Tadano AW-250TG-3 Aerial Platform (Circuit Diagrams & Data) Service Manual SN 420454 - PDF DOWNLOAD

Publication No. AW-250TG-3/C2-1E

(Circuit Diagrams and Data)

01 Aerial Platform Model

AW-250TG-3 Applicable Serial No. 420454 --

Foreword Foreword This Service Manual (Circuit Diagrams and Data) describes the hydraulic circuits and electrical circuits applicable to the AW-250TG-3 (AMC3 specification) model aerial platform.

For the actual works, perform appropriate repair and service with referring to the separate repair manual, operation and maintenance manual, and parts catalog of the applicable model.

This manual applies to the aerial platform with the specification numbers below. Be sure to check the specification number on the nameplate of your aerial platform before operation.

When part replacement is needed, refer to the parts catalog first to check the disassembly unit as well as the parts sales unit.

1. Applicable spec. No.

SPEC.

NO.

SERIAL.

NO.

MFG.DATE. KAGAWA, JAPAN

ISA04-001601

Spec. No.

Applicable serial No.

AW-250-3-80120

420454 --

The contents of this manual may change a little depending on the improvements or others.

1

WA04-3650E

Foreword 2. Outline of specifications Spec. No.

Item

No. 1

Boom section

2

Basket

3

Basket swing angle

AW-250-3-80120 3-section hydraulic synchronized telescoping Made of steel tube, double-action hydraulic cylinder vertical interlocking type auto leveling system

cylinder type

 Basket swing angle: Left 60° to Right 60°

motor type

 Basket swing angle: Left 90° to Right 90°

4

Slow start/stop system



5

Boom swing speed control system



6

Boom elevation speed control system



7

Auto accelerator system



8

AMC3 (Automatic Moment Limiter)



9

Traveling control system



10

Vehicle tilt alarm



11

Traveling alarm



12

Boom swing alarm



13

Emergency stop system



14

Swing lock system



15

Foot switch (basket)



16

Touch switch



17

Emergency pump



18

Axle extension lock system



19

Steering system

Two-wheel steering

20

Engine

MITSUBISHI S6S-T

[Symbol]

: Mounted

--: Not mounted

: Optional

2

WA04-3650E

3. Group index A B C D E F G H

J K L M N

P Q R S T U V W X Y

Data, Adjustment and Checks

Z

System Diagrams 3

WA04-3650E

Y Z

Contents 4. Contents Spec. No.

Section

Chapter

AW-250-3-80120

Data, Adjustment, and Inspection Service Data

Y

Y-1 (Hydraulic Pressure)

Y-2

(Electric)

Y-3

Adjustment and Functional Check

Y-4

Inspection and Maintenance

Y-5

Adjusting Procedure

System Diagrams Hydraulic Circuit

Z-1 (Basket)

Z-2

(Swing Frame, Frame)

Z-3

(Basket)

Z-4

(Boom)

Z-5

(Swing Frame)

Z-6

(Frame)

Z-7

(Hydraulic Pump)

Z-8

(Basket)

Z-9

(Boom)

Z-10

(Swing Frame)

Z-11

(Frame)

Z-12

(Option)

Z-13

Electric Circuit

Location of Hydraulic Parts

Z

Location of Electric Parts

4

WA04-3650E

Y Data, Adjustment and Checks

Contents Y-1 Service Data ..................................... 1

Y-2 Adjusting Procedure (Hydraulic) .. 10

1.

Preset pressure ........................................ 1

1.

Adjustment of relieving pressure ............. 10

2.

Oil level ..................................................... 2

2.

Leveling cylinder bleeding ....................... 15

3.

4.

5.

Hydraulic equipment ................................. 2 3.1

Hydraulic pump .......................................... 2

3.2

Hydraulic motor .......................................... 2

3.3

Hydraulic cylinder ....................................... 2

2.1

Bleeding operation .................................... 16

2.2

Leveling adjustment

2.3

Pressurizing the leveling circuit ................ 17

after bleeding operation ...................... 17

Swing section ........................................... 2

Y-3 Adjusting Procedure (Electric)...... 18

Boom section ............................................ 3

1.

5.1

Slide plate ................................................... 3

5.2

Clearance between slide plate

Adjustment of axle extension detector switch ............................. 18 1.1

Adjustment of detector switch ................... 18

and boom ............................................. 3 5.3

Boom bend and deformation ...................... 4

5.4

Boom telescoping wire rope ....................... 5

6.

Leveling system ........................................ 5

7.

Other regulating devices ........................... 6 7.1

2.

Elevation angle control

Adjustment of axle extension/retraction control detector switch (reed switch) ..... 19 2.1

Removal of reed switch............................. 20

2.2

Installation of reed switch .......................... 20

2.3

Operation check of reed switch ................ 21

2.4

Adjustment of switch operating position (a-contact type) ................................... 22

(AMC automatic stop position) ............. 6 7.2

Boom length control (AMC automatic stop position) ............. 7

8.

9.

Integration test (no-load operation speed).............. 8

3.

Adjustment of touch switch ...................... 23

4.

Adjustment of AMC ................................. 24 4.1

Adjustment of boom length detector zero/span ............................................ 24

4.2

Mass table ................................................ 9

Adjustment of boom elevation angle detector zero/span .............................. 25

4.3

Adjustment of boom swing angle detector zero/span ............................................ 26

i

Y

4.4

Adjustment of moment zero/span and

1.1

Cautions of inspections and

1.2

Inspection and

adjustment of working radius

maintenance ....................................... 52

(measurement radius) ........................ 27 4.5

10° and 50° moment write-in method ....... 31

4.6

Offset adjustment for

maintenance intervals ......................... 52

boom operation valve ......................... 32 4.7

Offset adjustment for traveling operation valve ................................................... 34

4.8

Valve span adjustment ............................. 35

4.9

Selecting acceleration method ................. 36

4.10 Adjustment of accelerator (engine) span .................. 37 4.11 Adjustment of machine (carrier) inclination angle detector zero ............................ 39 4.12 Fuzzy control adjustment ......................... 40 4.13 Initialization of adjusted values and selected values................................... 41 4.14 Selecting of special specification ............. 42

5.

Data 5.1

.................................................... 43

Detector specifications ............................. 43

2.

Inspection................................................ 53

3.

Safety parts requiring regular replacement ..................... 53

4.

Greasing ................................................. 53

5.

Gear oil ................................................... 53

6.

Engine .................................................... 53

7.

Engine cooling system ............................ 53

8.

Fuel system............................................. 53

9.

Tire

.................................................... 53

10. Hydraulic system ..................................... 53

Y-4 Adjustment and Functional Check................... 45 1.

Adjustment of steering wheel .................. 45

2.

Adjustment of slide plate clearances ....... 46 2.1

Front axle.................................................. 46

2.2

Rear axle .................................................. 47

3.

Installation of hydraulic pump.................. 48

4.

Adjustment of tension in boom telescoping wire rope ......... 49

5.

Adjustment of tension in hoses and cables inside boom ...................... 50 5.1

Adjustment of hose inside boom .............. 50

5.2

Adjustment of tension

11. Swing system .......................................... 54 12. Electrical system ..................................... 54 13. Boom .................................................... 54 14. Oils and greases ..................................... 54 15. Consumable parts ................................... 54 16. Others (compulsion release method)....... 54

in cable inside boom .......................... 51

Y-5 Inspection and Maintenance ......... 52 1.

Inspection and maintenance ................... 52

ii

Y-1

Y-1

Service Data Y-1

Service Data

[NOTICE] ♦ The preset pressure shall be the values for check and adjustment. ♦ Standard values are values at time of vehicle shipment from Tadano. Limit values are the limits at which adjustment or part replacement is necessary. ♦ Hydraulic oil: ISO VG32 equivalent, Oil temperature: 40±5°C

1. Preset pressure For the measuring points and measuring methods, refer to “Y-2 Adjusting Procedure (Hydraulic Pressure)”.

Item

Symbol

1

Relief valve (for pump P1 main circuit)

2

Port relief valve

3

Port relief valve

4

Port relief valve

5

kgf/cm

R1

22.0 to 23.0

225 to 235

Do not let the pressure exceed 2 24.5 MPa {250 kgf/cm }.

PR1

21.6 to 22.0

220 to 225

For boom raising circuit

PR2

8.8 to 9.8

90 to 100

For boom lowering circuit

PR3

11.3 to 12.3

115 to 125

For boom extending circuit

PR4

16.7 to 17.7

160 to 170

For boom retracting circuit

21.1 to 22.1

215 to 225

PR7

5.4 to 6.4

55 to 65

For basket right swing circuit

PR8

6.4 to 7.4

65 to 75

For basket left swing circuit

5.9 to 6.9

60 to 70

PR6

Port relief valve Motor type swing

Remarks

2

MPa

PR5

Cylinder type swing

Standard pressure

PR7 PR8

For boom right swing circuit For boom left swing circuit

For basket right swing circuit For basket left swing circuit

6

Relief valve (for pump P2 main circuit)

R2

15.2 to 16.2

155 to 165

7

Sequence valve

R4

2.9 to 3.4

30 to 35

8

Relief valve

R5

11.3 to 12.3

115 to 125

For axle extension circuit

9

Relief valve

R3

11.3 to 12.3

115 to 125

For steering circuit

Tighten the valve fully.

Applicable to the specification with no jacks

444-011-10100

1

WY01-2270E

0 △

Y-1

Y-1

Service Data 2. Oil level Item Hydraulic oil tank Oil level

Gear oil

Standard (L) HIGH

152

LOW Swing speed reducer Traveling motor speed reducer

146

TADANO Hydraulic Oil LL Mobilgear 600XP 320

1.9 2.5 x 2 places

Engine oil

Remarks

SAE 90, API GL-4 SAE 10W-30, API CF-4 or above

18.0

3. Hydraulic equipment 3.1 Hydraulic pump Item Displacement 3 (cm /rev)

Driven by engine Driven by emergency motor

Standard

Remarks

52.6

Pump P1

15.6

Pump P2

3.46

Pump P1

1.66

Pump P2

3.2 Hydraulic motor Item

Displacement 3 (cm /rev)

Standard Swing

39.3

Traveling (rear wheels)

55.8

Basket/ boomswing

369

3.3 Hydraulic cylinder Item Retracting amount at spontaneous retraction: 1.

2.

3.

Elevating

Basket: No load Telescoping Lever operation: Neutral position after extending operation Leveling Engine: Stop

Standard

Limit

3 mm or less / 30 minutes

6 mm or less / 30 minutes

Boom: Level, fully retracted

6 mm or less / 30 minutes

9 mm or less / 30 minutes

Elevating angle: Max. Boom: Extended approx.10 cm

1 mm or less / 30 minutes

3 mm or less / 30 minutes

Boom: Level, fully retracted Basket: Front Cock for leveling: Open

4. Swing section Item Horizontal play Amount of swing play

Hunting during swing Vertical play

Standard

Remarks

3.0 mm Max.

(TES)

12 Max.

(TES)

1.2 mm Max.

(TES)

2

WY01-2270E

Remarks

Y-1

Y-1

Service Data 5. Boom section 5.1 Slide plate Standard (mm)

Thickness to be replaced (mm)

Top

31

29

Side

10

8.5

Bottom

12

10

Top

12

10

Side

10

8.5

Bottom

12

10

35 x 28.5

33.5 x 25.5

Side

9

7.5

Bottom

9

8

Top

15

12

Side (Upper)

9

7.5

Side (Lower)

34

32.5

Bottom

9

8

Location Base boom section

Front

Front 2nd boom section

Corner section

Top Rear

Top boom section

Rear

5.2 Clearance between slide plate and boom Location Left-right (one side)

Standard (mm) Boom head

Less than 0.3

Boom foot end

0.5 to 1

Upper and lower (total)

Remarks

1 to 2

442-004-80000

3

WY01-2270E

0 △

Y-1

Y-1

Service Data 5.3 Boom bend and deformation Item

Standard (mm)

Overall boom bending

Free of large vertical or horizontal (at full extension, maximum elevation angle, rated bends along the entire boom length. load)

Remarks With machine level, adjust pads as appropriate.

IWY01-001001

L

B OR C

(Lengthwise direction)

IWY01-0010E02

Lateral

Vertical

Individual boom bends

Presence of indentions at boom overlap section (bend of floor plate)

Base boom section B ≤ 16.2

B ≤ 1.5 × L /1000

2nd boom section B ≤ 16.6 Top boom section B ≤ 16.2

L: Boom length of each boom section

Base boom section C ≤ 10.8

C ≤ 1.0 × L /1000

2nd boom section C ≤ 11.1 Top boom section C ≤ 10.8

L: Boom length of each boom section

2nd boom section D ≤ 3.0

D ≤ t/2

Top boom section D ≤ 2.3

t D IWY01-001003

Check for deformation of side plate

Free of large deformation, particularly on the compression side (where larger load is applied than other places of the plate).

Check for twisting in the lengthwise direction when boom is fully extended

E≤5

E IWY01-001004

Check for dents and other localized indentation.

Depth F

F≤2 Check the dents whose L1 is 50 or larger.

Generally dent G on the 4 corners cannot be repaired.

L1

G

IWY01-0010E05

442-004-80000

4

WY01-2270E

0 △

Y-1

Y-1

Service Data 5.4 Boom telescoping wire rope Item Wire rope diameter

Standard

12 mm (Nominal diameter) 11.2 mm Wire rope for boom retraction (Nominal diameter) Wire rope for boom extension

Number of cut Wire rope for boom extension wire elements Wire rope for boom retraction Tightening torque of adjusting nut

Limit

Wire rope for boom extension Wire rope for boom retraction

Remarks

11.2 mm 10.5 mm

---

13 pcs

29.4 N-m {3.0 kgf-m}

---

442-004-80000

Configuration symbol: IWRC 6×Fi(29)O/O

444-005-80400

1. Replace the wire rope if 10% or more of the wires (except filler wires) in a lay are broken.

Criteria for wire rope replacement

2. Replace the wire rope if the diameter is reduced by more than 7% of the nominal diameter.

3. Replace the wire rope if it is kinked.

4. Replace the wire rope if it is deformed or corroded.

5. Replace the wire rope if it has been degraded by heat.

6. Leveling system Item

Standard

Measurement of angle displacement 1 1. Lower the boom to horizontal and determine the measuring point of the basket.

