Tadano Faun AML-LIIC Load Moment Indicator Service Manual W301-0131E - PDF DOWNLOAD

Publication No. W301-0131E

01 Load Moment Indicator Model

AML-LⅡ ⅡC

Introduction This service manual covers the load moment indicator (AML-LⅡC) installed on the TADANO cranes in the chart below.

In undertaking repair, refer to the separate operation and maintenance manual, parts catalog, and crane-covering service manual for pertinent information.

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

2001.9.

Applicable crane model TR-450XL-4 Specification numbers: (1) GR-450-1-00101 (2M2D-specification) (2) GR-450-1-00102 (1M1D-specification) (3) GR-450-1-00103 (1M1D-specification) Use this manual for machines with the load moment indicator (AML-LⅡC) even if the crane model is other than the above.

Some of the parts described herein may differ slightly from the actual parts used due to improvement.

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W301-0131E

Contents Required Adjustment After AML System Parts

Introduction .......................................................... 1

Replacement.......................................49

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

Other Functions and How to Use Them.............50

Components of the Load Moment Indicator (AML-LⅡC) Main Unit.......................... 4 Diagram of the Load Moment Indicator (AML-LⅡC) System ............................. 5

1.

Language ..................................................50

2.

Overload History Display ..........................50

3.

Erasing the Overload History....................51

Input/Output Signals of the Load Moment Indicator

Functions of and How to Use Maintenance Mode

(AML-LⅡC) System ............................. 6 Configuration and Functions of the Load Moment

1.

Program Version Display ..........................52

Indicator System .................................11

2.

Data ID Number Display ...........................52

3.

Di Check....................................................52

4.

Ai Check....................................................53

5.

Elevating Cylinder Oil Pressure Monitor ...53

6.

Do Check ..................................................54

7.

MDT Monitor

[OPERATION] Names and Functions of Load Moment Indicator Main Unit Parts................................... 15

(Multiplex Data Transmitter Monitor) ..54

Selecting Operational Status ............................. 21 Load Moment Indicator Pre-operational Inspection

8.

Key Switch Check .....................................54

........................................................... 25

9.

Display Check ...........................................55

How to Use the Working Range Limit Function.....

10.

Error Data Display.....................................55

........................................................... 26

11.

Erasing the Error Data ..............................55

Display Alteration............................................... 30

12.

OP (Option) Board Check .........................56

13.

Ao Check...................................................56

14.

Sio Check..................................................57

15.

Adjust Monitor ...........................................57

[ADJUSTMENT AND MAINTENANCE] General: Adjustment Mode and Maintenance Mode 1.

16.

Overload History Display ..........................57

17.

Erasing the Overload History....................57

18.

Clock Adjustment ......................................57

Keys and Switches for

Error Message

Adjustment and Maintenance............. 31 2.

Mode Construction and Menu .................. 32

1.

Display of Error Message..........................58

3.

Method of Shifting Modes......................... 33

2.

How to Read the Error Message ..............58

4.

Method of Menu Selection........................ 34

3.

How to Read the Error History..................58

4.

Troubleshooting Table...............................59

Functions of and How to Use Adjustment Mode

4.1

Group Code 0 ...........................................59

Adjustment Procedures ..................................... 35

4.2

Group Code 1 ...........................................70

1.

Adjustment Initialization............................ 35

4.3

Group Code 2 ...........................................72

2.

Capacity Setting ....................................... 36

4.4

Group Code 3 ...........................................75

3.

Boom Length Adjustment ......................... 38

4.

Boom Angle Adjustment........................... 38

5.

Swing Angle Adjustment .......................... 39

1.

Removing Front Panel/Display Board.......76

6.

Outrigger Extension Width Adjustment .... 40

2.

Removing Rear Panel/Connector Board

7.

Moment Adjustment ................................. 42

8.

Clock Adjustment ..................................... 45

9.

Adjustment of Swing Output..................... 46

10.

Adjustment of Elevation Output................ 47

Disassembly of AML Main Unit

/Current Output Board ........................76 3.

Removing CPU Board/Analog Board

3.1

Notes on ROM/EEPROM Replacement ...77

/Power Board ......................................77

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W301-0131E

Contents [INFORMATION AND DATA] Adjustment Value Table ..................................... 78 Specification No. : GR-450-1-00101 (2M2D-specification) .......................... 78 Specification No. : GR-450-1-00103 (1M1D-specification) .......................... 79 Multiplex Data Transmitter (MDT) Input/Output Nos. and Corresponding Signals................ 80 Checking the Detectors ..................................... 81 1. Boom Length Detector ............................. 81 2. Boom Angle Detector ............................... 81 3. Swing Angle Detector............................... 81 4. Outrigger Extension Width Detector......... 81 5. Pressure Sensor for Moment Detection ... 82 Fuses

........................................................... 83

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W301-0131E

Components of the Load Moment Indicator (AML-LⅡ C) 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 SiF1GND 26 SiF1SRC 27 SiF1TXD+ 28 SiF1TXD29 SiF1RXD+ 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

SOL1, 2 FUSE: 250V 2A

Swing

SOL3, 4 FUSE: 250V 2A

Elevating

SOL 6 SOL5, FUSE: 250V 2A

Swing free

Fuse PWMFREQ CNTL 1

CNTL 2

CNTL 3

CNTL 4

ZERO SPAN ZERO SPAN ZERO SPAN ZERO SPAN

Right Swing Left Swing Boom Raise Boom Lower

CAL/CLOCK

CNTL 6

SPAN

Boom Retraction (Not used.)

CN4 PLD

ROM 1

Output adjustment trimmer (Adjusted by AML maker.

Do not touch.)

Right side view (Name plate) Moment display contrast adjuster LCD panel contrast adjuster Current output board (for Slow stop)

Lifting height indicative symbol

Load radius limit restriction indicative symbol

Boom length display

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)

Load radius display

Lower boom angle limit restriction key

CN2 Connector

LCD panel

Upper boom angle limit restriction key

SOL5, 6 fuse (2A) Slow stop (Swing free)

Connector board

Load radius indicative symbol

m

Boom angle display

Over-front position symbol

Lifting height restriction key

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 4

W301-0131E

CN2 CN3

CPU board

Rated lifting capacity display

%

CPU

ROM 0

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

Lower boom angle limit restriction symbol

CN1

EEPROM

ZERO Swing CNTL Free 5 SPAN ZERO

Battery

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

Power board Analog board CPU board Display board

Right side view

IW301-0131E18

Diagram of the Load Moment Indicator (AML-LⅡ C) System

Boom angle detector

CONNECTOR BOARD A C B D E

Boom length detector

Pressure sensor (Main)

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

24(V)

Pressure sensor for moment detection (Elevating)

Auto.stop signal output SOL.

Alarm signal output

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

SOL 1, 2 (2A) SOL 3, 4 (2A)

Fuses

Jib setting control output SOL. Lever manipulation detection input Slow stop(Swing)

Slow stop(Elevating)

Multiplex data transmitter lower unit Speed sensor

Limit switch

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

DISPLAY BOARD

Current Amplifier Circuit

SOL 5, 6 (2A)

CPU BOARD

SIF 1 (2A)

CHR display

SIF 2 (2A)

LCD panel (1) MAIN (3A)

ROM

POWER BOARD

+20V

RLY1, 2 (3A)

+12V

RLY3, 4 (3A)

Relay

DC power block

RLY7, 8 (3A)

Buzzer LCD panel (2)

CAL/CLOCK

SCI KEY input

-12V

LCD SW. backlights

+5V

RLY5, 6 (3A)

EEPROM

CPU RAM

Fuses

Serial input/output circuit

Latch

CN2

BUZZER

Outrigger extension width detector (4 peace)

SOL 5, 6 (2A) SOL 1, 2 (2A) SOL 3, 4 (2A)

CN1

Swing angle detector

Working condition input

CURRENT OUTPUT BOARD

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

O.C.Tr. output block

Latch

ANALOG BOARD

Di SW. input block

Latch

Buffer

Analog multiplexer

A/D converter

CN3

Multiplex data transmitter upper unit

90 - 100% 100% -

AML external indicator output (option)

Working condition input

Torque converter pressure sensor Slow stop (Swing free)

Working condition input

5

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

W301-0131E

Pressure sensor analog detector power supply

IW301-0131E17

Input/Output Signals of the Load Moment Indicator (AML-LⅡ C) System As shown in the “Diagram of the Load Moment Indicator (AML-LⅡC) System” on the previous page, the display board, CPU board, analog board, power board, current output board and connector board consist inside the load moment indicator. 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

3

ANAIN A

4

ANAIN B

5

ANAIN C

9

ANAIN D

10

ANAIN E

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

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

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

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

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

Signal name: Two blocking detection switch input

13

Di1

Switch input representing whether two-blocking condition exists.

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

Switch OFF (H): The hook currently in use is two-blocking.

Signal name: Boom full retraction detection switch input

15

Di3

Switch input representing whether the boom is fully retracted.

Switch ON (L): Boom in fully retracted state.

Switch OFF (H): The boom is not fully retracted.

Signal name: Jib stowed condition detection switch input

16

Di4

Switch input representing whether the jib is stowed.

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

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

Signal name: Swing stop cancel switch input

22

ACC

Switch input representing whether the swing stop is cancelled.

Switch ON (L): Swing stop is cancelled.

Switch OFF (H): Swing stop is functioning.

Signal name: Anti-twoblock disable switch input

24

Di5

Switch input representing whether automatic stop caused by two-blocking is overridden.

Switch ON (L): Automatic stop caused by two-blocking is cancelled and the alarm buzzer does not sound.

Switch OFF (H): Anti-twoblock function is ready.

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

25

Di6

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

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

6

W301-0131E

Input/Output Signals of the Load Moment Indicator (AML-LⅡ C) System CN 1 connector Pin No.

Signal names and functions

Name

Signal name: Elevation slow stop cancel switch input 26

Di7

Switch input representing whether elevation slow stop is cancelled.

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

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

Signal name: Over-front detection switch input

28

Di9

Switch input representing whether the boom is in the over-front area.

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

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

Signal name: Swing angle detector 1,2 selection (swing dead angle detection) switch input

29

Di10

Switch input representing whether the boom is in the swing dead angle.

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

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

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 two-blocking or the AML main unit is out of order.

Relay ON (24V): Normal operation is available.

Relay OFF (0V): The crane operation is stopped.

Relay output

1

RLY 1

Crane condition

ON

Moment ratio < 90％

ON

90％ ≦ Moment ratio < 100％

OFF

Moment ratio ≧ 100％

OFF

Two-blocking.

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.

-

OFF

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

Maximum (22’11-5/8”) (7m)

Moment ratio ≧ 94％

Middle (21’3-7/8”) (6.5m)

Moment ratio ≧ 94％

Middle (16’4-7/8”) (5m)

Moment ratio ≧ 92％

7

W301-0131E

Input/Output Signals of the Load Moment Indicator (AML-LⅡ C) System CN 2 connector Pin No.

Signal names and functions

name

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

Relay ON (24V): Alarm buzzer is output.

Relay OFF (0V): Alarm buzzer is not output.

Relay output OFF ON/OFF 4

RLY 4

Moment condition Moment ratio < 90％ 90％ ≦ Moment ratio < 100％

ON

Moment ratio ≧ 100％

-

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

ON/OFF

ON

Maximum (22’11-5/8”) (7m)

84％ ≦ Moment ratio < 94％

Middle (21’3-7/8”) (6.5m)

84％ ≦ Moment ratio < 94％

Middle (16’4-7/8”) (5m)

82％ ≦ Moment ratio < 92％

Maximum (22’11-5/8”) (7m)

Moment ratio ≧ 94％

Middle (21’3-7/8”) (6.5m)

Moment ratio ≧ 94％

Middle (16’4-7/8”) (5m)

Moment ratio ≧ 92％

Signal name: Two-blocking alarm relay output 7

RLY 7

This relay contact turns ON and the alarm buzzer is output when the hook block is two-blocking.

Relay ON (24V): Alarm buzzer is output.

Relay OFF (0V): Alarm buzzer is not output.

Signal name: Jib set control relay output

8

RLY 8

This relay contact turns ON and hydraulic pressure in the boom telescoping circuit drops when jib set status is registered.

Relay ON (24V): Hydraulic pressure in the boom telescoping circuit is lower.

Relay OFF (0V): Hydraulic pressure is normal.

Signal name: Main winch hoist-up operation detector switch input

9

Di11

Input from the switch detecting hoist-up operation of the main winch.

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

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

Signal name: Aux. winch hoist-up operation detector switch input

11

Di13

Input from the switch detecting hoist-up operation of the auxiliary winch.

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

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

Signal name: Right swing proportional control valve output

13

CNTL 1P

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.

14

CNTL 1N

Signal name: Ground terminal for right swing proportional control valve Signal name: Left swing proportional control valve output

15

CNTL 2P

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.

8

W301-0131E

Input/Output Signals of the Load Moment Indicator (AML-LⅡ C) System CN 2 connector Pin No.

name

16

CNTL 2N

Signal names and functions Signal name: Ground terminal for left swing proportional control valve Signal name: Boom extending operation detector switch input

17

Di15

Input from the switch detecting boom extending operation.

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

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

Signal name: Boom raising operation detector switch input

19

Di17

Input from the switch detecting boom raising operation.

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

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

Signal name: Boom lowering operation detector switch input

20

Di18

Input from the switch detecting boom lowering operation.

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

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

Signal name: Right swing operation detector switch input

21

Di19

Input from the switch detecting right swing operation.

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

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

Signal name: Left swing operation detector switch input

22

Di20

Input from the switch detecting left swing operation.

