Publication No.

TR-100M-1/C2-1E

01

Rough Terrain Crane

TR-100M-1
Model

Applicable Serial No. FC0790 -

 Foreword

Foreword

This manual contains all the hydraulic and electric circuit diagrams for the Model TR-100M-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-100M-1-00105
TR-100M-1-00106
FC0790 -
TR-100M-1-00107
TR-100M-1-00108

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

 WA04-0000E
 Foreword

2. Contents
Spec. No.
Chapter Section TR-100M- TR-100M- TR-100M- TR-100M-
1-00105 1-00106 1-00107 1-00108

Data, Adjustment and Checks

Specifications Y-1

Weight Table Y-2

Adjustment (pressure) Y-3

Y
Adjustment (electric) Y-4

Adjustment and Checks Y-5

System Diagrams

Hydraulic Circuit Z-1

Electric circuit (crane) Z-3

Electric circuit (carrier) Z-4

Z
Torque converter circuit Z-5

Brake circuit Z-6

 WA04-0000E
 Data, Adjustment and Checks
Contents
Y-1 Specification. ................................. 1
Engine..........................................................1
Hydraulic unit. ..............................................1
Y-2 Weight list....................................... 2
Y-3 Adjustment (pressure). ................. 3
Hydraulic circuit unit.....................................3
1. Hydraulic pilot control valve........................ 4
2. Solenoid valve............................................ 4
3. Solenoid control valve................................ 4
4. Priority valve............................................... 5
5. Hydraulic valve........................................... 5
Air circuit unit................................................6
Converter circuit unit ...................................6
Y-4 Adjustment (electric)..................... 7
Switch adjustment........................................7
1. Boom front position detection (CS12). ....... 7
2. Boom rear position detection (CS23)......... 7
3. Swing dead angle detection (CS24)........... 8
4. Top boom full retraction detection (L7)....... 8
5. 2nd boom full retraction detection (L8)....... 8
6. Straight driving detection (CS20). .............. 9
Outrigger extension length detector
adjustment...........................................10
Y-5 Adjustment and checks. ............. 11

Break-in of the pump.................................. 11
1. Steering/swing pump
(double gear pump)......................... 11
2. Main pump (double gear pump)............... 11
Winch system.............................................12
1. Check procedure of N2 gas filling pressure
of the accumulator. .................................... 12
2. Procedure for removing accumulated
pressure from accumulator circuit... 12
3. Adjustment of brake pedal (Both main and
auxiliary winches)............................ 12
4. Brake circuit bleeding.............................. 13
5. Winch brake band adjustment
(For both main and auxiliary winch brakes).. 14
6. Winch clutch circuit bleeding procedure
(Both main and auxiliary winches)... 15
7. Adjustment of winch clutch
(Both main and auxiliary winches)... 15
8. Bleeding procedure for the counterbalance
valve for winch motor . .................... 15
Swing system.............................................15
1. Swing motor bleeding............................... 15
Power generating system...........................16
1. Engine revolution adjustment................... 16
2. Accelerator pedal adjustment................... 17
3. Check procedure of the stall speed.......... 18
Brake system. ............................................18
1. Brake pedal adjustment............................ 18
2. Brake circuit bleeding procedure.............. 18
Y
3. Clearance adjustment of parking brake.... 19
 4. Parking brake and spring chamber
connection procedure...................... 19

Steering system. ........................................19

1. Steering wheel angle adjustment............. 19

Operation check.........................................20
1. Exhaust brake operation check
procedure........................................ 20
2. Reverse steering operation check
procedure........................................ 20
3. Rear steering lock pin operation check
procedure........................................ 21
4. Overshift prevention device operation check
procedure........................................ 22
5. Outrigger operation status indicator check
procedure........................................ 22
6. Spring lock device operation check
procedure........................................ 23

ii
Y- 1 Y- 1
Specification

Engine Hydraulic unit

1. Engine speed 1. Hydraulic pump (for elevating, telescoping, winch)

Idling speed (IDL): 750 to 800 rpm (1) Pump speed (reduction gear ratio: 1.091)
Maximum speed (MAX)
Idling speed (IDL): 710 rpm
PTO"OFF", speed with no load: 3150 to 3300 rpm
Maximum speed (MAX): 1950 rpm
PTO"OFF", speed with no load, speed-limiting device ON
: 2600 to 2650 rpm
(2) Discharge rate
PTO"ON", speed with no load: 2100 to 2150 rpm
Stall speed: approximately 2420 rpm (reference value)
Pump 1
Pump 2

2. Hydraulic pump (for steering, outrigger and swing)

(1) Pump speed (reduction gear ratio: 1.179)

Idling speed (IDL): 660 rpm

Maximum speed (MAX): 2735 rpm

(2) Discharge rate

Pump 3
Pump 4

3. Charging pump (for torque converter)

(1) Pump speed (Reduction gear ratio: 1.179)

Idling speed (IDL): 660 rpm

Maximum speed (MAX): 2735 rpm

(2) Discharge rate: 23.7cm3 /rev

4. Hydraulic motor (winch)

Displacement: 45.6 cm3 /rev

5. Hydraulic motor (Swing)

Displacement: 22.9 cm3 /rev

6. Hydraulic motor (Cabin cooler)

Displacement: 23.0 cm3 /rev

7. Accumulator
N2 gas filling pressure: 65 3 kgf/cm2 (Ambient temperature 20 C)

 Y01-1810E
Y- 2 Y- 2
Weight list

The approximate weights (specific dry weights) of the major parts are given below.

[Spec. No.]

(Unit: kg)

Spec. No.
Part name

X type (including inner case, outer case and slide cylinder)

Outrigger Ass’y
H type (including inner case, slide cylinder and jack cylinder)

Jack cylinder

Swing table Ass’y (excluding boom and elevating cylinder)

Swing bearing

Swing drive unit (including hydraulic motor)

Swing motor

Elevating cylinder

Winch Ass’y (including hydraulic motor)

Winch motor

Boom Ass’y (including telescoping cylinder)

Jib

Telescoping cylinder

Rotary joint

Hydraulic pump (for P.T.O.)

Hydraulic pump (for steering)

Engine

Torque converter

Transmission

Axle (including leaf spring and steering cylinder)

 Y02-1880E
Y- 3 Y- 3
Adjustment (pressure)

Hydraulic circuit unit

Pressure setting table

Set pressure Relief valve Engine speed

Circuit (kgf/cm 3) code
Check point
(rpm)
Check method

Hoist Lock the brake for main winch or Aux winch, then hoist up in first
up gear on the lock side.
Standard
Standard winch Hoist Indication of AML Lock the brake for Aux winch, and then move the boom
down lowering lever and the boom hoisting-down lever in full stroke.

Hoist Lock the brake for the main winch, and then move the boom
down lowering lever and the boom hoisting-down lever in full stroke.