2. Place a level at the measuring point on the basket and measure the basket standard tilt angle.

3. Repeat the elevating (raising/lowering) operation to the stroke ends for 10 cycles.

1° or less

4. Stop the basket at the measuring point determined in the step 1 by boom lowering operation.

5. Measure the displacement in the basket angle.

Measurement of angle displacement 2 Start from the step 4 of the measurement 1 stated above.

1. Lower the boom from the measuring point.

2° or less

2. Stop the basket at the measuring point by boom raising operation.

3. Measure the displacement in the basket angle.

5

WY01-2270E

Y-1

Y-1

Service Data 7. Other regulating devices 7.1 Elevation angle control (AMC automatic stop position) Measuring method - Place loads in the following table in the basket, and extend the boom so that the boom lengths in the following table are acquired.

Raise the boom fully and lower the boom by inching movement until it stops automatically. At that state, measure the working radius.

- The working radius in the following table indicates the distance from the “center of boom rotation” to the inside of the basket end.

- Make sure that the boom can smoothly raise/lower (elevating operation) within a certain range (with the rated load carried).

Axle

Load on basket (kg)

Boom length (m)

Remarks

450

14.35 to 15.85 (Specified value: 15.10)

Conditions for measurement:

* 250

17.78 to 19.64 (Specified value: 18.71)

- Load on basket: 150 kg, 250 kg, 450 kg

450

9.65 to 10.65 (Specified value: 10.15)

- Position where load is applied: 563 mm from the inside of the basket frame

250

12.11 to 13.37 (Specified value: 12.74)

- Basket swing angle: 0° (in front of the boom)

150

13.74 to 15.18 (Specified value: 14.46)

Extended

Retracted

Working radius at automatic stop condition R (m): 95 to 105% of the specified value

24.20

- Pump rotational speed: Idling

*: Moment span point

TIS01-40905 TIS02-40905

6

WY01-2270E

Y-1

Y-1

Service Data 7.2 Boom length control (AMC automatic stop position) Measuring method - Place the specified load in the basket and fully retract the boom.

Set the boom elevation angle to 0° (level), and extend the boom by inching operation to the automatic stop length (100%).

At that state, measure the working radius.

- The working radius in the following table means the distance from the “center of boom rotation” to the inside of the basket end.

- Make sure that the boom can smoothly extend/retract (telescoping operation) within a certain range (with the rated load carried).

Axle

Extended

Load on basket (kg)

Boom angle (°)

450

17.61 to 19.45 (Specified value: 18.53)

250

20.10 to 22.20 (Specified value: 21.15)

150

22.36 to 24.70 (Specified value: 23.53)

0

Retracted

Working radius at automatic stop condition R (m): 95 to 105% of the specified value

450

13.92 to 15.38 (Specified value: 14.65)

250

15.96 to 17.64 (Specified value: 16.80)

150

17.18 to 18.98 (Specified value: 18.08)

Remarks

Conditions for measurement: - Load on basket: 150 kg, 250 kg, 450 kg - Position where load is applied: 563 mm from the inside of the basket frame - Basket swing angle: 0° (in front of the boom head) - Pump rotational speed: Idling

TIS01-40905 TIS02-40905

7

WY01-2270E

Y-1

Y-1

Service Data 8. Integration test (no-load operation speed) Standard

Remarks (Before test, set accelerator SW to “H”.)

Up

52±5.0

Down

58±5.0

- Boom: Fully retracted - Basket swing angle: 0°

Extension

93±9.0

Retraction

77±7.0

Item Elevation (seconds/stroke) Telescoping (seconds/stroke) Boom swing (seconds/turn)

Basket swing (seconds/stroke)

Swung by cylinder Swung by motor

Right Left Right Left Right Left Forward

High-speed

Traveling (seconds/20 m)

Reverse Forward

Low-speed

Extra low-speed Steering (seconds/stroke)

Reverse Forward Reverse Right Left

75±7.0

- Boom angle: Max. - Basket swing angle: 0° - Boom: Fully retracted - Boom angle: Max.

- Swing range: Left 60° to Right 60° - Boom: Fully retracted Approx. 20 - Difference in time between left and right swing shall be 8 seconds or less.

- Swing range: Left 90° to Right 90° - Boom: Fully retracted Approx. 25 - Difference in time between left and right swing shall be 10 seconds or less.

- Boom: Fully retracted - Boom elevation angle: Horizontal 16±2.0 - High/low speed selector: High (Traveling speed: 4.5 km/h) - Boom: Fully retracted - Boom elevation angle: Horizontal Approx. 42 - High/low speed selector: Low (Traveling speed: 1.7 km/h) - Boom: Fully retracted - Boom angle: Over 10° 50±5.0 - High/low speed selector: Low (Traveling speed: 1.4 km/h) Approx. 8 - To protect tires, do not steer the vehicle at rest.

- When measuring, slowly travel and perform Approx. 6 steering operation.

444-011-01040

8

WY01-2270E

0 △

Y-1 .

Y-1 .

Service Data 9. Mass table The approximate mass of main components is shown in the table below.

When dismounting and remounting parts, select appropriate hoisting equipment in accordance with the indicated mass.

Assembly name

Mass (kg)

Basket Assy (Includes: post, basket swing unit) (Excludes: head guard, working lamp)

Approx. 200

Boom Assy (Includes: boom telescoping cylinder, boom top leveling cylinder) (Excludes: basket Assy)

Approx. 2300

Elevating cylinder

Approx. 200

Swing bearing

Approx. 80

Swing frame counterweight

Approx. 2700

Front axle (Excludes: wheel Assy)

Approx. 800

Rear axle (Includes: wheel drive unit) (Excludes: wheel Assy)

Approx. 870

Rear wheel drive unit

Approx. 150 (one side)

Wheel Assy (Includes: tire, tire wheel)

Approx. 200 (one wheel)

Engine (Includes: hydraulic pump)

Approx. 400

9

WY01-2270E

Y-2

Y-2

Adjusting Procedure (Hydraulic) Y-2

Adjusting Procedure (Hydraulic)

1. Adjustment of relieving pressure [NOTICE] ♦ For the pump startup, refer to the “Starting procedure of pump” on the next page. ♦ For the positions of pressure adjustment and measurement (Pressure takeout area GP1 to 4), refer to page12 and after. ♦ Adjust the engine rotational speed prior to this adjustment. For the details of the adjustment method, refer to Y-3 “Adjusting Procedure (Electric).” ♦ Make this adjustment with the hydraulic oil temperature at 40±10°C. Adjust the oil temperature by the boom elevating or retracting operation after the engine warm-up. ♦ To adjust the pressure and check after the adjustment, follow the order of the item No. in the “Pressure setting table” below. ♦ For the pressure setting of each valve, refer to Y-1 “Service Data”.

Pressure setting table System/component

1

Relief valve for pump P1 main circuit

2

Boom elevating

3

4

Boom telescoping

Boom swing

Basket swing (by cylinder)

5

Item

Pressure measuring position Item within ( ) indicates accelerator position.

R1

GP1 (High)

Raising

PR1

GP1 (High)

Lowering

PR2

GP1 (Low)

Extension

PR3

GP1 (High)

Retraction

PR4

GP1 (High)

Right

PR5

Left

PR6

Right

PR7

Left

PR8

Right

PR7

GP1 (High)

Basket swing (by motor)

GP1 (Low)

GP1 (Low) Left

PR8

10

Adjustment procedure - With the boom directed toward the traveling motor, place chocks on the tires (4 pcs).

- High/low speed selector: High - Boom elevation angle: Level - Adjust the pressure during “traveling forward” operation Adjust the pressure at the stroke end for boom raising operation.

Adjust the pressure at the stroke end for boom lowering operation.

Adjust the pressure at the stroke end for boom extending operation.

Adjust the pressure at the stroke end for boom retracting operation.

Insert the swing lock pin, and adjust the pressure at boom clockwise swing operation.

Insert the swing lock pin, and adjust the pressure at boom counterclockwise swing operation.

Adjust the pressure at the stroke end for basket right swing operation.

Adjust the pressure at the stroke end for basket left swing operation.

Adjust the pressure at the stroke end for right swing operation. (As the rotation end is stopper type, stop the operation once when the basket reaches the end. Then perform the operation again.)

Adjust the pressure at the stroke end for left swing operation. (As the rotation end is stopper type, stop the operation once when the basket reaches the end. Then perform the operation again.)

WY02-1182E

Y-2

Y-2

Adjusting Procedure (Hydraulic)

System/component

Item

Pressure measuring position Item within ( ) indicates accelerator position.

6

Relief valve for pump P2 main circuit

R2

GP2 (High)

7

Sequence valve

R4

GP2 (Low)

8

Relief valve for axle extension

R5

GP3 (Low)

GP4 (Low) 9

Relief valve for steering

R3 Adjustment is not necessary. (Tighten the valve fully.)

Adjustment procedure Adjust the pressure at the right stroke end for steering operation.

Note: To protect tires, do not steer the vehicle at rest.

After pressure regulation, seal it up.

Adjust the pressure by pushing the emergency switch and without doing any operation.

Operating the control lever on the side of traveling frame, adjust the pressure at the stroke end for axle extending operation.

(When the accelerator switch is in Low, the engine speed of No. 8 only becomes the idling state, and others become the idle-up state.)

After pressure regulation, seal it up.

Adjust the pressure at the left stroke end for steering operation.

Note To protect tires, do not steer the vehicle at rest.

After pressure regulation, seal it up.

Applicable to the specification with no jacks

[NOTICE]  Set the upper and lower accelerator switches to the specified positions.

When the position is Low; For item Nos. 1 to 5, press the emergency switch and operate the lever for emergency controls of the control valves on the swing frame.

From item No. 6, press the emergency switch and operate the lower or the upper controls (except for No. 8).

When the position is High; With the AMC display select switch, set as follows: SSW1 = ON, SSW2 = ON, RSW1 = 3, RSW2 = C. For Item No. 1, operate the lever for emergency controls of the control valves on the swing frame while the traveling lever on the upper controls is kept turned toward “FORWARD.” (Two persons are required).

For item Nos. 2 to 5, press the emergency switch and operate the lever for emergency controls of the control valves on the swing frame.

Form item No. 6, press the emergency switch and operate the lower or the upper controls.

Starting procedure of pump (running-in) 1. Main pump

2. Emergency pump Other

1) Fill up the hydraulic oil tank.

2) Set the accelerator to Low. 3) Slightly move the starter key toward the start side 5 times for bleeding.

(Inching operation) (At this time, do not start the engine.)

4) Start the engine, and perform idling run for 10 minutes as the running-in.

Press the emergency switch and operate the emergency pump for 30 seconds.

When disassembling the suction part for maintenance, perform items 1 and 2 above.

After that, be sure to perform bleeding with the accelerator in Low. In addition, to raise the temperature for pressure regulation, perform it when no bubble by bleeding exists in the hydraulic oil tank.

444-011-10100

11

WY02-1182E

0 △

444-011-00130

0 △

Y-2

Y-2

Adjusting Procedure (Hydraulic)

Pressure measuring position (Swing frame)

12

WY02-1182E

Y-2

Y-2

Adjusting Procedure (Hydraulic) Pressure adjusting position (Swing frame)

13

WY02-1182E

Y-2

Y-2

Adjusting Procedure (Hydraulic) Pressure adjusting position and pressure measuring position (Lower frame)

0 △ 0 △ 0 444-011-00110 △

444-011-00130 444-011-00120

14

WY02-1182E

Y-2

Y-2

Adjusting Procedure (Hydraulic) 2. Leveling cylinder bleeding [NOTICE]  Visually check the inside of the hydraulic oil tank. If any bubble is observed in the oil, stop the bleeding operation until air bubbles disappear.  If the boom is extended with only the cock (C) for leveling opened, the boom telescoping cylinder may be damaged.  Be sure to perform “2.3 Pressurizing the leveling circuit” after bleeding and leveling adjustment. When oil temperature is 10°C higher than outside air temperature, cool the oil enough before this operation.

C

B B

15

C

WY02-1182E

Y-2

Y-2

Adjusting Procedure (Hydraulic) 2.1 Bleeding operation

5. Remove the right cover from the top boom section and connect two vinyl hoses (4 × 6) to the air

1. Fully retract the boom.

bleeding plugs (2 places).

2. Open the hinged cover at “A” in the previous figure on the swing frame, and fully loosen both cocks for leveling by turning them counterclockwise. (The valve is fully opened.)

[NOTICE]  Fix the vinyl hoses with fasteners or similar items.

6. Loosen the air bleeding plugs (2 places) little by 3. With the lower control switch (AMC panel) set to

turning them 1/6 turn.

ON,

7. By operating the switch on the lower control (AMC

[1] By performing elevating operation (raising)

panel), perform the bleeding operation by

and telescoping operation (retraction)

repeating tilting the basket forward (boom

simultaneously, raise the boom to the highest

retracting operation) and tilting the basket

angle.

backward (boom extending operation) for 3 to 5

[2] Then by performing elevating operation

times until no bubble can be observed in the

(lowering) and telescoping operation (extension)

flowing hydraulic oil.

simultaneously, lower the boom to the angle just before the basket touches the ground.

