SSJ00003 Rev 2

SP12C / SP400C
SP14CJ / SP460CJ

営 業 企 画 部・サ ービ ス 企 画 課
 Chapter A Introduction

Introduction
This manual describes correct adjustment and servicing procedures for Boom
type self- propelled Elevation work platform: SP12C / SP400C and SP14CJ /
SP460CJ in order to ensure safe and reliable operation, the most effective use
of superb performance and excellent features for your satisfaction.

Qualified personnel should read this manual carefully and understand the
descriptions correctly before making any repair or maintenance works.

Always be sure of the following items when conducting repair or maintenance

works.

Use only the spare parts approved by the manufacturer, particularly for load-
supporting components (Structural components including chassis, turntable,
boom section and platform) and safety related components (Scheduled
replacement parts listed in the page 7-6).

Use proper tools, lifting equipment and suitable workshop.

It is strictly forbidden to make modifications to the machine without obtaining

AICHI’s written approval.
Constant improvement of its products is
Constant improvement of its products is AICHI’s policy.
Therefore, specifications of the machine are subject to change without prior
notice.

SSJ00003 a
Chapter A Introduction

Location of Serial number plate

When you contact Aichi / Aichi dealer for Technical support, Parts order / inquiry or Warraty
claim, Inform Commercial name / Model code, Serial number and Date of manufacture
inscribed on the serial number plate.

Commercial name / Model code

CE model ANSI model
Commercial name SP12C SP14CJ SP400C SP460CJ
Model code SP12CSM SP14CJM SP12CSM SP14CJM

Meaning of model code

S P 1 2 C S M
① ② ③④⑤

① Machine type: SP --- Boom type self propelled with wheel

② Maximum platform height in metric
③ Machine generation
④ Boom type: S --- without Fly jib, J --- with Fly jib
⑤ Machine size: M --- middle

b SSJ00008
 Chapter A Introduction

Safety warnings and safety signal words

Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.

Indicates a hazardous situation which, if not avoided, could result in death or

serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor /

moderate injury or property damage.

Information not related to personal injury or property damage.

SSJ00008 c
Index

Index

Chapter A
Introduction --------------- a
Location of Serial number plate --------------- b
Safety warnings --------------- c

Chapter 1 General information

Specifications --------------- 1-2
Overall dimensions --------------- 1-4
Work range diagram --------------- 1-8
Safety devices --------------- 1-9

Chapter 2 Mechanical components

Chassis --------------- 2-2
Turntable --------------- 2-3
Hydraulic pump installation --------------- 2-4
Turntable bearing --------------- 2-5
Boom rotation gearbox --------------- 2-7
Boom --------------- 2-8
1. Structure --------------- 2-8
2. Inspection procedures --------------- 2-9
3. Extension / Retruction wire rope --------------- 2-11
4. Adjustment of Extension / Retruction wire rope --------------- 2-12
5. Cable guide --------------- 2-14
6. Removal and installation of Cable guide --------------- 2-15
Fly jib --------------- 2-35
Platform (Adjustment of Overload limit switch) --------------- 2-36

Chapter 3 Hydraulic components

Locations of Hydraulic components --------------- 3-2
HST pump --------------- 3-4
Gear pump --------------- 3-5
Emergency pump --------------- 3-6
Hydraulic oil tank --------------- 3-7
Filters --------------- 3-8
Main control valve --------------- 3-9
Elevation cylinder --------------- 3-12
Single holding valve for Elevation cylinder --------------- 3-13
Telescope cylinder --------------- 3-15

i SSJ00008
 Index

Boom rotation motor --------------- 3-17

Rotary actuator --------------- 3-18
Platform rotation solenoid valve --------------- 3-20
Platform rotation / Fly jib solenoid valve --------------- 3-21
Fly jib cylinder --------------- 3-22
Double holding valve for Fly jib cylinder --------------- 3-23
Valve unit for Platform leveling and Steering --------------- 3-24
Platform leveling cylinder, Upper --------------- 3-26
Double holding valve for
Platform leveling cylinder, Upper --------------- 3-27
Platform leveling cylinder, Lower --------------- 3-28
Steering cylinder --------------- 3-29
Swivel joint --------------- 3-30
Flow divider valve --------------- 3-31
Travel motor --------------- 3-32
Valve unit for Oscillation axle, Parking brake and
Travel speed select --------------- 3-33
Parking brake release valve --------------- 3-34
Oscillation axle cylinder --------------- 3-35
Oscillation axle lock valve --------------- 3-36

Chapter 4 Electric components

Locations of Electric components --------------- 4-2
Upper control box --------------- 4-3
CPU board M6 --------------- 4-5
LED board --------------- 4-8
Joystick controller --------------- 4-9
Lower control box --------------- 4-10
CPU board M5-B --------------- 4-13
Accelerator control unit --------------- 4-16
Key switch --------------- 4-17
Engine relay box --------------- 4-18
Tilt sensor (Longitudinal, Lateral) --------------- 4-19
Tilt sensor (Omni-directional) --------------- 4-20
Limit switches --------------- 4-21

Chapter 5 Trouble shooting

Trouble shooting by LED indication on Upper /
Lower control box --------------- 5-2
Emergency operations --------------- 5-7

SSJ00008 ii
Index

Chapter 6 Inspection and Adjustment

Engine speed measurement procedures --------------- 6-2
Relief valve pre-set pressure measurement
and adjustment procedures --------------- 6-3

Chapter 7 Scheduled maintenance

Scheduled inspection table --------------- 7-2
Lubrication --------------- 7-4
Scheduled replacement parts --------------- 7-6
Daily inspection sheet --------------- 7-7
Periodical inspection sheet --------------- 7-8

Chapter 8 Appendix
Hydraulic circuit diagram --------------- 8-2
Electric circuit diagram, Upper --------------- 8-3
Electric circuit diagram, Lower --------------- 8-5
Electric wiring diagram, Upper --------------- 8-7
Electric wiring diagram, Lower --------------- 8-8
Electric wiring diagram, Engine --------------- 8-10
Water proof connector --------------- 8-11
Color code of Wires --------------- 8-13
Tightening torque standard --------------- 8-14

Chapter 9 Engine
Safety warnings for Engine maintenance --------------- 9-2
Component identification --------------- 9-4
Periodical maintenance procedures --------------- 9-5

iii SSJ00008
 Chapter 1 General Information

Chapter 1
General Information

SSJ00003 1-1
Chapter 1 General Information

Specifications (CE models)

Commercial name SP12C SP14CJ
Model code SP12CSM SP14CJM
Platform height maximum 12.0 m 13.9 m
Horizontal outreach maximum 10.9 m 12.7 m
Platform capacity (6ft) 250 kg (2 Persons + tools: 90 kg)
Platform capacity (8ft) 227 kg (2 Persons + tools: 67 kg)
Performance

Platform rotation +/-90 deg

Turntable rotation 360 deg (Continuous)
Maximum allowable wind speed 12.5 m/s
Maximum allowable tilt angle 5 deg
Maximum allowable manual side force 400 N (41kg)
Gradeability (stowed) 45 % (24 deg)
Ground Clearance 330 mm
Minimum turning radius 5.0 m
Overall length-6ft 6.86 m 7.56 m
Overall length-8ft 7.02 m 7.72 m
Overall width-6ft 2.30 m
Measurements

Overall width-8ft 2.45 m

Overall height 2.00 m
Inside diameter of Platform -6ft 1.76x0.72x1.1 m
Inside diameter of Platform -8ft 2.36x0.86x1.1 m
Wheel Base 2.34 m
Tread 2.00 m
Tires 12-16.5 Form-Filled
Vehicle weight 7,015 kg 8,200 kg
Max. tire loading force 3,800 kg 4,130 kg
Max. tire ground contact pressure 518 kPa 526 kPa
Engine YANMAR 4TNV88 (4 Cylinder Diesel 33kW)
source
Power

Auxiliary Power unit DC12V

Fuel Tank Capacity 120 L
Hydraulic Tank Capacity 190 L
Elevation Up 39 - 51 s
Down 39 - 51 s
Telescope Out 24 - 36 s
Function Speed

In 19 - 31 s
Rotation 120 - 150 s / 360 deg
Jib Elevation Up - 20 - 30 s
Down - 15 - 25 s
Platform Rotation 10 - 20 s / -90 ∼ +90 deg
Travel speed (High) 6.4 - 8.0 km/h
Travel speed (Low) 1.0 - 1.4 km/h

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

1-2 Rev 2 SSJ00003

 Chapter 1 General Information

Specifications (ANSI models)

Commercial name SP400C SP460CJ
Model code SP12CSM SP14CJM
Platform height maximum 39 ft 4 in 45 ft 7 in
Horizontal outreach maximum 35 ft 9 in 41 ft 8 in
Platform capacity (6ft) 550 lbs (2 Persons)
Platform capacity (8ft) 500 lbs (2 Persons)
Performance

Platform rotation +/-90 deg

Turntable rotation 360 deg (Continuous)
Maximum allowable wind speed 28 mph
Maximum allowable manual side force 150 lbs
Gradeability (stowed) 45 % (24 deg)
Ground Clearance 13 in
Minimum turning radius 16 ft 5 in
Overall length-6ft 22 ft 6 in 24 ft 9 in
Overall length-8ft 23 ft 25 ft 4 in
Overall width-6ft 7 ft 7 in
Measurements

Overall width-8ft 8 ft
Overall height 6 ft 7 in
Inside diameter of Platform -6ft 5 ft 9 in x 2 ft 4 in x 3 ft 7 in
Inside diameter of Platform -8ft 7 ft 9 in x 2 ft 9 in x 3 ft 7 in
Wheel Base 7 ft 8 in
Tread 6 ft 7 in
Tires 12-16.5 Form-Filled
Vehicle weight 15,470 lbs 18,080 lbs
Max. tire loading force 8,378 lbs 9,105 lbs
Max. tire ground contact pressure 75.1 PSI 76.3 PSI
Engine YANMAR 4TNV88 (4 Cylinder Diesel 33kW)
source
Power

Auxiliary Power unit DC12V

Fuel Tank Capacity 31.7 gallons
Hydraulic Tank Capacity 50.2 gallons
Elevation Up 39 - 51 s
Down 39 - 51 s
Telescope Out 24 - 36 s
Function Speed

In 19 - 31 s
Rotation 120 - 150 s / 360 deg
Jib Elevation Up - 20 - 30 s
Down - 15 - 25 s
Platform Rotation 10 - 20 s / -90 ∼ +90 deg
Travel speed (High) 4.0 - 5.0 mph
Travel speed (Low) 0.65 - 0.90 mph

The ANSI model has been manufactured to conform to all applicable requirements of
Occupational Safety and Health Administration (OSHA) and
American National Standards Institute (ANSI)

SSJ00003 Rev 2 1-3

Chapter 1 General Information

Overall dimensions (SP12C / SP12CSM) CE model

6 feet platform

8 feet platform

1-4 Rev 2 SSJ00003

 Chapter 1 General Information

Overall dimensions (SP14CJ / SP14CJM) CE model

6 feet platform

8 feet platform

SSJ00003 Rev 2 1-5

Chapter 1 General Information

Overall dimensions (SP400C / SP12CSM) ANSI model

6 feet platform

8 feet platform

1-6 Rev 2 SSJ00003

 Chapter 1 General Information

Overall dimensions (SP460CJ / SP14CJM) ANSI model

6 feet platform

8 feet platform

SSJ00003 Rev 2 1-7

Chapter 1 General Information

Work range diagram

Rated load 6 feet platform : 250 kg (550 lbs)
8 feet platform : 227 kg (500 lbs)

SP12C / SP12CSM SP400C / SP12CSM

SP14CJ / SP14CJM SP460CJ / SP14CJM

1) The boom deflection is not taken into account in the above working range diagram.
2) The working range shown in the diagram is obtained in any boom rotated directions.
3) It is assumed that the machine is on firm and level surface.

1-8 Rev 2 SSJ00003

 Chapter 1 General Information

Safety devices
No Name Main function
Protect the hydraulic components by relieving abnormally high pressure in the
1 Relief valve
hydraulic system.
Single holding valve on Prevents the boom from natural descent in the event of hydraulic hose
2
Boom elevation cylinder breakage.
Double holding valve on Prevents the boom from natural descent in the event of hydraulic hose
3
Boom telescope cylinder breakage.
Double holding valve on
4 Maintains the platform level in the event of hydraulic hose breakage.
Upper leveling cylinder
Double holding valve on
Prevents the fly- jib from natural descent in the event of hydraulic hose
5 Fly- jib cylinder
breakage.
(SP14CJ / SP460CJ)
The boom, fly-jib, platform and traveling functions are disabled unless the foot
6 Foot switch
switch is depressed.
This system cancel the foot switch / enable switch if any of the boom, fly-jib,
7 Foot switch cancel system platform and traveling function is not operated more than 20 seconds.
Release the switch once, then operate again to enable the functions.
Enable switch The boom, fly-jib and platform functions from the lower control panel are
8
(Lower control) disabled unless the enable switch is operated.
The motion alarm buzzer sounds when the machine is in motion to warn the
9 Motion alarm buzzer
people nearby.

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

11 Tilt alarm buzzer The tilt alarm buzzer sounds, if the machine tilts more than 5 degrees.

The high speed traveling is disabled, unless the boom is retracted, lowered
12 Travel speed limit system
under the horizontal and rotated to rear center of the machine.
Fixes the turntable to the chassis to prevent the turntable from being rotated
13 Rotation lock pin
when transporting the machine.
Auxiliary hydraulic pump driven by the battery. And used to lower the platform
14 Emergency pump
in the event of engine or main pump failure.
Before moving the machine, sound the alarm horn to warn the people around
15 Alarm horn
the machine.
Boom wire rope failure
This system disables the boom extending functions in the event of the boom
16 detecting system
extension wire rope failure.
(CE model)
Overload sensing This system disables all of the functions, Overload warning light blinks and
17
system (CE model) Overload buzzer sounds when the platform is overloaded.
Boom / Travel function
This system stops all of the functions when the travel and boom operations are
18 interlock system
conducted simultaneously.
(CE model)
Oscillation axle locking The system locks the oscillation axle unless the boom is rotated to rear center
19
system of the chassis, or the boom is retracted and lowered under the horizontal.

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Chapter 1 General Information

This page intensionally left blank.

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 Chapter 2 Mechanical Components

Chapter 2
Mechanical Components

SSJ00003 2-1
Chapter 2 Mechanical Components

Chassis Tightening torque :

275 +/- 27 N-m
(28.0 +/- 2.8 kg-m)
[203 +/- 20 ft-lbs]
Apply thread lock agent : Loctite 262

Tightening torque :
536 +/- 53 N-m
(55.0 +/- 5.5 kg-m) Inner soft zone
[395 +/- 39 ft-lbs]
Apply thread lock agent : Loctite 262

Outer soft zone

Tightening torque :
275 +/- 27 N-m
Tightening torque : (28.0 +/- 2.8 kg-m)
275 +/- 27 N-m [203 +/- 20 ft-lbs]
(28.0 +/- 2.8 kg-m)
[203 +/- 20 ft-lbs]
Apply thread lock agent : Loctite 262

Fig. 2-1 Chassis

2-2 SSJ00003
 Chapter 2 Mechanical Components

Turntable

Tightening torque :
384 +/- 38 N-m
(39.0 +/- 3.9 kg-m)
[283 +/- 28 ft-lbs]
Apply thread lock agent : Loctite 262

Fig. 2-2 Turntable

Wear pads

Swing tray
Turntable

Wear pads [454-0000744] x4

Machine screw [036-30816] x 8
Apply thread lock agent : Loctite 262

Fig. 2-3 Wear pads for swing tray

SSJ00003 2-3
Chapter 2 Mechanical Components

Hydraulic pump installation

Engine flywheel

Coupling boss

Coupling
Tightening torque :
85 - 94 N-m
(8.7 - 9.5 kg-m)
[63 - 69 ft-lbs]

Flange
HST pump
Gear pump

Tightening torque :
Tightening torque :
75.2 +/- 7.5 N-m
22.0 +/- 2.2 N-m
(7.7 +/- 0.7 kg-m)
(2.3 +/- 0.2 kg-m)
[55.5 +/- 5.5 ft-lbs]
[16.4 +/- 1.6 ft-lbs]

Apply grease on the spline shaft

of the pump before installation.

Fig. 2-4 Hydraulic pump installation

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 Chapter 2 Mechanical Components

Turntable bearing (372-0000044)

This turntable bearing is mounted between the chassis and the turntable, and enables the turntable to
rotate freely over the chassis.

Inspection
1. Check the anchor bolts and nuts for looseness, omission and any other damage.
a. Loose bolts should be removed and checked for damaged threads and deformation.
b. When re-installing anchor bolts or nuts, apply thread lock agent to the threads.
* Recommended thread lock agent: Loctite 262.
c. Tighten anchor bolts by the specific tightening torque.
* Specified tightening torque
Anchor bolt for Turntable : 384 +/- 38 N-m (39.0 +/- 3.9 kg-m) [283 +/- 28 ft-lbs]
Anchor bolt for Chassis : 536 +/- 53 N-m (55.0 +/- 5.5 kg-m) [395 +/- 39 ft-lbs]

In case it is hard to loosen anchor bolts due to lock agent, heat them up by using a gas burner to melt
the agent.
The heated or removed bolts and nuts should be replaced with new ones.
2. Check the ring gear for cracks and any other damage.
To make the cracks obvious, use a liquid penetrant test such as a color check.
3. Check the backlash between the ring gear of the turntable bearing and the pinion gear of the rotation
gearbox.
* Standard backlash: 0.2 - 0.3 mm (0.008 - 0.012 in) or less.

To check the backlash, rotate the turntable and insert a lead wire between the ring gear and the
pinion gear of the turntable gearbox to crush the wire, and then measure the thickness of the crushed
lead wire.
If the backlash is inadequate, adjust it by moving the rotation gearbox.
Anchor bolt for Turntable
Tightening torque :
384 +/- 38 N-m
(39.0 +/- 3.9 kg-m)
[283 +/- 28 ft-lbs]
Anchor bolt for Chassis Apply thread lock agent : Loctite 262
Tightening torque :
536 +/- 53 N-m
(55.0 +/- 5.5 kg-m)
[395 +/- 39 ft-lbs] Turntable
Apply thread lock agent : Loctite 262
Spacer
Steel ball

Ring gear
Chassis

Fig. 2-5 Turntable bearing

SSJ00003 2-5
Chapter 2 Mechanical Components

4. Check the free-play between inner and outer races of the turntable bearing as follows.
a. Set a dial gauge between the turntable and the chassis as shown in the Fig. 2-6.
b. Retract and raise the boom fully, and set the pointer of the dial gauge at ZERO.
c. Lower the boom, set it horizontally, extend it fully to its maximum outreach and then read the dial
gauge again.
The reading of the gauge is the numerical value of free-play.
* Standard free-play: 0.9 mm (0.035 in).
* Serviceable limit: 3.0 mm (0.118 in).

The turntable bearing should be replaced, if the free-play exceeds the serviceable limit.

50 mm (2 in)

Turntable
Dial gauge Turntable bearing

Chassis

Fig. 2-6 Checking freeplay

2-6 SSJ00003
 Chapter 2 Mechanical Components

Boom rotation gearbox (372-0000082A)

The boom rotation gearbox reduces the rotation speed of the hydraulic motor and increases
the torque to rotate the turntable through the turntable bearing.

Specifications
* Type : Worm gear
* Reduction ratio : 1/50
* Gear oil : Shell Spirax EP-90
* Oil change interval : 1,200 hours or annually

Oil drain plug Oil level gauge

Fig. 2-7 Boom rotation gearbox

Inspection
1. Check the gear oil level and replenish the oil, if necessary.
Recommended gear oil --- Shell Spirax EP- 90
To check the oil level, screw in the oil level gauge (Dipstick)
fully into the gearbox first, then remove the dipstick.
The proper oil level is between the two lines on the dipstick
as shown in the Fig.2-8. Oil level

Fig. 2-8 Oil level gauge

Adjustment
Stopper
1. Check the backlash following instruction in Bolt (1)
the page 2-5 and adjust if it is necessary.
1) Screw out the bolt (1)so that the rotation
gearbox touches to the stopper.
2) Screw in the two bolts (2) alternately so that
the backlash between Rotation gearbox and Turntable
bearing become 02 -0.3 mm [0.008- 0.012 in]
3) Tighten the four bolts (3) to fix the rotation
gearbox. Apply thread lock agent before
tightening the bolts.
Bolt (3)
Recommended thread lock agent : Loctite 262
4) Tighten the bolt (1) and two bolts (2) and Bolt (2) Bolt (2)
then tighten their lock nuts.
Fig. 2-9 Backlash adjustment

SSJ00003 2-7
Chapter 2 Mechanical Components

Boom
1. Structure
The boom consists of the 1st, 2nd, and 3rd boom sections, Boom telescope cylinder, the Extension/
Retraction wire ropes, Hydraulic hoses, Electric cables and Sheaves.
The 2nd boom section is extended or retracted directly by the Boom telescope cylinder.
However, the 3rd boom section is telescoped by the movement of the 2nd boom section through the
extension and retraction wire ropes.
The 1st and 2nd boom sections are connected by the Boom telescope cylinder, which directly ex-
tends and retracts the 2nd boom section.
While, the 3rd boom section is connected to the 2nd boom section by the extension and retraction wire
ropes as shown in the figure below.
The retraction wire ropes are connected to the tail of the 3rd boom section through the tail sheave
installed on the tail of the 2nd boom section.
The extension wire ropes are also connected to the tail of the 3rd boom section through the head
sheave that is installed on the head of the 2nd boom section.
The 2nd boom section is extended by the Boom telescope cylinder together with the head sheave
coming along. As a result, the 3rd boom section is pulled by the extension wire rope and accordingly
goes out of the 2nd boom section.
When retracting the boom, the 2nd boom section is retracted by the Boom telescope cylinder together
with the tail sheave coming along. As a result, the 3rd boom section is pulled by the retraction wire rope
and accordingly goes into the 2nd boom section.

