FS-305AS

OPERATION MANUAL
Self-propelled Crawler type Aerial platform
Model SR12B /ISR40B
SR12B J/ISR4 0BJ

SR12B/ISR40B

SR12BJ/ISR40BJ

Important: Please, read and understand this manual before using the machine.

1152 RYOKE, AGEO, SAITAMA, JAPAN

Introduction

Thank you very much for making your purchase from Aichi Corporation.

This manual describes the correct operation and handling procedures of the self-propelled
crawler type aerial platforms SR12B/ISR40B and SR12BJ/ISR40BJ. Follow the instructions
described in this manual to ensure the maximum operational efficiency and the utmost safety of
these machines.

Operations of these machines not in accordance with the instructions described in this manual
may lead to problems, resulting in damage and increasing risk of danger. Please, be sure to read
and understand this manual before using these machines.

＊ Always keep this manual and the record of Aichi pre-delivery functional tests with the
machine.

＊ When you transfer the use or ownership of the machine, please attach this manual to the
machine for the next user.

＊ For any doubts you may have about handling, inspections or service parts, please contact
our business offices or the authorized service shops. At that time, you are requested to quote
the model, serial number, manufactured date marked on the serial number plate.

＊ Use only the service 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 tests should be conducted by
the approved agent, if a modification that would affect the stability, strength or performance of
the machine was made. Detail of major alterations and repairs must be recorded on the
inspection check sheets that are included in the separate service manual.

＊ The user of this machine shall obtain the guidance and approval of the manufacturer, in the
event of any special working method or conditions, which are outside those specified by the
manufacturer.

＊ Your attention is drawn to certain changes in illustrations or contents which may be made
without notice.
 INDEX
I Qualifications of Operator ----------------------------------------------------------- 1
II Name of Components ------------------------------------------------------------------ 2
III Specifications ---------------------------------------------------------------------------- 3
1. Main specifications ------------------------------------------------------------------ 3
2. Work range diagram ----------------------------------------------------------------- 4
IV Pre-start Checks ------------------------------------------------------------------------- 5
V Periodic Inspections -------------------------------------------------------------------- 8
VI For Safety --------------------------------------------------------------------------------- 9
1. Before starting operation ------------------------------------------------------------ 9
2. During operation ---------------------------------------------------------------------- 12
3. After operation ------------------------------------------------------------------------ 19
VII Machine Setting up -------------------------------------------------------------------- 20
VIII Safety Devices -------------------------------------------------------------------------- 21
1. A list of safety devices --------------------------------------------------------------- 21
2. Travel speed limit system------------------------------------------------------------ 22
3. Travel function limit system--------------------------------------------------------- 23
IX Control Panels -------------------------------------------------------------------------- 24
1. Lower control panel ---------------------------------------------------------------- 24
2. Upper control panel ---------------------------------------------------------------- 25
3. Pictorial symbols -------------------------------------------------------------------- 26
X Operating Method ---------------------------------------------------------------------- 27
1. Engine start operation -------------------------------------------------------------- 27
1.1 Engine start operation from Lower control --------------------------------- 27
1.2 Engine start operation from Upper control --------------------------------- 29
2. Engine stop operation -------------------------------------------------------------- 30
3. Lower control (Operation from Ground) ---------------------------------------- 31
3.1 Boom and Fly jib operation --------------------------------------------------- 31
3.2 Emergency stop operation ---------------------------------------------------- 33
3.3 Emergency pump operation -------------------------------------------------- 34
3.4 Platform level adjustment ---------------------------------------------------- 35
3.5 Indicator lights ------------------------------------------------------------------ 36
3.6 Limit cancel switch ------------------------------------------------------------ 37
4. Upper control (Operation from Platform) -------------------------------------- 38
4.1 Foot switch --------------------------------------------------------------------- 38
4.2 Travel operation --------------------------------------------------------------- 39
4.3 Boom raising and lowering operation -------------------------------------- 41
4.4 Boom rotation operation ------------------------------------------------------ 42
4.5 Boom telescope operation ---------------------------------------------------- 42
 4.6 Platform rotation operation --------------------------------------------------- 42
4.7 Fly jib operation ---------------------------------------------------------------- 42
4.8 Emergency stop operation ----------------------------------------------------- 43
4.9 Emergency pump operation -------------------------------------------------- 44
4.10 Alarm horn operation -------------------------------------------------------- 44
4.11 Platform level adjustments -------------------------------------------------- 45
4.12 Indicator lights ---------------------------------------------------------------- 46
XI Operation Points ------------------------------------------------------------------------ 47
XII Transportation ------------------------------------------------------------------------- 48
1. When using loading ramp --------------------------------------------------------- 48
2. When hoisting ---------------------------------------------------------------------- 50
XIII Lubrication ---------------------------------------------------------------------------- 51
1. Recommended lubricants --------------------------------------------------------- 51
2. Lubrication points and intervals -------------------------------------------------- 52
XIV Daily Care ------------------------------------------------------------------------------ 54
1. Hydraulic oil ------------------------------------------------------------------------ 54
2. Gear oil for Rotation gearbox ---------------------------------------------------- 55
3. Gear oil for Travel gearbox ------------------------------------------------------- 55
4. Fuel ----------------------------------------------------------------------------------- 56
5. Engine -------------------------------------------------------------------------------- 56
6. Wire ropes --------------------------------------------------------------------------- 57
7. Fuses ---------------------------------------------------------------------------------- 57
8. Hydraulic hoses --------------------------------------------------------------------- 58
9. Crawler ------------------------------------------------------------------------------- 59
XV Storage for long periods ------------------------------------------------------------- 61
XVI Optional equipment operation method ------------------------------------------ 62
1. Work light --------------------------------------------------------------------------- 62
2. AC power outlet -------------------------------------------------------------------- 62
3. Travel remote control -------------------------------------------------------------- 62
XVII Decals ----------------------------------------------------------------------------------- 63
 I Qualifications of Operator

The operator of this machine must receive safety training to ensure safe operation.

Safety training

Incorrect use of the machine may cause serious injury or death.

All personnel who operate this machine are requested to receive safety training, and only the trained and
authorized personnel are allowed to operate this machine.

(For safety training, use this manual.)

Safety Training! Certificate of Safety training

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II Name of Components

② ③
①

⑤
⑥

⑦
⑧ ⑦
⑪
⑨
⑫
⑲ ⑩

⑰ ⑯ ⑮
⑱ ⑭ ⑬
SR12B/ISR40B

⑳
SR12BJ/ISR40JB

No. Name No. Name

1 Engine compartment 11 Upper control
2 Rotation lock pin 12 Platform
3 Foot switch 13 3rd boom section
4 --------------------------------- 14 2nd boom section
5 Manual holder 15 1st boom section
6 Turntable 16 Travel motor
7 Lifting ring 17 Chassis frame
8 Hydraulic oil reservoir 18 Track
9 Lower control 19 Fuel tank
10 Rotary actuator for Platform rotation 20 Fly jib