8. Tighten the air bleeding plugs (2 places) and remove the vinyl hoses.

Repeat the operation above for 5 times.

9. Place caps on the air bleeding plugs (2 places)

4. Lower the boom (to almost horizontal just before

and install the cover.

the basket touches the ground when the basket is

10. After performing the leveling adjustment of the

tilted forward).

basket, fully tighten both cocks for leveling by turning them clockwise. (The valves are fully closed.) For leveling adjustment, refer to the next page “Leveling adjustment after bleeding operation”.

[NOTICE]  Be sure to open or close both cocks at the same time. If the boom is extended with only the cock (C) for leveling opened, the boom telescoping cylinder may be damaged.

444-010-20200

16

WY02-1182E

1 △

Y-2 .

Y-2 .

Adjusting Procedure (Hydraulic) 2.2 Leveling adjustment after bleeding operation

2.3 Pressurizing the leveling circuit Operating condition  With no load on the basket  Oil temperature inside the circuit is around outside air temperature 1. Fully loosen both cocks for leveling by turning them countercloclwise. (The valves are fully opened.)

2. By flipping the telescoping switch to the “retraction” side, pull up the basket approx. 2° (in backward tilting).

1. Open the hinged cover at “A” in the previous

3. Fully turn both cocks for leveling clockwise. (The

figure on the swing frame, and fully loosen both

valves are fully closed.)

cocks for leveling by turning them

4. Fully retract the boom and fully raise the boom.

counterclockwise.

5. Turn the cock (B) for leveling counterclockwise for

2. By manipulating the telescoping switch, set the

a half turn. (The valve is slightly opened.)

basket in a horizontal position.  When the basket is in a forward tilting position, flip the telescoping switch to the retracting side to pull up the basket.  When the basket is in a backward tilting position, flip the telescoping switch to the extending side to pull down the basket.

C

B

6. While pulling down the basket (by flipping the telescoping switch to the extending side), fully turn to the cocks (B) for leveling clockwise. (The valve is fully closed.)

3. Once the basket is in a horizontal position, fully turn both cocks for leveling clockwise to close the

7. Lower the boom until the floor face of the basket

valve. (The valve is fully closed.)

goes to the eye-level.

4. Repeat boom elevating operation and boom

8. Make sure the basket is horizontal.  If the basket is not horizontal, adjust the tilt angle described step 2 and repeat the operation as above.

telescoping operation for the full stroke several times to make sure that the basket is always kept horizontal.  If further adjustment is needed, repeat the adjustment.

5. Proceed to “2.3 Pressurizing the leveling circuit”.

444-010-20200

17

WY02-1182E

1 △

Y-3

Y-3

Adjusting Procedure (Electric) Y-3

Adjusting Procedure (Electric)

1. Adjustment of axle extension detector switch [NOTICE]  Adjust the axle clearance before conducting this adjustment.

Refer to “Y-4: Adjustment and Functional Check.”  Park the vehicle on as level and hard ground as possible.  After adjustment, apply thread lock (ThreeBond 1401 or equivalent) to the threads of the fixing bolts.

3. Push the detection switch against the inner case further 2 mm from the switch-over point (from ON to OFF) and fix it there.

1.1 Adjustment of detector switch

4. Lift the wheels with jacks and fully extend the

1. Fully retract the axles.

axles. Then make sure that the detector switches

2. Loosen the fixing bolts, and place the detector

on both sides are turned ON.

switch so that the tip roller is pressed against the axle.

LH front and rear (viewed downward)

RH front and rear (viewed downward)

18

WY04-1830E

448-002-10000

5 △

444-005-80700

0 △

Y-3

Y-3

Adjusting Procedure (Electric) 2. Adjustment of axle extension/retraction control detector switch (reed switch) [NOTICE]  Appearance or others may be different from the machine parts shown in this manual. There is no significant difference on function, disassembly procedures and others, however, be sure to check the part number of the machine and distribution unit described in the part catalog before disassembly operation.

- Position of detector switches

19

WY04-1830E

Y-3

Y-3

Adjusting Procedure (Electric) 2.1 Removal of reed switch

2.2 Installation of reed switch

1. Remove the connector, and then the wiring

1. For preparation of “Adjustment of switch

binding band.

operating position” to be described later, measure the thickness of the removed shim.

2. Loosen two hexagon socket head bolts (M4 × 15)

Any one of the shims is inserted.

which fix the reed switch, and take out the shim

- 0.3 mm thickness (Part No.: 366-364-35090)

and the reed switch.

- 0.5 mm thickness (Part No.: 366-364-35100) - 0.7 mm thickness (Part No.: 366-364-35110) 2. Prepare a new reed switch.

[NOTICE]  The a-contact type reed switch is used. Be sure to use correct switch.

3. With two hexagon socket head bolts (M4 × 15), install a shim and new reed switch to the valve.

3. On the switch installation surface and shim

Tightening torque: 2.94 N⋅m {0.3 kgf⋅m}

surface, remove the affixed/protruded paint film.

- Switch installation surface

- Surface of shim

[NOTICE]  To reuse the shims, do not dispose them.

20

WY04-1830E

Y-3

Y-3

Adjusting Procedure (Electric) 2.3 Operation check of reed switch Check that the reed switch operates as shown in the table below when the spool of the axle extend/retract control valve is operated. If the switch does not operate as shown in the table below, follow “Adjustment of switch operating position” to be described later for making adjustment.

[NOTICE]  The a-contact type reed switch is used.  The color of white, black and red in the table below indicates the color of switch wiring. (Refer to the circuit diagram below.)

Contact type of reed switch

Color of wiring

A-contact type

Between white and black Between red and black

Spool pulled-out side (Pulled-out amount: 0.6 to 2.1 mm)

When spool is in neutral

Spool pushed-in side (Pushed-in amount: 0.6 to 2.1 mm)

Changes from ON to OFF.

OFF

OFF

OFF

OFF

Changes from OFF to ON

Note: In the table, “ON” indicates continuity on the contact, and “OFF” indicates no-continuity on the contact.

State of spool when the switch is operated

Circuit diagram of the detector switch -

a-contact type

ON/OFF state of contact -

21

a-contact type

WY04-1830E

Y-3

Y-3

Adjusting Procedure (Electric) 2.4 Adjustment of switch operating position (a-contact type)

Case 2: The operating position of the reed switch is shifted to the spool pulled-out side.

- The contact between white and black turns OFF even when the spool pulled-out amount is less than 0.6 mm. or - The contact between red and black turns ON after the spool pushed-in amount exceeds 2.1 mm.

When the operating position of the detector switch (reed switch) is displaced, adjustment of the operating position is necessary.

The operating position of the switch is adjusted by changing the thickness of the shim to be installed in between the switch the valve.

Follow the procedure below to change the

Adjustment method: Replace the shim with a

thickness of the shim and adjust the switch

thinner one. (Replace the 0.5 mm shim with a

operating position.

0.3 mm shim.)

Three types of the shims are available.

- 0.3 mm thickness (Part No.: 366-364-35090) - 0.5 mm thickness (Part No.: 366-364-35100) - 0.7 mm thickness (Part No.: 366-364-35110) Usually, adjustment can be completed by replacing a shim.

Adjustment of shim Case 1: The operating position of the reed switch is shifted to the spool pushed-in side.

- The contact between white and black turns ON after the spool pulled-out amount exceeds 2.1 mm. or - The contact between red and black turns OFF even when the spool pushed-in amount is less than 0.6 mm.

Adjustment method: Replace the shim with a thicker one. (Replace the 0.5 mm shim with a 0.7 mm shim.)

Example: OFF position between white and black: 2.2 mm, ON position between red and black: 0.5 mm

366-686-40000

22

WY04-1830E

2 △

Y-3

Y-3

Adjusting Procedure (Electric) 3. Adjustment of touch switch

444-308-80000

23

WY04-1830E

3 △

Y-3

Y-3

Adjusting Procedure (Electric) 4. Adjustment of AMC

Switch layout

4.1 Adjustment of boom length detector zero/span

Start

Fully retract the boom.

Set AMC to SSW1 = ON (adjustment mode) SSW2 = OFF (mode 1) RSW1 = "1" RSW2 = "1"

Mode 2 (ON) Monitor mode (OFF) (SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Zero adjustment

Depress the write-in switch about 3 seconds. (automatic adjustment) When the digital display stops flashing and continuously lights up, the write-in operation is completed.

(SSW1 normal position)

Mode 1 (OFF)

View when the front panel is removed.

Fully extend the boom.

The zero point displayed value and the span point displayed value when normal are as follows. m - Zero point displayed value: 9.80

Depress the write-in switch about 3 seconds. (automatic adjustment) When the digital display stops flashing and continuously lights up, the write-in operation is completed.

- Span point displayed value: 24.20

Span adjustment

Set AMC to SSW1 = ON (adjustment mode) SSW2 = ON (mode 2) RSW1 = "1" RSW2 = "1"

m

[NOTICE]  Adjust with safe boom direction and boom angle even when the boom fully extended.  When extending the boom fully, use the emergency controls.  If pressing the write-in switch cannot make the digital display stop flashing, take the following measures.

1. Release the write-in switch, and wait for 1 second or more.

2. Press the write-in switch again for 1 second or more.

When the digital display lights up, the write-in operation is completed.  Operate the boom to check that the written value is within the range of the tolerance after adjustment.

When checking the written value, also change SSW and RSW of the AMC to the same positions as adjustment.

- When checking zero adjustment value SSW1 = ON, SSW2 = OFF RSW1 = "1", RSW2 = "1 - When checking span adjustment value SSW1 = ON, SSW2 = ON 0 RSW1 = "1", RSW2 = "1" 444-011-01020 △

Return AMC to the monitor mode.

SSW1=OFF, SSW2=OFF, RSW1=“0”, RSW2=“0”.

End

IW301-0190E23

IW319-0130E28

24

WY04-1830E

Y-3

Y-3

Adjusting Procedure (Electric) 4.2 Adjustment of boom elevation angle detector zero/span

Switch layout

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

(SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Mode 1 (OFF)

View when the front panel is removed.

IW301-0190E23

[NOTICE]  Use the spirit-level type angle meter as the measuring instrument.  If pressing the write-in switch cannot make the digital display stop flashing, take the following measures.

1. Release the write-in switch, and wait for 1 second or more.

2. Press the write-in switch again for 1 second or more.

When the digital display lights up, the write-in operation is completed.

444-011-01020

25

WY04-1830E

0 △

Y-3

Y-3

Adjusting Procedure (Electric) 4.3 Adjustment of boom swing angle detector zero/span

Switch layout

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Mode 1 (OFF)

(SSW2 normal position)

View when the front panel is removed.

IW301-0190E23

[NOTICE]  If pressing the write-in switch cannot make the digital display stop flashing, take the following measures.

1. Release the write-in switch, and wait for 1 second or more.

2. Press the write-in switch again for 1 second or more.

When the digital display lights up, the write-in operation is completed.  For the boom swing angle, refer to the figure bellow.

444-011-01020

26

WY04-1830E

0 △

Y-3

Y-3

Adjusting Procedure (Electric) 4.4 Adjustment of moment zero/span and adjustment of working radius (measurement radius)

4.4.1 Things to be done before adjustment Make sure that the things described in the NOTICE below have been completed before making this adjustment. Otherwise, correct adjustment cannot be achieved.

[NOTICE]  In this paragraph, the working radius that is used for the adjustment of the AMC unit is referred to as “measurement radius”.

Do not mix up this term with the generally used term “working radius”.

[NOTICE]  Before making this adjustment, the zero/span adjustments of the detectors for swing angle, boom length and boom angle have been completed.

Check that the resistances of the strain gauges are correct.

(The resistance values are stated in “5. Data.”)

- “Working radius”: Horizontal distance from the boom swing center to the inside of the basket end

 Before making this adjustment, once return the offset value by “automatic zero adjustment” to “0”.

- “Measurement radius” (used for adjustment of AMC unit):

- How to reset the offset value to “0”

Horizontal distance from the boom swing center to

1. On AMC, set the SSW and RSW as follows.

- SSW1 = ON, SSW2 = OFF - RSW1 = "D", RSW2 = "7"

the center of the top boom pivot pin

2. Press the Write-in switch. When "0" is indicated on the digital display, this operation is completed.

Then the offset value returns to “0.”

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

(SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Mode 1 (OFF)

View when the front panel is removed.

IW301-0190E23

Remarks: If an automatic adjustment by the “automatic zero adjustment” has been made to set the 10° moment at AMC pre-operation inspection, “ • • • • ” appears on the digital display during adjustment operation and further adjustment is disabled.

“Automatic zero adjustment” is to press all of the four switches below at the same time.

Switch layout

27

WY04-1830E

Y-3

Y-3

Y-3

Adjusting Procedure (Electric) Notes:

4.4.2 Adjustment procedure

1. Remove all options (such as head guard, working lamp) installed on the basket before adjustment. If the options cannot be removed, reduce mass options from the basket loads W 1 and W 2.

For reducing mass from W 1 and W 2, refer to the list on the next page.

2. Start elevating operation from the point at least 3° away from the desired angle.

(Be sure to set the boom at the desired boom angle by raising/lowering the boom at least 3°.)

3. Numerals displayed at moment zero adjustment and span adjustment for the leveling cylinder represent voltage (µV).

4. When either the Up or Down switch is pressed, the digital display stops lighting and starts flashing.

5. If pressing the Write-in switch cannot make the digital display stop flashing, take the following measures.

1. Release the Write-in switch, and wait for 1 second or more.

2. Press the Write-in switch again for 1 second or more.

The digital display lights up, and the write-in operation is completed.

6. For releasing pressure from the elevating cylinder and leveling cylinder, refer to 4.4.3.

For basket leveling adjustment, refer to Y-2 “Adjusting Procedure (Hydraulic).”

