do not incorporate different option configurations.

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1-3

Chapter 1 General Information

Specifications : SV08EWL, SV10EWL

Weight *3

Measurements

Performance

Commercial Name / Model Code

SV08EWL / SV08E1WL SV10EWL / SV10E1WL Max 7,920 mm 9,680 mm Platform Floor Height Min 1,215 mm Platform to 7.92 m 450 kg (2 persons + tools : 290 kg) Indoor Total 320 kg ----Platform to 9.68 m (No Wind) (2 persons + tools : 160 kg) Rated Extension Deck 120 kg (1 person + tools : 40 kg) Working Outdoor Platform to 7.9 m 450 kg (1 persons + tools : 370 kg) Load (Max. Wind Total 320 kg ----Platform to 9.68 m Speed: (1 persons + tools : 240 kg) 12.5 m/s) Extension Deck 120 kg (1 person + tools : 40 kg) Maximum Allowable Tilt Angle 0 deg Maximum Travel Speed *2 Stowed 4.0 km/h (Level Surface) Elevated 0.8 km/h Up 32 - 48 s / 6.7 m 44 - 66 s / 8.5 m Platform Lift Speed *1 Down 40 - 60 s / 6.7 m 48 - 72 s / 8.5 m Gradeability *1 *2 (Stowed) 25 % (14 deg) Inside 0 mm Minimum Turning Radius Outside 2,580 mm Overall Fold Down Raised 2,500 mm Length Guardrail Folded 2,685 mm Overall Width 1,170 mm Overall Fold Down Raised 2,325 mm Height Guardrail Folded 1,990 mm 130 mm Ground Stowed Pothole Protector Clearance Deployed 20 mm Wheelbase 2,080 mm Tread (Front, Rear) 1,045 mm Platform Inner Dimensions (L x W x H) 2,405 x 1,035 x 1,110 mm Extension Length 1,270 mm 406 x 125 mm Tires (Diameter x Width) Gross Weight

2,770 kg

Maximum Tire Loading Force

1,100 kg

2,960 kg

Power source

1.0 kW AC Motor Power Output (Travel) 2.0 kW DC Motor Power Output (Platform Lift, Steering) Battery Model Trojan T105 Battery Capacity 185 Ah Battery Voltage 6V x 4 Fixed Current, Fixed Voltage Charging Method Input Voltage AC 100 - 240 V Charger Frequency 45 - 65 Hz Maximum Output Current 25 A DC 24 V System Voltage Rated Hydraulic Pressure 17.2 Mpa (175 kg/cm2) 5.7 L Hydraulic Oil Tank Capacity These machines are intended for both indoor and outdoor use.

Advisable atmospheric temperature range: -20 to +40 deg C *1 Function speeds and gradeability assume there is 1 person on the platform and the battery is fully charged. *2 Travel speed and gradeability are subject to surface conditions and sufficient traction. *3 Weight informations are approximate and do not incorporate different option configurations.

1-4

SSJ00066

Chapter 1 General Information

Overall dimensions : SV06ENS

R

mm

1 1,7

0

in ]

[73.6

.3

in ]

[67 m

m

680 mm [26.8 in]

70 R1,8

1,510 mm [59.4 in] 1,870 mm [73.6 in]

1,990 mm [78.3 in]

880 mm [34.6 in]

Deployed: 20 mm [0.787 in]

Stowed: 130 mm [5.1 in]

155 mm [6.1 in]

Retracted: 1770 mm [69.7 in] Extended: 2,670 mm [105.1 in]

710 mm [28.0 in] 810 mm [31.9 in]

SSJ00066

1-5

Chapter 1 General Information

Overall dimensions : SV06ENL 0 mm

,0 R2

25

[88.5

in]

.7

79 m[

in ]

m

680 mm [26.8 in]

R2,25

185 mm [7.28 in]

1,865 mm [73.3 in] 2,205 mm [86.7 in]

1,845 mm [72.6 in]

Stowed: 130 mm [5.1 in] Deployed: 20 mm [0.787 in]

1,095 mm [43.1 in]

155 mm [6.1 in]

Retracted: 2,205 mm [86.7 in] Extended: 3,105 mm [122.2 in]

685 mm [26.9 in]

1,880 mm [73.9 in] 2,300 mm [90.6 in]

810 mm [31.9 in]

Overall dimensions : SV08ENL (CE model) mm

,0 R2

[88.5

in]

.7

25

79 m[

in ]

m

680 mm [26.8 in]

0 R2,25

185 mm [7.28 in]

1,880 mm [73.9 in] 2,300 mm [90.6 in]

1,970 mm [77.6 in] 1,990 mm [78.2 in] 2,325 mm [91.4 in]

Stowed: 130 mm [5.1 in] Deployed: 20 mm [0.787 in]

1,215 mm [47.8 in]

155 mm [6.1 in]

Retracted: 2,205 mm [86.7 in] Extended: 3,105 mm [122.2 in]

685 mm [26.9 in] 810 mm [31.9 in]

1-6

SSJ00066

Chapter 1 General Information

R2,

580

mm

,3 R2

1.5

[10

in ]

.9

60

in ]

[92 m

m

1,035 mm [40.7 in]

Overall dimensions : SV08EWL

1,970 mm [77.6 in] 1,990 mm [78.2 in] 2,325 mm [91.4 in]

1,215 mm [47.8 in]

Deployed: 20 mm [0.787 in]

Stowed: 130 mm [5.1 in]

155 mm [6.1 in]

Retracted: 2,405 mm [94.7 in] Extended: 3,675 mm [144.7 in]

2,080 mm [81.8 in] 2,500 mm [98.4 in]

185 mm [7.28 in]

1,045 mm [41.1 in] 1,170 mm [46.1 in]

R2,

580

mm

,3 R2

1.5

[10

60

in ]

.9

in ]

[92 m

m

1,035 mm [40.7 in]

Overall dimensions : SV10EWL (CE model)

185 mm [7.28 in]

SSJ00066

2,080 mm [81.8 in] 2,500 mm [98.4 in]

1,970 mm [77.6 in] 1,990 mm [78.2 in] 2,325 mm [91.4 in]

1,215 mm [47.8 in]

Deployed: 20 mm [0.787 in]

Stowed: 130 mm [5.1 in]

155 mm [6.1 in]

Retracted: 2,405 mm [94.7 in] Extended: 3,675 mm [144.7 in]

1,045 mm [41.1 in] 1,170 mm [46.1 in]

1-7

Chapter 1 General Information

Safety devices No.

Name

Main function

1

Emergency stop Device

The machine is equipped with readily identifiable emergency stop buttons, located at both the upper and lower controls. It stops all of the movements of the machine when this button is pressed.

2

Emergency lowering

The emergency lowering handle is located at the rear side of the machine.

The handle is connected, by a cable, to the holding valve on the lift cylinder.

Pulling the handle opens the valve spool, lowering the platform.

3

Guardrail system

There are guardrails on all sides of the platform to help prevent persons in the platform from falling off the platform. The entry gate is part of the guardrail system and must be securely fastened after entering the platform.

4

Lanyard anchorage point

If the personal fall protective equipment is used to prevent persons in the platform from falling off the platform, attach to only the authorized lanyard anchorage points provided in the platform.

5

Pothole protector

When the platform has been raised, the pothole protectors come down automatically.

It provides pothole protection for traveling raised platform.

6

Pothole protector interlock

If the pothole protectors are unable to lock in position because an object is caught under it, the machine will not travel and the platform will not be raised.

7

Safety prop

The safety prop is a support pole that prevents the scissor arms from lowering when it is necessary to do maintenance work under the scissor arms or platform.

8

Battery disconnect system

The battery disconnector located in the left battery box cuts off the battery electrically. When electrical maintenance is performed, always disconnect the battery using the disconnector.

When the machine is on a slope, the tilt light goes on.

When the machine is tilted at or beyond the angles listed in the table below, this system sounds the tilt alarm buzzer, and disables the platform lift-up function and the travel function according to the platform height.

Model

SV06ENS

9

Platform lift up limit system

SV06ENL

SV08ENL

SV08EWL

SV10EWL

1-8

Tilt angle (Deg) Longitudinal

3

3

3

3

3

Lateral

Platform height (m)

1.5

5.7 (Full)

2

4.3

2.5

3.4

3

2.7

1.5

6 (Full)

2

4.5

2.5

3.7

3

3

1.5

7.7 (Full)

2

6

2.5

4.9

3

4

2

7.9 (Full)

2.5

6.7

3

6

2

9.7 (Full)

2.5

6.7

3

6

SSJ00066

Chapter 1 General Information

Name

No.

10 Enable switch

Main function The platform lift, travel and steering functions are disabled unless the enable switch is operated.

11

Enable switch cancel system

This system cancels the enable switch if any of the platform lift, travel and steering functions are not operated for more than 20 seconds after operating the enable switch. As well as, the system cancels the functions if the enable switch is not operated for more than 20 seconds after operating any of the platform lift, travel and steering function. At this time, the system failure light turns on. In this case, release all controls and the system failure light will turn off. And then operate again to enable the functions.

12

Overload sensing system

This system disables all of the functions, Overload warning light flashes and Overload buzzer sounds when the platform is overloaded.

Platform lift down limit 13 system

SSJ00066

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.

1-9

Chapter 1 General Information

This page intentionally left blank.

1-10

SSJ00066

Chapter 2 Mechanical Components

Chapter 2 Mechanical Components

SSJ00066

2-1

Chapter 2 Mechanical Components

Chassis SV06ENS Weight (327 kg) [721 lbs]

Battery box (Right)

Travel motor

Battery box (Left)

Steering cylinder

Tie rod

Front wheel

Earth belt

Pothole protector

Rear wheel

SV06ENL, SV08ENL Battery box (Right)

Weight (55 kg) [121 lbs]

Steering cylinder

Tie rod

Travel motor

Battery box (Left)

Weight (325 kg) [717 lbs]

Front wheel

Earth belt

Pothole protector

Rear wheel

Fig. 2-1 Chassis (SV06ENS, SV06ENL and SV08ENL)

2-2

SSJ00066

Chapter 2 Mechanical Components

SV08EWL, SV10EWL Battery box (Right)

Steering cylinder

Tie rod

Travel motor

Front wheel

Weight SV08EWL : 355 kg [783 lbs] SV10EWL : 555 kg [1,224 lbs]

Earth belt

Battery box (Left)

Pothole protector

Rear wheel

Fig. 2-2 Chassis (SV08EWL and SV10EWL)

SSJ00066

2-3

Chapter 2 Mechanical Components

Traveling and steering system

Tie rod Steering cylinder

Travel motor Electric magnetic brake

A Retaining ring

Flat washer

Chassis frame Retaining ring

* Boss for travel motor bracket

* Lock pin Flat washer

Bushing

Steering cylinder

* Composite bearing

Collar Tie rod

Travel motor bracket

Flat washer

Washer

Retaining ring Retaining ring

* Bushing

Wheel / Tire * Boss for tie rod Gearbox * Apply grease (Shell Albania EP2) to outer surface of composite bearings, bushing, lock pin and boss before assembling.

A detail Fig. 2-3 Traveling and steering system

2-4

SSJ00066

Chapter 2 Mechanical Components Travel motor bracket

Gearbox

Travel motor Bolt: M6 x4 (Attachement of travel motor) Tightenint torque: 7.2 N-m (0.7 kgf-m) [5.3 ft-lbs] Apply thread lock agent (Loctite 263)

* Bolt: 440-0000285 x5

Bolt: 011-60830 x6 Flat washer: 030-00008 x6 Tightening torque: 32.9 N-m (3.4 kgf-m) [24.3 ft-lbs] Apply thread lock agent (Loctite 263)

Front wheel Chassis frame

1

Cap

4

3 2

5

* Bolt: 440-0000285 x5

Hub

Castle nut: 021-03224 Cotter pin: 043-05045 Flat washer: 048-11035

Rear wheel

* Tighten wheel fixing bolts (440-0000285) in order shown in above figure.

Tighten them in three steps as below.

1. 28 - 42 N-m (2.9 - 4.2 kgf-m) [21 - 30 ft-lbs] 2. 91 - 112 N-m (9.3 - 11.4 kgf-m) [68 - 82 ft-lbs] 3. 142 - 163 N-m (14.5 - 16.6 kgf-m) [105 - 120 ft-lbs]

Fig. 2-4 Installation of wheel / Travel motor

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2-5

Chapter 2 Mechanical Components Travel gearbox Replace gearoil evely 1,200 working hours or annually.

Lubricant: Gear oil (ISO VG68) Quantity: 0.3 litter [0.08 gal] x2 Procedures 1) Rotate the wheel to place the drain and oil level plug at the bottom.

2) Set the oil pan under the drain and oil level plug.

3) Remove oil filler plug, and then drain and oil level plug to drain the old gear oil.

4) Rotate the wheel 90 degrees to place the oil filler plug at the top.

5) Fill the new gearoil from the oil filler plug until new oil comes out from the drain and oil level plug.

Gear oil grade: ISO VG68 Gear oil capacity: prox. 300 mL 6) Tighten both plugs.

Tightening torque: 8.2 - 10.7 N-m (0.83 - 1.10 kgf-m) [6.1 - 7.9 ft-lbs]

Oil filler plug

Drain and Oil level plug

Draining position

Filling position

Fig. 2-5 Travel gearbox

2-6

SSJ00066

Chapter 2 Mechanical Components Tire Check the tire for cut, deformation and wear of tread groove.

Replace if any tread groove is worn out.

For SV06ENS (378-0001107) 100 mm (3.9 in)

280 mm (11 in)

323 mm (12.7 in)

3.5 mm (0.14 in)

A

4.5 mm (0.18 in)

B

A

B Detail Tread groove

Section A-A

For SV06ENL, SV08ENL, SV08EWL and SV10EWL (378-0001074A) 125 mm (4.9 in)

3.5 mm (0.14 in)

406 mm (16 in)

354 mm (13.9 in)

C

4.5 mm (0.18 in)

D Detail Tread groove

C

D Section C-C

Fig. 2-6 Wheel / Tire

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2-7

Chapter 2 Mechanical Components

Scissor arms SV06ENS Wear pad

Lift cylinder

3rd arm (Inner) 2nd arm (Inner) 1st arm (Inner)

Safety prop 3rd arm (Outer) 2nd arm (Outer, Right) 1st arm (Outer)

2nd arm (Outer, Left) Wear pad

Chassis frame

SV06ENL Lift cylinder

Wear pad

Safety prop

3rd arm (Inner) 2nd arm (Inner) 1st arm (Inner)

3rd arm (Outer) 2nd arm (Outer, Right) 1st arm (Outer)

2nd arm (Outer, Left) Wear pad

Chassis frame

SV08ENL Wear pad

Lift cylinder

4th arm (Inner) 3rd arm (Inner) 2nd arm (Inner) 1st arm (Inner)

Safety prop 4th arm (Outer) 3rd arm (Outer, Right) 2nd arm (Outer, Right) 1st arm (Outer)

3rd arm (Outer, Left) 2nd arm (Outer, Left) Wear pad

Chassis frame

Fig. 2-7 Scissor arms (SV06ENS, SV06ENL, SV08ENL)

2-8

SSJ00066

Chapter 2 Mechanical Components

SV08EWL, SV10EWL Lift cylinder

Wear pad

3rd arm (Outer, Left) 2nd arm (Outer, Left) Wear pad

Safety prop

4th arm (Inner) 3rd arm (Inner) 2nd arm (Inner) 1st arm (Inner)

4th arm (Outer) 3rd arm (Outer, Right) 2nd arm (Outer, Right) 1st arm (Outer)

Chassis frame

Fig. 2-8 Scissor arms (SV08EWL, SV10EWL)

SSJ00066

2-9

1 4 7 10

A

C C

3 6 9

A E E

2 5 7 11

D D F

F

Pivot pin: 445-0000960

Wear pad: 454-0001136

B

SV06ENS

B

Chapter 2 Mechanical Components

Self lock nut: 028-70210

G 3rd arm (Inner) Wear pad: 454-0001135

Section A-A (No.1)

3rd arm (Outer)

Bolt: 011-31060

Section B-B (No. 2)

Bolt: 011-31060

Pivot pin: 445-0000959 (No. 3, 4) 445-0000957 (No. 9) Bolt: Retaining ring: 011-31060 041-30025

Retaining ring: 041-30025

Pivot pin: 445-0000957

Arm (Inner)

G G

Washer: 443-0000528

Arm (Outer)

Arm (Inner)

Arm (Outer)

Composite bearing: 341-0000238

Self lock nut: 028-70210

Self lock nut: 028-70210

Section C-C (No. 3, 4, 9)

Composite bearing: 341-0000238

Washer: 443-0000528

Section D-D (No. 5, 6, 7, 8) Bolt: 011-31060

1st arm (Outer)

1st arm (Inner)

1st arm (Inner)

G

Wear pad: 454-0001137

Chassis frame

Section E-E (No. 10)

Self lock nut: 028-70210

Pivot pin: 445-0000956

Section F-F (No. 11)

Chassis frame

Bolt

Self lock nut: 028-70210 0.5 - 1.0 mm

View G

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.

Apply grease (Shell Alvania EP2) to pivot pins before assembling.

Fig. 2-9 Detail of Scissor arms (SV06ENS)

2-10

SSJ00066

Chapter 2 Mechanical Components

A

1 4 7 10

C C D D

3 6 9

A E

# for SV06ENL ## for SV08ENL

2 5 8 11

E

B

B

SV06ENL

F F

A

1 4 7 10 13

D D

3 6 9 12

A

E

2 5 8 11 14

E

B

B

SV08ENL

C C F F

Pivot pin: 445-0000972

Self lock nut: 028-70210

Wear pad: 454-0001157 G

Wear pad: 454-0001156 3rd arm (Inner) # 4th arm (Inner) ##

Bolt: 011-31070

3rd arm (Outer) # 4th arm (Outer) ##

Section A-A (No.1)

Retaining ring: 041-30032

Section B-B (No. 2)

Pivot pin: 445-0000965 (No. 5) #, (No. 6, 8) ## 445-0000967 (No. 3) #

Bolt: 012-31020

Arm (Outer) G

Harden washer: 030-10010

Arm (Inner) Composite bearing: 341-0000234

Washer: 443-0000526

Self lock nut: 028-70210

Section C-C (No. 3, 5) #, (No. 6, 8) ## Bolt

Self lock nut: 028-70210 0.5 - 1.0 mm

View G

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.

Apply grease (Shell Alvania EP2) to pivot pins before assembling.

Fig. 2-10 Detail of Scissor arms (SV06ENL, SV08ENL) 1 SSJ00066

2-11

Chapter 2 Mechanical Components

A

1 4 7 10

C C D D

3 6 9

A E

B

B

SV06ENL # for SV06ENL ## for SV08ENL

2 5 8 11

E

F F

A

1 4 7 10 13

D D

3 6 9 12

A

E

B

B

SV08ENL 2 5 8 11 14

E

C C F F

Pivot pin: 445-0000965 (No. 6, 7, 8, 9) #, (No. 5, 7, 9, 10, 11, 12) ## 445-0000967 (No. 4) #, (No. 3, 4) ## Retaining ring: 041-30032 Bolt: 011-31070 G Arm (Outer) Washer: 443-0000526

Arm (Inner)

Composite bearing: 341-0000234

Self lock nut: 028-70210

Section D-D (No. 4, 6, 7, 8, 9) #, (No. 3, 4, 5, 7, 9, 10, 11, 12) ## Bolt: 011-31070

1st arm (Outer)

1st arm (Inner)

1st arm (Inner)

G

Wear pad: 454-0001158

Chassis frame

Section E-E (No. 10) #, (No. 13) ##

Self lock nut: 028-70210

Pivot pin: 445-0000964

Chassis frame

Section F-F (No. 11) #, (No. 14) ##

Bolt

Self lock nut: 028-70210 0.5 - 1.0 mm

View G

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.

Apply grease (Shell Alvania EP2) to pivot pins before assembling.

