TL-250M-3/C1-1E. Publication No. Truck Crane Model TL-250M-3. Applicable Serial No

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1 Publication No. TL-250M-3/C1-1E 01 Truck Crane Model TL-250M-3 Applicable Serial No

2 Foreword Foreword This manual contains all the hydraulic and electric circuit diagrams for the Model TL-250M-3 truck 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 ISA Spec. No. TL-250M TL-250M TL-250M TL-250M Applicable serial No We reserve the right to modify the design for improvements, etc. without notice. W E

3 Foreword 2. Contents Chapter Section Spec. No. TL-250M Data, Adjustment and Checks Y Specifications Y-1 Standard tightening torque table Y-2 Weight table Y-3 Adjustment (pressure) Y-4 Adjustment (electric) Y-5 Adjustment and checks Y-6 System Diagrams Z Hydraulic Circuit Z-1 Electrical parts mounting position Electric Circuit ( ) (wiring diagram) Electric Circuit ( ) (wiring diagram) Z-2 Z-3 Z-4 2 WA E

4 Data, Adjustment and Checks Contents Y-1. Specifications... 1 PTO... 1 Hydraulic unit Hydraulic pump Hydraulic motor (winch) Hydraulic motor (Oil cooler / option) Speed reducer (winch) Swing drive unit Accumulator... 1 Y-2. Standard tightening torque table 2 Y-3. Weight table... 3 Y-4. Adjustment (pressure)... 4 Hydraulic circuit... 4 Pressure setting table... 4 Pressure adjustment... 5 Y-5. Adjustment (electric)... 7 Switch adjustment Switch S1 (main winch hoisting-up. operation detection switch),. Switch S3 (auxiliary winch hoisting-up. operation detection switch),. Switch S6 (boom extension operation. detection switch),. Switch S7 (boom raising operation. detection switch),. Switch S8 (boom lowering operation. detection switch) S19 switch. (front jack load detecting switch) S20 switch (outrigger stowing operation detection switch) Switch for outrigger accelerator SD1 (main), SD2 (auxiliary) switches. (drum rotation detection switch/option)... 7 Y

5 Y-6. Adjustment and checks... 8 Swing system Master cylinder mounting and adjusting procedure Swing brake circuit bleeding procedure Swing circuit bleeding procedure... 8 Winch system Master cylinder mounting and adjusting procedure Winch brake circuit bleeding procedure Winch brake adjusting procedure Clutch cylinder bleeding procedure Winch clutch adjusting procedure Accumulator pressure checking procedure for nitrogen gas (N2) Crane operation Accelerator circuit bleeding procedure Accelerator (pump rotation) adjustment.. 12 i i

6 Y- 1. Y- 1. Specifications PTO Gear ratio Carrier Gear ratio NISSAN KG45S MITSUBISHI K303 Hydraulic unit 1. Hydraulic pump 1) Pump speed Idling speed (IDL) Max. speed (MAX) Speed at outrigger operation 2) Discharge rate 2. Hydraulic motor (winch) Oil intake rate : cc / rev 3. Hydraulic motor (Oil cooler / option) Oil intake rate : 12.0 cc / rev 4. Speed reducer (winch) Reduction gear ratio: 1/ Swing drive unit 1) Oil intake rate : 45.1 cc / rev 2) Reduction gear ratio: Accumulator N2 gas filling pressure: 80 ± 3 kg/cm 2 (20 C) 1

7 Y- 2. Y- 2. Standard tightening torque table Standard tightening torque table For the bolts whose tightening torque is not specified, use the values in the following table. Kind Calling (M) Coarse Fine 2

8 Y- 3. Y- 3. Weight table In the table below, the weights of major components are given in terms of weight codes. When dismounting/ remounting these components, select a proper lifting sling based on the approximate weight of a component to be lifted. Code Weight Code Weight Code Weight [Spec. No.] Part name Spec. No. Outrigger inner case Ass'y Swing table ASS'Y (excluding boom, elevation cylinder, counter balance weight) Swing bearing Elevating cylinder Winch Jib Boom Ass'y (included telescoping cylinder) Counter balance weight 3

