Publication No.

TR-200M-4/C1-1E

01

Rough Terrain Crane

Model
TR-200M-4
Applicable Serial No. 521479 --

ｃ2005
◯
PRINTED IN JAPAN
0503 K
 Foreword

Foreword

This material is the one that Publication No. TR-200M-4/C-02J was replaced from Japanese with
English.

This circuit diagrams applies to the cranes with the specification numbers given below.
Check the specification number on the nameplate of your crane.

Read the separate operation, maintenance manual, and the parts catalog for repair and maintenance of the
crane in conjunction with this manual. If the parts needs to be replaced, check the disassemble units and sales
units in the parts catalog before replacing them.

1. Applicable spec. No.

SPEC. NO. SERIAL. NO.

MFG.DATE.

KAGAWA, JAPAN

ISA04-001601

Spec. No. Applicable serial No.

TR-200M-4-00109 521479～

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

1 WA04-1720E
 Foreword

2. Contents
Spec. No.
Section
TR-200M-4-00109

Hydraulic Circuit Z-1

Electric Circuit (Crane) Z-2

Electric Circuit (Carrier) Z-3

Torque Converter Circuit Z-4

Brake Circuit (Pneumatic Circuit) Z-5

2 WA04-1720E
 Z
System Diagrams

Contents

Z-1 Hydraulic Circuit .............................. 1

Z-2 Electric Circuit (Crane) ...................... 2

Z-3 Electric Circuit (Carrier)..................... 3

Z-4 Torque Converter Circuit................... 4

Z-5 Brake Circuit (Pneumatic Circuit)..... 5

Z
i
Z-1. Z-1. Z-1.
Hydraulic Circuit

Z-1 Hydraulic Circuit Standard circuit (the option is not included.)

Solenoid valve (reverse steering)
Rotary joint
(Front:Right steering) Priority valve
Steering cylinder
Orbitrol
Master cylinder

Manual control valve

(Front:Left steering)

Cab cooler (option) Unload

valve

Solenoid valve (nose dive prevention) Oil cooler

Spring lock cylinder
Elevating cylinder
Pilot check valve
Manual control valve
Counterbalance valve Counterbalance valve

Telescoping cylinder

Check valve
Charging pump

Counterbalance valve
Hydraulic motor
Flow
Hydraulic valve control
valve
Aux. winch
Pressure
gauge
Solenoid control
Pilot check valve
valve Shuttle valve Main winch

Winch Winch
Front right Front left clutch
brake
Pilot check valve band

Hydraulic
Front Front valve
left right Hydraulic
pump

Extension cylinder
Rear right Rear left
Hydraulic pump
(emergency steering) Hydraulic
pump Clutch valve
Rear Rear
left right
Solenoid valve Main

Jack cylinder Hydraulic oil tank Aux.

Master cylinder IWZ01-1370E01

344-009-70000 2

1 WZ01-1370E 1
 Z-2
Z-2.

〔Notice〕
This program includes options ; is based on the following conditions :
1.Crane : traveling condition
2.PTO switch : OFF
3.Boom : fully retracted, over-the-front
4.Hook blocks : overwound
5.Starter switch : OFF
AML-M1 6.Control levers : neutral positions

Power supply (6V)

Electric Circuit (Crane)

Boom length input Boom angle Notice:

Boom angle input detector Mark ※1 shows a power supply harness, stored in
the relay box ,to compulsively operate the solenoid
for relief valve vent when AML is in abnormal.
Moment Boom angle
Moment input detector
detector
Starter switch
Power supply (24V)

Crane
performance Over-front area detection switch
input

2
Over-front area detection

JIB selection (FiX / Tilt JIB) 4th /5th boom section (jib) selector switch
2nd boom section
Boom full retraction full retraction switch

Mid. boom full retraction

Swing dead angle detection

Electric Circuit (Crane)

Overwind (two-blocking) detection

External warning indicator Cord reel Overwind /two-blocking detection switch (boom)

External indicator

WZ03-2500E
Buzzer 5
External indicator (100%~)
PTO switch AML override
switch Overwind (two-blocking) buzzer
AML override Backward stability For stop indicator lamp Buzzer 3
indicator lamp working range limitation
AML vent solenoid valve
Auto. stop
Overwind cutout
(anti-twoblock) disable

Relay Over load stop disable

1 pole R1, 3, 4, 5, 6, 7, 9, 10, 14 Emergency stop disable Overwind cutout (anti-twoblock) Failure warning lamp
disable switch
2 poles R2, 8 Buzzer

Telescoping control No.1

Telescoping control No.2 4th/ 5th boom section selector switch

5th boom section extending detection switch

External power supply (0V)

Left side area detection switch
Cord reel
Z-2.

