Tadano Faun AML-LIID Overload Prevention Device Service Manual W301-0351E - PDF DOWNLOAD

Publication No.

W301-0351E

Service Manual (AML-L D)

01 Overload Prevention Device Model

PRINTED IN JAPAN 0703

E

W301-0351E

ｃ ◯2007

AML-L D

Foreword Foreword This service manual covers the Overload Prevention device (AML) installed on the TADANO cranes in the chart below.

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

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

1. Applicable spec. No. / Crane model 2007.3.

Applicable crane model TL-300E-3 Specification numbers: (1) TL-300E-3-00107 Use this manual for machines with the AML-L D even if the crane model is other than the above.

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

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W301-0351E

Foreword 2. Contents

2. Mode Structure and Menu ...............................33 3. Method of Shifting Modes................................35 4. Method of Menu Selection...............................36

Foreword .................................................. 1 1. Applicable spec. No. / Crane model.................. 1 2. Contents............................................................ 2

Required Adjustment After AML System Parts Replacement ................37

Components of the AML (AML-L D) Main Unit .................................. 4

Functions of and How to Use Adjustment Mode...................38

1. Panel ............................................................. 4 2. Internal view and name plate ............................ 5 3. Internal block diagram....................................... 6

Adjustment Procedures .................................. 38 1. Adjustment Initialization...................................39 1.1 Procedure of Conversion Factors Resetting................................39 1.2 Procedures of Moment Adjustment Resetting..........................39 2. Capacity Setting...............................................40 2.1 Procedure of Head-off Capacity Setting ...40 2.2 Procedure of Jib Selection ........................41 2.3 Procedure of Single Top Selection............41 2.4 Procedure of Winch Drum Posirion Setting...................................42 3. Boom Length Adjustment ................................43 4. Boom Angle Adjustment ..................................44 5. Swing Angle Adjustment ..................................45 6. Outrigger Extension Width Adjustment............46 7. Moment Adjustment.........................................47 7.1 Moment Zero-point Adjustment.................48 7.2 Moment Span Preliminary Adjustment......49 7.3 Moment Zero-point Check and Fine Adjustment ..................................49 7.4 Load Radius Adjustment ...........................50 7.5 Moment Span Fine Adjustment .................50 7.6 Moment Zero-point Recheck ....................51 8. Clock Adjustment.............................................52 Other Functions and How to Use Them ...............53 1.Language ........................................................53 2.Overload History Display.................................53 3.Erasing the Overload History ..........................54

Diagram of the AML System (TL-300E-3)............................... 7

Input/Output Signals of the AML System (TL-300E-3)............................... 8

[OPERATION].......................................... 13

Functions of and How to Use User Mode (TL-300E-3)............................. 13 Mode Structure ..................................................... 13 Configuration and Functions of the AML System ....................................... 14 Names and Functions of AML Main Unit Parts .... 17 Selecting Operational Status................................ 23 Selecting Front Jack Staus................................... 24 AML Pre-operational Inspection........................... 27 How to Use the Working Range Limit Function ... 28 Display Alteration ................................................. 31

[ADJUSTMENT AND MAINTENANCE] .. 32

General:Adjustment Mode and Maintenance Mode ................ 32 1. Keys and Switches for Adjustment and Maintenance....................................... 32

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Foreword Functions of and How to Use Maintenance Mode ................ 55

Checking the Detectors (TL-300E-3) .............................81

1. Program Version Display ................................ 55 2. Data ID Number Display ................................. 55 3. Di Check.......................................................... 55 4. Ai Check.......................................................... 56 5. Elevating Cylinder Oil Pressure Monitor ......... 56 6. Do Check ........................................................ 57 7. MDT Monitor (Multiplex Data Transmitter Monitor) .............................................. 57 8. Key Switch Check ........................................... 57 9. Display Check ................................................. 57 10. Error Data Display........................................... 58 11. Erasing the Error Data .................................... 58 12.Option Board Check........................................ 59 13.Ao Check......................................................... 59 14. Sio Check........................................................ 59 15.Adjust Monitor ................................................. 59 16.Overload History Display ................................ 59 17.Erasing the Overload History .......................... 59 18.Clock Adjustment ............................................ 59

1. Boom Length Detector.....................................81 2. Boom Angle Detector.......................................81 3. Swing Angle Detector ......................................82 4. Outrigger Extension Width Detector ................82 5. Pressure Sensor for Moment Detection ..........83

Fuses

.................................................84

Replacing the Clock Battery ..................85

Error Message ........................................ 61 1. Display of Error Message................................ 61 2. How to Read the Error Message..................... 61 3. How to Read the Error History ........................ 61 4. Troubleshooting Table ..................................... 62 4.1 Group Code 0 ........................................... 62 4.2 Group Code 1 ........................................... 71 4.3 Group Code 2 ........................................... 72 4.4 Group Code 3 ........................................... 76

Disassembly of AML Main Unit ............. 77 1. Removing Front Panel/Display Board............. 77 2. Removing Rear Panel/Connector Board......... 77 3. Removing CPU Board/Analog Board /Power Board.................................................. 78 3.1 Notes on ROM/EEPROM Replacement... 78

