Publication No. TL-200M-4/C1-1E. Truck Crane TL-200M-4. Model. Applicable Serial No PRINTED IN JAPAN 0611 E

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1 Publication No. TL-200M-4/C1-1E 01 Truck Crane Model TL-200M-4 Applicable Serial No c2006 PRINTED IN JAPAN 0611 E

2 Foreword Foreword This circuit diagrams contains all the hydraulic and electric circuit diagrams for the Model TL-200M-4 truck crane. This manual applied to the cranes of the Spec. No. 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 in conjunction 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 ISA Spec. No. Applicable serial No. TL-200M TL-200M TL-200M TL-200M We reserve the right to modify the design without notice for improvements, etc. 1 WA E

3 Foreword Contents Chapter Section Spec. No. TL-200M Data, Adjustment & Checks Specifications Y-1 Weight table Y-2 Y Adjustment (pressure) Y-3 Adjustment (electric) Y-4 Adjustment and checks Y-5 System Diagrams Hydraulic Circuit Z-1 Z Electric Circuit Z-2 Wiring diagram Z-3 2 WA E

4 Y Data, Adjustment and Checks Contents Y-1 Specifications...1 P.T.O... 1 Hydraulic unit... 1 Y-2 Weight table...2 Y-3 Adjustment (pressure)...3 Hydraulic circuit... 3 Y-4 Adjustment (electric)...7 Switch adjustment... 7 Y-5 Adjustment and checks...9 Swing system... 9 Winch system Crane operation Y i

5 Y-1. Specifications Y-1. P.T.O Gear ratio Carrier Gear ratio Nissan W-KW450MN Mitsubishi W-KV208M Hydraulic unit 1. Hydraulic pump 1) Pump speed Idling speed : rpm Max. speed : rpm Pump speed when outriggers are operated : rpm 2) Discharge rate P1 P2 P3 70.4cc/rev 70.4cc/rev 29.2cc/rev 2. Hydraulic motor (winch) Oil intake rate : 155.6cc/rev 3. Hydraulic motor (oil cooler/option) Oil intake rate : 12.0cc/rev 4. Speed reducer (winch) Reduction gear ratio : 1/ Swing drive unit 1) Oil intake rate : 45.1cc/rev 2)Reduction gear ratio : Accumulator N2 gas filling pressure : 80±3kg/cm 2 (20 C) 1 WY E

6 Y-2. Weight table Y-2. In the weight table below, the weights of major components are given in terms of weight codes A through T. When dismounting and remounting these components, find their approximate weight in the table and select proper slinging tools on the basis of the given weight. Code Weight (kg) Code Weight (kg) Code Weight (kg) A 0~250 H 1,750~2,000 O 3,500~3,750 B 250~500 I 2,000~2,250 P 3,750~4,000 C 500~750 J 2,250~2,500 Q 4,000~4,250 D 750~1,000 K 2,500~2,750 R 4,250~4,500 E 1,000~1,250 L 2,750~3,000 S 4,500~4,750 F 1,250~1,500 M 3,000~3,250 T 4,750~5,000 G 1,500~1,750 N 3,250~3,500 [ Spec. number ] 1 : TL-200M : TL-200M : TL-200M : TL-200M Part name Spec. number Outrigger inner case Ass'y B B B B Swing table Ass'y (excluding boom, elevating cylinder, and counterbalance weight) J J J J Swing bearing B B B B Elevating cylinder C C C C Winch B B B B Jib B B B B Boom Ass'y R R R R Counterbalance weight G G G G 2 WY E

