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TR-500M-1/C1-1E
01
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.
MFG.DATE.
KAGAWA, JAPAN
ISA04-001601
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
Specifications Y-1
System Diagrams
Electric circuit
Z-3 Z-4
(electrical parts location diagram)
WA04-0000E
Data, Adjustment and Checks
Contents
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
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
Crane operation......................................40
1. Procedure for
adjusting engine rotation................. 40
2. Procedure for
adjusting accelerator pedal. ............ 41
Brake system..........................................42
iii
Y- 1 Y- 1
Specifications
Engine
1. Engine rotation speed
Hydraulic equipment
1. Hydraulic pump (for crane)
7. Accumulator
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.
[Spec number]
Spec No.
Component name
Y02-0280E
Y- 3 Y- 3
Adjustment procedure (pressure)
Priority valve
(steering circuit) Relief valve (RV5)
Onload pressure
Unload valve
Unload pressure
Reducing valve
Thermostat
(for hydraulic oil temperature indicator lamp)
Y03-0410E
Y- 3 Y- 3
Adjustment procedure (pressure)
Y03-0410E
Y- 3 Y- 3
Adjustment procedure (pressure)
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.
Pressure outlet
(PT1/4)
(T joint section)
Front
Y03-0410E
Y- 3 Y- 3
Adjustment procedure (pressure)
4. Priority valve
Relief valve, RV5
Installation location: Side of the swing drive unit
Front
6. Unload valve
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)
Y03-0410E
Y- 4 Y- 4
Adjustment procedure (pressure)
Reducing valve
Overload relief valve
Counter balance valve
(for main and auxiliary winches) Pilot pressure during valve opening
Thermostat
(for hydraulic oil temperature indicator lamp)
Y03-0610E
Y- 4 Y- 4
Adjustment procedure (pressure)
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.
Pressure outlet
(PT1/4) 5. Boom telescoping control valve
(T joint section)
Installation location: Rear of the swing table
Front
Pressure outlet (PT1/4)
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
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
12 Y03-0610E
Y- 4 Y- 4
Adjustment procedure (pressure)
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)
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)
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
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
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
16 Y04-0500E
Y- 5 Y- 5
Adjustment procedure (electric)
Jib
Tilt direction
Red
White
Black
Shield
17 Y04-0500E
Y- 6 Y- 6
Adjustment procedure (electric)
Swing frame
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
Make sure that the switch is operated when
dimension A is 27.5±1 mm.
Stopper bolt
In free status
ON position
19 Y04-0510E
Y- 6 Y- 6
Adjustment procedure (electric)
Unlock
Lock
20 Y04-0510E
Y- 7 Y- 7
Adjustment and checks
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.
NOTICE
Be sure to turn “OFF” the PTO switch to
unload the accumulator charging circuit.
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
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”.
22 Y05-0381E
Y- 7 Y- 7
Adjustment and checks
Master cylinder
Brake pedal
Pedal end
Adjusting bolt
Push rod
Lock nut
Brake pedal
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
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.
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.
24 Y05-0381E
Y- 7 Y- 7
Adjustment and checks
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
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
NOTICE
As the winches are subjected to the
accumulator pressure, pay due attention to
splash of brake oil.
4) O
pen the bleeder screw of the winch clutch
cylinder to bleed.
26 Y05-0381E
Y- 7 Y- 7
Adjustment and checks
Telescoping system
1. Procedure for bleeding in power tilt jib circuit
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.
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
2. Speed control
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.
28 Y05-0381E
Y- 7 Y- 7
Adjustment and checks
Rod (a)
Lever (b)
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”.
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.
29 Y05-0381E
Y- 7 Y- 7
Adjustment and checks
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.
Brake system
1. Procedure for adjusting brake pedal
Roller
Plunger
30 Y05-0381E
Y- 7 Y- 7
Adjustment and checks
NOTICE
There are two boosters.
Booster Bleed while paying attention to splash of
brake oil and oil quantity in the oil reservoir.
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.
Steering system
Stopper bolt B Tie rod Stopper bolt A 1. Procedure for adjusting tire steering angle
31 Y05-0381E
Y- 7 Y- 7
Adjustment and checks
[Reference]
Electric transmission
1. Failure diagnosis for turbo control system
Item Remarks
(user (dealer
mode) mode)
32 Y05-0381E
Y- 7 Y- 7
Adjustment and checks
(Example)
(Long) (Short) For No.3 lack sensor error
1st time 2nd time Code: 1 - 3
(Note)
The lamp goes out for 2.4 seconds before the
code is displayed.
