Tadano Faun AML-LIID Overload Prevention Device Service Manual W301-0251E - PDF DOWNLOAD

Publication No. W301-0251E

Service Manual 01 Overload Prevention Device Model

AML-LIID TADANO LTD.

Foreword 1. Applicable Spec. No. / Crane Model Foreword

December, 2006 Crane model applicable of this service manual Truck crane TS-75M-1

This service manual is compiled to provide information on the AML-LIID (overload prevention device) that is

Spec. No.: (1) TS-75M-1-***21 (2) TS-75M-1-***22

mounted on the Truck Crane TS-75M-1, GT-250C-1,

Truck crane GT-250C-1

and GT-350C-1.

Spec. No.: (1) GT-250C-1-90101 Truck crane GT-350C-1

"Diagram of the AML-LIID System" and "Input/Output Signals of the AML-LIID System" offers the general

Spec. No.: (1) GT-350C-1-90101

description on the electrical circuit. For the detailed electrical circuit, refer to the service manual (electrical circuit diagrams) of each model.

For the actual works, perform appropriate repair and service with referring to the separate operation and maintenance manual, parts catalog, and service manual for each model.

Use this manual for machines with the AML-LIID even if the crane model is other than the above.

When part replacement is needed, refer to the parts catalog first to check the disassembly unit as well as the parts sales unit.

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

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Foreword 2. Contents

Names and Functions of the Parts ........................49 Registering Operating Conditions..........................53 Pre-operational Inspection on the AML.................58 How to Use the Working Area Limiting Function ...59 Action against AML System Error ..........................64

Foreword............................................................ 1 1. Applicable Spec. No. / Crane Model ............... 1 2. Contents............................................................ 2

[ADJUSTMENT AND MAINTENANCE]

Components of the AML-LIID Main Unit ............ 4 1. Panel................................................................. 4 2. Internal View and Name Plate .......................... 5 3. Internal Block Diagram ..................................... 6

Outline of Adjustment Mode and Maintenance Mode ........................................ 65 1. Keys and Switches for Adjustment and Maintenance....................................................65 2. Mode Structure and Menu...............................66 3. Method of Shifting Modes................................67 4. Method of Menu Selection ..............................68

Diagram of the AML-LIID System (TS-75M-1)....................................................... 7 Input/Output Signals of the AML-LIID System (TS-75M-1)....................................................... 8

Required Adjustment After AML System Parts Replacement ........................................ 69

Diagram of the AML-LIID System (GT-250C-1) ................................................... 13

Functions of and How to Use Adjustment Mode.............................................................. 70

Input/Output Signals of the AML-LIID System (GT-250C-1) ................................................... 14

Adjustment Procedures .........................................70 1. Adjustment Initialization ..................................71 1.1 Procedure of "Conversion Factors Resetting"...................................................71 1.2 Procedure of "Moment Adjustment Resetting"...................................................71 2. Boom Length Adjustment ................................72 3. Boom Angle Adjustment ..................................73 4. Moment Adjustment.........................................74 4.1 Moment Zero-point Adjustment..................75 4.2 Moment Span Preliminary Adjustment.......75 4.3 Moment Zero-point Check and Fine Adjustment .................................................76 4.4 Load Radius Adjustment............................76 4.5 Moment Span Fine Adjustment..................77 4.6 Moment Zero-point Recheck .....................78 5. Clock Adjustment.............................................79 6. Other Functions and How to Use Them..........80 6.1. Language ...................................................80 6.2. Overload History Display ...........................80 6.3 Erasing the Overload History.....................81

Diagram of the AML-LIID System (GT-350C-1) ................................................... 22 Input/Output Signals of the AML-LIID System (GT-350C-1) ................................................... 23 [OPERATION] Functions of and How to Use User Mode (TS-75M-1)..................................................... 32 Mode Structure ...................................................... 32 Configuration and Functions of the AML System .. 33 Names and Functions of the Parts........................ 35 Registering Operating Conditions ......................... 39 Pre-operational Inspection on the AML ................ 42 How to Use the Working Area Limiting Function... 43 Action against AML System Error ......................... 44

Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) ................................ 45 Mode Structure ...................................................... 45 Configuration and Functions of the AML System .. 46 System Configuration............................................ 48

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Foreword

Functions of and How to Use Maintenance Mode .............................................................. 82

INFORMATION AND DATA (GT-250C-1) ...... 107 1. Setting before adjustment .............................107 2. Detector adjustment ......................................107 3. Setting after adjustment ................................108

1. Program Version Display ................................ 82 2. Data ID Number Display ................................. 82 3. Di Check ......................................................... 82 4. Ai Check ......................................................... 83 5. Elevating Cylinder Oil Pressure Monitor......... 83 6. Do Check ........................................................ 83 7. Key Switch Check........................................... 84 8. Display Unit Check ......................................... 84 9. Error Data Display .......................................... 84 10. Erasing the Error Data .................................... 85 11. Option (OP) Board Check............................... 85 12. Ao Check ........................................................ 85 13. Sio Check ....................................................... 86 14. Adjust Monitor................................................. 86 15. Overload History Display ................................ 87 16. Erasing the Overload History.......................... 87 17. Clock Adjustment ............................................ 87

INFORMATION AND DATA (GT-350C-1) ...... 109 1. Setting before adjustment .............................109 2. Detector adjustment ......................................109 3. Setting after adjustment ................................ 110

Checking the Detectors (TS-75M-1) .............. 111 1. Boom Length Detector .................................. 111 2. Boom Angle Detector .................................... 111 3. Pressure Sensor for Moment Detection ........ 112

Checking the Detectors (GT-250C-1) .............113 1.

2.

3.

4.

Boom Length Detector .................................. 113 Boom Angle Detector .................................... 114 Swing Angle Detector .................................... 115 Pressure Sensor for Moment Detection ........ 115

Error Message ................................................. 88 Checking the Detectors (GT-350C-1) .............116

1. Display of Error Message ............................... 88 2. How to Read the Error Message .................... 88 3. How to Read the Error History........................ 88 4. Troubleshooting Table..................................... 89 4.1 Group Code 0............................................ 89 4.2 Group Code 1............................................ 97 4.3 Group Code 2............................................ 99 4.4 Group Code 3.......................................... 102

1.

2.

3.

4.

Boom Length Detector .................................. 116 Boom Angle Detector .................................... 116 Swing Angle Detector .................................... 117 Pressure Sensor for Moment Detection ........ 117

Fuse ...............................................................118 Replacing Clock Battery .................................119

Disassembly of AML Main Unit ...................... 103 1. Removing Front Panel/Display Board .......... 103 2. Removing Rear Panel/Connector Board ...... 103 3. Removing CPU Board/Analog Board / Power Board ................................................. 104 3.1 Notes on ROM/EEPROM Replacement.. 104

INFORMATION AND DATA (TS-75M-1) ........ 105 1. Setting before adjustment............................. 105 2. Detector adjustment...................................... 105 3. Setting after adjustment................................ 106

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Components of the AML-LIID Main Unit Components of the AML-LIID Main Unit 1. Panel RLY5, 6 fuse (3A)

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

RLY7, 8 fuse (3A)

Main fuse (3A)

SIF1 fuse (2A) SIF2 fuse (2A)

Moment input short-circuit switch (Not functioning)

Abnormality display LED (CPU abnormality) Moment zero adjuster

Protect switch Selects to “OFF” position at adjusting mode

(Adjusted by AML maker. Do not touch.)

Top view Boom lift symbol

Moment display Jib length symbol

Boom angle symbol

Jib angle symbol Upper boom angle limit symbol

Jib lift symbol Single top lift symbol

Boom length symbol Jib angle display

Actual load display

Scroll-up key

Rated lifting capacity display

Scroll-down key

Load radius symbol

Lifting height limit symbol

Load radius limit symbol

Lifting height symbol

Lifting height limit indicator lamp

Boom length display Lower boom angle limit symbol

Upper boom angle limit indicator lamp

Boom angle display Lower boom angle limit indicator lamp

Counterweight condition symbol Load radius display

Lower boom angle limit key

LCD panel

Upper boom angle limit key

Front position symbol

Lifting height limit key

Front jack condition symbol

Load radius limit indicator lamp

Outrigger condition symbol

Right swing limit indicator lamp

On-rubber condition symbol

Left swing limit indicator lamp

Suspension lock condition symbol

Load radius limit key

Rear jack condition symbol

Display alteration key

Left outrigger condition selector key Set key

On-rubber condition selector key

Decrease key

Right outrigger condition selector key

Inspection key

On-rubber condition selector key Lift status selector key

Number of part-lines key Increase key

Front view

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Components of the AML-LIID Main Unit 2. Internal View and Name Plate

CAL/CLOCK

Battery

Right side view (Name plate) Connector terminal Nos.

CPU board

Moment display contrast adjuster LCD panel contrast adjuster Connector board

CN1 connector

CN2 connector

CN3 connector CN4 connector (Not used.)

Power board Analog board CPU board Display board

Right side view

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Components of the AML-LIID Main Unit 3. Internal Block Diagram CONNECTOR BOARD

Fuses

CPU BOARD

Fuses

Relay

CAL/CLOCK

POWER BOARD

BUZZER

DC power block

DISPLAY BOARD

Current loop circuit

CHR display

KEY input Latch

LCD panel (1) O.C. Tr. Output block

Latch

LCD panel (2)

LCD SW. backlights Di SW input block

ANALOG BOARD Buffer

Latch

Analog multiplexer

Buffer

A/D converter

Pressure sensor analog detector power supply

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Diagram of the AML-LIID System (TS-75M-1) Diagram of the AML-LIID System (TS-75M-1) Boom angle detector

CONNECTOR BOARD

Boom length detector

Auto. stop override signal input

Front jack selector Working condition input Pressure sensor for moment detection (elevating cylinder)

Auto. stop signal output (AML vent)

External indicator lamp (OP) Alarm signal output (buzzer)

Lever manipulation detection input

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Input/Output Signals of the AML-LIID System (TS-75M-1) Input/Output Signals of the AML-LIID System (TS-75M-1) As shown in the "Diagram of the AML-LIID System" on the previous page, the inside of the AML-LIID is composed of the display board, CPU board, analog board, power board, and connector board. All the input/output signals go through the connector board. Below are the names of the signals that are input to/output from the CN1 and CN2 connectors, and the descriptions of their functions.

1. Names and functions of signals input to/output from CN1 connector are shown below: CN 1 connector

Signal names and functions

Pin No.

Name

1

DET1GND

Signal name: Ground for boom length detector and boom angle detector Input voltage: DC 0 V

DET1SRC

Signal name: Impressed voltage output to boom length detector and boom angle detector Output voltage: DC 4.5 V

2

Signal name: Boom length detector input Analog input to detect the boom length.

Input voltage: DC 0 to 4.5 V 3

ANAIN A

Reference data Input voltage at boom full retraction (6.6 m): 0.73 V (Ai check A/D conversion value: 330) Input voltage at boom full extension (21.3 m): 2.24 V (Ai check A/D conversion value 1018) Signal name: Boom angle detector input Analog input to detect the boom angle.

Input voltage: DC 0 to 4.5 V

4

ANAIN B

6

DET1SLD

13

15

Di1

Di3

Reference data Input voltage at boom angle of 0°: 0.7 V (Ai check A/D conversion value: 307) Input voltage at boom angle of 80°: 3.7 V (Ai check A/D conversion value: 1671) Signal name: Shield of boom length detector and boom angle detector Input voltage: DC 0 V Signal name: Overwind detection switch input Switch input to detect the overwinding of hook block.

Switch ON (DC 0 V): The hook block is in normal status.

Switch OFF (DC 24 V): The hook block is in overwinding status.

Signal name: Boom full retraction detection switch input (only applicable for Spec TS-75M-1-***22) Switch input to detect that the boom is fully retracted.

Switch ON (DC 0 V): The boom is in full retraction status.

Switch OFF (DC 24 V): The boom is not in full retraction status.

Reference data When the boom telescoping cylinder stroke extends 3 mm, the boom full retraction detection switch does not detect the full retraction status.

17

MB

18

MB

Signal name: Power for circuit from battery Input voltage: DC 24 V

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Input/Output Signals of the AML-LIID System (TS-75M-1) CN 1 connector Pin No.

Name

19

RB

20

RB

Signal names and functions Signal name: Power for relay from battery Input voltage: DC 24 V

Di5

Signal name: Overwind cutout release switch input Switch input to detect that the overwind cutout function of the hook block is canceled.

Switch ON (DC 0 V): Crane stop status due to detection of overwinding of the hook block is canceled.

Switch OFF (DC 24 V): The overwind cutout function of the hook block works.

Di6

Signal name: AML emergency switch input Switch input to detect that the AML overload automatic stop function is canceled.

Switch ON (DC 0 V): The overload automatic stop function of the AML is canceled.

Switch OFF (DC 24 V): The overload automatic stop function of the AML works.

Di7

Signal name: Front jack selector switch input Switch input to detect that the front jack is selected.

Switch ON (DC 0 V): The front jack function works.

Switch OFF (DC 24 V): The front jack function is canceled.

28

Di9

Signal name: Over-front area detection switch input Switch input to detect the swing position (within 60 right forward, 65 left forward).

Switch ON (DC 0 V): The swing position is in the front side.

Switch OFF (DC 5 V): The swing position is in the direction other than front.

30

GND

31

GND

32

MOGND/ DET3GND

Signal name: Ground for pressure sensor for moment detection Input voltage: DC 0 V

33

MOSRC/ DET3SRC

Signal name: Impressed voltage output to pressure sensor for moment detection Output voltage: DC 5 V

34

MOINP/ ANAING

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

Input voltage: DC 0 to 5 V

35

MOINN/ ANAINH

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

Input voltage: DC 0 to 5 V

36

MOSLD/ DET3SLD

Signal name: Shield of pressure sensor for moment detection Input voltage: DC 0 V

24

25

26

Signal name: Electrical ground Output voltage: DC 0 V

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Input/Output Signals of the AML-LIID System (TS-75M-1)

2. Names and functions of signals input to/output from CN2 connector are shown below: CN 2 connector Pin No.

Signal names and functions

Name

Signal name: Automatic stop 1 (AML vent) relay output When the crane is overloaded, when the hook block is overwound, when the operation goes beyond the working limit area, when the backward stability control is activated and the crane is operated toward critical side, or when the AML main unit is out of order, this relay contact turns OFF and crane operation is stopped.

Relay ON (DC 24 V): Normal status Relay OFF (DC 0 V): Crane stop status When the AML emergency switch is set to "非常用," this relay output is changed from OFF to ON, and the automatic stop function of the AML is canceled.

The overwind cutout function of the hook block is also canceled.

Relay output ON

Crane operation status Moment load factor < 90% 90%  Moment load factor < 100% Moment load factor  100% The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering) is stopped.

1

RLY 1

OFF

When the hook block is overwound The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering) is stopped.

When the working area limit has been registered and the crane operation other than swinging goes beyond the limit area The crane operation which goes beyond the limit area is stopped.

When the AML system is out of order All the crane operations other than swinging are stopped.

Relay output

Other control functions When the moment is abnormal When the actual load value calculated inside the AML becomes negative, the crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering) is stopped.

OFF

When the boom reaches the elevation stroke end When the boom deviates from the boom angle range in which the extension/retraction side pressure of the elevating cylinder can be properly detected (-7 to 80), the boom elevating operation is stopped.

When stowing the boom in the boom rest, if the message [モ ーメントイジョウ] appears in the AML, raise the boom slightly and stow again.

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Input/Output Signals of the AML-LIID System (TS-75M-1) CN 2 connector Pin No.

4

Signal names and functions

Name

RLY 4

Signal name: AML alarm relay output When the crane is overloaded, this relay contact turns ON, and the buzzer sounds.

Relay ON (DC 24 V): The alarm buzzer sounds.

Relay OFF (DC 0 V): The alarm buzzer does not sound.

Relay output OFF ON/OFF ON

5

6

RLY 5

RLY 6

Conditions for alarming Moment load factor < 90% 90% ≤ Moment load factor < 100% Moment load factor ≥ 100%

Signal name: 90% alarm output When the moment load factor is 90% or more and less than 100%, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 90% lights.

OC output OFF (DC 24 V): The external indicator lamp indicating 90% goes out.

Signal name: 100% alarm output When the moment load factor is 100% or more, or when overload and overwound automatic stop functions are canceled, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 100% lights.

OC output OFF (DC 24 V): The external indicator lamp indicating 100% goes out.

Conditions with which the OC output turns ON Moment load factor ≥ 100% Overwind cutout release switch: "Press" AML emergency switch: "非常用"

7

9

17

19

RLY 7

Signal name: Overwinding alarm relay output When the hook block is overwound, this relay contact turns ON and the buzzer sounds.

Relay ON (DC 24 V): The alarm buzzer sounds.

Relay OFF (DC 0 V): Normal status

Di11

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

Switch ON (DC 0 V): No hoist-up operation of the main winch is detected.

Switch OFF (DC 5 V): Hoist-up operation of the main winch is detected.

Di15

Signal name: Boom extending operation detection switch input Input from the switch detecting boom extending operation.

Switch ON (DC 0 V): No boom extending operation is detected.

Switch OFF (DC 5 V): Boom extending operation is detected.

Di17

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

Switch ON (DC 0 V): No boom raising operation is detected.

Switch OFF (DC 5 V): Boom raising operation is detected.

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Input/Output Signals of the AML-LIID System (TS-75M-1) CN 2 connector Pin No.

20

Name

Di18

Signal names and functions Signal name: Boom lowering operation detection switch input Input from the switch detecting boom lowering operation.

Switch ON (DC 0 V): No boom lowering operation is detected.

Switch OFF (DC 5 V): Boom lowering operation is detected.

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Diagram of the AML-LIID System (GT-250C-1) Diagram of the AML-LIID System (GT-250C-1)

(*1): Applicable Serial No: From JA0218

Boom angle detector

CONNECTOR BOARD

Boom length detector

Swing angle detector

Pressure sensor (Main)

Working condition input

Front jack setting input Auto. stop override signal input

Pressure sensor (Elevating) Alarm signal output

Auto. stop signal output

Buzzer Telescoping control output

Lever manipulation detection input

AML external indicator output (option)

Working condition input

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Input/Output Signals of the AML-LIID System (GT-250C-1) Input/Output Signals of the AML-LIID System (GT-250C-1) As shown in the "Diagram of the AML-LIID System" on the previous page, the inside of the AML-LIID is composed of the display board, CPU board, analog board, power board, and connector board. All the input/output signals go through the connector board. Below are the names of the signals that are input to/output from the CN1, CN2, and CN3 connectors, and the descriptions of their functions.

Names and functions of signals input to/output from CN1 connector are shown below: CN 1 connector

Signal names and functions

Pin No.

Name

1

DET1GND

Signal name: Ground for boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Input voltage: DC 0 V

DET1SRC

Signal name: Impressed voltage output to boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Output voltage: DC 4.5 V

2

Signal name: Boom length detector input Analog input to detect the boom length.

Input voltage: DC 0 to 4.5 V 3

ANAIN A

Reference data With GT-250C-1 Input voltage at boom full retraction (10 m): 0.47 V (Ai check A/D conversion value: 213) Input voltage at boom full extension (32.2 m): 2.74 V (Ai check A/D conversion value: 1248) Signal name: Boom angle detector input Analog input to detect the boom angle.

Input voltage: DC 0 to 4.5 V

4

ANAIN B

Reference data With GT-250C-1 Input voltage at boom angle of -2.94°: 0.57 V (Ai check A/D conversion value: 258) Input voltage at boom angle of 81.04°: 3.71 V (Ai check A/D conversion value: 1687) Signal name: Swing angle detector 1 input Analog input from the swing angle detector 1 to detect the swing angle.

Input voltage: DC 0 to 4.5 V

5

6

ANAIN C

DET1SLD

Reference data With GT-250C-1 Input voltage at swing angle of 0°: 1.16 V (Ai check A/D conversion value: 527) Input voltage at swing angle of 180°: 3.47 V (Ai check A/D conversion value: 1578) Signal name: Shield of boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Input voltage: DC 0 V

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Input/Output Signals of the AML-LIID System (GT-250C-1) CN 1 connector Pin No.

Name

7

DET2GND

8

DET2SRC

Signal names and functions Signal name: Ground for main hydraulic pressure sensor and accumulator pressure sensor Input voltage: DC 0 V Signal name: Impressed voltage output to main hydraulic pressure sensor and accumulator pressure sensor Output voltage: DC 4.5 V Signal name: Swing angle detector 2 input Analog input from the swing angle detector 2 to detect the swing angle.

Input voltage: DC 0 to 4.5 V

9

10

12

13

ANAIN D

ANAIN E

DET2SLD

Di1

Reference data With GT-250C-1 Input voltage at swing angle of 0°: 3.47 V (Ai check A/D conversion value: 1578) Input voltage at swing angle of 180°: 1.16 V (Ai check A/D conversion value: 527) Signal name: Main hydraulic pressure sensor input Analog input to detect the main hydraulic pressure.