- Conditions for span adjustment (Refer to Note 1 and the list on the next page.)

Spec.

Direction of basket

Measurement radius R

Load W 1

Load W 2

AW-250-3-80120

Front

14.78 m

250 kg

450 kg

θ1 10°

θ2 66°

Measurement radius R: Horizontal distance from the boom swing center to the center of the top boom pivot pin

- Moment % display check list at boom elevating operation (Check in the order of θ1 → θ2 and θ2 → θ1. Repeat two times.)

10°

Boom angle

θ1

30° → ←

50° → ←

60° → ←

66° θ2

% display at boom raising % display at boom lowering Difference ±

- Location of load on basket in span adjustment

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

(SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

Subsequently perform “10° and 50° moment write-in method”.

28

WY04-1830E

RSW1

Control boards

Mode 1 (OFF)

View when the front panel is removed.

IW301-0190E23

28

Y-3

Y-3

Adjusting Procedure (Electric) List of reducing mass for option for basket during adjustment of moment zero / span Optional part

4.4.3 Pressure relieving of elevating cylinder and leveling cylinder

Reducing mass (kg)

Follow the procedure below to release pressure

Not set

from the elevating cylinder and leveling cylinder.

[1] How to release pressure from elevating cylinder

(As of March, 2012)

1. Remove load from the basket.

2. Prepare a stand to receive the boom.

[NOTICE]  Prepare a stand with sufficient strength because the boom is pressed against it subsequently.

3. Stop the engine with the boom being pressed against the stand by boom lowering operation.

4. To release the pressure in the elevating cylinder, move the manual control lever (boom elevation) on the emergency control valve in both raising and lowering directions a few times with the engine being stopped.

29

WY04-1830E

Y-3

Y-3

Adjusting Procedure (Electric) [2] How to release pressure from leveling cylinder 1. Stop the engine.

2. Open the leveling cock B (cylinder rod side).

Move the manual operation lever (boom telescoping) on the emergency control valve in both extending and retracting directions a few times with the engine being stopped.

[NOTICE]  Relieve the pressure of the leveling cylinder on the rod side and then that on the tube side.

3. Open the leveling cock C (cylinder tube side).

Move the manual control lever (boom telescoping) on the operation valve in both extending and retracting directions a few times with the engine being stopped.

4. Slightly move the leveling cylinder for the basket by hand to check that there is some rattle.

5. Close the leveling cock B and C.

444-011-01090 444-011-01060

30

WY04-1830E

4 △ 0 △

Y-3

Y-3

Adjusting Procedure (Electric) 4.5 10° and 50° moment write-in method Switch layout

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

(SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Mode 1 (OFF)

View when the front panel is removed.

IW301-0190E23

[NOTICE]  Perform this adjustment after completing zero/span adjustment for boom length/elevating angle detectors and moment.

(Refer to “4.4 Adjustment of moment zero/span and adjustment of working radius”.)  Install all options such as head guard and working lamp to the basket before adjustment (writing-in).  If the automatic offset is adjusted to match the 10° moment at AMC pre-operational inspection, the written-in value of 10° moment and 50° moment cannot be changed.

In the case of changing the written-in value, adjust the moment zero/span adjustment again and then writing-in the 10° moment and 50° moment.  If pressing the Write-in switch cannot make the digital display stop flashing, take the following measures.

1. Release the Write-in switch, and wait for 1 second or more.

2. Press the Write-in switch again for 1 second or more.

When the digital display lights up, the write-in operation is completed.

444-011-01070

31

WY04-1830E

0 △

Y-3

Y-3

Adjusting Procedure (Electric) 4.6 Offset adjustment for boom operation valve To improve the accuracy during slow start and slow stop, adjust as shown below to store the “operation signal voltage at the point when the cylinder, motor, etc., start action” into AMC.

32

WY04-1830E

Y-3

Y-3

Adjusting Procedure (Electric) [NOTES]

Table 1: Correction value for valve offset adjustment

1. The select switch changes over between manual adjustment mode and automatic adjustment mode.

When this switch is pressed one time, the mode changes over (When this switch is pressed twice, it returns to the mode before it is pressed).

Boom telescoping 25

Boom elevation 30

Boom swing 30

Table 2: RSW1 and RSW2 selecting position and adjusted item comparison

2. To bleed the valve, shift the manual lever of the valve back and forth to the full stroke positions.

Operate the lever intermittently 5 times. (With operation to the full stroke positions, air is bled to the tank path).

RSW1

8

RSW2

1

3. During adjustment, set the lower accelerator switch to the low speed.

2

4. Measure each operation twice. If the dispersion is 5% or less, write in the 2nd measurement as it is.

However, in a case where the dispersion exceeds 5%, measure a 3rd time and write in the larger value of the closest two among the three measured values.

3

A

･･･

Boom extension (%) ･･･ Boom retraction (%) Boom raising (%) ･･･ Boom lowering (%) Boom right swing (%)

Boom left swing (%)

･･･

5. When the control switch or control lever is released during automatic adjustment, the automatic adjustment is suspended and the value before starting the adjustment is set.

6. To eliminate an error due to backlash of the detector, start the adjustment after slightly operating the control toward the direction of the adjustment.

7. Make this adjustment with the hydraulic oil temperature 45±5°C. 8. If pressing the Write-in switch cannot make the digital display stop flashing, take the following measures.

1. Release the Write-in switch, and wait for 1 second or more.

2. Press the Write-in switch again for 1 second or more.

When the digital display lights up, the write-in operation is completed.

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

(SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Mode 1 (OFF)

View when the front panel is removed.

IW301-0190E23

444-011-01030

33

WY04-1830E

0 △

Y-3

Y-3

Y-3

Adjusting Procedure (Electric) 4.7 Offset adjustment for traveling operation valve

[NOTES]

In order to increase the accuracy of slow start and slow stop, perform the following adjustment to store “operation signal voltage at the point when the machine

1. Increase or decrease the displayed value 1 by 1 for adjustment unless otherwise specified.

starts to travel” into the AMC.

2. Measure each operation twice, and if the dispersion is 1% or less, write in the value obtained by subtracting 40 from the second adjustment value.

However, if the dispersion exceeds 1%, make a third measurement and write in the larger value of the closest two among the three measured values.

3. Set both of the accelerator switch and travel speed select switch to “L” during adjustment.

4. To eliminate an error due to backlash of the detector, start the adjustment after slightly operating the control toward the direction of the adjustment.

5. Make this adjustment with the hydraulic oil temperature 45±5°C. 6. If pressing the Write-in switch cannot make the digital display stop flashing, take the following measures.

1. Release the Write-in switch, and wait for 1 second or more.

2. Press the Write-in switch again for 1 second or more.

When the digital display lights up, the write-in operation is completed.

Switch layout

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

Mode 1 (OFF)

SSW2 SSW1 RSW2

RSW1

Control boards

Adjustment mode (ON)

(SSW2 normal position)

View when the front panel is removed.

IW301-0190E23

Table 1: RSW1 and RSW2 selecting position and adjusted item comparison RSW1 RSW2

C

8

･･･

A

Travel right forward (%)

･･･

Travel right backward (%) 444-010-21040

34

WY04-1830E

1 △

34

Y-3

Y-3

Y-3

Adjusting Procedure (Electric) 4.8 Valve span adjustment

[NOTICE]  Make this adjustment after pump revolution speed adjustment, pressure adjustment and valve automatic offset adjustment.  When operating the machine for this adjustment, use the upper controls.

The valve span adjustment is to secure the operation speed with no-load.

(With this adjustment, “operation signal voltage at the maximum flow rate of the valve” is stored to AMC.) Before this adjustment, follow the procedure in “Table 1” to measure the no-load speed. Then only for items which are out of standard, adjust the valve span.

[NOTICE] ♦ When measuring the operation speed with no load and checking the speed after adjustment, set the SSWs and RSWs of the AMC unit to the same positions as described in the flow chart below for this span adjustment.

 Set the accelerator switch to “H” during this adjustment.  Make this adjustment with the hydraulic oil temperature 45±5°C.  If pressing the Write-in switch cannot make the digital display stop flashing, take the following measures.

1. Release the Write-in switch, and wait for 1 second or more.

2. Then press the Write-in switch again for 1 second or more.

When the digital display lights up, the write-in operation is completed.

Table 2: Switch positions for span adjustment Rotary switch Adjustment item SSW2 RSW1 RSW2 Boom extension

9

1

OFF

Boom retraction

B

1

OFF

Boom raising

9

2

OFF

Boom lowering

B

2

OFF

Boom right swing

9

3

OFF

Boom left swing

B

3

OFF

Travel forward

9

C

ON

Travel backward

B

C

ON

Table 1: Measurement procedures of operation speed with no load Standard speed (second)

Item Boom telescoping Boom elevating Boom swing

Basket swing

Travel (Very low speed)

Measurement procedures

Extension

62±6

Retraction

57±5

With the axles extended and at the maximum boom elevation angle (72°), measure the boom telescoping time from boom full retraction to boom full extension, and vice versa.

50±5

With the boom fully retracted, measure the boom elevation time from the minimum (stroke end) to the maximum, and vice versa.

75±7

With the boom fully retracted and at the maximum boom elevation angle, measure the boom swing time from 0° to 360° (at a steady speed).

Raising Lowering Left Right Motor-type

Cylinder-t ype

Left Right Left Right

Forward

Approx. 25 Approx. 20

50±5

Backward

Forward Travel (High speed)

This is not required to be adjusted - Motor-type (right/left 90°) Allowable difference of right and left: 10 s (reference) - Cylinder-type (right/left 60°) Allowable difference of right and left: 8 s (reference) Change in the span adjustment value for high-speed travel links to the traveling speed for very-low- speed travel.

For the travel span adjustment, check whether the value of very low speed is within the standard. Then adjust so that it is within the standard for the high speed travel.

Very low speed:

Measure the traveling time of 20 m with boom fully retracted, boom elevation angle 20°, and high/low speed select or set in low

High speed:

Measure the traveling time of 20 m with boom fully retracted, boom elevation angle 0°, and high/low speed selector set in high

16±2 Backward

Switch layout

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

(SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Mode 1 (OFF)

View when the front panel is removed.

35

WY04-1830E

IW301-0190E23

444-011-01040

0 △

35

Y-3

Y-3

Adjusting Procedure (Electric) 4.9 Selecting acceleration method

Switch layout

When a circuit board of AMC is replaced because it is defective etc., make the following adjustment.

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

(SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Mode 1 (OFF)

View when the front panel is removed.

IW301-0190E23

[NOTICE]  When the Up or Down switch is pressed, the digital display, which has continuously lighted up, starts flashing.  After adjustment, set SSW and RSW of AMC as shown below and confirm that the acceleration method is correctly set.

- SSW1 = OFF, SSW2 = ON - RSW1 = "D", RSW2 = "B"

- Acceleration method selecting table Acceleration method No acceleration setting (initial value) Chopper control method with idle-up function Chopper control method without idle-up function

Value

 If pressing the Write-in switch cannot make the digital display stop flashing, take the following measures.

1. Release the Write-in switch, and wait for 1 second or more.

2. Press the Write-in switch again for 1 second or more.

When the digital display lights up, the write-in operation is completed.

Remarks

0 1 2

On/off control method with idle-up function

3

On/off control method without idle-up function

4

Manual acceleration method

5

AW Series (Option) For standard specification, select 0.

424-039-81090

36

WY04-1830E

3 △

Y-3

Y-3

Adjusting Procedure (Electric) 4.10 Adjustment of accelerator (engine) span

37

WY04-1830E

Y-3

Y-3

Adjusting Procedure (Electric) Switch layout

[Notes] 1. If pressing the Write-in switch cannot make the digital display stop flashing, take the following measures.

1). Release the Write-in switch, and wait for 1 second or more.

2). Press the Write-in switch again for 1 second or more.

When the digital display lights up, the write-in operation is completed.

2. Raise the hydraulic pressure in the traveling circuit to the relief cracking pressure as follows.

Block the port A1 circuit. Alternatively, with the traveling state (boom set to the motor side), apply ratchets to the front side of four tiers. Then with high/low selector switch in High position and boom elevation angle at horizontal, attempt forward traveling operation.

3. Adjustment of the idling setting bolt is not necessary.

(It has been adjusted by the manufacturer.)

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

(SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Mode 1 (OFF)

Push-pull cable adjustment screw (B, C) details View when the front panel is removed.

IW301-0190E23

Location of the port A1

444-011-01010

38

WY04-1830E

1 △

Y-3

Y-3

Y-3

Adjusting Procedure (Electric) 4.11 Adjustment of machine (carrier) inclination angle detector zero

[NOTICE]  If pressing the write-in switch cannot make the digital display stop flashing, take the following measures.

1. Release the write-in switch, and wait for 1 second or more.

2. Press the write-in switch again for 1 second or more.

When the digital display lights up, the write-in operation is completed.  After completing adjustment, set SSW, RSW as follows to check that they are correctly adjusted.

- SSW1 = OFF、SSW2 = OFF - RSW1 = “3” - RSW2 = “A” or “B” (Set to A when checking longitudinal tilt of the machine, and set to B when checking lateral tilt.)

- How to check After changing the display on the AMC, tilt the machine as shown in Fig. 1 and Fig. 2 to check that the displayed values of the tilt angle are as follows.

- Nose up: - Nose down: - Tilt right: - Tilt left:

+θ -θ +θ -θ Switch layout

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

(SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Mode 1 (OFF)

View when the front panel is removed.

IW301-0190E23

444-010-21070

39

WY04-1830E

2 △

39

Y-3

Y-3

Y-3

Adjusting Procedure (Electric) 4.12 Fuzzy control adjustment Make the following adjustment when the fuzzy adjustment values are newly stored due to parts replacement etc. or the fuzzy values are initialized.