9 Y- 4. Y- 4. Adjustment (pressure) Hydraulic circuit Pressure setting table Item Pressure ( ) Note Manual control valve (quadruple) Winch main circuit Elevating/telescoping circuit Boom raising circuit Boom lowering circuit Boom extending circuit Boom retracting circuit Relief valve for main winch hoist-down circuit (1) Relief valve for auxiliary winch hoist-down circuit (2) Manual control valve (for outrigger) Outrigger main circuit Front jack circuit Manual control valve (for swing) Screw in Relief valve (RV1) Relief valve (RV2) Port relief valve (PR2) Port relief valve (PR1) Port relief valve (PR3) Port relief valve (PR4) Port relief valve (PR6) Port relief valve (PR5) Relief valve (RV3) Port relief valve (PR7) Counterbalance valve (winch) On load pressure Unload pressure Overload relief valve Unload valve (accumulator filling circuit) Intermediate pressure setting valve Cracking pressure Overload relief valve (cracking pressure) Counterbalance valve (elevating) Counterbalance valve (telescoping) Pressure switch (front jack) Pressure gauge (for accumulator) Flow control valve (for oil cooler) Cracking pressure Cracking pressure Front jack load (inner pressure) Pressure switch (PS1) Working pressure (Note) 1. Applied to the product numbers #340360, # and # (Note) 2. Applied to the product numbers # #

10 Y- 4. Y- 4. Adjustment (pressure) Pressure adjustment 2) Boom elevating/telescoping main circuit (relief valve RV2) Fully tighten the adjusting screw of the port relief valve PR4 for boom retracting. 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 its MAX speed. Note) After adjusting RV2, be sure to adjust the port relief valve PR4 according to 6). 3) Boom raising circuit (port relief valve, PR2) With the elevating cylinder fully retracted, perform the elevating lever raising operation to measure the pressure when the pump rotation is at MAX. Pressure gauge Pressure gauge for accumulator 4) 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 as its MAX speed. Oil temperature: 50±5 C 1. Manual control valve (quadruplet) 5) 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 its MAX speed. 6) Boom retracting circuit (port relief valve PR4) With the boom telescoping cylinder fully retracted, move the boom telescoping lever to the retraction position and measure the pressure while the pump is running at its MAX speed. 2. Relief valve for main winch hoist-down circuit (port relief valve, PR6) With the main winch drum locked, set the main winch lever to hoist-down side to measure the pressure when the winch high-speed selector switch is OFF and the pump rotation is at IDL. 3. Relief valve for auxiliary winch hoist-down circuit (port relief valve, PR5) 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 high-speed switch turned off, measure the pressure while the pump is running at its MAX speed. With the auxiliary winch sets drum locked, set the auxiliary winch lever to hoist-down side to measure the pressure when the winch high-speed selector switch is OFF and the pump rotation is at IDL. 5

11 Y- 4. Y- 4. Adjustment (pressure) 4. Manual control valve (for swing) Accumulator filling circuit At the pump rotation IDL with the winch lever in neutral and the winch drum locked, repeat shifting the clutch lever between ON and FREE to measure the pressure where the accumulator pressure changes from descent to ascent (onload pressure). Also, after the on-load pressure measurement, set the clutch lever to the ON position to measure the pressure where the accumulator pressure will stop rising (unload pressure). 5. Manual control valve (for outrigger) 1) Outrigger main circuit (relief valve, RV3) Install the pressure gauge to the PG port of the control valve then perform the jack stowing operation with the jack cylinder fully retracted to measure the pressure. 2) Front jack circuit (port relief valve, PR7) Install the pressure gauge to the PG port of the control valve then perform the front jack extending operation to measure the pressure. 6

