Tadano Faun All Terrain Crane AR-1000M-1 Circuit Diagram Manual SN GA5002 - PDF DOWNLOAD

Publication No.

AR-1000M-1/C2-1E

01 All Terrain Crane Model

AR-1000M-1 Applicable Serial No.

GA5002 -

Foreword

Foreword This manual contains all the hydraulic and electric circuit diagrams for the Model AR-1000M-1 all terrain crane.

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

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

1. Applicable spec. NO.

SPEC.

NO.

SERIAL.

NO.

MFG.DATE. KAGAWA, JAPAN

ISA04-001601

Spec. No.

Applicable serial No.

AR-1000M-1-90101

GA5002 -

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

W04-0000E

Foreword

2. Contents Chapter

Spec. No.

Section

AR-1000M-1-90101

Data, Adjustment and Checks

Y

Specifications

Y-1

Weight Table

Y-2

Adjustment (Pressure)

Y-3

Adjustment (Electric)

Y-4

Adjustment and Checks

Y-5

System Diagrams Hydraulic Circuit

Z

Electric Circuit

Upper

Z-1

Upper

Z-3

Crane electrical equipment

Z-4

Electric circuit for mounting/ dismounting revolving superstructure, counterweight

Z-5

Engine electric circuit

Z-6

Lower

Z-7

Air conditioner

Z-8

Upper wiring 1 (cab)

Z-9

Upper wiring 2 (swing table)

Z-10

Engine wiring

Z-11

WA04-0000E

Data, Adjustment and Checks Contents Y-1. Specifications. .............................. 1

6. Switch S13 (jib full retraction detection)..... 8 7. Switch S33 (jib tilt cylinder cock state detection)... 8 8. Switch S32 (swing lock pin detection)........ 8 9. Boom stowing detection switch.................. 8 10. Switch S23 (S24) (counterweight mounting/ dismounting cylinder extending side stroke end detection) Switch S25 (S26) (counterweight mounting/dismounting cylinder retracting side stroke end detection (standard weight)) Switch S37 (S38) (counterweight mounting/ dismounting cylinder retracting side stroke end (extra weight)) Switch S27 (S28) (counterweight lock detection) Switch S29 (S30) (counterweight lock cancel detection) Switch S31 (extra weight I mounting detection) Switch S36 (extra weight II mounting detection)........................................... 9 11. Winch drum rotation detection switch (SD1, SD2)........................................ 9

Engine..........................................................1 1. Engine speed. ............................................ 1

Hydraulic unit. ..............................................1 1. Hydraulic pump. ......................................... 1 2. Hydraulic motor (for winch). ....................... 1 3. Swing drive unit.......................................... 1 4. Accumulator................................................ 1

Speed reducer..............................................1 1. Winch speed reducer. ................................ 1

Y-2. Weight table. ................................. 2 Y-3. Adjustment (pressure). ................ 3 Hydraulic circuit............................................3 Pressure setting table..................................... 3 Pressure adjustment . .................................... 4

Y-4. Adjustment (electric).................... 7 1. Switch S11 (4th/top boom section full retraction detection), Switch S15 (2nd/3rd boom section full retraction detection)............................ 7 2. Switch S18 (cab tilt detection).................... 7 3. Switch S19 (lever stand tilt detection)........ 7

Potentiometer adjustment..........................10 1. Jib tilt angle detector. ............................... 10 2. Swing angle detector................................ 10 3. Wire layer number detector...................... 10

Switch adjustment........................................7

Y

4. Switch S20 (main winch dead wrap detection), Switch S21 (auxiliary winch dead wrap detection).... 7 5. Switch S12 (jib tilting operation detection).... 8

Y-5. Adjustment and checks. ............ 11 Hydraulic pressure generating system....... 11 1. Air bleeding procedure of pump. .............. 11 2. Procedure of checking N2 gas filling pressure in accumulator.................. 12

Swing system.............................................12 1. Swing pilot circuit bleeding procedure...... 12 2. Swing brake circuit bleeding procedure. .. 12

Winch system.............................................12 1. Winch brake circuit air bleeding procedure..... 12 2. Adjustment of disorderly winding prevention roller. ............................................... 13

Telescoping system....................................13 1. Power-tilt jib circuit bleeding procedure.... 13 2. Power-extension jib circuit bleeding procedure........................................ 13

Crane operation. ........................................14 1. Operation pilot circuit air bleeding procedure........................................ 14 2. Engine speed adjustment......................... 15

ii

Y- 1 .

Y- 1 .

Specifications Engine

Speed reducer

1. Engine speed

1. Winch speed reducer

Idling speed (IDL.) Middle speed (MID.) Max. speed (MAX.)

Reduction gear ratio : 1 / 31.9545 (main and auxiliary winches) (when low noise stopper is installed)

Speed at mounting/dismounting (MAX.)

Hydraulic unit 1. Hydraulic pump 1) Pump speed (reduction gear ratio: 1.00) Idling speed (IDL.) Middle speed (MID.) Max. sped (MAX.) Speed at mounting/dismounting (MAX.)

2) Discharge rate

2. Hydraulic motor (for winch) 1) For main winch Oil intake rate: 180 cc / rev 2) For auxiliary winch Oil intake rate: 180 cc / rev

3. Swing drive unit Hydraulic motor oil intake rate : 99 cc / rev Reduction gear ratio at speed reducer : 1 / 34.704

4. Accumulator N2 gas filling pressure : 25 ± 3 kg / cm 2 (20°C)

Y01-1010E

Y- 2 .

Y- 2 .

Weight table In the weight table below, the weights of major components are given in terms of weight codes A through T by crane spec. Nos. When dismounting and remounting these components, find their approximate weight given in the table under the applicable Spec. No. and select proper slinging tools on the basis of the given weight.

Code

Weight

Code

Weight

Code

Weight

[Spec. number]

Spec. number

Part name Swing table Assy (carried by trailer) Swing bearing Boom elevating cylinder Winch Jib Boom A’ssy (including telescoping cylinder) Engine (for crane) Standard weight Counterweight

Extra weight I Extra weight II

Front lifter for mounting/dismounting crane unit Rear lifter for mounting/dismounting crane unit

Y02-0840E

Y- 3 .

Y- 3 .

Adjustment (pressure) Hydraulic circuit Pressure setting table

Item

Remarks

Set pressure

Hydraulic pilot control valve (quintuplet) P1 pump main circuit P2 pump main circuit Main winch hoist-up circuit Auxiliary winch hoist-up circuit Main winch hoist-down circuit Auxiliary winch hoist-down circuit Boom telescoping/extending circuit Boom telescoping/retracting circuit Jib tilt raising (retracting) circuit Jib tilt lowering (extending) circuit Boom lowering circuit

Relief valve (RV1) Relief valve (RV2) Screw in Screw in

Port relief valve (PR9) Port relief valve (PR7) Port relief valve (PR8) Port relief valve (PR6) Port relief valve (PR2) Port relief valve (PR3) Port relief valve (PR4) Port relief valve (PR5) Port relief valve (PR1)

Telescoping control valve

Overload relief valve (OR1)

Hydraulic pilot control valve (swing)

Overload relief valve

Remote control valve

Relief valve Main relief valve (RV5, (C)) Back pressure valve (D) Reducing valve (D) Relief valve (F)

Solenoid valve (power tilt jib, for selecting tilt/telescoping)

Overload relief valve (OR2, cracking pressure)

Solenoid valve (for venting pilot line)

Relief valve (RV4) Screw in

Relief valve (for jib extending circuit)

Relief valve (RV6)

Relief valve (for jib extension circuit pressure reduction)

Port relief valve (PR11)

Relief valve (for swing circuit)

Relief valve (RV3)

Relief valve (counterweight rotator circuit)

Relief valve (RV7) Pilot pressure (cracking pressure)

Counterbalance valve (for main winch)

Overload relief valve Pilot pressure (cracking pressure)

Counterbalance valve (for auxiliary winch)

Overload relief valve

Counterbalance valve (for elevating)

Pilot pressure (cracking pressure)

Counterbalance valve (for boom telescoping)

Pilot pressure (cracking pressure)

Accumulator

Nitrogen gas filling pressure

Operation detection switch

Pressure switch Operating pressure

Y03-1090E

Y- 3 .

Y- 3 .

Adjustment (pressure) Pressure adjustment

3) Boom elevating/lowering circuit (port relief valve, PR1) Fully retract the boom elevating cylinder.

Oil temperature: 50±5 °C, hydraulic oil: ISO VG46

Move the boom elevating operation lever to the boom hoistdown side to check the pressure value shown on the multidisplay.

1. Hydraulic pressure pilot control valve (quintuplet)

Pump speed: MAX (2000 rpm) 4) Boom telescoping/extending circuit (port relief valve PR2) Set the telescoping type selector switch to extending side in series.

Set the winch/boom elevating/telescoping/jib high speed selector switch to elevating/telescoping/jib high speed side.

Fully extend the 2nd and the 3rd boom sections.

Move the telescoping operation lever to the boom extending side (do not press the 4th/top boom extending switch) to check the pressure value shown on the multi-display.

Pump speed: MAX (2000 rpm) 5) Telescoping/retracting circuit (port relief valve PR3) Fully retract the boom.

Move the telescoping operation lever to the boom retracting side to check the pressure value shown on the multi-display.

Pump speed: MAX (2000 rpm)

1) P1 pump main circuit (relief valve, RV1) Release the port for releasing the main winch brake to air. (Install a blind plug to the removed pipe)

6) Jib tilt raising (retracting) circuit (port relief valve PR4)

Shift the winch/elevating/telescoping/jib high speed selector switch to neutral.

Set the boom/jib selector switch to “jib tilt” position.

Move the main winch operation lever to hoist-up side to check the pressure value shown on the multi-display.

Fully retract the jib tilt cylinder.

Move the jib operation lever to the jib raising side to check the pressure value shown on the multi-display.

Pump speed: MAX (2000 rpm) 2) P2 pump main circuit (relief valve, RV2)

Pump speed: MAX (2000 rpm) 7) Jib tilt lowering (extending) circuit (port relief valve PR5)

Turn ON the boom elevating slow stop cancel switch.

Fully extend the boom elevating cylinder.

Move the boom elevating operation lever to the boom hoist-up side to check the pressure value shown on the multi-display.

Fully tighten the port relief valve (PR11) for jib extension circuit pressure reduction.

Pump speed: MAX (2000 rpm)

Y03-1090E

Y- 3 .

Y- 3 .

Adjustment (pressure) Set the boom/jib selector switch to the “jib tilt “position.

Install the pressure gauge to the pressure check port of the telescoping control valve.

Fully extend the jib tilt cylinder.

Fully ex tend only the 2nd boom using the boom correction switch.

Move the jib operation lever to the jib lowering side to check the pressure value shown on the multi-display.

Shift the winch/boom elevating/telescoping/jib high speed selector switch to the boom elevating/telescoping/ jib high speed side.

Pump speed: MAX (2000 rpm) Note)

Shift the boom telescoping lever to the boom extending side to measure the pressure when the 3rd boom is extending.

For adjustment of port relief valve (PR5), loosen the adjusting screw to some extent then tighten to adjust.

Pump speed: MAX (2000 rpm)

3. Relief valve (for swing circuit, RV3)

After adjusting PR5, be sure to adjust the port relief PR 11 as described in section 5.

8) Auxiliary winch hoist-down circuit (port relief valve PR6)

Set the auxiliary winch drum in a drum-lock state.

Set the winch/boom elevating/telescoping/jib high speed selector switch to the neutral position.

Move the auxiliary winch operation lever to the hoistdown side to check the pressure value shown on the multi-display.

Lock the swing table with the swing brake.

Pump speed: IDL (600 rpm)

Turn ON the swing slow stop cancel switch.

Move the boom swing lever to the right swing side or left swing side to check the pressure value shown on the multi-display.

9) Main winch hoist-down circuit (port relief valve PR8)

Pump speed: MAX (2000 rpm)

Set the main winch drum in a drum-lock state.

4. Solenoid valve (RV4 for pilot line vent)

Set the winch/boom elevating/telescoping/jib high speed selector switch to the neutral position.

Move the main winch operation lever to the hoist-down side to check the pressure value shown on the multidisplay.

Pump speed: IDL (600 rpm)

2. Telescoping control valve G port

Install the pressure gauge to the G port of the solenoid valve.

Check the pressure when the crane operation lever is in neutral.

Pressure check port (PT1/4) Overload relief valve (OR1)

Pump speed: IDL (600 rpm)

Y03-1090E

Y- 3 .

Y- 3 .

Adjustment (pressure) 5. Relief valve (for jib extension circuit pressure reduction, PR11)

A f t e r f u l l y r et r a c t i n g t h e c o u nt e r we i g ht m o u nt i n g / dismounting cylinder, shift the counter weight cylinder telescoping switch to “raising” side to adjust the pressure.

Pump speed: MAX (2000 rpm)

7. Relief valve (RV7 for counterweight rotator circuit)

Shift the boom/jib selector switch to the “jib tilt” position.

Fully extend the jib telescoping cylinder.

Move the jib operation lever to the jib extending side to check the pressure value shown on the multi-display.

Pump speed: MAX (2000 rpm)

6. Remote control valve (main relief valve, RV5(C))

G port

Install the pressure gauge to the G port of the remote control valve.

Fully extend the counter weight mounting/dismounting cylinder.

Shift the counterweight lock/release switch to the lock side and measure the pressure after the counterweight lock pin (counterweight mounting/dismounting cylinder rod section) has moved to the lock position.

Pump speed: IDL (600 rpm)

Install the pressure gauge to the G port of the remote control valve.

Shift the crane mounting/dismounting switch to “working” side.

Shift the RC computer selector switch of the remote control device to the “manual” side.

Y03-1090E

Y- 4 .

Y- 4 .

Adjustment (electric) Switch adjustment

2) A djust so that the limit switch is lowered by 1 mm (for one turn of fixing nut) from the state of section1) then lock with the fixing nut.

NOTICE For the locations of the switches, refer to LOCATIONS OF ELECTRIC PARTS in chapter Z. 1. S witch S11 (4th/top boom section full retraction detection), switch S15 (2nd/3rd boom section full retraction detection)

Lever stand (winch, elevating)

1) M ake sure that each switch works 5-8 mm short of full retraction of the 4th/top boom sections and 2nd/3rd boom sections respectively.

Base boom section

Fixing nut

2nd boom section 3rd boom section

Boom full retracting state

4th boom section

Top boom section

Tightening torque: 36-40 kg-cm Apply screw locking compound

4. Switch S20 (main winch dead wrap detection), switch S21 (auxiliary winch dead wrap detection)

2. Switch S18 (cab tilt detection) 1) A djust so that dimension A shown in the figure below becomes 3.0 mm with the crane cab laid on the cab support (i.e., with the cab tilt cylinder retracted fully.)