Adjustment Value Table......................... 78 Specification No. : TL-300E-3-00107 (2M2D-specification) ........................ 78

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Components of the AML(AML-L D) Main Unit Components of the AML(AML-L D) Main Unit 1. Panel

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Components of the AML(AML-L D) Main Unit 2. Internal view and name plate

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Components of the AML(AML-L D) Main Unit 3. Internal block diagram

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Diagram of the AML System (TL-300E-3) Diagram of the AML System (TL-300E-3)

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Input/output Signals of the AML System (TL-300E-3) Input/output Signals of the AML System (TL-300E-3) As shown in the “Diagram of the AML System” on the previous page, the display board, CPU board, analog board, power board and connector board consist inside the AML. The following lists describe the names and functions of the input/output signals on CN1, CN2 and CN3 cnnectors.

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

Name

Signal names and functions

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ANAIN A

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

Input voltage: DC 0 to 4.5 V

4

ANAIN B

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

Input voltage: DC 0 to 4.5 V

ANAIN C

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

Input voltage: DC 0 to 4.5 V

9

ANAIN D

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

Input voltage: DC 0 to 4.5 V

10

ANAIN E

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

Input voltage: DC 0 to 4.5 V

ANAIN F

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

Input voltage: DC 0 to 4.5 V

5

11

13

14

24

Di1

Signal name: Overwind detection switch input Switch input representing whether overwinding condition exists.

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

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

Di2

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

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

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

Di5

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

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

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

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Input/output Signals of the AML System (TL-300E-3) CN 1 connector Pin No.

25

26

27

29

34

35

Name

Signal names and functions

Di6

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

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

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

Di7

Signal name: Front jack state register switch input Switch input representing whether the front jack state register switch “used” position.

Switch ON (DC0V): The switch is in “used” position.

Switch OFF (DC5V): The switch is in “unused” position.

Di8

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

Switch ON (DC0V): The jib is stowed.

Switch OFF (DC5V): The jib is not stowed.

Di10

Signal name: Swing position check switch input Switch input representing whether the swing position is over-left-side.

Switch ON (DC0V): The swing position is over-left-side.

Switch OFF (DC5V): The swing position is not over-left-side.

ANAING

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

Input voltage: DC 0 to 5 V

ANAINH

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

Input voltage: DC 0 to 5 V

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Input/output Signals of the AML System (TL-300E-3) CN2 connector signals and functions are shown below: CN 2 connector Pin No.

Signal names and functions

name

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

Relay ON (DC24V): Normal operation is available.

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

Relay output 1

3

RLY 1

RLY3

Crane condition

ON

Moment ratio < 90%

ON

90%

OFF

Moment ratio 100% While the boom lift with the jib mounted is performed, the relay output turns OFF when the moment ratio becomes as follows: Moment ratio 85 %

OFF

Ooverwinding.

OFF

Failure in the AML unit.

Moment ratio < 100%

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

Relay ON (DC24V): Alarm buzzer is output.

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

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

Relay ON (DC24V): Alarm buzzer is output.

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

Relay output

4

Moment condition

OFF

Moment ratio < 90%

OFF

Moment ratio < 75% (with the jib mounted) 90%

RLY 4 ON/OFF

Moment ratio < 100%

While the boom lift with the jib mounted is performed, the relay output turns ON/OFF when the moment ratio becomes as follows: below.

Moment ratio < 85% 75% Moment ratio

100%

While the boom lift with the jib mounted is performed, the relay output turns ON when the moment ratio becomes as follows: Moment ratio 85% Signal name: Telescoping control relay output < Extension > The relay turns ON (DC24V) and 4th/top boom sections extend under either of following condition.

1. The boom length is 12.5m or more. < Retraction > The relay turns OFF (DC0V) and 2nd/3rd boom section retracts under either of following condition.

1. The boom length is 12.48m or less.

ON

5

RLY 5

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Input/output Signals of the AML System (TL-300E-3) CN 2 connector Pin No.

8

9

11

17

19

20

name

Signal names and functions

RLY 8

Signal name: Accumulator low pressure alarm relay output This relay contact turns ON and the alarm buzzer is output when the accumulator pressure is 10.3MPa (1494psi) or less.

Relay ON (DC24V): Alarm buzzer is output.

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

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

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

Di13

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

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

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

Di15

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

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

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

Di17

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

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

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

Di18

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

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

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

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Input/output Signals of the AML System (TL-300E-3) CN3 connector signals and functions are shown below: CN 3 connector Pin No.

Signal names and functions

Name

2

TR2

3

TR3

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

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

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

While the boom lift with the jib mounted is performed, OC output turns ON when the moment ratio reaches the range below: Moment ratio < 85% 75% Signal name: AML 100% alarm output OC (Open collector) output turns ON when the load moment ratio exceeds 100% or automatic stop function is cancelled.

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

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

Condition to turn ON OC output Moment ratio

100%

While the boom lift with the jib mounted is performed, OC output turns ON when the moment ratio reaches the range below: 85% Moment ratio Anti-twoblock disable switch: pressed Override key switch ON position and PTO switch in OVERRIDE position.