12 Y- 5. Y- 5. Adjustment (electric) Switch adjustment Nut (a) NOTICE For the locations of the switches, refer to LOCATIONS OF ELECTRIC PARTS in Chapter Z. 1. Switch S1 (main winch hoisting-up operation detection switch), Switch S3 (auxiliary winch hoisting-up operation detection switch), Switch S6 (boom extension operation detection switch), Switch S7 (boom raising operation detection switch), Switch S8 (boom lowering operation detection switch) 3. S20 switch (outrigger stowing operation detection switch) 1) Adjust with the nut (a) so that the dimension A in the next figure becomes 1.0 mm in the state that the outrigger extending/stowing control lever is in neutral. 2) After the adjustment, fix the nut (a) with screw locking compound (THREE BOND 1401 or equivalent.) Boom elevating Boom telescoping Auxiliary winch Main winch Outrigger extending/ stowing operating lever Limit switch Nut (a) 4. Switch for outrigger accelerator 1) Adjust with the nut (a) so that the limit switch is turned ON at the position where the outrigger extension/stowing operation lever is moved by 4±1 mm from the neutral position. Limit switch 2) After adjustment, fix the nut (a) with screw lock compound (THREE BOND 1401 or equivalent.) Nut (a) Limit switch Outrigger extension/ stowing operation lever Spool controling rod Cam Nut (a) 1) Adjust with the nut (a) so that the NO contact point of the limit switch is turned OFF in the position where the spool moves mm from the neutral position. 2) After the adjustment, fix the nut (a) with the screw-locking compound (equivalent to THREE BOND 1401.) 5. SD1 (main), SD2 (auxiliary) switches (drum rotation detection switch/option) Adjust so that the clearance A between the switch and the drum in the following figure becomes mm. Proximity switch 2. S19 switch (front jack load detecting switch) Adjust with the nut (a) so that the dimension A becomes approximately 16.7 mm (equivalent to the pressure 135 kg/cm2.)

13 Y- 6. Y- 6. 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 completed, 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 piston when the swing brake lever is free. Adjusting nut Push rod Master cylinder 3. Swing circuit bleeding procedure After replacing the oil in the hydraulic oil tank or removing the pump or equipment on the P3 discharge side (manual control valve for outrigger, rotary joint, etc.), bleed the swing circuit of air as follows. 2. Swing brake circuit bleeding procedure 1) Start the engine to run the pump. 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. 2) Insert a vinyl hose in the bleeder screw on the master cylinder. VT port 3) Pull the swing brake open the bleeder screw, and close the bleeder screw before releasing the swing brake. Repeat this procedure until discharged fluid contains no more air bubbles. Once no air bubbles are visible, 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). 8

14 Y- 6. Y- 6. Adjustment and checks Winch system 1. Master cylinder mounting and adjusting procedure Master cylinder Approx. 20 C Floor board B. Foot brake cylinder Brake pedal 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 angle between the brake pedal and the floor board is about 20 when the brake pedal is not depressed. NOTICE Manually move and release the pedal and make sure that the piston of the master cylinder is completely returned. 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. Once no air bubbles are visible, close the bleeder screw while the fluid is still flowing out. NOTICE Pay attention to the fluid level in the brake fluid reservoir. 2) Turn bolt (a) until the clearance [A] is eliminated when the brake pedal is not depressed. 3) Depress the pedal and adjust the 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 a 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. Once no air bubbles are visible, close the bleeder screw while the fluid is still flowing out. 3. Winch brake adjusting procedure 1) Turn the 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. 3) Use a wrench to tentatively tighten the stroke adjustment nut (a) until the clearance between the drum and shoe is eliminated. (This can be known as it becomes hard to turn the wrench.) 4) Tighten the synchronizing bolt (b) until it becomes hard to turn the wrench so that Y becomes 0 when the clearance X is 0. Secure the bolt with a nut and lock it with wire to prevent it from loosening.

15 Y- 6. Y- 6. Adjustment and checks NOTICE Make sure that the dimension L is within the range of 15.0±2.0 mm. 5) Engage the clutch and loosen the stroke adjustment nut (a) until X becomes 2.5 to 3.0 mm. 9) After completing the adjustment of the clearances A and B, turn the slinging bolt and the retaining bolt to get a uniform clearance between the brake band and 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. Slinging bolt NOTICE Before tightening the nut (a) for adjustment, set the drum lock lever to the lock position and the clutch lever to the FREE position. Stroke adjustment nut (a) Retaining bolt 10) After the adjustment in the step 9) is completed, reeve the rope for the maximum allowable number of turns and raise the boom to the maximum angle, then check that the hook can descend quickly. Synchronizing bolt (b) Safety wire 11) Hoist a load equivalent to N times (N: number of turns of rope) the maximum allowable load per rope and make sure 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 nameplate. Never lift a load exceeding the rated lifting capacity. 12) After adjusting the brake band, put a label so that the righthand edge of the marker lies on the black line. 6) After the above-mentioned adjustment procedure is completed, return the clutch to the FREE position and the drum lock lever to the LOCK position, and then set the winch control lever to the neutral position. Red Black line 7) Turn bolt (c) until the clearance A becomes 0.4 to 0.5 mm. 8) Turn bolt (d) until the clearance B becomes 0.4 to 0.5 mm. Marker Blue NOTICE Be careful not to over tighten the bolt (d), or there is a possibility that lowering operation at high speed may not be achieved when loaded. (If not loaded, lowering operations can be done at high speed.) 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 of air. 1 0