Disorderly winding prevention roller

Cab Lower end of cab

Bolt

Cab support

Winch drum

Nut

3. Switch S19 (lever stand tilt detection) 1) Push the limit switch into the actuated position with the lever stand (for winch and elevation control) tilted down by approx. 16 degrees as shown in next figure and install it (by temporary tightening.)

1) P repare a plate whose thickness is 5 mm and secure the clearance of 5 mm between the winch drum and the disorderly winding prevention roller.

Y04-0920E

Y- 4 .

Y- 4 .

Adjustment (electric) 2) Loosen the bolt and let it contact the switch roller.

Loosen the bolt for one turn further from the switch operation position (equivalent to 1.5 mm of the roller pushing amount) then lock it with the nut to which the screw lock is applied.

Cock

Apply screw lock

Cock “closed” state

5. Switch S12 (jib tilting operation detection) 1) M ake the jib offset angle to 5 degrees (i.e., the jib tilt cylinder is fully retracted.) Under such a condition, adjust the adjusting bolt so that the limit switch is pushed a half turn further from the actuated position (where its contact points COM and NO becomes connected.)

8. Switch S32 (swing lock pin detection) 1) Adjust the dimension A shown in the figure below to 22 mm.

Apply THREE BOND 1035.

Adjusting bolt Swing table

Jib

6. Switch S13 (jib full retraction detection) Swing lock pin

1) Adjust the lever to be 47 ± 0.5 mm (A) in switch free.

2) M ake sure that each switch works 5-8 mm short of full retraction of the 2nd boom sections.

9. Boom stowing detection switch 1) With the boom stowed on the boom rest, adjust the dimension A (the clearance between the proximity switch and the support) shown in the figure below to 2.0 mm.

Boom

Rear end of 2nd jib Base jib Boom stowing detec tion switch (proximity switch)

Support

7. Switch S33 (jib tilt cylinder cock state detection) 1) Loosen the cock from the “closed” state. Adjust so that the NC contact is turned ON (energized) at the point where dimension A in the figure becomes 4-6 mm.

Y04-0920E

Boom rest

Y- 4 .

Y- 4 .

Adjustment (electric) 10. Switch S23 (S24) ( counterweight mounting/ dismounting cylinder extending side stroke end detection) Switch S25 (S26) ( counterweight mounting/ dismounting cylinder retracting side stroke end detection (standard weight)) Switch S37 (S38) ( counterweight mounting/ dismounting cylinder retracting side stroke end (extra weight)) Switch S27 (S28) (counterweight lock detection) Switch S29 (S30) ( counterweight lock cancel detection) Switch S31 (extra weight I mounting detection) Switch S36 (extra weight II mounting detection)

Switch Switch S27, S28, S29, S30 Rot ator sec t ion of t he counterweight mounting/ dismounting cylinder

(Proximity switch)

Rod

Front of crane 1) Adjust so that dimension Y in the above figure becomes 12 mm (dimension X: 1 mm).

Switch S31, S36

(Proximity switch) Standard counterweight lower surface

C ounter wei ght (standard)

1) Adjust the dimension X shown in the figure above to 1 mm.

2) Mount the extra counterweight then check if the proximity switch works.

Counterweight mounting/dismounting cylinder (left)

Counterweight mounting/dismounting cylinder (right)

Switch S23, S24, S25, S26, S37, S38

11. Winch drum rotation detection switch (SD1, SD2) 1) Install the proximity switch so that the dimension from the top of the proximity switch to the support installed on the winch drum becomes 4.0 mm.

(Proximity switch)

Support (winch)

Cylinder stroke detection rod

Winch drum

Support

1) Adjust so that dimension Y in the figure above becomes 20±0.5 mm.

2) Telescope the counterweight mounting/dismounting cylinder and check that the proximity switch does not interfere with the rod for detection cylinder stroke.

Proximity switch

Y04-0920E

Y- 4 .

Y- 4 .

Adjustment (electric) 3. Wire layer number detector

Potentiometer adjustment 1. Jib tilt angle detector After installing the angle detector, set the jib tilt angle to 5 ° (jib tilt cylinder full retraction.)

Disorderly winding prevention roller

After measuring total resistance of the potentiometer, adjust the resistance between A-C to the value corresponding to the total resistance referring to the table below and lock the potentiometer.

Total resistance ( ) (Between A-D)

Adjusted value ( )±4 (Between A-C)

Winch drum

Potentiometer Bolt B

(Apply screw locking compound)

Disorderly winding prevention roller, lever

Bolt A

(Apply screw locking compound)

Lever Lever base section Jib

Connector

Direction of tilt

Red

1) I n the state that the center line between the potentiometer and the lever is horizontalized, adjust the bolt A at the lever base section so that the resistance between the terminals of connector 1 and 2 becomes 200±10 Ω.

White Black Shield

2) A fter the abovementioned adjustment, install with the bolt B so that the disorderly winding prevention roller lever and the potentiometer is horizontalized.

View A

2. Swing angle detector Refer to ROTARY JOINT in chapter N.

10

Y04-0920E

Y- 5 .

Y- 5 .

Adjustment and checks

This section covers the procedures to be applied when performing adjustments and checks in areas other than the pressure and electric areas, which have been covered in the preceding sections.

Hydraulic pressure generating system

Air bleeder plug (drain hose connected)

1. Air bleeding procedure of pump NOTICE W henever the hydraulic pump or hydraulic oil is

Hydraulic oil pump A’ssy

replaced, be sure to bleed the pump circuit of air.

1. After replacement of the hydraulic pump or hydraulic oil, adjust the

7. I f no abnormal sound is heard, turn ON the PTO switch and continue

hydraulic oil to a specified amount.

the idling for 5 minutes with no load. (Be sure to perform with no load.)

2. Remove the air breather at the top of the hydraulic oil tank and install the tank pressurizing treatment device.

8. During running, check for abnormal sound or heat from the hydraulic pump, and any oil leakage from the whole system.

NOTICE o prevent damage to the hydraulic oil tank, use a T Tadano-recommended pressurizing treatment device.

NOTICE o not operate the hydraulic cylinder with the tank D pressurizing treatment device installed.

hen pressurizing the hydraulic oil tank without using W the pressurizing treatment device, adjust the pressure to 0.2-0.3 kg/cm 2 and never let it exceed 0.5 kg/cm 2 .

9. If no abnormality is found, stop the engine and assemble the tank

he pressurizing treatment device has been sealed T after adjusting the pressure to 0.3 kg/cm 2 . During use, check the pressure gauge not to exceed 0.5 kg/cm 2 .

pressurizing treatment device at the top of the hydraulic oil tank to the original air breather.

10. N ow bleeding is complete. When the hydraulic pump is replaced, perform break in of the pump subsequently.

3. S lowly loosen the air bleeder plug of the pump (at this time, maintain the state as is when the drain hose is connected) and wait until the hydraulic oil containing air comes out.

[Tank pressurizing treatment device] 4. A fter confirming no more air is coming out, tighten the air bleeder Supply compressed air here (M8)

plug while the hydraulic oil comes out. Perform this for all the pumps.

5. W ith the hydraulic oil tank pressurized, start the engine with the

Pressure gauge

PTO switch turned OFF. After idling for approx. 5 seconds, rapidly repeat turning ON-OFF the PTO switch and check for abnormal

Reducing valve

sound.

Screw onto the

6. If any abnormal sound is heard, bleed the hydraulic pump again.

hydraulic oil tank.

Valve A’ssy (A) (part No.: 919-999-30740)

11

Y05-1020E

Y- 5 .

Y- 5 .

Adjustment and checks Swing system

Supply compressed air here (M8)

1. Swing pilot circuit bleeding procedure 1) Lock the swing table.

Pressure gauge

2) Insert the vinyl hose into the bleeder screw of the hydraulic pilot control valve.

Reducing valve

3) Perform swing operation and open the bleeder screw. When air bubbles disappear from the outflowing oil, tighten the screw.

Screw onto the hydraulic oil tank.

Bleeder screw

Bleeder screw

Valve A’ssy (B) (part No.: 919-999-30750)

2. Procedure of checking N2 gas filling pressure in accumulator 1) Lock the swing table.

2) With the pump stopped, shift the swing brake canceling switch (SN4) between ON and OFF repeatedly to decrease the accumulator pressure.

Remove accumulator pressure sensor (PS2) and install the pressure gauge.

Hydraulic pilot control valve (swing)

2. Swing brake circuit bleeding procedure

3) Remove accumulator pressure sensor (PS2) and install the pressure gauge.

1) Lock the swing table.

2) Shift the swing brake canceling switch between ON and OFF repeatedly and bleed the brake circuit of air.

NOTICE void spattering of oil because it may be under A accumulator pressure.

Winch system

4) Run the pump to send pressurized oil to the accumulator.

5) W ith the pump stopped again, shift the swing brake canceling switch (SN4) between ON and OFF repeatedly to decrease the accumulator pressure. The pressure gauge reading descends slowly at the beginning. It drops rapidly after reaching a certain pressure value. The points that the descending speed of the reading changes is nitrogen gas filling pressure.

1. Winch brake circuit air bleeding procedure 1) Shift the winch lever from hoist-up position via neutral position to hoistdown position and vise versa repeatedly to bleed the brake pilot circuit.

NOTICE Avoid overwinding of the hook block.

2) Bleed the pilot circuit for hydraulic valve (for releasing winch brake) as described in step 1).

Slowly Filling gas pressure

Rapidly

12

Y05-1020E

Y- 5 .

Y- 5 .

Adjustment and checks 2. Adjustment of disorderly winding prevention roller

Tilt cylinder

Without the wire rope, adjust the adjusting bolt so that the clearance A between the winch drum and the roller becomes 5 mm.

Connect the hoses to each other.

(Connect a left-hand hose to another lefthand one and a right-hand hose to another right-hand one.)

Roller

Winch drum

Adjusting bolt

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

5) R epeat raising and lowering the jib several times by power-tilt operation to bleed the circuit completely.

(Reference) D o not use the bleeder plug of the counterbalance valve for bleeding jib circuit because the extraction of air is poor.

2. Power-extension jib circuit bleeding procedure

Telescoping system

1) Bleed the jib extension cylinder only and attach it to the jib.

1. Power-tilt jib circuit bleeding procedure

2) C onnect the hoses for the jib extension cylinder directly to each other, and form the circulation circuit as shown in the figure below.

Then telescope the jib to bleed the circuit.

1) Bleed the jib tilt cylinder only and attach it to the jib.

2) Connect the hoses for the jib tilt cylinder directly to each other, and form the circulation circuit as shown in the figure below.

3) B leed the circuit by raising the jib (retracting tilt cylinder) after opening jib tilt cylinder cock.

Counterbalance valve

Counterbalance valve

Cock

Solenoid valve (for selecting jib tilt/jib telescoping circuit)

Solenoid valve (for selecting jib tilt/jib telescoping circuit)

Hose reel

Hose reel

13

Y05-1020E

Y- 5 .

Y- 5 .

Adjustment and checks

Extension cylinder

Connect the hoses to each other (connect a hose for extension to another one for extension and a hose for retraction to another one for retraction) 3) Connect the hydraulic hose with the jib extension cylinder.

4) Repeat retracting and extending the jib several times by powerextension operation to bleed the circuit completely.

Crane operation 1. Operation pilot circuit air bleeding procedure 1) Loosen the air bleeder plug (a1-a10) of the hydraulic pilot control valve (quintuplet) and perform each crane operation. When the air bubbles in the outflowing oil disappears, tighten the plug.

NOTICE Avoid spattering of oil. cknowledge the danger involved in crane operation A and perform appropriate operations.

14

Y05-1020E

Y- 5 .

Y- 5 .

Adjustment and checks 2. Engine speed adjustment

Accelerator pedal Bolt g Bolt d

Stopper

Pin

Rod h

Lever f

Governor speed lever Engine

Bolt c Lever e

Hanger Bolt b

Accelerator cylinder Cable

To governor speed lever

1) Confirm the engine speed at idling is in the range of 600 + 5 00 rpm.

To accelerator pedal

5) Slowly step on the accelerator pedal with the stopper rotating (two-dot chain line in the figure) and adjust the bolt d so that the accelerator pedal contacts the bolt d at the engine speed of 1400±50 rpm.

2) A djust the c able so that the c learanc e a bet ween the accelerator cylinder rod and the lever f becomes 1 mm at idling.

Also, confirm the clearance between the rod h and the pin is 3-5 mm at idling.

6) Perform remote control operation to mount/dismount the crane part and in the state the accelerator cylinder is extended by rotating the remote control switch accelerator dial, adjust the bolt c so that the engine speed becomes 1500±50 rpm.

3) Slowly step on the accelerator pedal and adjust the bolt b so that the lever e contacts the bolt b when the engine speed is 2000±25 rpm.

4) A fter the abovementioned adjustment, adjust the bolt g so that the accelerator pedal contacts the bolt g at the engine MAX speed of 2000±25 rpm.