Input voltage: DC 0 to 4.5 V Reference data Input voltage at main hydraulic pressure of 0 MPa: 0.45 V Input voltage at main hydraulic pressure of 29.4 MPa: 4.05 V Signal name: Shield of main hydraulic pressure sensor and accumulator pressure sensor Input voltage: DC 0 V Signal name: Overwind detection switch input Switch input to detect the overwinding of hook block.

Switch ON (DC 0 V): The hook block is in normal status.

Switch OFF (DC 24 V): The hook block is in overwinding status.

With GT-250C-1 Signal name: 3rd/top boom sections full retraction detection switch input Switch input to detect that the 3rd/top boom sections are fully retracted.

Switch ON (DC 0 V): 3rd/top boom sections are in full retraction status.

Switch OFF (DC 24 V): 3rd/top boom sections are not in full retraction status.

15

Di3

17

MB

18

MB

19

RB

20

RB

Reference data In the case (1) or (2) below, the AML judges that the boom full retraction detection switch is abnormal, and the error message [ゼンシュク SW2 イジョ ウ] is displayed.

(1) When the boom length detection value is 17.0 m or less, the boom full retraction detection switch does not detect the boom full retraction status.

(2) When the boom length detection value is 17.8 m or more, the boom full retraction detection switch detects the boom full retraction status.

Signal name: Power for circuit from battery Input voltage: DC 24 V Signal name: Power for relay from battery Input voltage: DC 24 V

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Input/Output Signals of the AML-LIID System (GT-250C-1) CN 1 connector Pin No.

Name

Signal names and functions

ACC

Signal name: Front jack switch input Power input to detect that the front jack is set.

Input voltage: DC 24 V Switch ON (DC 24 V): The front jack is set.

Switch OFF (DC 0 V): The front jack is not set.

Di5

Signal name: Overwind cutout release switch input Switch input to detect that the overwind cutout function of the hook block is canceled.

Switch ON (DC 0 V): Crane stop status due to detection of overwinding of the hook block is canceled.

Switch OFF (DC 24 V): The overwind cutout function of the hook block works.

Di6

Signal name: AML emergency switch input Switch input to detect that the AML overload automatic stop function is canceled.

Switch ON (DC 0 V): The overload automatic stop function of the AML is canceled.

Switch OFF (DC 24 V): The automatic stop function of the AML works.

Di8

With GT-250C-1 Signal name: Jib stowed detection switch input Switch input to detect that the jib is stowed.

Switch ON (DC 0 V): The jib stowed status is detected.

Switch OFF (DC 24 V): The jib stowed status is not detected.

29

Di10

Signal name: Swing angle detector 1, 2 selector (swing dead angle detection) switch input Switch input to detect the swing position (right lateral side).

Switch ON (DC 0 V): The swing position is in the right lateral side.

Switch OFF (DC 5 V): The swing position is in the left lateral side.

30

GND

Signal name: Electrical ground Output voltage: DC 0 V

31

GND

32

MOGND/ DET3GND

Signal name: Ground for pressure sensor for moment detection Input voltage: DC 0 V

33

MOSRC/ DET3SRC

Signal name: Impressed voltage output to pressure sensor for moment detection Output voltage: DC 5 V

34

MOINP/ ANAING

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

Input voltage: DC 0 to 5 V

35

MOINN/ ANAINH

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

Input voltage: DC 0 to 5 V

36

MOSLD/ DET3SLD

22

24

25

27

Signal name: Shield of pressure sensor for moment detection Input voltage: DC 0 V

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Input/Output Signals of the AML-LIID System (GT-250C-1) Names and functions of signals input to/output from CN2 connector are shown below: CN 2 connector Pin No.

Signal names and functions

Name

Signal name: Automatic stop 1 (AML vent) relay output When the crane is overloaded, when the hook block is overwound, when the operation goes beyond the working limit area, when the backward stability control is activated and the crane is operated toward critical side, or when the AML main unit is out of order, this relay contact turns OFF and crane operation is stopped.

Relay ON (DC 24 V): Normal status Relay OFF (DC 0 V): Crane stop status When the AML emergency switch is set to "非常用," the key switch is set to "解 除," and the PTO switch is turned "ON," this relay output is changed from OFF to ON, and the automatic stop function of the AML is canceled when Di6 "DC 0 V" is input.

When the overwind cutout release switch is set to "非常," the automatic stop function is canceled when Di5 "DC 0 V" is input.

Relay output ON

Crane operation status Moment load factor < 90% 90%  Moment load factor < 100% Moment load factor  100% The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering) is stopped.

While the boom lift is performed with the jib mounted (extended), the relay output turns OFF when the moment load factor becomes as follows: Moment load factor  85% When the hook block is overwound The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering) is stopped.

1

RLY 1

OFF

When the working area limit has been registered and the crane operation other than swinging goes beyond the limit area The crane operation which goes beyond the limit area is stopped.

When the AML system is out of order All the crane operations other than swinging are stopped.

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Input/Output Signals of the AML-LIID System (GT-250C-1) CN 2 connector Pin No.

Signal names and functions

Name

Other control functions

1

RLY 1

OFF

When the moment is abnormal When the actual load value calculated inside the AML becomes negative, the crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering) is stopped. However, it is not stopped while the boom is retracted to the traveling posture.

When all the conditions below are satisfied, the AML judges that the boom is being retracted to the traveling posture.

With GT-250C-1 (1) The boom angle is 2° or less.

(2) The boom length is 10.5 m or less.

(3) The swing position is within front 10°.

When the boom reaches the elevation stroke end When the boom deviates from the boom angle range in which the extension/retraction side pressure of the elevating cylinder can be properly detected (GT-250C-1: -2.4° to 80.6°), the boom elevating operation is stopped.

In the boom angle range of 80.4° or more, when the extension/retraction side pressure of the elevating cylinder cannot be properly detected and the moment load factor becomes 100% or more, the automatic stop function by overloading (stop of boom lowering operation) is canceled.

Signal name: AML alarm relay output When the crane is overloaded, this relay contact turns ON, and the buzzer sounds.

Relay ON (DC 24 V): The alarm buzzer sounds.

Relay OFF (DC 0 V): The alarm buzzer does not sound.

Relay output

Conditions for alarming Moment load factor < 90%

OFF 4

RLY 4

While the boom lift is performed with the jib mounted (extended) Moment load factor < 75% 90% ≤ Moment load factor < 100%

ON/OFF

While the boom lift is performed with the jib mounted (extended), the relay output turns ON/OFF when the moment load factor becomes as follows: 75% ≤ Moment load factor < 85% Moment load factor ≥ 100%

ON

While the boom lift is performed with the jib mounted (extended), the relay output turns ON when the moment load factor becomes as follows: Moment load factor ≥ 85%

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Input/Output Signals of the AML-LIID System (GT-250C-1) CN 2 connector Pin No.

5

6

7

9

11

17

19

20

Name

RLY 5

RLY 6

RLY 7

Di11

Di13

Di15

Di17

Di18

Signal names and functions Signal name: Telescoping control relay output With GT-250C-1 When (Boom length ≥ 17.8m) or (boom length is 17.0 to 17.8 m, and the next boom section extension switch turns "ON" (Di24 "DC 0 V")), or (Di3 "DC 5V," 3rd/top boom full retraction is detected), the relay output turns ON. Relay ON (DC 24 V): 3rd to top boom sections telescope.

Relay OFF (DC 0 V): 2nd boom section telescopes.

Signal name: Jib lock lamp relay output When the jib is in the mounting status (with the jib retracting detection CS10 "Open"), the relay output turns ON, and the lamp lights.

Relay ON (DC 24 V): Jib lock lamp lights.

Relay OFF (DC 0 V): Jib is in stowed status.

Signal name: Overwinding alarm relay output When the hook block is overwound, this relay contact turns ON and the buzzer sounds.

Relay ON (DC 24 V): The alarm buzzer sounds.

Relay OFF (DC 0 V): Normal status Signal name: Main winch hoist-up operation detection switch input Input from the switch detecting hoist-up operation of the main winch.

Switch ON (DC 0 V): No hoist-up operation of the main winch is detected.

Switch OFF (DC 5 V): Hoist-up operation of the main winch is detected.

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

Switch ON (DC 0 V): No hoist-up operation of the auxiliary winch is detected.

Switch OFF (DC 5 V): Hoist-up operation of the auxiliary winch is detected.

Signal name: Boom extending operation detection switch input Input from the switch detecting boom extending operation.

Switch ON (DC 0 V): No boom extending operation is detected.

Switch OFF (DC 5 V): Boom extending operation is detected.

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

Switch ON (DC 0 V): No boom raising operation is detected.

Switch OFF (DC 5 V): Boom raising operation is detected.

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

Switch ON (DC 0 V): No boom lowering operation is detected.

Switch OFF (DC 5 V): Boom lowering operation is detected.

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Input/Output Signals of the AML-LIID System (GT-250C-1) Names and functions of signals input to/output from CN3 connector are shown below: CN 3 connector Pin No.

2

Name

TR2

Signal names and functions Signal name: 90% alarm output When the moment load factor is 90% or more and less than 100%, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 90% lights.

OC output OFF (DC 24 V): The external indicator lamp indicating 90% goes out.

While the boom lift is performed with the jib mounted, the OC output turns ON when the moment load factor is 75% or more and less than 85%.

Signal name: 100% alarm output When the moment load factor is 100% or more, or when the overload and overwound automatic stop function is canceled, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 100% lights.

OC output OFF (DC 24 V): The external indicator lamp indicating 100% goes out.

3

TR3

Signal name: 100% alarm output When the moment load factor is 100% or more, or when the overload and overwound automatic stop function is canceled, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 100% lights.

OC output OFF (DC 24 V): The external indicator lamp indicating 100% goes out.

Conditions under which the OC output turns ON Moment load factor ≥ 100% Overwind cutout release switch: "Press" AML emergency switch: "非常用" While the boom lift is performed with the jib mounted (extended), the OC output turns ON when the moment load factor becomes as follows: Moment load factor ≥ 85% Also, under the condition below, the AML judges that the jib is mounted (extended).

When Di8 input signal is "DC 24 V"

4

22

TR4

With GT-250C-1 Signal name: Front jack overload warning output OC (open collector) output ON (DC 0 V): When the front jack overload detection switch is "ON," the buzzer sounds.

OC (open collector) output OFF (DC 24 V): When the front jack overload detection switch is "OFF," the buzzer does not sound.

Di22

Signal name: Front jack/outrigger retracting operation input Input from the outrigger retraction switch Switch ON (DC 0 V): Outrigger retracting operation Switch OFF (DC 5 V): Not outrigger retracting operation

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Input/Output Signals of the AML-LIID System (GT-250C-1) CN 3 connector Pin No. 23

24

Name

Signal names and functions

Di23

Signal name: Front jack overload detection switch input Switch ON (DC 0 V): Not front jack overload state Switch OFF (DC 5 V): Front jack overload state

Di24

Signal name: Top end boom (3rd/top boom sections) extension switch input Switch ON (DC 0 V): Extends from top end boom (3rd/top boom sections).

Switch OFF (DC 5 V): Does not extend from top end boom (3rd/top boom sections).

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Diagram of the AML-LIID System (GT-350C-1) Diagram of the AML-LIID System (GT-350C-1) CONNECTOR BOARD

Boom angle detector

Boom length detector

Swing angle detector

Pressure sensor (Main)

Working condition input

Front jack setting input Auto. stop override signal input

Pressure sensor (Elevating) Alarm signal output Buzzer

Auto. stop signal output Telescoping control output

Lever manipulation detection input

AML external indicator output (option)

Working condition input

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Input/Output Signals of the AML-LIID System (GT-350C-1) Input/Output Signals of the AML-LIID System (GT-350C-1) As shown in the "Diagram of the AML-LIID System" on the previous page, the inside of the AML-LIID is composed of the display board, CPU board, analog board, power board, and connector board. All the input/output signals go through the connector board. Below are the names of the signals that are input to/output from the CN1, CN2, and CN3 connectors, and the descriptions of their functions.

Names and functions of signals input to/output from CN1 connector are shown below: CN 1 connector Pin No.

Name

Signal names and functions

1

DET1GND

Signal name: Ground for boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Input voltage: DC 0 V

2

DET1SRC

Signal name: Impressed voltage output to boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Output voltage: DC 4.5 V Signal name: Boom length detector input Analog input to detect the boom length.

Input voltage: DC 0 to 4.5 V

3

ANAIN A

4

ANAIN B

Reference data With GT-350C-1 Input voltage at boom full retraction (10.6 m): 0.40 V (Ai check A/D conversion value: 181) Input voltage at boom full extension (34.0 m): 2.78 V (Ai check A/D conversion value: 1264) Signal name: Boom angle detector input Analog input to detect the boom angle.

Input voltage: DC 0 to 4.5 V Reference data With GT-350C-1 Input voltage at boom angle of -2.95°: 0.56 V (Ai check A/D conversion value: 256) Input voltage at boom angle of 80.94°: 3.71 V (Ai check A/D conversion value: 1687) Signal name: Swing angle detector 1 input Analog input from the swing angle detector 1 to detect the swing angle.

Input voltage: DC 0 to 4.5 V

5

ANAIN C

6

DET1SLD

7

DET2GND

Reference data With GT-350C-1 Input voltage at swing angle of 0°: 1.16 V (Ai check A/D conversion value: 527) Input voltage at swing angle of 180°: 3.47 V (Ai check A/D conversion value: 1578) Signal name: Shield of boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Input voltage: DC 0 V Signal name: Ground for main hydraulic pressure sensor and accumulator pressure sensor Input voltage: DC 0 V

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Input/Output Signals of the AML-LIID System (GT-350C-1) CN 1 connector Pin No.

Name

8

DET2SRC

Signal names and functions Signal name: Impressed voltage output to main hydraulic pressure sensor and accumulator pressure sensor Output voltage: DC 4.5 V Signal name: Swing angle detector 2 input Analog input from the swing angle detector 2 to detect the swing angle.

Input voltage: DC 0 to 4.5 V

9

10

12

13

ANAIN D

ANAIN E

DET2SLD

Di1

Reference data With GT-350C-1 Input voltage at swing angle of 0°: 3.47 V (Ai check A/D conversion value: 1578) Input voltage at swing angle of 180°: 1.16 V (Ai check A/D conversion value: 527) Signal name: Main hydraulic pressure sensor input Analog input to detect the main hydraulic pressure.

Input voltage: DC 0 to 4.5 V Reference data Input voltage at main hydraulic pressure of 0 MPa: 0.45 V Input voltage at main hydraulic pressure of 29.4 MPa: 4.05 V Signal name: Shield of main hydraulic pressure sensor and accumulator pressure sensor Input voltage: DC 0 V Signal name: Overwind detection switch input Switch input to detect the overwinding of hook block.

Switch ON (DC 0 V): The hook block is in normal status.

Switch OFF (DC 24 V): The hook block is in overwinding status.

Signal name: 2nd boom section full retraction detection switch input Switch input to detect that the 2nd boom section is fully retracted.

Switch ON (DC 0 V): The 2nd boom section is in full retraction status.

Switch OFF (DC 24 V): The 2nd boom section is not in full retraction status.

14

15

Di2

Di3

Reference data In the case (1) or (2) below, the AML judges that the boom full retraction detection switch is abnormal, and the error message [ゼンシュク SW1 イジョ ウ] is displayed.

(1) When the boom length detection value is 10.2 m or less, the boom full retraction detection switch does not detect the boom full retraction status.

(2) When the boom length detection value is 11.0 m or more, the boom full retraction detection switch detects the boom full retraction status.

With GT-350C-1 Signal name: 3rd/top boom sections full retraction detection switch input Switch input to detect that the 3rd/top boom sections are fully retracted.

Switch ON (DC 0 V): 3rd/top boom sections are in full retraction status.

Switch OFF (DC 24 V): 3rd/top boom sections are not in full retraction status

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Input/Output Signals of the AML-LIID System (GT-350C-1) CN 1 connector Pin No.

Name

15

Di3

17

MB

18

MB

19

RB

20

RB

22

24

25

ACC

Di5

Di6

Signal names and functions Reference data In the case (1) or (2) below, the AML judges that the boom full retraction detection switch is abnormal, and the error message [ゼンシュク SW2 イジョ ウ] is displayed.

(1) When the boom length detection value is 18.0 m or less, the boom full retraction detection switch does not detect the boom full retraction status.

(2) When the boom length detection value is 18.8 m or more, the boom full retraction detection switch detects the boom full retraction status.

Signal name: Power for circuit from battery Input voltage: DC 24 V Signal name: Power for relay from battery Input voltage: DC 24 V Signal name: Front jack switch input Power input to detect that the front jack is set.

Input voltage: DC 24 V Switch ON (DC 24 V): The front jack is set.

Switch OFF (DC 0 V): The front jack is not set.

Signal name: Overwind cutout release switch input Switch input to detect that the overwind cutout function of the hook block is canceled.

Switch ON (DC 0 V): Crane stop status due to detection of overwinding of the hook block is canceled.

Switch OFF (DC 24 V): The overwind cutout function of the hook block works.

Signal name: AML emergency switch input Switch input to detect that the AML overload automatic stop function is canceled.

Switch ON (DC 0 V): The overload automatic stop function of the AML is canceled.

Switch OFF (DC 24 V): The automatic stop function of the AML works.

Di8

With GT-350C-1 Signal name: jib stowed detection switch input Switch input to detect that the jib is stowed.

Switch ON (DC 0 V): The jib stowed status is detected.

Switch OFF (DC 24 V): The jib stowed status is not detected.

29

Di10

Signal name: Swing angle detector 1, 2 selector (swing dead angle detection) switch input Switch input to detect the swing position (right lateral side).

Switch ON (DC 0 V): The swing position is in the right lateral side.

Switch OFF (DC 5 V): The swing position is in the left lateral side.

30

GND

Signal name: Electrical ground Output voltage: DC 0 V

31

GND

32

MOGND/

27

Signal name: Ground for pressure sensor for moment detection

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Input/Output Signals of the AML-LIID System (GT-350C-1) CN 1 connector Pin No.

Signal names and functions

Name DET3GND

Input voltage: DC 0 V

MOSRC/ DET3SRC

Signal name: Impressed voltage output to pressure sensor for moment detection Output voltage: DC 5 V

MOINP/ ANAING

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

Input voltage: DC 0 to 5 V

35

MOINN/ ANAINH

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

Input voltage: DC 0 to 5 V

36

MOSLD/ DET3SLD

33

34

Signal name: Shield of pressure sensor for moment detection Input voltage: DC 0 V

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Input/Output Signals of the AML-LIID System (GT-350C-1) Names and functions of signals input to/output from CN2 connector are shown below: CN 2 connector Pin No

Signal names and functions

Name

Signal name: Automatic stop 1 (AML vent) relay output When the crane is overloaded, when the hook block is overwound, when the operation goes beyond the working limit area, when the backward stability control is activated and the crane is operated toward critical side, or when the AML main unit is out of order, this relay contact turns OFF and crane operation is stopped.

Relay ON (DC 24 V): Normal status Relay OFF (DC 0 V): Crane stop status When the AML emergency switch is set to "非常用," the key switch is set to "解 除," and the PTO switch is turned "ON," this relay output is changed from OFF to ON, and the automatic stop function of the AML is canceled when Di6 "DC 0 V" is input.

When the overwind cutout release switch is set to "非常," the automatic stop function is canceled when Di5 "DC 0 V" is input.

Relay output ON

Crane operation status Moment load factor < 90% 90%  Moment load factor < 100% Moment load factor  100% The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering) is stopped.

1

While the boom lift is performed with the jib mounted (extended), the relay output turns OFF when the moment load factor becomes as follows: Moment load factor  85%

RLY 1

When the hook block is overwound The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering) is stopped.

OFF

When the working area limit has been registered and the crane operation other than swinging goes beyond the limit area The crane operation which goes beyond the limit area is stopped.

When the AML system is out of order All the crane operations other than swinging are stopped.

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Input/Output Signals of the AML-LIID System (GT-350C-1) CN 2 connector Pin No

Signal names and functions

Name

Other control functions

1

3

RLY 1

RLY3

OFF

When the moment is abnormal When the actual load value calculated inside the AML becomes negative, the crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering) is stopped. However, it is not stopped while the boom is retracted to the traveling posture.

When all the conditions below are satisfied, the AML judges that the boom is being retracted to the traveling posture.

With GT-350C-1 (1) The boom angle is 2° or less.

(2) The boom length is 10.5 m or less.

(3) The swing position is within front 10°.

When the boom reaches the elevation stroke end When the boom deviates from the boom angle range in which the extension/retraction side pressure of the elevating cylinder can be properly detected (GT-350C-1: -2.4° to 80.6°), the boom elevating operation is stopped.

In the boom angle range of 80.4° or more, when the extension/retraction side pressure of the elevating cylinder cannot be properly detected and the moment load factor becomes 100% or more, the automatic stop function by overloading (stop of boom lowering operation) is canceled.