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

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

Signal name: Boom raising proportional control valve output

23

CNTL 3P

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

24

CNTL 3N

Signal name: Ground terminal for boom raising proportional control valve Signal name: Boom lowering proportional control valve output

25

CNTL 4P

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

26

CNTL 4N

Signal name: Ground terminal for boom lowering proportional control valve

9

W301-0131E

Input/Output Signals of the Load Moment Indicator (AML-LⅡ C) System 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 output turns ON when the Load moment ratio is between 90% and 100%.

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

OC (Open collector) output “OFF” : 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 (22’11-5/8”) (7m)

84％ ≦ Moment ratio < 94％

Middle (21’3-7/8”) (6.5m)

84％ ≦ Moment ratio < 94％

Middle (16’4-7/8”) (5m)

82％ ≦ Moment ratio < 92％

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

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

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

Condition to turn ON OC output Moment ratio ≧ 100％ 3

TR3

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 (22’11-5/8”) (7m)

Moment ratio ≧ 94％

Middle (21’3-7/8”) (6.5m)

Moment ratio ≧ 94％

Middle (16’4-7/8”) (5m)

Moment ratio ≧ 92％

Signal name: Outrigger state emergency register switch input 10

Di25

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 (L): Emergency registration of outrigger extension width is available.

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

Signal name: Swing relief proportional control valve output

16

CNTL 5P

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 Signal name: Swing free/lock selector switch input

21

Di21

Switch input representing whether swing free condition is selected.

Switch ON (L): Swing free condition is selected.

Switch OFF (H): Swing lock condition is selected.

10

W301-0131E

Configuration and Functions of the Load Moment Indicator System Configuration and Functions of the Load Moment Indicator System

(2) Working range limit functions When any working range limit is registered to the load moment indicator, the crane is controlled so

The load moment indicator system is a safety

that the crane work posture does not exceed this

device provided to prevent overloading of the

registered working range limit. When the boom

crane which may cause it to overturn or be

reaches the previously registered restriction,

damaged.

buzzer sounds, and the crane operation stops.

The load moment indicator system has various kinds of functions, including the following typical

(3) Slow stop function

functions. Based on the registered work

In the following cases, the boom elevation speed

conditions by operator selection and the signals

or the boom swing speed gradually decreases to

from various sensors, the crane operations are

stop before the boom reaches the stoppage

controlled.

position.

(1) Automatic stop function for overloading

・When the automatic stop is caused by overloading

The load moment indicator calculates and

(Boom lowering will stop.)

compares the working and rated moment values

・When the elevating cylinder reaches its stroke end

and displays them as a percentage. When the

(Boom raising will stop.)

working moment exceeds the rated moment (100% or more), failure message is shown, alarm

・When the automatic stop is caused by working

buzzer sounds, and the crane operation toward

range limit function (Boom elevation will stop.)

the critical side stops.

・When the automatic stop is caused by backward stability during on-rubber operation (Boom raising will stop.) ・When the automatic stop is caused by working range limit function during on-outrigger operation (Boom swing will stop.)

On-outrigger operation

On-rubber operation

Hoisting up Automatic stop

Boom lowering

by overloading

Boom extension Swing

—

Stop by backward stability

Boom raising

—

Stop at stroke end

Boom raising

Stop by working range restriction : Slow stop

Boom raising/lowering Boom extension Swing

: Stop

: Not stop —: Not relevant

11

IW301-0131E50

W301-0131E

Configuration and Functions of the Load Moment Indicator System Load Moment Indicator 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

θ

Boom status

Working range limits

Number of part-lines of rope Load moment indicator unit External warning lamps (option)

Alarm buzzer Display panel

°

Stop output when: Moment ratio exceeds 100% Twoblocking occurs Moment exceeding limit for boom with jib mounted Load moment indicator system error occurs

°

Backward stability control activated

Swing restricted

Working range limit signal output

Boom extension halted

Boom lowering halted

Hoisting up halted

Boom raising halted Boom retraction halted

Upper boom angle restricted Lower boom angle restricted

Lifting height restricted

Load radius restricted

θu

H θL R IW301-0131E51

12

W301-0131E

Configuration and Functions of the Load Moment Indicator System Automatic Stop Functions Causes of automatic stop

Operation

Alarm Functions Halted movement

・ Moment ratio

・Hoisting up

exceeds 100% (*1)

・Boom lowering

・ Overwinding

・Boom extension

Condition Alarm A control is moved toward Moment display: Displays critical side (hoist up, [Warning:0024]. boom lowering or boom Buzzer: Sounds continuously. extension) while overwinding condition exists.

Overwind cutout function Moment display: Displays is deactivated with the [Warning:0015]. winch overwound.

External warning lamps: Red lamp is lit.

Buzzer: Sounds continuously.

Moment ratio exceeds Moment display: Yellow segment 90% is lit.

External warning lamps : Orange lamp is lit.

Buzzer: Sounds intermittently.

A control is moved toward Moment display: Displays critical side while moment [Warning:0023]. ratio exceeds 100% External warning lamps : Red lamp is lit.

Buzzer: Sounds continuously.

AML system error Moment display: Displays failure messages.

AML buzzer: Sounds 3 seconds.

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

Associated restriction indicator lamp flashes.

AML buzzer: Sounds 3 seconds.

Slow stop control Moment display: Displays [Warning:0081] or [0082] AML Buzzer: Sounds 3 seconds.

Boom lift with jib mounted on boom*

・ AML system error

Working range limit

Upper boom angle restricted

・Boom raising ・ Boom lift

Lower boom angle ・ Single top lift restricted

・Boom lowering

・ Jib lift

Lifting height

・Boom raising

restricted

・Boom extension

Load radius

・Boom lowering

restricted

・Boom extension

Swing restricted

・Boom swing IW301-0131E52

(*1): 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 (22'11-5/8"[7.0 m]) Middle (21' 3-7/8"[6.5 m])

94% or more

Middle (16' 4-7/8"[5.0 m])

92% or more

94% or more IW301-0131E53

(1)Moment ratio is Moment display: Corresponding between 84% and 94%. segment is lit.

(2)Moment ratio is External warning lamps between 84% and 94%. Orange lamp is lit.

(3)Moment ratio is Buzzer: Sounds intermittently. between 82% and 92%.

(1)Moment ratio exceeds Moment display: Displays 94%.

[Warning:0088].

(2)Moment ratio exceeds External warning lamps : Red 94%. lamp is lit.

(3)Moment ratio exceeds Buzzer: Sounds continuously.

92%.

Buzz

IW301-0131E55

IW301-0131E54

*(1) is applicable when the outriggers are extended to maximum (22’ 11-5/8”).

(2) is applicable when the outriggers are extended to middle (21’ 3-7/8”).

(3) is applicable when the outriggers are extended to middle (16’ 4-7/8”).

13

W301-0131E

Configuration and Functions of the Load Moment Indicator System

◆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.

14

W301-0131E

Names and Functions of Load Moment Indicator Main Unit Parts Names and Functions of Load Moment Indicator Main Unit Parts Bargraph display

Display panel 1 ° m

° %

Display panel 2 Control

IW301-0131E56

15

W301-0131E

Names and Functions of Load Moment Indicator Main Unit Parts Bargraph Display 3

1

2

4

Usually on

0-89

90-99

Each frame representing 10%

100-109

110 or more than that

Each frame representing 2.5%

Each frame representing 2.5% IW301-0131E57

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 pressure when the display alteration key is held down.

Also displays error messages when the load moment indicator or any of its associated devices fail(s).

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.

16

W301-0131E

Names and Functions of Load Moment Indicator Main Unit Parts Display Panel 1 1

2

3

17

20

5

゜ m

15 14

16

21

18

13

6

゜ %

19

7

17

8 11

10

9 IW301-0131E58

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

9. Load radius limit restriction indicative symbol

select key is pressed, or the display alteration key

This symbol, while marked up, means the value

is held down, the number of part-lines of ropes is

shown in the load radius display (11) represents

displayed. Also, when the upper boom angle

the load radius limit. Note that the load radius

restriction function is registered, the registered

indicative symbol (10) is also displayed at the

upper boom angle restricted value is displayed as

same time.

long as the register key is pressed on.

10.

2. Number of part-lines of indicative symbol

Load radius indicative symbol

This symbol, while marked up, means the value

This symbol shows that the jib angle display (1)

shown in the load radius display (11) represents

indicates the number of part-lines of rope.

the load radius.

3. Boom length indicative symbol

11.Load radius display

This symbol, while marked up, means the value

Normally displays the crane's load radius.

in the boom length display (13) is a boom length

Displays the boom swing angle while the display

value.

alteration key is held down.

5. Jib angle indicative symbol

When the load radius limit restriction function is

This symbol, while marked up, means the value

activated, the load radius limit restriction value is

shown in the jib angle display (1) represents the

displayed while the register key is held down.

offset angle.

13.

Boom length display

Usually displays boom length.

6. Jib lift indicative symbol Is marked up when the jib lift is selected,

Displays the lifting height while the display

indicating the condition of the jib.

alteration key is pressed.

When the lifting height restriction function is

7. Real load display

effective, this displays lifting height restriction

Displays the real load.

value while the register key is being pressed.

17

W301-0131E

Names and Functions of Load Moment Indicator Main Unit Parts

14.

18.

Lifting height indicative symbol

Lower boom angle limit restriction symbol

This symbol, while marked up, means the value

This symbol, while marked up, means the boom

in the boom length display (13) is a lifting height.

angle display (19) displays the registered lower

15.

boom angle restricted value.

Lifting height restriction symbol

19.

This symbol, while marked up, means the value

Boom angle display

in the boom length display (13) is a lifting height

Normally displays the boom angle.

restriction value.

Displays the moment % when the display

The lifting height symbol (14) is marked up

alteration key is held down. When the restriction

simultaneously.

function is activated, the lower boom angle limit

16.

restriction value is displayed while the register

Upper boom angle limit restriction symbol

key is held down.

Indicates that the jib angle display (1) displays the

20.

registered boom angle upper restricted value.

17.

Boom lift indicative symbol

Is marked up when the boom lift is selected.

Boom angle indicative symbol

21.

Indicates that the boom angle display (19)

Single-top lift indicative symbol

Is marked up when the single-top lift is selected.

displays the boom angle.

Controls 14 13 12 11

15

10 16 17 18

9

19 8

20

7 6

1

2

3

4

1. Increase key

5

IW301-0131E59

5. Check key

Used to increase the selected value.

Used to check the AML system functions.

2. Decrease key

6. Register key

Used to decrease the selected value.

Used to register a selected state.

3. Outrigger mode select key

7. Display alteration key

Used to select the outrigger status.

Used to alternate the displays on display panel 1.

4. Lift mode select key

8. load radius restriction key

Used to select the lift status.

Used to activate and release the load radius limiting function.

18

W301-0131E

Names and Functions of Load Moment Indicator Main Unit Parts

9. load radius restriction indicator lamp

15.

Lifting height restriction indicator lamp

Lights up when the load radius limiting function is

Lights up when lifting height limiting function is

activated.

activated.

10.

Lower boom angle limit restriction key

16.

Right swing restriction key

Used to activate and release the lower most

Used to activate and release the right swing

boom angle limiting function.

limiting function.

11.Lower boom angle limit restriction indicator lamp

17.

Right swing restriction indicator lamp

Lights up when the lower most boom angle

Lights up when the right swing limiting function is

limiting function is activated.

activated.

12.

Upper boom angle limit restriction key

18.

Left swing restriction key

Used to activate and release the upper most

Used to activate and release the left swing

boom angle limiting function.

limiting function.

13.

Upper boom angle limit restriction indicator

19.

Left swing restriction indicator lamp

lamp

Lights up when the left swing limiting function is

Lights up when the upper most boom angle

activated.

limiting function is activated.

14.

20.

Lifting height restriction key

Number of part-lines of rope select key

Used to register a number of part-lines of rope.

Used to activate and release the lifting height limiting function.

Display Panel 2 5 1 3 2 4

2

3

3

2 3 IW301-0131E60

1. Over-front position symbol

2. Outrigger state indicative symbol

Indicates that the boom is swung into the

Displays the way the outriggers are extended.

over-front position.

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

19

W301-0131E

Names and Functions of Load Moment Indicator Main Unit Parts

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.

4. Suspension lock state indicative symbol Displays that the suspensions are locked up.

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

20

W301-0131E

Selecting Operational Status Selecting Operational Status

(1) On-outrigger operation When the outrigger mode select key is pressed,

WARNING

the outrigger state indicative symbol flashes in

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.

accordance with the status that the load moment indicator detects on.

After making sure that the display conforms to the 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

Selecting Outrigger Status

display and real load display will return to normal display conditions, meaning that the state has

◆The "on-rubber stationary" status is the default

been registered.

status and is automatically selected when the power supply is turned on (the PTO switch is

Actual outrigger extension condition

placed in the "ON" position). ◆Turning the power off (PTO switch: OFF)

Displayed outrigger status

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.

Register the outrigger state using the outrigger

IW301-0131E62

mode select key and the register key.

Fully extended (22' 11-5/8" [7.0m]) ° m

Mid. extended (21' 3-7/8" [6.5m]) ° %

Mid. extended (16' 4-7/8" [5.0m]) IW301-0131E63

Register key

Outrigger mode select key IW301-0131E61

21

W301-0131E

Selecting Operational Status Selecting Lift Status

(2) On-rubber operation Press the outrigger mode select key repeatedly

◆The boom lift status is the default status and is

until the display conforms to the actual condition

automatically selected (the boom lift indicative

(on-rubber stationary operation or on-rubber

symbol is marked up) when the power supply is

creep operation). Then press the register key.

turned on (the PTO switch is placed in the ON

The moment display, rated lifting capacity display

position).

and real load display will return to normal display

◆Turning the power off (PTO switch: OFF)

conditions, meaning that the on-rubber state has

automatically erases all the previous settings

been registered.

stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the

On-rubber stationary operation

power has been last turned off, enter the settings

On-rubber creep operation

all over again.