15

Y05-1020E

System Diagrams Contents Z-1 Hydraulic Circuit (Upper)............ 1 Z-3 Electric Circuit (Upper)................ 5 Z-4 Electric Circuit (Crane electrical equipment).... 10 Z-5 Electric Circuit (Electric circuit for mounting/ dismounting revolving superstructure,counterweight)...... 11 Z-6 Electric Circuit (Engine electric circuit)............. 14 Z-7 Electric Circuit (Lower)............. 15 Z-8 Electric Circuit (Air conditioner)......................... 17 Z-9 Electric Circuit (Upper wiring 1 (cab))................ 19 Z-10 Electric Circuit (Upper wiring 2 (swing table))..... 25 Z-11 Electric Circuit (Engine wiring)........................... 27

Z

Z-1

Swing brale cylinder

Z-1

Hydraulic Circuit

Cylinder for jib EXT

Cylinder for jib telescoping

Z-1 Stop valve

Swing drive unit

Upper hydraulic circuit

Cylinder (for swing lock pin release)

Remote control valve

Jib tilt cylinder

Pilot check valve

Hose reel

Solenoid valve (for swing brake) Hydraulic pilot control valve

Slide cylinder

Front lifter

Hydraulic valve (for 4th · top telescoping)

Counter balance valve

Hydraulic valve (for synchronized telescoping / sequential telescoping selector)

Counter balance valve

Telescoping cylinder

Manual control valve Cock

Solenoid valve (for swing lock pin release)

Jack cylinder Solenoid valve (for drum lock release)

Pilot check valve

Solenoid valve (for jib tilt / jib telescoping circuit selection)

Relief valve Cylinder (for drum lock release)

Rear lifter Main winch

Jack cylinder Pilot check valve

Rotater (counter weight, lock / release)

Hydraulic valve (for swing / dismounting circuit selection)

(lowering)

Telescoping control valve

Winch brake cylinder

Hydraulic valve

Counter balance valve

Relief valve (for jib telescoping circuit)

(raising)

Counter weight mounting / dismounting cylinder

Relief valve (for jib telescoping circuit reducing pressure)

(raising) (lowering)

Pilot check valve

Cab tilt cylinder

Aux. winch

Hydraulic motor, counter balance valve

Check valve Cock

Pilot check valve

Hose reel

(lock) (release)

Relief valve

Elevation cylinder

Flow divider

Check valve

(dismounting)

Pilot check valve

(mounting)

Solenoid valve (for jib telescoping circuit reducing pressure)

Superstructure mounting / dismounting cylinder Solenoid valve (for automatic stop)

Accelerator cylinder Solenoid valve (for swing pilot line vent) Remote control valve

Solenoid valve (for preventing flow control valve leak when high speed)

Solenoid control relief valve Solenoid valve (for boom / jib control pilot line selection)

Swing

Check valve

Telescoping jib

(for control with stamp)

Pressure sensor

Telescoping

Hydraulic pilot control valve Solenoid valve (for winch speed selection)

Shuttle valve (for control with stamp) Elevation

Cylinder (for camera elevation)

Hydraulic pump

Solenoid control relief valve

Solenoid valve (for camera elevation selection) Thermostat

Aux. winch

Main winch

Oil cooler

Accumulator

Elevation

Check valve

Solenoid valve (for pilot line vent) Pressure sensor

Solenoid valve (for oil cooler)

1

Z01-4870E

Check valve

Oil filter Oil tank

1

Z-1

Z-1

Swing brale cylinder

Hydraulic Circuit

Cylinder for jib EXT

Cylinder for jib telescoping

Z-1 Stop valve

Swing drive unit

Upper hydraulic circuit

Cylinder (for swing lock pin release)

Remote control valve

Jib tilt cylinder

Pilot check valve

Counter balance valve Hose reel

Solenoid valve (for swing brake) Hydraulic pilot control valve

Slide cylinder

Front lifter

Hydraulic valve (for 4th · top telescoping)

Hydraulic valve (for synchronized telescoping / sequential telescoping selector)

Counter balance valve

Telescoping cylinder

Manual control valve Cock

Solenoid valve (for swing lock pin release)

Jack cylinder Solenoid valve (for drum lock release)

Pilot check valve

Solenoid valve (for jib tilt / jib telescoping circuit selection)

Solenoid valve (for Inching swing selector)

Cylinder (for drum lock release)

Rear lifter Main winch

Jack cylinder Rotater (counter weight, lock / release)

Pilot check valve

(lock)

Hydraulic valve (for swing / dismounting circuit selection)

(release)

Relief valve

(lowering)

Cock

(raising)

Counter weight mounting / dismounting cylinder

(raising)

Telescoping control valve

Hose reel

Winch brake cylinder

Hydraulic valve

Counter balance valve

Relief valve (for jib telescoping circuit)

Relief valve (for jib telescoping circuit reducing pressure)

(lowering)

Pilot check valve

Cab tilt cylinder

Pilot check valve

Aux. winch

Hydraulic motor, counter balance valve

Check valve

Elevation cylinder

Flow divider

Relief valve

(dismounting)

Pilot check valve

Check valve

(mounting)

Solenoid valve (for jib telescoping circuit reducing pressure)

Superstructure mounting / dismounting cylinder Solenoid valve (for automatic stop)

Accelerator cylinder Solenoid valve (for swing pilot line vent) Remote control valve

Solenoid valve (for preventing flow control valve leak when high speed)

Solenoid control relief valve Solenoid valve (for boom / jib control pilot line selection)

Swing

Check valve

Telescoping jib

(for control with stamp)

Pressure sensor

Telescoping

Hydraulic pilot control valve Solenoid valve (for winch speed selection)

Shuttle valve (for control with stamp) Elevation

Cylinder (for camera elevation)

Hydraulic pump

Solenoid control relief valve

Solenoid valve (for camera elevation selection) Thermostat

Aux. winch

Main winch

Oil cooler NOTE Accumulator

Elevation

Check valve

Solenoid valve (for pilot line vent) Pressure sensor

Solenoid valve (for oil cooler)

2

Z01-4870E

1 sign is applied by the serial No. machine in figure below.

Applicable serial No

Check valve

Oil filter Oil tank

2

Z-1

Z-1

Z-1

Hydraulic Circuit Swing brale cylinder

Upper hydraulic circuit

Cylinder (for swing lock pin release) Counter balance valve

Remote control valve

Hose reel

Solenoid valve (for swing brake)

Swing drive unit

Telescoping cylinder

Hydraulic pilot control valve

Slide cylinder

Solenoid valve (for swing lock pin release)

Front lifter Jack cylinder Pilot check valve

Solenoid valve (for drum lock release)

Drun lock (MW)

Flow divider

Elevation cylinder

Cylinder (for drum lock release)

Rear lifter Jack cylinder (Counter weight rotator, lock / release)

Winch brake cylinder

Hydraulic valve (for swing / dismounting circuit selection)

(lock)

Main winch

Aux. winch Telescoping control valve

(release)

Relief valve

Hydraulic valve

(lowering)

Cock

(raising)

Counter weight mounting / dismounting cylinder

(raising)

Cab tilt cylinder

(lowering)

Hydraulic motor, counter balance valve

Counter balance valve

Relief valve (for elevation low pressure)

Relief valve (for telescoping low pressure)

Relief valve (swing)

(dismounting)

Pilot check valve

Check valve

(mounting)

Solenoid valve (for elevation lowering low pressure)

Superstructure mounting / dismounting cylinder

Solenoid valve (for automatic stop)

Remote control accelerator cylinder Solenoid valve (for swing pilot line vent)

Remote control valve

Solenoid valve (for preventing flow control valve leak when high speed)

Solenoid control relief valve Solenoid valve (for boom / jib control pilot line selection)

Swing

Check valve

Pilot control valve Telescoping jib

Telescoping stamp type pedal Pressure sensor

Shuttle valve Solenoid valve (for winch speed selection)

Telescoping stamp type pedal

Solenoid control relief valve

Cylinder (for camera elevation)

Hydraulic pump

Solenoid valve (for camera elevation selection)

Solenoid valve (for pilot line vent) Thermostat

Aux. winch

Main winch

Accumulator

Elevation

Oil cooler Check valve

Check valve

Pressure sensor

Solenoid valve (for oil cooler)

3

Z01-4870E

Oil filter Oil tank

3

Z-1

Z-1

Z-1

Hydraulic Circuit

Swing brale cylinder

Upper hydraulic circuit

Cylinder (for swing lock pin release) Remote control valve

Hose reel

Solenoid valve (for swing brake)

Swing drive unit

Counter balance valve

Telescoping cylinder

Hydraulic pilot control valve

Slide cylinder

Solenoid valve (for swing lock pin release)

Front lifter Jack cylinder Pilot check valve

Solenoid valve (for drum lock release)

Drun lock (MW)

Flow divider

Elevation cylinder

Relief valve (for Inching swing selection)

Rear lifter Jack cylinder

Winch brake cylinder

Main winch

Aux. winch Telescoping control valve

(lock)

(Counter weight rotator, lock / release)

(release)

(lowering)

Cock

(raising)

Counter weight mounting / dismounting cylinder

(raising)

Cab tilt cylinder

(lowering)

Hydraulic valve

Hydraulic motor, counter balance valve

Hydraulic valve (for swing / dismounting circuit selection)

Counter balance valve

Relief valve (swing)

(dismounting)

Pilot check valve

Check valve

(mounting)

Superstructure mounting / dismounting cylinder

Solenoid valve (for automatic stop)

Remote control accelerator cylinder Solenoid valve (for swing pilot line vent) Remote control valve

Solenoid control relief valve

Solenoid valve (for boom / jib control pilot line selection)

Swing

Check valve

Pilot control valve Telescoping jib

Telescoping stamp type pedal Pressure sensor

Shuttle valve Solenoid valve (for winch speed selection)

Telescoping stamp type pedal

Solenoid control relief valve

Cylinder (for camera elevation)

Hydraulic pump

Solenoid valve (for camera elevation selection)

Solenoid valve (for pilot line vent) Aux. winch

Thermostat

Main winch

Accumulator

Elevation

Oil cooler Check valve

Check valve

Pressure sensor

Solenoid valve (for oil cooler)

4

Z01-4870E

Oil filter Oil tank

4

5 Option

(Installed on the rear end of the swing table for monitoring winch)

Marks

Color

the sectional area of electric wire (mm2)

A color of trace that mixed with a ground color A ground color of electric wire

Method of indication for wiring

Crane running Boom section full retraction Boom forward position Overwinding Starter switch : OFF Control lever : neutral

to AML-V power supply of main body

Swing brake indicator lamp

for winch high-speed selection

Swing free / lock selector SW (S lever) Winch / elevation · telescoping · jib high speed selector SW

for camera elevation selection for main winch drum lock release for aux. winch drum lock release for swing lock pin release

Camera elevation selector SW Main winch drum lock release SW Aux. winch drum lock release SW Swing lock pin release SW

for elevation · telescoping · jib high speed selection

for preventing flow control leaking when high speed

for swing free selection

for swing brake release

for pilot circuit vent

Buzzer 2

Cab tilt indicator lamp

Hydraulic oil 50°C detector SW

Shield

Controller

Main/aux. selection input

Tail lamp input

External reset input

Phase B input by proximity switch (aux.)

Phase A input by proximity switch (aux.)

to working lamp SW

Jib mounting / dismounting selector SW

Main/aux. selection input

Drum rotation detector SW

Swing angle detector

Boom length · angle detector

(Boom length detector)

(Boom angle detector)

Converter

for swing pilot vent

for No.3 CYL

for No.2 CYL

for No.1 CYL

for 4th · top telescoping

Accumulator low pressure warning lamp

for automatic stop

AML abnormality indicator lamp

Engine revolution sensor

for oil cooler

Jib removed indicator lamp

(Aux.)

(Main)

Number of layers of wire detector

Swing left detection (contact broken during swinging left)

Swing right detection (contact broken during swinging right)

Elevation lowering detection (contact broken during lowering)

Telescoping RET detection (contact broken during retracting)

AML external indicator lamp

Red

Yellow

Green

Synchronized telescoping / Sequential telescoping mode indicator lamp

Synchronized telescoping mode indicator lamp

Shield

Option

(Swing stop proportional control solenoid valve)

Jib working indicator lamp

AML alarm buzzer

Jib full RET detector SW

Solenoid control relief valve (Elevation slow stop proportional control solenoid valve)

Swing lock pin indicator lamp

Elevation slow stop cancel indicator lamp

Jib length detector

Jib angle detector

Jib tilting operation detector SW

Jib elevation pin insertion detector SW

Swing stop release indicator lamp

Shield

Shield

4th · top boom full RET detector SW

S/T overwinding detector SW

for jib tilt / jib telescoping circuit selection

for jib tilt / jib telescoping circuit selection

for Boom / jib control pilot selection

for Boom / jib control pilot selection

Power tilt jib telescoping indicator lamp

Power tilt jib tilt indicator lamp

Boom telescoping indicator lamp

for jib EXT circuit reducing pressure selection

Sequential telescoping mode indicator lamp

AML external indicator lamp selector SW

3rd boom correction SW

2ndm 3rd boom emergency SW

Swing voice alarm unit

Phase B input by proximity switch (main)

Shield

Shield

Signal transmitter (for power tilt jib)

For emergency in AML failure

(Accumulator pressure sensor)

Elevation slow stop cancel SW

Swing stop cancel SW

Swing

Elevation

Constant current amplifier

Boom telescoping mode selector SW

Power supply

Shield

Boom overwinding detection (contact broken during overwinding)

Overwinding release SW

Cock state detector SW for jib tilt cylinder

Cord reel

(Main pressure sensor)

4th · top boom correction SW

Phase A input by proximity switch (main)

Hook amount of movement indicator

Buzzer 3

Shield

Shield

2nd boom correction SW

Swing alarm selector SW

Shield

Swing

Elevation

Signal transmitter (for swing, elevation stop)

Signal transmitter (for outrigger)

to Carrier · light SW

4th · top boom EXT SW 4th · top boom emergency SW

Shield

Lower electric circuit

Cord reel

Cord reel

AML emergenct SW

Buzzer 4

Moment detector

Swing dead angle detection

Rotary joint

2nd · 3rd boom full RET detector SW

to working lamp

Swing free / lock selector SW (M lever)

Swing free / lock selector SW (panel)

Swing brale release SW

Lever stand tilt detector SW (contact broken for tilting down)

Cab tilt detector SW

Power supply

Telescoping control output No.2

Telescoping control output No.1

Buzzer output (AML alarm)

Buzzer output (accumulator low-pressure alarm)

Jib tilt working alarm

Automatic stop 2 (telescoping stop valve) Automatic stop 3 (due to instability in the rear portion、etc)

Automatic stop 1 (due to overload、 overwinding、etc)

External indicator lamp (-90%) External indicator lamp (90-100%) External indicator lamp (100%-) F/J overloading alarm Swing stop Jib tilt alarm Over-rear area output Incorrect jib set

Shield Shield

Shield

Shield

Shield

to L working SW

Noise filter

Jib tilt

Jib telescoping

Telescoping EXT detection (contact broken during EXT)

Power tilt jib RET detector SW

Upper electric circuit

Boom angle input Main pressure input Boom length input Accumulator pressure input Swing angle input

(CRT display dims while lamp is turned ON.)

SN22 boom / jib Boom telescoping selector SW

Power tilt jib lowering, (EXT) detection (contact broken during lowering, extending)

Superstructure & counter weight mounting / dismounting electric circuit Power tilt jib raising, (RET) detection (contact broken during raising, retractiong)

wrap detection

Aux. remaining

MAIN remaining wrap detection

Superstructure & counter weight mounting / dismounting electric circuit Superstructure & counter weight mounting / dismounting electric circuit Superstructure & counter weight mounting / dismounting electric circuit

Elevation raising detection (contact broken during raising)

Aux. winch hoist-down detection (contact broken during hoisting down)

Electric Circuit

This figure is shown the state of below.