4

21

22

23

24

TR4

Signal name: Front jack overload warning output OC (Open collector) output turns ON when the front jack overload detection switch is ON. OC output “ON” (DC0V): The horn sounds.

OC output “OFF” (DC24V): The horn does not sound.

Di21

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

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

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

Di22

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

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

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

Di23

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

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

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

Di24

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

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

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

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W301-0351E

Functions of and How to Use User Mode (TL-300E-3) [OPERATION]

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

Functions of and How to Use User Mode (TL-300E-3)

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

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

POWER ON

Protect switch ON

MAINTENANCE MODE

USER MODE

Protect switch OFF

ADJUSTMENT MODE

POWER ON

IW301-0212E05

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

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

HALT

WDT

ZERO

PROTECT ON

OFF

MOMENT SHORT

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

Protect switch Abnormality display LED Top view

IW301-0132E35

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Functions of and How to Use User Mode (TL-300E-3) Configuration and Functions of the AML System

(2) Automatic stop function to prevent overwinding when the hook block is overhoisted, failure message is shown, alarm buzzer sounds, and the crane operation toward the critical side stops.

The AML system is a safety device provided to prevent overloading of the crane which may cause it to overturn or be damaged.

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

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

(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.

On-outrigger operation Automatic stop by overloading

Hoisting up Boom lowering Boom extension

: Stop

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Functions of and How to Use User Mode (TL-300E-3) AML System Configuration

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Functions of and How to Use User Mode (TL-300E-3) Condition Working range limit function activated.

Alarm Moment display: Displays failure messages.

Associated restriction indicator lamp flashes.

AML Buzzer: Sounds 3seconds.

Boom lift with jib mounted on boom Moment ratio is between Moment display: Applicable segment(s) is lit.

75% to 85% with External warning lamps : outrigger at Mid Orange lamp is lit. extension.

Moment ratio is between Buzzer: Sounds intermittently.

80% to 90% with outrigger at Max. extension.

Moment ratio is 85% or Moment display: Displays [Warning:0088]. more with outrigger at External warning lamps : Red Mid extension.

Moment ratio is between lamp is lit.

Buzzer: Sounds continuously.

90% or more with outrigger at Max. extension.

Automatic Stop Functions

Working range limit

Causes of automatic stop •Moment ratio is 100% or more (*1) •Overwinding •AML system error Upper boom angle restricted Lower boom angle restricted Lifting height restricted Load radius restricted

Operation

Halted movement •Hoisting up •Boom lowering •Boom extension

•Boom lift •Single top lift •Jib lift

•Boom raising •Boom lowering •Boom raising •Boom extension •Boom lowering •Boom extension

(*1):For the boom lift with the jib mounted, automatic stop will work when the moment is 85% or more.

Alarm Functions

[NOTICE]

Condition Alarm Winch is overwound Buzzer:Sounds continuously.

Moment display: Displays A control is moved toward critical side (hoist [Warning:0024].

Buzzer: Sounds continuously. up, boom lowering or boom extension) while overwinding condition exists.

Overwind cutout function Moment display: Displays is deactivated while the [Warning:0015]. hook block overwinding. External warning lamps: Red lamp is lit.

Buzzer: Sounds continuously.

Moment ratio is 90% to Moment display: Yellow 99%. segment(s) is lit.

External warning lamps: Orange lamp is lit.

Buzzer: Sounds intermittently.

Moment ratio is 100% or Moment display: Red segment(s) more is lit while ratio is up to 110%, and all segments are lit when 110% is exceeded.

External warning lamps: Red lamp is lit.

Buzzer: Sounds continuously.

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

Buzzer: Sounds continuously.

AML system errer Moment display: Displays failure messages.

AML Buzzer: Sounds 3 seconds.

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

"AML buzzer" is the device inside the AML unit, outputting beeping sound.

The AML buzzer sounds for 3 seconds every time a message appears.

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Functions of and How to Use User Mode (TL-300E-3) Names and Functions of AML Main Unit Parts

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Functions of and How to Use User Mode (TL-300E-3)

Bargraph Display 3

1

2

4

Usually on

0-89

90-99

Each frame representing 10%

100-109

110 or more than that

Each frame representing 2.5%

Each frame representing 2.5% IW301-0131E57

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

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

4. Scroll-down key

2. Moment display

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

Normally displays a moment ratio on a bargraph.

Displays the main-circuit pressure when the display alteration key is pressed.

Also displays error messages when an operational or system error occurs.

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Functions of and How to Use User Mode (TL-300E-3) Display Panel 1

9. Load radius limit symbol

1. Jib angle display

This symbol indicates that the load radius display [11] is showing the registered load radius limit value.

The load radius symbol [10] is also displayed at the same time.

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

When the number of parts of line select key or the display alteration key is pressed, the number of parts of line is displayed. Also, when an upper boom angle limit has been registered, the registered upper boom angle limit value is displayed while the register key is pressed.

10. Load radius symbol This symbol indicates that the load radius display [11] is showing the load radius.

2. Number of parts of line symbol

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

Displays the boom swing angle while the display alteration key is pressed.