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

Marked up

Flashing

Marked up

Marked up

IW301-0131E64 ° m

◆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.

Register key

Lift mode select key IW301-0131E65

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. ◆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

22

W301-0131E

Selecting Operational Status display 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.

(1) Boom lift

(2) Single top lift

(3) Jib set (mounting or stowage)

(4) Jib lift : 28.9 ft (8.8m) jib, 5°offset

(5) Jib lift : 28.9 ft (8.8m) jib, 25°offset

(6) Jib lift : 28.9 ft (8.8m) jib, 45°offset

(7) Jib lift : 50.0 ft (15.2m) jib, 5°offset

(8) Jib lift : 50.0 ft (15.2m) jib, 25°offset

(9) Jib lift : 50.0 ft (15.2m) jib, 45°offset

IW301-0131E66

23

W301-0131E

Selecting Operational Status Selecting Number of Part-lines of Rope

◆When the power supply is turned on (i.e. PTO switch ON), the standard 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.

corresponding to a work condition is selected.

Register the number of part-lines of rope using the number of part-lines of rope select key and the register key.

◆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.

Number of part-lines of rope indicative symbol Number of part-lines of rope

°

Number of part-lines of rope select key Decrease key Increase key

Register key

IW301-0131E67

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

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

The number of part-lines of rope symbol will flash,

set, press the register key and register the

and the number of part-lines of rope will be

number. Then, the number of part-lines of rope

shown on the jib angle display in a flashing mode.

symbol will be turned off and the jib angle display will return to a normal status.

2. Press the increase or the decrease key to set the

◆The number of part-lines of rope can be

number of part-lines of rope at a desired value.

confirmed by pressing the display alteration key.

◆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.

24

W301-0131E

Load Moment Indicator Pre-operational Inspection Load Moment Indicator Pre-operational Inspection

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

WARNING

3. Make sure that the display on the display panels

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

conforms to the actual crane conditions.

(1) Boom length (2) Boom angle (3) Jib angle……shown while jib lift is selected

Before starting operation, check that the load

(4) Real load……Make sure that the approximately

moment indicator works in good condition, as

mass of the hook block while no

follows:

load is on the hook block ◆The real load is not shown correctly if the lift

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

status is not registered correctly.

moment indicator is in the following conditions: ・ Moment display……All segments are marked up.

(5) Outrigger state indicative symbol

・ Display panel (1 and 2) (6) Boom position indicator

………………………All segments are marked up. ・ Working range restriction indicator lamp

(7) Over-front position symbol

………………………………All six lamps light up.

……shown while the boom is in over-front area

・ Alarm buzzer………………Sounds continuously. ・ Movement toward critical sides

3

………………………………Automatically halted

2 1

Buzz

4 6 Bargraph display

゜

Display panel 1 ° m

Display panel 2 ° %

7 5

IW301-0131E68

25

W301-0131E

IW301-0131E69

How to Use the Working Range Limit Function 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

[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.

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

The working range restricting function makes the

stays lit and the buzzer stops.

boom automatically stop at the previously

Thereafter, the upper or lower boom angle limit

registered boom angles (upper and lower), lifting

restriction indicator lamp flashes and the buzzer

height, load radius and swing angle,

sounds continuously whenever the upper or lower

The function is useful for handling a load in a

limit previously registered is reached.

confined place because it defines the area in

To cancel the boom angle limit function, press the

which the boom can operate.

boom angle limit restriction key again. The

◆Turning the power off (PTO switch: OFF)

corresponding boom angle limit restriction

automatically erases all the previous settings

indicator lamp will go off.

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

Upper boom angle limit restriction indicator lamp

Lifting height restricted

°

Lower boom angle limit restriction indicator lamp

θu H θL

Lower boom angle limit restriction key Load radius restricted

Swing restricted

Upper boom angle limit restriction key IW301-0131E71

R IW301-0131E70

26

W301-0131E

How to Use the Working Range Limit Function Lifting Height Limit

Swing 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

a swing restriction key. The corresponding swing

restriction indicator lamp will flash and the buzzer

restriction indicator will flash and the buzzer will

will sound continuously, indicating that the limit

sound continuously, indicating that the swing

height has been stored in the memory. When the

angle limit has been registered in the memory.

boom is moved back to a height within the set

When the boom is swing back to an angle within

limit, the lifting height restriction indicator lamp

the set limit, the swing restriction lamp stops

stops flashing and stays lit and the buzzer stops.

flashing and stays lit and the buzzer stops.

Thereafter, the lifting height restriction indicator

Thereafter, a swing restriction indicator lamp will

lamp flashes and the buzzer sounds continuously

flash and the buzzer will sound whenever the limit

whenever the height limit previously registered is

previously registered is reached. (The swinging

reached.

boom stops automatically.)

To cancel the height limit function, press the lifting

To cancel the restriction function, press the

height restriction key again. The corresponding

corresponding swing restriction key again. The

lifting height restriction indicator lamp will go off.

corresponding swing restriction indicator lamp will go out. ◆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

Lifting height restriction indicator lamp

OFF, the automatic stop does not work even if the boom is swung to the limit. In this case, the

Lifting height restriction key

corresponding swing restriction indicator lamp flashes, a message appears and the AML buzzer beeps for three seconds. Take care when swinging the boom.

IW301-0131E72

Left swing restriction indicator lamp °

Right swing restriction indicator lamp

Right swing restriction key Left swing restriction key IW301-0131E73

27

W301-0131E

How to Use the Working Range Limit Function 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.

°

Load radius restriction indicator lamp Load radius restriction key

IW301-0131E74

28

W301-0131E

How to Use the Working Range Limit Function 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". ◆This display is not available when preoperational load moment indicator 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

Load radius restriction values Boom position indicator

Register key Swing limit restriction values

IW301-0131E75

29

W301-0131E

Display Alteration 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

psi

M＊＊＊＊

Unit

Main-circuit pressure Meaning main circuit pressure

IW301-0131E76

Display Panel 1 ◆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＊＊＊＊

psi

Lifting height

Moment ratio Real load

%

Rated lifting capacity Swing angle

Display alteration key IW301-0131E77

30

W301-0131E

General: Adjustment Mode and Maintenance Mode General: Adjustment Mode and Maintenance Mode 1. Keys and Switches for Adjustment and Maintenance

HALT

ZERO

WDT

PROTECT ON

OFF

MOMENT SHORT

1. Scroll-up key Moment display 2. Scroll-down key

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 IW301-0131E01

1. Scroll-up key

7. Check key

Used to see the previous lines of message

Used for ”Do Check” and ”Ao Check” functions in

displayed on the moment display.

the maintenance mode.

2. Scroll-down key

8. Moment input short-circuit switch

Used to see the next lines of messages displayed

Not used for this machine.

on the moment display.

9. Protect switch

3. Register key

Set this switch to OFF when changing the mode

Used to register the selected state and write the

from user mode to adjustment mode. With this

adjustment value in EEPROM.

switch OFF, data in the EEPROM becomes rewritable.

4. Increase key

10.Moment zero adjuster

Used to increase the adjustment value.

This adjuster is for adjustment by the AML

5. Decrease key

manufacturer’s service personnel. Do not tamper.

Used to decrease the adjustment value.

11.Abnormality display LED

6. Display alteration key

Lights when the AML is in abnormal conditions or

Used to change the display to the upper menu.

when the AML adjustment is initialized.

31

W301-0131E

General: Adjustment Mode and Maintenance Mode 2. Mode Construction and Menu

3. Maintenance Mode: Used to make functional checks of AML. This

USER MODE

mode has the following menus:

MAINTENANCE MODE

MAIN MENU [・Maintenance]

SUB-MENU [：Prog. version] [：Data ID. number]

ADJUSTMENT MODE

[・Adjust clock]

IW301-0131E07

[：Di check] [：Ai check] [：Disp ELEV PRES]

1. The AML device has three modes and AML

[：Do check]

functions are allotted for these models.

[：MDT Monitor]

2. User Mode:

[：Key SW check]

Used to indicate moment ratio or to perform AML

[：Display check]

pre-opetational inspection (Normally used).

[：Disp. err data] [：Erase err data]

In normal use, turn ON the protect switch

[：Disp. O/L data]

mounted on the adjustment window on the top of

[：Erase O/L data]

AML. AML will go to the user mode when the

[：OP board check]

power turns on.

[：Ao check] [：Sio check] [：Adjust Monitor]

HALT

WDT

ZERO

PROTECT

Used to make detector adjustment. This mode has the following menus:

ON

OFF

MOMENT SHORT

4. Adjustment Mode:

MAIN MENU Protect switch Top view

[・Adjust]

SUB-MENU [：Adjust L&A] [：Adj. work rad]

IW301-0131E03

[：Adjust MMT] [・Adjust CNT dat]

[：Adj. ELV speed]

[・Adjust AO]

[：Adjust AO Ofs.]

[：Reset ELV data] [：Reset AO Ofs.] [・Initialize L&A]

[：Reset DEF. FCT]

[・Initialize MMT]

[：Reset zero. span]

[・Disp. O/L data]

[：Reset PCSN]

[・Erase O/L data] [・Adjust PCSN] [・Reg. Capac.]

[：Head-OFF Capac]

[・Language]

[：Jib Select]] [：S/T Select] [：Winch drum PSN]

32

W301-0131E

General: Adjustment Mode and Maintenance Mode 3. Method of Shifting Modes Scroll-up key

Moment display

HALT

WDT

ZERO

PROTECT ON

OFF

MOMENT SHORT

Scroll-down key

Protect switch Top view

IW301-0131E03

Register key Display alteration key IW301-0131E04

1. “User mode”

→

4. “Adjustment mode”

“Maintenance mode”

→

“User mode”

Press the scroll-up key, scroll-down key, and

While the main menu of the adjustment mode is

register key at the same time. Then, the moment

displayed, turn ON the protect switch. Then AML

display changes from the bargraph to

will go back to “User mode” and bargraph will be

[・Maintenance]. This display denotes the

displayed on the moment display.

“Maintenance mode”.

2. “Maintenance mode”

→

“User 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”.

33

W301-0131E

General: Adjustment Mode and Maintenance Mode 4. Method of Menu Selection Scroll-up key

Moment display Scroll-down key

Register key Display alteration key IW301-0131E04

(Ex. “：Adjust MMT”)

1. When AML is in “Maintenance mode” or

The “↓” mark after the menu name indicates that

“Adjustment mode”, the main menu is displayed on the moment display of bargraph display portion.

Displayed menu changes by means of the

the depression of the scroll-down key calls for another menu.

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.

3. By pressing the display alteration key, the display changes to the upper menu.

4. The following marks displayed in the menu: “・”, “：” 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.

34

W301-0131E

Functions of and How to Use Adjustment Mode Functions of and How to Use Adjustment Mode

1. Adjustment Initialization [NOTE] Adjustment initialization should be performed only when EEPROM is replaced.

Adjustment Procedures

1. By the adjustment initialization, the conversion factors stored within the AML program that convert

WARNING

detected voltage input from the detectors into

Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety.

physical volumes is written onto the EEPROM. 2. Perform the initialization only once before the first adjustment takes place. If this initialization is done while adjustments are being made, you must

[NOTE]

restart the adjustment from the very beginning.

You can adjust boom length, boom angle, swing angle, and outrigger extension width in random order.

3. For adjustment initialization, you have to execute

You can adjust swing output and elevation output in random order.

the following two menus.

Before shipment from the factory, erase-protect the overload history. (See the “Erasing the Overload History” function in the adjustment mode.)

Initialize the conversion factors for boom length,

[・Initialize L&A]： angle, and deflection. [・Initialize MMT]： Initialize the conversion factors for moment.

The adjustment items and procedures are as follows: 1. Adjustment Initialization

1.1 Procedure of Conversion Factors Resetting

2. Capacity Setting

1. Select the main menu [・Initialize L&A↓] in the adjustment mode, and press the register key to

3. Boom Length Adjustment

select the menu.

4. Boom Angle Adjustment

2. When [：Reset DEF. FCT↓] appears, reset the

5. Swing Angle Adjustment

deflection factor by pressing the register key.

6. Outrigger Extension Width Adjustment

3. When the message [Done] appears, the deflection factor resetting is completed. Press the display

7. Moment Adjustment (Including load radius

alteration key to return to the main menu.

adjustment)

4. Press the register key again to select the main

8. Clock Adjustment

menu [・Initialize L&A↓] in the adjustment mode.

9. Adjustment of Swing Output

5. When [：Reset DEF. FCT↓] appears, press the

10.Adjustment of Elevation Output

scroll-down key to display [：Reset zero. span], and then press the register key to reset the zero span factor.

6. When the message [Done] appears, the zero span factor resetting is completed.

Press the display alteration key to return to the main menu.

35

W301-0131E

Functions of and How to Use Adjustment Mode 1.2 Procedures of Moment Adjustment Resetting

2.1 Procedure of Head-off Capacity Setting [NOTE]

1. Select the main menu [・Initialize MMT↓] in the

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.

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.

1. Select the main menu [・Reg. Capac.↓] in the

3. When the message [Done] appears, the moment adjustment resetting is completed.

adjustment mode, and press the register key to

Press the display alteration key to return to the

select the menu.

main menu.

