Tadano Faun AML-LIIB Overload Prevention Device Service Manual W301-0212E - PDF DOWNLOAD

Publication No.

W301-0212E

Service Manual (AML-L B)

02 Overload Prevention Device Model

PRINTED IN JAPAN 0401

K

W301-0212E

ｃ ◯2004

AML-L B

Foreword Foreword

1. Applicable Spec. No. 2004.1.

This service manual covers the overload prevention

Applicable crane model

device (AML-L B) installed on the TADANO cranes in the chart below.

GT-550E-1

In undertaking repair, refer to the separate operation and maintenance manual, parts catalog, and

Specification numbers:

crane-covering service manual for pertinent

(1) GT-550E-1-10102

information.

(2) GT-550E-1-10202

If the parts replacement is required, check the disassembly and order units from the applicable parts

GR-120N-1

catalog.

Specification numbers: (1) GR-120N-1-00103 GR-700EXL-1 Specification numbers: (1) GR-700E-1-00101 (2) GR-700E-1-00102 Use this manual for machines with the overload prevention device (AML-L B) even if the crane model is other than the above.

Please note that, for product Improvement, some changes may have been incorporated in the machine that are not covered in this manual.

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W301-0212E

Foreword 2. Contents 1.

Applicable Spec. No................................... 1

2.

Contents .................................................... 2

Names and Functions of AML Main Unit Parts ...........................58 Selecting Operational Status..............................64 AML Pre-operational Inspection.........................68 How to Use the Working Range Limit Function .....................................68 How to Use the Elevation Speed Adjustment Function ..............................................70 Display Alteration ...............................................72

Components of the AML (AML-L B) Main Unit . 5 Diagram of the AML (AML-L B) System (GT-550E-1) ................................... 6

Functions of and How to Use User Mode (GR-700EXL-1) ............................ 73

Input/Output Signals of the AML (AML-L B) System (GT-550E-1) ...................... 7

Diagram of the AML (AML-L B) System (GR-700EXL-1) ............................ 27

Mode Structure...................................................73 Configuration and Functions of the AML System..............................74 Names and Functions of AML Main Unit Parts ..78 Selecting Operational Status..............................84 Selecting Winch Condition .................................88 Selecting Jib Mounted Condition........................88 AML Pre-operational Inspection.........................89 How to Use the Working Range Limit Function .90 Display Alteration ...............................................94

Input/Output Signals of the AML (AML-L B) System (GR-700EXL-1) ............... 28

[ADJUSTMENT AND MAINTENANCE].......... 95

Diagram of the AML (AML-L B) System (GR-120N-1) ................................ 13 Input/Output Signals of the AML (AML-L B) System (GR-120N-1) ................... 14

[OPERATION]................................................. 35

General: Adjustment Mode and Maintenance Mode ...................... 95

Functions of and How to Use User Mode (GT-550E-1) ................................. 35

1. Keys and Switches for Adjustment and Maintenance .......................................95 2. Mode Structure and Menu ...............................96 3. Method of Shifting Modes................................98 4. Method of Menu Selection...............................99

Mode Structure .................................................. 35 Configuration and Functions of the AML System ....................................... 36 Names and Functions of AML Main Unit Parts .......................... 39 Selecting Operational Status ............................. 45 AML Pre-operational Inspection ........................ 48 How to Use the Working Range Limit Function ..................................... 49 Display Alteration ............................................... 53

Required Adjustment After AML System Parts Replacement.............................. 100 Functions of and How to Use Adjustment Mode................ 101 Adjustment Procedures ......................................101 1. Adjustment Initialization.................................102 1.1 Procedure of Conversion Factors Resetting..............................102 1.2 Procedures of Moment Adjustment Resetting........................102

Functions of and How to Use User Mode (GR-120N-1) ................................ 54 Mode Structure .................................................. 54 Configuration and Functions of the AML System ....................................... 55

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W301-0212E

Foreword 8. Key Switch Check..........................................124 9. Display Check................................................125 10.Error Data Display .........................................125 11. Erasing the Error Data ...................................125 12.OP (Option) Board Check..............................126 13.Ao Check .......................................................126 14.Sio Check ......................................................127 15.Adjust Monitor................................................127 16.Overload History Display ...............................127 17.Erasing the Overload History.........................127 18.Clock Adjustment ...........................................127

2. Capacity Setting ............................................ 103 2.1 Procedure of Head-off Capacity Setting ............................... 103 2.2 Procedure of Jib Selection ..................... 104 2.3 Procedure of Single Top Selection ......... 104 2.4 Procedure of Winch Drum Position Setting ................................ 105 3. Boom Length Adjustment.............................. 106 4. Boom Angle Adjustment................................ 107 5. Swing Angle Adjustment ............................... 108 6. Outrigger Extension Width Adjustment ......... 109 7. Moment Adjustment ...................................... 110 7.1 Moment Zero-point Adjustment ...............111 7.1 Moment Zero-point Adjustment ...............111 7.2 Moment Span Preliminary Adjustment ... 112 7.3 Moment Zero-point Check and Fine Adjustment................................ 112 7.4 Load Radius Adjustment ........................ 113 7.5 Moment Span Fine Adjustment .............. 113 7.6 Moment Zero-point Recheck .................. 114 8. Clock Adjustment .......................................... 115 9. Adjustment of Swing Output ......................... 116 9.1 Procedure of Resetting Ao Offset Value. 116 9.2 Adjustment of Swing Output (Ao offset adjustment) ...................... 116 10.Adjustment of Elevation Output .................... 118 10.1 Procedure of Resetting Elevation Data .. 118 10.2 Adjustment of Elevation Output (elevation speed adjustment) ........... 118 Other Functions and How to Use Them............. 120 1. Language ...................................................... 120 2. Overload History Display............................... 120 3. Erasing the Overload History ........................ 121

Error Message .............................................. 128 1. Display of Error Message ..............................128 2. How to Read the Error Message ...................128 3. How to Read the Error History.......................128 4. Troubleshooting Table ...................................129 4.1 Group Code 0 .........................................129 4.2 Group Code 1 .........................................138 4.3 Group Code 2 .........................................140 4.4 Group Code 3 .........................................143

Disassembly of AML Main Unit..................... 144 1. Removing Front Panel/Display Board ...........144 2. Removing Rear Panel/Connector Board /Current Output Board............144 3. Removing CPU Board/Analog Board /Power Board .........................145 3.1 Notes on ROM/EEPROM Replacement .145

[INFORMATION AND DATA] ....................... 146 Adjustment Value Table ................................ 146 Specification No. : GT-550E-1-10102 ..............146 Specification No. : GT-550E-1-10202 ..............146 Specification No. : GR-120N-1-00103..............148 Specification No. : GR-700E-1-00101..............150 Specification No. : GR-700E-1-00102..............150

Functions of and How to Use Maintenance Mode..................... 122 1. Program Version Display .............................. 122 2. Data ID Number Display ............................... 122 3. Di Check........................................................ 122 4. Ai Check........................................................ 123 5. Elevating Cylinder Oil Pressure Monitor ....... 123 6. Do Check ...................................................... 124 7. MDT Monitor (Multiplex Data Transmitter Monitor) ............................................ 124

MDT (Multiplex Data Transmitter) Input/Output Nos. and Corresponding Signals............... 152 Checking the Detectors (GT-550E-1) ........... 153 1. Boom Length Detector...................................153

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W301-0212E

Foreword 2. Boom Angle Detector .................................... 153 3. Swing Angle Detector.................................... 154 4. Outrigger Extension Width Detector ............. 154 5. Pressure Sensor for Moment Detection........ 155

Check the Detectors (GR-120N-1/GR-700EXL-1) ....... 156 1. Boom Length Detector .................................. 156 2. Boom Angle Detector .................................... 156 3. Swing Angle Detector.................................... 157 4. Outrigger Extension Width Detector ............. 157 5. Pressure Sensor for Moment Detection........ 158

Fuses

................................................... 159

Replacing the Clock Battery ......................... 160

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W301-0212E

Components of the AML (AML-L B) Main Unit Components of the AML (AML-L B) Main Unit RLY3, 4 fuse (3A) RLY1, 2 fuse (3A) MAIN fuse (3A)

CN1

RLY5, 6 fuse (3A) RLY7, 8 fuse (3A)

SIF1 fuse (2A)

Moment input short-circuit switch (Not used.)

HALT

WDT

ZERO

PROTECT

MOMENT SHORT

SIF2 fuse (2A)

Abnormality display LED (CPU abnormality.)

Protect switch (Selects to "OFF" position at adjusting mode.)

Moment zero adjuster (Adjusted by AML maker. Do not touch.)

Top view Boom lift indicative symbol

Moment display

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

MBGND MBGND

17 18 MOGND/ANGND 19 MOSRC/+5V 20 MOINP/ANAING 21 MOINN/ANAINH 22 MOSLD/ANSLD 23 24 25 26 SiF1GND 27 SiF1SRC 28 SiF1TXD+ 29 SiF1TXDSiF1RXD+ SiF1RXDSiF1SLD

MBPW MBPW RLYPW RLYPW TC ACC

23 24 25 26 27 28 29 30 31 32 33 34

CNTL3P CNTL3N CNTL4P CNTL4N CNTLSLD SiF2GND SiF2SRC SiF2TXD+ SiF2TXDSiF2RXD+ SiF2RXDSiF2SLD

CNTL1P CNTL1N CNTL2P CNTL2N Di-15 Di-16 Di-17 Di-18 Di-19 Di-20

16 17 18 19 20 21 22 23 24

CNTL5P CNTL5N CNTL6P CNTL6N CNTLSLD Di-21 Di-22 Di-23 Di-24

7 8 9

RTS CTS

Boom angle indicative symbol

13 14 15 16 17 18 19 20 21 22

Di-5 Di-6 Di-7 Di-8 Di-9 Di-10

CN2

CN3 10 11 12 13 14 15

Di-25 Di-26 Di-27 Di-28

4 5 6

RD SG

CN4

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

DET1GND DET1SRC ANAINA ANAINB ANAINC DET1SLD DET2GND DET2SRC ANAIND ANAINE ANAINF DET2SLD Di-1 Di-2 Di-3 Di-4

1 2 3 4 5 6 7 8 9 10 11 12

RLY 1 RLY 2 RLY 3 RLY 4 RLY 5 RLY 6 RLY 7 RLY 8 Di-11 Di-12 Di-13 Di-14

1 2 3 4 5 6 7 8 9

TR-1 TR-2 TR-3 TR-4 TR-5 TR-6 TR-7 TR-8

1 2 3

FG DSR TD

Connector terminal Nos.

Jib angle indicative symbol

Number of part-lines of indicative symbol Upper boom angle limit restriction symbol

Jib lift indicative symbol

Boom length indicative symbol

Single-top lift indicative symbol

Jib angle display

Real load display

Scroll-up key Scroll-down key Lifting height restriction symbol

Rated lifting capacity display

Lifting height indicative symbol

Load radius limit restriction indicative symbol

SOL1, 2 FUSE: 250V 2A

Swing

SOL3, 4 FUSE: 250V 2A

Elevating

SOL SOL5, 6 FUSE: 250V 2A

Swing free (GR-120N-1: Not used.)

Fuse PWMFREQ CNTL 1

CNTL 2

CNTL 3

CNTL 4

CNTL 5

CNTL 6

ZERO SPAN ZERO SPAN ZERO SPAN ZERO SPAN

Right Swing Left Swing Boom Raise Boom Lower

ZERO SPAN

Boom Retraction (Not used.)

m

Boom angle display

CN4 PLD

CPU

ROM 0

Right side view (Name plate)

CN2 CN3

CPU board

Moment display contrast adjuster LCD panel contrast adjuster Current output board (for Slow stop) Connector board

Lifting height restriction indicator lamp

SOL1, 2 fuse (2A) Slow stop (Swing)

Upper boom angle limit restriction indicator lamp

CN1 Connector

Lower boom angle limit restriction indicator lamp

SOL3, 4 fuse (2A) Slow stop (Elevating)

Lower boom angle limit restriction key

CN2 Connector

Upper boom angle limit restriction key

SOL5, 6 fuse (2A) Slow stop (Swing free) (GR-120N-1: Not used.)

t %

Load radius display

max t

m

LCD panel Over-front position symbol

Lifting height restriction key

Front jack symbol

CN3 Connector

Load radius restriction indicator lamp

Outrigger state indicative symbol

Right swing restriction indicator lamp

"On-rubber" (Outrigger-not-in-use) state indicative symbol

CN4 Connector (Not used.)

Left swing restriction indicator lamp Load radius restriction key

Suspension lock state indicative symbol

Display alteration key

Increase key

Register key

Boom position indicator

Right swing restriction key

Decrease key Outrigger mode select key Lift mode select key

Number of part-lines of rope select key Check key Left swing restriction key

Front view 5

CN1

ROM 1

Output adjustment trimmer (Adjusted by AML maker.

Do not touch.)

m

Lower boom angle limit restriction symbol

Battery

EEPROM

ZERO Swing Free SPAN (GR-120N-1: Not used.)

Load radius indicative symbol

Boom length display

CAL/CLOCK

W301-0212E

Output adjustment trimmer (Adjusted by AML maker. Do not touch.)

Power board Analog board CPU board Display board

Right side view

IW301-0211E01

Diagram of the AML (AML-L B) System (GT-550E-1) Diagram of the AML (AML-L B) System (GT-550E-1) 3 (B) 2 (W) 1 (R)

Boom angle detector

Boom length detector

CUP1

3 2 1

CUP2

3 2 1

Swing angle detector

R W B

Pressure sensor (Main)

CONNECTOR BOARD

B B A R R C W W B G B D E

3 (B) 2 (W) 1 (R)

R W

R W

G B

G B

Auto. stop override signal input Auto. stop override signal input

24(V) Pressure sensor for moment detection R R (Elevating) W B

W B

R W B

R W B

Alarm signal output

Auto.stop signal output SOL.

Buzzer

Telescoping control output SOL. Lever manipulation detection input

Slow stop(Swing)

Working condition signal input (Outrigger)

Slow stop(Elevating)

Outrigger extension width detector (4 peace)

SOL5, 6 (2A) SOL1, 2 (2A) SOL3, 4 (2A)

CN1

R W B

Working condition input

CURRENT OUTPUT BOARD

Transmitter (Type2)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

DET1GND DET1SRC ANAINA ANAINB ANAINC DET1SLD DET2GND DET2SRC ANAIND ANAINE ANAINF DET2SLD Di1 Di2 Di3 Di4 MB MB RB RB TC ACC NC Di5 Di6 Di7 Di8 Di9 Di10 GND GND DET3GND DET3SRC ANAING ANAINH DET3SLD NC NC SIF1GND SIF1SRC SIF1TXD+ SIF1TXDSIF1RXD+ SIF1RXDSIF1SLD

Latch

Fuses

Di SW. input block

SOL1, 2 (2A) SOL3, 4 (2A)

Fuses

Current Amplifier Circuit

SOL5, 6 (2A)

CPU BOARD

SIF 1 (2A)

SIF 2 (2A) MAIN (3A)

POWER BOARD

EEPROM

Buzzer

RAM

CAL/CLOCK

SCI

CPU

Fuses RLY1, 2 (3A) RLY3, 4 (3A)

Relay

+20V

DC power block

-12V +5V

RLY5, 6 (3A) RLY7, 8 (3A)

Key input

+12V

LCD panel (1)

Serial input/output circuit LCD panel (2)

LCD SW . backlights

Latch RLY1 RLY2 RLY3 RLY4 RLY5 RLY6 RLY7 RLY8 Di11 Di12 Di13 Di14 CNTL1P CNTL1N CNTL2P CNTL2N Di15 Di16 Di17 Di18 Di19 Di20 CNTL3P CNTL3N CNTL4P CNTL4N CNTLSLD SIF2GND SIF2SRC SIF2TXD+ SIF2TXDSIF2RXD+ SIF2RXDSIF2SLD

DISPLAY BOARD CHR display

CN2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

ROM

O.C.Tr. output block

Latch

ANALOG BOARD

Di SW. input block

Latch

Buffer

Buffer

Analog multiplexer

A/D converter

CN3 24(V)

90 - 100% 100% AML external indicator output

Working condition input

Slow stop (Swing free)

6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

W301-0212E

TR1 TR2 TR3 TR4 TR5 TR6 TR7 TR8 NC Di25 Di26 Di27 Di28 NC NC (CNTL5P) (CNTL5N) (CNTL6P) (CNTL6N) CNTLSLD Di21 Di22 Di23 Di24

Pressure sensor analog detector power supply

IW301-0211E02

Input/Output Signals of the AML (AML-L B) System (GT-550E-1) Input/Output Signals of the AML (AML-L B) System (GT-550E-1) As shown in the “Diagram of the AML (AML-L B) System” on the previous page, the display board, CPU board, analog board, power board, current output board and connector board consist inside the AML. The following lists describe the names and functions of the input/output signals on CN1, CN2 and CN3 cnnectors.

CN1 connector signals and functions are shown below: CN 1 connector Pin No.

Name

Signal names and functions

ANAIN A

Signal name: Boom length detector input Analog input representing detected boom length.

Input voltage: DC 0 to 4.5 V

4

ANAIN B

Signal name: Boom angle detector input Analog input representing detected boom angle.

Input voltage: DC 0 to 4.5 V

5

ANAIN C

Signal name: Swing angle detector 1 input Analog input from the swing detector 1 representing detected swing angle.

Input voltage: DC 0 to 4.5 V

ANAIN D

Signal name: Swing angle detector 2 input Analog input from the swing detector 2 representing detected swing angle.

Input voltage: DC 0 to 4.5 V

ANAIN E

Signal name: Main hydraulic pressure sensor input Analog input representing detected main hydraulic pressure.

Input voltage: DC 0 to 4.5 V

3

9

10

13

14

15

16

22

Di1

Signal name: Overwind detector switch (L4) 137input Input from a hook overwind detection switch.

Switch ON (DC0V): A hook is in normal state.

Switch OFF (DC24V): Detecting a hook overwind.

Di2

Signal name: 2nd boom full-retraction detection switch (L8) 135 input Switch input used detecting the boom state.

Switch ON (DC0V): 2nd boom in fully retracted state.

Switch OFF (DC24V): 2nd boom in extended state.

Di3

Signal name: 3rd-top boom full-retraction detection switch (L7) 136 input Switch input used detecting the boom state.

Switch ON (DC0V): 3rd-top boom in fully retracted state.

Switch OFF (DC24V): 3rd-top boom in extended state.

Di4

Signal name: Swing free, lock select switch (S15) 140 input Switch input used detecting the swing free, lock state.

Switch ON (DC0V): Swing lock device; Free.

Switch OFF (DC24V): Swing lock device; Lock.

ACC

Signal name: Swing slow stop release switch (S14) 142 input When release a crane motion stop state caused by a swing slow stop, make this switch “ON”.

Switch ON (DC24V): Release a swing slow stop state.

Switch OFF (DC0V): Not cancel a swing slow stop state.

7

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GT-550E-1) CN 1 connector Pin No.

Name

Signal names and functions

Di5

Signal name: Overwind cutout release switch (S3) 143 input When release a crane motion stop state caused by a hook overwind detection, make this switch “ON”.

Switch ON (DC0V): Release a hook overwind cutout state and buzzer alarm.

Switch OFF (DC24V): A hook overwind cutout state.

Di6

Signal name: AML cutout release switch (SK1) (S19) 149, 150 input When release a crane motion stop state caused by a hook over-wind detection, make this switch “ON”.

Switch ON (DC0V): Release a overload stop state.

Switch OFF (DC24V): Not cancel a overload stop state.

Di7

Signal name: Elevating slow stop release switch (S22) 141 input When release a crane motion stop state caused by a elevating slow stop, make this switch “ON”.

Switch ON (DC0V): Release a elevating slow stop state.

Switch OFF (DC24V): Not cancel a elevating slow stop state.

Di8

Signal name: Jib set pin detection (Jib extension detection) switch (L1) 144 input This signal represents extended or retracted state of the jib.

Switch ON (DC0V): Jib in retracted state.

Switch OFF (DC24V): Jib in extended state.

Di9

Signal name: Jib automatic lock pin detection switch (CS10) 145 input This signal represents locked or unlocked state to the jib.

Switch ON (DC0V): Jib in automatic lock state.

Switch OFF (DC5V): Jib in automatic unlock state.

29

Di10

Signal name: Swing angle detector 1,2 selection switch (CS11) 146 input This signal represents the boom swing position (Swing blind corner).

Switch ON (DC0V): Boom in left over-side area.

Switch OFF (DC5V): Boom in right over-side area.

34

ANAING

Signal name: Input for pressure sensor for moment detection (extension side) Analog input to detect the elevating cylinder extension pressure.

Input voltage: DC 0 to 5 V

ANAINH

Signal name: Input for pressure sensor for moment detection (retraction side) Analog input to detect the elevating cylinder retraction pressure.

Input voltage: DC 0 to 5 V

24

25

26

27

28

35

8

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GT-550E-1) CN2 connector signals and functions are shown below: CN 2 connector Pin No.

Signal names and functions

Name

Signal name: Automatic stop 1 relay output When a overload or a hook overwind is detected, or when AML is in failure, or in any likewise situation, this relay output goes “OFF” and stops the crane motion.

Relay ON (DC24V): The crane motion is normal.

Relay OFF (DC0V): The crane motion is auto. Stopped.

Crane work operation

1

RLY 1

Relay output

Moment load ratio < 90%

ON

90%

ON

Moment load ratio < 100%

Moment load ratio

100%

OFF

Overwinding occurred.

OFF

Crane movement exceeded any registered working range limit.

OFF

Failure in the AML unit.

OFF

Operated to critical side when rearward stability control activated.

OFF

Boom lift with jib mounted on boom.

80%

Moment load ratio < 90%

Moment load ratio

ON

90%

OFF

Signal name: AML alarm relay output On occurrence of an overload, this output energizes the relay to turn on the buzzer 3 (280Hz Low).

Relay ON (DC24V): Alarm buzzer sounds.

Relay OFF (DC0V): Alarm buzzer does not sound.

4

RLY 4

Raising alarm conditions Moment ratio < 90% 90%

OFF

Moment ratio < 100%

Moment ratio

Relay output ON/OFF

100%

ON

Boom lift with jib mounted on boom.

80%

Moment ratio < 90%

Moment ratio

5

6

7

ON/OFF

90%

ON

RLY 5

Signal name: Telescoping control relay output Output for switch between 3rd-top boom telescoping and 2nd boom telescoping.

Relay ON (DC24V): 3rd-top boom sections are telescoped.

Relay OFF (DC0V): 2nd boom sections are telescoped.

RLY 6

Signal name: Jib lock lamp relay output When the jib set pin is extracted, this output energizes lamp lights up.

Relay ON (DC24V): Jib lock lamp lights up when the jib set pin is extracted.

Relay OFF (DC0V): Normal condition.

RLY 7

Signal name: Overwind alarm relay output When an overwind state is detected, this output energizes the relay to turn on the buzzer.

Relay ON (DC24V): Overwind alarm buzzer sounds.

Relay OFF (DC0V): Normal condition.

9

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GT-550E-1) CN 2 connector Pin No.

9

11

Name

Signal names and functions

Di11

Signal name: Main winch hoist-up detection switch (PS1) 29 input Input from the main winch hoist-up detection switch.

Switch ON (DC0V): Main winch hoist-up operation is not detected.

Switch OFF (DC5V): Main winch hoist-up operation is detected.

Di13

Signal name: Auxiliary winch wind detection switch (PS2) 35 input Input from the aux. winch hoist-up detection switch.

Switch ON (DC0V): Aux. winch hoist-up operation is not detected.

Switch OFF (DC5V): Aux. winch hoist-up operation is detected.

13

CNTL 1P

Signal name: Swing right proportional valve output When swing to clockwise, over the deviation angle start point, AML outputs the controlled to the right proportional valve (PRP3) 65-1.

Swing will be stopped at specified position where calculated in the AML-L B. Output value when starts the deceleration is 56% × 800mA, 24V rectangular wave.

Output voltage: Square wave 0 to 24V

14

CNTL 1N

Signal name: Swing right proportional valve COM (-) Input voltage: DC0V

15

CNTL 2P

Signal name: Swing left proportional valve output When swing to clockwise, over the deviation angle start point, outputs the controlled to the left proportional valve (PRP4) 65-2.

Swing will be stopped same as above.

Output voltage: Square wave 0 to 24V

16

CNTL 2N

Signal name: Swing left proportional valve COM (-) Input voltage: DC0V

17

18

19

20

21

Di15

Signal name: Boom extension detection switch (PS3) 2M2D 31,1M1D 43 input Input from the boom extension operation detection switch.

Switch ON (DC0V): Boom extension operation is not detected.

Switch OFF (DC5V): Boom extension operation is detected.

Di16

Signal name: Boom retraction detection switch (PS4) 2M2D 33,1M1D 44 input Input from the boom retraction operation detection switch.

Switch ON (DC0V): Boom retraction operation is not detected.

Switch OFF (DC5V): Boom retraction operation is detected.

Di17

Signal name: Boom raising operation detection switch (PS5) 26 input Input from the boom raising operation detection switch.

Switch ON (DC0V): Boom raising operation is not detected.

Switch OFF (DC5V): Boom raising operation is detected.

Di18

Signal name: Boom lowering operation detection switch (PS6) 22 input Input from the boom lowering operation detection switch.

Switch ON (DC0V): Boom lowering operation is not detected.

Switch OFF (DC5V): Boom lowering operation is detected.

Di19

Signal name: Boom right operation detection switch (PS9) 38 input Input from the right swing operation detection switch.

Switch ON (DC0V): Swing right operation is not detected.

Switch OFF (DC5V): Swing right operation is detected.

10

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GT-550E-1) CN 2 connector Pin No.

22

Name

Di20

Signal names and functions Signal name: Boom left operation detection switch (PS10) 39 input Input from the left swing operation detection switch.

Switch ON (DC0V): Swing left operation is not detected.

Switch OFF (DC5V): Swing left operation is detected.

23

CNTL3 P

Signal name: Boom raising proportional valve output When raise the boom to nearly elevating cylinder stroke end, AML outputs the controlled current to the boom raising proportional valve (PRP1) 27-2. Raising the boom will be stopped at 0.5° lower than elevating cylinder stroke end due to the protection of the shock.

Output voltage: Square wave 0 to 24V

24

CNTL 3N

Signal name: Boom raising proportional valve common pat (-) Input voltage: DC0V

25

CNTL 4P

Signal name: Boom lowering proportional valve output When lower the boom to nearly elevating cylinder stroke end, AML outputs the controlled current to the boom lowering proportional valve (PRP2) 27-1. Lowering the boom will be stopped at 0.5° higher than elevating cylinder stroke end due to the protection of the shock.

Output voltage: Square wave 0 to 24V

26

CNTL 4N

Signal name: Boom lowering proportional valve common pat (-) Input voltage: DC0V

11

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GT-550E-1) CN3 connector signals and functions are shown below: CN 3 connector Pin No.

2

3

4

10

12

13

Name

Signal names and functions

TR 2

Signal name: AML 90% (80%)*1 alarm output Outputs if the load moment is in a range between 90% (80%)*1 and 100% (90%)*1.

90% and 100% not inclusive (80% and 90% not inclusive)*1.

OC (Open collector) output “ON” (DC0V): The external indicator 90% (80%)*1 turns on.

OC (Open collector) output “OFF” (DC24V): The external indicator 90% (80%)*1 turns off.

TR 3

Signal name: AML 100% (90%)*1 alarm output Outputs if the load moment is 100% (90%)*1 or more.

OC (Open collector) output “ON” (DC0V): The external indicator 100% (90%)*1 turns on.

OC (Open collector) output “OFF” (DC24V): The external indicator 100% (90%)*1 turns off.

TR 4

Signal name: Front jack overload warning output OC (Open collector) output “ON” (DC0V): Buzzer [130] sounds when the front jack overload detection switch is ON. OC (Open collector) output “OFF” (DC24V): Buzzer [130] does not sound when the front jack overload detection switch is OFF.

Di25

Signal name: Outrigger stowing operation detection switch input Switch ON (DC0V): The outrigger stowing operation is detected.

Switch OFF (DC5V): The outrigger stowing operation is not detected.

Di27

Signal name: Telescoping method selector switch (S31) 157 input Switch ON (DC0V): Special telescoping method.

Switch OFF (DC5V): Sequential telescoping method.

Di28

Signal name: Head-end boom sections (3rd, 4th and top) extension switch (S7) [158] input Switch ON (DC0V): Head-end boom sections (3rd, 4th and top) extend first.

Switch OFF (DC5V): Head-end boom sections (3rd, 4th and top) do not extend first.

16

CNTL5P

Signal name: Proportional valve (For swing relief) input Used to control swing slow stop while free swing mode is active.

Output voltage: Square wave 0 to 24V

17

CNTL5N

Signal name: Proportional valve (For swing relief) common pat (-) Input voltage: DC0V

*1: For the boom lift mode with the jib mounted on the boom, apply the values marked with *1.

(The alarm and automatic stop function at the values lower than the ones they do in the boom lift mode with no jib mounted on the boom.)

12

W301-0212E

Diagram of the AML (AML-L B) System (GR-120N-1) Diagram of the AML (AML-L B) System (GR-120N-1) CONNECTOR BOARD

Boom angle detector A C B D E

Boom length detector

Pressure sensor (Main)

24(V)

Auto. stop override signal input Auto. stop override signal input

Working condition input Pressure sensor for moment detection (Elevating) Jib angle detector

Transmitter Alarm signal output

Hook-in control output SOL.

SOL5, 6 (2A) SOL1, 2 (2A) SOL3, 4 (2A)

CN1

Swing angle detector

Pressure sensor (Accumulator)

CURRENT OUTPUT BOARD

Auto.stop signal output SOL. Telescoping control output SOL.

BUZZER

Slow stop(Swing)

Lever manipulation detection input

Slow stop(Elevating) Combination meter Outrigger extension width detector (4 peace)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

DET1GND DET1SRC ANAINA ANAINB ANAINC DET1SLD DET2GND DET2SRC ANAIND ANAINE ANAINF DET2SLD Di1 Di2 Di3 Di4 MB MB RB RB TC ACC NC Di5 Di6 Di7 Di8 Di9 Di10 GND GND DET3GND DET3SRC ANAING ANAINH DET3SLD NC NC SIF1GND SIF1SRC SIF1TXD+ SIF1TXDSIF1RXD+ SIF1RXDSIF1SLD

Latch

Fuses

Di SW. input block

SOL1, 2 (2A) SOL3, 4 (2A)

Fuses

Current Amplifier Circuit

SOL5, 6 (2A)

CPU BOARD

SIF 1 (2A)

SIF 2 (2A) MAIN (3A)

POWER BOARD

EEPROM

Buzzer

RAM

CAL/CLOCK

SCI

CPU

Fuses RLY1, 2 (3A) RLY3, 4 (3A)

Relay

+20V

DC power block

-12V +5V

RLY5, 6 (3A) RLY7, 8 (3A)

Key input

+12V

LCD panel (1)

Serial input/output circuit LCD panel (2)

LCD SW . backlights

Latch RLY1 RLY2 RLY3 RLY4 RLY5 RLY6 RLY7 RLY8 Di11 Di12 Di13 Di14 CNTL1P CNTL1N CNTL2P CNTL2N Di15 Di16 Di17 Di18 Di19 Di20 CNTL3P CNTL3N CNTL4P CNTL4N CNTLSLD SIF2GND SIF2SRC SIF2TXD+ SIF2TXDSIF2RXD+ SIF2RXDSIF2SLD

DISPLAY BOARD CHR display

CN2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

ROM

O.C.Tr. output block

Latch

ANALOG BOARD

Di SW. input block

Latch

Buffer

Buffer

Analog multiplexer

A/D converter

CN3

lower unit upper unit Outrigger retraction operation MDT (multiplex data transmitter) detection input

- 90% 90 - 100% 100% -

AML external indicator output (option)

Output for high-speed hoist down

Working condition input

13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

W301-0212E

TR1 TR2 TR3 TR4 TR5 TR6 TR7 TR8 NC Di25 Di26 Di27 Di28 NC NC (CNTL5P) (CNTL5N) (CNTL6P) (CNTL6N) CNTLSLD Di21 Di22 Di23 Di24

Pressure sensor analog detector power supply

IW301-0211E36

Input/Output Signals of the AML (AML-L B) System (GR-120N-1) Input/Output Signals of the AML (AML-L B) System (GR-120N-1) As shown in the “Diagram of the AML (AML-L B) System” on the previous page, the display board, CPU board, analog board, power board, current output board and connector board consist inside the AML. The following lists describe the names and functions of the input/output signals on CN1, CN2 and CN3 cnnectors.