Fig. 2-11 Detail of Scissor arms (SV06ENL, SV08ENL) 2

2-12

SSJ00066

1 4 7 10 13

A

D D

3 6 9 12

A

E

B

SV08EWL, SV10EWL

B

Chapter 2 Mechanical Components

2 5 8 11 14

E

C C F F

Wear pad: 454-0001157 Pivot pin: 445-0000976

Self lock nut: 028-70210

G 4th arm (Inner) Wear pad: 454-0001156

Section A-A (No.1)

4th arm (Outer)

Shim: 443-0000553 (t=0.5) or 443-0000554 (t=1.5) Washer: 443-0000526

Bolt: 011-31070

Section B-B (No. 2) Pivot pin: 445-0000965 (No. 8, 10)

Bolt: 012-31020

Arm (Outer)

G

H

Harden washer: 030-10010

Arm (Inner)

Retaining ring: 041-30032

Composite bearing: 341-0000234

Self lock nut: 028-70210

Section C-C (No. 8, 10) Bolt

Self lock nut: 028-70210 0.5 - 1.0 mm

View G

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.

Apply grease (Shell Alvania EP2) to pivot pins before assembling.

Shim Washer

Boss of Outer arm 0.1 - 0.5 mm

H detail

Push outer arm against inner arm to minimize the crearance between inner and outer arms, and then adjust the crearance between boss of outer arm and shim to 0-1 - 0-5 mm by adding/reducing shims.

Fig. 2-12 Detail of Scissor arms (SV08EWL, SV10EWL) 1 SSJ00066

2-13

1 4 7 10 13

A 3 6 9 12

A

E

D D

2 5 8 11 14

E

Shim: 443-0000553 (t=0.5) or 443-0000554 (t=1.5)

B

SV08EWL, SV10EWL

B

Chapter 2 Mechanical Components

C C F F

Pivot pin: (No. 3, 4, 5, 6, 7, 9, 11, 12)

Washer: 443-0000526

Bolt: 011-31070

G

H Arm (Outer)

Retaining ring: 041-30032

Arm (Inner)

Composite bearing: 341-0000234

Self lock nut: 028-70210

Section D-D (No. 3, 4, 5, 6, 7, 9, 11, 12) Bolt: 011-31070

1st arm (Outer)

1st arm (Inner)

1st arm (Inner)

G

Wear pad: 454-0001158

Chassis frame

Self lock nut: 028-70210

Pivot pin: 445-0000974

Chassis frame

Section F-F (No. 14)

Section E-E (No. 13) Bolt

Self lock nut: 028-70210 0.5 - 1.0 mm

View G

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.

Apply grease (Shell Alvania EP2) to pivot pins before assembling.

Shim Washer

Boss of Outer arm 0.1 - 0.5 mm

H detail

Push outer arm against inner arm to minimize the crearance between inner and outer arms, and then adjust the crearance between boss of outer arm and shim to 0-1 - 0-5 mm by adding/reducing shims.

Fig. 2-13 Detail of Scissor arms (SV08EWL, SV10EWL) 2

2-14

SSJ00066

Chapter 2 Mechanical Components Link for Lift cylinder (SV08ENL, SV08EWL, SV10EWL) Link J

K

J

K

Roller

L

4th arm (Inner) 3rd arm (Inner) Lift cylinder

Pivot pin

3rd arm (Inner)

Bolt: 011-31070

Pivot pin

Link

3rd arm (Inner)

Lift cylinder

Link

G

Self lock nut: 028-70210

Self lock nut: 028-70210

Section J-J

Bolt: 011-31055 Apply thread lock agent (Loctite 263)

Section K-K

Harden washer: 030-10010 x2

Pivot pin Cap screw: 013-61020 x2 Tightening torque: 39.0 - 47.6 N-m (4.0 - 4.8 kgf-m) [29 - 35 ft-lbs]

Roller

Link

Key plate

View L

Bolt

Self lock nut: 028-70210 0.5 - 1.0 mm

View G

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.

Apply grease (Shell Alvania EP2) to pivot pins before assembling.

Fig. 2-14 Link for Lift cylinder

SSJ00066

2-15

Chapter 2 Mechanical Components

Wear pad Wear pads for SV06ENL, SV08ENL, SV08EWL and SV10EWL

Wear pads for SV06ENS

454-0001156A (Upper, Rear) *1

454-0001135A (Upper, Rear) *1

40 mm (1.57 in)

Outside

45 mm (1.77 in)

Nominal height: 120 mm [4.72 in] Serviceable limit: 118.3 mm [4.66 in]

454-0001136B (Upper, Front) *1

454-0001157B (Upper, Front) *1

100 mm (3.93 in)

Outside

35 mm (1.38 in)

40 mm (1.57 in)

120 mm (4.72 in)

60 mm (2.36 in)

Inside

Inside 80 mm (3.14 in)

Outside

45 mm (1.77 in)

Nominal height: 120 mm [4.72 in] Serviceable limit: 118.3 mm [4.66 in]

454-0001137A (Lower, Front) *2

454-0001158A (Lower, Front)

ut

C

C

ut

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

x2

27.5 mm (1.08 in)

105 mm (4.13 in)

52.5 mm (2.07 in)

C

C

ut

ut

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

x2

Inside

x2

Inside

60 mm (2.36 in)

Outside

120 mm (4.72 in)

52.5 mm (2.07 in)

105 mm (4.13 in)

2

2

x ut

x ut

C

75 mm (2.95 in)

C

64 mm (2.51 in)

35 mm (1.38 in)

60 mm (2.36 in)

Inside Inside

39.5 mm (1.56 in)

Nominal height: 57 mm [2.24 in] Serviceable limit: 55.3 mm [2.18 in]

Outside

90 mm (3.54 in)

57 mm (2.24 in)

x2 Outside

90 mm (3.54 in)

44 mm (1.73 in)

Nominal height: 90 mm [3.54 in] Serviceable limit: 88.3 mm [3.48 in]

Check the height of the wear pads.

Replace them if the height is shorter than the serviceable limit. *1 Install the wear pads so that the long side becomes upper position. *2 Install the wear pads so that the short side becomes upper position.

Fig. 2-15 Wear pad

2-16

SSJ00066

Chapter 2 Mechanical Components

Platform SV06ENS Upper control box

Extension deck release handle D

A B Manual holder Extension deck SV06ENL, SV08ENL

E

Door

Extension deck release handle

Upper control box

C

D

A B Manual holder Extension deck SV08EWL, SV10EWL

E

Door

Extension deck release handle

Upper control box C D C

A B Manual holder Extension deck

Door

E

Fig. 2-16 Platform SSJ00066

2-17

Chapter 2 Mechanical Components Extension deck Platform

Platform

Roller Pivot pin

A Detail

Roller Pivot pin

Bolt: 011-30820 Spring washer: 030-20008 Flat washer: 030-00008 Apply thread lock agent (Loctite 263)

Extension deck

B Detail

Extension deck Bolt: 011-30855 Self lock nut: 028-70208

Bolt: 011-30860 Self lock nut: 028-70208

Bolt: 011-30855 Self lock nut: 028-70208 * Platform Extension deck release handle

C Detail

D Detail

3 mm [0.12 in]

8 - 12 mm [0.32 - 0.47 in]

0 - 2 mm [0 - 0.08 in]

Hook

E Detail

Door

Lever SV06ENS, SV06ENL and SV08ENL : 11 - 15 mm [0.44 - 0.59 in] SV08EWL and SV10EWL : 9 - 13 mm [0.36 - 0.43 in] Adjustment of clearance around door

Fig. 2-17 Detail of Paltform

2-18

SSJ00066

Chapter 2 Mechanical Components

Pothole protector 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.

SV06ENS Tightening torque: 39 - 47 N-m (4.0 - 4.7 kgf-m) [29 - 34 ft-lbs] Pin Apply grease (Shell Alvania EP2) Pothole link (LH) Pothole actuator

Pothole link (RH) Lock pin (Pothole link - Pothole guard) Insert it from the front side.

Apply grease (Shell Alvania EP2) Lock pin (Frame - Pothole guard) Apply grease (Shell Alvania EP2) Tightening torque: 39.0 - 47 N-m (4.0 - 4.7 kgf-m) [29.0 - 35.0 ft-lbs] Pothole guard (LH)

Pothole limit switch: 5C1-0918500 x2 Tightening torque: 4.9 - 5.8 N-m (0.5 - 0.6 kgf-m) [3.7 - 4.3 ft-lbs] Apply thread lock agent (Loctite 263)

Pothole guard (RH)

View from Front Apply grease (Shell Alvania EP2) to contacting surface between pothole actuator and pothole links

Lock pin (Frame - Pothole link) Apply grease (Shell Alvania EP2)

View from Rear

Spring

Fig. 2-18 Pothole protector (SV06ENS) SSJ00066

2-19

Chapter 2 Mechanical Components

SV06ENL, SV08ENL Tightening torque: 39 - 47 N-m (4.0 - 4.7 kgf-m) [29 - 34 ft-lbs]

Pin Apply grease (Shell Alvania EP2)

Pothole link (LH)

Pothole actuator

Pothole link (RH) Lock pin (Pothole link - Pothole guard) Insert it from the front side.

Apply grease (Shell Alvania EP2) Lock pin (Frame - Pothole guard) Apply grease (Shell Alvania EP2) Tightening torque: 39.0 - 47 N-m (4.0 - 4.7 kgf-m) [29.0 - 35.0 ft-lbs] Pothole guard (LH)

Pothole limit switch: 5C1-0918500 x2 Tightening torque: 4.9 - 5.8 N-m (0.5 - 0.6 kgf-m) [3.7 - 4.3 ft-lbs] Apply thread lock agent (Loctite 263)

Pothole guard (RH)

View from Front Apply grease (Shell Alvania EP2) to contacting surface between pothole actuator and pothole links

Lock pin (Frame - Pothole link) Apply grease (Shell Alvania EP2)

Spring

View from Rear

Fig. 2-19 Pothole protector (SV06ENL, SV08ENL)

2-20

SSJ00066

Chapter 2 Mechanical Components

SV08EWL SV10EWL Tightening torque: 39 - 47 N-m (4.0 - 4.7 kgf-m) [29 - 34 ft-lbs] Pin Apply grease (Shell Alvania EP2)

Pothole actuator

Pothole link (LH)

Pothole link (RH) Lock pin (Pothole link - Pothole guard) Insert it from the front side.

Apply grease (Shell Alvania EP2) Lock pin (Frame - Pothole guard) Apply grease (Shell Alvania EP2)

Pothole guard (LH)

Spring

Tightening torque: 39.0 - 47 N-m (4.0 - 4.7 kgf-m) [29.0 - 35.0 ft-lbs]

Pothole guard (RH)

Pothole limit switch: 5C1-0918500 x2 Tightening torque: 4.9 - 5.8 N-m (0.5 - 0.6 kgf-m) [3.7 - 4.3 ft-lbs] Apply thread lock agent (Loctite 263)

View from Front Apply grease (Shell Alvania EP2) to contacting surface between pothole actuator and pothole links

Lock pin (Frame - Pothole link) Apply grease (Shell Alvania EP2)

View from Rear

Fig. 2-20 Pothole protector (SV08EWL, SV10EWL)

SSJ00066

2-21

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 to hold them in stowed position.

Pothole guard

Pothole link

KBZ00002

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

Fig. 2-21 Function of the Pothole protector

2-22

SSJ00066

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

Operating position

Limit switches

Limit switches

Pothole L/S (Right)

Pothole L/S (Right) Fuse holder

Inverter unit SW3 (19)

Fuse holder

28G

Pothole L/S (Left) 29G

28G

Inverter unit SW3 (19)

Pothole L/S (Left) 29G

Fig. 2-22 Pothole limit switches Relay CR-10 is closed, 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 opened when the pothole guards are stowed.

SSJ00066

2-23

Chapter 2 Mechanical Components

This page intentionally left blank.

2-24

SSJ00066

Chapter 3 Hydraulic Components

Chapter 3 Hydraulic Components

SSJ00066

3-1

Chapter 3 Hydraulic Components

Locations of Hydraulic components Steering cylinder

Valve unit

Power unit

SV06ENS, SV06ENL and SV08ENL Valve unit

Steering cylinder

Power unit

SV08EWL and SV10EWL

A

Holding valve (Platform lift down solenoid valve)

Lift cylinder

View A

Fig. 3-1 Location of Hydraulic components

3-2

SSJ00066

Chapter 3 Hydraulic Components

Power unit (300-0000183 for SV06ENS 300-0000182 for SV06ENL, SV08ENL, SV08EWL and SV10EWL) The power unit consists of DC motor, Gear pump, Relief valve, Check valve and Hydraulic oil tank to supply pressurized oil to Platform lift circuit and Steering circuit.

Specifications

Part No.

300-0000183

Hydraulic oil tank Oil capacity

300-0000182

DC motor

Rated voltage

3.5 liters [0.92 gal] DC24V

Gear pump

Displacement

3.18 cc/rev

Relief valve

Preset pressure

17.2 - 17.7 MPa (175 - 180 kg/cm2) [2,500 - 2,550 PSI]

Relief valve Tightening torque : 17.5 - 19.8 N-m (1.8 - 2.0kgf-m) [13.0 - 14.6 ft-lbs]

5.0 liters [1.32 gal]

Oil filler cap

T port

Terminal x2 Tightening torque : Max 6.2 N-m (0.63 kgf-m) [4.5 ft-lbs]

P port

DC motor Check valve Tightening torque : 24.4 - 27.1 N-m (2.5 - 2.7kgf-m) [18 - 20 ft-lbs]

Oil reservoir Screw x4 Tightening torque : 5.1 - 7.3 N-m (0.52 - 0.74 kgf-m) [3.8 - 5.3 ft-lbs]

Clamp band Tightening torque : 2.2 - 2.8 N-m (0.23 - 0.28 kgf-m) [1.7 - 2.0 ft-lbs]

Hydraulic circuit P

T R1

Hydraulic pump Suction strainer

Oil reservoir

Main relief valve (R1) --Preset pressure : 17.2 +0.5 / 0 Mpa (175 +5 / 0 kgf/cm2) [2,500 +50 / 0 PSI]

Fig. 3-2 Power unit SSJ00066

3-3

Chapter 3 Hydraulic Components

Valve unit (302-0059300) The valve unit is located in the power unit box to control steering and platform lift Up Specifications.

Rated voltage

DC24V Platform lift up sol.V

Coil resistance

28.5 ohms (at 20 deg C [68 deg F])

Steering sol.V Rated pressure

33.8 ohms (at 20 deg C [68 deg F])

Maximum flow volume (P port)

15 liters / min [4.0 gal / min]

D port (G 3/8)

17.2 MPa (175 kg/cm2) [2,500 PSI]

G port (G 1/4) Platform Lift Up solenoid valve

C port (G 3/8)

P port

Plug for Orifice

T port Steering solenoid valve

B port (G 1/4)

A port (G 1/4)

Hydraulic circuit

C

D

A B

Platform Lift Up solenoid valve

Steering solenoid valve

G P

T

Orifice (d = 3.0 mm)

Fig. 3-3 Valve unit

3-4

SSJ00066

Chapter 3 Hydraulic Components Pressure gauge connecting procedures 1) Raise up the platform, set up the safety prop, and then lower the platform until the safety prop supports the platform.

Use safety prop to support the scissor arms when working under the platform / scissor arms to avoid accidental descent of the platform 2) Turn off the key switch.

3) Take the cover shown in Fig 3-4 off from the rear end of the chassis frame.

Take the cover off SV06ENS (Bolt : M6 x 4) SV06ENL, SV08ENL (Bolt : M6 x 5) SV08EWL, SV10EWL (Bolt : M6 x 9)

Fig. 3-4 Cover on the rear end of the chassis frame 4) Plug off the G-port on the valve unit.

Wait for 1 minute after turning off the key switch to depressurize the circuit before removing the plug.

5) Install adaptor on the G-port.

6) Connect pressure gauge to the adaptor.

Pressure gauge disconnecting procedures 1) Raise up the platform, set up the safety prop, and then lower the platform until the safety prop supports the platform.

2) Turn off the key switch, and then wait for 1 minute to depressurize the circuit.

3) Disconnect the pressure gauge.

4) Remove the adaptor from the G-port of the valve unit.

5) Plug the G-port. Tighten the plug with specific tightening torque.

Specific tightening torque : 20.6 - 25.0 N-m (2.1 - 2.5 kgf-m) [15.2 - 18.4 ft-lbs] 6) Wipe off spreaded hydraulic oil if any.

7) Put back the cover on the rear end of the chassis frame.

SSJ00066

3-5

Chapter 3 Hydraulic Components

Holding valve (Platform lift down solenoid valve) (302-0059400) The holding valve is attached on the lift cylinder to prevent it from natural descent.

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

Specifications

Rated voltage

DC24V

Coil resistance

33.8 ohms (at 20 deg C [68 deg F])

Rated pressure

17.2 MPa (175 kg/cm2) [2,500 PSI]

Maximum flow volume

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.

Platform lift down solenoid valve

Check valve

Plug for orifice

A port (G 3/8)

Hydraulic circuit

C port (7/16-20 UNF-2B) Tightening torque of pressure sensor : 30 - 35 N-m (3.1 - 3.6 kgf-m) [23 - 26 ft-lbs]

A

B port

Orifice (d = 1.9 mm)

C : for Pressure sensor (Main)

B : To Lift cylinder Check valve

Platform lift down solenoid valve

Fig. 3-5 Holding valve

Use safety prop properly to support the Scissor arms when removing the Holding valve.

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

3-6

SSJ00066

Chapter 3 Hydraulic Components

Steering cylinder (303-0073900)

2 - G 1/4

Tightening torque: 147 - 167 N-m (15 - 17 kgf-m) [109 - 123 ft-lbs]

No. 1 2 3

Descriptions Cylinder tube Piston rod Piston

4 5 6 7

Self-lock nit Slipper seal * Wear ring * Guide

8 9 10

Bushing Ring O-ring *

11 12 13 14

Dust seal * U-packing * Snap ring O-ring *

15

Bushing 㻖㻌㻯㼛㼚㼠㼑㼚㼠㼟㻌㼛㼒㻌㻿㼑㼍㼘㻌㼗㼕㼠

Fig. 3-6 Steering cylinder

SSJ00066

3-7

Chapter 3 Hydraulic Components

for for for for

SV06ENS SV06ENL SV08ENL SV08EWL and SV10EWL)

D3

W2

W1

Lift cylinder (303-0077500 303-0077600 303-0077700 303-0077800

Port for Pressure sensor (Sub) (7/16-20 UNF-2B) Tightening torque of pressure sensor : 30 - 35 N-m (3.1 - 3.6 kgf-m) [23 - 26 ft-lbs]

T1 T2

D4

T3

D2

D1

D5

Stroke : L2 Retracted length : L1 No. 1

Descriptions Buck up ring *

No. 11

Descriptions Rod

2 3 4

Bushing Bushing * Fitting

12 13 14

Rod end Rod seal * Cylinder tube

5 6 7 8

Nylon ring * O-ring * O-ring * Piston

15 16 17

Wear ring * Wiper * Wire ring

9 10

Piston seal * Retainer 㻖㻌㻯㼛㼚㼠㼑㼚㼠㼟㻌㼛㼒㻌㻿㼑㼍㼘㻌㼗㼕㼠

Fig. 3-7 Lift cylinder

3-8

SSJ00066

Chapter 3 Hydraulic Components

Lift cylinder

SV06ENS

SV06ENL

SV08ENL

SV08EWL

SV10EWL

303-0077500

303-0077600

303-0077700

303-0077800

303-0077800

Diameter D1

mm

45

55

55

60

60

inch

1.77

2.17

2.17

2.36

2.36

Diameter D2

mm

70

80

80

100

100

inch

2.76

3.15

3.15

3.94

3.94

Diameter D3

mm

80

90

90

114.3

114.3

inch

3.15

3.54

3.54

4.5

4.5

Diameter D4

mm

32.02 - 32.15

32.02 - 32.15

32.02 - 32.15

32.02 - 32.15

32.02 - 32.15

inch

1.261 - 1.265

1.261 - 1.265

1.261 - 1.265

1.261 - 1.265

1.261 - 1.265

Diameter D5

mm

32.02 - 32.15

32.02 - 32.15

32.02 - 32.15

32.02 - 32.15

32.02 - 32.15

inch

1.261 - 1.265

1.261 - 1.265

1.261 - 1.265

1.261 - 1.265

1.261 - 1.265

Width

mm

189 - 191

189 - 191

189 - 191

189 - 191

189 - 191

W1

inch

7.45 - 7.51

7.45 - 7.51

7.45 - 7.51

7.45 - 7.51

7.45 - 7.51

Width

mm

189 - 191

94 - 96

94 - 96

121 - 123

121 - 123

W2

inch

7.45 - 7.51

3.71 - 3.77

3.71 - 3.77

4.77 - 4.84

4.77 - 4.84

Retracted length L1

mm

1281 - 1285

1487 - 1491

1487 - 1491

1702 - 1706

1702 - 1706

inch

50.44 - 50.59

58.55 - 58.70

58.55 - 58.70

67 01 - 67.16

67 01 - 67.16

Stroke L2

mm

1094 - 1097

1148 - 1151

1183 - 1186

1440 - 1443

1440 - 1443

43.08 - 43.18 81 - 95 8.3 - 9.6 60 - 70 380 - 406 38.8 - 41.4 281 - 299 183 - 210 18.7 - 21.4 135 - 154