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 III Specifications
1. Main specifications
Model SR12B / ISR40B SR12BJ / ISR40BJ
Dimensions Overall length 6.34 m (20ft – 10in) 7.715m (25ft – 4in)
Overall width 2.30 m (7ft – 7in)
Overall height 1.995 m (6ft – 7in)
Minimum ground clearance 305 mm (12.0 in)
Tail swing 0.60 m (2ft – 0in)
Gross weight 7,445 kg (16,413 LBS) 8,240 kg (18,166 LBS)
Gradeability 58% (30 degrees)
Maximum allowable tilt angle 5 degrees
Maximum ground contact pressure 0.66 kg/cm2 (9.39 PSI) 0.74 kg/cm2 (10.53 PSI)
Platform Rated load 250 kg (550 LBS) or
2 persons + Tools 90 kg (200 LBS)
Size (L x W x H) 1.8 x 0.75 x 1.1 m (5ft-11in x 2ft-6in x 3ft-7in)
Maximum allowable manual side force 400 N (41 kg) (90LBS)
Maximum platform floor height 12.1 m (39ft – 8in)
Maximum outreach 10.7 m (35ft – 1in) 11.3 m (37ft – 1in)
Rotation angle 180 degrees
Boom Boom angle -19 ~ +70 degrees
Boom length 4.80 ~ 10.91 m 4.80 ~ 9.92 m
(15ft – 9in ~ 35ft – 10in) (15ft – 9in ~ 32ft – 7in)
Rotation angle 360 degrees (Continuous)
Fly jib Jib angle --------------------------- -45 ~ +71 degrees
Jib length --------------------------- 1.22 m (4ft – 0in)
Engine Model Isuzu 3LD1 PA-49
Euro- 1 (Old type)

Total displacement 1,496 cc (91 in3)

Maximum output power 21.0 kw/2,400 rpm (28.2 HP/2,400 rpm)
Maximum output torque 9.41 kg-m/1,700 rpm (68.1 ft-lbs/1,700 rpm)
Fuel tank capacity 95 liters (25.1 gallons)
Engine rpm Low 1,150 rpm
High 2,400 rpm
Model Isuzu 3CE1, PZP01
Euro- 2 (New type)

Total displacement 1,642 cc (100.2 in3)

Maximum output power 21.5 kw/2,400 rpm (28.8 HP/2,400 rpm)
Maximum output torque 11.1 kg-m/1,200 rpm (80.4 ft-lbs/1,200 rpm)
Fuel tank capacity 95 liters (25.1 gallons)
Engine rpm Low 1,150 rpm
High 2,400 rpm
Battery voltage DC12 volts
Actuating Boom elevation UP 50 seconds 45 seconds
speed Down 50 seconds 45 seconds
Fly jib elevation Up --------------------------- 20 seconds
Down --------------------------- 18 seconds
Boom telescope Out 25 seconds 23 seconds
In 25 seconds 23 seconds
Boom rotation CW 110 seconds 115 seconds
CCW 110 seconds 115 seconds
Platform rotation CW 11 seconds
CCW 11 seconds
Traveling High speed 1.5 km/hour (0.93 MPH)
Low speed 0.9 km/hour (0.56 MPH)
Hydraulic Rated pressure 250 kg/cm2 (3,556 PSI)
system Hydraulic tank capacity 145 liters (38.3 gallons)
Recommended hydraulic oil Shell Tellus oil T22
* Airborne noise emissions do not exceed a sound pressure level of 85 dB(A) at the operating positions.
* The vibration emitted by the machine does not exceed 0.5m/s2 (19.7 in/s2) on the work platform.
* This machine is designed for both indoor and outdoor use.

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2. Work range diagram

32’ 10”
13’ 1”

19’ 8”

26’ 3”

39’ 4”
-6’ 7”

6’ 7”
0
45’ 11”

39’ 4”

32’ 10”

26’ 3”

Platform height
19’ 8”

13’ 1”

6’ 7”

- 6’ 7”

Work radius
SR12B / ISR40B

32’ 10”
13’ 1”

19’ 8”

26’ 3”

39’ 4”
-6’ 7”

6’ 7”
0

45’ 11”

39’ 4”

32’ 10”

26’ 3”
Platform height

19’ 8”

13’ 1”

6’ 7”

- 6’ 7”

Work radius
SR12BJ / ISR40BJ

The work range of the platform shown in the above diagram is obtained at any boom-rotated directions.

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 IV Pre-start Checks
Always perform the pre-start checks before using the machine.
Pre-start checks must also be conducted before using the machine which:
has been stored for a long period.
is a new machine.
has been serviced or repaired.

Set up the machine on firm and level surface and the following items should be check thoroughly.
Danger: When checking the machine under the platform or the boom, use safety support to
prevent the platform and boom from unexpected descent.
Caution: If any abnormality is observed, stop using the machine and contact Aichi service shop for
inspections.
Advice: Use only the AICHI genuine parts for repairs.
(1) Check fuel, engine oil, cooling water and hydraulic oil and replenish, if necessary.

Advice: Retract and lower the boom fully before checking the hydraulic oil level.
(2) Check the boom, the platform and the chassis for cracks, deformations. Also, check each bolt and
nut for looseness.

(3) Check that the greasing points are lubricated sufficiently.

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(4) Check that all of the decals are readable.

Caution: Damaged or dirty decals cannot be read properly and should be replaced.
(5) After starting and warming up the engine, operate the machine thoroughly from the lower control
and make sure that all of the functions are normal.

Caution: Check the functions by operating the machine from the lower control first, then from
the upper control.
(6) Operate the machine, press the emergency stop switch and make sure that the engine is shut down
and the functions stop immediately.

(7) Check the hydraulic components, hoses and pipes for oil leakage.

(8) Check the boom telescoping wire ropes for any damage.
(a) No wobble or unsteady movements when telescoping the boom.
(b) No damage on the wire rope ends.

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(9) Elevate the platform, and then make sure that the platform does not descend naturally.

(10) If there are no abnormalities or problems so far, step on the platform and check the following
items.
(a) Operate the machine, press the Emergency stop switch and make sure that the engine is shut
down and the movement stops immediately.
(b) Operate the machine, release the foot switch and make sure that the movement stops
immediately.
(c) Rotate the platform and make sure that the platform rotates smoothly without excessive free
play.
(d) Operate the machine thoroughly from the upper control and make sure that all of the
functions are normal.

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 V Periodic Inspections
Conduct the monthly and annual inspections and keep all records for three years.

Advice:

Use the separate service manual for recording the inspection results.


For inspections, contact Aichi service shop.

Periodic Inspection

Danger:


When you are obliged inspect or repair the machine under the boom and the platform, use a
safety support to prevent the boom and the platform from unexpected descent.

8
 VI For Safety
1. Before starting operation
(1) Only the trained and authorized personnel are allowed to operate the machine.

(2) Always wear safety gears e.g. hardhat, safety shoes and safety harness. The authorized safety
harness should be used.

Wear hardhat and

safety shoes!

(3) Wear neat and fitting clothes to avoid snagging.

(4) Nominate a supervisor and operate the machine according to his/her instructions.

(5) Always follow the correct procedures and safety rules outlined in this manual, and also that of
your supervisor.

Attention
Safe work

Prevent accident Procedure

9
(6) Observe all of the national and local laws and regulations.

(7) Keep inflammable substances (fuel, oil, etc.) away from fire.

Fuel

(8) Do not operate the machine when you are intoxicated or fatigued.

Don’t work!

(9) Stop using the machine in bad weather

Criteria of bad weather:

Strong wind・・・・Average wind velocity over l0 minute period is over 12.5 m/sec (28 MPH).
Heavy rain ・・・Rainfall of 50 mm (2.0 inches) or more.
Heavy snow・・・Settled snow of 25 cm (9.8 inches) or more.
Thunder / Lightening.
Even when the conditions are below the criteria above, follow the instructions of your supervisor.

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 The criteria of wind velocity at 10 meters (33 feet) above ground are as follows.

Wind velocity at 10 m Situation on the ground

(33 feet) above ground
5.5 ~ 8.0 m Dust rises and paper flies.
(12.3 ~ 17.9 MPH) Twigs move.
8.0 ~ 10.8 m Heavily-leaf trees sway and waves cresting in ponds
(17.9 ~ 24.2 MPH) or lakes can be seen.
10.8 ~ 13.9 m Large trees sway. Overhead power lines hum.
(24.2 ~ 31.1 MPH) Umbrellas are difficult to use.
13.9 ~ 17.2 m Whole trees swing.
(31.1 ~ 38.5 MPH) Walking against the wind is difficult.
Generally, the higher we go, the higher the wind velocity is. Therefore, when the platform is
elevated, be careful so that the wind velocity at the platform does not exceed 12.5 m/sec
(28MPH).
(10) Do not make any modifications to the machine without obtaining the manufacturer’s approval.