CN1 connector signals and functions are shown below: CN 1 connector

Signal names and functions

Pin No.

Name

1

DET1GND

Signal name: Ground for analog detector 1 Input voltage: DC0V

2

DET1SRC

Signal name: Applied voltage output for analog detector 1 Output voltage: DC4.5V Signal name: Boom length detector input Analog input representing detected boom length.

Input voltage: DC 0 to 4.5 V

3

ANAIN A

Date for reference Input voltage when the boom is fully retracted (5.3 m): 0.45 V (The A/D value converted by Ai check is 203.)

Input voltage when the boom is fully extended (23.8 m): 2.07 V (The digital value converted by Ai check is 944.)

Signal name: Boom angle detector input Analog input representing detected boom angle.

Input voltage: DC 0 to 4.5 V

4

ANAIN B

Date for reference Input voltage when the boom angle is –2.7°: 0.57 V (The A/D value converted by Ai check is 261.)

Input voltage when the boom angle is 82.4°: 3.76 V (The digital value converted by Ai check is 1712.)

5

ANAIN C

Signal name: Swing angle detector 1 input Analog input from the swing angle detector 1 representing detected swing angle.

Input voltage: DC 0 to 4.5 V

6

DET1SLD

Signal name: Shield for analog detector 1 Input voltage: DC0V

7

DET2GND

Signal name: Ground for analog detector 2 Input voltage: DC0V

8

DET2SRC

Signal name: Applied voltage output for analog detector 2 Output voltage: DC4.5V

ANAIN D

Signal name: Swing angle detector 2 input Analog input from the swing angle detector 2 representing detected swing angle.

Input voltage: DC 0 to 4.5 V

9

10

ANAIN E

Signal name: Main hydraulic pressure sensor input Analog input representing detected main hydraulic pressure.

Input voltage: DC 0 to 4.5 V Date for reference Input voltage when the main hydraulic pressure is 0 MPa.: 0.45 V.

14

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GR-120N-1) CN 1 connector Pin No.

11

Name

ANAIN F

Signal names and functions Signal name: Accumulator pressure sensor input Analog input representing detected accumulator pressure.

Input voltage: DC 0 to 4.5 V Date for reference Input voltage when the accumulator pressure is 0 MPa.: 0.45 V.

12

13

DET2SLD

Di1

Signal name: Shield for analog detector 2 Input voltage: DC0V Signal name: Overwinding detection switch input Switch input representing whether overwinding condition exists.

Switch ON (DC0V): The hook currently in use is in normal state.

Switch OFF (DC24V): The hook currently in use is overwinding.

Signal name: 2nd/3rd boom sections full retraction detection switch input Switch input representing whether the 2nd/3rd boom sections are fully retracted.

Switch ON (DC0V): 2nd/3rd boom sections in fully retracted state.

Switch OFF (DC24V): 2nd/3rd boom sections are not fully retracted.

14

Di2

Data for reference If the following (1) or (2) condition exists, the AML assumes that the boom full retraction detector switch is faulty and displays the error message “Error: 0021”.

(1) The boom full retraction detector switch does not detect the fully retracted state when the boom length detector input is 4.9 m or less.

(2) The boom full retraction detector switch detects the fully retracted state when the boom length detector input is 5.7m or more.

Signal name: 4th/5th/top boom sections full retraction detection switch input Switch input representing whether the 4th/5th/top boom sections are fully retracted.

Switch ON (DC0V): 4th/5th/top boom sections in fully retracted state.

Switch OFF (DC24V): 4th/5th/top boom sections are not fully retracted.

15

Di3

16

Di4

17

MB

18

MB

19

RB

20

RB

Data for reference If the following (1) or (2) condition exists, the AML assumes that the boom full retraction detector switch is abnormal and displays the error message “Error: 0018”.

(1) The boom full retraction detector switch does not detect the fully retracted state when the boom length detector input is 12.3 m or less.

(2) The boom full retraction detector switch detects the fully retracted state when the boom length detector input is 13.1 m or more.

Signal name: Jib lock pin detection switch input Switch input representing whether the jib is stowed.

Switch ON (DC0V): The jib is in stowed condition.

Switch OFF (DC24V): The jib is out of stowed condition.

Signal name: DC power supply from battery for circuit Input voltage: DC24V Signal name: DC power supply from battery for relay Input voltage: DC24V

15

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GR-120N-1) CN 1 connector Pin No.

Name

Signal names and functions

ACC

Signal name: Swing stop/override switch input Switch input representing whether the swing stop is cancelled.

Input voltage: DC24V Switch ON (DC24V): Swing stop is cancelled.

Switch OFF (DC0V): Swing stop is functioning.

Di5

Signal name: Overwind cutout disable switch input Switch input representing whether automatic stop caused by overwinding is overridden.

Switch ON (DC0V): Automatic stop caused by overwinding is cancelled and the alarm buzzer does not sound.

Switch OFF (DC24V): Overwind cutout function is ready.

Di6

Signal name: AML emergency switch input Switch input representing whether automatic stop caused by overloading is overridden.

Switch ON (DC0V): Automatic stop caused by overloading is cancelled.

Switch OFF (DC24V): Automatic stop function is ready.

Di7

Signal name: Elevation slow stop/override switch input Switch input representing whether elevation slow stop is cancelled.

Switch ON (DC0V): Slow stop function is cancelled.

Switch OFF (DC24V): Slow stop function is ready.

Di8

Signal name: Jib set pin inserted condition detector switch input Switch input representing whether the jib set pin is inserted.

Switch ON (DC0V): The jib set pin is in inserted condition.

Switch OFF (DC24V): The jib set pin is out of inserted condition.

Di9

Signal name: Over-front detection switch input Switch input representing whether the boom is in the over-front area.

Switch ON (DC0V): The boom is in the over-front area.

Switch OFF (DC5V): The boom is out of the over-front area.

29

Di10

Signal name: Swing angle detector 1,2 selection (swing dead angle detection) switch input Switch input representing whether the boom is in the over-left area.

Switch ON (DC0V): The boom is in the over-left.

Switch OFF (DC5V): The boom is in the over-right.

30

GND

31

GND

32

MOGND/ DET3GND

Signal name: Ground for pressure sensor (moment detection) Input voltage: DC0V

33

MOSRC/ DET3SRC

Signal name: Applied voltage output for pressure sensor (moment detection) Output voltage: DC5V

22

24

25

26

27

28

34

MOINP/ ANAING

Signal name: Electric ground Output voltage: DC0V

Signal name: Input for pressure sensor for moment detection (extension side) Analog input to detect the elevating cylinder extension pressure.

Input voltage: DC 0 to 5 V

16

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GR-120N-1) CN 1 connector

Signal names and functions

Pin No.

Name

35

MOINN/ ANAINH

Signal name: Input for pressure sensor for moment detection (retraction side) Analog input to detect the elevating cylinder retraction pressure.

Input voltage: DC 0 to 5 V

36

MOSLD/ DET3SLD

Signal name: Shield for pressure sensor (moment detection) Input voltage: DC0V

39

SIF1GND

Signal name: Ground for serial port 1 Input voltage: DC0V

40

SIF1SRC

Signal name: Power supply for serial port 1 Output voltage: DC24V

43

SIF1RXD+

Signal name: Receiving (+) input signal for serial port 1

44

SIF1RXD-

Signal name: Receiving (-) input signal for serial port 1

The received data from the transmitter on the boom head (*1)

(*1): Received signal name Jib angle 45

SIF1SLD

Signal name: Shield for serial port 1 Input voltage: DC0V

CN2 connector signals and functions are shown below: CN 2 connector Pin No.

Signal names and functions

Name

Signal name: Automatic stop relay output This relay contact turns OFF and stops crane operation when the crane is overloaded, the hook is overwound or the AML main unit is out of order.

When the boom elevation stops, the slow stop function activates simultaneously. (The current controlled by the AML is output from the boom raising proportional valve output CNTL3P or the boom lowering proportional valve input CNTL4P to activate the slow stop function.)

However, the slow stop function is not activated when the elevation slow stop/override switch is set to “OVERRIDE”.

Relay ON (DC24V): Normal operation is available.

Relay OFF (DC0V): The crane operation is stopped.

1

RLY 1

When the AML emergency switch is set to “Emergency” and the PTO switch is set to “OVERRIDE”, this relay output is shifted from OFF to ON and the AML automatic stop function is cancelled. The overwind cutout function is also cancelled by the diode circuit.

Relay output

Crane condition Moment ratio < 90% 90%

Moment ratio < 100%

ON

17

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GR-120N-1) CN 2 connector Pin No.

Signal names and functions

Name Relay output

Crane condition Moment ratio 100% The crane operation toward the critical side (main winch hoist-up, auxiliary winch hoist-up, boom extension, boom lowering or jib tilt lowering (*1)) is stopped. (*1): Only for machines with power-tilt jib While the boom lift with the jib mounted is performed, the relay output turns OFF when the moment ratio becomes as follows: Moment ratio 90 % While the jib set pin is out of the inserted condition, the AML assumes that the jib is mounted.

OFF

When the hook block is overwound: The crane operation toward the critical side (main winch hoist-up, auxiliary winch hoist-up, boom extension, boom lowering or jib tilt lowering (*1)) is stopped. (*1): Only for machines with power-tilt jib When the overwind cutout disable switch is pressed in this state, the relay output is shifted from OFF to ON and the overwind cutout function is cancelled.

The crane operations except boom swing exceed the limit while the working range limit is registered.

Crane operations beyond the limit are stopped.

1

Failure in the AML unit.

All the crane operations except the boom swing are stopped.

RLY 1 Relay output

OFF

Other control functions When the moment is abnormal When the actual load value calculated in the AML becomes negative, the crane operation toward the critical side (main winch hoist-up, auxiliary winch hoist-up, boom extension, boom lowering or jib tilt lowering (*1)) is stopped. However, the operation does not stop while the boom is being stowed to the traveling configuration.

When all the following conditions are satisfied, the AML assumes that the boom is in process of the stowage to the traveling configuration.

(1) Boom angle is 2°or less. (*2) (2) Boom length is 5.4 m or less.

(3) The swing position is within 10° in over-front area. (*1): For machines with power-tilt jib only (*2): For machines up to FD0126, the boom angle is –1.7° or less

18

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GR-120N-1) CN 2 connector Pin No.

Signal names and functions

Name Relay output

Other control functions When the HOOK-IN operation is performed: When the following conditions are satisfied, this relay output turns OFF and the HOOK-IN control relay output RLY8 turns ON. (1) PTO switch is ON (I).

(2) Boom lift or single top lift status is registered in the AML. (3) Boom is fully retracted. (*1) (4) Boom angle is 2°or less.

(5) Overwind cutout disable switch is pressed. (*1): When the 2nd/3rd boom section full retraction detector switch contact is closed, the AML assumes that the boom is fully retracted.

1

RLY 1

OFF

When the boom reaches its elevation stroke end: When the boom is out of the boom angle range (–1.7° to 81.9°) where the pressure of the elevation cylinder on the extension and retraction side can be detected normally, the boom elevation stops. However, the operation does not stop while the boom is being stowed to the traveling configuration.

When all the following conditions are satisfied, the AML assumes that the boom is in process of the stowage to the traveling configuration.

(1) Boom angle is –1.7°or less.

(2) Boom length is 5.4 m or less.

(3) The swing position is within 10° in over-front area.

If the pressure on the extension and retraction sides of the elevation cylinder cannot be normally detected and the moment ratio becomes 100% or more while the boom angle is between 81.9° and 83°, the automatic stop halting (boom lowering operation) due to overloading is cancelled.

Jib fall prevention while the jib is being mounted or stowed When all the following conditions are satisfied, the boom extension stops.

Jib (jib lock pin) is stowed; jib set pin is out of inserted condition; the boom angle is 75° or less.

Upper boom angle restriction while the jib is being mounted or stowed The boom angle becomes 78° while the jib is mounted or stowed, the boom raising operation stops.

When the jib tension rod buckling prevention activates (*1) While the jib set pin is inserted into the boom bottom surface, i.e. the jib is stowed, the jib tilt cylinder is not retracted even if jib tilt lowering is attempted. (*1): Only for machines with power-tilt jib

19

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GR-120N-1) CN 2 connector Pin No.

3

Signal names and functions

Name

RLY 3

Signal name: Accumulator low pressure alarm relay output This relay contact turns ON and outputs alarm buzzer when the accumulator pressure is approx. 8.8 MPa (90 kgf/cm2) or less.

Relay ON (DC24V): Alarm buzzer is output.

Relay OFF (DC0V): Alarm buzzer is not output.

Signal name: AML alarm relay output This relay contact turns ON and outputs alarm buzzer when the crane is overloaded.

Relay ON (DC24V): Alarm buzzer is output.

Relay OFF (DC0V): Alarm buzzer is not output.

Relay output OFF

Moment condition Moment ratio < 90% 90％

4

RLY 4

ON/OFF

Moment ratio < 100%

While the boom lift with the jib mounted is performed, the relay output turns ON/OFF when the moment ratio reaches the range below.

80% Moment ratio < 90% When the jib set pin is out of inserted condition, the AML assumes that the jib is mounted.

Moment ratio

ON

5

RLY 5

100%

While the boom lift with the jib mounted is performed, the relay output turns ON when the moment ratio reaches the range below.

90% Moment ratio When the jib set pin is out of inserted condition, the AML assumes that the jib is mounted.

Signal name: Telescoping control relay output When the boom length is extended or retracted beyond the specified length (12.5 m), this relay contact turns ON/OFF and the 4th/5th/top boom sections or 2nd/3rd boom sections extend or retract.

Relay ON (DC24V): 4th, 5th and top boom sections extend or retract.

Relay OFF (DC0V): 2nd and 3rd boom sections extend or retract.

Signal name: Overwinding alarm relay output This relay contact turns ON and the alarm buzzer is output when the hook block is overwinding.

Relay ON (DC24V): Alarm buzzer is output.

Relay OFF (DC0V): Alarm buzzer is not output.

7

RLY 7

20

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GR-120N-1) CN 2 connector Pin No.

8

Name

RLY 8

Signal names and functions Signal name: HOOK-IN control relay output When the HOOK-IN operation is performed, this relay contact turns ON, automatic stop 1 (AML vent) relay output RLY1 turns OFF, and the pressure in the winch hydraulic circuit drops.

Relay ON (DC24V): The pressure in the winch hydraulic circuit drops.

Relay OFF (DC0V): The pressure in the winch hydraulic circuit is normal.

When all the following conditions are satisfied, the AML assumes that the HOOK-IN operation is performed.

(1) PTO switch is ON (I).

(2) Boom lift or single top lift status is registered in the AML. (3) Boom is fully retracted. (*1) (4) Boom angle is 2° or less.

(5) Overwind cutout disable switch is pressed. (*1): When the 2nd/3rd boom section full retraction detection switch contact is closed, the AML assumes that the boom is fully retracted.

9

10

11

Di11

Signal name: Main winch hoist-up operation detector switch input Input from the switch detecting hoist-up operation of the main winch.

Switch ON (DC0V): No hoist-up operation of the main winch is detected.

Switch OFF (DC5V): Hoist-up operation of the main winch is detected.

Di12

Signal name: Main winch hoist-down operation detector switch input Input from the switch detecting hoist-down operation of the main winch.

Switch ON (DC0V): No hoist-down operation of the main winch is detected.

Switch OFF (DC5V): Hoist-down operation of the main winch is detected.

Di13

Signal name: Aux. winch hoist-up operation detector switch input Input from the switch detecting hoist-up operation of the auxiliary winch.

Switch ON (DC0V): No hoist-up operation of the auxiliary winch is detected.

Switch OFF (DC5V): Hoist-up operation of the auxiliary winch is detected.

Signal name: Aux. winch hoist-down operation detector switch input Input from the switch detecting hoist-down operation of the auxiliary winch.

Switch ON (DC0V): No hoist-down operation of the auxiliary winch is detected.

Switch OFF (DC5V): Hoist-down operation of the auxiliary winch is detected.

12

Di14

21

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GR-120N-1) CN 2 connector Pin No.

13

Name

CNTL 1P

Signal names and functions Signal name: Right swing proportional control valve output Current controlled by the AML is output from the AML to the right swing proportional control valve when the right swing is stopped by automatic swing stop. However, in the following conditions, the automatic swing stop does not activate.

(1) Swing stop/override switch is set to “OVERRIDE”.

(2) Outriggers are not extended.

(3) AML emergency switch is set to “Emergency” and the PTO switch is set to “OVERRIDE”.

Output voltage: Square wave 0 to 24V Crane condition that causes the automatic swing stop The moment ratio exceeds 100% due to right swing while the extension widths of four outriggers are different.

The moment ratio reaches 90% or more (not 100%) while the boom lift with the jib mounted is performed.

When the jib set pin is out of inserted condition, the AML assumes that the jib is mounted.

The crane operation exceeds the right swing limit when the swing stop limit is registered.

14

15

CNTL 1N

CNTL 2P

Signal name: Ground terminal for right swing proportional control valve Input voltage: DC0V Signal name: Left swing proportional control valve output Current controlled by the AML is output from the AML to the left swing proportional control valve when the left swing is stopped by automatic swing stop. However, in the following conditions, the automatic swing stop is not activated.

(1) Swing stop/override switch is set to “OVERRIDE”.

(2) Outriggers are not extended.

(3) AML emergency switch is set to “Emergency” and the PTO switch is set to “OVERRIDE”.

Output voltage: Square wave 0 to 24V Crane condition that causes the automatic swing stop The moment ratio exceeds 100% due to left swing while the extension widths of four outriggers are different.

The moment ratio reaches 90% or more (not 100%) while the boom lift with the jib mounted is performed.

When the jib set pin is out of inserted condition, the AML assumes that the jib is mounted.

The crane operation exceeds the left swing limit when the swing stop limit is registered.

Signal name: Ground terminal for left swing proportional control valve Input voltage: DC0V

16

CNTL 2N

22

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GR-120N-1) CN 2 connector Pin No.

17

18

19

20

21

22

23

Name

Signal names and functions

Di15

Signal name: Boom extending/jib tilt lowering (*1) operation detector switch input Input from the switch detecting boom extending/jib tilt lowering operation.

Switch ON (DC0V): No boom extending/jib tilt lowering operation is detected.

Switch OFF (DC5V): Boom extending/jib tilt lowering operation is detected. (*1): Only for machines with power-tilt jib

Di16

Signal name: Boom retracting/jib tilt raising (*1) operation detector switch input Input from the switch detecting boom retracting/jib tilt raising operation.

Switch ON (DC0V): No boom retracting /jib tilt raising operation is detected.

Switch OFF (DC5V): Boom retracting /jib tilt raising operation is detected. (*1): Only for machines with power-tilt jib

Di17

Signal name: Boom raising operation detector switch input Input from the switch detecting boom raising operation.

Switch ON (DC0V): No boom raising operation is detected.

Switch OFF (DC5V): Boom raising operation is detected.

Di18

Signal name: Boom lowering operation detector switch input Input from the switch detecting boom lowering operation.

Switch ON (DC0V): No boom lowering operation is detected.

Switch OFF (DC5V): Boom lowering operation is detected.

Di19

Signal name: Right swing operation detector switch input Input from the switch detecting right swing operation.

Switch ON (DC0V): No right swing operation is detected.

Switch OFF (DC5V): Right swing operation is detected.

Di20

Signal name: Left swing operation detector switch input Input from the switch detecting left swing operation.

Switch ON (DC0V): No left swing operation is detected.

Switch OFF (DC5V): Left swing operation is detected.

CNTL 3P

Signal name: Boom raising proportional control valve output Current controlled by the AML is output from the AML to the boom raising proportional control valve when the boom raising is stopped by elevation slow stop. However, when the elevation slow stop/override switch is set to “OVERRIDE”, the elevation slow stop is not activated.

Output voltage: Square wave 0 to 24V For the crane conditions that cause the elevation slow stop, refer to the automatic stop 1 (AML vent) relay output RLY1.

24

25

CNTL 3N

CNTL 4P

Signal name: Ground terminal for boom raising proportional control valve Input voltage: DC0V Signal name: Boom lowering proportional control valve output Current controlled by the AML is output from the AML to the boom lowering proportional control valve when the boom lowering is stopped by elevation slow stop. However, when the elevation slow stop/override switch is set to “OVERRIDE”, the elevation slow stop is not activated.

Output voltage: Square wave 0 to 24V For the crane conditions that cause the elevation slow stop, refer to the automatic stop 1 (AML vent) relay output RLY1.

23

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GR-120N-1) CN 2 connector

Signal names and functions

Pin No.

Name

26

CNTL 4N

Signal name: Ground terminal for boom lowering proportional control valve Input voltage: DC0V

30

SIF2TXD+

Signal name: Transmitting (+) output signal for serial port 2

SIF2TXD-

Signal name: Transmitting (-) output signal for serial port 2

31

Transmitting data to MDT

(*1)

(*1): Transmitting signal name Do1 AML override (AML warning indicator lamp) Do2 Jib lock indicator 1 (Jib lock lamp) Do3 HOOK-IN (HOOK IN indicator lamp) Do4 Fixed jib (boom extension indicator lamp/jib tilt indicator lamp) Do6 Outrigger stowing control detection return transmitting Do7 Jib lock indicator 2 (Jib lock lamp) 32 33

SIF2RXD+ SIF2RXD-

Signal name: Receiving (+) input signal for serial port 2 Signal name: Receiving (-) input signal for serial port 2

Receiving data from MDT

(*2)

(*2): Received signal name ANIN2 O/R(FL) (*3) ANIN3 O/R(FR) (*3) ANIN4 O/R(RL) (*3) ANIN5 O/R(RR) (*3) Di1 Outrigger retracting control detection (Monitoring signal for relay output RY6 of the MDT lower unit) (*3): Data for reference X-type outriggers Input voltage at the minimum outrigger extension width: 0.82 V (The A/D value converted by Ai check is 337.)

Input voltage at the maximum outrigger extension width: 3.22 V (The A/D value converted by Ai check is 1317.)

H-type outriggers Input voltage at the minimum outrigger extension width: 0.89 V (The A/D value converted by Ai check is 336.)

Input voltage at the maximum outrigger extension width: 3.11 V (The A/D value converted by Ai check is 1274.)

34

SIF2SLD

Signal name: Shield for serial port 2 Input voltage: DC0V

24

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Input/Output Signals of the AML (AML-L B) System (GR-120N-1) CN3 connector signals and functions are shown below: CN 3 connector Pin No.

1

Signal names and functions

Name

TR1

Signal name: AML 90% or less (safety) output OC (Open collector) output turns ON when the moment ratio is less than 90%.

OC output “ON” (DC0V): External indicator lamp indicating 90% is lit.

OC output “OFF” (DC24V): External indicator lamp indicating 90% goes out.

While the boom lift with the jib mounted is performed, OC output turns ON when the moment ratio is 80% or less.

When the jib set pin is out of inserted condition, the AML assumes that the jib is mounted.

2

TR2

Signal name: AML 90% alarm output OC (Open collector) output turns ON when the moment ratio is between 90% and 100%.

OC output “ON” (DC0V): External indicator lamp indicating 90% is lit.

OC output “OFF” (DC24V): External indicator lamp indicating 90% goes out.

While the boom lift with the jib mounted is performed, OC output turns ON when the moment ratio reaches the range below: 80% Moment ratio < 90% When the jib set pin is out of inserted condition, the AML assumes that the jib is mounted.

Signal name: AML 100% alarm output OC (Open collector) output turns ON when the moment ratio exceeds 100% or automatic stop function is cancelled.

OC output “ON” (DC0V): External indicator lamp indicating 100% is lit.

OC output “OFF” (DC24V): External indicator lamp indicating 100% goes out.

Condition to turn ON OC output Moment ratio

3

TR3

100%

While the boom lift with the jib mounted is performed, OC output turns ON when the moment ratio reaches the range below: Moment ratio 90% When the jib set pin is out of inserted condition, the AML assumes that the jib is mounted.

Overwind cutout disable switch: Pressed Swing stop/override switch: “OVERRIDE” AML emergency switch: “Emergency” + PTO switch: “OVERRIDE”

4

TR4

Signal name: Auxiliary winch high-speed hoist-down operation output OC (Open collector) output turns ON when the auxiliary winch hoist-down operation is detected with the actual load less than the specified value (200kg).

High-speed hoist-down operation is performed when the auxiliary winch high-speed down hoisting switch is set to ON. OC output ON (DC0V): High-speed hoist-down operation is performed.

OC output OFF (DC24V): Normal hoist-down operation is performed.

25

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GR-120N-1) CN 3 connector Pin No.

5

21

Name

Signal names and functions

TR5

Signal name: Main winch high-speed hoist-down operation output OC (Open collector) output turns ON when the main winch hoist-down operation is detected with the actual load less than the specified value (300kg).

High-speed hoist-down operation is performed when the main winch high-speed down hoisting switch is set to ON. OC output ON (DC0V): High-speed hoist-down operation is performed.

OC output OFF (DC24V): Normal hoist-down operation is performed.

Di21

Signal name: Boom telescoping/jib operation selector switch input Switch input representing whether the jib operation is detected.

Switch ON (DC0V): Jib operation is selected.

Switch OFF (DC5V): Boom telescoping condition is selected.

26

W301-0212E

Diagram of the AML (AML-L B) System (GR-700EXL-1) Diagram of the AML (AML-L B) System (GR-700EXL-1) Boom angle detector

CONNECTOR BOARD A C B D E

Boom length detector

Pressure sensor (Main)

Swing free input Auto. stop override signal input

Working condition input

Auto. stop override signal input

24(V)

Pressure sensor for moment detection (Elevating)

Auto.stop signal output SOL.

BUZZER Top cyl. select output SOL. Lever manipulation detection input Slow stop(Swing)

Outrigger extension width detector (4 peace)

Slow stop(Elevating)

MDT (multiplex data transmitter) lower unit

Outrigger retraction operation detection input

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

DET1GND DET1SRC ANAINA ANAINB ANAINC DET1SLD DET2GND DET2SRC ANAIND ANAINE ANAINF DET2SLD Di1 Di2 Di3 Di4 MB MB RB RB TC ACC NC Di5 Di6 Di7 Di8 Di9 Di10 GND GND DET3GND DET3SRC ANAING ANAINH DET3SLD NC NC SIF1GND SIF1SRC SIF1TXD+ SIF1TXDSIF1RXD+ SIF1RXDSIF1SLD

Latch

Fuses

Di SW. input block

SOL1, 2 (2A) SOL3, 4 (2A)

Fuses

Current Amplifier Circuit

SOL5, 6 (2A)

CPU BOARD

SIF 1 (2A)

SIF 2 (2A) MAIN (3A)

POWER BOARD

EEPROM

Buzzer

RAM

CAL/CLOCK

SCI

CPU

Fuses RLY1, 2 (3A) RLY3, 4 (3A)

Relay

+20V

DC power block

-12V +5V

RLY5, 6 (3A) RLY7, 8 (3A)

Key input

+12V

LCD panel (1)

Serial input/output circuit LCD panel (2)

LCD SW . backlights

Latch RLY1 RLY2 RLY3 RLY4 RLY5 RLY6 RLY7 RLY8 Di11 Di12 Di13 Di14 CNTL1P CNTL1N CNTL2P CNTL2N Di15 Di16 Di17 Di18 Di19 Di20 CNTL3P CNTL3N CNTL4P CNTL4N CNTLSLD SIF2GND SIF2SRC SIF2TXD+ SIF2TXDSIF2RXD+ SIF2RXDSIF2SLD

DISPLAY BOARD CHR display

CN2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

ROM

O.C.Tr. output block

Latch

ANALOG BOARD

Di SW. input block

Latch

Buffer

Buffer

Analog multiplexer

A/D converter

CN3

MDT (multiplex data transmitter) upper unit Jib set output

90 - 100% 100% -

AML external indicator output (option)

Indicator lamp

Slow stop (Swing free)

Working condition input

SOL5, 6 (2A) SOL1, 2 (2A) SOL3, 4 (2A)

CN1

Swing angle detector

Alarm signal output

CURRENT OUTPUT BOARD

Counterweight equipped detection input

Over - unwind detection input

27

W301-0212E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

TR1 TR2 TR3 TR4 TR5 TR6 TR7 TR8 NC Di25 Di26 Di27 Di28 NC NC (CNTL5P) (CNTL5N) (CNTL6P) (CNTL6N) CNTLSLD Di21 Di22 Di23 Di24

Pressure sensor analog detector power supply

IW301-0212E01

Input/Output Signals of the AML (AML-L B) System (GR-700EXL-1) Input/Output Signals of the AML (AML-L B) System (GR-700EXL-1) As shown in the “Diagram of the AML (AML-L B) System” on the previous page, the display board, CPU board, analog board, power board, current output board and connector board consist inside the AML. The following lists describe the names and functions of the input/output signals on CN1, CN2 and CN3 cnnectors.

CN1 connector signals and functions are shown below: CN 1 connector Pin No. 3

4

5

9

10

13

14

15

16

Name

Signal names and functions

ANAIN A

Signal name: Boom length detector input Analog input representing detected boom length.

Input voltage: DC 0 to 4.5 V

ANAIN B

Signal name: Boom angle detector input Analog input representing detected boom angle.

Input voltage: DC 0 to 4.5 V

ANAIN C

Signal name: Swing angle detector 1 input Analog input from the swing angle detector 1 representing detected swing angle.

Input voltage: DC 0 to 4.5 V

ANAIN D

Signal name: Swing angle detector 2 input Analog input from the swing angle detector 2 representing detected swing angle.

Input voltage: DC 0 to 4.5 V

ANAIN E

Signal name: Main hydraulic pressure sensor input Analog input representing detected main hydraulic pressure.

Input voltage: DC 0 to 4.5 V

Di1

Signal name: Overwinding detection switch (L4) input Switch input representing whether overwinding condition exists.

Switch ON (DC0V): The hook currently in use is in normal state.

Switch OFF (DC24V): The hook currently in use is overwinding.

Di2

Signal name: 2nd boom section full retraction detection switch (L8) input Switch input representing whether the 2nd boom section is fully retracted.

Switch ON (DC0V): 2nd boom section is fully retracted.

Switch OFF (DC24V): 2nd boom section is not fully retracted.

Di3

Signal name: 3rd/top boom sections full retraction detection switch (L7) input Switch input representing whether the 3rd/top boom sections are fully retracted.

Switch ON (DC0V): 3rd/top boom sections are fully retracted.

Switch OFF (DC24V): 3rd/top boom sections are not fully retracted.

Di4

Signal name: Swing free/lock selector swith (S15) input Switch input representing whether the swing is free/lock state.

Switch ON (DC0V): Swing lock device is free.

Switch OFF (DC24V): Swing lock device is lock.

28

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Input/Output Signals of the AML (AML-L B) System (GR-700EXL-1) CN 1 connector Pin No.

Name

Signal names and functions

ACC

Signal name: Swing stop cancel switch (S14) input Switch input representing whether the swing stop is cancelled.