With PTO:ON ( ), with the boom section full retracted and the
Hook in elevation full lowered (Indicator lamp ON), keep pressing the
overwind cutout release switch to move the main winch hoisting-up
lever in full stroke.

Maximize the boom elevation angle and then move the boom-
Raising elevating lever to the boom raising side in full stroke.
Elevation
Lowering
Minimize the boom elevation angle and then move the boom-
elevating lever to the boom lowering side in full stroke.

With the swing brake “ON" and the boom stowed on the boom rest,
Swing operate the boom swinging.

Outrigger After extending or retracting with PTO-OFF at idle running, speed

(Spring lock) up the Eng speed gradually to 3000 rpm, then set.

On-load
Apply the winch brake and set PTO to "ON".
Unloading for Repeat ON-FREE of the clutch lever (by one lever) and then
accumulator Unload remove Acc pressure to confirm the initial accumulating pressure
and the complete pressure.

Steering Without jacking up by operation on the right, stroke end the

steering cylinder.

Transmission clutch 12 or more Pressure gauge

pressure of front meter
panel
With air conditioner ON and compressor ON
40 or less If malfunction occurs, replace the valve because the adjustment is
impossible.
Hydraulic pilot
Operation of all the crane: neutral
30 or more If malfunction occurs, replace the valve because the adjustment is
impossible.

Note: 1. Oil temperature: 50±5 °C (hydraulic oil: ISO VG46)

2. Each switching operation is performed at idle running. Raise the engine rotation afterwards.

 Y03-2490E
Y- 3 Y- 3
Adjustment (pressure)

1. Hydraulic pilot control valve 3. Solenoid control valve

Winch, elevation, swing circuittable Outrigger (Spring lock) circuit

Installing location of valve: rear of the cabin

(1) Install the pressure gauge to the pressure outlet.

(2) Set PTO to "OFF".

(3) After extending or retracting at idle running then

stroking end, maximize the Eng speed to 3000
rpm gradually, then set.

Specification with spring lock

Pressure outlet

2. Solenoid valve
Specification without spring lock
Hook-in circuit
Pressure outlet
Installing location of valve: right rear of
the swing table

 Y03-2490E
Y- 3 Y- 3
Adjustment (pressure)

4. Priority valve 5. Hydraulic valve

Steering circuit Unloading circuit for accumulator

Installing location of valve: left rear of the swing table

(1) Install the pressure gauge to the pressure outlet.
(1) Install the pressure gauge to the pressure outlet.
(2) Set PTO switch to “OFF".
(2) When adjusting to the high-pressure side, tighten
(3) Without jacking up, operate the steering (to the right the adjusting bolt. When adjusting to the low-
rotation,) then keep stroking end the steering cylinder pressure side, loosen it. Each time adjusted, repeat
to measure the pressure value. ON-FREE of the clutch switch and then check the
accumulation.
Engine speed
NOTICE
Priority valve
The adjusting pressure of this relief valve is not
Installing location of valve: lower part of the cabin proportional to the amount of the tightening of
adjusting screw. Check the set pressure with ON-
FREE of the clutch switch each time you adjust.
Do not tighten too hard.
For the unloading pressure gradually declines
because of the leakage of this valve, read a value
right after the completion of accumulation.

Pressure outlet

Solenoid valve (for steering selection, triple)

Installing location of valve: rear of the front axle

Pressure outlet

 Y03-2490E
Y- 3 Y- 3
Adjustment (pressure)

Air circuit unit

Pressure setting table

Name Set pressure (kgf/cm2) Note

Injecting pressure
Pressure regulator When unloaded, check the recovery action
Releasing pressure of air dryer.

Cracking pressure
Safety valve
Full-flow pressure

Lights-on pressure
Low-pressure indicator
Lights-off pressure For warning air pressure
For rear-wheel brake
Reducing valve Check the swing table air tank PT 1/2 plug unit.

Reducing valve For auxiliary brake

Stop lamp switch

Lights-on pressure
Low-pressure switch
Lights-off pressure For parking brake
Inlet pressure Opened when the inlet pressure becomes 5.5 0.35.
Protection valve Both the inlet pressure and the outlet pressure are to be 7.0 kgf/cm2. When
Outlet pressure 3.5 or more the outlet pressure is gradually reduced, it is closed at 3.5 kgf/cm2 or more.

Converter circuit unit

Pressure setting table

Pressure (kgf/cm2)
Name Note

Torque converter outlet pressure 1.5 or more

Lock up clutch pressure At 3000 rpm

PTO clutch pressure 12 or more

Transmission clutch pressure 12 or more Pressure indication on front meter panel

Transmission lubricating pressure (axial end pressure) 0.05 or more

 Y03-2490E
Y- 4 Y- 4
Adjustment (electric)

Switch adjustment 2. Boom rear position detection (CS23)

1. Boom front position detection (CS12)
(1) Apply screw-locking compound (equivalent to THREE BOND
1401) to the screw of the switch in advance.
(2) Point the boom to the right in front.
(3) Adjust the clearance between the switch detection face and
the dock to the dimension shown in Fig.1, and then fix.
Tightening torque: 8 to 9 kgf-cm
(1) A pply screw-locking compound (equivalent to THREE
BOND 1401) to the screw of the switch in advance.
(2) Adjust the clearance between the switch detection face and
the dock to the dimension shown in Fig.2 at the position
where swinging 180° to the rear direction from the traveling
configuration, and then fix.
Nut tightening torque: 8 to 9 kgf-cm

Switch

Left swing View A

Nut

Right swing
Swing frame
8 to 9 kgf-cm base plate
(Nut)

Frame at the bottom

Upper plate

Rotary joint (front left)

 Y04-1390E
Y- 4 Y- 4
Adjustment (electric)

3. Swing dead angle detection (CS24) 4. Top boom full retraction detection (L7)
(1) A pply screw-locking compound (equivalent to Adjust the switch to work at the position of 5-8
THREE BOND 1401) to the screw of the switch millimeters short of full retraction.
in advance.
(2) Swing as the swing detection face overlaps the
side of the cam. (Point the boom to the left side.)
(3) A djust the c learanc e bet ween the swing
detection face and the cam to the dimension
shown in Fig.3, and then fix.
Nut tightening torque: 8 to 9 kgf-cm

Lower part of the rotary joint

Switch
(top boom, right side of the tip)
Dock
(5th boom)

5. 2nd boom full retraction detection (L8)

Switch At the position where the No.1 telescoping cylinder
extends by 3 mm, adjust the switch to the discontinuity.
After adjustment, apply screw-locking compound to fix.

