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Publication No.

TR-500M-1/C1-1E

01

Rough Terrain Crane


TR-500M-1
Model

Applicable Serial No. 580170 -


Foreword

Foreword

This manual contains all the hydraulic and electric circuit diagrams for the Model TR-500M-1 rough terrain crane.

This manual is applicable to the machine of the Spec. Nos. given below. Before using this manual, check the
Spec. No. of your unit in the nameplate on the machine.

For proper repair and maintenance operations, use this manual together with the appropriate service manual,
operation and maintenance manual and the related parts catalog furnished separately.

1. Applicable spec. NO.

SPEC. NO. SERIAL. NO.

MFG.DATE.

KAGAWA, JAPAN

ISA04-001601

Spec. No. Applicable serial No.


TR-500M-1-00103
580170 -
TR-500M-1-00104

We reserve the right to modify the design for improvements, etc. without notice.

 WA04-0000E
Foreword

2. Contents
Spec. No.
Chapter Section TR-500M- TR-500M-
1-00103 1-00104

Data, Adjustment and Checks

Specifications Y-1

Weight Table Y-2

Adjustment (pressure) Y-3 Y-4


Y
Adjustment (electric) Y-5 Y-6

Adjustment and Checks Y-7 Y-8

System Diagrams

Hydraulic Circuit Z-1 Z-2

Electric circuit
Z-3 Z-4
(electrical parts location diagram)

Electric circuit (crane) Z-5 Z-6

Z Electric circuit (carrier) Z-7

Torque converter circuit Z-8

Brake circuit Z-9

 WA04-0000E
Data, Adjustment and Checks

Contents

Y-1 Specifications. ............................... 1 Air circuit section.....................................13

Engine.......................................................1 Converter circuit section. ........................13

Hydraulic equipment.................................1
Y-5 Adjustment procedure
(electric)...................................... 14
Y-2 Weight list....................................... 2
Switch adjustment procedure. ................14
Y-3 Adjustment procedure 1. L10 switch (main winch hoist-up detection)
(pressure)..................................... 3 L11 switch (main winch hoist-down detection)
L12 switch (boom extending detection)
Hydraulic circuit section............................3 L13 switch (boom retracting detection)
1. Manual control valve. ................................. 4 L14 switch (boom raising detection)
2. Solenoid control valve................................ 5 L15 switch (boom lowering detection)
3. Flow control valve....................................... 5 L16 switch (auxiliary winch hoist-up detection)
4. Priority valve............................................... 6 L17 switch (jib tilt raising detection)
5. Boom telescoping control valve.................. 6 L18 switch (jib tilt lowering detection)....... 14
6. Unload valve............................................... 6 2. L3 switch
7. Reducing valve........................................... 7 (detection of boom front position).... 14
3. L20 switch
Air circuit section.......................................8
(detection of boom rear position)..... 14
Converter circuit section. ..........................8 4. L1 switch
(detection of 4th and top boom full retraction)........ 15
Y-4 Adjustment procedure 5. L2 switch (detection of left area). ............. 15
(pressure)..................................... 9 6. L8 switch (detection of jib tilt operation)... 15
7. L9 switch (detection of jib full retraction).. 15
Hydraulic circuit section............................9 8. L6 switch
1. Manual control valve. ............................... 10 (detection of maximum mast angle)...... 15
2. Solenoid control valve.............................. 10 9. L7 switch
3. Flow control valve..................................... 11 (detection of minimum mast angle)....... 16
4. Priority valve............................................. 11 10. L21 switch
5. Boom telescoping control valve................ 11 (detection of mode switching
Y
6. Unload valve............................................. 12 (economy/power)). .......................... 16
7. Reducing valve......................................... 12


1. Pump bleeding procedure........................ 21
11. L
 22 switch (detection of
Swing system..........................................22
rear steering lock pin operation)................ 16
1. Procedure for adjusting master cylinder
12. L23 switch (detection of straight driving). ... 16
mounting status............................... 22
13. Idling switch............................................ 16
2. Procedure of
Procedure of bleeding in swing brake circuit. ....... 22
potentiometer adjustment....................17
Winch system. ........................................22
1. Jib tilt angle detector. ............................... 17
1. Procedure for checking N2 gas filling
pressure in the accumulator............ 22
Y-6 Adjustment procedure (electric) 18
2. Procedure for adjusting brake pedal
Switch adjustment procedure. ................18 (Main and auxiliary winches)........... 23
1. L10 switch (main winch hoist-up detection) 3. Bleeding procedure in brake circuit.......... 23
L12 switch (boom extending detection) 4. Procedure for
L13 switch (boom retracting detection) adjusting the winch brake band....... 24
L14 switch (boom raising detection) 5. Procedure for
L15 switch (boom lowering detection) bleeding in winch clutch circuit........ 26
L16 switch (auxiliary winch hoist-up detection) 6. Procedure for bleeding in winch circuit
L17 switch (jib tilt lowering detection) (counter balance valve)................... 26
L19 switch (main winch 2nd speed detection, Telescoping system. ...............................27
optional and series circuit)
1. Procedure for
L21 switch (jib tilt raising detection). ........ 18
bleeding in power tilt jib circuit......... 27
2. L3 switch
2. Procedure for bleeding of
(detection of boom front position).... 18
power extension jib circuit............... 27
3. L20 switch
(detection of boom rear position)..... 18 Crane operation......................................28
4. L
 1 switch 1. Procedure for
(detection of 4th, 5th and top boom full retraction). .... 19 adjusting engine rotation................. 28
5. L2 switch (detection of left area). ............. 19 2. Procedure for
6. L31 switch (detection of jib lock pin)......... 19 adjusting accelerator pedal. ............ 29
7. C
 S1 switch
Driving power generating system. ..........30
(detection of automatic pin insertion)..... 19
8. L
 21 switch 1. Procedure for
(detection of mode switching checking stall rotation speed........... 30
(economy/power)). .......................... 19 Brake system..........................................30
9. L
 22 switch 1. Procedure for adjusting brake pedal. ....... 30
(detection of rear steering lock pin operation). ..... 20 2. Procedure for bleeding in brake circuit..... 31
10. L23 switch 3. Procedure for
(detection of straight driving)........... 20 adjusting parking brake clearance......... 31
11. Idling switch............................................ 20 4. Procedure for connecting parking brake
and spring chamber......................... 31
Y-7 Adjustment and checks. ............. 21

Hydraulic system. ...................................21

ii
Steering system......................................31 1. Procedure for adjusting brake pedal. ....... 42
1. Procedure for 2. Procedure for bleeding in brake circuit..... 42
adjusting tire steering angle. ........... 31 3. Procedure for
adjusting parking brake clearance......... 42
Electric transmission...............................32 4. Procedure for connecting parking brake
1. Failure diagnosis for and spring chamber......................... 43
turbo control system........................ 32
Steering system......................................43
Option. ....................................................33 1. Procedure for
1. Procedure for adjusting tire steering angle. ........... 43
filling air conditioner refrigerant gas....... 33
Electric transmission...............................44
Y-8 Adjustment and checks. ............. 36 1. Failure diagnosis for
turbo control system........................ 44
Hydraulic system. ...................................36
Option. ....................................................45
1. Pump bleeding procedure........................ 36
1. Procedure for
Swing system..........................................36 filling air conditioner refrigerant gas....... 45
1. P
 rocedure for adjusting master cylinder
mounting status............................... 36
2. Procedure of
bleeding in swing brake circuit. ....... 36

Winch system. ........................................37


1. P
 rocedure for checking N2 gas filling
pressure in the accumulator............ 37
2. P
 rocedure for adjusting brake pedal
(Main and auxiliary winches)........... 37
3. Procedure of bleeding in brake circuit...... 37
4. Procedure for
adjusting the winch brake band....... 38
5. Procedure for
bleeding in winch clutch circuit........ 39
6. P
 rocedure for bleeding in winch circuit
(counter balance valve)................... 39

Crane operation......................................40
1. Procedure for
adjusting engine rotation................. 40
2. Procedure for
adjusting accelerator pedal. ............ 41

Driving power generating system. ..........42


1. Procedure for
checking stall rotation speed........... 42

Brake system..........................................42

iii
Y- 1 Y- 1
Specifications

Engine
1. Engine rotation speed

Idling speed (IDL): 600 +50 0 rpm

Maximum rotation speed (MAX)


Rotation speed during PTO “OFF” with no load
Rotation speed during PTO “ON” with no load
Rotation speed at a stall: Approx. 1650 rpm (reference value)

Hydraulic equipment
1. Hydraulic pump (for crane)

1) Pump rotation speed (Reduction gear ratio: 0.771)


Idling speed (IDL)
Maximum rotation speed (MAX)
2) Discharge rate

2. Hydraulic pump (for steering)

1) Pump rotation speed (Reduction gear ratio: 0.854)


Idling speed (IDL)
Maximum rotation speed (MAX)
2) Discharge rate

3. Charging pump (for torque converter)

1) Pump rotation speed (Reduction gear ratio: 0.821)


Idling speed (IDL)
Maximum rotation speed (MAX)
2) Discharge rate: 33.3cc/rev

4. Emergency steering pump

1) Pump rotation speed


Rotation speed of transmission output shaft

2) Discharge rate: 15.5cc/rev

5 Hydraulic motor (winch)

Oil intake rate: 180cc/rev (main and auxiliary winches)

6. Swing drive unit

1) Oil intake rate: 45.1cc/rev


2) Reduction gear ratio: 81

7. Accumulator

N2 gas filling pressure:


80±3 kg/cm 2 (when ambient temperature is 20 °C)

 Y01-0410E
Y- 2 Y- 2
Weight list

The following table shows weights of main components using symbols. Become familiar with the overview of
those weights to select the proper lifting bracket for installation.

Symbol Weight (kg) Symbol Weight (kg) Symbol Weight (kg)

[Spec number]

Spec No.
Component name

Outrigger inner case Ass’y


Swing table Ass’y (excluding boom and elevating cylinder)
Swing bearing
Elevating cylinder
Winch Ass’y
Jib
Boom Ass’y (including telescoping cylinder)
Counter balance weight
Axle
Engine

 Y02-0280E
Y- 3 Y- 3
Adjustment procedure (pressure)

Hydraulic circuit section


Setting pressure table

Name Setting pressures (kg/cm 2 ) Remarks


Manual control valve
Winch hoist-up circuit Relief valve (RV1)
Main winch hoist-down circuit Port relief valve (PR1)
Auxiliary winch hoist-down circuit Port relief valve (PR2)
Boom raisig, winch hoist-up circuit Relief valve (RV2)
Boom lowering circuit Port relief valve (PR5)
Boom extending circuit Port relief valve (PR3)
Boom retracting circuit Port relief valve (PR4)
Power tilt jib raising circuit Port relief valve (PR7)
(power extension jib retracting)

Power tilt jib lowering circuit


(power extension jib extending) Port relief valve (PR6)

Solenoid control valve


(outrigger, swing circuit) Relief valve (RV3)

Manual control valve Overload relief valve (R A)


(for swing operation)
Relief valve (RB)
Flow control valve
(spring lock & oil cooler circuit) Relief valve (RV4)

Priority valve
(steering circuit) Relief valve (RV5)

Boom telescoping control valve Relief valve (RV6)


Solenoid valve Relief valve (RV7),
(for power tilt/extension jib switching) cracking pressure
Solenoid valve
(for options and air conditioner) Relief valve (RV8)

Onload pressure
Unload valve
Unload pressure
Reducing valve

Counter balance valve Overload relief valve


(for main and auxiliary winches)
Pilot pressure at cracking
Accumulator Nitrogen gas filling pressure

Pressure gauge (for accumulator) Pressure switch (PS1) setting pressure

Thermostat
(for hydraulic oil temperature indicator lamp)

 Y03-0410E
Y- 3 Y- 3
Adjustment procedure (pressure)

Pressure adjustment procedure

Oil temperature: 50±5 °C, Hydraulic oil: ISO VG 46

1. Manual control valve

1) Winch hoist-up circuit


(Relief valve, RV1)

Block the hoist-up port of the main winch or
auxiliary winch.
Turn
 “ON (I)” the PTO switch.
Move
 the winch operation lever of which the
port is blocked to hoist-up 1st speed, and then
measure the pressure with the pressure gauge
in the cab.
Engine rotation speed: MAX (1500 rpm)

2) Boom raising, winch hoist-up circuit


(Relief valve, RV2)

Turn “ON (I)” the PTO switch.

Fully extend the boom elevating cylinder.

Move the boom elevating lever to the boom
raising side, and then measure the pressure
with the pressure gauge in the cab.
Engine rotation speed: MAX (1500 rpm)

3) Boom lowering circuit


(Port relief valve, PR5)
Turn “ON (I)” the PTO switch.
Fully retract the boom elevating cylinder.

Move the boom elevating lever to the boom
lowering side, and then measure the pressure
with the pressure gauge in the cab.
Engine rotation speed: IDL (600 rpm)

4) Boom extending circuit


(Port relief valve, PR3)
Turn “ON (I)” the PTO switch.
Fully extend the 2nd and 3rd booms.

Move the boom telescoping lever to the boom
extending side (without pressing the 4th and
top boom extending switches), and then
measure the pressure with the pressure gauge
in the cab.
Engine rotation speed: MAX (1500 rpm)

5) Boom retaracting circuit


(Port relief valve, PR4)
Turn “ON (I)” the PTO switch.
Fully retract the boom.

Move the boom telescoping lever to the boom
retracting side, and then measure the pressure
with the pressure gauge in the cab.
Engine rotation speed: MAX (1500 rpm)

6) Power tilt jib raising circuit


(power extension jib retracting)
(Port relief valve, PR7)
Turn “ON (I)” the PTO switch.

