SME-322

SERVICE MANUAL
NH09A / INH30A
 INTRODUCTION
This manual describes correct adjustment and servicing procedures
for NH09A / INH30A AERIAL PLATFORM in order to ensure
the most effective use of superb performance
and excellent features for your satisfaction.

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 and safety-related components.
Do not make any modifications to the machine
without obtaining the manufacturer’s approval.
The design check, the manufacturing check as well as
the practical test should be conducted by the approved agent,
if the modification which would affect the stability, strength or
performance of the machine is made.

Please, note that the numerical values in this manual

may be subject to change due to engineering improvement.

Customer Service Division

Aichi Corporation
 I N D E X

1. General information
Overall dimensions -------------------------------------------------------------------- 1-2
Overall dimensions (for the machine with bucket rotation system) ------ 1-2-1
Specifications ------------------------------------------------------------------------- 1-3
Working range chart ---------------------------------------------------------------- 1-4

2. Mechanical section
Tower ----------------------------------------------------------------------------------- 2-2
Turntable -------------------------------------------------------------------------------- 2-3
T.T.B. (Turntable bearing) ----------------------------------------------------------- 2-4
Rotation gearbox ----------------------------------------------------------------------- 2-5
Boom -------------------------------------------------------------------------------------- 2-8
Boom head --------------------------------------------------------------------------- 2-12
Bucket ----------------------------------------------------------------------------------- 2-13

3. Hydraulic section
Locations of hydraulic components ----------------------------------------------- 3-2
Oil reservoir ---------------------------------------------------------------------------- 3-3
Hydraulic filters ------------------------------------------------------------------------ 3-4
Hydraulic pump ------------------------------------------------------------------------ 3-6
Emergency pump unit ---------------------------------------------------------------- 3-7
Main control valve --------------------------------------------------------------------- 3-8
Elevation cylinder ------------------------------------------------------------------- 3-10
Holding valve (for Elevation cylinder) ------------------------------------------- 3-11
Telescoping cylinder ----------------------------------------------------------------- 3-14
Holding valve (for Telescoping cylinder) ---------------------------------------- 3-15
Lower levelling cylinder ------------------------------------------------------------- 3-18
Upper levelling cylinder ------------------------------------------------------------- 3-19
Holding valve (for Upper levelling cylinder) ----------------------------------- 3-20
Rotation motor ----------------------------------------------------------------------- 3-21
Solenoid valve (for boom rotation brake) --------------------------------------- 3-22
Check valve --------------------------------------------------------------------------- 3-23
Rotary actuator ----------------------------------------------------------------------- 3-24
Solenoid valve (for bucket rotation) ---------------------------------------------- 3-25
4. Electric section
Locations of electric components --------------------------------------------------- 4-2
Main control box ---------------------------------------------------------------------- 4-3
Upper control box ---------------------------------------------------------------------- 4-7
Upper control box (for the machine with bucket rotation system) -------- 4-7-1
Lower control box -------------------------------------------------------------------- 4-8
Rotation angle limit system --------------------------------------------------------- 4-9
Boom retraction end system -------------------------------------------------------- 4-12
Relay (for Emergency pump) ------------------------------------------------------ 4-14

5. Electric circuit for individual system

Engine control system ----------------------------------------------------------------- 5-2
Elevation system ---------------------------------------------------------------------- 5-3
Elevation system (for the machine with bucket rotation system) -------- 5-4
Telescoping system ------------------------------------------------------------------- 5-5
Telescoping system (for the machine with bucket rotation system) --------- 5-6
Rotation system -------------------------------------------------------------------- 5-7
Rotation system (for the machine with bucket rotation system) ------- 5-8
Bucket leveling system ---------------------------------------------------------------- 5-9
Bucket leveling system (for the machine with bucket rotation system) --- 5-10
Boom/Engine interlock system --------------------------------------------------- 5-11
Bucket rotation system -------------------------------------------------------------- 5-12
Emergency pump system ----------------------------------------------------------- 5-13

6. Maintenance and Adjustment

System pressure adjustment procedures ------------------------------------------ 6-2
Lubrication ----------------------------------------------------------------------------- 6-4
Maintenance schedule --------------------------------------------------------------- 6-5
Software of adjustment tool -------------------------------------------------------- 6-6

7. Appendix
Hydraulic circuit diagram --------------------------------------------------------- 7-2
Hydraulic circuit diagram (for the machine with bucket rotation system) -7-3
Electric circuit diagram --------------------------------------------------------------- 7-5
Electric wiring chart ---------------------------------------------------------------- 7-6
Electric circuit diagram (for the machine with bucket rotation system) --- 7-7
Chassis wire harness ------------------------------------------------------------------- 7-8
8. Inspection manual
Procedures of Daily inspection ---------------------------------------------------- 8-1
Daily inspection check sheet -------------------------------------------------------- 8-3
Procedures of Periodical inspection ----------------------------------------------- 8-5
Function test -------------------------------------------------------------------------- 8-10
Periodical inspection check sheet -------------------------------------------------- 8-11
Function test check sheet ------------------------------------------------------------ 8-13
Major alteration and repair -------------------------------------------------------- 8-14
 1
GENERAL INFORMATION

1-1
Overall dimensions

1-2
 600-0001320

Overall dimensions (for the machine with bucket rotation system)

1-2-1
 Specifications
Model NH09A INH30A
Chassis Isuzu NPR70GL
Bucket Rated load 182 kg 400 LBS
Inner dimensions (L x W x H) 610 x 610 x 1070 2.0 x 2.0 x 3.5 in
mm
Maximum floor height 9.017 m 29 ft 7 in
Maximum working radius 6.3 m 20 ft 8 in
Boom Boom length 4,410 ~ 7,525 mm 14ft-6in~24ft-8in
Boom angle -12 ~ 77 degrees
Rotation angle Right : 185 degrees
Left : 185 degrees
Actuating speed Elevation Up 15 ~ 22 seconds
Down 15 ~ 22 seconds
at the flow of Telescoping Out 10 ~ 17 seconds
10 litters / min
(2.64 gallons / min)
In 10 ~ 17 seconds
Rotation C.W 60 5 seconds / 360 degrees
C.C.W 60 5 seconds / 360 degrees
Hydraulic Hydraulic oil Tank capacity 30 litters 8 gallons
system Recommended oil Shell Tellus oil T22
Rated pressure 175 kg / cm2 2500 PSI

1-3
Working range chart

NOTE :
1. The deflection of boom is not considered in the working range chart.
2. The working range is calculated, assuming that the machine is set up on
firm and level ground.

1-4
 2
MECHANICAL SECTION

2-1
 Tower (7E9-0006100)
The tower is mounted on the chassis frame through the raiser.

Fig.2-1

1. Inspection

Check the anchor bolts of the tower for looseness, omissions and any other
damages.
Loose bolts should be removed and checked for damaged thread and
disfigurement.
Tightening torque : 33 ~ 44 kg-m (240 ~ 320 ft-lbs).

2-2
 Turntable (7F0-0006500)
The turntable is mounted on the tower through the turntable bearing, and is rotated
by the rotation motor and the rotation gear box.

Fig.2-2

1. Inspection

Check the anchor bolts of the turntable for looseness, omissions and any other
damages.
* Loose anchor bolts should be removed and checked for damaged thread and
disfigurement.
* Before tightening the anchor bolts, apply the thread lock agent to the thread, and
tighten them by the specific tightening torque.
Recommended thread lock agent: 3 Bond 1305N.
Specific tightening torque: 10.1 ~ 13.6 kgf-m (73 ~ 98 ft-lbs)
NOTE:
Before removing the anchor bolts, use a gas burner and heat the bolts red-hot to
remove the thread lock agent.

2-3
 Turntable bearing (372-0000019)
The turntable bearing is mounted between the tower and the turntable, and enables
the turntable to rotate.

Section : A - A

Fig-2-3

1. Inspection

1. Check the anchor bolts and nuts for looseness, omissions and any other damages.
a. Loose bolts and nuts should be removed and checked for damaged threads and
disfigurement.
b. Before tightening the anchor bolts or nuts, apply thread lock agent to the
threads.
- Recommended thread lock agent: 3 Bond 1305N
c. Tighten the anchor bolts and nuts by the specific tightening torque.
- Specific tightening torque: 10.1 ~ 13.6 kgf-m (73 ~ 98 ft-lbs)
NOTE: Before removing the anchor bolts and nuts, use a gas burner and heat
them red hot to remove the thread lock agent applied on the thread of
each bolt and nut.
2. Check the ring gear for cracks, scorings and any other damages.