Cam
Nut
No.1 telescoping cylinder

Switch Nut Adjusting bolt

Rear end of base boom

 Y04-1890E
Y- 4 Y- 4
Adjustment (electric)

6. Straight driving detection (CS20)

(1) Apply screw-locking compound (equivalent to
THREE BOND 1401) to the screw of the switch
in advance.
(2) Set the rear wheels in the straight driving condition.
(3) Adjust the clearance between the swing detection
face and the dock to the dimension shown in Fig.6,
and then fix.

Nut tightening torque: 10kgf-cm or less

(Right side of the rear axle)

Switch

Nut

Dock

 Y0-1390E
Y- 4 Y- 4
Adjustment (electric)

Outrigger extension length detector adjustment 4. Outrigger extension length span adjustment

Outrigger extension length zero/span adjustment switch (1) Extend the outrigger fully.

Outrigger extension length zero/span adjustment switch (2) Press the outrigger zero/span adjustment switch once.

If the extension length is within a proper range, “99" will be indicated

then the light will go off after 2 seconds (adjustment completed.)

Error indication is shown if the extension length is out of the range.

Error No. Error point

System check switch
Front left
Emergency transmission switch
Front right
Rear left
1. Set the PTO switch to ON.
Rear right
2. Press the outrigger zero/span adjustment switch
for 3 times within 3 seconds then put it in an
adjustment mode. (“77" is indicated on the error
number indicator of the upper power transmission
unit.) NOTICE
3. Outrigger extension length zero adjustment
If error indication is shown, the procedure after the
(1) Stow the outrigger. adjustment mode described in the item 2 must be
repeated after repairing the failure part (replacement
(2) P ress the outrigger zero/span adjustment of the outrigger extension detector, or others) for
switch once. completing the adjustment.

“00" is indicated if the extension length is within the proper range.

Error indication is shown if the extension length is out of the
proper range.
Error No. Error point
Front left
Front right
Rear left
Rear right

NOTICE

If error indication is shown, the procedure after the

adjustment mode described on item 2 must be repeated
after repairing the failure part (replacement of the
outrigger extension detector or adjustment of the zero
mark when installed, or others) for proceeding to the
span adjustment described in the item 4.

10 Y04-1390E
Y- 5 Y- 5
Adjustment and checks

2. Main pump (double gear pump)

This section describes adjustment and check
procedures except for pressure and electricity
listed in the previous section. (1) Fill up the oil tank with hydraulic oil.

(When pressurizing the tank, perform

it at 0.15 kgf/cm or less.
2
)
Break-in of the pump (2) After starting the engine, set PTO-ON, then break in
all the pumps simultaneously for 10 minutes at idle
running.
NOTICE

After the pump or the lines of suction

(Unload
with PTO-ON for supply to the accumulator.)
relief is operated simultaneously

unit is assembled, be sure to perform

break-in before the first start of driving.

1. Steering/swing pump (double gear pump)

(1) Fill up the oil tank with hydraulic oil.

(2) W hile stopping the engine, loosen the air

bleeding plug of the suction flange on the
steering pump, then bleed on the suction side
and tighten.

(When pressurizing the tank, perform

it at 0.15 kgf/cm or less.
2 )
(3) Start the engine with (PTO-OFF), then bleed
inside of the circuit for 1 minute at idle running
(approximately 750 rpm)

(
At this moment, as long as PTO-ON is
not set, the unload relief is consistently
in unloading condition.
)
Steering/swing
pump

Air bleeding
plug

Torque
converter

Main pump

11 Y05-1790E
Y- 5 Y- 5
Adjustment and checks

Winch system 3. Adjustment of brake pedal

(Both main and auxiliary winches)
1. Check procedure of N2 gas filling pressure of the accumulator
(1) P ull out the connecter of the PTO solenoid (1) In the pedal free state, perform adjustment (dimension D
valve on the torque converter body. approximately 25 mm) for the dimension
3 B to be 213 mm by
0
(2) If switching the clutch switch between “ON" and “FREE" is repeated the adjusting bolt.
while the winch brake pedal is pressed on and with observing the
accumulator pressure at AML work under the following conditions, (2) Perform adjustment (dimension C approximately 91 mm)
the pressure value descends slowly at the beginning. However, after for the push rod length of the master cylinder to set a play
reaching a certain pressure value, it descends drastically. This point at the tip of brake pedal from 2 to 5 mm.
where the indicated pressure descending speed changes indicates
the value of N 2 gas filling pressure.
Conditions: PTO switch (ON)
Engine speed: IDL (750 to 800 rpm)
Air conditioner: Not used
2. Procedure for removing accumulated pressure
from accumulator circuit
Note
Master cylinder
High-pressured hydraulic oil is consistently supplied
from the accumulator within the accumulator circuit
(with red paints applied on the pipes.)
If this circuit is carelessly disassembled, spurting of
the high-pressured oil may cause injury.
When disassembling the valve or pipes inside of
accumulator circuit, firstly remove the accumulated
pressure of accumulator.

Tip of the brake pedal

(1) Stop the engine.
(2) Insert the vinyl hose, etc. to the bleeder of the winch clutch
cylinder, then with loosening the bleeder screw carefully Push rod
and gradually, remove the accumulated pressure of Nut
accumulator. Adjusting bolt
Nut
Bleeder tightening torque: 70 to 120 kgf-cm

12 Y05-1790E
Y- 5 Y- 5
Adjustment and checks

4. Brake circuit bleeding
NOTICE
Avoid spattering of oil and pay attention
to the oil level in the oil reservoir.
(4) Loosen the bleeder screw with the brake pedal
pressed on. Before the brake pedal touches the
floor, tighten the screw. Repeat this operation
until no air bubbles are found in the oil that
outflows.

When restoring the brake pedal, tighten

the bleeder screw so that the ambient air
will not enter other way round.

Hydraulic oil is used for the winch brake

system.
Do not use by mixing the general brake
fluid.

Automatic brake cylinder bleeding

(1) Set the PTO switch to "ON ( )".

(2) Set the clutch selector switch for winch to "ON".

(3) Insert the vinyl hose to the bleeder screw of the

brake cylinder.

(4) Set the winch lever to the hoisting-down side and

loosen the bleeder screw, then tighten the bleeder
screw when the outflow oil contains no more
bubbles.

Foot brake cylinder bleeding

(1) Place the hook on the ground and slightly loosen

the wire rope to a degree the rope is not irregularly
wound.

(2) S et the clutch selector switch for winch to

" FREE". As the winch automatic brake is
released, fix the drum with a wire, etc. to
prevent rotation.

(3) Insert the vinyl hose into the bleeder screw of

brake cylinder.

13 Y05-1790E
Y- 5 Y- 5
Adjustment and checks

5. Winch brake band adjustment (6) Loosen the band-adjusting nut (a).
(For both main and auxiliary winch brakes)
(7) T
 urn "ON" the clutch selector switch for winch
and adjust the band-adjusting nut (a) until the
Adjustment for disassembly dimension X becomes 2.5 to 3mm.