45.20 - 45.31 81 - 95 8.3 - 9.6 60 - 70 434 - 460 44.3 - 46.9 321 - 339 295 - 321 30.1 - 32.7 218 - 236

46.58 - 46.69 81 - 95 8.3 - 9.6 60 - 70 434 - 460 44.3 - 46.9 321 - 339 295 - 321 30.1 - 32.7 218 - 236

56.70 - 56.81 81 - 95 8.3 - 9.6 60 - 70 543 - 569 55.4 - 58.0 401 - 419 295 - 321 30.1 - 32.7 218 - 236

56.70 - 56.81 81 - 95 8.3 - 9.6 60 - 70 543 - 569 55.4 - 58.0 401 - 419 295 - 321 30.1 - 32.7 218 - 236

inch N-m Tightening kgf-m torque T1 ft-lbs N-m Tightening kgf-m torque T2 ft-lbs N-m Tightening kgf-m torque T3 ft-lbs

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

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

SSJ00066

3-9

Chapter 3 Hydraulic Components

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3-10

SSJ00066

Chapter 4 Electric Components

Chapter 4 Electric Components

SSJ00066

4-1

Chapter 4 Electric Components

Locations of Electric components Travel motor (Right)

Travel motor (Left)

Inverter unit

Pothole limit switch

Battery

Battery charger

Alarm buzzer / Horn

Relay CR-10

Lower control box

Fuse (300A)

Contactor

SV06ENS

Travel motor (Right)

Travel motor (Left)

Inverter unit

Pothole limit switch

Battery

Contactor

Battery charger

Fuse (300A)

Lower control box

Relay CR-10

Alarm buzzer / Horn

SV06ENL and SV08ENL

Fig. 4-1 Location of Electric components

4-2

SSJ00066

Chapter 4 Electric Components Travel motor (Right)

Inverter unit (Right)

Pothole limit switch

Battery

Lower control box

Battery charger

Steering sensor

Travel motor (Left)

Inverter unit (Left)

Contactor

Fuse (300A)

Relay CR-10

Alarm buzzer / Horn

SV08EWL and SV10EWL Upper control box

Pressure sensor (Sub) Pressure sensor (Main)

Platform height sensor

Fig. 4-2 Location of Electric components

SSJ00066

4-3

Chapter 4 Electric Components

Upper control box 11

12

10 9

5 6 7 * SV06ENL (Indoor) (Outdoor)

* SV08ENL SV10EWL

2

3

1

*4

(Zone A) (Zone B)

Bracket

8

CN.96

Clearance : More than 5 mm CN.90 (Metal connector) Nut

Cap Lock washer CN.98

Gasket

CN.95

CN.98

Fig. 4-3 Upper control box No. Descriptions

Part number

Switch cover / cap

1 Emergency stop button

320-0007201

2 Horn button

320-0027600

320-0028900

3 Lift / Travel select switch

173-01101

173-40000

173-01101

173-40000

4

Capacity select switch (SV06ENL, SV08ENL and SV10ENL)

5 Lift / Travel joystick controller with Steering switch 6 Steering switch

324-0024101

7 Enable switch 8 Sub CPU board 9 Overload warning light 10 Tilt warning light

G999290097

11 System failure light 12 Battery level indicator

4-4

SSJ00066

Chapter 4 Electric Components Electric schematic Upper control box Lift / Travel joystick controller

Sub CPU board

Speed Joystick +5V Joystick Speed signal Joystick GND

Power Output GND

Direction select Power Output GND

Right

Steering s/w

Left

Tilt alarm buzzer Joystick +5V Joystick Direction select signal Joystick GND Overload warning light Steer Right

Tilt warning light

Steer Left

Enable s/w

System failure light

Enable s/w

Battery level indicator 4 Travel

Lift / Travel select s/w

Lift

Mode select Travel

Battery level indicator 3 Battery level indicator 2

Mode select Lift

Battery level indicator 1

Horn button

Horn button Indoor / Zone A Outdoor / Zone B

Emergency stop button

Capacity select switch (SV06ENL) Upper control box

Capacity select s/w

Capacity select switch (SV08ENL and SV10EWL) Sub CPU board

Upper control box

Sub CPU board

Joystick +5V

Joystick +5V

Indoor

Zone A

Outdoor

Zone B

Capacity select s/w

Fig. 4-4 Electric schematic

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4-5

Chapter 4 Electric Components Connectors

To Lift / Travel Joystick controller

98 (Plug)

Black

98 (Receptacle)

Black

Joystick +5V Joystick Speed signal Joystick GND Joystick +5V Joystick Direction select signal Joystick GND Steer Right Steer Left Enable s/w Power for Sttering sw

Lift

Travel

Lift / Travel select s/w

Horn button

Capacity select switch (SV06ENL, SV08ENL and SV10EWL)

Delete

Indoor / Zone A

Upper control box

Emergency stop button

Female, Black

Male, Black

90 Metal connector (Receptacle)

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4-6

Capacity select s/w Outdoor / Zone B

Sub CPU board

Fig. 4-5 Connectors

Chapter 4 Electric Components

Lift / Travel joystick controller (324-0024101) Joystick controller is installed on the upper control box to control the Platform lift, Travel and Steering.

Left

Steering Right

Y

Steering Left

G

+5V

L

Enable switch

V

+5V

R

GND

B

Speed signal

Br

+5V

LW

GND

WB

Steering switch

Right 20 deg (Down / Rev)

20 deg (Up / Fwd)

Enable switch

Enable switch

Speed control

O

Direction signal

Direction select

Speed control Speed control output 4.0V Direction select

2.5V 1.0V Fwd Full

Neutral

Rev Full

Fig. 4-6 Lift / Travel Joystick controller

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4-7

Chapter 4 Electric Components

Sub CPU board Sub CPU board is installed in the upper control box to input signals from Joystick controller and switches on the upper control box.

It communicates with Main CPU board M6 in the lower control box and inverter unit to control each function.

It is equipped with LEDs to indicates system failure, overload warning, Tilt warning and battery level.

Upper control panel

4 mm (0.16 in)

Sub CPU board

Connector J1

Connector

J1

Fig. 4-7 Sub CPU board

4-8

SSJ00066

Chapter 4 Electric Components Input / Output characteristics &RORU FRGH RI ZLUHV 6LJQDO 1R &RQQHFWRU 1R 3LQ 1R

Lift / Travel joystick controller Power Output GND

5 6 9 - : .$ - % .* -

+5 volts 0 ~ +5 volts (Lift / Travel speed signal) GND

Power Output GND

5< 6 9 - :< .$ - %< .* -

+5 volts 0 ~ +5 volts (Direction select signal) GND

Enable s/w Steering s/w

Right Left

3 ' -

+5 volts Enable switch (On)

:% ' - 2 ' -

+5 volts Steering switch (Right) +5 volts Steering switch (Left)

5% ' - *\ ' -

Lift / Travel select switch +5 volts (Travel) +5 volts (Lift)

Lift / Travel select s/w Travel Lift

Horn button *% ' -

Capacity select s/w (SV06ENL, SV08EWL and SV10EWL) Indoor / Zone A Outdoor / Zone B

/ ' - <% ' - 5 ' -

Battery charger Battery charge interlock Output +24V when the battery charger is not charging.

Fuse (300A)

+5 volts

Capacity select switch +5 volts (Indoor / Zone A) +5 volts (Outdoor / Zone B) +5 volts

Tilt alarm buzzer Overload warning light

Emergency stop button (Lower)

Tilt warning light

Emergency stop button (Upper)

System failure light Battery level indicator 4

Relay Key s/w CR-10

Battery level indicator 3 Battery level indicator 2

Fuse (10A)

Battery level indicator 1

Battery (24V)

5 9V - 5 9V - % *1' - % *1' -

3/ &$1B+ - 3/ &$1B70 - %5 &$1B+ - %: &$1B/ -

SSJ00066

+24 volts Power for CPU +24 volts Power for CPU GND GND

Communication lines among * Main CPU board M6, * Sub CPU board, * Inverter unit (Right and Left) * Battery level indicator / Hourmeter

4-9

Chapter 4 Electric Components

Lower control box CN.53 CN.51 CN.55 CN.54 CN.74

CN.52 CN.56 Limit CN.50 Release

View A-A 1

2

3

5

8

7

6

4

No. Descriptions

Part number

1 Key switch

378-0000701

Switch cap

2 Emergency stop button

320-0007201

3 Enable / Pre-operation check switch

173-01212

173-40000

4 Lift switch

173-01212

173-40000

5 Multi-function indicattor / Hourmeter

381-0000058

6 Battery charger indicator light

368-0000132

7 Override switch

173-01102

8 CPU board M6 (Main)

G999290128

173-40000

Fig. 4-8 Lower control box

4-10

SSJ00066

Female, Gray

Emergency stop button

Lower Upper

Upper

Emergency stop COM Key sw ON Key sw ON Key sw COM Enable sw COM Lift sw COM Override sw COM Emergency stop Key sw COM Key s/w Upper Key s/w Lower Enable s/w Pre-operation check s/w Lift s/w Up Lift s/w Down Override s/w Limit Override s/w Release

Male, Gray

Key s/w

Female, Green

Lower

Female, Yellow Male, Yellow

Male, Gray

Enable / Pre-operation check s/w

Pre-operation check

SSJ00066 Lift s/w

Override s/w

Female, Gray

Limit Release

Adjust mode select connector

Battery charger indicator light

Male, Gray

Green

Female, Green

Male, Green

Red

Female, White

Female, Yellow

Battery level indicator / Hourmeter

Main CPU board M6

Female, Green

Male, Green

Male, Yellow

For Adjustment tool

Chapter 4 Electric Components

Connectors

Fig. 4-9 Connectors

4-11

Up Down

Enable

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. 4-10 Key switch

4-12

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Chapter 4 Electric Components

Multi-function indicator (381-0000058) In normal condition, the digital display indicates battery level .

When problem occurs, the digital display indicates diagnostic code and three digit number.

See page 5-2 for “Troubleshooting by diagnostic code”.

In adjustment mode, the digital display indicates machine’s status, input and output of CPU boards / Inverter unit.

See page 5-14 for “Troubleshooting by monitoring”.

Digital display Wrench icon Hourmeter Hourmeter icon

㸿

Connector

View A Fig. 4-11 Multi-function indicator SSJ00066

4-13

Chapter 4 Electric Components

Main CPU board “M6” CPU board M6 (Main) is installed in the lower control box to input signals frm switches and sensors on the chassis frame and output to the solenoid valves.

It communicates with Sub CPU board in the upper control box and inverter unit to control each function.

It is eqquipped with two tilt sensors to ditect the vehicle’s Lateral and Longitudinal tilt angles.

Board tilt direction SD card slot

Connectors J3

J1 1

4

1

7

J4 1

10

21

28

11

20

29

36

J6

J7

5

1

12

6

1

J9 8

5

1

Fig. 4-12 Main CPU board “M6”

4-14

SSJ00066

SSJ00066

Fuse (10A)

Battery (24V)

Fuse (300A)

Upper Lower

Key s/w

Up Down

Power Output GND

Pressure sensor (Main)

Limit Rerease

Override s/w

Lift s/w

Enable Pre-operation check

Enable / Pre-operation check s/w

Emergency stop button (Upper)

Relay CR-10

Output +24V when the battery charger is not charging.

Battery charge interlock

Battery charger

Emergency stop button (Lower)

Platform height sensor

Steering angle sensor (SV08ENL / SV2646E, SV10ENL / SV3246E)

/: 9S - /: 9S - /: 9S - /5 9V - 5: 9EDF - % )* - % )* -

: .$ -

2 ' - %U ' -

*< ' - *: ' -

:< ' - :* ' -

*5 ' - < ' -

*% ' - */ ' -

5 .9 - : .$ - % .* - 5 .9 - : .$ - % .* -

5 .9 - : .$ - % .* -

GND GND

+24 volts +24 volts +24 volts +24 volts +24 volts

Power for CPU Power for CPU Power for CPU Power for CPU Backup for Memory

+1.0 ~ 5.0 volts (0 ~ 20MPa)

+24 volts +24 volts

+24 volts Override switch (Limit) +24 volts Override switch (Release)

+24 volts Lift switch (Up) +24 volts Lift switch (Down)

Enable / Pre-operation check s/w +24 volts (Enable) +24 volts (Pre-operation check)

+24 volts Key switch (Upper) +24 volts Key switch (Lower)

+5 volts +1.1 ~ 2.5 ~ 4.2 volts (Left end ~ Center ~ Right end) GND +5 volts +4.8 ~ 1.8 volts (Min ~ Max) GND +5 volts +4.8 ~ 1.8 volts (Min ~ Max) GND

&RORU FRGH RI ZLUHV 6LJQDO 1R &RQQHFWRU 1R 3LQ 1R

- 27 /

- 35; 5 - 37; %U - 36* 2 - )* < - :( * - 36* /

- 27 3%

Steering Left sol.

Steering Right sol.

Platform Lift Down sol.

- 27 /J5 - ' /J5 - 27 3<

Platform Lift Up sol.

Alarm buzzer / Horn

Beacon light (Option)

- 27 */ - ' *

- 27 *5

Communication lines among - &$1B+ %5 * Main CPU board M6, - &$1B/ %: * Sub CPU board, * Inverter unit (Right and Left) * Battery level indicator / Hourmeter

for Adjustment

by Handy tool

+24 volts

+24 volts

+24 volts +24 volts

+24 volts +24 volts

+24 volts

Outputs when * the Travel / Platform lift function is operated. * the Horn is operated. * the Emergency switch is in Release position.

+24 volts

3LQ 1R &RQQHFWRU 1R 6LJQDO 1R &RORU FRGH RI ZLUHV

Chapter 4 Electric Components

Input / Output characteristics

4-15

Chapter 4 Electric Components

Inverter unit Inverter unit controls output to travel motors and DC motor

Connector

Fig. 4-13 Inverter unit

4-16

SSJ00066

Chapter 4 Electric Components Input / Output characteristics (SV06ENS, SV06ENL and SV08ENL) &RORU FRGH RI ZLUHV 3LQ 1R 6LJQDO 1R

Travel motor (Left)

Motor coil

*\5 7+0

Signal from Thermosensor (Left).

:5 66

Signal from Rev sensor (Left).

Thermo sensor

Rev sensor Electric magnetic brake

%U5 62/

Travel motor (Right)

Control current for Electric magnetic brake Ref. +24 volts when Travel function is not operated. +0.45 ~ 0.40 volts when Travel function is operated (Min ~ Max)

5 8 : 9

Motor coil

% : *\ $1 *\ 6 9B

Thermo sensor

5 66 : 66

Rev sensor

< 62/ 287

Electric magnetic brake

Battery charger Battery charge interlock Output +12V when the battery charger is not charging.

%U 62/

Emergency stop button (Lower) Emergency stop button (Upper) Key s/w

Pressure sensor (Sub) *\ $1

Fuse (10A)

/5 .(<67$57 /5 62/ ,1

Battery (24V)

3 6: Pothole protector limit switches

+Signal from Thermosensor (Right) +5 volts Power for thermosensor (Right) +10~12 volts Power for Rev sensor.

Signal from Rev sensor (Right).

Output +24 volts when the Emergency stop switches at Upper and Lower control box are pulled and Key switch is in Upper or Lower position.

Control current for Electric magnetic brake Ref. +24 volts when Travel function is not operated. +0.45 ~ 0.40 volts when Travel function is operated (Min ~ Max)

+1.0 ~ 5.0 volts (0 ~ 20MPa)

Relay CR-10 *% 6(16*1'

Fuse (300A)

Control current for Travel motors.

/J5 62/

Contactor 3% 62/

GND for sensors +24 volts Inputs when the Emergency stop buttons at Upper and Lower control box are pulled and Key switch is in Upper or Lower position. +24 volts Inputs when the pothole protector is in operating position.

Output +24 volts when the Emergency stop switches at Upper and Lower control box are pulled and Key switch is in Upper or Lower position.

Control current for Contactor.

% % 3 DC motor for Power unit

SSJ00066

% &$1B+ %: &$1B/ %: &$1 5 * &$1*1' %

Control current for DC motor (Power unit).

Communication lines among * Main CPU board M6, * Sub CPU board, * Battery level indicator / Hourmeter GND

4-17

Chapter 4 Electric Components Input / Output characteristics (SV08EWL and SV10EWL &RORU FRGH RI ZLUHV 3LQ 1R 6LJQDO 1R % &$1B+ %: &$1B/ * &$1*1' % /5 .(<67$57 /5 6: %

Travel motor (Left)

Inverter unit (Left)

Communication lines among * Main CPU board M6, * Sub CPU board, * Battery level indicator / Hourmeter * Inverter unit (Right) GND +24 volts Inputs when the Emergency stop buttons at Upper and Lower control box are pulled and Key switch is in Upper or Lower position.

5 8 : 9

Motor coil

% : %* 6(16*1' *\5 7+0 :5 66

Thermo sensor

5% 66

Control current for Travel motors.

GND for sensors Signal from Thermosensor (Left).

Signal from Rev sensor (Left). +10~12 volts Power for Rev sensor.

Rev sensor

Inverter unit (Right)

Electric magnetic brake

%U5 62/

Travel motor (Right) 5 8 : 9

Motor coil

% :

*\ $1 Thermo sensor

Rev sensor

Battery charger Battery charge interlock Output +12V when the battery charger is not charging.

+10~12 volts Power for Rev sensor.

Signal from Rev sensor (Right).

Pressure sensor (Sub) *\ $1

Emergency stop button (Upper)

Output +24 volts when the Emergency stop switches at Upper and Lower control box are pulled and Key switch is in Upper or Lower position.

Control current for Electric magnetic brake Ref. +24 volts when Travel function is not operated. +0.45 ~ 0.40 volts when Travel function is operated (Min ~ Max) +1.0 ~ 5.0 volts (0 ~ 20MPa)

Key s/w *% 6(16*1'

Fuse (300A)

+Signal from Thermosensor (Right)

: 66

%U 62/

Emergency stop button (Lower)

Control current for Travel motors.

5 66

< 62/ 287

Electric magnetic brake

Control current for Electric magnetic brake Ref. +24 volts when Travel function is not operated. +0.45 ~ 0.40 volts when Travel function is operated (Min ~ Max)

Fuse (10A)

/5 .(<67$57 Relay CR-10

Battery (24V)

/5 62/ ,1 3 6:

Pothole protector limit switches

/J5 62/

Contactor 3% 62/

GND for sensors +24 volts Inputs when the Emergency stop buttons at Upper and Lower control box are pulled and Key switch is in Upper or Lower position. +24 volts Inputs when the pothole protector is in operating position.

Output +24 volts when the Emergency stop switches at Upper and Lower control box are pulled and Key switch is in Upper or Lower position.

Control current for Contactor.

% % 3 DC motor for Power unit

4-18

% &$1B+ %: &$1B/ %: &$1 5 * &$1*1' %

Control current for DC motor (Power unit).

Communication lines among * Main CPU board M6, * Sub CPU board, * Battery level indicator / Hourmeter GND

SSJ00066

Chapter 4 Electric Components

Platform height sensor (382-0006600) Platform height is calculated from angle of 1st inner arm detected by the platform height sensor.

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

POT 2 (Resistance between Red and Blue)

60 degrees 15 degrees

120 degrees 150 degrees Angle

Fig. 4-14 Platform height sensor Nut Tightening torque: 1.8 - 2.2 N-m (0.19 - 0.22 kgf-m) [1.4 - 1.6 ft-lbs] * Do not impose torque to the shaft of the sensor.

(Hold the arm when tightening nut)

A B 1st arm inner

Platform height sensor * Rotate the sensor counterclockwise when tightening screws

Arm Bolt x2 Apply thread lock agent (Loctite 263)

Bracket Guide

View A

View B

Fig. 4-15 Installation of the platform height sensor SSJ00066

4-19

Chapter 4 Electric Components

Steering angle sensor (382-0006400)

SV08EWL and SV10EWL

The steering angle sensor is located under the chassis frame to detect the steering angle.