Input voltage: DC24V Switch ON (DC24V): Swing stop is cancelled.

Switch OFF (DC0V): Swing stop is functioning.

Di5

Signal name: Overwind cutput disable switch (S3) input Switch input representing whether automatic stop caused by overwinding is overridden.

Switch ON (DC0V): Automatic stop caused by overwinding is cancelled and the alarm buzzer does not sound.

Switch OFF (DC24V): Overwind cutout function is ready.

Di6

Signal name: Override key switch (SK1) input Switch input representing whether automatic stop caused by overloading is overridden.

Switch ON (DC0V): Automatic stop caused by overloading is cancelled.

Switch OFF (DC24V): Automatic stop function is ready.

Di7

Signal name: Elevation slow stop cancel switch (S22) input Switch input representing whether elevation slow stop is cancelled.

Switch ON (DC0V): Slow stop function is cancelled.

Switch OFF (DC24V): Slow stop function is ready.

Di8

Signal name: Jib stowed detection switch (CS10) input Switch input representing whether the jib is stowed.

Switch ON (DC0V): The jib is stowed.

Switch OFF (DC24V): The jib is not stowed.

Di9

Signal name: Over-front detection switch (CS12) input Switch input representing whether the boom is in the over-front area.

Switch ON (DC0V): The boom is in the over-front area.

Switch OFF (DC5V): The boom is out of the over-front area.

29

Di10

Signal name: Swing angle detector 1,2 selection (swing dead angle detection) switch (CS11) input Switch input representing whether the boom is in the swing dead angle.

Switch ON (DC0V): The boom is in the over-left.

Switch OFF (DC5V): The boom is in the over-right.

34

ANAING

Signal name: Input for pressure sensor for moment detection (extension side) Analog input to detect the elevating cylinder extension pressure.

Input voltage: DC 0 to 5 V

ANAINH

Signal name: Input for pressure sensor for moment detection (retraction side) Analog input to detect the elevating cylinder retraction pressure.

Input voltage: DC 0 to 5 V

22

24

25

26

27

28

35

29

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Input/Output Signals of the AML (AML-L B) System (GR-700EXL-1) CN2 connector signals and functions are shown below: CN 2 connector Pin No.

Signal names and functions

name

Signal name: Automatic stop relay output This relay contact turns OFF and stops crane operation when the crane is overloaded, the hook is overwound or the AML main unit is out of order.

Relay ON (DC24V): Normal operation is available.

Relay OFF (DC0V): The crane operation is stopped.

Relay output

Crane condition

ON

Moment ratio < 90%

ON

90%

Moment ratio < 100%

Moment ratio 1

RLY 1 OFF

100%

While boom lift with the jib mounted is performed, the crane operation stops autmatically when the load moment ratio reaches the ranges listed below, depending on the outrigger extension width.

Maximum (7.2m)

Moment ratio

93%

Middle (6.7m)

Moment ratio

92%

Middle (5.5m)

Moment ratio

91%

OFF

Overwinding.

OFF

The crane movement going beyond the restriction while working range limit is registered.

OFF

Failure in the AML unit.

OFF

Operated to critical side when backward stability control activated.

Signal name: AML alarm relay output This relay contact turns ON and outputs alarm buzzer when the crane is overloaded.

Relay ON (DC24V): Alarm buzzer is output.

Relay OFF (DC0V): Alarm buzzer is not output.

Relay output OFF

Moment condition Moment ratio < 90% 90%

4

RLY 4

ON/OFF

Moment ratio < 100%

While boom lift with the jib mounted is performed, the alarm buzzer is output when the load moment ratio reaches the ranges listed below, depending on the outrigger extension width.

Maximum (7.2m)

84%

Moment ratio < 94%

Middle (6.7m)

84%

Moment ratio < 94%

Middle (5.5m)

82%

Moment ratio < 92%

Moment ratio

ON

100%

While boom lift with the jib mounted is performed, the alarm buzzer is output when the load moment ratio reaches the ranges listed below, depending on the outrigger extension width.

Maximum (7.2m)

Moment ratio

94%

Middle (6.7m)

Moment ratio

94%

Middle (5.5m)

Moment ratio

92%

30

W301-0212E

Input/Output Signals of the AML (AML-L B) System (GR-700EXL-1) CN 2 connector Pin No.

5

7

9

11

13

name

Signal names and functions

RLY 5

Signal name: Telescoping control relay output When the boom length is extended or retracted beyond the specified length, this relay contact turns ON/OFF and the 3rd /top boom sections or 2nd boom section extend or retract.

Relay ON (DC24V): 3rd top boom sections extend or retract.

Relay OFF (DC0V): 2nd boom section extend or retract.

RLY 7

Signal name: Overwinding alarm relay output This relay contact turns ON and the alarm buzzer is output when the hook block is overwinding.

Relay ON (DC24V): Alarm buzzer is output.

Relay OFF (DC0V): Alarm buzzer is not output.

Di11

Signal name: Main winch hoist-up operation detector switch input Input from the switch detecting hoist-up operation of the main winch.

Switch ON (DC0V): No hoist-up operation of the main winch is detected.

Switch OFF (DC5V): Hoist-up operation of the main winch is detected.

Di13

Signal name: Aux. winch hoist-up operation detector switch input Input from the switch detecting hoist-up operation of the auxiliary winch.

Switch ON (DC0V): No hoist-up operation of the auxiliary winch is detected.

Switch OFF (DC5V): Hoist-up operation of the auxiliary winch is detected.

CNTL 1P

Signal name: Right swing proportional control valve output Current controlled by the AML is output from the AML to the right swing proportional control valve when the right swing is stopped by automatic swing stop. However, in the following conditions, the automatic swing stop does not activate.

(1) Swing stop/override switch is set to “OVERRIDE”.

(2) Outriggers are not extended.

(3) AML emergency switch is set to “Emergency” and the PTO switch is set to “OVERRIDE”.

Output voltage: Square wave 0 to 24V Crane condition that causes the automatic swing stop The moment ratio exceeds 100% due to right swing while the extension widths of four outriggers are different.

The moment ratio reaches 90% or more (not 100%) while the boom lift with the jib mounted is performed.

When the jib set pin is out of inserted condition, the AML assumes that the jib is mounted.

The crane operation exceeds the right swing limit when the swing stop limit is registered.

14

CNTL 1N

Signal name: Ground terminal for right swing proportional control valve Input voltage: DC0V

31

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Input/Output Signals of the AML (AML-L B) System (GR-700EXL-1) CN 2 connector Pin No.

15

name

CNTL 2P

Signal names and functions Signal name: Left swing proportional control valve output Current controlled by the AML is output from the AML to the left swing proportional control valve when the left swing is stopped by automatic swing stop. However, in the following conditions, the automatic swing stop is not activated.

(1) Swing stop/override switch is set to “OVERRIDE”.

(2) Outriggers are not extended.

(3) AML emergency switch is set to “Emergency” and the PTO switch is set to “OVERRIDE”.

Output voltage: Square wave 0 to 24V Crane condition that causes the automatic swing stop The moment ratio exceeds 100% due to left swing while the extension widths of four outriggers are different.

The moment ratio reaches 90% or more (not 100%) while the boom lift with the jib mounted is performed.

When the jib set pin is out of inserted condition, the AML assumes that the jib is mounted.

The crane operation exceeds the left swing limit when the swing stop limit is registered.

16

17

18

19

20

21

22

CNTL 2N

Signal name: Ground terminal for left swing proportional control valve Input voltage: DC0V

Di15

Signal name: Boom extending operation detector switch (PS3) input Input from the switch detecting boom extending operation.

Switch ON (DC0V): No boom extending operation is detected.

Switch OFF (DC5V): Boom extending operation is detected.

Di16

Signal name: Winch selector switch (S32) input Switch input representing whether Auxiliary wiche is employed.

Input from the switch detecting boom retracting operation.

Switch ON (DC0V): Auxiliary winch is employed.

Switch OFF (DC5V): Main winch is employed.

Di17

Signal name: Boom raising operation detector switch (PS5) input Input from the switch detecting boom raising operation.

Switch ON (DC0V): No boom raising operation is detected.

Switch OFF (DC5V): Boom raising operation is detected.

Di18

Signal name: Boom lowering operation detector switch (PS6) input Input from the switch detecting boom lowering operation.

Switch ON (DC0V): No boom lowering operation is detected.

Switch OFF (DC5V): Boom lowering operation is detected.

Di19

Signal name: Right swing operation detector switch (PS9) input Input from the switch detecting right swing operation.

Switch ON (DC0V): No right swing operation is detected.

Switch OFF (DC5V): Right swing operation is detected.

Di20

Signal name: Left swing operation detector switch (PS10) input Input from the switch detecting left swing operation.

Switch ON (DC0V): No left swing operation is detected.

Switch OFF (DC5V): Left swing operation is detected.

32

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Input/Output Signals of the AML (AML-L B) System (GR-700EXL-1) CN 2 connector Pin No.

Signal names and functions

name

23

CNTL 3P

Signal name: Boom raising proportional control valve output Current controlled by the AML is output from the AML to the boom raising proportional control valve when the boom raising is stopped by elevation slow stop.

Output voltage: Square wave 0 to 24V

24

CNTL 3N

Signal name: Ground terminal for boom raising proportional control valve Input voltage: DC0V

25

CNTL 4P

Signal name: Boom lowering proportional control valve output Current controlled by the AML is output from the AML to the boom lowering proportional control valve when the boom lowering is stopped by elevation slow stop.

Output voltage: Square wave 0 to 24V

26

CNTL 4N

Signal name: Ground terminal for boom lowering proportional control valve Input voltage: DC0V

CN3 connector signals and functions are shown below: CN 3 connector Pin No.

Signal names and functions

Name

Signal name: AML 90% alarm output OC (Open collector) output turns ON when the Load moment ratio is between 90% and 100%.

OC output “ON” (DC0V): External indicator lamp indicating 90% is lit.

OC output “OFF” (DC24V): External indicator lamp indicating 90% goes out.

2

TR2

While boom lift with the jib mounted is performed, OC output turns ON when the load moment ratio reaches the ranges listed below, depending on the outrigger extension width.

Maximum (7.2m)

84%

Moment ratio < 94%

Middle (6.7m)

84%

Moment ratio < 94%

Middle (5.5m)

82%

Moment ratio < 92%

Signal name: AML 100% alarm output OC (Open collector) output turns ON when the load moment ratio exceeds 100% or automatic stop function is cancelled.

OC output “ON” (DC0V): External indicator lamp indicating 100% is lit.

OC output “OFF” (DC24V): External indicator lamp indicating 100% goes out.

Condition to turn ON OC output Moment ratio 3

TR3

100%

Anti-twoblock disable switch: pressed.

Swing stop cancel switch: “OFF”.

Override key switch ON position and PTO switch in OVERRIDE position.

While boom lift with the jib mounted is performed, OC output turns ON when the load moment ratio reaches the ranges listed below, depending on the outrigger extension width.

Maximum (7.2m)

Moment ratio

93%

Middle (6.7m)

Moment ratio

92%

Middle (5.5m)

Moment ratio

91%

33

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Input/Output Signals of the AML (AML-L B) System (GR-700EXL-1) CN 3 connector Pin No.

5

6

10

13

Name

Signal names and functions

TR5

Signal name: Jib set output OC (Open collector) output turns ON when setting to the jib set with the boom state selection key of AML. OC output “ON” (DC0V): The jib set pin can be pulled out.

OC output “OFF” (DC24V): The jib set pin cannot be pulled out.

TR6

Signal name: Auxiliary winch employed output OC (Open collector) output turns ON when the the auxiliary winch employed is selected The winch selection indicator lamp is lit when the winch selection switch is set to the auxiliary winch side.

OC output “ON” (DC0V): The winch selection indicator lamp is lit.

OC output “OFF” (DC24V): Normally, the winch selection indicator lamp goes out.

Di25

Signal name: Outrigger state emergency register switch (SK2) input Switch input representing whether emergency registration of outrigger extension width to the AML during malfunction of the outrigger extension detector system is available.

Switch ON (DC0V): Emergency registration of outrigger extension width is available.

Switch OFF (DC5V): No emergency registration is available.

Di28

Signal name: Boom secondary extending switch (S7) input Switch input to extend the 3rd/top boom sections.

Switch ON (DC0V): The boom secondary extending switch is pressed.

Switch OFF (DC5V): The boom secondary extending switch is not pressed.

16

CNTL 5P

Signal name: Swing relief proportional control valve output Current controlled by the AML is output from the AML to the swing relief proportional control valve when boom swing is stopped by swing slow stop while swing free condition is selected.

17

CNTL 5N

Signal name: Ground terminal for swing relief proportional control valve output Input voltage: DC0V

21

22

23

24

Di21

Signal name: Jib state switch (SK4) input Switch input to select the state of jib-mounted or jib-unmounted.

Switch ON (DC0V): Jib-unmounted is selected.

Switch OFF (DC5V): Jib-mounted is selected.

Di22

Signal name: C/W mount detection switch (CS18) input (Only for TR-800XXL-4) Switch input representing whether the C/W is mounted.

Switch ON (DC0V): C/W is mounted.

Switch OFF (DC5V): C/W is not mounted.

Di23

Signal name: Main rope run-out detection switch (LS17) input Switch input representing whether main rope is over-unwind.

Switch ON (DC0V): Main rope is not over-unwind.

Switch OFF (DC5V): Main rope is over-unwind.

Di24

Signal name: Aux. rope run-out detection switch (LS18) input Switch input representing whether Aux. rope is over-unwind.

Switch ON (DC0V): Aux. rope is not over-unwind.

Switch OFF (DC5V): Aux. rope is over-unwind.

34

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Functions of and How to Use User Mode (GT-550E-1) [OPERATION]

2. Maintenance Mode: Used to make functional checks of AML. See the “ADJUSTMENT AND MAINTENANCE” section.

Functions of and How to Use User Mode (GT-550E-1)

3. Adjustment Mode: Used to make detector adjustment. See the “ADJUSTMENT AND MAINTENANCE” section.

Mode Structure The AML device has three modes and AML functions are allotted for these models.

POWER ON

Protect switch ON Protect switch OFF

MAINTENANCE MODE

USER MODE

ADJUSTMENT MODE

POWER ON

IW301-0212E05

1. User Mode: Used to indicate moment ratio or to perform AML pre-opetational inspection (Normally used).

In normal use, turn ON the protect switch mounted on the adjustment window on the top of AML. AML will go to the user mode when the power turns on.

The abnormality display LED lights when the AML

HALT

ZERO

WDT

PROTECT ON

OFF

MOMENT SHORT

is in abnormal conditions (to indicate that the CPU is faulty).

Protect switch Abnormality display LED Top view

IW301-0132E35

35

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Functions of and How to Use User Mode (GT-550E-1) Configuration and Functions of the AML System

(4)Slow stop function

The AML (Automatic Moment Limiter) system is a

In the following cases, the boom elevation spead

safety device provided to prevent overloading of the crane which may cause it to overturn or be damaged.

The AML system has various kinds of functions, including the following four typical functions.

Based on the registered work conditions by operator selection and the signals from various sensors, the crane operations are controlled.

or the swing speed gradually decreases to stop before theboom reaches the stoppage position.

• When the automatic stop si caused by overloading (Boom lowering and swing will stop.)

• When the elevating cylinder reaches its storoke end (Boom raising/lowering will stop.)

• When the automatic stop is caused by working

(1)Automatic stop function for overloading

range limit function (Boom raising/lowering will stop.)

The AML calculates and compares the working and rated moment values and displays them as a percentage. When the working moment exceeds the rated moment (100% or more), failure message is shown, alarm buzzer sounds, and the crane operation toward the critical side stops.

• When the automatic stop is caused by boom upper angle restriction (Boom raising and boom retraction will stop.)

• When the autmatic stop is caused by working range limit function (Swing will stop.)

(2)Automatic stop function by boom upper angle restriction

The situation of automatic stop due to automatic stop function and working range limit function is as listed below, depending on the working condition: : Slow stop : Stop

To prevent jib from contacting the hook block or wire rope during boom lift or single top lift, a message and an alarm is output and boom raising and boom retraction are halted in the following conditions:

Hoisting up Automatic stop by overloading

The boom is raised over approx. 76 dgrees while the boom extension is less than approx. 2 m.

Boom lowering Boom extension Swing

The boom extension is reduced less than approx.

2 m while the boom angle is over approx.

76 dgrees.

(3)Working range limit functions

Boom retraction

Stop at stroke end

Boom raising/lowering

Stop by working range restriction

When any working range limit is registered to AML, the crane is controlled so that the crane work posture does not exceed this registered working range limit. When the boom reaches the previously registered restriction, buzzer sounds, and the crane operation stops.

Boom raising

Boom upper angle restriction

Boom raising/lowering Boom extension Swing

[NOTICE] While the elevation slow stop cancel switch is in “OFF” position, the slow stop function for boom elevation is deactivated.

While the swing stop cancel swich is in “OFF” position, swing does not stop automatically.

36

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Functions of and How to Use User Mode (GT-550E-1) AML System Configuration Boom length signal

Boom angle signal

Moment ratio signal

Swing angle signal

Crane control position signal

L W

Outrigger extension width detector Operator selection

Outrigger status

L

Lift status Working range limits Number of part-lines of rope

AML unit Alarm buzzer Display panel

External warning lamps

m

m

t %

Stop output when:

max t

m

Boom upper Moment ratio exceeds angle 100% restriction Overwinding occurs Moment exceeding limit for boom with jib mounted AML system error occurs

Swing restricted

Working range limit signal output

Boom extension halted

Boom lowering halted

Hoisting up halted

Swinging Boom raising halted toward halted critical side Boom retracting halted

Upper boom angle restricted Lower boom angle restricted

Lifting height restricted

Load radius restricted

u H

L R

IW301-0211E03

37

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Functions of and How to Use User Mode (GT-550E-1) Automatic Stop Functions Causes of automatic stop Moment ratio exceeds 100% (*1) Overwinding AML system error

Condition

Operation

Halted movement

Moment ratio exceeds 100%

Moment display: Displays [Warning:0023].

External warning lamps: Red lamp is lit.

Buzzer: Sounds continuously.

Moment display: AML system error Displays failure messages.

Buzzer: Sounds 3 seconds.

Moment display: Working range limit Displays failure function activated. messages.

Associated restriction indicator lamp flashes.

Buzzer: Sounds continuously.

AML buzzer: Sounds 3 seconds.

Operated to critical side Moment display: Displays [Warning:0026] when boom angle Buzzer: exceeds the upper limit Sounds 3 seconds.

Slow stop control Moment display: Displays [Warning:0081] or [0082].

Buzzer: Sounds intermittently.

Boom lift with jib mounted on boom (1) Moment ratio is Moment display: between 75%and Green segment(s) is lit.

85% External warning lamps: Orange lamp is lit.

Buzzer: Sounds intermittently.

(2) Moment ratio Moment display: exceeds 85% Displays [Warning:0088].

External warning lamps: Red lamp is lit.

Buzzer: Sounds continuously.

Hoisting up Boom lowering Boom extension Boom swing

Working range limit

Upper boom Boom raising Boom lift angle restricted Single top lift Lower boom Boom lowering Jib lift angle restricted Lifting height Boom raising restricted Boom extension Load radius Boom lowering restricted Boom extension Swing Boom swing restricted Boom raising Boom upper angle Boom lift restriction (*2) Single top lift Boom retraction (*1):For the boom lift with the jib mounted, automatic stop will work when the moment exceeds 85%. (*2):To avoid the main hook block contacting the jib, this function prevents the concurrence of the boom angle exceeding 76 dgrees and boom retraction beyond the boom length of 11.3 m.

Alarm Functions Condition

Alarm

Winch lever is moved toward critical side (hoist up, boom lowering or boom extension) while overwinding condition exists.

Overwind cutout function is released with the while overwinding condition exists.

Moment display: Displays [Warning:0024].

Buzzer: Sounds continuously.

Moment ratio exceeds 90%

Alarm

Moment display: Displays [Warning:0015].

External warning lamps: Red lamp is lit.

Buzzer: Sounds continuously.

[NOTICE] ◆In the above table, "Buzzer" is the device outside the AML unit, outputting buzzing sound.

"AML buzzer" is the device inside the AML unit, outputting beeping sound. ◆The AML buzzer sounds for 3 seconds every time a message appears. It outputs long sounds when slow stop control is activated and outputs short sounds when other controls are activated.

Moment display: Yellow segment(s) is lit.

External warning lamps: Orange lamp is lit.

Buzzer: Sounds intermittently.

38

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Functions of and How to Use User Mode (GT-550E-1) Names and Functions of AML Main Unit Parts Bargraph display

Display panel 1 m

m

t %

Display panel 2

max t

m

Control

IW301-0211E05

39

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Functions of and How to Use User Mode (GT-550E-1) Bar graph Display

1

3

2

4

Usually on

0-89

Each frame representing 10%

90-99

100-109

110 or more than that

Each frame representing 2.5%

Each frame representing 2.5% IW301-0211E06

1. Moment ratio mark The moment ratios on the bargraph are color coded as follows: safe (green), notice (yellow) and limit (red).

2. Moment display Normally displays a moment ratio on a bargraph.

Displays the main-circuit oil pressure and torque converter oil pressure when the display alteration key is held down.

Also displays error messages when the AML or any of its associated devices fails.

3. Scroll-up key Used to see the previous lines of message displayed on the moment display.

4. Scroll-down key Used to see the next lines of messages displayed on the moment display.

40

W301-0212E

Functions of and How to Use User Mode (GT-550E-1) Display Panel 1 1

2

3

5

O

m

15 14

17 20 21 18 t

16 m

13

6

O

%

17

7

max t

8

m

19

11

10 9 IW301-0211E07

8. Rated lifting capacity display

1. Jib angle display

Displays the rated lifting capacity.

When jib lift is selected, the jib angle offset is displayed.

When the number of part-lines of rope select key is pressed, or the display select key is kept being pressed, the number of part-lines of ropes is displayed. Also, when the upper boom angle restriction function is activated, the registered upper boom angle limit value is displayed as long as the register key is kept being pressed.

9. Load radius limit restriction indicative symbol Comes on to indicate that the value shown in the load radius display-11 represents the load radius limit. Note that the load radius indicative symbol-10 is also displayed at the same time.

10. Load radius indicative symbol Indicates that the value shown in the load radius display-11 represents the load radius.

2. Number of part-lines of indicative symbol This symbol shows that the jib angle display-1 indicates the number of part-lines of rope.

11. Load radius display Normally displays the crane's load radius.

When the load radius limit restriction function is activated, the load radius limit restriction value is displayed while the register key is held down.

3. Boom length indicative symbol This symbol, while marked up, means the value in the boom length display-13 is a boom length value.

13. Boom length display Usually displays boom length.

Displays the lifting height while the display alteration key is pressed.

When the lifting height restriction function is effective, this displays lifting height restriction value, while the register key is being pressed.

5. Jib angle indicative symbol Comes on to indicate that the value shown in the jib angle display-1 represents the offset angle.

6. Jib lift indicative symbol Comes on when the jib lift is selected to represent the registered jib status.

14. Lifting height indicative symbol This symbol, while marked up, means the value in the boom length display-13 is a lifting height.

7. Real load display Displays the real load.

41

W301-0212E

Functions of and How to Use User Mode (GT-550E-1)

15. Lifting height restriction symbol This symbol, while marked up, means the value in the boom length display-13 is a lifting height restriction value.

The lifting height symbol-14 is marked up simultaneously.

16. Upper boom angle limit restriction symbol Indicates that the jib angle display-1 displays the registered boom angle upper restricted value.

17. Boom angle indicative symbol Indicates that the boom angle display-19 displays the boom angle.

18. Lower boom angle limit restriction symbol Indicates that the boom angle display-19 displays the registered lower boom angle restricted value.

19. Boom angle display Normally displays the boom angle.

Displays the moment % when the display alteration key is held down. When the restriction function is activated, the lower boom angle limit restriction value is displayed while the register key is held down.

20. Boom lift indicative symbol Comes on when the boom lift is selected.

21. Single-top lift indicative symbol Comes on when the single-top lift is selected.

42

W301-0212E

Functions of and How to Use User Mode (GT-550E-1) Controls 14 13 12 11

15

10 16

17

9

19 18

8

20

7 6

1

2

3

4

5 IW301-0211E08

10. Lower boom angle limit restriction key

1. Increase key

Used to activate and cancel the lower most boom angle limiting function.

Used to increase the selected value.

2. Decrease key

11. Lower boom angle limit restriction indicator lamp

Used to decrease the selected value.

Lights up when the lowermost boom angle limiting function is activated.

3. Outrigger mode select key Used to select the outrigger status.

12. Upper boom angle limit restriction key Used to activate and cancel the upper most boom angle limiting function.

4. Lift mode select key Used to select the lift status.

5. Check key

13. Upper boom angle limit restriction indicator lamp

Used to check the AML system functions.

Lights up when the uppermost boom angle limiting function is activated.

6. Register key Used to register the selected state.

14. Lifting height restriction key Used to activate and cancel the lifting height limiting function.

7. Display alteration key Used to alternate the displays on display panel 1.

15. Lifting height restriction indicator lamp Lights up when lifting height limiting function is activated.

8. Load radius restriction key Use to activate and cancel the load radius limiting function.

16. Right swing restriction key

9. Load radius restriction indicator lamp Lights up when the load radius limiting function is activated.

Used to activate and cancel the right swing limiting function.

17. Right swing restriction indicator lamp Lights up when the right swing limiting function is activated

43

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Functions of and How to Use User Mode (GT-550E-1) 18. Left swing restriction key Used to activate and cancel the left swing limiting function.

19. Left swing restriction indicator lamp Lights up when the left swing limiting function is activated.

20. Number of part-lines of rope select key Used to register a number of part-lines of rope.

Display Panel 2 4

1

3 2

2

3 2

2

3

3 IW301-0211E09

1. Front jack symbol Indicates that the front jack is used.

2. Outrigger state indicative symbol Displays the way the outriggers are extended.

3. "On-rubber" (Outrigger-not-in-use) state indicative symbol Comes on when the starter switch in the crane operator’s cab is turned “ON”.

4. Boom position indicator Displays the boom position in 10 dgrees increments.

44

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Functions of and How to Use User Mode (GT-550E-1) Selecting Operational Status

When the outrigger mode select key is pressed,

WARNING

the outrigger state indicative symbols and front jack symbol flash in accordance with the status that the AML detects on.

Should the operational status be incorrectly registered, the crane might overturn or be damaged, leading to a serious accident. Prior to every operation, check that the registered status corresponds to the actual status of the crane.

After making sure that the display conforms to the

Selecting Outrigger Status [NOTICE] ◆The "on-rubber" state indicative symbol is marked up when the power supply is turned on (the PTO switch in the carrier driver’s cab is turned ON after the engine is started). (The outrigger state indicative symbols and front jack symbol remain off.) ◆Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power has been last turned off, enter the settings all over again.

actual outrigger conditions, press the register key.

The outrigger state indicative symbol will change from flashing into being marked up continuously and the moment display, rated lifting capacity display and real load display will return to normal display conditions, meaning that the state has been registered.

Actual outrigger status

Representation of outrigger status on the AML

Register the outrigger status using the outrigger mode select key and register key.

IW301-0211E11

m

Front jack mode indicative symbol

Fully extended (6.8m)

m

t ％

max t

Mid. extended (4.6m) m

Register key

Min. extended (2.39m)

IW301-0211E12

Outrigger state indicative symbol

[NOTICE]

Outrigger mode select key

◆If an outrigger or the front jack is stowed after registration of outrigger status, the registered status is erased. In this case, register the outrigger status again before starting crane operation.

IW301-0211E10

45

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Functions of and How to Use User Mode (GT-550E-1) registered.

(When the jib set status is selected, the jib lift indicative symbol will remain flashing.) ◆Select the boom lift status when lifting a load on the boom with the jib mounted. ◆Select a jib lift status when lifting a single load using both the boom and jib.

Selecting Lift Status [NOTICE] ◆The boom lift status is the default status and is automatically selected (the boom indicator lamp lights) when the power supply is turned on (the PTO switch is placed in the ON position). ◆Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power was last turned off, enter the settings all over again.

(1) Boom lift

Register the lift status using the lift mode select

(2) Single top lift

key and register key.

(3) Jib set (mounting or stowage)

m

m

t %

(4) Jib lift: 9.0m jib, 5 dgrees offset

max t

m

Register key

(5) Jib lift: 9.0m jib, 25 dgrees offset

(6) Jib lift: 9.0m jib, 45 dgrees offset

Lift mode select key IW301-0211E13

(7) Jib lift: 14.6m jib, 5 dgrees offset

Each time the lift mode select key is pressed, the mode changes. The status changes in numerical sequence, from (1) to (9), as shown below. The display returns to (1) if you press the switch when status (9) is shown on the display. Select the status that corresponds to the actual lift status.

(8) Jib lift: 14.6m jib, 25 dgrees offset

[NOTICE] ◆After making sure that the display conforms to the actual lift status, press the register key. The corresponding lift indicative symbol will change from flashing into being marked up continuously and the moment display, rated lifting capacity display and real load display will return to normal display conditions, meaning that the status has been

(9) Jib lift: 14.6m jib, 45 dgrees offset

IW301-0211E14

46

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Functions of and How to Use User Mode (GT-550E-1) Selecting Number of Part-lines of Rope

1. Press the number of part-lines o f rope select key.

The number of part-lines of rope symbol will flash, and the number of part-lines of rope will be shown on the jib angle display in a flashing mode.

[NOTICE] If the registered number of part-lines of rope is smaller than the standard number, a maximum allowable lifting load is limited, depending on the registered number. In case the number is registered as ‘0’, however, a process takes place as if the standard number were registered.

Similarly, a process takes place on the basis of the standard number of part-lines of rope if the registered number is larger than the standard number or other than the values specified for your model.

When the power supply is turned on (i.e. PTO switch ON), the standard number of part-lines of rope corresponding to a work condition is selected.

2. Press the increase or the decrease key to set the number of part-lines of rope at a desired value.

[NOTICE] When the increase or the decrease key is pressed, a numeral showing the number of rope changes from flashing to being marked up, showing a fixed value for the increase or decrease.

When the increase or the decrease key is kept pressed, the number of rope continuously increases or decreases.

Register the number of part-lines of rope by use of

3. Once the intended number of part-lines of rope is

the number of part-lines of rope select key, as follows:

set, press the register key and register the number.

Then, the number of part-lines of rope symbol is turned off and the jib angle display returns to a normal status.

Number of part-lines of rope indicative symbol

[NOTICE] The number of part-lines of rope can be confirmed by pressing the display alteration key.

Number of part-lines of rope m

t max t m

Decrease key

Number of part-lines of rope select key Register key

Increase key

IW301-0211E53

47

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Functions of and How to Use User Mode (GT-550E-1) AML Pre-operational Inspection

2. Press either the set key, display alteration key or check key to return the display to the normal condition.

WARNING Operating the crane with a malfunctioning AML could cause the crane to overturn or be damaged. Be sure to perform the pre-operational inspection on the AML system and start the crane only after ensuring that the system is operating properly.

3. Make sure that the display on the display panels conforms to the actual crane conditions.

(1) Boom length (2) Boom angle

Before starting operation, check that the AML

(3) Jib angle ......shown while jib lift is selected

works in good condition, as follows:

(4) Real load .....Make sure that the approximate

1. Press the check key and make sure that the AML

mass of the hook block while no load is on the hook block.

is in the following conditions: Moment display ....... All segments are marked up.

[NOTICE] The real load is not shown correctly if the lift status is not registered correctly.

Display panel (1 and 2) ........ All segments are marked up.

(5) Outrigger state indicative symbol

Working range restriction indicator lamp

Alarm buzzer

.................... All six lamps light up.

(6) Front jack symbol

.................... Sounds continuously.