2nd boom section

1st boom section Boom telescope cylinder 3rd boom section

2nd boom tail sheave Retraction wire rope Extension wire rope 2nd boom head sheave

Fig. 2-10 Structure of the boom

2-8 SSJ00003
 Chapter 2 Mechanical Components

2. Inspection procedurese
The boom is to be disassembled for a detailed inspection every 5 years.
1. Clearance between each boom section.
1) Check the clearance between each wear pad and boom section.

Lateral direction

Boom head Boom tail Vertical direction

Fig. 2-11 Clearance inspection
Lateral direction,
Vertical direction
Sum of Right and Left
Clearance between 0.5 - 1.0 mm 0.5 - 0.9 mm
boom head
1st and 2nd boom (0.020 - 0.039 in) (0.020 - 0.035 in)
sections 0.6 - 1.1 mm 0.5 - 1.1 mm
boom tail
(0.024 - 0.043 in) (0.020 - 0.043 in)
Clearance between 0.5 - 1.0 mm 0.5 - 0.9 mm
boom head
2nd and 3rd boom (0.020 - 0.039 in) (0.020 - 0.035 in)
sections 0.5 - 0.9 mm 0.5 - 0.9 mm
boom tail
(0.020 - 0.035 in) (0.020 - 0.035 in)
2) If the clearance is not adequate, adjust the clearance by adding or reducing
the spacers installed under each wear pad.
Check each wear pad for wear, and replace them if the thickness is thinner than serviceable limit.

Serviceable limit of ware pad

1st boom section Lower 2nd boom section Lower
Nominal thickness : 12 mm (0.47 in) Nominal thickness : 15 mm (0.59 in)
Serviceable limit : 10 mm (0.39 in) Serviceable limit : 13 mm (0.51 in)

1st boom section Side 2nd boom section Side

Nominal dimension : 15 mm (0.59 in) Nominal dimension : 40 mm (1.58 in)
Serviceable limit : 13 mm (0.51 in) Serviceable limit : 38 mm (1.50 in)

Apply a thread lock agent to the thread of each setscrew for wear pad before setting.
Recommended thread lock agent: Loctite 262

2. Bend of boom section.

1) Set the boom horizontally and extend it fully.
2) Visually check the bend of each boom section and disassemble the boom to measure the
bend, if the excessive bend is observed.

* Serviceable limit Fig. 2-12 Bend inspection

1st boom section 2nd boom section 3rd boom section
4,700 mm 4,523 mm 4,748 mm
Length L
(15 ft 5.0 in) (14 ft 10.1 in) (15 ft 6.9 in)
Serviceable Vertical direction A 7.1 mm (0.28 in) 6.8 mm (0.27 in) 7.1 mm (0.28 in)
limit Lateral direction B 4.7 mm (0.19 in) 4.5 mm (0.18 in) 4.7 mm (0.19 in)

SSJ00003 Rev 1 2-9

Chapter 2 Mechanical Components

3. Dents, scratches
Check the each boom section for both dents and scratches thoroughly. If any dent or scratch that exceeds
the serviceable limit is observed, replace the boom section.
* Serviceable limit:
Length = 50 mm [1.97 in], and/or Depth = 2 mm [0.08 in].

Fig. 2-13 Dent inspection

4. Dents on bottom plate of the 2nd and 3rd boom sections

Check the bottom plate of the 2nd and 3rd boom section for dents caused by contact with wear pads.
If any dent that exceeds the serviceable limit is observed, replace the boom section.
* Serviceable limit: 1.6 mm

D : Depth
Wear pad t : Thickness of the bottom plate 3.2 mm

Fig. 2-14 Dent on the bottom plate of the boom section

5. Cracks.
Check each boom section thoroughly for cracks. For fine cracks, use COLOR CHECK
or penetrant check.
Pay special attention, when checking each pin boss and welded section.

6. Lubrications
Check the grease on the inner surface of each boom section and apply molybdenum grease.

Apply grease
to these area

1st boom
section

3rd boom sec.

2nd boom 2nd boom sec.

section 1st boom sec.

3rd boom
section

* Do not apply grease to the end of each boom section.

Fig. 2-15 Lubrication of the boom section
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 Chapter 2 Mechanical Components

3. Extension / Retraction wire rope

After disassembling the boom, inspect the extension and retraction wire ropes as follows.

1) Measure the diameter of both the extension and retraction wire ropes, using a slide calipers.
Replace the wire rope, if the decrease of the diameter is more than 3 % of the nominal diameter.

Nominal diameter Serviceable limit

Retarction wire rope 12.0 mm (0.47 in) 11.7 mm (0.46 in)
Extension wire rope 12.0 mm (0.47 in) 11.7 mm (0.46 in)

Fig. 2-16 Wire diameter

2) Check for broken wires.
If you find 3 or more single wires cut in one twist stroke, replace the wire rope.

Fig. 2-17 Broken wires

3) Check wire ropes for rust formation.

If the rust is penetrated into the rope, replace the wire rope.

Fig. 2-18 Rust formation

4) If any kinks are observed, replace the wire rope.

Also, a deformed wire rope requires replacement.

Fig. 2-19 Kink, Deformation

5) Check carefully the end sections of the wire rope, especially sections A and B.
Replace the wire rope, if any defects are found.

Fig. 2-20 Wire rope end

SSJ00003 2-11
Chapter 2 Mechanical Components

4. Adjustment of Extension / Retraction wire rope

Adjust the tension of the Extension/Retraction wire ropes as follows.

L1 : 430 - 450 mm
[1 ft 4.9 in - 1 ft 5.7 in]

Lock nut B Adjust nut B Adjust nut A Lock nut A

L2 :
80 mm
Extension wire rope Retraction wire rope
[3.15 in]
Fig. 2-21 Wire rope adjustment

1) Set the boom horizontally and retract it fully.

2) Unlock the Lock nuts B, turn the Adjust nuts B and adjust the Dimension L2 to 80 mm [3.15 in].

Do not twist the wire ropes when turning the adjust and lock nuts.

3) Loosen the Lock nuts A and the Adjust nuts A at the terminal end of the retraction wire ropes,
and then make sure that the 6 plate springs, shims, 2 washers and 1 collar are assemble at the
end of the retraction wire rope as shown in the Fig. 2-21.

Set this water drain

Washer to the bottom side.

Retraction wire rope Washer

Lock nut A
Plate springs (6 pcs) Collar Shims Adjust nut A

Fig. 2-22 Retraction wire end

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 Chapter 2 Mechanical Components

4) Tighten the Adjust nut A until the washers touch the collar as shown in the fig. 2-22.

13.2 mm
(0.52 in)
When brand-new wire ropes are installed,
tighten the Adjust nut A by 13.2 mm (0.52 in) more.

Fig. 2-23 Tighten the adjust nut

5) Measure the Dimension L1 and make sure that it is 430 - 450 mm [1 ft 4.9 in - 1 ft 5.7 in].
6) Adjust the Dimension L1 as follows, if the Dimension L1 is not 430 - 450 mm [1 ft 4.9 in - 1 ft 5.7 in].
* In case the Dimension L1 is shorter than 430 mm [1 ft 4.9 in].
Screw out the Adjust nuts A and screw in the Adjust nuts B to adjust the Dimension L1
to 430 - 450 mm [1 ft 4.9 in - 1 ft 5.7 in].

* In case the Dimension L1 is longer than 450 mm [1 ft 5.7 in].

Screw out the Adjust nuts B and screw in the Adjust nuts A to adjust the Dimension L1
to 430 - 450 mm [1 ft 4.9 in - 1 ft 5.7 in].

7) Repeat the steps 5 and 6, and then tighten the Lock nuts A and B.

8) Telescope the boom several times, retract the boom fully, and then make sure that
Dimension L1 is 430 - 450 mm [1 ft 4.9 in - 1 ft 5.7 ft].

When replacing the Plate springs with the new ones, make sure to insert the correct Shims
by following the next instructions.

Plate springs Collar Shims

Fig. 2-24 Plate springs, Collar and Shims

1) Stack the new 6 Plate springs on level surface, and then measure the Overall height (H1)
of the plate springs.
2) Measure the Height (H2) of the Collar.

3) Determine the Thickness (H3) of the Shims using the following formula.
H3 = H1 – H2 – 3.6 mm (0.142 in)
The following shims are provided as service parts.

Part number Thickness of Shim

443-0000197 0.5 mm (0.02 in)
443-0000198 0.1 mm (0.004 in)

SSJ00003 2-13
Chapter 2 Mechanical Components

5. Cable guide

Plate (5K0-0532400)

Cable guide bracket (Upper)

Attach to the 3rd boom section Cable guide bracket (Lower)
Attach to the 1st boom section
Plate (5K0-0532400)

Vertical separator
Section B
View A

more than 70 mm
[2.76 in]

Section C View F

Wrap the hoses and cables by cover

(338-0000020 Water hose, 250 mm [10 in])

Detail H
View G

No. Hoses No. Cables, Wire

1 Hose (P) 6 14 core cable
2 Hose (T1) 7 16 core cable with shield wires
3 Hose (T2) 8 4 core cable for AC outlet
4 Hose (Platform leveling, Up) (CE model and ANSI model)
5 Hose (Platform leveling, Down) 9 Wire for Boom length limit switch

Fig. 2-25 Cable guide

2-14 SSJ00003
 Chapter 2 Mechanical Components

6. Removal and installation of Cable guide

SP12C (SP400C) Removal

1) Set the machine on firm and level surface.
2) Set the boom horizontal, extend the boom about 100
mm [4 in]and then turn off the main key switch.
3) Support the platform by crane or forklift.
4) Take the cover on the platform off. (Fig. 2-26)
5) Disconnect the boom cables (14 cores: Connector
126Gy, 127Gy) and (16 cores: Connector 122Gy,
Cover
128Gy, 129Gy). (Fig. 2-27)
[Connector 129Gy is for CE and ANSI model only] Fig. 2-26
6) Disconnect the cable (4 cores) for AC outlet from the
receptacle if it is equipped.
7) Tag, Disconnect the T1 hose, P hose and T2 hose
from the platform rotation solenoid valve (Fig. 2-28),
and then plug the fittings on the valve and hose ends. Platform rotation
solenoid valve

Fig. 2-28
Fig. 2-27

8) Take the 3rd boom front cover and cylinder boot off.
(Fig. 2-29)

Fig. 2-29

SSJ00003 Rev 2 2-15

Chapter 2 Mechanical Components

9) Tag, disconnect the hoses for upper leveling cylinder and then plug the fittings on the hose ends.
(Fig. 2-30)

Fig. 2-30

10) Take the U bolt fixing the boom cable and hoses off. (Fig. 2-31)

Fig. 2-31

11) Cut cable ties fixing the boom cables and then pull out the hoses and boom cables from the guard and
hole at the top of the 3rd boom section. (Fig. 2-32)

Pull out the hoses and boom cables

Fig. 2-32

2-16 Rev 1 SSJ00003

 Chapter 2 Mechanical Components

12) Bundle the boom cables and hoses up, and then tie the leading rope to the 4 cores cable for AC outlet
(Fig. 2-33)

Fig. 2-33

Use leading rope longer than 8 meters [26 ft] to pass through the boom section.

13) Open the boom length limit switch cover located under the 1st boom section, and then disconnect the
cable for the boom length limit switch (Connector 572Br) (Fig. 2-34).

Fig. 2-34

14) Wind the disconnected cable and then put it on the cable guide bracket (Lower). (Fig. 2-35)

Fig. 2-35

15) Remove the cable guide fixing bolts. (Fig. 2-36)

Fig. 2-36

SSJ00003 Rev 1 2-17

Chapter 2 Mechanical Components

16) Take the turntable rear cover off. (Fig. 2-37)

Fig. 2-37

17) Open the engine cover, take the key plate and then pull the lower leveling cylinder upper pivot pin out
using slide hummer (Fig. 2-38).

Fig. 2-38

18) Lay down the lower leveling cylinder. (Fig. 2-39)

Fig. 2-39
2-18 Rev 1 SSJ00003
 Chapter 2 Mechanical Components

19) Disconnect the cable for the boom wire rope failure limit switches (Connector 530Br, 531Br) and then
cut cable ties fixing the cables (Fig. 2-40) [CE model only]

Fig. 2-40

20) Disconnect the cables listed below. Connectors are located behind the lower control box. (Fig. 2-41)
* Boom cable (14 cores: Connector 518Gy and 546Br)
* Boom cable (16 cores: Connector 516Gy, 517Gy and 521Gy)
[Connector 521Gy is for CE and ANSI model only]
* Cable for Boom length limit switch (Connector 534Gy)
* Cable for Boom wire rope failure limit switches (Connector 503Gy) [CE model only]
* Boom cable (4 cores) for AC outlet (Disconnect from the receptacle if it is equipped)

F M Horn
546Br, 2p

Boom cable (14 cores) F M

518Gy, 8p
M F
516Gy, 4p
Lower control box

Boom cable (16 cores) M F

517Gy, 4p

M F

Cable for 521Gy, 8p (CE and ANSI model only)

Boom wire rope failure F M
limit switches
503Gy, 2p (CE model only)
Cable for
M F
Boom length limit switch M F
534Gy, 2p Boom angle L/S
Boom cable (4 cores) Boom rotation angle L/S 504Gy, 4p
Receptacle
for AC outlet
Fig. 2-41
SSJ00003 Rev 2 2-19
Chapter 2 Mechanical Components

21) Tag, Disconnect the T1 hose, T2 hose, P hose, Platform leveling Up hose and Down hose from the
adaptor block (Fig. 2-42), and then plug the fittings on the adaptor block and hose ends.

Fig. 2-42

22) Take the guide fixed to the tail end of 3rd boom section off. (Fig. 2-43)

Fig. 2-43

2-20 Rev 1 SSJ00003

 Chapter 2 Mechanical Components

23) Remove the cable guide, and then lay it on the stable place. (Fig. 2-44)

Fig. 2-44

SSJ00003 Rev 1 2-21

Chapter 2 Mechanical Components

24) Remove clamps, and then pull out the cables and hoses from the cable guide bracket (Lower).
(Fig. 2-45)

Fig. 2-45

25) Remove the cable guide from the cable guide bracket (Lower). (Fig. 2-46)
26) Open the cable guide by using screw driver (Flat), and then remove the cables and hoses (Fig. 2-47)

Fig. 2-46

Fig. 2-47

2-22 Rev 1 SSJ00003

 Chapter 2 Mechanical Components

SP14CJ (SP460CJ) Removal

1) Set the machine on firm and level surface.
2) Set the boom horizontal, Lower the fly-jib to put the
platform on the wooden block and then turn off the
main key switch.
3) Take the cover on the right side of the fly-jib off.
(Fig. 2-48)
4) Disconnect the boom cables (14 cores: Connector
126Gy, 127Gy) and (16 cores: Connector 122Gy,
128Gy, 129Gy). (Fig. 2-49)
[Connector 129Gy is for CE and ANSI model only]
5) Disconnect the cable (4 cores) for AC outlet from the
receptacle if it is equipped.
6) Tag, Disconnect the T1 hose, P hose and T2 hose Fig. 2-48
and then plug the fittings on the hose ends.
(Fig. 2-50)
7) Follow the SP12C (SP400C) removal instructions
step 8 (Page 15) to step 26 (Page 22) to remove the
cable guide.

Fig. 2-49

Fig. 2-50

SSJ00003 Rev 2 2-23

Chapter 2 Mechanical Components

SP12C (SP400C) Installation

1) When replacing the boom cables and/or hydraulic hoses with new one, put the designated colored
vinyl tape on them to identify each cable/hose and their specific position as shown in Fig. 2-51 and
Fig. 2-52.

Designated color and detail of Hydraulic hoses

Platform side Turntable side

P hose 2,650 mm [8 ft 8.3 in] 1,150 mm [3 ft 9.3 in]

Part No: S30997-11 1,900 mm [6 ft 2.8 in]
Length: 15,270 mm 740 mm [2 ft 5.1 in]
[50 ft 4.3 in]

Red Red x2

T1 hose 2,180 mm [7 ft 1.8 in] 1,100 mm [3 ft 7.3 in]

Part No: S30997-12 1,430 mm [4 ft 8.3 in]
Length: 14,800 mm 270 mm [10.6 in]
[48 ft 6.7 in]

Blue Blue x2

T2 hose 2,185 mm [7 ft 2.0 in] 1,100 mm [3 ft 7.3 in]

Part No: S30997-13 1,430 mm [4 ft 8.3 in]
Length: 14,680 mm 270 mm [10.6 in]
[48 ft 2.0 in]

Orange Orange x2

Hose for Platform leveling 2,650 mm [8 ft 8.3 in] 1,150 mm [3 ft 9.3 in]
(Up)
Part No: S31038-20
Length: 13,400 mm
[43 ft 11.6 in]
Green Green x2

Hose for Platform leveling 2,650 mm [8 ft 8.3 in] 1,150 mm [3 ft 9.3 in]
(Down)
Part No: S31038-20
Length: 13,400 mm
[43 ft 11.6 in]
Gray Gray x2

Yellow
White

Fig. 2-51

2-24 Rev 1 SSJ00003

 Chapter 2 Mechanical Components

Designated color and detail of Boom cables

Boom cable (16 cores) 1,140 mm

Part No: 5C1-0465100 14,090 mm [46 ft 2.7 in] [3 ft 8.9 in]
Length: 15,350 mm 2,615 mm [8 ft 7.0 in]
[50 ft 4.3 in] 1,850 mm [6 ft 0.8 in]
Platform side 1,005 mm Turntable side
Connector No: [3 ft 3.6 in] Connector No:
122 740 mm 516
128 [2 ft 5.1 in] 517
129 680 mm 521
130 140 mm [2 ft 2.8 in] 570
131 [5.5 in]

Boom cable (14 cores) 1,140 mm

Part No: 5C1-0465000 14,230 mm [46 ft 8.2 in] [3 ft 8.9 in]
Length: 15,390 mm 2,600 mm [8 ft 6.4 in]
[50 ft 5.9 in] 1,850 mm [6 ft 0.8 in]
Platform side 945 mm Turntable side
Connector No: [3 ft 1.2 in] Connector No:
125 680 mm 518
126 150 mm [2 ft 2.8 in] 519
127 [5.9 in] 546
132 571

Boom cable (4 cores) 14,230 mm [46 ft 8.2 in]

for AC outlet 2,600 mm [8 ft 6.4 in] 1,140 mm 1,955 mm
Part No: 5C1-0468900 1,850 mm [6 ft 0.8 in] [3 ft 8.9 in] [6 ft 5.0 in]
Length: 19,960 mm
[65 ft 5.8 in]

Cable for Boom length limit switch 645 mm 1,140 mm 400 mm

Part No: 5C1-0466800 [2 ft 1.4 in] [3 ft 8.9 in] [1 ft 3.7 in]
Length: 6,110 mm
[20 ft 0.6 in]
Limit switch side Connector No: 572 Turntable side Connector No: 534

Yellow
White

Fig. 2-52

SSJ00003 Rev 1 2-25

Chapter 2 Mechanical Components

2) Set the boom cables and hoses in the cable guide as shown in Fig. 2-53

Fig. 2-53

Make sure that all covers are securely closed, or the cable guide may be damaged while extending /
retracting the boom.