7 Y-3 Y-3 Adjustment (pressure) Hydraulic circuit Pressure setting table Item Pressure (kg/cm 2 ) Note Manual control valve (quadruple) - - winch main circuit 240±5 Relief valve (RV1) Boom elevating/telescoping main circuit 210±5 Relief valve (RV2) Boom raising circuit Screw in Port relief valve (PR2) Boom lowering circuit Port relief valve (PR1) Boom extending circuit 150±5 Port relief valve (PR3) Boom retracting circuit 210±5 Port relief valve (PR4) Manual control valve (for outriggers) - - Outrigger main circuit 210±5 Relief valve (RV3) Front jack circuit Port relief valve (PR7) Manual control valve (for boom swing) Loading pressure Unload valve 0 (accumulator filling 165±5 Unloading pressure circuit) (50L/min) Overload relief valve (40L/min) Free swing setting valve Counterbalance valve (winch) 18 valve opening pressure 280 (5L/min) Overload relief valve (valve opening pressure) Counterbalance valve (elevation) 17.2 valve opening pressure Counterbalance valve (telescoping) 17.2 valve opening pressure Pressure switch (front jack) 175 Front jack load (internal pressure) 27±3 Front jack up pressure (working pressure) Pressure gauge (for accumulator) 100±5 Pressure switch (PS1) Flow control valve (for oil cooler) 30 Switching pressure 3 WY E

8 Y-3 Y-3 Adjustment (pressure) Pressure adjustment high-speed switch turned off, measure the pressure while the pump is running at the MAX speed. 2) Boom elevating/telescoping main circuit (relief valve RV2) Fully tighten the adjuster screw of port relief valve PR4 for the boom telescoping. Move the boom telescoping lever to the retraction position with the boom telescoping cylinder fully retracted and measure the pressure while the pump is running at the MAX speed. Note) After adjusting RV2, always adjust the port relief valve PR4 referring to 6). Oil temperature : 50±5 C 1. Manual control valve (quadruple) 3) Boom lowering circuit (port relief valve PR1) With the boom elevating cylinder fully retracted, move the boom elevating lever to the lowering position and measure the pressure while the pump is running at the IDL speed. 4) Boom extending circuit (port relief valve PR3) Move the boom telescoping lever to the extension position to extend the telescoping cylinder to its stroke end and measure the pressure while the pump is running at the MAX speed. 5) Boom retracting circuit (port relief valve PR4) Move the boom telescoping lever to the retraction position with the boom telescoping cylinder fully retracted and measure the pressure while the pump is running at the MAX speed. 2. Manual control valve (for swing) Accumulator filling circuit 1) Winch main circuit (relief valve RV1) Plug the main winch winding port or apply a line pull load of 3.0 tons. With the main winch lever in the hoist-up position and the winch With the pump speed at IDL, the winch lever in the neutral position and the winch drum locked, switch the clutch lever between "ON" and "FREE" repeatedly and measure the pressure at which the accumulator pressure changes from dropping to rising (loading pressure). Then move the clutch lever to the "ON" position and measure the pressure at which the accumulator pressure stops 4 WY E

9 Y-3 Y-3 Adjustment (pressure) rising (unloading pressure). 5 WY E

10 Y-3. Adjustment (pressure) Y Manual control valve (for outrigger) 1) Outrigger main circuit (relief valve RV3) Install a pressure gauge to the PG port of the control valve. With the jack cylinder fully retracted, perform retraction operation for the jack and measure the pressure. 2) Front jack circuit (port relief valve PR7) Install a pressure gauge to the PG port of the control valve. With the outriggers set, perform extending operation for the front jack and measure the pressure. 6 WY E

11 Y-4 Y-4 Adjustment (electric) Switch adjustment NOTICE For the locations of the switches, refer to LOCATIONS OF ELECTRIC PARTS in chapter Z. 2. Switch 19 (front jack load detection) Adjust the nut [a] so that dimension A becomes about 18.4 mm (pressure 175 kg/cm 2 ). 1. Switch S1 (main winch hoisting-up detection); Switch S3 (auxiliary winch hoisting-up detection); Switch S6 (boom extension detection); Switch S7 (boom raising detection); Switch S8 (boom lowering detection) 3. Switch S20 (outrigger retraction operation detector switch), Switch S21 (outrigger extension operation detector switch) 1) With the outrigger extension/retraction lever in the neutral position, turn nut [a] until dimension A shown in the figure below becomes 1.5 mm. 2) After the adjustment is complete, use screw locking compound (THREE-BOND 1401 or equivalent) to secure the nut [a]. 1) Adjust the nut [a] so that the contact NO of the limit switch becomes OFF when the spool is shifted 1.0 to 2.0 mm from the neutral position. 2) After the adjustment is complete, use screw locking compound (THREE-BOND 1401 or equivalent) to secure the nut [a]. 7 WY E