2. Press the scroll-up or scroll-down key to display [：Head-Off Capac↓], and then press the register key to select the menu.

3. The currently registered head-off capacity value is

2. Capacity Setting

indicated on the moment display.

Display example:

[NOTE]

[Capacity 99.2 kp]

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 TR-450XL-4, refer to the Service Manual specified for each crane model.

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 0.1 klbs. If the key is held

1. The crane capacity data is stored in the ROM. This setting is performed to partially change the

down, the value increases or decreases in steps of

crane capacity data in the ROM.

10klbs.

5. When the desired head-off capacity value is

2. The crane capacity data normally does not need

reached, press the register key to save it.

this setting.

6. Press the display alteration key to exit the menu.

3. For the capacity setting, select one of the four sub-menus indicated below. [：Head-Off Capac]： Used to set the maximum rated lifting capacity to

2.2 Procedure of Jib Selection

the specified value. [：Jib Select]：

[NOTE] 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.

Used to change the capacity for jib-mounted condition to the capacity for jib-unmounted condition. [：S/T Select]：

1. Select the main menu [・Reg. Capac.↓] in the

Used to change the capacity for single-top-mounted condition to the capacity for

adjustment mode, and press the register key to

single-top unmounted condition.

select the menu.

[：Winch drum PSN]： Used to specify the mounting position of winch drum for capacity adjustment.

36

W301-0131E

Functions of and How to Use Adjustment Mode [S/T=Mounted↓]

2. Press the scroll-up or scroll-down key to display [：Jib Select↓], and then press the register key to

↓Press the scroll-up key.

select the menu.

[S/T：Not Mounted] When ” = ” is indicated, it means that the displayed

3. The currently registered jib capacity condition is

condition is registered currently.

indicated on the moment display. Using the

4. When the desired condition is displayed, press the

scroll-up or scroll-down key, adjust it to the desired condition .

register key for confirmation. When the setting is

Display example：

completed, “：” in the single top condition display

[Jib = Mounted↓]

changes to “ = ”.

↓Press the scroll-up key.

Display example：

[Jib：Not Mounted]

[S/T：Not Mounted]

When “ = ” is indicated, it means that the

↓Press the register key.

displayed condition is registered currently.

[S/T = Not Mounted] 5. Press the display alteration key to exit the menu.

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]

2.4 Procedure of Winch Drum Position Setting [NOTE] 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.

↓Press the register key.

[Jib = Not Mounted] 5. Press the display alteration key to exit the menu.

1. Select the main menu [・Reg. Capac.↓] in the adjustment mode, and press the register key to

2.3 Procedure of Single Top Selection

select the menu.

[NOTE]

2. Press the scroll-up or scroll-down key to display

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.

[：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

1. Select the main menu [・Reg. Capac.↓] in the adjustment mode, and press the register key to

condition.

select the menu.

Display example: [Winch drum = FR↓]

2. Press the scroll-up or scroll-down key to display

↓Press the scroll-up key.

[：S/T Select↓], and then press the register key to

[Winch drum：F↓]

select the menu.

↓Press the scroll-up key.

[Winch drum：R]

3. The currently registered single top capacity

In the above examples, “F” means the condition

condition is indicated on the moment display.

with single winch mounted at the front. “R” means

Using the scroll-up or scroll-down key, adjust it to

the condition with single winch mounted at the rear.

the desired condition.

“FR” means the condition with double winches

Display example：

mounted at the front and rear.

37

W301-0131E

Functions of and How to Use Adjustment Mode Press the register key for registration.

The conditions with “ = ” is the currently registered condition.

5. Fully extend the boom.

4. When the desired condition is displayed, press

6. Press the scroll-down key until the boom length

the register key for confirmation. When the setting

span adjustment display [Boom Ls] appears.

has been completed, “：” in the winch drum condition display changes to “ = ”.

7. Press the increase or decrease key so that the

Display example：

value of boom length span adjustment display

[Winch drum：F↓]

[Boom Ls] becomes the span adjustment value in

↓Press the register key.

“Adjustment Value Table”. Press the register key

[Winch drum = F↓]

for registration.

5. Press the display alteration key to exit the menu.

8. Fully retract the boom again.

9. Press the scroll-up key until the boom length zero-point adjustment display [Boom Lz] appears.

3. Boom Length Adjustment

10.Has the boom length zero-point adjustment display [Boom Lz] become the zero-point

WARNING

adjustment value in “Adjustment Value Table” ?

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.

[NOTE] 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 TR-450XL-4, 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.

4. Boom Angle Adjustment WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety.

[NOTE] 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 TR-450XL-4, refer to the Service Manual specified for each crane model.

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.

Always perform the boom lowering operation when adjusting the boom angle to the adjustment condition. Measure the boom angle with a level angle meter.

3. Fully retract the boom.

1. Select the main menu [・Adjust↓] in the

4. Press the increase or decrease key so that the

adjustment mode, and press the register key to

value of boom length zero-point adjustment

select the menu.

display [Boom Lz] becomes the zero-point adjustment value in “Adjustment Value Table”.

38

W301-0131E

Functions of and How to Use Adjustment Mode 2. When [：Adjust L&A↓] is displayed, press the

5. Swing Angle Adjustment

register key to select the menu.

WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety.

3. Set the actual boom angle to the condition of the zero-point adjustment specified in “Adjustment Value Table” by lowering the boom.

[NOTE] Since the swing angles involve a hysteresis, always make adjustment after a stop from rightward movement.

4. Press the scroll-up or scroll-down key until the boom angle zero-point adjustment display [Boom Az] appears.

1. Select the main menu [・Adjust↓] in the

5. Press the increase or decrease key so that the

adjustment mode, and press the register key to

value of boom angle zero-point adjustment

select the menu.

display [Boom Az] becomes the zero-point adjustment value in “Adjustment Value Table”.

2. When [：Adjust L&A↓] is displayed, press the

Press the register key for registration.

register key to select the menu.

6. Raise the boom to just before the upper stroke end, and then adjust the actual boom angle to the 3. Set the boom to the zero-point adjustment

condition of the span-point adjustment specified in “Adjustment Value Table” by lowering the

reference position (on the front centerline) by

boom.

swinging it rightward.

4. Press the scroll-up or scroll-down key until the

7. Press the scroll-up or scroll-down key until the boom angle span adjustment display [Boom As]

swing angle 1 zero-point adjustment display [SW

appears.

AG 1z] appears.

8. Press the increase or decrease key so that the

5. Adjust the increase or decrease key so that the

value of boom angle span adjustment display

value of swing angle 1 zero-point adjustment

[Boom As] becomes the span adjustment value in

display [SW AG 1z] will become 0 ± 0.3 . Press

“Adjustment Value Table”. Press the register key

the register key for registrarion.

o

for registration.

6. With the swing position unchanged, press the scroll-up or scroll-down key until the swing angle 2

9. Bring the actual boom angle to the zero-point adjustment value in “Adjustment Value Table”

zero-point adjustment display [SW AG 2z]

again.

appears.

7. Adjust the increase or decrease key so that the

10.Press the scroll-up or scroll-down key until the boom angle zero-point adjustment display [Boom

value of swing angle 2 zero-point adjustment

Az] appears.

display [SW AG 2z] will become 360 ± 0.3 .

o

Press the register key for registration.

11.Has the value of boom angle zero-point 8. Set the boom to the span- point adjustment

adjustment display [Boom Az] become the zero-point adjustment value in “Adjustment Value

reference position (on the rear centerline) by

Table” ?

swinging it rightward.

NO

9. Press the scroll-up or scroll-down key until the

YES

swing angle 1 span-point adjustment display [SW 12.Press the display alteration key to exit the menu.

AG 1s] appears.

39

W301-0131E

Functions of and How to Use Adjustment Mode 3. Fully retract all the outrigger beams.

10.Press the increase or decrease key so that the value of swing angle 1 span-point adjustment

4. Press the scroll-up or scroll-down key until the

o

display [SW AG 1s] will become 180 ± 0.3 .

right-front outrigger extension width zero-point

Press the register key for registration.

adjustment display [RFO/R Lz] appears.

11.With the swing position unchanged, press the

5. Press the increase or decrease key so that the

scroll-up or scroll-down key until the swing angle

value of the right-front outrigger extension width

2 span-point adjustment display [SW AG 2s]

zero-point adjustment display [RFO/R Lz]

appears.

conforms to the zero-point adjustment value in

12.Press the increase or decrease key so that the

“Adjustment Value Table”. Press the register key for registration.

value of swing angle 2 span-point adjustment o

display [SW AG 2s] will become 180 ± 0.3 .

6. Adjust and register the values of the right-rear,

Press the register key for registration.

left-front and left-rear outrigger extension width

13.Set the boom again to the zero-point adjustment

zero-point adjustment in the same manner as the

reference position (on the front centerline) by

one of the right-front outrigger extension width

swinging it clockwise.

zero-point adjustment.

Right-rear outrigger : Adjust [RRO/R Lz] display

14.Check the swing angle 1 and 2 zero-point

Left-front outrigger : Adjust [LFO/R Lz] display

adjustment displays [SW AG 1z] and [SW AG 2z]

Left-rear outrigger :

by pressing the scroll-up or scroll-down key. Does

7. Fully extend all the outrigger beams.

each display indicate the angle below?

SW AG 1z：0 ± 0.6

Adjust [LRO/R Lz] display

o

SW AG 2z：360 ± 0.6 NO

8. Press the scroll-up or scroll-down key until the

o

right-front outrigger extension width span YES

adjustment display [RFO/R Ls] appears.

15.Press the display alteration key to exit the menu.

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”.

6. Outrigger Extension Width Adjustment

Press the register key for registration.

[NOTE]

10.Adjust and register the values of the right-rear,

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 TR-450XL-4, refer to the Service Manual specified for each crane model.

left-front and left-rear outriggers extension width

1. Select the main manu [・Adjust↓] in the

Left-rear outrigger :

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

adjustment mode, and press the register key to

Adjust [LRO/R Ls] display

11.Fully retract all the outrigger beams again.

select the menu.

12.Press the scroll-up or scroll-down key until the

2. When [：Adjust L&A↓] is displayed, press the

right-front outrigger extension width zero-point

register key to select the menu.

adjustment display [RFO/R Lz] appears.

13.Does the right-front outrigger extension width

40

W301-0131E

Functions of and How to Use Adjustment Mode 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” ?

NO

YES

14.Press the display alteration key to exit the menu.

41

W301-0131E

Functions of and How to Use Adjustment Mode (5)Hook block position: Hoisted down just clear of ground surface or vehicle structure

7. Moment Adjustment

(6)Actual status and registered status of number of part-lines: Standard number of part-lines when main boom is fully extended

WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety.

(7)Hook block: Refer to “Adjustment Value Table”.

(Stow auxiliary hook block.)

1. Select the main menu [･Adjust↓] in the

[NOTE]

adjustment mode, and press the register key to

◆Before starting moment adjustment, raise the hydraulic oil temperature to approx.122°F(50℃) by alternate raising and lowering the boom.

select the menu.

2. When [:Adjust L&A↓] is displayed, press the

◆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 TR-450XL-4, refer to the Service Manual specified for each crane model.

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

◆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.

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.

The procedure to adjust moment is as follows:

Moment zero-point adjustment display: Display [X.XXX z ＊＊＊.＊% ↓]

7.1 Moment Zero-point Adjustment

Moment ratio(%)

7.2 Moment Span Preliminary Adjustment

Shows zero-point adjustment

7.3 Moment Zero-point Check and Fine Adjustment

state

7.4 Load Radius Adjustment

Moment detector input(mV)

7.5 Moment Span Fine Adjustment

The actual load value less than 1 klbs is shown as follows:

7.6 Moment Zero-point Recheck

0.00 to 0.99 klbs: “000” to “099”

End of moment adjustment

-0.99 to -0.01 klbs: “-99” to “-01”

7.1 Moment Zero-point Adjustment

4. After the adjustment, press the register key to save the adjusted value.

[NOTE] ◆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”.

5. Proceed to “7.2 Moment Span Preliminary Adjustment”.

◆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”.)

42

W301-0131E

Functions of and How to Use Adjustment Mode 7.2 Moment Span Preliminary Adjustment

2. Raise the boom until it almost reaches to the maximum point, and then lower it until the boom

[NOTE]

angle display corresponds to the condition of the

◆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”.

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

1. Continued from “7.1 Moment Zero-point

moment zero-point adjustment display appears.

Adjustment”.

Moment zero-point adjustment display:

2. Lower the boom to set the boom angle to the

Display [X.XXX z ＊＊＊.＊% ↓]

condition of the span preliminary adjustment.

Moment ratio(%)

(Hook block position:Hoisted down until it almost touches ground surface)

Shows zero-point adjustment state

3. Press the scroll-up or scroll-down key until the moment span adjustment display appears.

Moment detector input(mV)

Moment span adjustment display: Display [X.XXX s ＊＊＊.＊%]

4. Has the indicated value become the zero-point adjustment value?

Moment ratio(%)

The actual load value less than 1 klbs is shown as follows:

Shows span adjustment state

0.00 to 0.99 klbs: “000” to “099”

Moment detector input(mV)

-0.99 to -0.01 klbs: “-99” to “-01”

4. Adjust the value indicated in the actual load value

YES

indicator finely with the increase or decrease key

NO

5. Make an adjustment with the increase or

to conform it to the adjustment value of the span preliminary adjustment.

decrease key so that the result becomes the

The actual load value less than 1 klbs is shown as

zero-point adjustment value. Then, press the

follows:

register key to save the adjusted value.