Swing angle and Jib angle input

5th boom section performance indicator lamp

External power supply (+5V)

4th boom section performance indicator lamp
External address signal

Status signal Aux. winch hoisting up detection switch

Winch hoisting up detection input
Main winch hoisting up detection switch
Winch hoisting down detection input

Boom retraction detection input

Boom extending detection switch
Boom extending detection input
Boom raising detection switch
Boom raising detection input

Boom lowering detection input

Boom lowering detection switch
Jib tilt raising detection input

Jib tilt lowering detection input

Buzzer 4
Pressure switch
Swing free / lock selector switch (accumulator pressure)

Swing free / lock selector switch (main)

Solenoid valve
Swing free / lock selector switch (aux.) (swing free / lock select)
To relay RE

Main winch drum rotation indicator

To transmitter
upper unit

Thermo. indicator lamp 50℃ (122°

F)
Electric circuit
(carrier)

To open roof window

Thermo. switch 50℃ (122°
F) warning buzzer
Aux. winch drum rotation indicator
Main winch drum rotation Power supply (12V)
sensor (option)
To transmitter
Thermo. switch upper unit
70℃ (158° F) Aux. winch drum rotation
sensor (option)
Thermo. indicator lamp 70℃ (158°
F)
IWZ03-2500E01

344-111-90000
2

2
Z-2.
Z-3. Z-3. Z-3.
Electric Circuit (Carrier)

Pilot lamp

Z-3 Electric Circuit (Carrier) Working lamp Working lamp (boom top) 3W Working lamp
(LH 60W) (Boom 60W) (RH 60W)
Relay RA (horn) Buzzer 2
Solenoid valve Applicable
(air horn)

Roof window switch

Opened roof window Applicable
warning unit
Relay RH
(right turn signal)
1:Turn signal (right) 7: - 13: High/Low select
2:O/R sw. neutral position 8: P BRAKE 14: 4WD Applicable
3:P.T.O 9: AUX. BRAKE 15: R STEER Horn
Temperature gauge (engine water) Speedometer Air pressure gauge switch
4:SP LOCK 10: EX. BRAKE 16: 4 STEER
Temperature gauge (T/C oil) Tachometer Fuel gauge 5:BEAM 11: LOW AIR PRESS 17: R/CENTER Cigarette Buzzer 1
6:CHG 12: ENG. OIL 18: LOCK PIN lighter Relay RC Applicable
Starter switch (left turn signal)
Lever P
Head lamp (LH) Head lamp (RH)
2:Working lamp Combination
switch Applicable Passing beam (65W) Parking 4W GY
6: Turn signal (left) Flasher unit
Beam (50W+55W) Clearance 10W G
Turn 25W+25W GB
Combination lamp (LH) Combination lamp (RH)

P.T.O. switch
Electric circuit Relay
(crane) (for head lamp)
Air dryer heater

Power mode switch Door switch

(power /econo mode select) Solenoid valve
(outrigger jack / slide select)
Room lamp (10W)
Slide Jack Slide Jack Ext. Ret. Solenoid valve
(outrigger ext./ret. select)
Steering mode selector switch

Parking brake switch

Low air
pressure switch (Lamp (shoulder
of the road))
Spring lock switch Limit switch
(reservoir)
Pick up sensor (speed)
Lamp switch
Steering lock release switch (correction) Solenoid valve (shoulder of the road)
(spring lock)
Relay RI2
Low pressure switch Solenoid valve
(steering shift) (Lamp (shoulder
(for parking brake) of the road))
Flasher relay 1 4WD Crab

Defroster switch Relay RK (anti-nose dive)