Modifications
are prohibited.

Advice: Do not add anything to the machine, which could increase the wind load, e.g. “Notice
boards” on the platform.
(11) Do not wash the sections where the washing prohibition decals are affixed. In particular, do not
use pressurized water.

Advice: Wipe off dirt from electrical components using dry cloths.

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2. During operation

(1) After starting the engine, warm up the machine without loading the engine.

(2) This machine is not allowed to travel on public highways.

(3) Do not use the machine near electric power lines.

Danger:

This machine is not electrically insulated. Do not approach or make contact electrical
conductors.

Keep a safe distance from electric power lines and apparatus. Failure to do so may result in
death or serious injury.
For safe distance, check the national or local regulations. If no national or local regulation is
available, use the table below.

Voltage range (Phase to Phase) Minimum safe approach distance

0 to 300 V Avoid contact
Over 300V to 50 KV 3.05 meters (10 feet)
Over 50 KV to 200 KV 4.60 meters (15 feet)
Over 200 KV to 350 KV 6.10 meters (20 feet)
Over350 KV to 500 KV 7.62 meters (25 feet)
Over 500 KV to 750 KV 10.67 meters (35 feet)
Over 750 KV to 1,000 KV 13.72 meters (45 feet)

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(4) It is highly recommended to fully retract the boom and set it under the horizontal before traveling
over a curb or on any rough terrain, then travel very slowly and carefully.
The machine suddenly inclines and the platform jumps up or down roughly just after the gravity
center of the machine pass the curb as shown in the following figures.
Danger: Before traveling over a curb or on any rough terrain, check the overhead obstacles as
well as the clearance between the platform and the ground, and then travel very slowly
and carefully. If not, it may results in serious injury or death.

13
 Large

Small

(5) Before starting traveling, make sure the traveling direction of the machine by checking the arrow
marks located on the chassis.

Advice:

The arrow indicates the forward direction.

Before traveling, check the surroundings and make sure that no persons or obstacles are in
the traveling direction. If your vision is poor, have a guide to assist you.

(6) Do not elevate the platform on soft or uneven ground.

The maximum ground contact pressure of this machine is:
* SR12B / ISR40B -------- 0.66 kgf/cm2 (9.39 PSI).
* SR12BJ / ISR20BJ ------ 0.74 kgf/cm2 (10.53 PSI).

Danger: The machine may tip over on soft or uneven ground.

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(7) Do not elevate the platform on a slope.

Beep
Beep

Over 5°

Danger: The tilt alarm buzzer sounds, if the machine tilts more than 5 degrees. Do not elevate
the platform, if the tilt alarm buzzer sounds.
(8) When you are obliged to travel on the slope of more than 5 degrees for the purpose of
transportation, be sure to retract the boom fully and lower the boom under the horizontal.

Beep-
Beep-

Retract the boom fully and

lower it under the horizontal.

Over 5°

Caution: Do not attempt to travel on the steep slope, which exceeds the gradeability of the
machine.
(9) Be sure to wear a safety harness, and fasten its lanyard to the specified anchor point on the
platform. Only authorized safety harness should be used.

(10) Check the surroundings before traveling, and make sure that no person or obstacle is around the
machine.

15
(11) Check the surroundings before operating the boom, and make sure that no person or obstacle is
either around you or around the machine.

Caution:
Make sure that no person or obstacle is around the turntable before rotating the boom.
Take care that your hands on the handrail are not caught in other obstacles.
(12) Do not operate the machine roughly.

Caution: When you reverse the operating direction, bring the machine to a standstill, then
operate the control lever or switch to the opposite direction.
(13) If any malfunction is in the platform leveling system, stop using the machine immediately and
contact Aichi service shop for inspections.
(14) Do not reach out of the platform.

Danger:
Always keep your feet firmly on the platform floor and conduct operations with stable
posture.
Do not step on the handrail.

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(15) Do not use a ladder or step on the platform.

(16) Do not leave or enter the platform while the platform is elevated.

(17) Do not drop anything from the platform.

(18) Do not allow any person to get under the boom and the platform.

(19) No smoke or fire on the platform.

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(20) When gas cutting or arc welding is conducted on the platform, take necessary measures. For
example, cover the machine with fireproof sheet so that no sparks or fragments hit the machine,
especially the batteries and the hydraulic hoses.
Danger: If a spark enters the machine, it may cause a fire.
(21) If the counterweights hit an obstacle, the counterweight-mounting unit may be damage. In this
case, contact Aichi service shop for inspections.
Danger: If the counterweight-mounting unit is damaged, the counterweight may be detached
during traveling or transport, resulting in serious injury or death.
(22) Do not use the machine with the counterweight detached. The machine may tip over, resulting in
serious injury or death.
(23) Do not conduct the following operations, which may cause the tipping over or serious damage to
the machine.
(a) Do not push or pull any objects by operating the machine.

(b) Do not hoist any objects with a hook or a rope fixed to the boom and the platform.

(c) Do not overload the platform. The specific working load is marked on the platform.

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(24) Do not conduct the followings that may damage the platform leveling system.
(a) Do not press the platform against any overhead structure by elevating the platform.

(b) Do not hit or push any objects by traveling.

Danger: If either of the above operations has been conducted, stop using the machine and
contact Aichi service shop for inspections.
If not, the platform may tilt excessively, resulting in serious injury or death.

3. After operation

(1) Retract and lower the boom fully.

(2) Take all tools and materials from the platform.

(3) Shut down the engine by turning off the engine key switch and then remove the key.

Caution: Remove the key to prevent any possible danger caused by unauthorized use.

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 VII Machine setting up
(1) Always set up the machine on firm and level surface before elevating the platform.
Danger: Do not elevate the platform on soft or uneven surface, as the machine may tip over,
resulting in serious injury or death
Advice: The maximum ground contact pressure of this machine is;
SR12B / ISR40B -------- 0.66 kgf/cm2 (9.39 PSI).
SR12BJ / ISR40BJ ------ 0.74 kgf/cm2 (10.53 PSI).
(2) Park the machine near the working target.

(3) Do not obstruct the transit of other vehicles and passers-by, and do not permit any unauthorized
person to enter the working area.

Caution: Place warning signs, indicate detours and install crash- prevention guard.

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 VIII Safety Devices
Safety devices are fitted for safe operation and for protecting the machine from damages.

1. A list of Safety devices.

Safety device Functions
Relief valves These valves relieve abnormally high pressure to protect
the hydraulic system.
Single holding valve on Boom This valve prevents the natural descent of the boom in the
elevation cylinder event of hydraulic hose breakage.
Double holding valve on Boom This valve prevents the boom from natural retraction or
telescope cylinder extension in the event of hydraulic hose breakage.
Single holding valve on Fly jib cylinder This valve prevents the natural descent of the fly jib in the
(for SR12BJ/ISR40BJ only) event of the hydraulic hose breakage.
Double pilot check valve on Upper This valve maintains the platform level in the event of
leveling cylinder hydraulic hose breakage.
Motion alarm buzzer This alarm buzzer sounds while the machine is in motion
to warn the personnel nearby.
Foot switch The boom, fly jib, traveling and platform rotating
operations from the platform are disabled unless the foot
switch is depressed.
Emergency stop switch This switch shuts down the engine and stops all of the
movements of the machine.
Tilt Alarm buzzer This alarm buzzer sounds when the machine tilts more
than 5 degrees.
Emergency pump This auxiliary pump is driven by the battery and is used to
lower the platform in the event of engine or main pump
failure.
Alarm horn Before starting operation, sound the alarm horn to warn
the personnel near the working area.
Travel speed limit system This system automatically limits the travel speed
corresponding to various boom statuses.
For the specific function of this system, see the clause of
“2. Travel speed limit system”
Travel function limit system This system automatically disables the travel function
corresponding to the boom status and the tilt angle of the
machine.
For the specific function of this system, see the clause of
“3. Travel function limit system”.
Overload sensing system This system disables all of the functions when the platform
is overloaded.
Boom wire rope failure sensing system This system disables the boom extending function in the
event of wire rope failure.
Boom / Travel interlock system This system stops all of the functions when the travel and
boom operations are performed simultaneously.
Rotation lock pin This lock pin is used to fix the turntable with the chassis to
prevent the turntable being rotated while transporting the
machine.