0.00 to 0.99 klbs: “000” to “099” -0.99 to -0.01 klbs: “-99” to “-01” 6. Press the display alteration key to exit the menu.

5. After the adjustment, press the register key to save the adjusted value.

7.4 Load Radius Adjustment

6. Proceed to “7.3 Moment Zero-point Check and

[NOTE]

Fine Adjustment”.

◆For the conditions and adjustment value of the load radius adjustment, refer to the load radius adjustment item in the “Adjustment Value Table”.

7.3 Moment Zero-point Check and Fine Adjustment

◆Set the crane as follows:

[NOTE]

(1)Outriggers mode: Fully extended

◆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”.

(2)Lift mode: Boom lift (Stow jib and single top)

1. Continued from “7.2 Moment Span Preliminary

(5)Hook block: Refer to “Adjustment Value Table”.

(Stow auxiliary hook block.)

(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

Adjustment”.

43

W301-0131E

Functions of and How to Use Adjustment Mode (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.)

3. Press the scroll-down key until the moment span adjustment display appears.

Moment span adjustment display: Display [X.XXX s ＊＊＊.＊%] Moment ratio(%)

1. Select the main menu [･Adjust↓] in the

Shows span adjustment state

adjustment mode, and press the register key to select the menu.

Moment detector input(mV)

2. Press the scroll-down key until the load radius

4. Using the increase or decrease key, adjust the

adjustment display [:Adj. work rad↓] appears.

indicated value so that it becomes the span fine

Then, press the register key to select the menu.

adjustment value. Then, press the register key to save the adjusted value.

3. Press the increase or decrease key so that the

The actual load value less than 1 klbs is shown as

load radius adjustment display [Rad. 1s] becomes

follows:

the load radius adjustment value. Press the

0.00 to 0.99 klbs: “000” to “099”

register key for that registration.

-0.99 to -0.01 klbs: “-99” to “-01”

4. Press the display alteration key to exit the menu.

5. Proceed to “7.6 Moment Zero-point Recheck”.

7.5 Moment Span Fine Adjustment

7.6 Moment Zero-point Recheck

[NOTE]

[NOTE]

◆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”.

◆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”.

◆Set the crane as follows: (1)Outriggers mode: Fully extended

1. Continued from “7.5 Moment Span Fine

(2)Lift mode: Boom lift (Stow jib and single top)

Adjustment”.

(3)Boom length: Fully extended

2. Retract the boom fully.

(4)Boom angle: Lower boom until the boom angle display corresponds to condition of span fine adjustment.

3. Raise the boom until it almost reaches to the

(5)Hook block position: Hoisted down until it almost touches ground surface or vehicle structure.

maximum point, and then lower the boom until the

(6)Actual status and registered status of number of part-lines: Standard number of part-lines when main boom is fully extended.

adjustment condition. (Hoist down the hook block

boom angle display corresponds to the zero-point until it almost touches the ground surface or chassis.)

(7)Hook block: Refer to “Adjustment Value Table”.

(Stow auxiliary hook block.)

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.

44

W301-0131E

Functions of and How to Use Adjustment Mode 8. Clock Adjustment

4. Press the scroll-up or scroll-down key until the moment zero-point adjustment display appears.

AML has calender and clock IC inside, which is

Moment zero-point adjustment display:

used for recording errors. Adjust the clock in the

Display [X.XXX z ＊＊＊.＊% ↓]

following procedure. Adjust the clock in the maintenance mode.

Moment ratio(%)

1. Select the main menu [･Adjust clock] in the

Shows zero-point adjustment

maintenance mode, and press the register key to

state

select the menu.

Moment detector input(mV)

2.When the time is displayed on the moment display,

5. Has the indicated value become the zero-point

press the scroll-up or scroll-down key to bring the

adjustment value?

cursor to the place to be adjusted.

The actual load value less than 1 klbs is shown as

Time is displayed in the 24-hour basis. The cursor

follows:

lies under a numeral.

0.00 to 0.99 klbs: “000” to “099”

Display example:[ 99. 8. 23 16:30]

-0.99 to -0.01 klbs: “-99” to “-01” YES

Cursor

NO

3. Press the increase or decrease key to change the

6. Make fine adjustment as shown below. (The

value to be adjusted.

following fine adjustment procedures are

4. After the adjustment, press the register key to put

extracted from “7.3 Moment Zero-point Check and

the adjustment value onto the IC. If there are

Fine Adjustment”.)

plural adjustment places, move the cursor for

(1)Make an adjustment with the increase or

adjustment in order. Finally press the register key.

decrease key so that the result becomes the

5. press the display alteration key to exit the menu.

zero-point adjustment value. Then, press the register key to save the adjusted value.

(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”.

8. Press the display alteration key to exit the menu.

The moment adjustment is completed.

45

W301-0131E

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

[NOTE]

RV] (the left swing output adjustment display [42

◆Always reset the Ao offset value before adjustment of swing output (Ao offset adjustment).

SWG LV] for the left swing output adjustment) appears and a cursor comes on under the output value.

9.1 Procedure of Resetting Ao Offset Value

Display example: [41 SWG RV 0 0↓]

1. Select the main menu [･Adjust AO↓] in the adjustment mode, and press the register key to

Actual output value

select the menu.

Output value

2. When [:Adjust AO Ofs.↓] is displayed, press the

4. Press the increasse or decrease key to conform

scroll-down key until the display [:Reset AO Ofs.]

the output value of the right swing output

appears. Press the register key to select the

adjustment display [41 SWG RV] to the standard

menu.

value of the swing output. Remember that actual output value will also change in this situation.

3. When [Reset OK?] appears, reset the Ao offset

Display example:

value by pressing the register key.

[41 SWG RV 35 35↓]

4. When the message [Done] appears, the Ao offset value resetting is completed. Press the display

Actual output value

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:

[NOTE]

[41 SWG RV 35 35↓]

◆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 TR-450XL-4, refer to the Service Manual specified for each crane model.

Actual output value Output value 6. While keeping the swing control lever fully to the

◆Set the crane as follows:

right swing side, raise the engine speed to

(1)Outriggers mode: Fully extended

maximum. Then press the increase or decrease

(2)Lift mode: Boom lift (Stow jib and single top.)

key so that the boom swing will stop under this

(3)Boom length: Fully retracted

condition.

(4)Boom angle: As high as possible (Lowered boom can constitute a hazard when swung.)

Display example: [41 SWG RV 35 37↓]

(5)Hook block position: Hoisted up as much as possible

Actual output value

(6)Hydraulic oil temperature: Approx.122°F(50℃)

Output value 1. Select the main menu [･Adjust AO↓] in the

7. Press the register key to save the adjusted value

adjustment mode, and press the register key to

in EEPROM. Now the adjustment of the right

select the menu.

swing output is completed.

2. When [:Adjust AO Ofs.↓] is displayed, press the

8. Adjust and save the left swing output in the same

register key to select the menu.

manner as the right swing output adjustment.

46

W301-0131E

Functions of and How to Use Adjustment Mode 2. When [:Adj. ELV speed↓] is displayed, press the

Then press the display alteration key to exit the

register key to select the menu.

menu. (For the left swing output adjustment, substitute “left swing output adjustment display

3. Press the scroll-up or scroll-down key until the

[42 SWG LV]” for “right swing output adjustment

boom raising measurement display [Adjust ELV

display [41 SWG RV]”.)

UP↓] appears and press the register key to select the menu. (The boom lowering measurement display is [Adjust ELV DN↓].)

10.Adjustment of Elevation Output

4. When [Retract Boom] appears, retract the boom fully.

[NOTE]

This message does not appear if the boom is

◆Always reset the elevation data before adjustment of elevation output (elevation speed adjustment).

already retracted fully.

5. When [Boom A ＊＊.＊°] appears, lower the

10.1Procedure of Resetting Elevation Data

boom to or below the displayed angle. However, do not retract the elevating cylinder to its stroke

1. Select the main menu [･Adjust CNT dat↓] in the

end.

adjustment mode, and press the register key to

This message does not appear if the boom is

select the menu.

already lowered to or below the specified angle.

2. When [:Adj. ELV speed↓] is displayed, press the

6. When the following messages appear, press the

scroll-down key until the display [:Reset ELV data]

register key to select the menu.

appears. Press the register key to select the

Display:

menu.

[Start CNT Adj.↓] [JS neutral↓]

3. When [Reset OK?] appears, reset the elevation

[Push reg. key]

data by pressing the register key.

7. When the following messages appear, shift the

4. When the message [Done] appears, the elevation data resetting is completed.

boom elevating control lever fully to the boom

Press the display alteration key to return to the

raising side while keeping the engine revolution at

main menu.

the maximum. Maintain this situation until the end of the measurement.

10.2Adjustment of Elevation Output (elevation speed adjustment)

[ELV Ope. MAX↓]

[NOTE]

[Engine MAX]

Display:

◆Set the crane as follows:

8. The following message will appear during

(1)Outriggers mode: Fully extended

measurement.

(2)Lift mode: Boom lift (Stow jib and single top.)

Display example:

(3)Boom length: Fully retracted

[pi=＊＊.＊ CV=＊＊＊]

(4)Hook block position: Hoisted up as much as possible (Take care not to overwind during adjustment work.)

Elevating cylinder velocity Output pilot pressure

(5)Hydraulic oil temperature: Approx.122°F(50℃)

If the elevating cylinder rod moves almost all the

1. Select the main menu [･Adjust CNT dat↓] in the

way to its stroke end during measurement, it stops

adjustment mode, and press the register key to

automatically and the following messages will

select the menu.

appear. Reattempt from the step 5.

47

W301-0131E

Functions of and How to Use Adjustment Mode Display example: [Stroke end↓] [Boom A ＊＊.＊°] To cancel the measurement, return the boom elevating control lever to the neutral position and press the display alteration key to exit the menu.

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.

48

W301-0131E

Functions of and How to Use Adjustment Mode Required Adjustment After AML System Parts Replacement [NOTE] ◆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.

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

AML unit

Display board

None

CPU board (When reusing EEPROM removed from the broken CPU board.)

Clock adjustment

EEPROM

All adjustments are required as shown in “Adjustment Procedures” on page 35.

ROM

None

Analog board

Boom length adjustment Boom angle adjustment Swing angle adjustment Moment adjustment

Power board

None

Current output board (Option board)

None

Connector board

None

49

W301-0131E

Functions of and How to Use Adjustment Mode Other Functions and How to Use Them

ratio appears. Select it by pressing the register key.

Display:

1. Language

[:Disp. Late data↓] ↓↑

The menu [Language] is used to change the

[:Disp. Max. data]

language for message appearing on the moment display. The message on the menu [Language] is

3. Display of latest overload data

always displayed in English.

The selection of [:Disp. Late data↓] results in the latest registered overload history data being

1. Select the main menu [･Language] in the adjustment mode, and press the register key to

displayed. The time when overload history data

select the menu.

has been registered is indicated in the moment display.

2. When message for language selection appears,

To view the next data on record (up to 50 items),

operate the scroll-up or scroll-down key to display

press the scroll-down key.

the aimed language.

Display example:

Moment display

[= Japanese ↓]

Display example: [99. 01. 23 12:35↓]

↓Press the scroll-down key. [: English]

Shows the number of registered items.

(50 items maximum.)

The sign “=” at the left side of the message shows that the language is currently set to be used.

Serial number. (of overload data in order of lateness.)

3. When the aimed language is displayed, press the

Shows the overload ratio.

(Max. 400%)

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 adjustment mode, and press the register key to

IW301-0131E05

select the menu.

2. Use the scroll-up or scroll-down key until the menu of latest overload ratio or peak overload

50

W301-0131E

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

[NOTE]

registered greatest overload history data being

◆The overload history data (record of crane operation when moment load ratio exceeds the set limit) can be erased. 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. (Before shipment from the factory, the latest history data has been erased three times forcibly to disable erasing after shipment.)

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).

1. Select the main menu [･Erase O/L data↓] in the adjustment mode, and press the register key to

Moment display

select the menu.

Display example: [99. 01. 23 12:35↓]

2. Use the scroll-up or scroll-down key to display the

↓

overload history data item to be erased. Select it

[125% 14.5f 45.0°↓]

by pressing the register key.

Display:

Indicates boom length.

[:Erase Late dat↓]

Serial number. (of overload data in order of greatness.)

↓↑

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.

4. When the message [Done] appears, the overload record data is now erased. Press the display alteration key to exit the menu.

Indicates swing position.

Indicates outrigger status.

Indicates actual load.

Indicates rated lifting capacity.

IW301-0131E06

5. Press the display alteration key to exit the menu.

51

W301-0131E

Functions of and How to Use Maintenance Mode Functions of and How to Use Maintenance Mode

(4)Data date display:

1. Program Version Display

(5)Revision date display:

Indicates the date of making up data.

Display example:[95, 12, 27↓]

Indicates the date of data revision.

ROM program version is displayed.

Display example:[96, 01, 23]

1. Select the main menu [･Maintenance↓] in the

3. Di Check

maintenance mode, and press the register key to select the menu.

The input state of Di (external contact switch) is

2. When [:Prog. version↓] is displayed, press the

displayed.

register key to select the menu.

1. Select the main menu [･Maintenance↓] in the

3. When the below program version appears, press

maintenance mode, and press the register key to

the display alteration key to exit the menu.

select the menu.

Display example:

2. Press the scroll-up or scroll-down key until the

[AML-L L0204↓]

display [:Di check↓] appears, and then press the

program version number

register key to select the menu.