Tachometer sensor Use
output prohibition
Tachometer output
Relay RR Solenoid valve Solenoid valve (anti-nose dive)
Speedometer sensor (spring lock release)
Relay RD (N start) input
Relay RG Speedometer output Low pressure switch (anti-nose dive)
(emergency Solenoid valve
Relay RB (12V Drum rotation sensor input (M)
(PTO)
transmission illumination at Drum rotation sensor input (S) Solenoid valve
select) nighttime) (rear steering lock) Fuel sender
Power supply (24V)
Relay RG
Speedometer sensor
0V Tachograph
Speed sensor (S)
Mission selector switch Power supply (24V) input
Flow divider
Auto. lubrication (grease)
Solenoid valve Relay RP switch
Power supply (24V)
emergency Grease pump
Drum (governor select)
indicator transmission
(Main) 0V power supply
Solenoid valve
Working lamp switch Solenoid valve (engine stop) select
(reverse steering select) Drum Use prohibition
Electric circuit indicator Solenoid valve Tachometer sensor
(crane)
(Aux.) (aux. brake)
Solenoid valve
Relay RL (parking brake)
24V
Pilot lamp (3W)
0V
Reverse steering switch Solenoid valve Solenoid valve
Use prohibition
(High/Low select) (lock up) Relay RH
Use prohibition
Limit switch (clearance lamp)
(over-rear detection) Solenoid valve
(2 /4 wheel drive select)
Exhaust brake switch
Relay RE Use prohibition Solenoid valve
(spring lock condition) (exhaust brake)
Main winch hoisting up detection
Relay RJ
Relay RF (head light) Aux. winch hoisting up detection
Low pressure switch Limit switch (battery hold)
Lock pin switch Rear steering lock release (correction)
(engine oil) (idling condition detection) Pressure
Emergency transmission
switch
Head lamp (High)
(stop lamp)
Clearance
Rear steering lock release
Emergency mission switch Use prohibition
Rear steering lock Thermo. sender
DC-DC converter Air heater relay (T/C oil temp.) Alternator
Exhaust brake
System check switch Use prohibition
Spring lock condition restriction
Thermo sender
HI/LO, 2/4 wheel drive select (1) Use prohibition (engine water temp.)
Relay RM
HI/LO, 2/4 wheel drive select (2)
emergency
PTO switch condition detection transmission
Outrigger switch 4 wheel steering select
(Jack / Slide select) Crab steering
Air heater relay
Spring lock
Spring lock release Safety relay Air heater
Head lamp (Low)
Outrigger switch Power/ economy mode select
(Ext. / Ret. select) Clearance (drum indicator illumination decrease in lights) Transmission selector solenoid valve
Parking brake switch condition Solenoid valve
detection (outrigger jack / slide select)
N Use prohibition
1 Slide Jack Slide Jack Starter
ALL 2 relay
D Relay RS
R transmission
Outrigger extension / retraction select select Relay RM
FL (Jack/Slide select) Starter motor Battery
Individual operation switch FL FR Battery relay
Outrigger jack/ slide select
RL
RR Limit switch
FR
Use prohibition Use (steering lock pin)
prohibition

Relay RO
RL (O/R ext./ret. select)

Relay RY
Jack/Slide selector switch

RR Ext./Ret. select switch

Roof window Turn signal lamp Tail, stop & parking lamp
wiper switch Combination lamp (RH)
Roof window wiper motor Windshield wiper motor
High /Low & 2/4wheel drive Straight ahead detection
selector switch proximity switch
Radio ALL Turn signal 25W GY
Washer motor Stop 25W GW Condenser
FL
Tail 10W G
Parking 3W GL
Series,clamshell FR
Relay RG, RM, RN
RL
Power supply Intermittent wiper relay Turn signal lamp Explain of relay terminal (bottom view)
Heater selection SW

License lamp Back up lamp Back up buzzer

(inside relay box)

(inside relay box)

Tail & stop/parking lamp (12W) (25W)

To fuse (15A)

Fan
To relay RZ1

RR Combination lamp (LH)

Cab cooler Cab cooler switch
compressor Fan To combination switch
switch assy assy Cab cooler assy
Outrigger operation box (lower) IWZ03-2510E01
347-504-20000 5

3 WZ03-2510 3
Z-4. Z-4. Z-4.
Torque Converter Circuit

Z-4 Torque Converter Circuit

Transmission

Lubricant quantity control valve

Torque converter Temperature gauge

Torque converter outlet pressure

regulator valve
Oil cooler

Pressure gauge
Modulating valve

Main regulator valve

Lock-up clutch

Torque converter
inlet relief valve
Solenoid valve

PTO clutch

Line filter

Charging pump

Strainer

Solenoid valve (lock-up clutch)

IWZ05-0260E01

347-403-60000 0

4 WZ05-0260E 4
Z-5. Z-5. Z-5.
Brake Circuit (Pneumatic Circuit)

Rotary joint
Z-5 Brake Circuit (Pneumatic Circuit)
Brake valve
Pressure switch (stop lamp)
Pressure gauge

Pressure switch (anti-nose dive)

Shuttle valve Accelerator valve

Air cylinder
(accelerator)
Solenoid valve Solenoid valve
(auxiliary brake)

Front
Reducing valve
Air cylinder
(engine stop)
Horn

Air cylinder Air cylinder

(2/4 wheel drive selection) (exhaust brake)

Rear
Air cylinder
(High/Low speed selection)

Low-pressure indicator
(air pressure warning) Air cylinder
(steering lock)
Safety valve
Parking brake chamber
Air drier
Oil reservoir

Pressure switch Reducing valve

(parking brake)

Pressure regulator
Booster
Air compressor

Air tank

Booster Drain cock

IWZ06-0300E01

347-403-10000 0

5 WZ06-0300E 5
Head Office Ko-34,Sinden-cho, Takamatsu, Japan

Overseas Service Group

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

History of revision
1
2
3
4
5