AT-250TG-1/C1-1E. Publication No. Circuit Diagrams. Aerial Platform. AT-250TG-1 Applicable Serial No Model

Transcription

1 ublication No. AT-250T-1/C1-1E Circuit Diagrams 01 Aerial latform Model AT-250T-1 Applicable Serial No

2 Foreword Foreword This manual is the one that ublication No. AT-250T-1/C-04J, AT-250T-1/-01 SU.1J was replaced from Japanese with English. This maintenance manual describes all systems and devices incorporated in the AT-250T-1 Aerial ork latform and explains procedures for repair, maintenance and adjustment. This manual is applicable to machines with the specification numbers given below. e sure to check the specification number on the name plate attached to the aerial work platform before using this manual. 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. Document No. SEC. N. SEIA. MF.DATE. N. KAAA, JAAN ISA Applicable spec. No. Spec. No. Applicable serial No. 1 AT AT-250T-1/C1-1E 1~ ~ 2 AT lease note that, for product improvement, some changes may have been incorporated in the machine that are not covered in this manual. 1

3 Foreword Table of contents Chapter Clause AT-250- AT Checks and Adjustments -1 Spec. No. Hydraulic circuit Z-1 Z-2 Z Electric circuit diagram (Upper structure) Z-3 Z-4 Electric circuit diagram (ower structure, Mitsubishi) Electric circuit diagram (ower structure, Isuzu) Electric circuit diagram (ower structure, Hino) Electric circuit diagram (ower structure, UD Trucks) Z-5 Z-6 Z-7 Z-8 Z-9 Z-10 Z-11 2

4 Chapter DCUMENTATIN, ADJUSTMENTS/CHECKS Table of contents -1 Checks and Adjustments...4 Instructions for Adjusting otentiometer/roximity Switch for Swing Angle Detection Instructions for adjusting potentiometer Instructions for adjusting proximity... 5 Instructions for Adjusting Swing Angle Display... 6 Instructions for adjusting no-load operation speed alve offset adjustment Adjustments with mechanical stopper... 8 Error ist(error Codes)

5 -1-1 Checks and Adjustments -1 Checks and Adjustments Instructions for Adjusting otentiometer/roximity Switch for Swing Angle Detection Instructions for adjusting potentiometer/proximity 1. Instructions for adjusting potentiometer 1.) otate to the right to align swing position to the 270 position. oom in forward-facing position 0 2.) Measure resistance between terminals 5-6 on connector CN80. Move potentiometer and fix when minimum resistance value is within 0 to 15Ω. esistance esistance Swing angle Swing angle Diagram of potentiometer resistance change E

6 -1-1 Checks and Adjustments 2. Instructions for adjusting proximity This adjustment is performed with the proximity connected to AM. 1.) otate to the right to align swing position to the 0 position. 2.) ith the cam and proximity initially separated from one another, push proximity in direction A until the proximity ED lights. 3.) Continue to push another 1.5 to 2mm in the A direction then fix in place (nut M12 x 1). roximity S N (Conduction) roximity Cam pen (Concave) Closed (Convex) ED linking ED FF roximity operation diagram (eference) E

7 -1-1 Checks and Adjustments Instructions for Adjusting Swing Angle Display STAT Set display selector to position "5" when adjusting. Set display selector to position "6" swing the boom until swing angle is 0 ±0.3 (Front of vehicle). swing the boom until swing angle is 180 ±0.3 (ear of vehicle). Initiate adjustment mode by pressing the 3 es (swing angle display selector, U and DN es) simultaneously. (alue indicator blinks when adjustment mode initiated) "Initiate adjustment mode by simultaneously pressing the 3 es (swing angle display selector, U and DN es). (alue indicator blinks when adjustment mode initiated) " Adjust by pressing U or DN until displayed swing angle is 0 ±0.3. Adjust by pressing U or DN until displayed swing angle is 180 ±0.3. "ress swing angle display selector to set. (Check that value indicator stops blinking while the is being pressed. Then, release the. If the number display starts blinking again, settings are complete.) " ress swing angle display selector to set. (Check that value indicator stops blinking while the is being pressed. Then, release the. If the number display starts blinking again, settings are complete.) swing the boom until swing angle is 180 ±0.3 (ear of vehicle). swing the boom until swing angle is 0 ±0.3 (Front of vehicle). Adjust by pressing U or DN until displayed swing angle is 180 ±0.3. Adjust by pressing U or DN until displayed swing angle is 0 ±0.3. "ress swing angle display selector to set. (Check that value indicator stops blinking while the is being pressed. Then, release the. If the number display starts blinking again, settings are complete.) " "ress swing angle display selector to set. Check that value indicator stops blinking while the is being pressed. Then, release the. If the number display starts blinking again, settings are complete.) " swing the boom until swing angle is 0 ±0.3 (Front of vehicle). swing the boom until swing angle is 180 ±0.3 (ear of vehicle). N Is error of swing angle display ±0.7(deg) or less? N Is error of swing angle display ±0.7(deg) or less? ES ES eturn display selector to position "0" when adjusting (Moment % display) END Caution 1: For boom swing angle, see the diagram below. Front of vehicle Switch layout Swing angle display selector U Caution 2: Swing angle measurement method [Standard] A 1 swing angle is equivalent to 8mm along the circumference of the swing gear cover. DN E