Z03-6520E to L working SW

Main winch hoist-up Main winch hoist-down Aux. winch hoist-up Aux. winch hoist-down Telescoping EXT Telescoping RET Elevation raising Elevation lowering Swing right Swing left Swing dead angle detection Boom telescoping mode selection C/W mounting conditon detection 1 C/W mounting conditon detection 2 Swing lock pin detection Cancelling boom raising limit during jib set Boom full RET detection Power tilt jib RET detection Overwinding cutout SW input Main winch dead wrap detection Auxiliary winch dead wrap detection Power tilt jib mounting/stowing selection Power tilt jib telescoping operation selection Dismounting Power tilt jib raising, RET detection Power tilt jib lowering, EXT selection Elevation high speed selection Top boom full RET Overwinding detection Engine high speed detection

AML controller (AML - V)

Aux. winch hoist-up detection (contact broken during hoisting up)

Main winch hoist-down detection (contact broken during hoisting down)

Z-3

Camera

Speaker

from battery

from starter SW AC terminal

from main fuse

Fuse box Crane electrical equipment circuit

Main winch hoist-up detection (contact broken during hoisting up)

Z-3 Z-3

5

6 Option

(Installed on the rear end of the swing table for monitoring winch)

sign is applied by the serial No. machine in figure below.

Color

Telescoping control output No.2

Telescoping control output No.1

Buzzer output (AML alarm)

Swing brake indicator lamp

for winch high-speed selection

Swing free / lock selector SW (S lever) Winch / elevation · telescoping · jib high speed selector SW

for Inching swing selection

for camera elevation selection for main winch drum lock release for aux. winch drum lock release for swing lock pin release

Inching swing selector SW

Camera elevation selector SW Main winch drum lock release SW Aux. winch drum lock release SW Swing lock pin release SW

for elevation · telescoping · jib high speed selection

for preventing flow control leaking when high speed

for swing free selection

for swing brake release

for pilot circuit vent

Buzzer 2

Cab tilt indicator lamp

AML emergenct SW

Buzzer 4

Shield

Shield

2nd boom correction SW

Buzzer 3

Shield

Phase B input by proximity switch (main)

Hydraulic oil 50°C detector SW

Shield

Controller

Main/aux. selection input

Tail lamp input

External reset input

Phase B input by proximity switch (aux.)

Elevation slow stop cancel SW

Shield

Shield

to working lamp SW

Jib mounting / dismounting selector SW

Main/aux. selection input

Reset input

Swing angle detector

Boom length · angle detector

(Boom length detector)

for automatic stop

Shield

AML external indicator lamp

Number of layers of wire detector

for oil cooler

Engine revolution sensor

(Aux.)

(Main)

Swing left detection (contact broken during swinging left)

Swing right detection (contact broken during swinging right)

Elevation lowering detection (contact broken during lowering)

Telescoping RET detection (contact broken during retracting)

Red

Yellow

Green

Synchronized telescoping / Sequential telescoping mode indicator lamp

for No.3 CYL

for No.2 CYL

for No.1 CYL

for 4th · top telescoping

Accumulator low pressure warning lamp

Jib removed indicator lamp

Drum rotation detector SW

Converter

for swing pilot vent

(Swing stop proportional control solenoid valve)

Solenoid control relief valve (Elevation slow stop proportional control solenoid valve)

AML abnormality indicator lamp

Synchronized telescoping mode indicator lamp

detector SW

Option

Jib elevation pin insertion detector SW

Jib full RET

(Boom angle detector)

Cock state detector SW for jib tilt cylinder

Jib working indicator lamp

Sequential telescoping mode indicator lamp

AML external indicator lamp selector SW

3rd boom correction SW

2ndm 3rd boom emergency SW

Jib length detector

Jib angle detector

Jib tilting operation detector SW

Swing lock pin indicator lamp

Elevation slow stop cancel indicator lamp

Swing stop release indicator lamp

Shield

Shield

4th · top boom full RET detector SW

S/T overwinding detector SW

for jib tilt / jib telescoping circuit selection

for jib tilt / jib telescoping circuit selection

for Boom / jib control pilot selection

for Boom / jib control pilot selection

Power tilt jib telescoping indicator lamp

Power tilt jib tilt indicator lamp

Boom telescoping indicator lamp

AML alarm buzzer

Signal transmitter (for power tilt jib)

For emergency in AML failure

(Accumulator pressure sensor)

Swing voice alarm unit

Phase A input by proximity switch (main)

Phase A input by proximity switch (aux.)

Swing stop cancel SW

Swing

Elevation

Boom telescoping mode selector SW

Power supply

Shield

Boom overwinding detection (contact broken during overwinding)

Overwinding release SW

Constant current amplifier

Elevation speed selection

Cord reel

(Main pressure sensor)

4th · top boom correction SW

Swing alarm selector SW

Hook amount of movement indicator

4th · top boom emergency SW

Swing

Elevation

Boom elevating slow stop cancel

Signal transmitter (for outrigger)

to Carrier · light SW

4th · top boom EXT SW

2nd · 3rd boom full RET detector SW

Swing free / lock selector SW (M lever)

Swing free / lock selector SW (panel)

Swing brale release SW

Cab tilt detector SW

10A Power supply

Lever stand tilt detector SW (contact broken for tilting down)

to AML-V power supply of main body

NOTE

Marks

the sectional area of electric wire (mm2)

A color of trace that mixed with a ground color A ground color of electric wire

Method of indication for wiring

Crane running Boom section full retraction Boom forward position Overwinding Starter switch : OFF Control lever : neutral

Buzzer output (accumulator low-pressure alarm)

Jib tilt working alarm

Automatic stop 2 (telescoping stop valve) Automatic stop 3 (due to instability in the rear portion、etc)

Automatic stop 1 (due to overload、 overwinding、etc)

External indicator lamp (-90%) External indicator lamp (90-100%) External indicator lamp (100%-) F/J overloading alarm Swing stop Jib tilt alarm Over-rear area output Incorrect jib set Over-front area output

Shield Shield

Moment detector

Shield

Cord reel

Cord reel

Lower electric circuit

Signal transmitter (for swing, elevation stop)

Swing dead angle detection

Shield

to working lamp

Rotary joint

Shield

Shield

to L working SW

Noise filter

Jib tilt

Jib telescoping

for jib EXT circuit reducing pressure selection

Power tilt jib RET detector SW

Upper electric circuit

Boom angle input Main pressure input Boom length input Accumulator pressure input Swing angle input

(CRT display dims while lamp is turned ON.)

SN22 boom / jib Boom telescoping selector SW

Superstructure & counter weight mounting / dismounting electric circuit Power tilt jib raising, (RET) detection (contact broken during raising, retractiong) Power tilt jib lowering, (EXT) detection (contact broken during lowering, extending)

wrap detection

Aux. remaining

MAIN remaining wrap detection

Superstructure & counter weight mounting / dismounting electric circuit Superstructure & counter weight mounting / dismounting electric circuit Superstructure & counter weight mounting / dismounting electric circuit

Elevation raising detection (contact broken during raising)

Telescoping EXT detection (contact broken during extending)

Aux. winch hoist-down detection (contact broken during hoisting down)

Electric Circuit

This figure is shown the state of below.

Z03-6520E to L working SW

AML abnormality

Main winch hoist-up Main winch hoist-down Aux. winch hoist-up Aux. winch hoist-down Telescoping EXT Telescoping RET Elevation raising Elevation lowering Swing right Swing left Swing dead angle detection Boom telescoping mode selection C/W mounting conditon detection 1 C/W mounting conditon detection 2 Swing lock pin detection Cancelling boom raising limit during jib set Boom full RET detection Power tilt jib RET detection Overwinding cutout SW input Main winch dead wrap detection Auxiliary winch dead wrap detection Power tilt jib mounting/stowing selection Power tilt jib telescoping operation selection Dismounting Power tilt jib raising, RET detection Power tilt jib lowering, EXT selection Elevation high speed selection Top boom full RET Overwinding detection Engine high speed detection

AML controller (AML - V)

Aux. winch hoist-up detection (contact broken during hoisting up)

Main winch hoist-down detection (contact broken during hoisting down)

Z-3

Camera

Speaker

from battery

from starter SW AC terminal

from main fuse

Fuse box Crane electrical equipment circuit

Main winch hoist-up detection (contact broken during hoisting up)

Z-3 Z-3

6

from battery

from starter SW AC terminal

from main fuse

7 Z03-6520E Color

for winch high-speed selection

Swing free / lock selector SW (S lever) Winch / elevation · telescoping · jib high speed selector SW

for Inching swing selection

for camera elevation selection for main winch drum lock release for aux. winch drum lock release for swing lock pin release

Inching swing selector SW

Camera elevation selector SW Main winch drum lock release SW Aux. winch drum lock release SW Swing lock pin release SW

for elevation · telescoping · jib high speed selection

SOL for prevention leakage in high-speed operation

for swing free selection Swing free / lock selector SW (M lever)

Swing free / lock selector SW (panel)

Swing brake release SOL

Buzzer 2

Cab tilt indicator lamp

Swing brale release SW

Swing brake indicator lamp

4th · top boom emergency SW

Shield

Shield

Swing alarm selector SW

Hydraulic oil 50°C detector SW

Shield

Controller

Main/aux. selection input

Tail lamp input

Display clear input

Initialize input

External reset input

Phase B input by proximity switch (aux.)

Phase A input by proximity switch (aux.)

Phase B input by proximity switch (main)

Power supply

Shield

Elevation slow stop cancel SW

Shield

Shield

to working lamp SW

Jib mounting / dismounting selector SW

Main/aux. selection input

Reset input

Drum rotation detector SW

AML external indicator lamp selector SW

Boom telescoping selector SW

No.2 CYL correction

2ndm 3rd boom emergency SW

For emergency in AML failure

(Accumulator pressure sensor)

(Main pressure sensor)

Swing automatic stop cancel SW

Swing

Elevation

Converter

Swing stop

Swing automatic stop proportional control solenoid valve

Elevation slow stop proportional control solenoid valve

Option

Jib elevation pin insertion detector SW

Swing angle detector

(Boom length detector)

AML abnormality indicator lamp

Jib working indicator lamp

Jib removed indicator lamp

AML external indicator lamp

Engine revolution sensor

Swing left detection (contact broken during swinging left)

Swing right detection (contact broken during swinging right)

Elevation lowering detection (contact broken during lowering)

Telescoping RET detection (contact broken during retracting)

Red

Yellow

Green

SOL for Synchronized telescoping

Oil cooler selector SOL

Synchronized telescoping mode indicator lamp

Sequential telescoping mode indicator lamp

SOL for No.3 CYL

SOL for No.2 CYL

SOL for No.1 CYL

Top cylinder selector SOL

Accumulator low pressure warning lamp

for AML vent

Jib full RET detector SW

(Boom angle detector)

Tilt stop valve screw in detector SW

Jib tilting operation detector SW

Jib length detector

Jib angle detector

Top boom full RET detector SW

S/T overwinding detector SW

Tilt, telescoping selector SOL

Swing lock pin indicator lamp

Elevation slow stop cancel indicator lamp

Swing stop release indicator lamp

Shield

Shield

Jib hydraulic source selector SOL

Jib hydraulic source selector SOL

Tilt, telescoping selector SOL

Boom

Boom

Full automatic jib telescoping indicator lamp

Full automatic jib tilt indicator lamp

Boom telescoping indicator lamp

AML alarm buzzer

top boom

digital

Transmitter analog

Boom overwinding detection (contact broken during overwinding)

Overwinding release SW

Constant current amplifier

Elevation speed selection

Cord reel

Swing voice alarm unit

No.3 CYL correction

No.1 CYL correction

Buzzer 3

Shield

Cord reel

Cord reel

Phase A input by proximity switch (main)

Top boom EXT SW

AML emergenct SW

Buzzer 4

2nd · 3rd boom full RET detector SW

Control lever pilot circuit vent SOL

Cab tilt detector SW

10A Power supply

Telescoping control output No.2

Telescoping control output No.1

Buzzer output (AML alarm)

Buzzer output (accumulator low-pressure alarm)

Jib tilt working alarm

Automatic stop 2 (telescoping stop valve) Automatic stop 3 (due to instability in the rear portion、etc)

Automatic stop 1 (due to overload、 overwinding、etc)

Shield Shield

Lever stand tilt detector SW (contact broken for tilting down)

To power supply of multi-display main body

sign is applied GA5135 ~ .

Symbol

the sectional area of electric wire (mm2)

A color of trace that mixed with a ground color A ground color of electric wire

Method of indication for wiring

This figure is shown the state of below.

Crane running Boom section full retraction Boom forward position Overwinding Starter switch : OFF Control lever : neutral

Option

External indicator lamp (-90%) External indicator lamp (90-100%) External indicator lamp (100%-) F/J overloading alarm Swing stop Jib tilt alarm Over-rear area output Incorrect jib set Over-front area output

Boom angle input Main pressure input Boom length input Accumulator pressure input Swing angle input

Moment detector

Shield

Swing

Elevation

Boom elevating slow stop cancel

Transmitter ASS’Y Signal

to Carrier · light SW

Wiring diagram crane lower

Transmitter

Swing dead angle detection

Shield

to working lamp

Swivel joint

Noise filter

Jib tilt

Jib telescoping

Jib EXT reducing pressure SOL

Full automatic jib stowing detector SW

Upper electric circuit

Shield

Shield

to L working SW

SN22 boom / jib Boom telescoping selector SW

FAJ lowering, EXT detector (contact broken during lowering, EXT)

FAJ raising, RET detector (contact broken during raising, RET)

to wiring diagram, mounting / dismounting

wrap detection

Aux. remaining

MAIN remaining wrap detection

to wiring diagram, mounting / dismounting

to wiring diagram, mounting / dismounting

to wiring diagram, mounting / dismounting

Elevation raising detection (contact broken during raising)

Telescoping EXT detection (contact broken during extending)

Aux. winch hoist-down detection (contact broken during hoisting down)

Electric Circuit

(Installed on the rear end of the swing table for monitoring winch)

Engine high speed detection AML abnormality

(CRT display dims while lamp is turned ON.)

With medium current filter

Overwinding detection

Top boom full RET

Main winch hoist-up Main winch hoist-down Aux. winch hoist-up Aux. winch hoist-down Telescoping EXT Telescoping RET Elevation raising Elevation lowering Swing right Swing left Swing dead angle detection Boom telescoping mode selection C/W mounting conditon detection 1 C/W mounting conditon detection 2 Swing lock pin detection Cancelling boom raising limit during jib set Boom full RET detection Full automatic jib RET detection Overwinding cutout SW input Main winch dead wrap detection Auxiliary winch dead wrap detection Full automatic jib mounting/stowing selection FAJ telescoping operation selection Dismounting FAJ raising, RET detection FAJ lowering, EXT selection Elevation high speed selection

AML controller (AML - V)

Aux. winch hoist-up detection (contact broken during hoisting up)

Main winch hoist-down detection (contact broken during hoisting down)

Z-3

Camera

Speaker (installed in rear side in the cab.)