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2. Travel speed limit system
This system automatically limits the travel speed corresponding to the boom status as follows.

45゜
B
5゜

Area Boom status Travel speed

A Boom angle ≧ 45゜ 0.3 km/hour (0.19 MPH)
Boom extension = Min ~ Max The travel speed is limited to 0.3 km/hour (0.19 MPH)
regardless of the positions of the travel speed select switch.
B 5゜＜ Boom angle ＜ 45゜ 0.5 km/hour (0.31 MPH)
Boom extension = Min ~ Max The travel speed is limited to 0.5 km/hour (0.31 MPH)
Boom angle ＜ 5゜ regardless of the positions of the travel speed select switch.
Boom extension = Not fully retracted
C Boom angle ＜ 5゜ The travel speed is 1.5 km/hour (0.93 MPH), when the
Boom extension = Fully retracted travel speed select switch is positioned at HIGH speed.
The travel speed is 0.9 km/hour (0.56 MPH), when the
travel speed select switch is positioned at LOW speed.

22
3. Travel function limit system
This system disables the travel function corresponding to the boom status and the machine tilt angle as
follows.

45°
B

Area Boom status Functions

A Boo angle ≧ 45゜ The travel function is disabled regardless of boom extension,
Boom extension = Min ~ Max when the machine tilt angle exceeds 5 degrees.
B Boo angle ＜ 45゜ The travel function is disabled unless the boom is fully
Boom extension = Not fully retracted retracted, when the machine tilt angle exceeds 5 degrees.
C Boo angle ＜ 45゜ The travel function is available regardless of the machine tilt
Boom extension = Fully retracted angle.

23
 IX Control Panels

1. Lower control panel

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22

No. Name No. Name

1 Metal connector 12 Limit cancel switch
for Travel remote control (Option)
2 Fuse holder 13 Engine key switch
3 Pre-heat light 14 Hour meter
4 System failure light 15 Dead-man switch
5 Fuel level light 16 Fly jib switch
(for SR12BJ/ISR40JB only)
6 Tilt warning light 17 Travel remote control select switch
(Option)
7 Oil pressure light 18 Boom rotation switch
8 Overload warning light 19 Emergency pump switch
9 Overheat warning light 20 Boom telescope switch
10 Charge light 21 Boom elevation switch
11 Emergency stop switch 22 Platform level adjust switch

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2. Upper control panel

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21

No. Name No. Name

1 Platform level adjust switch 12 Horn switch
2 Travel speed select switch 13 Fly jib switch
(for SR12BJ/ISR40BJ only)
3 Emergency pump switch 14 Platform rotation switch
4 Work light switch (Option) 15 Boom rotation joystick controller
5 Hydraulic generator switch 16 Boom telescope joystick controller
(Option for USA)
6 Hydraulic generator light (Option for USA) 17 Boom elevation joystick controller
7 System failure light 18 Travel (Left) joystick controller
8 Tilt warning light 19 Travel (Right) joystick controller
9 Overload warning light 20 Engine start switch
10 Fuel level light 21 Emergency stop switch
11 Engine failure light

25
3. Pictorial symbols

OFF Engine failure indicator

Lower control Horn

Pre-heat Tilt warning indicator

Engine start Overload warning indicator

Upper control System failure indicator

Pre-heat indicator Emergency pump

Fuel level indicator Pre-start check

Engine oil pressure indicator High speed

Engine overheat indicator Low speed

Charge indicator Boom rotation

Boom elevation Boom telescope

Platform rotation Platform level adjustment

Fly jib Travel, Right

Travel, Left

26
 X Operating Method

1. Engine start operation

1.1 Engine start operation from Lower control

Start the engine from the lower control as follows.
(1) Turn the engine key switch on the lower control to its LOWER control position, and then make
sure that both of the oil pressure and charge lights go on.
Pre-heat light Fuel level light Charge light

LOWER control

Engine key switch

Hour meter Oil pressure light Overheat warning light

The functions of each indicator light and hour meters are as follows.
a) Charge light.
After starting the engine, this light goes off. If the light goes on whilst the engine is in motion,
it is because of a charging system failure.
Caution: If this light goes on whilst the engine is in motion, stop using the machine and
check the charging system, e.g. alternator and fan belt.
b) Oil pressure light.
After starting the engine, this light goes off. The engine automatically stops and this light goes
on in the event that the engine oil pressure decreases abnormally.
Caution: If the engine stops and this light goes on, check the engine lubrication system, e.g.
shortage or leakage of engine oil or oil filter clogging.
c) Overheat warning light.
When the engine cooling water temperature rises abnormally, the engine automatically stops
and this light goes on to protect the engine from overheat. This light stays off when the engine
key switch is just turned to its LOWER control position.
Danger: When the engine is overheated, do not remove the radiator cap. As the heated
water may splash out, resulting in scald.
Caution: If the engine stops and this light goes on, stop using the machine and check the
engine cooling system, e.g. coolant shortage and broken fan belt.

27
 d) Fuel level light.
This light goes on when the fuel level is low. Refill the fuel tank with diesel fuel, if this light
goes on. This light goes on when the remaining fuel reaches about 23 liters (6 gallons).
e) Hour meter
The hour meter runs while the engine is in motion.
(2) Push in the key and turn the engine key switch to its “START” position to start the engine.

START

Caution: Once the engine is started, immediately release the key from its start position. Do not
hold the key in its start position for more than 10 seconds continuously, as this may
damage the starter motor.
(3) If the engine is cold and difficult to start, turn the engine key switch to its PRE-HEAT position
and hold there for about 5 second, and then start the engine. The pre-heat light goes on when the
engine key switch is turned to its PRE-HEAT position.

PRE-HEAT

(4) After starting the engine, idle the engine for about 5 minutes for warming up.

28
1.2 Engine start operation from Upper control
Start the engine from the Upper control as follows.
(1) Turn the engine key switch to its UPPER control position at the Lower control panel.

UPPER control

(2) Step on the platform, then operates the engine start switch without depressing the foot switch to
start the engine.
Fuel level light Engine failure light

Engine start switch

The engine failure and fuel level lights located on the upper control panel function as follows.
a) Engine failure light.
When the engine key switch is set to its UPPER control position, the engine failure light on
the upper control panel goes on, and then the light goes off as soon as the engine starts.
Caution: If the engine failure light goes on whilst the engine is in motion, it is because of an
engine failure. So, stop using the machine immediately and check the engine. To
identify the engine failure, check the charge, oil pressure and overheat warning lights
located on the lower control panel.
b) Fuel level light.
This light goes on when the fuel level is low. Refill the fuel tank with diesel fuel, if this light
goes on. This light goes on when the remaining fuel reaches about 23 liters (6 gallons).

29
2. Engine stop operation

To shut down the engine from the lower control, either press the emergency stop switch or turn the
engine key switch to its “OFF” position on the lower control panel.
When shutting down the engine from the upper control, press the emergency stop switch on the upper
control panel.
Emergency stop switch

OFF

Engine key switch

Lower control panel

Emergency stop switch

Upper control panel

30
3. Lower control (Operation from Ground)
Be sure to set the engine key switch in its LOWER control position to operate the machine from the
lower control.
LOWER control

3.1 Boom and Fly jib operation

Hold the dead-man switch in its ON position and operate each boom control switch or the fly jib
switch to operate the boom and fly jib functions.