Usually the learned values are stored every time an automatic stowing operation is performed after aerial platform operation.

[NOTICE]  Make this adjustment only when basket vertical and horizontal movement function (option) is installed.  This adjustment must be carried out after all other adjustments.

Conditions for adjustment

Boom movement at adjustment

Vertical/horizontal operation start posture Boom angle

Basket swing angle

0°

0°

0°

0°

Fully retracted length + 1 m

70°

0°

Fully extended length - 3 m

70°

0°

Item

Boom length

Start posture for vertical operation

Fully retracted length + 1 m Fully extended length - 3 m

Start posture for horizontal operation along boom telescoping direction

- Vertical operation

- Load on basket: 0 kg (with one person) - Accelerator: "H”

Switch layout

- Hydraulic oil temperature: 40±5°C

- Horizontal operation along boom telescoping direction (horizontal movement operation to move basket forward and backward)

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

(SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Mode 1 (OFF)

View when the front panel is removed.

IW301-0190E23

Initialization of fuzzy values This is needed when vertical/horizontal movement operation cannot be performed normally. By making a fuzzy control adjustment after initializing the fuzzy values according the following steps, operational malfunction in vertical/horizontal movement operation can be rectified. (Refer to 5.12 “Initialization of adjusted values and selected values”.)

• Initialization method: Set AMC to SSW1 = ON, SSW2 = OFF, RSW1 = "C", RSW2 = "F".

Then press the Up switch and Write-in switch at the same time. Once “100” appears on the digital display, initialization is completed.

40

WY04-1830E

444-010-21080

0 △

40

Y-3

Y-3

Adjusting Procedure (Electric) 4.13 Initialization of adjusted values and selected values When the fuzzy adjustment values are considered erroneous or an “AMC unit data setting error (E008)” has occurred, it is necessary to initialize the adjusted values and selected values.

Perform initialization of such values by setting the AMC switches according to the table below.

Adjusted value/ selected value to be initialized AML / AWL selected performance number

All of adjusted values

All of fuzzy adjusted values

SSW/RSW selector position

Condition when initialization is SSW1 SSW2 RSW1 RSW2 needed

ON

ON

ON

ON

ON

OFF

D

C

C

1

1

F

Displayed value when switch setting is changed and initialization method

- Setting method: Display the correct E008 occurs performance number by though no board pressing the Up/Down is replaced switch, and then press the Write-in switch.

If initialization is made with this operation, perform AMC adjustment completely again.

E008 occurs after - Displayed value at switch a board is setting change: 0 replaced - Initialization method: Press the Up switch and Write-in switch at the same time.

- Displayed value at switch Vertical/ setting change: 0 horizontal - Initialization method: movement Press the Up switch and operation is Write-in switch at the unusual *1 same time.

Change in displayed value during initialization and at its completion

---

From 0 to 100 (“100” means completion of initialization.)

From 0 to 100 (“100” means completion of initialization.)

*1: After completing initialization, make fuzzy adjustment of basket vertical/horizontal movement.

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

Mode 1 (OFF)

(SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Switch layout

View when the front panel is removed.

IW301-0190E23

W319-0013E △

41

WY04-1830E

Y-3

Y-3

Adjusting Procedure (Electric) 4.14 Selecting of special specification

Switch layout

When you replace the AMC board, adjust as follows.

Mode 2 (ON) Monitor mode (OFF)

(SSW1 normal position)

(SSW2 normal position)

Adjustment mode (ON)

SSW2 SSW1 RSW2

RSW1

Control boards

Mode 1 (OFF)

View when the front panel is removed.

IW301-0190E23

[Notes] 1. When you press the up or down switch, the digital display starts flashing from the state of being lit.

2. If pressing the Write-in switch cannot make the digital display stop flashing, take the following measures.

1). Release the Write-in switch, and wait for 1 second or more.

2). Then press the Write-in switch again for 1 second or more.

When the digital display lights up, the write-in operation is completed.

List of selecting special specification Spec.No.

Selecting value

Engine stop caused by touch SW

Engine stop due to overheat

Traveling restriction due to machine configuration

Remarks

AW-250-3-80101 AW-250-3-80120

0

○

○

○

General spec.

○: provided

●: not provided

444-011-11010

42

WY04-1830E

0 △

Y-3

Y-3

Adjusting Procedure (Electric) 5. Data 5.1 Detector specifications - Boom length detector, boom elevation angle detector, boom swing angle detector, and boom tilt angle detector [NOTICE]  For the detector check, check the voltage with the AMC monitor using the AMC monitor mode.

Detector specification

Condition for voltage check

Detector voltage (*1)

Boom length detector

Aerial platform state

Boom fully retracted

Total resistance (*2)

2000±100 Ω

Potentiometer resistance (*2)

300±60 Ω

Condition for voltage check

SSW and RSW positions

Aerial platform state

0.75±0.2 V

2.5±0.2 V

0.85±0.2 V (420450 -) SSW1 = OFF SSW2 = ON RSW1 = "1" RSW2 = "1"

Detector specification

Boom tilt angle detector (Front/back of swing frame)

0.81±0.2 V (- 420449)

SSW and RSW positions

Detector specification

Boom elevation angle detector

SSW1 = OFF SSW2 = ON RSW1 = "1" RSW2 = "2" Boom stowing state (Boom elevation angle: −10°)

Boom swing angle detector

SSW1 = OFF SSW2 = ON RSW1 = "3" RSW2 = "A" Leveled vehicle

[1]

[2]

Boom tilt angle detector (Right/left of swing frame)

1.21±0.2 V

3.79±0.2 V

2.5±0.2 V

SSW1 = OFF SSW2 = ON RSW1 = "1" RSW2 = "3"

SSW1 = OFF SSW2 = ON RSW1 = "2" RSW2 = "3"

SSW1 = OFF SSW2 = ON RSW1 = "3" RSW2 = "B"

Boom stowing state Boom stowing state (Boom swing angle: 0°) (Boom swing angle: 0°)

Total resistance (*2)

1000±150 Ω

1000±150 Ω

Potentiometer resistance (*2)

242±48 Ω

758±150 Ω

(*1): The voltage of each detector is displayed up to the 2nd decimal place. (*2): The resistances are only for reference.

43

WY04-1830E

Leveled vehicle

Y-3 .

Y-3 .

Adjusting Procedure (Electric)

- Moment detector [NOTICE]  Check the moment detector by measuring its resistances after switching off the power.

Detector specification

Elevating moment detector Measuring terminal CNA1 F

Leveling moment detector

Standard value

1–22 Bridge resistance

Insulation resistance

1–3 5–22

Measuring terminal CNA1 F 1–23

182±1 Ω

1–4 5–23

3–5

4–5

1–Swing frame

1–Swing frame

5–Swing frame 6–22

Standard value

200 MΩ or more

3–6

5–Swing frame 6–23

91±1 Ω

200 MΩ or more

4–6

- Measure after removing CN M (elevating - Measure after removing CN ML (leveling cylinder moment detector connector). cylinder moment detector connector).

(In order to eliminate a sneak path problem.)

(In order to eliminate a sneak path problem.)

Condition for resistance check - Use a tester to measure at connector CNA1 (female) on AMC.

- Use a tester to measure at connector CNA1 (female) on AMC.

444-011-01050

44

WY04-1830E

1 △

Y-4

Y-4

Adjustment and Functional Check Y-4

Adjustment and Functional Check

1. Adjustment of steering wheel With the front wheels in the straight driving position, make adjustment so that the amount of toe-in is 0 mm.

1. Adjust the cylinders and the rods to the following dimensions.

[NOTICE]  Install the rod (with the side with a slit downward).

Reference

2. Make sure that the wheels are steered straight.

Steered angle

3. Make sure that the amount of toe-in is 0 mm.

(Measure the distances between the centers of the width of the right and left wheels. Make sure that the measured values at the front end and rear end of the wheels are the same.)

Axle

α°

β°

Retracted

50°

34°

Extended

46°

32°

Remarks:

If the difference is not within the allowable limits,

The angles of α and β become opposite to

adjust the toe-in by turning the turnbuckles of the

each other when the vehicle turns right.

rod. At that time, do not tamper the cylinder.

447-202-20000

45

WY05-2971E

0 △

Y-4

Y-4

Adjustment and Functional Check

Y-4

2. Adjustment of slide plate clearances 2.1 Front axle

446-109-41000

46

WY05-2971E

2 △

46

Y-4

Y-4

Adjustment and Functional Check

Y-4

2.2 Rear axle

446-109-45000

47

WY05-2971E

6 △

47

Y-4

Y-4

Adjustment and Functional Check 3. Installation of hydraulic pump

3. Using the bolts (d), install the rubber body of the coupling Assy to the flywheel.

1. Drive the spring pins (a) (4 pcs) into the flywheel

[NOTICE]

to fix the rubber body with the flywheel.

 Apply a small amount of grease to the bolt bearing surface and tighten the bolt while pressing D to prevent the rubber body from being set as shown with the broken line in the View C.

2. Drive spring pins (b) (8 pcs.) in the cylindrical hub to the specific height. Then tighten four bolts (c) to fix the rubber body and the cylindrical hub.

 The bolts (c) and (d) (8 pcs.) (supplied with the coupling assy) are coated with screw locking compound (blue). Complete tightening each bolt quickly.

[NOTICE]  When tightening the bolt (c), drive each bolt temporarily for approx. two turns, and then fully tighten it.

4. Install the support and then the hydraulic pump.

[NOTICE]  Apply grease to the splined portion of the hydraulic pump input shaft.

444-216-70000

48

WY05-2971E

1 △

Y-4

Y-4

Adjustment and Functional Check 4. Adjustment of tension in boom telescoping wire rope [NOTICE] (Preparation before working) Before adjustment, set the boom horizontal. Loosen the clamp (heads of the base boom section and the top boom section) fixing the cables in the boom (in order to prevent excessive tensioning of cables in the boom). Set the dimension L at the end of the base boom section to 45 mm.

(The dimension shall not exceed 65mm in order to prevent excessive tensioning of the hoses in the boom.) Apply grease on the adjustment thread and check for smooth rotation. Prepare a torque wrench (which can measure in 0.1kgf·m).

1. Set the boom horizontally, and retract the

3. Make sure that the distance between the front end

telescoping cylinder fully.

of the 2nd boom section and the center of the top boom pivot pin is as shown in the below figure.

2. After tightening the adjustment nuts lightly until

If not, go back to the step 2.

the extension wire ropes and retraction wire ropes run out of slack, tighten them further as follows: • Nuts for extension wire rope (2 pcs.) : 11 turns • Nuts for retraction wire rope (2 pcs.) : 6.5 turns [NOTICE] Two wire ropes for boom extension and two wire ropes for boom retraction are employed. Tension in right and left wire ropes shall be equal. The dimension L shall not exceed 65mm during adjustment.

4. Make sure that the tightening torque of the adjustment nuts falls within the standard value. If insufficient, tighten them further to the specified torque.

Standard of tightening torque: • Adjustment nut for extension wire rope: 29.4 N･m {3.0 kgf·m} • Adjustment nut for extension wire rope: 29.4 N･m {3.0 kgf·m} 5. Proceed to “5. Adjustment of tension in hoses and cables inside boom” in the next section.

444-005-80400

49

WY05-2971E

1 △

Y-4

Y-4

Adjustment and Functional Check 5. Adjustment of tension in hoses and cables inside boom [NOTICE] Make sure to complete the “Adjustment of tension in telescoping wire rope” before this adjustment.

5.1 Adjustment of hose inside boom

4. Visually check if the hoses in the boom contact

1. Adjust the boom telescoping wire ropes so that

the sag stoppers.

the distance from the center of the top boom pivot

Sag stopper 1 Sag stopper 2 Sag stopper 3 Evaluation

pin to the front end of the 2nd boom section is as described in the previous page (270

mm).

(Refer to “Adjustment of tension in boom telescoping wire rope” in the previous page.)

2. Loosen the clamps fixing the cable in the boom.

○

○

×

Normal

○ × ○

× × ○

× × ○

Insufficient Insufficient Over tension

○: Sag stopper separates from hose ×: Sag stopper contacts hose

The clamps are on the heads of the base boom section and top boom section.

5. Adjust position of the multi-groove sheave so that the “normal” condition on the above table is met.

3. Temporarily adjust so that the dimension L of the multi-groove sheave on the head of the base

[NOTICE]

boom section becomes 65 mm.

Adjust so that a dimension L of position of multi-groove sheave is in a range from 60 to 100mm.

Then proceed to “Adjustment of tension in cable inside boom.”

50

WY05-2971E

Y-4 .

Y-4 .

Adjustment and Functional Check 5.2 Adjustment of tension in cable inside boom 1. Measure the dimension of position of the multi-groove sheave by steps 3 to 4 of the “Adjustment of tension in hose Inside boom.”

2. Fix the cable clamp on the head of the top boom section.

3. Loosen the adjustment nut for the multi-groove sheave.

4. Pull the cables at the head of the base boom section and fix them with the clamp.

5. Return the position of the multi-groove sheave to the position measured by step 1.

6. Visually check tension of the cables from end of the boom.

[NOTICE] All cables shall be in tension of “normal.”

Sag stopper 1 Sag stopper 2 Sag stopper 3 Evaluation

○

×

×

Normal

× ○ ○

× ○ ○

× × ○

Over tension

Insufficient Over tension

○: Sag stopper separates from cable ×: Sag stopper contacts cable 7. Repeat steps 3 to 6 until the “normal” condition is met.

After that, repeat full retraction and full extension of the boom 3–5 times, and re-check tension of the hoses and cables.