8 -1-1 Checks and Adjustments Instructions for adjusting no-load operation speed No-load operation speed should be measured in accordance with the table at right. erform 1. alve offset adjustment only for items not meeting the criteria at right. If speed does meet the criteria at right after performing this adjustment, perform together with 2.Adjustments with mechanical stopper. Measurement criteria for no-load operation speed Conditions Temperature of hydraulic oil shall be 40±5 C ump M shall be at maximum setting Measurement performed from swing table side. ucket set to forward-facing position Item Speed (Sec.) rocedure Elevation Up 45±7 Down 45±7 Full retraction of beam Telescoping oom swing Ext. 50±8 et. 45±7 eft 60±9 60±9 eft/ difference Max. elevation angle oom fully retracted at max. elevation angle 1. alve offset adjustment Adjusting telescoping speed STAT "Set [13] ""display selector S" to [A]. (alue indicator displays "0")" "Initiate adjustment mode by simultaneously pressing the 3 es, [8] ""Swing angle display selector S"", [9] ""oom length display selector S"", and [10]""oom angle display selector S"" es. (""0"" blinks on the value indicator)" Adjusting extension speed Adjusting retraction speed ress U S ( [8] "Swing angle display selector S") (Currently memorized factor will be displayed). ress DN S ( [10] "oom angle display selector S") (Currently memorized factor will be displayed). "To change speed, press U S/DN S.Increase value to increase speed.educe value to decrease speed. " "ress [9] ""oom length display selector S"". (After 2 seconds have elapsed, value indicator displays ""0"") (Setting complete)" eturn [13] "Display selector S" to [0]. N Does speed meet above criteria? U S DN S ES END E

9 -1-1 Checks and Adjustments Adjusting elevation speed STAT Adjusting swing speed STAT Set [13] "Display selector S" to []. (alue indicator displays "0") Set [13] "Display selector S" to [C]. (alue indicator displays "0") "Initiate adjustment mode by simultaneously pressing the 3 es, [9] ""oom length display selector S"", [10] ""oom angle display selector S"", and [7] ""/ ext. width display selector S"" es. (""0"" blinks on the value indicator)" "Initiate adjustment mode by simultaneously pressing the 3 es, [8] ""Swing angle display selector S"", " [9] "oom length display selector S", and [7] "/ ext. width display selector S" es. ("0" blinks on the value indicator) Adjusting elevating speed Adjusting lowering speed Adjusting right swing speed Adjusting left swing speed ress U S ( [7] "utrigger display selector S") (Currently memorized factor will be displayed). ress DN S ( [9] "oom length display selector S") (Currently memorized factor will be displayed). ress U S ( [7] "utrigger display selector S") (Currently memorized factor will be displayed). ress DN S ( [9] "oom length display selector S") (Currently memorized factor will be displayed). "To change speed, press U S/DN S. Increase value to increase speed. educe value to decrease speed. " To change speed, press U S/DN S. Increase value to increase speed. educe value to decrease speed. "ress [10] ""oom angle display selector S"". (After 2 seconds have elapsed, value indicator displays ""0"") (Setting complete)" ress [8] "Swing angle display selector S". (After 2 seconds have elapsed, value indicator displays "0") (Setting complete) eturn [13] "Display selector S" to [0]. eturn [13] "Display selector S" to [0]. N Does speed meet above criteria? N Does speed meet above criteria? ES ES END END U S U S DN S DN S 2. Adjustments with mechanical stopper 1.) oosen adjusting bolts on electromagnetic proportional valve until bolts are approx. 10mm from flange face of valve. 2.) erform adjustments with engine running ( S/High). 3.) ress operation at swing table side. The manual control lever for the electromagnetic proportional valve moves. 4.) Now tighten stroke control bolts until they come into contact with the stopper. (e aware that oil leaks from screw sections when lock nuts are loosened.) 5.) Measure operation speed for manual control lever operation and check that this speed is within the adjustment range. If outside the adjustment range, perform adjustment again using different tightening torque on the adjusting bolts. Adjusting bolt /Ext./ower eft side Manual control lever eft/et./aise side Detail view - Control valve Adjusting bolt E

10 -1-1 Checks and Adjustments Error ist(error Codes) Error No Description Details utput CU error Not set AM error 1 M error 2 ±12 power supply failure 3 A/D error Fault on AM main unit Unloading output alve drive output neutral alve power FF 4 fault / not jacked-up See above 4 INK utrigger signal line fault INK 7 INK 8 INK 9 INK 10 INK emote control power supply FF Input signal error (emote control) Input signal error (Telescoping remote control) Input signal error (Elevation remote control) Input signal error (Swing remote control) Input signal neutral error (emote control) Input neutral error (Telescoping remote control) Input neutral error (Elevation remote control) Input neutral error (Swing remote control) ire breakage (Elevation moment signal) ire breakage (eveling moment signal) 13 oom length detector error 14 oom angle detector error Swing angle detector error 17 Swing position combination fault 18 Swing position exceeded ire breakage on signal line for pulse outrigger indicator emote control power is FF ire breakage/short-circuit on 2 or more remote control input signals ire breakage/short-circuit on remote control input signal (Telescoping) ire breakage/short-circuit on remote control input signal (Elevation) ire breakage/short-circuit on remote control input signal (Swing) 2 or more remote control input signals outside neutral range when power N emote control input signal (Telescoping) outside neutral range when power N emote control input signal (Elevation) outside neutral range when power N emote control input signal (Swing) outside neutral range when power N ire breakage on moment detector for elevation cylinder ire breakage on moment detector for leveling cylinder Fault/wire breakage/short-circuit on boom length detector Fault/wire breakage/short-circuit on boom angle detector Fault/wire breakage/short-circuit on swing angle detector or swing dead angle detector Fault/wire breakage/short-circuit on limit for swing position detector Fault/wire breakage/short-circuit on limit for swing position detector See above emote control stopped elevant remote control stopped emote control (Telescoping) stopped emote control (Elevation) stopped emote control (Swing) stopped All remote control stopped Unloading output alve drive output neutral alve power FF E