* Soft zone
“S” marks stamped on the inner and outer races of the turntable bearing indicate
the starting and finishing points of the heat treatment and these sections are
weaker than the other sections.
When replacing the turntable bearing, make sure to set both of the soft zone marks
to the positions shown in Fig.2-3.
2-4
 Rotation gearbox (370-0000028)
The rotation gearbox reduces the rotation speed (rpm) of the hydraulic motor and
increases the torque to rotate the turntable through the turntable bearing.
Type: Worm gear.
Reduction ratio -------------------------- 1 / 30
Gear oil capacity ------------------------ 0.75 liters (0.2 gallons)
Recommended gear oil grade ---------- Shell Omala 320.
Oil change interval ---------------------- Every 1,200 working hours or annually.

Fig.2-4

2-5
1. Inspection

1. Check the gear oil level. Also, check the gear oil for contamination.
NOTE: The machine should be level when checking the oil level.
a. Remove the level plug and make sure that the oil level is as high as the level
plug
hole.
b. If metallic particles are found in the gear oil, check the gears and the bearings
for wear.
2. Operate the rotation gear box, and check for abnormal noise, oil leakage and
any other abnormal functions.
3. Check the teeth on pinion gear for excessive wear, scorings and cracks.
4. Check the backlash between the pinion gear and the ring gear of the turntable
bearing.
- Specific backlash : 0.6 mm (0.024 in) or less.
To check the backlash, rotate the turntable and crush a lead-wire between the
pinion and the ring gear of the turntable bearing, then measure the thickness of the
crushed lead wire.
If the backlash is inadequate, loosen the anchor bolts of the rotation gearbox and
adjust the position of the rotation gear box by the pusher bolts.

Fig.2-5

2-6
2. Manual operation

Rotate the boom manually as follows in case of emergency.

1. Remove the rotation motor from the gear box.

2. Rotate the worm shaft by using the attached tool shown in the figure below.

Plate (5F0002600)

Fig.2-6

2-7
Boom (7K0-0007600)

Fig.2-7
2 -8
1. Inspections

The boom is to be disassembled for a detailed inspection every 7 years.

1. Check each wear pad for wear and replace the wear pad, if necessary.
Also, check the clearance between each wear pad and boom section and adjust
the
clearance, if necessary.
See the clause of “2. Wear pads” for detail.

2. Bend of boom section.

1) Set the boom horizontally and extend it fully.
2) Visually check the each boom section for bend.
3) If the bend checked visually seems to be excessive, stretch a thread over the
boom section, and measure the bend accurately as shown in Fig: 2-8.
If the bend exceeds the serviceable limit, replace the boom section.
Note: Remove the deflection of the boom section which is caused by the
weight
of the boom and the bucket before measuring the deflection.

Serviceable limit 1st boom section: 4.0 mm (0.16 in)

2nd boom section: 1.5 mm (0.06 in)

Fig.2-8

3. Dents, Scratches.
Check each boom section for dents, scratches thoroughly.
If the dent or scratch which exceeds the serviceable limit, replace the boom
section.
* Serviceable limit: Length: 50mm (2 in), and Depth: 2 mm (0.04 in).

4. Cracks.
Check each boom section for cracks thoroughly.
For fine cracks, use a “COLOR CHECK” or penetration check.
* Pay particular attention, when checking each pin boss and welded part.

2-9
2. Wear pads

Fig. 2-9 Fig. 2-10

Fig. 2-11
A. Wear pads installed on the head of the 1 st boom section shown in Fig. 2-9 and 2-11.
1. Check each wear pad by measuring the thickness (L) shown in Fig 2-11 and
replace the wear pad, if the thickness (L) reaches the serviceable limit.
Serviceable limit: 55 mm (2.1 in).
Thickness (L) of new wear pad: 65 mm (2.6 in)
2. Check the clearance between each wear pad and the 2 nd boom section and adjust
the clearance to as follows.
1) Loosen all of the set screws, then screw out all of the wear pads (1, 2, 3, 4
and 5).
2) Insert the thickness gauges of 1 mm (0.04in) between both of the wear pads (2
and 3) and the 2 nd boom section, then screw in the wear pads (2 and 3) alternatel y
until the 2nd boom section is centered in the 1 st boom section.
3) Insert the thickness gauges of 1 mm (0.04 in) between the wear pads (1and 4)
and the 2 nd boom section, screw in each wear pad and adjust the clearance to 1
mm (0.04 in).
2-10
 4) Insert the thickness gauge of 2 mm (0.08 in) between the wear pad (5) and
the 2 nd boom section, screw in the wear pad and adjust the clearance to 2
mm (0.08 in).
5) Tighten all of the set screws securely.

B. Wear pads installed on the tail end of the 2 nd boom section shown in Fig.2-10.
These wear pads are to be checked after disassembling the boom.
1. Check the thickness of each wear pad and replace the wear pad, if the
thickness reaches the serviceable limit.
Serviceable limit: 12 mm (0.47 in)
Thickness of new wear pad: 15 mm (0.59 in)
2. Check the clearance between each wear pad and the 1 st boom section, then
adjust the clearance to the specific value.
Specific clearance:
Wear pad 1 ----- 2.0 ~ 3.0 mm (0.08 ~ 0.12 in)
Wear pad 2 ----- 1.0 ~ 2.0 mm (0.04 ~ 0.08 in)
Adjust the clearance by adding or reducing the spacers installed under each
wear pad.
Apply a thread lock agent to the thread of the wear pad fixing screws before
tightening.

2-11
 Boom head (7K9-0007500)
The boom head is installed on the top of the 2nd boom section to hold the bucket.

Fig.2-12

1. Inspection

2. Check the bolts for looseness, omissions and any other damages.
Loose bolts should be removed and checked for damaged thread and
disfigurement.
Tightening torque : 2.6 kg-m (18.8 ft-lbs).

2-12
 7 L1-0014800/385-0000031C

Bucket
Rated load ----------------------- 182 kg (400 lbs) for H1A/190 kg (420 lbs) for D01
Inner dimensions (L x W x H) ------------- 610 x 610 x 1070mm (2.0 x 2.0 x 3.5 ft)

Fig.2-13
NOTE: The difference by the machine specifications between the two types of
bucket is the location of its opening.

2-13
 3
HYDRAULIC SECTION
 Locations of Hydraulic components
Hydraulic components are located as shown in the figure below.

Fig.3-1

3-2
 Oil reservoir (5S0-0004300)
The oil reservoir is mounted on the side of the tower, and supplies the hydraulic oil
to
all of the hydraulic system.

Capacity --------------------------- 30 liters (8 gallons)

Recommended hydraulic oil ----- Shell Tellus oil T22
Oil change interval --------------- Every 1200 hours or annually
For new machine, the first oil change should be
conducted after 300 hours or 3 months use.

Fig.3-2

Note :
* Set the machine on level ground and stow the boom on the boom rest properly
when checking the oil level.
* Replace the high-pressure filter and clean the suction filter when changing the
hydraulic oil.

3-3
 Hydraulic filters

1. High-pressure filter (305-0000019)

The high-pressure filter is installed in the hydraulic line between the hydraulic
pump and the main control valve to eliminate contaminants contained in the
hydraulic oil.
Rated flow -------------------------------------- 15 liters / min (4.0 gallons /min)
Rated pressure --------------------------------- 175 kgf / cm 2 (2500 PSI)
Filtration degree ------------------------------- 12 micron
By-pass valve cracking pressure ------------- 5 kgf / cm 2 (70PSI)
Element replacement interval ---------------- 1,200 hours or annually

Fig.3-3

Descriptions Part No.

1 Head ---------------
2 Case ---------------
3 Element G319050020
4 Spring G319050021
5 O-ring G319050009
6 By-pass valve G319050022

3-4
2. Suction filter (305-01600)
The suction filter is installed at the end of the suction pipe in the oil reservoir
to eliminate contaminants contained in the hydraulic oil.
Rated flow -------------------------------------- 35 liters / min (9.2 gallons /min)
Filtration degree ------------------------------- 105 micron

Fig.3-4

3. In-line filter (305-0000010)

The in-line filter is installed at the P port of the main control valve to eliminate
contaminants contained in the hydraulic oil.
Rated flow -------------------------------------- 50 liters / min (13.2 gallons /min)
Rated pressure --------------------------------- 175 kgf / cm 2 (2500 PSI)
Filtration degree ------------------------------- 100 mesh

Fig.3-5

3-5
 Hydraulic pump (300-0000030)
The hydraulic pump is driven by the PTO through the pump drive shaft to supply
pressurized oil to the hydraulic system.

