Publication No. AW-160SX-1/C1-1E 01 Aerial Platform Model AW-160SX-1 AW-210SX-1 Applicable Serial No. : AW-160SX 260063 and onwards Applicable Serial No. : AW-210SX 265012 and onwards
Introduction Introduction The hydraulic and electrical circuit diagrams are collected in this manual for the Model AW-160SX-1, AW-210SX-1 Super Deck aerial platform. Read the separate service manual, operation and maintenance manual and the parts catalogue for additional indispensable information on the serial platform in conjunction with this manual. This manual applies to the aerial platform with the Spec. No. given below. Check the Spec. No. of your aerial platform in the nameplate on the aerial platform. Check the disassembly parts delivery units in PARTS CATALOGUE first when the parts need to be replaced. 1. Applicable spec. No. SPEC. NO. SERIAL. NO. MFG.DATE. KAGAWA, JAPAN ISA04-001601 Spec. No. Applicable serial No. AW-160S-1-80201 AW-210S-1-80201 260063~ 265012~ We reserve the right to modify the design without Notice for improvements, etc. 1 WA04-0870E
Contents 2. Contents Chapter Item AW-160S-1-80201 Data, Adjustment & Checks Spec. No. AW-210S-1-80201 Service Data Y-1 Adjustment(Hydraulic) Y-2 Y Adjustment(Electric) Y-3 Adjustment and Function and Confirmation Y-4 Inspection and Procedure Y-5 System Diagrams Hydraulic Circuit Z-1 Electric Circuit Upper Z-2 Lower Z-3 Boom Z-4 Hydraulic Component Location Deck Z-5 Swing Frame Z-6 Z Frame Z-7 Boom Z-8 Detection Z-9 Electric Component Location Deck Z-10 Swing Frame Z-11 Frame Z-12 2 WA04-0870E
Y Data, Adjustment & Check 目 次 Service Data... 1 1. Specifications... 1 2. Weight table... 2 Adjustment (Hydraulic)... 3 1. Pressure adjustment on valves... 3 2. Measurement ports... 4 Adjustment (Electric)... 5 1. Boom rest adjustment... 5 2. Deck stopper adjustment... 6 3. Deck section level gauge adjustment... 7 Adjustment and Function and Confirmation... 8 3. Adjusting clearances...10 3.1 Steering assembly... 10 3.2 Axle assembly... 11 3.3 Radiator assembly... 12 4. Swing speed reducer installation and adjustment...13 4.1 Swing assembly (Swing frame)... 13 4.2 Swing assembly (Deck swing)... 14 Inspection and Procedure...15 1. Emergency procedure...15 1.1 If the Vehicle engine or hydraulic pump Fails... 15 1.2 When boom and platform cannot be stowed... 15 1.3 Towing the aerial platform... 16 2. Interval of maintenance and replacement...17 2.1 Overhaul of the hydraulic cylinders every 4 years... 17 2.2 Interval for inspecting and replacing the wire rope for boom telescoping... 17 2.3 Hydraulic hoses replacement... 19 1. Engine speed(pump revolution) adjustment... 8 2. Engine coupling adjustment... 9 Y i
Y-1 Y-1 Service Data Service Data 1. Specifications Name Item Spec. No. AW-160S-1-80201 AW-210S-1-80201 V3300-EB Engine Model Rated output Maximum torque Vertical water-cooled 4-cycle diesel 49.3kw(67.0ps) / 2400rpm 217.4N m(22.2kgf m) / 1400~1600rpm Variable piston pump No.1 35cm 3 / rev Gear pump Displacement No.2 15.9cm 3 / rev Emergency pump No.1 No.2 3.46cm 3 / rev 1.66cm 3 / rev Speed reducer section Reduction ratio 1/42 Hydraulic unit Swing unit Output torque(maximum) 2120N m(216kgf m) Lubrication Oil level Approx. 1.9L oil Brand Mobil Gear 632 Hydraulic motor section Displacement 39.3cm 3 / rev Speed reducer section Reduction ratio 1/12 Output torque(maximum) 725N m(74.0kgf m) Deck swing unit Lubrication oil Oil level 0.52L Brand Mobil Gear 632 Hydraulic motor section Displacement 25.0cm 3 / rev 1 WY01-0390E