11 -1-1 Checks and Adjustments Error No Description Details utput Fault on function signal combination 0/ extension width combination fault 21 alve failure Fault/wire breakage/short-circuit on for function Fault/wire breakage/short-circuit on 0/ extension width detector Failure of 2 or more valves, wire breakage 22 Telescoping valve failure Telescoping valve failure, wire breakage 23 Elevation valve failure Elevation valve failure, wire breakage 24 Swing valve failure Swing valve failure, wire breakage Neutral error for 2 or more Di remote control input signals Neutral error for Di remote control (Telescoping) input signal Neutral error for Di remote control (Elevation) input signal Neutral error for Di remote control (Swing) input signal Neutral error for automatic stowing Di input signal Telescoping Danfoss valve, stationary status inconsistency (spool in neutral position) error Elevation Danfoss valve, stationary status inconsistency (spool in neutral position) error Swing Danfoss valve, stationary status inconsistency (spool in neutral position) error Error on neutral swing detection for Danfoss valve (S) 2 or more Di remote control input signals at operation side when power N, or on error recovery Di remote control (Telescoping) input signal at operation side when power N, or on error recovery Di remote control (Elevation) input signal at operation side when power N, or on error recovery Di remote control (Swing) input signal at operation side when power N, or on error recovery Di remote control (Automatic stowing) input signal at operation side when power N, or on error recovery Telecoping valve operating without telescoping valve drive output Elevation valve operating without elevation valve drive output Swing valve operating without swing valve drive output Neutral swing detection (S) for swing valve detecting valve neutral position despite existence of swing valve drive output. 99 AM adjustment mode AM adjustment mode in progress Unloading output alve drive output neutral alve power FF E

12 Chapter Z System circuit diagram Table of contents Z-1 Hydraulic Circuit (AT )...12 Z-2 Hydraulic Circuit (AT )...13 Z-3 Electric circuit diagram (Upper structure) (AT )...14 Z-4 Electric circuit diagram (Upper structure) (AT )...16 Z-9 Electric circuit diagram (ower structure, Hino) (AT )...25 Z-10 Electric circuit diagram (ower structure, Hino) (AT )...27 Z-11 Electric circuit diagram (ower structure, UD Trucks)...28 Z-5 Electric circuit diagram (ower structure, Mitsubishi) (AT )...17 Z-6 Electric circuit diagram (ower structure, Mitsubishi) (AT )...21 Z-7 Electric circuit diagram (ower structure, Isuzu) (AT )...22 Z-8 Electric circuit diagram (ower structure, Isuzu) (AT )...24 Z 11

13 Z - 1 Hydraulic Circuit Z - 1 Z - 1 Applicable Serial No. : Applicable Serial No. 1 : : ilot check valve Extension cylinder Manual control valve Solenoid control valve (3-valve) Solenoid valve (For unload) Elevating cylinder Jack cylinder Counterbalance valve eveling cylinder (Upper) ilot check valve elief valve oom eveling cylinder (ower) Select valve Telescoping cylinder (eft swing) Counterbalance valve ilot check valve Hydraulic motor (For swing) otary joint Check valve il filter Hydraulic pump 1 2 Z E

14 Z - 1 Hydraulic Circuit Z - 1 Z - 1 Applicable Serial No. : Jack Slide utrigger control valves Applicable Serial No. 1 : / outrigger Jack Slide Elevating /F outrigger eveling Jack Slide oom /F outrigger Jack Slide eveling / outrigger Telescoping oom swing auge port (24 electric motor) Swivel joint 1 3 Z E

15 Z - 3 Z - 3 Z - 3 Upper structure Ⅰ Applicable Serial No. : S Solenoid valve (For unload) pump S S stop lamp stop S alve power relay Conditions for output of AM UT1 1. Jacked up 2. stop /FF 3. Foot /N 4. Moment 100% or less 5. Swing, elevation, or telescoping in progress (excl. basket swing) (asket swing) (Speech synthesizer device) (asket circuit power supply) (Unloading valve) (AM power supply) (Foot S relay) ( ) (asket working lamp) Speech synthesizer control unit Speaker for audio warning Terminal No. Audio warnings anzenwokakuninshitesagyouwokaishishitekudasai. Start work after confirming it is safe to do so. (nly output twice) kinkyuuteishisuicchiwooshiteimasu. kaizyoshitekudasai. ou have pressed the emergency stop. elease. (epeat on operation) jakkigasecchisareteimasen. secchishitekudasai. Jack not in position. Set jack in position. (epeat on operation) nimotsunotsumisugidesu. nimotsuwooroshitekudasai. verloaded. educe load. (epeats) sagyouhan igagenkaidesu. At limit of working range. (epeats) syaryounichikazukimashita.hanaretekudasai. ou have approached the carrier. Move away from the carrier. (hen operated in direction of interference control zone) oom 2. iring without indication is either AS. 85mm 2 or CTF. 75mm 2 Applicable Serial No. 1 : Automatic N at 100% stowing start moment Speaker for position display audio warning 2 : Touch S (Engine stop) Touch S ( stop) Ext. oom telescoping S et. oom elevating S Down Up Automatic preparation/stowing S oom swing S eft stop S stop lamp Automatic preparation/ stowing S Foot S AM main unit power supply (0) Unloading valve power supply Foot S/N during lower operation Upper control override for automatic stowing Swing motor M1 Swing motor M2 Engine STAT/ST S Auto stop & Foot S/FF Moment 100% (strength capacity zone) Moment 100% (Stability zone) alve power supply Interference prevention asket swing operation Automatic stowing start position display Control valve/swing operation / Ext. S2 MID width signal S1 MAX S S AM main unit power supply (+24) / Ext. eft S2 MID width signal eft S1 MAX signal Swing position signal (dead angle position) asket swing detection S Swing-stop-during-automatic-stowing stop position detection S () Swing-stop-during-automatic-stowing stop position detection S (eft) Automatic preparation/stowing S swing operation eft swing operation Elevation operation ower operation Ext. operation et. operation stop Foot S detection Engine rotation, emergency pump rotation detection alve failure detection alve failure detection alve failure detection eft asket swing S Converter board et. Down Ext. Up eft Swing motor M1 Swing motor M2 Telescoping operation Elevation operation oom swinging Detector power supply 1 oom length signal Elevation angle signal Detector power supply 2 oom swing angle signal () () ength detector Angle detector Swing dead angle detection Conduction during dead angle of swing potentiometer Swing-stop-during-auto matic-stowing position Conduction when right swing stowing Swing-stop-during-automaticstowing position Conduction when left swing stowing peration guidance output when not jacked-up stop N during S N/peration operation/audio guidance output warning output eft eft Swing motor Swing motor Swing motor M1 eft Swing motor M2 eft Detector power supply 3 Swing angle detector Swing operation signal input Elevation operation signal input Telescoping operation signal input Swing operation signal output Elevation operation signal output Telescoping operation signal output ower supply Elevation eveling / extension width logic Upper S ower S Moment detector power supply 1 Moment signal Moment detector power supply 2 Moment signal () () Hi (pen) Hi (pen) o (Close) Hi (pen) o (Close) o (Close) Moment detector for elevating cylinder Moment detector for leveling cylinder rounding ower supply peration command signal utput on failure event rounding ower supply peration command signal utput on failure event Elevation rounding ower supply peration command signal Telescoping utput on failure event Solenoid control valve (3-valve) oom swing otary joint / extension width MID / extension width MAX / extension width MID / extension width MAX ower supply ower supply Starting engine Male connector (in assignments viewed from mating face) 100 power outlet (100, 15A) orking lamp lack hite ed lue ellow reen range ink iolet own ight green 0.85 / ase color for electric wire Automatic stowing stop S stop lamp 1 4 Z E 1 4