12 Y-4. Adjustment (electric) Y Switch S23 (outrigger extension/retraction operation detector switch; applicable to Mitsubishi carrier) 1) Adjust the nut [a] so that the limit switch becomes ON when the outrigger extension/retraction lever is shifted 4±1 mm from the neutral position. 6. Switches SD1 (main) and SD2 (aux.) (drum rotation detection switch/option) Adjust until clearance between each switch and drum (dimension A shown in figure below) becomes mm. 2) After the adjustment is complete, use screw locking compound (THREE-BOND 1401 or equivalent) to secure the nut [a]. 5. Switches RF1, RF2, RR1, RR2, LF1, LF2, LR1, and LR2 (outrigger extended width detection proximity switch). Adjust it so that B dimension shown in the figure below becomes 12 mm (1mm in A dimension). 8 WY E

13 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. 4) After bleeding the master cylinder is complete, proceed with the swing driving unit. Bleed the swing driving unit in the same manner as for the master cylinder. Swing system 1. Master cylinder mounting and adjusting procedure There must be a play of about 0.5 mm between the push rod and the piston when the swing brake lever is free. 3. Swing circuit bleeding procedure After hydraulic oil replacement or removing the pump or equipment on the P3 discharge side (manual control valve for outrigger, rotary joint, etc.), bleed the swing circuit as follows: 2. Swing brake circuit bleeding procedure 1) Start the engine to run the pump. 2) Insert the vinyl hose in the bleeder screw on the master cylinder. 1) Remove the plug of the VT port on the manual control valve (for swing), and make the supply valve "normally open". Under such a condition, start the engine and bleed the circuit about one minute at idle. After bleeding is completed, stop the engine and plug the VT port. 3) Pull the swing brake and open the bleeder screw to bleed the hydraulic system; and close the bleeder screw before releasing the swing brake. Repeat this procedure until discharged fluid contains no air bubbles; and close the bleeder screw while the fluid is still flowing out. 2) Run the engine and make sure that the pressure builds up in the accumulator. If the pressure does not build up, repeat the step 1). 9 WY E

14 Y-5 Y-5 Adjustment and checks Winch system 1. Master cylinder mounting procedure B. Foot brake cylinder 1) Set the drum lock lever to the lock position. 2) Set the clutch lever to the "Free" position. 1) Adjust the rod of the master cylinder so that the brake pedal has an angle of 20 to the floor board with no pressure applied to the brake pedal. NOTICE Manually move and release the pedal and verify that the piston of the master cylinder is completely returned. 2) Turn bolt [a] until clearance [A] is eliminated with the pedal not depressed. 3) Depress the brake pedal and open the bleeder screw on the brake cylinder, and close the screw before releasing the brake pedal. Repeat this procedure until discharged brake fluid contains no air bubbles; and close the bleeder screw while the fluid is still flowing out. NOTICE Pay attention to the fluid level in the brake fluid reservoir. 3) Depress the pedal and adjust bolt [b] so that the stroke of the master cylinder becomes 24 mm. 2. Winch brake circuit bleeding procedure A. Automatic brake cylinder 1) Set the drum lock lever to the lock position. 2) Insert the vinyl hose in the bleeder screw on the brake cylinder. 3) Set the clutch lever to the "Free" position. 4) Open the bleeder screw to bleed the hydraulic system until discharged fluid contains no air bubbles; and close the bleeder screw while the fluid is still flowing out. 3. Winch brake adjusting procedure 1) Turn synchronizing bolt [b] until [L] becomes 18.0 mm. 2) With the clutch lever in the "FREE" position and the drum lock lever in the "LOCK" position, set the winch control lever to the neutral position. 10 WY E

