Publication No.

AR-2000M-2/C2-1E

01

All Terrain Crane

AR-2000M-2
Model

Applicable Serial No. GB0062 -

 Foreword

Foreword

This manual contains all the hydraulic and electric circuit diagrams for the Model AR-2000M-2 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-2000M-2-10101 GB0062 -

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

 W04-0000E
 Foreword

2. Contents
Spec. No.
Chapter Section AR-
2000M-2-10101

Data, Adjustment and Checks

Specifications Y-1
Weight Table Y-2
Adjustment
Y-3
Y (Pressure)
Adjustment (Electric) Y-4
Adjustment and Checks Y-5

System Diagrams
Hydraulic Circuit (Upper) Z-1
Hydraulic Circuit (Lower) Z-2
Air Circuit Z-3
Electric Circuit (Wiring
Z diagram)
Z-4

Electric Circuit (Wiring

Z-5
diagram)

 WA04-0000E
 Data, Adjustment and Checks

Contents

Y-1. Specification. ................................ 1 Y-5. Adjustment and checks. ............ 15

Engine..........................................................1 Hydraulic pressure generating system.......15

1. Pump bleeding procedure........................ 15
Hydraulic unit. ..............................................1
2. Hydraulic motor bleeding procedure. ....... 15
1. Hydraulic pump. ......................................... 1
3. Hydraulic pilot control valve (quintuple)
2. Hydraulic motor.......................................... 1
bleeding procedure.......................... 15
3. Accumulator................................................ 1
Swing system.............................................15
Y-2. Weight table. ................................. 2 1. Air bleeding procedure for hydraulic pilot
control valve (for swing). ................. 15
Y-3. Adjustment procedure (pressure). ... 3 2. Adjustment of swing lock pin.................... 15
3. Swing bearing gear backlash adjustment
Hydraulic circuit section. ..............................4 procedure........................................ 16

Winch system.............................................16
Y-4. Adjustment procedure (electric).... 5
1. Winch brake circuit bleeding procedure... 16
Switch adjustment procedure.......................5 2. Winch circuit bleeding procedure............. 16
Boom section.................................................. 5 3. S
 lack cable prevention roller adjusting
Luffing jib section............................................ 8 procedure (main/auxiliary winches)..... 16
Operation section......................................... 10 4. Drum lock device adjustment procedure
Swing frame section..................................... 11 (main/auxiliary winches).................. 17

Potentiometer adjustment procedure.........14 Crane operation. ........................................17

1. Engine speed adjustment procedure........ 17


Y- 1 . Y- 1 .
Specification

Engine
Engine no-load speed

Engine working status Speed without load (rpm)

Idling

Middle (Middle stopper installation)

Maximum

Hydraulic unit
1. Hydraulic pump
Pump displacement and speed ratio

Pump No. Displacement Pump speed /

Engine speed

2. Hydraulic motor
Motor oil intake rate

Oil intake rate

Motor name
Main winch
Auxiliary winch
Hose reel (for No.4 telescoping cylinder)
Mini winch
(For reeving luffing jib elevation wire rope)
Swing drive unit

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

 Y01-2210E
Y- 2 . Y- 2 .
Weight table

The approximate weight (specific dry weights) of major components are in the weight table below.

[Spec. No.]

(Unit : kg)
Spec No.
Part name

Swing table ASS'Y (excluding boom elevating cylinder, counterweight,

swing bearing, engine winch)

Swing bearing

Swing speed reducer (including swing motor)

Swing motor

Elevation cylinder

Boom ASS'Y (including telescoping cylinder)

Full automatic luffing jib (including telescoping cylinder,
elevation cylinder, jib support)
Refer to
Luffing jib operation
manual.

Main
Winch (including winch motor)
Auxiliary

Winch motor

Main
Wire rope (for winch)
Auxiliary
Refer to
Counter weight operation
manual.

Rotary joint

Outrigger inner case Assy

(including extension cylinder, jack cylinder)

Engine (including hydraulic pump for crane)

Hydraulic pump for crane

 Y02-1740E
Y- 3 . Y- 3 . Y- 3 .
Adjustment (pressure)

Hydraulic circuit section

No. on the Section for Adjustment (setting) pressure
Hydraulic circuit or system
Section for pressure pressure (unspecified common difference Pump rotation
Operation lever
equipment name diagram adjustment check is to be ±5 kgf/cm 2 )
and direction
Procedure
PG
Pilot circuit Relief installation All lever neutral Tilt down the operation lever stand to the operation side.
PG
Pilot pressure supply circuit Reducing installation All lever neutral Tilt down the operation lever stand to the operation side.

Tilt down the brake release pilot circuit, winch 2nd speed SW and winch and
Winch Main relief R1 Hoist-up telescoping/elevation high speed SW to the block side, “OFF” side and “winch
high speed” side respectively.
Tilt down the brake release pilot circuit, winch 2nd speed selection SW and winch
Port relief PR7 Hoist-down and telescoping/elevation high speed SW to the block side, “OFF” (low speed)
side and “neutral” position respectively. (Main)

Tilt down the brake release pilot circuit, winch 2nd speed selection SW and winch
Port relief PR8 Hoist-down and telescoping/elevation high speed SW to the block side, “OFF” (low speed) Pressure adjustment condition
side and “neutral” position respectively. (Auxiliary)
Oil type and oil temperature Equivalent to ISO VG46
Boom elevating Main relief R2 Raising Boom “raising” side stroke end. Tilt down the winch and telescoping/elevation high @ engine

No load speed
speed SW to the “telescoping/elevation high speed” side. Shift the boom elevation Superstructure
slow stop cancel switch to ON. However, adjust pressure after tightening PR2.
@ engine

Telescoping Port relief PR3 Extending No. 1 Cyl stroke end or demagnetize the valve 26. Set the winch and telescoping/
elevation high speed to the “neutral” position. Lower machinery

Telescoping “retracting” side stroke end

Telescoping Port relief PR4 Retracting Tilt down the winch and telescoping/elevation high speed SW to the “winch and
telescoping/elevation high speed” side

Elevating Port relief PR1 Lowering Boom “lowering” side stroke end. Set the winch and telescoping/elevation high Caution and procedure for pump start-up (superstructure)
speed SW to the “neutral” position.
1. Before engine (pump) start-up
Port relief PR2 Tightening
1) Demagnetize the relief valve 11 in the 4th pump circuit to shift to the
unload state.
Mounting/dismounting Port relief PR5 Tightening
Superstructure

2) Perform bleeding from the pump 1 R port (until the hydraulic oil is discharged.)

Jib Port relief PR6 Retracting Set the telescoping lever operation selector switch to “jib telescoping” and winch 3) All the operation levers to be in the neutral position.
and telescoping/elevation high speed SW to the “neutral” position.
2. After engine (pump) start-up
Swing Overload relief PR5 Maker set 1) Do not perform high-speed operation immediately after start-up.
Apply the swing brake. Shift the boom elevation slow stop cancel switch to ON.
Relief R1 Right and left Shift the inching swing SW to “OFF”. Shift the swing free/lock selector SW to the
2) Supply or discharge the hydraulic oil from the drain port of each motor.
swing “lock” side.
3) E xcite the relief valve 11 in the 4th pump circuit and tilt down the operation
Relief R6 Maker set condition: lever stand to the operation side. (Pilot pressure is generated.)

Relief Accelerator MAX 3. In a state that operation is possible for each actuator
C/W, cab movement PG C/W raising C/W mounting/dismounting jack Cyl raising side stroke end.
with the remote
installation
control BOX. 1) Perform bleeding from the spring chamber of the winch counter balance valve.
(Perform no load hoist-up operation.)
Accelerator MAX
Relief (rear end) PG
C/W lowering Extending stroke end
with the remote
installation
control BOX.

PG Bottom pin mounting/

Note: 1. Pressure marked with * is possible by multiple display as well.
Relief (front end) installation dismounting Cyl Extending stroke end
Accelerator MAX with Mountnig /
Relief (middle) PG
installation the remote control dismounting ring In the state that the hose to the mounting/dismounting ring
BOX. rotation Cyl. EXT rotation Cyl is not connected.
Relief
PG Speed reducer rotation
Extending stroke end Reference value
installation Cyl, extending

Hose reel drive circuit Reducing PG All lever to be Tilt down the operation lever stand to the operation side. Pump Discharge rate Pump speed/engine speed
installation neutral
Telescoping valve Overload relief P1 (for winch)
PG Extending Fully extend No. 2 and No. 3 Cyl. Only No. 4 Cyl is extending.
installation Turn “ON” the telescoping/elevation high speed SW. P2 (for telescoping/elevating)

Overload relief Maker set P3 (for swing/remote control)

Counter balance for
winch P4 (for pilot)
Pilot pressure (Cracking) Maker set
Counter balance for
elevating Pilot pressure (Cracking) Maker set

Relief Maker set Maker set condition: 40 ℓ/min, 32 cst

Relief Maker set Maker set condition: 40 ℓ/min, 32 cst

L/J mast cyl. circuit Relief PG Mast cyl. Mast Cyl. stroke end, differential pressure PA-PB to be
installation extending secured
PG
Mini winch circuit Relief installation Winding Rope sheathing to be fixed

1
3 WY02-0040E
Y03-2280E 3
Y- 3 . Y- 3 .
Adjustment procedure (pressure)

Hydraulic circuit section

Pressure setting table

Item Pressure (kfg/cm 2 ) Remarks

On-load
Pressure control valve For actuating regular valve with a built-in
Unload compressor

Cracking
Safety valve For air tank
Closing

Turn-on
Pressure switch For air tank
Turn-off

Cracking
Stop valve For swing lock security
Closing

Cracking
Stop valve For drum lock security
Closing

For controlling boom lock pin actuation

Reducing valve (when Inlet pressure 7 kgf / cm 2 ) speed

 Y03-2280E
Y- 4 . Y- 4 .
Adjustment procedure (electric)

Switch adjustment procedure

Boom section

3rd/4th/top boom full

retraction detection
switch

2nd boom full retraction detection switch

 Y04-1660E
Y- 4 . Y- 4 .
Adjustment procedure (electric)

1. S
 15 switch (2nd boom full retracting detection)
S11 switch (3rd, 4th, top boom full retracting
detection)

Install a switch so that the contact points change

at the position of before 3-6 centimeter of full
retraction.