444-006-10300 444-005-80900

51

WY05-2971E

0 △ 2 △

Y-5

Y-5

Inspection and Maintenance Y-5

Inspection and Maintenance

4. Do not adjust the engine governor, the safety

1. Inspection and maintenance

valve for the hydraulic equipment, etc. that are properly set before shipment.

WARNING Neglecting inspection and maintenance may make it impossible to find troubles in the early stages and may lead to accidents. Be sure to carry out periodic inspection and immediately repair abnormal sections, if any.

5. Be careful not to spray water or steam onto any electrical components at the time of a washing job.

6. Do not overhaul electronic components (AMC etc.) at any time.

Proper inspection and maintenance helps ensure

7. Do not remodel or modify the aerial platform.

safety and extends the service life of the aerial

1.2 Inspection and maintenance intervals

platform. In order to fully take advantage of its performance, inspect and service the platform at

The inspection and maintenance intervals are

recommended intervals to prevent occurrence of

based on the readings of the hour meter or the

failures and to identify their existence as early as

number of elapsed calendar months. Undertake the

possible.

work at the interval whichever comes first.

In particular, it is required to pay careful attention to the following items:

♦ The inspection intervals are based on the

1. Proper operation of controls and instruments

assumption that the aerial platform will be used

2. Proper amount of hydraulic oil, fuel, cooling water,

platform is used under severe or unusual

under normal operating conditions. If the aerial

lubricating oil, etc., and any leakage.

conditions, shorten the intervals accordingly.

3. Occurrences of abnormal sounds, heat generation, etc.

4. Looseness or missing sets of bolts and nuts.

5. Breakage, deformation, and wear of structures and components.

6. Operations of each section in compliance with the specifications.

1.1 Cautions of inspections and maintenance 1. Implement the work with utmost care for safety.

2. Establish a maintenance schedule suitable for the service conditions and environment, to perform the inspection and maintenance work effectively.

3. Be sure to use specified fuel and oil/grease. Also, use genuine components when making replacements, otherwise the aerial platform may be excluded from the scope of TADANO's guarantee.

52

WY05-1082E

Y-5

Y-5

Inspection and Maintenance 2. Inspection

7. Engine cooling system

Refer to operation and maintenance manual of the

Refer to operation and maintenance manual of the

applicable model for the following items.

applicable model for the following items.

1. Pre-operational inspection

1. Maintenance table

2. Periodic inspection (monthly inspection)

2. Cooling water level check

3. Periodic inspection (annual inspection)

8. Fuel system

3. Safety parts requiring regular replacement

Refer to operation and maintenance manual of the

Refer to operation and maintenance manual of the

1. Maintenance table

applicable model for the following items.

applicable model for safety parts requiring regular

2. Fuel tank oil level check

replacement.

9. Tire

4. Greasing

Refer to operation and maintenance manual of the

Refer to operation and maintenance manual of the

applicable model for the following items.

applicable model for the following items.

1. Maintenance table

1. Maintenance table

2. Tire wear check

2. Greasing chart

3. Tire rotation

5. Gear oil

4. Bolt looseness check

Refer to operation and maintenance manual of the applicable model for the following items.

10. Hydraulic system

1. Maintenance table

Refer to operation and maintenance manual of the applicable model for the following items.

2. Swing speed reducer oil check

1. Maintenance table

3. Swing speed reducer oil replacement

2. Oil level check

4. Wheel driving unit oil check

3. Oil replacement

5. Wheel driving unit oil replacement

4. Return filter replacement

6. Engine

5. Air breather element replacement

Refer to operation and maintenance manual of the applicable model for the following items.

1. Maintenance table 2. Air cleaner check 3. Element cleaning 4. Element replacement

53

WY05-1082E

Y-5 .

Y-5 .

Inspection and Maintenance 11. Swing system

14. Oils and greases

Refer to operation and maintenance manual of the

Refer to operation and maintenance manual of the

applicable model for the following items.

applicable model for the following items.

1. Maintenance table

1. Oils and greases table

2. Swing bearing mounting bolt check

2. Recommended oils and greases

12. Electrical system

15. Consumable parts

Refer to operation and maintenance manual of the

Refer to operation and maintenance manual of the

applicable model for the following items.

applicable model for the following items.

1. Maintenance table

1. Filters

2. Battery electrolyte level check

2. Fuses

3. Replacing fuses

16. Others (compulsion release method)

13. Boom

WARNING

Refer to operation and maintenance manual of the

Because overload protector (AMC3) does not operate, work is strictly prohibited in the following condition.

This is the tentative measure until the aerial platform is put into the state of storage at emergency.

Install the fuse on the original position promptly after storage.

applicable model for the following items.

1. Maintenance table 2. Adjustment of tension in telescoping wire rope 3. Adjustment of tension in hoses and cable inside boom

If the emergency storage operation is impossible

4. Slide plate wear check

with an emergency switch, detach the fuse (AMC power source) shown in the figure below. (Operation is available.)

54

WY05-1082E

Z System Diagrams Contents Z-1 Hydraulic Circuit .............................. 1

Z-7 Location of Hydraulic Parts (Frame) ................................... 12

Z-2 Electric Circuit (Basket) .................. 2

1.

Frame .................................................... 12

2.

Control Assy ............................................ 13

Z-3 Electric Circuit (Swing Frame, Frame) ...................................... 3

Z-8 Location of Hydraulic Parts (Hydraulic Pump) ................... 14

Z-4 Location of Hydraulic Parts (Basket) .................................... 4

1.

Powertrain ............................................... 14

1.

Motor type................................................. 4

2.

Pump piping ............................................ 15

2.

Cylinder type ............................................. 5

3.

Solenoid valve ......................................... 16

4.

Suction .................................................... 17

Z-5 Location of Hydraulic Parts (Boom) ...................................... 6

Z-9 Location of Electric Parts (Basket) .................................. 18

Z-6 Location of Hydraulic Parts (Swing Frame) .......................... 7

1.

Basket wiring ........................................... 18

1.

Swivel ...................................................... 7

2.

Panel .................................................... 19

2.

Swing ...................................................... 8

3.

Foot switch .............................................. 20

3.

Derrick ...................................................... 9

4.

Touch switch ........................................... 21

4.

Telescoping/leveling ................................ 10

5.

Return ..................................................... 11

Z-10 Location of Electric Parts (Boom) .................................... 22

Z i

Z-11 Location of Electric Parts (Swing Frame) ........................ 23 1.

Swing frame wiring ................................. 23

2.

Relay box................................................ 24

Z-12 Location of Electric Parts (Frame) ................................... 25 Z-13 Location of Electric Parts (Option) .................................. 26 1.

Vertical/horizontal movement selector switch ............................. 26

2.

Horizontal operation switch and vertical operation switch .......................... 27

3.

Rotary beacon ........................................ 28

4.

Headlamp ............................................... 29

ii

Hydraulic Circuit

Z-1 .

Z-1

Z-1 .

Z-1 .

Hydraulic Circuit

1

WZ01-2490E

424-010-90000

0 △

1

Z-2.

Z-2.

Z-2.

Electric Circuit (Basket) Z-2 Electric Circuit (Basket) Note 1. This diagram indicates the state with stowed (traveling configuration) and power OFF. 2. If sectional area is not indicated, use the wiring of AVS0.85.

3. CN numbers: CNB1 to B7, BF, CN1, 2, CN51 to 53, 55 to 62, CN70, CN71, CNJ1 to J4 4. For CNB3, BF, and CNJ1 to J4, use gold plated terminals.

5. For each terminal hole of SWP connector not used, insert a waterproof plug.

6. For each SWP connector not used, insert a SWP connector for waterproof.

7. Cables in the STM are: CNB3, B4, B7, BF: 0.5 mm\U + 00B2\U + 00D730 core CNB1, B2: 0.5 mm\U + 00B2\U + 00D730 core CNB5, B6: 0.5 mm\U + 00B2\U + 00D730 core

Joystick R/L L/W Gy B

Signal transmitter (basket) 24 V specification

1 2 3 4 5 6

L/Y

(STM)

1 2 3 4 5 6

W/Y

1 2 3 4 5 6 7 8

R/L L/W G/L Y/L B/R

R/L Y/L Gy B

Gy

1 2 3 4 5 6

R/Y

1 2 3 4 5 6

L/G

Detector power supply 5 V Spare AI107 Spare 108 Spare 109 Spare 110 Detector power supply 0 V

Shield

To electric circuit diagram of swing frame

Upper power supply ground 1 Upper power supply +24 V 2 Serial communication (STM→AMC +) 3 Serial communication (STM→AMC -) 4 Serial communication (STM←AMC +) 5 Serial communication (STM←AMC -) 6 Emergency stop 7 8

1.25B 1.25R 1.25W 1.25G 1.25Y 1.25L 1.25Br 1.25V

1 2 3 4 5 6 7 8

B/G R/W Y/R B/Y W/L B/W Y

Sb

M CN2 F

Working lamp power supply ground 1 Working lamp power supply ground 2 Working lamp power supply +24 V 3 Working lamp power supply +24 V 4 5 6 7 8

M CN52 F

B/L 1 B/L 2 W 3 W 4 5 6 7 8

1.25B 1.25R 1.25W 1.25G 1.25Y 1.25L 1.25Br 1.25V

1 2 3 4 5 6

Control power supply (MBPOW) Ｐower supply (24V IN) Ｐower supply (24V IN) GND (ground) GND (ground) GND (ground) Serial communication (STM ← AMC +) Serial communication (STM → AMC -) Serial communication (STM ← AMC +) Serial communication (STM → AMC -) Do101 Spare Spare 102 1.6 A Spare 103 Alarm buzzer 104

5V output

24 V output

BOOT TXD GND GND TXD

DI101 102 103 104 105 106 107 108 DI110 111 112 113 114 GND GND

Neutral switch telescoping Neutral switch swing Neutral switch elevating Neutral switch traveling Horn switch Headlamp switch Turn signal switch (right) Turn signal switch (left) Engine start signal Engine stop signal Accelerator high-speed Emergency pump signal Accelerator low

24 V output

24 V input

Shield

F CN1 M

1 2 3 4 5 6 7 8

24 V output

24 V input

F CN51 M

F CN61 M

Shield

Shield 1.25B 1.25R 1.25W 1.25G 1.25Y 1.25L 1.25Br 1.25V

M CN2 F

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

M CN62 F

Up

Down

Connector terminal No. (View from connected side)

Elevating operation Neutral switch elevating

M

1 2 4 5

R W B B R L

Back

For.

Traveling operation

1.25R 1.25W 1.25R 2 1.25W 3 1

1.25B 1.25B

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

L/Y W/Y R/Y L/G G/O P/B W/R Lg/B Br/R W/G G G/R Br/G B B

Br/G

1

G/Y L V V W/B Br V V

1.25W 1.25R 1.25Y 1.25G 1.25R 1.25W 1.25G 1.25Y

Start Engine switch Stop Accelerator high (D) Emergency pump (M)

DI116 DI123 124 125 126 127 128 GND

F CNB4 M Spare Swing (right) Swing (left) Steering (right) Steering (left) Toggle switch operation check signal

Emergency stop signal

1 2 3 4 5 6 7 8

Option (Individual type emergency pump, Accelerator switch)

CN70 M 2 3 1

1.25B 1.25L 1.25B 1.25L

L/O Y B

G/Y L W/B Br V L/O B

G G/R

R W B

Accelerator high Emergency pump

Option (Manual accelerator) CN70 M Accelerator R 2 high/low G/R W 3

Right Swing switch Left Right Steering switch Left

1

W B

Emergency pump

1

R R

Lg/R

24VOUT Do111 112 113 114 115 116 117 118 DI129 130

Engine warning lamp Low fuel level warning lamp Platform inclination indicator lamp Spare Spare Spare Spare Spare Verical/horizontal operation check signal

Spare

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

L/B Lg/Y Br/B

Emergency stop switch CN71 M

W R

High/low speed select switch

B

Horn switch

L/B

B

R

R/W

Engine warning lamp (red)

Lg/Y

B

R

R/W

Low fuel level warning lamp (red)

Br/B

B

R

R/W

Platform inclination indicator lamp (red)

Option (Foot switch x 2) Foot switch 1 CN55 M

DI109 115 DI117 118 119 120 121 122 Do105 106 107 108 109 110

Upper foot switch Touch switch Vertical up Vertical down Horizontal forward Horizontal backward Vertical/horizontal operation High/low speed select signal 100% indicator lamp Emergency stop indicator lamp Engine running indicator lamp

Vertical/horizontal select indicator lamp

Traveling enable indicator lamp Spare V_POW V_POW

M CNB2 F 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

G/W

B

G

W

G/B

B

R

R/W

Traveling enable indicator lamp (green)

W

L/R

B

R

R/W

Emergency stop indicator lamp (red)

Y/G

B

G

W

Engine running indicator lamp (green)

Lg B

F

M 1 G/O 2 W 3

(Power)

R

1 R 2 B

Alarm buzzer

F CN55 M Lg B

1 2 3

Foot switch

F CN56 M O

B

1 B 2 R 3 W

Touch switch CN57 M

F CN57 M

Y/B R/B Y/W P Lg/L W Br/Y Y/O

1 2 3 4 5 6 W 7 Br/Y 8 Y/O

1 2 3 4 5 6 7 8

Option (Vertical/horizontal proportional type)

B

W R

W

Vertical/horizontal movement selector switch

CN57 M

Y/B 1 R/B 2 Y/W 3 P 4 V 5 W 6 V 7 Y/O 8

Vertical/horizontal indicator lamp (red)

V V

R W G Y

V V

W R Y G

P/B B

1 2

1 2

1 2 3

1 2 3

1 2

B R W

Right Turn signal switch Left

1 2

W B

L

Up Vertical Down operation switch For. Horizontal Back. operation switch

forward: Retraction up side (Holizontal Holizontal backward: Extension down side)

R

W

Vertical/horizontal indicator lamp (red)

W

Tremolo buzzer

Option (interference prevention sensor on basket) F CN75 M W G

Working lamp

B

BZ

Headlamp switch

Option

F CN60 M W B/L

Y/O

Option

F CN59 M B W/R Lg/B

W B

L

W

Option

F CN58 M

B

B

Y/O

Boom

R/W

2 1 4 6 3

F CN53 M

R R

Foot switch 2

B

Selector switch

Lg/L

Lg O Y/B R/B Y/W P Br/Y Lg/R G/B L/R Y/G Y/O G/W

R

Moment indicator lamp (red)

B

M CN52 F

F 3 B/W 2 1 W

CN55

R/W Sb

3 6

Yazaki SWP waterproof connector

Neutral switch traveling

F CN71 M

F CNB5 M

1.6 A

1 2 3 4 5 6 7 8

Br/R W/G G G/R B

Shield 1 2 3 4 5 6 7 8

R W B B R L

Mounted to AW-250, 370 only

24 V input

1.25B 1.25R 1.25W 1.25G 1.25Y 1.25L 1.25Br 1.25V

Swing operation Neutral switch swing

G/O

100 mA

1 2 3 4 5 6 7 8

L

F CNJ4 M

1 2 3 4 5 6

F CNB6 M

Boom

AW-370TG

R

F CN70 M

M CNBF F Shield

M CNB7 F

F CNB1 M

F CN51 M

R W B B R L

F CNJ3 M R/L B/R Gy B

F CN1 M

Neutral switch telescoping

G/O B B/W P Br/W

Detector power supply 5 V Telescoping AI101 Swing 102 Elevating 103 Traveling 104 Spare 105 Spare 106 Detector power supply 0 V

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Telescoping operation

F CNJ2 M

M CNB3 F

R/W R/W R/W B/G B/G B/G Y/R B/Y W/L B/W

Ext. Ret.