When a load radius limit has been registered, the registered load radius limit value is displayed while the register key is pressed.

This symbol indicates that the jib angle display [1] is showing the number of parts of line.

3. Boom length symbol This symbol indicates that the boom length display [13] is showing the boom length.

5. Jib angle symbol

13. Boom length display

This symbol indicates that the jib angle display [1] is showing the jib offset angle.

Normally displays the boom length.

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

When a lifting height limit has been registered, the registered lifting height limit value is displayed while the register key is pressed.

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

Its also indicates the condition of the jib.

7. Actual load display Displays the actual load.

14. Lifting height symbol This symbol indicates the boom length display [13] is showing the lifting height.

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

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Functions of and How to Use User Mode (TL-300E-3)

19. Boom angle display

15. Lifting height limit symbol

Normally displays the boom angle.

Displays the moment ratio when the display alteration key is pressed.

When a lower boom angle limit has been registered, the registered lower boom angle limit value is displayed while the register key is pressed.

This symbol indicates that the boom length display [13] is showing the registered lifting height limit value.

The lifting height symbol [14] is also displayed at the same time.

16. Upper boom angle limit symbol This symbol indicates that the jib angle display [1] is showing the registered upper boom angle limit value.

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

17. Boom angle symbol This symbol indicates that the boom angle display [19] is showing the boom angle.

21. Single top lift symbol This symbol indicates that the Single top lift is selected.

18. Lower boom angle limit symbol This symbol indicates that the boom angle display [19] is showing the registered lower boom angle limit value.

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Functions of and How to Use User Mode (TL-300E-3) Controls

10.Load radius restriction key

1. Increase key

Used to activate and release the load radius limiting function.

Used to increase the selected value.

2. Decrease key

11.Display alteration key

Used to decrease the selected value.

Used to alter the displays on display panel 1.

3. Lifting height restriction key Used to activate and release the lifting height limiting function.

12.Register key Used to register a selected status.

4. Lifting height restriction indicator lamp

13.Check key Used to check the AML system functions.

Lights up when lifting height limiting function is activated.

14.Lift mode select key

5. Upper boom angle restriction indicator lamp

Used to select the lift status.

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

15.On-rubber mode select key Not used for this machine.

6. Lower boom angle restriction indicator lamp Lights up when the lowermost boom angle limiting function is activated.

16.Right outrigger status select key Used to select the right outrigger extension status on the AML.

7. Upper boom angle restriction key

17.Left outrigger status select key

Used to activate and release the uppermost boom angle limiting function.

Used to select the left outrigger extension status on the AML.

8. Lower boom angle restriction key

18.Number of parts of line select key Used to select the a number of parts of line.

Used to activate and release the lowermost boom angle limiting function.

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

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Functions of and How to Use User Mode (TL-300E-3) Display Panel 2

3. Boom position indicator

1. Front jack symbol

Indicates the boom position in 10° increments.

Indicates that the front jack is used.

4. "On-rubber" (Outrigger-not-in-use) state symbol Comes on when the starter switch in the crane operator's cab is turned "ON".

2. Outrigger state symbol Indicates the way the outriggers are extended.

Flashes while an outrigger state is in process of being registered, and lights up when the registration is completed.

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Functions of and How to Use User Mode (TL-300E-3) Selecting Operational Status

Register the outrigger status using the right or left outrigger status select key and the register 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.

Selecting Outrigger Status [NOTICE] !Register right and left outrigger extension status separately on the AML. If the front and rear outrigger extension widths differ, register the smaller extension width as shown in the figure below.

Every time an outrigger status select key is pressed, the corresponding outrigger state symbols flash and alternate between Minimum extension status, middle extension status and full extension status.

After selecting the right and left outrigger status according to the actual condition of the outriggers, press the register key. The outrigger state symbols will change from flashing to continuous lighting, meaning that the outrigger status has been registered.

!The "on-rubber" state symbol lights up when the power supply is turned on (the PTO switch in the carrier driver's cab is turned ON after the engine is started). !Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power has been last turned off, enter the settings all over again.

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Functions of and How to Use User Mode (TL-300E-3) Selecting Front Jack Status [NOTICE] ◆The rated lifting capacity varies with the front jack condition. The "Rated Lifting Capacity Table" section in this manual describes how the pattern of the working areas and the rated lifting capacity in each area change when the condition of the front jack changes. Read thoroughly and understand the section before registering front jack status.

Use the front jack status register switch to register the front jack status.

(1) When front jack is used: Set the front jack status register switch to ON. The front jack symbol will light, indicating that the front jack used status has been registered.

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

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Functions of and How to Use User Mode (TL-300E-3) Selecting Lift Status [NOTICE] The boom lift status is the default status and is automatically selected (the boom lift symbol lights up) when the power supply is turned on (the PTO switch is placed in the ON position).

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

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

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

[NOTICE] !After making sure that the display conforms to the actual lift status, press the register key. The corresponding lift indicative symbol will change from flashing to continuous lighting, and the moment display, rated lifting capacity display and actual load display will return to normal display conditions, meaning that the status has been registered.