Tightening torque : 50 - 60 kgf - cm

For S11, set the roller lever of (2) For S15, set the roller lever of (7) to
to the above position the above position

2. 2nd boom lock pin detector switch

S27 : Insertion detection (Right)
S28 : Insertion detection (Left)
S40 : Extraction detection (Right)
S41 : Extraction detection (Left)

Install the switch with the 2nd boom lock pin is

inserted or extracted until the stroke end then 4-6
mm further pushed from the position where the
switch is operated.

Tightening torque : 50 - 60 kgf - cm

2nd boom lock pin

(Insertion status)

Boom center axis

Connect with wiring ASS'Y (Swing

Connect with wiring ASS'Y (Swing
table) of 0.85Y terminal
table) of CN33 connector
2nd lock pin extraction detection switch
2nd lock pin extraction detection switch

Connect with wiring ASS'Y (Swing

table) of 0.85G terminal Connect with wiring ASS'Y (Swing table) of CN28 connector
2nd lock pin insertion detection switch
2nd lock pin insertion detection switch
View A

 Y04-1660E
Y- 4 . Y- 4 .
Adjustment procedure (electric)

For S28, S41, set the roller lever For S27, S40, set the roller lever to the above
to the above position (2 types) position (2 types)

3. Boom, jib connecting pin mechanical lock detector SW

S30: right side
S31: left side Free state of switch

(1) Insert the boom jib connecting pin to shift to the

mechanical lock state

(2) P
 ress the switch roller against the mechanical
lock lever, and from the position where the switch
actuates (be turned ON), press 5 mm more. Then
tighten with a bolt.

Tightening torque : 50 - 60 kgf-cm

Boom jib connecting pin inserted state

Unlocked state with

CYL retracted

Locked state with

CYL extended

Right: S30
Opposite side Opposite side
Left: S31

(To CN232 at the opposite side)

Detail of B

 Y04-1660E
Y- 4 . Y- 4 .
Adjustment procedure (electric)

Luffing jib section

Mast 2

Cylinder for back stop

Mast cylinder
Jib support Mast 1

1. S35 switch (lufting jib tilt angle MIN. detection) 2. S36 switch (lufting jib tilt angle MAX. detection)

Mast 2

Jib support

Spring

Mast 1

(1) Set the clearance marked with * (2 points) to 0 mm (1) Set the clearance A dimension between the mast
with the spring at free height. 1 and the jib support to 20±2 mm.

(2) Displace the switch in the direction of the arrow K (2) Install the switch with a bolt to the position where
as much as possible (in order to make the switch the switch is changed from “ON” to “OFF”.
roller contact the flat face of the piston.)

(3) Press the roller 2 mm more from the point where Caution
the switch is changed from “ON” to “OFF”.
R
 oller lever of the switch is to be adjusted to
(4) Displace the switch in the direction of the arrow the dimension in Fig. 19 in the free state then
B to find the point where the contact is changed fixed.
from “OFF” to “ON”.
From that point, move the switch 17±1 mm in the
direction of the arrow B to install.

(5) C
 onfirm that the tilt angle is in a MIN. state (main
winch stops hoisting up) at 0±0.5 ° when the
lufting jib tilt angle is decreased.

 Y04-1660E
Y- 4 . Y- 4 .
Adjustment procedure (electric)
(3) Check 4. S38 switch (mast cylinder and mast 2 contact
detection (right side))
1) Hang up the 11 m lufting jib directly below at S39 switch (mast cylinder and mast 2 contact
the boom elevating angle of 62 °. detection (left side))

2) Tilt the mast forward then tension wire is to be

installed to the jib end in the position where the
main winch “hoist-down” stops. (Tilt MAX.) Mast cylinder

3. S37 switch (mast cylinder full extension detection) Mast 2

State when the switch is changed

from “ON” to “OFF”

Stopper ASS'Y
State of the back stop
cylinder full extension
(1) In the state that the mast cylinder and the mast
2 contact each other, from the point where the
State of the back stop
cylinder full extension switch is changed from “ON” to “OFF”, move the
switch 5 to 8 mm in the direction of the arrow K
then install with a bolt.

(2) Check the indicator lamp lights up when the mast

cylinder and 2 pieces of mast contact each other.

Caution

 oller lever of each switch is to be adjusted to

R
the following dimension then fixed.

(1) In the state of the back stop cylinder full extension,
from the point where the switch is changed from
“OFF” to “ON”, move the switch 2 to 4 mm in the
direction of the arrow H then tighten with a bolt.

(2) Check

1) Indicator lamp in the cab is to be turned off in

the state of back stop cylinder full extension.

2) Within the range of 15 to 34 mm retracted from

the full extension state, indicator lamp in the
cab is to light up.
At this time, depressed portion of the back
stop cylinder and the convex portion of stopper
ASSY shall contact each other at the center.

 Y04-1660E
Y- 4 . Y- 4 .
Adjustment procedure (electric)

5. S
 29 switch Operation section
(FLJ 2nd/top boom full retraction detection)

1. S19 switch (lever stand tilt detection)

Support
Lever stand
(winch, elevating)

With the boom fully retracted, press the switch against

the support. Press the switch 3 to 6 mm more from
the switching point of the switch contact then tighten
it with a bolt.
Installing nut
Tightening torque 36 - 40 kg-cm
Tightening torque: 50 - 60 kgf-cm Apply screw locking compound.

(1) Push the limit switch into the actuated position

with the lever stand (for winch and elevation
control) tilted down by approx. 16 degrees and
install it (by temporary tightening.)

(2) Adjust the limit switch lowering it by 1 mm (one

turn of fixing nut) from state of the step 1, and
lock the switch with the fixing nut.

10 Y04-1660E
Y- 4 . Y- 4 .
Adjustment procedure (electric)

Swing frame section

1. S32 switch (swing lock pin detection)

Detail of A

Elevating cylinder
lower pivot pin

Swing lock pin, when locked

(1) Mate the switch end with the boss inner face.

(2) From that position, rotate the switch for 1/2 to 1

turn. (Switch end recedes by 0.5 to 1 mm from
the boss inner face.)

(3) Lift up the swing lock pin. Check that even when
the pin moves to the opposite side of the switch
by the rattling amount with the boss, switch
indicator lamp lights up (switch contacts are
“OFF”.)

(4) Drop the swing lock pin. Check that the switch
indicator lamp lights off (switch contacts are “ON”.)

11 Y04-1660E
Y- 4 . Y- 4 .
Adjustment procedure (electric)

2. Dead wrap detection switch

S20: main
S21: auxiliary

Detail of A

State of 0th layer

Switch S20, S21

Adjustment bolt

Apply screw locking

compound.

Stopper bolt

Slack cable prevention roller

support

(1) Clearance marked with * (2 points) is to be (3) Press the switch for 1/2 turn with the adjustment
secured. bolt from the position the switch is turned “OFF”
(equivalent to stroke of 0.625 mm.)
(2) Support of the slack cable prevention roller is to
touch the stopper bolt. (4) Lock with a nut.

12 Y04-1660E
Y- 4 . Y- 4 .
Adjustment procedure (electric)

(3) Apply screw locking compound.

3. S18 switch (cab tilt detection)
Tightening torque: 3.5 - 4 kgf-m

Cab 5. C ounter weight upper and lower cylinder full

Cab lower end face retraction detection
S25 switch: right side
S26 switch: left side

Cab support
(proximity switch)face

With the crane cab supported by the cab support

section (cab tilt cylinder full retraction,) dimension
A in the figure below is to be adjusted to 3.0 mm.

4. C ounter weight upper and lower cylinder full

extension detection
S23 switch: right side
S24 switch: left side
(1) With the counterweight upper and lower cylinder
fully retracted, install the proximity switch with a
nut so that the dimension A is 2 to 3 mm.

(2) Insert the counterweight lock pin and extend the

Air cylinder
Counterweight lock pin upper and lower cylinder until it touches the pin.
Check the proximity switch is turned “ON”. (Switch
indicator lamp lights up.)

Upper and lower (3) Apply screw locking compound to the nut.
cylinder rod

Tightening torque: 3.5 - 4 kgf-m

Cable is not to touch

the air cylinder

(1) Adjust the clearance A between the proximity switch

and the upper and lower cylinder rod to 5±1 mm.

(2) With the counterweight upper and lower cylinder

full extension, move the proximity switch upward 5
to 8 mm from the proximity switch actuated point
(the point where switch indicator lamp changes to
light up or light off), then tighten with a nut.

13 Y04-1660E
Y- 4 . Y- 4 .
Adjustment procedure (electric)

Potentiometer adjustment procedure

1. Jib angle detector (full auto lufting jib)
(1) A
 fter installing the jib angle detector, set the jib tilt angle
to 0 ° and measure the resistance value between A and D.

(2) A
 gainst the resistance values between A and D, adjust
the resistance values between C and D to the following
values (rotate the shaft of angle detector) and fix.

Resistance value ( ) Adjustment value ( ) ± 4

(A-D) (C-D)

Jib pivot pin

Jib support

Apply grease to Jib angle detector

inside low section
Apply screw locking compound

14 Y04-1660E
Y- 5 . Y- 5 .
Adjustment and checks

(8) N
 ow bleeding is complete. If the hydraulic pump has
This section covers the procedures to be applied when been replaced, break in the pump subsequently.
performing adjustments and checks in areas other
than the pressure and electric areas, which have been
covered in the preceding sections.

2. Hydraulic motor bleeding procedure

Hydraulic pressure generating system
Start the engine and either add hydraulic oil or allow oil
1. Pump bleeding procedure to spill out through the drain port of the following motor.

NOTICE · Winch motor (main and auxiliary)

Whenever the upper hydraulic pump or hydraulic oil · Swing motor
is replaced, be sure to bleed the pump circuit of air · Motor for hose reel (for No. 4 telescoping cylinder)
according to the following procedure.