(7) Boom position indicator

Movement toward critical sides

3

......................Automatically halted

2 1

Buzz

4

Bargraph display

7

m

t o

max t

Display panel 1 m m

Display panel 2 m

t %

max t

m

6 5

Check key

IW301-0211E17

IW301-0211E16

48

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Functions of and How to Use User Mode (GT-550E-1) How to Use the Working Range Limit Function

Boom Angle Limit

[NOTICE]

Raise or lower the boom to the desired angle, and

◆If the selected working range limits allow the crane to approach too close to an obstruction, the crane may be contacted or hit, depending on the operational status and the manner in which the load is handled. When selecting limits, allow sufficient clearance.

press the boom upper or lower limit restriction key.

The corresponding limit restriction indicator lamp will flash and the buzzer will sound continuously, indicating that the limit boom angle has been registered in the memory. When the boom is moved back to an angle within the set limit, the limit restriction indicator lamp stops flashing and stays illuminated and the buzzer stops.

The working range restricting function makes the boom automatically stop at the previously registered boom angles (upper and lower), lifting height and radius.

Thereafter, the upper or lower boom angle limit restriction indicator lamp flashes and the buzzer sounds continuously whenever the upper or lower limit previously registered is reached.

If makes the alarm sound when the boom reaches the previously registered swing restriction.

The function is useful for handing a load in a

To cancel the boom angle limit function, press the boom angle limit restriction key again. The corresponding boom angle limit restriction indicator lamp will go off.

confined place because it defines the area in which the boom can operate.

[NOTICE] ◆Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power has been last turned off, enter the settings all over again.

m

Upper boom angle restricted Lower boom angle restricted

t

Lifting height restricted

Upper boom angle limit restriction indicator lamp

max t

m

Lower boom angle limit restriction indicator lamp

u Lower boom angle limit restriction key

H L Load radius restricted

Upper boom angle limit restriction key

Swing restricted IW301-0211E19

R IW301-0211E18

49

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Functions of and How to Use User Mode (GT-550E-1) Swing Limit

Lifting Height Limit Move the boom to the desired height, and press

Swing the boom to the desired position, and press

the lifting height restriction key. The lifting height restriction indicator lamp will flash and the buzzer will sound continuously, indicating that the limit height has been registered in the memory. When the boom is moved back to a height within the set limit, the lifting height restriction indicator lamp stops flashing and stays illuminated and the buzzer stops.

Thereafter, the lifting height restriction indicator lamp flashes and the buzzer sounds continuously whenever the height limit previously registered is reached.

To cancel the height limit function, press the lifting height restriction key again. The corresponding lifting height restriction indicator lamp will go off.

a swing restriction key. The corresponding swing restriction indicator will flash and the buzzer will sound continuously, indicating that the swing angle limit has been registered in the memory.

When the boom is swing back to an angle within the set limit, the swing restriction lamp stops flashing and stays lit and the buzzer stops.

Thereafter, a swing restriction indicator lamp will flash and the buzzer will sound whenever the limit previously registered is reached. (The swinging boom stops automatically.)

To cancel the restriction function, press the corresponding swing restriction key again. The corresponding swing restriction indicator lamp will go out.

[NOTICE]

m

t

When registering the swing angle limit, register both the right and left boom swinging restriction positions.

Registering only one side cannot fulfill this working range limit function nor make the alarm buzzer sound.

While the swing stop cancel switch is set to OFF, the automatic stop does not work even if the boom is swung to the limit. In this case, the corresponding swing restriction indicator lamp flashes, a message appears and the AML buzzer beeps for three seconds. Take care when swinging the boom.

Lifting height restriction indicator lamp

max t

m

Lifting height restriction key

IW301-0211E20

m

t

Left swing restriction indicator lamp

max t

m

Right swing restriction indicator lamp

Right swing restriction key Left swing restriction key IW301-0211E21

50

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Functions of and How to Use User Mode (GT-550E-1) Load Radius Limit Move the boom to the desired load radius, and press the load radius restriction key. The load radius restriction indicator lamp will flash and the buzzer will sound continuously, indicating that the limit load radius has been registered in the memory. When the boom is moved back toward the non-critical side, the load radius restriction indicator lamp stops flashing and stays illuminated and the buzzer stops.

The load radius restriction indicator lamp flashes and the buzzer sounds continuously whenever the limit previously registered is reached.

To cancel the load radius limit function, press the load radius restriction key again. The corresponding load radius restriction indicator lamp will go off.

m

t

max t

m

Load radius restriction indicator lamp Load radius restriction key

IW301-0211E22

51

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Functions of and How to Use User Mode (GT-550E-1) Display of Working Range Restriction Values Press in the register key while working range restricting functions are registered.

While the key is being pressed in, the registered working range restriction values are displayed. On the moment display will be displayed a message “Working range”.

[NOTICE] ◆This display is not available when preoperational AML check is made and when working state is registered. ◆When working range restricting functions are not registered, the message “—“ will be displayed.

Upper boom angle limit restriction values

Working range

Lower boom angle limit restriction values

Lifting height restriction values m

t

Load radius restriction values

max t

Boom position indicator m

Register key Swing limit restriction values

IW301-0211E23

52

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Functions of and How to Use User Mode (GT-550E-1) Display Alteration Displays on the moment display and the display panel 1 can be altered, as shown below in the figures, while the display alteration key is being pushed. The indicative symbols are displayed, too.

Moment Display

M* * *. *

MPa

Unit

Main circuit pressure

IW301-0211E24

Display Panel 1 [NOTICE] ◆Displays on the real load display and the rated lifting capacity display do not alter even when the display alteration key is pressed in.

Number of part-lines of rope M * * *. *

MPa

Lifting height

Moment ratio Real load m %

max t

Rated lifting capacity Swing angle

Display alteration key IW301-0211E25

53

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Functions of and How to Use User Mode (GR-120N-1) Functions of and How to Use User Mode (GR-120N-1)

2. Maintenance Mode: Used to make functional checks of AML. See the “ADJUSTMENT AND MAINTENANCE” section.

Mode Structure

3. Adjustment Mode:

The AML device has three modes and AML

Used to make detector adjustment. See the “ADJUSTMENT AND MAINTENANCE” section.

functions are allotted for these models.

POWER ON

Protect switch ON

MAINTENANCE MODE

USER MODE

Protect switch OFF

ADJUSTMENT MODE

POWER ON

IW301-0212E05

1. User Mode: Used to indicate moment ratio or to perform AML pre-opetational inspection (Normally used).

In normal use, turn ON the protect switch mounted on the adjustment window on the top of AML. AML will go to the user mode when the power turns on.

HALT

WDT

ZERO

PROTECT ON

OFF

MOMENT SHORT

The abnormality display LED lights when the AML is in abnormal conditions (to indicate that the CPU is faulty).

Protect switch Abnormality display LED Top view

IW301-0132E35

54

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Functions of and How to Use User Mode (GR-120N-1) Configuration and Functions of the AML System

(2) Working range limit functions When any working range limit is registered to AML, the crane is controlled so that the crane work posture does not exceed this registered working range limit. When the boom reaches the previously registered restriction, failure message is shown, alarm buzzer sounds, and the crane operation stops.

AML system has various kinds of functions, including the following four typical functions. Based on the registered work conditions by operator selection and the signals from various sensors, the crane operations are controlled.

(1) Automatic stop function for overloading

(3) Slow stop function

The AML calculates and compares the working and rated moment values and displays them as a percentage. When the working moment exceeds the rated moment (100% or more), failure message is shown, alarm buzzer sounds, and the crane operation toward the critical side stops.

When the boom elevation stops in the above (1) or (2) case or reaches the stroke ends, the elevating speed slows down before the boom elevation stops.

The above automatic stop, working range restricting and slow stop functions are available depending on the conditions shown in the following table:

On-outrigger operation

On-rubber operation

Hoisting up Automatic stop by overloading

Boom lowering Boom extension Swing

Stop at stroke end Stop by working range restriction

×

Boom raising/lowering Boom raising/lowering Swing

×

Boom extension ：Slow stop

[NOTICE]

：Stop ×：Not stop

[NOTICE]

When swing stop/override switch is shifted to "Override" side, swing stop does not activate.

When elevation slow stop/override switch is shifted to "Override" side, boom elevation slow stop does not activate.

Override

Override

Stop SWING STOP OVERRIDE

Stop

ELEV. SLOW STOP OVERRIDE

IW301-0211E37

IW301-0211E38

55

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Functions of and How to Use User Mode (GR-120N-1)

(4) Alarm function Condition

(5) Elevation speed adjustment function The maximum elevation speed with the boom extended can be adjusted.

Alarm

Overwinding

Buzzer: Sounds continuously.

Moment ratio is between 90% and 100%

Moment display: Associated yellow segments are lit.

Buzzer: Sounds intermittently.

Moment ratio exceeds 100%

Moment display: Associated segments are lit until the moment reaches 110%; all segments are lit when moment exceeds 110%.

Buzzer: Sounds continuously.

Crane operation needs to be controlled

Moment display: Displays control messages.

Buzzer: Beeps 3 seconds. (*1)

Working range restricting function activated

Associated restriction indicator lamp flashes.

Buzzer: Beeps 3 seconds. (*1)

AML system error

Moment display: Displays failure messages.

Buzzer: Beeps 3 seconds. (*1)

(*1): There are two types of buzzer sounds as follows: When slow stop control is activated: Long sounds When other controls are activated: Short sounds

56

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Functions of and How to Use User Mode (GR-120N-1) Boom length signal

Over-front area signal

Moment signal

Elevation angle signal

L

Crane control signal

W

θ

Swing angle signal Operator input

Outrigger status

Outrigger extension signal

Lift status

Working range limits

AML unit

Alarm buzzer Display panel

AML external warning lamps (option)

Automatic stop signal output Moment ratio 100% or higher Overwinding

Boom extension halted

Boom lowering halted

Hoisting up halted

Work area limit signal output

Swinging halted toward critical side

Left swing restricted Right swing restricted

Upper boom angle restricted Lower boom angle restricted

Lifting height restricted

Load radius restricted

u H

L R IW301-0212E02

57

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Functions of and How to Use User Mode (GR-120N-1) Names and Functions of AML Main Unit Parts Bargraph display

Display panel 1 m

m

t %

Display panel 2

max t

m

Control

IW301-0211E05

58

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Functions of and How to Use User Mode (GR-120N-1) Bar graph Display

1

3

2

4

Usually on

0-89

Each frame representing 10%

90-99

100-109

110 or more than that

Each frame representing 2.5%

Each frame representing 2.5% IW301-0211E06

1. Moment ratio mark The moment ratios on the bargraph are color coded as follows: safe (green), notice (yellow) and limit (red).

2. Moment display Normally displays a moment ratio on a bargraph.

Displays the main-circuit oil pressure and torque converter oil pressure when the display alteration key is held down.

Also displays error messages when the AML or any of its associated devices fails.

3. Scroll-up key Used to see the previous lines of message displayed on the moment display.

4. Scroll-down key Used to see the next lines of messages displayed on the moment display.

59

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Functions of and How to Use User Mode (GR-120N-1) Display Panel 1

1

2

3

22

5

O

m

15 14

17 20 21 18 t

16 m

13

6

O

%

7

max t

17

8

m

19

11

10

9

IW301-0212E03

8. Rated lifting capacity display

1. Jib angle display

Displays the rated lifting capacity.

When jib lift is selected, the jib angle offset is displayed.

When the number of part-lines of rope select key is pressed, or the display select key is kept being pressed, the number of part-lines of ropes is displayed. Also, when the upper boom angle restriction function is activated, the registered upper boom angle limit value is displayed as long as the register key is kept being pressed.

9. Load radius limit restriction indicative symbol Comes on to indicate that the value shown in the load radius display-11 represents the load radius limit. Note that the load radius indicative symbol-10 is also displayed at the same time.

10. Load radius indicative symbol Indicates that the value shown in the load radius display-11 represents the load radius.

2. Number of part-lines of indicative symbol This symbol shows that the jib angle display-1 indicates the number of part-lines of rope.

11. Load radius display Normally displays the crane's load radius.

When the load radius limit restriction function is activated, the load radius limit restriction value is displayed while the register key is held down.

3. Boom length indicative symbol This symbol, while marked up, means the value in the boom length display-13 is a boom length value.

13. Boom length display Usually displays boom length.

Displays the lifting height while the display alteration key is pressed.

When the lifting height restriction function is effective, this displays lifting height restriction value, while the register key is being pressed.

5. Jib angle indicative symbol Comes on to indicate that the value shown in the jib angle display-1 represents the offset angle.

6. Jib lift indicative symbol Comes on when the jib lift is selected to represent the registered jib status.

14. Lifting height indicative symbol

7. Real load display

This symbol, while marked up, means the value in the boom length display-13 is a lifting height.

Displays the real load.

60

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Functions of and How to Use User Mode (GR-120N-1)

15. Lifting height restriction symbol This symbol, while marked up, means the value in the boom length display-13 is a lifting height restriction value.

The lifting height symbol-14 is marked up simultaneously.

16. Upper boom angle limit restriction symbol Indicates that the jib angle display-1 displays the registered boom angle upper restricted value.

17. Boom angle indicative symbol Indicates that the boom angle display-19 displays the boom angle.

18. Lower boom angle limit restriction symbol Indicates that the boom angle display-19 displays the registered lower boom angle restricted value.

19. Boom angle display Normally displays the boom angle.

Displays the moment % when the display alteration key is held down. When the restriction function is activated, the lower boom angle limit restriction value is displayed while the register key is held down.

20. Boom lift indicative symbol Comes on when the boom lift is selected.

21. Single-top lift indicative symbol Comes on when the single-top lift is selected.

22. Jib length indicative symbol This symbol shows that the jib angle display-1 indicates the jib length.

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Functions of and How to Use User Mode (GR-120N-1) Controls 14 13 12 11

15

10 16

17

9

19 18

8

20

7 6

1

2

3

4

5 IW301-0211E08

10. Lower boom angle limit restriction key

1. Increase key

Used to activate and cancel the lower most boom angle limiting function.

Used to increase the selected value.

2. Decrease key

11. Lower boom angle limit restriction indicator lamp

Used to decrease the selected value.

Lights up when the lowermost boom angle limiting function is activated.

3. Outrigger mode select key Used to select the outrigger status.

12. Upper boom angle limit restriction key Used to activate and cancel the upper most boom angle limiting function.

4. Lift mode select key Used to select the lift status.

5. Check key

13. Upper boom angle limit restriction indicator lamp

Used to check the AML system functions.

Lights up when the uppermost boom angle limiting function is activated.

6. Register key Used to register the selected state.

14. Lifting height restriction key Used to activate and cancel the lifting height limiting function.

7. Display alteration key Used to alternate the displays on display panel 1.

15. Lifting height restriction indicator lamp Lights up when lifting height limiting function is activated.

8. Load radius restriction key Use to activate and cancel the load radius limiting function.

16. Right swing restriction key

9. Load radius restriction indicator lamp Lights up when the load radius limiting function is activated.

Used to activate and cancel the right swing limiting function.

17. Right swing restriction indicator lamp Lights up when the right swing limiting function is activated

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Functions of and How to Use User Mode (GR-120N-1) 18. Left swing restriction key Used to activate and cancel the left swing limiting function.

19. Left swing restriction indicator lamp Lights up when the left swing limiting function is activated.

20. Number of part-lines of rope select key Used to register a number of part-lines of rope.

Display Panel 2 5 1 3 2 4

2

3

3

2 3

IW301-0231E10

4. Suspension lock state indicative symbol

1. Over-front position symbol

Displays that the suspensions are locked up.

Indicates that the boom is swung into the over-front position.

5. Boom position indicator Displays the boom position in 10° increments.

2. Outrigger state indicative symbol Displays the way the outriggers are extended.

Flashes while an outrigger state is being selected and is marked up while it registered.

3. "on-rubber" (Outrigger-not-in-use) state indicative symbol Indicates that the on-rubber operation (non-outrigger operation) is selected.

Marked up when the stationary on-rubber operation is selected, and flashes when the traveling on-rubber (creep) operation is selected.

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Functions of and How to Use User Mode (GR-120N-1) Selecting Operational Status

(1)On-outrigger operation

WARNING

Press the outrigger position selector key. The AML automatically detects the current outrigger position and displays the detected position by flashing the corresponding outrigger position symbols.

Check that the outrigger position symbols flashing on the display match the actual outrigger position.

If they do, press the register key to store the outrigger position to the AML memory. The outrigger position symbols will be marked up when the outrigger position is registered.

Incorrectly entering the operation status into the AML can result in a serious accident such as the crane falling over or being damaged. Before starting a crane operation, make sure that the operation status stored in the AML matches the actual operation status.

Selecting Outrigger Status [NOTICE] The on-rubber status is automatically set when the AML is turned on.

Even when you turn the AML off (by setting the PTO switch to OFF), the currently registered operation status is retained in the AML. The stored data is available next time you turn on the AML. Note, however, that the data is erased after 2 hours.

If you have interrupted the operation for more than 2 hours, register the operation status again into the AML before resuming the operation.

Use the outrigger position selector key to register the outrigger position into the AML. Then follow the procedure described in the following paragraphs.

IW301-0211E46

The outrigger positions are displayed as follows.

X-type outrigger Max. extension (4.7 m) Middle extension (4.3 m) Middle extension (3.5 m)

Outrigger position

Middle extension (2.5 m)

symbol

Min. extension (1.7 m) IW301-0211E47

Register key

H-type outrigger On-rubber symbol

Outrigger position selector key

Max. extension (4.7 m) IW301-0211E45

Middle extension (4.3 m) Middle extension (3.5 m) Middle extension (2.5 m) Min. extension (1.64 m) IW301-0211E48

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Functions of and How to Use User Mode (GR-120N-1) (2)On-rubber stationary operation Press the outrigger position selector key. At this time, the outrigger position symbols flash. Press the outrigger position selector key again. At this time, the outrigger position symbols go out and the on-rubber symbol becomes marked up. The on-rubber status is now registered in the AML memory.

Selecting Lift Status [NOTICE] The single top lift status is automatically selected when the power supply is turned on.

Even when you turn the AML off (by setting the PTO switch to OFF), the currently registered operation status is retained in the AML. The registered data is available next time you turn on the AML. Note, however, that the data is erased after 2 hours. If you have interrupted the operation for more than 2 hours, register the operation status again into the AML before resuming the operation.

Marked up

Jib symbol Single top symbol

IW301-0211E49

Boom symbol

(3)On-rubber creep operation Press the outrigger position selector key to flash the tire part of the on-rubber symbol becomes marked up. The on-rubber status is now registered in the AML memory.

Register key

Flashing

Lift status selector key IW301-0211E51

The lift status selector key is used to register the lift status. Each time the lift status selector key is pressed, the lift status changes. The status changes in numerical sequence as shown in the following table. The display returns to (1) if you press the switch when status (9) is displayed on the screen. Register the status that corresponds to the actual lift status.

Marked up

Flashing IW301-0211E50

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Functions of and How to Use User Mode (GR-120N-1)

Display

Type of lift

Single top lift

(1)

Jib set (mounting or stowage)

(2)

Jib lift Jib length: 3.6 m, Jib offset angle: 5°

(3)

Jib lift Jib length: 3.6 m, Jib offset angle: 25°

(4)

Jib lift Jib length: 3.6 m, Jib offset angle: 45°

(5)

Jib lift Jib length: 5.5 m, Jib offset angle: 5°

(6)

Jib lift Jib length: 5.5 m, Jib offset angle: 25°

(7)

Jib lift Jib length: 5.5 m, Jib offset angle: 45°

(8)

Boom lift

(9)

Flashing

O

O

O

O

O

O

IW301-0211E52

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Functions of and How to Use User Mode (GR-120N-1) Selecting Number of Part-lines of Rope

1. Press the number of part-lines o f rope select key.

The number of part-lines of rope symbol will flash, and the number of part-lines of rope will be shown on the jib angle display in a flashing mode.

[NOTICE] If the registered number of part-lines of rope is smaller than the standard number, a maximum allowable lifting load is limited, depending on the registered number. In case the number is registered as ‘0’, however, a process takes place as if the standard number were registered.

Similarly, a process takes place on the basis of the standard number of part-lines of rope if the registered number is larger than the standard number or other than the values specified for your model.

When the power supply is turned on (i.e. PTO switch ON), the standard number of part-lines of rope corresponding to a work condition is selected.

2. Press the increase or the decrease key to set the number of part-lines of rope at a desired value.

[NOTICE] When the increase or the decrease key is pressed, a numeral showing the number of rope changes from flashing to being marked up, showing a fixed value for the increase or decrease.

When the increase or the decrease key is kept pressed, the number of rope continuously increases or decreases.

Register the number of part-lines of rope by use of

3. Once the intended number of part-lines of rope is

the number of part-lines of rope select key, as follows:

set, press the register key and register the number.

Then, the number of part-lines of rope symbol is turned off and the jib angle display returns to a normal status.

Number of part-lines of rope indicative symbol

[NOTICE] The number of part-lines of rope can be confirmed by pressing the display alteration key.

Number of part-lines of rope m

t max t m

Decrease key

Number of part-lines of rope select key Register key

Increase key

IW301-0211E53

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Functions of and How to Use User Mode (GR-120N-1) AML Pre-operational Inspection

How to Use the Working Range Limit Function [NOTICE]

WARNING

Do not register a limit position into the AML with the boom positioned very close to an obstacle. If you do, a collision with the obstacle may occur under some operating conditions or with certain control procedures. Provide enough clearance between limit positions and obstacles.

Operating the crane with a malfunctioning AML could cause the crane to overturn or be damaged. Be sure to perform the pre-operational inspection on the AML system and start the crane only after ensuring that the system is operating properly.

The working range restricting function automatically stop the boom telescoping, elevation, or swing operation when the preset elevation angle (upper/lower limits), lifting height, load radius, or swing angle (right/left) is reached.

The working range limit function is useful for handling a load in a confined place because it defines the area in which the boom can operate.

Before starting operation, check that the AML works in good condition, as follows: 1. Press the check key and make sure that the AML is in the following conditions: ・Display panel (1 and 2) ….. …..All segments are marked up. ・Moment display….. …..All segments are marked up. ・Working range restriction indicator lamp….. …..All lamps light up. ・Alarm buzzer….. …..Sounds continuously. ・Movement toward critical sides….. …..Automatically halted.

Elevation angle upper limit Elevation angle lower limit Lifting height limit Load radius limit Left swing limit Right swing limit

Automatic stop and warning buzzer (3-second beeping)

[NOTICE]

2. Press either the register key, display alteration key

When the swing stop/override switch is set to the override position, the warning buzzer sounds, but the swing limit function does not automatically stop the swing operation.

Even when you turn the AML off (by setting the PTO switch to OFF), the limit position data is retained in the AML. The stored data is available next time you turn on the AML. Note, however, that the data is erased after 2 hours. If you have interrupted the operation for more than 2 hours, register the limit position again into the AML before resuming the operation.

or check key to return the display to the normal condition. (Bar graphs are indicated on the moment display.)

3. Make sure that the display on the display panels conforms to the actual crane conditions.

(1) Boom length (2) Boom angle (3) Jib angle (Jib length) ….. …..shown while jib lift is selected.

(4) Real load ….. …..Make sure that the approximate mass of the hook block while no load is on the hook block.

Working range restriction keys

Indicator lamps

Swing limit range

[NOTICE] The real load is not shown correctly if the lift status is not registered correctly.

(5) Outrigger position (6) Swing position display (7) Over-front area symbol (when the boom is positioned in the front area)

IW301-0211E54

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Functions of and How to Use User Mode (GR-120N-1) Lifting Height Limit

Working Range Limit Values Press in the register key while the working range

Move the boom to the desired height, and press

limit functions are registered. While the key is being pressed, the registered working range limit values are displayed. The message "Working range" will be displayed on the moment ratio display.

the lifting height limit key. The lifting height symbol will flash, indicating that the current lifting height has been registered in the memory as the lifting height limit.

When the boom is moved back to a height within the set limit, the lifting height restriction indicator lamp stops flashing and remains lit. When the lifting height again reaches the set limit, the indicator lamp flashes. At the same time, the boom movement (raising or extending) automatically stops, and the warning buzzer sounds (3-second beeping). To cancel the registered limit, press the lifting height limit key again. The lifting height symbol will go off.

Upper boom angle restriction value Lifting height restriction value

Working range

Lower boom angle restriction value m

t max t m

Load radius restriction value

Swing restriction value

Load Radius Limit Move the boom to the desired load radius, and press the load radius limit key. The load radius limit symbol will flash, indicating that the current load radius has been registered in the memory as the load radius limit. When the boom is moved back to a load radius within the set limit, the load radius restriction indicator lamp stops flashing and remains lit. When the load radius again reaches the set limit, the indicator lamp flashes. At the same time, the boom movement (lowering or extending) automatically stops, and the warning buzzer sounds (3-second beeping).

To cancel the registered limit, press the load radius limit key again. The load radius limit symbol will go off.

Register key IW301-0211E55

Boom Angle Limit Raise or lower the boom to the desired angle, and press the elevation angle upper or lower key. The corresponding limit symbol will flash, indicating that the current boom angle has been registered in the memory as the boom angle upper or lower limit.

When the boom is moved back to an angle within the set limit, the restriction indicator lamp stops flashing and remain lit. When the boom angle again reaches the set limit, the indicator lamp flashes. At the same time, the boom movement (raising or lowering) automatically stops, and the warning buzzer sounds (3-second beeping). To cancel the registered limit, press the elevation angle upper or lower key again. The corresponding elevation angle limit symbol will go off.

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Functions of and How to Use User Mode (GR-120N-1) How to Use the Elevation Speed Adjustment Function

Swing Limit To register a swing limit, swing to the desired

The elevation speed adjustment function works to

angle, and press the right or left swing limit key. At this time, the corresponding swing limit indicator lamp flashes and the buzzer sounds (3-second beeping). The current swing angle is registered as the right or left swing angle. When you swing back to an angle within the limit, the buzzer (3-second beeping) stops, and the swing angle limit indicator lamp stops flashing and remains lit. When you swing again to the limit angle, the swing operation automatically stops and the buzzer sounds (3-second beeping).

To cancel the registered limit, press the right or left swing limit key again. Then the corresponding swing limit indicator lamp will go off.

adjust the maximum elevation speed with the boom extended.

Registering the Elevation Speed

Decrease key

[NOTICE]

Increase key

Use the swing limit function with both the right and left swing limits defined. The swing limit function may not warn you when it should if used with only one of the swing limits defined.

The swing limit function does not automatically stop the swing operation when the swing stop/override switch is set to the override position. When the preset limit is reached, the swing restriction indicator lamp flashes, a warning message appears, and the warning buzzer of the AML unit sounds (3-second beeping), but the automatic stop function is not available. Perform swing operations carefully.

IW301-0211E56

Use the increase and decrease keys to adjust the elevation speed limit. When the increase or decrease key is pressed, the indication on the bar graph display will go out, and the elevation speed adjustment rate will appear as follows:

Up 100%

Dwn 100% Maximum speed for boom lowering Maximum speed for boom raising IW301-0211E57

To change the elevation speed adjustment rate, press the increase or decrease key while the elevation speed adjustment rate is displayed on the bar graph display. The adjustment rate can be adjusted from 0% (stop) to 100% (normal speed) in 10% increments.

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Functions of and How to Use User Mode (GR-120N-1) To adjust the boom raising and lowering speeds individually, press the increase or decrease key during the boom elevating operation.

Actual Elevation Speed When Registering the Elevation Speed Adjustment The elevation speed adjustment rate (%) is based

・While raising the boom:

on the elevation speed with the boom fully extended. Therefore, the boom moves at the normal speed (shown on the display) when the boom is fully retracted.

The relation between the elevation speed adjustment rate and the actual elevation speed is as follows: (1) When setting the adjustment value to 0% Fully retracted….. …..Moves at the normal speed Extended to the middle….. …..Moves at half normal speed Fully extended….. …..Stops (Hardly moves at all) (2) When setting the adjustment value to 50% Fully retracted….. …..Moves at the normal speed Extended to the middle….. …..Moves at 75% of the normal speed Fully extended….. …..Moves at half normal speed (3) When setting the adjustment value to 100% Fully retracted….. …..Moves at the normal speed Extended to the middle….. …..Moves at the normal speed Fully extended….. …..Moves at the normal speed

Boom raising speed is adjusted. ・While lowering the boom: Boom lowering speed is adjusted. ・While the boom elevating operation is not performed: Boom raising and lowering speeds are adjusted simultaneously.

[NOTICE] If the increase and decrease keys are not left unpressed at least for approx. 10 seconds, the indication on the bar graph display is returned to the normal state (bar graphs are displayed on the moment ratio display) even if the registration is not completed.

Even if you turned the AML off (by setting the PTO switch to OFF), the adjustment rate data is stored in the AML. The stored data is available next time you turn on the AML. When the AML is turned on, all the segments on the moment ratio display become marked up, the elevation speed adjustment rate appears for 2 or 3 seconds, and then the display returns to the normal state (bar graphs are displayed on the moment ratio display).

Maximum elevation speed Normal speed

100%

75% 50%

50%

25% 0% Stop Fully retracted

Boom length Extended to Fully the middle extended IW301-0211E58

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Functions of and How to Use User Mode (GR-120N-1) Display Alteration Displays on the moment ratio display and the display panel 1 can be altered, as shown below in the figures, while the display alteration key is being pushed. The indicative symbols are displayed, too.

Moment ratio Display

M ***. * A ***. * MPa

Unit

Accumulator pressure Main oil pressure

IW301-0211E61

Display Panel 1 ◆Displays on the actual load display and the rated lifting capacity display do not alter even when the display alteration key is pressed in.

Number of part-lines of rope M ***. * A ***. * MPa

Lifting height

Moment ratio Actual load m %

max t

Rated lifting capacity Swing angle

Display alteration key IW301-0211E62

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Functions of and How to Use User Mode (GR-700EXL-1) Functions of and How to Use User Mode (GR-700EXL-1)

2. Maintenance Mode:

Mode Structure

3. Adjustment Mode:

Used to make functional checks of AML. See the “ADJUSTMENT AND MAINTENANCE” section.

Used to make detector adjustment. See the “ADJUSTMENT AND MAINTENANCE” section.

The AML device has three modes and AML functions are allotted for these models.

POWER ON

Protect switch ON Protect switch OFF

MAINTENANCE MODE

USER MODE

ADJUSTMENT MODE

POWER ON

IW301-0212E05

1. User Mode: Used to indicate moment ratio or to perform AML pre-opetational inspection (Normally used).

In normal use, turn ON the protect switch mounted on the adjustment window on the top of AML. AML will go to the user mode when the power turns on.

The abnormality display LED lights when the AML

HALT

ZERO

WDT

PROTECT ON

OFF

MOMENT SHORT

is in abnormal conditions (to indicate that the CPU is faulty).

Protect switch Abnormality display LED Top view

IW301-0132E35

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Functions of and How to Use User Mode (GR-700EXL-1) Configuration and Functions of the AML System

(3) Working range limit functions When any working range limit is registered to the AML, the crane is controlled so that the crane work posture does not exceed this registered working range limit. When the boom reaches the previously registered restriction, buzzer sounds, and the crane operation stops.

The AML(Automatic Moment Limiter) system is a safety device provided to prevent overloading of the crane which may cause it to overturn or be damaged.

The AML system has various kinds of functions, including the following typical functions. Based on the registered work conditions by operator selection and the signals from various sensors, the crane operations are controlled.

(4) Slow stop function In the following cases, the boom elevation speed or the swing speed gradually decreases to stop before the boom reaches the stoppage position.

(1) Automatic stop function for overloading

• When the automatic stop is caused by overloading (Boom lowering will and swing stop.)

The AML calculates and compares the working and rated moment values and displays them as a percentage. When the working moment exceeds the rated moment (100% or more), failure message is shown, alarm buzzer sounds, and the crane operation toward the critical side stops.