16 Z - 3 Z - 3 Z - 3 Upper structure Ⅱ Applicable Serial No. : S Unloading valve S S stop lamp stop S Conditions for output of AM UT1 Condition 1 (hen operated from basket side) 1-1 Jacked-up 1-2 stop /FF (Closed) 1-3 Foot /N (Closed) 1-4 Moment less than 100% 1-5 Swing, elevation, or telescoping operated from basket side, automatic stowing operated (excl. basket swing) 1-6 Not operated from swing table side 1-7 Interference prevention function not operational (Elevation/Swing operation interference side only) Condition 2 (hen operated from swing table side) 2-1 Jacked-up 2-2 stop /FF (Closed) 2-3 Moment less than 100% 2-4 Swing, elevation, or telescoping operated from swing table side, automatic stowing operated 2-5 Interference prevention function not operational (Elevation/Swing operation interference side only) (asket swing) (Speech synthesizer device) (asket circuit power supply) (Unloading valve) (AM power supply) (Swing relay) ( ) (asket working lamp) Speech synthesizer control unit Speaker for audio warning Terminal No. Audio warnings anzenwokakuninshitesagyouwokaishishitekudasai. Start work after confirming it is safe to do so. (nly output once) kinkyuuteishisuicchiwooshiteimasu. kaizyoshitekudasai. ou have pressed the emergency stop. elease. (epeat on operation) jakkigasecchisareteimasen. secchishitekudasai. Jack not in position. Set jack in position. (epeat on operation) nimotsunotsumisugidesu. nimotsuwooroshitekudasai. verloaded. educe load. (epeats) sagyouhan igagenkaidesu. At limit of working range. (epeats) syaryounichikazukimashita.hanaretekudasai. ou have approached the carrier. Move away from the carrier. (hen operated in direction of interference control zone) oom 2. iring without indication is either AS. 85mm 2 or CTF. 75mm 2 Applicable Serial No. 1 : Automatic stowing N at 100% start position moment Speaker for display audio warning : : : Touch S (Engine stop) Touch S ( stop) oom telescoping S Ext. et. Down oom elevating S Up Automatic preparation/stowing S stop S oom swing S eft stop lamp Automatic preparation/stowing S eft asket swing S AM main unit power supply (0) alve power relay Unloading valve power supply Swing motor relay power For jacking-up interlock (Swing) Engine STAT/ST S Auto stop & foot S interlock signal Moment 100% (strength capacity zone) Moment 100% (Stability zone) alve power supply Interference prevention Automatic stowing start position display peration input interlock signal / Ext. S2 MID width signal S1 MAX AM main unit power supply (+24) / Ext. eft S2 MID width signal eft S1 MAX signal Swing position signal (dead angle position) Automatic preparation/stowing S (ucket side) Swing-stop-during-automatic-stowing stop position detection S () Swing-stop-during-automatic-stowing stop position detection S (eft) Automatic preparation/stowing S (ower) swing operation eft swing operation Elevation operation ower operation Ext. operation et. operation stop Foot S detection Engine rotation, emergency pump rotation detection alve failure detection (Elevation) alve failure detection (Telescoping) alve failure detection (Swing) Control unit Elevation output Telescoping output Swing output Converter board S pump S Down Ext. Up Elevation et. Telescoping eft oom swing Swing dead angle detection Swing motor M1 Detector power supply 1 oom length signal input Elev. angle signal input Detector power supply 2 Detector power supply 3 () () Swing angle signal input Neutral swing detection for Danfoss valve (Analog) ength detector Angle detector Swing angle detector Conduction during dead angle of swing potentiometer Swing-stop-during-automaticstowing position () Conduction when right swing stowing Swing-stop-during-automaticstowing position (eft) Conduction when left swing stowing peration guidance output when not jacked-up stop S N/peration guidance output N during operation/audio warning output eft eft Swing motor M2 Swing motor M1 eft ower input for operation signal output Elevation eveling Upper S ower S Elevation operation signal input Telescoping operation signal input Swing operation signal input Elevation operation signal output (For valve drive) Telescoping operation signal output (For valve drive) Swing operation signal output (For valve drive) Moment detector power supply 1 Moment signal Moment detector power supply 2 Moment signal / extension width logic () () Hi (pen) Hi (pen) o (Close) Hi (pen) o (Close) o (Close) Moment detector for elevating cylinder Moment detector for leveling cylinder rounding ower supply peration command signal utput on failure event rounding ower supply peration command signal utput on failure event rounding ower supply peration command signal utput on failure event Control valve (Danfoss proportional valve) Neutral swing detection for Danfoss valve (S) Elevation Telescoping oom swing oom swing Center joint / extension width MID / extension width MAX / extension width MID / extension width MAX ower supply ower supply (Engine rotation) Starting engine Male connector (in assignments viewed from mating face) AZAKI S waterproof connector AZAKI S waterproof connector orking lamp Foot S 100 power outlet (100, 15A) Swing motor Swing motor lack hite ed lue ellow reen range ink iolet own ight green 0.85 / Swing motor M2 eft ase color for electric wire 1 5 Z E 1 5