16 Y- 6. Y- 6. Adjustment and checks Crane operation 5. Winch clutch adjusting procedure 1) Set the drum lock lever to the lock position, and the clutch lever to the "FREE" position. 1. Accelerator circuit bleeding procedure 1) Depress the accelerator pedal and open the bleeder screw (located on the right side of the rotary joint) to bleed the circuit, and close the bleeder screw before releasing the accelerator pedal. Repeat this procedure until discharged fluid contains no air bubbles. Once no air bubbles are visible, close the bleeder screw while the fluid is still flowing out. 2) Turn the adjusting nut on the wheel cylinder in the direction of the arrow to expanding side until it cannot turn any more. Then, turn the adjusting nut to the retracting side until the clearance between the drum and the clutch shoe is adjusted to mm. (Inside of swing table) [Reference] Returning for 4 scales results in a clearance of about 0.26 mm. 2) Also bleed the control cylinder of air in the same manner as mentioned in the step 1). NISSAN carrier : Bleeder screw 6. Accumulator pressure checking procedure for nitrogen gas (N2) 1) Set the drum lock lever to the lock position. Control cylinder 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 drop rapidly from a certain pressure level. The pressure from which the reading drops rapidly is the charged pressure of the nitrogen gas (N2) in the accumulator. MITSUBISHI carrier : (Frame inside) Bleeder screw Slowly Control cylinder Charged gas pressure Suddenly (Frame inside) 11

17 Y- 6. Y- 6. Adjustment and checks 2. Accelerator (pump rotation) adjustment 1) A djust t h e ac c e l e r ator p e dal angle θ to C (approximately 105 mm in the dimension A) by the pushrod then lock with the nut (a). Master cylinder Nut (a) Accelerator pedal Bolt (b) 3) After operating the accelerator pedal once or twice, adjust the bolt (f) so that the lever (d) returns completely at idle running. 4) Check that the pump rotation is at a specified speed at idle running. Next, check that the pump speed is a specified speed when the control lever contacts with the set bolt for the governor maximum rotation, stepping on the accelerator pedal gradually. (For Mitsubishi carrier, adjust the lever (d) so that it contacts the bolt (g) at this time.) (Measuring condition) No load Transmission is in neutral (N) position Oil temperature is 50±5 C Accelerator circuit is bled of air Pushrod 2) When the control cylinder is working, adjust the bolt (c) for Nissan Carrier, and adjust the dimension l with the nut (i) to mm for Mitsubishi Carrier so that the piston moves from the position where extended by 1-3 mm from the stroke end at the retraction side (90-92 mm in the dimension L.) (For Nissan Carrier, leave a stroke of 1-3 mm at the cylinder retracting side with the lever (d) contacting the bolt (c).) After the adjustment described above, adjust the rod (e) so that the control lever contacts the set bolt for governor idling. 5) Stop the accelerator in the position where the control lever contacts the set bolt for the governor maximum rotation and the pump speed becomes MAX to set the bolt (b). 6) Perform the accelerator adjustment for operating the outrigger with the procedure described below. Operate the manual control valve (for outrigger) to adjust so that the speed at the outrigger operation can be obtained when the air cylinder is working, letting the bolt (h) contact the lever (k). Nissan carrier : Nissan carrier: Lever (d) Bolt (c) Rod (e) Lever (k) Air cylinder Bolt (h) Bolt (f) Mitsubishi carrier: Mitsubishi carrier : Rod (e) Lever (d) Nut (i) Bolt (f) Lever (k) Air cylinder Bolt (inside) (g) Bolt (outside) (h) Bolt (h) Governor control lever 1 2

18 System Diagrams Z-1 Hydraulic Circuit... 1 Z-2 Electrical parts mounting position... 2 Z-3 Electric Circuit ( ) (wiring diagram)... 3 Z-4 Electric Circuit ( ) (wiring diagram)... 4 Contents Z i