3) Fix the boom cables and hoses to the cable guide bracket (Upper) by clamp. (Fig. 2-54)

Fig. 2-54

2-26 Rev 1 SSJ00003

 Chapter 2 Mechanical Components

4) Wrap the hoses and cables by cover. (Fig. 2-55)

Fig. 2-55

5) Fix the hoses for platform leveling to the top of the cable guide bracket (Upper). (Fig. 2-56

Fig. 2-56

6) Install the cable guide to the cable guide bracket (Lower). (Fig. 2-57)

Fig. 2-57
SSJ00003 Rev 1 2-27
Chapter 2 Mechanical Components

7) Set the boom cables and hoses in the cable guide bracket (Lower) as shown in Fig. 2-58

Fig. 2-58

2-28 Rev 1 SSJ00003

 Chapter 2 Mechanical Components

8) Wind the cable for the boom length limit switch and then put it on the cable guide bracket (Lower).
(Fig. 2-59)

Fig. 2-59

9) Bundle the boom cables and hoses up, and then tie the leading rope to the 4 cores cable for AC outlet
(Fig. 2-60)

Fig. 2-60

10) Insert the cable guide into the boom section. (Fig. 2-61)

Fig. 2-61

11) Fix the cable guide bracket (Lower) to the 1st boom section and cable guide bracket (Upper) to the 3rd
boom section. (Fig. 2-62)

Fig. 2-62

SSJ00003 Rev 1 2-29

Chapter 2 Mechanical Components

12) Install the guide. (Fig. 2-63)

Fig. 2-63

13) Connect the cable for Boom length limit switch (Connector 572Br) ,Set the cable as shown in Fig. 2-64
to prevent the cable from interference with bottom of 2nd boom section and then install the boom
length limit switch cover

Fig. 2-64

14) Insert the T1 hose, T2 hose, P hose, Platform leveling Up hose and Down hose to the cover (Fig. 2-65),
and then connect them to the adaptor block. (Page. 2-20, Fig. 2-42)

Fig. 2-65

2-30 Rev 1 SSJ00003

 Chapter 2 Mechanical Components

15) Connect the cables listed below. (Page. 2-19, Fig. 2-41)
* Boom cable (14 cores: Connector 518Gy and 546Br)
* Boom cable (16 cores: Connector 516Gy, 517Gy and 521Gy)
[Connector 521Gy is for CE and ANSI model only]
* Cable for Boom length limit switch (Connector 534Gy)
* Cable for Boom wire rope failure limit switches (Connector 503Gy) [CE model only]
* Boom cable (4 cores) for AC outlet (Disconnect from the receptacle if it is equipped)

16) Connect the cable for the boom wire rope failure limit switches (Connector 530Br, 531Br) and then fix
them by cable tie. (Page. 2-19, Fig. 2-40) [CE model only]

17) Fix the lower leveling cylinder to the boom. (Fig. 2-66)

Fig. 2-66

18) Install the turntable rear cover. (Page. 2-18, Fig. 2-37)
19) Fix the cables and hoses with cover to the left side of the 3rd boom section by U-bolt. Apply thread lock
agent (Loctite 262) to the U-bolt before tightening (Page. 2-16, Fig. 2-31)

20) Connect the hoses for upper leveling cylinder. (Page. 2-16, Fig. 2-30)

21) Install the 3rd boom front cover. Apply thread lock agent (Loctite 262) to the fixing bolts before
tightening. (Page. 2-15, Fig. 2-29)

SSJ00003 Rev 2 2-31

Chapter 2 Mechanical Components

22) Arrange the hoses and cables as shown in the Fig. 2-67.

Fig. 2-67
2-32 Rev 1 SSJ00003
 Chapter 2 Mechanical Components

23) Connect the T1 hose, P hose and T2 hose to the platform rotation solenoid valve. (Page. 2-15,
Fig. 2-28)
24) Connect the boom cables (14 cores: Connector 126Gy, 127Gy) and (16 cores: Connector 122Gy,
128Gy, 129Gy). (Page. 2-15, Fig. 2-27)
[Connector 129Gy is for CE and ANSI model only]
25) Connect the cable (4 cores) for AC outlet from the receptacle if it is equipped.
26) Install the cover on the platform. (Page. 2-15, Fig. 2-26)

SSJ00003 Rev 2 2-33

Chapter 2 Mechanical Components

SP14CJ (SP460CJ) Installation

1) Follow the SP12C (SP400C) Installation instructions step 1 (Page 24) to step 21 (Page 31) to install the
cable guide.
2) Arrange the hoses and cables as shown in the Fig. 2-68.

Fig. 2-68

3) Connect the T1 hose, P hose and T2 hose.

4) Connect the boom cables (14 cores: Connector 126Gy, 127Gy) and (16 cores: Connector 122Gy, 128Gy,
129Gy).
[Connector 129Gy is for CE and ANSI model only]
5) Connect the cable (4 cores) for AC outlet from the receptacle if it is equipped.
6) Install the cover on the right side of the fly jib. (Page. 2-23, Fig. 2-48).

2-34 Rev 2 SSJ00003

 Chapter 2 Mechanical Components

Fly jib (for SP14CJ/SP460CJ)

Upper jib Marking (White)

Fly jib cylinder

Lower jib
Fly jib bracket

No. Hoses No. Cables, Wire

1 Hose (P) 6 14 core cable
2 Hose (T1) 7 16 core cable with shield wires
3 Hose (T2) 8 4 core cable for AC outlet
(CE model and ANSI model)

Fig. 2-69 Fly jib

SSJ00003 2-35
Chapter 2 Mechanical Components

Platform (Adjustment of Overload limit switch) (CE model)

Test weight position 1
Z

Y
Center of the
rotary actuator

Test weight position 2

Lock nut for adjust bolt

Limit switch bracket
Overload limit switch

Spring bolt
X + 5 mm (0.2 in)
82 mm (3.2 in)

Spring

Lock nut for Adjust bolt Stopper bolt

Spring bolt spring bolt Lock nut for stopper bolt
Detail G

Fig. 2-70 Platform (Overload limit switch)

2-36 Rev 2 SSJ00003

 Chapter 2 Mechanical Components

Adjustment procedures of Overload limit switch

1. Adjust the spring length to 82 mm (3.2 in) by tightening the spring bolt, and then lock the lock nut.
2. Load the platform with the test weight shown in the table below at the Test weight position 1, and then
shake the platform several times.
3. Move the weight to the Test weight position 2, and then shake the platform several times.
4. Perform the above steps 2 and 3 five times to settle the spring and the linkages.
5. Load the platform with the test weight at the Test weight position 1, and then turn the Adjust bolt so that
the limit switch is switched on.
6. Move the weight to the Test weight position 2, and then make sure that the limit switch switches on.
If the limit switch does not switch on, perform the followings.
1) Turn the Adjust bolt again until the limit switch switches on.
2) Move the test weight to the Test weight position 1 again, and then make sure that the limit switch
switches on.
3) If the limit switch does not switch on, repeat the steps 2 to 6.
7. Lock the lock nut.
8. Measure the clearance “X X” between the Roller of the overload limit switch and the Adjust bolt.
Adjust the clearance between the limit switch bracket and the stopper bolts to X + 5 mm (X + 0.2 in)
and then lock the lock nut to prevent the limit switch from breakage that is caused by overloading.

Platform Platform Dimension Dimension Test

size capacity Y Z waight
250 kg 590 mm 890 mm 285 kg
6 feet
[550 lbs] [1 ft 11 in] [3 ft 11 in] [630 lbs]
227 kg 870 mm 1,040 mm 260 kg
8 feet
[500 lbs] [2 ft 10 in] [3 ft 5 in] [570 lbs]

SSJ00003 Rev 2 2-37

Chapter 2 Mechanical Components

This page intensionally left blank.

2-38 SSJ00003
 Chapter 3 Hydraulic Components

Chapter 3
Hydraulic Components

SSJ00003 3-1
Chapter 3 Hydraulic Components

Locations of Hydraulic components Fly jib cylinder

(for SP14CJ/SP460CJ)
[303-0037200]
Platform leveling cylinder (Upper) Double holding valve
[303-0037100A] [302-0034000]
Double holding valve
[302-05847A]

Boom telescope cylinder

[303-0037000C]

B view

C view

Rotary actuator
[407-0000505C]
A view Platform rotation solenoid valve
[SP12C/SP400C : 302-0034300]
Platform rotation / Fly jib
solenoid valve
[SP14CJ/SP460CJ : 302-0034400]

Platform leveling Oscillation axle cylinder Boom elevation cylinder

cylinder (Lower) [303-0036400] [303-0037400B]
[303-0037500C] Oscillation axle lock valve Single holding valve
[302-0034100A] [302-0011702]

Travel motor
Steering cylinder [301-0000071B]
[303-0037300A]

Flow divider
[302-0033000B]
Parking brake
Check valve release valve
[302-0023115] [302-0035000]

Swivel joint Flow divider

[307-0000113] [302-0032900B]

A view

Fig. 3-1 Location of Hydraulic components 1

3-2 SSJ00003
 Chapter 3 Hydraulic Components

Valve unit (for Travel functions)

[302-0032500A]

Charge filter
[305-0000073]

High-pressure filter
[305-0000017]

Gear pump HST pump

[300-0000115] [300-0000109B]
Emergency pump
Hydraulic oil tank [300-0000065]
[378-0000695C] Suction filter
[305-06597] B view

Main control valve

[302-0034200A]
Valve unit
(for Platform leveling and steering)
[302-0034500A]

Boom rotation motor

[301-0000022]
C view

Fig. 3-2 Location of Hydraulic components 2

SSJ00003 3-3
Chapter 3 Hydraulic Components

HST pump (300-0000109B)

Plunger pump Displacement 0 - 51 cm3/rev [0 - 3.1 in3/rev]
(for Travel HST system) Rated pressure 34.3 MPa (350 kgf/cm2) [5,000 PSI]
Displacement 15.6 cm3/rev [0.95 in3/rev]
Charge pump
Rated pressure 2.4 +/- 0.07 MPa (24 +/- 0.7 kgf/cm2) [350 +/- 10 PSI]
Rated voltage DC12V
Solenoid Rated current 1.6 A
Coil resistance 5.3 ohms (at 20 degrees C)

Relief valve (R1)

Relief valve (R2)
Outlet port (D)
Gauge port (M2) to Charge filter
Gauge port (M3)
Port (B)
Travel REV

Port (A)
Travel FWD Case drain port (L2) Case drain port (L1) Inlet port (S)
Gauge port (M1) for Charge pump
Inlet port (E)
from Charge filter
From Charge filter To Charge filter

Relief valve (R1)

Travel FWD

Travel REV
Hydraulic oil tank

Relief valve (R2)

Fig. 3-3 HST pump

3-4 Rev 2 SSJ00003

 Chapter 3 Hydraulic Components

Gear pump (300-0000115)

Displacement Rated pressure

Gear pump 1
16.2 cm3/rev [0.99 in3/rev] 20.6 MPa (210 kgf/cm2) [3,000 PSI]
for Boom function
Gear pump 2
for Platform, Fly jib 11.6 cm3/rev [0.71 in3/rev] 20.6 MPa (210 kgf/cm2) [3,000 PSI]
and Steering function

Outlet port
Gear pump 2

Outlet port View A Hydraulic circuit diagram

Gear pump 1

Suction port

Fig. 3-4 Gear pump

SSJ00003 Rev 2 3-5

Chapter 3 Hydraulic Components

Emergency pump (300-0000065)

DC motor DC 12 Volts
Rated pressure 17.2 MPa (175 kgf/cm2) [2,500 PSI]
Displacement 1.66 cm3/rev [0.10 in3/rev]

Contactor

Outlet port
Suction port

Fig. 3-5 Emergency pump

3-6 SSJ00003
 Chapter 3 Hydraulic Components

Hydraulic oil tank (3780000695C)

Oil capacity 190 liters [50.2 gal]

Recommended hydraulic oil Shell Tellus T22
Oil change interval Every 1,200 working hours or annually

Level gauge
Oil filler

Suction filter
305-06597

Drain plug
Fig. 3-6 Hydraulic oil tank

SSJ00003 3-7
Chapter 3 Hydraulic Components

Filters
High-pressure filter (305-0000017)

Rated pressure 20.6 MPa (210 kgf/cm2) [3,000 PSI]

Rated flow volume 50 liters / min [13.2 gal / min]
Filteration accuracy 30 microns
By-pass valve
0.5 MPa (5.0 kgf/cm2) [73 PSI]
cracking pressure
Replacement interval Every 1,200 working hours or annually
Element part number G319050014

Fig. 3-7 High-pressure filter

Charge filter (305-0000073)

Rated pressure 7 MPa (70 kgf/cm2) [1,000 PSI]

Rated flow volume 50 liters / min [13.2 gal / min]
Filteration accuracy 30 microns
By-pass valve
0.1 MPa (1.0 kgf/cm2) [15 PSI]
cracking pressure
Replacement interval Every 1,200 working hours or annually
Element part number G319050032

Suction filter (305-06597)

Fig. 3-8 Charge filter
Rated flow volume 200 liters / min [52.8 gal / min]
Filteration accuracy 105 microns
Replacement interval Every 1,200 working hours or annually

Fig. 3-9 Suction filter

3-8 Rev 2 SSJ00003

 Chapter 3 Hydraulic Components

Main control valve (302-0034200A)

Rated pressure 20.6 MPa (210 kgf/cm2) [3,000 PSI]
Rated flow 80 liters/min [21.1 gal/min]
Relief valve Main relief valve 20.6 MPa (210 kgf/cm2) [3,000 PSI]
pre-set Port reliaf valve (Telescope, In) 17.6 MPa (180 kgf/cm2) [2,550 PSI]
pressure Port reliaf valve (Elevation, Down) 14.7 MPa (150 kgf/cm2) [2,150 PSI]
Rated voltage DC 12 V
Solenoid Rated current 1.6 A
Coil resistance 3.2 ohms (at 20 degrees C)

Telescope Elevation Rotation

Out Up C.W.

Gauge port (P’)

P port
T port

Main
reliaf
valve

Port reliaf valve

(Elevation, Down)

Telescope Elevation Rotation

Port reliaf valve
In Down C.C.W.
Manual control lever (Telescope, In)

Fig. 3-10 Main control valve

SSJ00003 Rev 2 3-9

Chapter 3 Hydraulic Components

Sectional drawings

D - D Section

B - B Section
C - C Section

A - A Section

Fig. 3-11 Sectional drawings

3-10 SSJ00003
 Chapter 3 Hydraulic Components

Hydraulic circuit

Telescope Elevation Rotation

Gauge port Out In Up Down C.W. C.C.W

P port

T port

Main reliaf valve Port reliaf valve Port reliaf valve

(Telescope, In) (Elevation, Down)

Fig. 3-12 Hydraulic circuit

SSJ00003 3-11
Chapter 3 Hydraulic Components

Elevation cylinder (303-0037400B)

Dr port B port

A port
Lock the Spherical bearing (6) at
4 points using a center punch Tightening torque : 16.7 +/- 3 Nm
(1.7 +/- 0.3 Kg-m)
after being press- fitted.
[12.3 +/- 2.2 ft-lbs]

Tightening torque : 1060 +/- 235 Nm Tightening torque : 1830 +/- 180 Nm
(108 +/- 24 Kg-m) (187 +/- 18 Kg-m)
[782 +/- 173 ft-lbs] [1350 +/- 130 ft-lbs]

1 Cylinder tube 13 O-ring

Hydraulic circuit
2 Piston rod 14 Wear ring
3 Cylinder head 15 U-ring
4 Piston 16 Backup ring
5 Single holding valve 17 O-ring
6 Spherical bushing 18 Bushing
7 Bushing 19 Grease nipple
8 Dust seal 20 Bolt (M8 x 60)
9 U-ring 21 Flat washer
10 Backup ring 22 Set screw (M8 x 25)
11 O-ring 23 Cap screw (M8 x 30)
12 Backup ring 24 O-ring

Fig. 3-13 Elevation cylinder

3-12 SSJ00003
 Chapter 3 Hydraulic Components

Single holding valve for Elevation cylinder (302-0011702)

The Single holding valve is mounted on the Boom elevation cylinder to prevent the cylinder
from natural retraction.
Rated pressure 24.5 MPa (250 kgf/cm2) [3,550 PSI]
Rated flow 30 liters/min [7.9 gal/min]

1 Body 11 Plug
2 Holding valve 12 O-ring
3 Check valve 13 Orifice
4 Cap 14 Plug
5 O-ring 15 Flange
6 O-ring 16 Cap screw
7 O-ring 17 O-ring
8 O-ring
9 Spring
10 Piston

Fig. 3-14 Single holding valve

SSJ00008 3-13
Chapter 3 Hydraulic Components

Inspection procedures

Measure the natural descent of the boom elevation cylinder as follows to check the internal oil leakage of
the boom elevation cylinder.
1. Set up the machine on firm and level surface.
2. Raise the boom and set the boom at the boom angle of about 45 degrees, then shut down the engine.
3. Apply the mark on the piston rod of the boom elevation cylinder, then measure the Dimension A as
shown in Fig. 3-15.

Fig. 3-15 Inspection procedures of natural descent

Do not damage the piston rod when applying the mark.

4. Leave the machine for 10 minutes, and then measure the Dimension A’.
A - A’ = Natural descent
Serviceable limit of natural descent —— 2 mm (0.08 in) / 10 minutes.
5. If the natural descent exceeds the serviceable limit, check the single holding valve and the boom
elevation cylinder for internal oil leakage.
Follow the next procedures to identify which has internal oil leakage, the single holding valve or the
boom elevation cylinder.
1) Support the boom using a crane to prevent the boom from sudden descent.
2) Disconnect the hydraulic hoses that are connected to the single holding valve.

Loosen the hydraulic hose fittings slowly when disconnecting the hydraulic hoses.
3) Lower the hoisting hook of the crane to load the boom elevation cylinder with the gravity of the boom,
and then check if the hydraulic oil leaks from the single holding valve.
If the hydraulic oil leaks from the single holding valve, it indicates that the internal oil leakage is in the
single holding valve.
No oil leakage indicates that the internal oil leakage is in the boom elevation cylinder.

Do not remove the single holding valve without supporting the boom.
If the single holding valve is removed or loosened, the boom will fall, resulting in death or
serious injury.

3-14 Rev 2 SSJ00008

 Chapter 3 Hydraulic Components

Telescope cylinder (303-0037000C) Tightening torque :

Tightening torque : 1177 +/- 98 Nm
Tightening torque : 530 +/- 122 Nm 15.7 +/- 2.94 Nm (120 +/- 10 Kg-m)
(54 +/- 12 Kg-m) (1.6 +/- 0.3 Kg-m) [870 +/- 70 ft-lbs]
[390 +/- 90 ft-lbs] [11.6 +/- 2.1 ft-lbs]

Tightening torque : 22.5 +/- 0.98 Nm

(2.3 +/- 0.1 Kg-m)
[16.6 +/- 0.7 ft-lbs]

Tightening torque : 166.7 +/- 8.33 Nm

(17 +/- 0.85 Kg-m)
[123 +/- 6 ft-lbs]
Tightening torque : 17.2 +/- 2.5 Nm
(1.75 +/- 0.25 Kg-m)
[12.7 +/- 1.8 ft-lbs]

Hydraulic circuit

Tightening torque :
3.77 +/- 0.19 Nm
(0.38 +/- 0.02 Kg-m)
[2.78 +/- 0.14 ft-lbs]
Tightening torque : 108 +/- 10 Nm
(11 +/- 1.0 Kg-m)
[80 +/- 7 ft-lbs]
1 Cylinder tube 11 Spacer 21 Holding valve
2 Piston rod 12 Piston 22 Valve body
3 Cylinder head 13 Wear ring 23 O-ring
4 Bushing 14 U-ring 24 Cap screw
5 U-ring 15 Backup ring 25 Plug
6 Backup ring 16 O-ring 26 O-ring
7 Wiper ring 17 Backup ring 27 Name plate
8 O-ring 18 Set screw
9 O-ring 19 Holding valve
10 Lock washer 20 Plug
Fig. 3-16 Telescope cylinder

SSJ00008 Rev 2 3-15

Chapter 3 Hydraulic Components

Inspection procedures

Measure the natural descent of the boom telescope cylinder as follows to check the internal oil leakage
of the holding valve.
1. Set up the machine on firm and level surface.
2. Raise the boom fully and extend the boom about 1 meter (3 feet), then shut down the engine.
3. Apply the mark on the 2nd boom section, and then measure the Dimension A as shown in Fig. 3-17.

Fig. 3-17 Inspection procedures of natural descent

4. Leave the machine for 10 minutes, and then measure the Dimension A’.
A - A’ = Natural descent
Serviceable limit of natural descent —— 2 mm (0.08 in) / 10 minutes.
5. If the natural descent exceeds the serviceable limit, check the holding valve and the boom telescope
cylinder for internal oil leakage.
Follow the next procedures to identify which has internal oil leakage, the holding valve or the boom
telescope cylinder.
1) Raise the boom fully and extend the boom about 1 meter (3 feet).
2) Disconnect the hydraulic hoses that are connected to the holding valve, and then check if the hydraulic
oil leaks from the holding valve.

Loosen the hydraulic hose fittings slowly when disconnecting the hydraulic hoses.
If the hydraulic oil leaks from the holding valve, it indicates that the internal oil leakage is in the holding
valve.
No oil leakage indicates that the internal oil leakage is in the boom telescope cylinder.

Retract the boom fully and set it about 5 degrees when removing the holding valve.
If the holding valve is removed or loosened while the boom is not retracted fully or set below horizontal, the
2nd boom section will retract or extend suddenly, may result in death or serious injury.