Main winch is shown in this figure. NOTICE

Band-adjusting nut (a) When adjusting the band-adjusting nut (a)

(f) by tightening, measure the dimension X with
the winch clutch selector switch "ON" after
tightening once with the switch "FREE"

(8) Set the clutch selector switch for winch to "FREE"

and then adjust the clearance between the spot
(e) A and the B (between the winch drum and the
brake band) to 0.5 mm with the bolt (c) and the
bolt (d).

NOTICE

Notice that if adjusting the bolt (d) too hard,

free fall may not occur with load though it
occurs with no load.
(c)
(d) When the clutch selector switch for winch is
set to "FREE", confirm there is no clearance
at the spot Z.

(9) Adjust the bolt (e) and (f) to uniform the clearance
between the winch drum and the brake band.

(10) After the adjustment is completed, set the clutch

Adjusting bolt (b) selector switch for winch to "ON" and the brake
band in the braking state. Then attach a sticker so
that the edge of the marker meets the black line
part of the sticker.

Red
Black line

Blue
(1) Set the adjusting bolt (b) at L 18 mm. Marker

(2) Fix the drum with a wire, etc. to prevent rotation.

(3) S et the clutch selector switch for winch to

" FREE" to release the winch brake band
(X=0 mm)
(4) T ighten the band-adjusting nut (a) until the
clearance between the winch drum and the brake
band disappears. (Until the wrench becomes
heavy.)

(5) Tighten the adjusting bolt (b) to Y 0 mm until the

wrench becomes heavy, then lock with the lock nut.
And lock the adjusting bolt b with the wire. (Notice
that the clearance will appear on the Z spot if the
bolt is tightened too hard.)

14 Y05-1790E
Y- 5
Adjustment and checks
Adjustment when the lining is worn
(1) Place the hook on the ground then slightly loosen
the wire rope to a degree the rope is irregularly
wound.
(2) Fix the drum with a wire, etc. to prevent rotation.
(3) W hen the brake band is in the braking state,
adjust by tightening the band nut (a) until the edge
of the marker matches the black line part of the
sticker.
NOTICE
Tighten the band-adjusting nut (a) when
the clutch selector switch is set to "FREE"
and the brake band is released. After the
tightening, confirm the marker point with
the clutch lever "ON".
(4) Avoid rotating the band-adjusting nut (a) together
and fix with the lock nut.
(5) Adjust with the bolt (c) and (d) to set the clearance
between the spot A and the B to 0.5 mm.
(6) Adjust the bolt (e) and (f) so that the clearance
between the winch drum and the brake band is
uniform.
6. Winch clutch circuit bleeding procedure
(Both main and auxiliary winches)
NOTICE
Avoid spattering of oil because it may be
under accumulator pressure.
Set the PTO switch to "ON ( )" and move the
winch clutch lever to "ON".
(1) Set the PTO switch to "ON ( )" and the clutch
selector switch for winch to "ON".
(2) B leed by opening the bleeder screw of the
winch clutch cylinder.
(3) Bleed the clutch cylinder on the opposite side
with the same procedure.
15
Y- 5
7. Adjustment of winch clutch
(Both main and auxiliary winches)
(1) P lace the hook on the ground and slightly
loosen the wire rope to a degree the rope is not
irregularly wound.
(2) Step on the winch brake pedal so that the winch
drum does not rotate.
NOTICE
During the clutch selector switch is in
"FREE" position, be sure to keep stepping
on the brake pedal.
(3) Rotate the adjuster of the wheel cylinder until the
lining contacts with the drum lightly. (Observe
the adjuster in front and the shoe spreads by
levoversion.)
(4) Reverse the adjuster by 10 to 11 scales. (The
clearance between the drum and the lining
becomes 0.5 to 0.6 mm.)
(5) Repeat switching between "ON" and "FREE" by
the clutch selector switch 3 times. (Repeat putting
and removing pressure on the wheel cylinder.)
(6) Confirm the descending of the hook by the free-
fall operation)
8. Bleeding procedure for the counterbalance
valve for winch motor
(1) Step on the winch brake pedal.
(2) Set the clutch selector switch to "FREE".
(3) Loosen the bleeding plug of the counterbalance
valve while hoisting-up at idle running.
Swing system
1. Swing motor bleeding
Fill the oil from the drain port of the swing motor.
Operate slowly (for approximately 1 minute) then
bleed inside of the case.
Y05-1790E
Y- 5 Y- 5
Adjustment and checks

Power generating system

1. Engine revolution adjustment

The figure below indicates the idle running in the traveling state (PTO, OFF).

Adjuster E Idling switch

Air cylinder for PTO

Lever B
Nut
Engine stop
control lever At front of vehicle
Stopper C
Engine stop solenoid Torque converter
Adjuster F

Stopper D

Accelerator cylinder

Idling
Speed control
lever

Rod A
Paint-lock after the adjustment
(both ends)

16 Y05-1790E
Y- 5
Adjustment and checks
(1) Speed control
1. A djust with the stopper C to keep the idling
speed at 750 to 800 rpm. (PTO switch "OFF")
After adjustment, paint-lock the stopper C.
2. Set the solenoid valve for speed-limiting device
in non-energization state then step on the
accelerator pedal. Adjust the length of the rod A
until the engine speed becomes 2600 to 2650
rpm.
3. Energize to the solenoid valve for speed limiting
device then step on the accelerator pedal.
Confirm that the speed control lever contacts
with the stopper D.
4. S et the PTO switch to "ON" and step on the
accelerator pedal. Adjust the engine speed as
shown below by the adjuster E. At this moment,
step on the pedal gradually and avoid rotating the
engine at the speed of 2550 rpm or more.
After adjustment, paint-lock the adjuster E.
Engine speed (rpm)
Idling
Limiting device
(2) Installation of air cylinder for PTO
Adjust the middle of the bolt head of the adjuster E
to be perpendicular to the lever B in the PTO"ON"
c ondition then inst all. A pply screw- locking
compound to the nut and tighten.
Tightening torque:450 to 500 kgf-cm
After adjustment, paint-lock the adjuster E.
(3) Adjustment of idling switch(for exhaust brake)
Adjust by the adjuster F so that the switch is turned
"ON" at the engine speed of 800 to 850 rpm.
However, the upper limit at idling must be 50 to
100 rpm lower than the speed at the time the idling
switch is running.
After adjustment, paint-lock the adjuster F.
17
Y- 5
2. Accelerator pedal adjustment
NOTICE
This adjustment must be performed
after the engine revolution adjustment
previously described in 1.
(1) Fixed accelerator adjustment
In the idling state, after fully inserting the knob
for idling adjustment and putting the head of
bolt A to the lever B, reverse the bolt A one
revolution and lock with the nut.
(2) Idling adjustment by accelerator pedal.
NOTICE
This adjustment must be performed
after adjusting the fixed accelerator.
The value of air pressure must be over
that of low-pressure alarm.
1. In the state that the knob for idling adjustment
is screwed in fully, screw in the bolt (c) and
then raise the speed to be higher than the
idling revolution.
2. Loosen the bolt (c) until it becomes the idling
revolution, then reverse one-fourth revolution
and lock the nut.
(3) N o-load maximum revolution adjustment by
accelerator pedal
Step on the pedal to the minimum stroke that
assures the no-load maximum speed. After
putting the adjusting bolt D to the pedal, tighten
one more revolution and lock by the nut.
Knob for idling adjustment
Bolt A
Lever B
Throttle valve
Bolt C
Idling
Bolt D
Y05-1790E
Y- 5 Y- 5
Adjustment and checks