Signal name: Jib set control relay output When the boom is fully retracted (both Di2 and Di3 are ON) and the AML is set to Jib set, the relay output turns ON and the jib can be mounted/stowed.

Relay ON (DC24 V): When the jib lock pin is pulled out, the jib mounting/stowing operable lamp lights. Jib can be mounted/stowed.

Relay OFF (DC0 V): Even if the jib lock pin is pulled out, the jib mounting/stowing operable lamp does not light. Jib cannot be mounted/stowed.

Signal name: AML alarm relay output When the crane is overloaded, this relay contact turns ON, and the buzzer sounds.

Relay ON (DC 24 V): The alarm buzzer sounds.

Relay OFF (DC 0 V): The alarm buzzer does not sound.

Relay output

Conditions for alarming Moment load factor < 90%

4

RLY 4

OFF

While the boom lift is performed with the jib mounted (extended) Moment load factor < 75% 90% ≤ Moment load factor < 100%

ON/OFF

While the boom lift is performed with the jib mounted (extended), the relay output turns ON/OFF when the moment load factor becomes as follows: 75% ≤ Moment load factor < 85%

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Input/Output Signals of the AML-LIID System (GT-350C-1) CN 2 connector Pin No

Signal names and functions

Name

Moment load factor ≥ 100% 4

5

6

7

9

11

17

19

20

RLY 4

ON

While the boom lift is performed with the jib mounted (extended), the relay output turns ON when the moment load factor becomes as follows: Moment load factor ≥ 85%

RLY 5

Signal name: Telescoping control relay output With GT-350C-1 When (Boom length ≥ 18.8 m) or (boom length is 18.0 to 18.8 m, and the next boom section extension switch turns "ON" (Di24 "DC 0 V")), or (Di3 "DC 5 V," 3rd/top boom full retraction is detected), the relay output turns ON. Relay ON (DC 24 V): 3rd to top boom sections telescope.

Relay OFF (DC 0 V): 2nd boom section telescopes.

RLY 6

Signal name: Jib lock lamp relay output When the jib is mounted (the jib stowed detection CS10 is "Open"), the relay output turns ON and the lamp lights.

Relay ON (DC24 V): Jib lock lamp lights.

Relay OFF (DC0 V): Jib is in stowed status.

RLY 7

Signal name: Overwinding alarm relay output When the hook block is overwound, this relay contact turns ON and the buzzer sounds.

Relay ON (DC 24 V): The alarm buzzer sounds.

Relay OFF (DC 0 V): Normal status

Di11

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

Switch ON (DC 0 V): No hoist-up operation of the main winch is detected.

Switch OFF (DC 5 V): Hoist-up operation of the main winch is detected.

Di13

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

Switch ON (DC 0 V): No hoist-up operation of the auxiliary winch is detected.

Switch OFF (DC 5 V): Hoist-up operation of the auxiliary winch is detected.

Di15

Signal name: Boom extending operation detection switch input Input from the switch detecting boom extending operation.

Switch ON (DC 0 V): No boom extending operation is detected.

Switch OFF (DC 5 V): Boom extending operation is detected.

Di17

Di18

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

Switch ON (DC 0 V): No boom raising operation is detected.

Switch OFF (DC 5 V): Boom raising operation is detected.

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

Switch ON (DC 0 V): No boom lowering operation is detected.

Switch OFF (DC 5 V): Boom lowering operation is detected.

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Input/Output Signals of the AML-LIID System (GT-350C-1) Names and functions of signals input to/output from CN3 connector are shown below: CN 3 connector Pin No.

2

Name

TR2

Signal names and functions Signal name: 90% alarm output When the moment load factor is 90% or more and less than 100%, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 90% lights.

OC output OFF (DC 24 V): The external indicator lamp indicating 90% goes out.

While the boom lift is performed with the jib mounted, the OC output turns ON when the moment load factor is 75% or more and less than 85%.

Signal name: 100% alarm output When the moment load factor is 100% or more, or when the overload and overwound automatic stop function is canceled, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 100% lights.

OC output OFF (DC 24 V): The external indicator lamp indicating 100% goes out.

3

TR3

Signal name: 100% alarm output When the moment load factor is 100% or more, or when the overload and overwound automatic stop function is canceled, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 100% lights.

OC output OFF (DC 24 V): The external indicator lamp indicating 100% goes out.

Conditions under which the OC output turns ON Moment load factor ≥ 100% Overwind cutout release switch: "Press" AML emergency switch: "非常用" While the boom lift is performed with the jib mounted (extended), the OC output turns ON when the moment load factor becomes as follows: Moment load factor ≥ 85% Also, under the condition below, the AML judges that the jib is mounted (extended).

When Di8 input signal is "DC 24 V"

TR4

With GT-350C-1 Signal name: Front jack overload warning output OC (open collector) output ON (DC 0 V): When the front jack overload detection switch is "ON," the buzzer sounds.

OC (open collector) output OFF (DC 24 V): When the front jack overload detection switch is "OFF," the buzzer does not sound.

22

Di22

Signal name: Front jack/outrigger retracting operation input Input from the outrigger retraction switch.

Switch ON (DC 0 V): Outrigger retracting operation Switch OFF (DC 5 V): Not outrigger retracting operation

23

Di23

Signal name: Front jack overload detection switch input Switch ON (DC 0 V): Not front jack overload state Switch OFF (DC 5 V): Front jack overload state

4

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Input/Output Signals of the AML-LIID System (GT-350C-1) CN 3 connector Pin No.

24

Name

Di24

Signal names and functions Signal name: Top end boom (3rd to top boom sections) extension switch input Switch ON (DC 0 V): Extends from top end boom (3rd to top boom sections).

Switch OFF (DC 5 V): Does not extend from top end boom (3rd to top boom sections).

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Functions of and How to Use User Mode (TS-75M-1) [OPERATION]

2. Maintenance Mode: Used to make functional checks of the AML. Refer to the "ADJUSTMENT AND MAINTENANCE" section.

Functions of and How to Use User Mode (TS-75M-1)

3. Adjustment Mode:

Mode Structure

Used to make detector adjustment. Refer to the "ADJUSTMENT AND MAINTENANCE" section.

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

POWER ON 電源 ON

Protect プロテクト switch スイッチ

MAINTENANCE MODE 保守モード

USER MODE ユーザーモード

ON ON Protect プロテクト switch スイッチ OFF OFF

調整モード ADJUSTMENT MODE

POWER ON 電源 ON

IW301-0153J03

1. User Mode: Used to indicate moment load factor or to perform AML pre-operational inspection (Normally used).

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

HALT

ON

OFF

WDT

PROTECT

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

Protect 異常表示LED Abnormality switch display LED プロテクトスイッチ Top上面 view

IW301-0141J35

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Functions of and How to Use User Mode (TS-75M-1) Configuration and Functions of the AML System The AML system has various kinds of functions, including the following five typical functions.

Based on the work conditions registered in the AML and the signals from various sensors, these functions control the crane operations.

Moment load factor 100% or more

Alarm Buzzer: Sounds continuously.

Moment display: Applicable bargraph is lit red until the moment load factor is up to 110% (*1). When 110% is exceeded, all the bargraphs are lit.

Buzzer: Sounds continuously.

Crane is Moment display: operated Displays an error message. toward the AML external indicator lamp: Lights critical side red. with moment Buzzer: Sounds continuously. load factor of 100% or more.

When the backward stability control is activated, the crane operation toward critical side is stopped.

Not used in this machine.

The availability of the above described automatic stop function and working area limit functions is as shown in the table below depending on the individual operation. Be careful that turning the AML emergency switch to "非常用," and the crane starter switch to "ON" will change the center warning lamp to "AML warning" state and deactivate all the above AML stop functions (the troubleshooting function of the system).

Crane operation control required

Moment display: Displays the control message.

Buzzer: Beep (only for 3 seconds)

Working area The corresponding limit indicator lamp limit function flashes. activated Buzzer: Beep (only for 3 seconds) AML system error

On-outrigger operation





Moment load Moment display: factor Applicable bargraph is lit yellow 90% or more (*1). and less than Buzzer: Sounds intermittently.

100%

4. Automatic stop function for the backward stability

Boom extension

Boom extension

Crane is Moment display: operated Displays an error message. toward the Buzzer: Continuous tremolo sound critical side with the hook block overwound

When the hook block is overwound, the hoisting-up operation of the crane is stopped.





Overwinding

3. Automatic stop function to prevent overwinding

Boom lowering

Boom raising/lowering

Condition

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



Stop by working area limit



5. Alarm Functions

The AML calculates and compares the working and rated moment values and displays their ratio.

When the working moment exceeds the rated moment (100% or more), failure message is shown, alarm buzzer sounds, and the crane operation toward the critical side stops.

Hoisting up

Boom raising/lowering

: Stop : No stop

1. Automatic stop function to prevent overloading

Automatic stop by overloading

Stop at the stroke end

Moment display: Displays an error message.

Buzzer: Beep (only for 3 seconds)

*1: Refers to the seal area on the moment display.

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Functions of and How to Use User Mode (TS-75M-1)

Boom length detection

Boom angle detection

Moment load factor detection

Front position detection

Crane operation detection

Operator input

Registration of the outrigger condition Registration of the front jack condition Registration of the lift status

Registration of the working area limits AML unit

Alarm buzzer

AML external indicator lamps (option)

Display panel

- Moment load factor is 100%

- The working area limit signal is output.

or more.

- Overwinding occurs.

- AML system error

Boom extension halted

Boom lowering halted

Hoisting up halted

Upper boom angle restricted Lower boom angle restricted

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Lifting height restricted

Load radius restricted

Functions of and How to Use User Mode (TS-75M-1) Names and Functions of the Parts

A.

Bargraph display

AML (Main Unit) Scroll-up key

Bargraph display

Load factor mark

Scroll-down key

Moment display

Display panel 1

Display panel 2 Normally lights 0 to 89% 10% per segment 90 to 99% 2.5% per segment

Controls section

110% or more 100 to 109% 2.5% per segment

1. Load factor mark The moment load factors on the bargraph are color coded as follows: safe (green), notice (yellow) and limit (red) 2. Moment display Normally displays a moment load factor on a bargraph and in value. Also displays error messages when detects an error in a detector or others.

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 message displayed on the moment display.

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Functions of and How to Use User Mode (TS-75M-1) B. Display panel 1

9. Load radius display Normally displays the crane’s load radius. When the load radius limit function is activated, the registered load radius limit value is displayed while the set key is pressed.

10. Boom angle display Normally displays the boom angle. When the lower limit function of boom angle is activated, the registered limit value is displayed while the set key is pressed.

11, 12. Boom angle symbols This symbol indicates that the boom angle display 10 is showing the boom angle.

13. Single top lift symbol This symbol indicates that the single top performance is selected.

1. Boom length symbol This symbol indicates that the boom length display 20 is showing the boom length.

14. Boom lift symbol This symbol indicates that the boom lift is selected.

2. Jib length symbol Not used in this machine.

15, 16. Lower boom angle limit symbols This symbol indicates that the boom angle display 10 is showing the registered lower boom angle limit value.

3. Jib angle symbol Not used in this machine.

4. Jib lift symbol Not used in this machine.

17, 18. Upper boom angle limit symbols

5. Actual load display Displays the actual load.

This symbol indicates that the boom angle display 23 is showing the registered upper boom angle limit value.

6. Rated lifting capacity display Displays the rated lifting capacity.

19. Counterweight condition symbol Not used in this machine

7. Load radius limit symbol This symbol indicates that the load radius display 9 is showing the registered load radius limit value.

The load radius symbol 8 is also lit at the same time when this symbol is lit.

20. Boom length display Normally displays the boom length. Displays the lifting height while the display alteration key is pressed. When the lifting height limit function is activated, the registered limit value is displayed while the set key is pressed.

8. Load radius symbol This symbol indicates that the load radius display 9 is showing the load radius.

21. Lifting height symbol This symbol indicates that the boom length display 20 is showing the lifting height.

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W301-0251E

Functions of and How to Use User Mode (TS-75M-1) 6. Set key Used to register a selected status.

22. Lifting height limit symbol This symbol indicates that the boom length display 20 is showing the registered lifting height limit value. The lifting height symbol 21 is lit at the same time when this symbol is lit.

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

8. Load radius limit key

23. Jib angle display

Used to activate and release the load radius limiting function.

When the upper boom angle limit function is activated, the upper boom angle limit value is displayed while the set key is pressed.

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

24. Number of part lines symbol Not used in this machine.

10. Lower boom angle limit key Used to activate and release the lowermost boom angle limiting function.

C. Controls section

11. Lower boom angle limit indicator lamp Lights when the lower boom angle limiting function is registered.

12. Upper boom angle limit key Used to activate and release the uppermost boom angle limiting function.

13. Upper boom angle limit indicator lamp Lights when the upper boom angle limiting function is registered.

14. Lifting height limit key Used to activate and release the lifting height limiting function.

1. Left outrigger condition selector key Used to select the left outrigger extension status.

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

2. Right outrigger condition selector key Used to select the right outrigger extension status.

3. On-rubber condition selector key Not used in this machine.

If the key is pressed unexpectedly, the machine moves to the on-rubber registration standby status. (The on-rubber condition symbol flashes.) Press the display alteration key 7 to return to the original state.

16. Increase key Not used in this machine 17. Decrease key Not used in this machine 18. Number of part-lines key Not used in this machine.

If the key is pressed unexpectedly, the message [ロープデータガアリマセン] appears.

Press the display alteration key 7 to return to the original state.

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

5. Inspection key Used to perform the pre-operational inspection of the AML system.

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Functions of and How to Use User Mode (TS-75M-1)

6. Front jack condition symbol

D. Display panel 2

Lights when the front jack condition register switch is ON, indicating that the front jack using status has been registered.

7. Rear jack condition symbol Not used in this machine.

1. Front position symbol Lights when the swing position comes to the front position, indicating front area operation.

2. Swing position display Displays the swing position of the boom for the right and left sides respectively.

Swing position: Right

Swing position: Left

3. Outrigger condition symbol Indicates the outrigger extension condition by symbol.

Flashes while the on-outrigger condition is being registered, and stays lit after the registration is completed.

4. On-rubber condition symbol Lights when the power is ON. 5. Suspension lock condition symbol Not used in this machine.

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Functions of and How to Use User Mode (TS-75M-1) Registering Operating Conditions

The outrigger condition symbol changes from "flashing" to "being lit" to indicate that the condition has been successfully registered.

WARNING Should the operational status be incorrectly registered, the crane may 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.

Registration of Outrigger Condition [NOTICE] Register right and left outrigger condition separately on the AML. If the front and rear outrigger extension widths differ, register the smaller extension width as shown in the figure below.

Left front/rear middle extension

Left front middle extension

Left rear middle extension

Set key Right outrigger condition selector key Left outrigger condition selector key

Middle extension Set key Either extension status on the left is registered as middle extension.

Flashes Maximum extension

When the power supply is turned on, the

Flashes

on-rubber condition symbol is automatically lit.

Even after the power supply is turned off, the

Lights

Set key

Lights

Registration of Front Jack Condition

registered data is stored, and when the power supply is turned on again, the system is resumed with the registered operation status. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again.

To register the front jack condition, use the front jack condition register switch.

1. When the front jack is used: Set the front jack condition register switch to (ON).

The front jack condition symbol will light, indicating that the front jack condition has been registered.

To register the outrigger condition, use the outrigger condition selector key and set key.

Each time the outrigger condition selector key is pressed, the outrigger condition symbol flashes with alternate display of "Middle extension" → "Maximum extension" → "Middle extension" → "Maximum extension." After adjusting the right and left symbol display to the actual outrigger extension, press the set key.

2. When the front jack is not used: Turn the front jack condition register switch to (OFF).

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Functions of and How to Use User Mode (TS-75M-1)

Front jack condition symbol

Front jack condition register switch

Registration of Lift Status [NOTICE] When the power supply is turned on, the boom lift is automatically selected.

Even after the power supply is turned off, the registered data is stored, and when the power supply is turned on again, the system is resumed with the registered operation status. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again.

Set key Lift status selector key Boom lift

Flashes

Set key

Lights

Single top lift Flashes

To register the lift status, use the lift status selector key and set key.

Each time the lift status selector key is pressed, the display alternates in the sequence of "ブーム" → "シ ングルトップ" → "ブーム" → "シングルトップ" …

After adjusting the working lift status, press the set key.

The symbol changes from "flashing" to "being lit," and the registration of the lift status is completed.

The numerical value corresponding to the crane load radius display registered to the AML is displayed on the load display, rated load display, and load radius display.

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Set key

Lights

Functions of and How to Use User Mode (TS-75M-1)

Display Alteration Operation While the display alteration key is being pressed, the contents displayed on the display panel 1 can be altered. At the same time, the indicated symbol is displayed according to the displayed contents.

[NOTICE] The displays enclosed by square as shown in the figure change. Even if the display alteration key is pressed, the contents displayed on the actual load display, rated lifting capacity display, and load radius display will not change.

Although "0" is displayed on the jib angle display, it has no particular meaning in case of this machine.

Displays 0.

Lifting height

Moment load factor Actual load

Rated lifting capacity Load radius

Display alteration key

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Functions of and How to Use User Mode (TS-75M-1) Pre-operational Inspection on the AML WARNING

Bargrapgh display

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

Display panel 1 Display panel 2

[NOTICE]

Buzz

Before starting operation, check that the AML system works in good condition, as follows: 1. Press the inspection key and make sure that the AML is in the following conditions: (1) Bargraph display: All segments light (as shown in the figure).

(2) Display panel 1 and 2 lamps: All segments light (as shown in the figure).

(3) Working area limit indicator lamp (4): All segments light.

(4) Alarm buzzer: Sounds continuously.

(5) Movement toward critical sides: Automatically halted.

Inspection key

2. Press the set key, display alteration key, or inspection key to return the display to the normal condition (a bargraph must be shown on the moment display).

3. Visually check that values and symbols shown on the display panel 1 and 2 represent the actual crane conditions, particularly on the following items.

(1) Boom length (2) Boom angle (3) Actual load With no load on hook, make sure that an approximate mass of the hook block is shown.

[NOTICE] The actual load is not shown correctly if the lift status of the AML is not registered correctly.

(4) Outrigger condition symbol (5) Front jack condition symbol (6) Front position symbol (7) Swing position display

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Functions of and How to Use User Mode (TS-75M-1) How to Use the Working Area Limiting Function

Display of Working Area Limit Values Press the set key while the working area limit function is activated. While the set key is pressed, the working area limit values registered in the indicator shown below are displayed.

Also the message "ハンイセイゲンチ ヒョウジ" appears on the moment display.

When the load radius is not registered, "― ― ―" is displayed on the display.

WARNING The swing operation range cannot be restricted. Pay sufficient attention when the extension status of outriggers differs or the performance varies due to operation area with no front jack used.

If the capacity is exceeded during swing and the alarm buzzer sounds, stop swinging immediately and bring down the lifted load onto the ground or swing to the opposite side to avoid danger.

Upper boom angle limit value

[NOTICE]

Load radius limit value

Even after the power supply is turned off, the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation status. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again.

- Upper boom angle limit - Lower boom angle limit - Lifting height limit - Load radius limit

Set key

Automatic stop and alarm buzzer (AML built-in buzzer sounds for 3 seconds.)

Upper boom angle limit Lifting height limit Lower boom angle limit

Lower boom angle limit value

Lifting height limit value

If the working area limit is registered very close to an obstacle, there is a risk of the crane colliding with the obstacle, depending on the operational status and the manner in which the load is handled.

Secure a sufficient allowance when registering.

The working area limit function limits operation of the boom to the pre-registered boom angle (upper limit, lower limit), lifting height, and load radius. Use this function when performing operation in a place where there are obstacles around the machine, requiring the working-area limitation of the boom.

Load radius limit

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Functions of and How to Use User Mode (TS-75M-1) Action against AML System Error

Load Radius Limit Move the boom to a desired limit load radius, and

WARNING

press the load radius limit key. The load radius limit indicator lamp will flash, indicating that the load radius limit has been registered in the memory. When the boom is moved back to a load radius within the set limit, the load radius limit indicator lamp stops flashing and stays lit.

Thereafter, the load radius limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the load radius previously registered is reached. (Boom lowering and extending stop automatically.) To cancel the load radius limit, press the load radius limit key again.

The load radius limit indicator lamp will go out.

When the AML emergency switch is used, the AML automatic stop function is canceled. It is extremely dangerous to use this switch during normal operation. Never use it. Use it only when the crane cannot be operated due to AML system failure. Before using this switch, bring down the lifted load onto the ground first, and then retract the boom. Subsequently, stow the boom by the elevating/swing operation.

When the crane operation cannot be recovered to the normal state even if the recovery operation corresponding to the message indicating the error is performed, the system is in error. When the system is in error, the crane cannot be operated.

In this case, the AML emergency switch is used to stow the crane. When the key is inserted into the key hole of the AML emergency switch, the crane can be operated only while the key is being held to the (ON) position.

(ON) position : Automatic stop is canceled.