3. Hydraulic pilot control valve (quintuple)

(1) Fill the oil tank with hydraulic oil. bleeding procedure
(1) D
 e-energize the solenoid valve (SL49) for automatic
(2) P
 ut the crane control box for elevating/winch in a
stop and keep the crane in a condition when it is
stowage position. (in order to de-energize the solenoid
automatically stopped.
in the solenoid valve for pilot circuit vent and unload the
circuit)
(2) F
 ully move each lever to its stroke end and keep that
condition at least 20 seconds under the following
(3) With the engine stopped, loosen the air bleeder plug (R)
condition.
on the hydraulic pump.
· Engine speed: IDL (650±20 rpm)
· Oil temperature: 50 °C or higher

Swing system
1. Air bleeding procedure for hydraulic pilot
control valve (for swing)
(1) L
 ock the swing table after changing the swing brake
Air bleeder plug (R) switch to "brake" side.

(2) K
 eep the status for 20 seconds after changing the
swing control lever to left or right swing (full stroke).
(4) Once no air bubbles are visible, close the air bleeder
plug while the hydraulic oil is still flowing out. · Engine speed: IDL (650±20 rpm)

(5) S
 tart and run the engine at idle for approx. 5 seconds. 2. Adjustment of swing lock pin
Then check for unusual sounds.
When the swing lock pin actuates to the free side
If there is any abnormal sound, bleed the (withdrawal direction,) adjust with the cylinder rod screw
hydraulic pump again. so that the pin upper end face allowance A = 12±2 mm.

(6) If no abnormal sound is heard, be sure to continuously Elevating cylinder lower support pin
run the engine at idle for 5 minutes with no load.
When free When locked
During idle running, check any abnormal
sound or heat from the hydraulic pump and
any oil leakage from the piping system.

(7) After making sure that there is no abnormality, stop the

engine. Cylinder rod screw

15 Y05-2170E
Y- 5 . Y- 5 .
Adjustment and checks

3. Swing bearing gear backlash adjustment 2. Winch circuit bleeding procedure

procedure
(1) Set the swing lock pin. (1) L
 oosen the air bleeder plug on the counterbalance
valve.
(2) Allow the swing drive unit to freely swing.

(3) Apply pressure to the retraction side of the mounting/

dismounting cylinder to turn the eccentric plate. This
makes the pinion gear pushed against the ring gear
with no (0 mm) backlash.

(4) Tighten the bolt until it touches the stopper plate that is
built in the eccentric plate. Air bleeder plug

(5) T
 hen tighten the bolt further for additional two and half
turns.

(6) Tighten the nut to prevent the bolt from loosening.

Mounting/dismounting cylinder Nut
Bolt

(2) B
 leed the circuit by performing a hoisting operation
without load on hook.

NOTICE

Be very careful to prevent oil from splashing.

(3) T
 ighten the air bleeder plug on the counterbalance
valve.

3. S
 lack cable prevention roller adjusting procedure
(main/auxiliary winches)

Stopper plate (built into eccentric plate) (1) Install the slack cable prevention roller so that the right
and left clearances F (approx. 6 mm) with the drum
kicker becomes the same as each other.

Winch system Slack cable prevention roller

1. Winch brake circuit bleeding procedure

(1) O perate the winch control lever from “hoist- Winch drum
up” position via “neutral position” to hoist-down”
position and vise versa repeatedly to bleed the
brake pilot circuit.
NOTICE

Avoid overwinding the hook block.

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

16 Y05-2170E
Y- 5 . Y- 5 .
Adjustment and checks

(2) A
 djust the clearance B between the slack cable
prevention roller and the winch drum to 8 mm with the
Crane operation
bolt D.
1. Engine speed adjustment procedure

1. Idling speed (IDL) adjustment

Slack cable
prevention roller (1) With the engine speed control lever in contact
with the bolt A, make sure that the engine
speed is 650±20 rpm.
C (Nut)

D (Bolt)
(2) In the above state of 1. 1), adjust the clearance
G2 between the clevis and pin to 3 to 5 mm with
Winch drum the clevis at the end of manual accelerator knob.

Spring 2. Maximum speed (MAX) adjustment

(1) With the lever in contact with the bolt C, make

sure that the engine speed is 1910 to 1980 rpm.
Because the bolt B has been adjusted and sealed
for 1980 rpm, it cannot be further adjusted.
(3) Adjust the spring height E to 110 mm with the nut C.

3. Middle speed (MID) adjustment

4. Drum lock device adjustment procedure (1) Turn the stopper bolt E of the accelerator pedal
(main/auxiliary winches)
to the position “when in use”, and adjust the
(1) When locking the drum engine speed to 1300±50 rpm with the bolt E.
Then secure the bolt with a nut.
1) Shut off air pressure to the air cylinder.
4. Engine speed adjustment procedure at the time of
2) Adjust the air cylinder mounting position to make B =
mounting and dismounting operation
125 mm with the nut.
(1) Adjust the cable dimension X at idle to 128±1
3) Adjust the clearance D between the pawl and winch
mm with the adjusting nut of the cable.
drum to 5 mm with the shim.

(2) When releasing the drum (2) W ith the accelerator set to MAX (accelerator
cylinder at stroke end) with the control box of the
1) Apply air pressure to the air cylinder. remote control device, adjust the engine speed
to 1300±100 rpm by changing the accelerator
2) Make sure that the clearance C between the pawl position.
and the winch drum groove is 23 mm or more.
(3) Retract the rod of the accelerator cylinder and
make sure that there is a clearance G1 of at
Nut least 2 mm.
Air cylinder
Shim

Winch drum
Pawl

Pawl
Winch drum View E

17 Y05-2170E
Y- 5 . Y- 5 .
Adjustment and checks

Manual accelerator knob

Accelerator pedal

Lever

Bolt E (when stowed)

Bolt E (when in use)
Bolt C

Cable

Accelerator cylinder

Pin Clevis

Bolt B

Bolt A

Speed control lever

18 Y05-2170E
 System Diagrams

Contents

Z-1 Hydraulic Circuit (Upper)............ 1

Z-2 Hydraulic Circuit (Lower)............ 4

Z-3 Air Circuit..................................... 5

Z-4 Electric Circuit............................. 6

Z-5 Electric Circuit........................... 15

Z

Z-1 Z-1
Hydraulic Circuit
Upper hydraulic circuit
Auxiliary winch Main winch Relief valve
Telescoping cylider

Solenoid valve
(for brake release)
Hydraulic motor Luffing jib circuit Full automatic luffing jib Swing drive unit
Hose reel
(for No.2)

(for No.3)
counter balance
valve (for No.4) Hydraulic pilot control valve
(swing)
Remote control valve (for jib) Flow divider

Counter balance valve Telescoping control

Auxiliary Main valve
Swing Telescoping Telescoping Elevation wire wire Elevation Solenoid valve
(Pedal) (Pedal) (for full automatic luffing jib /
mounting / dismounting lifter
operation pilot circuit selection)

Solenoid valve (for bleeding remained pressure

during using jib)
Hydraulic valve
(for telescoping cylinder
No.1 / No.2, No.3,
Cylinder No.4 selection)
(winch drum Solenoid valve Solenoid valve
for camera elevation) (for boom / jib operation (for full automatic luffing jib /
pilot circuit selection) luffing jib tilt operation pilot
circuit selection) Shuttle valve
Solenoid valve
(for camera elevation) Elevation cylinder
Solenoid control
Shuttle valve relief valve
Shuttle valve (for swing slow stop)

Hydraulic
valve

Solenoid valve Solenoid valve

(for winch speed selection Shuttle (for winch operation Solenoid valve
valve when luffing jib (for swing stop)
Shuttle valve
mounting / dismounting) Solenoid valve
(for automatic stop)

Stop valve
Counter balance
valve
Oil filter
Pilot check valve

Solenoid control relief valve

(for elevation slow stop)

Check valve

(Left) Counter weight raising/lowering cylinder (Right)

Hydraulic motor
(for No.4 cylinder
(Left) (Right) hose reel)
Shuttle valve
Counter weight Remote control valve
mounting/dismounting
Check valve cylinder
cylinder for rotation
Solenoid valve Reducing valve
(counter weight
mounting / dismounting
cylinder for rotation circuit vent)

Select valve
Shuttle valve Shuttle valve

Pressure
gauge
Chech valve

Check
valve
Swing drive unit Shuttle valve Hydraulic control valve
mounting / dismounting Reliefe valve Solenoid valve (for pump (quintuple)
cylinder (swing drive unit regulator pilot circuit merge)
for mounting / disounting Solenoid valve
Swing bearing circuit)
(for winch high-speed)
mounting / dismounting cylinder

Boom bottom pin Boom bottom pin

mounting / dismounting mounting / dismounting
Pressure
cylinder (right) cylinder (left)
Hydraulic valve (for switching valve
swing/dismounting circuit) Hydraulic pump

Relief valve
Hydraulic motor (for winch circuit)
(for reeving luffing jib
elevation wire rope)

Cab tilt cylinder Accumulator

Pressure Solenoid valve

sensor (for pilot circuit vent)
Pilot check valve Check valve
Oil cooler
Relief valve
(for counter weight mounting / dismounting cylinder
raising / lowering and rotation
swing bearing mounting / dismounting boom bottom pin circuit)
Oil filter
Reducing valve
(for pilot circuit)
Oil tank
Accelerator cylinder

1 Z01-3370E 1
 Z-1

Counter balance
valve
Jib elevetion cylinder

Hydraulic valve Counter

(for operating jib elevating) balance
valve
Full automatic luffing jib circuit

Jib telescoping cylinder

Relief valve
(jib mounting / dismounting
winch hoisting up circuit)
Solenoid valve
(for jib mounting /
dismounting operation)
Hydraulic motor
Hydraulic valve
(for operating jib
telescoping)

2
Counter balance valve
Jib mounting / dismounting winch
Solenoid valve
(for operating jib top height adjustment)
Hydraulic Circuit

Relief valve
(jib mounting / dismounting
winch hoisting down circuit)