17 Z - 4 Z - 4 Z - 4 Upper structure Applicable Serial No. : S S S stop lamp stop S Conditions for output of AM UT1 Condition 1 (hen operated from basket side) 1-1 Jacked-up 1-2 stop /FF (Closed) 1-3 Foot /N (Closed) 1-4 Moment less than 100% 1-5 Swing, elevation, or telescoping operated from basket side, automatic stowing operated (excl. basket swing) 1-6 Not operated from swing table side 1-7 Interference prevention function not operational (Elevation/Swing operation interference side only) Condition 2 (hen operated from swing table side) 2-1 Jacked-up 2-2 stop /FF (Closed) 2-3 Moment less than 100% 2-4 Swing, elevation, or telescoping operated from swing table side, automatic stowing operated 2-5 Interference prevention function not operational (Elevation/Swing operation interference side only) (asket swing) (Speech synthesizer device) (asket circuit power supply) (Unloading valve) (AM power supply) (Swing relay) ( ) (asket working lamp) Speech synthesizer control unit Speaker for audio warning Terminal No. Audio warnings anzenwokakuninshitesagyouwokaishishitekudasai. Start work after confirming it is safe to do so. (nly output once) kinkyuuteishisuicchiwooshiteimasu. kaizyoshitekudasai. ou have pressed the emergency stop. elease. (epeat on operation) jakkigasecchisareteimasen. secchishitekudasai. Jack not in position. Set jack in position. (epeat on operation) nimotsunotsumisugidesu. nimotsuwooroshitekudasai. verloaded. educe load. (epeats) sagyouhan igagenkaidesu. At limit of working range. (epeats) syaryounichikazukimashita.hanaretekudasai. ou have approached the carrier. Move away from the carrier. (hen operated in direction of interference control zone) oom 2. iring without indication is either AS. 85mm 2 or CTF. 75mm 2 Applicable Serial No. 1 : Automatic N at 100% Speaker stowing start moment for audio position display warning Touch S (Engine stop) Touch S ( stop) Ext. oom telescoping S et. Automatic preparation/stowing S oom elevating S Down Up stop S oom swing S eft stop lamp Automatic preparation/stowing S eft asket swing S AM main unit power supply (0) alve power relay Unloading valve power supply Swing motor relay power For jacking-up interlock (Swing) Engine STAT/ST S Auto stop & foot S interlock signal Moment 100% (strength capacity zone) Moment 100% (Stability zone) alve power supply Interference prevention Automatic stowing start position display peration input interlock signal / Ext. S2 MID width signal S1 MAX AM main unit power supply (+24) / Ext. eft S2 MID width signal eft S1 MAX signal Swing position signal (dead angle position) Automatic preparation/stowing S (ucket side) Swing-stop-during-automatic-stowing stop position detection S () Swing-stop-during-automatic-stowing stop position detection S (eft) Automatic preparation/stowing S (ower) swing operation eft swing operation Elevation operation ower operation Ext. operation et. operation stop Foot S detection Engine rotation, emergency pump rotation detection alve failure detection (Elevation) alve failure detection (Telescoping) alve failure detection (Swing) Control unit Elevation output Telescoping output Swing output Converter board S S Down Ext. Up Elevation et. Telescoping eft oom swing ength detector Swing dead angle detection Swing motor M1 Detector power supply 1 oom length signal input Elev. angle signal input () Angle detector Swing-stop-during-automaticstowing position () Conduction when right swing stowing Swing motor M2 Detector power supply 2 Swing angle signal input 1 Swing angle signal input 2 () Swing angle detector Swing-stop-during-automaticstowing position (eft) Conduction when left swing stowing peration guidance output when not jacked-up stop S N/peration guidance output N during operation/audio warning output eft eft Swing motor M1 eft Detector power supply 3 Elevation operation signal input Telescoping operation signal input Swing operation signal input orking lamp Foot S Swing motor Swing motor Swing motor M2 eft ower input for operation signal output Elevation eveling Elevation operation signal output (For valve drive) Telescoping operation signal output (For valve drive) Swing operation signal output (For valve drive) Moment detector power supply 1 Moment signal Moment detector power supply 2 Moment signal () () rounding ower supply peration command signal utput on failure event rounding ower supply peration command signal utput on failure event rounding ower supply peration command signal utput on failure event Elevation Telescoping oom swing Swivel joint Control valve Moment detector (Danfoss proportional valve) for elevating cylinder Male connector (in assignments viewed from mating face) AZAKI S waterproof connector 100 power outlet (100, 15A) lack hite ed lue ellow reen range ink iolet own ight green 0.85 / ase color for electric wire Moment detector for leveling cylinder ower supply (24) ower supply (24) Starting engine Unloading release AZAKI S waterproof connector 1 6 Z E 1 6

18 Z - 5 Z - 5 Z - 5 ower structure Ⅰ Mitsubishi U-FK415F Applicable Serial No. : ower supply (1) ower supply (2) Engine start Male connector (in assignments viewed from mating face) 2. Figures in < > represent terminal numbers. 3. Cross-section area of wiring without indication is 0.85mm elay ASS For outrigger indicator otary joint Applicable Serial No. 1 : : : : utrigger indicator Thermo Engine STAT/ST utlet for 100 power supply ower structure power supply relay orking lamp power supply relay Upper structure power supply relay 1 Upper structure power supply relay 2 orking lamp relay utrigger operation detection ower structure control relay Safety relay Engine start relay utrigger indicator Flasher / jacking-up detection limit (4 places) Self retaining relay for interlock relay /F outrigger / outrigger Flasher unit arning lamp (ption, 4 locations) Alternator Engine/ rotation selector detection relay pump relay / outrigger 0.85 / /F outrigger ase color for electric wire solenoid 1 solenoid 2 Engine stop solenoid Starter relay Starter motor ackup T N detection S Motor for emergency pump lack hite ed lue ellow reen range ink iolet own ight green Starter 1 7 Z E 1 7