3. Check procedure of the stall speed 2. Brake circuit bleeding procedure

Follow the procedures below for confirming the (1) W ith enough compressed air in the reservoir,
stall speed for the reason of degradation of output step on the brake pedal and bleed by opening
or the increased temperature of the converter oil, the bleeder screw of the booster. Tighten the
etc. screw before restoring the brake pedal. Repeat
this operation until air bubbles disappear in the
NOTICE outflow oil, and then tighten the screw while the
oil outflows.
When stalling, do not drive for more
than 30 seconds or at 90 °C of the oil
temperature as sudden heat generation Bleeder screw tightening torque: 70 to 130 kgf-cm
occurs inside of the torque converter.
A s t h e t o r q u e c o nve r t e r i s a t i t s Booster (front)
maximum torque, be careful of dashing
out of the vehicle. Booster (Rear)
(1) Set the switch and the lever under the following conditions.
PTO switch: "OFF"
Change lever: "D" range (3rd)
Driving speed selector switch: "4-wheel Hi"
Emergency transmission switch: "ON"
Service brake: "ON"

(2) Step on the accelerator pedal fully until the engine

speed becomes stable, then read the speed.
Standard maximum engine rotation speed in the stall state :
approximately 2420 rpm

Brake system
Bleeder screw
1. Brake pedal adjustment

(1) Adjust so that the adjusting bolt contacts the

valve stopper with the roller touched with the NOTICE
plunger by the weight of the pedal.
There are 2 boosters, one for the front
wheels and other for the rear wheels.
Avoid spattering of oil and pay attention
Brake valve to the oil level in the oil reservoir.

Adjusting bolt (2) Bleed the wheel cylinder of the axle by the same
procedure described in the previous (1).

Roller Bleeder screw

Indicator hole

Plunger

18 Y05-1790E
Y- 5 Y- 5
Adjustment and checks

3. Clearance adjustment of parking brake Steering system

(1) Jack up the crane and set the parking brake free. 1. Steering wheel angle adjustment

Tire size
(2) Rotate the brake drum and adjust the adjusting hole of the
drum to match the star wheel of the adjuster Ass’y.
Tie-rod end tightening bolt
Tie rod
(3) Put a screwdriver into the adjusting hole. Expand the shoe Stopper bolt B Stopper bolt A
(in the direction of an arrow) till the resistance to the drum
rotation is felt. Reverse 8-gear tooth of the star wheel. Then,
the clearance between the lining and the brake drum will be
adjusted to the standard clearance as 0.23 mm.

Spring chamber

(1) Jack up and operate the steering cylinder for 2 to 3 times by

the 4-wheel steering (to bleed the cylinder).

(2) Before adjusting the steering wheel angle, check the sideslip
amounts for both front and rear wheels are within 3 mm by
the sideslip tester.
Adjusting hole If the values do not meet with this, loosen the tie-rod end
tightening bolts of the tie rod right and left, and adjust the
toe-in by turning the tie-rod.

4. Parking brake and spring chamber connection Tightening torque of tie-rod end tightening bolt
procedure
(3) Jack up on the horizontal ground (equalize the heights of
(1) Hold the parking brake lever at zero. (Intermediate position of the right and left tires) and then adjust the steering wheel
the play of lever) angle in the direction A to 29.5 01 by the stopper bolt A, and
the steering wheel angle in the direction B to 29.5 01 by the
(2) Set the parking brake switch to "OFF" and stroke end the stopper bolt B with the steering wheel angle measurement
spring chamber, then adjust the length by rod and connect device.
with the lever.
(4) Adjust the front axle as in (3).
(3) Confirm that there is no drag of the drum under this condition [Reference]
and lock the nut.
King pin angle
Camber
Caster
Zero point Toe-in

Rod
Nut
Play

19 Y05-1790E
Y- 5 Y- 5
Adjustment and checks

Operation check
1. Exhaust brake operation check procedure

Step Operation Check

Set the exhaust switch to "ON". Indicator lamp lights up. (Combination meter section)

Shift lever "N" range

Switch the shift lever from "N" range to "D" range,

Operation of exhaust brake

and raise the vehicle speed to be over 1 km/h.
Step on the accelerator pedal

Take off your foot from the accelerator pedal.

"D" range
Decrease the vehicle speed under
1 km/h by the service brake. "2" or "1" range
Take off your foot from the service brake at the vehicle speed of
1 km/h or more.

Switch the shift lever to "N" range.

Remark : Check the operation of the exhaust brake by the sound of the engine or the
performance of the air cylinder for exhaust.

2. Reverse steering operation check procedure

Step Operation Check

Set the reverse steering switch to "ON".

Indicator lamp lights up.
Swing the boom to the rear of the vehicle. (Reverse steering switch section)
Tires move in the direction where the steering
Turn the steering wheel to right or to left. wheel is turned.

20 Y05-1790E
Y- 5 Y- 5
Adjustment and checks

3. Rear steering lock pin operation check procedure

(1) In the "Release" state of the lock pin

Step Operation Check

Switch the rear steering lock switch to "Release". "LOCK PIN" and "R/CENTER" indicator
lamps on (Combination meter section)

Switch the steering selector switch to "4-wheel", The built-in indicator lamp of the selected
"Crab steering" or "Rear" mode. switch lights up.

Tires move in the selected steering mode.

Turn the steering wheel. "R/CENTER" indicator lamp lights off.

Turn the steering wheel and put the rear wheel in a straight advance poasition. "R/CENTER" indicator lamp lights up.

Switch the rear steering lock switch to "Lock".

"LOCK PIN" and "R/CENTER" indicator
Turn the steering wheel slowly and operate the lamps light off. (Combination meter section)
lock pin, then lock the rear steering. The built-in indicator lamp selected in Step
No.2 above lights up.

(2) In the "Lock" state of the lock pin

Step Operation Check

Switch the rear steering lock switch to "Release". "LOCK PIN" indicator lamp lights off. (Combination meter section)
Switch the steering selector switch to "4-wheel", With the "2-wheel" indicator lamp lit up, the built-
"Crab steering" or "Rear" mode. in indicator lamp of the selected switch blinks.