19 Z-1 Z-1 Hydraulic circuit Oil reservoir Master cylinder (For winch brake) Brake cylinder Boom telescoping cylinder Note : 1, As for product number #331369, #340371, and #360050, the number of accumulators is one. 2, About A and B there is a title machine that doesn't equip it. Please refer to the adjustment points (pressure relation) for the presence of equipment. Clutch cylinder Hydraulic valve Hose reel Master cylinder (For accelerator ) Hydraulic motor Elevating cylinder Counterbalance valve Counterbalance valve Accumulator Hydraulic valve (For winch brake) Clutch valve Counterbalance valve Manual control valve Pressure gauge Swing drive unit Oil filter Check valve Control cylinder Master cylinder (for swing brake) Pilot check valve Jack cylinder Extension cylinder Manual control valve Solenoid valve (for automatic stop) Solenoid valve (For winch high-speed) Rotary joint Oil filter Hydraulic pump Front jack cylinder Manual control valve Oil filter Pressure gauge Oil cooler Flow control valve Oil tank 1

20 Z-2 Z-2 Electric circuit Locations of electric parts Elevation Telescoping Sub winch Main winch Buzzer Fuse Note : SN23 is applied since # and #

21 Z-3 Z-3 Electric circuit Applies to the model that exceeds 12m in total length. Front lamp 3WX2 Tail lamp At start Heating unit Heater Boom lamp 60W Head light 60WX2 Working lamp switch Starter switch Wiper switch Roof Fuse box Front Accumulator reducing detection switch Buzzer Cigar lighter 10A Horn (lever) Radio Fan switch Cab lamp 10W External driving power supply External driving power supply AML power supply Boom angle detector Boom length detector Moment detector AML power supply Front jack switch Rotary joint Swing dead angle detector SW Cord reel Overwinding detector switch boom Overwinding Single top external indicator lamp (90% bitter orange) external indicator lamp (100% red) O/R retract control detection switch When AML breaks down, it is connected. emergency For AML vent (positive) Overwinding abnormality Rear stability working range limitation Overwinding cutout Front jack load detection switch Option Option Jib cancel Overwinding cancel switch 3rd/top boom section extension switch Buzzer AML abnormality cancel cancel switch buzzer interlocking switch switch (Lever) Starter switch Starter switch Fuse for crane Swing angle detector Carrier light switch External data bus Main switch For 3rd/top boom section telescoping 2nd boom section emergency telescoping switch 3rd/top boom section emergency telescoping switch For fuel cutting Crane career side 3rd/top boom section full retraction detector switch Cord reel Winch high-speed selector switch (Lever) Winch high-speed selector switch For winch high-speed (Lever) For swing free Swing free/lock selector SW Drum rotation lamp Rotation detector switch Rotation detector switch Winch hoist-up detection switch Boom extension detection switch Boom raising detection switch Boom lowering detection switch This program includes options ; is based on the following conditions : 1. Crane:traveling condition 2. Main switch : off 3. PTO interlocking switch : off 4. Boom : fuiiy retracted 5. Hook blocks : overwound Wiring and the switch in the part of the sign are applied to product number # , # , and # Surge absorber 3

22 Z-4 Z-4 Electric circuit To boom Solenoid valve (for swing free/lock change) Working lamp (left) Rotary joint Note : the sign part wiring is applied to product number # , # , #34533-, and # The swing table taillight is applied to the model that exceeds 12m in total length. The switch of solenoid valve SL2 and the expansion and contraction lever is not applied to 3rd boom section. To cab wiring Heater main switch Radio Cigar lighter Switch Drum rotation indicator Swing table Tail lamp (left) Accumulator decompression perception switch Buzzer drum rotation detector switch drum rotation detector switch Fuse box Buzzer Solenoid valve (for 3rd/top boom section telescoping) Solenoid valve (for automatic stop) Solenoid valve (for winch high-speed) Horn relay swing lever Elevating lever Working lamp (right) Swing table Tail lamp (right) Boom raising control detection switch Boom lowering control detection switch Horn Telescoping lever Winch hoist-up control detection switch Boom extension control detection switch Winch lever Winch hoist-up control detection switch Winch lever 4

23 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

24 2008 PRINTED IN JAPAN 0803 E