Y-1. Service Data Y-1. 2. Weight table The approximate weights of main components are shown in the table below. When dismounting and remounting parts, select appropriate hoisting equipment in Accordance with the indicated weights. kg No. 1 Parts name Boom assembly(including telescoping cylinder, wiring and piping) Spec. No. AW-160S-1-8021 AW-210S-1-80201 959 1,604 2 Deck assembly(including control box for rotary jyoint(deck)) 445 3 Deck swing unit(including hydrauic motor) 28 4 Swing bearing(for deck) 31 5 Swing unit(including hydrauic motor) 47 6 Swing bearing 77 7 Elevating cylinder(including counterbalance valve) 149 161 8 Leveling cylinder(including counterbalance valve) 56 60 9 Rotary joint 70 10 Deck frame assembly 76 11 Swing frame assembly(including wiring and piping) 3,098 3,100 12 Steering cylinder(including wiring and piping) 19 13 Axle(For front)(per 1 piece) 141 14 Axle(For rear)( Per 1 piece) 90 15 Wheel(Per 1 piece) 186 16 Solenoid control valve 56 17 Lower frame(including wiring and piping) 4,712 18 Variable piston pump(including gear pump) 32 19 Emergency pump 11 20 Engine and its related components [NOTICE] The indicated weights do not include the weight of hydraulic oil. 2 WY01-0390E
Y-2 Y-2 Adjustment (Hydraulic) Y-2 Adjustment (Hydraulic) 1. Pressure adjustment on valves 3 WY02-0090E 3
Y-2. Adjustment (Hydraulic) Y-2. Y-2. 2. Measurement ports 4 WY02-0090E 4
Y-3 Y-3 Adjustment (Electric) Y-3 Adjustment (Electric) 1. Boom rest adjustment 5 WY04-0300E 5
Y-3 Y-3 Adjustment (Electric) Y-3 2. Deck stopper adjustment 6 WY04-0300E 6
Y-3. Adjustment (Electric) Y-3. 3. Deck section level gauge adjustment 7 WY04-0300E
Y-4 Y-4 Adjustment and Function and Confirmation Y-4 Adjustment and Function and Confirmation 1. Engine speed(pump revolution)adjustment 8 WY05-0280E 8
Y-4 Y-4 Adjustment and Function and Confirmation Y-4 2. Engine coupling adjustment 9 WY05-0280E 9
Y-4 Y-4 Adjustment and Function and Confirmation Y-4 3. Adjusting clearances 3.1 Steering assembly 10 WY05-0280E 10
Y-4 Y-4 Adjustment and Function and Confirmation Y-4 3.2 Axle assembly 11 WY05-0280E 11
Y-4 Y-4 Adjustment and Function and Confirmation Y-4 3.3 Radiator assembly 12 WY05-0280E 12
Y-4 Y-4 Adjustment and Function and Confirmation Y-4 4. Swing speed reducer installation and adjustment 4.1 Swing assembly (Swing frame) 13 WY05-0280E 13
Y-4 Y-4 Adjustment and Function and Confirmation Y-4 4.2 Swing assembly (Deck swing) 14 WY05-0280E 14
Y-5 Y-5 Inspection and Procedure Inspection and Procedure 1. Emergency procedure WARNING It is very dangerous to operate a defective aerial platform. Immediately after performing an emergency procedure due to a failure of the aerial platform, contact your nearest TADANO distributor or dealer for inspection and maintenance. 1.1 If the vehicle engine or hydraulic pump fails [NOTICE] Continuously operating the emergency pump over a long period of time may cause a failure. Be sure not to operate the emergency pump for more than 30 seconds. Also, before starting up the pump again, pause for at least 30 seconds. Controls 1.2 When boom and platform cannot be stowed WARNING Turning ON the emergency switch resets the stop functions of the AMC system. Therefore, erroneous operation in this condition may cause the machine to overturn. Use this switch in case of an emergency only. Before using the emergency switch, retract the boom fully, and then move the platform toward a safe working area. [NOTICE] During boom swing and travelling operations, the swing frame and the machine body move. Operate the machine slowly with