Boom elevation
switch
Dead-man switch

Boom telescope switch

Fly jib switch Boom rotation switch
(Equipped only on SR12BJ/ISR40BJ.)

3.1.1 Boom raising and lowering operation

Hold the dead-man switch in its ON position and operate the boom elevation switch to raise or lower
the boom.

Boom up Up

Stop

Boom down
Down

Caution: Do not press the boom and the platform against ground by lowering the boom.

31
3.1.2 Boom rotating operation
Hold the dead-man switch in its ON position and operate the boom rotation switch to rotate the boom.

CW Stop CCW

CCW

CW

Danger: Before rotating the boom, check that no obstacle interferes with the turntable.
Advice: The boom may not be rotated smoothly when the machine is tilted.

3.1.3 Boom telescope operation

Hold the dead-man switch in its ON position and operate the boom telescope switch to extend or
retract the boom.

Extend Extend
Stop

Retract
Retract

3.1.4 Fly jib operation (Only for SR12BJ / ISR40BJ)

Hold the dead-man switch in its ON position and operate the fly jib switch to raise or lower the fly jib.

Up
Up

Stop

Down
Down

32
3.2 Emergency stop operation
Use the emergency stop switch. When the emergency stop switch is pressed, the engine stops and all
of the functions are disabled. Press the emergency stop switch in the following cases;
(1) When shutting down the engine.
(2) When a person on the ground judges that the operation from the platform is unsafe.
(3) When the machine is uncontrollable due to malfunctions.

Emergency stop switch

Advice: To resume operation, pull the emergency stop switch.

Caution:
If the boom descends gradually after the emergency stop switch is pressed, this may be a
natural descent of the hydraulic cylinder. In this case, restart the engine with the engine key
switch and operate the boom to prevent the boom and the platform from coming into contact
with any obstacles. Then, lower the platform to the ground and stop using the machine.
If the emergency stop switch was used as a result of malfunctions, stop using the machine
immediately and contact Aichi service shop for inspections.

33
3.3 Emergency pump operation
If the machine does not work due to engine or main pump failure, use the emergency pump to lower
the platform. To operate the boom and the fly jib using the emergency pump, operate each boom
function or fly jib switch with the emergency pump switch held in its ON position.
Advice: It is not necessary to hold the dead-man switch in its ON position when operating the boom
and the fly jib using the emergency pump.

Emergency pump switch

30 seconds Rest 30 seconds

Operate

Emergency pump
operation cycle diagram

Operate 30 seconds
Rest
30 seconds
Caution:
Operate the emergency pump every other 30 seconds. Continuous operation in excess of 30
seconds may damage the emergency pump.
Do not impose heavy load to the emergency pump, e.g. by attempting travel operation.
Advice:
In the event that the emergency stop switch has been pressed at the upper control with no
operator on the platform and it is necessary to lower the platform, you can lower the platform
using the emergency pump from the lower control.
The engine automatically stops as you operate the emergency pump from the lower control
while the engine key switch is in its UPPER control position.

34
3.4 Platform level adjustment
Danger: Do not allow any person or object on the platform when adjusting the platform level
from the lower control.

Platform level
adjust switch

Dead-man switch

Hold the dead-man switch in its ON position and operate the platform level adjust switch to adjust the
platform level.

UP UP
UP

UP
DOWN
DOWN

DOWN DOWN

SR12B/ISR40B SR12BJ/ISR40BJ

35
3.5 Indicator lights
The following indicator lights are equipped on the lower control panel
① ② ③ ④ ⑤ ⑥ ⑦ ⑧

1 Pre-heat light 5 Overload warning light

2 System failure light 6 Oil pressure light
3 Tilt warning light 7 Overheat warning light
4 Fuel level light 8 Charge light
(1) Pre-heat light
This light goes on when the engine key switch is turned to its PRE-HEAT position. Pre-heat the
engine for about 5 seconds when you start the engine in cold weather.
(2) System failure light
This light blinks, in the event of a computer control system failure. Stop using the machine and
contact Aichi service shop for inspections, if this light blinks.
(3) Tilt warning light
This light goes on and the tilt alarm buzzer sounds when the machine tilts more than 5 degrees.
Do not elevate the platform when this light goes on.
(4) Fuel level light
This light goes on when the fuel level is low. Refill the fuel tank with diesel fuel when this light
goes on. This light goes on when the remaining fuel reaches 23 liters (6 gallons).
(5) Overload warning light
This light blinks, the alarm buzzer sounds and all of the functions are disabled when the platform
is overloaded.
(6) Oil pressure light
After starting the engine, this light goes off. The engine stops and this light goes on in the event
that the engine oil pressure lowers abnormally. Check the engine lubrication system, e.g. shortage
of engine oil, if this light goes on.
(7) Overheat warning light
In the event that the engine cooling water temperature rises abnormally, the engine stops and this
light goes on to protect the engine from overheat. Check the engine cooling system, e.g. coolant
level and fan belt, if this light goes on.
(8) Charge light
After starting the engine this light goes off, check the charging system, e.g. alternator and fan belt,
if this light goes on while the engine is in motion.

36
3.6 Limit cancel switch
In the event that the “System failure light” blinks and the machine does not work due to computer
control system failure, hold this limit cancel switch in its ON position and lower the platform, and then
stop using the machine. The alarm buzzer sounds when the limit cancel switch is operated.
Caution:
Do not use this switch except when emergency.
System failure light

Limit cancel switch

Advice:
This limit cancel switch also cancels the functions of the overload sensing system. In the event
that the overload sensing system disables all of the functions and it is necessary to lower the
platform, hold this limit cancel switch in its ON position, retract the boom fully, and then lower
the platform.

37
4. Upper control (Operation from Platform)

Be sure to set the engine key switch in its UPPER control position to operate the machine from the
platform

UPPER control

Danger:
Always wear an authorized safety harness and hook its lanyard to the specified anchor while
you are on the platform.
Always stand on the platform floor firmly and maintain a safe posture while you are on the
platform.
Do not reach out of the platform.
Caution:
Prior to operate the machine on the platform, check that the platform is level and adjust the
platform level, if necessary.
When using the machine for paintwork, first move the platform to the working position, and
then be sure to close the cover of the upper control to protect the decals, joystick controllers,
control switches and indicator lights.
Wipe off oil and water spilt on the platform floor so that personnel do not slip and fall on the
platform.
Check the surroundings and make sure that no person or obstacle is around you or around the
machine before operating the machine.
Especially be careful before rotating the boom. Check that no person or obstacle is around the
turntable.
Do not leave anything around the joystick controllers and the switches, which may be caught in,
causing unintended movements.

4.1 Foot switch

Depress the foot switch to operate the machine on the platform. However, the following functions are
available without depressing the foot switch.
Engine start operation Foot switch
Emergency stop operation
Horn operation
Work light operation (Option)

Caution: Do not disable the foot switch in any way e.g. by binding.

38
4.2 Travel operation

Use the travel joystick controllers and the travel speed select switch to perform the travel operations.
Travel speed select switch

Travel joystick controllers

Caution:
When the turntable is rotated 180 degrees, the traveling direction becomes the opposite of the
joystick controllers operating directions. Before traveling, always check the arrows located on the
chassis to make sure the traveling direction.

Arrows

Forward Reverse

Caution:
Before traveling, make sure that no persons or obstacles are in the traveling direction.
When traveling on rough terrain or on slope, retract the boom fully and set the boom under the
horizontal.
Danger:
When traveling over a curb, retract the boom fully and set it under the horizontal, then travel the
machine very slowly and carefully. The machine suddenly inclines and the platform jumps up or
down roughly just after the gravity center of the machine pass the curb as shown in the figure below.
Check the overhead obstacles as well as the clearance between the platform and the ground, and then
travel very slowly and carefully. If not, it may results in serious injury or death. For further detail,
see the chapter “VI For Safety”, section “2. During operation” of this manual.