3. Di input state is displayed. Display changes by

2. Data ID Number Display

scroll-up or scroll-down key.

Press the display alteration key to exit the menu.

Information of ROM data is displayed.

Display example (Di1):

1. Select the main menu [･Maintenance↓] in the

[ 01 Over-wind of ↓]

maintenance mode, and press the register key to

Indicates switch state

select the menu.

on : active

2. Find the display [:Data ID. number↓] by the

of : not active

scroll-up or scroll-down key, and then press the

Switch name

register key to select the menu.

Indicates Di input terminal number.

3. Display changes by scroll-up or scroll-down key.

01 to 28 : Di 1 to Di 28

Press the display alteration key to exit the menu.

T : TC

The ROM data is displayed as follows:

A : ACC

(1)ID number display:

No indication: Serial port input (Di from multiplex

Indicates ROM ID number (revision number

data transmitter and signal

included).

transmitter)

Display example:[750200↓]

[NOTE]

(2)Specification number display:

◆Switch state means on/off state which the AML program judges logically.

Indicates crane spec. number.

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.

Display example:[TR-500-3-00101↓] (3)Code number display: Indicates parts code number of AML. Display example:[361-175-02000↓]

52

W301-0131E

Functions of and How to Use Maintenance Mode rof: Logically switch is not active, but physical contact is on.

08:Pressure input (ANAING) 09:Pressure input (ANAINH)

◆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 program, the Di switch input states may not be indicated in the numerical order of Di switch input numbers.

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) [NOTE] ◆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.

2. Press the scroll-up or scroll-down key until the

The cylinder extension lateral pressure and

display [:Ai check↓] appears, and then press the

retraction lateral pressure which are detected for

register key to select the menu.

moment calculation are displayed.

3. Ai input state is displayed. Display changes by

1. Select the main menu [･Maintenance↓] in the

scroll-up or scroll-down key.

maintenance mode, and press the register key to

Press the display alteration key to exit the menu.

select the menu.

Display example (ANAiNB):

2. Press the scroll-up or scroll-down key until the

[ 02 Boom A 1201 ok ↓]

display [:Disp ELEV PRES↓] appears, and then

When detected input is within

press the register key to select the menu.

the normal input range, “ok” appears; when it is out of the

3. The elevating cylinder extension lateral pressure

range, then “ng” appears at this

and retraction lateral pressure are displayed.

portion.

Press the display alteration key to exit the menu.

Display example:

A/D converted value of analog input.

[ E＊＊＊.＊ R＊＊＊.＊ psi ]

Analog detector name

Unit

Logical number of analog input in the program.

Retraction oil pressure

00:Moment input (MOINP, MOINN)

Extension oil pressure

01:ANAiNA 02:ANAiNB 03:ANAiNC 04:ANAiND 05:ANAiNE 06:ANAiNF 07:Analog detector source (DET1SRC, DET2SRC)

53

W301-0131E

Functions of and How to Use Maintenance Mode 6. Do Check

7. MDT Monitor (Multiplex Data Transmitter Monitor)

The output state of Do (Digital output: relay output and open collector transistor output) is displayed.

The input/output state of the multiplex data

Also, you can invert the current state of selected

transmitter (MDT) is displayed.

output.

1. Select the main menu [･Maintenance↓] in the 1. Select the main menu [･Maintenance↓] in the

maintenance mode, and press the register key to

maintenance mode, and press the register key to

select the menu.

select the menu.

2. Press the scroll-up or scroll-down key until the 2. Press the scroll-up or scroll-down key until the

display [:MDT Monitor↓] appears, and then press

display [:Do check↓] appears, and then press the

the register key to select the menu.

register key to select the menu.

3. The input/output state of the multiplex data 3. Do output state is displayed. Display changes by

transmitter (MDT) is displayed. Display changes

scroll-up or scroll-down key. Press the display

by increase or decrease key. Press the display

alteration key to exit the menu.

alteration key to exit the menu.

Display example (RLY1):

Display example:

[ 00 Stoppage of ↓]

[ No.123 Val. 1]

Current output state

Input/output state Digital input/output:

Output name

1:ON

Logical output port number

0:OFF

00 to 07:RLY1 to PLY8

Analog input/output:

(relay output)

represented in numerals from 0

10 to 17:TR1 to TR8

through 255.

(open collector output)

Input/output number

[NOTE]

[NOTE]

◆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.

◆For the signal represented by the displayed input/output No., see the “Multiplex Data Transmitter (MDT) 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

4. During the above Do output monitoring procedure,

whether it works normally or not.

output state will be inverted while you are

1. Select the main menu [･Maintenance↓] in the

pressing the check key.

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.

54

W301-0131E

Functions of and How to Use Maintenance Mode 3. The display

changes to the error code display.

[－－－－－－－－－・－－－－－－]

Display example:

appears. Press any key other than the display

[ Error:2003↓]

alteration key, and the corresponding portion of

(3)The mark “↓” on the error code display shows

display changes from “-“ to “◯” while you are

the another errors exist.

pressing the key. Press the display alteration key

Press the scroll-down key to display the next error

to exit the menu.

code.

9. Display Check

Total number of stored items.

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

IW301-0131E08

select the menu.

2. Press the scroll-up or scroll-down key until the

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

3. The error codes are displayed on the moment

information.

indicator and display panel. Press the display

1. Select the main menu [･Maintenance↓] in the

alteration key to exit the menu and return to the

maintenance mode, and press the register key to

ordinary display state.

select the menu.

(1)The moment indicator displays the time when

2. Press the scroll-up or scroll-down key until the

error occurred.

display [:Erase err data↓] appears, and then

Display example:

press the register key to select the menu.

[ 96. 01. 23 12:35↓]

3. When the message [Erase OK? ]appears, press

(2)When the scroll-down key, the time display

55

W301-0131E

Functions of and How to Use Maintenance Mode 13.Ao Check

the register key.

4. When the message [Done] is displayed, the error

The Ao (analog output) state is displayed with an

data is now erased. Press the display alteration

output value of the specified percentage.

key to exit the menu.

1. Select the main menu [･Maintenance↓] in the maintenance mode, and press the register key to

12.OP (Option) Board Check

select the menu.

The state of the incorporated option board (analog

2. Press the scroll-up or scroll-down key until the

output, wire detection) is indicated.

display [:Ao 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

3. Ao output state is displayed as below.

select the menu.

Display changes by scroll-up or scroll-down key.

Press the display alteration key to exit the menu.

2. Press the scroll-up or scroll-down key until the display [:OP board check↓] appears, and then

Display example (CNTL1P･CNTL1N):

press the register key to select the menu.

[ 41 SWG RV 0 0↓] Output level for checking

3. The sort of the incorporated option board is displayed (Up to two option boards can be

indicates at what percentage of

incorporated). Display changes by scroll-up or

the maximum level the value is to

scroll-down key. Press the display alteration key

be output.

to exit the menu.

Output level indicates at what

Display example:

percentage of the maximum level

[ 1 Valve control↓]

the value is being output.

Option board name

Output name

(1 valve control : Circuit board for analog output) (2 Rope LGTH DET : Circuit board for detecting

Ao output terminal number

wire rope movement to indicate hook block

11-19:Output to serial port 1 (Signal transmitter)

position)

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) [NOTE] ◆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

56

W301-0131E

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

The same items as shown in the [･Adjust ↓]

increased or decreased by 10% for the increase

menu of the main menu of the adjustment mode

key and by 5% for the decrease key. When the

appears. However, adjustment is not available.

level exceeds 100%, it returns to 0% (conversely,

1. Select the main menu [･Maintenance↓] in the

when the level reaches 0%, it returns to 100%.)

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,

2. Press the scroll-up or scroll-down key until the

press the check key; output level for checking will

display [:Adjust Monitor↓] appears, and then

be output while the key is held down. The

press the register key to select the menu.

displayed output level value blinks.

3. The same items as shown in the [･Adjust ↓] menu of the main menu of the adjustment mode

14.Sio Check

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

16. Overload History Display

maintenance mode, and press the register key to select the menu.

The overload history display in the maintenance

2. Press the scroll-up or scroll-down key until the

mode has the same function as that of in the

display [:Sio check↓] appears, and then press the

adjustment mode.

register key to select the menu.

See the “Other Functions and How to Use Them” in the “Functions of and How to Use Adjustment

3. Serial port state is displayed. Display changes by

Mode” section.

scroll-up or scroll-down key. Press the display alteration key to exit the menu.

Display example:

17.Erasing the Overload History

[Serial port1 OK ↓]

Erasing the overload history in the maintenance

Serial port state

mode has the same function as that of in the

OK : Normal

adjustment mode.

NG : Abnormal

See the “Other Functions and How to Use Them”

NU : Not used

in the “Functions of and How to Use Adjustment Mode” section.

Serial port name (Serial port 1:serial communication circuit to signal transmitter)

18.Clock Adjustment

(Serial port 2:serial communication circuit to multiplex data transmitter)

Clock adjustment is included in the functions of the maintenance mode. However, see the “Adjustment Procedures” in the “Functions of and How to Use Adjustment Mode” section for how to adjust the clock.

57

W301-0131E

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.

[NOTE]

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

Displays a failure message

1:Abnormal communication 2:Abnormal detector 3:Abnormality inside AML 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 1. If AML system detects the trouble in ordinary use

condition, it does not always mean that there is a

(user mode), it makes beep sound as well as

problem in the system when an error message is

displays error message on the moment display.

displayed.

Display example:

4. For this reason, warning-related error messages

[Error:2001]

are not registered in the system’s error history

Shows that an error of error code 2001 has

memory. Warning-related error messages are

occurred.

shown in the moment display in the same way as message for other group codes.

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 being used, only beep sound informs the operator

1. Error history records 50 errors, maximum, of the

of the occurrence of trouble. The display on the

group code, in order of occurrence. Those beyond

moment display, however, does not change to the

50 will be made to disappear in the order of

error message display automatically. Current

occurrence.

message keeps displayed.

2. See the “Error Data Display” in the “Functions of

4. To confirm the error message in the adjustment or

and How to Use Maintenance Mode” section for

maintenance mode, press the lift height limit key.

reading the error history.

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.)

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.

58

W301-0131E

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:

Outrigger beam has retracted and O/R extended width decreases, close to the lifting capacity change over point.

Cause:

Outrigger beam(s) have just retracted.

Action:

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 under-slung jib.

(Only applicable to the machines with under-slung jib)

Cause:

Boom angle is smaller than that required for jib setting.

Action:

Raise the boom till safety angle for jib setting.

Message

Description

Error : 0006 Warning : 0011

Improperly inserted jib lock pin (0006) Jib pin not inserted (0011) (Only for TR-200M-5γ)

Situation:

Jib lock pins are in incorrect states. Boom extending operation is stopped automatically at the time of jib setting or jib stowing.

Cause:

Both jib set and automatic lock pins have been inserted. (0006) Jib connecting pins have not been inserted. (0011)

Action:

Correct the lock pins property inserted.

Message

Description

Warning : 0010

Close to the swing angle restriction

＊The error code is applicable only to models with the slow swing stop function.

Situation:

The boom is just close to the swing restriction angle.

Cause:

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 released. (swing is not automatically stopped)

Action:

Swing the boom away from the swing restriction point.

Release the swing area restriction function.

59

W301-0131E

Error Message

Message

Description

Warning : 0012

Rear stability auto. stop range

Situation:

Boom elevation automatically stops when the crane’s condition becomes the rear stability auto. stop range.

Cause:

The boom is raised too high.

The outrigger extension width is insufficient.

Action:

Lower the boom.

Increase the outrigger extention width and set the AML again.

Message

Description

Error : 0013 Error : 0014

Over-front detection switch is defected Over-front or over-rear detection switch is/are defected

Situation:

The swing angle dose not conform with the condition detected by the swing position detection switch.

Cause:

Over-front detection switch is defected, over-front or/and over-rear detection switch is/are defected, or its wiring is open.

Swing angle detector is defected or maladjusted. ＊For the specified value of the swing angle detector, refer to the “Checking the Detectors” in the INFORMATION AND DATA section.

Action:

Investigate the possible causes described above.

The input status can be checked with “Di & Ai check” function from the “Maintenance” menu.

The judgement result by the “Di check” is displayed by “ON” “OFF”, and displayed for “Normality” the “Ai check” result as “OK”.

Message

Description

Warning : 0015

Overwinding condition

Situation:

Overwinding detection switch has been turned off while overwind status.

Cause:

Main or auxiliary hook block has been wound up excessively.

Overwinding detection switch is defected, or its wiring is cut.

(The error occurs if overwind is detected while overwind cut-out release switch is depressing)

Action:

Lower the main or auxiliary winch.

Check the overwinding detection switch and it’s wiring.

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:

Crane is automatically stopped while the outrigger, boom, jib and counterweight settings are out of the allowable condition, and change the control lever to dangerous direction.

Cause:

The outrigger, boom, jib and counterweight settings are improper.

Action:

Register the operation status again.

60

W301-0131E

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:

Crane is automatically stopped when change a control lever to dangerous direction, while the 2nd boom fully retraction detector switch does not detect fully retraction in spite of the 2nd boom is fully retracted and vice versa.

Cause:

Boom full retraction detection switch is faulty, or its wiring is open.

Boom length sensor is defected or maladjusted.

The AML itself is defected. ＊For the specified value of the boom length detector, refer to the “Checking the Detectors” in the INFORMATION AND DATA section.

Action:

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. (Normal: ”OK” is displayed) Defective parts are exchanged, a necessary adjustment should be done.