attention to your footing. If all operations are disabled after an operator on the platform press the stop switch, the platform cannot be lowered by normal operation at the lower controls. Upper controls Lower controls Emergency pump switch ON Also, in case of an AMC or electrical system failure, operations of the aerial platform may be disabled. In such conditions, perform the following procedure to rescue the personnel from the platform and stow the aerial platform. IWY05-0290E01 Lower Controls Lower the platform by operating the control switches while holding the emergency pump switch to the ON side. Upper Controls Lower the platform by depressing the foot switch and operating the control switches or levers while operating the emergency pump switch to the ON side. 15 WY05-0290E
Y-5 Y-5 Inspection and Procedure Controls Right swing (platform swing) Right swing (boom swing) Extend (boom telescoping) Raise (boom elevation) Forward (travelling) Emergency switch Left Emergency switch Emergency steering switch Right 1.3 Towing the aerial platform WARNING During a towing operation, the motor lock (travel brake) cannot be activated. Do not perform a towing operation on a downhill slope where the aerial platform may travel spontaneously. Perform the towing operation on a level ground. After completion of a towing operation, return the motor to locked condition immediately. Operation Emergency steering switch Backward (travelling) Lower (boom elevation) Retract (boom telescoping) Left swing (boom swing) Left swing (platform swing) IWY05-0290E02 1. Open the cover of the emergency controls located at the right of the swing frame. 2. Press and hold the emergency switch. Make sure that the starter switch of the lower controls is set to ON. 3. Stow the aerial platform by operating the manual control lever. [NOTICE] If a towing operation is continued for a long time at a high speed, the travelling unit (reduction gear) may become abnormally hot. To prevent this, observe the following instructions during towing operations. The towing speed should be approximately equal to walking speed (approx. 3 km/h). Continuous towing should not exceed 10minutes. After a towing operation, take a pause for approx. 20 minutes, then re-start the towing operation. 1. Install the aerial platform on a level ground, and make sure that no torque is applied to the tires. 2. Chock the tires. If steering operation is required, use the emergency steering switch. 16 WY05-0290E
Y-5 Y-5 Inspection and Procedure 3. Turn over the cap centered on each driving wheel motor (front, rear, right and left) to set the motor free. Cap Motor locked Motor free 2. Interval of maintenance and replacement 2.1 Overhaul of the hydraulic cylinders every 4 years TADANO recommends that the hydraulic cylinders Should be overhauled every 4 years in addition to Monthly and annual inspections. When overhauling the hydraulic cylinders, replace every consumable part, including oil seals and O-rings. 2.2 Interval for inspecting and replacing the wire rope for boom telescoping 1. Inspection interval Every 4 years Cap IWY05-0290E03 4. Using the towing hook provided at the front or rear of the machine frame, tow the aerial platform with thorough attention to the surrounding conditions. 5. After completion of a towing operation, return the caps to the original orientation to set the motor locked. Inspect the wire rope for boom telescoping every 4 years.(inspect the wire rope when disassembling the boom in order to overhaul the telescoping cylinder.) 2. Replacement interval Every 10 years or when the wire rope is deteriorated Replace the wire rope if any of the following condition are met. 1) It has been used for more than 10 years. 2) The inspection has shown the wire rope to be in any of the following conditions: (1) Ten percent or more of the wires(expept filler wires) in a lay are broken. (The criteria are explained using the illustrations below, based on a standard wire rope consisting of six strands.) Core Wire Strand Filler wire IWY05-0290E04 17 WY05-0290E