Type --------------------------------- Gear type

Displacement ----------------------- 16 liters / min (4.2 gallons / min)
Rated pressure ---------------------- 175 kgf / cm 2 (2500 PSI)
Rotating speed ---------------------- 700 rpm

Fig.3-6

01 Front cover 06 Rear cover 56 Washer

02 Body 50 Back up strip 57 Bush
03 Drive gear 51 Gasket 65 Oil seal
04 Driven gear 52 Gasket 70 Retainer ring
05 Side plate 55 Bolt

3-6
 Emergency pump unit (300-01813)
The emergency pump unit consists of the DC motor and the gear pump, and is driven
by the batteries to supply hydraulic pressure in the event of main pump or engine
failure.

DC motor ---------------------------- DC12V

Displacement ----------------------- 1.7 cc / rev (0.10 in3 / rev)
Rated pressure ---------------------- 175 kgf / cm 2 (2500 PSI)

Fig.3-7

CAUTION : Do not drive the emergency pump for more than 30 seconds
continuously and allow the interval of 30 seconds or more
before driving the emergency pump again.

3-7
 Main control valve (302-0013100)
The main control valve controls the “Rotation”, “Elevation”, “Telescoping” and
“Bucket leveling” systems.

Fig.3-8

3-8
 Fig.3-9

Relief valve pre-set pressure:

Relief valve P1 : 175 kg / cm 2 (2500 PSI)
Relief valve P2 : 130 kg / cm 2 (1850 PSI)
Relief valve P3 : 130 kg / cm 2 (1850 PSI)

3-9
 Elevation cylinder (303-0008900)
The elevation cylinder is equipped with the holding valve to prevent the cylinder
from natural decent.

1 Cylinder
2 Piston rod
3 Bushing guide
4 Piston
5 Bushing
6 Bushing
7 Dust seal
8 Back-up ring
9 Packing
10 Packing
11 Wear ring
12 O-ring
13 O-ring
14 O-ring
15 Self lock nut
16 Bolt
17 Spring washer
18 Holding valve
19 Spherical bearing
20 Cap bolt
21 O-ring
22 Plain washer

Fig.3-10

3-10
 Holding valve (for Elevation cylinder) (302-0010900)
The holding valve is mounted on the elevation cylinder to prevent the cylinder from
natural descent.

Cracking pressure:
Counter valance valve ------------------------------------- 25 kg / cm 2 (360 PSI)
Check valve ------------------------------------------------- 1.0 kg / cm 2 (14 PSI)
Pilot check valve ------------------------------------------- 0.3 kg / cm 2 (4.3 PSI)

Fig.3-11

3-11
 1 Counter valance valve cartridge 7 Spool
(The check valve is built in this valve.) 8 Spring
2 Body 9 Piston stopper
3 Plug 10 Spring
4 Pilot check valve cartridge 11 O-ring
5 piston 12 Back-up ring
6 Piston rod 13 O-ring

1. Inspection

Check the internal oil leakage of the holding valve by measuring the natural descent
of the boom elevation cylinder as follows.
1. Set up the machine on firm and level ground.
2. Raise the boom and set the boom at the boom angle of 45 degrees, then stop the
engine.
3. Apply the mark on the piston rod of the boom elevation cylinder, then measure
the dimension A as shown in the figure below.

CAUTION : Do not damage the piston rod by applying the mark.

Fig.3-12

4. Leave the machine for 10 minutes, 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 elevation cylinder for internal oil leakage.
Follow the next procedures to identify which has internal oil leakage
(the holding valve or the boom elevation cylinder).
1) Hold the boom by crane to prevent the boom from sudden descent.
2) Disconnect the hydraulic hose which is connected to the “A port” of the
holding valve.

CAUTION : Loosen the hydraulic hose fitting slowly when disconnecting

the hydraulic hose.

3-12
3) Lower the hoisting hook of the crane to load the boom elevation cylinder with
the gravity of the boom, then check if the hydraulic o il leaks from the holding
valve.
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 in the boom elevation
cylinder.

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

3-13
 Telescoping cylinder (303-0009100)
The telescoping cylinder is equipped with the holding valve to prevent the cylinder
from natural descent.

1 Cylinder
2 Rod
3 Cylinder head
4 Bushing
5 Wear ring
6 Packing
7 Back-up ring
8 Dust seal
9 Snap ring
10 O-ring
11 Back-up ring
12 O-ring
13 Piston
14 Packing
15 Back-up ring
16 Wear ring
17 O-ring
18 Set Screw
19 Spacer
20 Holding valve
21 O-ring
22 Bolt

Fig.3-13

3-14
 Holding valve (for Telescoping cylinder) (302-0010800)
The holding valve is mounted on the telescoping cylinder to prevent the cylinder
from
natural descent.

Cracking pressure
Pilot check valve ------------ 10 kg / cm 2 (140 PSI)
Check valve A --------------- 3.5 kg / cm 2 (50 PSI)
Sequence valve -------------- 10 kg / cm 2 (5.7 PSI)
Check valve B --------------- 0.4 kg / cm 2 (140 PSI)

Fig.3-14

3-15
 Fig.3-15

1. Inspection

Check the internal oil leakage of the holding valve by measuring the natural descent
of the boom telescoping cylinder as follows.
1. Set up the machine on firm and level ground.
2. Raise the boom fully and extend the boom about 1 meter (3 feet), then stop the
engine.
3. Apply the mark on the 2nd boom section, then measure the dimension A as shown
in the figure below.

Fig-3-16

3-16
4. Leave the machine for 10 minutes, 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 telescoping cylinder for internal oil leakage.
Follow the next procedures to identify which has internal oil leakage
(the holding valve or the boom telescoping cylinder).
1) Raise the boom fully and extend the boom about 1 meter (3 feet).
2) Disconnect the hydraulic hose which is connected to the “A port” of the holding
valve, then check if the hydraulic oil leaks from the holding valve.

CAUTION : Loosen the hydraulic hose fittings slowly when disconnecting

the hydraulic hose.

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 telescoping
cylinder.

CAUTION : The boom should be fully retracted when removing the holding
valve.
If the holding valve is removed or loosened while the boom is
extended, the 2nd boom section will retract suddenly, resulting
in the damage to the machine.

3-17
Lower leveling cylinder (303-0011300)

1 Cylinder tube
2 Piston rod
3 Cylinder head
4 U-ring
5 Dust seal
6 O-ring
7 Back-up ring
8 O-ring
9 Piston
10 Wear ring
11 U-ring
12 Back-up ring
13 U-ring holder
14 O-ring
15 Set screw

Fig.3-17

3-18
Upper leveling cylinder (303-0011200)

1 Cylinder tube
2 Piston rod
3 Cylinder head
4 U-ring
5 Dust seal
6 O-ring
7 Back-up ring
8 O-ring
9 Piston
10 Wear ring
11 U-ring
12 Back-up ring
13 U-ring holder
14 O-ring
15 Set screw
16 Holding valve
17 Bolt

Fig.3-18

3-19
 Holding valve (for Upper leveling cylinder) (302-0014100)
The holding valve is mounted on the upper leveling cylinder.
It confines the hydraulic oil into the upper leveling cylinder to keep the bucket level
in an emergency situation such as hydraulic line failure.

Cracking pressure
Counter valance valve ------------------------------------- 21 kg / cm 2 (300 PSI)
Check valve ------------------------------------------------- 0.5 kg / cm 2 (7.1 PSI)
Preset pressure of relief valve ------------------------------- 130 kg / cm 2 (1850 PSI)

Fig.3-19

3-20
 Rotation motor (301-0000036)
The rotation motor is installed on the rotation gearbox to rotate the turntable.

Type ----------------------------- Orbit type

Rated pressure ------------------ 175 kg / cm 2 (2500 PSI)
Displacement ------------------- 54 cc / rev (3.3 in3 )

Fig.3-20

1 Screw 13 Needle bearing

2 G roller 14 Screw
3 Drive 15 Piston pin
4 End plug 16 Oil seal
5 Seal washer 17 Dust seal
6 Key 18 O-ring
7 Spacer plate 22 O-ring
8 Flange 28 Piston cover
9 Bearing race 29 Screw
10 Output shaft 30 O-ring
11 Housing 31 Spring
12 Back-up ring

3-21
 301-0010700

Solenoid valve (for boom rotation brake)

This solenoid valve releases the rotation brake when the rotation switch is operated.

Electric circuit Hydraulic circuit

Fig.3-21

3-22
 Check valve (301-0000026)
The check valve is installed in the outlet lines of the main and emergency pumps to
prevent the counter flow and to protect the pumps.