With the lock pin release switch pressed, remove the lock "LOCK PIN" and "R/CENTER" indicator lamps
pin by turning the steering wheel right and left slowly. light up. (Combination meter section)

Turn the steering wheel. Tires move in the selected steering mode.
"R/CENTER" indicator lamp lights off
Turn the steering wheel and put the rear wheels at the straight driving point. "R/CENTER" indicator lamp lights up.

Switch the rear steering lock switch to "Lock".

"LOCK PIN" and "R /CENTER" indicator
Turn the steering wheel slowly and operate the lock pin, lamps light off. (Combination meter section)
then lock the rear steering. The built-in indicator lamp selected in Step
No.2 above lights off.

21 Y05-1790E
Y- 5 Y-5
Adjustment and checks

4. Overshift prevention device operation check procedure

Step Operation Check

After jacking up, accelerate to 35 km/h without full acceleration

in the 4-wheel drive, "D" range of Hi range modes.
Reduce the speed gradually and hold at 30 km/h.

Switch the shift lever to the "2nd" range. Transmission does not shift down to "2nd".
Reduce the speed gradually Transmission shifts down to "2nd".

Reduce the speed gradually and hold at 20 km/h.

Switch the shift lever from "D" range via "2" to "1". Transmission does not shift down to "1st".

Reduce the speed gradually. Transmission shifts down to "1st".

5. Outrigger operation status indicator check procedure

Step Operation Check

Switch the shift lever to the range other than "N"
with the main switch "ON".
Operate the outrigger extension and stowage Indicator lamp lights up.
switch. (Combination meter section)

Press the outrigger collective control switch. Outrigger does not operate.
Switch the shift lever to the "N" range with the The indicator lamp blinks.
main switch "ON".
Press the outrigger collective control switch. Outrigger operates.

22 Y05-1790E
Y- 5 Y- 5
Adjustment and checks

6. Spring lock device operation check procedure

Step Operation Check

In on-tire configuration with the boom in over-front area or
over-rear area, set the shift lever to "N" range, the vehicle
speed to 0 km/h, and the engine speed to 750 rpm.

Keep pressing the spring lock switch to the "Lock" side. The indicator lamp starts blinking after 1 second. (Computer section)
The indicator lamp lights up at 8 seconds after the blinking start.

Take off your hand from the spring lock switch. Spring lock cylinders fully extend
Stop the engine. (at 4 points).

Restart the engine. Indicator lamp lights up.

Keep pressing the spring lock switch to the "Free" Indicator lamp starts blinking after 1 second.
side. Indicator lamp lights up at 8 seconds after the blinking start.
Take off your hand from the spring lock switch. Spring lock cylinders fully retract
Stop the engine. (at 4 points).

23 Y05-1790E
 System Diagrams

Contents

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

Z-3 Electric circuit

(Crane).......................................... 2

Z-4 Electric circuit

(Carrier). ....................................... 3

Z-5 Torque converter circuit. ............ 4

Z-6 Brake circuit................................. 5

Z

Z-1 Z-1 Z-1
Hydraulic Circuit

Solenoid valve
(F: Right steering)

(Rear)

(F: Left steering)

Rotary joint Priority valve

(4-wheels)

(Reverse)

Steering cylinder

Orbitrol

(Vent for remote (Swing brake)

Cabin cooler control)
Hydraulic valve

Swing drive unit

Solenoid valve

Oil cooler
Swing

(Fook in) (for AML vent)

Elevating cylinder
Pilot check valve
Option
Spring lock cylinder
Telescoping

Solenoid control valve

Counter balance valve

Check valve
Pressure
sensor

Accumulator Telescoping cylinder

Pressure
Aux. winch sensor

Check valve Main winch

Clutch valve Telescoping cylinder

Winch clutch

Elevating Hydraulic motor (Main winch)

Extension cylinder Remote control valve

Pilot check valve Counter balance valve

Winch brake

Hydraulic motor (Aux. winch)

Jack cylinder
Hydraulic pump

Hydraulic pump Counter balance valve

Hydraulic control valve

Oil filter

Serial No. of changed machine NOTE

1. Mark of spring lock cylinder (FL), (FR), (RL), (RR) shows
Solenoid valve installation location of cylinders.
Oil tank 2. Mark of solenoid valve for outrigger (FL), (FR), (RL), (RR) shows
installation location of themselves.

1 Z01-3870E 1
 Z-3

Shield

Boom angle detector

Boom length detector

(AML cancel) Shield
SPS 1 (Main pressure sensor)

Shield

Boom length input

Boom angle input SPS 2 (Accumulator pressure sensor)
Swing angle 1 input
Shield Shield
Swing angle detector 1

2
Swing angle 2 input
Main pressure input Swing angle detector 2
Accumulator pressure input Shield L8 (2nd, 3rd boom full retraction detection, Contact during full retracting)
Electric Circuit

Overwinding detector
2nd, 3rd boom full retraction detector
4th - top boom full retraction detector
L7 (4th - top boom full retraction detection, Contact during full retracting)

Cord reel L4 (Boom overwinding detection)

L5 (Single top overwinding detection)

Z03-4710E
(Contact during overwinding)
(Contact during overwinding)

Overwinding cutout disable

AML canceling
PTO switch

Switch position Over-front area detection

Contact CS 12 (Over-front area detection detection)
Swing dead angle detection (Contact during over-front area)

Relay

pole Shield

Moment detector
Z-3

pole

to Upper transmission unit

Wiring diagram (Vehicle)
Diode

Shield For AML vent

Automatic stop 1
For emergency in AML failure
Automatic stop 2 (telescoping stop cancel)
Buzzer output (accumulator low pressure alarm)
Buzzer 3
Switch
Buzzer output (AML alarm)
S7 (4th - top boom extending)
Toggle switch Telescoping control output For fook in
Push switch
Buzzer output (Overwinding alarm)
Proximity switch
Fook in For top cylinder
Pressure switch
MAIN hoist-up
Buzzer 4
MAIN hoist-down
Aux. hoist-up
Limit switch
Aux. hoist-down
Key switch
Seesaw switch
PS 1 Main hoist-up detection (Contact during hoist-up)
PS 2 Aux. hoist-up detection (Contact during hoist-up)
PS 3 Telescoping extending detection
Telescoping extending (Contact during extending)
Telescoping retracting
PS 5 Elevation raising detection
Elevating raising (Contact during raising)
PS 6 Elevation lowering detection (Contact during lowering)
Elevating lowering
PS 9 Swing right detection
Swing right (Contact during right)
PS 10 Swing left detection (Contact during left)
Swing left

PS 11 (Clutch pressure detection)