Fuse box Wiring diagram (Crane electrical equipment circuit)

Main winch hoist-up detection (contact broken during hoisting up)

Z-3 Z-3

7

from battery

from starter SW AC terminal

from main fuse

8 Z03-6520E Color

for camera elevation selection for main winch drum lock release for aux. winch drum lock release for swing lock pin release

Main winch drum lock release SW Aux. winch drum lock release SW Swing lock pin release SW

Telescoping/elevating speed selector SOL

for elevation · telescoping · jib high speed selection

SOL for winch high-speed selection

SOL for swing free

Swing brake release SOL

Camera elevation selector SW

Crane operation highspeed selector SW

Swing free / lock selector SW (S lever)

Swing free / lock selector SW (M lever)

Swing free / lock selector SW (panel)

Swing brale release SW

Control lever pilot circuit vent SOL

Boom lowering reducing pressure SOL

Shield

Wiring diagram crane lower

Shield

Shield

Hydraulic oil 50°C detector SW

Shield

Controller

Main/aux. selection input

Tail lamp input

External reset input

Phase B input by proximity switch (aux.)

Phase A input by proximity switch (aux.)

Phase B input by proximity switch (main)

Phase A input by proximity switch (main)

Power supply

Constant current amplifier

Elevation slow stop cancel SW

Shield

Shield

to working lamp SW Main/aux. selection input

Shield

AML external indicator lamp

Red

Yellow

Oil cooler selector SOL

Engine revolution sensor

Swing left detection (contact broken during swinging left)

Swing right detection (contact broken during swinging right)

Elevation lowering detection (contact broken during lowering)

Telescoping RET detection (contact broken during retracting)

SOL for No.3 CYL

SOL for No.2 CYL

SOL for No.1 CYL

Accumulator low pressure warning lamp

for AML vent

AML abnormality indicator lamp

Green

Swing angle detector

(Boom length detector)

(Boom angle detector)

Converter

Swing stop

Swing automatic stop proportional control solenoid valve

Elevation slow stop proportional control solenoid valve

S/T overwinding detector SW

Swing lock pin indicator lamp

Elevation slow stop cancel indicator lamp

Swing stop release indicator lamp

AML alarm buzzer

Drum rotation detector SW

AML external indicator lamp selector SW

Reset input

No.2 CYL correction

2ndm 3rd boom emergency SW

For emergency in AML failure

(Accumulator pressure sensor)

(Main pressure sensor)

Swing automatic stop cancel SW

Swing

Elevation

Swing voice alarm unit

No.3 CYL correction

No.1 CYL correction

Swing alarm selector SW

AML emergenct SW

Swing

Elevation

Transmitter ASS’Y Signal

to Carrier · light SW

Transmitter

Swing dead angle detection

Moment detector

Full RET detector SW

Boom lowering reducing pressure indicator lamp

Shield Shield

Swing brake indicator lamp

Boom lowering reducing pressure S/W

10A Power supply

Buzzer output (AML alarm)

Buzzer output (accumulator low-pressure alarm)

Automatic stop 2 (telescoping stop valve) Automatic stop 3 (due to instability in the rear portion、etc)

Automatic stop 1 (due to overload、 overwinding、etc)

Over-front area output

Lever stand tilt detector SW (contact broken for tilting down)

To power supply of multi-display main body

sign is applied GA5135 ~ .

Marks

the sectional area of electric wire (mm2)

A color of trace that mixed with a ground color A ground color of electric wire

Method of indication for wiring

This figure is shown the state of below.

Crane running Boom section full retraction Boom forward position Overwinding Starter switch : OFF Control lever : neutral

Option

Over-rear area output

Swing stop

External indicator lamp (-90%) External indicator lamp (90-100%) External indicator lamp (100%-)

Boom angle input Main pressure input Boom length input Accumulator pressure input Swing angle input

Shield

to working lamp

Swivel joint

Cord reel

Boom overwinding detection (contact broken during overwinding)

Overwinding release SW

Upper electric circuit

Shield

to L working SW

to wiring diagram, mounting / dismounting

wrap detection

Aux. remaining

MAIN remaining wrap detection

to wiring diagram, mounting / dismounting

to wiring diagram, mounting / dismounting

to wiring diagram, mounting / dismounting

Elevation raising detection (contact broken during raising)

Telescoping EXT detection (contact broken during extending)

Aux. winch hoist-down detection (contact broken during hoisting down)

Electric Circuit

(Installed on the rear end of the swing table for monitoring winch)

Engine high speed detection

Overwinding detection

(CRT display dims while lamp is turned ON.)

With medium current filter

Elevation high speed selection

Dismounting

Overwinding cutout SW input Main winch dead wrap detection Auxiliary winch dead wrap detection

Boom full RET detection

C/W mounting conditon detection 1 C/W mounting conditon detection 2 Swing lock pin detection

Main winch hoist-up Main winch hoist-down Aux. winch hoist-up Aux. winch hoist-down Telescoping EXT Telescoping RET Elevation raising Elevation lowering Swing right Swing left Swing dead angle detection

AML controller (AML - V)

Aux. winch hoist-up detection (contact broken during hoisting up)

Main winch hoist-down detection (contact broken during hoisting down)

Z-3

Camera

Speaker (installed in rear side in the cab.)

Fuse box Wiring diagram (Crane electrical equipment circuit)

Main winch hoist-up detection (contact broken during hoisting up)

Z-3 Z-3

8

from battery

from starter SW AC terminal

from main fuse

9 Z03-6520E Color

Swing brake indicator lamp

Buzzer 2

Cab tilt indicator lamp

for camera elevation selection for main winch drum lock release for aux. winch drum lock release for swing lock pin release

Main winch drum lock release SW Aux. winch drum lock release SW Swing lock pin release SW

Telescoping/elevating speed selector SOL

for elevation · telescoping · jib high speed selection

SOL for winch high-speed selection

SOL for swing free

Swing brake release SOL

Shield

Wiring diagram crane lower

Shield

Shield

Hydraulic oil 50°C detector SW

Shield

Controller

Main/aux. selection input

Tail lamp input

External reset input

Phase B input by proximity switch (aux.)

Phase A input by proximity switch (aux.)

Phase B input by proximity switch (main)

Phase A input by proximity switch (main)

Power supply

Elevation slow stop cancel SW

Shield

Shield

to working lamp SW Main/aux. selection input

Shield

AML external indicator lamp

Red

Yellow

Oil cooler selector SOL

Engine revolution sensor

Swing left detection (contact broken during swinging left)

Swing right detection (contact broken during swinging right)

Elevation lowering detection (contact broken during lowering)

Telescoping RET detection (contact broken during retracting)

SOL for No.3 CYL

SOL for No.2 CYL

SOL for No.1 CYL

SOL for top CYL selection

Accumulator low pressure warning lamp

for AML vent

AML abnormality indicator lamp

Green

Swing angle detector

(Boom length detector)

(Boom angle detector)

Converter

Swing stop

Swing automatic stop proportional control solenoid valve

Elevation slow stop proportional control solenoid valve

S/T overwinding detector SW

Swing lock pin indicator lamp

Elevation slow stop cancel indicator lamp

Swing stop release indicator lamp

AML alarm buzzer

Drum rotation detector SW

AML external indicator lamp selector SW

Reset input

No.2 CYL correction

For emergency in AML failure

(Accumulator pressure sensor)

(Main pressure sensor)

Swing automatic stop cancel SW

Swing

Elevation

Constant current amplifier

Elevation speed selection

Swing voice alarm unit

No.3 CYL correction

No.1 CYL correction

Swing alarm selector SW

AML emergenct SW

Swing

Elevation

Boom elevating slow stop cancel

Transmitter ASS’Y Signal

to Carrier · light SW

Transmitter

Swing dead angle detection

Moment detector

Full RET detector SW

Control lever pilot circuit vent SOL

Shield Shield

Camera elevation selector SW

Crane operation highspeed selector SW

Swing free / lock selector SW (S lever)

Swing free / lock selector SW (M lever)

Swing free / lock selector SW (panel)

Swing brale release SW

Cab tilt detector SW

10A Power supply

Buzzer output (AML alarm)

Buzzer output (accumulator low-pressure alarm)

Automatic stop 2 (telescoping stop valve) Automatic stop 3 (due to instability in the rear portion、etc)

Automatic stop 1 (due to overload、 overwinding、etc)

Over-front area output

Lever stand tilt detector SW (contact broken for tilting down)

To power supply of multi-display main body

sign is applied GA5135 ~ .

Marks

the sectional area of electric wire (mm2)

A color of trace that mixed with a ground color A ground color of electric wire

Method of indication for wiring

This figure is shown the state of below.

Crane running Boom section full retraction Boom forward position Overwinding Starter switch : OFF Control lever : neutral

Option

Over-rear area output

Swing stop

External indicator lamp (-90%) External indicator lamp (90-100%) External indicator lamp (100%-)

Boom angle input Main pressure input Boom length input Accumulator pressure input Swing angle input

Shield

to working lamp

Swivel joint

Cord reel

Boom overwinding detection (contact broken during overwinding)

Overwinding release SW

Upper electric circuit

Shield

to L working SW

to wiring diagram, mounting / dismounting

wrap detection

Aux. remaining

MAIN remaining wrap detection

to wiring diagram, mounting / dismounting

to wiring diagram, mounting / dismounting

to wiring diagram, mounting / dismounting

Elevation raising detection (contact broken during raising)

Telescoping EXT detection (contact broken during extending)

Aux. winch hoist-down detection (contact broken during hoisting down)

Electric Circuit

(Installed on the rear end of the swing table for monitoring winch)

AML abnormality

Engine high speed detection

Overwinding detection

(CRT display dims while lamp is turned ON.)

With medium current filter

Elevation high speed selection

Dismounting

Overwinding cutout SW input Main winch dead wrap detection Auxiliary winch dead wrap detection

Boom full RET detection

C/W mounting conditon detection 1 C/W mounting conditon detection 2 Swing lock pin detection

Main winch hoist-up Main winch hoist-down Aux. winch hoist-up Aux. winch hoist-down Telescoping EXT Telescoping RET Elevation raising Elevation lowering Swing right Swing left Swing dead angle detection

AML controller (AML - V)

Aux. winch hoist-up detection (contact broken during hoisting up)

Main winch hoist-down detection (contact broken during hoisting down)

Z-3

Camera

Speaker (installed in rear side in the cab.)

Fuse box Wiring diagram (Crane electrical equipment circuit)

Main winch hoist-up detection (contact broken during hoisting up)

Z-3 Z-3

9

Z-4

Z-4

Electric Circuit Crane electrical equipment circuit

Water temperature gauge

Temperature sender unit

Fuel gauge

Fuel sender unit Horn

Power supply for mounting/dismounting

Horn switch (Swing lever)

NISSAN carrier only

[radio] power supply illumination illumination power supply

Speaker (left) Speaker (right

Upper electric circuit

Fuse box

to CN 2 - 49, 50 to CN 1 - 35 to CN 2 - 59, 60 to accessory circuit AML power supply, solenoid

AML controller Cigar lighter

to panel lamp

from main fuse from starter switch AC terminal

to control amplifier

to blower motor, etc.

Panel switch Boom lamp

from battery

Working lamp Winch drum illumination lamp

Working lamp SW

Front lamp

Wiper motor

Intermittent wiper relay

Rotary joint

Rear lamp

Wiper motor

Intermittent wiper relay

Washer motor

To carrier light SW

Front

Roof

Window washer

Front wiper switch

Room lamp

10

Z03-6530E

Roof wiper switch Opened door detector SW (Contact broken for door left open)

10

11 Z03-6540E Swing lock pin detection

C/W mounting conditon detection 1 C/W mounting conditon detection 2

Dismounting

Counterweight lock/release control emergency switch

to fuse A

mounting/dismounting ring lock/release control switch

Cab tilt control switch

Counterweight lock/release control switch

Counterweight cylinder telescoping control switch

Crane dismounting SW

Counter weight lock release indicator lamp

Counter weight lock indicator lamp

Counter weight improper setup warning lamp

C/W cylinder full extension indicator lamp

Crane dismount indicator lamp

C/W cylinder extending stroke end detection (left)

Hydraulic valve (for switching swing/ dismounting circuit)

Accelerator cylinder

Control unit (for mounting/ disounting)

Counter weight lock release detection (left)

Counter weight lock detection (left)

(Standard weight)

C/W cylinder retracting stroke end detection (left)

Extra weight mounting conditon detection

Swing lock pin detection

Extra weight mounting conditon detection

Counter weight lock release detection (right)

Counter weight lock detection (right)

C/W cylinder retracting stroke end detection (right)

(Standard weight)

C/W cylinder retracting stroke end detection (left) (Extra weight) C/W cylinder retracting (Extra weight) stroke end detection (right)

C/W cylinder extending stroke end detection (right) (Contact for stroke end)

Lock Lock release

Cab tilting up

Cab tilting down

Counterweight lock release Counterweight lock

Counterweight EXT Counterweight RET

Remote control valve (for mounting/dismounting)

Z-5 Z-5

Electric Circuit

Electric circuit for mounting/dismounting revolving superstructure、counterweight

11

C/W mounting conditon detection 1 C/W mounting conditon detection 2 Swing lock pin detection

Dismounting

Counterweight lock/release control emergency switch

to fuse A

12 Z03-6540E mounting/dismounting ring lock/release control switch

Cab tilt control switch

Counterweight lock/release control switch

Counterweight cylinder telescoping control switch

Crane dismounting SW

Counter weight lock release indicator lamp

Counter weight lock indicator lamp

Counter weight lock release indicator lamp

Counter weight lock indicator lamp

Counter weight improper setup warning lamp

C/W cylinder full extension indicator lamp

Crane dismount indicator lamp

Counter weight lock release detection (left)

Counter weight lock detection (left)

(Standard weight)

C/W cylinder retracting stroke end detection (left)

C/W cylinder retracting stroke end detection (left) (Extra weight)

C/W cylinder extending stroke end detection (left)

Hydraulic valve (for switching swing/ dismounting circuit)

Accelerator cylinder

Control unit (for mounting/ disounting)

Counter weight lock release detection (right)

Counter weight lock detection (right)

Counter weight lock release detection (left)

Counter weight lock detection (left)

Extra weight mounting conditon detection

Swing lock pin detection

Extra weight mounting conditon detection

Counter weight lock release detection (right)

Counter weight lock detection (right)

C/W cylinder retracting stroke end detection (right)

(Standard weight)

(Extra weight)

C/W cylinder retracting stroke end detection (right)

C/W cylinder extending stroke end detection (right) (Contact for stroke end)

Lock Lock release

Cab tilting up

Cab tilting down

Counterweight lock release Counterweight lock

Counterweight EXT Counterweight RET

Remote control valve (for mounting/dismounting)

Z-5 Z-5

Electric Circuit

Electric circuit for mounting/dismounting revolving superstructure、counterweight

12

Z-5

Z-5

Electric Circuit Electric circuit for mounting/dismounting revolving superstructure、counterweight to fuse A