15 Y-5 Y-5 Adjustment and checks 3) Use a spanner to tentatively tighten stroke adjustment nut [a] until clearance between the drum and shoe is eliminated (the spanner becomes heavy to turn). 4) Tighten the synchronizing bolt [b] until the wrench becomes heavy to turn so that Y becomes 0 when the clearance X is 0. Fix the bolt with the nut and lock it with wire to prevent loosening. 6) After the above-mentioned adjustment procedure is completed, return the clutch to the "FREE" position and the drum lock to "Lock" position, and then set the winch control lever to the neutral position. 7) Turn bolt [c] until clearance A becomes 0.4 to 0.5mm. 8) Turn bolt [d] until clearance B becomes 0.4 to 0.5mm. NOTICE Measure L dimension to verify that it is within the range of 15.0±2.0 mm. 5) Engage the clutch and loosen stroke adjustment nut [a] until X becomes 2.5 to 3.0 mm. NOTICE If nut [a] is to be tightened for adjustment, set the drum lock lever to the lock position and the clutch lever to the "FREE" position before tightening the nut. NOTICE Be careful not to overtighten bolt [d]. An over-tightened bolt can impede the quick lowerinng in loaded conditions, even though it may have no influence on the quick lowering in no-load conditions. 9) After completing the adjustment of clearance A and B, turn to adjust the slinging bolt and the retaining bolt so that an uniform clearance may be obtained between the brake band and the drum. Check that there is no clearance at Z area shown in the figure at the step 5 when the clutch is in the "FREE" position. 10) After the adjustments in step 9) are complete, reeve the rope at the maximum allowable number of turns and raise the boom to the maximum angle, then check that the hook can descend quickly. 11 WY E

16 Y-5 Y-5 Adjustment and checks 11) Hoist a load equivalent to N times (N: number of turns of rope) the maximum allowable load per rope and check the ensure that no slip occurs between the brake band and drum when the winch control lever is set to the neutral position. NOTICE The maximum allowable load per rope is described in the "Rated lifting capacity" table. Never lift a load exceeding the rated lifting capacity. 12) After adjusting the brake band, put the label so that a right-hand edge of the marker comes above the black section. 5. Winch clutch adjusting procedure 1) Set the drum lock lever to the lock position, and the clutch lever to "FREE". 2) Turn the adjusting nut on the wheel cylinder in the arrow direction to expand the clutch shoes until they come in contact with the drum. Then, return the adjusting nut to back off the shoes until the clearance between the drum and shoes is adjusted to mm. Reference Returning through 4 notches adjusts the clearance to about 0.26 mm. 6. Checking accumulator (N2) gas 4. Clutch cylinder bleeding procedure 1) Rotate the drum until the bleeder screw is located at the top. 2) With the winch control lever in the neutral position, set the clutch lever to "ON" and open the bleeder screw to bleed the clutch. 1) Set the drum lock lever to the lock position. 2) With the engine stopped, watch the pressure gauge while moving the clutch lever between "ON" and "FREE" repeatedly. First, the pressure gauge reading will drop gradually, and then it will start to drop rapidly from a certain pressure level. The pressure from which the reading starts to drop rapidly is the N2 gas pressure in the accumulator. 12 WY E

17 Y-5 Y-5 Adjustment and checks Crane operation 1. Accelerator circuit bleeding procedure 1) Depress the accelerator pedal and open the bleeder screw (located on the front right side of the rotary joint) to bleed the circuit. Close the bleeder screw before releasing the accelerator pedal. Repeat this procedure until discharged fluid contains no air bubbles; and close the bleeder screw while the fluid is still flowing out. 2. Accelerator (pump speed) adjustment procedure 1) Adjust the angle of accelerator pedal θ to degree (approx. 105 mm in terms of dimension A) with the push rod and lock the rod with nut [a]. 0 2) Also bleed the control cylinder in the same manner as mentioned in step 1). 2) Adjust bolt [c] so that the piston begins to operate from the position 1-3 mm away from the retraction-side stroke end (that is, stroke of 1-3 mm is left on the retraction side when bolt [c] touches lever [d]). (Dimension L must be mm.) For Mitsubishi carrier, adjust l dimension to approx mm. Adjust rod [e] until the control lever comes in contact with the governor idling set bolt. 13 WY E