(When the jib set status is selected, the jib lift symbol will remain flashing.) !Select the boom lift status when lifting a load on the boom with the jib mounted.

[NOTICE] !Select a jib lift status when lifting a single load using both the boom and jib.

25

W301-0351E

Functions of and How to Use User Mode (TL-300E-3) Selecting Number of Parts of line [NOTICE] If the registered number of parts of line is smaller than the standard number, a maximum allowable lifting load is limited, depending on the registered number. If zero(0) is registered, however, the AML performs as if the standard number were registered.

Similarly, the AML works on the basis of the standard number of parts of line if the registered number is larger than the standard number, or other than the values specified for your model.

When the power supply is turned on (i.e. PTO switch ON), the standard number of parts of line corresponding to the work condition is selected.

Register the number of parts of line by use of the number of parts of line select key and the register key, as follows:

1. Press the number of parts of line select key. The number of parts of line symbol will flash, and the number of parts of line will be shown on the jib angle display in a flashing mode.

3. Once the intended number of parts of line is set, press the register key to register the number.

Then, the number of parts of line symbol will be turned off and the jib angle display will return to a normal status.

2. Press the increase or the decrease key to set the number to the actual number of parts of line.

[NOTICE] The number of parts of line can be confirmed by pressing the display alteration key.

[NOTICE] When the increase or the decrease key is pressed, a numeral showing the number of parts of line changes from flashing to lighting, and increases or decreases.

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

26

W301-0351E

Functions of and How to Use User Mode (TL-300E-3) AML Pre-operational Inspection

(1) Boom length (2) Boom angle

WARNING

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

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.

(4) 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 is not registered correctly.

Before starting operation, check that the AML works in good condition, as follows:

(5) Outrigger state symbol

1. Press the check key and make sure that the AML is in the following conditions: • Moment display……All segments light up.

• Display panel (1 and 2) ………………………All segments light up.

• Working range restriction indicator lamp ………………………………All four lamps light up.

• Alarm buzzer………………Sounds continuously.

(6) Front jack symbol (7) Boom position indicator

• Movement toward critical sides ………………………………Automatically halted

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

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

27

W301-0351E

Functions of and How to Use User Mode (TL-300E-3) How to Use the Working Range Limit Function

Boom Angle Limit Raise or lower the boom to the desired angle, and press the boom upper or lower angle restriction key. The corresponding restriction indicator lamp will flash, indicating that the boom angle limit has been registered in the memory. When the boom is moved back to an angle within the set limit, the restriction indicator lamp stops flashing and stays illuminated.

Thereafter, the upper or lower boom angle restriction indicator lamp flashes and the AML buzzer sounds for 3 seconds whenever the upper or lower limit previously registered is reached.

(Boom raising or lowering stops automatically.)

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

[NOTICE] If the working range 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.

When registering a range limit, allow a sufficient clearance to avoid collision.

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

The function is useful for handling a load in a confined place because it defines the area in which the boom can operate.

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

28

W301-0351E

Functions of and How to Use User Mode (TL-300E-3) Lifting Height Limit

Load Radius Limit

Move the boom to the desired height, and press

Move the boom to the desired load radius, and

the lifting height restriction key. The lifting height restriction indicator lamp will flash, 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 restriction indicator lamp stops flashing and stays illuminated.

Thereafter, the lifting height restriction indicator lamp flashes and the AML buzzer sounds for 3 seconds whenever the height limit previously registered is reached. (Boom raising and extending stop automatically.)

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

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

Thereafter, the load radius restriction indicator lamp flashes and the AML buzzer sounds for 3 seconds whenever the limit previously registered is reached. (Boom extending and lowering stop automatically.)

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

29

W301-0351E

Functions of and How to Use User Mode (TL-300E-3) Display of Working Range Limit Values Press the register key while working range limits have been registered.

While the key is being pressed, the registered working range limit values are displayed. On the moment display will be displayed a message "Working range".

[NOTICE] This display is not made during a preoperational check of the AML and when a working state is being registered.

When working range limits are not registered, the message "---" will be displayed.

30

W301-0351E

Functions of and How to Use User Mode (TL-300E-3) Display Alteration Displays on the moment display and the display panel 1 can be altered, as shown below in the figures, by pressing the display alteration key. The indicative symbols are displayed, too.

Display Panel 1 [NOTICE] Displays on the actual load display and the rated load display do not alter even when the display alteration key is pressed.

31

W301-0351E

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

HALT

WDT

ZERO

PROTECT ON

OFF

MOMENT SHORT

1. Keys and Switches for Adjustment and Maintenance

8. Moment input short-circuit switch 9. Protect switch 10. Moment zero adjuster 11. Abnormality display LED Top view IW301-0131E02

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

7. Check key Used for ”Do Check” and ”Ao Check” functions in the maintenance mode.

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

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

9. Protect switch

3. Register key

Set this switch to OFF when changing the mode from user mode to adjustment mode. With this switch OFF, data in the EEPROM becomes rewritable.

Used to register the selected state and write the adjustment value in EEPROM. 4. Increase key

10.Moment zero adjuster

Used to increase the adjustment value.

This adjuster is for adjustment by the AML manufacturer’s service personnel. Do not tamper.