Shift the jib tilt/telescoping selector switch to
the “tilt” side.
 the power tilt jib in the operating status and
Put
minimize the jib tilt angle.

Move the jib operation lever to the tilt raising
side, and then measure the pressure with the
pressure gauge in the cab.
Engine rotation speed: MAX (1500 rpm)

 Y03-0410E
Y- 3 Y- 3
Adjustment procedure (pressure)

7) Power tilt jib lowering circuit


(power extension jib extending)
(Port relief valve, PR6)
Turn “ON (I)” the PTO switch.

Shift the jib tilt/telescoping selector switch to
the “tilt” side.
 the power tilt jib in the operating status,
Put
and maximize the jib tilt angle.

Move the jib operation lever to the tilt lowering
side, and then measure the pressure with the
pressure gauge in the cab.
Engine rotation speed: IDL (600 rpm)

2. Solenoid control valve

Installation location: Left of the frame center



Install a pressure gauge to the pressure outlet,
Pressure outlet and loosen the adjustment screw of the relief
(PT1/4) valve.
Turn “OFF” the PTO switch.

After stowing the outrigger at idling rotation
Relief valve RV3 from the outrigger stowing status, gradually
increase the engine rotation speed to the
maximum. In this status, adjust the pressure to
the setting value.
Engine rotation speed: MAX (2200 rpm)

NOTICE
Because the check valve is provided inside
the solenoid control valve, pressure is not
reduced even when the adjustment screw is
loosened if the pressure beyond the setting
value is shut in. Thus, when the adjustment
screw has been loosened, return the outrigger
extending/stowing selector switch to the
Relief valve RV4 neutral position once to remove the shut-in
pressure.

3. Flow control valve

Installation location: Lower left side of the frame center


Install a pressure gauge to the pressure outlet.
Turn “ON (I)” the PTO switch.

Shift the spring lock switch to “LOCK I” and
the spring lock “UP/DOWN” selector switch to
“DOWN” to perform the spring lock operation,
and then measure the pressure.
Engine rotation speed: MAX (1500 rpm)

Pressure outlet
(PT1/4)
(T joint section)

Front

Flow control valve


Solenoid valve for spring lock

 Y03-0410E
Y- 3 Y- 3
Adjustment procedure (pressure)

4. Priority valve
Relief valve, RV5
Installation location: Side of the swing drive unit

Install a pressure gauge to the pressure outlet.


Turn “OFF” the PTO switch.

Perform steering operation (clockwise rotation)
without jack-up, fully extend the steering
cylinder, and then measure the pressure.
Engine rotation speed: MAX (2200 rpm)

Pressure outlet (PT1/4)


Rotary joint

Front

5. Boom telescoping control valve


Pressure outlet (PT1/4)
Installation location: Rear of the swing table

Install a pressure gauge to the pressure outlet.


Turn “ON (I)” the PTO switch.

Stroke end only the 2nd boom by using the
2nd boom correction switch.

Move the boom telescoping lever to the
boom extending side, and then measure the
pressure.
Engine rotation speed: MAX (1500 rpm)

Relief valve, RV6

6. Unload valve

Installation location: Left side of the swing table

1) Procedure of pressure accumulation check

Adjustment screw Turn “ON (I)” the POT switch.


Lock the main (auxiliary) winch drum.

Adjust the engine rotation speed to maximum
(1500 rpm)

Shift the main (auxiliary) clutch lever to “ON”
and then “FREE” repeatedly to reduce the
accumulator pressure. Stop the clutch lever
operation when the accumulating pressure
status changes from drop to rise.

NOTICE
Operate the clutch slowly after the pressure
has dropped close to the accumulation start
pressure.

 Y03-0410E
Y- 3 Y- 3
Adjustment procedure (pressure)


Read the accumulation start pressure (onload
pressure) and accumulation end pressure
(unload pressure) with the pressure gauge for
the accumulator.

NOTICE
Read the unload pressure value immediately
after the completion of pressure accumulation.

2) Adjustment procedure

Tighten the adjustment bolt to adjust to the
high pressure side and loosen it to adjust to
the low pressure side. Check the accumulation
pressure every time adjustment (described in
step1) above) is performed.

7. Reducing valve
Adjustment screw
Installation location: Right side of the swing table

Turn “ON (I)” the PTO switch.
Fully extend the boom elevating cylinder.

Move the boom elevating lever to the boom
raising side, and then measure the pressure
with the pressure gauge for the accumulator.
Engine rotation speed: MAX (1500 rpm)

NOTICE
Switch the lever slowly to prevent the surge
pressure.

 Y03-0410E
Y- 3 Y- 3
Adjustment procedure (pressure)

Air circuit section

Setting pressure table

Name Symbol Setting pressures (kg/cm 2 ) Remarks


On-load
Pressure regulator
Unload
Cracking pressure
Safety valve
Full-flow pressure
Pressure switch (for stop lamp) Closed circuit during 0.3 +0.2
-0.1 kg/cm 2 or more
Low pressure switch (for anti nose dive)
Closed circuit during 3.8±0.2 kg/cm 2 or more
Low pressure switch (for parking brake)
Turn-on pressure
Low pressure indicator (for air pressure alarm)
Turn-off pressure
Reducing valve (for front wheels)
Reducing valve (for rear wheels)
Reducing valve (for auxiliary brake)

Converter circuit section

Setting pressure table

Setting pressures (kg/cm 2 )


Name Remarks

Torque converter inlet pressure 1.3 or more

Torque converter outlet pressure 1 or more

Lockup clutch pressure


PTO clutch pressure 12 or more
Transmission clutch pressure 10 or more Check with the clutch oil gauge
Transmission lubrication pressure

 Y03-0410E
Y- 4 Y- 4
Adjustment procedure (pressure)

Hydraulic circuit section

Setting pressure table

Name Setting pressures (kg/cm 2 ) Remarks

Manual control valve


Winch hoist-up circuit Relief valve (RV1)

Main winch hoist-down circuit Port relief valve (PR1)

Auxiliary winch hoist-down circuit Port relief valve (PR2)

Boom raising, winch hoist-up circuit Relief valve (RV2)

Boom lowering circuit Port relief valve (PR5)

Boom extending circuit Port relief valve (PR3)

Boom retaracting circuit Port relief valve (PR4)

Power tilt jib raising circuit Port relief valve (PR7)

Power tilt jib lowering circuit Port relief valve (PR6)


Solenoid control valve Relief valve (RV3)
(outrigger, swing circuit)
Overload relief valve (R A)
Manual control valve
(for swing operation) Relief valve (RB)
Flow control valve Relief valve (RV4)
(spring lock & oil cooler circuit)
Priority valve Relief valve (RV5)
(steering circuit)
Telescoping control valve Relief valve (RV6)
Solenoid valve Relief valve (RV8)
(for options and air conditioner)
Relief valve (for side-up cylinder)
Side-up jib extension circuit
Side-up jib stowing circuit
Onload pressure
Unload valve
Unload pressure

Reducing valve
Overload relief valve
Counter balance valve
(for main and auxiliary winches) Pilot pressure during valve opening

Accumulator Nitrogen gas filling pressure

Pressure gauge (for accumulator) Pressure switch (PSI) setting pressure

Thermostat
(for hydraulic oil temperature indicator lamp)

 Y03-0610E
Y- 4 Y- 4
Adjustment procedure (pressure)

Pressure adjustment procedure 4) Boom extending circuit


(port relief valve, PR3)
Oil temperature: 50±5 °C, hydraulic oil: ISO VG 46 Turn “ON (I)” the PTO switch.
Fully extend the 2nd and 3rd booms.

Move the boom telescoping lever to the boom
1. Manual control valve extending side (without pressing the 4th and
top boom extending switches), and then
measure the pressure with the pressure gauge
in the cab.
Engine rotation speed: MAX (1500 rpm)

5) Boom retaracting circuit


(port relief valve, PR4)
Turn “ON (I)” the PTO switch.
Fully retract the boom.

Move the boom telescoping lever to the boom
retracting side, and then measure the pressure
with the pressure gauge in the cab.
Engine rotation speed: MAX (1500 rpm)

6) Power tilt jib raising circuit


(port relief valve, PR7)
Turn “ON (I)” the PTO switch.
 the power tilt jib in the operating status and
Put
minimize the jib tilt angle.

Move the jib operation lever to the tilt raising
side, and then measure the pressure with the
pressure gauge in the cab.
Engine rotation speed: IDL (600 rpm)

7) Power tilt jib lowering circuit


(port relief valve, PR6)
Turn “ON (I)” the PTO switch.
 the power tilt jib in the operating status and
Put
maximize the jib tilt angle.

Move the jib operation lever to the tilt lowering
1) Winch hoist-up circuit (relief valve, RV1) side, and then measure the pressure with the

Block the hoist-up side port of the main or pressure gauge in the cab.
auxiliary winch. Engine rotation speed: IDL (600 rpm)
Turn “ON (I)” the PTO switch.

Move the winch operation lever of which the
port was blocked to the hoist-up side 1st
speed, and then measure the pressure with 2. Solenoid control valve
the pressure gauge in the cab.
Engine rotation speed: MAX (1500 rpm)
Installation location: Left of the frame center
2) Boom raising, winch hoist-up circuit
(Relief valve, RV2)
Turn “ON (I)” the PTO switch.
Fully extend the boom elevating cylinder.

Move the boom elevating lever to the boom
raising side, and then measure the pressure Pressure outlet (PT1/4)
with the pressure gauge in the cab.
Engine rotation speed: MAX (1500 rpm)

3) Boom lowering circuit Relief valve RV3


(port relief valve, PR5)
Turn “ON (I)” the PTO switch.
Fully retract the boom elevating cylinder.

Move the boom elevating lever to the boom
lowering side, and then measure the pressure
with the pressure gauge in the cab.
Engine rotation speed: IDL (600 rpm)

10 Y03-0610E
Y- 4 Y- 4
Adjustment procedure (pressure)


Install a pressure gauge to the pressure outlet, 4. Priority valve
and loosen the adjustment screw of the relief
valve.

Turn “OFF” the PTO switch. Installation location: Side of the swing drive unit

After stowing the outrigger at idling rotation
from the outrigger stowing status, gradually
increase the engine rotation speed to the Relief valve, RV5
maximum. In this status, adjust the pressure to
the setting value.
Engine rotation speed: MAX (2200 rpm)
NOTICE
Because the check valve is provided inside
the solenoid control valve, pressure is not
reduced even when the adjustment screw is
loosened if the pressure beyond the setting
value is shut in. Thus, when the adjustment
screw has been loosened, return the outrigger
extending/stowing selector switch to the Pressure outlet (PT1/4)
neutral position once to remove the shut-in Rotary joint
pressure.

3. Flow control valve

Installation location: Lower left side of the frame center


Front

Relief valve RV4

Install a pressure gauge to the pressure outlet.


Turn “OFF” the PTO switch.

Perform steering operation (clockwise rotation)
without jack-up, fully extend the steering
cylinder, and then measure the pressure.
Engine rotation speed: MAX (2200 rpm)

Pressure outlet
(PT1/4) 5. Boom telescoping control valve
(T joint section)
Installation location: Rear of the swing table
Front
Pressure outlet (PT1/4)

Flow control valve


Solenoid valve for spring lock

Install a pressure gauge to the pressure outlet.



Turn “ON (I)” the PTO switch.

Shift the spring lock switch to “LOCK I” and
the spring lock “UP/DOWN” selector switch to
“DOWN” to perform the spring lock operation,
and then measure the pressure.
Engine rotation speed: MAX (1500 rpm) Relief valve, RV6

11 Y03-0610E
Y- 4 Y- 4
Adjustment procedure (pressure)


Install a pressure gauge to the pressure outlet.
Turn “ON (I)” the PTO switch. 7. Reducing valve

Stroke end only the 2nd boom by using the
2nd boom correction switch. Installation location: Right side of the swing table

Move the boom telescoping lever to the
boom extending side, and then measure the Adjustment screw
pressure.
Engine rotation speed: MAX (1500 rpm)

6. Unload valve

Installation location: Left side of the swing table


Turn “ON (I)” the PTO switch.
Fully extend the elevating cylinder.

Move the boom elevating lever to the boom
raising side, and then measure the pressure
with the pressure gauge for the accumulator.
Engine rotation speed: MAX (1500 rpm)
Adjustment screw NOTICE
Switch the lever slowly to prevent the surge
pressure.

1) Procedure of pressure accumulation

Turn “ON (I)” the POT switch.


Drum-lock the main (auxiliary) winch drum.

Adjust the engine rotation speed to maximum
(1500 rpm)

Shift the main (auxiliary) clutch lever to “ON”
and then “FREE” repeatedly to reduce the
accumulator pressure. Stop the clutch lever
operation when the accumulating pressure
status changes from drop to rise.

NOTICE
Operate the clutch slowly after the pressure
had dropped close to the accumulation start
pressure.


Read the accumulation start pressure (onload
pressure) and accumulation end pressure
(unload pressure) with the pressure gauge for
the accumulator.

NOTICE
Read the unload pressure value immediately
after the completion of pressure accumulation.

2) Adjustment procedure

Tighten the adjustment bolt to adjust to the


high pressure side and loosen it to adjust to
the low pressure side. Check the accumulation
pressure every time adjustment (described in
step1) above) is performed.