Specifications Resistance : 2.0 k ohm Detectable angle : 110 degrees

Connector

Output characteristics

R VCC

Resistance between R and W

W OUT

B GND

55 degrees 5 degrees

110 degrees 120 degrees Angle

Fig. 4-16 Steering angle sensor Steering cylinder

Tie rod Steering angle sensor

A

Arm

B

View A

Guide Nut Tightening torque: 1.8 - 2.2 N-m (0.19 - 0.22 kgf-m) [1.4 - 1.6 ft-lbs] * Do not impose torque to the shaft of the sensor.

(Hold the arm when tightening nut)

View B Fig. 4-17 Installation of the Steering angle sensor

4-20

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Chapter 4 Electric Components

Travel motor (AC induction motor) (322-0016800) The Travel motor is installed on each front wheel bracket to drive machine.

Maximum tightening torque : 5.0 N-m (0.5 kgf-m) [3.6 ft-lbs] Upper nut Maximum tightening torque : 8.0 N-m (0.8 kgf-m) [5.9 ft-lbs]

㸿 Ball bearing

ȭ

ȭ

ȭ

0$;

Maximum tightening torque : 5.0 N-m (0.5 kgf-m) [3.6 ft-lbs]

0$;

ȭ

Maximum tightening torque : 8.0 N-m (0.8 kgf-m) [5.9 ft-lbs]

Maximum tightening torque : 2.0 N-m (0.2 kgf-m) [1.4 ft-lbs]

View A Fig. 4-18 Travel motor (AC induction motor) Specifications : AC 15 volts Rated voltage : 1.0 kw Rated output power : 60 min Rated operation time Maximum output torque : 23 N-m (2.3 kg-m) [16.9 ft-lb] Thermo sensor resistance : 1,000 ohms at 100 degrees C (212 degrees F)

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4-21

Chapter 4 Electric Components for Rev sensor Cap screw : (M5 x 30 mm) x 3 Deutsche for Thermo sensor

Apply Thread lock agent (Loctite 243) Tightening torque : 1.7 - 2.0 N-m (0.17 - 0.20 kgf-m) [1.3 - 1.5 ft-lbs] Electric magnetic brake

Grommet

Section A-A

B view

Travel motor Screw : 340-0000130 (M4 x 8 mm) x 3 Cover : 5E0-0758600 O-ring : 111-01300 Tightening torque : 1.7 - 2.0 N-m (0.17 - 0.20 kgf-m) [1.3 - 1.5 ft-lbs]

Fig. 4-19 Travel motor assermbly

4-22

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Chapter 4 Electric Components

Electric magnetic brake (370-0000139) 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 Minimum brake release voltage Weight

DC 24 volts 16 volts 1.5 kg [36.4 lbs]

Manual release screw (M5 x 20 mm) x 2

Spring x 9 Friction plate Collar x 3

Field assembly Cap screw : (M5 x 30 mm) x 3 Apply Thread lock agent (Loctite 243) Armature Tightening torque : 1.7 - 2.0 N-m (0.17 - 0.20 kgf-m) [1.3 - 1.5 ft-lbs]

Friction disc

Fig. 4-20 Electric magnetic brake Refer to page 5-28 for brake release by brake release connector.

SSJ00066

4-23

Chapter 4 Electric Components Disassemble and reassemble the electric magnetic brake

Do not disassemble the brake when the machine is on the slope or the machine will run away and may 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.

Connector cover

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.4-21) 5. Unscrew the three screws (M4 x 8 mm) that secure the brake cover. (Fig.4-21) 6. Take the brake cover off.

Screw M4 x 8 mm Brake cover

Fig. 4-21

Connector (Gray)

7. Disconnect the gray connector. (Fig.4-22) White wires 8. Unscrew the three cap screws (M5 x 30 mm) that secure the field assembly. (Fig.4-22) Grommet 9. Take the field assembly off. Pull the white wires into inside of the housing with the field assembly Field assembly through the grommet. (Fig. 4-22)

Cap screw (M5 x 30 mm)

Fig. 4-22 Do not lose nine springs behind the field assembly.

(Fig. 4-23) 10. Take the armature out. (Fig. 4-23)

Collar

Spring

Do not lose three collars around the armature.

(Fig. 4-23)

Armature Fig. 4-23

4-24

SSJ00066

Chapter 4 Electric Components 11. Take the friction plate out. (Fig. 4-24)

Friction plate Fig. 4-24 2) Reassemble 1. Install the friction disk.

2. Install the armature and three collars.

Set the slit of the armature to the top so that the white wires can pass through the slit.

Collar 3. Set the nine springs onto the field assembly, install it to the housing with pulling out the white wires.

4. Secure the field assembly with three cap screws.

Apply thread lock agent (Loctite 243) Tightening torque : 1.7 - 2.0 N-m (0.17 - 0.20 kgf-m) [1.3 - 1.5 ft-lb] 5. Install the brake cover.

White wires

Slit Armature

Fig. 4-25

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

7. Secure the brake cover with three screws.

O-ring

Fig. 4-26

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4-25

Chapter 4 Electric Components

Battery charger (322-0016200) The battery charger is located in the battery box to charge the batteries.

Fig. 4-27 Battery charger Specifications Rated input voltage Input voltage range Maximum input current Output voltage Output current Battery

4-26

: Single phase AC 100, 120, 200, 230 volts : AC 85 - 265 volts (45 - 65 Hz) : 12 A : DC 24 volts : 25 A : Trojan T105

SSJ00066

Chapter 4 Electric Components Battery charger indicator light LEDs on Battery charger Ammeter (Amber)

Solid: Flashing:

80% Charge (Amber)

Solid: Flashing:

Displays approximate scale of current output bulk phase.

High internal temperature, current output reduced.

When battery is not connected: Each LED flashes once in sequence.

Bulk charge phase complete, 80% charged. In Absorption phase.

When battery is not connected: Flash 3 times.

Charging complete. Charger in Maintenance Mode.

Absorption phase complete. In Finish phase

100% Charge (Green)

Solid:

AC On (Amber)

Solid: Flashing:

AC Power good Low AC Voltage, check voltage and extension cord length (no longer than 30 m [100 ft]).

Fault (Red)

Flashing:

Charger error. Reset charger power and refer to Troubleshooting table.

Flashing:

LEDs beside Lower control box Green

Solid: Flashing:

SSJ00066

Chargin complete.

Charger in Maintenance Mode.

Short: <80% Charge.

Long: >80% Charge.

When battery is not connected: Flash 3 times.

Amber

Flashing:

Reduced Power Mode: Low AC Voltage or High internal charger temperature.

Red

Flashing:

Charger error. Reset charger power and refer to Troubleshooting table.

4-27

Chapter 4 Electric Components Trouble shooting by LED status Red Flashes

4-28

Cause

Solution

Battery High Voltage

Check battery size and condition.

This fault will automatically clear once the condition has been corrected.

Battery Low Voltage

Check battery size and condition.

This fault will automatically clear once the condition has been corrected.

Charge Timeout caused by battery pack not reaching required voltage.

Charger output was reduced due to high temperatures.

Check connections.

Operate charger at a lower ambient temperature Reset charger (interrupt AC power for 15 seconds)

Check Battery: battery could not be trickle charged up to minimum voltage.

Check for shorted or damaged cells.

Reset charger (interrupt AC power for 15 seconds)

Over-Temperature: Charger shut down due to high internal temperature.

Ensure sufficient cooling air flow and reset charger (interrupt AC power for 15 seconds).

Charger Internal Fault

Reset charger (interrupt AC power for 15 seconds). Return to qualified service depot if fault persists.

SSJ00066

Chapter 4 Electric Components Battery charge profile (Algorithm) setting procedures Set the charge profile (Algorithm) of the battery charger after replacing battery charger or replacing batteries with different type.

Checking current charge profile 1) Check that the charge cable is not plugged into power outlet. (Fig. 4-28) 2) Disconnect battery disconnector, and then wait for 30 seconds. (Fig. 4-29) 3) Plug the charge cable into power outlet.

All LEDs on battery charger go on once, and then 80% charge LED (Amber) on battery charger blinks to indicate charge profile ID No. as shown in Table below.

The indication repeats for 11 seconds.

4) Unplug the charge cable from the power outlet.

5) Connect battery disconnector.

Charge cable

Fig. 4-28

Battery disconnector

Fig. 4-29 ID No. 3

Battery type Trojan T105, T125

Indication pattern

䖤䖤䖤 Off

Blink 3 times 23

EB100 200Ah

43

Trojan T105-AGM

䖤䖤 Blink twice

䖤䖤䖤 Off

Blink 3 times

䖤䖤䖤䖤

䖤䖤䖤 Off

Blink 4 times 239

AMF90 180Ah

䖤䖤

䖤䖤䖤

Blink Off Blink twice 3 times

Blink 3 times

䖤䖤䖤䖤䖤䖤䖤䖤䖤 Off

Blink 9 times

80% charge LED (Amber)

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4-29

Chapter 4 Electric Components Changing charge profile 1) Check that the charge cable is not plugged into power outlet.

2) Disconnect battery disconnector, and then wait for 30 seconds.

3) Plug the charge cable into power outlet.

All LEDs on battery charger go on once, and then 80% charge LED (Amber) on battery charger blinks to indicate charge profile ID No. for 11 seconds.

4) While the charge profile number is displayed (for 11 seconds), connect the battery disconnector for 3.0 seconds (+/- 0.5 seconds).

5) Disconnect the battery disconnector. The charge profile ID No. will advance.

6) To advance the charge profile ID No. Further, repeat step 4 and 5 within 30 seconds.

7) When the desired charge profile ID no. Is indicated on the LED, connect the battery disconnector and then wait for 10 seconds (until the relay in the battery charger clicks) to set the new charge profile.

8) Unplug the charge cable from the power outlet.

9) Follow the step 2 and 3 to check that the charge profile ID No. has changed as desired.

4-30

SSJ00066

Chapter 4 Electric Components

Contactor (320-0029000) This contactor is energized when the emergency stop buttons at upper and lower control box are pulled and key switch is in upper or lower position to supply power supply for the travel AC motor and DC motor on power unit through the sevcon controller.

Specifications Rated voltage : DC 24 volts Rated current : 350 A Coil resistance : 44 ohms

Tightening torque of terminal : 13.4 - 14.6 N-m (1.37 - 1.48 kgf-m) [9.9 - 10.7 ft-lbs]

Fig. 4-30 Contactor

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4-31

Chapter 4 Electric Components

Pressure sensor (312-0000043) Pressure sensor (Main) is installed on the holding valve on the lift cylinder.

Pressure sensor (Sub) is installed on the lift cylinder.

They sense the pressure imposed in the bottom room of the cylinder to detect the platform load.

Specifications

22 mm

Rated voltage : +8 - 30 volts Output voltage : +1 - 5 volts Pressure range : 0 - 20 MPa (0 - 200 kgf/cm2) [0 - 2,900 PSI]

B

C

A

(7/16-20 UNF-2A) Tightening torque of pressure sensor : 30 - 35 N-m (3.1 - 3.6 kgf-m) [23 - 26 ft-lbs]

Output characteristics

Electric circuit

A Power

Output voltage

C Output B GND Pressure Fig. 4-31 Pressure sensor

4-32

SSJ00066

Chapter 5 Troubleshooting

Chapter 5 Troubleshooting

SSJ00066

5-1

Chapter 5 Troubleshooting

Troubleshooting by diagnostic code Multi-function indicator on the lower control box indicates diagnostic code on its display and the system failure light on the upper control box goes on or blinks to indicates error conditions when error occurs.

System failure light

Multi-function indicator

Diagnostic code indication area

Upper control box

Lower control box

Fig. 5-1 Locations of Multi-function indicator / System failure light Code

No.

System failure light

Descriptions

Tilt alarm (Travel limitation)

LMT 001

LMT 002

LMT 003

5-2

OFF

Causes

1. Machine tilts more than specific angle and Platform height is higher than specific height.

2. Incorrect installation of Platform height sensor.

3. Incorrect calibration of Tilt sensor (Longitudinal and/or Lateral).

4. Incorrect calibration of Platform height sensor. * See page 1-9 for specific tilt angle and platform height.

Countermeasures

1. Lower the platform.

Set the machine on level surface.

2. Check and rectify the installation of the Platform height sensor.

3. Perform the Tilt sensor calibration.

4. Perform the Platform height sensor calibration.

OFF

1. Set the machine on level surface.

Tilt alarm 1. Machine tilts more than 7.0 (Platform lift up degrees longitudinally and / or limitation) laterally.

2. Incorrect calibration of Tilt sensor 2. Perform the Tilt sensor calibration.

(Longitudinal and/or Lateral).

OFF

Platform height limitation (Zone A) (SV08ENL, SV10EWL)

Platform has reached its maximum Lower the platform.

Turn the Capacity select switch to "B" platform height for "Zone A" while position.

Capacity select switch is in "A" position.

SSJ00066

Chapter 5 Troubleshooting Code

No.

System failure light

Descriptions

Excessive platform height (Zone A) (SV08ENL, SV10EWL) LMT 004

OFF

LMT 005

OFF

LMT 006

OFF

LMT 008

LMT 011

LMT 012

LMT 013

SSJ00066

Countermeasures

Platform has exceeded its maximum platform height for "Zone A" while the Capacity select switch is in "A" position.

1. Capacity select switch is turned to 1. Turn the Capacity select switch to "A" position while the platform "B" position. height is in "Zone B".

Lower the platform.

2. Incorrect installation of Platform 2. Check and rectify the installation height sensor. of the Platform height sensor.

3. Incorrect calibration of Platform 3. Perform the Platform height height sensor. sensor calibration.

Overload alarm Platform is overloaded.

Unload the platform.

Pre-operation check

Pre-operation switch is turned on.

Release the Pre-operation check switch.

Pothole error

Inverter unit does not receive the signal from pothole limit switches although 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 Inverter unit.

4. Faulty Limit switches.

Blinks 7 times

Adjustment mode LMT 00E

Causes

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 Inverter unit.

4. Replace the Limit switches.

OFF

1. Communication cable for Handy 1. Disconnect the communication tool is connected to the connector cable from the connector Cn.299.

Cn.299 but the software is not 2. Disconnect the connector Cn9 started. and Cn58, and then connect each 2. Adjust mode select connectors connector with their original (Cn.9 and Cn.58) are connected. counterpart.

OFF

Battery voltage 1. Power supply to Main CPU board 1. Charge the battery. error M6 or Inverter unit is lower than 17 volts.

Power supply to Sub CPU board is lower than 16 volts.

2. Faulty Main CPU board M6.

2. Replace the Main CPU board M6.

3. Faulty Sub CPU board.

3. Replace the Sub CPU board.

OFF

OFF

Travel motor (Right) Temperature error

1. Temperature of Travel motor (Right) is above 150 degrees C (302 degrees F).

2. Faulty thermo sensor on the Travel motor (Right).

1. Turn off the key switch and leave the machine until the Travel motor get cool.

2. Replace the travel motor.

Travel motor (Left) Temperature error

1. Temperature of Travel motor (Left) is above 150 degrees C (302 degrees F).

2. Faulty thermo sensor on the Travel motor (Left).

1. Turn off the key switch and leave the machine until the Travel motor get cool.

2. Replace the travel motor.

5-3

Chapter 5 Troubleshooting Code

No.

LMT 014

LMT 015

ERR 201

LMT 211

LMT 212

LMT 213

System failure light

Descriptions

Countermeasures

OFF

Inverter unit (Right) Temperature error

1. Temperature of Inverter unit (Right) is above 80 degrees C (176 degrees F).

2. Faulty Inverter unit (Right).

1. Turn off the key switch and leave the machine until the Inverter unit get cool.

2. Replace the Inverter unit.

OFF

Inverter unit (Left) Temperature error (SV08EWL, SV10EWL)

1. Temperature of Inverter unit (Right) is above 80 degrees C (176 degrees F).

2. Faulty Inverter unit (Left).

1. Turn off the key switch and leave the machine until the Inverter unit get cool.

2. Replace the Inverter unit.

Key switch error

Main CPU board M6 inputs both Lower and Upper control select signals at the same time, or do not 1. Rectify the electric lines between input both signal.. the Key switch and Main CPU 1. Faulty electric lines between Key board M6. switch and Main CPU board M6 . 2. Replace the Key switch.

2. Faulty Key switch.

Operation Time-out (Upper, Enable sw)

1. Enable switch, Joystick controller or Steering switch was already operated when turning Key switch on or pulling up Emergency stop button.

2. Enable switch is operated more than 20 seconds without operating Joystick controller or Steering switch.

3. Joystick controller or Steering switch is operated more than 20 seconds without operating Enable switch.

4. Faulty electric lines between Enable switch, Joystick controller or Steering switch and Sub CPU board.

5. Faulty Enable switch, Joystick controller or Steering switch.

Blinks 9 times

ON

ON

ON

Operation Time-out (Upper, Joystick controller) Operation Time-out (Upper, Steering sw)

Capacity select switch error (SV06ENL, Blinks SV08ENL, ERR 214 9 SV10EWL) times

5-4

Causes

1. Release (Return to neutral position) the Enable switch, Joystick controller or Steering switch.

2. Release (Return to neutral position) the Enable switch, Joystick controller or Steering switch.

3. Release (Return to neutral position) the Enable switch, Joystick controller or Steering switch.

4. Rectify the electric lines between the Enable switch, Joystick controller or Steering switch and Sub CPU board.

5. Replace the Enable switch, Joystick controller or Steering switch.

Sub CPU board inputs both "Indoor / Zone A" and "Outdoor / Zone B" mode select signals at the same time, or do not input both signal.

1. Rectify the electric lines between 1. Faulty electric lines between the Capacity select switch and Capacity select switch and Sub Sub CPU board.

CPU board.

2. Replace the Capacity select 2. Faulty Capacity select switch. switch.

SSJ00066

Chapter 5 Troubleshooting Code

No.

System failure light

Descriptions

Causes

Lift / Travel select Blinks switch error ERR 215 9 times

LMT 221

ON

LMT 222

ON

LMT 223

ON

Sub CPU board inputs both Lift and Travel select signals at the same time, or do not input both signal.

1. Faulty electric lines between Lift / Travel select switch and Sub CPU board.

2. Faulty Lift / Travel select switch.

Operation 1. Enable switch, Lift switch or Time-out Override switch was already (Lower, operated when turning Key switch Enable sw) on or pulling up Emergency stop button.

2. Enable switch is operated more than 20 seconds without Operation operating Lift switch.

Time-out 3. Lift switch is operated more than (Lower, Lift sw) 20 seconds without operating enable switch.

4. Override switch is operated more than 20 seconds without operating Lift switch.

Operation 5. Faulty electric lines between Time-out Enable switch, Lift switch or (Lower, Override switch and Main CPU Override sw) board M6.

6. Faulty Enable switch, Lift switch or Override switch.

Override switch Main CPU board M6 inputs both error Limit and Release signals at the same time, or do not input both Blinks signal.

ERR 224 14 1. Faulty electric lines between times Override switch and Main CPU board M6.

2. Faulty Override switch.

Countermeasures

1. Rectify the electric lines between the Lift / Travel select switch and Sub CPU board.

2. Replace the Lift / Travel select switch.

1. Release (Return to neutral position) the Enable switch, Lift switch or Override switch.

2. Release (Return to neutral position) the Enable switch, Lift switch or Override switch.

3. Release (Return to neutral position) the Enable switch, Lift switch or Override switch.

4. Release (Return to neutral position) the Enable switch, Lift switch or Override switch.

5. Rectify the electric lines between the Enable switch, Lift switch or Override switch and Main CPU board M6.

6. Replace the Enable switch, Lift switch or Override switch.

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

2. Replace the Override switch.

Tilt sensor (Longitudinal) Blinks error ERR 301 10 times

Input from Tilt sensor (Longitudinal) is out of specific range.

1. Incorrect calibration of the Tilt 1. Perform the Tilt sensor sensor (Longitudinal).

(Longitudinal) calibration.

2. Faulty Tilt sensor (Longitudinal) 2. Replace the Main CPU board M6. on the Main CPU board M6.

Tilt sensor (Lateral) error

Input from Tilt sensor (Lateral) is out of specific range.