(OFF) position : Automatic stop

Load radius limit indicator lamp

When the AML emergency switch is set to the (ON) position, the AML external indicator lamp (option) lights red to inform the workers concerned of that.

Load radius limit key

AML emergency switch

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) Functions of and How to Use User Mode (GT-250C-1/GT-350C-1)

2. Maintenance Mode: Used to make functional checks of the AML. Refer to the "ADJUSTMENT AND MAINTENANCE" section.

Mode Structure

3. Adjustment Mode:

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

Used to make detector adjustment. Refer to the "ADJUSTMENT AND MAINTENANCE" section.

POWER ON 電源 ON

Protect プロテクト switch スイッチ

MAINTENANCE MODE 保守モード

USER MODE ユーザーモード

ON ON Protect プロテクト switch スイッチ OFF OFF

調整モード ADJUSTMENT MODE

POWER ON 電源 ON

IW301-0153J03

1. User Mode: Used to indicate moment load factor or to perform AML pre-operational inspection (Normally used).

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

HALT

WDT

ZERO

PROTECT ON

OFF

MOMENT SHORT

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

Protect異常表示LED Abnormality switch display LED プロテクトスイッチ Top 上面 view

IW301-0151J35

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) 4. Telescoping control function Controls the alteration of 3rd to top boom sections and 2nd boom section telescoping.

Configuration and Functions of the AML System The AML system has various kinds of functions, including the following five typical functions.

Based on the work conditions registered in the AML and the signals from various sensors, these functions control the crane operations.

1. Automatic stop function to prevent overloading The AML calculates and compares the working and rated moment values and displays their ratio.

When the working moment exceeds the rated moment (100% or more), failure message is shown, alarm buzzer sounds, and the crane operation toward the critical side stops.

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

The availability of the above described automatic stop function and working area limit functions is as shown in the table below depending on the individual operation. Be careful that turning the AML emergency switch to "非常用," the key switch to "解除," and the PTO switch to "ON" will change the center warning lamp to "AML warning" state and deactivate all the above AML stop functions (the troubleshooting function of the system).

On-outrigger operation Automatic stop by overloading Stop by working area limit

Hoisting up



Boom lowering



Boom extension



Boom raising/lowering



Boom extension



:Stop :No stop -: Not related (Note): When the boom lift is performed with the jib mounted, the crane automatically stops when the moment load factor becomes 85% or more.

3. Automatic stop function to prevent overwinding When the hook block is overwound, the hoisting-up operation of the crane is stopped.

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) 5. Alarm Functions Condition Overwinding

The meaning of the buzzers in the table are as follows: Buzzer: AML external buzzer ("Buzz") AML buzzer: AML built-in buzzer ("Beep")

Alarm

Buzzer: Tremolo sound

Crane is Moment display: operated toward Displays [warning:0024]. the critical side Buzzer: Tremolo sound with the hook block overwound

AML buzzer sounds for 3 seconds every time a message appears. *1: Refers to the seal area on the moment display.

Overwind cutout Moment display: function is Displays [warning:0015]. canceled with External indicator lamp: Lights red. the hook block Buzzer: Tremolo sound overwound Moment load factor 90% or more and less than 100%

Moment display: Applicable bargraph is lit yellow (*1).

External indicator lamp: Lights orange.

Buzzer: Sounds intermittently.

Moment load factor 100% or more

Moment display: Applicable bargraph is lit red until the moment load factor is up to 110% (*1). When 110% is exceeded, all the bargraphs are lit.

External indicator lamp: Lights red.

Buzzer: Sounds continuously.

Crane is Moment display: operated toward Displays [warning:0023]. the critical side External indicator lamp: Lights red. with moment Buzzer: Sounds continuously. load factor of 100% or more.

AML system error

Moment display: Displays an error message.

AML Buzzer: For 3 seconds

Working area limit function activated

Moment display: Displays an error message.

Applicable limit lamp flashes.

AML Buzzer: For 3 seconds

Moment at boom lift with jib mounted Moment display: Applicable bargraph is lit yellow 75% or more to (*1). less than 85% External indicator lamp: Lights orange.

Buzzer: Sounds intermittently.

85% or more

Moment display: Displays [warning:0088].

External indicator lamp: Lights red.

Buzzer: Sounds intermittently.

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) System Configuration Boom length detection

Boom angle detection

Moment load factor detection

Crane operation detection

Swing angle detection

Registration of the outrigger condition

Operator input

Registration of the front jack condition Registration of the lifting height condition Registration of the working area limits Registration of the number of part-lines AML unit

Alarm buzzer Display panel

AM external indicator lamps (option)

Stop output:

- Moment load factor is 100% or more.

- Overwinding - Stop by jib mounting limit - AML error

The working area limit signal is output.

Boom extension halted

Boom lowering halted

Hoisting up halted

Upper boom angle restricted Lower boom angle restricted

48

Lifting height restricted

W301-0251E

Load radius restricted

Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) Names and Functions of the Parts

A. Bargraph display

AML (Main Unit) Scroll-up key Bargraph display

Load factor mark

Scroll-down key

Moment display

Display panel 1

Display panel 2 Normally lights 0 to 89% 10% per segment 90 to 99% 2.5% per segment

110% or more 100 to 109% 2.5% per segment

1. Load factor mark The moment load factors on the bargraph are color coded as follows: safe (green), notice (yellow) and limit (red) Controls section

2. Moment display Normally displays a moment load factor on a bargraph and in value. Also displays error messages when detects an error in a detector or others.

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 message displayed on the moment display.

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) registered load radius limit value is displayed while the set key is pressed.

B. Display panel 1

10. Boom angle display Normally displays the boom angle. When the lower limit function of boom angle is activated, the registered limit value is displayed while the set key is pressed.

11, 12. Boom angle symbols This symbol indicates that the boom angle display 10 is showing the boom angle.

13. Single top lift symbol This symbol indicates that the single top performance is selected.

1. Boom length symbol This symbol indicates that the boom length display 20 is showing the boom length.

14. Boom lift symbol

2. Jib length symbol

15, 16. Lower boom angle limit symbols

This symbol indicates that the boom lift is selected.

This symbol indicates that the boom angle display 10 is showing the registered lower boom angle limit value.

Not used in this machine.

3. Jib angle symbol This symbol indicates that the jib angle display 23 is showing the jib offset angle.

17, 18. Upper boom angle limit symbols This symbol indicates that the jib angle display 23 is showing the registered upper boom angle limit value.

4. Jib lift symbol This symbol indicates that the jib lift is selected.

It also indicates the condition of the jib.

19. Counterweight condition symbol

5. Actual load display

Not used in this machine.

Displays the actual load.

20. Boom length display

6. Rated lifting capacity display

Normally displays the boom length. Displays the lifting height while the display alteration key is pressed. When the lifting height limit function is activated, the registered limit value is displayed while the set key is pressed.

Displays the rated lifting capacity.

7. Load radius limit symbol This symbol indicates that the load radius display 9 is showing the registered load radius limit value.

The load radius symbol 8 is also lit at the same time when this symbol is lit.

21. Lifting height symbol This symbol indicates that the boom length display 20 is showing the lifting height.

8. Load radius symbol This symbol indicates that the load radius display 9 is showing the load radius.

22. Lifting height limit symbol This symbol indicates that the boom length display 20 is showing the registered lifting height limit value. The lifting height symbol 21 is lit at the same time when this symbol is lit.

9. Load radius display Normally displays the crane’s load radius. When the load radius limit function is activated, the

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) 23. Jib angle display When the upper boom angle limit function is activated, the upper boom angle limit value is displayed while the set key is pressed.

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

8. Load radius limit key Used to activate and release the load radius limiting function.

24. Number of part-lines symbol This symbol indicates the number of part lines.

9. Load radius limit indicator lamp Lights when the load radius limiting function is registered.

10. Lower boom angle limit key Used to activate and release the lowermost boom angle limiting function.

C. Controls section

11. Lower boom angle limit indicator lamp Lights when the lower boom angle limit function is registered.

12. Upper boom angle limit key Used to activate and release the uppermost boom angle limiting function.

13. Upper boom angle limit indicator lamp Lights when the upper boom angle limit function is registered.

1. Left outrigger condition selector key Used to select the left outrigger extension status.

14. Lifting height limit key Used to activate and release the lifting height limiting function.

2. Right outrigger condition selector key Used to select the right outrigger extension status.

15. Lifting height limit indicator lamp

3. On-rubber condition selector key

Lights when lifting height limiting function is registered.

Not used in this machine.

If the key is pressed unexpectedly, the machine moves to the on-rubber registration standby status. (The on-rubber condition symbol flashes.) Press the display alteration key 7 to return to the original state.

16. Increase key Used to increase the selected value.

17. Decrease key Used to decrease the selected value.

4. Lift status selector key Used to select the boom lift status.

18. Number of part-lines selector key Used to register the number of part lines.

5. Inspection key Used to perform the pre-operational inspection of the AML system.

6. Set key Used to register a selected status.

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) D. Display panel 2

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

2. Outrigger condition symbol Indicates the outrigger extension condition by symbol. Flashes while the outrigger condition is being registered, and stays lit after the registration is completed.

3. Swing position display Displays the boom swing position for every 10°.

4. On-rubber condition symbol When the starter switch in the crane cab is turned "ON" and the power is turned on, this display lights.

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) Registering Operating Conditions

To register the outrigger condition, use the outrigger condition selector key and set key.

WARNING Should the operational status be incorrectly registered, the crane may 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.

Registration of Outrigger Condition [NOTICE] Register right and left outrigger condition separately on the AML. If the front and rear outrigger extension widths differ, register the smaller extension width as shown in the figure below.

Left front/rear middle extension

Left front middle extension

Set key

Left rear middle extension

Right outrigger condition selector key Left outrigger condition selector key

Either extension status on the left is registered as middle extension.

Each time the outrigger condition selector key is pressed, the outrigger condition symbol flashes with alternate display of [Middle extension] → [Maximum extension] → [Middle extension] → [Maximum extension]. After adjusting the right and left symbol display to the actual outrigger extension, press the set key.

The outrigger condition symbol changes from "flashing" to "being lit" to indicate that the condition has been successfully registered.

When the power supply is turned on (the engine begins running and the PTO switch in the cab is turned "ON"), the on-rubber condition symbol lights.

Even after the power supply is turned off (PTO switch: OFF), the AML stores the operational status if the power supply is turned on again within approximately 2 hours. However, the maximum storage period is 2 hours. If 2 hours or more have passed after the power supply was turned off (PTO switch: OFF), the registered data is automatically erased. To resume the operation, register the settings all over again.

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) Registration of Front Jack Condition

Registration of Lift Status

The rated lifting capacity varies due to whether

When the power supply is turned on (PTO switch:

the front jack is present.

How working area and rated lifting capacity vary is described in "Rated Lifting Capacity Table."

Read thoroughly and understand "Rated Lifting Capacity Table," then register the front jack condition.

ON), the boom lift is automatically selected.

Even after the power supply is turned off (PTO switch: OFF), the AML stores the operational status if the power supply is turned on again within approximately 2 hours. However, the maximum storage period is 2 hours. If 2 hours or more have passed after the power supply was turned off (PTO switch: OFF), the registered data is automatically erased. To resume the operation, register the settings all over again.

To register the front jack condition, use the front jack condition register switch.

1. When the front jack is used: Set the front jack condition register switch to "ON." The switch indicator lights. The front jack condition symbol will light, indicating that the front jack condition has been registered.

To register the lift status, use the lift status selector key and set key.

2. When the front jack is not used: Set the front jack condition register switch to "OFF." The switch indicator goes out.

Front jack condition register switch

Set key

Front jack condition symbol

Lift status selector key

Each time the lift status selector key is pressed, the display changes in numerical sequence from (1) to (5)*1.

The display returns to (1) if you press the key when (5)*1 is shown on the display. Select the status that corresponds to the actual lift status.

When the desired operation status is obtained, press the set key. The lift status symbol changes from "flashing" to "being lit."

Also, the displays of the bargraph, rated lifting capacity, and actual load return to normal display

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) status, indicating that the status is registered.

(When the jib set status is selected, the lift status symbol remains "flashing.")

When performing the boom lift with the jib mounted, register the boom lift. *1: With GT-350C-1, the number is (9).

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) Before lifting one piece of load with the boom and jib, register the jib lift.

With GT-250C-1

With GT-350C-1

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) Registration of Number of Part Lines

 When the increase key or decrease key is kept pressing, the number of part lines is increased or decreased continuously.

3. When the desired number of part lines is obtained, press the set key and register it. The number of part-lines symbol will go out, and the jib angle display will return to the normal status.  When pressing the display alteration key, you can check the number of part lines.

[NOTICE]  When the registered number of part lines is smaller than the standard number of part lines, the maximum lifting capacity is restricted by the registered number of part lines. However, when the number of part lines is registered as "0," the standard number of part lines will be applied.  When the registered number of part lines is larger than the standard number of part lines, or when no number of part lines matches the data of any crane model, the standard number of part lines will be applied.  When the power supply is turned on (PTO switch: ON), the standard number of part lines (initial value) that corresponds to the operation status will be set.

To register the number of part lines, use the number of part-lines selector key and set key.

Number Number of of partpart lineslines

Number of part-lines symbol

Number of part-lines selector key Set key

1. Press the number of part-lines selector key. The number of part-lines symbol flashes, and the number of part lines is displayed on the jib angle display and flashes.

2. Press the increase key or decrease key to obtain the desired number of part lines.  When the increase key or decrease key is pressed, the numeral of the number of part lines changes from "flashing" to "being lit," and the numeral is increased or decreased.

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) Pre-operational Inspection on the AML

3. Visually check that values and symbols shown on the display panel 1 and 2 represent the actual crane conditions, particularly on the following items.

(1) Boom length (2) Boom angle (3) Jib angle Displayed when jib lift is selected.

(4) Actual load With no load on hook, make sure that an approximate mass of the hook block is shown.

The actual load is not shown correctly if the lift status of the AML is not registered correctly.

(5) Outrigger condition symbol (6) Front jack condition symbol (7) Swing position display

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

[NOTICE] Before starting operation, check that the AML system works in good condition, as follows: 1. Press the inspection key and make sure that the AML is in the following conditions: (1) Bargraph display: All segments light (as shown in the figure).

(2) Display panel 1 and 2 lamps: All segments light (as shown in the figure).

(3) Working area limit indicator lamp (4): All segments light.

(4) Alarm buzzer: Sounds continuously.

(5) Movement toward critical sides: Automatically halted.

Bargraph display Display panel 1 Display panel 2

Buzz

Inspection key

2. Press the set key, display alteration key, or inspection key to return the display to the normal condition (a bargraph must be shown on the moment display).

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) Boom Angle Limit

How to Use the Working Area Limiting Function

Move the boom to a desired limit boom angle, and press the upper boom angle limit key or lower boom angle limit key. The corresponding boom angle limit indicator lamp will flash, and the alarm buzzer will sound continuously, indicating that the boom angle limit has been registered in the memory. When the boom is moved back to a lifting angle within the set limit, the boom angle limit indicator lamp stops flashing and stays lit, and the alarm buzzer stops. Thereafter, the boom angle limit indicator lamp flashes and the alarm buzzer sounds continuously whenever the boom angle previously registered is reached. (Boom raising and lowering stop automatically.) To cancel the boom angle limit, press the upper boom angle limit key or lower boom angle limit key again. The corresponding boom angle limit indicator lamp will go out.

WARNING The swing operation range cannot be restricted. Pay sufficient attention when the extension status of outriggers differs or the performance varies due to operation area with no front jack used.

If the capacity is exceeded during swing and the alarm buzzer sounds, stop swinging immediately and bring down the lifted load onto the ground or swing to the opposite side to avoid danger.

[NOTICE]  If the working area limit is registered very close to an obstacle, there is a risk of the crane colliding with the obstacle, depending on the operational status and the manner in which the load is handled.

Secure a sufficient allowance when registering.

The working area limit function limits operation of the boom to the pre-registered boom angle (upper limit, lower limit), lifting height, and load radius. Use this function when performing operation in a place where there are obstacles around the machine, requiring the working-area limitation of the boom.  Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation status.

However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again.

- Upper boom angle limit - Lower boom angle limit - Lifting height limit - Load radius limit

Upper boom angle limit indicator lamp Lower boom angle limit indicator lamp

Automatic stop and alarm buzzer (AML built-in buzzer sounds for 3 seconds.)

Upper boom angle limit Lifting height limit Lower boom angle limit

Lower boom angle limit key Upper boom angle limit key

Load radius limit

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) Lifting Height Limit

Load Radius Limit

Move the boom to a desired limit height, and

Move the boom to a desired limit load radius, and

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

Thereafter, the lifting height limit indicator lamp flashes and the alarm buzzer sounds continuously whenever the height limit previously registered is reached. (Boom raising and extending stop automatically.)

To cancel the height limit, press the lifting height limit key again. The lifting height limit indicator lamp will go out.

press the load radius limit key. The load radius limit indicator lamp will flash and the alarm buzzer will sound continuously, indicating that the load radius limit has been registered in the memory.

When the boom is moved back to a load radius within the set limit, the load radius limit indicator lamp stops flashing and stays lit, and the alarm buzzer stops. Thereafter, the load radius limit indicator lamp flashes and the alarm buzzer sounds continuously whenever the load radius previously registered is reached. (Boom lowering and extending stop automatically.)

To cancel the load radius limit, press the load radius limit key again. The load radius limit indicator lamp will go out.

Lifting height limit indicator lamp Load radius limit indicator lamp

Lifting height limit key

Load radius limit key

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) Display of Working Area Limit Values

Display Alteration Operation

While the working area limit function is being

While pressing the display alteration key, you can

registered, press the set key. While the key is being pressed, the registered working area limit value is displayed on the display shown in the figure below. The message [Warning range] is displayed on the moment display.

Excluded during AML pre-operational inspection and operation status registration.

When no working area limit function is registered, [― ― ―] is displayed on the display.

alter the display content between the moment display and the display panel 1. At the same time, the indicating symbol is displayed according to the display content.

Moment display

Display panel 1 Even if the display alteration key is pressed, the contents of the actual load display and rated lifting capacity display does not change.

Set key

Number of part lines

Moment load factor

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) Recovery Operation at Stop

2. Stop by jib mounting limit - Moment display: Displays [Warning: 0088].

- Buzzer: Continuous sound

Recover immediately by the procedure below.

1. Moment load factor is 100% or more - Moment display: Displays [Warning: 0023].

- Buzzer: Continuous sound

3. Overwinding - Moment display: Displays [Warning: 0024].

- Buzzer: Tremolo sound

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1)

4. The upper boom angle limit function is activated.

6. The lifting height limit function is activated.

- Moment display: Displays [Warning: 0026].

- Buzzer: Continuous sound - The upper boom angle limit indicator lamp flashes.

- Moment display: Displays [Warning: 0028].

- Buzzer: Continuous sound - The lifting height limit indicator lamp flashes.

7. The load radius limit function is activated.

5. The lower boom angle limit function is activated.

- Moment display: Displays [Warning: 0029].

- Buzzer: Continuous sound -The load radius limit indicator lamp flashes.

- Moment display: Displays [Warning: 0027].

- Buzzer: Continuous sound - The lower boom angle limit indicator lamp flashes.

Cancel working area limit.

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Functions of and How to Use User Mode (GT-250C-1/GT-350C-1) Action against AML System Error

[NOTICE]

How to use AML override switch and AML override key switch

 Entrust the key of the AML override key switch to the crane administrator or construction responsible personnel.

WARNING The AML stop function can be canceled only when the AML override switch is set to "ON" and the AML override key switch is set to "ON." It is extremely dangerous to use these switches during normal operation. Never use them. Use them only when the crane cannot be operated due to AML system failure. Before using these switches, bring down the lifted load onto the ground first, and then retract the boom.

Subsequently, stow the boom by the elevating/swing operation.

When the crane operation cannot be recovered to the normal state even if the recovery operation corresponding to the message indicating the error is performed, the system is in error. When the system is in error, the crane cannot be operated.

In this case, these switches are used to stow the crane.

When the key is inserted into the key hole of the AML override key switch and set to "ON" and the AML override switch is being held to "ON," the AML emergency warning lamp lights and the crane can be operated.

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Outline of Adjustment Mode and Maintenance Mode [ADJUSTMENT AND MAINTENANCE] Outline of Adjustment Mode and Maintenance Mode 1. Keys and Switches for Adjustment and Maintenance 1.

Scroll-up key 1.スクロールアップキー 2.2.スクロールダウンキー Scroll-down key Moment display モーメント

表示キー

°

m

m

HALT

WDT

OFF

m

ZERO

MOMENT SHORT

max t

PROTECT

t ° ％

ON

4.4.増キー Increase key 5.5.減キー Decrease key

7.点検キー 7. Inspection key

8.モーメント入力短絡スイッチ 8. Moment input short-circuit switch 9.プロテクトスイッチ 9. Protect switch 10.モーメント零調整器 10. Moment zero adjuster 11.異常表示LED 11. Abnormality display LED 上面 IW301-0151J02 Top view

3.セットキー Display alteration key 3. Set key 6.6.表示切替キー IW301-0251J04

7. Inspection key

1. Scroll-up key

Used for "Do Check" and "Ao Check" functions in the maintenance mode.