Traveling direction

39
4.2.1 Travel speed select switch
The high and low traveling speeds are available. Set the travel speed select switch to select the high or
low travel speed.

Travel speed
select switch

Travel joystick controllers

Danger:
Do not set the travel speed select switch to its High-speed position and travel in the high speed
when traveling over a curb.
Advice:
The travel speed and travel functions are automatically limited by the functions of the travel
speed limit and travel function limit systems. See “Chapter VIII”, “Sections 2 and 3” for the
detail of the systems.

4.2.2 Straight forward and reverse

Depress the foot switch and operate both the travel joystick controllers to the traveling direction.
Forward
Reverse

Caution: Before traveling, always check the arrows located on the chassis to make sure the
traveling direction.

4.2.3 Pivot turn

Depress the foot switch and operate one of the travel joystick controllers as shown in the figures
below.
(a) Forward / Reverse turn to the left
Forward
Reverse

40
(b) Forward / Reverse turn to the right

Forward
Reverse
4.2.4 Spin turn
Depress the foot switch and operate the travel joystick controllers as shown in the figure below to make the
CW or CCW spin turn.

Spin turn CCW

Spin turn CW

4.3 Boom raising and lowering operation

Depress the foot switch and operate the boom elevation joystick controller to raise or lower the boom
Raise
Lower

Caution: Do not press the boom or the platform against the ground by lowering the boom.

41
4.4 Boom rotation operation
Depress the foot switch and operate the boom rotation joystick controller to rotate the boom.

CW CCW

Danger: Before rotating the boom, make sure that no person or obstacle is around the turntable as
the turntable protrudes beyond the machine width.

4.5 Boom telescope operation

Depress the foot switch and operate the boom telescope joystick controller to extend or retract the
boom.
Retract
Extend

4.6 Platform rotation operation

Depress the foot switch and operate the platform rotation switch to rotate the platform.

CW CCW

Caution: When traveling, rotate the platform to its central position.

4.7 Fly jib operation (for SR12BJ/ISR40BJ only)

Depress the foot switch and operate the fly jib switch to raise or lower the fly jib.
Raise
Lower

42
4.8 Emergency stop operation
Press the emergency stop switch. When this switch is pressed, the engine stops and all of the functions
are disabled.
Press the emergency stop switch in the following cases:
(1) When shutting down the engine.
(2) When personnel on the platform stops the machine movements to avoid danger.
(3) When the machine is uncontrollable due to malfunction.

Engine start switch

Emergency
stop switch

Advice: To resume the operations, pull the emergency stop switch.

Danger:
If the boom descends gradually after pressing the emergency stop switch, this may be caused
by a natural descent of the hydraulic cylinder. In this case, restart the engine with the engine
start switch and operate the boom and the fly jib to prevent the boom, the fly jib and the
platform from coming into contact with any obstacles. Then, lower the platform to the ground
and stop using the machine.
If the emergency stop switch was used as a result of malfunctions, stop using the machine and
contact Aichi service shop for inspections.

43
4.9 Emergency pump operation
If the machine does not work due to engine or main pump failure, lower the platform using the
emergency pump.
Emergency pump switch

30 seconds
Rest 30 seconds
Operate

Emergency pump
operation cycle diagram

Operate 30 seconds
Rest
30 seconds

Caution:
Operate the emergency pump every other 30 seconds. The continuous operation in excess of
30 seconds may damage the emergency pump.
Do not impose heavy load to the emergency pump, e.g. by attempting travel operation.

4.10 Alarm horn operation

The horn sounds when the horn switch is pressed. Sound horn to warn personnel in the working area
before starting operations.

Horn switch

44
4.11 Platform level adjustments
Depress the foot switch and operate the platform level adjust switch to level the platform.

Platform level adjust switch

UP UP
UP

UP
DOWN
DOWN

DOWN DOWN

SR12B/ISR40B SR12BJ/ISR40BJ

45
4.12 Indicator lights
The following indicator lights are installed on the upper control panel.

System failure light Fuel level light

Engine failure light

Tilt warning light Overload warning light

(1) System failure light

This light blinks in the event of computer control system failure. Stop using the machine and
contact Aichi service shop for inspections, if this light blinks.
(2) Engine failure light
This light goes on in the event of an engine failure e.g. failed charging system, abnormally low oil
pressure and abnormally high cooling water temperature. Check the indicator lights located on the
lower control panel to identify the cause.
(3) Tilt warning light
This light goes on and the alarm buzzer sounds when the machine tilts more than 3 degrees. Do
not elevate the platform, if this light goes on.
(4) Fuel level light
This light goes on when the fuel level is low. Refill the fuel tank with diesel fuel when this light
goes on. This light goes on when the remaining fuel reaches 23 liters (8 gallons).
(5) Overload warning light
This light blinks, the alarm buzzer sounds and all of the functions are disabled when the platform
is overloaded.

46
 XI Operation Points
Park the machine on firm level surface before elevating the platform. The machine may tip over, if
parked on soft or uneven surface.
The maximum ground contact pressure of this machine is:
SR12B / ISR40B ----------- 0.66 kg/cm2 (9.39 PSI).
SR12BJ / ISR40BJ --------- 0.74 kg/cm2 (10.53 PSI).
(1) Set up the machine close to the working target.

Shortest distance

(2) Rotate, and elevate the boom until the working target is in line with the boom extending direction.

(3) Extend the boom until the working target is within a comfortable working range.

Advice: Operate the fly jib and rotate the platform, if necessary.
(4) After finishing the work, reverse the above procedures to lower the platform.

47
 XII Transportation
1. When using loading ramp
When loading or unloading the machine onto/from the transport vehicle using a loading ramp, observe
the following items:
(1) Load/unload the machine to/from the transport vehicle on firm and level surface.
Danger:
The tracks of the machine may fall off, if the transport vehicle or the loading ramps incline
excessively.
When loading and unloading, be sure to have a guide assist you so that the tracks do not fall
off the ramp and the transport vehicle bed.
(2) After loading the machine onto the transport vehicle, be sure to engage the rotation lock pin to
lock the turntable and prevent the turntable from being rotated during the transportation.
Advice:
Rotate the turntable slowly to align the both rotation lock pin holes located on the turntable
and on chassis, then insert the rotation lock pin into their holes.
Rotation lock pin
Lock pin hole

Rotation gearbox

(3) Check that all doors and covers of the machine are closed and latched securely.
(4) Tie down the chassis of the machine to the transport vehicle bed securely.
(5) Tie down the boom and the fly jib with placing a wood block under the boom and fly jib head to
prevent the boom and the fly jib from bouncing during the transportation.
(6) Tie down the platform so that it is not swung during the transportation. At this time, be sure to
allow the clearance between the bottom of the platform and the transport vehicle bed.
(7) Do not tighten the tie down the chains marked (*) too much. Tighten them just so that the platform
is not swung or bounced during the transportation.
See the figures on the following page for the detail of tie down procedures.

48
 Rotation lock pin

*
Clearance

Tie down rings

Wood block

SR12B/ISR40B

Rotation lock pin

Clearance
Tie down rings

Wood block

SR12BJ/ISR40BJ

49
2. When hoisting the machine
Pass the sling chains or wire ropes through the hoisting rings located on the turntable and hoist the
machine slowly.
Gravity
centerline
Sling chain or wire ripe

1.42 m 4ft-8in

SR12B/ISR40B

Gravity
centerline
Sling chain or wire ripe

1.33 m 4ft-4in

Caution:
SR12BJ/ISR40BJ
Use sling chains or wire ropes strong enough to withstand the weight of the machine. The gross
weight of the machine is as shown in the table below

Model Weight
SR12B / ISR40B 7,445 kg (16,413 LBS)
SR12BJ / ISR40BJ 8,240 kg (18,166 LBS)
Be sure to retract and lower the boom fully before hoisting the machine.