12 Y03-0610E
Y- 4 Y- 4
Adjustment procedure (pressure)

Air circuit section

Setting pressure table

Name Symbol Setting pressures (kg/cm 2 ) Remarks


On-load
Pressure regulator
Unload
Cracking pressure
Safety valve
Full-flow pressure
Pressure switch (for stop lamp) Closed circuit during 0.3 +0.2
-0.1 kg/cm
2
or more
Low pressure switch (for anti nose dive)
Closed circuit during 3.8±0.2 kg/cm 2 or more
Low pressure switch (for parking brake)

Low pressure indicator Turn-on pressure


(for air pressure alarm)
Turn-off pressure
Reducing valve (for front wheels)
Reducing valve (for rear wheels)
Reducing valve (for auxiliary brake)

Converter circuit section

Setting pressure table

Setting pressures (kg/cm 2 )


Name Remarks

Torque converter inlet pressure 1.3 or more

Torque converter outlet pressure 1 or more

Lockup clutch pressure


PTO clutch pressure 12 or more

Transmission clutch pressure 10 or more Check with the clutch oil gauge
Transmission lubrication pressure

13 Y03-0610E
Y- 5 Y- 5
Adjustment procedure (electric)

Switch adjustment procedure


Control valve operation lever position
Switch
For the switch installation locations, Pulled Neutral Pressed
refer to the electric circuit section in Chapter Z.

1. L10 switch (main winch hoist-up detection)


L11 switch (main winch hoist-down detection)
L12 switch (boom extending detection)
L13 switch (boom retracting detection)
L14 switch (boom raising detection)
L15 switch (boom lowering detection) Adjust each switch so that it turns ON (energized)
or OFF (not energized) when each spool has moved
L16 switch (auxiliary winch hoist-up detection) from the neutral position by 0.5 to 2.5 mm.
L17 switch (jib tilt raising detection)
L18 switch (jib tilt lowering detection)
2. L3 switch (detection of boom front position)

Turn the boom frontward, insert the swing lock pin,


and make the boom angle horizontal. In this status,
make an adjustment so that the limit switch is pushed
Boom lowering Boom raising further from the operating position (between switch
Boom extending Boom retracting contact points COM and NO is connected) by 1.5±0.2
mm.

Swing frame

Switch operating
position
Jib tilt raising
Auxiliary (jib telescoping retraction)
winch hoist-up
Jib tilt lowering
(jib telescoping extension)
3. L20 switch (detection of boom rear position)

Turn the boom backward and make the boom angle


horizontal. In this status, make an adjustment so that
the limit switch is pushed further from the operating
position (between switch contact points COM and
NO is connected) by 1.5±0.2 mm.

Main winch hoist-down

Main winch hoist-up


Cam

Switch operating
position

14 Y04-0500E
Y- 5 Y- 5
Adjustment procedure (electric)

4. L1 switch (detection of 4th and top boom full retraction) 7. L9 switch (detection of jib full retraction)

Adjust the lever angle so that dimension A becomes 
Adjust the lever angle so that dimension A becomes
41 mm in the free status. 47±0.5 mm in the free status.

Make sure that the switch is operated at the position 
Make sure that the switch is operated at the position
5 to 8 mm short of full retraction of the top boom. 5 to 8 mm short of full retraction of the 2nd jib.

4th boom
3rd boom

Fully retracted status of boom

5. L2 switch (detection of left area)

Turn the boom toward the left area. In this status,


make an adjustment so that the limit switch is pushed Base jib 2nd jib
further from the operating position
(between switch contact points COM and NC is
disconnected) by 2.5 mm.
8. L6 switch (detection of maximum mast angle)

While the mast angle is maximum (state that


mast A is in contact with the jib support), make an
adjustment so that the limit switch is pushed further
from the operating position (between switch contact
points COM and NC is disconnected) by 1.5±0.5 mm.

Switch operating Cam (rotary joint)


position

6. L8 switch (detection of jib tilt operation)

Minimize the jib tilt angle (fully retract the jib tilt
cylinder). In this status, make an adjustment by the
adjustment bolt so that the limit switch is pushed
further from the operating position (between switch
contact points COM and NO is disconnected) by half
turn.
Adjustment bolt

Jib support B Mast A

Jib
15 Y04-0500E
Y- 5 Y- 5
Adjustment procedure (electric)

9. L7 switch (detection of minimum mast angle) 11. L22 switch (detection of rear steering lock
pin operation)

Adjust the stopper with bolt A so that dimension A
becomes 5 mm in the free status. While the rear steering is in the locked status, make

Make an adjustment with the switch nut so that the an adjustment so that the limit switch is pushed
limit switch comes to the operating position (between further from the operating position (between switch
switch contact points COM and NC is disconnected) contact points COM and NO is connected) by 1 to 1.5
when the stopper has moved by 0.5 to 2.0 mm. mm.

Stopper

Unlock

Lock

Bolt A

10. L21 switch (detection of mode switching 12. L23 switch (detection of straight driving)
(economy/power))
Step on the accelerator pedal to make sure that the While the rear steering is in the locked status, make
switch is operated (turned ON) when the dimension an adjustment so that the limit switch is pushed
between the accelerator stopper bolt and cab floor further from the operating position (between switch
plate (dimension A) is 3 to 5 mm. contact points COM and NC is disconnected) by 1 to
1.5 mm.

Stopper bolt
13. Idling switch

Refer to the engine control section in “Adjustment


and check procedure”.

16 Y04-0500E
Y- 5 Y- 5
Adjustment procedure (electric)

Procedure of potentiometer adjustment


1. Jib tilt angle detector
After installing the jib tilt angle detector, adjust the jib
tilt angle to 0°. Measure the resistance between A
and D (total resistance). Then, adjust the resistance
between C and D to the value corresponding to the
total resistance value as shown in the following table,
and lock the potentiometer.
Total resistance (Ω) Adjustment value±4Ω (Ω)
(between A and D) (between C and D)

Jib

Tilt direction

Red

White
Black
Shield

17 Y04-0500E
Y- 6 Y- 6
Adjustment procedure (electric)

Switch adjustment procedure Control valve operation lever position


Switch
For the switch installation locations, Pulled Neutral Pressed
refer to the electric circuit section in Chapter Z.

1. L10 switch (main winch hoist-up detection)


L12 switch (boom extending detection)
L13 switch (boom retracting detection)
L14 switch (boom raising detection) Hoist-up 2nd Hoist-up 1st – Neutral – Hoist-down 1st Hoist-down 2nd
L15 switch (boom lowering detection)
L16 switch (auxiliary winch hoist-up detection)
L17 switch (jib tilt lowering detection) Adjust each switch so that it turns ON (energized)
L19 switch ( main winch 2nd speed detection, or OFF (not energized) when each spool has moved
optional and series circuit) from the neutral position by 0.5 to 2.5 mm. For the
L21 switch (jib tilt raising detection) L19 switch, make an adjustment so that both hoist-
up and hoist-down turn OFF (not energized) when
the spool has moved from the 1st notch position by
0.5-2.0 mm.

2. L3 switch (detection of boom front position)


Boom lowering Boom raising
Boom extending Boom retacting Turn the boom frontward, insert the swing lock pin,
and make the boom angle horizontal. In this status,
make an adjustment so that the limit switch is pushed
further from the operating position (between switch
contact points COM and NO is connected) by 1.5±0.2
mm.

Swing frame

Jib tilt raising


(jib retracting)
Main winch Switch operating
hoist-up Jib tilt lowering position
Auxiliary winch (jib extending)
hoist-up

3. L20 switch (detection of boom rear position)

Turn the boom backward and make the boom angle


horizontal. In this status, make an adjustment so that
the limit switch is pushed further from the operating
position (between switch contact points COM and
NO is connected) by 1.5±0.2 mm.

Main winch hoist-down

Main winch hoist-up


Cam

Switch operating
position

18 Y04-0510E
Y- 6 Y- 6
Adjustment procedure (electric)

4. L1 switch (detection of 4th, 5th and top boom 7. CS1 switch (detection of automatic pin insertion)
full retraction)

Adjust the lever angle so that dimension A becomes Make an adjustment so that dimension A becomes
41 mm in the free status. 4+1/0 mm in the automatic pin inserted status.

Make sure that the switch is operated at the position
5 to 8 mm short of full retraction of the 4th boom.
Jib support
4th boom
3rd boom

Fully retracted status of boom

5. L2 switch (detection of left area)



Turn the boom toward the left area. In this status, Automatic pin
make an adjustment so that the limit switch is
pushed further from the operating position (between
switch contact points COM and NC is disconnected)
by 2.5 mm. 8. L21 switch (detection of mode switching
(economy/power))
Step on the accelerator pedal to make sure that the
switch is operated (turned ON) when the dimension
between the accelerator stopper bolt and cab floor
plate (dimension A) is 3 to 5 mm.

Switch operating position Cam (rotary joint)

6. L31 switch (detection of jib lock pin)


Make sure that the switch is operated when
dimension A is 27.5±1 mm.

Jib lock pin insertion direction

Stopper bolt

In free status

ON position

19 Y04-0510E
Y- 6 Y- 6
Adjustment procedure (electric)

9. L22 switch (detection of rear steering lock pin


operation)
While the rear steering is in the locked status, make
an adjustment so that the limit switch is pushed
further from the operating position (between switch
contact points COM and NO is connected) by 1 to 1.5
mm.

Unlock

Lock

10. L23 switch (detection of straight driving)

While the rear steering is in the locked status, make


an adjustment so that the limit switch is pushed
further from the operating position (between switch
contact points COM and NC is disconnected) by 1 to
1.5 mm.

11. Idling switch

Refer to the engine control section in “Adjustment


and check procedure”.

20 Y04-0510E
Y- 7 Y- 7
Adjustment and checks

This section describes Adjustment and check


procedures for the components other than those
related to pressure and electricity.

Hydraulic system
1. Pump bleeding procedure

NOTICE
W h e n r e p l a c i n g t h e hyd r a u l i c p u m p o r
hydraulic oil, be sure to bleed the pump by the
following procedures.

1) Fill the oil tank with hydraulic oil.

2) Start the engine, keep the engine running for


about one minute with the PTO “OFF” and at
idling rotation, then bleed the double gear pump
circuit.

NOTICE
Be sure to turn “OFF” the PTO switch to
unload the accumulator charging circuit.

3) Stop the engine, remove the bleeder plug on the


Plug double plunger pump, and then feed hydraulic
Plug oil until the case is filled with oil. After feeding,
install the plug.

4) S
 tart the engine, keep the engine running for
about one minute with the PTO “ON (I)” and at
idling rotation, then bleed the double plunger
pump circuit. If the pump has been replaced,
perform break-in operation for about ten
minutes in this status.

NOTICE
After starting the engine, check that pressure
is accumulated in the accumulator. Unless
accumulated, repeat the bleeding in the
previous step 2) again.

21 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

Swing system
1. Procedure for adjusting master cylinder
Yoke mounting status
Master cylinder
1) While the swing brake lever is in the lowered
status, make an adjustment using the yoke
so that play of the master cylinder push-rod
becomes 0 to 0.5 mm.

To brake
lever

Push rod
2. Procedure of bleeding in swing brake circuit

1) Start the engine and rotate the pump.

2) Insert a vinyl hose into the bleeder screw of the


master cylinder.

3) Pull the swing brake lever, open the bleeder


screw, and then tighten the screw before
returning the swing brake lever.Repeat this until
discharged oil contains no more air bubbles.
When no air bubbles remain, tighten the screw
during oil discharge.

4) In the same manner, perform bleeding for the


swing drive unit.

Winch system
1. Procedure for checking N2 gas filling pressure
Slowly in the accumulator
Sealing gas
pressure 1) Switch the drum lock lever to “LOCK”.

2) Stop the engine and repeat switching the clutch


lever for winch to “ON” and “FREE” while
paying attention to the pressure gauge. The
Rapidly pressure slowly decreases at the beginning,
however, when it reaches a certain pressure,
it rapidly decreases. This point where the
displayed pressure decrease speed changes is
the pressure for filling N2 gas.

22 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

2. Procedure for adjusting brake pedal


(Main and auxiliary winches)

1) Adjust the pedal with the adjusting bolt so that


dimension A shown in the following figure is
202 +30 mm in a pedal free state.

2) Adjust push-rod length of the master cylinder so


that play at the brake pedal end is 2 to 5mm.

Master cylinder

Brake pedal

Pedal end

Adjusting bolt
Push rod

Lock nut
Brake pedal

3. Bleeding procedure in brake circuit

1. Main and auxiliary winch circuit

Bleeding for automatic brake cylinder

1) Move the drum lock lever to the lock side.

2) Insert a vinyl hose into the bleeder screw of the


brake cylinder.

3) Put the clutch lever in a “free” state.

4) O
 pen the bleeder screw and perform bleeding
until discharged oil contains no more air
bubbles. When no air bubbles remain, tighten
the screw during oil discharge.

23 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

Bleeding for foot brake cylinder

1) Shift the drum lock lever to the lock side.

2) Shift the clutch lever to “free”.

3) Insert a vinyl hose into the bleeder screw


halfway through the brake pipe.

4) S
 tep on the brake pedal and open the bleeder
screw to bleed. Then, when discharged oil
contains no more air bubbles, tighten the screw
during oil discharge.

NOTICE
Pay attention to splash of brake oil and oil
quantity in the oil reservoir.

5) Perform bleeding for the brake cylinder section


in the same manner.

4. Procedure for adjusting the winch brake band

1. Main and auxiliary winch brake


Stroke adjusting nut (a)
Adjustment procedure during disassembly

The left drawing shows the main winch.


The auxiliary winch location is symmetric with
respect to the center line.