Used to see the previous lines of message displayed on the moment display.

8. Moment input short-circuit switch Not used for this machine.

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

9. Protect switch

3. Set key

Set this switch to OFF when changing the mode from user mode to adjustment mode. With this switch OFF, data can be written in the EEPROM.

Used to confirm the selected menu item and write the adjustment value in EEPROM.

10. Moment zero adjuster

4. Increase key

Do not touch. This adjuster is for adjustment by the AML manufacturer's service personnel.

Used to increase the adjustment value.

5. Decrease key Used to decrease the adjustment value.

11. Abnormality display LED Lights when the AML is in abnormal conditions or when the AML adjustment is initialized (reset).

6. Display alteration key Used to change the display to the upper menu.

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Outline of Adjustment Mode and Maintenance Mode 2. Mode Structure and Menu

2. Maintenance Mode: Used to make functional checks of the AML. This mode has the following menus:

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

MAIN MENU

SUB-MENU

[･ホシュ] [･トケイ チョウセイ]

Used to indicate moment load factor or to perform AML pre-operational inspection (Normally used).

［：プログラムバージョン］ ［：データシュベツ］ ［：DI チェック］ ［：AI チェック］ ［：キフクアツリョク モニタ］ ［：DO チェック］ ［：MDT モニタ］（*1） ［：キースイッチ チェック］ ［：ヒョウジキ チェック］ ［：エラーリレキ ヒョウジ］ ［：エラーリレキ ショウキョ］ ［：ウンテンリレキ ヒョウジ］ ［：ウンテンリレキ ショウキョ］ ［：OP ボードチェック］ ［：AO チェック］ ［：SIO チェック］ ［：チョウセイ モニタ］ (*1) : Not apply to the models (TS-75M-1, GT-250C-1, and GT-350C-1) without MDT (Multiplex Data Transmitter)

In normal use, turn ON the protect switch

3. Adjustment Mode:

POWER ON 電源 ON

Protect プロテクト switch スイッチ

MAINTENANCE MODE 保守モード

USER MODE ユーザーモード

ON ON Protect プロテクト switch スイッチ OFF OFF

調整モード ADJUSTMENT MODE

POWER ON 電源 ON

IW301-0153J03

1. User Mode:

mounted on the adjustment window on the top of the AML. The AML will go to the user mode when the power turns on.

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

SUB-MENU

[･チョウセイ]

［：ナガサカクド チョウセイ］ ［：サギョウハンケイ チョウセイ］ ［：モーメント チョウセイ］ ［：キフクトクセイ チョウセイ］ ［：キフクトクセイ リセット］ ［：チヂミトクセイ チョウセイ］（*1） （*1） ［：チヂミトクセイ リセット］ ［：AO オフセット チョウセイ］ ［：AO オフセット リセット］ ［：タワミケイスウ リセット］ ［：ゼロ･スパン リセット］ ［：セイドデータ リセット］（*2）

HALT

ZERO

WDT

PROTECT

[･AO チョウセイ]

OFF

MOMENT SHORT

[･セイギョデータチョウセイ]

ON

[･ケイスウ リセット]

ON Protect switch プロテクトスイッチ Top View 上面

[･モーメントチョウセイ リセット] [･ウンテンリレキ ヒョウジ] [･ウンテンリレキショウキョ] [･セイド シュウセイ](*2) [･Language]

IW301-0151J03

(*1)

: Not apply to TS-75M-1, GT-250C-1, and GT-350C-1. (*2): Do not use.

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Outline of Adjustment Mode and Maintenance Mode 3. Method of Shifting Modes OFF

HALT

ZERO

WDT

OFF

MOMENT SHORT

PROTECT

ON Scroll-up key スクロールアップキー Scroll-down key スクロールダウンキー

ON

Moment display モーメント 表示キー

Protect switch プロテクトスイッチ

°

m

m

Top View 上面

t ° ％

IW301-0151J03

max t

m

POWER ON 電源 ON

1 Protect プロテクト スイッチ switch

Display alteration key 表示切替キー

Protect プロテクト switch スイッチ

IW301-0251J05

OFF OFF

MAINTENANCE MODE

2

ON ON

セットキー Set key

保守モード

ユーザーモード USER MODE

3 4

5

調整モード

ADJUSTMENT MODE

POWER ON 電源 ON

IW301-0153J05

4. "Adjustment mode"  "User mode" While the main menu of the adjustment mode is displayed, turn ON the protect switch.

Then, the moment display changes to the bargraph. This display denotes the "User mode."

1. "User mode"  "Maintenance mode" Press the scroll-up key, scroll-down key, and set key at the same time.

Then, the moment display changes from the bargraph to [･ホシュ]. This display denotes the "Maintenance mode."

5. " Maintenance mode "  " Adjustment mode "

2. "Maintenance mode"  "User mode"

While the main menu of the maintenance mode is displayed, turn OFF the protect switch.

Then, the moment display changes to [･チョウセ イ]. This display denotes the "Adjustment mode."

Press the display alteration key.

Then, the moment display changes to the bargraph. This display denotes the "User mode."

3. "User mode"  "Adjustment mode" Turn OFF the protect switch at the adjustment window on the top of the AML. Then, the moment display changes from the bargraph to [･チョウセイ]. This display denotes the "Adjustment mode."

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Outline of Adjustment Mode and Maintenance Mode 4. Method of Menu Selection Scroll-up key スクロールアップキー Scroll-down key スクロールダウンキー Moment display モーメント 表示キー

°

m

m

t ° ％

max t

m

セットキー Set key

Display alteration key 表示切替キー

IW301-0251J05

1. When the AML enters "Maintenance mode" or

4. The following marks displayed in the menu: "," ":,"

"Adjustment mode," first the main menu is displayed on the moment display.

Displayed main menu item can be changed by means of the scroll-up or scroll-down key.

Press the set key to select the displayed item.

and "" When a main menu is displayed, the mark "" stands before the menu name. (Ex. [･チョウセイ ↓]) When a sub-menu is displayed, the mark ":" stands before the menu name. (Ex. [：モーメント チョウセイ]) The "" mark after the menu name indicates that the depression of the scroll-down key calls for another menu.

2. If the selected item in the main menu has any sub-menus, the sub-menus are displayed on the moment display.

You can select a desired item in the sub-menu in the same way as in the main menu by means of the scroll-up, scroll-down, and set keys.

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

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Required Adjustment After AML System Parts Replacement Required Adjustment After AML System Parts Replacement [NOTICE] EEPROM stores the adjustment values for each specification number. When replacing the CPU board, remove the EEPROM from the broken CPU board and reuse it. Then, all adjustment works except the clock adjustment can be omitted. Visually check that the values such as the boom length and boom angle, and the symbols displayed on the display panels 1 and 2 on the AML correspond to the actual crane conditions.

Replaced part

Required adjustment

Boom length detector

Boom length adjustment

Boom angle detector Swing angle detector

Boom angle adjustment (*1)

Swing angle adjustment (*1)

Outrigger extension width detector (*2)

Outrigger extension width adjustment (*2)

Jib angle detector (*2)

Jib angle adjustment (*2)

Jib length detector (*2)

Jib length adjustment (*2)

Pressure sensor for moment detection

Moment adjustment

Display board

None

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

CPU board (When EEPROM is not to be reused) EEPROM

AML unit

(*1) (*2)

ROM

Clock adjustment Perform adjustment initialization and take every step of the adjustment. For the adjustment items and procedure, refer to "Adjustment Procedures" on the subsequent page in the "Functions of and How to Use Adjustment Mode" section.

None

Analog board

Boom length adjustment Boom angle adjustment Swing angle adjustment (*1) Jib angle adjustment (*2) Jib length adjustment (*2) Moment adjustment

Power board

None

Connector board

None

: Not apply to TS-75M-1. : Not apply to TS-75M-1, GT-250C-1 and GT-350C-1.

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Functions of and How to Use Adjustment Mode Functions of and How to Use Adjustment Mode Adjustment Procedures WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety.

[NOTICE] You can adjust the boom length and boom angle in random order.

After whole adjustment is completed, erase-protect the overload history, referring to "Erasing the Overload History" in the "Functions of How to Use Adjustment Mode" section.

The adjustment items and procedures are as follows: 1. Adjustment Initialization 2. Boom Length Adjustment 3. Boom Angle Adjustment 4. Swing Angle Adjustment (*1) 5. Outrigger Extension Width Adjustment (*2) 6. Jib Angle Adjustment (*2) 7. Jib Length Adjustment (*2) 8. Moment Adjustment (including load radius adjustment) 9. Clock Adjustment Adjustment Completed Erasing the Overload History (*1) (*2)

: Not apply to TS-75M-1. : Not apply to TS-75M-1, GT-250C-1 and GT-350C-1.

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Functions of and How to Use Adjustment Mode 1. Adjustment Initialization

press the scroll-down key to display [：ゼロ･スパ ン リセット], and then press the set key to reset the zero span factor.

[NOTICE] Adjustment initialization should be performed only when EEPROM is replaced.

When the CPU board is replaced, if the EEPROM removed from the faulty CPU board is to be reused, no adjustment initialization is required.

6. When the message [ケイスウヲリセットシマシ タ] appears, the zero span factor resetting is completed. Press the display alteration key to return to the main menu.

By the adjustment initialization, the conversion

1.2 Procedure of "Moment Adjustment Resetting"

factors (specification for each specification number) stored within the AML program that convert detected voltage input from the detectors into physical volumes are read out from the P-ROM and written onto the EEPROM.

1. Select the item [･モーメントチョウセイ リセッ ト↓] in the main menu of the adjustment mode, and press the set key to confirm.

2. When [モーメントゼロチョウ

Perform the initialization only once before the first adjustment takes place. If this initialization is done while adjustments are being made, you must restart the adjustment from the very beginning.

リセット]

appears, reset the moment adjustment by pressing the set key.

3. When the message [モーメントヲリセットシマシ タ] appears, the moment adjustment resetting is completed. Press the display alteration key to return to the main menu.

For the adjustment initialization, you have to execute the following two menu items. [･ケイスウ リセット]: Initializes the conversion factors that convert into physical volumes in the program for the boom length, angle, and deflection. [･モーメントチョウセイ リセット]: Initializes the conversion factors that convert into physical volumes in the program for the moment.

1.1 Procedure of "Conversion Factors Resetting" 1. Select the item [･ケイスウ リセット↓] in the main menu of the adjustment mode, and press the set key to confirm.

2. When [：タワミケイスウ リセット↓] appears, reset the deflection factor by pressing the set key.

3. When the message [ケイスウヲリセットシマシ タ] appears, the deflection factor resetting is completed. Press the display alteration key to return to the main menu.

4. Select the item [･ケイスウ リセット↓] in the main menu of the adjustment mode, and press the set key again to confirm.

5. When [：タワミケイスウ リセット↓] appears,

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Functions of and How to Use Adjustment Mode 2. Boom Length Adjustment

10. Has the boom length zero-point adjustment display [ブーム Lz] become the zero-point adjustment value in "Adjustment Value Table" ?

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

NO

YES

11. Press the display alteration key to exit the menu item.

[NOTICE] The conditions and values for boom length adjustment vary depending on the specification number. Refer to "Adjustment Value Table" in the INFORMATION AND DATA section.

When the length detector has been just installed and its cord has not yet been unwound or wound, go through the entire boom telescoping cycle to have the cord naturally wound up onto the drum.

1. Select the item [･チョウセイ↓] in the main menu of the adjustment mode, and press the set key to confirm.

2. When [：ナガサカクド チョウセイ↓] is displayed, press the set key to select the menu item.

3. Retract the boom fully.

4. Press the increase or decrease key so that the value of boom length zero-point adjustment display [ブーム Lz] becomes the zero-point adjustment value in "Adjustment Value Table."

Press the set key for registration.

5. Extend the boom fully.

6. Press the scroll-down key until the boom length span adjustment display [ブーム Ls] appears.

7. Press the increase or decrease key so that the value of boom length span adjustment display [ブ ーム Ls] becomes the span adjustment value in "Adjustment Value Table." Press the set key for registration.

8. Retract the boom fully again.

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

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Functions of and How to Use Adjustment Mode 3. Boom Angle Adjustment

value of boom angle span adjustment display [ブ ームカク s] becomes the span adjustment value in "Adjustment Value Table." Press the set key for registration.

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

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

[NOTICE]  The conditions and values for boom angle adjustment vary depending on the specification number. Refer to "Adjustment Value Table" in the INFORMATION AND DATA section.  When setting the boom angle to "Adjustment condition," always perform the setting by lowering the boom. Use a spirit level goniometer to measure the actual boom angle.

10. Press the scroll-up or scroll-down key until the boom angle zero-point adjustment display [ブーム カク z] appears.

11. Has the value of boom angle zero-point adjustment display [ブームカク z] become the zero-point adjustment value in "Adjustment Value Table" ?

1. Select the item [･チョウセイ↓] in the main menu of the adjustment mode, and press the set key to confirm.

NO

YES

12. Press the display alteration key to exit the menu

2. When [：ナガサカクド チョウセイ↓] is displayed, press the set key to select the menu item.

item.

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

4. Press the scroll-up or scroll-down key until the boom angle zero-point adjustment display [ブーム カク z] appears.

5. Press the increase or decrease key so that the value of boom angle zero-point adjustment display [ブームカク z] becomes the zero-point adjustment value in "Adjustment Value Table." Press the set key for registration.

6. Raise the boom to a point just before the upper stroke end of the elevating cylinder, and then adjust the actual boom angle to the condition of the span adjustment specified in "Adjustment Value Table" by lowering the boom.

7. Press the scroll-up or scroll-down key until the boom angle span adjustment display [ブームカク s] appears.

8. Press the increase or decrease key so that the

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Functions of and How to Use Adjustment Mode 4. Moment Adjustment WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety.

[NOTICE]  Before starting moment adjustment, raise the hydraulic oil temperature to approx. 50C by alternately raising and lowering the boom.  The conditions and values for moment adjustment vary depending on the specification number. Refer to "Adjustment Value Table" in the INFORMATION AND DATA section.  If the moment zero-point value is not within the tolerance at "4.6 Moment Zero-point Recheck," return to "4.3 Moment Zero-point Check and Fine Adjustment," and follow the order shown by the broken line to make a fine adjustment.

The procedure to adjust the moment is as follows: 4.1 Moment Zero-point Adjustment 4.2 Moment Span Preliminary Adjustment 4.3 Moment Zero-point Check and Fine Adjustment 4.4 Load Radius Adjustment 4.5 Moment Span Fine Adjustment 4.6 Moment Zero-point Recheck YES End of moment adjustment

NO

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Functions of and How to Use Adjustment Mode 4.1 Moment Zero-point Adjustment

The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t → "000" to "099" -0.99 to -0.01 t → "-99" to "-01"

[NOTICE] For the conditions and values for moment zero-point adjustment, refer to the moment zero-point adjustment value in "Adjustment Value Table."

Set the crane as follows: (1) Actual and registered statuses of outriggers: Fully extended (2) Actual and registered statuses of boom: Main boom (Jib and single top stowed) (3) Boom length: Fully retracted (4) Boom angle: Raise boom to an angle just before the maximum boom angle, and then adjust the value of boom angle display to the condition of the zero-point adjustment specified in "Adjustment Value Table" by lowering the boom.

(5) Hook block position: Overwinding status (6) Number of part lines: Standard number of part lines when the main boom is fully extended (7) Hook block: Refer to "Adjustment Value Table."

(Auxiliary hook block stowed) (8) There may be other adjustment conditions in addition to those described above depending on the crane model. Refer to "Adjustment Value Table" for details.

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

5. Proceed to "4.2 Moment Span Preliminary Adjustment."

4.2 Moment Span Preliminary Adjustment [NOTICE] For the conditions and values for moment span preliminary adjustment, refer to the moment span preliminary adjustment value in "Adjustment Value Table."

1. Continued from "4.1 Moment Zero-point Adjustment."

2. Set the value shown on the boom angle display to the condition of the span preliminary adjustment specified in "Adjustment Value Table" by lowering the boom. (Hoist down the hook block to a position just clear of ground surface.)

1. Select the item [･チョウセイ↓] in the main menu of the adjustment mode, and press the set key to confirm.

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

Moment span adjustment display: Display [X.XXXs***.*%↓]

2. When [：ナガサカクド チョウセイ↓] is displayed, press the scroll-down key until the display [：モー メント チョウセイ] appears. Press the set key to select the menu item.

Moment load factor (%) Shows span adjustment state.

3. While the moment zero-point adjustment is Detection distortion voltage (mV)

displayed, fine adjust the value shown on the actual load display to the zero-point adjustment value in "Adjustment Value Table," using the increase or decrease key.

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

4. Fine adjust the value shown on the actual load display to the span preliminary adjustment value in "Adjustment Value Table," using the increase or decrease key.

The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t → "000" to "099" -0.99 to -0.01 t → "-99" to "-01"

Moment load factor (%) Shows zero-point adjustment state.

5. After the adjustment, press the set key to register

Detection distortion voltage (mV)

the adjusted value.

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Functions of and How to Use Adjustment Mode item.

6. Proceed to "4.3 Moment Zero-point Check and Fine Adjustment."

4.4 Load Radius Adjustment

4.3 Moment Zero-point Check and Fine Adjustment

[NOTICE] For the conditions and values for load radius adjustment, refer to the load radius adjustment value in "Adjustment Value Table."

Set the crane as follows: (1) Actual and registered statuses of outriggers: Fully extended (2) Actual and registered statuses of boom: Main boom (Jib and single top stowed) (3) Boom length: Fully extended (4) Number of part lines: Standard number of part lines when the main boom is fully extended (5) Hook block: Refer to "Adjustment Value Table."

(Auxiliary hook block stowed) (6) Load radius: After lifting the rated lifting capacity of load radius adjustment condition, set the actual load radius to the value of load radius adjustment condition (load radius) in "Adjustment Value Table" by lowering the boom. (Cancel AML automatic stop function when overload hinders boom lowering.)

(7) There may be other adjustment conditions in addition to those described above depending on the crane model. Refer to "Adjustment Value Table" for details.

[NOTICE] For the conditions and values for moment zero-point check and fine adjustment, refer to the moment zero-point adjustment value in "Adjustment Value Table."

1. Continued from "4.2 Moment Span Preliminary Adjustment."

2. Raise boom to an angle just before the maximum boom angle, and then adjust the value of boom angle display to the condition of the zero-point adjustment specified in "Adjustment Value Table" by lowering the boom. (Set the hook block position to the overwinding status.)

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

Moment zero-point adjustment display: Display [X.XXXz***.*%↓] Moment load factor (%)

1. Select the item [･チョウセイ↓] in the main menu of the adjustment mode, and press the set key to confirm.

Shows zero-point adjustment state.

Detection distortion voltage (mV) 4. Has the value shown on the actual load display

2. When [：ナガサカクド チョウセイ↓] is displayed,

become the zero-point adjustment value in "Adjustment Value Table"?

The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t → "000" to "099" -0.99 to -0.01 t → "-99" to "-01"

press the scroll-down key until the display [：サギ ョウハンケイ チョウセイ↓] appears. Press the set key to select the menu item.

YES

3. Press the increase or decrease key so that the value of load radius adjustment display [ハンケイ 1s] becomes the load radius adjustment value in "Adjustment Value Table." Press the set key for registration.

NO

5. Fine adjust the value shown on the actual load display to the zero-point adjustment value in "Adjustment Value Table," using the increase or decrease key. Press the set key for registration.

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

6. Press the display alteration key to exit the menu

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Functions of and How to Use Adjustment Mode 4.5 Moment Span Fine Adjustment

The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t → "000" to "099" -0.99 to -0.01 t → "-99" to "-01"

[NOTICE] For the conditions and values for moment span fine adjustment, refer to the moment span fine adjustment value in "Adjustment Value Table."

Set the crane as follows: (1) Actual and registered statuses of outriggers: Fully extended (2) Actual and registered statuses of boom: Main boom (Jib and single top stowed) (3) Boom length: Fully extended (4) Boom angle: Set the value shown on the boom angle display to the condition of the span fine adjustment specified in "Adjustment Value Table" by lowering the boom.

(5) Hook block position: Hoist down the hook block to a position just clear of ground surface.

(6) Number of part lines: Standard number of part lines when the main boom is fully extended (7) Hook block: Refer to "Adjustment Value Table."

(Auxiliary hook block stowed) (8) There may be other adjustment conditions in addition to those described above depending on the crane model. Refer to "Adjustment Value Table" for details.

5. Proceed to "4.6 Moment Zero-point Recheck."

1. Select the item [･チョウセイ↓] in the main menu of the adjustment mode, and press the set key to confirm.

2. When [：ナガサカクド チョウセイ↓] is displayed, press the scroll-down key until the display [：モー メント チョウセイ] appears. Press the set key to select the menu item.