F CNJ1 M R/L G/L Gy B

AW-215, 250TG

R W B B R L

CN56a M

1 W 2 3 B

Cancel switch

1 B 2 R 3 W

F CN56b M W R

1 B 2 R 3 W

Touch switch

Touch switch F CN76 M R L G B

1 2 3 4

R B L W

2

1

3

4

Touch switch F CN77 M L B G B

1 2 3 4

R B L W

2

1

3

4

IWZ03-490001Ea

2

WZ03-4901E

444-107-00000 0

2

Z-3.

Z-3.

Z-3.

Electric Circuit (Swing frame , Frame)

1

PS CN M JP

Hour meter IG

1.25R 1.25W/B 1.25W/B 1.25W/B 1.25W/B 1.25W/B 1.25W/B 1.25W/B 1.25W/B

E Y

AC

BR C

F CN23 M

5W

Fuse

B

BR

AC

R1

R2

C

Preheating OFF ON Start

1.25B 1.25R 1.25W 1.25G 1.25Y 1.25L 1.25Br 1.25V 1.25B 1.25B 1.25W/Y 1.25W/Y 2B 2B

B

8B

Fuse

8W

65A

Emergency pump relay

R B

30B

Y/R 0.5R/W Y/R Y/O

B

F CN24 M

3W/B 1.25R

Swash plate angle selector SOL

Preheater

Y B

CND2

CNE2

CNE1

5Y

Horn

1 2

F CN28 M

Engine unit

Safety relay

(At engine running: 24 V)

S E L R P

Injection pump

R Horn

S B H Y/R

1

W R B

G W R B W/L

B/W

(At engine stop: earth)

Glow relay W R

Oil pressure SW

G

2 1

R

5R

G/O

1

(At emergency: earth)

2 1

Water temperature SW

B Y

5Y 5W

2 1

W/L P L/O

+

R/W

B SW

Starter

Down

-

L

M

Up

L

B/W

Br

0.5G/W P/B G/R 0.5Y/B

P/B 0.5G/W G/R 0.5Y/B B

1 2 3 FM

R B

Swing: traveling buzzer Fuel sensor

CN27

1.25Y/W 1.25R/W 1.25R/B 0.5G/L P/B

Starter switch

R2 B

1.25R/W 1.25R/L 1.25Y/R 1.25R/B 1.25R/G 1.25P/B 1.25Lg/R 1.25Br/R 1.25R/Y

CN29

R1

1.25B 1.25R 1.25W 1.25G 1.25Y 1.25L 1.25Br 1.25V

1.25R/L

P G/R B

U

Fuel gauge

1.25B 1.25Br/R 0.5R/Y 0.5G/Y 0.5Y/L 0.5L/Y Gy

Y

12 1.25W/R Spare 10 A 11 1.25L/R Spare 10 A 10 1.25R/W Engine startup 10 A 9 Valve power supply 10 A 1.25R/L 8 1.25Y/R Headlamp, horn 15 A 7 1.25R/B Engine related 10 A 6 AMC power supply 10 A 1.25R/G 5 1.25P/B Relay circuit 10 A 4 1.25Lg/R Emergency power supply 10 A 3 1.25Br/R Upper power supply 10 A 2 1.25R/Y Working lamp 1 10 A

Accelerator motor with potentiometer

R 24V W Br B Y G

(1A)

G/R

12 1.25W 11 1.25L 10 1.25R 9 1.25G 8 1.25Y 7 1.25Sb 6 1.25Gy 5 1.25P 4 1.25Lg 3 1.25Br 2 1.25O 1

R B

Series/parallel selector SOL

30B

370TG only (selection for AW-250)

L/W

R/G L/W

1 2

Headlamp Headlamp

0.5B/R

B

L/B B 1 R/L R 2

(At energized: Traveling motor series {high speed})

Y/G

0.5B/R Y/R

Y

B

R B

1.25B

40B

R

1 2

Turn signal lamp right Rotary beacon

Swivel joint

Y/L

L/R L/R

3 2 P 1 B

P

B

L/R L/R

W R B

R

Steering Left

2 1 4 6 3 R

Power saving relay 1

3 1 4 2 R

Power saving relay 2

3 1 4 2 R

2 1 4 6 3 R

Power saving Engine speed realy3 detection relay

3 1 4 2 R

Emergency stop relay

3 1 4 2

3 1 4 2

3 1 4 2

3 1 4 2

R

R

R

R

Upper emergency stop relay

Engine stop relay

Engine start relay

Emergency pump relay

3 1 4 2 R

Emergency switch limit relay

3 1 4 2 R

Accelerator up relay

3 1 4 2 R

Accelerator down relay

3 1 4 2 R

Right swing relay

3 1 4 2 R

Left swing relay

Axle extension detection switch (Rear right)

B/Y

L/R Y/O

CN105 MF

P

B

1.25R

Lg/B 1 B/R 2

R

L/W

CNR4 FM

L/Y

L/W

M

1.25G/W 1.25L/R

B

F CN16 M

B Steering R Right

1 2

Emergency pump

1 2

P

0.5R/W

(Five items above are optional.)

CNR14 FM

Br

R

1 2 3 4 5 6

3 2 V 1 P

B

Br/R

B/L

1 2 3 4

P

Jack steering on-load valve

F CN15 M

Headlamp Headlamp relay relay

1.25R 1.25B 1.25L 1.25W

R

Br/R

R

W R B

Preheating indicator lamp

V

R

Axle extension detection switch (Rear left)

Engine coolant temperature warning lamp

P

B

1.25G

1.25O 1.25W/R 1.25W/B

Engine oil pressure waning lamp

R

R

R

Turn signal Turn signal Rotary beacon left right relay

1 2 3

Battery charge warning lamp

Lg/Y

R

F CN17 M

B/R 3 Br 2 Br 1

Inclination warning lamp

B

M CN72 F

relay

P Lg/L 0.5R/G Br/G 0.5B/G 0.5W/L

CN106 MF

Axle stowage indicator lamp

P

1.25R/Y 1.25W/Y O P/B

AW-250, 370TG only

R

Y/L Br/W Br/R Br/Y

CN30

Emergency stop indicator lamp

1 2 3 4

2 4 1 3

1 2 3 4

W

M CN21 F R/L 0.5R/G 1 W/L 0.5W/L 2 B/G 0.5B/G 3 4 Y/B 0.5Y/B 5 L/W L/W 6 B/L B/L 7 G/O G/O 8 W/G W/G 9 G/W G/Y 10 B/R B/R Lg/B 11 Lg/B 12 R/G R/G 13 Lg/W 14 Lg/W 15 16

2 4 1 3

CN104 MF

W/B 1 R 2 B 3 Y 4 5 L 6

B W

1 2

Relay box

P B

M CN70

Manual L Accelerator H

2 4 1 3

0.5G/W P/B G/R 0.5Y/B

W R B

W/B 1 W 2 B 3 Y 4 5 L 6

Y/L B/Y L/Y Br V Lg/Y

Front jack operation detection switch

M CN70

W

Accelerator high

W

F CN22 M

Turn signal lamp left

Alternator

Emergency pump

Emergency pump

0.5R/W

E L R

Option (Individual type emergency pump, Option (Manual accelerator switch) Accelerator switch)

Battery charge warning lamp Inclination warning lamp Axle stowage indicator lamp Emergency stop indicator lamp

Main pump on-load valve

60B

R/G

100 mA type

Br/Y

60B

Br/B L/O B O

2 4 1 3

CNR11 FM

1 2 3 4 5 6

2 4 1 3

Frasher

3 2 Y 1 V

W R B Y G L

Accelerator high (D)

2 4 1 3

W R B

Emergency pump (M)

Engine coolant temperature warning lamp Engine oil pressure warning lamp

Br/Y

60B

M CN70 F

1.6 A type

Axle extension detection switch (Front right)

W

R Lg Br/W O

CNR1 FM

B

DO 25 26 27 28 DO 33 34 35 36 37 38 39 40

CN103 MF

Lower control switch

W/G G/W

1 2 3 4

Emergency stop switch

1 2 3 4

L

B/G

3 2 G 1 Y

Y G

Right

R

(At energized: Traveling motor high speed)

Axle extension detection switch (Front left)

W R

Left

R/L Br/B

CN50

G G 1 W W 2 G/B G/B 3 Y/W Y/W 4 P P 5 Lg Lg 6 Br Br 7 L L 8 Lg/W Lg/W 9 O O 10 R/G R/G 11 L/O L/O 12 Br/B Br/B 13 B B 14

Emergency steering switch

B R W

1 2 3

F CN11 M

CNR2 MF

Control switch Down B Boom elevating Up

M CN20 F

F CN13 M

F CN14 M

1.25Y 1.25Br 1.25G 1.25Gy

L

Y G

Valve output (Spare) Valve output (Spare) Before/after traveling (-) Valve output (Spare) Valve output (Spare) Spare(-) Valve output (Spare) Valve output (Spare) Spare(-) Valve output (Spare) Valve output (Spare) Spare(-) Valve output (Spare) Valve output (Spare) Spare(-) Valve output (Spare) Valve output (Spare) Spare(-) Emergency pump ON signal Engine start signal Engine stop signal Power-saving relay signal Spare Spare

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

Emergency control switch

W R B Y G L

1 2 3 4 5 6

R/L W/B

CNR12 MF

W R

Spare Spare Spare Spare

AO 11 12 13 14

(Left)

F CN12 M

Br/B

Axle operation detection switch

B

(+) Detector (-) power supply Shield Carrier inclination angle (for/back) AI 21 Carrier inclination angle (right/left) 22 Traveling detection (forward) 23 Traveling detection (backward) 24 Spare 25 (+) Anemometer (-) Accelerator high speed signal DI 33 Emergency pump signal 34 Axle extension detection signal 35 Axle operation signal 36 24 V Engine operating signal 37 discharge Engine hydraulic pressure switch 38 Water temperature switch 39 Fuel sensor 40 High/low speed select signal 41 Toggle switch operation check signal 42 Lower emergency stop switch 43 Lower control switch 44 24 V Engine preheating signal 45 suction Engine start signal 46 Emergency switch 47 Emergency switch check signal 48

(Right)

Platform swing

L SOL R

G/B R/L

CNR3 FM

Control switch Right Boom swing Left

L/O Br/B Lg/B B/R L/W G/O B/L Y/B V Br L O

L SOL R

B Y/B

CNR13 FM

Y G

(Backward)

Y/B

B/R 3 Br 2 Br 1

L

(Forward)

Traveling

R 1 B 2

B L/B G/B

CN101 MF

W R

R 1 B 2

F CNV8 M

1.25Lg/R

W R B

Ext. B Control switch Boom telescoping Ret.