Y-5 Y-5 Inspection and Procedure Length of 1 lay 1 2 3 4 5 6 IWY05-0290E05 (2) The diameter of the wire rope is reduced by more than 7 % of the nominal diameter. (4) A badly deformed or corroded wire rope. (A badly deformed wire rope refers to one whose strands are caved in or are loosened < i.e. bird caged > as shown, or whose core is exposed. A corroded wire rope refers to one which has evident pittings on the wire surfaces, or where corrosion has extended to the inside of the rope.) Diameter IWY05-0290E08 IWY05-0290E06 (3) A kinked wire rope(refers to a rope used in a looped state as shown in [1], which become knotty as in [2], [3] and [4] after use.) (5) A wire rope damaged by heat, burns or sparks. (6) A wire rope with a tip cracked, deformed or extremely corroded on either end. [1] [2] [3] [4] IWY05-0290E07 18 WY05-0290E
Y-5 Y-5 Inspection and Procedure 2.3 Hydraulic hoses replacement 1. General Every 4 years 2. Inside boom Every 5 years 3. On platform Every 3 years Replace the hydraulic hoses regularly. To find out replacement period, see the stamping on the hose-end fitting representing the date of caulking. The stamps differ depending on the hose manufacturers as shown below. BRIDGESTONE FLOWTECH-made hoses Location of stamping YOKOHAMA RUBBER-made hoses Location of stamping : 12 05 Meaning May (month code) Meaning the year (year code) IWY05-0290E10 : Code of month of caulking : Z 16 F 9 Jan. : 01 Jul. : 07 Feb. : 02 Aug. : 08 Meaning 1999 (The figure on the right-most place of the year of caulking is indicated.) Factory code (F: Fukuoka, H: Hyogo) Meaning date of 16th (date code) Meaning December (month code) IWY05-0290E09 Mar. : 03 Sep. : 09 Apr. : 04 Oct. : 10 May. : 05 Nov. : 11 Jun. : 06 Dec. : 12 : Code of month of caulking Jan. : 1 Jul. : 7 Feb. : 2 Aug. : 8 Mar. : 3 Sep. : 9 Apr. : 4 Oct. : X May. : 5 Nov. : Y Jun. : 6 Dec. : Z : Code of month of caulking 1991. : 3 1996. : 8 1992. : 4 1997. : 9 1993. : 5 1998. : 10 1994. : 6 1999. : 11 1995. : 7 2000. : 12 19 WY05-0290E
Y-5 Y-5 Inspection and Procedure TOKAI RUBBER INDUSTRIES-made hoses Location of stamp 1 (Stamp 2 is on the opposite side.) NITTA MOORE-made hoses : Code of month of caulking Location of stamp 1 (Stamp 2 is on the opposite side.) Stamp 1 : 9 Stamp 2 : Z 16 Meaning 1999 (The figure on the right-most place of the year of caulking is indicated.) Meaning date of 16th (date code) Meaning December (month code) IWY05-0290E11 Stamp 1 : C 8 Stamp 2 : Meaning 1998 (The figure on the right-most place of the year of caulking is indicated.) Meaning March (month code) Factory code (shown in alphabet) A IWY05-0290E12 : Code of month of caulking Jan. : 1 Jul. : 7 Feb. : 2 Aug. : 8 Mar. : 3 Sep. : 9 Jan. : A Feb. : B Mar. : C Jul. : G Aug. : H Sep. : I Apr. : 4 Oct. : X Apr. : D Oct. : J May. : 5 Nov. : Y May. : E Nov. : K Jun. : 6 Dec. : Z Jun. : F Dec. : L 20 WY05-0290E