Jib top height

adjustment cylinder

Z01-3370E
Jib connecting pin cylinder Pilot check valve

Hose reel (for jib)

Solenoid valve
(for operating jib connecting pin)
Z-1
 Z-1

Luffing jib circuit

Solenoid valve
Back stopper cylinder

Hydraulic check valve

Solenoid valve Pilot check valve

3
Hose reel

Luffing jib
Main boom overtopping boom
Mast cylinder
Hydraulic Circuit

Tank

Z01-3370E
Relief valve

Jib connecting (pin) cylinder

Solenoid valve
Z-1
 Z-2

Extension cylinder
Pilot check valve
Lower hydraulic circuit

Solenoid control valve

(Stowing) (Extension)

Pilot check valve

Jacj cylinder
Solenoid valve

4
Hydraulic Circuit

Solenoid valve C
to steering sircuit

Z01-2440E
Hydraulic
pump

Relief valve Nissan diesel circuit

(210 kgf / / engine speed
1330 100 rpm)
Oil filter
Z-2
 Z-3

Solenoid valve
Stop valve
(for drum lock security)

Stop valve
Solenoid valve (for swing lock security)

Reducing valve
Boom lock pin
Drum lock cylinder
cylinder

Safety valve

5
Swing lock pin cylinder
Air drier
Air Circuit

Air tank

Solenoid valve

Pressure switch

Z06-0400E
Drain plug Pressure switch

Air horn

Pressure regulator

Compressor
Z-3
 Z-4

Cab tilt detector SW Cab tilt indicator lamp

Crane operation highspeed selector SW Winch speed selector SOL
Buzzer 2
Regulator pilot pressure
merge SOL
Upper electric circuit

Operation lever tilt detector SW LY

(Contact for tilting) Operation lever pilot circuit vent SOL
Telescoping/elevating speed
selector SOL

Swing stop 2 SOL

Main winch drum lock Main winch drum lock Swing brake release SW Swing brake release SOL
release SOL release SOL
Swing brake indicator lamp
Aux. winch drum lock Aux. winch drum lock
release SW Main winch speed selector SW (on main winch lever)
release SW
Main winch speed
Main winch speed selector SW selector SOL

Aux. winch speed

Swing lock pin release SOL Swing lock pin release SOL Aux. winch speed selector SW selector SOL

Aux. winch speed selector SW (on aux. winch lever)

2nd lock pin insertion SOL (OFF insertion) 2nd lock pin insertion SOL
Swing free, lock selector SW (panel) Swing free selector SOL

Among points of contact of two poles in RL 9 · 10, one pole is in wiring diagram (mounting / dismounting).

6
AML controller
MAIN hoisting up MAIN hoisting up detection (Contact broken for hoisting up)
MAIN hoisting down MAIN hoisting down detection (Contact broken for hoisting down)
Electric Circuit

Aux. hoisting up Aux. hoisting up detection (Contact broken for hoisting up)
Aux. hoisting down Aux. hoisting down detection (Contact broken for hoisting down)
Telescoping EXT Telescoping EXT detection (Contact broken for extending)
Telescoping RET Telescoping RET detection (Contact broken for retracting)
Elevation raising Elevation raising detection (Contact broken for raising)
Elevation lowering Elevation lowering detection (Contact broken for lowering)
Swing right Swing right detection (Contact broken for swinging right)
Swing left Swing left detection (Contact broken for swinging left)
Swing dead angle detection
to
from main fuse Back stopper RET or FLJ raising

Z03-3650E
Inching swing selection input
Elevation speed input 2nd lock pin extraction 2nd lock pin 2nd lock pin extraction
indicator lamp extraction detection (right) detection (left) Inching swing selector SW
C / W distortion
detection wire breakage input to 2nd lock pin insertion 2nd lock pin 2nd lock pin insertion

WIRING DIAGRAM
Back stopper EXT or FLJ lowering
indicator lamp insertion detection (right) detection (left)
2nd boom full retraction detection
from starter SW,

(CRANE ELECTRICAL EQUIPMENT)

2nd boom lock pin insertion detection
AC terminal Overwinding cutout
Overwinding cutout SW input
from battery FLJ tilting up or telescoping RET FLJ Tilt raising selector SW
Boom Jib
or telescoping RET FLJ Tilt lowering telescoping Jib tilt telescoping Main winch
FLJ tilting down or telescoping EXT FLJ tilt indicator lamp
or telescoping EXT
Boom dismounting input FLJ telescoping indicator lamp
Boom telescoping jib selector SOL (ISO)
Boom elevation main selector SOL (TDN)
FLJ telescopnig operation selector Main boom telescoping indicator lamp
Dismounting
MAIN remaining wrap detection MAIN remaining wrap detection
Aux. remaining wrap detection Aux. remaining Boom telescoping main selector SOL (ISO)
wrap detection Boom telescoping jib selector SOL (TSO)
Elevation slow stop cancel
Top boom full RET Telescoping lever selector SW
Speaker (installed on the lateral With medium Overwinding detection Telescoping (elevation) lever main indicator lamp
Boom telescoping
side in the back inside cab) wave filter mode selection
AML cancel input 3rd / 4th / top boom full RET detector SW
S / T overwinding detector SW
Boom overwinding detection
Z-4

(Contact broken for overwinding)

to working lamp SW Cord reel
(The display of CRT darkens when ON. )
Noise filter
Noise filter
Shield Shield Shield Shield WIRING DIAGRAM
Shield
Cord reel

Noise filter
Shield Shield Shield Shield
Cord reel Shield Shield
Swivel joint Transmitter
to working lamp
TYPE O

FLJ inching tilt SOL

TYPE 2
Transmitter

Carrier main valve · jib carrying oil selector SOL

when fLJ dismounting
harnes
Swing dead angle detector SW

Remote control for FLJ

(Share with remote control for boom
Transmitter TYPE 5 Back stopper CYL operation SW bottom pin dismounting operation)
to
raising
FLJ tilt CYL
lowering
to operation SW

FLJ dismounting hoisting up or FLJ RET

extension
FLJ dismounting
retraction
CYL operation SW
FLJ dismounting hoisting down or FLJ EXT Mast CYL
Mast RET or FLJ jib top height adjustment CYL EXT Operation SW
FLJ jib top height adjustment
extension
CYL oepration SW
retraction
Mast EXT or FLJ jib top height adjustment CYL RET SW for boom · jib connecting pin
Boom · jib connecting pin insertion
insertion
Boom · jib connecting
extraction
pin operation SW
Boom · jib connecting pin extraction

Trigger SW
C / W distortion
detection wire breakage output Horn SW
to horn relay

DC-DC convertor

Controller
Earth
Earth

(Constant current amplifier)

Shield
Elevation speed selector
Camera

(installed on the rear

end of the swing table AML · transmitter · constant current amplifier
for monitoring winch) for emergency in failure

Option Elevation slow stop proportional

control solenoid valve

Swing stop proportional

control solenoid valve (for locking)

Swing slow stop cancel SW

Swing slow stop cancel indicator lamp

Shield (main pressure sensor)

Swing stop 1
Inching swing control proportional
solenoid valve
Shield (Accumulator
Shield Moment detector pressure Shield
C / W rod tension
Shield sensor)
Tension detector detector

Shield
Boom angle detector Elevation slow stop cancellation
indicator lamp

Elevation slow stop cancel SW

Boom angle input Boom length detector

C / W rotation CYL vent SOL
Main pressure input (Vent when OFF)
Main length input
Accumulator pressure input
Swing angle 1 input Shield
Swing angle detector 1
Swing angle 2 input C / W main CYL full extension C / W main CYL full extension
detector SW (right) detector SW (left)
(Contact broken for full extending) (Contact broken for full extension)

Shield
Shield Swing angle detector 2 C / W main CYL full retraction indicator lamp

FLJ : Full automatic luffing jib

C / W main CYL full retraction C / W main CYL full retraction
detector SW (right) detector SW (left)
(Contact for full retracting) (Contact for full retracting) LJ : Luffing jib
External indicator lamp (-90%) C / W : counter weight
External indicator lamp (90-100%) Jib hydraulic source bleeding SOL
When overwinding cutout
or external indicator lamp (100%-) Tension reduction stop indicator lamp
Tension reduction stop
Swing stop output
Swing lock pin insertion detector SW
(Contact for locking)
over-front · rear area
Over-rear area output

Jib hydraulic source bleeding output G

Back stopper full raising output Back stopper full raising nidicator lamp
Mast CYL control indicator lamp AML external indicator Y This figure is shown the state of below.
Mast CYL contact output selector SW
Boom · jib connecting pin Boom · jib connecting pin mechanical R
mechanical lock insertion output lock insertion indicator lamp Crane running
AML external indicator lamp
Swing lock pin insertion indicator lamp Boom full retraction
Boom front position
AML alarm buzzer
Overwinding
AML emergency SW AML abnormality indicator lamp
Automatic stop 1 For emergency in AML failure
Starter switch : OFF
(due to overload, overwinding, etc) For AML vent
Automatic stop 2 (telescoping stop valve)
Operation lever neutral position
Automatic stop 3 (due to instability in the rear portion) etc

Buzzer output (accumulator low pressure alarm) Accumulator low pressure warning lamp
Buzzer output (AML alarm) 2nd boom section emergency SW SOL for 3rd, 4th, top
Telescoping control output No.1
Telescoping control output No.2

Method of displaying wiring

SOL for 2nd

SW for 3rd, 4th, top

Power supply a color of trace that mixed with a ground color
To power supply of multi-display main body

a ground color of electric wire

the sectional area of electric wire ( )
Boom telescoping selector SW 3rd, 4th, top extension

2nd extension
Symbol Color
2nd full retraction detector SW 2nd extension indicator lamp
3rd, 4th, top extension indicator lamp
Next gear EXT SW (telescoping lever)

3rd boom section correction

SOL for No.2 CYL

4th boom section correction

SOL for No.3 CYL

Top boom section correction

SOL for No.4 CYL

Air reduction pressure detector SW Phase A input by proximity switch (main)