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.

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

32

W301-0351E

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

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

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

MAIN MENU

POWER ON

[• Maintenance] Protect switch ON

[• Adjust clock]

POWER ON

IW301-0212E05

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

HALT

ZERO

WDT

PROTECT ON

OFF

MOMENT SHORT

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

Protect switch ON

[: Di check] [: Ai check] [: Disp ELEV PRES] [: Do check] [: MDT Monitor] [: Key SW check] [: Display check] [: Disp. err data] [: Erase err data] [: Disp. O/L data] [: Erase O/L data] [: OP board check] [: Ao check] [: Sio check] [: Adjust Monitor]

ADJUSTMENT MODE

Top view

[: Prog. version] [: Data ID. number]

MAINTENANCE MODE

USER MODE

Protect switch OFF

SUB-MENU

IW301-0131E03

33

W301-0351E

General: Adjustment Mode and Maintenance Mode 3. Adjustment Mode: Used to make detector adjustment. This mode has the following menus: MAIN MENU [• Adjust]

SUB-MENU [: Adjust L & A]

*Boom length zero-point adjustment *Boom length span-point adjustment *Boom angle zero-point adjustment *Boom angle span-point adjustment *Swing angle zero-point adjustment *Swing angle span-point adjustment *Outrigger length zero-point adjustment *Outrigger length span-point adjustment *Load radius span adjustment *Moment zero-point adjustment *Moment span-point adjustment

[: Adj. work rad] [: Adjust MMT] [• Adjust CNT dat]

[• Adjust AO] [• Initialize L & A] [• Initialize MMT] [• Disp. O/L data] [• Erase O/L data] [• Adjust PCSN] (*1) [• Reg. Capac.]

[• Language]

(*1) (*2)

[: Adj. ELV speed] (*2)

[: Reset ELV data] (*2) [: Adjust AO Ofs.] (*2) [: Reset AO Ofs.] (*2) [: Reset DEF. FCT] [: Reset zero. span] [: Reset PCSN] (*1)

[: Head-OFF Capac] (*2) [: Jib Select]] (*2) [: S/T Select] [: Winch drum PSN]

: This menu is prohibited to be used. :In case of TL-300E, This menu is not applied.

34

W301-0351E

General: Adjustment Mode and Maintenance Mode

HALT

WDT

ZERO

PROTECT ON

OFF

MOMENT SHORT

3. Method of Shifting Modes

Protect switch Top view

IW301-0131E03

POWER ON

Protect switch ON Protect switch OFF

1 MAINTENANCE MODE

USER MODE 2 3

5

4 ADJUSTMENT MODE

POWER ON

IW301-0232E12

4. “Adjustment mode” → “User mode”

1. “User mode” → “Maintenance mode”

While the main menu of the adjustment mode is displayed, turn ON the protect switch. Then AML will go back to “User mode” and bargraph will be displayed on the moment display.

Press the scroll-up key, scroll-down key, and register key at the same time. Then, the moment display changes from the bargraph to [• Maintenance]. This display denotes the “Maintenance mode”.

5. “Maintenance mode” → “Adjustment mode”

2. “Maintenance mode” → “User mode”

While the main menu of the maintenance mode is displayed, turn OFF the protect switch. The moment display will change to [•Adjust], and will denote “Adjustment mode”.

Press the display alteration key. When the bargraph shows up on the moment display, AML goes back to the “User mode”.

3. “User mode” → “Adjustment mode” Turn OFF the protect switch at the adjustment window on the top of AML. Then, the moment display will change to [•Adjust], and will denote “Adjustment mode”.

35

W301-0351E

General: Adjustment Mode and Maintenance Mode 4. Method of Menu Selection

1. When AML is in “Maintenance mode” or “Adjustment mode”, the main menu is displayed on the moment display of bargraph display portion.

Displayed menu changes by means of the scroll-up or scroll-down key. Press the register key to select the displayed item.

2. If the selected item in the main menu has any sub-menus, the sub-menus are displayed on the moment display of bargraph display portion. You can select the sub-menu in the same way sa main menu selection.

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

When a main menu is displayed, the mark “•” stands before the menu name. (Ex. “•Adjust ”) When a sub-menu is displayed, the mark “:” stands before the menu name.

(Ex. “:Adjust MMT”) The “ ” mark after the menu name indicates that the depression of the scroll-down key calls for another menu.

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

36

W301-0351E

Required Adjustment After AML System Parts Replacement Required Adjustment After AML System Parts Replacement [NOTICE] EEPROM stores the adjustment values for each specification number. When replacing the CPU board, remove the EEPROM after removing it from the broken CPU board to dispense with adjustment work other than clock adjustment. Visually check that the value displays such as boom length and boom angle and symbol display on the display panels 1 and 2 on the AML conform the actual crane condition.

Replaced part

Required adjustment

Boom length detector

Boom length adjustment

Boom angle detector

Boom angle adjustment

Swing angle detector

Swing angle adjustment

Outrigger extension width detector

Outrigger extension width adjustment

Pressure sensor for moment detection

Moment adjustment

Display board

None CPU board only (When reusing EEPROM removed from the broken CPU board)

CPU board

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

AML unit

ROM

Clock adjustment Perform adjustment initialization and take every step of adjustment. For adjustment items and procedure, see “Adjustment Procedures” on the subsequent page in the “Function of and How to Use Adjustment Mode” section.