Option
1. Procedure for filling air conditioner refrigerant gas
20°C or more
Window
open
20°C or less
33 Y05-0381E
Y- 7 Y- 7
Adjustment and checks
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.)
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
R12
saturation
temperature
35 Y05-0381E
Y- 8 Y- 8
Adjustment and checks
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.
Plug Plug
36 Y05-0440E
Y- 8 Y- 8
Adjustment and checks
Rapidly
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.
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.
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.
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
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)
Rod (a)
Lever (b)
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
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.
Bolt (c)
41 Y05-0440E
Y- 8 Y- 8
Adjustment and checks
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.
Brake valve
Adjusting bolt
3. Procedure for adjusting parking brake clearance
42 Y05-0440E
Y- 8 Y- 8
Adjustment and checks
1) Keep the lever for the parking brake at the 0 Tire size Steering angle
point (middle position of play of the lever).
Play of lever
Steering system
1. Procedure for adjusting tire steering angle
43 Y05-0440E
Y- 8 Y- 8
Adjustment and checks
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)
(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
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)
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
Z-1 Z-1
Hydraulic circuit
Rotary joint
Solenoid valve (for steering select)
Orbitrol
Priority valve
For rear steering
Master cylinder
Unloading valve
Solenoid valve
(option : for series circuit)
Pressure
gauge
Reducing
valve
Pilot Flow
control Flow divider
check
valve valve Main
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
Solenoid valve
Unloading valve
Collateral circulation , major cycle
Rising temperature
Major cycle
Rising temperature, collateral circulation Major cycle
Motor Pump
Thermistor temperature gauge Heating
Capillary
Condenser Evaporator
Warm-up
Rising temperature
Collateral circulation
Major cycle
Collateral circulation
2 Z01-0580E
Z-2 Z-2
Hydraulic circuit
Elevating
(Up) cylinder Jib tilt cylinder
Solenoid valve
(option : for series circuit)
Pressure
gauge
Reducing
valve
Pilot Flow
check control Flow divider
valve valve
Main
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
Major cycle
Rising temperature, collateral circulation Major cycle
Motor Pump
Thermistor temperature gauge Heating
Capillary
Condenser Evaporator
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)
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
For series
Working lamp Relay 3P
For heater Detail of relay box inside
Cord reel
5 Z02-0550E
Z-3 Z-3
Electric circuit
Resistance
Resistance
Relay
Relay and
Fuse 60A Relay fuse box
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)
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)
For heater
Emergency transmission switch
Washer motor Relay
Multiplex data transmitter system
check switch
Relay 2P
For series
Working lamp Relay 3P
For heater Detail of relay box inside
Clearance lamp
Signal transmitter
Multiplex data transmission device
Cord reel
7 Z02-0560E
Z-4 Z-4
Electric circuit
Resistance
Resistance
Relay
Relay and
Fuse 60A Relay fuse box
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)
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
Boom length
Shield detector
(4th/top boom section full retraction detection)
Power supply Cord reel
(contact closed during full extension)
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
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
Tension detector
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
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
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)
Buzzer 4
(Accumulator low pressure SW)
(Temperature switch)
Temperature indicator
(ON at 70 or more.)
lamp (70 )
Z-7 Z-7
Electric circuit
Flasher unit
Horn relay
Power supply
Parking lamp
3. toggle switch
Top Mid. Bottom Switch name
2nd
3rd
2nd
3rd
2nd
3rd
2nd
3rd
2. Outrigger
(normal)
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)
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
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
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
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)
Valve, solenoid
(EXT/RET change)
Valve, solenoid
Parking brake
SW Valve, solenoid Valve, solenoid
Diagnosis lamp
Gear 2
Gear D
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)
Parking 3W GL
(in Relay box)
14 Z03-0450E
Z-7 Z-7
Electric circuit
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
Combustion
Preheating
Stop
Spark plug
Motor
15 Z03-0450E
Z-7 Z-7
Electric circuit
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
Button switch
(Main winch clutch lever)
(4) series
Series ON
Series SW
Solenoid for series
16 Z03-0450E
Z-7 Z-7
Electric circuit
Simultaneous operation/series SW
Solenoid for series
Series
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
Lock up
clutch
Modulating valve
Pressure gauge
PTO clutch
Torque converter
input relief valve
Hydraulic valve
Main governor
valve
Torque converter
Strainer
Transmission
18 Z05-0070E
Z-9 Z-9
Brake circuit
Pressure switch
(for stop lamp)
Pressure switch
(for anti nose dive)
Rear
Air cylinder
(for steering lock)
Reducing valve
SL57 (release)
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
History of revision
1
2
3
4
5
2008
PRINTED IN JAPAN
0803 E