• When the elevating cylinder reaches its stroke end (Boom raising/lowering will stop.)

• When the automatic stop is caused by working range limit function (Boom raising/lowering will stop.)

(2) Automatic stop function by backward instability When the boom is raised to 69°: in an over-side area with on-rubber operation.

• When the automatic stop is caused by backward instability during on-rubber operation (Boom raising will stop.)

• When the automatic stop is caused by working range limit function during on-outrigger operation (Swing will stop.)

The situation of automatic stop due to automatic stop function and working range limit function is as listed below, depending on the working condition.

On-outrigger operation

On-rubber operation

Hoisting up Automatic stop by overloading

Boom lowering Boom extension Swing

×

Stop by backward instability Boom raising Stop at stroke end Stop by working range restriction

-

Boom raising/lowering Boom raising/lowering Swing

×

Boom extension : Slow stop

74

: Stop × : Not stop - : Not relevant

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Functions of and How to Use User Mode (GR-700EXL-1) AML System Configuration Boom length signal

Boom angle signal

Moment ratio signal

L

Over-front area signal

Crane control position signal

W

θ

Outrigger extension width detector

Swing angle signal

Operator selection

Outrigger status

L

Lift status

θ

Working range limits Number of part-lines of rope Jib status Winch selection (single top and jib lift only)

AML unit Alarm buzzer

External warning lamps

Display panel

Stop output when: Backward Moment ratio exceeds 100% stability Overwindng occurs control Moment exceeding limit for activated boom with jib mounted AML system error occurs

Swing restricted

Working range limit signal output

Boom extension halted

Boom lowering halted

Hoisting up halted

Swinging halted toward critical side

Boom raising halted

Lifting height restricted

Upper boom angle restricted Lower boom angle restricted

Load radius restricted

u H

L R IW301-0212E04

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Functions of and How to Use User Mode (GR-700EXL-1) Alarm Functions

Automatic Stop Functions Causes of automatic stop

Operation

• Hoisting up

• Overwinding

• Boom extension

• AML system error

• Swing

Working range limit

• Moment ratio exceeds 100%(*1)

Upper boom angle restricted Lower boom angle restricted

• Boom lowering

• Boom raising • Boom lift • Single top lift

• Boom lowering

• Jib lift

Lifting height restricted

• Boom raising

Load radius restricted

• Boom lowering

Swing restricted

• Swing

• Boom extension • Boom extension

• Backward instability • Boom lift (*2) • Single top lift

(*1):

Condition Alarm Moment display: Displays A control is moved toward critical side (hoist up, boom [Warning:0024]. lowering or boom extension) Buzzer: Sounds continuously. while overwinding condition exists.

Overwind cutout function is Moment display: Displays [Warning:0015]. deactivated while overwinding codition exists. External warning lamps: Red lamp is lit.

Buzzer: Sounds continuously.

Moment ratio exceeds 90% Moment display: Yellow segment is lit.

External warning lamps: Orange lamp is lit.

Buzzer: Sounds continuously.

Moment display: Displays A control is moved toward [Warning:0023]. critical side While moment External warning lamps: Red ratio exceeds 100% lamp is lit.

Buzzer: Sounds continuously.

AML system errer Moment display: Displays failure messages.

AML Buzzer: Sounds 3 seconds.

Working range limit function Moment display: Displays activated. failure messages.

Associated restriction indicator lamp flashes.

AML Buzzer: Sounds 3 seconds.

Moment display: Displays Operated to cirtical side [Warning:0025]. when backward stability AML Buzzer: Sounds 3 control activated seconds.

Slow stop control Moment display: Displays [Warning:0081] or [0082] AML Buzzer: Sounds 3 seconds.

Boom lift with jib mounted on boom* (1) Moment ratio is between Moment display: Corresponding segment is lit.

84% and 94%.

(2) Moment ratio is between External warning lamps : Orange lamp is lit.

84% and 94%.

(3) Moment ratio is between Buzzer: Sounds intermittently.

82% and 92%.

Moment display: Displays (1) Moment ratio exceeds [Warning:0088].

94% External warning lamps : Red (2) Moment ratio exceeds lamp is lit.

94% Buzzer: Sounds continuously.

(3) Moment ratio exceeds 92%

Halted movement

• Boom raising

For the boom lift with the jib mounted,

automatic stop will work when the moment exceeds the value listed below, according to the outrigger extension width: Outrigger extension width

Moment

Maximum 7.2m Middle 6.7m Middle 5.5m

93% or more 92% or more 91% or more

Buzz

IW301-0131E54

(*2): Automatic stop will work when the boom is raised to 69° in an over-side area with on-rubber operation.

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Functions of and How to Use User Mode (GR-700EXL-1) (1) is applicable when the outriggers are extended to maximum 7.2m.

(2) is applicable when the outriggers are extended to middle 6.7m.

(3) is applicable when the outriggers are extended to middle 5.5m.

[NOTICE] In the above table, "Buzzer" is the device outside the AML unit, outputting buzzing sound.

"AML buzzer" is the device inside the AML unit, outputting beeping sound.

The AML buzzer sounds for 3 seconds every time a message appears. It outputs long sounds when slow stop control is activated and outputs short sounds when other controls are activated.

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Functions of and How to Use User Mode (GR-700EXL-1) Names and Functions of AML Main Unit Parts Bargraph display

Display panel 1 ゜ m

゜ ・

Display panel 2 Control

IW301-0231E08

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Functions of and How to Use User Mode (GR-700EXL-1)

Bar graph Display

1

3

2

4

Usually on

0-89

Each frame representing 10%

90-99

100-109

110 or more than that

Each frame representing 2.5%

Each frame representing 2.5% IW301-0211E06

1. Moment ratio mark The moment ratios on the bargraph are color coded as follows: safe (green), notice (yellow) and limit (red).

2. Moment display Normally displays a moment ratio on a bargraph.

Displays the main-circuit oil pressure and torque converter oil pressure when the display alteration key is held down.

Also displays error messages when the AML or any of its associated devices fails.

3. Scroll-up key Used to see the previous lines of message displayed on the moment display.

4. Scroll-down key Used to see the next lines of messages displayed on the moment display.

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Functions of and How to Use User Mode (GR-700EXL-1) Display Panel 1 1

2

3

17

20

5

゜ m

15

16

14

21

18

13

6

゜ ・

19

7

17

12 8

11

10

9

IW301-0231E09

8. Rated lifting capacity display

1. Jib angle display

Displays the rated lifting capacity.

When jib lift is selected, the jib angle offset is displayed. When the number of part-lines of rope select key is pressed, or the display alteration key is held down, the number of part-lines of ropes is displayed. Also, when the upper boom angle restriction function is registered, the registered upper boom angle restricted value is displayed as long as the register key is pressed on.

9. Load radius limit restriction indicative symbol This symbol, while marked up, means the value shown in the load radius display (11) represents the load radius limit. Note that the load radius indicative symbol (10) is also displayed at the same time.

10.Load radius indicative symbol This symbol, while marked up, means the value shown in the load radius display (11) represents the load radius.

2. Number of part-lines of indicative symbol This symbol shows that the jib angle display (1) indicates the number of part-lines of rope.

3. Boom length indicative symbol This symbol, while marked up, means the value in the boom length display (13) is a boom length value.

11. Load radius display Normally displays the crane's load radius.

Displays the boom swing angle while the display alteration key is held down.

When the load radius limit restriction function is activated, the load radius limit restriction value is displayed while the register key is held down.

5. Jib angle indicative symbol This symbol, while marked up, means the value shown in the jib angle display (1) represents the offset angle.

12. Counterweight state indicative symbol

6. Jib lift indicative symbol

Marked up when the operation with the counterweight mounted is selected, indicating its mounting state.

Is marked up when the jib lift is selected, indicating the condition of the jib.

7. Real load display Displays the real load.

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Functions of and How to Use User Mode (GR-700EXL-1)

17.Boom angle indicative symbol

13.Boom length display

Indicates that the boom angle display (19) displays the boom angle.

Usually displays boom length.

Displays the lifting height while the display alteration key is pressed.

When the lifting height restriction function is effective, this displays lifting height restriction value while the register key is being pressed.

18.Lower boom angle limit restriction symbol This symbol, while marked up, means the boom angle display (19) displays the registered lower boom angle restricted value.

14.Lifting height indicative symbol

19.Boom angle display Normally displays the boom angle.

Displays the moment % when the display alteration key is held down. When the restriction function is activated, the lower boom angle limit restriction value is displayed while the register key is held down.

This symbol, while marked up, means the value in the boom length display (13) is a lifting height.

15.Lifting height restriction symbol This symbol, while marked up, means the value in the boom length display (13) is a lifting height restriction value.

The lifting height symbol (14) is marked up simultaneously.

20.Boom lift indicative symbol Is marked up when the boom lift is selected.

16.Upper boom angle limit restriction symbol

21.Single-top lift indicative symbol

Indicates that the jib angle display (1) displays the registered boom angle upper restricted value.

Is marked up when the single-top lift is selected.

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Functions of and How to Use User Mode (GR-700EXL-1) Controls 14 13 12 11

15

10 16 17 18

9

19 8

20

7 6

1

2

3

4

5

IW301-0131E59

11. Lower boom angle limit restriction indicator lamp

1. Increase key

Lights up when the lower most boom angle limiting function is activated.

Used to increase the selected value.

2. Decrease key

12.Upper boom angle limit restriction key

Used to decrease the selected value.

Used to activate and release the upper most boom angle limiting function.

3. Outrigger mode select key Used to select the outrigger status.

13.Upper boom angle limit restriction indicator lamp Lights up when the upper most boom angle limiting function is activated.

4. Lift mode select key Used to select the lift status.

5. Check key

14.Lifting height restriction key

Used to check the AML system functions.

Used to activate and release the lifting height limiting function.

6. Register key Used to register a selected state.

15.Lifting height restriction indicator lamp Lights up when lifting height limiting function is activated.

7. Display alteration key Used to alternate the displays on display panel 1.

16.Right swing restriction key Used to activate and release the right swing limiting function.

8. Load radius restriction key Used to activate and release the load radius limiting function.

9. Load radius restriction indicator lamp Lights up when the load radius limiting function is activated.

17.Right swing restriction indicator lamp

10.Lower boom angle limit restriction key

18.Left swing restriction key

Lights up when the right swing limiting function is activated.

Used to activate and release the left swing limiting function.

Used to activate and release the lower most boom angle limiting function.

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Functions of and How to Use User Mode (GR-700EXL-1)

19.Left swing restriction indicator lamp Lights up when the left swing limiting function is activated.

20.Number of part-lines of rope select key Used to register a number of part-lines of rope.

Display Panel 2 5 1 3 2 4

2

3

3

2 3

IW301-0231E10

4. Suspension lock state indicative symbol Displays that the suspensions are locked up.

1. Over-front position symbol Indicates that the boom is swung into the over-front position.

5. Boom position indicator

2. Outrigger state indicative symbol

Displays the boom position in 10° increments.

Displays the way the outriggers are extended.

Flashes while an outrigger state is being selected and is marked up while it registered.

3. "on-rubber" (Outrigger-not-in-use) state indicative symbol Indicates that the on-rubber operation (non-outrigger operation) is selected.

Marked up when the stationary on-rubber operation is selected, and flashes when the traveling on-rubber (creep) operation is selected.

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Functions of and How to Use User Mode (GR-700EXL-1) Selecting Operational Status

[NOTICE] Crane operation is prohibited without full counterweigth installed.

Counterweigth state indicative symbol is marked up as shown below:

WARNING Should the operational status be incorrectly registered, the crane might overturn or be damaged, leading to a serious accident.

Prior to every operation, check that the registered status corresponds to the actual status of the crane.

Dismounting the Counterweight

Mounting the Counterweight

Selecting Outrigger Status [NOTICE] The "on-rubber stationary" status is the default status and is automatically selected when the power supply is turned on (the PTO switch is placed in the "ON" position).

Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power has been last turned off, enter the settings all over again.

IW301-0231E14

(1) On-outrigger operation When the outrigger mode select key is pressed, the outrigger state indicative symbol and counterweight state indicative symbol flashes in accordance with the status that the AML detects on.

After making sure that the display conforms to the actual outrigger conditions, press the register key.

The outrigger state indicative symbol and counterweight state indicative symbol will change from flashing into being marked up continuously and the moment display, rated lifting capacity display and real load display will return to normal display conditions, meaning that the state has been registered.

Register the outrigger state using the outrigger mode select key and the register key.

゜ m

゜ ・

Actual outrigger extension condition

Displayed outrigger status

Register key

IW301-0231E12

Outrigger mode select key IW301-0231E11

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Functions of and How to Use User Mode (GR-700EXL-1)

Fully extended (23' 7-1/2" (7.2m))

Mid. extended (21' 11-3/4" (6.7m))

Mid. extended (18' 1/2" (5.5m))

Min. extended (9' 2-1/4" (2.8m)) IW301-0231E13

(2) On-rubber operation Press the outrigger mode select key repeatedly until the display conforms to the actual condition (on-rubber stationary operation or on-rubber creep operation). Then press the register key. The moment display, rated lifting capacity display and real load display will return to normal display conditions, meaning that the on-rubber state has been registered.

On-rubber stationary operation

On-rubber creep operation

Marked up

Flashing

Marked up

Marked up

IW301-0131E64

[NOTICE] The outrigger status automatically changes to a on-rubber creep status when an operation is made for stowing the outrigger after the registration of the outrigger status. Be sure to again register the outrigger status, when necessary.

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Functions of and How to Use User Mode (GR-700EXL-1) will return to normal display conditions, meaning that the state has been registered.

(When the jib set status is selected, the jib lift indicative symbol will remain flashing.)

Select the boom lift status when lifting a load on the boom with the jib mounted.

Select the jib lift status when lifting a single load using both the boom and jib.

Selecting Lift Status [NOTICE] The boom lift status is the default status and is automatically selected (the boom lift indicative symbol is marked up) when the power supply is turned on (the PTO switch is placed in the ON position).

Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power has been last turned off, enter the settings all over again.

(1) Boom lift

(2) Single top lift

Register the lift status using the lift mode select key and the register key.

(3) Jib set (mounting or stowage)

m

(4) Jib lift : 32.5 ft (9.9m) jib, 3.5° offset

m

t %

max t

m

(5) Jib lift : 32.5 ft (9.9m) jib, 25° offset

Register key

(6) Jib lift : 32.5 ft (9.9m) jib, 45° offset

Lift mode select key IW301-0211E13

(7) Jib lift : 58.1 ft (17.7m) jib, 3.5° offset

Each time the lift mode select key is pressed, the mode changes in numerical sequence, from (1) to (9). The display returns to (1) if you press the switch while the status (9) is displayed on the screen. Select the status that corresponds to the actual lift status.

(8) Jib lift : 58.1 ft (17.7m) jib, 25° offset

[NOTICE]

(9) Jib lift : 58.1 ft (17.7m) jib, 45° offset

After selecting the intended lift status, press the register key to register the status. The corresponding indicative symbols will stop flashing and become marked up and the moment display, rated lifting capacity display and real load display

IW301-0231E15

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Functions of and How to Use User Mode (GR-700EXL-1) When the power supply is turned on (i.e. PTO switch ON), the standard number of part-lines of rope corresponding to a work condition is selected.

Selecting Number of Part-lines of Rope [NOTICE] If the registered number of part-lines of rope is smaller than the standard number, a maximum allowable lifting load is limited, depending on the registered number. In case the number is registered as ‘0’, however, a process takes place as if the standard number were registered.

Similarly, a process takes place on the basis of the standard number of part-lines of rope if the registered number is larger than the standard number.

Register the number of part-lines of rope using the number of part-lines of rope select key and the register key.

Number of part-lines of rope indicative symbol

Number of part-lines of rope

m

t

max t

Number of part-lines of rope select key

m

Decrease key Increase key

Register key

IW301-0211E15

3. Once the intended number of part-lines of rope is

1. Press the number of part-lines of rope select key.

set, press the register key and register the number.

Then, the number of part-lines of rope symbol will be turned off and the jib angle display will return to a normal status.

The number of part-lines of rope symbol will flash, and the number of part-lines of rope will be shown on the jib angle display in a flashing mode.

2. Press the increase or the decrease key to set the number of part-lines of rope at a desired value.

[NOTICE] The number of part-lines of rope can be confirmed by pressing the display alteration key.

[NOTICE] When the increase or the decrease key is pressed, a numeral showing the number of rope stops flashing and becomes continuously marked up, showing a fixed value for the increase or decrease.

When the increase or the decrease key is kept pressed, the number of rope continuously increases or decreases.

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Functions of and How to Use User Mode (GR700EXL-1) Selecting Winch Condition

Selecting Jib Mounted Condition

WARNING

WARNING

Select the correct winch according to the actual crane condition; otherwise the load moment indicator will show wrong moment ratio, leading you to damage or overturn the crane.

If the jib mounting/dismounting state is set improperly, the load moment indicator can not detect the actual load precisely. The crane operation in this condition could create hazard.

The lifting capacities vary depending on the

The jib can be dismounted from the crane body

operating condition. Register the winch selection using the winch selector switch so that the winch selection indicator lamp is as shown in the table below according to the operating condition.

when it is not used. The reduced mass of the crane body after jib removal will influence the precision of the load moment indicator. Use this switch to set the jib mounting /dismounting state to the load moment indicator.

[NOTICE]

When main winch is employed : Main Winch

When auxiliary winch is employed

The key can be inserted in/removed from either “REMOVED” or “EQUIPPED” position.

: Auxiliary Winch

(1) “REMOVED” Select this position when the jib is dismounted. The jib removed indicator lamp will light up.

Winch selector switch

(2) “EQUIPPED” Select this position when the jib is mounted. The jib removed indicator lamp will go off.

: Main Winch

: Auxiliary Winch

Jib removed indicator lamp

IW301-0231E16 2B

D E F

COOL

HO

MODE 3B-

The winch selection alternates between main winch and auxiliary winch each time the winch selector switch is pressed. When auxiliary winch is selected, the winch selection indicator lamp lights up.

Jib state switch

[NOTICE] For boom lift, always employ the main winch.

88

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IW301-0231E17

Functions of and How to Use User Mode (GR700EXL-1) AML Pre-operational Inspection

2. Press either the set key, display alteration key or check key to return the display to the normal condition.

WARNING Operating the crane with a malfunctioning AML could cause the crane to overturn or be damaged. Be sure to perform the pre-operational inspection on the AML system and start the crane only after ensuring that the system is operating properly.

3. Make sure that the display on the display panels conforms to the actual crane conditions.

(1) Boom length (2) Boom angle

Before starting operation, check that the AML

(3) Jib angle……shown while jib lift is selected

works in good condition, as follows:

(4) Real load……Make sure that the approximately mass of the hook block while no load is on the hook block

1. Press the check key and make sure that the AML is in the following conditions: • Moment display……All segments are marked up.

• Display panel (1 and 2) ………………………All segments are marked up.

• Working range restriction indicator lamp ………………………………All six lamps light up.

• Alarm buzzer………………Sounds continuously.

• Movement toward critical sides ………………………………Automatically halted

[NOTICE] The real load is not shown correctly if the lift status is not registered correctly.

(5) Outrigger state indicative symbol (6) Boom position indicator (7) Over-front position symbol ……shown while the boom is in over-front area (8) Counterweigth state indicative symbol

Buzz

3

Bargraph display

2 1

Display panel 1

4 8

m

Display panel 2

m

t %

゜

6

max t

m

7

Check key

5 IW301-0231E18

IW301-0211E16

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Functions of and How to Use User Mode (GR700EXL-1) How to Use the Working Range Limit Function

Boom Angle Limit Raise or lower the boom to the desired angle, and press the upper or lower boom angle limit restriction key. The corresponding limit restriction indicator lamp will flash and the buzzer will sound continuously, indicating that the limit boom angle has been stored in the memory. When the boom is moved back to an angle within the set limit, the limit restriction indicator lamp stops flashing and stays lit and the buzzer stops.

Thereafter, the upper or lower boom angle limit restriction indicator lamp flashes and the buzzer sounds continuously whenever the upper or lower limit previously registered is reached.

To cancel the boom angle limit function, press the boom angle limit restriction key again. The corresponding boom angle limit restriction indicator lamp will go off.

[NOTICE] If the selected working range limits allow the crane to approach too close to an obstruction, the crane may be contacted or hit, depending on the operational status and the manner in which the load is handled. When selecting limits, allow sufficient clearance.

The working range restricting function makes the boom automatically stop at the previously registered boom angles (upper and lower), lifting height, load radius and swing angle, The function is useful for handling a load in a confined place because it defines the area in which the boom can operate.

[NOTICE] Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power was last turned off, enter the settings all over again.

Upper boom angle restricted Lower boom angle restricted

m

Lifting height restricted

t

Upper boom angle limit restriction indicator lamp

max t

m

θu H

Lower boom angle limit restriction indicator lamp

Lower boom angle limit restriction key

θL

Upper boom angle limit restriction key

Load radius restricted

Swing restricted IW301-0211E19

R IW301-0131E70

90

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Functions of and How to Use User Mode (GR700EXL-1) Swing Limit

Lifting Height Limit Move the boom to the desired height, and press

Swing the boom to the desired position, and press

the lifting height restriction key. The lifting height restriction indicator lamp will flash and the buzzer will sound continuously, indicating that the limit height has been stored in the memory. When the boom is moved back to a height within the set limit, the lifting height restriction indicator lamp stops flashing and stays lit and the buzzer stops.

Thereafter, the lifting height restriction indicator lamp flashes and the buzzer sounds continuously whenever the height limit previously registered is reached.

To cancel the height limit function, press the lifting height restriction key again. The corresponding lifting height restriction indicator lamp will go off.

a swing restriction key. The corresponding swing restriction indicator will flash and the buzzer will sound continuously, indicating that the swing angle limit has been registered in the memory.

When the boom is swing back to an angle within the set limit, the swing restriction lamp stops flashing and stays lit and the buzzer stops.

Thereafter, a swing restriction indicator lamp will flash and the buzzer will sound whenever the limit previously registered is reached. (The swinging boom stops automatically.)

To cancel the restriction function, press the corresponding swing restriction key again. The corresponding swing restriction indicator lamp will go out.

[NOTICE]

m

t

When registering the swing angle limit, register both the right and left boom swinging restriction positions.

Registering only one side cannot fulfill this working range limit function nor make the alarm buzzer sound.

While the swing stop cancel switch is set to OFF, the automatic stop does not work even if the boom is swung to the limit. In this case, the corresponding swing restriction indicator lamp flashes, a message appears and the AML buzzer beeps for three seconds. Take care when swinging the boom.

Lifting height restriction indicator lamp

max t

m

Lifting height restriction key

IW301-0211E20

m

t

Left swing restriction indicator lamp

max t

m

Right swing restriction indicator lamp

Right swing restriction key Left swing restriction key IW301-0211E21

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Functions of and How to Use User Mode (GR700EXL-1) Load Radius Limit Move the boom to the desired load radius, and press the load radius restriction key. The load radius restriction indicator lamp will flash and the buzzer will sound continuously, indicating that the limit load radius has been stored in the memory.

When the boom is moved back toward the non-critical side, the load radius restriction indicator lamp stops flashing, and stays lit and the buzzer stops.

The load radius restriction indicator lamp flashes and the buzzer sounds continuously whenever the limit previously registered is reached.

To cancel the load radius limit function, press the load radius restriction key again. The corresponding load radius restriction indicator lamp will go off.

m

t

max t

m

Load radius restriction indicator lamp Load radius restriction key

IW301-0211E22

92

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Functions of and How to Use User Mode (GR700EXL-1) Display of Working Range Restriction Values Press in the register key while working range restricting functions are registered.

While the key is being pressed in, the registered working range restriction values are displayed. On the moment display will be displayed a message "Working range".

[NOTICE] This display is not available when preoperational AML check is made and when working state is registered.

When working range restricting functions are not registered, the message "---" will be displayed.

Upper boom angle limit restriction values

Working range

Lower boom angle limit restriction values

Lifting height restriction values m

t

Load radius restriction values

max t

Boom position indicator m

Register key Swing limit restriction values

IW301-0211E23

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Functions of and How to Use User Mode (GR700EXL-1) Display Alteration Displays on the moment display and the display panel 1 can be altered, as shown below in the figures, while the display alteration key is being pushed. The indicative symbols are displayed, too.

Moment Display

M* * *. *

MPa

Unit

Main circuit pressure

IW301-0211E24

Display Panel 1 [NOTICE] Displays on the real load display and the rated load display do not alter even when the display alteration key is pressed in.

Number of part-lines of rope M * * *. *

MPa

Lifting height

Moment ratio Real load m %

max t

Rated lifting capacity Swing angle

Display alteration key IW301-0211E25

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General: Adjustment Mode and Maintenance Mode [ADJUSTMENT AND MAINTENANCE] General: Adjustment Mode and Maintenance Mode 1. Keys and Switches for Adjustment and Maintenance 1. Scroll-up key Moment display 2. Scroll-down key

t

m

max t

HALT

WDT

ZERO

PROTECT ON

OFF

MOMENT SHORT

m

8. Moment input short-circuit switch 9. Protect switch 10. Moment zero adjuster 11. Abnormality display LED Top view IW301-0131E02

7. Check key 4. Increase key 3. Register key 5. Decrease key 6. Display alteration key IW301-0211E26

1. Scroll-up key Used to see the previous lines of message displayed on the moment display.

7. Check key Used for ”Do Check” and ”Ao Check” functions in the maintenance mode.

2. Scroll-down key Used to see the next lines of messages displayed on the moment display.

8. Moment input short-circuit switch Not used for this machine.

9. Protect switch

3. Register key

Set this switch to OFF when changing the mode from user mode to adjustment mode. With this switch OFF, data in the EEPROM becomes rewritable.

Used to register the selected state and write the adjustment value in EEPROM. 4. Increase key Used to increase the adjustment value.

5. Decrease key Used to decrease the adjustment value.

10.Moment zero adjuster This adjuster is for adjustment by the AML manufacturer’s service personnel. Do not tamper.

6. Display alteration key

11.Abnormality display LED Lights when the AML is in abnormal conditions or when the AML adjustment is initialized.

Used to change the display to the upper menu.

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General: Adjustment Mode and Maintenance Mode 2. Mode Structure and Menu

2. Maintenance Mode: Used to make functional checks of AML. This mode has the following menus:

The AML device has three modes and AML functions are allotted for these models.

MAIN MENU

POWER ON

[• Maintenance] Protect switch ON

MAINTENANCE MODE

USER MODE

Protect switch OFF

[• Adjust clock]

ADJUSTMENT MODE

POWER ON

IW301-0212E05

1. User Mode: Used to indicate moment ratio or to perform AML pre-opetational inspection (Normally used).

HALT

ZERO

WDT

PROTECT ON

OFF

MOMENT SHORT

In normal use, turn ON the protect switch mounted on the adjustment window on the top of AML. AML will go to the user mode when the power turns on.

ON

Top view

Protect switch IW301-0131E03

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SUB-MENU [: Prog. version] [: Data ID. number] [: Di check] [: Ai check] [: Disp ELEV PRES] [: Do check] [: MDT Monitor] [: Key SW check] [: Display check] [: Disp. err data] [: Erase err data] [: Disp. O/L data] [: Erase O/L data] [: OP board check] [: Ao check] [: Sio check] [: Adjust Monitor]

General: Adjustment Mode and Maintenance Mode 3. Adjustment Mode: Used to make detector adjustment. This mode has the following menus: MAIN MENU [• Adjust]

SUB-MENU [: Adjust L&A]

[: Adj. work rad] [: Adjust MMT] [• Adjust CNT dat]

[• Adjust AO] [• Initialize L&A] [• Initialize MMT] [• Disp. O/L data] [• Erase O/L data] [• Adjust PCSN] (*1) [• Reg. Capac.]

[• Language]

(*1)

[: Adj. ELV speed]

*Boom length zero-point adjustment *Boom length span-point adjustment *Boom angle zero-point adjustment *Boom angle span-point adjustment *Swing angle zero-point adjustment *Swing angle span-point adjustment *Outrigger length zero-point adjustment *Outrigger length span-point adjustment *Jib length zero-point adjustment *Jib length span-point adjustment *Jib angle zero-point adjustment *Jib angle span-point adjustment *Load radius span adjustment *Moment zero-point adjustment *Moment span-point adjustment [Adjust ELV UP] [Correct ELV UP] [Adjust ELV DN] [Correct ELV DN]

[: Reset ELV data] [: Adjust AO Ofs.] [: Reset AO Ofs.] [: Reset DEF. FCT] [: Reset zero. span] [: Erase PCSN] (*1)

[: Head-OFF Capac] [: Jib Select]] [: S/T Select] [: Winch drum PSN]

: This menu is prohibited to be used, except for Europe.

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General: Adjustment Mode and Maintenance Mode 3. Method of Shifting Modes Scroll-up key

Moment display

HALT

WDT

ZERO ON

OFF

MOMENT SHORT

PROTECT

Scroll-down key

OFF m

ON Protect switch

t

Top view

max t m

IW301-0131E03

POWER ON

Protect switch ON Protect switch OFF

1 MAINTENANCE MODE

USER MODE 2 3

5

4 ADJUSTMENT MODE

Register key Display alteration key

POWER ON

IW301-0211E28

IW301-0232E12

4. “Adjustment mode” → “User mode”

1. “User mode” → “Maintenance mode”

While the main menu of the adjustment mode is displayed, turn ON the protect switch. Then AML will go back to “User mode” and bargraph will be displayed on the moment display.

Press the scroll-up key, scroll-down key, and register key at the same time. Then, the moment display changes from the bargraph to [• Maintenance]. This display denotes the “Maintenance mode”.

5. “Maintenance mode” → “Adjustment mode”

2. “Maintenance mode” → “User mode”

While the main menu of the maintenance mode is displayed, turn OFF the protect switch. The moment display will change to [•Adjust], and will denote “Adjustment mode”.

Press the display alteration key. When the bargraph shows up on the moment display, AML goes back to the “User mode”.

3. “User mode” → “Adjustment mode” Turn OFF the protect switch at the adjustment window on the top of AML. Then, the moment display will change to [•Adjust], and will denote “Adjustment mode”.

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General: Adjustment Mode and Maintenance Mode 4. Method of Menu Selection Scroll-up key

Moment display Scroll-down key

m

t max t m

Register key Display alteration key IW301-0211E28

4. The following marks displayed in the menu: “•”, “:”

1. When AML is in “Maintenance mode” or “Adjustment mode”, the main menu is displayed on the moment display of bargraph display portion.

Displayed menu changes by means of the scroll-up or scroll-down key. Press the register key to select the displayed item.

2. If the selected item in the main menu has any sub-menus, the sub-menus are displayed on the moment display of bargraph display portion. You can select the sub-menu in the same way sa main menu selection.

and “ ”.

When a main menu is displayed, the mark “•” stands before the menu name. (Ex. “•Adjust ”) When a sub-menu is displayed, the mark “:” stands before the menu name.

(Ex. “:Adjust MMT”) The “ ” mark after the menu name indicates that the depression of the scroll-down key calls for another menu.

3. By pressing the display alteration key, the display changes to the upper menu.

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Required Adjustment After AML System Parts Replacement Required Adjustment After AML System Parts Replacement [NOTICE] EEPROM stores the adjustment values for each specification number. When replacing the CPU board, remove the EEPROM after removing it from the broken CPU board to dispense with adjustment work other than clock adjustment. Visually check that the value displays such as boom length and boom angle and symbol display on the display panels 1 and 2 on the AML conform the actual crane condition.