Maximum flow volume

P1 T1 ------------------------- 40 liters / min (10.6 gallons / min)
P2 T1 ------------------------- 5 liters / min (1.32 gallons / min)
Cracking pressure
P1 T1 ------------------------- 0.5 kg / cm 2 (7 PSI)
P2 T1 ------------------------- 0.8 kg / cm 2 (11 PSI)

Fig.3-22

3-23
 Rotary actuator (307-0000049)

This rotary actuator is located at the upper part of the bucket bracket, and operates the bucket rotation.
No. Description
1 Housing
2 Shaft weldment
3 Piston/Sleeve
4 End cap
5 Port plug
6 Setscrew
7 Locknut
9 Cap seal
10 Back-up ring
11 Rod seal
12 Piston seal
13 Bearing packing
14 Cap bearing
15 Shaft bearing
16 Thrust washer
17 Valve assembly
17A Valve cartridge
17B Valve cartridge

Fig. 3-23
Fig. 3-24

3-24
 5L1-0120000

Solenoid valve (for bucket rotation)

This solenoid valve is activated when the bucket rotation switch in the upper control
box is operated.

Hydraulic circuit

Fig.3-25

3-25
 4
ELECTLIC SECTION
 Locations of Electric components
Electric components are located as shown in the figure below.

Fig.4-1

4-2
 Connectors of main control box
Main control box (329-0022900)
CN1 CN2 CN3 CN4 CN5
The main control box is installed on the side of the tower to control the hydraulic system.

Male, White Male, White Male, Gray Male, Blue Male, Gray
CN6 CN7 CND1 CND2

Male, White Male, Green Female, Green Female, Green

Note: 1) The above figures are the views from the terminal sides.
2) The letters in each connector show the color codes of the wires.

CN1, CN5 CN2, CN3, CN4 CN6, CN7 CND1 CND2

Note: 1) The above figures are the views from the terminal sides.
2) The figures in each connector show the numbers of the terminal pins.

Fig.4-3
Fig.4-2

4-3
 Connectors of valve control unit
Pin Connector No.
No. J1 J2 J3 J4
1 GND VH2
2 GND VH1 TX
3 12V VH4 RX
4 12V VH6 SG
5 VH5
6 VL2
7 VL1 GND
8 VL4 /ADJ
9 VH3
10 VL3
11 VL6
12 VL5
13 DI15
14 DI12
15 DI10
16 DI08
17 DI14
18 DI05
19 DI03
20 DI01
21 DI16
22 DI13
Fig.4-4 23 DI11
24 DI09
25 DI07
Connectors of relays (CR3 and CR4)
26 DI06
CNR1 (for Relay CR4) CNR2 (for Relay CR3)
27 DI04
28 DI02

Note: The above figures are the views from the cable sides.
Note: The above figures are the views from the cable sides.

Connectors of relay board

CH1 CH2 CH3

CH4 CH5 CH6

Note: The above figures are the views from the cable sides .

4-4
Electric circuit diagram

Relay board

Fig.4-5
4 -5
 Functions of Relays

Relay No. Functions Remarks

CR1 This relay switches on to energise the unload solenoid valve when the elevation, telescoping, Unload solenoid valve
(on Relay board) rotation or bucket level switch is operated either at the upper or lower control.
Note: The unload solenoid valve is energised when both of the relays CR1 and CR9 switch on.
CR2 This relay switches on to start the engine when the engine start switch is operated either at the upper Engine start
(on Relay board) or lower control.
CR3 This relay switches off to shut down the engine when the emergency stop switch is operated at the Engine stop
upper control or when the engine stop switch is operated at the lower control.
CR4 This relay switches on to supply the main power of the machine when the main power switch is Main power
operated in the chassis cabin.
CR5 This relay switches on to supply the power to the emergency pump when the emergency pump Emergency pump
(on Relay board) switch is operated either at the upper or lower control.
CR6 This relay switches on to energise the rotation brake release solenoid valve when the rotation switch Rotation brake release

4-6
(on Relay board) is operated either at the upper or lower control.
CR7 This relay switches on to energise the leveling forward solenoid valve when the bucket level switch Bucket leveling (Forward)
(on Relay board) is operated to “FORWARD” position either at the upper or lower control.
CR8 This relay switches on to energise the leveling backward solenoid valve when the bucket level Bucket leveling (Backward)
(on Relay board) switch is operated to “BACKWARD” position either at the upper or lower control.
CR9 This relay switches on to energise the unload solenoid valve when the following operations are Unload solenoid valve
(on Relay board) performed.
1) when the dead man switch or the emergency pump switch is operated at the upper control.
2) when the dead man switch is operated at the lower control.
Note: The unload solenoid valve is energised when both of the relays CR9 and CR1 switch on.
CR10 This relay switches on to energise the hydraulic outlet solenoid valve when the hydraulic outlet Hydraulic outlet
(on Relay board) switch is operated at the upper control.
 Electric circuit diagram
Upper control box (329-0022001)

Fig.4-6 Fig.4-7

Connector of the upper control box

1 2

Male, White Male, White

4-7
 Electric circuit diagram 329-0036602A
Upper control box (for the machine with bucket rotation system)

Fig. 4-6-1
Connector of the upper control box

No. 1 No. 2

Fig. 4-7-1
Male, White Male, White

4-7-1
 Lower control box
The lower control box is stored in the right-hand side of the vehicle.
Electric circuit diagram Electric circuit diagram
(for the machine with bucket rotation system)

Fig.4-8

Connector of the lower control box Fig.4-9

1 2

Fig.4-9-1
Male, White Male, White

4-8
 Rotation angle limit syste m
The rotation angle limit system automatically stops the turntable rotation when the
boom is rotated 185 degrees either to clockwise or counter-clockwise direction.
This system consists of the hose cover bolted on the turntable, the lever and the limit
switches installed on the tower as shown in the figure below.
When the boom is rotated 185 degrees clockwise or counter-clockwise, the arm of
hose cover actuates one of the limit switches through the lever to stop the rotating
movements.

When the boom is rotated to the

rear center of the chassis.

When the boom is rotated 185

degrees counter-clockwise.

Fig.4-10

The rotation range is limited within the

area shown in the figure left.

Fig.4-11
4-9
Replacement procedures of limit switches

Removal
1. Remove the bolts A.

2. Remove the plate with the limit switch from

the tower.

3. Remove the limit switches from plate, then

disconnect the connector of the limit
switches.

Installation
1. Install the limit switch by reversing the
removal procedures, paying particular
attention to the following items.

1) Connect the limit switches correctly.

* Limit switch(CW)
Connect to the connector which has
Yellow/Green wire.
* Limit switch (CCW)
Connect to the connector which has
Yellow / Red wire.

2) Install the lever with the long arm side

faced the limit switch as shown in the
figure left.

2. Rotate the boom and make sure that the

movement stops automatically at the rotation
angle of 185 degrees.

Fig.4-12

4-10
Limit switch (171-26015)

Fig.4-13

4-11
 Boom retraction end syste m
The boom retraction end system stops the boom retraction gently when the boom is
fully retracted.
This system consists of the limit switch installed in the tail of the 1st boom, slider
installed on the tail of the 2nd boom and the release switch installed on the tower.
The slider actuates the limit switch just before the boom is fully retracted to cut the
“Telescoping In” signal from the Upper control box.
(The system works when the switch is operated at upper control box only).

Fig.4-14

Fig.4-15

Set the arm at 8 degrees when the limit switch is in neutral before installing.

4-12
Limit switch (5T9-00023-00)

Fig.4-16

4-13
 Relay (for Emergency pump) (320-01207)
This relay supplies power to the emergency pump when the emergency pump switch
is operated either at the upper or lower control.

Fig.4-17

4-14
 5
ELECTLIC CIRCUIT for INDIVIDUAL SYSTEM
Engine control system
Elevation system
Elevation system (for the machine with bucket rotation system)
Telescoping system
Telescoping system (for the machine with bucket rotation system)
Rotation system
Rotation system (for the machine with bucket rotation system)
Bucket leveling system
Bucket leveling system (for the machine with bucket rotation system)
Boom/Engine interlock system

CR14

CR13
Bucket rotation system
Emergency pump system
 6
MAINTENANCE AND ADJUSTMENT
 System pressure adjustment procedures
The relief valves (P1, P2 and P3) are installed on the main control valve.
Relief valve Pre-set pressure Functions
Main relief valve (P1) 175 ~ 180 kg / cm2 limits the Max. hydraulic pressure produced
(2,490 ~ 2,560 PSI) by the hydraulic pump.
Port relief valve (P2) 130 ~ 135 kg / cm2 limits the Max. hydraulic pressure imposed in
(1,850 ~ 1,920 PSI) the bucket levelling system (Forward).
Port relief valve (P3) 130 ~ 135 kg / cm2 limits the Max. hydraulic pressure imposed in
(1,850 ~ 1,920 PSI) the bucket levelling system (Backward).