1) Set adjusting bolt (b) so that L is equal to 18.0


mm.

2) Set the clutch to “FREE”, drum lock to “lock”,


and winch operation lever to neutral. (X=0 mm)

3) Temporarily tighten stroke adjusting nut (a) until


there is no more clearance between the drum
and shoe (spanner becomes heavy).

4) T
 ighten adjusting bolt (b) until the spanner
becomes heavy so that clearance Y becomes
Marker 0 mm when clearance X is 0 mm. After locking
the nut, prevent looseness using a wire.
Adjusting bolt (b) NOTICE
Measure dimension L to make sure that it is
within 15.0±2.0 mm.

5) Turn the clutch “ON”, and loosen stroke


adjusting nut (a) so that X becomes 3.0 to 3.5
mm.

Prevention of loosening NOTICE


When tightening nut (a) during adjustment,
shift the drum lock lever to the lock side once,
and then put the clutch in a“ FREE” state.

24 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

6) After the completion of the above adjustment,


set the clutch to “FREE” drum lock to “lock”, and
winch operation lever to neutral again.

7) Make an adjustment with bolt (c) so that


clearance A becomes 0.5 mm.

8) Make an adjustment with bolt (d) so that


clearance B becomes 0.5 mm.
NOTICE
If bolt (d) is tightened excessively, sharp
descent under load may be impossible even if
it is possible with no load.

9) After adjusting clearance A and B, adjust bolts


(e), (f), (g), and (h) so that clearance between
the brake band and drum becomes uniform.
While the clutch is set to “FREE”, make sure
that there is no clearance in the Z section.

10) After the completion of adjustment in step 9),


check that the hook descends sharply when the
number of rope hanging and elevating angle are
maximum.

11) Number of rope hanging: Hoist load equivalent


to the allowable load per N x one rope and
make sure that there is no sliding between the
brake band and drum while the winch operation
lever is in the neutral status.
NOTICE
The allowable load per one wire rope is
described on the“ rated lifting capacity” plate.
The load to hoist up at this time must not
exceed the“ rated lifting capacity”.

12) A
 fter adjusting the band, turn the clutch lever
Red Red “ON” to put the brake band in a braking status.
Black line Then, affix a sticker so that the marker edge
Black line matches the black line on the sticker.

Blue Blue
Marker Marker
Main winch Auxiliary winch

Adjustment procedure in the case of wear on the lining

1) While the brake band is under braking, tighten


and adjust stroke adjusting nut (a) until the
marker edge matches the black line on the
sticker.

NOTICE
When tightening stroke adjusting nut (a), shift
the drum lock lever to the lock side, and turn
the clutch to“ FREE” to release the brake
band. After tightening, turn the clutch “ON”
and check the marker position.

25 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

5. Procedure for bleeding in winch clutch circuit

I. Main and auxiliary winches

NOTICE
As the winches are subjected to the
accumulator pressure, pay due attention to
splash of brake oil.

1) Turn “ON (I)” the PTO switch and the winch


clutch lever “ON”.

2) Open the bleeder screw of the hydraulic valve


to bleed.

3) Operate the winch to adjust the position so that


the bleeder screw of the winch clutch cylinder
comes topside.

4) O
 pen the bleeder screw of the winch clutch
cylinder to bleed.

5) In the same manner, perform bleeding for the


clutch cylinder at the opposite side.

6. Procedure for bleeding in winch circuit


(counter balance valve)

I. Main and auxiliary winches

1) Loosen the bleeder plug.

Bleeder plug 2) First, repeat the hoist-up and hoist-down


operations at an idling rotation (by 1st speed),
gradually increase the engine rotation speed up
to the maximum, and then perform bleeding.

26 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

Telescoping system
1. Procedure for bleeding in power tilt jib circuit

1) Perform bleeding independently for the jib tilt


cylinder and mount it to the jib.
Solenoid valve 2) Directly connect the hoses for the jib tilt cylinder
(for power tilt/extension jib switching) to form the circulation circuit shown in the circuit
diagram on the left, perform the jib tilt operation,
Hose reel and bleed in the circuit.

Counter balance valve

Tilt cylinder

Connect hoses with each other


(both for right and left cylinders)

3) Connect the hydraulic hose to the jib tilt cylinder.

4) P
 ut the power tilt jib into an operating status,
and repeat the jib tilt operations several times to
bleed remaining in the circuit.

[Reference]
The bleeder plug of the counter balance
valve is not to be used because bleeding is
insufficient.

2. Procedure for bleeding of power extension jib


circuit
1) Perform bleeding independently for the jib
extension cylinder and mount it to the jib.
Solenoid valve 2) Directly connect the hoses for the jib extension
(for power tilt/extension jib switching) cylinder to form the circulation circuit shown in
Hose reel the circuit diagram on the left, perform the jib
telescoping operation, and bleed in the circuit.

27 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

Extension
cylinder

Connect hoses (for extending and retracting) 3) Connect the hydraulic hose to the jib extension
with each other cylinder.

4) P
 ut the power extension jib into an operating
status, and repeat the jib telescoping operations
several times to bleed remaining in the circuit.

Crane operation
1. Procedure for adjusting engine rotation

1. Engine stop

Move the engine stop cylinder to the stroke end


and adjust the cylinder mounting position so that
the engine stop lever comes 1 to 2 mm before the
stop position.

2. Speed control

1) Make an adjustment using stopper A so that the


idling speed becomes 600 to 650 rpm.

2) Extend return spring (d) by 1 to 2 mm from the


free length and mount it. (Approximately one
turn of the nut)

3) Turn “ON” the PTO switch and step on the


accelerator pedal. Adjust the length of rod (a) so
that the engine rotation speed becomes 1500
to 1550 rpm. At this time, step on the pedal
gradually so as not to exceed 1550 rpm.

4) T
 urn “OFF” the PTO switch and step on the
accelerator pedal. Check that the speed control
lever is in contact with stopper B.

5) Make an adjustment using adjuster A in an


idling status until the hanger of lever (c) touches
lever (b).

3. Idling switch (for exhaust brake)

Make an adjustment using adjuster B so that the


switch turns ON when the engine rotation speed is
650 to 700 rpm.
However, the upper limit of idling shall be 50 to
100 rpm lower than the operating speed of the
idling switch.

28 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

Rod (a)

Lever (b)

Engine operation position Paint lock to be performed after adjustment

Engine stop position


(MAX at PTO ON)

Engine stop cylinder


Accelerator cylinder

Engine stop lever

Stopper B Hanger

Lever (c)
Speed control lever Stopper A

Adjuster A
Return spring (d)
Idling switch
Adjuster B This drawing shows the state at idling
while the PTO switch is “OFF”.

2. Procedure for adjusting accelerator pedal

NOTICE
Perform this adjustment after the completion
of engine rotation adjustment described in
Bolt (c) section 1 above. The air pressure must be
more than the low pressure alarm pressure.

Throttle valve 1. Idling adjustment by accelerator pedal


Knob
Adjusting bolt (A) 1) Start the engine.
2) Tighten adjusting bolt (A) to raise the rotation
speed to reach the idling speed or more.
3) After returning adjusting bolt (A) until the
rotation speed decreases to the idling speed,
return it further for 1/4 turns, and then lock it
with the lock nut.

2. Adjustment of maximum rotation speed with no


Adjusting bolt (B) load by accelerator pedal

1) Step on the pedal up to the minimum stroke at


which the maximum rotation speed with no load
is ensured. After applying adjusting bolt (B) to
the cab frame, tighten the bolt further for one
turn and lock it with the lock nut.

29 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

3. Adjustment of idling adjustment knob

1) While fully screwing in the idling adjustment


knob (idling status), adjust clearance “Z”
between the pin and clevis to 1 to 2 mm and
lock the wire with bolt (c).

Driving power generating system


1. Procedure for checking stall rotation speed

When checking the stall rotation speed for the reason


that output is low or temperature of the converter oil
rises significantly, follow the procedure below.

NOTICE
During a stall, heat is generated rapidly in the
torque converter. Never perform operations
for 30 seconds or more or under the oil
temperature of 90° or more.

The torque converter generates the maximum


torque. Pay attention to running out of the
vehicle.
1) Set the switch and lever as follows:
PTO switch: “OFF”
Change lever: “D” range
Driving speed selector switch: “4-wheel Hi”
Emergency mission switch: “ON”

2) Apply the parking brake and service brake


securely.

3) Fully step on the accelerator pedal, and read


the rotation speed when the engine speed has
become steady.

Standard maximum engine speed during a stall:


approximately 1,650 rpm

Brake system
1. Procedure for adjusting brake pedal

1) While the roller is in contact with the plunger by


the pedal weight, make an adjustment so that
Brake valve the adjusting bolt comes in contact with the
Adjusting bolt valve stopper.

Roller

Plunger

30 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

2. Procedure for bleeding in brake circuit

Step on the brake pedal while compressed air is


contained sufficiently in the reservoir, and open
the bleeder screw of the booster to bleed. Tighten
Bleeder the screw before returning the brake pedal. Repeat
screw this until discharged brake oil contains no more air
bubbles. Tighten the screw during oil discharge when
no more air bubbles remain.

NOTICE
There are two boosters.
Booster Bleed while paying attention to splash of
brake oil and oil quantity in the oil reservoir.

3. Procedure for adjusting parking brake clearance

1) Jack up the crane to put the parking brake into


a free state.

2) Rotate the brake drum to match the adjusting


hole on the drum with the star wheel on the
adjustor Ass’y.
Spring 3) Insert a screw driver into the adjusting hole,
chamber and rotate the shoe (in the arrow direction) until
a resistance against the drum rotation is felt.
Return the starter wheel gear by 8 scales from
there, then the clearance between the lining
and the brake drum is adjusted to approximately
0.23 mm as a standard.

Adjusting hole
4. Procedure for connecting parking brake and
spring chamber
0 point
1) Keep the lever for the parking brake at the 0
Rod point (middle position of play of the lever).
2) Turn “OFF” the parking brake switch, move the
Play of lever spring chamber to the stroke end, and adjust
the length by the rod to connect it with the lever.

3) Confirm that there is no dragging by pulling in


this state, and lock it with the lock nut.

Steering system
Stopper bolt B Tie rod Stopper bolt A 1. Procedure for adjusting tire steering angle

Tire size: 18.00 R25

1) Jack up the crane, and operate the steering


cylinder a few times with the four-wheel steering
(to bleed in the cylinder).

31 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

2) Prior to the tire steering angle adjusting procedure,


check both the front and rear wheels that the tire
lateral slip amount is within ±3mm with a side slip
tester.
If the slip amount is deviated from this value, loosen
the tie rod end tightening bolts on the right and left of
the tie rod, and turn the tie rod to adjust the toe-in.

3) Jack up the crane on horizontal ground (so that right


and left tire heights are the same), and use a tire
steering angle measuring jig to adjust the steering
angle in direction A with stopper bolt A, and adjust the
steering angle in direction B with stopper bolt B.
Tire size Steering angle

4) Also adjust the rear wheels in the same way as in 3).

[Reference]

King pin angle


Camber
Caster
Toe-in

Electric transmission
1. Failure diagnosis for turbo control system

Failure diagnosis table

Failure display Judgment time (sec)


Phenomenon

Item Remarks

(user (dealer
mode) mode)

Normal During engine


Light OFF Light OFF operation

N (rotation) N Light ON Code Lit up by turning


sensor sensor the key ON while
pulse the engine is
signal is stopped.
absent. (Function to
(Long 1 check bulb
-Short 5) exhaustion of
DIAG. LAMP)
Lack (load) Wire Code
sensor break
or short Light ON
circuit
When
Water Wire Code temperature
temperature break Light OFF detected by the
sensor or short sensor is 120°C
circuit or more, or -30°
C or below, it is
regarded as an
error.

Boost sensor Wire Code


break
or short Flash
circuit

Boost control Over Code They are not


system boost detected in the
Flash following cases:
When the
engine rotation
speed is 600
Under Code rpm or below,
boost or 2200 rpm or
Light ON more
When error 3-2
or 1-3 has been
detected in the
dealer mode
Power Fuse Light ON Light ON When power
supply exhaustion supply voltage
voltage is 0 V

32 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

Control unit (Note)



DIAG. LAMP indicates the “TURBOWARN”
lamp on the front panel in the cab.

DIAG. SW indicates the male and female shur
plugs routed to the connector on the lower
surface of the turbo control unit.

Shur plug is connected.


Shur plug is disconnected.

DIAG. SW shall be ON during


normal operation.

<Failure display in user mode>


Light ON and Flash in the user mode are displayed
when a failure was judged and the failure has
continued for 1 minute. (They are not displayed
when the failure has been corrected within 1
minute.)
The other Light ON, Flash, and dealer mode are
displayed immediately after a failure has been
judged.

<Failure display in dealer mode>


In the dealer mode, failures are displayed by the
lamp flashing (long-short) code.

(Example)
(Long) (Short) For No.3 lack sensor error
1st time 2nd time Code: 1 - 3

1 cycle Short (lights up for 0.4 sec)


(Lamp goes out for 2.8 sec at the interval between codes.) Long (lights up for 1.2 sec)

As shown in the left figure, the code is repeated


3 times in 1 cycle. If a new failure does not occur
after that, the first code is returned and it is
displayed repeatedly 3 times.

(Note)
The lamp goes out for 2.4 seconds before the
code is displayed.