Main drum rotation detection
Air reduction alarm buzzer
Phase B input by proximity switch (main) Main drum rotation detection
Air reduction pressure alarm indicator lamp Phase A input by proximity switch (aux.)
Aux. drum rotation detection
Phase B input by proximity switch (aux.) Aux. drum rotation detection
External reset input Reset SW
Camera raising selector SW Camera raising selector SOL
Power supply
Swing voice alarm unit for OFF input signal

Power supply OFF input

Back light input to working lamp

Swing alarm selector SW Main · Aux. selector input
Power supply
Main · Aux. selector SW SN14
6

Hook amount of movement

indicator lamp
 Z-4

Cab tilt detector SW Cab tilt indicator lamp

Crane operation highspeed selector SW Winch speed selector SOL

Buzzer 2
Upper electric circuit

Regulator pilot pressure

merge SOL
Operation lever tilt detector SW LY
(Contact for tilting) Operation lever pilot circuit vent SOL
Telescoping/elevating speed
selector SOL
Swing stop 2 SOL

Main winch drum lock Main winch drum lock Swing brake release SW Swing brake release SOL
release SOL release SOL
Swing brake indicator lamp
Aux. winch drum lock Aux. winch drum lock
Main winch speed selector SW (on main winch lever)
release SW release SW
Main winch speed
Main winch speed selector SW selector SOL

Aux. winch speed

Swing lock pin release SOL Swing lock pin release SOL Aux. winch speed selector SW selector SOL

Aux. winch speed selector SW (on aux. winch lever)

2nd lock pin insertion SOL (OFF insertion) 2nd lock pin insertion SOL
Swing free, lock selector SW (panel) Swing free selector SOL

Among points of contact of two poles in RL 9 · 10, one pole is in wiring diagram (mounting / dismounting).

7
AML controller MAIN hoisting up detection (Contact broken for hoisting up)
Electric Circuit

MAIN hoisting up
MAIN hoisting down MAIN hoisting down detection (Contact broken for hoisting down)
Aux. hoisting up Aux. hoisting up detection (Contact broken for hoisting up)
Aux. hoisting down Aux. hoisting down detection (Contact broken for hoisting down)
Telescoping EXT Telescoping EXT detection (Contact broken for extending)
Telescoping RET Telescoping RET detection (Contact broken for retracting)
Elevation raising detection (Contact broken for raising)
Elevation raising
Elevation lowering Elevation lowering detection (Contact broken for lowering)
Swing right detection (Contact broken for swinging right)
Swing right
Swing left Swing left detection (Contact broken for swinging left)
Swing dead angle detection

Z03-3650E
to
from main fuse Back stopper RET or FLJ raising
Inching swing selection input
Elevation speed input 2nd lock pin extraction 2nd lock pin 2nd lock pin extraction
indicator lamp extraction detection (right) detection (left) Inching swing selector SW
C / W distortion
detection wire breakage input to 2nd lock pin insertion 2nd lock pin 2nd lock pin insertion

WIRING DIAGRAM
Back stopper EXT or FLJ lowering
indicator lamp insertion detection (right) detection (left)
from starter SW, 2nd boom full retraction detection

(CRANE ELECTRICAL EQUIPMENT)

AC terminal 2nd boom lock pin insertion detection
Overwinding cutout
Overwinding cutout SW input
from battery FLJ Tilt raising selector SW Boom Jib
FLJ tilting up or telescoping RET telescoping Jib tilt telescoping Main winch
or telescoping RET FLJ Tilt lowering FLJ tilt indicator lamp
FLJ tilting down or telescoping EXT
or telescoping EXT FLJ telescoping indicator lamp
Boom dismounting input
Boom telescoping jib selector SOL (TSO)
Boom elevation main selector SOL (TDN)
Main boom telescoping indicator lamp
FLJ telescopnig operation selector
Dismounting C / W emergency input
MAIN remaining wrap detection
MAIN remaining wrap detection Aux. remaining Boom telescoping main selector SOL (TSO)
Aux. remaining wrap detection wrap detection Boom telescoping jib selector SOL (TSO)
Elevation slow stop cancel It changes on TDN arrangement.
(dotted line part)
Top boom full RET Telescoping lever selector SW
Overwinding detection Telescoping (elevation) lever main indicator lamp
Speaker (installed on the lateral
With medium Boom telescoping
side in the back inside cab) mode selection
wave filter 3rd / 4th / top boom full RET detector SW
AML cancel input S / T overwinding detector SW
Z-4

C / W emergency
input
Boom overwinding detection
(Contact broken for overwinding)
to working lamp SW Cord reel
(The display of CRT darkens when ON. )
Noise filter
Noise filter
Shield Shield WIRING DIAGRAM
Shield Shield Shield
Cord reel

Noise filter
Shield Shield Shield Shield
Cord reel Shield
Shield
Swivel joint Transmitter
to working lamp
TYPE O

FLJ inching tilt SOL

TYPE 2
Transmitter

main valve · jib carrying oil selector SOL

Carrier when fLJ dismounting
harnes

Swing dead angle detector SW Remote control for FLJ

(Share with remote control for boom
Transmitter TYPE 5 Back stopper CYL operation SW bottom pin dismounting operation)
to
C / W emergency
input raising
FLJ tilt CYL
lowering
to operation SW
C / W emergency
input
FLJ dismounting hoisting up or FLJ RET
extension
FLJ dismounting
retraction
CYL operation SW
FLJ dismounting hoisting down or FLJ EXT Mast CYL
Operation SW
Mast RET or FLJ jib top height adjustment CYL EXT FLJ jib top height adjustment
extension
CYL oepration SW
retraction

Mast EXT or FLJ jib top height adjustment CYL RET

SW for boom · jib connecting pin
Boom · jib connecting pin insertion
insertion
Boom · jib connecting
extraction
pin operation SW
Boom · jib connecting pin extraction

Trigger SW
C / W distortion
detection wire breakage output Horn SW
to horn relay

DC-DC convertor

Controller
Earth
Earth

(Constant current amplifier)

Shield
Elevation speed selector
Camera

(installed on the rear

end of the swing table AML · transmitter · constant current amplifier
for monitoring winch) for emergency in failure

Option Elevation slow stop proportional

control solenoid valve

Swing stop proportional

control solenoid valve (for locking)

Swing slow stop cancel SW

Swing slow stop cancel indicator lamp

Shield (main pressure sensor)

Swing stop 1

Inching swing control proportional

solenoid valve
Shield (Accumulator
Shield Moment detector pressure
C / W rod tension Shield
Shield sensor)
Tension detector detector

Shield
Boom angle detector Elevation slow stop cancellation
indicator lamp

Elevation slow stop cancel SW

Boom angle input Boom length detector

C / W rotation CYL vent SOL
Main pressure input (Vent when OFF)
Main length input
Accumulator pressure input
Shield
Swing angle 1 input Swing angle detector 1 C / W main CYL full extension C / W main CYL full extension
Swing angle 2 input detector SW (right) detector SW (left)
(Contact broken for full extending) (Contact broken for full extension)

Shield
Swing angle detector 2 C / W main CYL full retraction indicator lamp
Shield

C / W main CYL full retraction C / W main CYL full retraction

detector SW (right) detector SW (left)
(Contact for full retracting) (Contact for full retracting)

External indicator lamp (-90%)

External indicator lamp (90-100%) Jib hydraulic source bleeding SOL
When overwinding cutout
or external indicator lamp (100%-) Tension reduction stop indicator lamp
Tension reduction stop
Swing stop output
Swing lock pin insertion detector SW
(Contact for locking)
over-front · rear area
Over-rear area output

Jib hydraulic source bleeding output G

Back stopper full raising output Back stopper full raising nidicator lamp
Y
Mast CYL control indicator lamp AML external indicator
Mast CYL contact output selector SW
Boom · jib connecting pin Boom · jib connecting pin mechanical R
mechanical lock insertion output lock insertion indicator lamp
AML external indicator lamp
Swing lock pin insertion indicator lamp

AML alarm buzzer

AML emergency SW AML abnormality indicator lamp

Automatic stop 1 For emergency in AML failure
(due to overload, overwinding, etc) For AML vent
Automatic stop 2 (telescoping stop valve)
Automatic stop 3 (due to instability in the rear portion) etc

Buzzer output (accumulator low pressure alarm) Accumulator low pressure warning lamp
Buzzer output (AML alarm) 2nd boom section emergency SW SOL for 3rd, 4th, top
Telescoping control output No.1
Telescoping control output No.2

SOL for 2nd

SW for 3rd, 4th, top

The first No. ~
The first No. ~

Power supply
To power supply of multi-display main body
Serial No. of changed machine

Boom telescoping selector SW 3rd, 4th, top extension

2nd extension

2nd full retraction detector SW 2nd extension indicator lamp

3rd, 4th, top extension indicator lamp
Next gear EXT SW (telescoping lever)

3rd boom section correction

SOL for No.2 CYL

4th boom section correction

SOL for No.3 CYL
Top boom section correction
SOL for No.4 CYL

Air reduction pressure detector SW Phase A input by proximity switch (main) Main drum rotation detection
Air reduction alarm buzzer
Phase B input by proximity switch (main) Main drum rotation detection
Air reduction pressure alarm indicator lamp Phase A input by proximity switch (aux.) Aux. drum rotation detection
Phase B input by proximity switch (aux.) Aux. drum rotation detection
External reset input Reset SW
Camera raising selector SW Camera raising selector SOL
Power supply
Swing voice alarm unit for OFF input signal

Power supply OFF input

to working lamp
Back light input
Swing alarm selector SW Power supply Main · Aux. selector input
Main · Aux. selector SW SN14
7

Hook amount of movement

indicator lamp
Z-4 Z-4
Electric Circuit

S (limit switch) SN (snap switch) RL (relay)