Replaced part

Required adjustment

Boom length detector

Boom length adjustment

Boom angle detector

Boom angle adjustment

Swing angle detector

Swing angle adjustment

Outrigger extension width detector

Outrigger extension width adjustment

Pressure sensor for moment detection

Moment adjustment

Display board

None CPU board only (When reusing EEPROM removed from the broken CPU board)

CPU board

CPU board (When EEPROM is not to be reused) EEPROM

AML unit ROM

Perform adjustment initialization and take every step of adjustment. For adjustment items and procedure, see “Adjustment Procedures” on the subsequent page in the “Function of and How to Use Adjustment Mode” section.

None

Analog board

Boom length adjustment Boom angle adjustment Swing angle adjustment Moment adjustment

Power board

None

Current output board (Option board)

Adjustment of swing output Adjustment of elevation output

Connector board

None

Right swing proportional control valve Proportional control valve for Slow stop

Clock adjustment

Left swing proportional control valve Boom raising proportional control valve Boom lowering proportional control valve

100

Adjustment of swing output

Adjustment of elevation output

W301-0212E

Functions of and How to Use Adjustment Mode Functions of and How to Use Adjustment Mode Adjustment Procedures WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety.

[NOTICE] You can adjust boom length, boom angle, swing angle, and outrigger extension width in random order.

You can adjust swing output and elevation output in random order.

After all adjustment is completed, erase-protect the overload history, referring to “Erasing the Overload History” in the “Functions of How to Use Adjustment Mode” section.

The adjustment items and procedures are as follows: 1. Adjustment Initialization 2. Capacity Setting 3. Boom Length Adjustment 4. Boom Angle Adjustment 5. Swing Angle Adjustment 6. Outrigger Extension Width Adjustment 7. Moment Adjustment (Including load radius adjustment) 8. Clock Adjustment 9. Adjustment of Swing Output 10.Adjustment of Elevation Output Adjustment completed Erasing the Overload History

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Functions of and How to Use Adjustment Mode 1. Adjustment Initialization

1.1 Procedure of Conversion Factors Resetting 1. Select the main menu [ • Initialize L&A ] in the

[NOTICE]

adjustment mode, and press the register key to select the menu.

Adjustment initialization should be performed only when EEPROM is replaced.

If the EEPROM removed from the faulty CPU board is reused when the CPU board is replaced, adjustment initialization is not required.

2. When [: Reset DEF. FCT ] appears, reset the deflection factor by pressing the register key.

By the adjustment initialization, the conversion factors (standard values specified for each specification) stored within the AML program that convert detected voltage input from the detectors into physical volumes is read out from the P-ROM and written onto the EEPROM.

3. When the message [Done] appears, the deflection

Perform the initialization only once before the first

5. When [: Reset DEF. FCT ] appears, press the scroll-down key to display [：Reset zero. span], and then press the register key to reset the zero span factor.

factor resetting is completed. Press the display alteration key to return to the main menu.

4. Press the register key again to select the main menu [•Initialize L&A ] in the adjustment mode.

adjustment takes place. If this initialization is done while adjustments are being made, you must restart the adjustment from the very beginning.

For adjustment initialization, you have to execute the following two menus.

[• Initialize L&A] : Initialize the conversion factors for boom length, angle, and deflection.

[• Initialize MMT] : Initialize the conversion factors for moment.

6. When the message [Done] appears, the zero span factor resetting is completed.

Press the display alteration key to return to the main menu.

1.2 Procedures of Moment Adjustment Resetting 1. Select the main menu [• Initialize MMT ] in the adjustment mode, and press the register key to select the menu.

2. When [Reset MMT] appears, reset the moment factor by pressing the register key.

3. When the message [Done] appears, the moment adjustment resetting is completed.

Press the display alteration key to return to the main menu.

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Functions of and How to Use Adjustment Mode 2. Capacity Setting [NOTICE]

2.1 Procedure of Head-off Capacity Setting [NOTICE] A head-off capacity value defined with this function is compared with the capacity (rated lifting capacity) data stored in the ROM, and the value whichever smaller is set as the capacity. Note that if the head-off capacity value is zero, the capacity data stored in the ROM is used.

Check the specification number of “Adjustment Value Table” in the INFORMATION AND DATA section whether your crane needs to perform this setting. For the models other than GT-550E-1, GR-120N-1 and GR-700EXL-1 refer to the Service Manual specified for each crane model.

1. Select the main menu [• Reg. Capac. ] in the adjustment mode, and press the register key to select the menu.

The crane capacity data is stored in the ROM. This setting is performed to partially change the crane capacity data in the ROM.

2. Press the scroll-up or scroll-down key to display

The crane capacity data normally does not need this setting.

[: Head-Off Capac ], and then press the register key to select the menu.

For the capacity setting, select one of the four

3. The currently registered head-off capacity value is

sub-menus indicated below. [: Head-Off Capac] : Used to set the maximum rated lifting capacity to the specified value. [: Jib Select] : Used to change the capacity for jib-mounted condition to the capacity for jib-unmounted condition. [: S/T Select] : Used to change the capacity for single-top-mounted condition to the capacity for single-top unmounted condition. [: Winch drum PSN] : Used to specify the mounting position of winch drum for capacity adjustment.

indicated on the moment display.

Display example: [Capacity 45.00t] 4. Press the increase or decrease key to adjust the head-off capacity value as desired.

Every time you press the increase or decreace key, the head-off capacity value increases or decreases in steps of 0.01t. If the key is held down, the value increases or decreases in steps of 1t.

5. When the desired head-off capacity value is reached, press the register key to save it.

6. Press the display alteration key to exit the menu.

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Functions of and How to Use Adjustment Mode 2.2 Procedure of Jib Selection

2.3 Procedure of Single Top Selection

[NOTICE]

[NOTICE]

When the jib-unmounted (detached) condition is selected, the jib capacity data stored in the ROM becomes unusable and also the jib mass is excluded from capacity calculation.

When the single-top-unmounted (detached) condition is selected, the single top capacity data stored in the ROM becomes unusable and also the single top mass is excluded from capacity calculation.

1. Select the main menu [• Reg. Capac. ] in the adjustment mode, and press the register key to select the menu.

2. Press the scroll-up or scroll-down key to display [: Jib Select ], and then press the register key to select the menu.

1. Select the main menu [• Reg. Capac. ] in the adjustment mode, and press the register key to select the menu.

2. Press the scroll-up or scroll-down key to display [: S/T Select ], and then press the register key to select the menu.

3. The currently registered jib capacity condition is indicated on the moment display. Using the scroll-up or scroll-down key, adjust it to the desired condition .

Display example: [Jib = Mounted ] Press the scroll-up key.

[Jib : Not Mounted] When “ = ” is indicated, it means that the displayed condition is registered currently.

3. The currently registered single top capacity

4. When the desired condition is displayed, press the register key for confirmation. When the setting is completed, “:” in the Jib condition display changes to “ = ”.

Display example: [Jib：Not Mounted] Press the register key.

[Jib = Not Mounted]

condition is indicated on the moment display.

Using the scroll-up or scroll-down key, adjust it to the desired condition.

Display example: [S/T=Mounted ] Press the scroll-up key.

[S/T : Not Mounted] When “ = ” is indicated, it means that the displayed condition is registered currently.

4. When the desired condition is displayed, press the register key for confirmation. When the setting is completed, “:” in the single top condition display changes to “ = ”.

Display example： [S/T : Not Mounted] Press the register key.

[S/T = Not Mounted]

5. Press the display alteration key to exit the menu.

5. Press the display alteration key to exit the menu.

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Functions of and How to Use Adjustment Mode 2.4 Procedure of Winch Drum Position Setting [NOTICE] The center of gravity of winch drum can be changed by adjusting the winch drum position. The calculation is performed according to the winch drum position setting by this function.

1. Select the main menu [• Reg. Capac. ] in the adjustment mode, and press the register key to select the menu.

2. Press the scroll-up or scroll-down key to display [: Winch drum PSN], and then press the register key to select the menu.

3. The currently registered jib capacity condition is indicated on the moment display. Using the scroll-up or scroll-down key, adjust it to the desired condition.

Display example: [Winch drum = FR ] Press the scroll-up key.

[Winch drum : F ] Press the scroll-up key.

[Winch drum : R] In the above examples, “F” means the condition with single winch mounted at the front. “R” means the condition with single winch mounted at the rear. “FR” means the condition with double winches mounted at the front and rear.

The conditions with “ = ” is the currently registered condition.

4. When the desired condition is displayed, press the register key for confirmation. When the setting has been completed, “:” in the winch drum condition display changes to “ = ”.

Display example: [Winch drum : F ] Press the register key.

[Winch drum = F ] 5. Press the display alteration key to exit the menu.

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Functions of and How to Use Adjustment Mode 3. Boom Length Adjustment

10.Has the boom length zero-point adjustment display [Boom Lz] become the zero-point adjustment value in “Adjustment Value Table” ?

WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety.

NO

YES

11.Press the display alteration key to exit the menu.

[NOTICE] Refer to “Adjustment Value Table” in the INFORMATION AND DATA section since the conditions and values for boom length adjustment vary depending on the specification number. For the models other than GT-550E-1, GR-120N-1 and GR-700EXL-1 refer to the Service Manual specified for each crane model.

When the length detector has only been installed and its cord has not yet been unwound on the drum, set the code wound naturally on the boom through the entire length during the boom telescopic operation.

1. Select the main menu [• Adjust ] in the adjustment mode, and press the register key to select the menu.

2. When [: Adjust L&A ] is displayed, press the register key to select the menu.

3. Fully retract the boom.

4. Press the increase or decrease key so that the value of boom length zero-point adjustment display [Boom Lz] becomes the zero-point adjustment value in “Adjustment Value Table”.

Press the register key for registration.

5. Fully extend the boom.

6. Press the scroll-down key until the boom length span adjustment display [Boom Ls] appears.

7. Press the increase or decrease key so that the value of boom length span adjustment display [Boom Ls] becomes the span adjustment value in “Adjustment Value Table”. Press the register key for registration.

8. Fully retract the boom again.

9. Press the scroll-up key until the boom length zero-point adjustment display [Boom Lz] appears.

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Functions of and How to Use Adjustment Mode 4. Boom Angle Adjustment 8. Press the increase or decrease key so that the

WARNING

value of boom angle span adjustment display [Boom As] becomes the span adjustment value in “Adjustment Value Table”. Press the register key for registration.

Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety.

[NOTICE] Refer to “Adjustment Value Table” in the INFORMATION AND DATA section since the conditions and values for boom angle adjustment vary depending on the specification number. For the models other than GT-550E-1, GR-120N-1 and GR-700EXL-1 refer to the Service Manual specified for each crane model.

Always perform the boom lowering operation when adjusting the boom angle to the adjustment condition. Measure the boom angle with a level angle meter.

1. Select the main menu [• Adjust ] in the adjustment mode, and press the register key to select the menu.

2. When [: Adjust L&A ] is displayed, press the register key to select the menu.

9. Bring the actual boom angle to the zero-point adjustment value in “Adjustment Value Table” again.

10.Press the scroll-up or scroll-down key until the boom angle zero-point adjustment display [Boom Az] appears.

11.Has the value of boom angle zero-point adjustment display [Boom Az] become the zero-point adjustment value in “Adjustment Value Table” ?

NO

YES

12.Press the display alteration key to exit the menu.

3. Set the actual boom angle to the condition of the zero-point adjustment specified in “Adjustment Value Table” by lowering the boom.

4. Press the scroll-up or scroll-down key until the boom angle zero-point adjustment display [Boom Az] appears.

5. Press the increase or decrease key so that the value of boom angle zero-point adjustment display [Boom Az] becomes the zero-point adjustment value in “Adjustment Value Table”. Press the register key for registration.

6. Raise the boom to just before the upper stroke end, and then adjust the actual boom angle to the condition of the span-point adjustment specified in “Adjustment Value Table” by lowering the boom.

7. Press the scroll-up or scroll-down key until the boom angle span adjustment display [Boom As] appears.

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Functions of and How to Use Adjustment Mode 5. Swing Angle Adjustment

10.Press the increase or decrease key so that the value of swing angle 1 span-point adjustment display [SW AG 1s] will become 180 ± 0.3°.

Press the register key for registration.

WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety.

11.With the swing position unchanged, press the scroll-up or scroll-down key until the swing angle 2 span-point adjustment display [SW AG 2s] appears.

[NOTICE] Since the swing angles involve a hysteresis, always make adjustment after a stop from rightward movement.

12.Press the increase or decrease key so that the value of swing angle 2 span-point adjustment display [SW AG 2s] will become 180 ± 0.3°.

Press the register key for registration.

1. Select the main menu [• Adjust ] in the adjustment mode, and press the register key to select the menu.

13.Set the boom again to the zero-point adjustment reference position (on the front centerline) by swinging it clockwise.

2. When [: Adjust L&A ] is displayed, press the register key to select the menu.

14.Check the swing angle 1 and 2 zero-point adjustment displays [SW AG 1z] and [SW AG 2z] by pressing the scroll-up or scroll-down key. Does each display indicate the angle below?

SW AG 1z：0 ± 0.6° SW AG 2z：360 ± 0.6°

3. Set the boom to the zero-point adjustment reference position (on the front centerline) by swinging it rightward.

4. Press the scroll-up or scroll-down key until the swing angle 1 zero-point adjustment display [SW AG 1z] appears.

NO

YES

15.Press the display alteration key to exit the menu.

5. Adjust the increase or decrease key so that the value of swing angle 1 zero-point adjustment display [SW AG 1z] will become 0 ± 0.3°. Press the register key for registrarion.

6. With the swing position unchanged, press the scroll-up or scroll-down key until the swing angle 2 zero-point adjustment display [SW AG 2z] appears.

7. Adjust the increase or decrease key so that the value of swing angle 2 zero-point adjustment display [SW AG 2z] will become 360 ± 0.3°. Press the register key for registration.

8. Set the boom to the span- point adjustment reference position (on the rear centerline) by swinging it rightward.

9. Press the scroll-up or scroll-down key until the swing angle 1 span-point adjustment display [SW AG 1s] appears.

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Functions of and How to Use Adjustment Mode 6. Outrigger Extension Width Adjustment

Press the register key for registration.

10.Adjust and register the values of the right-rear,

[NOTICE]

left-front and left-rear outriggers extension width span adjustment in the same manner as the one of the right-front outrigger extension width span adjustment.

Right-rear outrigger : Adjust [RRO/R Ls] display Left-front outrigger : Adjust [LFO/R Ls] display Left-rear outrigger : Adjust [LRO/R Ls] display

Refer to “Adjustment Value Table” in the INFORMATION AND DATA section since the conditions and values for outrigger extension width adjustment vary depending on the specification number. For the models other than GT-550E-1, GR-120N-1 and GR-700EXL-1 refer to the Service Manual specified for each crane model.

1. Select the main manu [• Adjust ] in the

11.Fully retract all the outrigger beams again.

adjustment mode, and press the register key to select the menu.

12.Press the scroll-up or scroll-down key until the right-front outrigger extension width zero-point adjustment display [RFO/R Lz] appears.

2. When [: Adjust L&A ] is displayed, press the register key to select the menu.

13.Does the right-front outrigger extension width zero-point adjustment display [RFO/R Lz] conform to the zero-point adjustment value in “Adjustment Value Table” ? And does each display for the right-rear outrigger [RRO/R Lz], for the left-front outrigger [LFO/R Lz], and for the left-rear outrigger [LRO/R Lz] conform to the zero-point adjustment value in “Adjustment Value Table” ?

3. Fully retract all the outrigger beams.

4. Press the scroll-up or scroll-down key until the right-front outrigger extension width zero-point adjustment display [RFO/R Lz] appears.

5. Press the increase or decrease key so that the value of the right-front outrigger extension width zero-point adjustment display [RFO/R Lz] conforms to the zero-point adjustment value in “Adjustment Value Table”. Press the register key for registration.

NO

YES

14.Press the display alteration key to exit the menu.

6. Adjust and register the values of the right-rear, left-front and left-rear outrigger extension width zero-point adjustment in the same manner as the one of the right-front outrigger extension width zero-point adjustment.

Right-rear outrigger : Adjust [RRO/R Lz] display Left-front outrigger : Adjust [LFO/R Lz] display Left-rear outrigger : Adjust [LRO/R Lz] display 7. Fully extend all the outrigger beams.

8. Press the scroll-up or scroll-down key until the right-front outrigger extension width span adjustment display [RFO/R Ls] appears.

9. Press the increase or decrease key so that value of the right-front outrigger extension width span adjustment display [RFO/R Ls] conforms to span adjustment value in “Adjustment Value Table”.

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Functions of and How to Use Adjustment Mode 7. Moment Adjustment WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety.

[NOTICE] Before starting moment adjustment, raise the hydraulic oil temperature to approx.50°C by alternate raising and lowering the boom.

Refer to “Adjustment Value Table” in the INFORMATION AND DATA section since the conditions and values for moment adjustment vary depending on the specification number. For the models other than GT-550E-1, GR-120N-1 and GR-700EXL-1 refer to the Service Manual specified for each crane model.

If the moment zero-point value is not within the tolerance at “7.6 Moment Zero-point Recheck”, follow the fine adjustment steps of the broken line process order.

The procedure to adjust moment is as follows: 7.1 Moment Zero-point Adjustment 7.2 Moment Span Preliminary Adjustment 7.3 Moment Zero-point Check and Fine Adjustment 7.4 Load Radius Adjustment 7.5 Moment Span Fine Adjustment 7.6 Moment Zero-point Recheck NO YES End of moment adjustment

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Functions of and How to Use Adjustment Mode 7.1 Moment Zero-point Adjustment

0.00 to 0.99 t: “000” to “099” -0.99 to -0.01 t: “-99” to “-01”

[NOTICE] For the conditions and adjustment value of the moment zero-point adjustment, refer to the moment zero-point adjustment item in the “Adjustment Value Table”.

Set the crane as follows: (1)Outriggers mode: Fully extended (2)Lift mode: Boom lift (Stow jib and single top) (3)Boom length: Fully retracted (4)Boom angle: Raise boom until it almost reaches to maximum point, and then lower it until boom angle display corresponds to condition of zero-point adjustment.(Refer to “Adjustment Value Table”.)

(5)Hook block position: Hoisted down just clear of ground surface or vehicle structure (6)Actual status and registered status of number of part-lines: Standard number of part-lines when main boom is fully extended (7)Hook block: Refer to “Adjustment Value Table”.

(Stow auxiliary hook block.)

(8)Refer to “Adjustment Value Table” according to the crane model, there might be a condition besides above.

4. After the adjustment, press the register key to save the adjusted value.

5. Proceed to “7.2 Moment Span Preliminary Adjustment”.

1. Select the main menu [• Adjust ] in the adjustment mode, and press the register key to select the menu.

2. When [:Adjust L&A ] is displayed, press the scroll-down key until the display [:Adjust MMT] appears. Press the register key to select the menu.

3. While the moment zero-point adjustment is displayed, adjust the value indicated in the actual load value indicator finely with the increase or decrease key to conform it to the adjustment value of the zero-point adjustment.

Moment zero-point adjustment display: Display [X.XXX z . % ] Moment ratio(%) Shows zero-point adjustment state Moment detector input(mV) The actual load value less than 1 klbs is shown as follows:

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Functions of and How to Use Adjustment Mode 7.2 Moment Span Preliminary Adjustment [NOTICE] For the conditions and adjustment value of the moment span preliminary adjustment, refer to the moment span preliminary adjustment item in the “Adjustment Value Table”.

7.3 Moment Zero-point Check and Fine Adjustment [NOTICE] For the conditions and adjustment value of the moment zero-point check and fine adjustment, refer to the moment zero-point adjustment item in the “Adjustment Value Table”.

1. Continued from “7.1 Moment Zero-point Adjustment”.

1. Continued from “7.2 Moment Span Preliminary Adjustment”.

2. Lower the boom to set the boom angle to the

2. Raise the boom until it almost reaches to the

condition of the span preliminary adjustment.

(Hook block position:Hoisted down until it almost touches ground surface)

maximum point, and then lower it until the boom angle display corresponds to the condition of the zero-point adjustment. (Hoist down the hook block until it almost touches the ground surface or chassis.)

3. Press the scroll-up or scroll-down key until the moment span adjustment display appears.

Moment span adjustment display: Display [X.XXX s . %]

3. Press the scroll-up or scroll-down key until the moment zero-point adjustment display appears.

Moment zero-point adjustment display: Display [X.XXX z . % ]

Moment ratio(%) Shows span adjustment state

Moment ratio(%)

Moment detector input(mV)

Shows zero-point adjustment

4. Adjust the value indicated in the actual load value indicator finely with the increase or decrease key to conform it to the adjustment value of the span preliminary adjustment.

The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t: “000” to “099” -0.99 to -0.01 t: “-99” to “-01”

state Moment detector input(mV) 4. Has the indicated value become the zero-point adjustment value?

The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t: “000” to “099” -0.99 to -0.01 t: “-99” to “-01”

5. After the adjustment, press the register key to save the adjusted value.

YES

6. Proceed to “7.3 Moment Zero-point Check and

NO

5. Make an adjustment with the increase or

Fine Adjustment”.

decrease key so that the result becomes the zero-point adjustment value. Then, press the register key to save the adjusted value.

6. Press the display alteration key to exit the menu.

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Functions of and How to Use Adjustment Mode 7.4 Load Radius Adjustment [NOTICE] For the conditions and adjustment value of the load radius adjustment, refer to the load radius adjustment item in the “Adjustment Value Table”.

Set the crane as follows: (1)Outriggers mode: Fully extended (2)Lift mode: Boom lift (Stow jib and single top) (3)Boom length: Fully extended (4)Actual status and registered status of number of part-lines: Standard number of part-lines when main boom is fully extended (5)Hook block: Refer to “Adjustment Value Table”.

(Stow auxiliary hook block.)

(6)Load radius: After lifting rated lifting capacity of load radius adjustment condition, set actual load radius to meet load radius adjustment condition (load radius) by boom lowering operation. (Cancel AML stop function when overload hinders boom lowering.)

(7)Refer to “Adjustment Value Table” according to the crane model, there might be a condition besides above.

(4)Boom angle: Lower boom until the boom angle display corresponds to condition of span fine adjustment.

(5)Hook block position: Hoisted down until it almost touches ground surface or vehicle structure.

(6)Actual status and registered status of number of part-lines: Standard number of part-lines when main boom is fully extended.

(7)Hook block: Refer to “Adjustment Value Table”.

(Stow auxiliary hook block.)

(8)Refer to “Adjustment Value Table” according to the crane model, there might be a condition besides above.

1. Select the main menu [• Adjust ] in the adjustment mode, and press the register key to select the menu.

1. Select the main menu [• Adjust ] in the adjustment mode, and press the register key to select the menu.

2. When [: Adjust L&A ] is displayed, press the scroll-down key until the display [:Adjust MMT] appears. Press the register key to select the menu.

3. Press the scroll-down key until the moment span adjustment display appears.

Moment span adjustment display: Display [X.XXX s . %] Moment ratio(%)

2. Press the scroll-down key until the load radius

Shows span adjustment state

adjustment display [: Adj. work rad ] appears.

Then, press the register key to select the menu.

Moment detector input(mV)

3. Press the increase or decrease key so that the

4. Using the increase or decrease key, adjust the

load radius adjustment display [Rad. 1s] becomes the load radius adjustment value. Press the register key for that registration.

indicated value so that it becomes the span fine adjustment value. Then, press the register key to save the adjusted value.

The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t: “000” to “099” -0.99 to -0.01 t: “-99” to “-01”

4. Press the display alteration key to exit the menu.

7.5 Moment Span Fine Adjustment [NOTICE]

5. Proceed to “7.6 Moment Zero-point Recheck”.

For the conditions and adjustment value of the moment span fine adjustment, refer to the moment span fine adjustment item in the “Adjustment Value Table”.

Set the crane as follows: (1)Outriggers mode: Fully extended (2)Lift mode: Boom lift (Stow jib and single top) (3)Boom length: Fully extended

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Functions of and How to Use Adjustment Mode 7.6 Moment Zero-point Recheck [NOTICE] For the conditions and adjustment value of the moment zero-point recheck, refer to the moment zero-point adjustment item in the “Adjustment Value Table”.

6. Make fine adjustment as shown below. (The following fine adjustment procedures are extracted from “7.3 Moment Zero-point Check and Fine Adjustment”.)

1. Continued from “7.5 Moment Span Fine Adjustment”.

(1)Make an adjustment with the increase or decrease key so that the result becomes the zero-point adjustment value. Then, press the register key to save the adjusted value.

2. Retract the boom fully.

3. Raise the boom until it almost reaches to the maximum point, and then lower the boom until the boom angle display corresponds to the zero-point adjustment condition. (Hoist down the hook block until it almost touches the ground surface or chassis.)

(2)Press the display alteration key to exit the menu.

7. Perform “7.5 Moment Span Fine Adjustment”.

Perform “7.6 Moment Zero-point Recheck”.

4. Press the scroll-up or scroll-down key until the moment zero-point adjustment display appears.

Moment zero-point adjustment display: Display [X.XXX z . % ]

8. Press the display alteration key to exit the menu.

The moment adjustment is completed.

Moment ratio(%) Shows zero-point adjustment state Moment detector input(mV) 5. Has the indicated value become the zero-point adjustment value?

The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t: “000” to “099” -0.99 to -0.01 t: “-99” to “-01” YES

NO

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Functions of and How to Use Adjustment Mode 8. Clock Adjustment AML has calender and clock IC inside, which is used for recording errors. Adjust the clock in the following procedure. Adjust the clock in the maintenance mode.

1. Select the main menu [• Adjust clock] in the maintenance mode, and press the register key to select the menu.

2. When the time is displayed on the moment display, press the scroll-up or scroll-down key to bring the cursor to the place to be adjusted.

Time is displayed in the 24-hour basis. The cursor lies under a numeral.

Display example:[ 99. 8. 23 16:30] Cursor 3. Press the increase or decrease key to change the value to be adjusted.

4. After the adjustment, press the register key to put the adjustment value onto the IC. If there are plural adjustment places, move the cursor for adjustment in order. Finally press the register key.

5. press the display alteration key to exit the menu.

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Functions of and How to Use Adjustment Mode 9. Adjustment of Swing Output

3. Press the scroll-up or scroll-down key until the right swing output adjustment display [41 SWG RV] (the left swing output adjustment display [42 SWG LV] for the left swing output adjustment) appears and a cursor comes on under the output value.

Display example: [41 SWG RV 0 0 ]

[NOTICE] Always reset the Ao offset value before adjustment of swing output (Ao offset adjustment).

9.1 Procedure of Resetting Ao Offset Value 1. Select the main menu [• Adjust AO ] in the

Actual output value

adjustment mode, and press the register key to select the menu.

Output value

2. When [:Adjust AO Ofs. ] is displayed, press the scroll-down key until the display [:Reset AO Ofs.] appears. Press the register key to select the menu.

4. Press the increasse or decrease key to conform the output value of the right swing output adjustment display [41 SWG RV] to the standard value of the swing output. Remember that actual output value will also change in this situation.

Display example: [41 SWG RV 35 35 ]

3. When [Reset OK?] appears, reset the Ao offset value by pressing the register key.

4. When the message [Done] appears, the Ao offset

Actual output value

value resetting is completed. Press the display alteration key to return to the main menu.

Output value

9.2 Adjustment of Swing Output (Ao offset adjustment)

5. Press the scroll-down key to move the cursor to under the actual output value.

Display example: [41 SWG RV 35 35 ]

[NOTICE] Refer to “Adjustment Value Table” in the INFORMATION AND DATA section since the standard value of the swing output varies depending on the specification number. For the models other than GT-550E-1, GR-120N-1 and GR-700EXL-1 refer to the Service Manual specified for each crane model.

Set the crane as follows: (1)Outriggers mode: Fully extended (2)Lift mode: Boom lift (Stow jib and single top.)

(3)Boom length: Fully retracted (4)Boom angle: As high as possible (Lowered boom can constitute a hazard when swung.)

(5)Hook block position: Hoisted up as much as possible (6)Hydraulic oil temperature: Approx. 50°C

Actual output value Output value 6. While keeping the swing control lever fully to the right swing side, raise the engine speed to maximum. Then press the increase or decrease key so that the boom swing will stop under this condition.

Display example: [41 SWG RV 35 37 ] Actual output value Output value 7. Press the register key to save the adjusted value

1. Select the main menu [• Adjust AO ] in the

in EEPROM. Now the adjustment of the right swing output is completed.

adjustment mode, and press the register key to select the menu.

2. When [: Adjust AO Ofs. ] is displayed, press the register key to select the menu.

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Functions of and How to Use Adjustment Mode

8. Adjust and save the left swing output in the same manner as the right swing output adjustment.

Then press the display alteration key to exit the menu. (For the left swing output adjustment, substitute “left swing output adjustment display [42 SWG LV]” for “right swing output adjustment display [41 SWG RV]”.)

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Functions of and How to Use Adjustment Mode 10. Adjustment of Elevation Output

4. When [Retract Boom] appears, retract the boom fully.

This message does not appear if the boom is already retracted fully.

[NOTICE] Always reset the elevation data before adjustment of elevation output (elevation speed adjustment).

5. When [Boom A

10.1 Procedure of Resetting Elevation Data

. ° ] appears, lower the boom

to or below the displayed angle. However, do not retract the elevating cylinder to its stroke end.

This message does not appear if the boom is already lowered to or below the specified angle.

1. Select the main menu [• Adjust CNT dat ] in the adjustment mode, and press the register key to select the menu.

6. When the following messages appear, press the

2. When [: Adj. ELV speed ] is displayed, press the scroll-down key until the display [:Reset ELV data] appears. Press the register key to select the menu.

register key to select the menu.

Display: [Start CNT Adj. ] [JS neutral ] [Push reg. key]

3. When [Reset OK?] appears, reset the elevation data by pressing the register key.

10.2 Adjustment of Elevation Output (elevation speed adjustment)

7. When the following messages appear, shift the boom elevating control lever fully to the boom raising side while keeping the engine revolution at the maximum. Maintain this situation until the end of the measurement.

Display: [ELV Ope. MAX ] [Engine MAX]

[NOTICE]

8. The following message will appear during

4. When the message [Done] appears, the elevation data resetting is completed.

Press the display alteration key to return to the main menu.

Set the crane as follows: (1)Outriggers mode: Fully extended (2)Lift mode: Boom lift (Stow jib and single top.)

(3)Boom length: Fully retracted (4)Hook block position: Hoisted up as much as possible (Take care not to overwind during adjustment work.)

(5)Hydraulic oil temperature: Approx. 50°C

measurement.

Display example: [pi= . CV= ] Elevating cylinder velocity Output pilot pressure If the elevating cylinder rod moves almost all the way to its stroke end during measurement, it stops automatically and the following messages will appear. Reattempt from the step 5.

Display example: [Stroke end ] [Boom A . °]

1. Select the main menu [• Adjust CNT dat ] in the adjustment mode, and press the register key to select the menu.

2. When [: Adj. ELV speed ] is displayed, press the register key to select the menu.

3. Press the scroll-up or scroll-down key until the boom raising measurement display [Adjust ELV UP ] appears and press the register key to select the menu. (The boom lowering measurement display is [Adjust ELV DN ].)

To cancel the measurement, return the boom elevating control lever to the neutral position and press the display alteration key to exit the menu.

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Functions of and How to Use Adjustment Mode 9. The measurement is completed when the elevating cylinder rod stops and the following messages appear.

Display: [Adjustment done ] [JS neutral] 10.Return the boom elevating control lever to the neutral position.

When [Push reg. key ] appears, press the register key to store the measured value into the EEPROM. You can see the measurement result as shown below if you press the scroll-down key while [Push reg. key ] is displayed.

Display example: [ N P= . C= ] Elevating cylinder velocity Output pilot pressure Indicating that the displayed data are Nth in sequence.

11.The measurement of the boom raising is completed when [Data recorded] appears. Press the display alteration key to return to the submenu [:Adj. ELV speed ].