Fig.6-1

Pressure measurement procedures

1. Set the machine on firm and level ground, then connect the pressure gauge to the G port of
the main control valve shown in the figure above.
2. Warm up the engine, engage the PTO.
3. Operate the boom to warm up the hydraulic oil temperature.
o o
The hydraulic oil temperature should be 30 ~ 40 C (86 ~ 104 F) when adjusting
the relief valves.
4. Retract the boom fully, then operate the boom telescoping switch to IN position to activate
the main relief valve(P1).
5. Read the pressure gauge and make sure that the pre-set pressure of the main relief valve
(P1) is within the specific value.
Specific pre-set pressure ---- 175 ~ 180 kg/cm2 (2,490 ~ 2,560 PSI)
7. Tilt the bucket to fully forward, then operate the bucket level switch to FORWARD
position to activate the port relief valve (P2).
8. Read the pressure gauge and make sure that the pre-set pressure of the port relief valve (P2)
is within the specific value.
Specific pre-set pressure ---- 130 ~ 135 kg/cm2 (1,850 ~ 1,920 PSI)
9. Tilt the bucket fully to backward, then operate the bucket level switch to BACKWARD
position to activate the port relief valve (P3).
10. Read the pressure gauge and make sure that the pre-set pressure of the port relief valve
(P3) is within the specific value.
Specific pre-set pressure ---- 130 ~ 135 kg/cm2 (1,850 ~ 1,920 PSI)

6-2
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, then check the pre-set pressure again and make
sure that the pressure is within the specific value.

Fig.6-2

CAUTION : Do not adjust the system pressure above the specific pre-set pressure.
Excessive pressure will stress the hydraulic system.

6-3
 Lubrication
All pivot and anchor pins of the boom and cylinders are equipped with dry bearings.
These bearings do not need to be lubricated.

Lubricate the turntable bearing monthly.

Supply grease to the turntable bearing through the grease fitting.
Rotate the boom several times and supply grease at each different rotation angle
to equalize the grease.

Recommended grease : Shell alvania grease EP-2

Fig.6-3

6-4
 Maintenance schedule
Maintenance schedule
No Items Monthly After first Annually Parts number of
3 months filters and
for new unit Recommended oil
1 Hydraulic oil Shell Tellus oil 22
(Change)
2 High-pressure Element: G319050020
filter O-ring: G319050009
(Change)
3 Suction filter
(Cleaning)
4 In-line filter 305-0000010
(Change)
5 Gear oil for Shell Omala oil 320
Rotation gear box
(Change)
6 Grease Shell
(Turntable Alvania grease EP2
bearing)

6-5
 Software of adjustment tool
This software is a tool to offer real-time displays of input/output and specify
a parameter when connected between a PC and a PD3 valve controller in use.
Main functions
1. Monitor of switch input
2. Monitor of analog input
3. Monitor of PWM output volume
4. Monitor of PWM feedback status
5. Monitor of error status
6. READ/WRITE of data settings to PD3 controller
7. READ/WRITE of all records to external memory devices
8. File output of all records in the text form
9. Output of remote control signals

1. Start-up of Adjustment Tool

(1) System requirements:
PC capable ---- IBM-PC/AT or 100% compatibles
CPU ------------ Intel 80486 or greater
Memory ------- 3.6 MB or greater
OS -------------- Windows 95 (MS-DOS Full-screen mode) or
higher version 100% compatible
NOTE: Do not open MS-DOS windows more than one at start-up.
(2) Connection:
Connect a communication cable between the PC and the PD3 as shown in Fig. 1.

Fig. 1
(3) Installation:
This software can be used by means of both “Floppy Disc Drive” and
“Hard Disc Drive”.
Copy and paste the following files when using HDD.
*Pd3tv.exe
*G100EN.prm

(4) Start-up:
Insert the adjustment software of INH30A into a floppy disc drive, and then
open MS-DOS Prompt as shown in Fig. 2 & Fig. 3.
NOTE: MS-DOS window must be used in the full screen mode.

6-6
 Fig. 2 Fig. 3
Type in A: as shown in Fig. 4.
NOTE: Type in CD C: PDTOOL (or a filename you named) when
Hard Disk Drive is in use.
Press the Enter key to get to Fig. 5 on display.

Fig. 4 Fig. 5

Type in the words PD3TV G100EN in uppercase as shown in Fig. 6.

Press the Enter key to get to Fig. 7 on display.

Fig. 6 Fig. 7
6-7
2. Monitor 1
When the Adjustment Tool is set up, the Monitor 1 is automatically brought into
effect, or the Monitor 1 is available by pressing F1 key.
It is possible to recognize if the Monitor 1 is active by checking the display.
*The letter [1] in the upper left corner of the screen is shown in green reverse video.
*The function button [Moni 1] is shown in blue reverse video.

Switch input:
Signal name Provision
DI 1 Elevation UP
DI 2 Elevation DOWN
DI 3 Telescope OUT
DI 4 Telescope IN
DI 5 Rotation CW *The yellow reverse video shows
DI 6 Rotation CCW the switch is turned on.
DI 7 Emergency stop

Analog input:
Signal name Provision
AI 1 Input value for Elevation
AI 2 Input value for Telescope
AI 3 Input value for Rotation
*The status of the above signal input and the main power are shown in
the range of 0~1023 A/D values.

6-8
 PWM output volume:
Signal name Provision
VH 1, 2 / VL 1, 2 PWM output for Elevation
VH 3, 4 / VL 3, 4 PWM output for Telescope
VH 5, 6 / VL 5, 6 PWM output for Rotation
*The output volume to the above signals are shown in the current
conversion values of 0 ~ 1700 mA.

PWM feedback status:

Signal name Provision
VH 1, 2 / VL 1, 2 PWM output feedback for Elevation
VH 3, 4 / VL 3, 4 PWM output feedback for Telescope
VH 5, 6 / VL 5, 6 PWM output feedback for Rotation
*The white reverse video shows the load current to the control valve
has been detected.

3. Monitor 2
The Monitor 2 is put into effect by pressing [F2] key on the Monitor screen.
It is possible to recognize if the Monitor 2 is active by checking the display.
*The letter [2] in the middle left side of the screen is shown in green reverse video.
*The function button [Moni 2] is shown in blue reverse video.

6-9
 Inner switch input:
The following status is shown in yellow reverse video when it is active.
*COLD switch on the circuit board (If you reset with this switch being
pressed, all data written on E2PROM will turn to the default value.)
*Signal name TEST (For manufacturer’s use only)
*Signal name JS (Joystick connection)
*Signal name ADJ (Detection of Adjustment Tool connection)

System version: The current version of software is indicated.

Error status: The error code and description are indicated to a maximum of
10 items.
Surveillance item Code Trigger
ROM error ------ ROM checksum error
RAM error ------ RAM READ/WRITE error
Exceptional interrupt ------ Unexpected interrupt to the system
Power source error ------ Source voltage is out of specific range
WDT error ------ Occurrence of inner WDT error
E2PROM error E23 E2PROM READ/WRITE error
A/D error E71 Timeout of inner A/D conversion
Valve status (Elevation) E90 When the valve output for Elevation is detected for more
E91 than 0.5 second even though the switch is held open.
(Telescope) E92 When the valve output for Telescope is detected for more
E93 than 0.5 second even though the switch is held open.
(Rotation) E94 When the valve output for Rotation is detected for more
E95 than 0.5 second even though the switch is held open.
Joystick status (Elevation) E65 Input A/D value from joystick is out of specific range
(Telescope) E66 Input A/D value from joystick is out of specific range
(Rotation) E67 Input A/D value from joystick is out of specific range
Neutral error (Elevation) E62 Elevation switch signal is detected at start-up
(Telescope) E63 Elevation switch signal is detected at start-up
(Rotation) E64 Elevation switch signal is detected at start-up

6-10
4. Alternate Communication
From the monitor screen, Monitor 1 and Monitor 2 communicate alternately by
hitting the function key [F9].
It is possible to recognize if the Alternate Communication is active by checking
the display. (Refer to Fig. 10)
*Both the letter [1] in the upper left corner and [2] in the middle left of the screen
are shown in green reverse video.
*The function button [Alt] is shown in blue reverse video.