None

Analog board

Boom length adjustment Boom angle adjustment Swing angle adjustment Moment adjustment

Power board

None

Connector board

None

37

W301-0351E

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

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

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

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

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

38

W301-0351E

Functions of and How to Use Adjustment Mode 1.1 Procedure of Conversion Factors Resetting

1. Adjustment Initialization

1. Select the main menu [ • Initialize L&A ] in the

[NOTICE]

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

Adjustment initialization should be performed only when EEPROM is replaced.

If the EEPROM removed from the faulty CPU board is reused when the CPU board is replaced, adjustment initialization is not required.

2. When [: Reset DEF. FCT ] appears, reset the deflection factor by pressing the register key.

By the adjustment initialization, the conversion factors (standard values specified for each specification) stored within the AML program that convert detected voltage input from the detectors into physical volumes is read out from the P-ROM and written onto the EEPROM.

3. When the message [Done] appears, the deflection

Perform the initialization only once before the first

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

factor resetting is completed. Press the display alteration key to return to the main menu.

4. Press the register key again to select the main menu [•Initialize L&A ] in the adjustment mode.

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

6. When the message [Done] appears, the zero

For adjustment initialization, you have to execute the following two menus.

[• Initialize L&A] : Initialize the conversion factors for boom length, angle, and deflection.

[• Initialize MMT] : Initialize the conversion factors for moment.

span factor resetting is completed.

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

1.2 Procedures of Moment Adjustment Resetting 1. Select the main menu [• Initialize MMT ] in the adjustment mode, and press the register key to select the menu.

2. When [Reset MMT] appears, reset the moment factor by pressing the register key.

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

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

39

W301-0351E

Functions of and How to Use Adjustment Mode 2.1 Procedure of Head-off Capacity Setting

2. Capacity Setting

[NOTICE]

[NOTICE]

A head-off capacity value defined with this function is compared with the capacity (rated lifting capacity) data stored in the ROM, and the value whichever smaller is set as the capacity. Note that if the head-off capacity value is zero, the capacity data stored in the ROM is used.

Check the specification number of “Adjustment Value Table” in the INFORMATION AND DATA section whether your crane needs to perform this setting.

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

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

The crane capacity data normally does not need this setting.

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

For the capacity setting, select one of the four sub-menus indicated below. [: Head-Off Capac] : Used to set the maximum rated lifting capacity to the specified value. [: Jib Select] : Used to change the capacity for jib-mounted condition to the capacity for jib-unmounted condition. [: S/T Select] : Used to change the capacity for single-top-mounted condition to the capacity for single-top unmounted condition. [: Winch drum PSN] : Used to specify the mounting position of winch drum for capacity adjustment.

3. The currently registered head-off capacity value is indicated on the moment display.

Display example: [Capacity 99.2 kp] (TR-450XL-4) 4. Press the increase or decrease key to adjust the head-off capacity value as desired.

Every time you press the increase or decreace key, the head-off capacity value increases or decreases in steps of 0.1 klbs. If the key is held down, the value increases or decreases in steps of 10klbs.

5. When the desired head-off capacity value is reached, press the register key to save it.

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

40

W301-0351E

Functions of and How to Use Adjustment Mode 2.2 Procedure of Jib Selection

2.3 Procedure of Single Top Selection

[NOTICE]

[NOTICE]

When the jib-unmounted (detached) condition is selected, the jib capacity data stored in the ROM becomes unusable and also the jib mass is excluded from capacity calculation.

When the single-top-unmounted (detached) condition is selected, the single top capacity data stored in the ROM becomes unusable and also the single top mass is excluded from capacity calculation.

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

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

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

2. Press the scroll-up or scroll-down key to display [: S/T Select ], and then press the register key to select the menu.

3. The currently registered jib capacity condition is indicated on the moment display. Using the scroll-up or scroll-down key, adjust it to the desired condition .

Display example: [Jib = Mounted ] Press the scroll-up key.

[Jib : Not Mounted] When “ = ” is indicated, it means that the displayed condition is registered currently.

3. The currently registered single top capacity condition is indicated on the moment display.

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

Display example: [S/T=Mounted ] Press the scroll-up key.

[S/T : Not Mounted] When “ = ” is indicated, it means that the displayed condition is registered currently.

4. When the desired condition is displayed, press the register key for confirmation. When the setting is completed, “:” in the Jib condition display changes to “ = ”.

Display example: [Jib：Not Mounted] Press the register key.

[Jib = Not Mounted]

4. When the desired condition is displayed, press the register key for confirmation. When the setting is completed, “:” in the single top condition display changes to “ = ”.

Display example： [S/T : Not Mounted] Press the register key.

[S/T = Not Mounted]

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

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

41

W301-0351E

Functions of and How to Use Adjustment Mode 2.4 Procedure of Winch Drum Position Setting [NOTICE] The center of gravity of winch drum can be changed by adjusting the winch drum position. The calculation is performed according to the winch drum position setting by this function.