12.Measure the boom lowering and store the measured value in the same manner described for boom raising. Press the display alteration key to exit the menu.

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Functions of and How to Use Adjustment Mode Other Functions and How to Use Them

Display: [:Disp. Late data ]

1. Language

[:Disp. Max. data]

The menu [Language] is used to change the

3. Display of latest overload data

language for message appearing on the moment display. The message on the menu [Language] is always displayed in English.

The selection of [:Disp. Late data ] results in the latest registered overload history data being displayed. The time when overload history data has been registered is indicated in the moment display.

To view the next data on record (up to 50 items), press the scroll-down key.

1. Select the main menu [• Language] in the adjustment mode, and press the register key to select the menu.

2. When message for language selection appears, operate the scroll-up or scroll-down key to display the aimed language.

Display example: [= Japanese ] Press the scroll-down key. [: English] The sign “=” at the left side of the message shows that the language is currently set to be used.

Moment display Display example: [99. 01. 23 12:35 ] Shows the number of registered items.

(50 items maximum.)

Serial number. (of overload data in order of lateness.)

Shows the overload ratio.

(Max. 400%)

3. When the aimed language is displayed, press the register key. After the registration, the sign “:” at the left side of message changes to “=”.

Display example: [: English] Press the register key. [=English] %

4. Press the display alteration key to exit the menu.

After this, the messages on the moment display are switched to the newly set language.

2. Overload History Display The records of crane operations beyond overloading limit are displayed. You can choose between the displays of latest overload data and of the greatest overload data.

1. Select the main menu [• Disp. O/L data ] in the IW301-0211E30

adjustment mode, and press the register key to select the menu.

2. Use the scroll-up or scroll-down key until the menu of latest overload ratio or peak overload ratio appears. Select it by pressing the register key.

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Functions of and How to Use Adjustment Mode 3. Erasing the Overload History

4. Display of greatest overload data The selection of [:Disp. Max. data] results in the registered greatest overload history data being displayed.

The time when overload history data has been registered is indicated in the moment display.

Press the scroll-down key, and load ratio, jib length, and jib angle will be displayed (jib length and jib angle are displayed only during the jib lift).

Further press the scroll-down key, and the display will change into the next information (up to 10 items).

[NOTICE] When the AML main unit or EEPROM is replaced for repair and all adjustment is completed, erase-protect the overload history.

Before delivering the machine to an user, erase-protect the overload history by erasing the latest history data three times.

You can erase the overload history data (record of crane operation when moment load ratio exceeds the set limit). Note that if the latest history data are erased three times, the menu will not appear, disabling the history data to be erased. At the time of the third erasure, the records of the greatest overload values will also be erased.

Moment display Display example: [99. 01. 23 12:35 ]

1. Select the main menu [• Erase O/L data ] in the adjustment mode, and press the register key to select the menu.

[125% 14.5f 45.0° ] Indicates boom length.

Serial number. (of overload data in order of greatness.)

2. Use the scroll-up or scroll-down key to display the overload history data item to be erased. Select it by pressing the register key.

Display: [:Erase Late dat ]

Indicates boom angle.

Indicates load radius.

Indicates lift status.

[:Erase Max. data] 3. When the message [Erase OK?] appears, press the register key to erase the data. t

m

4. When the message [Done] appears, the overload record data is now erased. Press the display alteration key to exit the menu.

max t

m

Indicates swing position.

Indicates outrigger status.

Indicates actual load.

Indicates rated lifting capacity.

IW301-0211E31

5. Press the display alteration key to exit the menu.

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Functions of and How to Use Maintenance Mode Functions of and How to Use Maintenance Mode 1. Program Version Display

(5)Revision date display: Indicates the date of data revision.

Display example:[96, 01, 23]

3. Di Check

ROM program version is displayed.

The input state of Di (external contact switch) is 1. Select the main menu [• Maintenance ] in the

displayed.

maintenance mode, and press the register key to select the menu.

1. Select the main menu [• Maintenance ] in the maintenance mode, and press the register key to select the menu.

2. When [:Prog. version ] is displayed, press the register key to select the menu.

2. Press the scroll-up or scroll-down key until the display [:Di check ] appears, and then press the register key to select the menu.

3. When the below program version appears, press the display alteration key to exit the menu.

Display example: [AML-L L0204 ]

3. Di input state is displayed. Display changes by scroll-up or scroll-down key.

Press the display alteration key to exit the menu.

Display example (Di1): [ 01 Over-wind of ]

program version number

2. Data ID Number Display Information of ROM data is displayed.

Indicates switch state

1. Select the main menu [• Maintenance ] in the maintenance mode, and press the register key to select the menu.

on : active of : not active Switch name

2. Find the display [:Data ID. number ] by the scroll-up or scroll-down key, and then press the register key to select the menu.

Indicates Di input terminal number.

01 to 28 : Di 1 to Di 28 T : TC A : ACC No indication: Serial port input (Di from multiplex data transmitter and signal transmitter)

3. Display changes by scroll-up or scroll-down key.

Press the display alteration key to exit the menu.

The ROM data is displayed as follows: (1)ID number display: Indicates ROM ID number (revision number included).

Display example:[750200 ]

[NOTICE] Switch state means on/off state which the AML program judges logically.

Usually, this matches to the physical condition of switch. However, if “r” is added in front of the displayed “on” or “of”, these have different meanings as below. ron: Logically switch is active, but physical contact is off. rof: Logically switch is not active, but physical contact is on.

Only the Di switch used for input in the program can be displayed. Since the display sequence of Di switch input states depends on the contents of the

(2)Specification number display: Indicates crane spec. number.

Display example:[TR-500-3-00101 ] (3)Code number display: Indicates parts code number of AML. Display example:[361-175-02000 ] (4)Data date display: Indicates the date of making up data.

Display example:[95, 12, 27 ]

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Functions of and How to Use Maintenance Mode program, the Di switch input states may not be indicated in the numerical order of Di switch input numbers.

[NOTICE] Only the Ai used for input in the program can be displayed. Since the display sequence of Ai input states depends on the contents of the program, the Ai input states may not be indicated in the numerical order of Ai input numbers.

4. Ai Check The input state of Ai (analog detector input) is displayed.

1. Select the main menu [• Maintenance ] in the

5. Elevating Cylinder Oil Pressure Monitor

maintenance mode, and press the register key to select the menu.

The cylinder extension lateral pressure and retraction lateral pressure which are detected for moment calculation are displayed.

2. Press the scroll-up or scroll-down key until the display [:Ai check ] appears, and then press the register key to select the menu.

1. Select the main menu [• Maintenance ] in the maintenance mode, and press the register key to select the menu.

3. Ai input state is displayed. Display changes by scroll-up or scroll-down key.

Press the display alteration key to exit the menu.

Display example (ANAiNB): [ 02 Boom A 1201 ok ]

2. Press the scroll-up or scroll-down key until the display [:Disp ELEV PRES ] appears, and then press the register key to select the menu.

3. The elevating cylinder extension lateral pressure

When detected input is within

and retraction lateral pressure are displayed.

Press the display alteration key to exit the menu.

Display example: [E . R . MPa ]

the normal input range, “ok” appears; when it is out of the range, then “ng” appears at this portion.

Unit

A/D converted value of analog input.

Retraction oil pressure

Analog detector name

Extension oil pressure

Logical number of analog input in the program.

00:Moment input (MOINP, MOINN) 01:ANAiNA 02:ANAiNB 03:ANAiNC 04:ANAiND 05:ANAiNE 06:ANAiNF 07:Analog detector source (DET1SRC, DET2SRC) 08:Pressure input (ANAING) 09:Pressure input (ANAINH) 11 to 15:Serial port-1 analog input 1 to 5 (Ai from signal transmitter) 21 to 25:Serial port-2 analog input 1 to 5 (Ai from multiplex data transmitter)

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Functions of and How to Use Maintenance Mode 7. MDT Monitor (Multiplex Data Transmitter Monitor)

6. Do Check The output state of Do (Digital output: relay output and open collector transistor output) is displayed.

Also, you can invert the current state of selected output.

The input/output state of the MDT (multiplex data transmitter) is displayed.

1. Select the main menu [• Maintenance ] in the

1. Select the main menu [• Maintenance ] in the

maintenance mode, and press the register key to select the menu.

maintenance mode, and press the register key to select the menu.

2. Press the scroll-up or scroll-down key until the display [:Do check ] appears, and then press the register key to select the menu.

2. Press the scroll-up or scroll-down key until the display [:MDT Monitor ] appears, and then press the register key to select the menu.

3. Do output state is displayed. Display changes by

3. The input/output state of the MDT (multiplex data

scroll-up or scroll-down key. Press the display alteration key to exit the menu.

Display example (RLY1): [ 00 Stoppage of ]

transmitter) is displayed. Display changes by increase or decrease key. Press the display alteration key to exit the menu.

Display example: [ No.123 Val. 1]

Current output state

Input/output state

Output name

Digital input/output: 1:ON 0:OFF Analog input/output: represented in numerals from 0 through 255.

Logical output port number 00 to 07:RLY1 to PLY8 (relay output) 10 to 17:TR1 to TR8 (open collector output) [NOTICE]

Input/output number

Output state means on/off state which the AML program judges logically (same as the Di). Usually, this matches to the physical condition of switch.

However, if “r” is added in front of the displayed “on” or “of”, these have different meanings as below. ron: Logically switch is active, but physical contact is off. rof: Logically switch is not active, but physical contact is on.

[NOTICE] For the signal represented by the displayed input/output No., see the “MDT (Multiplex Data Transmitter) Input/Output Nos. and Corresponding Signals” in the INFORMATION AND DATA section.

8. Key Switch Check Check the key switch on the AML front panel whether it works normally or not.

4. During the above Do output monitoring procedure, output state will be inverted while you are pressing the check key.

1. Select the main menu [• Maintenance ] in the maintenance mode, and press the register key to select the menu.

2. Press the scroll-up or scroll-down key until the display [:key SW check ] appears, and then press the register key to select the menu.

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Functions of and How to Use Maintenance Mode [ Error:2003 ]

3. The display [– – – – – – – – – • – – – – – –] appears. Press any key other than the display alteration key, and the corresponding portion of display changes from “-“ to “ ” while you are pressing the key. Press the display alteration key to exit the menu.

(3)The mark “ ” on the error code display shows the another errors exist.

Press the scroll-down key to display the next error code.

Total number of stored items.

9. Display Check

Serial number. (signifies what number the error is.)

The segments of LCD panels and LEDs of the AML indicator repeat to go on and off.

1. Select the main menu [• Maintenance ] in the maintenance mode, and press the register key to select the menu.

2. Press the scroll-up or scroll-down key until the display [:Display check ] appears, and then press the register key to select the menu.

3. The segments of LCD panels and LEDs of the AML indicator repeat to go on and off. Press the display alteration key to exit the menu and return to the ordinary display state.

10. Error Data Display Error data registered in the AML are displayed on the moment indicator and display panel 1.

If "C" mark is seen here, this is the living error.

Error code. This example shows the error code 2003.

1. Select the main menu [• Maintenance ] in the maintenance mode, and press the register key to select the menu.

2. Press the scroll-up or scroll-down key until the

IW301-0211E32

11. Erasing the Error Data

display [:Disp. err data ] appears, and then press the register key to select the menu.

Use this menu to erase the registered error data information.

3. The error codes are displayed on the moment

1. Select the main menu [• Maintenance ] in the maintenance mode, and press the register key to select the menu.

indicator and display panel. Press the display alteration key to exit the menu and return to the ordinary display state.

2. Press the scroll-up or scroll-down key until the

(1)The moment indicator displays the time when error occurred.

Display example: [ 96. 01. 23 12:35 ]

display [:Erase err data ] appears, and then press the register key to select the menu.

3. When the message [Erase OK? ]appears, press the register key.

(2)When the scroll-down key, the time display

4. When the message [Done] is displayed, the error data is now erased. Press the display alteration

changes to the error code display.

Display example:

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Functions of and How to Use Maintenance Mode 13. Ao Check

key to exit the menu.

12. OP (Option) Board Check

The Ao (analog output) state is displayed with an

The state of the incorporated option board (analog

output value of the specified percentage.

output, wire detection) is indicated.

1. Select the main menu [• Maintenance ] in the

1. Select the main menu [• Maintenance ] in the

maintenance mode, and press the register key to select the menu.

maintenance mode, and press the register key to select the menu.

2. Press the scroll-up or scroll-down key until the display [:Ao check ] appears, and then press the register key to select the menu.

2. Press the scroll-up or scroll-down key until the display [:OP board check ] appears, and then press the register key to select the menu.

3. Ao output state is displayed as below.

3. The sort of the incorporated option board is

Display changes by scroll-up or scroll-down key.

Press the display alteration key to exit the menu.

Display example (CNTL1P•CNTL1N): [ 41 SWG RV 0 0 ]

displayed (Up to two option boards can be incorporated). Display changes by scroll-up or scroll-down key. Press the display alteration key to exit the menu.

Display example: [ 1 Valve control ]

Output level for checking indicates at what percentage of the maximum level the value is to be output.

Option board name (1 valve control : Circuit board for analog output) (2 Rope LGTH DET : Circuit board for detecting wire rope movement to indicate hook block position)

Output level indicates at what percentage of the maximum level the value is being output.

Output name Ao output terminal number 11-19:Output to serial port 1 (Signal transmitter) 21-29:Output to serial port 2 (Multiplex data transmitter) 41-49:Output to option board (41:CNTL1P • CNTL1N) (42:CNTL2P • CNTL2N) (43:CNTL3P • CNTL3N) (44:CNTL4P • CNTL4N) [NOTICE] Only the Ao used for output in the program can be displayed. Since the display sequence of Ao output states depends on the contents of the program, the Ao output states may not be indicated in the numerical order of Ao output numbers.

4. How to see the output values for checking Using the increase or decrease key while the Ao output state is displayed, set up an output level for

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Functions of and How to Use Maintenance Mode 15. Adjust Monitor

checking. Every time you press the key, the level is increased or decreased by 1%. When the key is held down for more than one second, the level is increased or decreased by 10% for the increase key and by 5% for the decrease key. When the level exceeds 100%, it returns to 0% (conversely, when the level reaches 0%, it returns to 100%.)

The same items as shown in the [• Adjust ] menu of the main menu of the adjustment mode appears. However, adjustment is not available.

1. Select the main menu [• Maintenance ] in the maintenance mode, and press the register key to select the menu.

5. How to output the output values for checking While the output level for checking is indicated, press the check key; output level for checking will be output while the key is held down. The displayed output level value blinks.

2. Press the scroll-up or scroll-down key until the display [:Adjust Monitor ] appears, and then press the register key to select the menu.

3. The same items as shown in the [• Adjust ] menu

14. Sio Check

of the main menu of the adjustment mode are displayed.

Press the display alteration key to exit the menu.

The Sio (serial port) state is indicated.

1. Select the main menu [• Maintenance ] in the maintenance mode, and press the register key to select the menu.

16. Overload History Display The overload history display in the maintenance mode has the same function as that of in the adjustment mode.

See the “Overload History Display” in the “Functions of and How to Use Adjustment Mode” section.

2. Press the scroll-up or scroll-down key until the display [:Sio check ] appears, and then press the register key to select the menu.

3. Serial port state is displayed. Display changes by scroll-up or scroll-down key. Press the display alteration key to exit the menu.

Display example: [Serial port1 OK ]

17. Erasing the Overload History Erasing the overload history in the maintenance mode has the same function as that of in the adjustment mode.

See the “Erasing the Overload History” in the “Functions of and How to Use Adjustment Mode” section.

Serial port state OK : Normal NG : Abnormal NU : Not used

18. Clock Adjustment

Serial port name (Serial port 1:serial communication circuit to signal transmitter) (Serial port 2:serial communication circuit to multiplex data transmitter)

127

Clock adjustment is included in the functions of the maintenance mode. However, see the “Clock Adjustment” in the “Functions of and How to Use Adjustment Mode” section for how to adjust the clock.

W301-0212E

Error Message Error Message

2. How to Read the Error Message 1. Error code in the error message is represented by

1. Display of Error Message

four-digit codes.

[NOTICE]

Error code: E1 E2 E3 E4

The language (English or Japanese) of error message is selected at the [• Language] menu in the adjustment mode.

lndividual code Group code 0:Alarm 1:Abnormal communication 2:Abnormal detector 3:Abnormality inside AML

Displays a failure message

2. The highest rank (E1 in the above figure) indicates error groups. The each next three digit figure (E2 through E4 above) indicates individual error code under error groups.

IW301-0131E09

3. Since group code “0” indicates a warning condition, it does not always mean that there is a problem in the system when an error message is displayed.

1. If AML system detects the trouble in ordinary use (user mode), it makes beep sound as well as displays error message on the moment display.

Display example: [Error:2001]

4. For this reason, warning-related error messages are not registered in the system’s error history memory. Warning-related error messages are shown in the moment display in the same way as message for other group codes.

Shows that an error of error code 2001 has occurred.

2. This error message display continues till the cause is eliminated.

3. How to Read the Error History

3. While the adjustment or maintenance mode is 1. Error history records 50 errors, maximum, of the

being used, only beep sound informs the operator of the occurrence of trouble. The display on the moment display, however, does not change to the error message display automatically. Current message keeps displayed.

group code, in order of occurrence. Those beyond 50 will be made to disappear in the order of occurrence.

4. To confirm the error message in the adjustment or maintenance mode, press the lift height limit key.

While you are pressing the key, the error message is shown on the moment display. (It may take some seconds for the display to change.)

2. See the “Error Data Display” in the “Functions of and How to Use Maintenance Mode” section for reading the error history.

5. If trouble remains even when you return to the user mode after exiting adjustment or maintenance mode, corresponding error message appears on the moment display.

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Error Message 4. Troubleshooting Table 4.1 Group Code 0 Message

Description

Warning : 0001 Warning : 0002 Warning : 0003 Warning : 0004

Right front outrigger beam retraction Right rear outrigger beam retraction Left front outrigger beam retraction Left rear outrigger beam retraction

Situation: Cause: Action:

Outrigger beam has retracted and O/R extended width decreases, close to the lifting capacity change over point.

Outrigger beam(s) have just retracted.

Extend the outrigger beam again.

Message

Description

Error : 0005

Boom angle value becomes out of specified range

Situation:

Boom extension automatically stops during setting of the side-up jib.

(Only applicable to the machines with side-up jib)

Cause: Action:

Boom angle is smaller than that required for jib setting.

Raise the boom till safety angle for jib setting.

Message

Description

Error : 0006

Improperly inserted jib lock pin

Situation:

Cause: Action:

Boom extending operation is stopped automatically stops during setting or stowing of the side-up jib.

(Only applicable to the machines with side-up jib) Jib lock pins are in incorrect states.

(Jib lock, jib set and automatic lock pins have been inserted) Correct the lock pins property inserted.

Message

Description

Warning : 0010

Close to the swing angle restriction

Situation: Cause:

Action:

* The error code is applicable only to models with the slow swing stop function.

The boom is just close to the swing restriction angle.

The swing area restriction function is active, and the boom has been swung to a point just close to the limit. (The error code will remain displayed as long as the boom is in close to the limit for both left and right swing operation) Error code is displayed only when the slow swing stop function is canceled. (swing is not automatically stopped) Swing the boom away from the swing restriction point.

Cancel the swing area restriction function.

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Error Message

Message

Description

Warning : 0012

Rear stability auto. stop range

Situation: Cause: Action:

The rearward tipping load limit lowers below the current lifting load as the boom is swung.

The boom is raised too high.

The outrigger extension width is insufficient.

Lower the boom.

Increase the outrigger extention width.

Message

Description

Error : 0013 Error : 0014

Over-front detection switch is defective Over-front or over-rear detection switch is/are defective

Situation:

The swing angle does not conform with the condition detected by the over-front detection switch.

Over-front switch has detected as front though boom doesnot turn front.

(Obtains capacity of over-front detection switch as not in front.)

Cause:

Over-front detection switch is defective, over-front and/or over-rear detection switch is/are defective, or its wiring is open.

Swing angle detector is defective or maladjusted.

Investigate the possible causes described above.

The input status can be checked with “Ai & Di check” function from the “Maintenance” menu.

Action:

Message

Description

Warning : 0015

Two-blocking condition (When two-blocking stop function is cancelled)

Situation:

Cause: Action:

Two-blocking detection switch has been turned off (two-blocking status).

A crane does not stop automatically though the error code is displayed when two-blocking is cleared.

Main or auxiliary hook block has been wound up excessively.

Hoist down the main or auxiliary winch.

Message

Description

Error : 0016 Error : 0017

State 1 is not applied (Outrigger, Swing angle, CW, combinations) State 2 is not applied (Boom & Jib combination)

Situation: Cause: Action:

Crane is automatically stopped while the outrigger, boom, jib and counterweight settings are out of the allowable condition, and operation toward a critical conditions is attempted.

The outrigger, boom, jib and counterweight settings are improper.

Register the operation status again.

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Error Message

Message

Description

Error : 0018 Error : 0019 Error : 0020 Error : 0021

Boom full retraction switch 1 faulty Boom full retraction switch 2 faulty Boom full retraction switch 3 faulty Boom full retraction switch 4 faulty

Situation:

Cause:

Action:

Crane is automatically stopped when operation toward a critical condition is performed, when the specified boom section full retraction detector switch does not detect full retraction while the specified boom section is fully retracted, or vice versa.

Boom full retraction detection switch is faulty, or its wiring is open.

Boom length sensor is defective or maladjusted.

The AML itself is defective.

Perform inspection for the possible causes listed above.

The input status can be checked with “Ai & Di check” function from the “Maintenance” menu.

Message

Description

Warning : 0023

Stopped at 100% of crane performance

Situation:

Because the crane performance has exceeded 100%, a crane is automatically stopped when hoisting-up, boom lowering or boom extending is performed.

Cause: Action:

The allowable lifting capacity is exceeded.

Perfrom either of hoisting-down, boom raising, or boom retracting.

Message

Description

Warning : 0024

Stop due to two-blocking

Situation: Cause: Action:

Crane is automatically stopped when operation toward a critical condition is performed while the two-blocking detection switch is turned off (Two-blocking status).

Main or auxiliary winch hook block has been wound up excessively.

Hoist down the main or auxiliary winch.

Message

Description

Warning : 0025

Stopped due to backward stability

Situation: Cause: Action:

The crane is in a state where the backward stability is not assured, boom raising/retracting operation should be stopped automatically.

The boom angle is too large, or the boom length is insufficient.

The outrigger extension width is too small.

Lower the boom, extend the boom, or increases the extension width of outriggers.

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Error Message

Message

Description

Warning : 0026

Stopped at upper boom angle limit restriction

Situation: Cause: Action:

Crane operation is automatically stopped when operation toward a critical condition is attempted while boom angle exceeds the upper limit.

The upper boom angle limit restriction is set, and the boom angle has exceeded the limit.

Lower the boom.

Cancel the upper boom angle limit restriction.

Message

Description

Warning : 0027

Stopped at lower boom angle limit restriction

Situation:

Crane operation is automatically stopped when operation toward a critical condition is attempted while boom angle exceeds the lower limit.

Cause: Action:

The lower boom angle limit restriction is set, and the boom angle has exceeded the limit.

Raise the boom.

Cancel the lower boom angle limit restriction.

Message

Description

Warning : 0028

Stopped at lifting height restriction

Situation: Cause: Action:

Crane operation is automatically stopped when operation toward a critical condition is attempted while lifting height exceeds the limit.

The lifting height limit restriction is set, and the top boom head’s height has exceeded the limit.

Lower or retract the boom.

Cancel the lifting height restriction function.

Message

Description

Warning : 0029

Stopped at load radius restriction

Situation: Cause: Action:

Crane operation is automatically stopped when operation toward a critical condition is attempted while the load radius exceeds the limit.

The load radius restriction is set, and the load radius has exceeded the limit.

Raise or retract the boom.

Cancel the load radius restriction function.

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Error Message

Message

Description

Warning : 0034 Warning : 0035

Stopped by main winch over-unwinding prevention device Stopped by aux. winch over-unwinding prevention device

Situation: Cause: Action:

Hoisting-down is automatically stopped by over-unwinding prevention device as the main/aux. wire rope on the winch drum is drawing to the end.

The number of wire rope part line on the hook block is wrong.

The hook block position is too low.

Adjust the number of part line as specified, or perform winch winding operation.

Message

Description

Error : 0037

Defective accumulator pressure (sensor)

Situation:

Abnormal accumulator pressure is detected. (Only for models with accumlator pressure detector) (This message does not relate to the control by the AML)

Cause:

Accumulator pressure is too low.

Accumulator pressure detector is defective, or its wiring is open.

AML (analog circuit board) is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Action:

Message

Description

Error : 0041 Warning : 0078

Wrong counterweight state registered Altered counterweight state

Situation:

Cause:

Action:

Crane operation is automatically stopped when operation toward a critical condition is attempted when the detected counterweight status is different from the registered one.

(Applicable only to the error code 0041) (Crane does not stop automatically when “Warning:0078” is displayed) Defective counterweight state detector, improper installation or adjustment of the detector, open wiring of the detector circuit.

Altered combination of the counterweight.

Search for the cause of the detector defect. The status of any input from the detector can be checked using the “Di check” function from the “Maintenance” menu.

Register the counterweight state again.

Message

Description

Warning : 0042 Warning : 0043

Right swing restriction limit Left swing restriction limit

Situation: Cause: Action:

Boom is swing to a point exceeding the swing restriction limit setting. Crane is automatically stopped if swing automatic stop function is provided.

The swing restriction limit function is set, and swing position has been exceeded the limit.

Swing the boom in the opposite direction to the setting.

Cancel the swing restriction function.

133

W301-0212E

Error Message

Message

Description

Warning : 0046

Condition setting altered

Situation: Cause: Action:

Crane state has changed.

Outrigger jacks have been retracted.

Register operation status again.

Message

Description

Warning : 0047

Hook block contacts to the elevating cylinder

Situation:

Hook block approaches the space where it can hit the elevation cylinder rod.

Cause: Action:

Boom raised too high while it is almost fully retracted.

Extend or lower the boom.

Message

Description

Warning : 0056

Swing operation is dangerous

Situation: Cause: Action:

The lifting capacity will be exceeded if the boom is swung further.

The boom has been swung to a point just before the region where the capacity is reduced in retraction with outrigger extension width.

Swing the boom in the opposite direction.

Retract or raise the boom so that the lifting capacity will not be exceeded.

Message

Description

Warning : 0057 Warning : 0058 Warning : 0059 Warning : 0060

Right front outrigger state change Right rear outrigger state change Left front outrigger state change Left rear outrigger state change

Situation:

Cause: Action:

Outrigger state has changed as to decrease extension. Crane performance shifted to that with a smaller outrigger extension width.

A crane does not stop automatically.

Outrigger extension width has decreased unintentionally.

If reduced capacity does not matter, continue to use the crane. If the capacity is expected to be exceeded, re-extend the outrigger further and register working state again.

134

W301-0212E

Error Message

Message

Description

Error : 0067

Abnormal moment [Strain gauge detector] Does not stop

Warning : 0113

Abnormal moment [Pressure sensor detector] Can not operate to dangerous direction

Situation:

Cause:

Action:

Actual lifting load display value calculated in the AML becomes a minus value because of an abnormal moment detector.

Therefore, re-adjustment of the moment detector is required.

(0067: Only warning, automatic stop does not work) (0113: Crane operation is stopped when operation toward a critical condition is attempted) Abnormal detectors (Boom length detector, strain gauge type and/or pressure sensor type moment detector).

Maladjusted detector.

Abnormal AML main body (Analog board).

[Warning : 0113] Moment value can not be detected because the elevating cylinder has retracted to the stroke end. * This warning (0113) is output when actual lifting load display value that calculate in the AML becomes a minus value. Abnormal minus load value is difference due to the boom condition.

Readjust the corresponding detector (pressure sensor).

Investigate the detector which seems to be defective.

Input status from the detector can be confirmed by “Ai” check of “Maintenance” menu and “Elevating cylinder pressure monitor”. (“Ai” check related items: [Boom L], [Boom A], [MMT V], [DRC EXT], [DRC RTR] etc.)

Raise the boom. (error code: In case of 0113)

Message

Description

Error : 0068 Error : 0069 Error : 0070 Error : 0071 Error : 0072 Error : 0073 Error : 0074

Abnormal swing angle Abnormal boom length Abnormal boom angle Abnormal extension width of the right front outrigger Abnormal extension width of the right rear outrigger Abnormal extension width of the left front outrigger Abnormal extension width of the left rear outrigger

Situation:

The detected value from the corresponding detector is out of the normal range and the detector requires readjustment.

Alarm is output but automatic stop does not work. For the errors which cause automatic stop, see the fllowing ones.

Cause:

Action:

Abnormal swing angle

Message : 2016 - 2019, 2021

Abnormal boom length

Message : 2007, 2008

Abnormal boom angle

Message : 2004

Abnormal outrigger extension width

Message : 2009 – 2012

Misadjastment or misalignment.

Improper installation of the detector.

The AML itself is defective. (Analog board is defective) Readjust the corresponding detector.

Insrall the corresponding detector properly and readjust it.

If the detectors are not defective, replace the AML main unit (analog board).

135

W301-0212E

Error Message Message

Description

Warning : 0075

Spring lock state has changed

Situation: Cause: Action:

Spring lock state has changed.

(Only for models with spring lock state detection) Spring lock released unintentionally.

Spring lock has been released by mistake.

Set spring lock again.

Message

Description

Warning : 0077

Altered front or rear jack state

Situation:

The actual front or rear jack state has changed from the registered one.

(Only for models with spring lock state detection)

Cause:

Front or rear jack has operated.

Defective detector.

The AML itself is defective. (Analog board is defective) Return the front or rear jack to the original condition.

Check the detector using “Di check” function on “Maintenance” menu.

Action:

Message

Description

Warning : 0078

Altered counterweight state (refer to 0041)

Message

Description

Warning : 0081

Elevation motion slowing down

* This error code is applicable only to models with the slow elevation stop function.

Situation: Cause:

Action:

The boom elevation slow stop function is activated, slowing down boom elevation motion.

The boom has been elevated close to a stop angle (100% stop, restriction limit stop, stroke end stop, or rear stability stop), and the elevation slow stop function has been activated, and the elevation speed is reduced. (The error code is displayed only when the boom is being elevated) Stop operating the boom.

Operate the boom in the opposite direction, whether it is rising or lowering.

Cancel the boom angle limit restriction function.

Move the boom to the non-critical side.

Message

Description

Warning : 0082

Swing motion slowing down

Situation: Cause:

Action:

* This error code is applicable only to models with the slow swing stop function.

The slow swing stop function is activated, slowing down boom swing motion.

The boom has swung close to a stop angle (either 100% stop or range limit stop) and the slow swing stop function has been activated, and swing speed is reduced. (The error code is displayed only when the boom is being swung to the left or right) Stop the swing operation.

Swing away from the limit.

Retract or raise the boom so that the lifting capacity will not be exceeded.

Cancel the swing limit restriction function.

136

W301-0212E

Error Message

Message

Description

Warning : 0085

Elevation stopped at stroke end

Situation: Cause:

Action:

* Applicable to the models with the oil pressure detection method.

Crane operation is automatically stopped when operation toward a critical condition is attempted while boom elevating operation is stopped due to elevation stroke end.

Boom elevating is automatically stopped just before the elevating cylinder stroke end because the moment cannot be detected correctly by the oil pressure in the elevating cylinder if the cylinder is reached/extended to stroke end.

Stop operation which has caused automatic stop.

Operate the boom in the opposite direction which has caused automatic stop.

Message

Description

Warning : 0088

Stopped at jib limit

* This error code is applicable only to models with jib extension status monitoring.

Situation: Cause: Action:

Crane operation is automatically stopped when operation toward a critical condition such as hoisting-up, lowering or extending the boom is attempted.