1. Incorrect calibration of the Tilt 1. Perform the Tilt sensor (Lateral) sensor (Lateral). calibration.

2. Faulty Tilt sensor (Lateral) on the 2. Replace the Main CPU board M6.

Main CPU board M6.

ERR 302

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Blinks 10 times

5-5

Chapter 5 Troubleshooting Code

No.

System failure light

Descriptions

Causes

Input from Pressure sensor is out of specific range.

1. Incorrect calibration of the Blinks Pressure sensor.

ERR 303 11 2. Faulty electric lines between times Pressure sensor and Main CPU board M6.

3. Faulty Pressure sensor.

Steering angle Input from Steering angle sensor is sensor error out of specific range.

(SV08EWL, 1. Incorrect calibration of the Blinks SV10EWL) Steering angle sensor.

ERR 304 13 2. Faulty electric lines between times Steering angle sensor and Main CPU board M6.

3. Faulty Steering angle sensor.

Platform height Input from Platform height sensor is sensor error out of specific range.

1. Incorrect calibration of the Blinks Platform height sensor.

ERR 305 12 2. Faulty electric lines between times Platform height sensor and Main CPU board M6.

3. Faulty Platform height sensor.

Countermeasures

Pressure sensor error

Pre-operation check error

Blinks ERR 30B 8 times

Input from Tilt sensor (Longitudinal / Lateral) and/or Pressure sensor is out of specific range when the platform is stopped during preoperation check.

1. Machine is tilted.

2. Incorrect Tilt sensor (Longitudinal / Lateral) calibration.

3. Incorrect Pressure sensor calibration.

4. Faulty Tilt sensor (Longitudinal / Lateral) on the Main CPU board M6.

5. Faulty Pressure sensor.

Joystick Input from Joystick controller is out controller error of specific range.

Blinks 1. Faulty electric lines between ERR 30C 9 Joystick controller and Sub CPU times board 2. Faulty Joystick controller.

5-6

1. Perform the Pressure sensor calibration.

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

3. Replace the Pressure sensor.

1. Perform the Steering angle sensor calibration.

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

3. Replace the Steering angle sensor.

1. Perform the Platform height sensor calibration.

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

3. Replace the Platform height sensor.

1. Set the machine horizontal and perform the Pre-operation check.

2. Perform the Tilt sensor (Longitudinal / Lateral) calibration.

3. Perform the Pressure sensor calibration.

4. Replace the Main CPU board M6.

5. Replace the Pressure sensor.

1. Rectify the electric lines between the Joystick controller and Sub CPU board.

2. Replace the Joystick controller.

SSJ00066

Chapter 5 Troubleshooting Code

No.

System failure light

Descriptions

Blinks Communication ERR 601 Continu error -ously See Communication ERR603 error ERR 602 ERR604 ERR605 Communication

error between Main CPU Blinks board M6 and ERR 603 Continu Sub CPU -ously board

Communication

error between Main CPU board M6 and Blinks Inverter unit ERR 604 15 (Right)* times

Communication

error between Main CPU Blinks board M6 and ERR 605 15 Inverter unit times (Left) (SV08EWL, SV10EWL) Communication

-

error between Main CPU Blinks board M6 and 15  Multi function times indicator

SSJ00066

Causes

All CAN communication among Main CPU board M6, Sub CPU board and Inverter unit failed.

One of CAN communication among Main CPU board M6, Sub CPU board and Inverter unit failed.

Main CPU board M6 and Sub CPU board fail to communicate each other.

1. Faulty communication line between Main CPU board M6 and Sub CPU board.

2. Faulty Main CPU board M6.

3. Faulty Sub CPU board.

Main CPU board M6 and Inverter unit (Right)* fail to communicate each other.

1. Faulty communication line between Main CPU board M6 and Inverter unit (Right)*.

2. Faulty Main CPU board M6.

3. Faulty Inverter unit (Right)*. * SV08EWL / SV2646E, SV10EWL / SV3246E

Countermeasures

See ERR603, ERR604 and ERR605.

See ERR603, ERR604 and ERR605.

1. Rectify the communication line. between Main CPU board M6 and Sub CPU board.

2. Replace the Main CPU board M6.

3. Replace the Sub CPU board.

1. Rectify the communication line. between Main CPU board M6 and Inverter unit (Right)*.

2. Replace the Main CPU board M6.

3. Replace the Inverter unit (Right)*.

Main CPU board M6 and Inverter unit (Left) fail to communicate each other.

1. Faulty communication line 1. Rectify the communication line. between Main CPU board M6 between Main CPU board M6 and and Inverter unit (Left).

Inverter unit (Left).

2. Faulty Main CPU board M6.

2. Replace the Main CPU board M6.

3. Faulty Inverter unit (Left).

3. Replace the Inverter unit (Left).

Main CPU board M6 and Multifunction indicator fail to communicate each other.

1. Faulty communication line between Main CPU board M6 and Multi-function indicator.

2. Faulty Multi-function indicator.

3. Faulty Main CPU board M6.

1. Rectify the communication line. between Main CPU board M6 and Multi-function indicator.

2. Replace the Multi-function indicator.

3. Replace the Main CPU board M6.

5-7

Chapter 5 Troubleshooting Code

No.

System failure light

Descriptions

Causes

901 Blinks Faulty Faulty Main CPU board M6. or 15 command 904 times error Blinks Main CPU M6 Faulty Main CPU board M6.

ERR 905 15 AD timeout times error Main CPU M6 1. Incorrect parameters are Blinks EEPROM error memorized in Main CPU board ERR 909 Continu M6.

-ously 2. Faulty CPU board M6 (Main).

Blinks Main CPU M6 Faulty Main CPU board M6.

ERR 90A Continu CPU error

Countermeasures

Replace the Main CPU board M6.

ERR

Replace the Main CPU board M6.

1. Write the correct parameters into the Main CPU board M6, using handy tool.

2. Replace the Main CPU board M6.

Replace the Main CPU board M6.

-ously

Blinks Sub CPU AD ERR 915 Continu timeout error

Faulty Sub CPU board.

Replace the Sub CPU board.

Blinks Sub CPU CPU Faulty Sub CPU board.

ERR 91A Continu error

Replace the Sub CPU board.

-ously

-ously

5-8

SSJ00066

Chapter 5 Troubleshooting For SV06ENS, SV06ENL and SV08ENL Code

No.

System failure light

Descriptions

Causes

Travel motor Rev sensor Blinks error ERR 801 Twice

Countermeasures

1. Faulty electric lines between Inverter unit and Rev sensor on Travel motor.

2. Faulty Rev sensor on Travel motor.

3. Faulty Inverter unit.

Travel motor 1. Temperature of Travel motor Thermo sensor is above 180 degrees C error (356 degrees F) or below - 40 degrees C (- 40 degrees F).

Blinks ERR 802 2. Faulty electric lines between Twice Inverter unit and Thermo sensor on Travel motor.

3. Faulty thermo sensor on Travel motor.

Travel motor 1. Faulty electric lines between Brake error Inverter unit and Electric magnetic Blinks (Right) brake on Travel motor (Right).

ERR 803 Twice 2. Faulty Electric magnetic brake on Travel motor (Right).

3. Faulty Inverter unit.

Travel motor 1. Faulty electric lines between Brake error Inverter unit and Electric magnetic Blinks (Left) brake on Travel motor (Left).

ERR 804 Twice 2. Faulty Electric magnetic brake on Travel motor (Left).

3. Faulty Inverter unit.

3. Replace the Inverter unit.

1. Turn off the key switch and leave the machine until the Travel motor get cool.

Move the machine to warmer place.

2. Rectify the electric lines between Inverter unit and Thermo sensor on the Travel motor.

3. Replace the Travel motor.

1. Rectify the electric lines between Inverter unit and Electric magnetic brake on the Travel motor (Right).

2. Replace the Electric magnetic brake on the Travel motor (Right).

3. Replace the Inverter unit.

1. Rectify the electric lines between Inverter unit and Electric magnetic brake on the Travel motor (Left).

2. Replace the Electric magnetic brake on the Travel motor (Left).

3. Replace the Inverter unit.

Contactor error 1. Faulty electric lines between Inverter unit and Contactor.

2. Faulty Contactor.

Travel motor 1. Faulty electric lines between Blinks UVW error Inverter unit and Motor coil of ERR 806 Twice Travel motor.

2. Faulty Motor coil of Travel motor.

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

2. Replace the Contactor.

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

2. Replace the Travel motor.

ERR 805

SSJ00066

Blinks Twice

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

2. Replace the Travel motor.

5-9

Chapter 5 Troubleshooting For SV06ENS, SV06ENL and SV08ENL Code

No.

System failure light

Descriptions

Inverter unit error

Blinks ERR 809 Twice

5-10

Causes

Power supply to Inverter unit is out of specific range.

1. Faulty electric lines between batteries and Inverter unit.

2. Dead batteries.

3. Incorrect batteries.

Countermeasures

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

2. Charge the batteries.

3. Replace the batteries.

Temperature problem 4. Temperature of the Inverter unit is 4. Move the machine into warmer too cold. place.

5. Temperature of the Inverter unit is 5. Turn off the key switch and leave too hot. the machine until the Inverter unit get cool.

Short circuit between terminals (U, V or W) and Ground.

6. Faulty electric lines between 6. Rectify the electric lines between Inverter unit and Travel motor.

Inverter unit and Travel motor.

7. Faulty Inverter unit.

7. Replace the Inverter unit.

SSJ00066

Chapter 5 Troubleshooting For SV08EWL and SV10EWL Code

No.

System failure light

Descriptions

Causes

Travel motor Rev sensor 809 Blinks error (Right) ERR + Twice 801

809 Blinks ERR + Twice 802

1. Faulty electric lines between Inverter unit (Right) and Rev sensor on Travel motor (Right).

2. Faulty Rev sensor on Travel motor (Right).

3. Faulty Inverter unit (Right).

Travel motor 1. Temperature of Travel motor Thermo sensor (Right) is above 180 degrees C error (Right) (356 degrees F) or below - 40 degrees C (- 40 degrees F).

2. Faulty electric lines between Inverter unit (Right) and Thermo sensor on Travel motor (Right).

3. Faulty thermo sensor on Travel motor (Right).

Countermeasures

1. Rectify the electric lines between Inverter unit (Right) and Rev sensor on the Travel motor (Right).

2. Replace the Travel motor (Right).

3. Replace the Inverter unit (Right).

1. Turn off the key switch and leave the machine until the Travel motor get cool.

Move the machine to warmer place.

2. Rectify the electric lines between Inverter unit (Right) and Thermo sensor on the Travel motor (Right).

3. Replace the Travel motor (Right).

Travel motor Brake error 809 Blinks (Right) ERR + Twice 803

1. Faulty electric lines between 1. Rectify the electric lines between Inverter unit and Electric magnetic Inverter unit and Electric magnetic brake on Travel motor (Right). brake on the Travel motor (Right).

2. Faulty Electric magnetic brake on 2. Replace the Electric magnetic Travel motor (Right). brake on the Travel motor (Right).

3. Faulty Inverter unit.

3. Replace the Inverter unit.

Travel motor Brake error 809 Blinks (Left) ERR + Twice 804

1. Rectify the electric lines between Inverter unit and Electric magnetic brake on the Travel motor (Left).

2. Replace the Electric magnetic brake on the Travel motor (Left).

3. Replace the Inverter unit.

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

2. Replace the Contactor.

1. Rectify the electric lines between Inverter unit (Right) and Motor coil of the Travel motor (Right).

2. Replace the Travel motor (Right).

ERR

809 Blinks + Twice 805

ERR

809 Blinks + Twice 806

1. Faulty electric lines between Inverter unit and Electric magnetic brake on Travel motor (Left).

2. Faulty Electric magnetic brake on Travel motor (Left).

3. Faulty Inverter unit.

Contactor error 1. Faulty electric lines between Inverter unit and Contactor.

2. Faulty Contactor.

Travel motor 1. Faulty electric lines between UVW error Inverter unit (Right) and Motor coil (Right) of Travel motor (Right).

2. Faulty Motor coil of Travel motor (Right).

Travel motor Rev sensor 819 Blinks error (Left) ERR + Twice 801

SSJ00066

1. Faulty electric lines between Inverter unit (Left) and Rev sensor on Travel motor (Left).

2. Faulty Rev sensor on Travel motor (Left).

3. Faulty Inverter unit (Left).

1. Rectify the electric lines between Inverter unit (Left) and Rev sensor on the Travel motor (Left).

2. Replace the Travel motor (Left).

3. Replace the Inverter unit (Left).

5-11

Chapter 5 Troubleshooting For SV08EWL and SV10EWL Code

No.

System failure light

819 Blinks ERR + Twice 802

ERR

819 Blinks + Twice 806

Blinks ERR 809 Twice

Descriptions

Causes

1. Temperature of Travel motor Travel motor Thermo sensor (Left) is above 180 degrees C (356 degrees F) or below - 40 error (Left) degrees C (- 40 degrees F).

2. Faulty electric lines between Inverter unit (Left) and Thermo sensor on Travel motor (Left).

3. Faulty thermo sensor on Travel motor (Left).

1. Faulty electric lines between Travel motor Inverter unit (Left) and Motor coil UVW error of Travel motor (Left).

(Left) 2. Faulty Motor coil of Travel motor (Left).

Inverter unit Power supply to Inverter unit (Right) error (Right) is out of specific range.

1. Faulty electric lines between batteries and Inverter unit (Right).

2. Dead batteries.

3. Incorrect batteries.

Temperature problem 4. Temperature of the Inverter unit (Right) is too cold.

5. Temperature of the Inverter unit (Right) is too hot.

Short circuit between terminals (U, V or W) and Ground.

6. Faulty electric lines between Inverter unit (Right) and Travel motor (Right).

7. Faulty Inverter unit (Right).

5-12

Countermeasures

1. Turn off the key switch and leave the machine until the Travel motor get cool.

Move the machine to warmer place.

2. Rectify the electric lines between Inverter unit (Left) and Thermo sensor on the Travel motor (Left).

3. Replace the Travel motor (Left).

1. Rectify the electric lines between Inverter unit (Left) and Motor coil of the Travel motor (Left).

2. Replace the Travel motor (Left).

1. Rectify the electric lines between Batteries and Inverter unit (Right).

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 get cool.

6. Rectify the electric lines between Inverter unit (Right) and the Travel motor (Right) 7. Replace the Inverter unit (Right).

SSJ00066

Chapter 5 Troubleshooting For SV08EWL and SV10EWL Code

No.

System failure light

Descriptions

Inverter unit error (Left)

Blinks ERR 819 Twice

Causes

Power supply to Inverter unit (Left) is out of specific range.

1. Faulty electric lines between 1. Rectify the electric lines between batteries and Inverter unit (Left).

Batteries and Inverter unit (Left).

2. Dead batteries.

2. Charge the batteries.

3. Incorrect batteries.

3. Replace the batteries.

Temperature problem 4. Temperature of the Inverter unit (Left) is too cold.

5. Temperature of the Inverter unit (Left) is too hot.

Short circuit between terminals (U, V or W) and Ground.

6. Faulty electric lines between Inverter unit (Left) and Travel motor (Left).

7. Faulty Inverter unit (Left).

SSJ00066

Countermeasures

4. Move the machine into warmer place.

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

6. Rectify the electric lines between Inverter unit (Left) and the Travel motor (Left) 7. Replace the Inverter unit (Left).

5-13

Chapter 5 Troubleshooting

Troubleshooting by monitoring Multi-function indicator displays input / output status of the Main CPU board M6, Sub CPU board and Invertor unit while it is in the Adjustment mode.

1. Starting Adjustment mode 1) Turn off the Key switch.

2) Pull open the right side battery box.

3) Find the connector “9” (Gray, 2 poles) and “58” (Yellow, 2 poles). (Fig 7-1) Connector “9A” (male)

Right side battery box Connector “58B” (Female)

Fig. 5-2 Adjustment mode select connectors 4) Disconnect these connectors.

5) Connect “9A” (Male of Gray connector) and “58B” (Female of Yellow connector).

6) Turn the Key switch to its "Lower" position while holding down both Pre-operation check switch and the Lift switch.

Key switch

Multi-function indicator

Override switch Upper line (3 digit)

Lift switch

Lower line (6 digit)

Enable / Pre-operation check switch

Fig. 5-3 Lower control box / Multi-function indicator 7) The indicator displays “SEL” “MENU” when he Adjustment mode is successfully started.

SEL MENU

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Chapter 5 Troubleshooting

Upper line of the indicator displays “LMT” and “00E” alternately when Adjustment mode error occurs.

(Lower line keeps to indicate working hour) Turn off the Key switch, check the connection of the connector “9A” and “58B”, and then turn on the Key switch while holding down both Pre-operation check switch and the Lift switch.

After adjustment, Turn off the Key switch, Disconnect the connector “9A” and “58B”, and then connect them with their original mate.

LMT 999

00E 999

Operate toggle switches on the lower control box as follows while in the Adjustment mode. * Enable / Pre-operation check switch Push down the switch (Pre-operation check) to select item to be displayed on the indicator. * Override switch Pull the switch to front (Release) to decide display selection or editted value

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5-15

Chapter 5 Troubleshooting 2. Monitoring item list

MON POS

MON HEIGHT

MON TILTX1

MON TILTY1

MON TILTX2

MON TILTY2

MON PRESS

MON STEER

MON LINK

MON PRESS2

5-16

1) Position information This group displays status of the vehicle.

1-1. Platform height Platform height calculated based on the signal input from the Platform height sensor. (Unit: mm) 1-2. Longitudinal tilt angle (Main) Longitudinal tilt angle of the vehicle detected by the Tilt sensor (Longitudinal) built in the Main CPU board. (Unit: 0.01 degrees) +: Front-Up, -: Front-Down 1-3. Lateral tilt angle (Main) Lateral tilt angle of the vehicle detected by the Tilt sensor (Lateral) built in the Main CPU board. (Unit: 0.01 degrees) +: Right-Up, -: Right-Down 1-4. Longitudinal tilt angle (Sub) Longitudinal tilt angle of the vehicle detected by the Sub tilt sensor (Longitudinal) built in the Main CPU board. (Unit: 0.01 degrees) +: Front-Up, -: Front-Down 1-5. Lateral tilt angle (Sub) Lateral tilt angle of the vehicle detected by the Sub tilt sensor (Lateral) built in the Main CPU board. (Unit: 0.01 degrees) +: Right-Up, -: Right-Down 1-6. Lift cylinder pressure (Main) Pressure in bottom room of the lift cylinder calculated based on the signal input from the pressure sensor. (Unit: 0.01 kg/cm2) 1-7. Steering angle [for SV08EWL and SV10EWL] Steering angle calculated based on the signal input from the Steering angle sensor. (Unit: 0.1 degrees) +: Steer Right, -: Steer Left 1-8. 1st inner arm elevation angle Elevation angle of 1st inner arm calculated based on the signal input from the Platform height sensor. (Unit: 0.1 degrees) 1-9. Lift cylinder pressure (Sub) Output Pressure in bottom room of the lift cylinder calculated based on the signal input from the pressure sensor. (Unit: 0.01 kg/cm2)

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Chapter 5 Troubleshooting

MON DI LOW

2) Digital signal input at Lower control box This group displays On/Off signal input to the Main CPU board M6.

Display “1” when input 24V, Display “0” when no input.

They input 24V when both Emergency stop buttons on Upper and Lower control box are pulled up and satisfy the condition for each item described below.

DI

2-1. Key switch Upper <D1> Key switch is in “Upper” position.

UPPER

DI

2-2. Key switch Lower <D2> * Key switch is in “Lower” position.

LOWER

DI LOWENA

DI LIFTUP

DI LIFTDW

DI EXAM

DI LIMIT

2-3. Enable switch (Lower) <D3> * Key switch is in “Upper” or “Lower” position. * Enable / Pre-operation check swicth is in “Enable” position.

2-4. Lift switch Up <D4> * Key switch is in “Upper” or “Lower” position. * Lift switch is in “Up” position.

2-5. Lift switch Down <D5> * Key switch is in “Upper” or “Lower” position. * Lift switch is in “Down” position.

2-6. Pre-operation check switch <D6> * Key switch is in “Upper” or “Lower” position. * Enable / Pre-operation check swicth is in “Pre-operation check” position.

2-7. Override switch Limit <D7> * Key switch is in “Upper” or “Lower” position. * Override switch is in “Limit” position.

DI

2-8. Override switch Release <D8> * Key switch is in “Upper” or “Lower” position.

FREE

* Override switch is in “Release” position.