18 Y-5. Adjustment and checks Y-5. bolt [b]. 6) Adjust the accelerator for outrigger operation as follows: Nissan carrier : Operate the manual control valve (for outrigger) and use the turnbuckle of the outrigger adjustment rod connected to the lever to set the accelerator to the speed specified for outrigger control. Mitsubishi carrier : Adjust bolt [i] against lever [h] so that the pump runs at the speed for outrigger operation when the manual control valve (for outriggers) is operated to actuate the air cylinder. 3) Operate the accelerator pedal once or twice, then adjust bolt [f] so that lever [d] returns fully to the idling position when the accelerator pedal is released. 4) In the idling state, verify that the pump is running at the specified speed. Then depress the accelerator pedal slowly and make sure that the pump runs at the specified speed when the control lever touches the governor maximum rotation set bolt. (For Mitsubishi carrier, adjust at this time so that lever [d] touches bolt [g] simultaneously.) [Measurement condition] No load Gearbox: neutral (N) Fluid temperature: 50±5 degree Bleeding of the accelerator circuit is complete. 5) Hold the accelerator pedal at a position where the control lever comes in contact with the maximum speed set bolt, i.e., the pump speed reaches the maximum. Then adjust the hieght of 14 WY E

19 Z System Diagrams Z-1 HYdraulic circuit...1 Contents Z-2 Electric circuit...2 Upper electric circuit... 2 Lower electric circuit... 3 Z-3 Wiring diagram...4 Upper circuit wiring diagram... 4 Lower circuit wiring diagram... 5 Switch Ass'y Heater circuit (option)... 7 Z i

20 Z-1. Z-1. Z-1. Hydraulic circuit Oil reservoir Master cylinder (for winch brake) Brake cylinder Clutch cylinder Hose reel Telescoping cylinder Hydraulic valve Counterbalance valve Master cylinder (for accelerator) Hydraulic motor Elevating cylinder Counterbalance valve Accumulator Hydraulic valve (for winch brake) Counterbalance valve Manual control valve Pressure gauge Clutch valve Swing drive unit Oil filter Check valve Control cylinder Master cylinder (for swing brake) Extension cylinder Pilot check valve Jack cylinder Manual control valve Solenoid valve (for automatic stop) Solenoid valve (for high-speed winch operation) Oil cooler Front jack cylinder Rotary joint Flow control valve Hydraulic pump Oil filter Pressure gauge Manual control valve Oil tank IWZ E WZ E 1

21 Z-2 Z-2 Z-2 Electric circuit Upper electric circuit Applicable to machines whose total length exceeds 12 m Tail lamp Front lamp Heating unit (at start 9A) Heater Option Working lamp switch Boom lamp Starter switch Stop Roof Head lamp Fuse box Start Windshield wiper switch Front Buzzer (2) Accumulator low pressure detector switch Lever Horn Cigar lighter Radio Fan switch External drive power source AML power supply Cab lamp 10A Boom angle detector Boom length detector Rotary joint AML power supply Moment detector To corresponding lines in lower electric circuit diagram Front jack switch Front jack Outrigger extension detection L1 Outrigger extension detection R1 Outrigger retraction 3rd/top boom section full retraction Swing dead angle detection Overwinding Cord reel Swing dead angle detector switch Overwind detector switch Boom Single top Jib AML external indicator lamp (orange for 90%) AML abnormality 100% on AML Rear stability Overwinding cutout deactivation AML override AML external indicator lamp (red for 100%) For emergency due to AML failure Connected in case of AML failure Overwinding cutout disable switch For AML vent (normally on) AML abnormality cancellation AML buzzer (Lever) 3rd/top boom section extension switch Buzzer (1) AML override switch Swing angle detector External data bus Cord reel Option Option Option For 3rd/top boom section telescoping 3rd/top boom section emergency telescoping switch 2nd boom section emergency telescoping switch 3rd/top boom section full retraction detector switch Winch acceleration selector switch (Lever) Winch acceleration selector switch (Lever) For winch acceleration For swing free/lock select Swing free/lock selector switch Drum rotation indicator Rotation detector switch Rotation detector switch Winch hoisting detector switch This diagram is based on the following conditions: Crane: traveling configuration Hook block: overwound Main switch: OFF Boom: fully retracted Surge absorber Boom extending operation detector switch Boom raising operation detector switch Boom lowering operation detector switch IWZ E WZ E 2