Option
1. Procedure for filling air conditioner refrigerant gas

(1) Name of refrigerant gas: R12 (chlorofluorocarbon)

(2) Specified filling amount: 1600±50g

(3) Filling condition

Temperature Engine rotation speed (rpm)


Ambient Mode Fan control Cab
temperature switch switch switch

20°C or more
Window
open
20°C or less

33 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

(4) Inspection of filling amount



Devices to be used: gauge manifold,
thermistor thermometer
Inspection (or filling) procedure

[1] Stop the air conditioner. (Turn OFF the fan


and mode selector switch.)
[2] Connect the gauge manifold to the
compressor.
(The gauge side valve must be closed
before connection.)

[3] Operate the air conditioner under the


following conditions.

Temperature Engine rotation speed (rpm)


Ambient Mode Fan Oil
control Cab temp.
temperature switch switch
switch

20°C or more
Window 50 °C
open or more
20°C or less

(Compressor rotation speed (=1800 rpm) is converted into engine rotation speed.)

[4] Bring the sensor section of the thermistor


thermometer into intimate contact with
Sensor section the upper surface of the accumulator by
30 mm or more, and measure the surface
Sensor section temperature of the accumulator.

Close
contact
more than
30 mm

Accumulator
Thermistor thermometer
[5] Measure the pressure at the low pressure
side of the gauge manifold.
(Fill from the low pressure side)

34 Y05-0381E
Y- 7 Y- 7
Adjustment and checks

[6] Apply the accumulator surface temperature


and low pressure side pressure values
measured in [4] and [5] to the refrigerant
Accumulator surface temperature (°C)

filling judgment table on the left.

R12
saturation
temperature

Low pressure side pressure (kg/cm 2 )

Amount of refrigerant is appropriate


Amount of refrigerant is slightly insufficient
Amount of refrigerant is insufficient

[7] If the amount is “slightly insufficient” or


“insufficient” as a result of judgment in step
[6], fill refrigerant gas in steps of 50 g until it
reaches the appropriate amount.

35 Y05-0381E
Y- 8 Y- 8
Adjustment and checks

This section describes adjustment and check Swing system


procedure for the components other than those
1. Procedure for adjusting master cylinder
related to pressure and electricity. mounting status
1) While the swing brake lever is in the lowered
status, make an adjustment using the yoke
Hydraulic system so that play of the master cylinder push-rod
becomes 0 to 0.5 mm.
1. Pump bleeding procedure Yoke
Master cylinder
NOTICE
W h e n r e p l a c i n g t h e hyd r a u l i c p u m p o r
hydraulic oil, be sure to perform bleeding by
the following procedures.

1) Fill the oil tank with hydraulic oil. To brake


lever
2) Start the engine, keep the engine running for
about one minute with the PTO “OFF” and at
idling rotation, then bleed from the double gear
pump circuit. Push rod

NOTICE
Be sure to turn “OFF” the PTO switch so 2. Procedure of bleeding in swing brake circuit
that the accumulator charging circuit is in an
unload status. 1) Start the engine and rotate the pump.

2) Insert a vinyl hose into the bleeder screw of the


3) Stop the engine, remove the bleeder plug on the master cylinder.
double plunger pump, and then feed hydraulic
oil until the case is full of oil. After feeding,
install the plug.

Plug Plug

3) Pull the swing brake lever, open the bleeder


screw, and then tighten the screw before
returning the swing brake lever.
Repeat this until discharged oil contains no
more air bubbles. When no air bubbles remain,
tighten the screw during oil discharge.
4) S
 tart the engine, keep the engine running for
about one minute with the PTO “ON (I)” and 4) In the same manner, perform bleeding for the
at idling rotation, then bleed from the double swing drive unit.
plunger pump circuit. If the pump has been
replaced, perform break-in operation for about
ten minutes in this status.
NOTICE
After starting the engine, check that pressure
is accumulated in the accumulator. Unless
accumulated, perform the bleeding in the
previous step 2) again.

36 Y05-0440E
Y- 8 Y- 8
Adjustment and checks

Winch system 3. Procedure of bleeding in brake circuit


1. Procedure for checking N2 gas filling pressure I. Main and auxiliary winch circuit
in the accumulator
1) Switch the drum lock lever to “LOCK”.
Bleeding for automatic brake cylinder
2) S
 top the engine and repeat switching the clutch
lever for winch to “ON” and “FREE” while paying 1) Move the drum lock lever to the lock side.
attention to the pressure gauge. The pressure
slowly decreases at the beginning, however, when it 2) Insert a vinyl hose into the bleeder screw of the
reaches a certain pressure, it rapidly decreases. This brake cylinder.
point where the displayed pressure decrease speed
changes is N2 gas filling pressure. 3) Put the clutch lever in a “free” state.
Slowly
Sealing gas 4) O
 pen the bleeder screw and perform bleeding
pressure until discharged oil contains no more air
bubbles. When no air bubbles remain, tighten
the screw during oil discharge.

Rapidly

2. Procedure for adjusting brake pedal


(Main and auxiliary winches)
1) Adjust the pedal with the adjusting bolt so that
dimension A shown in the following figure is
202 +30 mm in a pedal free state.

2) Adjust push-rod length of the master cylinder so


that play at the brake pedal end is 2 to 5 mm.
Bleeding for foot brake cylinder

1) Shift the drum lock lever to the lock side.

2) Shift the clutch lever to “free”.

3) Insert a vinyl hose into the bleeder screw


halfway through the brake pipe.

4) S
 tep on the brake pedal and open the bleeder
Master cylinder screw to bleed. Then, when discharged oil
contains no more air bubbles, tighten the screw
during oil discharge.

Brake pedal
NOTICE
Bleed while paying attention to splash of
Pedal end brake oil and oil quantity in the oil reservoir.

5) Perform bleeding for the brake cylinder section


Adjusting bolt in the same manner.
Push rod

Lock nut
Brake pedal

37 Y05-0440E
Y- 8 Y- 8
Adjustment and checks

4. Procedure for adjusting the winch brake band 5) Turn the clutch “ON”, and loosen stroke
adjusting nut (a) so that X becomes 3.0 to 3.5
I. Main and auxiliary winch brake mm.

Adjustment procedure during disassembly NOTICE


When tightening nut (a) during adjustment,
The following figure shows the main winch. shift the drum lock lever to the lock side once,
The auxiliary winch location is symmetric with and then put the clutch in a “FREE” state.
respect to the center line.

Stroke adjusting nut (a) 6) After the completion of the above adjustment,
set the clutch to “FREE” drum lock to “lock”, and
winch operation lever to neutral again.

7) Make an adjustment with bolt (c) so that


clearance A becomes 0.5 mm.

8) Make an adjustment with bolt (d) so that


clearance B becomes 0.5 mm.
NOTICE
If bolt (d) is tightened excessively, sharp
descent under load may be impossible even if
it is possible with no load.

9) After adjusting clearance A and B, adjust bolts


(e), (f), (g), and (h) so that clearance between
the brake band and drum becomes uniform.
Marker While the clutch is set to “FREE”, make sure
that there is no clearance in the Z section.
Adjusting bolt (b) 10) After the completion of adjustment in step 9),
check that the hook descends sharply when the
number of rope hanging and elevating angle are
maximum.

11) Number of rope hanging: Hoist load equivalent


to the allowable load per N x one rope and
make sure that there is no sliding between the
brake band and drum while the winch operation
lever is in the neutral status.
Prevention of loosening
NOTICE
The allowable load per one wire rope is
described on the“ rated lifting capacity” plate.
The load to hoist up at this time must not
exceed the“ rated lifting capacity”.
1) Set adjusting bolt (b) so that L is equal to 18.0
mm.
12) A
 fter adjusting the band, turn the clutch lever
2) Set the clutch to “FREE”, drum lock to “lock”, “ON” to put the brake band in a braking status.
and winch operation lever to neutral. (X=0 mm) Then, affix a sticker so that the marker edge
matches the black line on the sticker.
3) Temporarily tighten stroke adjusting nut (a) until
there is no more clearance between the drum
and shoe (spanner becomes heavy).

4) T
 ighten adjusting bolt (b) until the spanner
becomes heavy so that clearance Y becomes
0 mm when clearance X is 0 mm. After locking
the nut, prevent looseness using a wire.

NOTICE
Measure dimension L to make sure that it is
within 15.0±2.0 mm.

38 Y05-0440E
Y- 8 Y- 8
Adjustment and checks

4) O
 pen the bleeder screw of the winch clutch
Red Red cylinder to bleed.
Black line Black line

Blue Blue
Marker Marker
Main winch Auxiliary winch

Adjustment procedure in the case of wear on the lining

1) While the brake band is under braking, tighten


and adjust stroke adjusting nut (a) until the
marker edge matches the black line on the
sticker. 5) In the same manner, perform bleeding for the
clutch cylinder at the opposite side.
NOTICE
When tightening stroke adjusting nut (a), shift
the drum lock lever to the lock side, and turn 6. Procedure for bleeding in winch circuit
(counter balance valve)
the clutch to“ FREE” to release the brake
band. After tightening, turn the clutch “ON”
and check the marker position. I. Main and auxiliary winches

1) Loosen the bleeder plug.


5. Procedure for bleeding in winch clutch circuit 2) First, repeat the hoist-up and hoist-down
operations at an idling rotation (by 1st speed),
I. Main and auxiliary winches gradually increase the engine rotation speed up
to the maximum, and then perform bleeding.
NOTICE
As the winches are subjected to the Bleeder plug
accumulator pressure, pay due attention to
splash of brake oil.

1) Turn “ON (I)” the PTO switch and the winch


clutch lever “ON”.

2) Open the bleeder screw of the hydraulic valve


to bleed.

3) Operate the winch to adjust the position so that


the bleeder screw of the winch clutch cylinder
comes topside.

39 Y05-0440E
Y- 8 Y- 8
Adjustment and checks

Crane operation 4) T
 urn “OFF” the PTO switch and step on the
accelerator pedal. Check that the speed control
lever is in contact with stopper B.
1. Procedure for adjusting engine rotation
5) Make an adjustment using adjuster A in an
1. Engine stop idling status until the hanger of lever (c) touches
lever (b).
Move the engine stop cylinder to the stroke end
and adjust the cylinder mounting position so that 3. Idling switch (for exhaust brake)
the engine stop lever comes 1 to 2 mm before the
stop position. Make an adjustment using adjuster B so that the
switch turns ON when the engine rotation speed is
2. Speed control 650 to 700 rpm.
However, the upper limit of idling shall be 50 to
1) Make an adjustment using stopper A so that the 100 rpm lower than the operating speed of the
idling speed becomes 600 to 650 rpm. idling switch.
2) Extend return spring (d) by 1 to 2 mm from the
free length and mount it. (Approximately one
turn of the nut)

3) Turn “ON” the PTO switch and step on the


accelerator pedal. Adjust the length of rod (a) so
that the engine rotation speed becomes 1500
to 1550 rpm. At this time, step on the pedal
gradually so as not to exceed 1550 rpm.

Rod (a)

Lever (b)

Engine operation position Paint lock to be performed after adjustment

Engine stop position


(MAX at PTO ON)

Engine stop cylinder


Accelerator cylinder

Engine stop lever

Stopper B Hanger

Lever (c)
Speed control lever Stopper A

Adjuster A
Return spring (d)
Idling switch
Adjuster B This drawing shows the state at idling
while the PTO switch is “OFF”.

40 Y05-0440E
Y- 8 Y- 8
Adjustment and checks

2. Procedure for adjusting accelerator pedal

NOTICE
Perform this adjustment after the completion
of engine rotation adjustment described in
section 1 above. The air pressure must be
more than the low pressure alarm pressure.

1. Idling adjustment by accelerator pedal

1) Start the engine.


2) Tighten adjusting bolt (A) to raise the rotation
speed to reach the idling speed or more.
3) After returning adjusting bolt (A) until the
rotation speed decreases to the idling speed,
return it further for 1/4 turns, and then lock it
with the lock nut.

2. Adjustment of maximum rotation speed with no


load by accelerator pedal

1) Step on the pedal up to the minimum stroke at


which the maximum rotation speed with no load
is ensured. After applying adjusting bolt (B) to
the cab frame, tighten the bolt further for one
turn and lock it with the lock nut.

3. Adjustment of idling adjustment knob

1) While fully screwing in the idling adjustment


knob (idling status), adjust clearance “Z”
between the pin and clevis to 1 to 2 mm and
lock the wire with bolt (c).

Bolt (c)

Knob Throttle valve


Adjusting bolt (A)

Adjusting bolt (B)

41 Y05-0440E
Y- 8 Y- 8
Adjustment and checks

Driving power generating system


NOTICE
1. Procedure for checking stall rotation speed There are two boosters.
Bleed while paying attention to splash of
When checking the stall rotation speed for the reason brake oil and oil quantity in the oil reservoir.
that output is low or temperature of the converter oil
rises significantly, follow the procedure below.

NOTICE
During a stall, heat is generated rapidly in the
torque converter. Never perform operations Bleeder
screw
for 30 seconds or more or under the oil
temperature of 90° or more.

The torque converter generates the maximum


torque. Pay attention to running out of the Booster
vehicle.
1) Set the switch and lever as follows:
PTO switch: “OFF”
Change lever: “D” range 2) Perform bleeding for the accelerator disc brake
Driving speed selector switch: “4-wheel Hi” in the same way as in step 1) above.
Emergency mission switch: “ON”
[Disc brake]
2) Apply the parking brake and service brake Both front and rear wheels: 4 points
securely.

3) Fully step on the accelerator pedal, and read


the rotation speed when the engine speed has
become steady.