Main upper C / W lock CYL operation 3P M Top full RET. (pole 3)
Main lower * * Backward stability (pole 1)
Aux upper Boom telescoping selector 2P A Telescoping mode (keep relay) (pole 2)
Aux lower Swing brake release 2P A 2nd full RET. (pole 2)
Telescoping RET. Swing lock pin release 2P A Main upper (pole 2)
Telescoping EXT. Drum lock (Aux.) 2P A Main lower (pole 3)
Elevation raising Drum lock (Main.) 2P A Aux. upper (pole 2)
Elevation lowering Working lamp 2P A Aux. lower (pole 2)
Swing right Wiper (roof) 3P A Swing right (pole 2)
Swing left Wiper (front) 3P A Swing left (pole 2)
3, 4 top full retraction Starter Key Nect gear SW (lever) (pole 2)
FLJ tilting up or RET. AML emergency Key Telescoping stop valve (pole 2)
FLJ tilting down or EXT. Overwinding stop selector P M C / W CYL full RET. detector (pole 2)
Swing dead angle Hook movement amount main Aux. selector 2P M Swing lock pin (pole 1) c
2nd full retraction Swing stop release P M Swing stop (pole 1) a
Overwiring (boom) 3rd, 4th, top emergency telescoping P M Lever stand tilt (pole 3)
Overwiring (S / T) 2nd emergency telescoping P M FLJ tilting up or RET. (pole 4)
Cab tilt * FLJ tilting down or EXT. (pole 4)
Lever stand tilt Top boom correction P M Jib hydraulic source bleeding output (pole 1) a
MAIN remaining wrap 4th boom correction P M Over-rear area (pole 1) b
Aux. remaining wrap detection 3rd boom correction P M Boom telescoping mode selection (pole 2) c
Opened door Telescoping lever selector Rotary Pilot pressure main selector cut (pole 3)
C / W cylinder full extension (right) Cab tilt 3P M External indicator lamp (-90%) (pole 1)
C / W cylinder full extension (left) Inching swing 2P A External indicator lamp (90-100%) (pole 1)
C / W cylinder full retraction (right) High speed (winch: telescoping, elevation) 3P M External indicator lamp (100%-) (pole 1)
C / W cylinder full retraction (left) Mounting / dismouinting operation 2P A When FLJ mounting / dismounting,
main valve jib carrying oil selector (pole 2)
2nd fixing pin insertion (right) AML external indicator lamp use selector P A 3rd, 4th, top SOL sdelector (pole 1) b
2nd fixing pin insertion (left) Main winch 2nd selector (M lever) 2nd SOL selector (pole 1) b
FLJ 2nd top full retraction Aux. winch 2nd selector (S lever) C / W main CYL full EXT. detector (pole 1)
Boom jib connecting pin mechanical lock insertion (right) Boom next gear telescoping (telescoping lever) Elevation slow stop cancellation (pole 1) c
Boom jib connecting pin mechanical lock insertion (left) Horn (swing lever) Cab tilt detector (pole 1) a
Swing lock pin Main winch 2nd gear selector Forward backward area output (pole 1) a
FLJ overwiring detector Aux. winch 2nd gear selector Hook movement amount indicator OFF (pole 1) a
L / J overwiring detector Swing alarm stop P A Overwinding detector (pole 1) a
L / J tilt MIN detector Hook amount reset 2P M *
L / J tilt MAX detector Window washer 3P M *
L / J back stopper full raising detector Elevationo speed selector Rotary *
L / J mast cylinder contact detector (right) Mini winch operation (remote control)
*
L / J mast cylinder contact detector (left) Main winch operation ( ) *
2nd fixing pin extraction (right ) Boom bottom pin left cylinder ( ) *
2nd fixing pin extraction (left) Boom bottom pin right cylinder ( ) *
Main drum rotation detector (A phase) Elevation slow stop cancellation ( )
*
Main drum rotation detector (B phase) Camera raising switch P M *
Aux drum rotation detector (A phase) *
*
Aux drum rotation detector (B phase) *
*
Back stopper cylinder operation *
Mast cylinder operation *
Boom jib connecting pin operation *
2nd fixing pin insertion *
(Direction for abbreviation)
P : push switch Swing free lock selector (panel) *
2P : 2 position switch * *
3P : 3 position switch * *
M : Momentary
A : Alternate

8 Z03-3650E
Z-4 Z-4
Electric Circuit
Crane electrical equipment circuit

Water temperature
gauge Temperature sender unit

Fuel gauge
Fuel sender unit
Jib set, power supply for Air horn
mounting / dismounting

Horn switch

Radio
Power supply
CLOCK illumination Speaker (left)
Illumination
BUCK UP power supply
Speaker (right)

WIRING DIAGRAM (CRANE CONTROL)

to CN 2-49, 50
to CN 1-35 AML controller
to CN 2-59, 60
to Accessory circuit
to AML power supply, solenoid
Cigarette lighter

to panel, lamp
from main fuse
to blower, motor etc.
to control amplifier
from starter switch
AC terminal Panel switch

from battery Boom lamp

Working lamp

Working lamp SW

Front lamp Tail lamp

Air drier

Wiper motor (front) Wiper motor (roof)

Intermittent Intermittent
wiper relay wiper relay
(front) (roof) Washer tank

Front roof
to carrier light switch

Window washer

Front wiper switch Roof wiper switch

Opened door detector SW

Contact broken for door left open

Room lamp

9 Z03-3650E
Z-4 Z-4
Electric Circuit
Electric circuit for mounting/dismounting

Coil of RL 9 10 are in WIRING DIAGRAM (CRANE CONTROL).

Coil of RL 9 --- OFF when swing right
Coil of RL 10 --- OFF when swing left
Switch panel in cab
Mounting / dismounting Crane dismount indicator lamp
to fuse A selector switch Swing, remote control selector SOL

Cab tilt operation switch

(Spare)

Main winch hoisting up

Main winch hoisting down

Remote control valve 1 (for mounting/dismounting C / W)

Earth
Box,
operation
Unloading V

Control unit
(for mounting /
Left boom bottom pinCYL (EXT.) dismounting C / W)
Left boom bottom pinCYL (RET.)
Mini winch hoisting up
Mini winch hoisting down
Cab tilt upper
Cab tilt down
Right boom bottom pinCYL (EXT.)
Right boom bottom pinCYL (RET.) Accelerator
cylinder

Remote control for boom base pivot pin removal cylinder operation
(Sharing with remote controller for mounting / dismounting)

Hoisting down
Mini winch operation switch
Hoisting up

Hoisting
down
Hoisting Main winch operation switch
up

Boom bottom pin

Insertion
CYL (left)
Removal

Boom bottom pin Trigger switch

Insertion
CYL (right)
Removal

to horn relay
Horn switch
(Spare) Spare SW
Spare indicator lamp

Stowing box for remote control device for boom base pivot removal cylinder operation

10 Z03-3650E
 Z-4

Signal transmitter (for jib)

Jib offset angle detector

Orientation of tilt

Shield

jib length detector

Shield

Shield

Wind velocity input FLJ telescoping / mounting dismounting

Electric circuit for full automatic luffing jib

selector switch
SOL for operating jib elevating (raising)
output

(lowering)
output

output
SOL for operating jib telescoping (RET.)

11
output (EXT.)
SOL for operating jib top height adjustment
SOL for operating jib (Hoisting
output
(EXT.) mounting / dismounting up)
(Hoisting
Electric Circuit

(RET.) down)
output

for operating jib connecting pin (insertion)

output

output
(removal)
Connect when FLJ Jib overwind
Overwinding detection switch
Overwinding

Z03-3650E
Jib length detector

Connect when boom S / T

Switch input
2nd top jib
Switch input Full retraction detector switch
Switch input
Switch input
Switch input Full automatic luffing jib
Switch input
Single top
Switch input
(right) Boom jib connection pin (left)
Switch input
Mechanical lock detector switch

Connect when FLJ

Boom overwind detection switch

Z-4

top S / T overwind detector switch

Boom length angle detetor
Boom full retraction (Upper electric circuit)
detector switch
Z-4 Z-4
Electric Circuit
Luffing jib electric circuit

Signal transmitter
(type D)

Angle detector

Shield

Shield

Luffing jib

Shield

Wind velocity input

Backstopper CYL telescoping SOL (RET.)

output

(EXT.)
output

output

output

Mast CYL telescoping SOL (RET.)

output

(EXT.)
output

SOL for jib connecting pin (insertion)

output

(removal)
output

Connect when LJ
Overwinding L/J overwinding detector SW
Overwinding

Connect when boom single top

Switch input
Tilt MIN detector switch
Switch input
Switch input
Tilt MAX detector switch
Back stopper full raising detector SW
Switch input
Contacting detector switch for mast CYL and mast (right)
Switch input
Contacting detector switch for mast CYL and mast (left)
Switch input
Switch input
Jib connecting pin (left)
Switch input
Mechanical lock insertion detector SW

Main boom overwind detector Single top overwind detector SW

3 4 Top full retraction detector SW

Main boom length detector

12 Z03-3650E
 Z-4

Lower electric circuit

All outrigger operation SW All outrigger operation SW

Lamp

Lamp
Front left outrigger slide Front left outrigger
Front left outrigger operation SW lock pin operation SW slide lock pin operation SW Front left outrigger operation SW

Rear left outrigger slide Rear left outrigger

Rear left outrigger operation SW lock pin operation SW Boom inter lock cancel SW Boom inter lock cancel SW slide lock pin operation SW Rear left outrigger operation SW

13
Electric Circuit

Rear right outrigger slide Rear right outrigger

Rear right outrigger operation SW
lock pin operation SW Slide / jack selector SW Slide / jack selector SW slide lock pin operation SW Rear right outrigger operation SW

Outrigger operation box (left)

Outrigger operation box (right)

Z03-3650E
Front left outrigger slide Front left outrigger
Front right outrigger operation SW lock pin operation SW Accelerator SW Accelerator SW slide lock pin operation SW Front right outrigger operation SW
Z-4

Front right outrigger

release SOL
Front right outrigger
lock SOL
Rear right outrigger
release SOL
Rear right outrigger
lock SOL
Rear left outrigger
release SOL
Rear left outrigger
lock SOL
Front left outrigger
release SOL
Front left outrigger
lock SOL
Power supply for outrigger

Front right outrigger

slide lock detection

Rear right outrigger

slide lock detection

Rear left outrigger

slide lock detection

Front left outrigger

slide lock detection
indicator lamp

Outrigger accelerator
SOL
Front right jack EXT
SOL
Front right slide EXT
SOL
Front right jack stowing
Crane backward configuration