6-11
5. Adjustment
The following functions are available on this display.
*READ/WRITE of Record (20 channels) or all Records (4 records) to PD3.
*READ/WRITE of all records to external memory devices.
*File output of all records in the text level.
NOTE: Do not change the values on channel 71~80, as they are for maker’s use only.
The Adjustment is put into effect by pressing [F5] key on the Monitor screen.
The first display on the Adjustment screen shows the initial values of all records,
and [Initial Val.] is indicated at the upper row as shown in Fig. 11.

6-12
READ of Record
Hit the function key [F2] on the Adjustment screen to read one record
from PD3, and [Controller] is indicated at the upper row as shown in Fig. 12.

When you press the function key [F4], all four records are read from PD3,
and it will ask you if you write the data to the file.
If you select [Yes] button, the [File Write] will be performed as described later.

6-13
 Renewal of numerical value (Refer to Fig. 13 & 14.)
The adjustment of the boom operational speed is available on this screen.
If you select [No] button on the previous screen, you have access to this.
*Adjustment procedures of operational speed
1. Hit the function key [F9] twice to get to the item No. 41 ~ 60.
2. Rewrite all numerical values of the item No. 47~52 into zero
for the time being.
(1) Select the No. 47 by the cursor key ( or ), and the line will be
displayed in yellow reverse video.
(2) Type in [0] at the end of the line.
NOTE: Before deleting the current data, take notes of them for later use.
(3) Press the [Enter] key. (The yellow reverse video moves to the lower
line at this moment, so go back to the No. 47 by using the cursor key.)
(4) Press the function key [F3].
(5) Select [Yes] button so that the New data turns to be zero.
(6) Follow the above procedures to change the data of No. 48 ~ 52.
3. Return to the No. 41, and reduce the numerical value till the Elevation UP
movement becomes disabled.
4. Increase the value by tens to find the point where the boom starts moving.
5. Press the function key [F3] to renew the PWM Offset Value.
6. Repeat the same procedures for the No. 42 ~ 46.
7. Return to the No. 47, and input the PWM Max. Value as you took notes.
8. Increase or decrease the value if the actual speed of the Elevation UP
movement measured is out of the specific range.
9. Press the function key [F3] to renew the PWM Maximum Value.
10. Repeat the same procedures for the No. 47 ~ 52 to determine the maximum
operational speed of each movement.

*The new value has been input. *The numerical value has been renewed.

6-14
File Write
It is possible to store all records in the external memory devices.
1. Hit the function key [F7] on the Adjustment screen, and select [Yes] button.
2. Hit the function key [F1] when the Filename selection screen is displayed.
3. Type in a filename or machine’s serial number that is convenient for later
recall with extension [.dat] at the end as shown in Fig. 15.

6-15
Print
It is possible to output all records to the current directory in the text level
of TEMP. PTN as shown in Fig. 16 by hitting the function key [F1] on
the Adjustment screen.
NOTE: It is advisable to put a name on the TEMP.PTN file for later recall
after exiting from this program as the file is rewritten each time you
hit the [F1] Print key.

6-16
6. Remote Output
It is possible to control outputs to the valve from personal computer.
*Remote control procedures
1. Hit the function key [F6] on the Monitor screen to get to the Remote screen
as shown in Fig. 17.
2. Move a yellow reverse video line to which you are going to input data by
the cursor key ( or ).
3. Type in a numerical value in the range of 0 ~ 1700 as shown in Fig. 18.
4. Move a yellow reverse video line to which you are going to output data by
the cursor key ( or ).
5. Hit the function key [F1].
The [>] mark is indicated at the left end when the output is in action.
6. Hit the function key [F2] to stop the single output after selecting each
movement by the cursor key.
7. Hit the function key [F3] to stop all outputs and turn all numerical values into
zero.

6-17
 7
APPENDIX
 Daily inspection procedures
The daily inspections should be performed with the machine being set up on firm and level surface.
Use the chassis manufacturer’s manual to check the chassis.
Unit Item Descriptions
PTO Abnormal noise Start the engine, engage the PTO, and then check for any abnormal noise.
Oil leakage Check for oil leakage.
Indicator lamp Engage and disengage the PTO and check if the PTO indicator lamp goes on
and off properly.
Hydraulic Oil level Stow the outriggers and the boom, and then check for hydraulic level and oil
oil reservoir Oil leakage leakage.
Outriggers, Cracks, Extend all of the outriggers and jacks, and check for cracks and
Jacks deformations deformations.
Abnormal nose, Operate the outriggers and jacks and check for any abnormal noise and
movements movements.
Oil leakage Check the outrigger control valve, outrigger cylinders and jack cylinders for
oil leakage.
Natural descent Extend all of the jacks to support the machine by jacks, and then check if the
jack cylinders retract naturally.
Turntable Cracks, Check the turntable for cracks and deformations.
deformations
Abnormal noise, Rotate the turntable, and check for any abnormal noise and movements.
movements
Boom, Fly Crack, Extend the boom fully and check each boom section and the fly jib for
jib deformation cracks and deformations.
Boom and Fly Check the pivot pins for any damage.
jib pivot pins
Abnormal noise, Raise, lower, telescope the boom and the fly jib and check for any abnormal
movements noise and movements.
Oil leakage Check the hydraulic cylinders for oil leakage.
Natural descent Elevate the platform and check if the elevation, telescope and fly jib
cylinders retract or extend naturally.
Platform Cracks, Check the platform and the platform rotation device for cracks and
deformations deformations.
Abnormal noise, Rotate the platform and check for any abnormal noise and movements.
movements
Oil leakage Check the platform levelling cylinders and the platform rotation motor for
oil leakage.
Platform Raise and lower the boom several times and check if the platform stays
levelling system level.
Crane Winch rope and Check winch rope and hook for any damages.
(Option) hook
Sub-boom Check the sub-boom for any damages.
Abnormal nose, Operate the winch and check for any abnormal noise and movements.
movements
Oil leakage Check the winch motor and hydraulic hoses for oil leakage.
Engine Cooling system Check the cooling water level.
power unit Check the cooling system for water leakage.
(Option) Lubrication Check the engine oil level.
system Check the engine for oil leakage.
Battery Battery Check the electrolyte level.
power unit Check if the batteries are fully charged.
(Option) Check the battery terminals for any damages.
Check the battery for electrolyte leakage.

8-1
 Unit Item Descriptions
Safety Interlock system Check the jack and the boom interlock systems for any abnormal functions.
devices. Emergency stop Operate the emergency stop switches or levers and check if all of the
system movements are disabled.
Emergency Operate the machine using the emergency pump and check if the machine
pump moves properly.
Moment limiter, Operate the boom and check the functions of the load moment limiter.
Work range limit Operate the boom and check the functions of the work range limit system.
system
Pre-start check Perform the pre-start check using the pre-start check switch and check for
system any abnormalities.
Other safety Check the functions of other safety devices.
devices
Other Engine start/stop Operate the engine start and stop switches and check if the engine starts and
devices. system stops properly.
Accelerator Operate the accelerator switch or knob and check for the functions.
Outrigger Extend and retract the outriggers and check if the outrigger indicator lamps
extension turn on and off corresponding to the extended length of each outrigger.
indicator
Boom automatic Operate the boom automatic storage switch and check if the boom is stowed
storage system onto the boom rest properly.
Boom Operate the boom near the cabin or outriggers and check if the boom
interference movement stops before hitting the cabin or outriggers.
limit system
Jack automatic Operate the jack automatic set-up switch and check if all of the jacks are set
set-up system up or stowed properly.
Auxiliary Check if the auxiliary battery located at the platform is fully charged.
battery Check if the spare battery is fully charged.
Horizontal and Operate the boom with selecting the horizontal and vertical control mode
vertical control and check if the platform moves horizontally and vertically.
Other devices Check the functions of other devices.
Decals Readability Check the decals for readability.