Standard maximum engine speed during a stall:


approximately 1,650 rpm
Bleeder screw
Brake system
1. Procedure for adjusting brake pedal

1) While the roller is in contact with the plunger by


the pedal weight, make an adjustment so that
the adjusting bolt comes in contact with the
valve stopper. Disc brake

Brake valve
Adjusting bolt
3. Procedure for adjusting parking brake clearance

Roller 1) Jack up the crane to put the parking brake into


a free state.

2) Rotate the brake drum to match the adjusting


Plunger hole on the drum with the star wheel on the
adjustor Ass’y.

3) Insert a screw driver into the adjusting hole,


2. Procedure for bleeding in brake circuit and rotate the shoe (in the arrow direction) until
a resistance against the drum rotation is felt.
1) Step on the brake pedal while compressed air Return the starter wheel gear by 8 scales from
is contained sufficiently in the reservoir, and there, then the clearance between the lining
open the bleeder screw of the booster to bleed. and the brake drum is adjusted to approximately
Tighten the screw before returning the brake 0.23 mm as a standard.
pedal. Repeat this until discharged brake oil
contains no more air bubbles. Tighten the screw
during oil discharge when no more air bubbles
remain.

42 Y05-0440E
Y- 8 Y- 8
Adjustment and checks

1) Jack up the crane, and operate the steering


Spring cylinder a few times with the four-wheel steering
chamber (to bleed in the cylinder).

2) Prior to the tire steering angle adjusting


procedure, check both the front and rear wheels
that the tire lateral slip amount is within ±3mm
with a side slip tester.
If the slip amount is deviated from this value,
loosen the tie rod end tightening bolts on the
right and left of the tie rod, and turn the tie rod
to adjust the toe-in.

3) Jack up the crane on horizontal ground (so that


right and left tire heights are the same), and use
Adjusting hole a tire steering angle measuring jig to adjust the
steering angle in direction A with stopper bolt A,
4. Procedure for connecting parking brake and and adjust the steering angle in direction B with
spring chamber stopper bolt B.

1) Keep the lever for the parking brake at the 0 Tire size Steering angle
point (middle position of play of the lever).

2) Turn “OFF” the parking brake switch, move the


spring chamber to the stroke end, and adjust
the length by the rod to connect it with the lever. 4) A
 lso adjust the rear wheels in the same way as in 3).

3) Confirm that there is no dragging by pulling in [Reference]


this state, and lock it with the lock nut.
King pin angle
Camber
0 point Caster
Toe-in
Rod

Play of lever

Steering system
1. Procedure for adjusting tire steering angle

Tire size: 18.00 R25

Stopper bolt B Tie rod Stopper bolt A

43 Y05-0440E
Y- 8 Y- 8
Adjustment and checks

Electric transmission <Failure display in user mode>


Light ON and Flash in the user mode are displayed
1. Failure diagnosis for turbo control system when a failure was judged and the failure has
continued for 1 minute. (They are not displayed
Failure diagnosis table when the failure has been corrected within 1
minute.)
The other Light ON, Flash, and dealer mode are
Failure display displayed immediately after a failure has been

Judgment time (sec)


judged.
Phenomenon

Item Remarks
<Failure display in dealer mode>
(user (dealer In the dealer mode, failures are displayed by the
mode) mode) lamp flashing (long-short) code.
During engine
Normal Light OFF Light OFF operation (Example)
N (rotation) N Code Lit up by turning For No.3 lack sensor error
sensor sensor Light ON the key ON while
the engine is
Code: 1 3
pulse
signal is stopped. Short (lights up for 0.4 sec)
absent. (Function to
(Long 1 check bulb Long (lights up for 1.2 sec)
-Short 5) exhaustion of
DIAG. LAMP)

Lack (load) Wire Code


sensor break
or short Light ON
circuit

Water Wire When


temperature break temperature
Light OFF Code detected by the
sensor or short sensor is 120°C
circuit or more, or -30°
C or below, it is
(Long) (Short)
regarded as an
error. 1st time 2nd time
Boost sensor Wire Code
break Flash 1 cycle
or short
circuit (Lamp goes out for 2.8 sec at the interval between codes.)
Boost control They are not
system detected in the
Over Code following cases:
boost Flash When the engine
rotation speed As shown in the above figure, the code is repeated
is 600 rpm or
below, or 2200
rpm or more
3 times in 1 cycle. If a new failure does not occur
Under Code When error 3-2 after that, the first code is returned and it is
Light ON or 1-3 has been displayed repeatedly 3 times.
boost detected in the
dealer mode
(Note)
Power Fuse Light ON Light ON When power
supply voltage is
The lamp goes out for 2.4 seconds before the
supply
voltage
exhaustion 0V code is displayed.

(Note)

DIAG. LAMP indicates the “TURBOWARN”
lamp on the front panel in the cab.

DIAG. SW indicates the male and female shur
plugs routed to the connector on the lower
surface of the turbo control unit.
Control unit

Shur plug is connected.


Shur plug is disconnected.

DIAG. SW shall be ON during


normal operation.

44 Y05-0440E
Y- 8 Y- 8
Adjustment and checks

Option
Sensor section
1. Procedure for filling air conditioner refrigerant gas
Sensor section
(1) Name of refrigerant gas: R12 (chlorofluorocarbon)

(2) Specified filling amount: 1600±50g Close


contact
(3) Filling condition more than
30 mm

Ambient Mode Fan Temperature Engine rotation speed (rpm)


temp. switch switch control Cab
switch
20°C
or more
Window
20°C open
or less

(4) Inspection of filling amount



Devices to be used: gauge manifold, Accumulator
thermistor thermometer Thermistor
Inspection (or filling) procedure thermometer
[1] S
 top the air conditioner. (Turn OFF the fan
and mode selector switch.) [5] Measure the pressure at the low pressure
[2] Connect the gauge manifold to the side of the gauge manifold.
compressor. (Fill from the low pressure side)
(The gauge side valve must be closed
before connection.) [6] Apply the accumulator surface temperature
and low pressure side pressure values
measured in [4] and [5] to the refrigerant
filling judgment table on the left.
Accumulator surface temperature (°C)

R12
saturation
temperature

[3] Operate
 the air conditioner under the
following conditions.
Ambient Mode Fan Temperature Engine rotation speed (rpm)
Oil
temp. switch switch control
switch
Cab
temp.
20°C
or more Window 50 °C Low pressure side pressure (kg/cm 2 )
20°C open ormore
or less
Amount of refrigerant is appropriate
(Compressor rotation speed (=1800 rpm) is converted into engine rotation speed.)
Amount of refrigerant is slightly insufficient
[4] B
 ring the sensor section of the thermistor Amount of refrigerant is insufficient
thermometer into intimate contact with
the upper surface of the accumulator by [7] If the amount is “slightly insufficient” or
30 mm or more, and measure the surface “insufficient” as a result of judgment in step
temperature of the accumulator. [6], fill refrigerant gas in steps of 50 g until it
reaches the appropriate amount.

45 Y05-0440E
System Diagrams

Contents

Z-1 Hydraulic Circuit ......................... 1

Z-2 Hydraulic Circuit ......................... 3

Z-3 Electric circuit


(Electrical parts location diagram)........ 5

Z-4 Electric circuit


(Electrical parts location diagram)........ 7

Z-5 Electric circuit


(Crane).......................................... 9

Z-6 Electric circuit


(Crane)........................................ 10

Z-7 Electric circuit


(Carrier). ..................................... 11

Z-8 Torque converter circuit. .......... 18

Z-9 Brake circuit............................... 19

Z

Z-1 Z-1
Hydraulic circuit

Rotary joint
Solenoid valve (for steering select)
Orbitrol
Priority valve
For rear steering
Master cylinder
Unloading valve

Flow control valve


Manual control valve
(4-wheel) (Crab)
Oil cooler

For reverse steering


Steering cylinder

Swing drive unit


Solenoid valve
(for spring lock and
nose dive prevention)
Spring lock cylinder Jib Solenoid valve Counterbalance valve
(for inching swing) Extension cylinder
Hose reel
(for nose dive
prevention)
Elevating
cylinder Tilt cylinder
(Up)
Pilot
check Stop
valve
(Down) Solenoid valve valve
Solenoid control valve Elevation
(for automatic stop) (option : for hydraulic out put device)
Solenoid valve Solenoid valve
(option : for (option : for Solenoid valve
clamshell) simultaneous (for jib tilt/extension
Pilot operation) Counterbalance select)
check valve Counterbalance valve
Charging pump Telescoping valve
Telescoping cylinder Counterbalance
valve
Hydraulic valve Hydraulic
valve

Solenoid control valve Aux. Hose reel


Check
valve

Solenoid valve
(option : for series circuit)

Pressure
gauge
Reducing
valve
Pilot Flow
control Flow divider
check
valve valve Main

Shuttle valve Solenoid control valve


(option : for hydraulic
out put device)
Extension cylinder
Telescoping control valve
Manual control valve
Winch clutch
Hydraulic pump Winch brake band Auxiliary winch
(for emergency Hydraulic Hydraulic pump
steering) Master cylinder
pump Auxiliary Main
Auxiliary

Main
Main winch
Hydraulic motor

Counterbalance valve
Hydraulic valve

Note : 1) When the option is not installed, it is connected between (A-A, B-B ).
2) sign part is plug, and K and L are connected with the drain.
Clutch valve 3)In TR500M1-00103, come already equipped with SL10.
Jack cylinder Moreover, SL9 and SL11 are the options.
Pilot
check valve
Oil tank

1 Z01-0580E
Z-1 Z-1
Hydraulic circuit

Air conditioner circuit (option)

Solenoid valve
Unloading valve
Collateral circulation , major cycle
Rising temperature

Thermistor temperature gauge

Major cycle
Rising temperature, collateral circulation Major cycle

Heat transfer equipment


Capillary Solenoid valve
Motor

Motor Pump
Thermistor temperature gauge Heating

Oil cooler Compressor


Solenoid valve Cooling
Accumulator
Outboor unit
Heating Solenoid valve

Capillary
Condenser Evaporator

Relation between temperature of oil when heating is Cooling


Inboor unit
used and operation of solenoid valve

Thermistor temperature gauge Solenoid valve


Operation

Warm-up
Rising temperature
Collateral circulation
Major cycle

Collateral circulation

2 Z01-0580E
Z-2 Z-2
Hydraulic circuit

Rotary joint Relief valve Counterbalance valve


Solenoid valve (for steering select)
Orbitrol
Priority
For rear steering valve
Side up Master cylinder
cylinder
Flow control
valve
Manual control valve
(4-wheel) (Crab)
A/C Solenoid valve
Unloading valve

For reverse steering


Steering cylinder

Swing drive unit


Solenoid valve
(for spring lock and
Spring lock cylinder nose dive prevention)
Jib
Solenoid valve
(for nose dive (for inching swing)
prevention)

Elevating
(Up) cylinder Jib tilt cylinder

(Down) Solenoid valve


(for automatic stop) Solenoid control valve Elevation
(option : for hydraulic out put device) Hose reel Counterbalance
Solenoid valve Solenoid valve
(option : for valve
(option : for simultaneous
clamshell) operation)
Pilot Counterbalance
Charging pump check valve
Telescoping valve
Telescoping cylinder Counterbalance
Hydraulic valve valve
Hydraulic
valve
Solenoid control valve Aux. Hose reel
Check
valve

Solenoid valve
(option : for series circuit)

Pressure
gauge
Reducing
valve
Pilot Flow
check control Flow divider
valve valve
Main

Shuttle valve Solenoid control valve


(option : for hydraulic
out put device)
Extension cylinder
Telescoping control valve
Manual control valve
Winch clutch
Hydraulic pump
(for emergency Winch brake band
Hydraulic Hydraulic pump Auxiliary winch
steering) Master cylinder
pump
Auxiliary Main
Auxiliary

Main

Main winch
Hydraulic motor

Counterbalance valve
Hydraulic valve

Note : 1) When the option is not installed, it is connected between (A-A, B-B ).
2) sign part is plug, and K and L are connected with the drain.
Jack cylinder Clutch valve
Pilot
check valve
Oil tank

3 Z01-0820E
Z-2 Z-2
Hydraulic circuit

Air conditioner circuit (option)

Unloading valve Solenoid valve


Collateral circulation , major cycle
Rising temperature

Thermistor temperature gauge

Major cycle
Rising temperature, collateral circulation Major cycle

Heat transfer equipment Solenoid valve


Capillary
Motor

Motor Pump
Thermistor temperature gauge Heating

Oil cooler Compressor


Solenoid valve Cooling
Accumulator
Outboor unit
Heating Solenoid valve

Capillary
Condenser Evaporator

Relation between temperature of oil when heating is Cooling


Inboor unit
used and operation of solenoid valve

Thermistor temperature gauge Solenoid valve


Operation

Warm-up
Rising temperature
Collateral circulation
Major cycle

Collateral circulation

4 Z01-0820E
Z-3 Z-3
Electric circuit
DC-DC converter Relay (for roof window forgetting close alarm)

Electrical parts location diagram

Air horn Working lamp Condenser (for heater noise prevention)

For heater
Emergency transmission switch
Washer motor Relay
Cord reel (for signal transmitter) Multiplex data transmitter system
check switch

Relay 2P
Relay 4P
For clamshell

Flasher relay 1 For heater

For series
Working lamp Relay 3P
For heater Detail of relay box inside

Buzzer 2 (roof window forgetting Windshield wiper motor


close alarm)
Buzzer 3
Working lamp
(AML alarm)

Relay (flasher unit) Signal transmitter

Buzzer 5 (overwinding alarm)


Buzzer 1 (low air pressure alarm)
Buzzer 4 (low accumulator pressure alarm)