Crane dismounting SW

Remote control valve (for mounting/dismounting)

Crane dismount indicator lamp Counterweight swing control emergency switch

Counterweight cylinder telescoping control switch

Counterweight EXT Counterweight RET Counterweight swing control switch

(Right swing)

Control unit (for mounting/ disounting)

(Left swing)

Accelerator cylinder Counterweight lock release Counterweight lock

Cab tilting down Cab tilting up

mounting/dismounting ring rotation switch

Lock Lock release

Dismounting

Swing, remote control selector SOL

C/W mounting conditon detection 1 C/W mounting conditon detection 2 Swing lock pin detection

C/W cylinder full extension indicator lamp C/W cylinder extending stroke end detection (right) (Contact for stroke end)

C/W cylinder extending stroke end detection (left) C/W cylinder retracting detection (left)

E/W cylinder retracting (right) (Contact for extending) C/W culinder RET detection (right) (Contact for extending)

C/W cylinder retracting detection (left)

Counter weight setup warning lamp Counter weight lock indicator lamp

Counter weight lock detection (right) (Contact for locking)

Counter weight lock detection (left)

Counter weight lock release indicator lamp

Counter weight lock release detection (right)

Counter weight lock release detection (left)

(Contact for releasing)

6.8 ton weight mounting detection

(Contact for mounting C/W)

Swing lock pin detection

(Contact for locking swing)

14 ton weight mounting detection (Contact for mounting C/W)

13

Z03-6540E

13

Z-6

Z-6

Electric Circuit Engine electric circuit Lamp Lamp (hydraulic (oil filter) pressure)

Lamp Lamp (air filter) (charging)

Air cleaner filter

Harness in cab (power supply line) Working lamp switch

Oil filter alarm switch

Water temperature gauge

Hydraulic pressure switch Temperature sender unit

Working lamp switch

Fuel gauge

Relay (engine stop)

Fuse box

Air conditioner power supply

Spare fuse Engine

Starter switch

Generator

in cab Engine stop motor

Battery relay Starter

Battery

14

Fuel sender unit Z03-6550E

Retarding unit

Safety relay

Heater relay

14

Z-7

Z-7

Electric Circuit

Carrier

Swing table

to working lamp Earth

to AML controller

Lower electric circuit

(Emergency)

Rotary joint

to carrier light SW

Shield

Extend/retract selector switch

Solenoid valve (engine low-speed)

Solenoid valve (FR) (slide/jack selection)

Solenoid valve (RR) (slide/jack selection)

Engine rotation selector switch

Front right outrigger extention length detector

Shield

Shield

Solenoid valve (engine high-speed)

Slide/jack selector switch

Front left outrigger extention length detector

Shield

Shield

Slide/jack selector relay Front right Front left Rear right Rear left

Rear right outrigger extention length detector

Shield

Shield

Outrigger control box (right side)

Front right

Swing lock pin (backward) detector SW

Rear left outrigger extention length detector

Shield

Shield Switch input Switch input Switch input F/J overloading O/R stowing F/J earth Switch input Switch input

Boom stowing detector SW

Load of front jack detector SW

Outrigger control relay (Controllable when turn on electricity)

outrigger stowing detector relay

Signal transmitter (for outrigger) Fuse

(Outrigger stowing) Slide/jack selector switch

Solenoid valve (F/J) (Front jack selection)

Solenoid valve (F/J) (Outrigger circuit selection)

Solenoid valve (extend/retract selection)

Solenoid valve (FL) (Slide/jack selection)

Solenoid valve (RL) (Slide/jack selection)

Engine rotation selector switch (F/J earth detection keep relay)

Extend/retract selector switch

(Timer relay)

Front jack earth detection pressure SW

(F/J earth detection)

Carrier side power supply

Terminal ASS’Y (Diode ASS’Y)

(Emergency)

15

Z03-6560E

Outrigger control box (left side)

15

Z-7

Z-7

Z-7

Electric Circuit Lower electric circuit Installed at FAUN.

to AML controller

Swing table

Rotary joint

Carrier

to working lamp

Swing lock pin detector SW

to carrier light SW

Boom interlock release SW

FR outrigger EXT length detector

Shield Accelerator SW

Slide / jack selector SW

Collective control switch

C/W mounting conditon detector relay (OFF during mounting)

Earth

Over-front area detector relay (ON during detecting over-front area)

to swing lock pin detector power supply

to suspension lock selector SW

to Power supply for outrigger

FR outrigger control SW

RR outrigger control SW

RL outrigger control SW

FL outrigger control SW

Right outrigger control box

Shield

Shield FL outrigger EXT length detector

Shield

Shield

Slide / jack selector SW

Shield Accelerator SW

Collective control switch

RR outrigger EXT length detector

Shield RL outrigger EXT length detector

Boom retracting detector SW

Shield

Shield

Switch input Switch input Switch input F/J overloading O/R stowing Switch input Switch input Switch input

(#GA5072 ~ #GA5088 only)

for Suspension lock release

for Slide EXT reducing pressure

for outrigger on loading

for FL slide EXT

for FL jack EXT

for RL slide RET

for FL jack RET

for RL slide EXT

for RL jack EXT

for RL slide RET

for RL jack RET

for RR slide RET

for RR jack RET

for RR slide EXT

for RR jack EXT

for FR slide RET

for FR jack RET

for FR slide EXT

for FR jack EXT

for outrigger accelerator

FR outrigger control SW

RR outrigger control SW

Signal transmitter (for outrigger)

RL outrigger control SW

FL outrigger control SW

Boom interlock release SW

Left outrigger control box

*1 Applicable serial No. sign is Applicable serial No. of relay, diode K617 (relay) of RTF100-4, V612 (diode) are used as alternative parts from #GA5036, #GA5065, #GA5066, #GA5069, #GA5070, #GA5072 ~ #GA5088, #GA5089.

16

Z03-6560E

16

Z-8

Z-8

Electric Circuit Air conditioner circuit (option)

Pressure switch (Dual switch for high/low-pressure)

Capacitor Control panel Blower switch

Mode selector SW

Heater

Panel lamp

Capacitor relay Working lamp switch

A/C unit

Power supply draw port

Blower relay

Compressor clutch relay Blower register

(Blower motor) (internal air thermistor)

(internal air thermistor) Blower motor

Water valve servo motor

Air conditioner control amplifier Servo motor for mode selector

Voltage check relay

17

Z04-6570E

17

Z-8

Z-8

Electric Circuit Air conditioner circuit (option)

Dual pressure switch

Control panel Blower switch Pressure switch for electric fan gear

Register for electric fan gear

Heater Mode selector SW

Panel lamp Panel lamp

Relay for electric fan

A/C unit

Blower relay

Power supply

Power supply Working lamp switch draw port

Compressor clutch relay

Blower register

internal air Blower motor thermistor (3820° K)

Water valve servo motor

Air conditioner control amplifier Servo motor for mode selector Voltage check relay

18

Z04-6570E

18

Z-9

Z-9

Z-9

Electric Circuit

Fuel gauge

Water temperature gauge

Upper wiring (cab)

AML cancel state warning

Accumulator low-pressure warning

Swing automatic stop cancel indication

Cab tilt state indication

Mounting / dismounting operation state indication

Hook amount of movement main / aux. selection

Swing lock pin selection

Swing brake state indication

Boom sequential telescoping indication

Jib tilt operation indication

Jib removed indicator lamp

Boom telescoping indicator lamp

Warning for air filter choking

Warning for charging

Jib telescoping indicator lamp

Boom synchronized telescoping indication

C/W lock release indication Winch, telescoping, elevation speed selection

Swing free selection

Swing brake release SW

Swing lock indication

Jib tilt indicator lamp

C/W CYL stroke end indication

Elevation slow stop cancel indication Hook amount of movement indication reset

C/W lock indication

C/W improper set warning

Boom telescoping mode selection

C/W telescoping operation selection

C/W free/lock selection

Crane dismounting SW

Working lamp SW

Eng. warning for oir filter choking

Eng. warning for oir pressure choking

Window washer SW

Wiper (roof)

Starter SW Wiper (front)

Capacitor for preventing front wiper motor noise

Capacitor for preventing roof wiper motor noise

Capacitor for preventing window washer motor noise

Phase A input by proximity switch (main) Phase B input by proximity switch (main) Phase A input by proximity switch (aux.)

Phase B input by proximity switch (aux.)

External reset input

Transmitter 5

Wiper relay (front)

Swing Elevation front

Swing Swing Elevation Elevation

roof

Window washer tank

Shield Y

Back lamp Main/aux. selection input Hook amount of movement indicator

Constant current amplifier

Wiper relay (roof)

Shield Y

Door SW for room lamp

Wiper (roof) Horn relay

Wiper (front) Stop relay Nissan Diesel Eng. spare parts Fuse box

Working lamp

Diode ASS’Y Converter Accelerator controller

AML controller

Keep relay

Boom telescoping Jib tilt

Jib telescoping

Cab tilt SW

Noise filter Swing alarm buzzer selector SW

to AML harness

Jib mounting/stowing selector SW

AML external indicator lamp selector SW

3rd boom corrector SW

Diode ASS’Y

Di 1 Di 2 Di 3 Di 4 Di 5 Di 6 Di 7 Di 8 Di 9 Di 10 Di 12 Di 13 Di 14 Di 15 Di 16 Di 17 Di 19

MAIN remaining wrap detection Aux. remaining wrap detection Jib dismounting FAJ tilt, telescoping selection Upper mounting / dismounting FAJ upper, RET FAJ lower, EXT Top full RET detecetion Overwinding cutout

Di 20 Di 21 Di 22 Di 23 Di 24 Di 25 Di 26 Di 28 Di 29

External indicator lamp (-90%) External indicator lamp (90-100%) External indicator lamp (100%-) F/J overload alarm output Swing stop output Jib tilt alarm output Over-rear area output Incorrect jib set output Over-front area output

TR 1 TR 2 TR 3 TR 4 TR 5 TR 6 TR 7 TR 8 TR 9

C/W emergency lock selector SW Automatic stop 1 (due to overload、overwinding、etc) Automatic stop 3 (due to instability in the rear portion) etc Jib tilt working output Buzzer output (accumulator low pressure alarm) Buzzer output (AML alarm) Telescoping control output No.1

Di

4th, top boom corrector SW

Main winch hoisting up Main winch hoisting down Aux. winch hoisting up Aux. winch hoisting down Telescoping EXT Telescoping RET Elevation raising Elevation lowering Swing right Swing left Boom telescoping mode selection C/W mounting conditon detection 1 C/W mounting conditon detection 2 Jib stowing detection Elevation raising stop cancel Boom full RET detection Overwinding cutout

4th, top boom emergency SW

Drum lock (Main) selection

Power supplu (24V) for clock

Power supplu (24V)

2nd, 3rd boom emergency SW

2nd boom corrector SW

Overwinding cutout SW

Swing stop release SW

Elevation slow stop cancel SW

Drum lock (Aux.) selection

Air conditioner ASS’Y

Inching swing SW AML Buzzer 1

for Slow stop emergency

Jib tilt working alarm buzzer 3

Camera elevation selection

AML canceling SW

to AML vent SOL in AML failure

Jib output stop alarm buzzer 4

Horn SW (swing lever)

Cab tilt alarm buzzer 2 Radio ASS’Y

Top boom EXT SW (telescoping lever) Cigar lighter Speaker for radio

Swing free SW (aux. winch lever)

Speaker for AML

Shield

Speaker for radio

Shield

Lever stand tilt detector SW (R)

Boom jib selection

NOTE 1 sign : Applicable serial No (4 places) : #GA5054 ~ 2 sign : Applicable serial No (1 place) : #GA5083, #GA5086 ~ #GA5088

Swing free SW (main winch lever) Winch drum rotation sensor Wiring ASS’Y (engine)

19

Z04-1250E

Wiring ASS’Y (swing table)

19

Z-9

Z-9

Z-9

Electric Circuit

Fuel gauge

Water temperature gauge

Upper wiring (cab) AML abnormality indicator lamp

Accumulator low-pressure warning

Swing automatic stop cancel indicator lamp

Cab tilt state indicator lamp

Crane dismount indicator lamp

Counter weight improper setup warning lamp

C/W lock indicator lamp

Swing lock indicator lamp

Swing brake state indicator lamp

Boom sequential telescoping indicator lamp

Jib tilt operation indicator lamp

Jib removed indicator lamp

Boom telescoping indicator lamp

Warning for air filter choking

Warning for charging

Jib tilt indicator lamp

Jib telescoping indicator lamp

Hook amount of movement indication reset

Hook amount of movement main / aux. selection

C/W cylinder full extension indicator lamp

Elevation slow stop cancel indicator lamp Swing lock pin release SW

Swing free/lock selection

Swing brake release SW

Boom synchronized telescoping indicator lamp

C/W lock release indicator lamp Winch/jib, telescoping/elevation high speed selector SW

Boom telescoping mode selector SW

C/W CYL telescoping operation SW

C/W free/lock operation SW

Eng. warning for oir pressure choking

Eng. warning for oir filter choking Crane dismounting SW

Working lamp SW

Window washer SW

Starter SW

Roof wiper SW

Front wiper SW

Capacitor for preventing front wiper motor noise

Capacitor for preventing roof wiper motor noise

Capacitor for preventing window washer motor noise

Elevation slow stop cancel input

Phase A input by proximity switch (main) Phase B input by proximity switch (main) Phase A input by proximity switch (aux.)

Phase B input by proximity switch (aux.)