3-16 Rev 2 SSJ00008

 Chapter 3 Hydraulic Components

Boom rotation motor (301-0000022)

The boom rotation motor is installed on the rotation gearbox to rotate the turntable

O-ring

Cover

Tightening torque Oil seal

: 49 - 59 Nm
(5.0 - 6.0Kg-m)
[37 - 43 ft-lbs]

B-B section A-A section

Drain port A port B port

Hydraulic circuit
B port

Drain port

A port

Fig. 3-18 Boom rotation motor

SSJ00003 Rev 2 3-17

Chapter 3 Hydraulic Components

Rotary actuator (407-0000505C)

The Platform rotary actuator is installed between the platform and the top of 3rd boom or
Fly- jib to rotate the platform.

Punch

C.W.

Tightening torque :
C.C.W. 18.6 Nm +/- 30%
(1.9 Kg-m +/- 30%)
[13.7 ft-lbs +/- 30%]

1 Air bleed plug

2 Steel ball
3 Shaft
4 O-ring
Apply grease : 5 Ball bearing
Shell Alvania EP2 6 Wear ring
7 Backup ring
Apply grease :
8 Packing
Shell Alvania EP2
9 Set screw
10 Head
11 Backup ring
12 O-ring
13 Body
14 Piston
15 Backup ring
16 Packing
17 O-ring
18 O-ring

Apply grease :
Shell Alvania EP2
2.5 mm
[0.1 in]

Tightening torque : Lock the Set screw (9) at

50 Nm +/- 10%
2 points using a center punch
(5.1 Kg-m +/- 10%)
View A
[37 ft-lbs +/- 10%]
Fig. 3-19 Rotary actuator
3-18 Rev 2 SSJ00003
 Chapter 3 Hydraulic Components

Function of Rotary actuator

1. Clockwise
1) Pressurized oil comes in to the lower room of the rotary actuator
and push up the piston as shown in the fig 3-20..
2) The piston and the shaft are threaded and mesh each other.
3) The piston rotates the shaft clockwise while it goes up.

Threaded section

2. Counter clockwise
1) Pressurized oil comes in to the upper room of
the rotary actuator and push down the piston as
shown in the fig 3-20..
2) The piston rotates the shaft counter clockwise
while it goes down.

Fig. 3-20 Function of Rotary actuator

SSJ00003 Rev 2 3-19

Chapter 3 Hydraulic Components

Platform rotation solenoid valve (302-0034300) for SP12C/SP400C

This valve is mounted on the Rotary actuator for Platform rotation to control the platform rotation functions.

Solenoid coil resistance 11.3 ohms

Relief valve (P8) Relief valve (P7)

Throttle
check valve Solenoid coil

Double pilot
check valve

Solenoid valve cartridge

Hydraulic circuit

Solenoid valve

Fig. 3-21 Platform rotation solenoid valve

Solenoid valve installation procedures

Follow the instructions below to install the Solenoid valve onto the manifold.
1. Insert the Solenoid valve cartridge (7) into the manifold, and then tighten the cartridge by the
tightening torque of 41 - 43 Nm (4.2 - 4.4 kg-m) [30 - 32 ft-lbs].
2. Install the 2 pieces of the Solenoid coils (1) onto the valve cartridge, and then tighten the Nut (17)
by the tightening torque of 4.0 - 5.0 Nm (0.4 - 0.5 kg-m) [3.0 - 3.7 ft-lbs].
3. Turn the Adjust screw (31) counter-clockwise to screw it out fully.
4. Install the Cap nut (32), and tighten it by the tightening torque of 5.0 - 6.0 Nm (0.5 - 0.6 kg-m)
[3.6 - 4.4 ft-lbs].

Do not allow the Adjust screw (31) to be turned when tightening the Cap nut (32).

3-20 Rev 2 SSJ00003

 Chapter 3 Hydraulic Components

Platform rotation / Fly jib solenoid valve (302-0034400) for SP14CJ/SP460CJ

This valve is mounted on the Rotary actuator to control the platform rotation and Fly jib articulation
functions.

Relief valve (P8) Relief valve (P7)

Throttle
check valve
Solenoid coil

Double pilot
check valve

Solenoid valve cartridge

Hydraulic circuit
Solenoid coil resistance 11.3 ohms

Solenoid valve

Fig. 3-22 Platform rotation / Fly jib solenoid valve

Solenoid valve installation procedures
Follow the instructions below to install the Solenoid valve onto the manifold.
1. Insert the Solenoid valve cartridge (7) into the manifold, and then tighten the cartridge by the
tightening torque of 41 - 43 Nm (4.2 - 4.4 kg-m) [30 - 32 ft-lbs].
2. Install the 2 pieces of the Solenoid coils (1) onto the valve cartridge, and then tighten the Nut (17)
by the tightening torque of 4.0 - 5.0 Nm (0.4 - 0.5 kg-m) [3.0 - 3.7 ft-lbs].
3. Turn the Adjust screw (31) counter-clockwise to screw it out fully.
4. Install the Cap nut (32), and tighten it by the tightening torque of 5.0 - 6.0 Nm (0.5 - 0.6 kg-m)
[3.6 - 4.4 ft-lbs].

Do not allow the Adjust screw (31) to be turned when tightening the Cap nut (32).

SSJ00003 Rev 2 3-21

Chapter 3 Hydraulic Components

Fly-jib cylinder (303-0037200) for SP14CJ/SP460CJ

Tightening torque : 16.7 +/- 3 Nm Tightening torque : 7 +/- 1.25 Nm

(1.7 +/- 0.3 Kg-m) (0.7 +/- 0.1 Kg-m)
[12.3 +/- 2.2 ft-lbs] [5.2 +/- 0.9 ft-lbs]

Tightening torque : 510 +/- 50 Nm Tightening torque : 422 +/- 96 Nm

(52 +/- 5 Kg-m) (43 +/- 9 Kg-m)
[376 +/- 36 ft-lbs] [311 +/- 70 ft-lbs]

Tightening torque : 16.7 +/- 3 Nm

(1.7 +/- 0.3 Kg-m)
[12.3 +/- 2.2 ft-lbs]

1 Cylinder tube 11 Backup ring 21 Steel ball

2 Piston rod 12 O-ring 22 Bolt
3 Cylinder head 13 Wear ring 23 Flat washer
4 Piston 14 U-ring 24 Cap screw
5 Holding valve 15 Backup ring 25 O-ring
6 Bushing 16 O-ring
7 Dust seal 17 Bushing
8 U-ring 18 Grease nipple
9 Backup ring 19 Grease nipple
10 O-ring 20 Cap screw

Fig. 3-23 Fly-jib cylinder

3-22 Rev 2 SSJ00003

 Chapter 3 Hydraulic Components

Double holding valve for Fly-jib cylinder (302-0034000) for SP14CJ/SP460CJ

The Double holding valve is equipped on the Fly- jib cylinder to prevent the cylinder from natural
retraction and extension.

Hydraulic circuit

Fig. 3-24 Double holding valve

SSJ00003 Rev 2 3-23

Chapter 3 Hydraulic Components

Valve unit for Platform leveling and Steering (302-0034500A)

The valve unit consists of the five solenoid valves, three relief valves and the flow priority valve to
supply pressurized oil to the Main control valve and Platform rotation solenoid valve (SP12C/SP400C)
or Platform rotation / Fly jib solenoid valve (SP14CJ/SP460CJ).
The valve also controls Platform leveling and Steering functions.

1 2 3 4
Solenoid coil resistance
1 4.8 ohms
2 4.8 ohms
3 6.25 ohms
5 4 6.25 ohms
5 8.8 ohms

16
14 15
A port P3 port P2 port E port M2 port

9
10

6 7 8 G port F port M1 port T1 port C port D port T port

P1 port B port
11 12 13 17

1 Steering solenoid valve Port

2 Steering / Platform, Fly-jib select solenoid valve A To Main control valve
3 Emergency solenoid valve B To Steering cylinder (Right)
4 Unloading solenoid valve C To Steering cylinder (Left)
5 Platform leveling solenoid valve From Platform rotation solenoid valve or
D
6 Relief valve 17.2 MPa (175 kgf/cm2) [2,500 PSI] Platform rotation / Fly-jib solenoid valve
7 Relief valve 22.5 MPa (230 kgf/cm2) [3,300 PSI] To Platform rotation solenoid valve or
E
8 Relief valve 22.5 MPa (230 kgf/cm2) [3,300 PSI] Platform rotation / Fly-jib solenoid valve
9 Flow priority valve F To Platform leveling cylinders (Down)
10 Orifice (0.8 mm) G To Platform leveling cylinders (Up)
11 Check valve P1 From Gear pump P1
12 Check valve P2 From Gear pump P2
13 Check valve P3 From Emergency pump
14 Check valve T To Hydraulic oil tank
15 Check valve T1 Pluged
16 Check valve M1 Gauge port
17 Check valve M2 Gauge port

Fig. 3-25 Valve unit

3-24 Rev 2 SSJ00003

 Chapter 3 Hydraulic Components

Hydraulic circuit

Platform rotation
Steering / Fly-jib Platform leveling
Right Left T P Down Up

1
8

Main 4 7
control 14 15
valve 9
5

10
16
2
11

6
3

17 13 12

Fig. 3-26 Hydraulic circuit

SSJ00003 Rev 2 3-25

Chapter 3 Hydraulic Components

Platform leveling cylinder, Upper (303-0037100A)

Tightening torque : 16.7 +/- 3 Nm

(1.7 +/- 0.3 Kg-m)
[12.3 +/- 2.2 ft-lbs]

Tightening torque : 690 +/- 70 Nm Tightening torque : 530 +/- 122 Nm

(70 +/- 7 Kg-m) (54 +/- 12 Kg-m)
[510 +/- 52 ft-lbs] [390 +/- 90 ft-lbs]

Tightening torque : 16.7 +/- 3 Nm

(1.7 +/- 0.3 Kg-m)
[12.3 +/- 2.2 ft-lbs]

1 Cylinder tube 11 Backup ring 21 Cap screw

2 Piston rod 12 O-ring 22 Cap screw
3 Cylinder head 13 Wear ring 23 O-ring
4 Piston 14 U-ring
5 Holding valve 15 Backup ring
6 Bushing 16 O-ring
7 Dust seal 17 Bushing
8 U-ring 18 Grease nipple
9 Backup ring 19 Cap screw
10 O-ring 20 Steel ball

Fig. 3-27Platform leveling cylinder (Upper)

3-26 Rev 2 SSJ00003

 Chapter 3 Hydraulic Components

Double holding valve for Platform leveling cylinder, Upper (302-05847A)

The Double holding valve is mounted on the Upper leveling cylinder to maintain the platform level in
the event of hydraulic hose breakage

Rated pressure 22.5 MPa (230 kgf/cm2) [3,300 PSI]

Rated flow 10 liters/min (2.64 gal/mi n)

Double holding valve

Upper leveling cylinder

1 Body 6 Cap 11 O-ring

2 Valve seat 7 Orifice 12 O-ring
3 Valve spool 8 Check valve 13 O-ring
4 Cap 9 O-ring 14 Plug
5 Spring 10 O-ring

Fig. 3-28 Double holding valve

SSJ00003 Rev 2 3-27

Chapter 3 Hydraulic Components

Platform leveling cylinder, Lower (303-0037500C)

Tightening torque : 690 +/- 70 Nm

(70 +/- 7 Kg-m)
[510 +/- 52 ft-lbs]

Tightening torque : 530 +/- 122 Nm

(54 +/- 12 Kg-m)
[390 +/- 90 ft-lbs]
Tightening torque : 16.7 +/- 3 Nm
(1.7 +/- 0.3 Kg-m)
[12.3 +/- 2.2 ft-lbs]

1 Cylinder tube 11 Backup ring 21 Steel ball

2 Piston rod 12 O-ring
3 Cylinder head 13 Wear ring
4 Piston 14 U-ring
5 Bushing 15 Backup ring
6 Bushing 16 O-ring
7 Dust seal 17 Bushing
8 U-ring 18 Grease nipple
9 Backup ring 19 Grease nipple
10 O-ring 20 Cap screw

Fig. 3-29 Platform leveling cylinder (Lower)

3-28 Rev 2 SSJ00003

 Chapter 3 Hydraulic Components

Steering cylinder (303-0037300A)

Tightening torque : 510 +/- 50 Nm

(52 +/- 5 Kg-m)
[376 +/- 536ft-lbs]

Tightening torque : 422 +/- 96 Nm

(43 +/- 9 Kg-m)
[310 +/- 70 ft-lbs]

Tightening torque : 16.7 +/- 3 Nm

(1.7 +/- 0.3 Kg-m)
[12.3 +/- 2.2 ft-lbs]

1 Cylinder tube 11 Backup ring

2 Piston rod 12 O-ring
3 Cylinder head 13 Wear ring
4 Piston 14 U-ring
5 Bushing 15 Backup ring
6 Bushing 16 O-ring
7 Dust seal 17 Bushing
8 U-ring 18 Grease nipple
9 Backup ring 19 Cap screw
10 O-ring 20 Steel ball

Fig. 3-30 Steering cylinder

SSJ00003 Rev 2 3-29

Chapter 3 Hydraulic Components

Swivel joint (307-0000113)

The swivel joint is installed at the rotation center of the turntable to provide the hydraulic oil passages
between the turntable and chassis.

Rated pressure A, 34.3 MPa (350 kgf/cm2) [5,000 PSI]

E 20.6 MPa (210 kgf/cm2) [3,000 PSI]
Dr 0.2 MPa (2 kgf/cm2) [28 PSI]
Rated flow A, 150 liters/min [39.6 Gal/min]
E 15 liters/min [3.96 Gal/min]
Dr 18 liters/min [4.76 Gal/min]

1 Bolt
2 Cover
3 O-ring
4 Snap ring
5 Ring
6 Plug
7 Body
8 Slipper seal
9 Oil seal
10 Snap ring
11 Shaft
12 Plug

Fig. 3-31 Swivel joint

3-30 Rev 2 SSJ00003

 Chapter 3 Hydraulic Components

Flow divider valve (302-0032900B, 302-0033000B)

One of Flow divider valve (302-0032900A) and two of Flow divider valves (302-0033000A) are installed
in the hydraulic circuit of the Traveling system to supply equal flow to the four of Travel motors.

302-0032900B 302-0033000B
Rated pressure 34.3 MPa (350 kgf/cm2) [5,000 PSI] 34.3 MPa (350 kgf/cm2) [5,000 PSI]
Rated flow 130 liters/min [34.3 Gal/min] 65 liters/min [17.2 Gal/min]
Flow dividing ratio
1:1 1:1
to A and B ports

302-0032900B 302-0033000B

1 Plug
2 Spring
Hydraulic circuit 3 Spring
5 Orifice
6 Body
7 Plunger
9 Plug
11 O-ring
12 O-ring

Fig. 3-32 Flow divider valve

SSJ00003 Rev 2 3-31

Chapter 3 Hydraulic Components

Travel motor (301-0000071B)

Motor type Plunger motor

Rated pressure 34.3MPa (350 kgf/cm2) [5,000 PSI]
Hydraulic motor
Low 31.5 cm3 [1.92 in3]
Displacement
High 18.0 cm3 [1.10 in3]
Gear type Planetary gear
Reduction ratio 1 : 31.2
Gear box
Recommended gear oil Shell Spirax EP90
Gear oil capacity 1.0 liter [0.26 gallons]
Rated pressure 4.9 MPa (50 kgf/cm2) [710 PSI]
Parking brake
Brake releasing pressure 1.5 MPa (15.3 kgf/cm2) [218 PSI]

Hydraulic circuit

Main port (A) Main port (B) B Pb

A P2 Dr
Pilot port for Pilot port for
Hi-Lo select parking brake release (Pb)
Drain port (Dr)
(P2)

Fig. 3-23 Travel motor

3-32 Rev 2 SSJ00003

 Chapter 3 Hydraulic Components

Valve unit for Oscillation axle, Parking brake and Travel speed select
(302-0032500A)
The valve unit consists of three solenoid valves to release the Oscillation axle lock, Parking brake
and select Hi-Lo speed of the travel motor.

Rated pressure 4.9 MPa (50 kgf/cm2) [710 PSI] Rated voltage DC12V
Rated flow volume 10 liters/min [2.64 gal/min] Solenoid coil resistance 8.3 ohms

Oscillation axle release Parking brake release Travel speed select

solenoid valve solenoid valve solenoid valve

Hydraulic circuit

Fig. 3-34 Valve unit

SSJ00003 Rev 2 3-33

Chapter 3 Hydraulic Components

Parking brake release valve (302-0035000)

The Parking brake release valve send the pilot pressure to travel motor to release the parking brake
when the travel function or steering is operated.
The valve is equipped with emergency hand pump to release the parking brake that enable to tow the
machine when the machine is stuck because of Engine, Hydraulic system or Electric system failure.

Rated pressure 20.6 MPa (210 kgf/cm2) [3,000 PSI]

Reducing valve 3.4 MPa (35 kgf/cm2) [500 PSI]
Hydraulic circuit
Steering Parking brake
Left Right (F/R) (F/L)

6 7
2
A port B port Br port Parking
8
brake
release
1 sol.V
3
5
4

1 2 3 Left Right Drain (R/L) (R/R)

Steering sol.V Parking brake

C port
D port

Dr port G port H port

4 F port E port 5 6 7 8

1 Reducing valve Port

2 Hand pump A From Valve unit (Steering sol.V, Right)
3 Needle valve B From Valve unit (Steering sol.V, Left)
4 Shuttle valve C To Steering cylinder (Right)
5 Shuttle valve D To Steering cylinder (Left)
6 Pilot check valve E Parking brake (Front/Left)
7 Pilot check valve F Parking brake (Front/Right)
8 Check valve G Parking brake (Rear/Right)
H Parking brake (Rear/Left)
Br From Valve unit (Parking brake release sol.V)
Dr To Hydraulic oil tank
Fig. 3-35 Parking brake release valve
3-34 Rev 2 SSJ00003
 Chapter 3 Hydraulic Components

Oscillation axle cylinder (303-0036400)

Tightening torque : 43 +/- 4 Nm
(4.4 +/- 0.4 Kg-m)
[31.7 +/- 3.0 ft-lbs]

Tightening torque : 1225 +/- 245 Nm Tightening torque : 343 +/- 49 Nm

(125 +/- 25 Kg-m) (35 +/- 5 Kg-m)
[904 +/- 180 ft-lbs] [253 +/- 36 ft-lbs]

1 Cylinder tube 11 O-ring

2 Piston rod 12 U-ring
3 Cylinder head 13 Backup ring
4 Piston 14 Wear ring
5 Dust seal 15 Nut
6 U-ring 16 Split pin
7 Backup ring 17 Holding valve
8 O-ring 18 Bolt
9 O-ring 19 Washer
10 Bushing 20 Retainer ring

Fig. 3-36 Oscillation axle cylinder

SSJ00003 Rev 2 3-35

Chapter 3 Hydraulic Components

Oscillation axle lock valve (302-0034100A)

Rated pressure 23.5 MPa (240 kgf/cm2) [3,400 PSI]

Rated flow volume 30 L/min [7.9 gal/min]
Counter valance valve cracking pressure 23.5 MPa (240 kgf/cm2) [3,400 PSI]

Oscillation axle cylinder

Hydraulic circuit

Fig. 3-37 Oscillation axle lock valve

3-36 Rev 2 SSJ00003

 Chapter 4 Electric Components

Chapter 4
Electric Components

SSJ00003 4-1
Chapter 4 Electric Components

Locations of Electric components Engine relay box

Battery
[5N5-0114100B]
[GS Yuasa 130E41R:
View A Boom wire rope failure 322-0008300]
limit switches (CE model)
[320-0005800]

Boom angle limit switch

[320-0005800]

Overload
limit switch (CE model)
[320-0002600] Fuel sensor
Tilt sensor [382-0000024]
(Lateral)
[382-0001600]

Alarm buzzer Horn

View B [324-0008001] [324-00821]

Motion alarm buzzer

[324-00832A]
Upper control box
Foot switch Lower control box
[320-04017C]
Alarm buzzer
Tilt sensor
[324-0008001]
(Longitudinal)
[382-0001600] Tilt sensor
(Omni-directional: CE model)
[382-0000019]

View A

Boom length limit switch

[320-0005800]

Boom rotation angle limit switch

[320-0005800]

View B

Fig. 4-1 Locations of Electric components

4-2 SSJ00003
 Chapter 4 Electric Components

Upper control box

1 Platform leveling s/w 173-01212 16 Joystick controller for Boom telescope 324-0008100
2 Travel speed select s/w 173-01111 17 Joystick controller for Boom elevation 324-0008100
3 Horn s/w 173-51100 18 Joystick controller for Travel 324-0008100
4 19
5 Rotating beacon s/w (Option) 173-00100 20 System failure light
6 Work light s/w (Option) 173-00100 21 Fuel level light
7 Head light s/w (Option) 173-00100 22 Engine failure light
8 Hydraulic generator s/w (Option) 173-00100 23 Power indicator light
329-0091300
9 24
10 Engine start / Emergency pump s/w 173-02212 25 Overload warning light (CE model)
11 Emergency stop button 320-0007201 26
12 Platform rotation s/w 320-05325 27 Tilt warning light
13 Fly-jib s/w (for SP14CJ/SP460CJ) 320-05325 28 Hydraulic generator light (Option)
14 Steering lever 324-0000033 29 CPU board M6 : Sub1 G309290016
15 Joystick controller for Boom rotation 324-0008100 30 CPU board M6 : Sub2 G309290017