Multiplex data transmission device Jib length detector

Intermittent wiper relay


Relay box
Moment detector
Boom angle detector

Winch drum Jib offset angle detector


(low accumulator detection)
rotation sensor
Signal transmitter

Cord reel

Power supply for air conditioner Boom length detector


Signal transmitter
Cable for AML trouble

5 Z02-0550E
Z-3 Z-3
Electric circuit

Resistance
Resistance

Battery relay Fuse


Safety relay

Relay

Relay and
Fuse 60A Relay fuse box

Air heater relay


Condenser

Relay and fuse box

Switch for auto greastar Fuel sender


Tachograph
Combination lamp
Combination lamp
Head lamp

Air dryer
Backup lamp
Back buzzer
Starter motor

Load (RACK)
Speed sensor sensor
license lamp
SL45 (Upper), SL42 (Lower)
Head lamp relay
SL44 (Upper), SL43 (Lower)
Thermo sender (coolant)

Water temperature sensor (for turbo control)

Low pressure switch


Multiplex data transmission device
Turbo control unit (engine oil)

Head lamp Combination lamp


Outrigger lower control box

Combination lamp
Multiplex data transmission device Air heater
Boost sensor

Tachometer sensor

Thermo sender
(torque converter oil temperature)
Pickup sensor
(speed)
Idling switch

6 Z02-0550E
Z-4 Z-4
Electric circuit
DC-DC converter Relay (for roof window forgetting close alarm)

Electrical parts location diagram

Working lamp Condenser (for heater noise prevention)


Air horn

For heater
Emergency transmission switch
Washer motor Relay
Multiplex data transmitter system
check switch

Relay 2P

For clamshell Relay 4P

Flasher relay 1 For heater

For series
Working lamp Relay 3P
For heater Detail of relay box inside

Buzzer 2 (roof window forgetting Windshield wiper motor


close alarm)
Buzzer 3 Working lamp
(AML alarm)

Relay (flasher unit)


Buzzer 5 (overwinding alarm)
Buzzer 1 (low air pressure alarm)
Buzzer 4 (low accumulator pressure alarm)

Clearance lamp
Signal transmitter
Multiplex data transmission device

Intermittent wiper relay


Relay box
Moment detector

Boom angle detector

Winch drum (low accumulator detection)


rotation sensor

Cord reel

Power supply for air conditioner Boom length detector

Cable for AML trouble

7 Z02-0560E
Z-4 Z-4
Electric circuit

Resistance
Resistance

Battery relay Fuse


Safety relay

Relay

Relay and
Fuse 60A Relay fuse box

Air heater relay


Condenser

Relay and fuse box

Switch for auto greastar Fuel sender


Tachograph
Combination lamp

Combination lamp
Head lamp

Air dryer
Backup lamp
Back buzzer
Starter motor

Load (RACK)
Speed sensor sensor
license lamp
SL45 (Upper), SL42 (Lower)
Head lamp relay
SL44 (Upper), SL43 (Lower)
Thermo sender (coolant)

Water temperature sensor (for turbo control)

Multiplex data transmission device Low pressure switch


Turbo control unit (engine oil)

Head lamp Combination lamp


Outrigger lower control box

Combination lamp
Multiplex data transmission device Air heater
Boost sensor

Tachometer sensor

Thermo sender
(torque converter oil temperature)
Pickup sensor
(speed)
Idling switch

8 Z02-0560E
Z-5

Power supply

Shield Boom angle


Shield detector
Moment detector Cord reel
Shield
Jib tilt/extension select solenoid

Boom length
Shield detector
(4th/top boom section full retraction detection)
Power supply Cord reel
(contact closed during full extension)

Luffing (Left area detection)


(contact closed on the left side)
Left area detection
Area forward detection
JIB selector (Area forward detection)
PTO switch Luffing (Jib tilt/extension select)
(contact closed during detecting over-front area)
Middle boom full extension
JIB tilt selector
Overwind detection
External indicator lamp for (Overwinding detection to boom)
external abnormality indicator lamp (90%-) (Jib tilt/extension select) (contact open for overwinding)
External indicator lamp (100%-) (Jib,
For urgent operation in AML failure single top overwinding detection)
For external overwind buzzer Cord reel
(contact open for overwinding)

9
Buzzer 5
Stop indicator lamp
To vent valve
Automatic stop
This figure is shown the state of below. solenoid valve To Telescoping
valve
1) State of crane running For overwinding cutout disable
Electric circuit

Solenoid for relief vent


2) PTO switch : OFF (Overwinding cutout disable)
For overloading stop cancel (Mast MAX. angle detector)
3) Boom section full retraction (Mast MIN. angle detector)
(contact open for mast MAX. angle) (contact open for mast MIN. angle)
4) Boom forward position For abnormality stop cancel
Buzzer 3
5) Hook : overwinding For buzzer
6) Starter switch is OFF Telescoping control output No.1
7) Control lever is neutral ( 4th/top boom section
Telescoping control output No.2 extension SW) Cord reel Jib offset angle detector

Z03-0440E
Shield Shield Shield Shield
Transmitter Transmitter
Power supply (SW for 4th/top boom section
emergency) (SW for 2nd/3rd boom section analog analog
emergency) digital digital
top boom top boom
Luffing jib yilt angle input
Power supply Luffing JIB Mis operation indicator lamp
5A Jib offset angle detector
Power supply timer Cord reel
Power supply Signal transmitter
analog digital
Shield
jib
Shield
Jib length detector
Option (detent)
L10 main winch hoist-up detection
(contact open during hoisting up)
MAIN hoisting up
MAIN hoisting down L11 main winch lowering detection Shield
Boom extending (contact closed during hoisting down)
Z-5

Boom retracting (Luffing)


Boom raising L12 boom extending detection (Jib tilt detector)
Boom lowering L13 boom retracting detection(contact open (contact open during boom extending)
during boom retracting) (Jib full extension detection)
SUB hoisting up
SUB hoisting down
Jib raising/retracting
Jib lowering/extending L14 boom raising detection
(contact open during boom raising)
L15 boom raising detection (contact open during boom lowering)
L16 Auxiliary winch hoist-up detection (contact open during hoisting up)
L17 Jib tilt raising/retracting detection (contact open during jib raising/retracting)
L18 Jib tilt lowering/extending detection (contact open during jib lowering/extending)

Power tilt working

Telescoping alarm buzzer Option (connector for work without jib)


Luffingjib set use (Connects when there is no jib. )
Telescoping stop valve relay
Jib offset angle alarm buzzer
Luffing use
There is no power tilt jib.

Wire number of part line selector SW


Method of indication for wiring (Inching swing (Luffing jib wire number of part line selection change
selector) (contact closed 1 part line) switch)

Solenoid for inching swing


A color of trace that Luffing set, Luffing use
mixed with a ground color

A ground color of electric wire Power tilt/extension operation indicator lamp

The sectional area of Buzzer 4


(Accumulator pressure)
electric wire (mm2)
Luffing JIB
Mark Color
Shield (Aux. swing free/lock selector)

Tension detector

(Main swing free/lock selector) Solenoid for swing


(Swing free/lock selector) free/lock selector
(3rd boom section telescoping correction)
Solenoid for No.1 cylinder
(2nd boom section telescoping correction)
Solenoid for No.2 cylinder

No.1/2 cylinder solenoid


Option (detent) Winch drum rotation display Solenoid for No.3 cylinder

Vehicle wiring diagram

12V power supply


To upper power

Winch drum rotation sensor


transmission unit

Temperature indicator lamp (50 ) (Temperature switch)


(ON at 50 or more.)
To upper power

Winch drum rotation display


transmission unit

Winch drum rotation sensor


Temperature indicator lamp (70 )
(Temperature switch)
(ON at 70 or more.)
3rd winch clutch select solenoid

(3rd winch clutch control)


3rd winch clutch select solenoid

Solenoid for 3rd winch brake

Clutch pressure confirmation indicator lamp (3rd winch clutch pressure)

3rd winch circuit


Z-6

Moment detector
Power supply

Boom angle
Shield detector Cord reel

Boom length
Shield detector
Cord reel
(5th/4th/top boom section full retraction detection)
Power supply (contact closed during full extension)
(Left area detection)
(contact closed on the left side)
Left area detection
Area forward detection
(Area forward detection)
PTO switch (contact closed during detecting over-front area)
(AML canceling Middle boom full extension
switch)
Overwind detection
AML canceling indicator lamp (Overwinding detection to boom)
External indicator lamp for
external abnormality indicator lamp (90%-) (contact open for overwinding)
External indicator lamp (100%-) (Jib,
single top overwinding detection)
For urgent operation in AML failure
For external overwind buzzer (contact open for overwinding)
Buzzer 5
Stop indicator lamp To vent valve

10
Automatic stop
solenoid valve To Telescoping
valve
For overwinding cutout disable Solenoid for relief vent
(Overwinding cutout disable)
For overloading stop cancel
Electric circuit

For abnormality stop cancel


Buzzer 3
For buzzer
This figure is shown the state of below.
1) State of crane running Telescoping control output No.1
(4th/5th/top boom section extension SW)
2) PTO switch : OFF Telescoping control output No.2 (SW for 2nd/3rd boom section emergency)
3) Boom section full retraction

Z03-0700E
4) Boom forward position Power supply
5) Hook : overwinding
(SW for 4th/5th/top boom section
6) Starter switch is OFF emergency) Power tilt jib
7) Control lever is neutral
Power supply Mis operation indicator lamp

5A Jib offset angle detector


Power supply timer Shield
Cord reel Transmitter
analog
digital

Note : AML canceling switch and Option top boom


AML canceling indicator lamp (detent)
are installed since #580117. L10 main winch hoist-up detection (contact open during hoisting up)
MAIN hoisting up
MAIN hoisting down L12 boom extending detection (contact open during boom extending)
Boom extending
Boom retracting L13 boom retracting detection(contact open during boom retracting)
Boom raising
Z-6

Boom lowering L14 boom raising detection (contact open during boom raising)
SUB hoisting up
Jib tilt lowering L15 boom raising detection (contact open during boom lowering)
Jib tilt raising
Jib look pin (insertion) L16 Auxiliary winch hoist-up detection (contact open during hoisting up)
Option
(detent) L21 Jib tilt raising detection (contact open during jib raising)

L17 Jib tilt lowering detection (contact open during jib lowering)

L31 Jib lock pin detection (contact closed put in a pin)

(Side up jib extend/retract Solenoid for side up jib extend/retract


select SW)
Method of indication for wiring
(Extend)
(Retract)
A color of trace that
mixed with a ground color
Automatic pin insertion warning lamp
A ground color of electric wire
The sectional area of Automatic pin insertion detection
electric wire (mm2)
(contact closed during automatic pin insertion)
(Inching swing selector)
Mark Color Solenoid for inching swing

Buzzer 4
(Accumulator low pressure SW)

(Aux. swing free/lock selector)

(Main swing free/lock


selector) Solenoid for swing
(Swing free/lock selector) free/lock selector
(3rd boom section telescoping correction)
Solenoid for No.1 cylinder
(2nd boom section telescoping correction) cylinder
Solenoid for No.2

No.1/2 cylinder solenoid


Option (detent) Winch drum
Solenoid for No.3
rotation display
Vehicle wiring diagram cylinder

Winch drum rotation sensor


12V power supply
To upper power
transmission unit

Temperature indicator lamp (50 ) (Temperature switch)


To upper power
transmission unit

(ON at 50 or more.) Winch drum


rotation display Winch drum rotation sensor

(Temperature switch)
Temperature indicator
(ON at 70 or more.)
lamp (70 )
Z-7 Z-7
Electric circuit

Switch connecting circuit 3. Turn signal lamp switch


Terminal Harness Lever position
1. Starter switch No. color Right Neutral Left Horn Connection

Flasher unit

Turn signal lamp


Turn signal lamp

Horn relay

4. Emergency flasher lamp and parking lamp switch

Terminal No. Harness OFF ON Connection


color
2. Combination switch Power supply

Turn signal lamp (right)


Turn signal lamp (left)

Power supply

Parking lamp

3. toggle switch
Top Mid. Bottom Switch name

Reverse steering switch


Emergency mission switch
Spring lock up/down select
switch
1. Lighting switch Rear steering lock pin switch

Terminal Harness Roof wiper switch


Connection
No. color
Power supply Parking brake switch
Drive (2 wheel / 4 wheel),
Head lamp speed (H / L) select switch

Power supply Slider/jack select switch


Extension/retraction select switch
Head lamp

Dimmer Spring lock switch


(bottom is momentary)
Power supply
Tail, clearance Working lamp switch
lamp

A, B, C in table show state as blow. Top, middle, bottom :


The key (for installing switch) side is
Lever : in other side
bottom.
Lever : neutral
Lever : in this side
Key
2. Wiper and window washer switch
Terminal Harness Wiper Washer Connection
No. color
Washer motor
Motor
(automatic stop)
Motor Lo
Ground
Motor Hi
Ground
11 Z03-0450E
Z-7 Z-7
Electric circuit
4. Processing explanation on inside of multiplex 4. Parking lamp, No.3 brake lamp,
data transmission device
low air pressure lamp, alarm buzzer 1
1. Lock up
Input state of Input state Output state of
1) Condition of lock up upper unit of lower unit upper unit
( i ) Economy (Normal) travel mode

Input state of lower unit


Input state of upper unit

2nd

3rd

2nd

3rd

Note Speed unit [km/h] 1 : Relay contact ON


0 : Relay contact OFF

Note : The value of table sign above has


been changed to 27 since #580097.
(ii ) Power (Full speed) travel mode
Input state of lower unit
Input state of upper unit