22 Z-2. Z-2. Z-2. Electric circuit Lower electric circuit Connected to corresponding lines in electric circuit diagram (upper) Rotary joint This diagram is based on the following conditions. 1. Crane: traveling configuration 2. PTO switch: OFF Front jack load detector switch (overload) Outrigger retracting operation detector switch Control unit (for outrigger extended width detection) Outrigger extending operation detector switch Front jack up pressure detection switch Outrigger extending/retracting operation detector switch Solenoid valve (for accelerator) Applicable to the Mitsubishi carriers PTO interlock switch PTO switch Starter switch Starter relay Fuse for crane Carrier light switch Main switch Front left O/R extended width detection proximity switch Front right O/R extended width detection proximity switch Rear left O/R extended width detection proximity switch Rear right O/R extended width detection proximity switch For fuel cut IWZ E02 Crane carrier side WZ E 3

23 Z-3 Z-3 Z-3 Electric circuit Upper circuit wiring diagram Cord reel Boom lamp Solenoid valve (for swing free/lock select) Working lamp (left) Within crane cab Rotary joint Accumulator low pressure detector switch Heater switch Radio Cigar lighter AML override switch Switch Ass'y To wiring in cab Drum rotation indicator Swing table tail lamp (left) Buzzer (1) Drum rotation detector switch Solenoid valve (for 3rd/top boom section telescoping) Solenoid valve (for AML vent) Solenoid valve (for winch acceleration) Horn relay Rh Horn Swing lever Elevating lever Working lamp (right) Swing table tail lamp (right) Boom raising operation detector switch Boom lowering operation detector switch Telescoping lever Winch hoist-up operation detector switch (aux.) Boom extending operation detector switch Winch lever (aux.) Winch hoist-up operation detector switch (main) Winch lever (main) IWZ E WZ E 4

24 Z-3 Z-3 Z-3 Electric circuit Lower circuit wiring diagram Front jack up pressure detector switch Front jack load detector switch (overload) The switches marked with * are applicable to the Mitsubishi carrier. Outrigger retracting operation detector switch Front left O/R extended width detector switch (proximity switch) Solenoid valve (for accelerator) Front right O/R extended width detector switch (proximity switch) Outrigger extending operation detector switch * * Outrigger extending/retracting operation detector switch PTO synchronized power supply (carrier-side wiring) Control unit (for outrigger extended width detection) Rear left O/R extended width detector switch (proximity switch) Carrier-side wiring Rear right O/R extended width detector switch (proximity switch) Rotary joint IWZ E WZ E 5

25 Z-3 Z-3 Z-3 Electric circuit Switch Ass'y Crane cab A switch marked with * is optional. Starter switch * IWZ E03 Radio WZ E 6

26 Z-3. Z-3. Z-3. Electric circuit Heater circuit (option) Relay Relay Relay Ass'y Control panel Ass'y Heater power supply switch Limit thermo Heater Ass'y Control thermo Control panel Ass'y MV : Solenoid valve I.P : Ignition plug M : Motor Limit thermo : OFF... Approx. 160 degree Celsius Control thermo : ON... Approx. 50 degree Celsius : OFF... Approx. 30 degree Celsius Rotary joint Combustion Preheating G : Low fire indicator R : Hi fire indicator W : Hot air indicator IWZ E WZ E 7

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) Tel fax 81 (3) History of revision

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