SOL
Front right slide stowing
SOL
Rear right jack EXT
SOL
Rear right slide EXT
SOL
Rear right jack stowing
SOL
Rear right slide stowing
SOL
Rear left jack stowing
circuit power supply

SOL
Rear left slide stowing
to suspension selector

SOL
Rear left jack EXT
SOL
Rear left slide EXT
SOL
Front left jack stowing
SOL
Rear left slide stowing
SOL
Front left jack EXT
SOL
Front left slide stowing
SOL
P2 pump selector
SOL
P1 pump selector
SOL
Soldering after
cut at TADANO

Slide EXT reduction

pressure SOL Y619
to suspension lock selector SW

Contact for stowing

Boom stowing detector SW
Contact for locking

Signal transmitter ASSY to carrier light SW to working lamp

(loading)
(loading)
Swing lock pin detector SW (rear)

AML controller to Di24

ASS’Y

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

AML controller to RD2-

AML controller to RD2+
Swivel joint

Shield
Shield
Shield
Shield

Carrier to swing table

Shield
Shield
Shield
Shield

13
Rear left O / R
Front left O / R

length detector
length detector
length detector
length detector

Rear right O / R
Front right O / R
 Z-4

Hydraulic
Oil filter Air filter Charging
pressure

to working
Water temperature switch
gauge
Electrical box (relay ASS’Y F)
Engine
stop relay
Engine electric circuit

to working
Fuel switch
gauge

Fuse box Air conditioner

power supply

Starter switch (Spare fuse)

14
Engine

(in cab) Engine stop

solenoid
Electric Circuit

Oil filter alarm SW

Hydraulic pressure SW

Temperature sender unit

Z03-3650E
Alternator

Air heater Starter motor

Battery
relay

Starter relay
Air cleaner
filter SW
Battery
Heater relay

Safety relay Fuel sender

Z-4

unit
Z-5 Z-5
Electric Circuit
Switch · panel (front)
Upper wiring (cab) Hook amount of movement Dismounting is not used
Boom · jib
connecting pin
Limit of angle between Backstopper contact Back tension
Cab tilt operation C / W main 2nd boom mast and base jib detection indicator reduction
indicator AML cancel Accumulator reduction Air reduction Swing slow condition condition CYL full Swing lock Swing brake 2nd boom
lock pin
mechanical lock
insertion Mast CYL / mast indication Air filter Charging alarm
stop cancel indication insertion
Back stopper full
contact indication choked alarm
condition alarm pressure alarm pressure alarm indication RET indication indication condition indication EXT
indication
detection EXT indication
indication indication
refer to NOTE 3
2nd boom
Phase A input by proximity switch (main) Elevaation 3, 4, top
lock pin
Oil filter Oil pressure
slow stop boom choked alarm reduction alarm
to wiring ASS’Y
Phase B input by proximity switch (main) EXT extraction
cancel
Phase A input by proximity switch (aux.) indication indication indication Boom telescoping ·
(swing table) Phase B input by proximity switch (aux.)
External reset input
main selector SOL
SUMI-tube
Power supply for OFF input signal to wiring ASS’Y (Heat shrinks from the center.
(swing table) Do not leave air.)
Power supply OFF input

Back light input

Soldering (2 places)
Main · Aux. selection input

gauge
temperature
Water
(before shrinking)

gauge
Fuel
Door switch
for room lamp
Starter switch
Diode installation procedures
Switch · panel (left overhead) Boom telescoping
FLJ tilt
FLJ telescoping
Working lamp Switch · panel (left knee) Radio ASS’Y Main
NOTE ) 1. Process the processing part with primer T of Shin-Etsu Chemical Co. Ltd.
(front of cab) Swing low before processing silicone and dry it for 30 minutes or more. (20 °C)
Swing alarm buzzer pressure selection
Wiper SW (front) selector SW operation SW 2. Wrap the PVC tape for protection and do the waterproof processing surely
over 24 hours after processing silicone.
Solder with AV line respectively.
Camera raising AML external
selector SW indicator lamp to wiring ASS’Y
selector SW
Room lamp
(engine)
Fuse box
Wiper SW top boom section correction 3, 4, top boom emergency
(roof) SW switch SW Shinetsu silicone Apply silicon between SUMI-tube
Room lamp PVC tape lines as well.tape

Cigar lighter 68 and 70 Terminal processing

4th boom section correction 2nd boom emergency

SW switch SW

Window washer SW

Capacitor
3rd boom section correction Overwinding cutout SW
SW
Wiper (front)

Working lamp
SW to telescoping stop valve
Window washer Wiper in AML failure
Swing slow stop cancel SW Elevation slow stop cancel SW
tank
relay Serial No. of changed machine

Roof Front
(front) to AML vent SOL

Wiper (roof)
Capacitor
in AML failure
The first No. ~
Crane dismounting SW
to proportional solenoid valve
for elevation slow stop or
The first No. ~
Capacitor
Wiper inching winch in AML failure The first No. ~
relay Diode ASS’Y
AML cancel key
Switch (roof) The first No. ~
Horn relay

Mast CYL
operation SW AML buzzer

DC-DC
Cab tilt
alarm buzzer convertor

Air reduction
Back stopper CYL operation SW alarm buzzer

Boom · jib
connecting
pin operation
to wiring ASS’Y
SW
Control lever · box (right) (swing table)
Control lever · box (left) Aux. winch speed Main winch speed Control lever
Horn SW Next gear EXT SW selector SW selector SW tilt detection AML controller
MAIN hoisting up
(swing lever) (EXT lever) (Aux. winch lever) (Main winch lever) (right)
MAIN hoisting down
Aux. hoisting up
Aux. hoisting down
Telescoping EXT
2nd boom lock pin operation SW
Telescoping RET
Elevation raising
Elevation rlowering
Swing right
Swing left
Back stopper RET or FLJ raising
Inching swing selection
input
Boom elevating speed selectoion
input
telescoping
selector SW C / W distortion detection
wire breakage input
Back stopper EXT or FLJ lowering
Boom full RET detection
2nd boom lock pin insertion detection (outside)
Telescoping lever (outside)
Overwinding cutout
selector SW (outside)
Boom Jib tilt Jib Main FLJ tilt upper or telescoping RET
telescoping telescoping winch
FLJ tilt lower or telescoping EXT
is not used Boom dismounting input
FLJ telescoping control selection Install in deck
Cab tilt SW MAIN remaining wrap detection (outside)
under the right cab
Aux. remaining wrap detection (outside)
(inside)
(Connect to remote control
Winch, telescoping/elevation for dismounting FLJ)
high speed selector SW Air conditioner Elevation slow stop cancel (inside)
Top full RET detection
ASS’Y Overwinding detection
Boom telescoping
selection
AML release
C / W emergency
input
C / W emergency
input
Elevation speed selector SW
Swing free lock
selector SW
Speaker for AML
Inching swing SW

External indicator lamp (-90%)

External indicator lamp (90-100%)
External indicator lamp (100%-)
Back tension reduction output
Swing brake Swing stop output
Main winch speed

release SW over-front · rear area output

selector SW

Rear area output

Jib hydraulic source bleeding output
Back stopper full raising output
Mast CYL contact output
Aux. winch speed

Boom · jib connecting pin mechanical lock

insertion output
selector SW

Swing lock
switch Automatic stop 1 (due to overload, overwinding, etc)
Automatic stop 2 (telescoping stop valve)
Automatic stop 3 (due to instability in the rear portion) etc
Buzzer output (accumulator low pressure alarm)
Buzzer output (AML alarm)
Drum lock SW (main)
Aux. drum lock SW

Telescoping control output No.1

Hook amount of movement indicator

Clock for
main · Aux. selector SW power supply

power supply

Hook amount of
movement
Switch · panel (right lower)
indicator
Boom telescoping · jib
reset SW selector SOL SOL 30 - 1

refer to
NOTE 3

Loudspeaker for
amplifier (option)

Speaker for Speaker for

radio (left) radio (right)

to wiring ASS’Y (swing table) to wiring ASS’Y (swnig table)

15 Z04-0880E 15
Z-5 Z-5
Electric Circuit
Upper wiring (swing table)

Air reduction detection Working lamp

Speaker for loudspeaker

Swing dead angle detector SW

MAIN remaining Roll the tape.
wrap detection Swivel joint
Air · horn
Aux. remaining wrap detection

Swing table length

indicator lamp
working lamp for monitoring
winch · drum
Elevation Elevation Telescoping Telescoping Aux. hoisting Aux. hoisting Main hoisting Main hoisting
Swing left Swing right Tilting down Tilting up
lowering raising EXT RET down up down up

from AML

Electric BOX (oil tank side)

AML external
indicator lamp

AML vent SOL

Jib hydraulic source bleeding SOL

C / W rotation CYL vent Boom

2nd full RET detection

Swing stop 1 SOL

Boom working lamp

from wirnig ASS’Y (cab)

Swing lock pin 3, 4, top full RET detection

insertion detection
Overwinding detection
Roll the tape. Roll the tape. Cord reel

Air drier Signal transmitter ASSY

Boom length indicator lamp
Regulator pilot pressure merge

2nd lock pin extraction

Aux. winch speed selector SOL detection (right) 2nd lock pin insertion detection (right)

Main winch speed selector SOL

Boom bottom pivot pin dismounting CYL
Telescoping/elevating speed selector SOL 2nd lock pin extraction detection (left) 2nd lock pin insertion detection (left)
Remote control for operation BOX

Swing control alarm

unit

Box, operation

Main winch hoisting down SOL Main winch hoisting up SOL

Remote control valve 1 (for dismounting C / W)

2nd SOL 3, 4, top SOL Control unit

( for dismounting C / W)

Left boom bottom pin CYL (EXT)

Left boom bottom pin CYL (RET)
Mini winch hoisting up
Mini winch hoisting down
Cab tilting up
Cab tilting down
Right boom bottom pin CYL (EXT)
Right boom bottom pin CYL (RET)
Pilot circuit vent SOL