In the state of AML setting to boom while extending the jib, is exceeding the lifting capacity.

Perform operation toward non-critical condition, such as hoisting-down, raising or retracting the boom.

Message

Description

Warning : 0113

Abnormal moment [Pressure senser detector] (refer to 0067)

Message

Description

Warning : 0117

Boom contact warning

Situation:

The boom approaches the mirror or engine cover, etc.

Cause:

The boom, stowing jib and/or elevating cylinder approach (es) the mirror or engine cover etc. of the carrier, there is a possibility to come in contact if operating the boom lowering or swinging further.

Operate watching the obstacles when operating the boom lowering or swinging.

Action:

137

W301-0212E

Error Message 4.2 Group Code 1 Message

Description

Error : 1001 Error : 1002

Serial port transmission line 1 open Selial port transmission line 2 open

Situation:

All operations except boom swing are unavailable because the transmitter cannot receive any signal from the AML.

Cause:

A part of wiring to the transmitter is open.

The connector pins of wiring to the transmitter are in poor contact.

The receiving circuit of transmitter or the transmitting circuit of AML is defective.

Check the wiring to the transmitter for continuity. If no continuity exists, replace or repair the wiring.

Replace the transmitter or AML’s power circuit board.

Action:

Message

Description

Error : 1003 Error : 1004

Serial port receiving line 1 open Serial port receiving line 2 open

Situation: Cause:

Action:

All operations except boom swing are unavailable because the AML cannot receive any signal from the transmitter.

The line from the transmitter includes open wiring or poorly contacting connection.

The transmitter is not connected (the connector is disconnected).

The receiving circuit of AML or the transmitting circuit of transmitter is defective.

The serial port fuse (SIF1, 2) of AML has blown.

Check the wiring to the transmitter for continuity. If no continuity exists, replace or repair the wiring.

Replace the transmitter or AML’s power circuit board.

Replace the serial port fuse of AML.

Message

Description

Error : 1005 Error : 1006

Transmitter 1 defect Transmitter 2 defect

Situation: Cause: Action:

All operations except boom swing are unavailable due to the faulty transmitter.

The internal circuit of transmitter is defective.

Replace the defective transmitter.

138

W301-0212E

Error Message

Message

Description

Error : 1007 Error : 1008 Error : 1009 Error : 1010

Transmitting data error at serial port 1 Transmitting data errot at serial port 2 Receiving data error at serial port 1 Receiving data error at serial port 2

Situation: Cause: Action:

All operations except boom swing are unavailable due to a discrepancy between the data transmitted/received by the AML and the data received/transmitted by the transmitter.

The data has been garbled due to noise (external radio wave interference).

The signal wire connection is in poor contact.

Turn off any device which is emitting strong noise.

Check the signal wire for poor connection. Repair or replace the wiring as appropriate.

Message

Description

Error : 1011 Error : 1012

Transmitter type improper (serial port 1) Transmitter type improper (serial port 2)

Situation:

All operations except boom swing are unavailable due to the wrong transmitter connected to the serial port.

Action:

Connect a proper transmitter to the serial port.

139

W301-0212E

Error Message 4.3 Group Code 2 Message

Description

Error : 2001

Moment detector trouble

Situation:

All operations except boom swing are unavailable due to the abnormal input value from the moment detector.

Cause:

The moment detector is defective, or its wiring is open.

The AML itself is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Action:

Message

Description

Error : 2003

Boom length detector trouble

Situation: Cause: Action:

All operations except boom swing are unavailable due to the abnormal input value from the boom length detector.

The boom length detector is defective, or its wiring is open.

The AML itself is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Message

Description

Error : 2004

Boom angle detector trouble

Situation: Cause: Action:

All operations except boom swing are unavailable due to the abnormal input value from the boom angle detector.

The boom angle detector is defective, or its wiring is open.

The AML itself is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Message

Description

Error : 2005

Jib length detector trouble

Situation:

All operations except boom swing are unavailable due to the abnormal input value from the jib length detector.

Cause:

The jib length detector is defective, or its wiring is open.

The transmitter unit is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Action:

140

W301-0212E

Error Message Message

Description

Error : 2006

Jib angle detector trouble

Situation: Cause: Action:

All operations except boom swing are unavailable due to the abnormal input value from the jib angle detector.

The jib angle detector is defective, or its wiring is open.

The transmitter unit is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Message

Description

Error : 2009 Error : 2010 Error : 2011 Error : 2012

Right front outrigger length detector trouble Right rear outrigger length detector trouble Left front outrigger length detector trouble Left rear outrigger length detector trouble

Situation:

The input data from the outrigger length detector are abnormal.

Cause:

The outrigger length detector is defective, or its wiring is open.

The AML outrigger length detector is maladjusted. (For multiplex data transmitter) The transmitter unit is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Action:

Message

Description

Error : 2017 Error : 2019

Swing angle detector 1 trouble (swing dead angle switch OFF) Swing angle detector 2 trouble (swing dead angle switch ON) (same as swing angle detector 1,2 select switch)

Situation: Cause:

Action:

All operations except boom swing are unavailable due to the input data from the swing angle detector inconsistent with the swing dead angle detector switch position.

Swing angle detector is faulty or maladjusted, or its wiring is open.

Swing dead angle detector switch is faulty or maladjusted, or its wiring is open.

The AML itself is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai & Di check” function from the “Maintenance” menu.

141

W301-0212E

Error Message

Message

Description

Error : 2021

Swing angle detector offset trouble

Situation: Cause: Action:

All operations except boom swing are unavailable due to the abnormal offset value of the swing angle detector 1 or 2.

The swing angle detector is faulty.

The AML itself is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Message

Description

Error : 2022 Error : 2023

Boom elevation cylinder extension pressure detector trouble Boom elevation cylinder retraction pressure detector trouble

Situation:

All operations except boom swing are unavailable due to the abnormal input value from the oil pressure detector in the boom elevating cylinder’s extension/retraction chamber.

Cause:

The pressure detector is defective, or its wiring is open.

The AML itself is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu. ( “Ai check” related items : [DRC EXT], [DRC RTR]

Action:

142

W301-0212E

Error Message 4.4 Group Code 3 Message

Description

Error : 3003

System trouble (sum check error)

Situation:

All operations except boom swing are unavailable because ROM has been found abnormal as a result of sum check.

Cause:

The AML‘s CPU board is defective.

ROM defective.

Replace the AML’s CPU board.

Replace ROM.

Action:

Message

Description

Error : 3006

System trouble (EEPROM defect)

Situation: Cause: Action:

All operations except boom swing are unavailable because AML cannot write on its nonvolatile memory (EEPROM).

The AML’s CPU board is defective.

EEPROM is defective.

Replace the AML’s CPU board or EEPROM.

Message

Description

Error : 3007 Error : 3008 Error : 3009 Error : 3011 Error : 3012 Error : 3013 Error : 3017

System trouble (RAM trouble) System trouble (RAM trouble) System trouble (CPU trouble) System trouble (bus error) System trouble (address error) System trouble (unauthorised instruction) System trouble (privilege violation)

Situation: Cause: Action:

All operations except boom swing are unavailable because software program cannot run normally.

The AML’s CPU board is defective.

Replace the AML’s CPU board.

If this error has occurred, the relevant error message is displayed and the AML stops processing. (There is a continuous beep and two LEDs in the adjustment window illuminate) While the AML’s CPU board is suspected to be defective, check the inside of the AML for any abnormality such as loose connectors.

Message

Description

Error : 3010

System trouble (A/D converter trouble)

Situation:

All operations except boom swing are unavailable due to abnormal input to the A/D converter.

Cause:

AML’s CPU board and/or analog board are defective.

Wiring for the analog defector is abnormal (short-circuit).

Replace the AML’s CPU board and/or analog board.

Check the connection (resistance) of analog detectors (one connected with AML itself).

Action:

143

W301-0212E

Disassembly of AML Main Unit Disassembly of AML Main Unit

2.

1.

[NOTICE]

Removing Front Panel/Display Board

[NOTICE] ◆Do not touch each front and rear face of the boards by hand when removing the boards.

◆Do not touch each front and rear face of the boards by hand when removing the boards.

1. Take off the rear panel, connector board and current output board as an assembly from the unit case by unscrewing screw(c).

1. Take off the front panel and display board as an assembly from the unit case by unscrewing screw(a).

Front panel

Removing Rear Panel/Connector Board /Current Output Board

Connector board Current output board Unit case

Display board a Unit case

c

Rear panel

IW301-0131E21 IW301-0131E19

2. Separate the current output board by unscrewing screw(d).

Then remove the spacer(e) and separate the connector board.

2. Separate the display board by unscrewing screw(b).

e Connector board

b

Current output board d

IW301-0131E22

Display board IW301-0131E20

144

W301-0212E

Disassembly of AML Main Unit 3.

Removing CPU Board/Analog Board /Power Board

[NOTICE] ◆Do not touch each front and rear face of the boards by hand when removing the boards.

1. Take off the front panel and display board as an

3.1 Notes on ROM/EEPROM Replacement [NOTICE] ◆EEPROM stores the adjustment values for each specification number. When replacing the CPU board, reuse the EEPROM after removing it from the broken CPU board.

assembly from the unit case by unscrewing screw(a). Then take off the rear panel, connector board and current output board as an assembly from the unit case by unscrewing screw(c).

Connector board Current output board

c

When replacing ROM and EEPROM, make sure that the concavities of IC and socket meet each other.

Rear panel

CAL/CLOCK

Battery CN1

EEPROM CN4 PLD

ROM 1 CPU

ROM 0

CN2 CN3

Front panel

a Unit case Display board

IW301-0131E23

CPU board IW301-0131E25

2. Take off the CPU board by unscrewing screw(f).

Then remove the spacer(h) and take off the analog board and power board as an assembly from the unit case. Next, separate the analog board by removing nut(g).

Analog board

h

Power board

Unit case

g

f CPU board IW301-0131E24

145

W301-0212E

Adjustment Value Table [INFORMATION AND DATA] Adjustment Value Table Specification No. : GT-550E-1-10102 Specification No. : GT-550E-1-10202 AML model

: AML-L B

AML code No.

: 361-904-70000

1. Setting before adjustment Capacity setting Head-off capacity setting

Jib selection

Single top selection

Winch drum position setting

Not set

Not set

Not set

Not set

2. Adjustment the detector Precautions for adjustment (*1) Adjust the center of dispersion to coincide to the adjusting value. (*2) Adjust the boom angle and the moment in the elevating lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) When adjusting the moment, make the number of part-lines of rope to the standard number (four part-lines) that is when boom fully extended, and set the AML as Boom status: Boom and Number of part-lines of rope:4.

The adjusting value is for 0.57 ton hook installed, and the value in the { } is for 0.4 ton hook installed.

Adjustment item

Boom length

Boom angle (*2)

Condition

Tolerance

Zero-point adjustment

Boom length: Fully retracted

11.10m

± 0.04m (± 0.08m for zero-point check)

Span adjustment

Boom length: Fully extended

42.00m

± 0.04m

Zero-point adjustment

Boom angle: 0°(actual value)

0°

± 0.1° (± 0.2° for zero-point check)

Span adjustment

Boom angle: 75°(actual value)

75°

± 0.1°

Zero-point adjustment

Swing angle1:0°

Swing position : front (Right swing)

Swing angle2:360°

Swing angle (*3) Span adjustment

Outrigger extension width

Adjustment value

Swing angle1:180° Swing angle2:180°

Swing position : rear (Right swing)

± 0.3° (± 0.6° for zero-point check) ± 0.3° (± 0.6° for zero-point check) ± 0.3° ± 0.3°

Zero-point adjustment

Outrigger extension width: MIN.

1.195m

± 0.006m (± 0.012m for zero-point check)

Span adjustment

Outrigger extension width: MAX.

3.400m

± 0.006m

146

W301-0212E

Adjustment Value Table

Adjustment item

Condition Boom length: Fully retracted

Zero-point adjustment

Boom angle: 75±0.1° (indicated value) Lifting capacity : Without load (0.57t {0.4t} hook only) Hook : Two-blocking status

Adjustment value

Tolerance

0.50t {0.33t} Hook block mass – Wire rope mass

± 0.14t

Boom length: Fully retracted Span preliminary adjustment Moment (*2) (*4)

Boom angle: 10±0.1° (indicated value) Lifting capacity : Without load (0.57t {0.4t} hook only) Hook : Hoisting-down until immediately before the ground plane

0.57t {0.40t}

± 0.03t

Hook block mass

Boom length: Fully extended Load radius adjustment

Load radius: 10.0m (actual value)

10.0m

± 0.14m

Rated lifting capacity: 8.00t Boom length: Fully extended Span fine adjustment

Boom angle: 45±0.1° (indicated value) Lifting capacity : Without load (0.57t {0.4t} hook only) Hook : Hoisting-down until immediately before the ground plane

3. Slow stop adjustment 1. Standard value of the swing output : 217 2. Measurement of elevating up and down characteristic 4. Setting after adjustment 1. Number of part-line : 4 line 2. Language switch : English

147

W301-0212E

0.57t {0.40t} Hook block mass

± 0.02t

Adjustment Value Table Specification No. : GR-120N-1-00103 AML model

: AML-L B

AML code No.

: 361-914-50000

1. Setting before adjustment Capacity setting Head-off capacity setting

Jib selection

Single top selection

Winch drum position setting

Not set

Not set

Not set

Not set

2. Adjustment the detector Precautions for adjustment (*1) Adjust the center of dispersion to coincide to the adjusting value. (*2) Adjust the boom angle and the moment in the elevating lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) When adjusting the moment, make the number of part-lines of rope to the standard number (four part-lines) that is when boom fully extended, and set the AML as Boom status: Boom and Number of part-lines of rope:4.

Adjustment item

Boom length

Boom angle (*2)

Condition

Tolerance

Zero-point adjustment

Boom length: Fully retracted

5.3m

± 0.04m (± 0.08m for zero-point check)

Span adjustment

Boom length: Fully extended

23.8m

± 0.04m

Zero-point adjustment

Boom angle: 0° (actual value)

0°

± 0.1° (± 0.2° for zero-point check)

Span adjustment

Boom angle: 80° (actual value)

80°

± 0.1°

Zero-point adjustment

Swing angle1:0°

Swing position : front (Right swing)

Swing angle2:360°

Swing angle (*3) Span adjustment

Outrigger extension width

Adjustment value

Swing angle1:180° Swing angle2:180°

Swing position : rear (Right swing)

± 0.3° (± 0.6° for zero-point check) ± 0.3° (± 0.6° for zero-point check) ± 0.3° ± 0.3°

Zero-point adjustment

Outrigger extension width: MIN.

0.820m

± 0.006m (± 0.012m for zero-point check)

Span adjustment

Outrigger extension width: MAX.

2.350m

±0.006m

148

W301-0212E

Adjustment Value Table

Adjustment item

Condition Boom length: Fully retracted

Zero-point adjustment

Boom angle: 80±0.1° (indicated value) Lifting capacity : Without load (0.09t hook only) Hook : Two-blocking status

Adjustment value

Tolerance

0.08t Hook block mass – Wire rope mass

± 0.04t

Boom length: Fully retracted Span preliminary adjustment Moment (*2) (*4)

Boom angle: 10±0.1° (indicated value) Lifting capacity : Without load (0.09t hook only) Hook : Hoisting-down until immediately before the ground plane

0.09t Hook block mass

± 0.02t

5.00m

± 0.04m

Boom length: Fully extended Load radius adjustment

Load radius: 5.0m (actual value) Rated lifting capacity: 3.00t Boom length: Fully extended

Span fine adjustment

Boom angle: 10±0.1° (indicated value) Lifting capacity : Without load (0.09t hook only) Hook : Hoisting-down until immediately before the ground plane

3. Slow stop adjustment 1. Standard value of the swing output : 217 2. Measurement of elevating up and down characteristic 4. Setting after adjustment 1. Number of part-line : 1 line 2. Language switch : English

149

W301-0212E

0.09t Hook block mass

± 0.00t

Adjustment Value Table Applicable serial No. △ 1 ：545484 ~

Specification No. : GR-700E-1-00101 Specification No. : GR-700E-1-00102 AML model

: AML-L B

AML code No.

: 361-915-70000

AML code No.

: 361-920-20000

1. Setting before adjustment Capacity setting Head-off capacity setting

Jib selection

Single top selection

Winch drum position setting

Not set

Not set

Not set

Set to “R” (rear)

2. Adjustment the detector Precautions for adjustment (*1) Adjust the center of dispersion to coincide to the adjusting value. (*2) Adjust the boom angle and the moment in the elevating lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) When adjusting the moment, make the number of part-lines of rope to the standard number (four part-lines) that is when boom fully extended, and set the AML as Boom status: Boom and Number of part-lines of rope:4.

1 ：The adjusting value is for 0.47 ton hook installed, and the value in the { } is for 0.85 ton hook installed.

Adjustment item

Boom length

Boom angle (*2)

Condition

Tolerance

Zero-point adjustment

Boom length: Fully retracted

11.5m

± 0.04m (± 0.08m for zero-point check)

Span adjustment

Boom length: Fully extended

44m

± 0.04m

Zero-point adjustment

Boom angle: 0°(actual value)

0°

± 0.1° (± 0.2° for zero-point check)

Span adjustment

Boom angle: 80°(actual value)

80°

± 0.1°

Zero-point adjustment

Swing angle1:0°

Swing position : front (Right swing)

Swing angle2:360°

Swing angle (*3) Span adjustment

Outrigger extension width

Adjustment value

Swing angle1:180° Swing angle2:180°

Swing position : rear (Right swing)

± 0.3° (± 0.6° for zero-point check) ± 0.3° (± 0.6° for zero-point check) ± 0.3° ± 0.3°

Zero-point adjustment

Outrigger extension width: MIN.

1.4m

± 0.006m (± 0.012m for zero-point check)

Span adjustment

Outrigger extension width: MAX.

3.6m

± 0.006m

150

W301-0212E

Adjustment Value Table Adjustment item

Condition Boom length: Fully retracted

Zero-point adjustment

Boom angle: 80±0.1° (indicated value) Lifting capacity : Without load 1 (0.47t {0.85t} hook only) Hook : Two-blocking status

Adjustment value

Tolerance

0.40t 1 {0.78t} Hook block mass

± 0.31t

minus Wire rope mass

Boom length: Fully retracted Span preliminary adjustment Moment (*2) (*4)

Boom angle: 10±0.1° (indicated value) Lifting capacity : Without load 1 (0.47t {0.85t} hook only) Hook : Hoisting-down until immediately before the ground plane

0.47t 1 {0.85t}

± 0.05t

Hook block mass

Boom length: Fully extended Load radius adjustment

Load radius:14.00m (actual value)

14.00m

±0.08m

Rated lifting capacity: 8.00t Boom length: Fully extended Span fine adjustment

Boom angle: 40±0.1° (indicated value) Lifting capacity : Without load 1 (0.47t {0.85t} hook only) Hook : Hoisting-down until immediately before the ground plane

0.47t 1 {0.85t}

± 0.02t

Hook block mass

1 ：The adjusting value is for 0.47 ton hook installed, and the value in the { } is for 0.85 ton hook installed.

3. Slow stop adjustment 1. Standard value of the swing output : 217 2. Measurement of elevating up and down characteristic 4. Setting after adjustment 1. Number of part-line : 1 line 2. Language switch : English

151

W301-0212E

MDT (Multiplex Data Transmitter) Input/Output Nos. and Corresponding Signals

MDT (Multiplex Data Transmitter) Input/Output Nos. and Corresponding Signals The following table does not apply to a machine that is not equipped with a multiplex data transmitter (that is, GT-550E-1 model).

Upper input

Upper output

Lower input

Input/ Input/ Input/ Input/ Input/ output Signal output Signal output Signal output Signal output No. No. No. No. No.

Lower output

Analog input

Signal

Input/ Input/ Input/ output Signal output Signal output Signal No. No. No. Upper Ai1 Upper Ai2 Upper Ai3 Upper Ai4 Upper Ai5 Upper Ai6 Upper Ai7 Upper Ai8 Upper Ai9 Upper Ai10 Lower Ai1 Lower Ai2 Lower Ai3 Lower Ai4 Lower Ai5 Lower Ai6 Lower Ai7 Lower Ai8 Lower Ai9 Lower Ai10 Lower Ai11 Lower Ai12

1

Di1

33

Di33

65

Tr1

89

Di1

121

PMONI1

137

MONI1

169

MONI33

201

2

Di2

34

Di34

66

Tr2

90

Di2

122

PMONI2

138

MONI2

170

MONI34

202

3

Di3

35

Di35

67

Tr3

91

Di3

123

PMONI3

139

MONI3

171

MONI35

203

4

Di4

36

Di36

68

Tr4

92

Di4

124

PMONI4

140

MONI4

172

MONI36

204

5

Di5

37

Di37

69

Tr5

93

Di5

125

PMONI5

141

MONI5

173

MONI37

205

6

Di6

38

Di38

70

Tr6

94

Di6

126

PMONI6

142

MONI6

174

MONI38

206

7

Di7

39

Di39

71

Tr7

95

Di7

127

PMONI7

143

MONI7

175

MONI39

207

8

Di8

40

Di40

72

Tr8

96

Di8

128

PMONI8

144

MONI8

176

MONI40

208

9

Di9

41

Di41

73

Tr9

97

Di9

129

PMONI9

145

MONI9

177

MONI41

209

10

Di10

42

Di42

74

Tr10

98

Di10

130

PMONI10

146

MONI10

178

MONI42

210

11

Di11

43

Di43

75

Tr11

99

Di11

131

PMONI11

147

MONI11

179

MONI43

211

12

Di12

44

Di44

76

Tr12

100

Di12

132

PMONI12

148

MONI12

180

MONI44

212

13

Di13

45

Di45

77

Tr13

101

Di13

133

PMONI13

149

MONI13

181

MONI45

213

14

Di14

46

Di46

78

Tr14

102

Di14

134

PMONI14

150

MONI14

182

MONI46

214

15

Di15

47

Di47

79

Tr15

103

Di15

135

PMONI15

151

MONI15

183

MONI47

215

16

Di16

48

Di48

80

Tr16

104

Di16

136

PMONI16

152

MONI16

184

MONI48

216

17

Di17

49

Di49

81

Tr17

105

Di17

153

MONI17

185

MONI49

217

18

Di18

50

Di50

82

Tr18

106

Di18

154

MONI18

186

MONI50

218

19

Di19

51

Di51

83

Tr19

107

Di19

155

MONI19

187

MONI51

219

20

Di20

52

Di52

84

Tr20

108

Di20

156

MONI20

188

MONI52

220

21

Di21

53

Di53

85

Tr21

109

Di21

157

MONI21

189

MONI53

221

22

Di22

54

Di54

86

Tr22

110

Di22

158

MONI22

190

MONI54

222

23

Di23

55

Di55

87

Tr23

111

Di23

159

MONI23

191

MONI55 Analog output

24

Di24

56

Di56

88

Tr24

112

Di24

160

MONI24

192

MONI56 Input/

25

Di25

57

Di57

113

Di25

161

MONI25

193

Tr1

output Signal No.

26

Di26

58

Di58

114

Di26

162

MONI26

194

Tr2

231

27

Di27

59

Di59

115

Di27

163

MONI27

195

Tr3

241

28

Di28

60

Di60

116

Di28

164

MONI28

196

Tr4

242

29

Di29

61

Di61

117

Di29

165

MONI29

197

MSOL1

243

30

Di30

62

Di62

118

Di30

166

MONI30

198

MSOL2

31

Di31

63

Di63

119

Di31

167

MONI31

32

Di32

64

Di64

120

Di32

168

MONI32

152

W301-0212E

Upper Ao1 Lower Ao1 Lower Ao2 Lower Ao3

Checking the Detectors (GT-550E-1) Checking the Detectors (GT-550E-1) 1.

2.

Boom Angle Detector

1. Retract the boom fully, set the boom angle to 0

Boom Length Detector

degree and turn off the PTO switch.

1. Retract the boom fully, set the boom angle to 0

2. Measure resistance of the potentiometer.

degree and turn off the PTO switch.

Checking at the connector of the detector

2. Measure resistance of the potentiometer.

Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D:833 ± 167Ω A-D:146 ± 29Ω

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D:833 ± 167Ω B-D:458 ± 92Ω

Boom angle detector

Boom angle detector

A

E

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

A

B

ANAINA 3 DET1GND 1

ANAINB 4

A

ANAINA 3 DET1GND 1

B D

D

D C

E C

E

C B

DET1SLD 6 DET1SRC 2

Boom length detector

B D

IW301-0131E10

Boom length detector IW301-0131E10

Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector.

Then pull out the CN1 connector and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1:833 ± 167Ω 4-1:146 ± 29Ω

Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector.

Then pull out the CN1 connector and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1:833 ± 167Ω 3-1:458 ± 92Ω

Boom angle detector DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

ANAINA 3 DET1GND 1

B D

Boom angle detector

45

16

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

45

30 ANAINA 3 DET1GND 1 30

1

16

1

B D

Boom length detector IW301-0132E33

Boom length detector IW301-0132E33

153

W301-0212E

Checking the Detectors (GT-550E-1) 3.

Swing Angle Detector

4.

1. Swing the boom to over-left and turn off the PTO

Outrigger Extension Width Detector

1. Stow the outriggers and disengage the PTO.

switch.

2. Remove the wire for the detector from the outrigger and hold the wire, letting it protruding by 80mm from the guide hold of the detector.

2. Measure resistance of the potentiometer.

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B:500 ± 75Ω W-B:0 - 15Ω

G

Plug

W

R

Shield

B

DET1SLD 6

Shield

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B

80 mm IW301-0151J27

3. Pull out the connector of the detector and

IW301-0131E11

measure resistance of the potentiometer. The specified resistance values are as follows: R-B:2000 ± 100Ω W-B:200 ± 30Ω

Checking at the CN1 connector of the AML Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1:500 ± 75Ω 5-1:0 - 15Ω

45

30

16

DET1SLD 6

Shield

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B

W

B

R

5V AVCC

R

IN Ai1

W

GND AGND

B

FR IW301-0211E34

1 IW301-0132E34

154

W301-0212E

Checking the Detectors (GT-550E-1) 5.

Pressure Sensor for Moment Detection

1. Engage the PTO. (5-V DC will be applied between R and B of the pressure sensor connector.)

2. Measure the output voltage between W and B of the pressure sensor connector.

W

B

R

DET3SRC 33

R

ANAING 34

W

DET3GND 32

B

(ANAINH 35)

SPS3

(SPS4)

IW301-0131E14

3. The output voltage between W and B is

Output (V DC)

proportional to the pressure in the elevating cylinder.

The specified value is as shown below.

4.5

0.5 0

Pressure (MPa)

35 IW301-0131E15

155

W301-0212E

Checking the Detectors (GR-120N-1/GR-700EXL-1) Checking the Detectors (GR-120N-1) 1.

2.

Boom Angle Detector

1. Retract the boom fully, set the boom angle to 0

Boom Length Detector

degree and turn off the PTO switch.

1. Retract the boom fully, set the boom angle to 0 degree and turn off the PTO switch.

2. Measure resistance of the potentiometer.

Checking at the connector of the detector

2. Measure resistance of the potentiometer.

Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D:833 ± 167Ω A-D:146 ± 29Ω

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D:833 ± 167Ω B-D:458 ± 92Ω

Boom angle detector

Boom angle detector

A

E

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

A

B

ANAINA 3 DET1GND 1

ANAINB 4

A

ANAINA 3 DET1GND 1

B D

D

D C

E C

E

C B

DET1SLD 6 DET1SRC 2

Boom length detector

B D

IW301-0131E10

Boom length detector IW301-0131E10

Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector.

Then pull out the CN1 connector and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1:833 ± 167Ω 4-1:146 ± 29Ω

Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector.

Then pull out the CN1 connector and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1:833 ± 167Ω 3-1:458 ± 92Ω

Boom angle detector DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

ANAINA 3 DET1GND 1

B D

Boom angle detector

45

16

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

ANAINA 3 DET1GND 1 30

1

45

30

B D

16

1

Boom length detector IW301-0132E33

Boom length detector IW301-0132E33

156

W301-0212E

Checking the Detectors (GR-120N-1/GR-700EXL-1) 3.

Swing Angle Detector

4.

1. Swing the boom to over-left and turn off the PTO

Outrigger Extension Width Detector

1. Stow the outriggers and turn the starter switch to

switch.

OFF.

2. Measure resistance of the potentiometer.

2. Remove the wire for the detector from the outrigger and hold the wire, letting it protruding by 80mm from the guide hold of the detector.

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B:500 ± 75Ω W-B:0 - 15Ω DET1SLD 6 G

Plug

W

R

Shield

B

Shield

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B

80 mm IW301-0151J27

IW301-0131E11

3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B:2000 ± 100Ω W-B:200 ± 30Ω

Checking at the CN1 connector of the AML Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1:500 ± 75Ω 5-1:0 - 15Ω

W

B

R

5V AVCC

R

IN Ai1

W

GND AGND

B

FL IW301-0131E13

45

30

16

DET1SLD 6

Shield

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B

1 IW301-0132E34

157

W301-0212E

Checking the Detectors (GR-120N-1/GR-700EXL-1) 5.

Pressure Sensor for Moment Detection

1. Turn ON the PTO switch. (5-V DC will be applied between R and B of the pressure sensor connector.)

2. Measure the output voltage between W and B of the pressure sensor connector.

W

B

R

DET3SRC 33

R

ANAING 34

W

DET3GND 32

B

(ANAINH 35)

SPS3

(SPS4)

IW301-0131E14

3. The output voltage between W and B is

Output (V DC)

proportional to the pressure in the elevating cylinder.

The specified value is as shown below.

4.5

0.5 0

Pressure (MPa)

35 IW301-0131E15

158

W301-0212E

Fuses Fuses RLY1, 2 MAIN

RLY3, 4

RLY5, 6

RLY7, 8 SIF2 SIF1

SOL1, 2 SOL3, 4 SOL5, 6

t

m

max t m

IW301-0211E35

SOL1,2 fuse (2A)

MAIN fuse (3A)

Common, with current output 1 and 2.

AML main fuse for whole unit.

SOL3,4 fuse (2A)

RLY1,2 fuse (3A) Common, with relay output 1 and 2.

Common, with current output 3 and 4.

RLY3,4 fuse (3A) Common, with relay output 3 and 4.

SOL5,6 fuse (2A) Common, with current output 5 and 6.

RLY5,6 fuse (3A) Common, with relay output 5 and 6.

RLY7,8 fuse (3A) Common, with relay output 7 and 8.

SIF1 fuse (2A) For SIF1SRC power supply output.

SIF2 fuse (2A) For SIF2SRC power supply output.

159

W301-0212E

Replacing the Clock Battery Replacing the Clock Battery

3. Attach a new battery on the CPU board by

[NOTICE] When the clock battery is worn out, the adjusting values, error codes and driving history cannot be backed up (saving data at power OFF).

Also, when the error code or driving history is recorded in AML, an accurate date and time cannot be recorded.

Two built-in clock batteries are on CPU board of the AML main unit.

Replace both 2 pieces when you replace the battery.

pressing the battery diagonally. (Refer to the figure below) The battery positive side must be faced up.

The built-in clock battery longevity is usually about 10 years.

If the built-in clock batteries are worn out, replace them according to the following procedures.

4. Install the CPU board in the AML main unit.

1. Remove the CPU board from the AML main unit.

5. Reconnect the connector to the board.

2. Remove the battery from the battery holder on CPU board by pressing the battery diagonally.

[NOTICE] When removing the battery, remove while holding the battery upper (positive side) because the battery may pop up.

160

W301-0212E

Head Office

Ko-34,Sinden-cho, Takamatsu, Japan

Overseas Service Dept.

Tadano Ryogoku Bldg.

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

1 Feb.2005 2 3 4 5

History of revision R-05-R002