50
 XIII Lubrication
1. Recommended lubricants
Hydraulic oil Gear oil Grease
Manu-
facturers General For cold Travel and Rotation Gear
General Molybdenum
purpose region gearboxes compound
Shell oil Tellus oil T22 Tellus oil T15 Spirax EP 90 Alvania EP Cardium Retinax AM
grease 2 compound
A or D
Esso oil Nuto H22 Standard gear oil 90 Lithtan EP2 JWS2563 Beacon Q2
― Esso gear oil GP80 Beacon EP2 Spartal
EP2200
Nidok EP2
Mobil oil DTE 24 Pegasus gear oil 90 Mobilux EP2 Mobiltac QQ Mobil grease
― special
Mobilube GX90
Nippon oil Super Highland Gearlube SP 90 Epiknock AP2 Cranoc New molynick
highland 22 wide 15 compound 1
Idemitsu Daphne super Daphne super Apoloil gear HE 90 Daphne Daphne open Daphne grease
kosan hydraulic oil hydro WR15 coronex gear oil No.1 M No.2
22 grease EP
No.2
Cosmo oil Cosmo hydro Cosmo gear GL-4 90 Cosmo grease Cosmo gear Cosmo
AW22 ― diner Max EP compound molybdenum
No.2 No.2 grease No.2
Japan Hydrax 22 Gear 4-90 Resonics Gear Resonics grease
energy ― grease EP-2 compound M-2
No.2
Mitsubishi Hydro fluid Diamond hypoid gear Diamond Mitsubishi Diamond
oil EP22 ― oil 90 multipurpose gear multipurpose M
EP grease 2 compound 2 grease 2
General oil Panol 22 G-gear 4-90 Gemico General gear Gemico grease
― grease compound 2 AD-1
ME-2

* Supply proper amount of machine oil to the hinges.

51
2. Lubrication points and intervals
2.1 Lubricate every 100 hours or one month

Lubricant: Grease (general)

Boom pivot pin Rotation bearing

Leveling cylinders

Elevation cylinder

Upper leveling cylinder

Elevation cylinder

Pivot pin for Fly jib

Rollers

Upper leveling cylinder

Fly jib cylinder Fly jib cylinder Pivot pin for Platform

52
2.2 Change oil every 1,200 hours or 12 months

Hydraulic oil tank Travel gearbox

(Hydraulic oil) (Gear oil)

Oil filler plug

Oil drain plug

Rotation gearbox
(Gear oil)

53
 XIV Daily Care
Various materials are used in the constructions of this machine and these materials wear or deteriorate
gradually. Some parts may be difficult to check for safety, so those parts should be replaced
periodically according to the predetermined serviceable lifetime.

1. Hydraulic oil

1.1 When replenishing

Check oil level with the oil level gauge equipped on the hydraulic oil tank, and refill to the level
through the oil filler cap.
Advice: Retract and lower the boom fully, before checking the oil level.
Oil filler cap
Oil reservoir

Oil level gauge

1.2 Hydraulic oil change (once a year)

(1) Lower and retract the boom fully.
(2) Remove the oil drain plug installed on the bottom of the tank and drain the hydraulic oil
thoroughly, then reinstall the oil drain plug.
(3) Refill the tank with new hydraulic oil with checking the oil level.
Advice: Hydraulic oil tank capacity: 145 liters (38.3 gallons)
(4) Replace the hydraulic oil filters at the same time.

Hydraulic oil filters

54
2. Gear oil for Rotation gearbox
Change the gear oil once a year or every 1,200 hours.
(1) Remove both of the oil drain and the oil level gauge to drain gear oil thoroughly.
(2) Reinstall the oil drain plug, and refill the gearbox with new gear oil.
Oil capacity: 1.7 liters (0.45 gallons).
(3) Reinstall oil level gauge.

Oil level gauge

Keep the oil level between these two lines

Drain plug

3. Gear oil for Travel gearbox

Change the gear oil once a year or every 1,200 hours.
(1) Travel the machine and set the oil drain plug at the lowest position as shown in the figure
below.
(2) Remove all of the oil drain, oil level and oil filler plugs to drain the gear oil.
(3) Reinstall the oil drain plug.
(4) Refill the gearbox with new gear oil through the oil filler port until the oil level reaches the oil
level port, and then reinstall the oil level and oil filler plugs.
Advice: Oil capacity: 1.0 liter (0.26 gallons) for one side

Oil filler plug

Oil level plug

Oil drain plug

55
4. Fuel
Use gas oil (Diesel fuel) as a fuel.
Check fuel level with the fuel level gauge, and refill to the level.
Advice: Tank capacity: 95 liters (25.1 gallons).

Fuel filler lid

Level gauge

5. Engine
See the engine manufacturers manual for the detail of engine maintenance.
A long life coolant (Freezing temperature of – 40℃) is filled in the new machine before shipping.

Engine oil filter

Engine oil filter

Oil level gauge Oil level gauge

New type Old type

Isuzu 3CE1, PZP01 Isuzu 3LD1, PA49

56
6. Wire ropes
Replace the wire rope, when any defects listed below are observed.
(1) Kinked rope.
(2) Stretched or corroded rope.
(3) Cut rope.
(4) If the decrease of the rope diameter exceeds 3% of the nominal diameter. See the figure below to
measure the rope diameter.
Advice: For replacement procedure, contact Aichi service shop.
One lay

In case of 6 strand

7. Fuses
The fuse holder is located on the lower control panel. If the machine does not work, the fuse may
have been blown.
Advice: When replacing the fuse, be sure to turn the engine key switch to its OFF position.

F1 20A CPU boards, Lower

F2 10A Emergency stop
F3 10A Upper control
F4 10A CPU board, Upper
F5 10A Engine
F6 10A Horn
F7 10A Work light (Option)
F8 5A Accelerator
Fuse arrangements

Fuse holder

57
8. Hydraulic hoses
If oil leaks from the hydraulic hose, stop using the machine immediately and contact Aichi service
shop. When ordering the hydraulic hoses, quote the following items to the service shop.
(1) Type of the hose: Rubber or Nylon
(2) Installed location on the machine
(3) Length of hydraulic hose: The dimension between the tips of both hose fittings.
Advice: The length is indicated on the “Hose fitting” as shown in the figure below. But this is
rubber hose only.
Length
Example: 95 (9.5)  950 mm
12  1,200 mm

(4) Type of “Hose fittings”

Hose fitting (male) Hose fitting (female)

(5) Size of hydraulic hose: Quote the wrench size of the hose fitting.

Wrench size
Hydraulic hose fitting 19, 22, 27

(6) Existence of armour

① Both sides armoured

② All armoured

③ Non armoured

58
9. Crawler
Sagging may occur on the tracks due to wear, so you are requested to adjust the track tension
periodically. If the tension is not appropriate, the tracks risk detachment.

9.1 Adjustment method

(1) Set up the machine on firm and level surface, retract the boom fully, and then rotate the boom
to the right or left side of the chassis.
(2) Set the “Boom stand B” and the “Wood block A” under the 1st boom section as shown in the
figure below.

Ａ
Ｂ

Caution: The “Wood block A” should be longer than the width of the 1st boom section, and
arrange it so that the boom comes to the center of the wood block. In the interest of
safety, make sure the stand is stable.
(3) Lower the boom slowly to press the boom against the wood block, and allow the clearance of 30
∼50 mm (1.2∼2.0 in) between the track and the ground.