DI

2-9. Hourmeter <D9> * Key switch is in “Upper” or “Lower” position.

HOUR

DI

2-10. Travel limitation <D10> * Key switch is in “Upper” or “Lower” position.

NOTSTW

DI

2-11. Lift Up solenoid Output check <D11> * When the main CPU board (M6) outputs to the Platform lift up solenoid valve.

UPSOLI

DI

2-12. Lift Down solenoid Output check <D12> * When the main CPU board (M6) outputs to the Platform lift down solenoid valve.

DWSOLI

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Chapter 5 Troubleshooting

MON DI UP

3) Digital signal input at Upper control box This group displays On/Off signal input to the Sub CPU board.

Display “1” when input 5V, Display “0” when no input.

They input 5V when both Emergency stop buttons on Upper and Lower control box are pulled up, Key switch is in “Upper” position and satisfy the condition for each item described below.

DI

3-1. Enable switch (Upper) <D1> Enable switch is in “On” position.

UPENA

DI

3-2. Travel Forward <D2> Not in use.

FWD

DI

3-3. Travel Backward <D3> Not in use.

REV

DI

3-4. Steering switch Right <D4> Steering switch is in “Right” position.

STEERR

DI

3-5. Steering switch Left <D5> Steering switch is in “Left” position.

STEERL

DI

3-6. Lift / Travel select switch Travel <D6> Lift / Travel select switch is in “Travel” position.

RUN

DI

3-7. Lift / Travel select switch Lift <D7> Lift / Travel select switch is in “Lift” position.

LIFT

DI

3-8. Horn button <D8> Horn button is pushed.

HORN

DI ZONEA

3-9. Capacity select switch Indoor / Zone A <D9> [SV06ENS and SV08EWL] Not in use [SV06ENL, SV08ENL and SV10EWL] Capacity select switch is in “Indoor / Zone A” position.

DI ZONEB

3-10. Capacity select switch Outdoor / Zone B <D10> [SV06ENS and SV08EWL] Always.

[SV06ENL, SV08ENL and SV10EWL] Capacity select switch is in “Outdoor / Zone B” position.

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Chapter 5 Troubleshooting

MON

4) Signal input at Inverter unit This group displays Input / Output of the Inverter unit.

INVERT

INV

4-1. Pothole limit switches <SW3> Displays “1” when the pothole protectors are deployed. (When inputs 24V)

POT

INV

4-2. Travel motor (Right) Temperature <SN3> Displays temperature of Travel motor (Right). (Unit: degrees Celsius)

TMP_MR

INV

4-3. Travel motor (Left) Temperature <THM+> Displays temperature of Travel motor (Left). (Unit: degrees Celsius)

TMP_ML

INV

4-4. Inverter unit (Right) Temperature Displays temperature of Travel motor (Right). (Unit: degrees Celsius)

TMP_DR

INV

4-5. Inverter unit (Left) Temperature [for SV08EWL and SV10EWL] Displays temperature of Travel motor (Left). (Unit: degrees Celsius)

TMP_DL

INV

4-6. Power supply to Inverter unit <KEYSTART> Displays power supply voltage to the Inverter unit. (Unit: 0.1 volt)

BATVOL

INV

4-7. Travel motor (Right) Speed <SS1> Displays revolving speed of Travel motor (Right). (Unit: rpm)

SPD_R

INV

4-8. Travel motor (Left) Speed <SS2> Displays revolving speed of Travel motor (Left). (Unit: rpm)

SPD_L

INV

4-9. Output current to Travel motor (Right) Displays output current to the Travel motor (Right). (Unit: Ampere)

CURR_R

INV CURR_L

INV

4-10. Output current to Travel motor (Left) [for SV08EWL and SV10EWL] Displays output current to the Travel motor (Left). (Unit: Ampere) 4-11. Platform stowage limit switch Not in use

DRVLMT

INV

4-12. Contactor check Not in use

CNTCHK

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Chapter 5 Troubleshooting

MON AI LOW

AI TILTX1

AI TILTY1

AI

5) Analog signal input at Lower control box This group displays tilt angle of the vehicle detected by the Tilt sensors and analog signal input to the Main CPU board M6 or Inverter unit..

5-1. Tilt sensor (Longitudinal) Main Longitudinal tilt angle of the vehicle detected by the Tilt sensor (Longitudinal) Main built in the Main CPU board. (Unit: 0.1 degrees) 5-2. Tilt sensor (Lateral) Main Lateral tilt angle of the vehicle detected by the Tilt sensor (Lateral) Main built in the Main CPU board. (Unit: 0.1 degrees) 5-3. Pressure sensor (Main) <KA1> AD value calculated based on the signal input from the pressure sensor (Main).

PRESS

AI

5-4. Steering angle sensor (Main) <KA2> AD value calculated based on the signal input from the Steering angle sensor.

STEER

AI

5-5. Platform height sensor (Main) <KA3> AD value calculated based on the signal input from the Platform height sensor.

LINK M

AI LINK S

AI BATTRY

AI TILTX2

AI TILTY2

AI

5-6. Platform height sensor (Sub) <KA4> AD value calculated based on the signal input from the Platform height sensor (Sub).

5-7. Power supply to Main CPU board M6 <Vs> AD value calculated based on the power supply voltage to the Main CPU board M6.

5-8. Tilt sensor (Longitudinal) Sub Longitudinal tilt angle of the vehicle detected by the Tilt sensor (Longitudinal) Sub built in the Main CPU board. (Unit: 0.1 degrees) 5-9. Tilt sensor (Lateral) Sub Lateral tilt angle of the vehicle detected by the Tilt sensor (Lateral) Sub built in the Main CPU board. (Unit: 0.1 degrees) 5-10. Pressure sensor (Sub) <AN1 (Inverter unit)> AD value calculated based on the signal input from the pressure sensor (Sub).

PRESS2

AI

5-11. Steering angle sensor (Sub) <KA2> Not in use.

STEER2

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Chapter 5 Troubleshooting

MON

6) Analog signal input at Upper control box This group displays analog signal input to the Sub CPU board.

AI UP

AI JOY

AI DIAL

AI

6-1. Joystick controller Speed signal <KA1> AD value calculayrd based on the signakl input from the Joystick controller.

(Speed signal) 6-2. Joystick controller Direction signal <KA2> AD value calculayrd based on the signakl input from the Joystick controller.

(Direction select signal) 6-3. Power supply to Sub CPU board <Vs> AD value calculated based on the power supply voltage to the Sub CPU board.

BATTRY

MON

7) Signal output at Lower control box This group displays output signal from the Main CPU board M6.

DO LOW

DO

7-1. Flash beacon light <OT1> Displays “1” when output 24V.

BEACON

DO

7-2. Horn <OT2> Displays “1” when output 24V.

HORN

DO

7-3. Platform lift Up solenoid valve <OT3> Displays “1” when output 24V.

LIFTUP

DO

7-4. Platform lift Down solenoid valve. <OT4> Displays “0 to 1000” according to the output value..

LIFTDW

DO

7-5. Steering solenoid valve (Right) <OT5> Displays “1” when output 24V.

STEERR

DO

7-6. Steering solenoid valve (Left) <OT6> Displays “1” when output 24V.

STEERL

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Chapter 5 Troubleshooting

MON

8) Signal output at Upper control box This group displays output signal from the Sub CPU board.

DO UP

DO

8-1. Tilt alarm buzzer <BZ1> Displays “1” when output.

ALARM

DO

8-2. Heavy load mode Displays “1” when output.

HEAVY

DO

8-3. System failure light <L1> Displays “1” when output.

ERR

DO

8-4. Overload warning light <L2> Displays “1” when output.

LOAD

DO

8-5. Tilt warning light <L3> Displays “1” when output.

TILT

DO

8-6. Battery level indicator 1 <L4> Displays “1” when output.

BATT1

DO

8-7. Battery level indicator 4 <L5> Displays “1” when output.

BATT4

DO

8-8. Battery level indicator 3 <L6> Displays “1” when output.

BATT3

DO

8-9. Battery level indicator 2 <L7> Displays “1” when output.

BATT2

MON

9) Signal output at Inverter unit This group displays output signal from the Inverter unit.

DO INV

DO

9-1. Output to DC motor for Power unit <P-> Displays “0 to 255”

PUMP

DO

9-2. Output to Electric magnetic brake (Right) <SOL2> Displays “0 to 255”

BRAKER

DO

9-3. Output to Electric magnetic brake (Left) <SOL3> Displays “0 to 255”

BRAKEL

DO

9-4. Output to Contactor <SOL4> Displays “0 to 255”

CONTAC 5-22

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5-23

Chapter 5 Troubleshooting 3. Flow chart (Structure of Adjustment mode) Monitor menu 㼇㻹㼑㼚㼡㻌㻸㼑㼓㼑㼚㼐㼉

㻿㻱㻸 㻹㻱㻺㼁 㻿㼠㼍㼞㼠㼡㼜㻌㼟㼏㼞㼑㼑㼚 㻿㻱㻸 㻭㻰㻶㼁㻿㼀 㻭㼐㼖㼡㼟㼠㼙㼑㼚㼠

㼇㻭㼞㼞㼛㼣㻌㻔㻿㼃㻌㼛㼜㼑㼞㼍㼠㼕㼛㼚㻕㻌㻸㼑㼓㼑㼚㼐㼉

㻌㻦㻌㼀㼛㼜㻌㼙㼑㼚㼡

㻌㻦㻌㻻㼢㼑㼞㼞㼕㼐㼑㻌㼟㼣㼕㼠㼏㼔䚷㻔㼀㼛㻌㼐㼑㼏㼕㼐㼑㻕

㻌㻦㻌㻹㼍㼕㼚㻌㼙㼑㼚㼡

㻌㻦㻌㻼㼞㼑㻙㻻㼜㼑㼞㼍㼠㼕㼛㼚㻌㻯㼔㼑㼏㼗㻌㻿㼣㼕㼠㼏㼔㻌㻔㼀㼛㻌㼟㼑㼘㼑㼏㼠㻕

㻌㻦㻌㻿㼡㼎㻌㼙㼑㼚㼡

㻿㻱㻸 㻼㻾㻹㻿㻱㼀 㻵㼚㼐㼕㼢㼕㼐㼡㼍㼘㻌㼟㼑㼠㼠㼕㼚㼓 㻿㻱㻸 㻹㻻㻺 㻹㼛㼚㼕㼠㼛㼞 㻿㻱㻸 㼂㻱㻾 㼂㼑㼞㼟㼕㼛㼚

5-24

㻹㻻㻺 㻼㻻㻿 㻼㼛㼟㼕㼠㼕㼛㼚

㻹㻻㻺 㻴㻱㻵㻳㻴㼀 㻼㼘㼍㼠㼒㼛㼞㼙㻌㼔㼑㼕㼓㼔㼠 㼇㼙㼙㼉

㻹㻻㻺 㼀㻵㻸㼀㼄㻝 㻸㼛㼚㼓㼕㼠㼡㼐㼕㼚㼍㼘㻌 㼠㼕㼘㼠㻌㼍㼚㼓㼘㼑㻌㻔㻹㼍㼕㼚㻕 㼇㻜㻚㻜㻝㻌㼐㼑㼓㼉

㻹㻻㻺 㼀㻵㻸㼀㼅㻝 㻸㼍㼠㼑㼞㼍㼘㻌㼠㼕㼘㼠㻌㼍㼚㼓㼘㼑 㻔㻹㼍㼕㼚㻕 㼇㻜㻚㻜㻝㻌㼐㼑㼓㼉

㻹㻻㻺 㼀㻵㻸㼀㼄㻞 㻸㼛㼚㼓㼕㼠㼡㼐㼕㼚㼍㼘 㼠㼕㼘㼠㻌㼍㼚㼓㼘㼑㻌㻔㻿㼡㼎㻕 㼇㻜㻚㻜㻝㻌㼐㼑㼓㼉

㻹㻻㻺 㼀㻵㻸㼀㼅㻞 㻸㼍㼠㼑㼞㼍㼘㻌㼠㼕㼘㼠㻌㼍㼚㼓㼘㼑 㻔㻿㼡㼎㻕 㼇㻜㻚㻜㻝㻌㼐㼑㼓㼉

㻹㻻㻺 㻼㻾㻱㻿㻿 㻸㼕㼒㼠㻌㼏㼥㼘㼕㼚㼐㼑㼞㻌 㼜㼞㼑㼟㼟㼡㼞㼑㻌㻔㻹㼍㼕㼚㻕 㼇㻜㻚㻜㻝㻌㼗㼓㻛㼏㼙㻞㼉

㻹㻻㻺 㻰㻵㻌㻸㻻㼃 㻸㼛㼣㼑㼞㻌㼟㼣㼕㼠㼏㼔㻌㼕㼚㼜㼡㼠

㻰㻵 㼁㻼㻼㻱㻾 㻷㼑㼥㻌㼟㼣㻌㼁㼜㼜㼑㼞 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻸㻻㼃㻱㻾 㻷㼑㼥㻌㼟㼣㻌㻸㼛㼣㼑㼞 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻸㻻㼃㻱㻺㻭 㻱㼚㼍㼎㼘㼑㻌㻔㻸㼛㼣㼑㼞㻕 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻸㻵㻲㼀㼁㻼 㻸㼕㼒㼠㻌㼡㼜 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻸㻵㻲㼀㻰㼃 㻸㼕㼒㼠㻌㼐㼛㼣㼚 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻱㼄㻭㻹 㻼㼞㼑㻙㻻㼜㼑㼞㼍㼠㼕㼛㼚㻌㻯㼔㼑㼏㼗 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻹㻻㻺 㻰㻵㻌㼁㻼 㼁㼜㼜㼑㼞㻌㼟㼣㼕㼠㼏㼔㻌㼕㼚㼜㼡㼠

㻰㻵 㼁㻼㻱㻺㻭 㻱㼚㼍㼎㼘㼑㻌㻔㼁㼜㼜㼑㼞㻕 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻲㼃㻰 㻺㼛㼠㻌㼕㼚㻌㼡㼟㼑

㻰㻵 㻾㻱㼂 㻺㼛㼠㻌㼕㼚㻌㼡㼟㼑

㻰㻵 㻿㼀㻱㻱㻾㻾 㻿㼠㼑㼑㼞㻌㼞㼕㼓㼔㼠 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻿㼀㻱㻱㻾㻸 㻿㼠㼑㼑㼞㻌㼘㼑㼒㼠 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻾㼁㻺 㼀㼞㼍㼢㼑㼘㻌㼟㼑㼘㼑㼏㼠 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻹㻻㻺 㻵㻺㼂 㻵㻺㼂㻱㻾㼀 㻼㻻㼀 㻵㼚㼢㼑㼞㼠㼑㼞㻌㼕㼚㼒㼛㼞㼙㼍㼠㼕㼛㼚 㻼㼛㼠㼔㼛㼘㼑㻌㼜㼞㼛㼠㼑㼏㼠㼛㼞㼟 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻵㻺㼂 㼀㻹㻼㼋㻹㻾 㻾㼕㼓㼔㼠㻌㼙㼛㼠㼛㼞㻌㼠㼑㼙㼜㻚 䠷㼐㼑㼓㼞㼑㼑㼟㻌㻯㼑㼘㼟㼕㼡㼟䠹

㻵㻺㼂 㼀㻹㻼㼋㻹㻸 㻸㼑㼒㼠㻌㼙㼛㼠㼛㼞㻌㼠㼑㼙㼜㻚 䠷㼐㼑㼓㼞㼑㼑㼟㻌㻯㼑㼘㼟㼕㼡㼟䠹

㻵㻺㼂 㼀㻹㻼㼋㻰㻾 㻾㼕㼓㼔㼠㻌㼕㼚㼢㼑㼞㼠㼑㼞㻌㼠㼑㼙㼜㻚 䠷㼐㼑㼓㼞㼑㼑㼟㻌㻯㼑㼘㼟㼕㼡㼟䠹

㻵㻺㼂 㼀㻹㻼㼋㻰㻸 㻸㼑㼒㼠㻌㼕㼚㼢㼑㼞㼠㼑㼞㻌㼠㼑㼙㼜㻚 䠷㼐㼑㼓㼞㼑㼑㼟㻌㻯㼑㼘㼟㼕㼡㼟䠹

㻵㻺㼂 㻮㻭㼀㼂㻻㻸 㻼㼛㼣㼑㼞㻌㼠㼛㻌㻵㼚㼢㼑㼞㼠㼑㼞 䠷㻜㻚㻝㼂䠹

㻹㻻㻺 㻭㻵㻌㻸㻻㼃 㻸㼛㼣㼑㼞㻌㼍㼚㼍㼘㼛㼓㻌㼕㼚㼜㼡㼠

㻭㻵 㼀㻵㻸㼀㼄㻝 㼀㼕㼘㼠㻌㼟㼑㼚㼟㼛㼞 㻸㼛㼚㼓㼕㼥㼡㼐㼕㼚㼍㼘㻌㻔㻹㼍㼕㼚㻕 㼇㻜㻚㻝㻌㼐㼑㼓㼉

㻭㻵 㼀㻵㻸㼀㼅㻝 㼀㼕㼘㼠㻌㼟㼑㼚㼟㼛㼞 㻸㼍㼠㼑㼞㼍㼘㻌㻔㻹㼍㼕㼚㻕 㼇㻜㻚㻝㻌㼐㼑㼓㼉

㻭㻵 㻼㻾㻱㻿㻿 㻼㼞㼑㼟㼟㼡㼞㼑㻌㼟㼑㼚㼟㼛㼞 㻔㻹㼍㼕㼚㻕 㼇㻭㻰㻌㼢㼍㼘㼡㼑㼉

㻭㻵 㻿㼀㻱㻱㻾 㻿㼠㼑㼑㼞㼕㼚㼓㻌㼍㼚㼓㼘㼑 㼟㼑㼚㼟㼛㼞㻌㻔㻹㼍㼕㼚㻕 㼇㻭㻰㻌㼢㼍㼘㼡㼑㼉

㻭㻵 㻸㻵㻺㻷㻌㻹 㻼㼘㼍㼠㼒㼛㼞㼙㻌㼔㼑㼕㼓㼔㼠 㼟㼑㼚㼟㼛㼞㻌㻔㻹㼍㼕㼚㻕 㼇㻭㻰㻌㼢㼍㼘㼡㼑㼉

㻭㻵 㻸㻵㻺㻷㻌㻿 㻼㼘㼍㼠㼒㼛㼞㼙㻌㼔㼑㼕㼓㼔㼠 㼟㼑㼚㼟㼛㼞㻌㻔㻿㼡㼎㻕 㼇㻭㻰㻌㼢㼍㼘㼡㼑㼉

㻹㻻㻺 㻭㻵㻌㼁㻼 㼁㼜㼜㼑㼞㻌㼍㼚㼍㼘㼛㼓㻌㼕㼚㼜㼡㼠

㻭㻵 㻶㻻㼅 㻶㼛㼥㼟㼠㼕㼏㼗 䠷㻭㻰㻌㼢㼍㼘㼡㼑䠹

㻭㻵 㻰㻵㻭㻸 㻿㼠㼑㼑㼞㼕㼚㼓㻌㼐㼕㼍㼘 䠷㻭㻰㻌㼢㼍㼘㼡㼑䠹

㻭㻵 㻮㻭㼀㼀㻾㼅 㻼㼛㼣㼑㼞㻌㼠㼛㻌 㻿㼡㼎㻌㻯㻼㼁 㼇㻭㻰㻌㼢㼍㼘㼡㼑㼉

㻭㻵 㻮㻭㻯㻷 㼀㼡㼞㼚㻌㼎㼍㼏㼗

㻹㼍㼕㼚 㼙㼑㼚㼡

㻹㻻㻺 㻰㻻㻌㻸㻻㼃 㻸㼛㼣㼑㼞㻌㼛㼡㼠㼜㼡㼠

㻰㻻 㻮㻱㻭㻯㻻㻺 㻲㼘㼍㼟㼔㻌㼎㼑㼍㼏㼛㼚 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻰㻻 㻴㻻㻾㻺 㻴㼛㼞㼚 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻰㻻 㻸㻵㻲㼀㼁㻼 㻸㼕㼒㼠㻌㼡㼜 䠷㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓䠹

㻰㻻 㻸㻵㻲㼀㻰㼃 㻸㼕㼒㼠㻌㼐㼛㼣㼚 㼇㻜㻚㻜㻝㻑㻌㼛㼡㼠㼜㼡㼠㼉

㻰㻻 㻿㼀㻱㻱㻾㻾 㻿㼠㼑㼑㼞㻌㼞㼕㼓㼔㼠 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻰㻻 㻿㼀㻱㻱㻾㻸 㻿㼠㼑㼑㼞㻌㼘㼑㼒㼠 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻹㻻㻺 㻰㻻㻌㼁㻼 㼁㼜㼜㼑㼞㻌㼛㼡㼠㼜㼡㼠

㻰㻻 㻭㻸㻭㻾㻹 㼀㼕㼘㼠㻌㼍㼘㼍㼞㼙㻌㼎㼡㼦㼦㼑㼞 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻰㻻 㻴㻱㻭㼂㼅 㻴㼑㼍㼢㼥㻌㼘㼛㼍㼐㻌㼙㼛㼐㼑 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻰㻻 㻱㻾㻾 㻿㼥㼟㼠㼑㼙㻌㼒㼍㼕㼘㼡㼞㼑㻌㼘㼕㼓㼔㼠 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻰㻻 㻸㻻㻭㻰 㻻㼢㼑㼞㼘㼛㼍㼐㻌㼘㼕㼓㼔㼠 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻰㻻 㼀㻵㻸㼀 㼀㼕㼘㼠㻌㼣㼍㼞㼚㼕㼚㼓㻌㼘㼕㼓㼔㼠 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻰㻻 㻮㻭㼀㼀㻝 㻮㼍㼠㼠㼑㼞㼥㻌㼘㼑㼢㼑㼘㻌㻝 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻹㻻㻺 㻰㻻㻌㻵㻺㼂 㻵㼚㼢㼑㼞㼠㼑㼞㻌㼛㼡㼠㼜㼡㼠

㻰㻻 㻼㼁㻹㻼 㻼㼡㼙㼜㻌㼛㼡㼠㼜㼡㼠 䠷㻜㻌㼠㼛㻌㻞㻡㻡㻦㻌㼛㼡㼠㼜㼡㼠䠹

㻰㻻 㻮㻾㻭㻷㻱㻾 㻮㼞㼍㼗㼑㻌㼞㼕㼓㼔㼠 㼇㻜㻌㼠㼛㻌㻞㻡㻡㻦㻌㻻㼡㼠㼜㼡㼠㼉

㻰㻻 㻮㻾㻭㻷㻱㻸 㻮㼞㼍㼗㼑㻌㼘㼑㼒㼠 㼇㻜㻌㼠㼛㻌㻞㻡㻡㻦㻌㻻㼡㼠㼜㼡㼠㼉

㻰㻻 㻯㻻㻺㼀㻭㻯 㻯㼛㼚㼠㼍㼏㼠㼛㼞 㼇㻜㻌㼠㼛㻌㻞㻡㻡㻦㻌㻻㼡㼠㼜㼡㼠㼉

㻰㻻 㻮㻭㻯㻷 㼀㼡㼞㼚㻌㼎㼍㼏㼗

㻹㼍㼕㼚 㼙㼑㼚㼡

㻹㻻㻺 㻮㻭㻯㻷 㼀㼡㼞㼚㻌㼎㼍㼏㼗

㼀㼛㼜 㼙㼑㼚㼡

SSJ00066

Chapter 5 Troubleshooting

㻹㻻㻺 㻿㼀㻱㻱㻾 㻿㼠㼑㼑㼞㼕㼚㼓㻌㼍㼚㼓㼘㼑 㼇㻜㻚㻝㻌㼐㼑㼓㼉

㻹㻻㻺 㻸㻵㻺㻷 㻝㼟㼠㻌㼕㼚㼚㼑㼞㻌㼍㼞㼙㻌 㼑㼘㼑㼢㼍㼠㼕㼛㼚㻌㼍㼚㼓㼘㼑 㼇㻜㻚㻝㻌㼐㼑㼓㼉

㻹㻻㻺 㻼㻾㻱㻿㻿㻞 㻸㼕㼒㼠㻌㼏㼥㼘㼕㼚㼐㼑㼞㻌 㼜㼞㼑㼟㼟㼡㼞㼑㻌㻔㻿㼡㼎㻕 㼇㻜㻚㻜㻝㻌㼗㼓㻛㼏㼙㻞㼉

㻹㻻㻺 㻮㻭㻯㻷 㼀㼡㼞㼚㻌㼎㼍㼏㼗

㻹㼍㼕㼚 㼙㼑㼚㼡

㻰㻵 㻸㻵㻹㻵㼀 㻻㼢㼑㼞㼞㼕㼐㼑㻌㻸㼕㼙㼕㼠 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻲㻾㻱㻱 㻻㼢㼑㼞㼞㼕㼐㼑㻌㼞㼑㼘㼑㼍㼟㼑 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻴㻻㼁㻾 㻴㼛㼡㼞㻌㼙㼑㼠㼑㼞 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻺㻻㼀㻿㼀㼃 㼀㼞㼍㼢㼑㼘㻌㼘㼕㼙㼕㼠㼍㼠㼕㼛㼚 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㼁㻼㻿㻻㻸㻵 㻸㼕㼒㼠㻌㼁㼜㻌㼟㼛㼘㻚㻌㻻㼡㼠㼜㼡㼠 㼇㻝㻌㻩㻌㼛㼡㼠㼜㼡㼠㼉

㻰㻵 㻰㻵 㻰㼃㻿㻻㻸㻵 㻮㻭㻯㻷 㻸㼕㼒㼠㻌㻰㼛㼣㼚㻌㼟㼛㼘㻚㻌㻻㼡㼠㼜㼡㼠 㼀㼡㼞㼚㻌㼎㼍㼏㼗 㼇㻝㻌㻩㻌㼛㼡㼠㼜㼡㼠㼉

㻰㻵 㻸㻵㻲㼀 㻸㼕㼒㼠㻌㼟㼑㼘㼑㼏㼠 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻴㻻㻾㻺 㻴㼛㼞㼚 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㼆㻻㻺㻱㻭 㻵㼚㼐㼛㼛㼞㻌㻛㻌㼆㼛㼚㼑㻌㻭 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㼆㻻㻺㻱㻮 㻻㼡㼠㼐㼛㼛㼞㻌㻛㻌㼆㼛㼚㼑㻌㻮 㼇㻝㻌㻩㻌㼟㼣㼕㼠㼏㼔㻌㼛㼚㼉

㻰㻵 㻮㻭㻯㻷 㼀㼡㼞㼚㻌㼎㼍㼏㼗

㻹㼍㼕㼚 㼙㼑㼚㼡

㻵㻺㼂 㻿㻼㻰㼋㻾 㻾㼕㼓㼔㼠㻌㼙㼛㼠㼛㼞㻌㼟㼜㼑㼑㼐 䠷㼞㼜㼙䠹

㻵㻺㼂 㻿㻼㻰㼋㻸 㻸㼑㼒㼠㻌㼙㼛㼠㼛㼞㻌㼟㼜㼑㼑㼐 䠷㼞㼜㼙䠹

㻵㻺㼂 㻯㼁㻾㻾㼋㻾 㻾㼕㼓㼔㼠㻌㼙㼛㼠㼛㼞㻌㼏㼡㼞㼞㼑㼚㼠 䠷㻭䠹

㻵㻺㼂 㻯㼁㻾㻾㼋㻸 㻸㼑㼒㼠㻌㼙㼛㼠㼛㼞㻌㼏㼡㼞㼞㼑㼚㼠 䠷㻭䠹

㻵㻺㼂 㻰㻾㼂㻸㻹㼀 㻺㼛㼠㻌㼕㼚㻌㼡㼟㼑

㻵㻺㼂 㻯㻺㼀㻯㻴㻷 㻺㼛㼠㻌㼕㼚㻌㼡㼟㼑

㻵㻺㼂 㻮㻭㻯㻷 㼀㼡㼞㼚㻌㼎㼍㼏㼗

㻭㻵 㻮㻭㼀㼀㻾㼅 㻼㼛㼣㼑㼞㻌㼠㼛㻌 㻹㼍㼕㼚㻌㻯㻼㼁 㼇㻭㻰㻌㼢㼍㼘㼡㼑㼉

㻭㻵 㼀㻵㻸㼀㼄㻞 㼀㼕㼘㼠㻌㼟㼑㼚㼟㼛㼞 㻸㼛㼚㼓㼕㼠㼡㼐㼕㼚㼍㼘㻌㻔㻿㼡㼎㻕 㼇㻜㻚㻝㻌㼐㼑㼓㼉

㻭㻵 㼀㻵㻸㼀㼅㻞 㼀㼕㼘㼠㻌㼟㼑㼚㼟㼛㼞 㻸㼍㼠㼑㼞㼍㼘㻌㻔㻿㼡㼎㻕 㼇㻜㻚㻝㻌㼐㼑㼓㼉

㻭㻵 㻼㻾㻱㻿㻿㻞 㻼㼞㼑㼟㼟㼡㼞㼑㻌㼟㼑㼚㼟㼛㼞 㻔㻿㼡㼎㻕 㼇㻭㻰㻌㼢㼍㼘㼡㼑㼉

㻭㻵 㻿㼀㻱㻱㻾㻞 㻿㼠㼑㼑㼞㼕㼚㼓㻌㼍㼚㼓㼘㼑 㼟㼑㼚㼟㼛㼞㻌㻔㻿㼡㼎㻕 㼇㻭㻰㻌㼢㼍㼘㼡㼑㼉

㻭㻵 㻮㻭㻯㻷 㼀㼡㼞㼚㻌㼎㼍㼏㼗

㻹㼍㼕㼚 㼙㼑㼚㼡

㻰㻻 㻮㻭㻯㻷 㼀㼡㼞㼚㻌㼎㼍㼏㼗

㻹㼍㼕㼚 㼙㼑㼚㼡

㻰㻻 㻮㻭㼀㼀㻠 㻮㼍㼠㼠㼑㼞㼥㻌㼘㼑㼢㼑㼘㻌㻠 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻰㻻 㻮㻭㼀㼀㻟 㻮㼍㼠㼠㼑㼞㼥㻌㼘㼑㼢㼑㼘㻌㻟 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻰㻻 㻮㻭㼀㼀㻞 㻮㼍㼠㼠㼑㼞㼥㻌㼘㼑㼢㼑㼘㻌㻞 㼇㻝㻌㻩㻌㻻㼡㼠㼜㼡㼠㼠㼕㼚㼓㼉

㻰㻻 㻮㻭㻯㻷 㼀㼡㼞㼚㻌㼎㼍㼏㼗

㻹㼍㼕㼚 㼙㼑㼚㼡

SSJ00066

㻹㼍㼕㼚 㼙㼑㼚㼡

㻹㼍㼕㼚 㼙㼑㼚㼡

5-25

Chapter 5 Troubleshooting

Emergency operations When the Platform lift, Travel and Steering functions are disabled because of any problem, operate the machine following the instruction described in this clause to stow the platform and then escape from working site.

Do not perform emergency operations described in this clause unless an immediate emergency exists.

These operations disable the machine's safety devices individually described in the applicable emergency operation and can allow unsafe movement of the machine that could result in death or serious injury.

Lower the platform and unload it before towing the machine.

Machine may tip over if towing the machine while the platform is lifted and / or loaded.

This will result in death or serious injury.

Override switch Platform lift, Travel and steering functions will be disabled when any sensor error occurs.

1. Platform lift down Operate platform lift switch to “Down” position with pushing override switch to stow the platform.

2. Travel and steering functions Push Override switch for more than one second, then operate travel joystick and steering switch to escape the machine from working site.

It enables these functions for 30 seconds. Alarm buzzer sounds at the same time.

The override switch does not enable travel and steering functions if tilt sensor error occurs.

In this case, use emergency lowering handle to stow the platform (See page 5-27) or Brake release connectors to tow the machine to escape from working site (See page 5-28) .

Override switch

Fig. 5-4 Override switch

5-26

SSJ00066

Chapter 5 Troubleshooting

Override switch operation will be recorded each time.

The history of override switch operation is popssible to read by using adjustment tool.

Date of “override switch operation”

Code of “override switch operation”

Fig. 5-5 History of override switch operation

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.5-6, so that the platform start lowering.

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

Emergency lowering handle

Fig. 5-6 Emergency lowering handle SSJ00066

5-27

Chapter 5 Troubleshooting

Brake release connector Free the steering linkage, parking brake on both Left and Right travel motor, 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.

Machine may tip over if towing the machine while the platform is lifted and / or loaded.

This will result in death or serious injury.

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

Steering lock pin

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

2. Free the parking brake by Brake release connectors a) Set up the wheel chocks in front and rear of all tires. b) Open the left side battery box. c) Disconnect the connector 24B, and then connect the Male side of 24B and Female side of 25B which is free (Pluged). d) Disconnect the connector 34B, and then connect the Male side of 34B and Female side of 35B which is free (Pluged).

Steering cylinder

Fig. 5-7 Steering lock pin

Brake release connector

e) Attach the sling chain or wire rope to the front or rear Fig. 5-8 Connector of hoisting rings. f) Remove the wheel chocks carefully and then tow the machine slowly. g) After towing the machine, Disconnect the connector 24B and 25B, and then connect Male and Female of the 24B. Disconnect the connector 34B and 35B, and then connect Male and Female of the 34B.

Hoisting ring

Hoisting ring

Front

Rear

Fig. 5-9 Hoisting ring Confirm correct operation of the parking brakes after the connectors 24B and 34B have been reconnected. Failure to confirm operation of the parking brakes could result in unexpected machine movement, this will result in death or serious injury.

5-28

SSJ00066

Chapter 5 Troubleshooting

Manual release screw When the parking brakes are not freed by changing Brake release connectors because of dead battery or faulty electric magnetic brakes, release the parking brake manually by using screws.

M5

a) Prepare four (4) screws.

Thread size: M5 Length: 20 mm 20 mm

Do not use longer screw, or it damages electric magnetic brake.

Fig. 5-10 Required screw

b) Set up the wheel chocks in front and rear of all tires. c) Open the cover of the travel motor. d) Insert two screws into electric magnetic brake on each travel motor. e) Screw them in until head of the screw touches to the surface of electric magnetic brake.

Do not tighten them, or it damages electric magnetic brake.

Manual release screw (M5 x 20 mm)

Cover

Screw (M4 x 8 mm)

Electric magnetic brake

Fig. 5-11 Manual release screw f) Attach the sling chain or wire rope to the front or rear of hoisting rings. g) Remove the wheel chocks carefully and then tow the machine slowly. h) After towing the machine, Remove the manual release screws from electric magnetic brakes, and then put the cover on each travel motor.

Confirm correct operation of the parking brakes after removing manual release screws.

Failure to confirm operation of the parking brakes could result in unexpected machine movement, this will result in death or serious injury.

SSJ00066

5-29

Chapter 5 Troubleshooting

This page intentionally left blank.

5-30

SSJ00066

Chapter 6 Inspection and Maintenance

Chapter 6 Inspection and Maintenance

SSJ00066

6-1

Chapter 6 Inspection and Maintenance

Daily inspection procedures The daily inspections should be performed with the machine being set up on firm and level surface.

See operation manual for detail.

1. Visual check Item Oil leakage

Machine

Damage

Descriptions Check around the machine for oil leakage before and after the pre-start check.

Check appearance of the machine for any damage.

Cracks, Deformation, Check for cracks, deformation and any damage.

Damage Cracks, Deformation, Check for cracks, deformation and any damage.

Damage

Scissor arms Platform

Switches

Cracks, Deformation, Check for cracks, deformation and any damage.

Damage Wet, Dirt, Damage Check for wet, dirt and any damage.

Wire harnesses Covers Guardrails

Damage Closed securely Attached properly

Bolts

Looseness, Damage, Check if any bolts are loose, damaged or missing.

Missing Missing, Legibility, Check if any decals are missing, illegible or damaged.

Damage

Other parts

Decals

Check for any damage.

Check that all covers are closed securely.

Check that all guardrails are attached properly.

Hydraulic oil tank Batteries

Hydraulic oil level Battery fluid leakage Battery fluid level

Tires, Wheels

Damage, Block, Wear Check for any damage, cut of block, uneven wear.

Fixing bolts Check fixing bolts for looseness or missing.

Installation, Ground Check that the antistatic strap is properly installed and touching to the ground.

Antistatic strap

Lower the platform fully and then check the hydraulic oil level.

Check battery for fluid leakage.

Check battery fluid level of each battery cell.

2. Function check Item Battery Level Check

Battery level

Lower Control Check

Buzzer sounds

Preoperation check

Stops between the red arrows.

Buzzer stops, System failure light goes off.

Descriptions Turn the key switch to "Upper" position and then check the battery level on Battery level indicator on upper control.

Raise the platform with holding "Pre-operation check switch" and check that the alarm buzzer sounds.

Keep raising up the platform until it automatically stops, and then check that the roller stopped between the red arrows on the chassis.

Release the "Pre-start check switch" and "Lift switch", and check that the alarm buzzer stops and the system failure light goes off.

Platform Lift Strange noise, Vibrations, Rattling

Emergency Stop

6-2

Raise and lower the platform completely several times, and check that the platform operates smoothly (no strange noise, vibration, or rattling).

Platform lift down limit Platform automatically stops at the height listed below when system lower it. * SV06ENS / SV06ENL : Approx. 1.5 m * SV08ENL : Approx. 1.8 m + SV08EWL / SV10EWL : Approx. 2.0 m All functions are Push the "Emergency stop button", attempt to raise and lower disabled. the platform, and check that the functions are disabled.

SSJ00066

Chapter 6 Inspection and Maintenance Item Natural Descent Check Natural descent Upper Control Check

Platform Lift Strange noise, Vibrations, Rattling

Descriptions Raise the platform 2.5 m, leave it for 5 minutes, and then check visually that the platform remains in its position.

Raise and lower the platform completely several times, and check that the platform moves smoothly (no strange noise, vibration, or rattling).

Platform lift down limit Platform automatically stops at the height listed below when system lower it. * SV06ENS / SV06ENL : Approx. 1.5 m * SV08ENL : Approx. 1.8 m + SV08EWL / SV10EWL : Approx. 2.0 m Travel

Steering Emergency Stop Pothole Pothole Protector Protector Check Interlock

Tilt Lateral Warning direction Check

Travel direction, Stop Operate Joystick slightly to forward and backward, and make sure that the machine travels correct directions, Return the joystick to neutral, and check that the machine stops.

Strange noise, Travel forward and backward several times, and check that the Vibrations, Rattling platform moves smoothly (no strange noise, vibration, or rattling).

Strange noise, Steer right and left several times, and check that the platform Vibrations, Rattling moves smoothly (no strange noise, vibration, or rattling).

All functions are disabled.

Damage, Movement

Push the "Emergency stop button", attempt to raise and lower the platform, and check that the functions are disabled.

Raise the platform 2.5 m, and check that the pothole protector are completely come down.

Lift Up, Travel functions are disabled.

Tilt light goes on,

Place a obstacle under the pothole protector, raise the platform 2.5 m, attempt to raise the platform, travel forward or backward, and check these functions are disabled.

Travel onto a slope more than 3.5 degrees to tilt the machine laterally, check that the tilt light goes on.

184 mm 3m

Fig. 6-1 Lateral direction Lift Up function is Raise up the platform, check that the platform stops before disabled. reaching 3 meters from the ground and alarm buzzer sounds.

Alarm buzzer sounds.

Travel onto a slope more Longitudinal Tilt light goes on, than 3.5 degrees to tilt the direction machine longitudinally, check that the tilt light goes on.

184 mm 3m

Fig. 6-2 Longitudinal direction

Limit Travel Speed Check

SSJ00066

Lift Up function is Raise up the platform, check that the platform stops before disabled. reaching 3 meters from the ground and alarm buzzer sounds.

Alarm buzzer sounds.

Travel at slow speed. Raise the platform more than 2.5 m, travel forward or backward and check that the machine travels at slow speed.

6-3

Chapter 6 Inspection and Maintenance

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

Items Battery box

Power unit

Monthly inspection Battery

Battery charger Hydraulic oil tank

DC motor

Chassis

6-4

Battery charge level Check the battery level indicator.

Battery fluid level

Check battery fluid level of each cell.

Damage, Corrosion on

Check battery terminals for corrosion and any damage.

Damage, Function (See page 4-26) Hydraulic oil level

Charge batteries, and check LED indication.

Lower the platform fully, and then check the hydraulic oil level.

Oil leakage

Check the hydraulic oil tank for oil leakage.

Raise the platform, and check there is no abnormal noise, vibration and excessive heat on DC motor.