Message

Description

Warning : 0023

Stopped at 100% of crane performance

Situation:

Crane is stopped automatically when control lever change to dangerous direction such as hoisting-up, boom lowering, or boom extending.

Cause:

The allowable lifting capacity is exceeded.

Action:

Control lever change to safety direction such as hoisting-down, boom raising, or boom retracting.

Message

Description

Warning : 0024

Stop due to overwinding and change a control lever to dangerous direction

Situation:

Overwinding detector switch has been turned off.

Crane operation is automatically stopped when control lever change to dangerous direction in this condition.

Cause:

Main or auxiliary winch hook block has been wound up excessively.

Overwinding detector switch is defected, or its wiring is open.

Action:

Lower the main or auxiliary winch.

Check the overwinding detector switch and it’s wiring.

Message

Description

Warning : 0025

Stopped due to rear stability

Situation:

The crane is in a state where the rear stability is not assured, boom elevating/retracting operation should be stopped automatically by AML-L.

Cause:

The boom angle is too large, or the boom lenght is insufficient.

The outrigger extension width is too small.

Action:

Lower the boom, extend the boom, or increases the extension width of outriggers.

61

W301-0131E

Error Message

Message

Description

Warning : 0026

Stopped at upper boom angle limit restriction

Situation:

Boom angle has exceeded upper limit range.

Crane operation is automatically stopped while control lever change to dangerous direction in this condition.

Cause:

The upper boom angle limit restriction is set, and the boom angle has exceeded the limit.

Action:

Lower the boom.

Reset the upper boom angle limit restriction.

Message

Description

Warning : 0027

Stopped at lower boom angle limit restriction

Situation:

Boom angle has exceeded lower boom angle limit restrection range.

Crane operation is automatically stopped while control lever change to dangerous direction in this condition.

Cause:

The lower boom angle limit restriction is set, and the boom angle has exceeded the limit.

Action:

Raise the boom.

Reset the lower boom angle limit restriction.

Message

Description

Warning : 0028

Stopped at lifting height limit restriction

Situation:

End of the top boom head has exceeded the lifting height limit restriction range.

Crane operation is automatically stopped while control lever change to dangerous direction in this condition.

Cause:

The lifting height limit restriction is set, and end of the top boom head’s height has exceeded the limit.

Action:

Lower or retract the boom.

Reset the lifting height limit restriction.

Message

Description

Warning : 0029

Stopped at load radius restriction

Situation:

Working radius has exceeded the load radius restriction limit.

Crane operation is automatically stopped while control lever change to dangerous direction in this condition.

Cause:

The load radius restriction is set, and the working radius has exceeded the limit.

Action:

Raise or retract the boom.

Reset the load radius limit restriction.

62

W301-0131E

Error Message

Message

Description

Warning : 0034 Warning : 0035

Stopped at main winch over-unwinding prevention device Stopped at aux. winch over-unwinding prevention device

Situation:

Winch lowering operation is automatically stopped by this over-unwinding prevention device, due to the main/aux. wire rope which on the it’s winch drum, is drawing to it’s end.

Cause:

The number of wire rope part line on the hook block is wrong.

The hook block position is too low.

Action:

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.

(Have not concern with AML’s control)

Cause:

Accumulator pressure is too low.

Accumulator pressure detector is defected, or its wiring is open.

AML (analog circuit board) is defected.

Action:

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. (Normal: ”OK” is displayed) Defective parts are exchanged, a necessary adjustment should be done.

Message

Description

Error : 0041 Warning : 0078

Wrong counterweight state registered Altered counterweight state

Situation:

Crane is automatically stopped when control lever change to dangerous direction while the detected counter weight status is different from the registered one. (Applicable only to the error code 0041)

Cause:

Defected counterweight state detector, improper installation or adjustment of the detector, open wiring of the detector circuit.

Altered combination of the counterweight.

Counterweight manual selector switch is shifted after registration of counterweight status.

(When input the value manually)

Action:

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. (Normal: ”OK” is displayed) Register the counterweight state again.

Message

Description

Warning : 0042 Warning : 0043

Right swing restriction limit Left swing restriction limit

Situation:

Boom is swing to a point exceeding the swing restriction limit setting.

Cause:

The swing restriction limit function is set, and swing position has been exceeded the limit.

Action:

Swing the boom in the opposite direction to the setting.

Reset the swing restriction limit function.

63

W301-0131E

Error Message

Message

Description

Warning : 0046

Condition setting altered

Situation:

Crane state has changed.

Cause:

Outrigger jacks have been retracted. (Unexpected outrigger jack retraction)

Action:

Register operation status again.

Message

Description

Warning : 0047

Hook block contacts to the elevating cylinder

Situation:

Hook block comes near the area which contacts with the elevate cylinder rod.

Cause:

Boom raised too high while boom neary fully retracted.

Action:

Extend or lower the boom.

Message

Description

Error : 0051

Tire contacts to the ground

Situation:

Any tire keeping contact with the ground while the crane is jacked up.

Cause:

Crane jacked up insafficiently.

Insufficient outrigger extension width.

Action:

Jack up the crane further. If the jack stroke is insafficient, place the wood blocks under the outrigger jacks.

Set the outrigger beam extension width more wider, again.

Message

Description

Warning : 0056

Swing operation is dangerous

Situation:

The lifting capacity will be exceeded if the boom is swung further.

Cause:

The boom has been swung to a point just before the region where the capacity is reduced in retraction with outrigger extension width. (The error code is displayed only when the boom is being swung to the left or right) On models with a swing slow stop function, the error code appears only when the slow stop function is released. (In this case, the error code is displayed only when the swing angle is changing)

Action:

Swing the boom in the opposite direction.

Retract or raise the boom so that the lifting capacity will not be exceeded.

64

W301-0131E

Error Message

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:

Outrigger state has changed as to decrease extension. Crane performance shifted to that with a smaller outrigger extension width.

Cause:

Outrigger extension width has decreased unintentionally.

Action:

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.

Message

Description

Warning : 0066

Over the wind speed limit

Situation:

The crane work becomes a danger because of the strong wind blow.

Cause:

The wind speed exceeds the allowable limit for the crane operation.

Action:

Retract the boom and stop the crane operation.

Message

Description

Error : 0067 Error : 0068 Error : 0069 Error : 0070 Error : 0071 Error : 0072 Error : 0073 Error : 0074

Abnormal moment [Refer to the Message 0113] 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:

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 defected. (Analog board is defected) ＊For the specified value of the each detectors, refer to the “Checking the Detectors” in the INFORMATION AND DATA section.

Action:

Readjust the corresponding detector.

Insrall the corresponding detector properly and readjust it.

If the detectors are not defect, replace the AML main body (analog board).

65

W301-0131E

Error Message

Message

Description

Warning : 0075

Spring lock state has changed

Situation:

Spring lock state has changed.

Cause:

Spring lock released unintentionally.

Spring lock has been released by mistake.

Action:

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.

Cause:

Front or rear jack has operated.

Defective detector.

The AML itself is defected. (Analog board is defected)

Action:

Return the front or rear jack to the original condition.

Check the detector using “Di check” function on “Maintenance” menu. (Normal: ”OK” is displayed)

Message

Description

Warning : 0078

Altered counterweight state

Situation:

The actual counterweight state has changed from the registered one.

Cause:

Defective detector.

The AML itself is defected. (Analog board is defected)

Action:

Check the detector using ”Di check” function on “Maintenance” menu.

Counter weight “Used” ; “ON” is displayed.

Message

Description

Warning : 0081

Elevation motion slowing down

＊This error code is applicable only to models with the slow elevation stop function.

Situation:

The boom elevation slow stop function is activated, slowing down boom elevation motion.

Cause:

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)

Action:

Stop operating the boom.

Operate the boom in the opposite direction, whether it is rising or lowering.

Reset the boom angle limit restriction function.

Move the boom to the non-critical side.

66

W301-0131E

Error Message

Message

Description

Warning : 0082

Swing motion slowing down

＊This error code is applicable only to models with the slow swing stop function.

Situation:

The slow swing stop function is activated, slowing down boom swing motion.

Cause:

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)

Action:

Stop the swing operation.

Swing away from the limit.

Retract or raise the boom so that the lifting capacity will not be exceeded.

Reset the swing limit restriction function.

Message

Description

Warning : 0085

Elevation stopped at stroke end

＊Applicable to the models with the oil pressure detection method.

Situation:

Boom elevating operation is stopped automatically because the end of elevation stroke has been reached. Crane operation is automatically stopped while. Iever change to dangerous direction in this condition.

Cause:

Boom elevating is automatically stopped just before the elevating cylinder storoke 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.

Action:

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 Moment exceeding limit for boom with jib mounted

＊This error code is applicable only to models with jib extension status monitoring.

Situation:

Crane has stopped automatically due to the moment exceeding limit while control lever change to dangerous direction such as wind-up, extend/lower the boom.

Cause:

During lifting load on the boom with the jib extended, the lifting capacity of main boom has exceeded the specified limit. (Specified limit is changed by outrigger width, counter weight, etc.)

Action:

Control lever change to safety direction such as wind-down, raise/retract boom.

Message

Description

Warning : 0090

Hook stowing prohibited area

Situation:

Hook-in operation can not operate. (stopped by overwinding)

Cause:

Hook-in operation will lead to a danger that the hook block will hit the boom bottom part.

Action:

Wind down the main or auxiliary winch.

Change the boom condition to enable hook-in operation.

67

W301-0131E

Error Message

Message

Description

Warning : 0093

Enabling angle for jib set

＊This error code is displayed with jibs of a type having rollers that engage with guides on the boom during extension and stowing without using any assist. rope (like the jib on TR-200EXC).

Situation:

Crane operation is automatically stopped when the elevation angle has reached the specified angle suitable for jib extention/stowing.

Cause:

The setting of AML is made “jib set “, the boom is raised and its elevation angle has reached the specified angle sutable for jib extension/stowing.

Angles suitable for jib extension/stowing are defined as follows: Extension A boom angle at which the jib will not either shake widely or interfere with the swing table in the motion that the rollers on the jib come off the guides on the boom when the boom is extended.

Stowing A boom angle at which the rollers on the jib to engage with the guides on the boom so that the jib can be stowed, when the boom is retracted.

Action:

During jib extension During jib stowing During other operation

: : :

Extend the boom to extend the jib.

Retract the boom to stow the jib.

Stop the boom if it is being raised.

Change the setting of AML to any other mode from “Jib set”.

68

W301-0131E

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:

Actual lifting load display value that calculate in the AML becomes minus value due to abnormal moment detector.

There fore, need re-adjustment of the moment detector.

(0067: Only warning, can not auto. stop) (0113: Crane operation is stopped while control lever change to dangerous direction)

Cause:

Abnormal detectors (Boom length detector, strain gauge type and/or pressure sensor type moment detector).

Abnormal detector’s adjustment.

Abnormal AML main body (Analog board).

[Warning : 0113] Moment value can not be detected due to the elevating cylinder has retracted to the stroke end. ＊This warning (0113) produces when actual lifting load display value that calculate in the AML. Abnormal minus load value is defference due to the boom condition.

Action:

Readjust the corresponding detector (pressure sensor).

The detector which seems to be defective is invesigdted.

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

Warning : 0115

Approximation to the elevation stop angle

Situation:

The crane will stop if boom elevation is continued. (Precautional warning)

Cause:

The boom angle becomes close to the position where the crane automatically stops due to the elevating cylinder stroke end or boom angle limit restriction functions (boom upper/lower limit, lifting height limit).

Action:

Stop boom operation.

Move the boom to the non-critical side.

69

W301-0131E

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 defected.

Action:

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.

Message

Description

Error : 1003 Error : 1004

Serial port receiving line 1 open Serial port receiving line 2 open

Situation:

All operations except boom swing are unavailable because the AML cannot receive any signal from the transmitter.

Cause:

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 defected.

The serial port fuse (SIF1, 2) of AML has blown.

Action:

Check the wiring to the transmitter for continuity. If no continuity exists, replace or repair the wiring.

Replace the transmitter or AML’s power circiut board.

Replace the serial port fuse of AML.

Message

Description

Error : 1005 Error : 1006

Transmitter 1 defect Transmitter 2 defect

Situation:

All operations except boom swing are unavailable due to the faulty transmitter.

Cause:

The internal circuit of transmitter is defected.

Action:

Replace the defective transmitter.

70

W301-0131E

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:

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.

Cause:

The data has been garbled due to noise (external radio wave interference).

The signal wire connection is in poor contact.

Action:

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.

71

W301-0131E

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 defected, or its wiring is open.

The AML moment adjustment is improrer.

The AML itself is defected. (Analog board is defected)

Action:

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. (Normal: “OK” is displayed) Defective parts are exchanged, a necessary adjustment should be done.

Message Error : 2004

Description Boom angle detector trouble

Situation:

All operations except boom swing are unavailable due to the abnormal input value from the boom angle detector.

Cause:

The boom angle detector is defected, or its wiring is open.

The AML itself is defected. (Analog board is defected)

Action:

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. (Normal: “OK” is displayed) Defective parts are exchanged, a necessary adjustment should be done.

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 defected, or its wiring is open.

The transmitter unit is defected.

Action:

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. (Normal: “OK” is displayed) Defective parts are exchanged, a necessary adjustment should be done.

Message

Description

Error : 2006

Jib angle detector trouble

Situation:

All operations except boom swing are unavailable due to the abnormal input value from the jib angle detector.

Cause:

The jib angle detector is defected, or its wiring is open.

The transmitter unit is defected.

Action:

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. (Normal: “OK” is displayed) Defective parts are exchanged, a necessary adjustment should be done.