8-2
 Daily inspection check sheet
Unit Item Results
Date
PTO Abnormal noise
Oil leakage
Indicator lamp Function
Damage
Hydraulic Oil level, Oil leakage
oil reservoir
Outriggers Cracks, deformations
Abnormal noise, movements
Oil leakage
Jack cylinder Natural
descent
Turntable Cracks, deformations
Abnormal noise, movements
Boom, Cracks, deformations
Fly jib Boom pivot pins Damage
Abnormal noise, movements
Oil leakage
Elevation Natural
cylinder descent
Telescope Natural
cylinder descent
Fly jib Natural
cylinder descent
Platform Cracks, deformations
Abnormal noise, movements
Oil leakage
Platform Function
levelling system
Crane Winch rope Damage
(Option) Hook Damage
Sub-boom Damage
Abnormal noise, movements
Oil leakage
Engine Cooling Water level
power unit system Water leakage
(Option) Fan Tension
belt Damage
Lubrication Oil level
system Oil leakage
Battery Battery Electrolyte
power unit level
(Option) Charged level
Damage
on terminals
Electrolyte
leakage
Safety Interlock Function
devices Emergency stop Function
Emergency Function
pump
Moment limiter Function
Work range limit Function
Pre-start check Function
Others Function

8-3
 Unit Item Results
Other Engine start/stop Function
devices Accelerator Function
Outrigger Function
extension
indicator
Boom automatic Function
storage
Boom Function
interference limit
Jack automatic Function
set-up
Auxiliary Charged
battery level
Horizontal Function
vertical control
Others Function
Decals Readability

Remarks

8-4
 Procedures of Periodical inspection
Perform the periodical inspection with the machine being set on firm and level surface.
Carry out the both descriptions of monthly and annual inspections when performing annual inspections.
Use the chassis manufacturer’s manual for checking the chassis.
Unit Item Monthly inspections Annual inspections
PTO Oil level, Check the oil level, contamination
contamination. and replenish or change oil, if
necessary.
Oil leakage. Check for oil leakage thoroughly.
Abnormal noise. Start the engine, engage the PTO
and check for abnormal noise.
Loose Check each bolt and nut for
bolts and nuts looseness.
Indicator lamp. Engage and disengage the PTO,
and check if the PTO indicator
lamp turns on and off properly.
Hydraulic Oil level, Check the oil level and replenish, Check the oil for contamination and
oil reservoir contamination. if necessary. change the oil, if necessary.
Oil change interval:
Every 1,200 hours or one year.
Oil leakage. Check for oil leakage thoroughly.
Hydraulic Oil leakage. Check for oil leakage thoroughly.
filters Replacement Replace the filter element.
Replacement interval:
Every 1,200 hours or one year.
Pump drive Loose Check each bolt and nut for
shaft and bolts and nuts looseness.
coupling Wear, deformation Check the drive shaft and the
coupling for wear and
deformation.
Lubrication Check for lubrication.
Hydraulic Loose Check the pump mounting bolts
pump bolts and nuts and nuts for looseness.
Abnormal noise Start the engine, engage the PTO
and check for abnormal noise.
Oil leakage Check for oil leakage.
Chassis Cracks, Check the chassis frame and the
frame, deformation sub-frame for cracks and
Sub-frame deformations.
Sub-frame Check each bracket for cracks and
mounting bracket deformation.
Sub-frame Check each bolt and nut for
mounting bolts and looseness.
nuts
Counter weight Check the counter weight
mounting brackets, bolts, and nuts
for any damage.
Outriggers, Cracks, Extend all of the outriggers and
Jacks deformation, wear the jacks and check for cracks,
deformation and wear.
Lubrication Check the outrigger arms and the
jack posts for lubrication.
Oil leakage Check for oil leakage.

8-5
 Unit Item Monthly inspections Annual inspections
Outriggers Natural descent Extend all of the jacks, support the
jacks machine by the jacks, and then
check the jack cylinders for natural
descent.
Serviceable limit:
1 mm (0.04 in)/10 min.
Rotation Loose Check each mounting bolt and nut
bearing bolts and nuts for looseness.
Wear, cracks Check the rotation bearing for
excessive wear and cracks.
Lubrication Check for lubrication.
Rotation Loose Check each mounting bolt and nut
gearbox bolts and nuts for looseness.
Oil leakage Check for oil leakage.
Lubrication Check the gear oil level and Change gear oil.
replenish, if necessary. Oil change interval:
Every 1,200 hours or one year.
Backlash Check the backlash between the pinion
of the rotation gearbox and the ring
gear of the rotation bearing.
Standard backlash: 0.6 mm (0.024 in)
Abnormal Rotate the turntable and check for
noise, movements abnormal noise and movements.
Turntable Cracks, deformation Check the turntable for cracks and
deformations.
Loose Check each bolt and nut for
bolts and nuts looseness.
Swivel Loose Check each bolt and nut for
joint bolts and nuts looseness.
Oil leakage Check for oil leakage.
Lubrication Check for lubrication.
Boom, Cracks, deformation Extend the boom and check for
Fly jib cracks and deformations.
Loose Check each bolt and nut for
bolts and nuts looseness.
Oil leakage Check for oil leakage.
Lubrication Check for lubrication and
lubricate, if necessary.
Extension/retraction Check each wire rope for any Check the tension on each wire rope.
wire ropes damage.
Electric cables, Check the tension on each electric
Photo fiber cable cable and photo fiber cable.
Wear pads Check each wear pad for wear.
Abnormal Raise, lower, telescope the boom
noise, movement and check for abnormal noise and
movements.
Natural descent Check the elevation, telescope and
fly jib cylinders for natural
descent.
Serviceable limit:
2 mm (0.08 in)/10 min.
Platform Cracks, deformation Check the platform and its
mounting bracket for cracks and
deformations.
Loose Check each bolt and nut for
bolts and nuts looseness.
Oil leakage Check for oil leakage.

8-6
 Unit Item Monthly inspections Annual inspections
Platform Abnormal Rotate the platform and check for
noise, movement abnormal noise and movements.
Platform levelling Raise and lower the boom and
system check if the platform stays level.
Crane Winch rope Check the winch rope for any
damage.
Hook Check the hook for cracks and
deformation.
Loose Check each bolt and nut for
bolts and nuts looseness.
Winch gearbox Check the gear oil level, and Change gear oil.
replenish, if necessary. Oil change interval:
Every 1,200 hours or one year.
Sub boom Check the sub boom for cracks
and deformations.
Oil leakage Check for oil leakage.
Abnormal Operate the crane and check for
noise, movements abnormal noise and movements.
Engine Engine oil Check the engine oil and replenish
power unit or change, if necessary.
(Option) Oil filter Check the oil filter and replace, if
necessary.
Oil leakage Check for oil leakage.
Cooling water Check the cooling water and
replenish or change, if necessary.
Water leakage Check for water leakage.
Fan belt Check the fan belt for wear and
tension.
Radiator hose Check each radiator hose for any
damage.
Air cleaner Check the air cleaner and clean or
replace, if necessary.
Fuel filter Check the fuel filter and replace, if
necessary.
Loose Check each bolt and nut for
bolts and nuts looseness.
Hydraulic pump Check for oil leakage.
Abnormal Operate the machine using the
noise, functions engine power unit and check for
any abnormal noise and functions.
Battery Battery Check electrolyte level and Check the electrolyte for specific
power unit replenish, if necessary. gravity.
(Option) Specific gravity: 1.26 ~ 1.28 (at 20 )
Check the battery for cracks and
electrolyte leakage.
Check each battery terminals for
any damage.
Check the battery tie-down bolts
and nuts for looseness.
Battery charger. Charge the battery and check for
any abnormal functions.
DC motor Check the brushes for wear.
Hydraulic pump Check for oil leakage.
Loose Check each bolt and nut for
bolts and nuts looseness.
Abnormal Operate the machine by the battery
noise, functions power unit and check for any
abnormal noise and functions.

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 Unit Item Monthly inspections Annual inspections
Relief Pre-set Check each relief valve setting pressure and
valves pressure make sure that the pressure is within the
specific range.
Control Control Check each control switch, lever and
panels switches, joystick controller for any damage.
levers,
Operate each control switch, lever
Joystick
and joystick controller and make sure
controllers
that it works properly.
Indicator Check each indicator lamp for any
lamps damage.
Check if each indicator lamp turns on
and off properly.
Safety Jack interlock 1. Stow the boom onto the boom rest.
devices system 2. Extend the jacks, make all of the
jacks contact with ground, and then
make sure that the jack ground
contact lamp goes on.
3. Retract one of the jacks until the
jack ground contact lamp goes off,
and then make sure the boom does
not rise from the boom rest.
Boom 1. Raise the boom from the boom
interlock rest.
system 2. Operate the jacks and make sure
that the jacks do not move.
Emergency Operate the emergency stop switches
stop system or levers and make sure that all of the
functions are disabled.
Emergency Operate the machine using the
pump emergency pump and make sure that
the machine moves properly.
Moment Operate the boom and make sure that Measure each work radius of the platform
limiter the moment limiter works properly. and make sure that the work radius is within
the specific range.
Work range Operate the boom and make sure that Measure each work radius of the platform
limit system the work range limit system works and make sure that the work radius is within
properly. the specific range.
Pre-start Conduct the pre-start check using the
check system pre-start check switch and check for
any abnormalities.
Other Check the functions of other safety
safety devices devices and make sure that they work
properly.
Other Engine Operate the engine start and stop
devices start/stop switches on the upper and the lower
system control panels and make sure that the
engine starts and stops properly.
Accelerator Operate the accelerator switch or
knob and make sure that the
accelerator works properly.
Outrigger Extend and retract each outrigger and
extension make sure that the outrigger
indicator extension indicator lamps turn on and
off properly corresponding to the
extended length of each outrigger.