Abnormal noise, Vibration, Excessive heat

Chassis frame Cracks, Deformation Check chassis frame for cracks and deformation.

Tire, Wheel Wear, Cut, Check tires for wear, cut and Deformation deformation.

Wheel nuts

Looseness

Check wheel nut for looseness.

Travel motor, Gearbox

Abnormal noise, Damage, Looseness of nuts / bolts

Electric magnetic brake

Function

Travel forward and backward, and check there is no abnormal noise from travel motor or gearbox.

Check travel motor and gearbox for loose bolt/nut and any damage.

Check that the machine stops when the joystick is returned to neutral position.

Steering linkage

Cracks, Deformation, Looseness of stopper bolt

Check steering linkage for cracks and deformation.

Check stopper bolt for looseness.

Steering cylinder Wire harnesses

Oil leakage, Damage Damage

Check steering cylinder for oil leakage and any damage.

Check wire harnesses for any damage.

Hydraulic hoses Pothole protector

Oil leakage, Damage Cracks, Deformation, Lubrication (See page 6-8)

Check hydraulic hoses for oil leakage and any damage.

Check pothole protector for cracks and deformation.

Apply grease.

Annual inspection Check specific gravity of the electrolyte in each cells using hydrometer.

Ref: 1.28 (at 20 deg C)

 

Check battery cables for any damage.

Replace hydraulic oil every 1,200 hours or annually.

            SSJ00066

Chapter 6 Inspection and Maintenance Items Scissor arms

Monthly inspection Scissor arms Safety prop

Platform

pivot pins

Damage

Check pivot pins for any damage.

Lift cylinder

Oil leakage, Damage, Natural descent

Check lift cylinder for oil leakage and any damage.

Raise the platform 2.5 m, leave it for 5 minutes, and then check visually that the platform remains in its position.

Check holding valve for oil leakage.

Pull emergency lowering handle and make sure that the platform lower.

Holding valve

Oil leakage, Function

Wire harnesses Hydraulic hoses Platform

Damage

Extension deck Guardrail

Lower control

Wire harnesses Switches Platform lift function

Emergency stop button

Upper control

Cracks, Deformation Check scissor arms for cracks and deformation.

Cracks, Check safety prop for cracks and Deformations deformation.

Check wire harnesses for any damage.

Oil leakage, Check hydraulic hoses for oil leakage Damage and any damage.

Cracks, Deformation Check platform for cracks and deformation.

Cracks, Deformation Check extension deck for cracks and deformation.

Cracks, Deformation Check guardrail for cracks and deformation.

Damage Check wire harnesses for any damage.

Damage Check switches for any damage.

Function, Abnormal Raise and lower the platform noise, Vibration, completely several times, and check Rattling that the platform operates smoothly (no strange noise, vibration, or rattling).

Damage, Function Push the Emergency stop button, attempt to raise and lower the platform, and check that the functions are disabled.

Check emergency stop button for any damage.

Damage, Legibility Check the indicator for legibility and any damage.

Battery level indicator / hour meter LEDs

Damage, Legibility

Check the LEDs for legibility and any damage.

Decals

Damage, Legibility

Switches, Joystick controller

Damage

Check the LEDs for legibility and any damage.

Check switches and joystick controller for any damage.

SSJ00066

Annual inspection

                  6-5

Chapter 6 Inspection and Maintenance Items Upper control

Monthly inspection Platform lift function

Function, Abnormal Raise and lower the platform noise, Vibration completely several times, and check that the platform operates smoothly (no strange noise, vibration, or rattling).

Travel function Function, Abnormal Travel forward and backward several noise, Vibration times, and check that the platform moves smoothly (no strange noise, vibration, or rattling).

Steering Function, Abnormal Steer right and left several times, and function noise, Vibration check that the platform moves smoothly (no strange noise, vibration, or rattling).

Emergency Damage, Function Push the Emergency stop button, stop button attempt to raise and lower the platform, and check that the functions are disabled.

Check emergency stop button for any damage.

LEDs Damage, Legibility Check the LEDs for legibility and any damage.

Safety devices

Decals

Damage, Legibility

Motion alarm buzzer

Sound

Tilt warning light,

Light,

Platform lift up Function, limit system, Tilt alarm buzzer

Sound

Check the LEDs for legibility and any damage.

Operate Travel and Platform lift functions and check that the motion alarm buzzer sounds.

Tilt the machine longitudinally more than 3.5 degrees, check that the tilt light goes on.

Raise up the platform, check that the platform stops before reaching 3 meters from the ground and alarm buzzer sounds.

Tilt the machine laterally more than 3.5 degrees, check that the tilt light goes on.

Raise up the platform, check that the platform stops before reaching 3 meters from the ground and alarm buzzer sounds.

6-6

Annual inspection

      



SSJ00066

Chapter 6 Inspection and Maintenance Items Safety devices

Monthly inspection Overload sensing system

Function

Travel speed limit system

Function

Platform lift down limit system

Function

Pothole protector interlock system

Function

Pre-operation check

Decals

SSJ00066

Platform stops at specific range

System failure light is not flashing (See page 5-2) Damage, Legibility, Missing

Annual inspection

Set the capacity select switch to "Indoor / Zone A" or "Outdoor / Zone B" position.

(SV06ENL, SV08ENL, SV10EWL only) Load the platform with the weight heavier than the weight listed below, then check that the platform lift up is disabled.

SV06ENS : 270 kg SV06ENL : 430 kg (Indoor) : 270 kg (Outdoor) SV08ENL : 430 kg (Zone A) : 270 kg (Zone B) SV08EWL : 520 kg SV10EWL : 520 kg (Zone A) : 380 kg (Zone B)



Raise the platform more than 2.5 m, travel forward or backward and check that the machine travels at slow speed.



Raise the platform more than 2.5 m, Lower the platform and check that the platform stops before lowering completely.

Place a obstacle under the pothole protector, raise the platform 2.5 m, attempt to raise the platform, travel forward or backward, and check these functions are disabled.

Raise the platform with holding "Preoperation check switch" until it automatically stops, and then check that the roller stopped between the red arrows on the chassis.

Check if the system failure light flashes.

Check if any decals are missing, illegible or damaged.

    

6-7

Chapter 6 Inspection and Maintenance

Lubrications Lubrication intervals

Location

Lubricating point

Interval

Lubricant

Quantity SV06ENS / SV1930E 3.5 liters [0.92 gal]

Hydraulic oil tank

Every 1 years or Hydraulic oil 1,200 working hours (ISO VG22)

Travel gearbox

Every 1 years or Gear oil 1,200 working hours (ISO VG68)

Pothole actuator, Pothole links

100 hours

SV06ENL / SV2032E SV08ENL / SV2632E SV08EWL / SV2646E SV10EWL / SV3246E 5.0 liters [1.32 gal]

Chassis

0.3 litters [0.08 gal]

Grease (General)

As required

Lubrication point Hydraulic oil tank

Travel gearbox Contacting surface between Pothole actuator and Pothole links

Pothole actuator

Pothole link

Fig. 6-3 Lubrication point Recommended lubricant Manufacturers

Hydraulic oil

Gearoil

Grease (General)

Shell oil

Tellus oil S2V22

Omala S2G68

Alvania EP grease 2

6-8

SSJ00066

Chapter 6 Inspection and Maintenance

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

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

Location Chassis

Scissor arms

Lower control box Upper control box

Items

Interval

Part number

Quantity

Platform height sensor

Every 8 years or 9,600 working hours

382-0006600

1

Limit switches for pothole protector

Every 4 years or 4,800 working hours

5C1-0918500 {320-0024200}

2

Pressure sensor

Every 8 years or 9,600 working hours

312-0000043

2

Emergency stop button

Every 4 years or 4,800 working hours

320-0007201

1

Override switch

Every 4 years or 4,800 working hours

173-01102 [173-40000]

1

Emergency stop button

Every 4 years or 4,800 working hours

320-0007201

1

{ } L/S without harness [ ] Switch cap

SSJ00066

6-9

Chapter 6 Inspection and Maintenance The parts listed in the table below are important for machine’s main function and highly recommended to replace at designated intervals.

Location Chassis

Lower control box

Upper control box

Items

Interval

Part number

Quantity

Contactor

Every 4 years or 4,800 working hours

320-0029000

1

Enable switch / Pre-operation check switch

Every 4 years or 4,800 working hours

173-01212 [173-40000]

1

Lift switch

Every 4 years or 4,800 working hours

173-01212 [173-40000]

1

Lift / Travel select switch

Every 4 years or 4,800 working hours

173-01101 [173-40000]

1

Lift / Travel joystick controller

Every 5 years or 6,000 working hours

324-0024101

1

Capacity select switch (SV06ENL, SV08ENL, SV10EWL)

Every 4 years or 4,800 working hours

173-01101 [173-40000]

1

[ ] Switch cap

6-10

SSJ00066

Item Oil leakage Machine Damage Cracks, Deformation, Damage Scissor arms Platform Cracks, Deformation, Damage Other parts Cracks, Deformation, Damage Switches Wet, Dirt, Damage Wire harnesses Damage Covers Closed securely Attached properly Guardrails Bolts Looseness, Damage, Missing Decals Missing, legibility, damage Hydraulic oil tank Hydraulic oil level Battery fluid leakage Batteries Battery fluid level Tire, Wheel Damage, Block, Wear Antistatic strap Attached properly Battery level Battery Level Check Buzzer sounds Pre-operation Stops between the red arrows check Buzzer stops, System failure light goes off Lower Control Strange noise, Vibration, Rattling Check Platform Lift Platform lift down limitation All functions are disabled Emergency Stop Natural descent Natural Descent Check Strange noise, Vibration, Rattling Platform Lift Platform lift down limitation Travel direction, Stop Upper Control Travel Strange noise, Vibration, Rattling Check Strange noise, Vibration, Rattling Steering All functions are disabled Emergency stop Pothole Pothole Protector Damage, Movement Lift Up, Travel functions are disabled Protector Check Interlock Tilt light goes on Lateral Lift Up function stops, alarm buzzer sounds Tilt Warning Tilt light goes on Check Longitudinal Lift Up function stops, alarm buzzer sounds Limited Travel Speed Check Travel at slow speed

See Operation manual for detailed inspection procedures

Serial number : 1

2

3

Pass :

4



5

6

7

8

Fail : X

Year :

Month :

6-11

Model :

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

N/A :

SSJ00066

Visual check Function check

Chapter 6 Inspection and Maintenance

Daily inspection check sheet

Chapter 6 Inspection and 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

Inspector

Result

Remarks

Battery charge level Battery fluid level Battery Battery box

Damage Corrosion on terminals Specific gravity *

Battery charger

Hydraulic oil tank Power unit DC motor

Damage, Function Damage on battery cables * Oil leakage Hydraulic oil level

Replacement interval Every 1,200 hours or annually

Abnormal noise, Vibration Excessive heat

Chassis frame

Cracks, Deformations

Tire, Wheel

Wear, Cut, Deformations

Wheel nuts

Looseness Abnormal noise

Travel motor, Gearbox

Damage Looseness of nuts / bolts

Chassis

Electric magnetic brake Steering linkage

Damage, Oil leakage Damage

Hydraulic hoses

Damage, Oil leakage Cracks, Deformations Lubrication

Scissor arms

Cracks, Deformations

Safety prop

Cracks, Deformations

Lift cylinder Holding valve

6-12

Looseness of stopper bolt

Wire harnesses

Pivot pins

Platform

Cracks, Deformations

Steering cylinder

Pothole protector

Scissor arms

Function

Damage Damage, Oil leakage Natural descent Oil leakage Function

Wire harnesses

Damage

Hydraulic hoses

Damage, Oil leakage

Platform

Cracks, Deformations

Extension deck

Cracks, Deformations

Guardrail

Cracks, Deformations

Wire harnesses

Damage

SSJ00066

Chapter 6 Inspection and Maintenance Items Switches Platform lift function

Result

Function Abnormal noise, Vibration

Lower control Emergency stop button

Damage, Function

Battery level indicator / hour meter

Damage, Legibility

LEDs

Damage, Legibility

Decals

Legibility

Switches, Joystick controller

Damage, Function, Smoothness

Platform lift function

Upper control

Travel function Steering function

Remarks

Damage, Function, Smoothness

Function Abnormal noise, Vibration Function Abnormal noise, Vibration Function Abnormal noise, Vibration

Emergency stop button

Damage, Function

LEDs

Damage, Legibility

Decals

Legibility

Motion alarm buzzer

Sound

Tilt warning light

Light

Platform lift up limit system Function

Safety devices

Tilt alarm buzzer

Sound

Overload sensing system

Function

Travel speed limit system

Function

Platform lift down limit system

Function

Pothole protector interlock Function system

Pre-operation check

Decals

SSJ00066

Platform stops at specific range Error indicator light is not flashing Damage, Legibility, Missing

6-13

Chapter 6 Inspection and Maintenance

Major alterations and repairs When major alteration and/or repair is carried out, record into the table below.

Data

6-14

Responsible person

Descriptions

Remarks

SSJ00066

Chapter 7 Appendix

Chapter 7 Appendix

SSJ00066

7-1

7-2

G

P

C

Platform Lift Up solenoid valve

Suction strainer

Hydraulic pump

R1

D

T

(302-0059400)

B

Oil reservoir

A

SV06ENS SV06ENL SV08ENL SV08EWL SV10EWL

303-0077500 303-0077600 303-0077700 303-0077800 303-0077800

300-0000183 300-0000182 300-0000182 300-0000182 300-0000182

Part number for Lift cylinder / Power unit Model ** Power unit * Lift cylinder

(303-0073900)

Steering cylinder

Lift cylinder *

(312-0000043)

Pressure sensor x2

Main relief valve (R1) --- Preset pressure : 17.2 +0.5 / 0 MPa (175 +5 / 0 kgf/cm2) [2,500 +50 / 0 PSI]

Power unit **

(302-0059300)

Valve unit

Steering solenoid valve

1/4"

1/4"

1/2"

3/8"

Holding valve (Platform Lift Down solenoid valve)

Chapter 7 Appendix

Hydraulic circuit diagram (601-0024400A)

SSJ00066

Chapter 7 Appendix

Water proof connector (Sumitomo) Female housing

Male housing

Number of pole

Number of pole

2 poles

4 poles

6 poles

8 poles

12 poles

Color

Parts number

White Gray Green Blue Brown Yellow White Gray Green Blue Brown Yellow White Gray Green Blue Brown Yellow White Gray Green Blue Brown Yellow White Gray Green

192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27 192-27

102 202 302 402 502 602 104 204 304 404 504 604 106 206 306 406 506 606 108 208 308 408 508 608 112 212 312

2 poles

4 poles

6 poles

8 poles

12 poles

Male housing (with Flange)

Color

Parts number

White Gray Green Blue Brown Yellow White Gray Green Blue Brown Yellow White Gray Green Blue Brown Yellow White Gray Green Blue Brown Yellow White Gray Green

192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28 192-28

102 202 302 402 502 602 104 204 304 404 504 604 106 206 306 406 506 606 108 208 308 408 508 608 112 212 312

Number of pole

4 poles

6 poles

8 poles

12 poles

Color

Parts number

White Gray Green Blue Brown Yellow White Gray Green Blue Brown Yellow White Gray Green Blue Brown Yellow White Gray Green

192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29 192-29

104 204 304 404 504 604 106 206 306 406 506 606 108 208 308 408 508 608 112 212 312

T erminal, Grommet Descriptions Terminal (Female, S) Terminal (Female, M) Terminal (Male, S) Terminal (Male, M) Grommet S (Blue) Grommet M (Brown) Dummy plug

Parts number 327-03662 327-03607 327-03661 327-03608 327-03660 327-03609 327-03663

Remarks for wire size: 0.5 mm2 for wire size: 0.85 - 2.0 mm2 for wire size: 0.5 mm2 for wire size: 0.85 - 2.0 mm2 for wire outer diameter: 1.5 - 2.0 mm for wire outer diameter: 2.0 - 2.9 mm

A view

A view

B view Fig. 7-1 Water proof connector SSJ00066

7-19

Chapter 7 Appendix

Pin arrangements of Water proof connector (Sumitomo) See the table below to specify the pin arrangements of water proof connectors when reading “electric wiring diagram”.

7-20

SSJ00066

Chapter 7 Appendix

Water proof connector (Deutsch DT) Housing Descriptions Housing (Male, 2 poles) Housing (Male, 3 poles) Housing (Male, 4 poles) Housing (Male, 6 poles) Housing (Male, 8 poles) Housing (Male, 12 poles) Housing (Female, 2 poles) Housing (Female, 3 poles) Housing (Female, 4 poles) Housing (Female, 6 poles) Housing (Female, 8 poles) Housing (Female, 12 poles) Terminal, Plug Descriptions Terminal (Female, S) for wire size: 0.5 - 1.25 mm2 Terminal (Female, L) for wire size: 2.0 mm2 Terminal (Male, S) for wire size: 0.5 - 1.25 mm2 Terminal (Male, L) for wire size: 2.0 mm2 Dummy plug

Parts number 192-68002 192-68003 192-68004 192-68006 192-68008 192-68012 192-67002 192-67003 192-67004 192-67006 192-67008 192-67012

Parts number 192-60100 192-60101 192-60110 192-60111 192-60200 192-60201 192-60210 192-60211 192-60400

Remarks Solid contacts Stamped and Formed contacts Solid contacts Stamped and Formed contacts Solid contacts Stamped and Formed contacts Solid contacts Stamped and Formed contacts

Plug

Plug

Terminal (Male) A Housing (Male)

Grommet (Included in housing)

Wedge (Included in housing)

Wedge (Included in housing)

Terminal (Female)

B

Housing (Female) Wedge (Included in housing)

Wedge (Included in housing)

Grommet (Included in housing)

Fig. 7-2 Water proof connector

SSJ00066

7-21

Chapter 7 Appendix

Pin arrangements of Water proof connector (Deutsch DT) See the table below to specify the pin arrangements of water proof connectors when reading “electric wiring diagram”.

Symbol

B view (Female connector)

12 poles

8 poles

6 poles

4 poles

3 poles

2 poles

A view (Male connector)

7-22

SSJ00066

Chapter 7 Appendix

Color code of wires See the table below to specify the colors of wires from the “Color codes”.

No.

Color codes

Color

No.

Color codes

Color

1

R

Red

31

GY

Green/ Yellow

2

Y

Yellow

32

GW

Green/ White

3

W

White

33

GB

Green/ Black

4

G

Green

34

GO

Green/ Orange

5

L

Blue

35

LR

Blue/ Red

6

B

Black

36

LY

Blue/ Yellow

7

V

Violet

37

LW

Blue/ White

8

P

Pink

38

LG

Blue/ Green

9

O

Orange

39

LB

Blue/ Black

10

Br

Brown

40

LO

Blue/ Orange

11

Lg

Light green

41

BR

Black/ Red

12

Lb

Light blue

42

BY

Black/ Yellow

13

Gy

Gray

43

BW

Black/ White

14

RY

Red/ Yellow

44

BG

Black/ Green

15

RW

Red/ White

45

BL

Black/ Blue

16

RG

Red/ Green

46

PY

Pink/ Yellow

17

RL

Red/ Blue

47

PL

Pink/ Blue

18

RB

Red/ Black

48

PB

Pink/ Black

19

YR

Yellow/ Red

49

OW

Orange/ White

20

YW

Yellow/ White

50

OB

Orange/ Black

21

YG

Yellow/ Green

51

BrR

Brown/ Red

22

YL

Yellow/ Blue

52

BrY

Brown/ Yellow

23

YB

Yellow/ Black

53

BrW

Brown/ White

24

WR

White/ Red

54

BrB

Brown/ Black

25

WY

White/ Yellow

55

LgR

Light green/ Red

26

WG

White/ Green

56

LgW

Light green/ White

27

WL

White/ Blue

57

LgB

Light green/ Black

28

WB

White/ Black

58

GyR

Gray/ Red

29

WBr

White/ Brown

59

GyB

Gray/ Black

30

GR

Green/ Red

SSJ00066

7-23

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 2 80 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 6T S45C 2 80 kg/cm

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

7-24

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

SSJ00066

Chapter 7 Appendix

Hexagon socket headed cap screws (10.9T)

Bolt 10.9T SCM435 2 100 kg/cm

Strength grade Material Tensile strength Size (mm) 5 6 8 10 12 14 16 18 20 22 24

SSJ00066

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

7-25