72

W301-0131E

Error Message

Message

Description

Error : 2007 Error : 2008

Boom length detector 1 trouble Boom length detector 2 trouble

Situation:

All operations except boom swing are unavailable due to the abnormal input value from the boom length detector.

Cause:

The boom angle detector is defected, or its wiring is open.

The AML itself is defected.

Action:

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. (Normal: “OK” is displayed) Defective parts are exchanged, a necessary adjustment should be done.

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 defected, or its wiring is open.

The AML outrigger length detector is maladjusted.

The transmitter unit is defected.

Action:

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. (Normal: “OK” is displayed) Defective parts are exchanged, a necessary adjustment should be done.

Message

Description

Error : 2016 Error : 2017 Error : 2019 Error : 2020

Swing angle detector 1 trouble (swing dead angle switch ON) Swing angle detector 1 trouble (swing dead angle switch OFF) Swing angle detector 2 trouble (swing dead angle switch ON) Swing angle detector 2 trouble (swing dead angle switch OFF) (same as swing angle detector 1,2 select switch)

Situation:

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.

Cause:

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 defected. (Analog board is defected)

Action:

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. (Normal: “OK” is displayed) The status of any input from the detector can be checked using the “Di check” function from the “Maintenance” menu. (Normal: “OK” is displayed) Defective parts are exchanged, a necessary adjustment should be done.

73

W301-0131E

Error Message

Message

Description

Error : 2021

Swing angle detector trouble

Situation:

All operations except boom swing are unavailable due to the abnormal offset value of the swing angle detector 1 or 2.

Cause:

The installation or adjustment of the swing angle detector 1 or 2 is improper.

The AML itself is defected. (Analog board is defected)

Action:

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. (Normal: “OK” is displayed) Defective parts are exchanged, a necessary adjustment should be done.

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 defected, or its wiring is open.

The AML itself is defected. (Analog board is defected)

Action:

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. (Normal: “OK” is displayed) Defective parts are exchanged, a necessary adjustment should be done.

74

W301-0131E

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 defected.

ROM defected.

Action:

Replace the AML’s CPU board.

Replace ROM.

Message Error : 3006

Description System trouble (EEPROM defect)

Situation:

All operations except boom swing are unavailable because AML cannot write on its nonvolatile memory (EEPROM).

Cause:

The AML’s CPU board is defected.

EEPROM is defected.

Action:

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:

All operations except boom swing are unavailable because software program cannot run normally.

Cause:

The AML’s CPU board is defected.

Action:

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 defected, 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 defected.

Action:

Replace the AML’s CPU board and/or analog board.

75

W301-0131E

Disassembly of AML Main Unit Disassembly of AML Main Unit

2. Removing Rear Panel/Connector Board/Current Output Board

1. Removing Front Panel/Display Board

[NOTE] ◆Do not touch each front and rear face of the boards by hand when removing the boards.

[NOTE] ◆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

1. Take off the front panel and display board as an

case by unscrewing screw(c).

assembly from the unit case by unscrewing screw(a).

Front panel

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

2. Separate the display board by unscrewing

screw(d).

screw(b).

Then remove the spacer(e) and separate the connector board. e Connector board

b

Current output board d

IW301-0131E22

Display board IW301-0131E20

76

W301-0131E

Disassembly of AML Main Unit 3. Removing CPU Board/Analog Board/Power Board

3.1 Notes on ROM/EEPROM Replacement

[NOTE]

◆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.

[NOTE]

◆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 assembly from the unit case by unscrewing

When replacing ROM and EEPROM, make sure

screw(a). Then take off the rear panel, connector

that the concavities of IC and socket meet each

board and current output board as an assembly

other.

from the unit case by unscrewing screw(c).

Connector board Current output board

c

CAL/CLOCK

Rear panel

Battery

EEPROM

CN1

CN4 PLD

ROM 1 CPU

ROM 0

CN2 CN3

Front panel

a Unit case Display board

CPU board

IW301-0131E23

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

77

W301-0131E

Adjustment Value Table Specification No. : GR-450-1-00101 (2M2D-specification) AML model

: AML-LⅡC

AML code No.

: 361-900-60000 Standard value of the swing output

Capacity setting Head-off capacity setting

Jib selection

Single top selection

Winch drum position setting

Not set

Not set

Not set

Not set

Adjustment item

Condition

Adjustment value

Tolerance

Zero-point adjustment

Boom length: Fully retracted

33.46ft

±0.13ft (±0.26ft for zero-point check)

Span adjustment

Boom length: Fully extended

108.27ft

±0.13ft

Zero-point adjustment

Boom angle: 0°(actual value)

0°

±0.1° (±0.2°for zero-point check)

Span adjustment

Boom angle: 78°(actual value)

78°

±0.1°

Zero-point adjustment

Outrigger extension width: MIN.

4.068ft

±0.02ft (±0.04ft for zero-point check)

Span adjustment

Outrigger extension width: MAX.

11.484ft

±0.02ft

1klbs (Hook block mass)

±0.44klbs

1klbs (Hook block mass)

±0.09klbs

Boom length

Boom angle

Outrigger extension width

217

Boom length: Fully retracted Zero-point adjustment

Boom angle: 78±0.1° (indicated value) Boom length: Fully retracted

Span preliminary adjustment

Moment (Main hook block used)

Boom angle: 10±0.1° (indicated value) Boom length: Fully extended

Load radius adjustment

Load radius: 25ft (actual value)

25ft

±0.2ft

Rated lifting capacity: 20klbs Boom length: Fully extended Span fine adjustment

Boom angle: 15±0.1° (indicated value)

78

W301-0131E

1klbs (Hook block mass)

±0.03klbs

Adjustment Value Table Specification No. : GR-450-1-00103 (1M1D-specification) AML model

: AML-LⅡC

AML code No.

: 361-905-90000, 361-906-00000 Standard value of the swing output

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)

Adjustment item

Condition

Adjustment value

Tolerance

Zero-point adjustment

Boom length: Fully retracted

33.46ft

±0.13ft (±0.26ft for zero-point check)

Span adjustment

Boom length: Fully extended

108.27ft

±0.13ft

Zero-point adjustment

Boom angle: 0°(actual value)

0°

±0.1° (±0.2°for zero-point check)

Span adjustment

Boom angle: 78°(actual value)

78°

±0.1°

Zero-point adjustment

Outrigger extension width: MIN.

4.068ft

±0.02ft (±0.04ft for zero-point check)

Span adjustment

Outrigger extension width: MAX.

11.484ft

±0.02ft

0.63klbs (Hook block mass)

±0.33klbs

0.63klbs (Hook block mass)

±0.07klbs

Boom length

Boom angle

Outrigger extension width

217

Boom length: Fully retracted Zero-point adjustment

Boom angle: 78±0.1° (indicated value) Boom length: Fully retracted

Span preliminary adjustment

Moment (Main hook block used)

Boom angle: 10±0.1° (indicated value) Boom length: Fully extended

Load radius adjustment

Load radius: 25ft (actual value)

25ft

±0.2ft

Rated lifting capacity: 20klbs Boom length: Fully extended Span fine adjustment

Boom angle: 15±0.1° (indicated value)

79

W301-0131E

0.63klbs (Hook block mass)

±0.02klbs

Multiplex Data Transmitter ( MDT) Input/Output Nos. and Corresponding Signals

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

Input/ Input/ Input/ Signal output Signal output Signal output Signal No. No. No. Upper PMONI1 137 MONI1 169 MONI33 201 Ai1 Upper PMONI2 138 MONI2 170 MONI34 202 Ai2 Upper PMONI3 139 MONI3 171 MONI35 203 Ai3 Upper PMONI4 140 MONI4 172 MONI36 204 Ai4 Upper PMONI5 141 MONI5 173 MONI37 205 Ai5 Upper PMONI6 142 MONI6 174 MONI38 206 Ai6 Upper PMONI7 143 MONI7 175 MONI39 207 Ai7 Upper PMONI8 144 MONI8 176 MONI40 208 Ai8 Upper PMONI9 145 MONI9 177 MONI41 209 Ai9 Upper PMONI10 146 MONI10 178 MONI42 210 Ai10 Lower PMONI11 147 MONI11 179 MONI43 211 Ai1 Lower PMONI12 148 MONI12 180 MONI44 212 Ai2 Lower PMONI13 149 MONI13 181 MONI45 213 Ai3 Lower PMONI14 150 MONI14 182 MONI46 214 Ai4 Lower PMONI15 151 MONI15 183 MONI47 215 Ai5 Lower PMONI16 152 MONI16 184 MONI48 216 Ai6 Lower 153 MONI17 185 MONI49 217 Ai7 Lower 154 MONI18 186 MONI50 218 Ai8 Lower 155 MONI19 187 MONI51 219 Ai9 Lower 156 MONI20 188 MONI52 220 Ai10 Lower 157 MONI21 189 MONI53 221 Ai11 Lower 158 MONI22 190 MONI54 222 Ai12

1

Di1

33

Di33

65

Tr1

89

Di1

121

2

Di2

34

Di34

66

Tr2

90

Di2

122

3

Di3

35

Di35

67

Tr3

91

Di3

123

4

Di4

36

Di36

68

Tr4

92

Di4

124

5

Di5

37

Di37

69

Tr5

93

Di5

125

6

Di6

38

Di38

70

Tr6

94

Di6

126

7

Di7

39

Di39

71

Tr7

95

Di7

127

8

Di8

40

Di40

72

Tr8

96

Di8

128

9

Di9

41

Di41

73

Tr9

97

Di9

129

10

Di10

42

Di42

74

Tr10

98

Di10

130

11

Di11

43

Di43

75

Tr11

99

Di11

131

12

Di12

44

Di44

76

Tr12

100

Di12

132

13

Di13

45

Di45

77

Tr13

101

Di13

133

14

Di14

46

Di46

78

Tr14

102

Di14

134

15

Di15

47

Di47

79

Tr15

103

Di15

135

16

Di16

48

Di48

80

Tr16

104

Di16

136

17

Di17

49

Di49

81

Tr17

105

Di17

18

Di18

50

Di50

82

Tr18

106

Di18

19

Di19

51

Di51

83

Tr19

107

Di19

20

Di20

52

Di52

84

Tr20

108

Di20

21

Di21

53

Di53

85

Tr21

109

Di21

22

Di22

54

Di54

86

Tr22

110

Di22

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

25

Di25

57

Di57

113

Di25

161

MONI25

193

MONI56 Input/ output Signal Tr1 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

80

W301-0131E

Upper Ao1 Lower Ao1 Lower Ao2 Lower Ao3

Checking the Detectors 1. Boom Length Detector

3. Swing Angle Detector

1. Retract the boom fully, set the boom angle to

1. Swing the boom to over-left and turn OFF the

0 degree and turn off the PTO switch.

PTO switch.

2. Pull out the connector of the detector and

2. Pull out the connector of the detector and

measure resistance of the potentiometer. The

measure resistance of the potentiometer. The

specified resistance values are as follows:

specified resistance values are as follows:

C-D:833±167Ω

R-B:500±75Ω

B-D:458±92Ω

W-B:0－15Ω Boom angle detector

DET1SLD 6 DET1SRC 2 A

E

B

ANAINB 4

E C

G

Plug

W

A

R

Shield

B

DET1SLD 6

Shield

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B IW301-0131E11

D ANAINA 3 DET1GND 1

C

B D

4. Outrigger Extension Width Detector Boom length detector

1. Stow the outriggers and turn the starter switch to

IW301-0131E10

OFF.

2. Boom Angle Detector

2. Remove the wire for the detector from the 1. Retract the boom fully, set the boom angle to

outrigger and hold the wire, letting it protruding by

0 degree and turn off the PTO switch.

3.1 in (80mm) from the guide hold of the detector.

2. 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 Boom angle detector

A

E

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

3.1 in (80 mm) IW301-0131E12

3. Pull out the connector of the detector and B

measure resistance of the potentiometer. The

D C

ANAINA 3 DET1GND 1

specified resistance values are as follows:

B D

R-B:2000±100Ω Boom length detector

W-B:200±30Ω

IW301-0131E10

W

B

R

5V AVCC

R

IN Ai1

W

GND AGND

B

FL IW301-0131E13

81

W301-0131E

Checking the Detectors 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 proportional to the pressure in the elevating cylinder.

Output (V DC)

The specified value is as shown below.

4.5

0.5 0

Pressure (MPa)

35 IW301-0131E15

82

W301-0131E

Fuses

RLY1, 2 MAIN

RLY3, 4

RLY5, 6

RLY7, 8 SIF2 SIF1

SOL1, 2 SOL3, 4 SOL5, 6

IW301-0131E16

MAIN fuse (3A)

SOL3,4 fuse (2A)

AML main fuse for whole unit.

Common, with current output 3 and 4.

RLY1,2 fuse (3A)

SOL5,6 fuse (2A)

Common, with relay output 1 and 2.

Common, with current output 5 and 6.

RLY3,4 fuse (3A) Common, with relay output 3 and 4.

RLY5,6 fuse (3A) Common, with relay output 5 and 6.

RLY7,8 fuse (3A) Common, with relay output 7 and 8.

SIF2 fuse (2A) For SIF2SRC power supply output.

SIF1 fuse (2A) For SIF1SRC power supply output.

SOL1,2 fuse (2A) Common, with current output 1 and 2.

83

W301-0131E

Head Office

Ko-34,Sinden-cho,

本社 香川県高松市新田町甲 34 番地

Takamatsu,Japan

History of revision 1 2 3 4 5

改訂履歴

TADANO. LTD

ｃ ◯2001

PRINTED IN JAPAN 0109

K