1. This figure is shown the state of below. Clutch pressure checking indicator lamp
S4 (Winch clutch selection) (Main)
Crane running PS 13 (Brake pressure detection)
(Contact during braking)
PTO switch : OFF
Boom section full retraction
Boom forward position Shield
For clutch selection
Overwinding
Starter switch : OFF PS 12 (Clutch pressure detection)

Control lever : Neutral Clutch pressure checking indicator lamp

S5 (Winch clutch selection) (Aux.)
2
2. The wiring size without special mention is 0.85mm . PS 14 (Brake pressure detection)
(Contact during braking)

For clutch selection

Remove and install this connector

when the main switch is necessary.
Swing warning lamp (Right)
Method of displaying wiring
a color of marking that mixed with a base color
a base color of wiring Swing warning lamp (Left)
the sectional area of electric wire (mm2)
Swing warning lamp
(Option)

a color of marking that mixed with a base color

a base color of wiring
the sectional area of electric wire (mm2) External indicator lamp (-90%)
External indicator lamp (90-100%)
Mark Wiring color External indicator lamp (100%-)
Fook in lamp

Lamp ASS’Y AML For remote control pressure vent

(Option)
For swing brake

S6 (Swing brake)

S3 (Overwinding cutput disable)

Outrigger stowing control detection
Spring lock status detection S2 (2nd, 3rd boom emergency telescoping)

S 1 (4th - top boom emergency telescoping)

Connect a male connector when adjusting AML 0 point.

to 12 V power supply

Winch drum speed sensor (Main)

to Upper transmission unit to Upper transmission unit

S 11 (extension width of outriggers adjusting 0, Winch drum speed sensor (Aux.)

span adjustment)
Wiring diagram (Vehicle)

For drum indicator (Main)

S 10 (Horn)
Light emitting type drum indicator
(Option) For drum indicator (Aux.)

S 18 (Main / Aux. selection)

(Contact during main)

S9 (Drum indicator main switch)

Feel of touch drum indicator

(Option)
2
Z-3
Z-4 Z-4 Z-4
Electric Circuit
Horn Front wiper motor
Combination meter
Note
Intermittent wiper relay Roof wiper motor Washer tank
(Roof wiper) 1.Outrigger control switch (FL),(FR),(RL),(RR) indicate each outrigger actuated position.
Relay Relay 2.About the connection of Outrigger J/S change relay RF3,
This figure indicates about H type outrigger.
Refer to Fig.-A for X type outrigger.
Buzzer 1
Relay RC2
3. No.900 to 999 in numbering of wirings indicate 12V system, the others indicate 24V system.
Door junction Wiper 4. [ ]mark numbers indicate the numbering of wiring end.
Power window motor
Power window SW 5. Diameter of wiring without indication is 0.85mm2.
Relay RC3 Head lamp Head lamp
Roof washer Combination
Wiper
switch
Lever P
Cab Cab
door body
Switch Combination lamp
(Horn) Relay RA5 Combination lamp
(Turn signal(Right)) Intermittent wiper relay Low beam
(Front wiper) Main beam
Position
Toggle switch
Relay RA6
Hazard (Turn signal(Left))
lamp
Parking Up Middle Down Name
Horn relay Clearance Outrigger control box light
Roof wiper (Parts provided with horn) Turn Outrigger (lower control) J/S selector, Outrigger (lower control) extention/retraction selector

Room lamp(10W) The upper sides of Up Middle and Down are the side opposite to the key ditch of Switch installation.
Working lamp(LH) 60W Working lamp boom 60W (Relay box (Front)) Working lamp(RH) 60W
Rocker switch

Up Middle Down Name

Input spare4(+)
Input spare3(+) Reverse steering, Working lamp, Emergency transmission, Step lamp, Oil cooler, Power mode
Flasher unit Engine start(+) Lock pin
Use prohibited Outrigger J/S selector, Outrigger extention/retraction selector, Hi/Lo, Two/four-wheel driving selection, Roof wiper
Room lamp(10W)
Charging lamp input Relay Auto-greastar
(Head lamp) Spring lock
Relay RA1 Swing dead angle detector
Relay RA2 Power window
Lock pin OUT detector

Switch
Lock pin IN detector
Straight driving detector
Note ( ) mark indicates momentary.
(Door) marked switch must be installed on the condition that Matsushita parts number mark is on the right side of operation part.Others must be installed regularly
Input spare2(-)
Lamp, step
Lamp, step(12W) HI\LO detector
Reed switch
4WD detector
Reed switch (Hi/Lo detector) Combination switch
Harness built-in cab Input spare1(-) Slider Jack
(4WD detector) Jack Slider
Hydraulic oil 85°C Solenoid
Solenoid Light switch circuit
temperature Low pressure switch (Temperature switch) valve
Exhaust brake switch
Engine oil low pressure valve
(Engine oil) Terminal
Hydraulic oil 85°C temperature Destination Terminal
color
Low pressure switch (Temperature switch) color
Air low pressure (Air)
Working lamp Brake fluid level detection Switch(proximity) Head lamp
Parking low pressure (Swing dead angle detector)
Dimmer
Low fuel alarm detection A:Press the lever P to the other side.
Low pressure switch B:Put the lever P in neutral.
Tail, Clearance
(Parking brake) Reed switch C:Pull the lever P.
(Receiver ASSY)
O/R length input FL Switch(proximity) Wiper/Washer switch circuit
O/R length detector FL
(Lock pin OUT detector)
Terminal Turn signal switch
Shield color Destination
Terminal Lever position
Destination
O/R length input FR Washer motor color
Motor(LO) Flasher unit
O/R length detector FR Switch(proximity) Amplifier Turn signal lamp
Drum indicator output (LED1) Shield (Lock pin IN detector)
O/R length input RL Motor(HI) Turn signal lamp
Drum indicator output (LED2)
Ground Horn solenoid
Drum indicator output (LED3)
Drum indicator output (LED4) O/R length detector RL
O/R length input RR Starter switch
Shield Switch(proximity)
Spare1 5V output Straight driving detection
Spare1 Analog A/D input Note
Torque converter sensor input Solenoid Return to 2
Spare1 O/R length detector RR valve automatically
Analog input COM Shield
Spare1 (Exhaust brake)
Spare2 5V output
Spare1
Spare2 Analog A/D input
Spare2 Return to 3
Spare2 Pressure sender
automatically
Spare2
Spare3 (Torque converter pressure) Remote switch
Air pressure sensor input (Idling detector)
Spare3
Shield Sensor input spare1
Pressure sender
Sensor input spare2
(Air pressure) 12V Power supply
Sensor input spare3 Pick up sensor Shoulder lamp
Use prohibited MDTCPU output
Auxiliary speed input (Speed (s))
Main speed input
Main speed output Tachometer sensor input Pick up sensor
(Double pole)
Tachometer sensor input (Engine speed)
12V for Main speed (Four pole)
Tachometer sensor output Relay terminal
Main speed input
Drum indicator input (Main) Speed sensor
Main speed output
Drum indicator input (Aux.)
Torque converter sensor output Relay RF3
Relay
24V Power supply (J/S selector)
Tachometer sensor output (Shoulder lamp)