External reset input

Signal transmitter (for swing, elevation stop)

Wiper relay (front)

Swing Elevation front

Shield Y

Swing Swing Elevation Elevation

roof

Window washer tank

Back lamp Main/aux. selection input Hook amount of movement indicator

Constant current amplifier

Wiper relay (roof)

Shield Y

Door SW for room lamp

(roof) Wiper motor

Horn relay

(front) Wiper motor

Stop relay

Fuse box Working lamp

Diode ASS’Y Converter

Accelerator controller

AML controller

Fuse

Keep relay

Boom telescoping Jib tilt

Noise filter to AML harness

Swing alarm buzzer selector SW

Jib mounting/stowing selector SW

4th, top boom corrector SW

Jib telescoping

Boom / jib selector SW

Di

MAIN remaining wrap detection Aux. remaining wrap detection Jib dismounting FAJ tilt, telescoping selection Upper mounting / dismounting FAJ upper, RET FAJ lower, EXT Top full RET detecetion Overwinding cutout

Di 20 Di 21 Di 22 Di 23 Di 24 Di 25 Di 26 Di 28 Di 29

External indicator lamp (-90%) External indicator lamp (90-100%) External indicator lamp (100%-) F/J overload alarm output Swing stop output Jib tilt alarm output Over-rear area output Incorrect jib set output Over-front area output

TR 1 TR 2 TR 3 TR 4 TR 5 TR 6 TR 7 TR 8 TR 9

Automatic stop 1 (due to overload、overwinding、etc) Automatic stop 3 (due to instability in the rear portion) etc Jib tilt working output Buzzer output (accumulator low pressure alarm) Buzzer output (AML alarm) Telescoping control output No.1

Drum lock (Main) selection

4th, top boom emergency SW

Di 1 Di 2 Di 3 Di 4 Di 5 Di 6 Di 7 Di 8 Di 9 Di 10 Di 12 Di 13 Di 14 Di 15 Di 16 Di 17 Di 19

Cab tilt operation SW

AML external indicator lamp selector SW

C/W emergency lock selector SW

Main winch hoisting up Main winch hoisting down Aux. winch hoisting up Aux. winch hoisting down Telescoping EXT Telescoping RET Elevation raising Elevation lowering Swing right Swing left Boom telescoping mode selection C/W mounting conditon detection 1 C/W mounting conditon detection 2 Jib stowing detection Elevation raising stop cancel Boom full RET detection Overwinding cutout

Power supplu (24V) for clock 3rd boom corrector SW

Diode ASS’Y

2nd, 3rd boom emergency SW

2nd boom corrector SW

Overwinding cutout SW

Swing stop release SW

Elevation slow stop cancel SW

Power supplu (24V)

Drum lock (Aux.) selection

Air conditioner ASS’Y

Inching swing SW

AML Buzzer 1

for Slow stop emergency

Camera elevation selection

AML emergency SW

to AML vent SOL in AML failure

Jib tilt working alarm buzzer 3

Jib output stop alarm buzzer 4

Horn SW (swing lever)

Cab tilt alarm buzzer 2 Radio ASS’Y

4th, top boom EXT SW (telescoping lever)

Cigar lighter Speaker for radio

Lever stand tilt detector SW

Speaker for radio

Swing free/lock selector SW (main winch lever)

Speaker for AML

Shield

Shield

Swing free/lock selector SW (aux. winch lever)

Boom jib selection

Engine wiring

20

Z04-1250E

NOTE 1 sign : Applicable serial No : GA5089 ~ GA5095, GA5097, GA5099, GA5101, GA5103, GA5104, GA5106, GA5107

Winch drum rotation sensor Upper wiring

(swing table)

20

Z-9

Z-9

Z-9

Electric Circuit

Fuel gauge

Water temperature gauge

Upper wiring (cab) AML abnormality indicator lamp

Accumulator low-pressure warning

Cab tilt state indicator lamp

Swing automatic stop cancel indicator lamp

Crane dismount indicator lamp

Counter weight improper setup warning lamp

C/W lock indicator lamp

Swing brake state indicator lamp

Swing lock indicator lamp

Boom sequential telescoping indicator lamp

Jib tilt operation indicator lamp

Boom telescoping indicator lamp

Jib removed indicator lamp

Warning for air filter choking

Warning for charging

Jib tilt indicator lamp

Jib telescoping indicator lamp

C/W cylinder full extension indicator lamp

Elevation slow stop cancel indicator lamp Hook amount of movement indication reset

Hook amount of movement main / aux. selection

Swing lock pin release SW

Swing free/lock selection

Swing brake release SW

Boom synchronized telescoping indicator lamp

C/W lock release indicator lamp Winch/jib, telescoping/elevation high speed selector SW

Boom telescoping mode selector SW

C/W CYL telescoping operation SW

C/W free/lock operation SW

Eng. warning for oir filter choking Crane dismounting SW

Working lamp SW

Eng. warning for oir pressure choking

Window washer SW

Starter SW

Roof wiper SW

Front wiper SW

Elevation speed selector volume

Capacitor for preventing front wiper motor noise

Capacitor for preventing roof wiper motor noise

Capacitor for preventing window washer motor noise

Elevation slow stop cancel input

Phase A input by proximity switch (main) Phase B input by proximity switch (main) Phase A input by proximity switch (aux.)

Phase B input by proximity switch (aux.)

External reset input

Signal transmitter (for swing, elevation stop)

Wiper relay (front)

Swing Elevation front

Swing Swing Elevation Elevation

roof

Window washer tank

Shield Y

Back lamp Main/aux. selection input Hook amount of movement indicator

Constant current amplifier

Wiper relay (roof) Shield Y

Door SW for room lamp

(roof) Horn relay

Wiper motor

(front) Stop relay

Wiper motor

Working lamp

Fuse box Diode ASS’Y Converter

Accelerator controller

AML controller

Fuse

Keep relay

Boom telescoping Jib tilt

Noise filter

Swing alarm buzzer selector SW

Jib mounting/stowing selector SW

4th, top boom corrector SW

Jib telescoping

Boom / jib selector SW

Di

Di 20 Di 21 Di 22 Di 23 Di 24 Di 25 Di 26 Di 28 Di 29

External indicator lamp (-90%) External indicator lamp (90-100%) External indicator lamp (100%-) F/J overload alarm output Swing stop output Jib tilt alarm output Over-rear area output Incorrect jib set output Over-front area output

TR 1 TR 2 TR 3 TR 4 TR 5 TR 6 TR 7 TR 8 TR 9

Automatic stop 1 (due to overload、overwinding、etc) Automatic stop 3 (due to instability in the rear portion) etc Jib tilt working output Buzzer output (accumulator low pressure alarm) Buzzer output (AML alarm) Telescoping control output No.1

Drum lock (Main) selection

4th, top boom emergency SW

MAIN remaining wrap detection Aux. remaining wrap detection Jib dismounting FAJ tilt, telescoping selection Upper mounting / dismounting FAJ upper, RET FAJ lower, EXT Top full RET detecetion Overwinding cutout

Cab tilt operation SW

AML external indicator lamp selector SW

C/W emergency lock selector SW

Di 1 Di 2 Di 3 Di 4 Di 5 Di 6 Di 7 Di 8 Di 9 Di 10 Di 12 Di 13 Di 14 Di 15 Di 16 Di 17 Di 19

Jib stowing detection Elevation high speed selection Engine high speed detection AML abnormality alarm

Main winch hoisting up Main winch hoisting down Aux. winch hoisting up Aux. winch hoisting down Telescoping EXT Telescoping RET Elevation raising Elevation lowering Swing right Swing left Boom telescoping mode selection C/W mounting conditon detection 1 C/W mounting conditon detection 2 Jib stowing detection Elevation raising stop cancel Boom full RET detection Overwinding cutout

Power supplu (24V) for clock 3rd boom corrector SW

Diode ASS’Y

Power supplu (24V)

2nd, 3rd boom emergency SW

2nd boom corrector SW

Overwinding cutout SW

Swing stop release SW

Elevation slow stop cancel SW

Drum lock (Aux.) selection

Air conditioner ASS’Y

Inching swing SW AML Buzzer 1

for Slow stop emergency

Jib tilt working alarm buzzer 3

Camera elevation selection

AML emergency SW

to AML vent SOL in AML failure Jib output stop alarm buzzer 4

Horn SW (swing lever)

Cab tilt alarm buzzer 2 Radio ASS’Y

4th, top boom EXT SW (telescoping lever) Cigar lighter Speaker for radio

Swing free/lock selector SW (aux. winch lever)

Speaker for AML

Shield

Speaker for radio

Shield

Lever stand tilt detector SW

Boom jib selection

Swing free/lock selector SW (main winch lever)

Winch drum rotation sensor Engine wiring

21

Z04-1250E

Upper wiring

(swing table)

21

Z-9

Z-9

Z-9

Electric Circuit

Fuel gauge

Water temperature gauge

Upper wiring (cab) AML abnormality indicator lamp

Accumulator low-pressure warning

Cab tilt state indicator lamp

Swing automatic stop cancel indicator lamp

Crane dismount indicator lamp

Counter weight improper setup warning lamp

C/W lock indicator lamp

Boom sequential telescoping indicator lamp

Swing brake state indicator lamp

Swing lock indicator lamp

Jib tilt operation indicator lamp

Jib removed indicator lamp

Boom telescoping indicator lamp Warning for air filter choking

Warning for charging

Eng. warning for oir filter choking

Eng. warning for oir pressure choking

Jib tilt indicator lamp

Jib telescoping indicator lamp

C/W cylinder full extension indicator lamp

Elevation slow stop cancel indicator lamp Hook amount of movement indication reset

Hook amount of movement main / aux. selection

Swing lock pin release SW

Swing free/lock selection

Swing brake release SW

Boom synchronized telescoping indicator lamp

C/W lock release indicator lamp Winch/jib, telescoping/elevation high speed selector SW

Boom telescoping mode selector SW

C/W CYL telescoping operation SW

C/W free/lock operation SW

Crane dismounting SW

Working lamp SW

Window washer SW

Starter SW

Roof wiper SW

Front wiper SW

Elevation speed selector volume

Capacitor for preventing front wiper motor noise

Capacitor for preventing roof wiper motor noise

Capacitor for preventing window washer motor noise

Elevation slow stop cancel input

Phase A input by proximity switch (main) Phase B input by proximity switch (main) Phase A input by proximity switch (aux.)

Phase B input by proximity switch (aux.)

External reset input

Signal transmitter (for swing, elevation stop)

Wiper relay (front)

Swing Elevation front

Swing Swing Elevation Elevation

roof

Window washer tank

Shield Y

Back lamp Main/aux. selection input Hook amount of movement indicator

Constant current amplifier

Wiper relay (roof)

Shield Y

Door SW for room lamp

(roof) Horn relay

Wiper motor

(front) Stop relay

Wiper motor

Working lamp

Fuse box Diode ASS’Y Converter

Accelerator controller

AML controller

Fuse

Keep relay

Boom telescoping Jib tilt

Jib telescoping

Boom / jib selector SW

Jib mounting/stowing selector SW

4th, top boom corrector SW

AML external indicator lamp selector SW

C/W emergency lock selector SW

Di

Di 20 Di 21 Di 22 Di 23 Di 24 Di 25 Di 26 Di 28 Di 29

External indicator lamp (-90%) External indicator lamp (90-100%) External indicator lamp (100%-) F/J overload alarm output Swing stop output Jib tilt alarm output Over-rear area output Incorrect jib set output Over-front area output

TR 1 TR 2 TR 3 TR 4 TR 5 TR 6 TR 7 TR 8 TR 9

Automatic stop 1 (due to overload、overwinding、etc) Automatic stop 3 (due to instability in the rear portion) etc Jib tilt working output Buzzer output (accumulator low pressure alarm) Buzzer output (AML alarm) Telescoping control output No.1

Drum lock (Main) selection

4th, top boom emergency SW

MAIN remaining wrap detection Aux. remaining wrap detection Jib dismounting FAJ tilt, telescoping selection Upper mounting / dismounting FAJ upper, RET FAJ lower, EXT Top full RET detecetion Overwinding cutout

Cab tilt operation SW

Noise filter Swing alarm buzzer selector SW

Di 1 Di 2 Di 3 Di 4 Di 5 Di 6 Di 7 Di 8 Di 9 Di 10 Di 12 Di 13 Di 14 Di 15 Di 16 Di 17 Di 19

Jib stowing detection Elevation high speed selection Engine high speed detection AML abnormality alarm

Main winch hoisting up Main winch hoisting down Aux. winch hoisting up Aux. winch hoisting down Telescoping EXT Telescoping RET Elevation raising Elevation lowering Swing right Swing left Boom telescoping mode selection C/W mounting conditon detection 1 C/W mounting conditon detection 2 Jib stowing detection Elevation raising stop cancel Boom full RET detection Overwinding cutout

Power supplu (24V) for clock 3rd boom corrector SW

Diode ASS’Y

2nd boom corrector SW

Power supplu (24V)

2nd, 3rd boom emergency SW

Drum lock (Aux.) selection

Overwinding cutout SW

Air conditioner ASS’Y

Swing stop release SW

Elevation slow stop cancel SW

Inching swing SW AML Buzzer 1 Jib tilt working alarm buzzer 3

Camera elevation selection

AML emergency SW

for Slow stop emergency to AML vent SOL in AML failure

Jib output stop alarm buzzer 4

Horn SW (swing lever)

Cab tilt alarm buzzer 2 Radio ASS’Y

4th, top boom EXT SW (telescoping lever) Cigar lighter Speaker for radio

Swing free/lock selector SW (aux. winch lever)

Speaker for AML

Swing free/lock selector SW (main winch lever)

Shield

Speaker for radio

Shield

Lever stand tilt detector SW

Boom jib selection

Winch drum rotation sensor Engine wiring

22

Z04-1250E

Upper wiring

(swing table)

22

Z-9

Z-9

Z-9

Electric Circuit

Fuel gauge

Water temperature gauge

Upper wiring (cab) AML cancel state warning

Hook amount of movement indication reset

Accumulator low-pressure warning

Hook amount of movement main / aux. selection

Swing automatic stop cancel indication

Cab tilt state indication

Mounting / dismounting operation state indication

Swing brake state indication

Boom sequential telescoping indication

Jib tilt operation indication

Jib removed indicator lamp

Boom telescoping indicator lamp Warning for air filter choking

Warning for charging

Jib telescoping indicator lamp

Boom synchronized telescoping indication

C/W lock release indication Winch, telescoping, elevation speed selection

Swing free selection

Swing brake release SW

Swing lock indication

Jib tilt indicator lamp

C/W CYL stroke end indication

Elevation slow stop cancel indication Swing lock pin selection

C/W lock indication

C/W improper set warning

Boom telescoping mode selection

C/W telescoping operation selection

C/W free/lock selection

Crane dismounting SW

Working lamp SW

Eng. warning for oir filter choking

Eng. warning for oir pressure choking

Window washer SW

Wiper (roof)

Starter SW Wiper (front)

Elevation speed selector volume

Capacitor for preventing front wiper motor noise

Capacitor for preventing roof wiper motor noise

Capacitor for preventing window washer motor noise

Elevation slow stop cancel input

Phase A input by proximity switch (main) Phase B input by proximity switch (main) Phase A input by proximity switch (aux.)

Phase B input by proximity switch (aux.)