30 mm∼50 mm (1.2 ~ 2.0 in)

Danger:
Be sure to perform the boom operations from the “Lower control.”
Do not lift up the track more than 50 mm (2.0 in) above the ground. If the track is lifted up
beyond what is necessary, the machine may become unstable.
(4) Supply grease to the “Grease cylinder” through the “Grease fitting” installed on the lubricator
shown in the following page to apply more tension to the track.
Adjust the dimension between the chassis frame and the track link shown in the following page to
95 ~ 105 mm (3.7∼4.1 in) to apply the specific tension on the track.
If the track is too tight, unscrew the “Lubricator” part away till the grease exudes.
Danger:
Do not loosen the grease fitting as it may pops out, resulting in serious injury.
Do not unscrew the “Lubricator” more than one full turn as it may pop out, resulting in
serious injury.

59
 A

A’

Chassis frame Track roller

Track link

Grease fitting

95 ~ 105 mm
(3.7 ~ 4.1 in)
(Lubricator)

Track shoe

(5) After adjusting one side, rotate the boom 180°, and adjust the other side in the same manner.
Advice: It is important to adjust the tension of left and right tracks equally.

9.2 Adjustment interval

Adjust the track tension at the intervals mentioned below.

Interval
First time on new machine After 10 ∼ 20 hours
Thereafter Every 800 hours or 6 months

60
 XV Storage for long periods
(1) Clean up the machine thoroughly.

(2) Lubricate each part of the machine thoroughly.

(3) Apply rust-prevention oil to the cylinder rods.

Caution: If the cylinder is left without rust-prevention oil, it may rust.

(4) Store the machine in a dry room. If storage outside is unavoidable, park the machine on firm level
surface and cover the machine using a water proof sheet.

(5) During long-term storage, conduct the following operations periodically.

Operate the boom to prevent corrosion of the lubricated sections.
Drive the machine regularly to prevent rust forming on the track links.

Advice: Wipe off the rust-prevention oil applied on the cylinder rod before operating the boom.

61
 XVI Optional Equipment Operating Method
Optional equipments are equipped on the request of the customer, so the devices described in this
chapter may not always be equipped on your machine.

1. Work light
When the work light switch on the upper control panel is turned on, the work light on the platform
goes on.
Advice: If the work light is kept lit while the engine is not in motion, the battery may be dead. Use
the work light only when the engine is in motion.

Work light

2. AC power outlet
Connect the mains supply to the AC input plug located at the turntable before using the electrical tools
on the platform.

3. Travel remote control

Connect the travel remote control box to the lower control panel, and then set the travel remote control
select switch in its REMOTE control position to travel the machine using the travel remote control box.
Travel remote control select switch

Travel remote control box

Remote control
Metal connector

Lower control
Emergency stop
Straight (Both tracks)
Right track

Left track
Forward
Reverse

62
XVII Decals
CAUTION
· Make sure that all decals are readable and in their specified places. Damaged or dirty decals may
obstruct safe operations. Replace the decals with new ones if necessary.

N5Y6-0001-00
Nameplate Pictorial

491-00003-35
491-00001-52
Do not power wash
Do not disable foot switch

A - view
491-00003-98 491-00003-30
Tip over hazard Operator’s qualification 491-00003-35 (on both sides)
491-00003-07 491-00001-59 Do not power wash
Manual located Emergency pump
inside
A

494-00003-62 494-04433
Platform capacityy Wind load
491-00003-33
491-00003-35
No power wash Operator’s check list
494-00003-63 494-04735 (on 4 corners)
Platform capacity Safety stripes
491-00001-49 (on both side inside)
Attach safety lanyard

63
 491-04792 (on both sides)
Pictorial decal Crashing hazard
Boom 182-01002 (on both sides)
Aichi logo

494-00002-53 (on both sides)

SKYMASTER

Fly jib

491-04792 (on both sides)

Pictorial decal Crashing hazard

491-04792 (on both sides)

Pictorial decal Crashing hazard

64
 491-00003-39 (on both sides)
Crushing hazard S49431-03
Noise
494-04720 (on both sides)
CE marking
493-00000-08
Serial number plate

494-04735 (on both sides) 494-04735 (on both sides)

Safety stripes 494-04400 Safety stripes
Cooling water drain

491-00001-65
Stand clear of swinging turret
491-00003-39 (on both sides)
491-04791 Crushing hazard
491-00003-39 (on both sides)
Crushing hazard Do not touch 494-00001-69 (inside the door)
Gear oil
494-00001-70
Rotation lock pin

491-00003-35 (inside the door)

Do not power wash
N491-0000-07 (inside the door)
B DC 12 volt system

491-00003-39
Crushing hazard
378-00000-24
Thermo label

B-view

65
 491-04791 491-00003-45
Hydraulic oil only
Do not touch
491-00001-60 494-01582
Hydraulic oil level gauge
Diesel fuel only

491-00001-55
Explosive fumes Lubrication
Hoisting procedures N5Y6-0015-00 (SR12B/ISR40B)
N5Y6-0016-00 (SR12B/ISR40B) N5Y6-0022-00 (SR12BJ/ISR40BJ)
N5Y6-0020-00 (SR12BJ/ISR40BJ) 491-00003-42
Transport Instruction Inspection records
N5Y6-0014-00 (SR12B/ISR40B)
N5Y6-0021-00 (SR12BJ/ISR40BJ)
491-00003-33
Operator’s check list

491-00003-09
Electrocution hazard
491-00003-30
Operator’s qualification 491-00003-35
Do not power wash
491-00003-40
Engine Instructions

Working range diagram

N5Y6-0017-00 (SR12B/ISR40B) 491-00001-59
N5Y6-0023-00 (SR12BJ/ISR40BJ) Emergency pump
N5Y6-0006-00 (inside the cover) 491-00003-18
Pre-heat Instructions
Fuse
N5Y6-0002-00
Nameplate Pictorial

66
 B C
A

494-00003-03
Travel FWD-Right
N5Y6-0018-00
Elevation-DOWN
N5Y6-0019-00 5Y6-01485-00 5Y6-01486-00
Telescope-IN Travel-Right.Boom function Travel-Left
5Y6-00715-00
Rotation-CCW
494-00003-04
Travel FWD-Left

A-detail (inside the cover) B-detail (inside the door)

491-00891
Coolant
EC label (engine)
EPA label (engine)
494-00002-54
Recommended engine oil
494-00003-35
Do not power wash

C-detail (inside the cover)

67
494-00001-69 (on both side)
Gear oil

68
 378-00000-24 491-00001-49

℃ 60 65 70 75 80 85 90 ℃

F 140 149 158 167 176 185 194 F

491-00001-52 491-00001-55

491-00001-59 491-00001-60

491-00001-65 491-00003-07

491-00003-09

69
491-00003-18

491-00003-30

491-00003-33

491-00003-35 491-00003-39

70
491-00003-40

491-00003-42

71
491-00003-45

491-00003-98

491-00891 491-04791

クーラント注入済
ＡＮＴＩ ＦＲＥＥＺＥ

年 月

凍結温度 freezing temp

−１５℃，−３０℃，−４０℃

491-00891

72
491-04792

493-00000-08

494-00001-69 494-00001-70

494-00002-53

494-00002-54

73
494-00003-03 494-00003-04

494-00003-62

492-00003-63

494-01582 494-04400

494-04433 494-04720

74
494-04735

5Y6-00715-00 5Y6-01485-00

5Y6-01486-00 N491-0000-07

N5Y6-0001-00

75
N5Y6-0002-00

N5Y6-0006-00 N5Y6-0014-00

76
N5Y6-0015-00

N5Y6-0016-00

77
N5Y6-0017-00

N5Y6-0018-00 N5Y6-0019-00

N5Y6-0020-00

78
N5Y6-0021-00

N5Y6-0022-00

79
N5Y6-0023-00

S4943100

80