Fig. 4-2 Upper control box

SSJ00003 Rev 1 4-3

Chapter 4 Electric Components

Electric circuit diagram

Connector

(SP14CJ / (CE model)

SP460CJ)
Fig. 4-3 Electric circuit diagram

4-4 Rev 2 SSJ00003

 Chapter 4 Electric Components

CPU board “M6” (Sub 1: G309290016, Sub 2: G309290017)

J4 J5

J1
J2 J3
J7
J8
J6
J9

Connectors

J1 J2
Vp Vp GND GND Vbac FG

J3
L4 L2 OT6 OT4 OT2
L3 L1 OT8 OT7 OT5 OT3 OT1

J4
D1 D3 D5 D7 D9 D11 D13 D15
D2 D4 D6 D8 D10 D12 D14 D16

J5
KV6 KA6 KG6 KV4 KA4 KG4 KV2 KA2 KG2
KV5 KA5 KG5 KV3 KA3 KG3 S5V KA1 KG1

J6 J7
485_H 486_L 485_TM CAN_H CAN_L CAN_TM FG
485_H 486_L FG CAN_H CAN_L CAN_TM FG

J8
Vcc /Vpp_EN FG /EXRES /WDT

J9
PTX PRX PSG FG /WE1 PSG

Fig. 4-4 CPU board “M6”

SSJ00003 Rev 1 4-5

Chapter 4 Electric Components

Input / Output characteristics (CPU board M6 : Sub1)

4-6 Rev 1 SSJ00003

 Chapter 4 Electric Components

Input / Output characteristics (CPU board M6 : Sub2)

SSJ00003 Rev 1 4-7

Chapter 4 Electric Components

LED board (329-0091300)

Connector

Electric diagram

1
2 System failure light
3 Fuel level light
4 Engine failure light
5 Power indicator light
6
7 Overload warning light (CE model)
8
9 Tilt warning light
10 Hydraulic generator light (Option)

Fig. 4-5 LED board

4-8 SSJ00003
 Chapter 4 Electric Components

Joystick controller (324-0008100)

Electric diagram
Direction selector switch

Potentiometer

1 Brown
2 Red
3 White
4 Black
5 Yellow
6 Green
7 Blue

Fig. 4-6 Joystick controller

SSJ00003 4-9
Chapter 4 Electric Components

Lower control box

Detail A

1 Emergency stop button 320-0007201 21 Glow light

2 Boom rotation s/w 173-01212 22 Engine oil pressure light
3 Platform rotation s/w 173-01212 23 Water temp. light 329-0091300
4 Boom elevation s/w 173-01212 24 Charge light
5 Boom telescope s/w 173-01212 25 Air cleaner clog light
6 Fly-jib s/w ( SP14CJ/SP460CJ) 173-01212 26 Relay CR-1 320-05306
7 Platform leveling s/w 173-01212 27 Relay CR-2 320-05306
8 Engine start / Emergency pump s/w 173-02212 28 Relay CR-3 320-05306
9 Travel speed select s/w 173-00100 29 Relay CR-4 320-05306
10 Pre-start check s/w 173-02102 30 Relay CR-5 320-05306
11 31 Relay CR-11 320-05306
12 Rotating beacon s/w (Option) 173-00100 32 CPU board M5-B G309290015
13 Enable s/w 173-01102 33 Accelerator control unit 329-0079701
14 Key s/w 378-0000701 34 Relay CR-12 320-05306
15 Hour meter 381-00112 35 Relay CR-10 320-05781
16 Fuel level light 36 Fuse box 320-0003900
17 Overload warning light (CE model) 37 Emergency s/w 173-02102
18 329-0091300
19 Tilt warning light
20 System failure light

Fig. 4-7 Lower Control box

4-10 Rev 1 SSJ00003

 Chapter 4 Electric Components

Electric circuit diagram

Fig. 4-8 Electric circuit diagram

SSJ00003 4-11
Chapter 4 Electric Components

Electric circuit diagram

Connector

Fig. 4-9 Electric circuit diagram

4-12 Rev 2 SSJ00003
 Chapter 4 Electric Components

CPU board “M5-B” (G309290015)

J2 J3 J8 J9 J4 J1

J5 J6 J7

Connectors

Fig. 4-10 CPU board “M5-B”

SSJ00003 Rev 1 4-13

Chapter 4 Electric Components

Input / Output characteristics (CPU board M5-B)

4-14 Rev 1 SSJ00003

 Chapter 4 Electric Components

SSJ00003 Rev 1 4-15

Chapter 4 Electric Components

Accelerator control unit (329-0079701)

Accelerator control unit is installed in the lower control box to send the signal to ECU to change the
engine speed.
Low speed (VR2) High speed (VR4)

Idling speed (VR5)

Mid speed (VR3)

Trimmer turning direction

Decrease

Increase
Engine speed for optional
Hydraulic generator (VR1)
Electric diagram

Fig. 4-11 Accelerator control unit

Engine speed Adjustment procedures

1. Warm up the engine.

2. Turn the trimmer VR5 to adjust the Idling speed to 1,050 rpm.
3. Turn the trimmer VR2 to adjust the Low speed to 1,800 rpm.
4. Turn the trimmer VR3 to adjust the Mid speed to 2,200 rpm.
5. Turn the trimmer VR4 to adjust the High speed to 2,700 rpm.
6. Turn the trimmer VR1 to adjust the engine speed for hydraulic generator to 1,400 rpm if it is equipped.

See page 6-2 for engine speed measurement procedures.

4-16 SSJ00003
 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 Control position Connection

OFF OFF ----------
P1 Upper control B - 1, B1 - 2
P2 Lower control B - 3, B1 - 4

Fig. 4-12 Key switch

SSJ00003 4-17
Chapter 4 Electric Components

Engine relay box (5N5-0114100B)

1 Key switch ON relay 320-05306

2 Engine start relay 320-05306
3 Engine stop relay 320-05306
4 Glow light relay 320-05306
5 Charge relay 320-05306
6 Starter relay G031780002
7 Glow relay G031780002
8 Rack actuator relay G031780003
9 Main relay G031780003
10 Fuse box ----------

Fig. 4-13 Engine relay box

4-18 Rev 1 SSJ00003

 Chapter 4 Electric Components

Tilt sensor (Longitudinal, Lateral) (382-0001600)

Two analog tilt sensors are installed on the turntable to sense the tilt angle of the machine in
longitudinal direction and lateral direction.
Tilt alarm buzzer sounds when the actual machine tilt angle (calculated from longitudinal and
lateral tilt angle) is more than 5 degrees.

Output characteristics

Output
voltage

Tilt angle

Fig. 4-14 Tilt sensor (Longitudinal, Rateral)

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

SSJ00003 4-19
Chapter 4 Electric Components

Tilt sensor (Omni-directional) (382-0000019) CE model

The tilt sensor (Omni-directional) is installed on the turntable to detect the machine tilt angle of 5 degrees.

This LED goes on when the tilt angle is

within 5 degrees.

Power

Switch
Out

GND

Fig. 4-15 Tilt sensor (Omni-directional)

4-20 SSJ00003
 Chapter 4 Electric Components

Limit switches (320-0002600, 320-0005800)

Boom angle Boom length Boom rotation angle

limit switch limit switch limit switch

Boom wire rope failure Overload limit switch (CE model)

limit switches (CE model)

320-0002600 320-0005800
Fig. 4-16 Limit switches

Travel speed is limited at Low

Boom angle Opens when the boom angle
speed, when one of these 320-00005800
limit switch is higher than 5 +/- 4 degrees.
limit switches is opened.

Boom length Opens when the boom is Oscillation axle is locked,

320-00005800
limit switch extended more than 600 mm. * When the Boom length
limit switch is opened.
Opens when the boom * When the Boom angle
Boom rotation angle rotation angle exceeds limit switch and Boom
320-00005800
limit switch 7.5 degrees from the rotation angle limit switch
rear center of the machine. are opened.
Boom wire rope failure
Open when the boom Boom telescope Out
limit switches 320-00005800
extension wire is cut or loose. function is disabled.
(CE model)
Overload limit switch Opens when the platform is All of the functions are
320-00002600
(CE model) overloaded. disabled.

SSJ00003 Rev 1 4-21

Chapter 4 Electric Components

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4-22 SSJ00003
 Chapter 5 Trouble shooting

Chapter 5
Trouble shooting

SSJ00003 5-1
Chapter 5 Trouble shooting

Trouble shooting by LED indication on Upper / Lower control box

LEDs on the Upper and Lower control panel goes on or blink as shown in the table below to indicate
the system error.

Upper control box Lower control box

Fig. 5-1 Locations of LEDs

No. Locations Descriptions LED status

1 Upper control panel System failure light Off LED stays off B9 LED blinks 9 times
2 Upper control panel Fuel level light On LED goes on B1 LED blinks 10 times
3 Upper control panel Engine failure light 0
BC LED blinks continuously B1 LED blinks 11 times
4 Upper control panel Power indicator light B2 LED blinks twice 1
B1 LED blinks 12 times
5 Upper control panel Tilt warning light B3 LED blinks 3 times 2
B1 LED blinks 13 times
6 Lower control panel System failure light B4 LED blinks 4 times 3
B1 LED blinks 14 times
B5 LED blinks 5 times 4
B1 LED blinks 15 times
B6 LED blinks 6 times 5
B1 LED blinks 16 times
B7 LED blinks 7 times 6
B1 LED blinks 17 times
B8 LED blinks 8 times 7

Error LED status

Causes Countermeasures
descriptions 1 2 3 4 5 6
No function is operated for more
Foot switch
Off Off Off BC Off Off than 20 seconds in spite of the foot Release the foot switch.
time out
switch is pressed.
CPU board M5-B and M6 (Sub1) fail
to communicate each other.
Communication
1. Faulty communication line 1. Rectify the communication line.
error
BC Off Off Off Off B2 between CPU board M5-B
(M5B -
and M6 (Sub1). 2. Replace the CPU board M6
M6 Sub1)
2. Faulty CPU board M6 (Sub1). (Sub2).
3. Faulty CPU board M5-B. 3. Replace the CPU board M5-B.
CPU board M5-B and M6 (Sub2) fail
Communication to communicate each other.
error 1. Faulty communication line 1. Rectify the communication line.
On Off Off B4 Off B2
(M5B - between CPU board M6 (Sub1)
M6 Sub2) and M6 (Sub2). 2. Replace the CPU board M6
2. Faulty CPU board M6 (Sub2). (Sub2).
CPU board M5-B and M6 (Sub2) fail
Communication to communicate each other.
error 1. Faulty communication line 1. Rectify the communication line.
On Off Off B5 Off B2
(M5B - between CPU board M6 (Sub2)
M6 Sub3) and M6 (Sub3). 2. Replace the CPU board M6
2. Faulty CPU board M6 (Sub3). (Sub3).

5-2 SSJ00003
 Chapter 5 Trouble shooting

Error LED status

Causes Countermeasures
descriptions 1 2 3 4 5 6
CPU board M5-B and M6 (Sub4) fail
to communicate each other.
Communication
1. Faulty communication line 1. Rectify the communication line.
error
On Off Off B6 Off B2 between CPU board M5-B
(M5B -
and M6 (Sub4). 2. Replace the CPU board M6
M6 Sub4)
2. Faulty CPU board M6 (Sub4). (Sub4).
3. Faulty CPU board M5-B. 3. Replace the CPU board M5-B.
1. Incorrect or damaged parameters 1. Write the correct parameters
are memorized in the CPU board into the CPU board M5-B,
EEPROM error On B3 Off Off Off B15
M5-B. using the Handy tool.
2. Faulty CPU board M5-B. 2. Replace the CPU board M5-B.
The CPU board M5-B has output to
the solenoids for Boom elevation,
Boom telescope, Boom rotation
and/or Travel in spite of no
PWM error On B4 Off Off Off B15 command.
1. Short circuit in the output lines to 1. Rectify the output lines to
the solenoid(s). the solenoid(s).
2. Faulty solenoid(s). 2. Replace the faulty solenoid(s).
3. Faulty CPU board M5-B. 3. Replace the CPU board M5-B.

The CPU board M5-B has output to

the Relays for unloading solenoid
valves, Travel speed select solenoid
and/or Parking brake release
solenoid in spite of no command.
ET error On B5 Off Off Off B15
1. Short circuit in the output lines to 1. Rectify the output lines to
the Relay(s) and/or solenoid(s). the Relay(s) and/or solenoid(s).
2. Faulty relay(s) 2. Replace the faulty relay(s).
3. Faulty solenoid(s). 3. Replace the faulty solenoid(s).
4. Faulty CPU board M5-B. 4. Replace the CPU board M5-B.
CPU error On Off Off Off Off B15 Faulty CPU board M5-B Replace the CPU board M5-B.
1. Water (Coolant) temperature is 1. Stop the engine and wait to
higher 110 degrees C. cool down the engine.

Water temp. Water temp sensor signal is more

On Off B2 Off Off B10
error than 4.8 volts or less than 0.2 volts.
2. Faulty electric lines between 2. Rectify the electric lines.
Water temp sensor and ECU. 3. Replace the Water temp
3. Faulty water temp sensor. sensor.

Oil pressure switch in not turned on Turn off the key switch once, and
while engine is stopped. then turn on it.
Oil pressure switch is not turned on If the error still occurs, check
Engine oil
On Off B3 Off Off B10 while engine is running. followings.
pressure error
1. Faulty electric lines to Oil 1. Rectify the electric lines.
pressure switch. 2. Replace the Oil pressure
2. Faulty Oil pressure switch. switch.
Battery charging switch in not turned Turn off the key switch once, and
on while engine is stopped. then turn on it.
Battery charging switch is not turned If the error still occurs, check
Charge error On Off B4 Off Off B10 on while engine is running. followings.
1. Faulty electric lines between 1. Rectify the electric lines.
Alternator and ECU.
2. Faulty Alternator. 2. Replace the Alternator.

SSJ00003 5-3
Chapter 5 Trouble shooting

Error LED status

Causes Countermeasures
descriptions 1 2 3 4 5 6
1. Air cleaner is clogged. 1. Clean or replace the air cleaner
element.
Air cleaner error On Off B5 Off Off B10 2. Faulty electric lines between Air 2. Rectify the electric lines.
cleaner sensor and ECU.
3. Faulty Air cleaner sensor. 3. Replace the Air cleaner sensor.
Input from Accelerator control unit is
more than 4.6 volts or less than 0.2
volts.
Accelerator 1. Incorrect adjustment of 1. Adjust the accelerator control
On Off B6 Off Off B10
sensor error accelerator control unit. unit.
2. Faulty electric lines between 2. Rectify the electric lines.
Accelerator control unit and ECU. 3. Replace the accelerator control
3. Faulty Accelerator control unit. unit.

Turn off the key switch once, and

then turn on it again.
If the error still occurs, check
Engine speed Faulty electric lines between Engine
On Off B7 Off Off B10 and rectify electric lines if
sensor error speed sensor and ECU.
necessary.
Ask Yanmar distributor to detail
check.
Turn off the key switch once, and
then turn on it again.
If the error still occurs, check
Rack position Faulty electric lines between Rack
On Off B8 Off Off B10 and rectify electric lines if
sensor error position sensor and ECU.
necessary.
Ask Yanmar distributor to detail
check.
Turn off the key switch once, and
then turn on it again.
If the error still occurs, check
Rack actuator Faulty electric lines between Rack
On Off B9 Off Off B10 and rectify electric lines if
error actuator and ECU.
necessary.
Ask Yanmar distributor to detail
check.
Check and rectify electric lines if
necessary.
CAN error On Off B10 Off Off B10 Faulty CAN communication lines.
Ask Yanmar distributor to detail
check.
Turn off the key switch once, and
then turn on it again.
If the error still occurs, check
Faulty electric lines between EGR
EGR valve error On Off B11 Off Off B10 and rectify electric lines if
valve and ECU.
necessary.
Ask Yanmar distributor to detail
check.
Turn off the key switch once, and
then turn on it again.
If the error still occurs, check
CSD solenoid Faulty electric lines between CSD
On Off B12 Off Off B10 and rectify electric lines if
valve error solenoid valve and ECU.
necessary.
Ask Yanmar distributor to detail
check.

5-4 SSJ00003
 Chapter 5 Trouble shooting

Error LED status

Causes Countermeasures
descriptions 1 2 3 4 5 6
1. Faulty electric lines between Turn off the key switch once, and
Main relay and ECU, then turn on it again.
2. Faulty electric lines between If the error still occurs, check
Relay error On Off B13 Off Off B10 Rack actuator relay and ECU and rectify electric lines if
3. Faulty electric lines between necessary.
Glow relay (Starting aid relay) Ask Yanmar distributor to detail
and ECU check.

Power supply to ECU is higher than

16 volts or lower than 10 volts.
Power supply to sensors are higher
than 5.5 volts or lower than 4.5 volts.
Power supply 1. Faulty electric lines between 1. Rectify the electric lines.
On Off B15 Off Off B10
voltage error Battery and ECU. 2. Charge the battery.
2. Faulty Battery. Replace the battery
if necessary.
3. Faulty ECU. 3. Ask Yanmar distributor to detail
check.

Turn off the key switch once, and

then turn on it.
ECU error On Off B17 Off Off B10 Faulty ECU.
If the error still occurs, ask Yanmar
distributor to detail check.

Input from Tilt sensors (Longitudinal)

and/or (Lateral) are out of specific
range during pre-start check.
Pre-start check 1. Pre-start check switch is operated 1. Release the pre-start check
On Off Off Off B2 B3
error when the machine is tilted . switch.
2. Incorrect calibration of the 2. Perform the Tilt sensor
Tilt sensors. calibration using handy tool.
3. Faulty Tilt sensors. 3. Replace the Tilt sensors.

Input from Tilt sensor (Longitudinal)

is out of specific range.
1. Incorrect calibration of the Tilt 1. Perform the Tilt sensor
sensor. calibration using handy tool.
Tilt sensor error 2. Faulty electric lines between 2. Rectify the electric lines
On Off Off Off B3 B4
(Longitudinal) Tilt sensor (Longitudinal) and between Tilt sensor
CPU board M5-B. (Longitudinal) and CPU board
M5-B.
3. Faulty Tilt sensor (Longitudinal). 3. Replace the Tilt sensor
(Longitudinal)

Input from Tilt sensor (Lateral) is out

of specific range.
1. Incorrect calibration of the Tilt 1. Perform the Tilt sensor
sensor. calibration using handy tool.
Tilt sensor error
On Off Off Off B4 B4 2. Faulty electric lines between 2. Rectify the electric lines
(Lateral)
Tilt sensor (Lateral) and between Tilt sensor (Lateral)
CPU board M5-B. and CPU board M5-B.
3. Faulty Tilt sensor (Lateral). 3. Replace the Tilt sensor
(Lateral)

SSJ00003 Rev 1 5-5

Chapter 5 Trouble shooting

Error LED status

Causes Countermeasures
descriptions 1 2 3 4 5 6

The difference of detected angle

between Tilt sensors
(Longitudinal/Lateral) and Tilt sensor
(Omni directional) exceed specific
angle.
1. Incorrect calibration of the 1. Perform the Tilt sensor
Tilt sensors. calibration using handy tool.
Tilt sensor
On Off Off Off B5 B4 2. Faulty electric lines between 2. Rectify the electric lines
duplication error
Tilt sensors (Longitudinal, Lateral between Tilt sensor
and/or Omni directional) and (Longitudinal, Lateral and/or
CPU board M5-B. Omni directional) and
CPU board M5-B.
3. Faulty Tilt sensors (Longitudinal, 3. Replace the Tilt sensor
Lateral and/or Omni directional). (Longitudinal, Lateral and/or
Omni directional)

Both Limit and Release signal input

at the same time.
Emergency 1. Faulty electric lines between 1. Rectify the electric lines
On Off Off Off B6 B5
switch error Emergency switch and between Emergency switch
CPU board M5-B. and CPU board M5-B.
2. Faulty Emergency switch. 2. Replace the Emergency switch.
No input from the Boom wire rope
failure L/S.
1. Faulty electric lines between 1. Rectify the electrical lines
Boom wire rope
On Off Off Off B7 B6 Boom wire rope L/S and between Boom wire rope failure
failure error
CPU board M5-B. L/S and CPU board M5-B.
2. Faulty Boom wire rope failure L/S. 2. Replace the Boom wire rope
failure L/S.

5-6 SSJ00003
 Chapter 5 Trouble shooting

Emergency operations
When the Boom, Fly-jib, Platform, Travel and/or Steering functions are disabled because of any
problem, operate the machine following the instruction desclibed in this clause to escape from
working site.

Lower the platform and unload it before towing the machine.