Z System Circuit 目 次 Hydraulic Circuit... 1 Electric Circuit (Upper)... 2 Electric Circuit (Lower)... 3 Hydraulic Component Location (Boom)... 4 1. For 160SX... 4 2. For 210SX... 5 Hydraulic Component Location (Deck)... 6 1. For 160SX... 6 2. For 210SX... 7 Hydraulic Component Location (Swing Frame)... 8 1. Swing frame (1)... 8 1.1 For 160SX... 8 1.2 For 210SX... 9 Electric Component Location (Boom)... 15 1. For 160SX... 15 2. For 210SX... 16 Electric Component Location (Detection)... 17 1. For 160SX (Parts assembly electric1,2)... 17 2. For 210SX (Parts assembly electric 1,2)... 19 Electric Component Location (Deck)... 21 Electric Component Location (Swing Frame)... 22 Electric Component Location (Frame)... 23 2. Swing frame (2)... 10 3. Swing frame (3)... 11 Hydraulic Component Location (Frame)... 12 1. Frame (Front)... 12 2. Frame (Rear)... 13 3. Frame (Brake)... 14 Z i
Z-1. Hydraulic Circuit Z-1. Z-1. Hydraulic Circuit 444-009-10000 1 1 WZ01-0580E 1
Z-2. Electric Circuit (Upper) Z-2. Z-2. Electric Circuit (Upper) 444-105-62000 3 2 WZ03-0820E 2
Z-3. Electric Circuit (Lower) Z-3. Z-3. Electric Circuit (Lower) 444-105-61000 3 3 WZ03-0830E 3
Z-4 Z-4 Hydraulic Component Location (Boom) Z-4 Hydraulic Component Location (Boom) 1. For 160SX 443-411-70000 1 4 WZ07-0290E 4
Z-4. Hydraulic Component Location (Boom) Z-4. Z-4. 2. For 210SX 443-411-60000 1 5 WZ07-0290E 5
Z-5 Z-5 Hydraulic Component Location (Deck) Z-5 Hydraulic Component Location (Deck) 1. For 160SX 443-411-80000 2 6 WZ07-0300E 6
Z-5. Hydraulic Component Location (Deck) Z-5. Z-5. 2. For 210SX 423-456-30000 0 7 WZ07-0300E 7
Z-6 Z-6 Hydraulic Component Location (Swing Frame) Z-6 Hydraulic Component Location (Swing Frame) 1. Swing frame (1) 1.1 For 160SX 443-411-41000 6 8 WZ07-0310E 8
Z-6 Z-6 Hydraulic Component Location (Swing Frame) Z-6 1.2 For 210SX 443-411-51000 5 9 WZ07-0310E 9
Z-6 Z-6 Hydraulic Component Location (Swing Frame) Z-6 2. Swing frame (2) 443-411-45000 7 10 WZ07-0310E 10
Z-6. Hydraulic Component Location (Swing Frame) Z-6. Z-6. 3. Swing frame (3) 443-411-46000 1 11 WZ07-0310E 11
Z-7 Z-7 Hydraulic Component Location (Frame) Z-7 Hydraulic Component Location (Frame) 1. Frame (Front) 446-403-71000 4 12 WZ07-0320E 12
Z-7 Z-7 Hydraulic Component Location (Frame) Z-7 2. Frame (Rear) 446-403-75000 6 13 WZ07-0320E 13
Z-7. Hydraulic Component Location (Frame) Z-7. Z-7. 3. Frame (Brake) 446-403-76000 0 14 WZ07-0320E 14
Z-8 Z-8 Electric Component Location (Boom) Z-8 Electric Component Location (Boom) 1. For 160SX 443-507-34000 1 15 WZ02-0570E 15
Z-8. Electric Component Location (Boom) Z-8. Z-8. 2. For 210SX 443-507-44000 1 16 WZ02-0570E 16
Z-9 Z-9 Electric Component Location (Detection) Z-9 Electric Component Location (Detection) 1. For 160SX(Parts assembly electric1,2) 443-507-35000 0 17 WZ02-0580E 17
Z-9 Z-9 Electric Component Location (Detection) Z-9 443-507-33000 0 18 WZ02-0580E 18
Z-9 Z-9 Electric Component Location (Detection) Z-9 2. For 210SX(Parts assembly electric1,2) 443-507-45000 0 19 WZ02-0580E 19
Z-9. Electric Component Location (Detection) Z-9. Z-9. 443-507-43000 0 20 WZ02-0580E 20
Z-10. Electric Component Location (Deck) Z-10. Z-10. Electric Component Location (Deck) 443-507-50000 2 21 WZ02-0590E 21
Z-11. Electric Component Location (Swing Frame) Z-11. Z-11. Electric Component Location (Swing Frame) 444-314-20001 2 22 WZ02-0600E 22
Z-12. Electric Component Location (Frame) Z-12. Electric Component Location (Frame) 446-500-40000 0 23 WZ02-0610E
Head Office Ko-34,Sinden-cho, Takamatsu, Japan Overseas Service Dept. Tadano Ryogoku Bldg. 4-12, Kamezawa 2-chome, Sumida-ku, Tokyo, Japan Tel. (03) 3621-7765 Tel fax (03) 3621-7785 1 2 3 4 5 History of revision