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

Moment span adjustment display: Display [X.XXXs***.*%↓] Moment load factor (%) Shows span adjustment state.

Detection distortion voltage (mV) 4. Press the increase or decrease key so that the value shown on the actual load display becomes the span fine adjustment value in "Adjustment Value Table." Press the set key for registration.

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Functions of and How to Use Adjustment Mode 4.6 Moment Zero-point Recheck [NOTICE]

(1) Fine adjust the value shown on the actual load

 For the conditions and values for moment zero-point recheck, refer to the moment zero-point adjustment value in "Adjustment Value Table."

display to the zero-point adjustment value in "Adjustment Value Table," using the increase or decrease key. Press the set key for registration.

1. Continued from "4.5 Moment Span Fine Adjustment."

(2) Press the display alteration key to exit the menu item.

2. Retract the boom fully.

7. Perform "4.5 Moment Span Fine Adjustment."

Perform "4.6 Moment Zero-point Recheck."

3. Raise the boom to an angle just before the maximum boom angle, and then adjust the value of boom angle display to the condition of the zero-point adjustment specified in "Adjustment Value Table" by lowering the boom. (Set the hook block position to the overwinding status.)

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

End of moment adjustment

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

Moment zero-point adjustment display: Display [X.XXXz***.*%] Moment load factor (%) Shows zero-point adjustment state.

Detection distortion voltage (mV) 5. Has the value shown on the actual load display become the zero-point adjustment value in "Adjustment Value Table"?

The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t  "000" to "099" -0.99 to -0.01 t  "-99" to "-01" YES

NO

6. Make the moment zero-point fine adjustment as shown below. (The following moment zero-point fine adjustment procedure is extracted from "4.3 Moment Zero-point Check and Fine Adjustment.")

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Functions of and How to Use Adjustment Mode 5. Clock Adjustment The AML has a calendar and clock IC inside, which is used to record errors.

Adjust the clock in the following procedure. The clock adjustment is included in the maintenance mode.

1. Select the item [･トケイチョウセイ] in the main menu of the maintenance mode, and press the set key to confirm.

2.When the time is displayed on the moment display, press the scroll-up or scroll-down key to bring the cursor to the place to be adjusted.

Time is displayed in the 24-hour basis. The cursor lies under a numeral.

Display example: [ 99. 8. 23 16:30] Cursor 3. Press the increase key or decrease key to change the value to be adjusted.

4. After the adjustment, press the set key to write the adjusted value onto the IC. If there are plural adjustment places, move the cursor for adjustment in order. Finally press the set key.

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

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Functions of and How to Use Adjustment Mode 6. Other Functions and How to Use Them

2. Press the scroll-up or scroll-down key until the menu items of the latest overload data or maximum overload data appear. Select either of them with the set key.

Display [：サイシンチ ヒョウジ↓]  [：サイダイチ ヒョウジ]

6.1. Language The menu item [Language] is used to change the language for messages appearing on the moment display. The message on the menu item [Language] is always displayed in English.

3. Display of latest overload data Selecting [：サイシンチ ヒョウジ↓] shows the latest data registered in the overload history. The time when the overload history data has been registered is indicated in the moment display.

Press the scroll-down key to show the next record. (up to 50 items)

1. Select the item [Language] in the main menu of the adjustment mode, and press the set key to confirm.

2. When the language selection display appears, press the scroll-up or scroll-down key to display the aimed language.

Display example [= Japanese]  Press the scroll-down key. [: English] The symbol "=" at the left of the displayed language indicates that the language is set at present.

Moment display Display example [99.01.23 12:35] Serial number 1からの連番 (means Nth overload history data) （何番目の運転履歴かを示す） Shows the number of そのときのオーバーロード 登録数を示す registered items 状態を示す Shows the overload factor. （最大50項目まで） (Max. 50 items) （最大400％まで） (Max. 400%)

3. When the aimed language is displayed, press the set key to set. After the setting, the symbol ":" at the left of the set language changes to "=," indicating that the setting is completed.

Display example [: English]  Press the set key. [= English]

°

m

t ° ％

max t

m

4. Press the display alteration key to exit the menu item. The messages appear in the newly set language after that.

Set key セットキー

6.2. Overload History Display

Display alteration key 表示切替キー

IW301-0251J06

The records of crane operations (with the moment However, no operation record will be stored in the following cases.

- The boom setting status is jib set.

- The boom setting status changes for overload.

- The rated lifting capacity = 0 t (including no performance and full retraction switch error).

load factor exceeding the overloading limit) registered in the AML are displayed. You can choose between the displays of latest overload data and of the maximum overload data.

1. Select the item [･ウンテンリレキ ヒョウジ↓] in the main menu of the adjustment mode, and press the set key to confirm.

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Functions of and How to Use Adjustment Mode - The boom setting status changes for overload.

- The rated lifting capacity = 0 t (including no performance and full retraction switch error).

Even if the rated lifting capacity becomes 0 t, when the overload status continues, the maximum load factor after that time is stored.

- The outrigger setting status is on-rubber.

- The elevating angle is the set value of the raising stroke end or more.

Even if the rated lifting capacity becomes 0 t, when the overload status continues, the maximum load factor after that time is stored.

- The elevating angle is the set value of the raising stroke end or more.

4. Display of maximum overload data Selecting [：サイダイチ ヒョウジ↓] shows the maximum data registered in the overload history.

The time when the overload history data has been registered is indicated in the moment display.

Press the scroll-down key to show the load factor, jib length, and jib angle. (The jib length and jib angle are displayed only during the jib lift.)

Press the scroll-down key again to show the next record. (up to 10 items)

6.3 Erasing the Overload History [NOTICE] When the AML main unit or EEPROM is replaced for repair and all adjustment is completed, erase-protect the overload history.

Before delivering the machine to a user, erase-protect the overload history by erasing the latest history data three times.

Moment display Display example [99.01.23 12:35↓] ↓ [125% 14.5 m 45.0°↓]

You can erase the overload history data (the record of crane operation when the moment load factor exceeds the set limit). Note that if the latest history data are erased three times, the menu will not appear, disabling the history data to be erased.

At the time of the third erasure, the records of the maximum overload values will also be erased.

Serial number 1からの連番 (means Nth overload history data.) （何番目の運転履歴かを示す） Indicates boom angle. ブーム角度を示す Indicates boom length.

Indicates load radius. ブーム長さを示す 作業半径を示す

1. Select the item [･ウンテンリレキショウキョ↓] in the main menu of the adjustment mode, and press the set key to confirm.

°

m

t

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

° max t °

m

表示切替キー Display alteration key セットキー Set key

Indicates旋回位置を示す swing position.

Indicates outrigger condition. アウトリガ状態を示す

menu item on which the overload history is to be erased appears. Select either of them with the set key.

Display [：サイシンチ ショウキョ↓] ↓↑ [：サイダイチ ショウキョ] 3. When [ショウキョ OK？] appears, erase the overload history by pressing the set key.

定格総荷重を示す Indicates rated lifting capacity.

Indicates actual load. 実荷重を示す IW301-0251J07

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

However, no operation record will be stored in the following cases.

- The boom setting status is jib set.

4. When the message [リレキ

ヲ ショウキョシマ

シタ] appears, the overload history data is now erased. Press the display alteration key to exit the menu item.

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

Display example [95, 12, 27↓] (5) Revision date display: Indicates the date of data revision.

Display example [96, 01, 23]

1. Program Version Display ROM program version is displayed.

3. Di Check

1. Select the menu item [･ホシュ↓], and press the The input state of Di (external contact switch) is

set key to confirm.

displayed.

2. When [：プログラムバージョン↓] is displayed, 1. Select the menu item [･ホシュ↓], and press the set key to confirm.

press the set key to select the menu item.

3. The program version is displayed. Press the display alteration key to exit the menu item.

Display example [AML-L L0204↓]

2. Press the scroll-up or scroll-down key until the menu item [：DI チェック↓] appears. Press the set key to select the menu item.

3. Di (external contact switch) input state is displayed. Press the scroll-up or scroll-down key until the desired data is displayed. Press the display alteration key to exit the menu item.

Display example (Di1) [01 カマキケンシュツ of ↓]

Program version

2. Data ID Number Display Information of ROM data is displayed.

1. Select the menu item [･ホシュ↓], and press the set key to confirm.

Switch state

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

on: Active of: Not active

menu item [：データシュベツ↓] appears. Press the set key to select the menu item.

Switch name Di input terminal number

3. The ROM data is displayed as follows: Press the

01 to 28: Di1 to Di28 T: TC input A: ACC input No indication: Serial port input (Di from multiplex data transmitter and signal transmitter)

scroll-up or scroll-down key until the desired ROM data is displayed. Press the display alteration key to exit the menu item.

(1) ROM ID number display: Indicates ROM ID number (revision number included).

Display example [750200↓]

[NOTICE] Switch state means ON/OFF state which the AML program judges logically. Usually, this matches to the physical condition of switch. However, if "r" is added as shown in the example below, the meaning differs. ron: Switch is active. (Physical contact is OFF.) rof: Switch is not active. (Physical contact is ON.)

(2) Specification number display: Indicates crane spec. number.

Display example [TR-500-3-00101↓] (3) Code number display: Indicates parts code number of AML. Display example [361-175-02000↓] (4) Data date display: Indicates the date of making up data.

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Functions of and How to Use Maintenance Mode 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 MDT) [NOTICE] Only the Ai used for input in the program can be displayed. Since the display sequence of Ai input states depends on the contents of the program, the Ai input states may not be indicated in the numerical order of Ai input numbers.

4. Ai Check The input state of Ai (analog detector input) is displayed.

1. Select the menu item [･ホシュ↓], and press the

5. Elevating Cylinder Oil Pressure Monitor

set key to confirm.

2. Press the scroll-up or scroll-down key until the menu item [：AI チェック↓] appears. Press the set key to select the menu item.

The cylinder extension lateral pressure and retraction lateral pressure which are detected for the moment calculation are displayed.

3. The input state of Ai (analog detector input) is displayed. Press the scroll-up or scroll-down key until the desired data is displayed. Press the display alteration key to exit the menu item.

Display example (ANAiNB) [02 ブームカク 1201 ok ↓]

1. Select the menu item [･ホシュ↓], and press the set key to confirm.

2. Press the scroll-up or scroll-down key until the menu item [：キフクアツリョク モニタ↓] appears. Press the set key to select the menu item.

When analog detector input value is within the normal input range, "ok" appears; when it is out of the range, then "ng" appears.

3. The elevating cylinder extension lateral pressure and retraction lateral pressure are displayed.

Press the display alteration key to exit the menu item.

Display example [E**.* R**.* MPa]

Analog detector input value (A/D converted value)

Unit

Analog detector name

Retraction oil pressure

Logical number in the program 00: Moment input (MOINP, MOINN) 01: ANAiNA 02: ANAiNB 03: ANAiNC 04: ANAiND 05: ANAiNE 06: ANAiNF 07: Analog detector source (DET1SRC, DET2SRC) 08: Pressure input (ANAING) 09: Pressure input (ANAINH)

Extension oil pressure

6. Do Check The output state of Do (Digital output: Relay output and open collector output) is displayed.

Also, you can invert the current state of selected output.

1. Select the menu item [･ホシュ↓], and press the set key to confirm.

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Functions of and How to Use Maintenance Mode 8. Display Unit Check

2. Press the scroll-up or scroll-down key until the menu item [：DO チェック↓] appears. Press the set key to select the menu item.

The segments of LCD panels and LEDs of the AML display repeat to go on and off.

3. Do (digital output) output state is displayed. Press 1. Select the menu item [･ホシュ↓], and press the

the scroll-up or scroll-down key until the desired data is displayed. Press the display alteration key to exit the menu item.

Display example (PLY1) [00 AML テイシ of↓]

set key to confirm.

2. Press the scroll-up or scroll-down key until the menu item [：ヒョウジキ チェック↓] appears.

Press the set key to select the menu item.

Present output state

3. The segments of LCD panels and LEDs of the AML display repeat to go on and off. Press the display alteration key to exit the menu item and return to the ordinary display state.

Output name Output port number 00 to 07: RLY1 to PLY8 (relay contact output) 10 to 17: TR1 to TR8 (open collector output)

9. Error Data Display

[NOTICE]

Error data registered in the AML are displayed on

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 as shown in the example below, the meaning differs. ron: Switch is active. (Physical contact is OFF.) rof: Switch is not active. (Physical contact is ON.)

the moment display and display panel 1.

1. Select the menu item [･ホシュ↓], and press the set key to confirm.

2. Press the scroll-up or scroll-down key until the menu item [：エラーリレキヒョウジ↓] appears.

Press the set key to select the menu item.

4. During the above Do output monitoring procedure, output state will be inverted while you are pressing the inspection key.

3. The error codes are displayed on the moment display and display panel 1. Press the display alteration key to exit the menu item and return to the ordinary display state.

7. Key Switch Check The key input on the AML control is checked.

(1) The moment display displays the time when the error occurred.

Display example [95. 01. 23 12:35↓]

1. Select the menu item [･ホシュ↓], and press the set key to confirm.

2. Press the scroll-up or scroll-down key until the menu item [：キースイッチ チェック↓] appears.

Press the set key to select the menu item.

(2) When the scroll-down key is pressed, the time display changes to the error code display.

Display example [ブーム ナガサイジョウ↓]

3. The following display appears. Press any key other than the display alteration key, and the corresponding portion of display changes from "-" to " " while you are pressing the key. Press the display alteration key to exit the menu item.

Display [---------･------]

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Functions of and How to Use Maintenance Mode 11. Option (OP) Board Check

(3) The mark "↓" on the error code display shows that another error exists. Press the scroll-down key to display the next error code.

The type of the incorporated option board (analog output, wire detection) is indicated.

記憶総数 Total number of stored items 1からの連番 Serial number （何番目のエラーであるかを示す） (means Nth error.)

1. Select the menu item [･ホシュ↓], and press the set key to confirm.

2. Press the scroll-up or scroll-down key until the menu item [：OP ボードチェック↓] appears. Press the set key to select the menu item.

3. The type of the incorporated option board is displayed. (Up to two option boards can be incorporated.) Press the scroll-up or scroll-down key until the desired data is displayed. Press the display alteration key to exit the menu item.

Display example [1 セイギョキバン↓] Option board name (1 セイギョバン: Analog output board) (2 ワイヤーケンシュツ: Wire rope movement detection board to indicate hook block position)

If “C” is displayed here, この部分に"C"が表示されている場合は現在 the error is present now. 発生中のエラーであることを示している Error code エラーコード This example shows error code この例はエラーコード2003 [ブームナガサイジョウ]を示す 2003 [ブームナガサイジョウ].

12. Ao Check

IW301-0251J08

The Ao (analog output) state is displayed with an

10. Erasing the Error Data

output value of the specified percentage.

1. Select the menu item [･ホシュ↓], and press the set key to confirm.

Use this menu item to erase the error information registered in the AML.

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

1. Select the menu item [･ホシュ↓], and press the set key to confirm.

menu item [：AO チェック↓] appears. Press the set key to select the menu item.

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

3. The state of Ao (analog output) is displayed. Press the scroll-up or scroll-down key until the desired data is displayed. Press the display alteration key to exit the menu item.

menu item [：エラーリレキショウキョ↓] appears.

Press the set key to select the menu item.

3. When [ショウキョ OK?] appears, erase the error data information by pressing the set key.

4. When the message [リレキヲショウキョシマシ タ] appears, the error data is now erased. Press the display alteration key to exit the menu item.

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

Display example (CNTL1P･CNTL1N) [41

センカイ RV 0 0↓]

The Sio (serial port) state is displayed.

Output level for checking indicates at what percentage of the maximum level the value is to be output.

1. Select the menu item [･ホシュ↓], and press the set key to confirm.

2. Press the scroll-up or scroll-down key until the menu item [：SIO チェック↓] appears. Press the set key to select the menu item.

Output level indicates at what percentage of the maximum level the value is being output.

3. The serial port state is displayed. Press the scroll-up or scroll-down key until the desired data is displayed. Press the display alteration key to exit the menu item.

Display example [シリアルポート 1 OK↓]

Output name Ao output terminal number 11-19: Output to serial port 1 (Signal transmitter) 21-29: Output to serial port 2 (MDT) 41-49: Output to option board (41: CNTL1P, CNTL1N) (42: CNTL2P, CNTL2N) (43: CNTL3P, CNTL3N) (44: CNTL4P, CNTL4N)

Serial port state OK : Normal NG : Abnormal NU : Not used Serial port name (Serial port 1: Serial communication circuit to signal transmitter) (Serial port 2: Serial communication circuit to MDT)

[NOTICE] Only the Ao used for output in the program can be displayed. Since the display sequence of Ao output states depends on the contents of the program, the Ao output states may not be indicated in the numerical order of Ao output numbers.

14. Adjust Monitor

4. How to set the output values for checking

The same items as shown in the [･チョウセイ↓] menu of the main menu of the adjustment mode appears. However, no adjustment is available.

With the Ao output state displayed, use the increase or decrease key to set up an output level for checking. Every time the key is pressed, the level is increased or decreased by 1%. When the key is held down for one second or longer, the level is increased by 10% for the increase key and decreased by 5% for the decrease key. When the level exceeds 100%, it returns to 0% (conversely, when the level reaches 0%, it returns to 100%.)

1. Select the menu item [･ホシュ↓], and press the set key to confirm.

2. Press the scroll-up or scroll-down key until the menu item [：チョウセイ モニタ↓] appears.

Press the set key to select the menu item.

3. The same items as shown in the [･チョウセイ↓] menu of the main menu of the adjustment mode appear. Press the display alteration key to exit the menu item.

5. How to output the output values for checking With the output level for checking indicated, press the inspection key; the output level for checking will be output while the key is held down. The displayed output value for checking flashes.

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Functions of and How to Use Maintenance Mode 15. Overload History Display The overload history display in the maintenance mode has the same functions as those in the adjustment mode. Refer to the "Overload History Display" in the "Functions of and How to Use Adjustment Mode" section.

16. Erasing the Overload History Erasing the overload history in the maintenance mode has the same functions as those in the adjustment mode. Refer to the "Erasing the Overload History" in the "Functions of and How to Use Adjustment Mode" section.

17. Clock Adjustment Clock adjustment is included in the functions of the maintenance mode. However, for how to adjust the clock, refer to the "Clock Adjustment" in the "Functions of and How to Use Adjustment Mode" section.

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W301-0251E

Error Message Error Message

maintenance mode, the corresponding error message appears on the moment display.

1. Display of Error Message

2. How to Read the Error Message

[NOTICE]

1. An error code in the error message is represented

The language (English or Japanese) of error message can be selected in the [⋅Language] menu of the adjustment mode.

When English is selected, only the error codes are displayed.

by four-digit codes.

Error code E1 E2 E3 E4 Individual code Group code

Displays error message. エラーメッセージを表示

0: Alarm 1: Abnormal communication 2: Abnormal detector 3: Abnormality inside the AML 2. The highest rank (E1 in the above figure) indicates an error group. The each next three digit figure (E2 through E4 above) indicates individual error code under the error group.

+ IW301-0151J09

1. If the program detects an abnormality in ordinary operation state (user mode), it generates beep sound as well as displays the error message on the moment display.

Display example [キフクヒズミセンサイジョウ↓] [(2001)]

3. Since the group code "0" indicates just an alarm condition, no error code is included in the error message. When the error message is displayed, it does not always mean that there is an abnormality in the system.

4. For this reason, no alarm-related error message is registered in the system's error data memory.

However, such an error message is displayed in the moment display as the messages for other group codes.

Shows that an error of error code 2001 has occurred.

2. This error message display continues until the cause is eliminated.

3. How to Read the Error History

3. While an operation in the adjustment or

1. Error data records up to 50 errors of the group codes 1, 2, and 3 only, in order of occurrence.

After 50th error is registered, the oldest one is erased every time a new one is registered.

maintenance mode is being made, only beep sound informs the operator of occurrence of an abnormality. The moment display, however, does not show the error message automatically. The present message remains displayed.

2. For reading the error history, refer to the "Error Data Display" in the "Functions of and How to Use Maintenance Mode" section.

4. To confirm the error message in this state, press the lift height limit key. While the key is pressed and held, the error message is shown on the moment display. (It may take some seconds for the display to show the error message.)

5. If the abnormality remains even when the user mode is resumed after exiting the adjustment or

88

W301-0251E

Error Message 4. Troubleshooting Table 4.1 Group Code 0 Error code

Message

Name

0001 0002 0003 0004

ミギマエ O/R チヂミ ミギウシロ O/R チヂミ ヒダリマエ O/R チヂミ ヒダリウシロ O/R チヂミ

Front right outrigger beam retraction Rear right outrigger beam retraction Front left outrigger beam retraction Rear left outrigger beam retraction

Status:

The outrigger extension width detection value decreases, close to the lifting capacity change over point. The machine does not stop automatically.

Cause: Action:

The outrigger slide is retracted.

Extend the outrigger slide again.

Error code

Message

Name

0005

ブームカクド ハンイガイ

Boom angle value becomes out of specified range.