External reset input

Constant current amplifier Wiper relay (front)

Transmitter 5 Swing Elevation

Initialize input Display clear input

front

Swing Swing Elevation Elevation

roof

Window washer tank

Back lamp Main/aux. selection input

Wiper relay (roof)

Hook amount of movement indicator

Door SW for room lamp

Wiper (roof) Horn relay

Wiper (front) Stop relay Nissan Diesel Eng. spare parts Fuse box

Working lamp

Diode ASS’Y Converter

Accelerator controller

AML controller

Keep relay

Boom telescoping Jib tilt

Noise filter

Swing alarm buzzer selector SW

Jib telescoping

4th, top boom corrector SW

C/W emergency lock selector SW

4th, top boom emergency SW

MAIN remaining wrap detection Aux. remaining wrap detection Jib dismounting FAJ tilt, telescoping selection Upper mounting / dismounting FAJ upper, RET FAJ lower, EXT Top full RET detecetion Overwinding cutout

Di 20 Di 21 Di 22 Di 23 Di 24 Di 25 Di 26 Di 28 Di 29

External indicator lamp (-90%) External indicator lamp (90-100%) External indicator lamp (100%-) F/J overload alarm output Swing stop output Jib tilt alarm output Over-rear area output Incorrect jib set output Over-front area output

TR 1 TR 2 TR 3 TR 4 TR 5 TR 6 TR 7 TR 8 TR 9

Cab tilt SW

AML external indicator lamp selector SW Di

Jib mounting/stowing selector SW

Di 1 Di 2 Di 3 Di 4 Di 5 Di 6 Di 7 Di 8 Di 9 Di 10 Di 12 Di 13 Di 14 Di 15 Di 16 Di 17 Di 19

Jib stowing detection Elevation high speed selection Engine high speed detection AML abnormality alarm

Main winch hoisting up Main winch hoisting down Aux. winch hoisting up Aux. winch hoisting down Telescoping EXT Telescoping RET Elevation raising Elevation lowering Swing right Swing left Boom telescoping mode selection C/W mounting conditon detection 1 C/W mounting conditon detection 2 Jib stowing detection Elevation raising stop cancel Boom full RET detection Overwinding cutout

Automatic stop 1 (due to overload、overwinding、etc) Automatic stop 3 (due to instability in the rear portion) etc Jib tilt working output Buzzer output (accumulator low pressure alarm) Buzzer output (AML alarm) Telescoping control output No.1

Drum lock (Main) selection

Power supplu (24V) for clock 3rd boom corrector SW

Diode ASS’Y

2nd, 3rd boom emergency SW

2nd boom corrector SW

Overwinding cutout SW

Swing stop release SW

Elevation slow stop cancel SW

Power supplu (24V)

Drum lock (Aux.) selection

Air conditioner ASS’Y

Inching swing SW AML Buzzer 1

for Slow stop emergency

Camera elevation selection

AML canceling SW

to AML vent SOL in AML failure

Jib tilt working alarm buzzer 3

Jib output stop alarm buzzer 4

Horn SW (swing lever)

Cab tilt alarm buzzer 2 Radio ASS’Y

Top boom EXT SW (telescoping lever)

Cigar lighter Speaker for radio

Lever stand tilt detector SW (R)

Speaker for radio

Swing free SW (aux. winch lever)

Speaker for AML

Boom jib selection

Swing free SW (main winch lever)

Wiring ASS’Y (engine)

23

Z04-1250E

Wiring ASS’Y (swing table)

23

Z-9

Z-9

Z-9

Fuel gauge

Upper wiring (cab)

Water temperature gauge

Electric Circuit

AML cancel state warning

Accumulator low-pressure warning

Swing automatic stop cancel indication

Cab tilt state indication

Mounting / dismounting operation state indication

C/W improper set warning

C/W CYL stroke end indication

Elevation slow stop cancel indication Hook amount of movement indication reset

Hook amount of movement main / aux. selection

Swing lock pin selection

Swing free selection

Swing brake release SW

C/W lock indication

Swing lock indication

Boom sequential telescoping indication

Swing brake state indication

Jib tilt operation indication

Jib removed indicator lamp

Boom telescoping indicator lamp

Warning for air filter choking

Warning for charging

Jib tilt indicator lamp

Winch, telescoping, elevation speed selection

Jib telescoping indicator lamp

Boom synchronized telescoping indication

C/W lock release indication Boom telescoping mode selection

C/W telescoping operation selection

C/W free/lock selection

Crane dismounting SW

Working lamp SW

Eng. warning for oir filter choking

Eng. warning for oir pressure choking

Window washer SW

Wiper (roof)

Starter SW Wiper (front)

Elevation speed selector volume

Capacitor for preventing front wiper motor noise

Capacitor for preventing roof wiper motor noise

Capacitor for preventing window washer motor noise

Elevation slow stop cancel input

Constant current amplifier

Phase A input by proximity switch (main) Phase B input by proximity switch (main) Phase A input by proximity switch (aux.)

Phase B input by proximity switch (aux.)

External reset input

Transmitter 5

Wiper relay (front)

Swing Elevation front

Initialize input Display clear input

Swing Swing Elevation Elevation

roof

Window washer tank

Back lamp Main/aux. selection input

Wiper relay (roof)

Hook amount of movement indicator

Door SW for room lamp

Wiper (roof) Horn relay

Wiper (front) Stop relay Nissan Diesel Eng. spare parts Fuse box

Working lamp

Diode ASS’Y Converter Accelerator controller

Keep relay

Boom telescoping

Jib tilt

Jib telescoping

AML external indicator lamp selector SW Di

Jib mounting/stowing selector SW

4th, top boom corrector SW

3rd boom corrector SW

Diode ASS’Y

MAIN remaining wrap detection Aux. remaining wrap detection Jib dismounting FAJ tilt, telescoping selection Upper mounting / dismounting FAJ upper, RET FAJ lower, EXT Top full RET detecetion Overwinding cutout

Di 20 Di 21 Di 22 Di 23 Di 24 Di 25 Di 26 Di 28 Di 29

External indicator lamp (-90%) External indicator lamp (90-100%) External indicator lamp (100%-) F/J overload alarm output Swing stop output Jib tilt alarm output Over-rear area output Incorrect jib set output Over-front area output

TR 1 TR 2 TR 3 TR 4 TR 5 TR 6 TR 7 TR 8 TR 9

Cab tilt SW

Noise filter Swing alarm buzzer selector SW

C/W emergency lock selector SW

Automatic stop 1 (due to overload、overwinding、etc) Automatic stop 3 (due to instability in the rear portion) etc Jib tilt working output Buzzer output (accumulator low pressure alarm) Buzzer output (AML alarm) Telescoping control output No.1

4th, top boom emergency SW

Drum lock (Main) selection

Power supplu (24V) for clock

Power supplu (24V)

2nd, 3rd boom emergency SW

2nd boom corrector SW

Overwinding cutout SW

Swing stop release SW

Elevation slow stop cancel SW

Di 1 Di 2 Di 3 Di 4 Di 5 Di 6 Di 7 Di 8 Di 9 Di 10 Di 12 Di 13 Di 14 Di 15 Di 16 Di 17 Di 19

Jib stowing detection Elevation high speed selection Engine high speed detection AML abnormality alarm

AML controller Main winch hoisting up Main winch hoisting down Aux. winch hoisting up Aux. winch hoisting down Telescoping EXT Telescoping RET Elevation raising Elevation lowering Swing right Swing left Boom telescoping mode selection C/W mounting conditon detection 1 C/W mounting conditon detection 2 Jib stowing detection Elevation raising stop cancel Boom full RET detection Overwinding cutout

Drum lock (Aux.) selection

Air conditioner ASS’Y

Inching swing SW AML Buzzer 1

for Slow stop emergency

Jib tilt working alarm buzzer 3

Camera elevation selection

AML canceling SW

to AML vent SOL in AML failure

Jib output stop alarm buzzer 4

Horn SW (swing lever)

Cab tilt alarm buzzer 2 Radio ASS’Y

Top boom EXT SW (telescoping lever)

Cigar lighter Speaker for radio

Lever stand tilt detector SW (R)

Speaker for radio

Speaker for AML

Swing free SW (aux. winch lever) Boom jib selection

Swing free SW (main winch lever)

Wiring ASS’Y (engine)

24

Z04-1250E

Wiring ASS’Y (swing table)

24

Z-10

Z-10

Z-10

Main winch hoisting up

Main winch hoisting down

Aux. winch hoisting up

Aux. winch hoisting down

Telescoping EXT

Jib lowering

Telescoping RET

Jib raising

Elevation lowering

Elevation raising

Swing right

Swing left

Connect with harness in cab.

Boom length indicator lamp

Carrier light SW

(swing table)

Swing table length indicator

Tilt, telescoping selector SOL

Tilt, telescoping selector SOL

Main winch hoisting up

Overwinding detection

Cord reel

Main winch hoisting down Aux. winch hoisting up Aux. winch hoisting down

CN1

Top full RET detection

Telescoping EXT

Cord reel Working lamp

Telescoping RET Elevation raising

Boom working lamp

Elevation lowering Swing right

C/W mounting detection 1

Swing light FAJ raising, RET FAJ lowering, RET

Jib stowing detection

CN10

C/W mounting detection 2 C/W harness left

Swing dead angle Jib tilt, telescoping Overwinding Top full RET Working lamp

2nd/3rd boom section full retraction detection

2nd, 3rd full RET 2nd, 3rd full RET

C/W mounting conditon detection 1

C/W harness right

C/W lock release C/W lock C/W retracting stroke C/W extending stroke end

Power supply for mounting/dismounting Swing lock pin Cab tilt C/W mounting conditon detection 2

Swing lock pin detection Working lamp (winch drum) (Main A)

(Main B)

(Aux. A)

(Aux. B)

Cab tilt detection

Swing rotation SW

Control unit

Drum rotation (Main A) Drum rotation (Main B)

Horn

Drum rotation (Aux. A) Drum rotation (Aux. B)

for remote control valve accelerator solenoid

C/W lock C/W lock release C/W cylinder EXT

Valve ASS’Y, remote control (for mounting / dismounting)

C/W cylinder RET

for remote control valve accelerator potentiometer

Cab tilt lowering Cab tilt raising

Aux. remaining wrap Main remaining wrap

Swing proportional control solenoid valve

Hydraulic oil 50°C

NOTE

1 sign is Applicable serial No : #GA5083, #GA5086 ~ #GA5088

25

Z04-1260E

Jib extension pressure reduction SOL SOL 25

Oil cooler selector SOL

Swing lock pin release SOL

Aux. winch drum lock release SOL

Main winch drum lock release SOL

Telescoping/elevating speed selector SOL SOL 2

Winch speed selector SOL

Top CYL selector SOL

Swing radio control selector SOL

Swing stop SOL

AML vent SOL

Camera elevation SOL

Swing free selector SOL

Swing brake release SOL

SOL for prevention leakage in high-speed operation

No.3 cylinder SOL

Connect with harness in cab.

No.2 cylinder SOL

Power supply

No.1 cylinder SOL

Unit

Synchronized telescoping mode selector SOL SOL 8

Swing operation alarm

Control lever pilot circuit vent SOL

Elevation proportional control solenoid valve

Inching swing SOL

Upper wiring

Swing dead angle detection

Electric Circuit

25

Z-10

Z-10

Z-10

Electric Circuit Upper wiring (swing table) Main winch hoisting up

Main winch hoisting down

Aux. winch Aux. winch Telescoping hoisting up hoisting down EXT

Jib lowering

Telescoping RET

Jib raising

Elevation lowering

Elevation raising

Swing right

Swing left Swing dead angle detection

Connect with harness in cab.

Carrier light SW

Boom length indicator lamp

Swing table length indicator

Tilt, telescoping selector SOL

Main winch hoisting up Tilt, telescoping selector SOL

Main winch hoisting down Aux. winch hoisting up Aux. winch hoisting down

Overwinding detection

Cord reel

Telescoping EXT

CN 1

Telescoping RET

Top full RET detection

Elevation raising Elevation lowering

Cord reel

Working lamp

Swing right Swing light

Boom working lamp

FAJ raising, RET

C/W mounting detection 1

FAJ lowering, RET CN 56

C/W mounting conditon detection C/W mounting conditon detection

Jib stowing detection C/W mounting detection 2 C/W harness left

Swing dead angle Jib tilt, telescoping Overwinding Top full RET Working lamp

2nd/3rd boom section full retraction detection

2nd, 3rd full RET 2nd, 3rd full RET

C/W harness right

C/W mounting conditon detection 1 C/W lock release C/W lock C/W retracting stroke C/W extending stroke end

Power supply for mounting/dismounting Swing lock pin Cab tilt C/W mounting conditon detection 2

Swing lock pin detection Working lamp (winch drum) (Main A)

(Main B)

(Aux. A)

(Aux. B)

Cab tilt detection Swing rotation SW

Control unit Drum rotation (Main A) Drum rotation (Main B)

Horn

Drum rotation (Aux. A) Drum rotation (Aux. B)

for remote control valve accelerator solenoid

C/W lock C/W lock release C/W cylinder EXT

Valve ASS’Y, remote control (for mounting / dismounting)

for remote control valve accelerator potentiometer

C/W cylinder RET Cab tilt lowering Cab tilt raising

NOTE

Swing proportional control solenoid valve

Aux. remaining wrap Main remaining wrap

Hydraulic oil 50°C

Jib extension pressure reduction SOL

AML vent SOL

1 sign is Applicable serial No : GA5089 ~ GA5095, GA5097, GA5099, GA5101, GA5103, GA5104, GA5106, GA5107 ~ 2 sign is Applicable serial No : #GA5108 ~ 3 sign is Applicable serial No : #GA5113 ~ 4 sign is Applicable serial No : #GA5130 ~

26

Z04-1260E

Jib extension pressure reduction SOL SOL 25

Oil cooler selector SOL

Swing lock pin release SOL

Aux. winch drum lock release SOL

Main winch drum lock release SOL

Telescoping/elevating speed selector SOL SOL 2

Winch speed selector SOL

Top CYL selector SOL

Swing radio control selector SOL

Swing stop SOL

AML vent SOL

Camera elevation SOL

Swing free selector SOL

Swing brake release SOL

SOL for prevention leakage in high-speed operation

No.3 cylinder SOL

No.2 cylinder SOL

Connect with harness in cab.

No.1 cylinder SOL

Power supply

Synchronized telescoping mode selector SOL SOL 8

Unit

Control lever pilot circuit vent SOL

Swing operation alarm

Inching swing SOL

Elevation proportional control solenoid valve

26

Z-11

Z-11

Electric Circuit Engine wiring

Lamp (oil filter) Ground of harness in cab

Lamp (hydraulic pressure)

Water temperature gauge

Lamp (air filter) Lamp (charging)

Harness in cab (power supply line)

Air cleaner filter sender Oil filter alarm switch

Working lamp SW

Hydraulic pressure switch Temperature sender unit

Fuel gauge

Earth Working lamp SW

Fuse box

Air conditioner power supply

Relay (engine stop)

Engine Generator Starter switch

in cab

Fuse

Engine stop motor

Battery relay Starter

Battery

Safety relay

27

Z04-1270E

Heater relay Fuel sender unit

27

Head Office

Ko-34,Sinden-cho, Takamatsu, Japan

Overseas Service Group Tadano Ryogoku Bldg.

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

History of revision 1 2 3 4 5

2008 PRINTED IN JAPAN

0803

E