Swing stop 2 SOL Earth

Unload · valve

Cab tilt detector SW

Swing lock pin release SOL

Winch speed selector SOL for driving potentiometer

Full RET detector SW
(left) Accelerator cylinder
Swing · remote control selector SOL
C / W main CYL condition detection

Swing brake release SOL

Transmitter
Full EXT detector SW
(left)
TYPE 5 Dismounting FLJ SOL
Elevation slow stop proportional control solenoid valve

Swing low pressure SOL

Swing stop proportional control solenoid valve
terminal base (for locking)
2nd lock pin insertion SOL
Proportional control solenoid valve for inching swing control

Full RET detector SW No.2 CYL SOL

(right)

No.3 CYL SOL

Aux. drum lock release SOL No.4 CYL SOL

Full EXT detector SW
(right)
Main drum lock release SOL Swing free selector SOL

Controller Camera raising selector SOL

(constant current amplifier)

Drum rotation detector SW Drum rotation detector SW Drum rotation detector SW Drum rotation detector SW
(MAIN · Phase A) (MAIN · Phase B) (Aux. · Phase A) (Aux. · Phase B)

from wiring ASS’Y (cab)

16 Z04-0880E 16
Z-5 Z-5
Electric Circuit
Air reduction detection Working lamp
Upper wiring
(swing table)
Speaker for loudspeaker

MAIN remaining Swing dead angle detector SW

wrap detection Roll the tape.
Swivel joint
Air · horn
Aux. remaining wrap detection NOTE ) 1. Process the processing part with primer T of Shin-Etsu Chemical Co. Ltd.
before processing silicone and dry it for 30 minutes or more. (20°C)
2. Process the processing part with primer T of Shin-Etsu Chemical Co. Ltd.
Swing table length before processing silicone and dry it for 30 minutes or more.
indicator lamp
Processing silicone part
working lamp for monitoring SUMI-tube
winch · drum Soldering
(5 places) (4 places)
Elevation Elevation Telescoping Telescoping Aux. hoisting Aux. hoisting Main hoisting Main hoisting
Swing left Swing right Tilting down Tilting up
lowering raising EXT RET down up down up

from AML

SUMI-tube

Shinetsu silicone
Apply silicon between lines as well.

SUMI-tube

Electric BOX (oil tank side) Terminal processing

AML external
indicator lamp

AML vent SOL

Jib hydraulic source bleeding SOL

C / W rotation CYL vent Boom

2nd full RET detection

Swing stop 1 SOL

Boom working lamp

from wirnig ASS’Y (cab)

Swing lock pin 3, 4, top full RET detection

insertion detection
Overwinding detection
Roll the tape. Roll the tape. Cord reel

Air drier Signal transmitter ASSY

Boom length indicator lamp
Regulator pilot pressure merge

2nd lock pin extraction

Aux. winch speed selector SOL detection (right) 2nd lock pin insertion detection (right)

Main winch speed selector SOL

Boom bottom pivot pin dismounting CYL
Telescoping/elevating speed selector SOL 2nd lock pin extraction detection (left) 2nd lock pin insertion detection (left)
Remote control for operation BOX

Swing control alarm

unit

Box, operation

Main winch hoisting down SOL Main winch hoisting up SOL

Remote control valve 1 (for dismounting C / W)

Control unit
2nd SOL 3, 4, top SOL
( for dismounting C / W)

Left boom bottom pin CYL (EXT)

Left boom bottom pin CYL (RET)
Mini winch hoisting up
Mini winch hoisting down
Cab tilting up
Cab tilting down
Right boom bottom pin CYL (EXT)
Right boom bottom pin CYL (RET)
Pilot circuit vent SOL

Swing stop 2 SOL Earth

Unload · valve

Cab tilt detector SW

Swing lock pin release SOL

Winch speed selector SOL for driving potentiometer

Full RET detector SW
(left) Accelerator cylinder
Swing · remote control selector SOL
C / W main CYL condition detection

Swing brake release SOL

Transmitter
Full EXT detector SW
(left) TYPE 5 Dismounting FLJ SOL

Elevation slow stop proportional control solenoid valve

Swing low pressure SOL
Swing stop proportional control solenoid valve
terminal base (for locking)
2nd lock pin insertion SOL
Proportional control solenoid valve for inching swing control
Lever arrangement
Full RET detector SW ISO : tighten together with GO and BW No.2 CYL SOL
(right)
TADANO : tighten together with BrW and BW
No.3 CYL SOL

Aux. drum lock release SOL No.4 CYL SOL

Full EXT detector SW
(right)
Main drum lock release SOL Swing free selector SOL

Controller Camera raising selector SOL

(constant current amplifier)

Drum rotation detector SW Drum rotation detector SW Drum rotation detector SW Drum rotation detector SW
(MAIN · Phase A) (MAIN · Phase B) (Aux. · Phase A) (Aux. · Phase B)

from wiring ASS’Y (cab)

17 Z04-0880E 17
 Z-5

SOL for operating elevation

Full automatic luffing jib wiring

SOL for operating telescoping

Signal transmitter (for jib)
output (raising) (lowering) SOL for operatiing jib top Jib length
output height adjustment detector
output (RET.) (EXT.)
output
Jib overwind
detector SW
output
output (EXT.) (RET.)

Overwinding 2nd top jib full retraction detector SW

Switch input
Switch input
Switch input
(hoisting up) (hoisting down)
Switch input

18
Switch input
Switch input
SOL for operating jib
Switch input
mounting / dismounting
Electric Circuit

Full automatic luffing jib wiring

Z04-0880E
FLJ FLJ
telescoping mounting /
dismounting

FLJ telescoping /
mounting dismounting selector SW
Z-5
 Z-5

Luffing jib wiring

Jib, base

Pass terminal
number 1 and 3.
(RET.) SOL for mast 1 CYL telescoping (EXT.) overwinding detector SW
output
output
output Spiral tube
output Within 200mm
(RET.) SOL for mast 2 CYL telescoping (EXT.) from CN 245
output
output

Overwinding
Switch input
Switch input

19
Switch input Tilt MIN detector SW
Switch input Taping Taping
Switch input
Luffing jib MAX tilt angle (mast 1 CYL full extension detector SW)
Switch input detector SW
Spiral tube
Back stopper CYL full raising detector SW
Electric Circuit

Switch input Within 900mm

from CN 245

Signal transmitter
(type O)

Spiral tube

Z04-0880E
Within 200mm Spiral tube
L / J overtopping boom section from CN 242 Within 400mm
from CN 242
Contacting detector switch for
mast 2 CYL and mast 2 (right)

Contacting detector switch for

mast 2 CYL and mast 2 (left)

Mast 2
Z-5
Z-5 Z-5
Electric Circuit
Engine wiring
Hydraulic
pressure Oil filter Air filter Charging

to working lamp SW
Water temperature
gauge

to working lamp SW
Fuel gauge

Air conditioner
power supply
Fuse box

Starter switch

9 or more 20 (before shrinking)

Harness in cab

SUMI-tube W3C - 3 / 8
(transparent)
Heat shrinks from the center.
Do not leave air.

Do not overflow the part of the caulking and wire from Sumi-tube edge.
Install 35, 36 after fixing the SUMI-tube.

Tighten together with the earth of Part A construction

the main body of the engine
Engine electrical box

Engine stop
Relay RJ Relay RX relay Engine

Engine stop solenoid

Oil filter alarm

Hydraulic pressure

Temperature sender unit

Alternator

Battery relay side

Starter motor

Air heater
8W side
15B side

Starter relay

Heater relay
Battery

Safety relay Fuel sender Air cleaner

unit filter

20 Z04-0880E 20
Z-5 Z-5 Serial No. of changed machine
Electric Circuit The first No. ~

Engine wiring
Hydraulic
pressure Oil filter Air filter Charging

to working lamp SW
Water temperature
gauge

to working lamp SW
Fuel gauge

Air conditioner
power supply
Fuse box

Starter switch

Harness in cab 9 or more 20 (before shrinking)

SUMI-tube W3C - 3 / 8
(transparent)
Heat shrinks from the center.
Do not leave air.

Do not overflow the part of the caulking and wire from Sumi-tube edge.
Install 35, 36 after fixing the SUMI-tube.

Tighten together with the earth of Part A construction

the main body of the engine
Engine electrical box

Engine stop
Relay RJ Relay RX relay Engine

Engine stop solenoid

Oil filter alarm

Hydraulic pressure

Temperature sender unit

Alternator

Battery relay side

Starter motor

Air heater
8W side
15B side

Starter relay

Heater relay
Battery Starter relay

Safety relay Fuel sender Air cleaner

unit filter
21 Z04-0880E
21
Z-5 Z-5
Electric Circuit

Air conditioner wiring

Dual pressure switch

Wiring diagram Circulation circuit

Control panel

Blower switch Panel illumination Panel illumination

Mode select switch Heater TEMP lamp lamp
Pressure switch for Register for
transforming electric fan transforming electric fan

Relay for electric fan

A / C unit

Blower relay Power

supply

Working lamp switch

Socket for taking out
power supply
Compressor
clutch relay

Water valve
servo motor

Blower register

Mode select
servo motor

Inner air thermistor

Blower motor

Water valve servo motor

Air conditioner control amplifier Blower register 1 Electric fan relay
Battery Blower register 2 Key switch
Amplifier fuse Cooler temperature setting resistance Mode select switch

Heater temperature setting resistance inter lock switch (FACE)

Battery fusible link MWV inter lock potentiometer Pressure switch for gear of electric fan
Control fuse Blower relay Register for gear of electric fan
Blower motor Compressor clutch relay inter lock switch (FOOT)
Capacitor electric fan motor Key switch relay (truck side) Inner air thermistor
Mode select servo motor Voltage check relay
Water valve servo motor Blower switch

Connecting table
Air conditioner control amplifier
Mode select servo motor

Voltage check relay

22 Z04-0880E 22
Head Office Ko-34,Sinden-cho, Takamatsu, Japan

Overseas Service Group

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

History of revision
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 2008
PRINTED IN JAPAN
0803 E