19 Z - 5 Z - 5 Z - 5 ower structure Ⅱ Mitsubishi U-FK335 Applicable Serial No. : ower supply (1) ower supply (2) Engine start ear ASS utlet for orking lamp Numbering of connector terminals (viewed from mating face) Applicable Serial No. 1 : : : : : : : relay ( / operated) Interlock self retaining relay (Energized when jack lifts carrier) (/ operated, pen) elay box ASS Fuse box otary joint Flasher Flasher unit Upper structure power supply relay 2 Upper structure power supply relay 1 ower structure control relay Flicker lamp orking lamp ackup power supply Engine STAT/ST 100 fuse Spare pump relay utrigger operation detection utrigger indicator / jacking-up detection limit (4 places) Thermo ower structure power supply relay ( T S N) Upper structure power supply relay 2 ( lower structure power supply relay N) Upper structure power supply relay 1 ( lower structure power supply relay N) ower structure control relay ( lower structure power supply relay N) Safety relay ( lower structure power supply relay N and engine stopped) Engine start relay ( lower structure power supply relay N and engine start S N) /F outrigger / outrigger arning lamp (ption, 4 locations) Flicker relay ( jack lifts carrier) Engine/ rotation selector detection relay (Energized when engine rotating, emergency pump cannot be operated) relay ( lower structure control relay N, emergency pump S N, and engine stopped) Engine stop relay connector ( lower structure power supply relay N, engine stop S N) peration ASS, engine control iring ASS, carrier / outrigger ackup T N detection S connector A: For Isuzu /F outrigger solenoid 1 solenoid 2 enerator Engine stop solenoid 6-pin connector Starter relay Starter motor + terminal T N detection S Apply insulating tape T N detection S Hour meter T indicator lamp lack hite ed lue ellow reen range ink iolet own ight green Motor for emergency pump 0.85 / ase color for electric wire 1 8 Z E 1 8

20 Z - 5 Z - 5 Z - 5 ower structure Ⅲ Mitsubishi U-FK337 Applicable Serial No. : ower supply (1) ower supply (2) Engine start ear ASS utlet for orking lamp Numbering of connector terminals (viewed from mating face) Applicable Serial No. 1 : : : : otary joint relay Interlock self retaining ( relay (Energized / operated) when jack lifts carrier, open when / operated) Flasher Flasher unit elay box ASS Fuse box Upper structure power supply relay 2 Upper structure power supply relay 1 ower structure control relay Flicker lamp orking lamp ackup power supply Engine STAT/ST 100 fuse Spare pump relay utrigger operation detection utrigger indicator / jacking-up detection limit (4 places) Thermo ower structure power supply relay (Energized when T S N) Upper structure power supply relay 2 (Energized when lower structure power supply relay N) Upper structure power supply relay 1 ( lower structure power supply relay N) ower structure control relay ( lower structure power supply relay N) Safety relay ( lower structure power supply relay N and engine stopped) Engine start relay ( lower structure power supply relay N and engine start S N) /F outrigger / outrigger arning lamp (ption, 4 locations) Flicker relay ( jack lifts carrier) Engine/ rotation selector detection relay (Energized when engine rotating, emergency pump cannot be operated) relay ( lower structure control relay N, emergency pump S N, engine stopped) connector : For Mitsubishi (Energized when lower structure power supply relay N and engine stop S N) peration ASS, engine control iring ASS, carrier /F outrigger / outrigger ackup peration detection T magnet valve Clutch S Motor for emergency pump connector A: For Isuzu/Nissan solenoid 1 solenoid 2 enerator Engine stop solenoid 6-pin connector Starter relay Starter motor + terminal T detection relay Hour meter T indicator lamp lack hite ed lue ellow reen range ink iolet own ight green 0.85 / ase color for electric wire 1 9 Z E 1 9

21 Z - 5 Z - 5 Z - 5 ower structure Ⅳ Mitsubishi KC-FH217N Applicable Serial No. : ower supply (1) ower supply (2) Engine start ear ASS utlet for orking lamp Numbering of connector terminals (viewed from mating face) Applicable Serial No. 1 : relay ( / operated) Interlock self retaining relay ( jack lifts carrier) (/ operated, pen) elay box ASS Fuse box Swivel joint Flasher Engine STAT/ST Flasher unit Upper structure power supply relay 2 Upper structure power supply relay 1 ower structure control relay Flicker lamp orking lamp ackup power supply 100 fuse Spare Spare pump relay utrigger operation detection utrigger indicator Thermo / jacking-up detection limit (4 places) ower structure power supply relay (Energized when T S N) Upper structure power supply relay 2 ( lower structure power supply relay N) Upper structure power supply relay 1 ( lower structure power supply relay N) ower structure control relay ( lower structure power supply relay N) Safety relay ( lower structure power supply relay N and engine stopped) Engine start relay ( lower structure power supply relay N and engine start S N) /F outrigger / outrigger peration, ASS, accelerator arning lamp (ption, 4 locations) solenoid 1 solenoid 2 Flicker relay ( jack lifts carrier) Engine/ rotation selector detection relay (Energized when engine rotating, emergency pump cannot be operated) relay ( lower structure control relay N, emergency pump S N, engine stopped) connector A ( lower structure power supply relay N, engine stop S N) iring ASS, carrier / outrigger T engagement detector /F outrigger AC generator Starter relay Magnetic Indicator lamp T detection S Fuel cut relay Engine stop motor Hour meter Motor for emergency pump lack hite ed lue ellow reen range ink iolet own ight green 0.85 / ase color for electric wire Starter Connection with + terminal Starter motor 2 0 Z E 2 0