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

Do not perform Emergency operations desclibed in this clause unless in case of emergency.
These operations disable the safety devices described in each item and allow unsafe movement of the
machine,
may cause the death or serious injury.

Emergency pump
1. Lower the platform using emergency pump in case of engine or hydraulic system failure
If the machine does not work due to the engine or main pump failure, use the emergency pump to
lower the platform. It is not necessary to turning on the dead-man switch when operating the boom
from the lower control with using the emergency pump.

Emergency pump switch

Fig. 5-2 Emergency pump switch

The emergency pump can only be used for only 30 seconds or less at a time, with a rest period
over 30 seconds between uses.
Do not use the emergency pump for normal work because it puts a great load on the pump.

SSJ00003 5-7
Chapter 5 Trouble shooting

Override switch
1. Lower the platform using override switch when the System failure occurs.
When the system failure occurs, System failure light on upper and lower control box blinks and some
functions may be disabled.
If the boom function is disabled due to system failure, use the override switch to lower the platform as
follows.

1) Take the cover on the lower control panel off.

2) Hold the override switch and make sure that the warning buzzer sounds.
3) Operate the boom telescope switch with holding override switch to retract the boom.
4) Operate the boom elevation switch with holding override switch to lower the boom.

System failure light

Override switch

Fig. 5-3 Override switch

Platform overload sensing system is disabled when the override switch is operated.
Do not put more weight on the platform or the machine may tip over result in death or serious injury.
Retract the boom first and then lower the boom to keep the working radius in minimum.

5-8 SSJ00003
 Chapter 5 Trouble shooting

Manual control lever

1. Lower the platform using manual control lever in case of electric system failure
If the boom function is disabled due to electric system failure, use the manual control lever to lower
the platform as follows.

1) Start the engine.

2) Open the turntable cover (Left, Rear).
3) Take the lever from the lever holder, and then put it into the hole under the solenoid valve.
4) Push the red button on unloading valve.
5) Operate the lever to control the boom function.

Main control valve

Boom rotation
C.W. -- C.C.W.
Boom elevation
Up ------ Down
Boom telescope
Out ------- In

Hole
Valve unit

Unloading valve

Fig. 5-4 Manual control lever

Platform overload sensing system does not disable the manual control lever operation.
Do not put more weight on the platform or the machine may tip over result in death or serious injury.
Retract the boom first and then lower the boom to keep the working radius in minimum.

SSJ00003 5-9
Chapter 5 Trouble shooting

Parking brake release hand pump

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

Retract the boom fully, Lower it under horizontal and unload the platform before towing the
machine.
Towing the machine with the boom raised, extended and/or the platform loaded make the
machine unstable and may tip over 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
result in death or serious injury.

Free the steering linkage Steering

1) Remove the steering lock pin cylinder

Tie rod

Steering
lock pin
Fig. 5-5 Steering lock pin
Free the parking brake by Parking brake release hand pump
1) Set up the wheel chocks in front and rear of all tires.
2) Open the right rear cover.
3) Loosen the lock nut behind the HST pump, and then screw in the bolt to push the HST pump
release pin on the relief valve R1 and R2.

HST pump
Relief valve (R2)

HST pump release pin Relief valve (R1)

Bolt

Relief valve (R1 or R2)

Lock nut Set the clearance to 1 mm (0.04 in)

after towing the machine.

Fig. 5-6 HST pump release pin

5-10 Rev 1 SSJ00003

 Chapter 5 Trouble shooting

4) Take the chassis cover (Rear).

5) Turn the needle valve clockwise to close it.
6) Push the hand pump until it becomes moderately hard.
7) Attach the sling chain or wire rope to the towing ring.
8) Remove the wheel chocks carefully and then tow the machine slowly.
9) After towing the machine, turn the needle valve counterclockwise to open it.

Parking brake release valve

Hand pump

Needle valve

Fig. 5-7 Parking brake release hand pump

10) Set the clearance to 1 mm (0.04 in) between HST pump release pin and bolt, and then lock the
lock nut.

Make sure that the parking brakes work correctly after opening the needle valve and setting
clearance of HST pump release pin, or the machine may run away result in death or serious
injury.

SSJ00003 Rev 1 5-11

Chapter 5 Trouble shooting

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5-12 SSJ00003
 Chapter 6 Inspection and Adjustment

Chapter 6
Inspection and Adjustment

SSJ00003 6-1
Chapter 6 Inspection and Adjustment

Engine speed measurement procedures

Specific engine speed
Engine speed (rpm)
Idling speed 1,050 +50/-0
Low speed 1,800 +50/-0
Mid speed 2,200 +50/-0
High speed 2,700 +50/-0
for Hydraulic generator (Option) 1,400 +50/-0

Engine speed measurement procedures

See page 4-16 for engine speed adjustment procedures

1. Set the machine on firm and level surface.

2. Warm up the engine and operate the machine to raise the hydraulic oil temperature to
50 +/- 10 degrees C (104-140 degrees F).
3. Measure the engine Idling speed without loading the engine.
4. Measure the engine Low speed as follows.
1) Retract the boom fully.
2) Measure the engine Low speed while operating Boom telescope In to activate the relief valve.
5. Measure the engine Mid speed as follows.
1) Retract the boom fully and raise the boom fully.
2) Measure the engine Mid speed while operating Boom telescope In and Boom elevation Up
simultaneously to activate the relief valve.
6. Measure the engine High speed as follows.
1) Set the wheel chocks in front and rear of all tires as shown in the figure below.

Fig. 6-1 Wheel chocks

2) Disconnect the connector (No.549, Gray, 4 poles) from Valve unit for Travel functions
(See page 3-2 for location of the valve unit) to lock the parking brake.
3) Retract the boom fully and lower the boom fully.
4) Measure the engine High speed while operating Boom elevation Down and Travel FWD
or REV simultaneously to activate the relief valve.
5) Connect the connector No.549 after measureing the engine High speed.
7. Measure the engine speed for Hydraulic generator as follows if it is equipped.
1) Turn on the Hydraulic generator switch.
2) Measure the engine speed while using electric tool to load the hydraulic generator.

6-2 SSJ00003
 Chapter 6 Inspection and Adjustment

Relief valve pre-set pressure measurement and adjustment procedures

Specific pre-set pressure

Relief valve Gauge port

Relief valve Pre-set pressure Pump speed Functions
locations (Size)
34.3 - 34.8 MPa
M1 High
R1 (350 - 355 kg/cm2) HST pump Travel FWD
(9/16-18 UNF) (2,700 rpm)
[4,980 - 5,050 PSI]
34.3 - 34.8 MPa
M2 High
R2 (350 - 355 kg/cm2) HST pump Travel REV
(9/16-18 UNF) (2,700 rpm)
[4,980 - 5,050 PSI]
17.2 - 17.7 MPa Valve unit for Platform rotation
M2 Low
R5 (175 - 180 kg/cm2) Platform leveling Platform leveling
(1/4) (1,800 rpm)
[2,500 - 2,570 PSI] and Steering Fly-jib, Steering
20.6 - 21.1 MPa Boom elevation Up
Main control P' Mid
R8 (210 - 215 kg/cm2) Boom telescope In
valve (1/4) (2,200 rpm)
[2,990 - 3,060 PSI] Boom rotation
17.6 - 18.1 MPa
Main control P' Mid
PR1 (180 - 185 kg/cm2) Boom telescope Out
valve (1/4) (2,200 rpm)
[2,550 - 2,620 PSI]
14.7 - 15.2 MPa
Main control P' Low
PR2 (150 - 155 kg/cm2) Boom elevation Down
valve (1/4) (1,800 rpm)
[2,130 - 2,200 PSI]

Pre-set pressure measurement procedures

Before measuring each pre- set pressure, set the machine on firm and level surface, start the engine,
and then operate the machine to warm up the hydraulic system.

1. Pre-set pressure of the Relief valve R1 and R2

M1
1) Stop the engine, connect the pressure gauge to gauge port “M1 M2
M1” and “M2
M2” of the HST pump.
(See page 3-3 for location of the HST pump)
Relief valve (R2)
M2
Gauge port “M2
M2”

M1
Gauge port “M1
M1”
Relief valve (R1)
Fig. 6-2 HST pump

SSJ00003 Rev 1 6-3

Chapter 6 Inspection and Adjustment

2) Set up the wheel chocks in front and rear of all tires as shown in the Fig. 6-1.
3) Start the engine.
4) Retract the boom fully and lower it under the horizontal.
5) Set the travel speed select switch to its High- speed position.
6) Operate the Travel joystick controller to Forward direction to activate the relief valve R1.
7) Read the Pressure gauge connected to the gauge port “M1 M1
M1” and make sure that the pre- set pressure
of the relief valve (R1) is within the specific value.
z Specific pre-set pressure: 34.3 - 34.8 MPa (350 - 355 kg/cm2) [4,980 - 5,050 PSI]
8) Operate the Travel joystick controller to Reverse direction to activate the relief valve R2.
9) Read the Pressure gauge connected to the gauge port “M2 M2
M2” and make sure that the pre- set pressure
of the relief valve (R2) is within the specific value.
z Specific pre-set pressure: 34.3 - 34.8 MPa (350 - 355 kg/cm2) [4,980 - 5,050 PSI]

2. Pre-set pressure of the Relief valve R5

1) Stop the engine, connect the pressure gauge to gauge port “M2 M2
M2” of the Valve unit for Platform
leveling and Steering.
(See page 3-3 for location of the Valve unit for Platform leveling and Steering.)

M2
Gauge port “M2
M2”

Relief valve (R5)

Fig. 6-3 Valve unit for Platform leveling and Steering

2) Start the engine.

3) Steer the front wheel to Left or Right end to activate the relief valve R5.
4) Read the Pressure gauge and make sure that the pre- set pressure of the relief valve (R5) is within
the specific value.
z Specific pre-set pressure: 17.2 - 17.7 MPa (175 - 180 kg/cm2) [2,500 - 2,570 PSI]

6-4 Rev 1 SSJ00003

 Chapter 6 Inspection and Adjustment

3. Pre-set pressure of the Relief valve R8

P’
1) Stop the engine, connect the pressure gauge to gauge port “P’
P’” of the Main control valve.
(See page 3-3 for location of the Main control valve.)

P’
Gauge port “P’
P’”

Relief valve (PR2)

Relief valve (R8)

Relief valve (PR1)

Fig. 6-4 Main control valve

2) Start the engine.
3) Retract the boom fully and then raise it fully.
4) Operate the Boom elevation Up and Boom telescope In simultaneously to activate the relief valve
R8.
5) Read the Pressure gauge and make sure that the pre- set pressure of the relief valve (R8) is within
the specific value.
z Specific pre-set pressure: 20.6 - 21.1 MPa (210 - 215 kg/cm2) [2,990 - 3,060 PSI]

4. Pre-set pressure of the Relief valve PR1

1) Stop the engine, connect the pressure gauge to gauge port “P’P’
P’” of the Main control valve.
(See page 3-3 for location of the Main control valve.)
2) Start the engine.
3) Raise the boom fully and then extend it fully.
4) Operate the Boom telescope Out to activate the relief valve PR1.
5) Read the Pressure gauge and make sure that the pre- set pressure of the relief valve (PR1) is within
the specific value.
z Specific pre-set pressure: 17.6 - 18.1 MPa (180 - 185 kg/cm2) [2,550 - 2,620 PSI]

SSJ00003 Rev 1 6-5

Chapter 6 Inspection and Adjustment

5. Pre-set pressure of the Relief valve PR2

1) Stop the engine, connect the pressure gauge to gauge port “P’P’
P’” of the Main control valve.
(See page 3-3 for location of the Main control valve.)
2) Start the engine.
3) Retract the boom fully and then lower it fully.
4) Operate the Boom elevation Down to activate the relief valve PR2.
5) Read the Pressure gauge and make sure that the pre- set pressure of the relief valve (PR2) is within
the specific value.
z Specific pre-set pressure: 14.7 - 15.2 MPa (150 - 155 kg/cm2) [2,130 - 2,200 PSI]

Pre-set pressure adjustment procedures

Adjust the relief valve as follows, if the pre- set pressure is not within the specific value.
1. Loosen the lock nut.
2. Adjust the pre- set pressure by turning the adjusting screw.
To increase the pressure, turn the adjusting screw clockwise.
To decrease the pressure, turn the adjusting screw counter- clockwise.
3. Lock the adjusting screw by the lock nut, and then check the pre- set pressure again and make sure
that the pressure is within the specific value.

Fig. 6-5 Adjustment of relief valve

6-6 Rev 1 SSJ00003

 Chapter 7 Scheduled maintenance

Chapter 7
Scheduled maintenance

SSJ00003 7-1
Chapter 7 Scheduled maintenance

Scheduled inspection table

1. Engine maintenance

Every Every
Every Every Every Every
1,000 hrs 2,000 hrs
Items Daily 50 250 500 1,500
or or every
hrs hrs hrs hrs
annually 2 years
Coolant Level, Replenish 1
Coolant
Replacement 1
Cooling
Radiator fin Check, Clean 1
system
Fan belt Tension 1* 1
Radiator hoses Replacement 1#
Oil level 1
Engine Engine oil
Replacement 1* 1
oil
Oil filter Replacement 1* 1
Fuel Fuel level, Replenish 1
Fuel filter Replacement 1
Fuel hoses Replacement 1#
Fuel Fuel tank Drain 1
Check 1
Water
Drain 1
sedimentor
Clean 1
Air Clean 1
Element
cleaner Replacement 1
Cylinder Adjust Intake / Exhaust valve clearance 1#
head Lap Intake / Exhaust valve seats 1#
Emission Inspect, clean and test Fuel injectors 1#
control Inspect Crankcase breather system 1#
1* For new machine, Perform these maintenance after 50 working hours for first time.
1# Ask your authorized Yanmar industrial engine dealer or distributor to perform these maintenance.
See Chapter 9 "Engine" for the detail.

2. Other maintenance
Items Daily inspection Monthly inspection Annual inspection
Battery Battery charge level, Damage, Corrosion
Battery Specific gravity
box Battery fluid level on terminals
Oil level, Replacement of
Hydraulic oil tank ←
Oil leakage hydraulic oil
Hydraulic
Hydraulic filters Oil leakage ← Replacement
system
Abnormal noise, Oil Looseness of bolts
Hydraulic pump ←
leakage and nuts
Chassis frame Cracks, Deformations ← ←
Tire, Wheel Wear, Cut ← ←
Wheel nuts Looseness ← ←
Abnormal noise, Damage, Oil leakage,
Travel motor, Gearbox Replacement of gear oil
Looseness of nuts
Parking brake Function ← ←
Chassis
Looseness of
Steering linkage Cracks, Deformations ←
stopper bolt
Steering cylinder Damage, Oil leakage ← ←
Wire harnesses, Hoses Oil leakage, Damage ← ←
Cracks, Deformations,
Oscillation axle ← ←
Movement

7-2 Rev 1 SSJ00003

 Chapter 7 Scheduled maintenance

Items Daily inspection Monthly inspection Annual inspection

Oscillation axle cylinder Damage, Oil leakage ← ←
Chassis pivot pins for axle and
Damage ← ←
cylinder
Looseness of bolts
Turntable bearing Wear, Crack ←
and nuts, Lubrication
Oil leakage, Backlash
Boom rotation gearbox Abnormal noise
Looseness of nuts Replacement of gear oil
Turntable
Looseness of bolts
Turntable Cracks, Deformations ←
and nuts
Looseness of bolts
Swivel joint Oil leakage ←
and nuts, Lubrication
Elevation, Telescope, Damage, Oil leakage,
Cylinder ← ←
Fly jib cylinders Natural descent
Cracks, Deformations, Disassemble the boom
Boom Abnormal noise, ← for detailed inspection
Movement every 5 years
Cracks, Deformations,
Fly jib Abnormal noise, ← ←
Movement
Boom
Pivot pins Damage ← ←
Extension /retraction Damage, Corrosion,
←
wire ropes Tension
Movements,
Cable guide Abnormal noise ←
Damage
Wear pads Wear
Platform Cracks, Deformations ← ←
Hand rail Cracks, Deformations ← ←
Platform
Oil leakage, Abnormal
Rotary actuator ← ←
noise, Movement
Platform
Leveling cylinder Oil leakage ← ←
leveling
system Functions Functions ← ←
Damage, Function,
Switches ← ←
Smoothness
Function, Abnormal
Lower Functions ← ←
noise, Vibration
control
Emergency stop button Damage, Function ← ←
LEDs Damage, Legibility ← ←
Decals Legibility ← ←
Switches, Damage, Function,
← ←
Joystick controllers Smoothness
Function, Abnormal
Upper Functions ← ←
noise, Vibration
control
Emergency stop button Damage, Function ← ←
LEDs Damage, Legibility ← ←
Decals Legibility ← ←
Foot switch Function ← ←
Motion alarm buzzer Sound ← ←
Safety Tilt alarm buzzer Sound ← ←
devices Emergency pump Function ← ←
Alarm horn Sound ← ←
Overload sensing system Function ←
Decals Legibility ← ←

SSJ00003 Rev 1 7-3

Chapter 7 Scheduled maintenance

Lubrications
Lubrication intervals

Location Lubricating point Interval Lubricant Quantity

1,200 working hours Hydraulic oil 190 litters
Chassis Hydraulic oil tank
or annually. (ISO VG22) [1.4 gal]
Travel motor Gear oil 1.0 litter x4
For new machine
gear box (SAE 90) [0.26 gallons x4]
(Initial replacement)
Boom rotation After 300 working hours Gear oil 1.0 litter
Turntable or 3 months
gear box (SAE 90) [0.26 gallons]

Refer 1 Molybdenum grease ---------------

100 hours
"Greasing point" 2 to 14 General grease ---------------

Recommended lubricant

Manufacturers Hydraulic oil Gear oil Molybdenum grease General grease

Shell oil Tellus oil T22 Spirax EP 90 Alvania HDX 2 Alvania EP grease 2
Mobil oil DTE 22 Pegasus gear oil 90 Mobilgrease special Mobilux EP2

Greasing point

2nd and 3rd boom section upper tail ware pads

1 (Take off the grommet on the 1st boom section upper surface to lubricate the
3rd boom section ware pads.)
2 Turntable bearing
3 Elevation cylinder - 1st boom section pivot pin
4 Jib bracket - Upper jib pivot pin (SP14CJ / SP460CJ)
5 Upper jib - Platform base pivot pin (SP14CJ / SP460CJ)
6 Elevation cylinder - Turntable pivot pin
7 1st boom section pivot pin
8 Lower leveling cylinder - 1st boom section pivot pin
9 Lower leveling cylinder - Turntable pivot pin
10 Steering cylinder - Chassis pivot pin
11 Steering cylinder - Wheel bracket pivot pin
3rd boom section - Platform base / Jib bracket pivot pin
12
Leveling cylinder - Platform base / Jib bracket pivot pin
13 Fly-jib cylinder - Upper jib pivot pin (SP14CJ / SP460CJ)
14 Lower jib - Platform base pivot pin (SP14CJ / SP460CJ)
Fly-jib cylinder - Jib bracket pivot pin (SP14CJ / SP460CJ)
15
Jib bracket - Lower jib pivot pin (SP14CJ / SP460CJ)

7-4 Rev 2 SSJ00003

 Chapter 7 Scheduled maintenance

Greasing point

Fig. 7-1 Greasing point

SSJ00003 Rev 1 7-5

Chapter 7 Scheduled maintenance

Scheduled replacement parts

The parts listed in the table below are related to safety devices and must be replaced at
designated intervals.
Location Items Interval Part number Quantity
Every 1 year or 305-0000017
High pressure filter 1
1,200 working hours (G319050014)
Every 1 year or 305-0000073
Charge filter 1
1,200 working hours (G319050032)
Every 1 year or
Suction filter 305-06597 1
1,200 working hours
Turntable
Tilt angle sensor Every 8 years or
382-0001600 2
Longitudinal, Lateral 9,600 working hours
Tilt angle sensor Every 8 years or
382-0000019 1
Omni-directional (CE model) 9,600 working hours
Every 4 years or
Boom angle limit switch 320-0005800 1
4,800 working hours
Every 4 years or
Boom Boom length limit switch 320-0005800 1
4,800 working hours
Every 4 years or
Chassis Boom rotation angle limit switch 320-0005800 1
4,800 working hours
Platform Overload limit switch Every 4 years or
320-0002600 1
base (CE, Japan model) 4,800 working hours
Lower Every 4 years or
Emergency stop button 320--0007201 1
control box 4,800 working hours
Upper Every 4 years or
Emergency stop button 320--0007201 1
control box 4,800 working hours
( ) : Element