2nd

3rd

2nd

3rd

Note Speed unit [km/h] 1 : Relay contact ON


0 : Relay contact OFF

2) Time-lag V = speed [km/h]


Note 1 : 24V 1 : Limit SW ON 1 : Transistor ON
0 : 0V 0 : Limit SW OFF 0 : Transistor OFF
2nd/3rd Hi
5. Transmission
Lock up signal
Input state of upper unit
Output state of lower unit

1st range (Sol1,3 : power-on,


operation

2. Outrigger
(normal)

(over-shift detection : feasible)


Manual

The transmission doesn't output it to 2nd range (Sol2,3 : power-on,


(over-shift detection : feasible)
41 W, 42 WR, 44 WY, and 45 PB ofa lower unit in the
settingsother than the neutral. Gears automatically change
Automatic operation

at change point of Power


Mode in Hi renge depending
on the speed.
3. Charging lamp
Gears automatically change
at change point of Economy
Input state of lower unit Output state of upper unit Mode in Hi renge depending
on the speed.
Gears automatically change
at change point in Low renge
depending on the speed.
operation
(normal)
Manual
Manual operation

When emergency transmission


switch is turned on, output about
transmission in lower unit is OFF.
(emergency)
Note

1 : Transistor ON In this time, transmission signal


Voltage 0 : Transistor OFF is sent to lower unit by rotary
Voltage wiring. And D range is 3rd range.
(Sol3 : power-on,
over-shift detection : infeasible)

1 : 24V
Note 0 : 0V

12 Z03-0450E
Z-7 Z-7
Electric circuit

6. Over running (engine) alarm (alarm 1) 10. Winch drum rotation display
Input state of upper unit Output state of upper unit Input state of upper unit Output state of upper unit
Wiring Drum indicator Drum indicator
(Input of unit)
(In unit)

As soon as PTO switch As soon as PTO switch


turns ON, Indicartor lamp turns ON, Indicartor lamp
1 : Repetition of (322) lights up. (326) lights up.
Note Erev = engine revolution transistor ON and OFF
As drum rotates there-after, As drum rotates there-after,
0 : Transistor OFF
lamp illumination shifts to lamp illumination shifts to
the right sequentially. the right sequentially.

Note
7. Drive (2 wheel / 4 wheel) select and Hi / Lo select 1 : 24V 1 : Transistor ON
0 : 0V 0 : Transistor OFF
Wiring
Input state of upper unit Output state of lower unit
Switch 11. Rear steering lock pin detector lamp
state
Input state of lower unit Output state of upper unit

No change No change
before before
Note

1 : 24V 1 : Relay contact ON 1 : Lock pin set ON 1 : Transistor ON


Note 0 : 0V 0 : Relay contact OFF 0 : Lock pin out OFF 0 : Transistor OFF

8. Exhaust brake 12. Rear steering lock


Output state of Input state Output state
Input state of upper unit lower unit Input state of upper unit of lower unit of lower unit

No change before

No change before
V = speed [km/h] 1 : limit SW 1 : Relay
Note

1 : Relay contact ON
1 : 24V 0 : Relay contact OFF 1 : 24V contact ON contact ON
0 : 0V 0 : 0V 0 : limit SW 0 : Relay
contactOFF contact OFF

9. Spring lock
13. Rear steering neutral detector lamp
Output
state Output state
Input state of upper unit of upper of unit lower Input state of lower unit Output state of upper unit
unit
Note

Keep spring lock

1 : limit SW contact ON 1 : Transistor ON


0 : limit SW contact OFF 0 : Transistor OFF
Spring locking
1:Power supply ON
14. Over running (traveling speed) alarm (alarm 1)
or a system check
Others : No change [Upper unit output ( 98 YO) control]
before Acceleration or
decelerate Buzzer
At acceleration Traveling speed 53km/h : discontinuous sound
1 : Transistor 1 : Relay conect ON
ON 0 : Relay conect OFF Traveling speed 56km/h : continuous sound
1 : 24V
0 : 0V 0 : Transistor When changing from 0 into 1, Traveling speed 54km/h : discontinuous sound
OFF DELAY1 is delayed 0.3 seconds. At decelerate Traveling speed 49km/h : OFF

13 Z03-0450E
Z-7 Z-7
Electric circuit
Relay Lamp, pilot
Valve, solenoid
(Air horn) (boom, top) 3W
Lamp, working (Horn) Buzzer 2 Lamp, working
Lamp, working
60W (RH)
(boom) 60W
Switch (Roof door)
Relay RM
Alarm unit for not forgetting to (Turn signal)
colse roof window

Turn signal Hi/Low select


Outrigger SW neutral (Reverse)
position detection
One shot Relay Rc
2. Work lamp Gauge, Gauge, circuit (Turn signal)
Gauge,
5. Turbo warn temperature temperature Speedometer Tachometer pressure Gauge, fuel Buzzer 1
(Water) Cigarette (for Low air
6. Turn signal (Oil) (Air) pressure alarm)
lighter Switch
Starter switch (Horn)

Head, lamp(RM)
Lever P
Combination
switch Flasher Head, lamp(LN)
unit
Low beam 65W
main beam 50W+55W
Lamp, combination(LN)

Lamp, combination
(RM)

PTO
switch
Wiring daiagram
(Crane) Relay
(Head lamp)

2W

4W
Steering mode Lamp, room
Air dryer
change switch Crab
Rear
Switch (Door)
Relay Ra (spring)
(Heater)

Slide FL Jack Slide FR Jack Valve, solenoid EXT RET

Valve, solenoid
(EXT/RET change)
Valve, solenoid

Parking brake
SW Valve, solenoid Valve, solenoid

Spring lock Switch, limit Switch, limit Sensor for


(Reservoir ASSY) (Reservoir ASSY) turbo control
SW (engine) Turbo control unit

Diagnosis lamp

Steering lock up/down


Hi/Low detection SW
select switch 4WD detection SW
Connector for Connector for DIAG
Valve, solenoid DDS-
Switch (low pressure) (Steering shift)
Switch (Low pressure)
(Parking) (Air) Relay RK (under nose dive)
Relay RG
Defroster (Emergency Sensor, pick up
(Speed)
switch Rear steering lock
transmission
change)
Out of use
Tachometer input
Resistance relief valve SW
Tachometer output Valve, solenoid
Fuse for prevention of
(Sp. lock Switch
damaging by a fire Speed sensor
check release) (Low pressure) Solenoid valve
Relay RD (N start) input(M) (unti-nose dive) (unti-nose dive)
Speed meter output Valve, solenoid
Drum rotation sensor input (M) (PTO)
Sender, fuel
Drum rotation sensor input (S)

Flasher relay 1 24V power supply


Tacho-
graph
Transmission
selector switch Valve , solenoid
Speed sensor input (S)
12V power supply Sensor, speedmeter (Rear steering lock) Divider, flow Pump
Auto greaster (grease)
Relay RB (12V night lamp) (grease)
System check
24V power supply Relay RP
(Emergency
Drum
transmission
Working lamp indicator
(M)
Valve, solenoid
Engine stop
Valve, solenoid
Governor change
PS change)

switch Wiring diagram


(Crane) Out of use
Relay RI
Drum
indicator
Automatic transmission (S)
Valve, solenoid Valve, solenoid
mode (power/ economy) Relay RL Parking brake 3rd brake Lamp, pilot

change switch Sensor, tachometer


Valve, solenoid
Reverse steering Out of use
Out of use
(Lock up)
Switch (limit) Valve, solenoid Valve, solenoid
switch (Backward position
detection)
2/4 drive change Hi/Lo change Relay RJ
(Clearance
Exhaust brake Relay RE lamp)
Valve, solenoid
(Spring lock condition)
switch Out of use Exhaust brake

Hoist-up detection (M)


Relay RF Hoist-up detection (S) Switch (limit)
Rear steering lock pin (Head light)
Rear steering lock release (for correction)
Switch (Oil, low pressure)
(Idling state detection)
switch Emergency transmission
Head lamp(Hi)
Emergency Clearance
mission SW Rear steering lock release
Out of use Alternator
SW (pressure)
Rear steering lock Sender, thermo (stop)
DC-DC converter Air heater brake (Oil)

Multiplex data Exhaust brake

transmission device Rear steering Sender, thermo


SW (pressure)
Spring lock regulate (Water)
check switch H/L change,2/4 drive change (1)
Out of use
Valve, solenoid
(stop)
Relay
H/L change,2/4 drive change (2) (reverse steering)
PTO switch detection
Slider / Jack Steering shift (4 wheel) Safety relay
selector switch Steering shift (Crab)
Spring lock Air heater relay
Spring lock release
Air heater
Head lamp (Lo)
Outrigger extend / retract Mode select (Power, economy)
Transmission selector valve
selector switch Clearance (for Drum indicator) Relay
Valve, solenoid Valve, solenoid
Parking brake switch detection (transmission selector)
Out of use
Gear 1 Slide RL Jack Slide RR Jack

Gear 2
Gear D

Starter motor Battery


EXT/RET change Relay RN
(Jack/Slide change)
Battery relay

J/S change

Switch (limit)
(Lock pin)
Out of use Out of use
Switch (limit)
Relay RO (straight driving)
Reverse steering (EXT/RET change) (Fill in‫ޓ‬straight driving)
Spring lock (up/down)

Slider/jack selector switch Lamp (combination, RH)

Outrigger extend/retract selector (Turn signal) (Tail ,Stop/Parking lamp)


switch
For roof wiper
Roof wiper motor
Drive (2 wheel/4 wheel), Windshield wiper motor Relay terminal explanation

Speed (H/L) Radio


change SW Washer motor Valve, solenoid Condenser
(reverse steering)

Cab lamp (10W) Series Lamp(Combination, LM)


(for indoor spirit Clamshell
Turn signal 25W GY
level lighting)
(Turn signal) Stop 25W GW Lamp (License) Lamp (Backup) Buzzer (Backup)
Hydraulic Intermittent wiper relay
Switches for Heater

toriide Tail 10W G 12W 25W


(Heater ASSY, control)

(Tail stop / parking)


To Relay RZ1

Parking 3W GL
(in Relay box)

(in Relay box)


To 15A Fuse

Fan switch Fan


A/C Ass’y
To combination
switch
Lower outrigger control BOX

14 Z03-0450E
Z-7 Z-7
Electric circuit

[Option electric circuit diagram]

Note : In TR-500M-1-00103, neither the clam shell nor the series are the options.
Moreover, the standard is set to simultaneous operation.

(1) Heater

Heater switch

Defroster switch
Resistance

Panel Ass’y
control Heater Ass’y
Defroster

Relay RZ1 Relay RZ2

limit thermo (turns off by 160 )


Solenoid valve

Combustion

Preheating
Stop
Spark plug

Motor

Warm air indicator lamp Heater Ass’y


Control panel Ass’y Control thermo
(turns ON by 55 ,
(turns OFF by 30 )

15 Z03-0450E
Z-7 Z-7
Electric circuit

(2) Clamshell, series


Clamshell ON Series ON

Clamshell/series SW
Solenoid for series
Series

Simultaneous operation
For main winch speed
selection detection
Solenoid for simultaneous operation

Clamshell
Solenoid for parallel

Button switch
(Main winch clutch lever)

(3) Clamshell
Clamshell ON

Clamshell SW
Simultaneous operation

Solenoid for simultaneous operation


Clamshell

Solenoid for parallel

Button switch
(Main winch clutch lever)

(4) series
Series ON

Series SW
Solenoid for series

For main winch speed


selection detection

16 Z03-0450E
Z-7 Z-7
Electric circuit

(5) Simultaneous operation, series


Simultaneous operation ON Series ON

Simultaneous operation/series SW
Solenoid for series
Series

For main winch speed


selection detection
Solenoid for simultaneous operation
Simultaneous
operation

(6) Simultaneous operation


Simultaneous operation ON

Simultaneous operation SW
Solenoid for simultaneous operation

17 Z03-0450E
Z-8 Z-8
Torque converter circuit

Temperature gauge
Oil cooler
Lubricating oil relief valve

Torque converter output


governor valve

Lock up
clutch

Modulating valve

Pressure gauge

PTO clutch
Torque converter
input relief valve

Hydraulic valve

Main governor
valve

Charging Line filter


pump

Torque converter

Strainer

Transmission

18 Z05-0070E
Z-9 Z-9
Brake circuit

Rotary joint Brake valve

Pressure switch
(for stop lamp)

Pressure switch
(for anti nose dive)

Shuttle valve Pressure gauge


Air cylinder
(for accelerator)
Throttle valve (accelerator)
Front (For engine highest
rotation restriction)
Reducing valve

Air cylinder Air cylinder


(for 2/4 wheel driving select) (for engine stop)

Rear

Air cylinder Air cylinder


(for Hi/Low select) (for exhaust brake)

Oil reservoir Air horn

Air cylinder
(for steering lock)

Reducing valve

SL57 (release)

Inflator Air dryer

Reducing valve Low-pressure indicator Unloading valve


Booster (for air pressure alarm)

Safety valve

Pressure regulator
Air compressor
Parking brake chamber

Low-pressure switch
(for parking brake)

19 Z06-0110E
Head Office Ko-34,Sinden-cho, Takamatsu, Japan

Overseas Service Group


Tadano Ryogoku Bldg.
4-12, Kamezawa 2-chome,
Sumida-ku,
Tokyo, Japan
Tel. 81 (3) 3621-7765
Tel fax 81 (3) 3621-7785

History of revision
1
2
3
4
5
2008
PRINTED IN JAPAN
0803 E