22 Z - 6 Z - 6 Z - 6 ower structure Mitsubishi KC-FH217N Applicable Serial No. : Mitsubishi KC-FH227N ower supply (1) ower supply (2) Engine start Unload release Unloading release solenoid 1 solenoid 2 utrigger operation detection ear ASS confirmation lamp selector 2. iring without indication is either AS. 85mm 2 or CTF. 75mm 2 2mm 2 wiring is ASS. 3mm2 wiring is AS. Applicable Serial No. 1 : : : : : : : , Numbering of connector terminals (viewed from mating face) Swivel joint oom stowing detection limit S Engine STAT/ST acant orking lamp Flasher utlet for AZAKI S waterproof connector elay flasher unit elay ower relay (F) ound waterproof connector with ratchet 100 fuse elay box ASS oom interlock release Upper structure power supply relay lower structure power supply relay N ower structure power supply relay T N ypass relay T S N Neutral relay neutral S N utrigger indicator Fuse box Upper structure power supply ower structure power supply ackup power supply orking lamp Flicker lamp elay Unload S utrigger jacking-up detector limit S (4 locations) (- conduction when jack lifts carrier) For lower structure unloading (uilt-in diode) /F outrigger extension width detector limit S / outrigger extension width detector limit S From T/M T S To T solenoid From AT ECU /F outrigger / outrigger T/M T relay (Hold-on) Truth table on outrigger extension width detector Extension width Close Close pen Close /F outrigger pen pen / outrigger Flicker lamp (ption, 4 locations) From T/M T S To T solenoid Combination meter section For AT carrier T/M T relay (Hold-on) iring ASS, carrier Earth point (Front-left side of sub-frame) (earth for emergency pump in same location) section For AT carrier From AT ECU Indicator lamp For MT carriers Indicator lamp For MT carriers T detection S Hour meter S (FF when accelerator depressed) Engine start relay engine stat S N For MT carriers Neutral S (FF when in neutral) Safety relay engine stopped Magnet valve for exhaust brake Engine/ rotation selector detection relay ( engine rotating, emergency pump cannot be operated) relay arking relay engine stop S N emergency pump S N parking S N / operation coupling relay Energized when outrigger in operation From AT inhibitor S From starter S From starter relay / operation detection relay / operation coupling relay energized, and boom interlock release S N or boom stowed T/M neutral relay / operation interlock / operation interlock relay open Hold-on relay for jack interlock jack lifts carrier pen when / operated ( in neutral) Flicker relay jack lifts carrier Flasher unit For MT carrier Starter relay T detection S Fuel cut relay arking S (N when parking) unit (DC motor pump unit) A section For AT carrier Switch with wiring system diagram for upper structure /F outrigger extension width detector limit S / outrigger extension width detector limit S Starter relay C section For AT carrier AC generator Magnetic Starter motor Starter Engine stop motor Connection with + terminal ( T S N) uzzer Neutral I.. arking brake I.. lack hite ed lue ellow reen range ink iolet own ight green 0.85 / ase color for electric wire 2 1 Z E 2 1

23 Z - 7 Z - 7 Z - 7 ower structure Ⅰ Isuzu U-N32FXN Applicable Serial No. : ower supply (1) ower supply (2) Engine start ear ASS utlet for orking lamp Numbering of connector terminals (viewed from mating face) Applicable Serial No. 1 : : : : : otary joint relay ( / operated) Interlock self retaining relay ( jack lifts carrier) (/ operated, pen) Flasher Flasher unit elay box ASS Fuse box Upper structure power supply relay 2 Upper structure power supply relay 1 ower structure control relay Flicker lamp orking lamp ackup power supply 6 : Engine STAT/ST 100 fuse Spare Spare pump relay utrigger operation detection utrigger indicator / jacking-up detection limit (4 places) Thermo ower structure power supply relay ( T S N) Upper structure power supply relay 2 ( lower structure power supply relay N) Upper structure power supply relay 1 ( lower structure power supply relay N) ower structure control Safety relay relay ( lower structure ( power supply relay N) lower structure power supply relay N and engine stopped) Engine start relay ( lower structure power supply relay N and engine start S N) /F outrigger / outrigger arning lamp (ption, 4 locations) Flicker relay (Energized when jack lifts carrier) Engine/ rotation selector detection relay ( engine rotating, emergency pump cannot be operated) relay ( lower structure control relay N, emergency pump S N, and engine stopped) connector AFor Isuzu (elay operated when lower structure power supply relay and engine stop S N) peration ASS, accelerator iring ASS, carrier /F outrigger / outrigger ackup Apply insulating tape T N detection S T N detection S Motor for emergency pump connector solenoid 1 solenoid 2 enerator Engine stop Starter relay Starter motor Starter + terminal Hour meter lack hite ed lue ellow reen range ink iolet own ight green 0.85 / ase color for electric wire 2 2 Z E 2 2

24 Z - 7 Z - 7 Z - 7 ower structure Ⅱ Isuzu U-N321XN Isuzu KC-N331XN Applicable Serial No. : ower supply (1) ower supply (2) Engine start ear ASS utlet for orking lamp Numbering of connector terminals (viewed from mating face) otary joint relay ( / operated) Interlock hold-on relay ( jack lifts carrier) (/ operated, pen) Flasher Flasher unit elay box ASS Fuse box Upper structure power supply relay 2 Upper structure power supply relay 1 ower structure control relay Flicker lamp orking lamp ackup power supply Engine STAT/ST 100 fuse Spare Spare pump relay utrigger operation detection utrigger indicator / jacking-up detection limit (4 places) Thermo ower structure power supply relay ( T S N) Upper structure power supply relay 2 ( lower structure power supply relay N) Upper structure power supply relay 1 ( lower structure power supply relay N) ower structure control relay ( lower structure power supply relay N) Safety relay ( lower structure power supply relay N and engine stopped) Engine start relay ( lower structure power supply relay N and engine start S N) /F outrigger / outrigger arning lamp (ption, 4 locations) Neutral relay Starter relay peration ASS, accelerator Service connector Flicker relay ( jack lifts carrier) Engine/ rotation selector detection relay ( engine rotating, emergency pump cannot be operated) relay ( lower structure control relay N, emergency pump S N, and engine stopped) connector AFor Isuzu (elay operated when lower structure power supply relay and engine stop S N) ackup lamp S Charge warning lamp (Inside meter) Sub-starter S Neutral /F outrigger / outrigger Charge relay Clutch S T relay T magnetic valve Hour meter connector Motor for emergency pump solenoid 1 solenoid 2 osition enerator Terminal Starter motor y 1 signal T detection relay iring ASS, carrier lack hite ed lue ellow reen range ink iolet own ight green 0.85 / ase color for electric wire Engine stop motor Starter 2 3 Z E 2 3