Displayed only for the machines with side-up jib.

Status: Boom extension automatically stops during setting of the side-up jib.

Cause: Boom angle is smaller than that required for jib setting.

Action: Raise the boom until a safety angle for jib setting is secured.

Error code

Message

Name

0011

ジブピン ミソウニュウ

The jib pin has not been inserted.

Status:

Cause: Action:

The pin status of a jib is incorrect.

The machine automatically stops by an operation toward the critical side (boom extension) from this status.

Both the connecting and setting pins of the jib have been inserted.

The connecting pin of the jib has not been inserted.

Bring the jib pins to the normal state.

Error code

Message

Name

0013

ゼンポウスイッチイジョウ

Abnormal over-front detection switch

Status:

The swing position does not conform with the status detected by the over-front detection switch.

No automatic stop is made.

The over-front detection switch has detected "Front" when the boom does not face to the front.

(At this time, obtains the capacity with the over-front detection switch being "Not in Front.")

Cause:

Over-front detection switch is abnormal or its cable is open.

Swing angle detector is abnormal or incorrectly adjusted.

Investigate the possible causes described above.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

Action:

89

W301-0251E

Error Message Error code

Message

Name

0015

カマキ ジョウタイ デス

Overwinding condition (when the stop function by overwinding is canceled)

Displayed when an overwinding condition is detected when the stop function by overwinding is canceled.

Status: The overwinding detection switch has been turned OFF. The machine does not stop automatically though the error code is displayed when overwinding is canceled.

Cause: Main or auxiliary hook block has been hoisted up excessively.

Overwinding detection switch is abnormal or its cable is open.

Action: Hoist down the main or auxiliary winch.

Investigate the overwinding switch and its wiring.

Error code

Message

Name

0016 0017

セイノウ ガ アリマセン セイノウ ガ アリマセン

Crane is out of capacity 1.

Crane is out of capacity 2.

Status:

The crane is in out-of-capacity status.

The machine automatically stops by an operation toward the critical side from this status.

Cause: Action:

The set operation status is not achieved.

Set each operation status correctly.

Operate the crane to bring it to the operation status within capacity.

Error code

Message

Name

0018 0019

ゼンシュク SW1 イジョウ ゼンシュク SW2 イジョウ

Abnormal boom full retraction switch 1 Abnormal boom full retraction switch 2

Status:

Cause:

Action:

At a specific boom section, the boom is fully retracted, but the boom full retraction detection switch does not detect the "Fully retracted" status.

On the contrary, at a specific boom section, the boom is not fully retracted, but the boom full retraction detection switch detects the "Fully retracted" status.

The machine automatically stops by an operation toward the critical side from this status.

Boom full retraction detection switch is abnormal or its wiring is open.

Boom length detector is abnormal or incorrectly adjusted.

AML main unit is abnormal. (Analog board is faulty.)

Investigate the possible causes described above.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

Replace any faulty parts and adjust as necessary.

"0018" indicates the error of boom full retraction switch of TS-75M-1.

"0019" indicates the error of 3rd/TOP boom sections full retraction switch of GT-250C-1 and GT-350C-1.

90

W301-0251E

Error Message Error code

Message

Name

0022

ジブスイッチ 1 イジョウ

Abnormal jib full retraction detection switch

Status:

Cause: Action:

The jib is fully retracted, but the jib full retraction detection switch is OFF (detects the "Not fully retracted" status.)

On the contrary, the jib is not fully retracted, but the jib full retraction detection switch is ON (detects the "Fully retracted" status.)

The machine automatically stops by an operation toward the critical side from this status.

Jib full retraction detection switch is abnormal or its cable is open.

Jib length detector is abnormal or incorrectly adjusted.

Investigate the jib full retraction detection switch. ([Di Check] related item: [ジブカマキ]) Investigate the jib length detector. ([Ai Check] related item: [テレジブ L]) The input status from a detection switch and detector can be checked in [Di Check] or [Ai Check] of the "Maintenance" menu. The judgment result of [Di Check] is shown by "on" or "of," and that of [Ai Check] is shown by "ok" when it is completed successfully. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

Replace any faulty parts and adjust as necessary.

Error code

Message

Name

0023

100% デ テイシ！

Stop by 100%

Status:

The machine stops automatically due to an operation toward the critical side (winch hoisting-up, boom lowering, boom extension).

Cause: Action:

Out of capacity Operate the machine on the safe side (winch hoisting-down, boom raising, boom retraction).

Error code 0024 Status: Cause: Action:

Message

Name

カマキ デ テイシ！

Stop by overwinding

Overwinding detection switch is OFF. The machine automatically stops by an operation toward the critical side from this status.

Main or auxiliary hook block has been wound up excessively.

Overwinding detection switch is abnormal or its cable is open.

Hoist down the main or auxiliary winch.

Investigate the overwinding switch and its wiring.

Error code

Message

Name

0026

ブームカクド セイゲン！

Stop by upper boom angle limit

Status: Cause: Action:

The boom angle exceeds the upper limit.

The machine automatically stops by an operation toward the critical side from this status.

The upper boom angle limit function has been set and the boom angle exceeds the limit value.

Lower the boom.

Cancel the upper boom angle limit function.

91

W301-0251E

Error Message Error code

Message

Name

0027

ブームカクド セイゲン！

Stop by lower boom angle limit

Status: Cause: Action:

The boom angle exceeds the lower limit.

The machine automatically stops by an operation toward the critical side from this status.

The lower boom angle limit function has been set and the boom angle exceeds the limit value.

Raise the boom.

Cancel the lower boom angle limit function.

Error code

Message

Name

0028

ヨウテイセイゲンデテイシ！

Stop by upper lifting height limit

Status:

The top end of the boom exceeds the lifting height limit.

The machine automatically stops by an operation toward the critical side from this status.

Cause:

The lifting height limit function has been set and the top end of the boom exceeds the limit value.

Lower or retract the boom.

Cancel the lifting height limit function.

Action:

Error code 0029 Status: Cause: Action:

Message

Name

ハンケイセイゲンデテイシ！

Stop by load radius limit

The load radius is out of the limit area.

The machine automatically stops by an operation toward the critical side from this status.

The load radius limit function has been set and the load radius exceeds the limit value.

Raise or retract the boom.

Cancel the load radius limit function.

Error code

Message

Name

0037

アキュムレータアツ イジョウ

Accumulator pressure abnormality

Status: Cause:

Action:

The value detected by the accumulator hydraulic pressure detector is abnormal.

The machine does not stop automatically. (Not directly related to the AML control.)

The accumulator hydraulic pressure lowers.

Hydraulic pressure detector is abnormal or its cable is open.

AML main unit (analog board) is abnormal.

Investigate the possible causes described above.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. (Normal: "ok" is displayed.)

Replace any faulty parts, and adjust as necessary.

Error code

Message

Name

0042 0043

ミギ センカイ ゲンド！ ヒダリ センカイ ゲンド！

Right swing limit Left swing limit

Status:

The swing position is out of the limit area. If the machine has the automatic swing stop function, it automatically stops.

Cause: Action:

The swing area limit function has been set and the swing position exceeds the limit value.

Swing the boom away from the swing-limited side.

Cancel the swing area limit function.

92

W301-0251E

Error Message Error code

Message

Name

0044

ジブカクノウジョウタイ！

Jib is in retracted status.

Displayed only for the machines with the jib mounting status detected.

Status: The machine stops automatically due to an operation toward the critical side (jib telescoping/extension, jib tilt down).

Cause: An operation toward the critical side with the jib retracted may buckle the tension rod or bracket.

Action: Stop an operation toward the critical side.

Error code

Message

Name

0046

ジョウタイヲ サイセッテイ！

Condition setting altered

Status:

The crane state has changed. The machine does not stop automatically.

Cause: Action:

Outrigger jack has been retracted. (Unexpected outrigger jack retraction movement) Set the operation status again.

Error code

Message

Name

0056

センカイ ソウサ ハ キケン！

The swing operation is dangerous.

Status:

Cause: Action:

An additional swing will make out-of-capacity status. The machine does not stop automatically.

(Displayed only during a left or right swing operation.)

The machine with the swing slow stop function displays only when the swing slow stop function is canceled. (At this time, displayed only during the swing angle change.)

The boom has been swung to a point just close to the limited capacity range, due to the outrigger extension width.

Swing to an opposite direction.

Retract or raise the boom to bring it within the capacity range.

Error code

Message

Name

0057 0058 0059 0060

ミギマエ O/R ヘンカ ミギウシロ O/R ヘンカ ヒダリマエ O/R ヘンカ ヒダリウシロ O/R ヘンカ

Front right outrigger status change Rear right outrigger status change Front left outrigger status change Rear left outrigger status change

Status: Cause: Action:

The outrigger status has changed and the capacity decreases to a smaller outrigger extension width. The machine does not stop automatically.

The outrigger extension width decreases unintentionally.

If a reduced capacity does not matter, continue to use the machine without change.

If an out-of-capacity status is expected, re-extend the outrigger further and register the working area again.

Error code

Message

Name

0062

ブームカクド オーバー！

Boom angle is exceeded.

Status:

The machine stops automatically by an operation toward the critical side (boom raising).

Cause:

With the jib stowing pin detached and the pivot pin (a pin at the left) among the jib connecting pins only inserted, the boom is over raised.

Operate in the safe side (boom lowering).

Insert the jib stowing pin. Insert the jib connecting pins at the left and right (both the pivot pin and connecting pin).

Action:

93

W301-0251E

Error Message Error code

Message

Name

0067 0113

モーメント イジョウ モーメント イジョウ

Abnormal moment [Distortion detection type] Does not stop.

Abnormal moment [Hydraulic pressure detection type] Cannot operate toward the critical side.

This alarm is triggered when the actual load value calculated inside the AML shows a negative value.

Abnormal negative load value range varies depending on the boom status.

Status:

Cause:

Action:

The actual load value calculated inside the AML shows a negative value due to abnormal moment detector. Therefore, re-adjustment of the detector is required. (Error code 0067: The alarm is triggered without automatic stop, error code 0113: The machine stopped by an operation toward the critical side.)

Detector is abnormal. (Abnormal boom length detector, boom angle detector, moment detector, or elevating cylinder pressure detector) Detector is incorrectly adjusted.

AML main unit is abnormal. (Analog board is faulty.)

The moment value cannot be detected correctly because the elevating cylinder has retracted to the boom lowering stroke end. (In case of error code 0113) Readjust the corresponding detector. Investigate the detector which seems to be faulty.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu or "Elevation Cylinder Oil Pressure Monitor." In "Ai Check," if it is normal, "ok" is displayed. ([Ai Check] related items: [ブーム L], [ブームカク], [モーメント V], [キフクノビ], [キ フクチヂミ], etc.)

For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

Raise the boom. (In case of error code 0113)

Error code

Message

Name

0068

センカイカクド イジョウ

Abnormal swing angle

Status:

The difference in the detected values between two swing angle detectors is out of the tolerance.

(The alarm is triggered without stop. For error codes 2016 through 2019, and 2021, the machine stops.)

Cause:

Detector is abnormal. (Swing angle detector) Detector is incorrectly adjusted.

AML main unit (analog board) is faulty.

The AML continuously checks the detected values of the swing angle. The AML judges that the tolerance is exceeded during the check operation.

Readjust the corresponding detector.

Investigate the swing angle detector.

Action:

Error code 0069 Status: Cause:

Action:

Message

Name

ブームナガサイジョウ

Abnormal boom length

The detected value of the boom length exceeds the upper or lower limit of the tolerance.

(The alarm is triggered without stop. For error codes 2007 and 2008, the machine stops.)

Detector is abnormal. (Boom length detector) Detector is incorrectly adjusted.

AML main unit (analog board) is faulty.

The AML continuously checks the detected values of the boom length. The AML judges that the upper or lower limit of the tolerance is exceeded during the check operation.

Readjust the corresponding detector.

Investigate the boom length detector.

94

W301-0251E

Error Message Error code

Message

Name

0070

ブームカクドイジョウ

Abnormal boom angle

Status: Cause:

Action:

The detected value of the boom angle exceeds the upper or lower limit of the tolerance.

(The alarm is triggered without stop. For error codes 2004, the machine stops.)

Detector is abnormal. (Boom length/angle detector) Detector is incorrectly adjusted.

AML main unit (analog board) is faulty.

The AML continuously checks the detected values of the boom angle. The AML judges that the upper or lower limit of the tolerance is exceeded during the check operation.

Readjust the corresponding detector.

Investigate the boom angle detector.

Error code

Message

Name

0071 0072 0073 0074

ミギマエ O/R イジョウ ミギウシロ O/R イジョウ ヒダリマエ O/R イジョウ ヒダリウシロ O/R イジョウ

Abnormal extension width of the front right outrigger Abnormal extension width of the rear right outrigger Abnormal extension width of the front left outrigger Abnormal extension width of the rear left outrigger

Status:

The detected value of the outrigger width exceeds the upper or lower limit of the tolerance.

(The alarm is triggered without stop. For error codes 2009 through 2012, the machine stops.)

Cause:

Detector is abnormal. (Outrigger extension width detector) Detector is incorrectly adjusted.

MDT (Multiplex Data Transmitter) main unit is faulty.

The AML continuously checks the detected values of the outrigger width. The AML judges that the upper or lower limit of the tolerance is exceeded during the check operation.

Readjust the corresponding detector.

Investigate the corresponding detector.

Action:

Error code

Message

Name

0085

キフク ストロークエンドデス

Elevation stopped at stroke end

Displayed only for [Hydraulic pressure detection type].

Status: The boom reaches the upper stroke end. (The boom has been elevated to the available limit.)

The machine automatically stops because an operation toward the critical side is attempted in this situation.

Cause: When the moment is detected in the hydraulic pressure in the elevating cylinder, the correct moment cannot be detected if the boom elevating cylinder reaches the stroke end.

Therefore, the automatic stop function intervenes in the boom elevating operation just before the boom elevating cylinder reaches the stroke end.

Action: Stop the operation which has caused the stop.

Operate the boom in the opposite direction which has caused the stop.

95

W301-0251E

Error Message Error code

Message

Name

0088

ジブツキ ゲンカイ テイシ

Stopped at jib limit

Displayed only for the machines with the jib mounting status detected.

Status: The crane automatically stops because an operation toward the critical side (winch hoisting-up, boom lowering, boom extension) is attempted when the moment has exceeded the specified value.

Cause: The moment load factor during the boom lift with the jib mounted exceeds the specified limit.

(The actual capacity varies depending on various conditions such as the outrigger extension width.)

Action: Operate the machine on the safe side (winch hoisting-down, boom raising, boom retraction).

Error code

Message

Name

0090

フックイン キンシ リョウイキ！

Hook-in prohibited area

Status:

No hook-in operation is possible. (Stops due to overwinding.)

Cause: Action:

If a hook-in is attempted, the hook block and boom lower part may contact.

Hoist down the main or auxiliary winch.

Adjust the boom status so that a hook-in operation is possible.

(Note): For the oversea models of GT-250C-1 and GT-350C-1, no error massage is displayed.

Only error code is displayed.

96

W301-0251E

Error Message 4.2 Group Code 1 Error code

Message

Name

1001 1002

トランスミッタ 1 イジョウ トランスミッタ 2 イジョウ

Serial port 1 transmission line open Serial port 2 transmission line open

Status:

The transmitter cannot receive any signals from the AML at all.

Therefore, all operations except boom swing are unavailable.

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 the transmitter or the transmitting circuit of the AML is faulty.

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

Replace the transmitter or AML power board.

Action:

Error code

Message

Name

1003 1004

トランスミッタ 1 イジョウ トランスミッタ 2 イジョウ

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

Status: Cause:

Action:

The signals from the transmitter cannot be received at all.

Therefore, all operations except boom swing are unavailable.

A part of wiring from the transmitter is open or in poor contact.

No transmitter is connected. (The connector is disconnected.)

The receiving circuit of the AML or the transmitting circuit of the transmitter is faulty.

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

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

Replace the transmitter or AML power board.

Replace the serial port fuse of the AML.

Error code

Message

Name

1005 1006

トランスミッタ 1 イジョウ トランスミッタ 2 イジョウ

Abnormal transmitter 1 Abnormal transmitter 2

Status: Cause: Action:

An abnormality is detected in the transmitter.

Therefore, all operations except boom swing are unavailable.

The internal circuit of the transmitter is abnormal.

Replace the transmitter.

Error code

Message

Name

1007 1008 1009 1010

トランスミッタ 1 イジョウ トランスミッタ 2 イジョウ トランスミッタ 1 イジョウ トランスミッタ 2 イジョウ

Serial port 1 transmitting data error Serial port 2 transmitting data error Serial port 1 receiving data error Serial port 2 receiving data error

Status:

The data transmitted (received) by the AML and that received (transmitted) by the transmitter are different.

Therefore, all operations except boom swing are unavailable.

Cause:

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

The signal wire connection is in poor contact.

Turn off any device which is emitting strong noise.

Check the signal line for poor contact. Repair or replace the wiring.

Action:

97

W301-0251E

Error Message

Error code

Message

Name

1011 1012

トランスミッタ 1 イジョウ トランスミッタ 2 イジョウ

Transmitter 1 type improper Transmitter 2 type improper

Status: Action:

A wrong transmitter is connected to the serial port.

Therefore, all operations except boom swing are unavailable.

Connect the correct transmitter to the serial port.

(Note): For the oversea models of GT-250C-1 and GT-350C-1, no error massage is displayed.

Only error code is displayed.

98

W301-0251E

Error Message 4.3 Group Code 2 Error code

Message

Name

2001

キフクヒズミセンサイジョウ

Abnormal moment detector

Status:

The input values detected by the moment detector are abnormal.

Therefore, all operations except boom swing are unavailable.

Cause:

Moment detector is abnormal or its cable is open.

The moment is not adjusted correctly by the AML. AML main unit is abnormal. (Analog board is faulty.)

Investigate the possible causes described above.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

Replace any faulty parts and adjust as necessary.

Action:

Error code

Message

Name

2003

ブームナガサイジョウ

Abnormal boom length detector

Status: Cause: Action:

The input values from the boom length detector are abnormal.

Therefore, all operations except boom swing are unavailable.

Boom length detector is abnormal or its cable is open.

AML main unit is abnormal. (Analog board is faulty.)

Investigate the possible causes described above.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

Replace any faulty parts and adjust as necessary.

Error code

Message

Name

2004

ブームカクド イジョウ

Abnormal boom angle detector

Status: Cause: Action:

The input values from the boom angle detector are abnormal.

Therefore, all operations except boom swing are unavailable.

Boom angle detector is abnormal or its cable is open.

AML main unit is abnormal. (Analog board is faulty.)

Investigate the possible causes described above.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

Replace any faulty parts and adjust as necessary.

99

W301-0251E

Error Message Error code

Message

Name

2005

ジブナガサ イジョウ

Abnormal jib length detector

Status: Cause: Action:

The input values from the jib length detector are abnormal.

Therefore, all operations except boom swing are unavailable.

Jib length detector is abnormal or its cable is open.

Transmitter unit is abnormal.

Investigate the possible causes described above.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

Replace any faulty parts and adjust as necessary.

Error code

Message

Name

2006

ジブカクド イジョウ

Abnormal jib angle detector

Status:

The input values from the jib angle detector are abnormal.

Therefore, all operations except boom swing are unavailable.

Cause:

Jib angle detector is abnormal or its cable is open.

Transmitter unit is abnormal.

Investigate the possible causes described above.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

Replace any faulty parts and adjust as necessary.

Action:

Error code

Message

Name

2009 2010 2011 2012

ミギマエ O/R イジョウ ミギウシロ O/R イジョウ ヒダリマエ O/R イジョウ ヒダリウシロ O/R イジョウ

Abnormal front right O/R length detector Abnormal rear right O/R length detector Abnormal front left O/R length detector Abnormal rear left O/R length detector

Status: Cause:

Action:

The input values from the outrigger length detector are abnormal. The machine does not stop automatically.

Outrigger length detector is abnormal or its cable is open.

Outrigger length detector of the AML has not been adjusted correctly.

Transmitter unit is abnormal.

Investigate the possible causes described above.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

Replace any faulty parts and adjust as necessary.

100

W301-0251E

Error Message Error code

Message

Name

2017 2019

センカイカクド イジョウ センカイカクド イジョウ

Abnormal swing angle detector 1 (swing dead angle switch OFF) Abnormal swing angle detector 2 (swing dead angle switch ON)

Status:

Cause:

Action:

The relation between the input values from the swing angle detector and swing dead angle detection switch is abnormal.

Therefore, all operations except boom swing are unavailable.

Swing angle detector is abnormal or incorrectly adjusted, or its cable is open.

Swing dead angle detection switch is abnormal or incorrectly adjusted, or its cable is open.

AML main unit is abnormal. (Analog board is faulty.)

Investigate the possible causes described above.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

The input status from the detection switch can be checked in "Di Check" item of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.")

Replace any faulty parts, and adjust as necessary.