The parts listed in the table below are important for machine’s main function and highly recommended
to replace at designated intervals.
Location Items Interval Part number Quantity
Every 4 years or
Platform Foot switch 320-04017 1
4,800 working hours
Enable switch 173-01102 1
Engine start /Emergency pump switch 173-02212 1
Boom elevation switch 173-01212 1
Lower Boom telescope switch Every 4 years or 173-01212 1
control box Boom rotation switch 4,800 working hours 173-01212 1
Platform rotation switch 173-01212 1
Platform leveling switch 173-01212 1
Fly-jib switch (SP14C/SP460CJ) 173-01212 1
Engine start /Emergency pump switch 173-02212 1
Platform rotation switch 320-05325 1
Every 4 years or
Platform leveling switch 173-01212 1
4,800 working hours
Fly-jib switch (SP14C/SP460CJ) 320-05325 1
Upper
Steering lever 324-0000033 1
control box
Boom elevation joystick controller 324-0008100 1
Boom telescope joystick controller Every 5 years or 324-0008100 1
Boom rotation joystick controller 6,000 working hours 324-0008100 1
Travel joystick controller 324-0008100 1

7-6 Rev 1 SSJ00003

 Chapter 7 Scheduled maintenance

SSJ00003 7-7
Chapter 7 Scheduled maintenance

Periodical inspection check sheet

Page 1/2
Model Spec No. Serial No. Hour meter Date Inspector

The items marked (*) should be inspected only on the annual inspections.
Ｉｔｅｍｓ Monthly inspection Result Remarks
Replacement interval
Coolant Coolant level
Every 1,000 hours or annually
Fan belt Check tension every 250 hours
Replacement interval
Radiator hoses
Every 2 years or 2,000 hours
Engine oil Oil level Replacement interval
Oil filter Every 250 hours
Engine
Replacement interval
Fuel filter
Every 500 hours
Fuel tank Drain every 250 hours
Drain every 50 hours
Water sedimentor
Clean every 500 hours
Replacement interval
Air cleaner element Clean every 250 hours
Every 500 hours
Battery charge level
Battery fluid level
Battery Battery Damage
Corrosion on terminals
Specific gravity * 1.28 at 20 degrees C
Oil leakage
Hydraulic oil tank Replacement interval
Hydraulic oil level
Hydraulic Every 1,200 hours or annually
Hydraulic filters Oil leakage
system
Abnormal noise, Oil leakage
Hydraulic pump
looseness of bolts and nuts
Chassis frame Cracks, Deformations
Tire, Wheel Wear, Cut
Wheel nuts Looseness
Abnormal noise
Damage Replacement interval of
Travel motor, Gearbox gear oil
Oil leakage Every 1,200 hours or annually
Looseness of nuts
Parking brake Function
Cracks, Deformations
Chassis Steering linkage
Looseness of stopper bolt
Steering cylinder Damage, Oil leakage
Oil leakage
Wire harnesses, Hoses
Damage
Cracks, Deformations
Oscillation axle
Movement
Damage
Oscillation axle cylinder
Oil leakage
Pivot pins for axle & cylinder Damage

7-8 SSJ00003
 Chapter 7 Scheduled maintenance

Page 2/E
The items marked (*) should be inspected only on the annual inspections.
Ｉｔｅｍｓ Daily inspection Result Remarks
Wear, Crack
Turntable bearing looseness of bolts and nuts
Lubrication
Abnormal noise Replacement interval of
Oil leakage gear oil
Boom rotation gearbox
Turntable Looseness of nuts Every 1,200 hours or annually
Backlash * (See page 2-5)
Cracks, Deformations
Turntable
looseness of bolts and nuts
Oil leakage
Swivel joint
looseness of bolts and nuts
Cracks, Deformations
Boom
Abnormal noise, Movement
Cracks, Deformations
Fly jib
Abnormal noise, Movement
Pivot pins Damage
Boom
Extension/retraction wire Damage, Corrosion
ropes Tension See page 2-12
Abnormal noise
Cable guide
Movement, Damage
Wear pads Wear (Thickness) * See page 2-9
Platform Cracks, Deformations
Hand rail Cracks, Deformations
Platform Oil leakage
Rotary actuator
Abnormal noise, Movement

Switches Damage, Function, Smoothness

Function
Functions
Lower control Abnormal noise, Vibration
Emergency stop button Damage, Function
LEDs Damage, Legibility
Decals Legibility
Switches,
Damage, Function, Smoothness
Joystick controller
Function
Functions
Upper control Abnormal noise, Vibration
Emergency stop button Damage, Function
LEDs Damage, Legibility
Decals Legibility
Foot switch Function
Motion alarm buzzer Sound
Safety Tilt alarm buzzer Sound
devices Emergency pump Function
Alarm horn Sound
Overload sensing system Function
Decals Legibility

SSJ00003 7-9
Chapter 7 Scheduled maintenance

This page intensionally left blank.

7-10 SSJ00003
 Chapter 8 Appendix

Chapter 8
Appendix

SSJ00003 8-1
 SP12C / SP400C
Relief valve pre-set pressure
Pump speed: Specified in the table below
Hydraulic oil temperature:
Pre-set pressure Pump speed Pump speed Rotary actuator

SSJ00003
[5,000 PSI] High High
Platform rotation sol.V
[350 PSI] Low Mid
[260 PSI] -------- Low
[2,500 PSI] Low Idling Platform rotation/
Fly jib sol.V
[3,250 PSI] --------
{3,000 PSI] Mid
Rotary actuator
[2,550 PSI] Mid
[2,150 PSI] Low
[3,000 PSI] --------
[2,500 PSI] --------
Fly jib cylinder
[500 PSI] --------
[3,400 PSI] -------- Double holding valve

Platform leveling
Adaptor filter cylinder (Upper)

Main control valve Double holding valve

CW

CCW
Boom rotation
Boom telescope cylinder
Hydraulic circuit diagram (601-0014900A)

Up

Boom elevation Down

Boom rotation motor
In

Out
Boom telescope
Boom elevation cylinder
Adaptor filter

Holding valve
Platform leveling
Adaptor filter cylinder (Lower)

Right Left Down Up

Valve unit
Steering sol.V
Flow
priority Platform
valve leveling
(13L/min) sol.V

Unloading
sol.V Steering/
Platform,
Fly jib
Emergency select sol.V
sol.V
Adaptor Valve unit
filter
Adaptor filter
High-pressure
filter
Parking brake
release sol.V
0.8
Charge filter
Travel speed
select sol.V
0.8
HST pump
Charge pump Plunger pump Oscillation axle
Emergency release sol.V
0.8
pump

Rev

Gear pump
Fwd

2nd pump

1st pump Suction filter

Swivel joint

Hydraulic oil tank

Steering cylinder

Rear/Left Front/Left
Flow divider

Parking brake release valve

High Low
High Low

Flow divider

Rear/Right Front/Right
M1 M1

Oscillation
axle cylinder
Flow divider
High
High

M2 M2
Travel motor
Low
Low

Oscillation
axle lock valve

Check valve
8-2
Chapter 8 Appendix
Electric circuit diagram, Upper (602-0071100A) 1/2 Chapter 8 Appendix

Upper control box

C.W.
Up Platform rotation sol.V
Boom elevation
Down C.C.W.

16 cores cable To Turntable

Out To Fly jib sol.V
Boom telescope with shield wire
(SP14CJ/SP460CJ)
In To Turntable
14 cores cable

C.W.
Boom rotation
C.C.W.

Fwd
Travel
Rev

Alarm buzzer

Right
Steering
Left Work light GND
LED board To Work light s/w (Option) Power for Work light
Platform C.W.
rotation C.C.W.

System failuer light To Fly jib s/w

(SP14CJ/SP460CJ) Head light
To Head light (Option) To Head light s/w (Option)
Backup (Vbac)
To Platform
leveling s/w Power for Upper CPU
Fuel level light
(CE/ANSI model) Upper CPU GND

Engine failure light

For Adjustment tool

Power indicator light

Power supply for Adjustment tool
Hydraulic generator
Horn s/w For Hydraulic generator (Option)
Power for Horn
Horn GND

To overload
Overload warning light warning light
(CE model) (CE model)
To Hydraulic
generator light
To Touch s/w buzzer relay (Option)
(Option)
High
Travel speed
Low
Tilt warning light select s/w
Slope
To Hydraulic generator relay (Option)

Hydraulic generator
light (Option)
To Panel light s/w (Option)
Rotating beacon
For Rotating beacon (Option)
To Rotating beacon relay (Option)

To Overload
To Touch s/w (Option)
L/S
(CE model) Emergency stop
Emergency stop button Power for Emergency stop
To Rotating
beacon
(Option) Engine start / Emergency pump s/w
Engine start
To Hydraulic Engine start Engine start
generator
(Option) Emergency pump

Foot s/w

Power for Upper control

SSJ00003 8-3
Electric circuit diagram, Upper (602-0071100A) 2/2 Chapter 8 Appendix

Fly jib (SP14CJ/SP460CJ) Touch switch (Option) 16 cores cable Rotating beacon with switch (Option) 16 cores cable
with shield wire with shield wire
Upper control box 14 cores cable Upper control box
Platform Upper control box
rotation s/w C.W.
CW Platform rotation sol.
CCW C.C.W. Travel speed
select s/w
Up Up
Down
Fly jib sol.
Fly-jib s/w Rotating beacon s/w
Down
Touch s/w
Emergency stop button

Engine start with Foot switch pressed (Option)

Overload limit switch (CE model) Platform leveling switch (CE/ANSI model)
Upper control box 14 cores cable
LED board Upper control box Upper control box Engine start/
Overload Emergency pump s/w Work light (Option) 14 cores cable
Platform rotation s/w
warning light CW Eng.start Upper control box
CCW Foot s/w
Overload
L/S Up Emergency pump Work light s/w
Down

Platform leveling s/w

Work light

Head light (Option) 16 cores cable

Hydraulic generator (Option) AC outlet (Option) with shield wire
Upper control box
4 cores cable
Upper control box 4 cores cable
Hydraulic
generator light Head light s/w

LED board Panel light (Option)

Travel speed select s/w Upper control box
Panel light
16 cores cable
with shield wire

Hydraulic
generator s/w

SSJ00003 Rev2 8-4

Electric circuit diagram, Lower (602-0071200A) 1/2 Chapter 8 Appendix
14 cores cable
Alarm buzzer LED board Overload Engine Air
To Fuel warning Tilt System oil Water cleaner
16 cores cable with shield wire
Platform level (CE model) worning failure Glow pressure temp. Charge crog

Power for Emergency stop

Power for Upper CPU

Power for Work light
Power for Horn

Power for Upper control

Work light GND

Emergency stop

Backup (Vbac)

GND

Engine start
Engine start

Horn
Head light
Hydraulic generator

Rotating beacon

For Adjustment tool

Power supply for Adjustment tool

To Overload warning light
(CE model)
Head light (Op)
Hydraulic generator (Op)
Rotating beacon (Op)

Work light (Op)

Work light (Op)
Horn

Main control valve

Tilt sensor (Longitudinal)
Up
Lower control box Boom elevation
Down
Tilt sensor (Lateral)
Key switch Out
Boom telescope
Terminal In
To Boom wire rope failure L/S
(CE model) Boom angle L/S C.W.
Position Boom rotation
Fuse box Boom elevation s/w To Tilt sensor C.C.W.
Upper Main relay Up (Omni-directional : CE model) Boom length L/S
Down HST pump
Lower Engine start/
Emergency pump s/w Boom telescope s/w
Out Boom rotation angle L/S Fwd
Engine In
Travel
start Rev
Boom rotation s/w
Key switch Emergency CW
Upper pump CCW Right
Platform rotation s/w Steering sol.V
Emergency CW Left
stop button CCW
Lower

Fly jib
Pre-start Enable s/w (SP14CJ/SP460CJ) Unload sol.V
check s/w
Platform leveling s/w
Up
Steering/Platform,
Down Fly jib select sol.V

Hour meter Override s/w

Enable
Emergency sol.V

Limit
Emergency pump
Release Accelerator Mid
Accelerator High
Engine stop
Stand-by
Up
Platform
leveling sol.V
(SP14CJ/SP460CJ)

Down

Fuel level sensor

Travel speed
Engine failure select sol.V

Travel Fwd
Travel Rev
Accelerator control unit Steering Right
Parking brake
Steering Left
release sol.V

Oscillation axle
release sol.V

Motion alarm buzzer

Power for Remote controller
Remote controller relay
Remote controller relay
Accelerator Signal

Fuel level sensor

Accelerator Power

Accelerator GND

Steering Right
Engine failure

Emergency stop

Emergency stop
Emergency pump

Enable signal

Steering Left
Engine start

Engine stop

Travel Fwd
Travel Rev
Key s/w ON

Glow light

Stand-by
+12V

+12V

GND

Engine Remote controller (Option)

SSJ00003 8-5
Electric circuit diagram, Lower (602-0071200A) 2/2 Chapter 8 Appendix

Fly jib (SP14CJ/SP460CJ) Boom wire rope failure limit switch (CE model) Remote controller (Option) Rotating beacon with switch (Option) Automatic rotating beacon (Option)
Lower control box Lower control box 16 cores cable with shield wire
Lower control box Lower control box
Platform
rotation s/w
CW Fuse box
CCW Boom wire rope failure L/Ss
Fly jib s/w Fuse box
Up
Lower control box

Remote controller

Emergency
Down

stop
Duplicated tilt sensor (CE model) Fuse box

Overload warning light (CE model) Tilt sensor

Lower control box (Omni-directional)
Lower control box
LED board Fwd Rev Right Left
Travel Steering
Fuse box
Overload
warning
light Fuse box
Rotating beacon
Touch switch (Option)
16 cores cable
with shield wire
Hydraulic generator (Option)
4 cores cable

16 cores cable Main relay

Battery
with shield wire

Fuse box Rotating beacon

Accelerator control unit
Head light (Option) 16 cores cable with shield wire
Lower control box Fuse box
Lower control box

AC outlet (Option)
Battery Lower control box
4 cores cable

Fuse box

Hydraulic generator sol.V Work light

(Option) 14 cores cable

Head light
Lower control box

Fuse box

Battery Battery

SSJ00003 Rev2 8-6

Electric Wiring diagram, Upper (602-0076600A) Chapter 8 Appendix

16 cores cable
with shield wire
To Turntable

14 cores cable
Upper control box
Fly jib (SP14CJ/SP460CJ)
To Turntable
C.W.
Platform C.W.

Upper control box

rotation sol.V
Platform rotation
C.C.W.
sol.V
Overload limit switch (CE model)
C.C.W.

Up
Fly jib sol.V
Down
Overload L/S Upper control box
Alarm buzzer

For Adjustment tool Hydraulic generator (Option) AC outlet (Option)

4 cores cable
4 cores cable

Work light GND

To Work light s/w (Option) Power for Work light

16 cores cable
with shield wire

Upper control box

Power for CPU
GND
Power for Horn
Horn

Panel light (Option)

Emergency stop
Power for Emergency stop
Power for Upper control

Backup (Vbac)
Engine start
Engine start Upper control box Panel light
Touch switch (Option)
To head light s/w (Option) Head light 16 cores cable
For Hydraulic generator (Option) Hydraulic generator
Rotating beacon with shield wire
For Rotating beacon (Option) Upper control box Rotating beacon (Option)

Upper control box 16 cores cable

with shield wire

Touch s/w

Head light (Option)

Upper control box 16 cores cable

Work light (Option) with shield wire
14 cores cable

Foot s/w Work light

Upper control box

SSJ00003 8-7
Electric circuit diagram, Lower (602-0076700A) 1/2 Chapter 8 Appendix

To Platform 14 cores cable

Main control valve
Horn

Tilt sensor (Longitudinal) Up

Boom elevation
Down

Power for Emergency stop

Alarm buzzer

Power for Back up (Vbac)

Power for Upper control
Hydraulic generator

Power for Upper CPU

Out

Rotating beacon
16 cores cable
Boom telescope

Emergency stop
Head light
(with Shield wire)
In

Work light

Engine start
Engine start
GND

GND
C.W.

Horn
For Adjustment tool Boom rotation
C.C.W.
Tilt sensor (Lateral)
HST pump

Fwd
Travel
Rev

Boom angle L/S

Hydraulic generator

Work light
AC outlet

Upper key switch

Rotating beacon

Right
Head light

Steering sol.V
Boom length L/S
Left

Boom rotation angle L/S Unload sol.V

Lower control box

Steering/Platform,
Fly jib select sol.V

Emergency sol.V

Up
Platform
leveling sol.V
(SP14CJ/
SP460CJ)
Down

Travel speed
select sol.V

Parking brake
Release sol.V

Oscillation axle
release sol.V

Horn

To Remote controller (Option)

Accelerator Signal

Fuel level sensor

Accelerator Power

Accelerator GND

Engine failure
Emergency pump

Motion alarm buzzer

Engine start

Engine stop
Key s/w ON

Glow light

Stand-by
GND
+12V
+12V

To Battery To Engine

SSJ00003 8-8
Electric circuit diagram, Lower (602-0076700A) 2/2 Chapter 8 Appendix

Boom wire rope failure limit switch (CE model) Touch switch (Option) Head light (Option)
Lower control box
Lower control box
16 cores cable
with shield wire

16 cores cable
Head light with shield wire

Lower control box Boom wire rope failure L/S

AC outlet (Option) Fusible link

Duplicated tilt sensor (CE model)

4 cores cable
Power
Output
GND

Lower control box Tilt sensor

(Omni-directional)

Remote controller (Option)

Lower control box
Remote Battery
controller

Rotating beacon (Option)

Lower control box
Rotating beacon

Hydraulic generator (Option)

Lower control box

16 cores cable
Hydraulic generator sol.V with shield wire

Fusible link
16 cores cable
with shield wire

Fusible link

4 cores cable
Battery

Battery
Work light (Option)
14 cores cable

Lower control box

SSJ00003 8-9
Electric wiring diagram, Engine (602-0076800B) Chapter 8 Appendix

Lower control box

Accelerator Signal
Accelerator Power
Fuel level sensor

Accelerator GND

Engine failure
Emergency pump
Engine start

Engine stop
Key s/w ON

Glow light

Stand-by
+12V
+12V

GND

Engine relay box

Engine stop relay

Key switch ON relay
Starter relay Glow relay

Glow light ralay

Engine start relay Main relay Rack actuator relay

Charge relay

Engine failure
Fuse box
Engine oil pressure

Engine speed
sensor
Emergency pump
Contactor
Fusible link
Fuel level sensor Rack
ECU
actuator
Fusible link

Fusible link
GND
(Engine CSD coil
mount
frame) GND
Fusible link (Engine
block)

Water temp.
sensor
Fusible link

Oil pressure
Battery s/w
Fusible link GND
(Engine
block)
Air cleaner sensor

Glow plug

GND(Turntable)

Starter B Starter S Alternator B Alternator

GND Feed pump
(Engine block)
GND
GND(Engine block) GND(Engine block)
(Engine mount frame)

SSJ00003 Rev2 8-10

 Chapter 8 Appendix

Water proof connector

A view

A view

B view
Fig. 7-1 Water proof connector
SSJ00003 8-11
Chapter 8 Appendix

Pin arrangements of Water proof connector

See the table below to specify the pin arrangements of water proof connectors when reading
“electric wiring diagram”.

2 poles
3 poles
4 poles
6 poles
8 poles
12 poles

8-12 SSJ00003
 Chapter 8 Appendix

Color code of wires

See the table below to specify the colors of wires from the “Color codes”.

Color Color
No. Color No. Color
codes codes
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

SSJ00003 8-13
Chapter 8 Appendix

Tightening torque standard

Hexagon headed bolts (8T or 8.8T) and nuts (6T)

Bolt Nut
Strength grade 8T or 8.8T 6T
Material S45C S45C
Tensile strength 80 kg/cm2 80 kg/cm2

Size Pitch Tightening torque

(mm) (mm) N-m kg-m ft-lbs
5 0.8 3.71 - 5.87 0.32 - 0.60 2.31 - 4.34
6 1.0 5.42 - 10.0 0.56 - 1.04 4.05 - 7.52
8 1.25 13.0 - 24.2 1.33 - 2.47 9.62 - 17.9
10 1.5 25.7 - 47.6 2.59 - 4.81 18.7 - 34.8
12 1.75 44.6 - 82.7 4.55 - 8.45 32.9 - 61.1
14 2.0 71.2 - 132 7.00 - 13.00 50.6 - 94.0
16 2.0 109 - 201 11.2 - 20.8 81.0 - 150
18 2.5 157 - 291 16.1 - 29.9 116 - 216
20 2.5 220 - 407 22.4 - 41.6 162 - 301
22 2.5 296 - 549 30.1 - 55.9 218 - 404
24 3.0 379 - 703 38.5 - 71.5 278 - 517

Hexagon headed bolts (10.9T) and nuts (8T)

Bolt Nut
Strength grade 10.9T 8T
Material SCM435 SCM435
2 2
Tensile strength 100 kg/cm 100 kg/cm

Size Pitch Tightening torque

(mm) (mm) N-m kg-m ft-lbs
5 0.8 7.21 - 8.79 0.73 - 0.90 5.28 - 6.51
6 1.0 12.3 - 15.1 1.26 - 1.54 9.11 - 11.1
8 1.25 29.7 - 36.2 3.06 - 3.74 22.1 - 27.1
10 1.5 58.5 - 71.3 5.94 - 7.26 43.0 - 52.5
12 1.75 102 - 124 9.90 - 12.10 71.6 - 87.5
14 2.0 162 - 197 16.2 - 19.8 117 - 143
16 2.0 247 - 302 25.2 - 30.8 182 - 223
18 2.5 364 - 422 35.1 - 42.9 254 - 310
20 2.5 483 - 589 49.5 - 60.5 358 - 438
22 2.5 652 - 795 66.6 - 81.4 482 - 589
24 3.0 835 - 1018 84.6 - 103 612 - 745

8-14 SSJ00003
 Chapter 8 Appendix

Hexagon socket headed cap screws (10.9T)

Bolt
Strength grade 10.9T
Material SCM435
Tensile strength 100 kg/cm2

Size Pitch Tightening torque

(mm) (mm) N-m kg-m ft-lbs
5 0.8 4.81 - 5.87 0.49 - 0.60 3.54 - 4.34
6 1.0 8.24 - 10.0 0.81 - 0.99 5.86 - 7.16
8 1.25 19.8 - 24.2 2.07 - 2.53 15.0 - 18.3
10 1.5 39.0 - 47.6 3.96 - 4.84 28.6 - 35.0
12 1.75 67.8 - 82.7 6.93 - 8.47 50.1 - 61.3
14 2.0 108 - 132 10.8 - 13.2 78.1 - 95.5
16 2.0 165 - 201 17.1 - 20.9 124 - 151
18 2.5 239 - 291 24.3 - 29.7 176 - 215
20 2.5 333 - 407 34.2 - 41.8 247 - 302
22 2.5 450 - 549 45.9 - 56.1 332 - 406
24 3.0 576 - 703 58.5 - 71.5 423 - 517

SSJ00003 8-15
Chapter 8 Appendix

This page intensionally left blank.