25 Z - 8 Z - 8 Z - 8 ower structure Isuzu KC-N331XN Applicable Serial No. : Isuzu KC-N333XN ower supply (1) ower supply (2) Engine start Unloading release Unloading release solenoid 1 solenoid 2 ear ASS confirmation lamp 2. iring without indication is either AS. 85mm 2 or CTF. 75mm 2 2mm 2 wiring is ASS. 3mm 2 wiring is AS. Applicable Serial No. 1 : : utrigger operation detection selector Numbering of connector terminals (viewed from mating face) Swivel joint oom stowing detection limit S Engine STAT/ST acant orking lamp Flasher utlet for AZAKI S waterproof connector elay flasher unit elay ower relay (F) ound waterproof connector with ratchet 100 fuse elay box ASS oom interlock release Upper structure power supply relay lower structure power supply relay N ower structure power supply relay T S N ypass relay in neutral Neutral relay neutral S FF utrigger indicator Fuse box Upper structure power supply ower structure power supply ackup power supply orking lamp Flicker lamp elay Unload S utrigger jacking-up detector limit S (4 locations) (- conduction when jack lifts carrier) For lower structure unloading (uilt-in diode) /F outrigger extension width detector limit S / outrigger extension width detector limit S /F outrigger / outrigger Earth point (Front-left side of sub-frame) Earth for emergency pump in same location Flasher unit Truth table on outrigger extension width detector Extension width Close Close pen Close pen pen / outrigger Service connector Starter relay Neutral relay Engine start relay engine stat S N Safety relay engine stopped rotation/engine selector detection relay engine stopped pump relay engine stop S N emergency pump S N arking relay / operation / operation coupling relay detection relay Energized / operation coupling parking S N when outrigger relay energized, and in operation boom interlock release S N or boom stowed / operation Hold-on relay for interlock jack interlock / operation interlock jack lifts carrier relay open pen when / operated Flicker relay jack lifts carrier Flicker lamp (ption, 4 locations) ackup lamp S Charge warning lamp (Inside meter) Hour meter uzzer Neutral I.. arking brake I.. Substarter S Neutral (N when in neutral) Charge relay /F outrigger enerator Clutch S T relay T magnetic valve unit (DC motor pump unit) /F outrigger extension width detector limit S / outrigger extension width detector limit S y 1 signal Engine stop motor osition Starter Terminal Starter motor iring ASS, carrier arking S (N when parking) lack hite ed lue ellow reen range ink iolet own ight green 0.85 / ase color for electric wire 2 4 Z E 2 4

26 Z - 9 Z - 9 Z - 9 ower structure Ⅰ Hino U-FD3AA Applicable Serial No. : ear ASS utlet for ower supply (1) ower supply (2) Engine start orking lamp Numbering of connector terminals (viewed from mating face) Applicable Serial No. 1 : : : : relay ( / operated) Interlock self retaining relay ( jack lifts carrier) (/ operated, pen) elay box ASS Fuse box otary joint Flasher Flasher unit Upper structure power supply relay 2 Upper structure power supply relay 1 ower structure control relay Flicker lamp orking lamp ackup power supply Engine STAT/ST 100 fuse Spare pump relay utrigger operation detection utrigger indicator / jacking-up detection limit (4 places) Thermo ower structure power supply relay (Energized when T S N) Upper structure power supply relay 2 (Energized when lower structure power supply relay N) Upper structure power supply relay 1 ( lower structure power supply relay N) ower structure control relay ( lower structure power supply relay N) Engine start relay ( lower structure power supply relay N and engine start S N) /F outrigger / outrigger arning lamp (ption, 4 locations) Flicker relay ( jack lifts carrier) Engine/ rotation selector detection relay ( engine rotating, emergency pump cannot be operated) relay ( l ower structure control relay N, emergency pump S N, and engine stopped) ( lower structure power supply relay N and engine stop S N) peration ASS, engine control iring ASS, carrier /F outrigger / outrigger Neutral T N detection S Motor for emergency pump solenoid 1 Alternator solenoid 2 Engine stop solenoid Starter relay Starter motor Key + terminal Hour meter lack hite ed lue ellow reen range ink iolet own ight green 0.85 / ase color for electric wire 2 5 Z E 2 5

27 Z - 9 Z - 9 Z - 9 ower structure Ⅱ Hino KC-FC3JAA Applicable Serial No. : ear ASS utlet for ower supply (1) ower supply (2) Engine start orking lamp Numbering of connector terminals (viewed from mating face) Applicable Serial No. 1 : relay ( / operated) Interlock self retaining relay ( jack lifts carrier) (/ operated, pen) elay box ASS Fuse box Upper structure power supply relay 2 Swivel joint Flasher Flasher unit Upper structure power supply relay 1 ower structure control relay Flicker lamp orking lamp ackup power supply Engine STAT/ST Spare Spare 100 fuse pump relay utrigger operation detection utrigger indicator / jacking-up detection limit (4 places) Thermo ower structure power supply relay (Energized when T S N) Upper structure power supply relay 2 ( lower structure power supply relay N) Upper structure power supply relay 1 (Energized when lower structure power supply relay N) ower structure control relay ( lower structure power supply relay N) Safety relay ( lower structure power supply relay N and engine stopped) Engine start relay ( lower structure power supply relay N and engine start S N) /F outrigger / outrigger arning lamp (ption, 4 locations) peration ASS, accelerator ne key relay Flicker relay ( jack lifts carrier) Engine/ pump rotation selector detection relay relay ( ( engine rotating, lower structure control relay N, emergency pump cannot be operated) emergency pump S N, and engine stopped) connector AFor Isuzu (elay operated when lower structure power supply relay and engine stop S N) Hour meter /F outrigger / outrigger Sub-starter S Neutral T Engine stop relay connector Alternator solenoid 1 Combination meter solenoid 2 il pressure S Dome ne motor Starter relay Starter motor Key + terminal ower relay T detection relay wiring ASS, carrier T position T lamp lack hite ed lue ellow reen range ink iolet own ight green Motor for emergency pump 0.85 / ase color for electric wire 2 6 Z E 2 6