(Up)

F CNV7 M

1.25Lg/R W/G

Y/R 0.5R/W Y/R L/R

Lower control panel

(Down)

Elevating

R 1 B 2

G/Y

CN49

Y/G L/G W/B G/R

(Left)

R 1 B 2

1 2 3 4 5 6

Y/R L/W Y/R B/G

G/R B/Y R/B

0.5B/W 0.5L/R 0.5G/R 0.5W/R 0.5W/Y 0.5L/B 0.5Sb 0.5P 0.5Br/B 0.5Lg/R 0.5Lg/W 0.5Br/Y 0.5Lg 0.5Br 0.5L L/G G/B L/B W/B 0.5Gy 0.5L/O

B/R 3 Br 2 Br 1

W 1 B 2 R 3

Output +

F CNAF M

0.5G/R 0.5Y/R 0.5B/W 0.5B/W 0.5L/R

CN107 MF

Traveling detection (Backward)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

0.5B/R 0.5G/W 0.5Y/W 0.5Y/R

CN48

M CN57 F

(Right)

Swing

R 1 B 2

F CNA4 M

F CNA3 M

R/B B/Y

R 1 B 2

F CNV9 M B 1 Sb 2 F CNV10 M B 1 L 2

Y/R 0.5W/B W/Y Br/R

W/B B/Y R/B

(Retraction)

R/L 1.25Lg/R B G/Y

W 1 B 2 R 3

Output +

0.5Br 0.5L

CN47

M CN56 F Traveling detection (Forward)

1.6 A type

0.5Sb 0.5Br/B

0.5Lg 0.5L

CN44

W

(Extension)

Telescoping

R 1 B 2

F CNV3 M

0.5R/W 0.5W/B 0.5R/B 0.5G/B 0.5Y/G

L R/L 0.5L/O R/L

B

0.5W/Y 0.5L/B

M

0.5Lg/W 0.5Br/Y

CN43

L

Y G

R 1 B 2

F CNV2 M

F CNV6 M

Sb R/L 0.5Gy R/L

W R

G W G/B Y/W P Lg Y/O L/B Sb Lg/Y Br/G G/L

F

CN2

0.5Lg/R 0.5Br/Y

CN42

B

B/G

1 2 3 4 5 6 7 8

0.5Y/L 0.5L/Y 0.5R/Y 0.5G/Y

Br/G P 0.5Y/G P

High/low speed selector switch

L

Y G

M CN19 F

CN1

F CNV1 M

0.5W/R 0.5L/B

F

F CNV5 M

CN41

Left

B

W R

M

0.5P 0.5Br/B

Lg/L P 0.5G/B P

Right

Y G

F

CN52

F CNV4 M

CN40

Left

L

R/L W/L

1.25R/L 1.25R/L 1.25R/L B B B

Y/B G/Y 0.5Y/W P/B

Right

W R

M

1 2 3 4 5 6 7 8

CN38

Back.

L B

R/G B

P/B Y/G R P/B

For.

Y G

CN37

Up

P/B 1.25R/W Lg P/B

W R

CN36

Down B

100 mA type

1.25Y/W 1.25G Br/W P/B

Y G

Y/L Br/W Br/R Br/Y Lg/R Lg/L

CN35

L

Left

G 1 W 2 G/B 3 Y/W 4 P 5 Lg 6 Y/O 7 L/B 8 Sb 9 Lg/Y 10 Br/G 11 G/L 12 Br 13 V 14 R/G 15 16

1 3 2 22 4 5 23 24 25 6 14 15 16 17 Serial communication (AMC3 → Operation box +) 18 Serial communication (AMC3 → Operation box -) 19 Serial communication (AMC3 ← Operation box +) 20 Serial communication (AMC3 ← Operation box -) 21 Spare AO 1 26 Spare 2 8 Spare 3 27 Spare 4 9 7 Headlamp ON DO 9 28 Turn signal right ON 10 10 Turn signal left ON 11 29 Accelerator motor up 12 11 Accelerator motor down 13 30 Spare 14 12 Spare 15 31 Hydraulic oil warning lamp 13 16 100% indicator 17 32 Horn signal 18 33 Swing/travel alarm buzzer 19 34 Emergency switch limit signal 35 20 TXD 36 37 For flash GND (earth) 38 terminal RXD 39 BOOT 60 Valve output (extension) 40 Valve output (retraction) 41 Boom telescoping (-) 42 Valve output (right) 43 Valve output (left) 44 Boom swing (-) 45 Valve output (down) 46 Valve output (up) 47 Boom elevating (-) 48 Valve output (before traveling) 49 Valve output (after traveling) 50 Before/after traveling (-) 51 Main unload valve DO 1 52 Steering right 2 53 Steering left 3 54 high/low selector SOL 4 55 Swing right 5 56 Swing left 6 57 Spare 7 58 Swash plate angle selector SOL 8 59

G/W Lg/W L/G Gy

W R

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Circuit power supply (24VIN) Circuit power supply (0VIN) Ｐower supply (24VIN) Ｐower supply (24VIN) Ｐower supply (24VIN) Ｐower supply (0VIN) Ｐower supply ( 0VIN) Ｐower supply ( 0VIN) Serial communication (AMC3→Spare +) Serial communication (AMC3→Spare -) Serial communication (AMC3←Spare +) Serial communication (AMC3←Spare -)

CN34

B

Right

G W G/B Y/W P Lg Y/O L/B Sb Lg/Y Br/G G/L Br V R/G

Y/B G/W L/G G/W

Swing control switch

L

Y G

CN33

Steering control switch

W R

Lg/L B

B 0.5G/L L/W L/O P/B

Traveling control switch

B

Gy (Shield) W W L/R P/B

Y/G L/G B/Y R/B

CN32

Elevating control switch

Ret.

R B/W

(+) Detector power supply Moment ( -) Shield Moment signal + Elevating Moment signal Moment signal + Leveling Moment signal (+) Detector power supply (-) Shield Boom length signal AI 1 Elevating angle signal 2 Platform turn angle 1 3 Platform turn angle 2 4 Spare DI 1 Spare 2 Spare 3 Spare 4 5V Spare 5 discharge Spare 6 Spare 7 Spare 8 Engine stop signal 9 Horn switch 10 Accelerator low speed signal 11 Spare 12 24 V Spare 13 discharge Spare 14 Swing dead angle detection 15 Hydraulic oil temperature switch 16 Detector power supply (+) Accelerator AI 5 Spare 6 Spare 7 Spare 8 Detector power supply (-) Operation signal Boom extension DI 17 Operation signal Boom retraction 18 Operation signal Swing right 19 Operation signal Swing left 20 Operation signal Boom down 21 Operation signal Boom up 22 24 V Operation signal Traveling backward 23 suction Operation signal Traveling forward 24 Operation signal Steering right 25 Operation signal Steering left 26 Operation signal Swing right 27 Operation signal Swing left 28

1.25R/B 1.25P O P/B

Swing control switch

Ext.

1 5 6 22 3 23 4 2 24 25 26 29 30 7 10 11 8 27 9 28 20 38 19 37 18 36 17 35 16 34 15 33 14 32 13 31 12 21 39 40 41 42 43 44 45 46 49 50 47 48 51 52 53 54 55 56 57 58 59 60

CN31

Telescoping control switch

R B/W P/B R L/R B/W Lg/R B

CN102 MF

Jig for adjustment

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

W R B

1 2

1 2 3 4 5 6 7 8

Y/R 0.5R/B W/Y Br/Y

Swing dead angle detection switch

R/Y Br P R/B Lg/B Br/B Lg Sb

1 2 3

R G

CN51

F

W/Y

Pot 1

R B B W G W G

M CNR5 F

F CNA2 M

CN46

M CN18 F

M

1 2 3 4 5 6 7 8

B Y/R

R W B Gy (Shield)

Pot 2 Platform swing angle detector

M CN55 F

Hydraulic oil thermostat switch Open at 80°C

JP: Jack {m}, Pin contact {M}

C Connector for detector

Relay

CN45

R 1 W 2 B 3 L 4

W 4 L 3 B 2 R 1

PS: Plug {f}, Socket contact {F}

B

W R B

Carrier inclination angle detector (R/L)

L B R

A

D

Rear jack operation detection switch

W B R

1 3

R/L

W R B Gy (Shield)

M CN A F Carrier inclination angle detector (F/R)

2 4

Note 1. This diagram indicates the state with power OFF. 2. For the sectional area wiring without any instruction, use the wiring of AVS0.85.

3. CN numbers: CN1, 2, 11 to 24, 27 to 38, 40 to 52, 55 to 57, 70 to 72, 101 to 107, CNA1 to A4, AF, CNM, ML, A, L, R1 to R5, R11 to R14, V1 to V10, E1, E2 ,D2 4. For ,CN17, CN21, CN55, CNA, CNAF, and CNR5, use a gold plated terminal.

5. For each terminal hole of SWP connector not used, insert a waterproof plug.

6. For each SWP connector not used, insert a SWP connector for waterproof.

Boom

AMC3

F CNA1 M

Current amplifier output

A W B R C G D Shield E

Boom angle detector

3 6

Shield

PS CN L JP Boom length detector

E

F

2 5

Yazaki CN(A) Yazaki SWP connector (2-pole) waterproof connector

R B W G

Current amplifier output

R A B B W C G D Shield E

1 4

2 F

Shield

Name of metal connector

Working lamp power supply earth Working lamp power supply earth Working lamp power supply +24 V Working lamp power supply +24 V

(JP) M

1.25Y/R

Elevating cylinder Moment detector

R B W G

Emergency stop

Connector terminal No. (View from connected side)

PS CN ML JP R A B B W C G D Shield E

Upper power supply ground Upper power supply +24 V

AW-250, 370TG only Leveling cylinder Moment detector

Serial communication (STM→AMC+) Serial communication (STM→AMC-) Serial communication (STM←AMC+) Serial communication (STM←AMC-)

Z-3 Electric Circuit (Swing Frame, Frame)

3 1 4 2 R

Emergency switch linked relay

IWZ03-490002Ea

3

WZ03-4901E

444-107-10000 0

3

Z-4 Z-4

Location of Hydraulic Parts (Basket)

Z-4

Location of Hydraulic Parts (Basket)

1. Motor type

443-407-10000

4

WZ07-2801E

2 △

Z-4 .

Location of Hydraulic Parts (Basket)

Z-4 .

2. Cylinder type

443-404-40000

5

WZ07-2801E

8 △

Z-5 .

Z-5

Location of Hydraulic Parts (Boom)

Z-5 .

Z-5 .

Location of Hydraulic Parts (Boom)

6

WZ07-2801E

443-412-30000

1 △

6

Z-6

Location of Hydraulic Parts (Swing Frame)

Z-6

Z-6

Z-6 Location of Hydraulic Parts (Swing Frame) 1. Swivel

7

WZ07-2801E

443-413-23000

1 △

7

Z-6

Location of Hydraulic Parts (Swing Frame)

Z-6

Z-6

2. Swing

8

WZ07-2801E

443-413-31000

1 △

8

Z-6

Location of Hydraulic Parts (Swing Frame)

Z-6

Z-6

3. Derrick

9

WZ07-2801E

443-413-25000

1 △

9

Z-6

Location of Hydraulic Parts (Swing Frame)

Z-6

Z-6

4. Telescoping/leveling

10

WZ07-2801E

443-413-32000

2 △

10

Z-6 .

Location of Hydraulic Parts (Swing Table)

Z-6 .

Z-6 .

5. Return

11

WZ07-2801E

443-413-27000

2 △

11

Z-7

Location of Hydraulic Parts (Frame)

Z-7

Z-7

Z-7 Location of Hydraulic Parts (Frame) 1. Frame

12

WZ07-2801E

446-404-00000

5 △

12

Z-7 .

Location of Hydraulic Parts (Frame)

Z-7 .

Z-7 .

2. Control Assy

13

WZ07-2801E

447-001-10000

2 △

13

Z-8

Location of Hydraulic Parts (Hydraulic Pump)

Z-8

Z-8

Z-8 Location of Hydraulic Parts (Hydraulic Pump) 1. Power train

14

WZ07-2801E

444-216-70000

1 △

14

Z-8

Location of Hydraulic Parts (Hydraulic Pump)

Z-8

Z-8

2. Pump piping

15

WZ07-2801E

443-413-22000

1 △

15

Z-8

Location of Hydraulic Parts (Hydraulic Pump)

Z-8

Z-8

3. Solenoid valve

16

WZ07-2801E

443-413-22400

1 △

16

Z-8 .

Location of Hydraulic Parts (Hydraulic Pump)

Z-8 .

Z-8 .

4. Suction

17

WZ07-2801E

443-413-21000

1 △

17

Z-9

Location of Electric Parts (Basket)

Z-9

Z-9

Z-9 Location of Electric Parts (Basket) 1. Basket wiring

18

WZ02-4901E

443-508-90000

1 △

18

Z-9

Location of Electric Parts (Basket)

Z-9

Z-9

2. Panel

19

WZ02-4901E

443-508-91000

2 △

19

Z-9

Location of Electric Parts (Basket)

Z-9

3. Foot switch

444-309-30000

20

WZ02-4901E

3 △

Z-9 .

Location of Electric Parts (Basket)

Z-9 .

4. Touch switch

444-308-80000

21

WZ02-4901E

3 △

Z-1 0 .

Z-10

Location of Electric Parts (Boom)

Z-1 0 .

Z-1 0 .

Location of Electric Parts (Boom)

22

WZ02-4901E

443-508-50000

2 △

22

Z-1 1

Location of Electric Parts (Swing Frame)

Z-1 1

Z-1 1

Z-11 Location of Electric Parts (Swing Frame) 1. Swing frame wiring

23

WZ02-4901E

444-315-30000

5 △

23

Z-1 1 .

Location of Electric Parts (Swing Frame)

Z-1 1 .

Z-1 1 .

2. Relay box

24

WZ02-4901E

444-315-31001

1 △

24

Z-1 2 .

Location of Electric Parts (Frame)

Z-1 2 .

Applicable serial No.

Z-1 2 .

5 ：HE0205 -△

Z-12 Location of Electric Parts (Frame)

25

WZ02-4901E

448-002-10000

5 △

25

Z-1 3

Location of Electric Parts (Option)

Z-1 3

Z-1 3

Z-13 Location of Electric Parts (Option) 1. Vertical/horizontal movement selector switch

26

WZ02-5331E

444-728-90000

0 △

26

Z-1 3

Location of Electric Parts (Option)

Z-1 3

Z-1 3

2. Horizontal operation switch and vertical operation switch

27

WZ02-5331E

444-729-00000

0 △

27

Z-1 3

Location of Electric Parts (Option)

Z-1 3

Z-1 3

3. Rotary beacon

28

WZ02-5331E

444-727-70000

1 △

444-727-90000

1 △

28

Z-1 3 .

Location of Electric Parts (Option)

Z-1 3 .

Z-1 3 .

4. Headlamp

29

WZ02-5331E

444-729-80000

0 △

444-729-10000

0 △

29

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