Shoulder lamp
Horn relay
Swing dead angle detection
Output spare 4 Fig.-A
(H type outrogger)
Output spare 3
Output spare 2
Glow lamp
Input spare2(+) Relay
High beam lamp (Clearance lamp)
Output spare 1 Input spare1(+)
Outrigger retraction control detection(+) Solenoid
O/R and SP lock detection valve
Outrigger SW neutral detection(+)
SP lock detection

Solenoid
valve

(Governor selector) Tachograph

Outrigger retraction control detection
Starter switch
Feel of touch type drum indicator output (Main)
Cigar lighter Feel of touch type drum indicator output (Aux.)
Crab steering
Rear steering Relay RB3
Flow divider
(PTO limiter)
Two-wheel steering (Grease)
Four-wheel steering Pump
Buzzer Solenoid (Grease)
valve
Air pressure sensor output(+)
Air pressure sensor output(-) (Rear steering lock)
Pilot lamp
Serial input4(+)
Serial input4(-) Serial transmitter circuit 4
Parking brake Serial input4(+) (for combination meter)
Serial input4(-)
Serial input3(+) Relay
Wiring diagram Serial input3(-) Serial transmitter circuit 3 Auto-greastar
(Crane) Serial input3(+) (for AML)
Serial input3(-) Relay RD1
Serial input2(+)
Serial input2(-) Serial transmitter circuit 2
Spare (Emergency
Serial input2(+)
transmission
Serial input2(-)
valve
Power mode Serial input1(-) selector)
Serial input1(+) Serial transmitter circuit 1 Relay RD2
Serial input1(+) (Lower transmission unit)
Serial input1(-)
System check input

Starter switch ON detection

Extension width of outriggers 0, span adjustment Relay RD3
HI/LOW selection
Working lamp
Two/four-wheel driving selection
Horn switch(Swing lever)
Input spare8(+)
Input spare7(+)
Input spare6(+)
Input spare5(+)
Exhaust brake Relay RC5 (Emergency transmission power supply selector)

Third brake lamp

Parking brake status detection Slider Jack Slider Jack
Solenoid Solenoid
Steering mode selection PTO switch detection valve
valve
HI/LO, two/four-wheel driving selector(1) Relay RA17(Steering power supply)
HI/LO, two/four-wheel driving selector(2) Relay RA9 (Battery selector)
Mode selector(Power/Economy)
Reverse Steering selection
Rear steering lock release(for correction)
Rear steering lock Relay
(J/S selector)
Head lamp(B)
Head lamp(A)
Relay RA10 (Engine stop)
Two-wheel steering
Four-wheel steering
Steering lock release (for correction) Crab steering Alternator
Lock Free
Rear steering Solenoid
valve
reverse steering SP lock

Spring lock
Clearance lamp
Oil cooler
Lock pin
Input spare4(+)
Input spare3(+)
S.P lock (free)
S.P lock (lock)
Four-wheel
Air heater relay Crab
Transmission selector valve
Emergency transmission Solenoid
valve
Change transmission Start block relay Engine stop relay
(Steering selector
valve)
Engine stop solenoid
Transmission selector

Input spare2(+) Air heater relay

Input spare1(+)
Extention
Retraction
Jack Solenoid
valve
Slider
Outrigger (Reverse steering)
(J/S selector) Extention Retraction
Solenoid Solenoid Air heater
Relay valve
valve (Extention/
(Emergency transmission selector) Retraction
(Rear steering) selector)
Starter motor Battery relay
Relay Battery
Solenoid (Extention/Retractionselector)
Backward detection valve
Drum indicator M/S selector Outrigger accelerator
Outrigger
AML release Relay RA7
(Extention/retraction selector) 24V Power supply (Oil cooler)
Input spare9(+)
(Accelerator)
Outrigger(Lower control)
(J/S selector) Pressure switch
Oil cooler Relay (Stop lamp)
Serial input1(-) Outrigger(Lower control) (Back up lamp)
Serial input1(+) (Extention/Retraction selector)
Forward detection(-) Serial transmitter circuit 1
(for upper transmission unit) Serial output1(+)
Hook-in(-) Fuel sender
Input spare2(-) Serial output1(-)
Relay System check input Solenoid
Input spare1(-)
Relay (N start) Use prohibited valve Thermo sender
(HI/LO selector)
(Emergency transmission Switch(proximity) Serial input(+)
(Engine coolant temperature)
selector) (Backward detection) Serial transmitter circuit 1 Serial input(-) Solenoid
Spare valve
Serial output(+) Thermo sender
Serial output(-) (Two/four-wheel driving selector) (Torque converter oil)

Back up lamp Buzzer(Back up)

Oil cooler Back up lamp License lamp
Solenoid
valve
Solenoid Tail/Stop lamp Turn signal Turn signal Tail
Air conditioner valve Speed limiter Turn signal Tail/Stop lamp
Air dryer Combination lamp Stop Combination lamp
(Lock up)
Heater Lamp
Outrigger lower control box

System check (No.3 brake)

Solenoid
valve

Radio Solenoid
valve

(Parking brake)

Timer

12V Output
Relay RA12
Converter
(Air conditioner)
24V Intput
Converter

3 Z03-4790E 3
Z-5 Z-5 Z-5
Torque converter Circuit

Torque converter case Temperature

sensor
Transmission case

Torque converter output Oil cooler

adjusting pressure valve Amount of lubricant control valve

Pressure
Torque converter input sensor
relief valve

Main adjusting pressure valve

Lock up valve P.T.O. valve

Lock up accumulator

Input axis

Line filter 20
Torque converter

Charging pump

By-pass drain
Output axis (Front)
Torque converter drain Output axis (Rear)

2-4 wheel drive Hi - Lo selector

selector air cylinder air cylinder

4 Z05-0200E 4
Z-6 Z-6 Z-6
Brake Circuit

Rotary joint Dual brake valve

Stop lamp SW

Outrigger control
Shuttle valve
Accelerator
Front Accelerator valve Pressure sensor

Engine speed control

for speed limiter
Auxiliary brake Reducing valve Reducing valve
Rear

Exhaust brake

Oil reserver
Hi-Lo selection

Engine speed control

for P.T.O. Drive selection
Inflator

Steering lock Air dryer

Protection valve
A.O.H. booster
Unload valve
Low pressure
indicator Safety valve Air compressor

Parking brake chamber Pressure regulator

Check valve

Drain cock

5 Z06-0340E 5
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
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 2008
PRINTED IN JAPAN
0803 E