Error code

Message

Name

2021

センカイカクド イジョウ

Abnormal swing angle detector

Status:

The offset of the swing angle detectors 1 or 2 is abnormal.

Therefore, all operations except boom swing are unavailable.

Cause:

The swing angle detectors 1 or 2 is wrongly mounted or incorrectly adjusted.

AML main unit is abnormal. (Analog board is faulty.)

Investigate the possible causes described above.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

Replace any faulty parts and adjust as necessary.

Action:

Error code

Message

Name

2022 2023

キフクノビアツ イジョウ キフクチヂミアツ イジョウ

Abnormal boom elevating cylinder extension pressure detector Abnormal boom elevating cylinder retraction pressure detector

Status:

Cause: Action:

The input values from the hydraulic pressure detector in the boom elevating cylinder's extension (retraction) chamber are abnormal.

Therefore, all operations except boom swing are unavailable.

Hydraulic pressure detector is abnormal or its cable is open.

AML main unit is abnormal.

Investigate the possible causes described above.

The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. ([Ai Check] related item: [キフクノビ], [キフクチヂミ]) If it is normal, "ok" is displayed.

For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section.

Replace any faulty parts and adjust as necessary.

(Note): For the oversea models of GT-250C-1 and GT-350C-1, no error massage is displayed.

Only error code is displayed.

101

W301-0251E

Error Message 4.4 Group Code 3 Error code

Message

Name

3003

システムイジョウ(3003)

System error (sum check error)

Status:

An error is found in ROM as a result of sum check.

Therefore, all operations except boom swing are unavailable.

Cause:

AML main unit is abnormal. (CPU board is faulty.)

ROM is abnormal.

Replace the AML main unit. (Replace the CPU board.)

Replace ROM.

Action:

Error code

Message

Name

3006

システムイジョウ(3006)

System error (EEPROM error)

Status: Cause: Action:

AML cannot write on its nonvolatile memory (EEPROM).

Therefore, all operations except boom swing are unavailable.

AML main unit is abnormal (CPU board is abnormal) or EEPROM is abnormal.

Replace the AML main unit (replace the CPU board) or replace EEPROM.

Error code

Message

Name

3007 3008 3009 3011 3012 3013 3017

システムイジョウ(3007) システムイジョウ(3008) システムイジョウ(3009) システムイジョウ(3011) システムイジョウ(3012) システムイジョウ(3013) システムイジョウ(3017)

System error (RAM error) System error (RAM error) System error (CPU error) System error (bus error) System error (address error) System error (unauthorized command) System error (privilege violation)

Status: Cause: Action:

The software program cannot run normally.

Therefore, all operations except boom swing are unavailable.

AML main unit is abnormal. (Abnormal CPU circuit board) Replace the AML main unit. (Replace the 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 light.)

When such a state occurs, the cause may exist in the AML itself. At first, check for an abnormality such as loose connector within the AML unit.

Error code

Message

Name

3010

システムイジョウ(3010)

System error (A/D converter error)

Status:

The input status of the A/D converter is abnormal.

Therefore, all operations except boom swing are unavailable.

Cause: Action:

AML main unit is abnormal. (CPU board or analog board is faulty.)

Replace the AML main unit. (Replace the CPU board or analog board.)

(Note): For the oversea models of GT-250C-1 and GT-350C-1, no error massage is displayed.

Only error code is displayed.

102

W301-0251E

Disassembly of AML Main Unit Disassembly of AML Main Unit 1. Removing Front Panel/Display Board

2. Removing Rear Panel/Connector Board [NOTICE] Do not touch each front and rear face of the boards by hand when removing the boards.

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

1. Remove the screws (c) and take off the rear panel and connector board as an assembly from the main unit case.

1. Remove the screws (a) and take off the front panel and display board as an assembly from the main unit case.

Connector board コネクタ基板

Front panel Display panel 表示基板 前面パネル Main unit case a 本体ケース

Rear panel 後面パネル c

Main unit case 本体ケース

IW301-0252J07 IW301-0252J10

2. Remove the spacers (e) and separate the connector board.

2. Remove the screws (b) and separate the display board.

コネクタ基板 Connector board

e

IW301-0252J08

b 表示基板 Display board IW301-0151J20

103

W301-0251E

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

3.1 Notes on ROM/EEPROM Replacement [NOTICE] EEPROM stores the adjustment values for each specification number. When replacing the CPU board, remove the EEPROM from the broken CPU board and reuse it.

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

1. Remove the screws (a) and take off the front

When replacing ROM or EEPROM, make sure that the concavities of the IC and socket meet each other.

panel and display board as an assembly from the main unit case. Remove the screws (c) and take off the rear panel and connector board as an assembly from the main unit case. コネクタ基板 Connector board

c

Rear panel 後面パネル Calendar/clock カレンダ／時計

電池 Batteries CN1

EEPROM CN4 PLD

ROM 1 CPU

ROM 0

CN2

a

Main unit case 本体ケース 表示基板 前面パネル Front panel Display board IW301-0252J09

CN3

2. Remove the screws (f) and separate the CPU

CPU board CPU基板

board. Then, remove the spacers (h) and take off the analog board and power board as an assembly from the main unit case. Remove the nuts (g) and separate the analog board.

Analog board アナログ基板

Power board 電源基板

IW301-0151J25

Main unit case 本体ケース

h g

f CPU基板 CPU board IW301-0151J24

104

W301-0251E

INFORMATION AND DATA (TS-75M-1) INFORMATION AND DATA (TS-75M-1) AML model: AML-LIID AML code No.: 361-919-50100

1. Setting before adjustment Capacity setting Head-off capacity setting

Jib selection

Single top selection

Winch drum position setting

Not set

Not set

Not set

Not set

2. Detector adjustment Precautions for adjustment (*1) Adjust the center of dispersion to coincide with the adjustment value. (*2) Adjust the boom angle and the moment in the boom lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) Before adjusting the moment, set the number of part lines to the standard number (four parts of line) for fully-extended boom, and set the boom status in the AML setting to "Boom."

Adjustment condition

Adjustment value

Tolerance

Zero-point adjustment

Boom length: Fully retracted

6.6 m

±0.04 m (±0.08 m for zero-point check)

Span adjustment

Boom length: Fully extended

21.3 m

±0.04 m

Zero-point adjustment

Boom angle: 0° (actual value)

0°

Adjustment item

Boom length

Boom angle (*2)

Span adjustment Zero-point adjustment

Moment (*2)(*4)

Preliminary span adjustment

Load radius adjustment

±0.1° (±0.2° for zero-point check)

Boom angle: 78° (actual 78° ±0.1° value) Boom length: Fully retracted 0.05 t Boom angle: 78±0.1° (indicated Hook block mass value) minus Load: Without load Wire rope mass Hook block: Overwound Boom length: Fully retracted Boom angle: 10±0.1° (indicated 0.07 t value) (Hook block mass) Load: Without load Hook block: Hoisted down close to the ground surface.

Boom length: Fully extended Load radius: 5 m (actual value) Rated lifting capacity: 2 t 5m

105

W301-0251E

±0.03 t

±0.01 t

±0.04 m

INFORMATION AND DATA (TS-75M-1)

Moment (*2)(*4)

Span fine adjustment

Boom length: Fully extended Boom angle: 10±0.1° (indicated value) Load: Without load Hook block: Hoisted down close to the ground surface.

0.07 t (Hook block mass)

3. Setting after adjustment - Setting of number of part lines: Not set - Language variation: Not set

106

W301-0251E

±0.01 t

INFORMATION AND DATA (GT-250C-1) INFORMATION AND DATA (GT-250C-1)

1 : From JA0034 △

Applicable Serial No.

AML model: AML-LIID AML code No.: 361-923-60000

1. Setting before adjustment Capacity setting Head-off capacity setting

Jib selection

Single top selection

Winch drum position setting

Not set

Not set

Not set

Not set

2. Detector adjustment Precautions for adjustment (*1) Adjust the center of dispersion to coincide with the adjustment value. (*2) Adjust the boom angle and the moment in the boom lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) Before adjusting the moment, set the number of part lines to the standard number (four parts of line) for fully-extended boom, and set the boom status to "Boom" and the number of part lines to "Four parts of line" in the AML setting.

Adjustment item

Boom length

Boom angle (*2)

Adjustment condition

Tolerance

Zero-point adjustment

Boom length: Fully retracted

10 m

±0.04 m (±0.08 m for zero-point check)

Span adjustment

Boom length: Fully extended

32.2 m

±0.04 m

Zero-point adjustment

Boom angle: 0° (actual value)

0°

±0.1° (±0.2° for zero-point check)

Span adjustment

Boom angle: 80° (actual value)

80°

±0.1°

Zero-point adjustment

Swing position: Front (right swing)

Span adjustment

Swing position: Rear (right swing)

Swing angle (*3)

Moment (A hook block with 25 t capacity is to be used.) (*2)(*4)

Adjustment value

Zero-point adjustment

±0.3° Swing angle 1: 0° (±0.6° for zero-point check) Swing angle 2: 360° Swing angle 1: 180° Swing angle 2: 180°

Boom length: Fully retracted Boom angle: 80±0.1° (indicated value) Load: Without load (0.25 t hook block only) Hook block: Overwound 1 0.27 t

107

W301-0251E

±0.3° (±0.6° for zero-point check) ±0.3° ±0.3°

1 0.22 t

0.20 t (Hook block mass minus Wire rope mass)

±0.12

INFORMATION AND DATA (GT-250C-1)

Moment (A hook block with 25 t capacity is to be used.) (*2)(*4)

Load radius adjustment

Span fine adjustment

Boom length: Fully extended Load radius: 7 m (actual value) Rated lifting capacity: 6.50 t Boom length: Fully extended Boom angle: 25±0.1° (indicated value) Load: Without load (0.25 t 1 0.27 t hook block only) Hook block: Hoisted down close to the ground surface.

3. Setting after adjustment - Setting of number of part lines: Not set - Language variation: English

108

W301-0251E

7m

1 0.27 t

0.25 t (Hook block mass)

±0.05 m

±0.01 t

INFORMATION AND DATA (GT-350C-1) INFORMATION AND DATA (GT-350C-1) AML model: AML-LIID AML code No.: 361-925-10000

1. Setting before adjustment Capacity setting Head-off capacity setting

Jib selection

Single top selection

Winch drum position setting

Not set

Not set

Not set

Not set

2. Detector adjustment Precautions for adjustment (*1) Adjust the center of dispersion to coincide with the adjustment value. (*2) Adjust the boom angle and the moment in the boom lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) Before adjusting the moment, set the number of part lines to the standard number (four parts of line) for fully-extended boom, and set the boom status to "Boom" and the number of part lines to "Four parts of line" in the AML setting.

Adjustment item Boom length

Boom angle (*2)

Adjustment condition

Adjustment value

Zero-point adjustment

Boom length: Fully retracted

10.6 m

Span adjustment

Boom length: Fully extended

34.0 m

Zero-point adjustment

Boom angle:0° (actual value)

0°

±0.1° (±0.2° for zero-point check)

Span adjustment

Boom angle: 80° (actual value)

80°

±0.1°

Swing angle 1: 0° Swing angle (*3)

Zero-point adjustment

Swing position: Front (right swing) Swing angle 2: 360°

Span adjustment

Moment (A hook block with 35 t capacity is to be used.) (*2)(*4)

Tolerance ±0.04 m (±0.08 m for zero-point check)

Zero-point adjustment

Load radius adjustment

±0.04 m

±0.3° (±0.6° for zero-point check) ±0.3° (±0.6° for zero-point check) ±0.3° ±0.3°

Swing position: Rear Swing angle 1: 180° (right swing) Swing angle 2: 180° Boom length: Fully retracted 0.34 t Boom angle: 80±0.1° (Hook block mass (indicated value) minus Load: Without load (0.39 t hook Wire rope mass) block only) Hook block: Overwound Boom length: Fully extended Load radius: 8 m (actual value) 8m Rated lifting capacity: 9.00 t

109

W301-0251E

±0.14

±0.05 m

INFORMATION AND DATA (GT-350C-1) Moment (A hook block with 35 t capacity is to be used.) (*2)(*4)

Span fine adjustment

Boom length: Fully extended Boom angle: 25±0.1° (indicated value) Load: Without load (0.39 t hook block only) Hook block: Hoisted down close to the ground surface

0.39 t (Hook block mass)

3. Setting after adjustment - Setting of number of part lines: Not set - Language variation: English

110

W301-0251E

±0.01 t

Checking the Detectors (TS-75M-1) Checking the Detectors (TS-75M-1)

2. Boom Angle Detector 1. Retract the boom fully, set the boom angle to 0°,

1. Boom Length Detector

and set the PTO switch to "OFF."

1. Retract the boom fully, set the boom angle to 0°,

2. Measure the resistance of the potentiometer.

and set the PTO switch to "OFF."

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D: 833±167 Ω A-D: 146±29 Ω

2. Measure the resistance of the potentiometer.

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D: 833±167 Ω B-D: 698±140 Ω

ブーム角度検出器 Boom angle detector

Boom angle detector ブーム角度検出器

A

E

A

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

D C

ANAINA 3 DET1GND 1

E

DET1SRC 2

C

ANAINB 4

A

ANAINA 3 DET1GND 1

B D

E

B

D C

B

DET1SLD 6

Boom length detector ブーム長さ検出器

B D

IW301-0151J10

Boom length detector ブーム長さ検出器

Checking at the CN1 connector of the AML

IW301-0151J10

Pull out the connector of the swing angle detector.

Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 833±167 Ω 4-1: 146±29 Ω

Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector.

Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 833±167 Ω 3-1: 698±140 Ω

Boom angle detector ブーム角度検出器

Boom angle detector ブーム角度検出器

45

16

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

ANAINA 3 DET1GND 1 30

1

45

30

B D

16

1

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

ANAINA 3 DET1GND 1

B D Boom length detector ブーム長さ検出器 IW301-0151J33

Boom length detector ブーム長さ検出器 IW301-0151J33

111

W301-0251E

Checking the Detectors (TS-75M-1) 3. Pressure Sensor for Moment Detection 1. Set the PTO switch to "ON." (5-V DC will be applied between R and B of the pressure sensor connector.)

2. Measure the output voltage between W and B of the pressure sensor connector.

W

B

R

DET3SRC 33

R

ANAING 34

W

DET3GND 32

B

(ANAINH 35)

SPS3

(SPS4)

IW301-0131E14

3. The output voltage between W and B is

Output出力電圧（V voltage (V DC) DC）

proportional to the pressure in the elevating cylinder. The specified value is as shown below.

4.5

0.5 0

35 Pressure 圧力（MPa）

IW301-0151J15

112

W301-0251E

Checking the Detectors (GT-250C-1) Checking the Detectors (GT-250C-1)

Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector.

Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows:

1. Boom Length Detector 1. Retract the boom fully, set the boom angle to 0°, and set the PTO switch to "OFF."

Resistance value

2-1: 833±167 Ω 3-1: 477±95 Ω

2. Measure the resistance of the potentiometer.

Boom angle detector

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: Applicable serial No.

Up to JA0217

Resistance value

C-D: 833±167 Ω B-D: 477±95 Ω

Boom length detector

ブーム角度検出器 Boom angle detector

A

E

B

D C

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

ANAINA 3 DET1GND 1

B D Boom length detector ブーム長さ検出器 IW301-0151J10

Applicable serial No.

From JA0218

Resistance value

R-G: 833±167 Ω W-G: 477±95 Ω Boom angle detector Shield

Plug Shield

Boom length detector

113

W301-0251E

Checking the Detectors (GT-250C-1) 2. Boom Angle Detector

Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector.

Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows:

1. Retract the boom fully, set the boom angle to 0°, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer.

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: Applicable serial No.

Up to JA0217

Resistance value

C-D: 833±167 Ω A-D: 146±29 Ω

Resistance value

2-1: 833±167 Ω 4-1: 146±29 Ω Boom angle detector

ブーム角度検出器 Boom angle detector

A

E

B

D C

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

ANAINA 3 DET1GND 1

B D

Boom length detector

Boom length detector ブーム長さ検出器 IW301-0151J10

Applicable serial No.

From JA0218

Resistance value

R-G: 833±167 Ω B-G: 146±29 Ω Boom angle detector Shield

Plug Shield

Boom length detector

114

W301-0251E

Checking the Detectors (GT-250C-1) 3. Swing Angle Detector 1. Swing the boom to front and set the PTO switch to

4. Pressure Sensor for Moment Detection

"OFF."

1. Set the PTO switch to "ON." (5-V DC will be applied between R and B of the pressure sensor connector.)

2. Measure the resistance of the potentiometer.

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 500±75 Ω W-B: 224.2±34 Ω G-B: 473.9±71 Ω

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

Shield シールド

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B

3. The output voltage between W and B is proportional to the pressure in the elevating cylinder. The specified value is as shown below.

IW301-0152J02

Checking at the CN1 connector of the AML Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 500±75 Ω 5-1: 224.2±34 Ω 9-1: 473.9±71 Ω

45

30

16

DET1SLD 6

Output出力電圧（V voltage (V DC) DC）

DET1SLD 6

4.5

0.5 0

シールド Shield

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B

1 IW301-0151J34

115

W301-0251E

35 Pressure 圧力（MPa）

IW301-0151J15

Checking the Detectors (GT-350C-1) Checking the Detectors (GT-350C-1)

2. Boom Angle Detector 1. Retract the boom fully, set the boom angle to 0°, and set the PTO switch to "OFF."

1. Boom Length Detector

2. Measure the resistance of the potentiometer.

1. Retract the boom fully, set the boom angle to 0°, and set the PTO switch to "OFF."

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-G: 833±167 Ω B-G: 146±29 Ω

2. Measure the resistance of the potentiometer.

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-G: 833±167 Ω W-G: 412±83Ω

Boom angle detector Shield

Plug

Boom Boomangle angledetector detector

Shield

Shield Shield

Plug Plug

Boom length detector

Shield Shield

Checking at the CN1 connector of the AML Boom Boomlength lengthdetector detector

Pull out the connector of the swing angle detector.

Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 833±167 Ω 4-1: 146±29 Ω

Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector.

Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 833±167 Ω 3-1: 412±83Ω

Boom angle detector

Boom angle detector

Boom length detector

Boom length detector

116

W301-0251E

Checking the Detectors (GT-350C-1) 3. Swing Angle Detector 1. Swing the boom to front and set the PTO switch to

4. Pressure Sensor for Moment Detection

"OFF."

1. Set the PTO switch to "ON." (5-V DC will be applied between R and B of the pressure sensor connector.)

2. Measure the resistance of the potentiometer.

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 500±75 Ω W-B: 224.2±34 Ω G-B: 473.9±71 Ω Shield シールド

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B

the pressure sensor connector.

W

30

シールド Shield

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B

ANAING 34

W

DET3GND 32

B

(ANAINH 35)

SPS3

(SPS4)

proportional to the pressure in the elevating cylinder. The specified value is as shown below.

Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 500±75 Ω 5-1: 224.2±34 Ω 9-1: 473.9±71 Ω

DET1SLD 6

R

3. The output voltage between W and B is

Checking at the CN1 connector of the AML

16

R

DET3SRC 33

IW301-0131E14

IW301-0152J02

45

B

Output出力電圧（V voltage (V DC) DC）

DET1SLD 6

2. Measure the output voltage between W and B of

4.5

0.5 0

1 IW301-0151J34

117

W301-0251E

35 Pressure 圧力（MPa）

IW301-0151J15

Fuse Fuse

MAIN fuse (3A) AML main fuse for whole unit.

RLY1, 2 fuse (3A) Common, with relay output 1 and 2.

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.

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

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

118

W301-0251E

Replacing Clock Battery Replacing Clock Battery [NOTICE]  When the built-in clock battery is worn out, the adjustment values, error codes, and driving history cannot be backed up (saving data at power OFF).

Also, when the error code or driving history is recorded in the AML, an accurate date and time cannot be recorded.

3. Set new batteries on the CPU board by pressing The built-in clock battery life is usually about 10

them diagonally. (Refer to the figure below.)

The battery positive side must face upward.

years.

If the built-in clock batteries are worn out, replace them according to the following procedure.

Lithium battery (PANASONIC BR1225)

1. In the Case of CPU Board Employing BR1225 Battery 1. Remove the CPU board from the AML main unit.

2. Remove the battery from the battery holder on CPU board by pressing the battery diagonally.  Two built-in clock batteries are on CPU board of the AML main unit.

Ensure to replace both 2 pieces at once.

4. Install the CPU board in the AML main unit.

5. Reconnect the connector to the board.

2. In the Case of CPU Board Employing CR2032 Battery [NOTICE]  One built-in clock battery is on CPU board of the AML main unit.

[NOTICE]  When removing the battery, remove while holding the battery upper (positive) side because the battery may pop up.

119

W301-0251E

Head Office

Ko-34,Sinden-cho, Takamatsu, Japan

Overseas Service Group Tadano Ryogoku Bldg.

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

History of revision 1 2 3 4 5

TADANO LTD.

ｃ2008 ◯

PRINTED IN JAPAN 0812

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