8-16 SSJ00003
 Chapter 9 Engine

Chapter 9
Engine

SSJ00003 9-1
Chapter 9 Engine

Safety warnings for Engine maintenance

FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive under certain conditions.
• When you remove any fuel system component to perform maintenance (such as
changing the fuel filter) place an approved container under the opening to catch
the fuel.
• NEVER use a shop rag to catch the fuel. Vapors from the rag are flammable and
explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system is under pressure and fuel could spray out
when you remove any fuel system component.
• NEVER use diesel fuel as a cleaning agent.
• Failure to comply will result in death or serious injury.

SCALD HAZARD!
• NEVER remove the radiator cap if the engine is hot. Steam and hot engine coolant
will spurt out and seriously burn you. Allow the engine to cool down before you
attempt to remove the radiator cap.
• Tighten the radiator cap securely after you check the radiator. Steam can spurt out
during engine operation if the cap is loose.
• ALWAYS check the level of the engine coolant by observing the reserve tank.
• Failure to comply will result in death or serious injury.

BURN HAZARD!
• If you must drain the engine oil while it is still hot, stay clear of the hot engine oil to avoid being burned.
• ALWAYS wear eye protection.
• Failure to comply could result in death or serious injury.

BURN HAZARD!
• Wait until the engine cools before you drain the engine coolant.
Hot engine coolant may splash and burn you.
• Failure to comply could result in death or serious injury.

9-2 Rev 1 SSJ00003

 Chapter 9 Engine

FLYING OBJECT HAZARD!

• ALWAYS wear eye protection when servicing the engine and when using compressed air or
high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor or moderate injury.

COOLANT HAZARD!
• Wear eye protection and rubber gloves when you handle long life or extended life engine coolant.
If contact with the eyes or skin should occur, flush eyes and wash immediately with clean water.
• Failure to comply may result in minor or moderate injury.

SSJ00003 Rev 1 9-3

Chapter 9 Engine

Component Identification

Fig.9-1

1 – Lifting Eye (Flywheel End) 15 – Intake Manifold

3 – Lifting Eye (Engine Cooling Fan End) 16 – Fuel Filter
4 – Engine Coolant Pump 17 – Fuel Inlet
5 – Engine Cooling Fan 18 – Fuel Return to Fuel Tank
6 – Crankshaft V-Pulley 19 – Top Filler Port (Engine Oil)
7 –V-Belt 20 –Rocker Arm Cover
8 – Side Filler Port (Engine Oil) 21 –Air Intake Port (From Air Cleaner)
9 – Drain Plug (Engine Oil) 22 – Flywheel
10 – Fuel Injection Pump 23 – Starter Motor
12 –Engine Oil Filter 24 –Exhaust Manifold
13 – Dipstick (Engine Oil) 25–Alternator
14 –Governor Lever

For detailed engine information, see Yanmar engine Operation manual / Service manual
Yanmar TNV series Operation Manual: Part number 0ATNV-G00101
Yanmar TNV series Service Manual: Part number 0BTNV-G00101

9-4 Rev 1 SSJ00003

 Chapter 9 Engine

Periodical maintenance procedures

After initial 50 hours of operation

1) Replace Engine Oil and Engine Oil Filter

The engine oil on a new engine becomes
contaminated from the initial break-in of internal parts.
It is very important that the initial oil change is performed
as scheduled.

Note: The oil drain plug may be in another

location if an optional oil pan is used.

Drain the engine oil as follows:

1. Make sure the engine is level.
2. Start the engine and bring it up to operating temperature.
3. Stop the engine.
4. Remove one of the oil filler caps (Fig.9-2, (1))
to vent the engine crankcase and allow the
engine oil to drain more easily.
5. Position a container under the engine to collect
waste oil.6. Remove the oil drain plug (Fig.9-3, (1))
from the engine oil pan. Allow oil to drain.
7. After all oil has been drained from the engine, Fig.9-2
reinstall the oil drain plug (Fig.9-3, (1)) and
tighten to 40-47 ft-lb (53.9-63.7 N·m, 5.5-6.5 kgf/m).
8. Dispose of used oil properly.

Remove the engine oil filter as follows:

1. Turn the engine oil filter (Fig.9-3, (2))
counterclockwise (Fig.9-3, (3)) using an oil
filter wrench.
2. Clean the engine oil filter mounting face.
3. Lightly coat the gasket on the new oil filter with
engine oil. Install the new engine oil filter
manually by turning it clockwise (Fig.9-3, (4))
until it contacts the mounting surface. Tighten to
14-17 ft-lb (19.6-23.5 N·m, 2.0-2.4 kgf/m) or
one additional turn using the oil filter wrench.

Engine oil filter part number:

129150-35153

Fig.9-3

SSJ00003 Rev 1 9-5

Chapter 9 Engine

4. Add new engine oil to the engine through either

of the oil filler ports as specified in Fig.9-4.
5. Warm up the engine by running it for 5 minutes
and check for any engine oil leaks.6.
After engine is warm, shut it off and let it sit for
10 minutes.
7. Recheck the engine oil level.
8. Add engine oil to engine oil filler port
(Fig.9-5, (5)) as needed until the level is
between the upper (Fig.9-5, (2)) and lower
lines (Fig.9-5, (3)) shown on the dipstick
(1)).
(Fig.9-5, (1))
Fig.9-4
9. Reinstall the oil filler cap (Fig.9-5, (4))
(4)). If any
engine oil is spilled, wipe it away with a clean cloth.

Fig.9-5

• Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal
engine components to seize and / or shorten engine life.
• Prevent dirt and debris from contaminating the engine oil. Carefully clean the oil cap / dipstick and
the surrounding area before you remove the cap.
• NEVER mix different types of engine oil. This may adversely affect the lubricating properties of the
engine oil.
• NEVER overfill. Overfilling may result in white exhaust smoke, engine overspeed or internal damage.

9-6 Rev 1 SSJ00003

 Chapter 9 Engine

2) Check and Adjust Cooling Fan V-Belt

The V-belt will slip if it does not have the proper
tension. This will prevent the alternator from
generating sufficient power. Also, the engine will
overheat due to the engine coolant pump pulley
slipping.

Check and adjust the V-belt tension (deflection) as

follows:
1. Press the V-belt down with your thumb with a
force of approximately 22 ft-lb (98 N·m, 10 kgf/m)
to check the deflection.
There are three positions to check for V-belt
tension (Fig.9-6, (A), (B) and (C)).
(C)) You can
Fig.9-6
check the tension at whichever position is the
most accessible. The proper deflection of a
used V-belt at each position is:
(A) 10-14 mm [3/8 - 1/2 in]
(B) 7-10 mm [1/4-3/8 in]
(C) 9-13 mm [5/16-1/2 in]
2. If necessary, adjust the V-belt tension. Loosen
the adjusting bolt (Fig.9-7, (1)) and move the
alternator (Fig.9-7, (2)) with a pry bar
(Fig.9-7, (3)) to tighten the V-belt to the
desired tension. Then tighten the adjusting bolt.
3. Tighten the V-belt to the proper tension. There
must be clearance (Fig.9-8, (1)) between the
V-belt and the bottom of the pulley groove. If
there is no clearance (Fig.9-8, (2)) between Fig.9-7
the V-belt and the bottom of the pulley groove,
replace the V-belt.
4. Check the V-belt for cracks, oil or wear. If any of
these conditions exist, replace the V-belt.
5. Install the new V-belt and adjust the proper
deflection.
The proper deflection of a new V-belt at each
position is:
(A) 8-12 mm [5/16 - 7/16 in]
(B) 5-8 mm [3/16-5/16 in]
(C) 7-11 mm [1/4-7/16 in]
6. After adjusting, run the engine for 5 minutes or
more. Check the tension again using the
specifications for a used V-belt.
Fig.9-8

SSJ00003 Rev 1 9-7

Chapter 9 Engine

Every 50 hours of operation

1) Drain Fuel Filter / Water Separator

Drain the fuel filter / water separator whenever there are contaminants, such as water, collected in the
bottom of the cup.
NEVER wait until the scheduled periodic maintenance if contaminants are discovered.
The separator cup is made from semi-transparent material. In the cup is a red-colored float ring.
The float ring will rise to the surface of the water to show how much needs to be drained.
Also, some optional fuel filter / water separators are equipped with a sensor to detect the amount of
contaminants. This sensor sends a signal to an indicator to alert the operator.

Drain the fuel filter / water separator as follows:

1. Position an approved container under the fuel
filter / water separator (Fig.9-9, (1)) to collect
the contaminants.
2. Close (Fig.9-9, (2)) the fuel cock (Fig.9-9, (3))(3)).
3. Loosen the drain cock (Fig.9-9, (4)) at the
bottom of the fuel filter / water separator. Drain
any water collected inside.
4. Hand-tighten the drain cock.
5. Open the fuel cock (Fig.9-9, (3))(3)).
6. Turn the key to the ON position for 10 to 15 seconds
to prime the diesel fuel system by the electric fuel pump
when you are done.
7. Check for fuel leaks.
Fig.9-9

NEVER use the starter motor to crank the engine in order to prime the fuel system.
This may cause the starter motor to overheat and damage the coils, pinion and / or ring gear.

If no water drips when the fuel filter / water separator drain cock is opened, loosen the air vent screw
on the top of the fuel filter / water separator by using a screwdriver to turn it counterclockwise 2-3 turns.
This may occur if the fuel filter / water separator is positioned higher than the fuel level in the fuel tank.
After draining the fuel filter / water separator, be sure to tighten the air vent screw.

9-8 Rev 1 SSJ00003

 Chapter 9 Engine

Every 250 hours of operation

1) Drain Fuel tank
1. Position an approved container under the diesel fuel tank (Fig.9-10, (1)) to collect the
contaminants.
2. Take the drain hose (Fig.9-10, (2)) from the clamp (Fig.9-10, (3)), and then put the end of the
hose into the container.
3. Remove the fuel cap (Fig.9-10, (4))
(4)).
4. Remove the drain plug (Fig.9-10, (5)) from the hose end to drain the contaminants (water, dirt, etc.)
from the bottom of the tank.
5. Drain the tank until clean diesel fuel with no water or dirt flows out. Reinstall and tighten the drain plug
firmly.
6. Reinstall the fuel cap.
7. Fix the drain hose by clamp.
8. Check for leaks.

(4)

(2)

(1) (5)
(3)
Fig.9-10

2) Replace Engine Oil and Engine Oil Filter

Change the engine oil every 250 hours of operation after the initial change at 50 hours.
Replace the engine oil filter at the same time.
See Replace Engine Oil and Engine Oil Filter on page 9-5.

SSJ00003 Rev 1 9-9

Chapter 9 Engine

3) Check and Clean Radiator Fins

Dirt and dust adhering to the radiator fins reduce
the cooling performance, causing overheating.
Make it a rule to check the radiator fins daily and
clean as needed.

Blow off dirt and dust from fins and radiator with
28 psi (0.19 MPa, 2 kgf/cm2) or less of
compressed air (Fig.9-11, (1)).
(1)) Be careful not to
damage the fins with the compressed air.
If there is a large amount of contamination on the
fins, apply detergent, thoroughly clean and rinse
with tap water. Fig.9-11

NEVER use high-pressure water or compressed air at greater than 28 psi (193 kPa; 19 686 mmAq) or a
wire brush to clean the radiator fins. Radiator fins damage easily.

4) Check and Adjust Cooling Fan V-Belt

Check and adjust the cooling fan V-belt every 250 hours of operation after the initial 50 hour V-belt
maintenance.
See Check and Adjust Cooling Fan V-Belt on page 9-7.

9-10 Rev 1 SSJ00003

 Chapter 9 Engine

5) Clean Air Cleaner Element

Note that a typical air cleaner is shown in Fig.9-12
and Fig.9-13 for illustrative purposes only.
The engine performance is adversely affected
when the air cleaner element is clogged with dust.
Be sure to clean the air filter element periodically.

1. Unlatch and remove the air cleaner cover

(1)).
(Fig.9-12, (1))
2. Remove the element (Fig.9-12, (2)) (outer Fig.9-12
element if equipped with two elements).
3. Blow air (Fig.9-12, (3)) through the element
from the inside out using 42-71 psi
(0.29-0.49 MPa, 3.0-5.0 kgf/cm2) compressed
air to remove the particulates. Use the lowest
possible air pressure to remove the dust without
damaging the element.
4. If the air cleaner is equipped with a double
element, only remove and replace the inner
element (Fig.9-13,
ig.9-13, (1)) if the engine lacks
power or the dust indicator actuates (if
equipped).
Fig.9-13
Note:
The inner element should not be removed when cleaning or replacing the outer element.
The inner element is used to prevent dust from entering the engine while servicing the outer element.

5. Replace the element with a new one if the element is damaged, excessively dirty or oily.
6. Clean inside of the air cleaner cover.
7. Reinstall the element into the air cleaner case (Fig.9-12, (4))
(4)).
8. Reinstall the air cleaner cover making sure you match the arrow (Fig.9-12, (5)) on the cover
with the arrow on the case (Fig.9-12, (6))
(6)).
9. Latch the air cleaner cover to the case.

• When the engine is operated in dusty conditions, clean the air cleaner element more frequently.
• NEVER operate the engine with the air cleaner element(s) removed.
This may allow foreign material to enter the engine and damage it.

SSJ00003 Rev 1 9-11

Chapter 9 Engine

Every 500 hours of operation

1) Replace Air Cleaner Element

Replace the air cleaner element (Fig.9-12, (2)) every 500 hours even if it is not damaged or dirty.
When replacing the element, clean the inside of the air cleaner case (Fig.9-12, (4))
(4)).
If the air cleaner is equipped with a double element, only remove and replace the inner element
(Fig.9-13, (1)) if the engine lacks power or the dust indicator actuates (if equipped).
This is in addition to replacing the outer element.

Air cleaner element part number:

119005-12571

2) Replace Fuel Filter

Replace the fuel filter at specified intervals
to prevent contaminants from adversely
affecting the diesel fuel flow.

1. Stop the engine and allow it to cool.

2. Close the fuel cock of the fuel filter / water
separator.
3. Remove the fuel filter using a filter wrench to
turn it to the left (Fig.9-14, (1))
(1)). When
removing the fuel filter, carefully hold it to
prevent the fuel from spilling. Wipe up all spilled
fuel.
4. Clean the filter mounting surface and apply a small Fig.9-14
amount of diesel fuel to the gasket of the new fuel filter.
5. Install the new fuel filter. Hand-tighten it to the right (Fig.9-14, (2)) until it comes in contact
with the mounting surface. Use a filter wrench and tighten to 14-17 ft-lb (19.6-23.5 N•m, 2.0-2.4 kgf/m)
or one additional turn using the filter wrench.
6. Open the fuel cock of the fuel filter / water separator.
7. Turn the key to the ON position for 10 to 15 seconds to prime the diesel fuel system by the electric
fuel pump.
8. Check for fuel leaks.

Engine oil filter part number:

119802-55801

9-12 Rev 1 SSJ00003

 Chapter 9 Engine

3) Clean Fuel Filter / Water Separator

Periodically clean the fuel filter / water
separator element and inside the cup.
1. Position an approved container under the cup
(Fig.9-15, (1)) of the fuel filter / water
separator to collect the contaminants.
2. Close (Fig.9-15, (2)) the fuel cock
(3)).
(Fig.9-15, (3))
3. Loosen the drain cock (Fig.9-15, (4)) and
drain the contaminants. See Drain Fuel Filter /
Separator on page 9-5.
4. Turn the retaining ring (Fig.9-15, (5)) to the
left (Fig.9-15, (10)) and remove the cup
(Fig.9-15, (1)).
(1)) If equipped, disconnect the
sensor wire (Fig.9-15, (7)) from the cup
before removing the cup.
5. Carefully hold the cup to prevent fuel from
spilling. If you spill any fuel, clean up the spill
completely.
6. Remove the float ring (Fig.9-15, (8)) from the
cup. Pour the contaminants into the container
and dispose of it properly.
7. Clean the element (Fig.9-15, (9)) and inside
cup. Replace the element if it is damaged.

Fig.9-15
Element part number
119802-55710

8. Install the element and O-ring in the bracket.

9. Position the float ring in the cup.
10. Check the condition of the O-ring. Replace if necessary.
11. Install the cup to the bracket by tightening the retaining ring to the right (Fig.9-15, (6)) to
11-15 ft-lb (15-20 N·m, 1.5-2.0 kfg/m).
12. Close the drain cock. Reconnect the sensor wire if equipped.
13. Open the fuel cock (Fig.9-15, (3)) (3)).
14. Turn the key to the ON position for 10 to 15 seconds to prime the diesel fuel system by the electric
fuel pump.
15. Check for leaks.

SSJ00003 Rev 1 9-13

Chapter 9 Engine

Every 1,000 hours of operation

1) Drain, Flush and Refill Cooling System With New Coolant

Engine coolant contaminated with rust or water

scale reduces the cooling effect. Even when
extended life engine coolant is properly mixed,
the engine coolant gets contaminated as its
ingredients deteriorate. Drain, flush and refill the
cooling system with new coolant every 1000 hours
or once a year, whichever comes first.

1. Allow engine and coolant to cool.

2. Remove the radiator cap (Fig.9-16, (1))(1)).
3. Remove the drain plug or open the drain cock
(Fig.9-16, (2)) at the bottom of the radiator
and drain the engine coolant.
4. Drain the coolant from the engine block. Fig.9-16
remove the coolant drain plug (Fig.9-17, (1))
from the engine block.
5. After draining the engine coolant, flush the
radiator and engine block to remove any rust,
scale and contaminants. Then reinstall and
tighten the drain plug or close the drain cock in
the radiator. Reinstall and tighten the engine
block drain plug or reconnect the coolant hose
at the oil cooler.
6. Fill radiator and engine with engine coolant.

Fig.9-17

2) Adjust Intake / Exhaust Valve Clearance

Proper adjustment is necessary to maintain the correct timing for opening and closing the valves.
Improper adjustment will cause the engine to run noisily, resulting in poor engine performance and
engine damage. Ask your authorized Yanmar industrial engine dealer or distributor to adjust the
intake / exhaust valve clearance.

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 Chapter 9 Engine

Every 1,500 hours of operation

1) Inspect, Clean and Test Fuel Injectors

Proper operation of the fuel injectors is required to obtain the optimum injection pattern for full engine
performance. The EPA / ARB requires that you have the injectors inspected, cleaned and tested
every 1500 hours. Ask your authorized Yanmar industrial engine dealer or distributor for this service.

2) Inspect Crankcase Breather System

Proper operation of the crankcase breather system is required to maintain the emission requirements
of the engine. The EPA / ARB requires that you have the crankcase breather system inspected
every 1500 hours. Ask your authorized Yanmar industrial engine dealer or distributor for this service.

Every 2,000 hours of operation

1) Check and Replace Fuel Hoses and Engine Coolant Hoses

Regularly check the fuel system and engine coolant system hoses. If they are cracked or degraded,
replace them. Replace the hoses at least every two years. Ask your authorized Yanmar industrial
engine dealer or distributor to replace fuel hoses and engine coolant system hoses.

2) Lap the Intake and Exhaust Valves

Adjustment is necessary to maintain proper contact of the valves and seats. Ask your authorized
Yanmar industrial engine dealer or distributor to lap the valve seats.

SSJ00003 Rev 1 9-15

Chapter 9 Engine

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