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 Unit Item Monthly inspections Annual inspections
Other Boom Operate the boom automatic storage
devices automatic switch and make sure that the boom
storage is stowed on the boom rest properly.
system
Boom Operate the boom near the cabin or
interference the outriggers and make sure that the
limit system boom movement stops before hitting
the cabin or outriggers.
Jack Operate the jack automatic set-up
automatic switch and make sure that all of the
set-up system jacks are set up or stowed properly.
Auxiliary Check the auxiliary batteries for any
battery damage.
Check the auxiliary battery charging
system and make sure the system
works properly.
Hydraulic Check the hydraulic outlets for oil Check the pre-set pressure of the hydraulic
outlets leakage and any damage. outlets and make sure that the pressure is
within the specific range.
AC power Check the AC power outlets for any
outlets damage.
Hydraulic Check the ultra-high pressure hose Check the output pre-set pressure of the
booster for any damage. hydraulic booster and make sure that the
pressure is within the specific range.
Operate the hydraulic booster and
check for oil leakage and its
functions.
Other devices Check the other devices for damages
and functions
Decals Readability Check all of the decals for readability
and any damage.

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 Withstand voltage tests
Perform the withstand voltage tests on the insulated buckets and bucket liners.
For the test methods and the test interval, check the national or local regulations.
If no national or local regulation is available, conduct the withstand voltage tests every 6
months by applying the specific withstand voltage to the bucket and the bucket liner for 10
minutes.

Function tests
Conduct the function tests annually with the machine being set on firm and level surface.
Test Item Descriptions
Load test Damage, 1. Extend all of the outriggers fully, extend the jacks and make sure that all of the
function, jacks have made firm contact with the ground.
Abnormal 2. Load the platform with the rated load, operate the boom thoroughly from the
noise lower control and make sure that the boom moves smoothly without any
abnormal noise.
Caution: Do not allow any person on the platform.
3. Check the machine thoroughly and make sure that no damage is on the machine.
Load test Damage, 1. Extend all of the outriggers fully, extend the jacks and make sure that all of the
on optional function, jacks have made firm contact with the ground.
crane abnormal 2. Set up the crane, load the crane with the rated lifting weight, raise and lower the
noise, load several times and make sure the crane works smoothly without any
natural abnormal noise.
descent 3. Leave the crane with the rated weight loaded, and make sure that the load does
not descend.
Speed test Boom 1. Step on the platform and retract the boom fully.
elevation (Only one person on the platform.)
speed 2. Raise and lower the boom to its full stroke, measure the boom rising and the
lowering speed (seconds/stroke) and make sure that the speed is within the
specific range.
Boom 1. Step on the platform and raise the boom fully.
telescope (Only one person on the platform.)
speed 2. Extend and retract the boom to its full stroke, measure the boom extending and
the retracting speed (seconds/stroke) and make sure that the speed is within the
specific range.
Boom 1. Step on the platform, retract the boom fully, and then raise it fully.
rotation (Only one person on the platform.)
speed 2. Rotate the turntable 360 degrees CW and CCW, measure the rotation speed
(seconds/stroke) and make sure that the speed is within the specific range.
Platform Step on the platform, rotate the platform CW and CCW, measure the platform
rotation rotation speed (seconds/stroke), and make sure that the speed is within the specific
speed range. (Only one person on the platform.)
Fly jib 1. Step on the platform and retract the boom fully.
speed (Only one person on the platform.)
2. Raise and lower the fly jib to its full stroke, measure the fly jib rising and the
lowering speed (seconds/stroke) and make sure that the speed is within the
specific range.

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 Periodical inspection check sheet
Model Spec No. Serial No. Hour meter Date Inspector

The items marked (*) should be inspected only on the annual inspections.
Unit Item Results Remarks
PTO Oil level, contamination leakage
Oil leakage
Abnormal noise
Loose bolts and nuts
Indicator lamp
Hydraulic Oil level, contamination Oil change interval:
oil reservoir Oil leakage 1,200 hours or one year.
Hydraulic Oil leakage Replacement interval:
filters Replacement 1,200 hours or one year.
Pump Loose bolts and nuts
drive shaft and Wear, deformations
coupling Lubrication
Hydraulic Loose bolts and nuts
pump Abnormal noise
Oil leakage
Chassis frame, Cracks, deformation
Sub-frame Sub-frame mounting Cracks,
brackets deformations
Sub-frame mounting Looseness
bolts and nuts
Counterweight anchor Looseness
bolts, nuts
Outriggers, Cracks, deformations
Jacks Lubrication
Oil leakage
Jack cylinder Natural descent
Rotation Loose bolts and nuts
bearing Wear, cracks
Lubrication
Rotation Loose bolts and nuts Gear oil change interval:
gearbox Oil leakage Every 1,200 hours or one year.
Lubrication
(*) Backlash between pinion and ring
gear (Backlash: 0.6 mm, 0.024 in)
Abnormal noise, movements
Turntable Cracks, deformations
Loose bolts and nuts
Swivel joint Loose bolts and nuts
Oil leakage
Lubrication
Boom, Fly jib Cracks, deformations
Loose bolts and nuts
Oil leakage
Lubrication
Extension/retraction Damage
wire ropes (*) Tension
Electric cables, (*) Tension
Photo fiber cable
Wear pads (*) Wear
Abnormal noise, movements

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 Unit Item Results Remarks
Boom, Fly jib Elevation cylinder Natural descent Serviceable limit of natural descent:
Telescope cylinder Natural descent 2 mm (0.08 in)/10 min.
Fly jib cylinder Natural descent
Platform Cracks, deformations
Loose bolts and nuts
Oil leakage
Abnormal noise, movements
Platform Function
levelling system
Crane Winch rope Damage Gear oil change interval:
Hook Cracks, deformations Every 1,200 hours or one year.
Winch gearbox Oil level
Sub boom Cracks deformations
Loose bolts and nuts
Oil leakage
Abnormal noise, movements
Engine Engine oil level, contamination
power unit Replacement of oil filter
(Option) Oil leakage
Cooling water level, contamination
Water leakage
Fan belt Wear, tension
Radiator hoses Damage
Air cleaner Blockage
Fuel filter Replacement
Hydraulic pump Oil leakage
Loose bolts and nuts
Abnormal noise, function
Battery Batteries Electrolyte Level Specific gravity of electrolyte:
power unit Leakage 1.26 ~ 1.28 (at 20 )
(Option) (*) Gravity
Damage on terminals
Looseness of tie-down bolts
and nuts
Battery charger Function
DC motor (*) Wear of brushes
Hydraulic pump Oil leakage
Loose bolts and nuts
Abnormal noise, functions
Relief valves (*) Pre-set pressure
Control panels Control switches, Damage
levers, Joystick
controllers Functions
Indicator lamps Damage
ON/OFF conditions
Safety devices Jack interlock system Function
Boom interlock system Function
Emergency stop system Function
Emergency pump Function
Moment limiter Function
(*) Work radius
Work range limit Function
System (*) Work radius
Pre-start check system Function
Other safety devices Function

8-12
 Unit Item Results Remarks
Other devices Engine start/stop system Function
Accelerator Function
Outrigger extension ON/OFF
indicator conditions
Boom automatic storage Function
system
Boom interference limit Function
system
Jack automatic set-up Function
System
Auxiliary Damage
battery Functions of
Battery charge system
Hydraulic Oil leakage, damage
outlets
(*) Pre-set pressure
AC power Damage
outlets
Hydraulic Damage on ultra-high
booster pressure hose
(*) Pre-set pressure
Other devices Damage, function
Decals Readability

Withstand voltage tests check sheet

Function tests check sheet

Test Item Results Remarks
Load test Function
Abnormal noise
Damage
Load test Function
on optional crane Abnormal noise
Natural descent
Damage
Speed test Boom elevation Up
Down
Boom telescope Out
In
Boom rotation CW
CCW
Platform rotation CW
CCW
Fly jib Up
Down

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Major alterations and repairs

8-14