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

2. Press the scroll-up or scroll-down key to display [: Winch drum PSN], and then press the register key to select the menu.

3. The currently registered jib capacity condition is indicated on the moment display. Using the scroll-up or scroll-down key, adjust it to the desired condition.

Display example: [Winch drum = FR ] Press the scroll-up key.

[Winch drum : F ] Press the scroll-up key.

[Winch drum : R] In the above examples, “F” means the condition with single winch mounted at the front. “R” means the condition with single winch mounted at the rear. “FR” means the condition with double winches mounted at the front and rear.

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

4. When the desired condition is displayed, press the register key for confirmation. When the setting has been completed, “:” in the winch drum condition display changes to “ = ”.

Display example: [Winch drum : F ] Press the register key.

[Winch drum = F ] 5. Press the display alteration key to exit the menu.

42

W301-0351E

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

10.Has the boom length zero-point adjustment display [Boom Lz] become the zero-point adjustment value in “Adjustment Value Table” ?

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

NO

YES

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

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

When the length detector has only been installed and its cord has not yet been unwound on the drum, set the code wound naturally on the boom through the entire length during the boom telescopic operation.

1. Select the main menu [• Adjust ] in the adjustment mode, and press the register key to select the menu.

2. When [: Adjust L&A ] is displayed, press the register key to select the menu.

3. Fully retract the boom.

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

Press the register key for registration.

5. Fully extend the boom.

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

7. Press the increase or decrease key so that the value of boom length span adjustment display [Boom Ls] becomes the span adjustment value in “Adjustment Value Table”. Press the register key for registration.

8. Fully retract the boom again.

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

43

W301-0351E

Functions of and How to Use Adjustment Mode 4. Boom Angle Adjustment

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

WARNING

9. Bring the actual boom angle to the zero-point

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

adjustment value in “Adjustment Value Table” again.

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

[NOTICE]

boom angle zero-point adjustment display [Boom Az] appears.

Refer to “Adjustment Value Table” in the INFORMATION AND DATA section since the conditions and values for boom angle adjustment vary depending on the specification number.

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

11.Has the value of boom angle zero-point adjustment display [Boom Az] become the zero-point adjustment value in “Adjustment Value Table” ?

NO

1. Select the main menu [• Adjust ] in the

YES

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

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

2. When [: Adjust L&A ] is displayed, press the register key to select the menu.

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

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

5. Press the increase or decrease key so that the value of boom angle zero-point adjustment display [Boom Az] becomes the zero-point adjustment value in “Adjustment Value Table”. Press the register key for registration.

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

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

8. Press the increase or decrease key so that the value of boom angle span adjustment display [Boom As] becomes the span adjustment value in

44

W301-0351E

Functions of and How to Use Adjustment Mode 5. Swing Angle Adjustment

10.Press the increase or decrease key so that the value of swing angle 1 span-point adjustment display [SW AG 1s] will become 180 ± 0.3°.

Press the register key for registration.

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

11.With the swing position unchanged, press the scroll-up or scroll-down key until the swing angle 2 span-point adjustment display [SW AG 2s] appears.

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

12.Press the increase or decrease key so that the value of swing angle 2 span-point adjustment display [SW AG 2s] will become 180 ± 0.3°.

Press the register key for registration.

1. Select the main menu [• Adjust ] in the adjustment mode, and press the register key to select the menu.

13.Set the boom again to the zero-point adjustment reference position (on the front centerline) by swinging it clockwise.

2. When [: Adjust L&A ] is displayed, press the register key to select the menu.

14.Check the swing angle 1 and 2 zero-point adjustment displays [SW AG 1z] and [SW AG 2z] by pressing the scroll-up or scroll-down key. Does each display indicate the angle below?

SW AG 1z：0 ± 0.6° SW AG 2z：360 ± 0.6°

3. Set the boom to the zero-point adjustment reference position (on the front centerline) by swinging it rightward.

4. Press the scroll-up or scroll-down key until the swing angle 1 zero-point adjustment display [SW AG 1z] appears.

NO

YES

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

5. Adjust the increase or decrease key so that the value of swing angle 1 zero-point adjustment display [SW AG 1z] will become 0 ± 0.3°. Press the register key for registrarion.

6. With the swing position unchanged, press the scroll-up or scroll-down key until the swing angle 2 zero-point adjustment display [SW AG 2z] appears.

7. Adjust the increase or decrease key so that the value of swing angle 2 zero-point adjustment display [SW AG 2z] will become 360 ± 0.3°. Press the register key for registration.

8. Set the boom to the span- point adjustment reference position (on the rear centerline) by swinging it rightward.

9. Press the scroll-up or scroll-down key until the swing angle 1 span-point adjustment display [SW AG 1s] appears.

45

W301-0351E

Functions of and How to Use Adjustment Mode 6. Outrigger Extension Width Adjustment

10.Adjust and register the values of the right-rear, left-front and left-rear outriggers extension width span adjustment in the same manner as the one of the right-front outrigger extension width span adjustment.

Right-rear outrigger : Adjust [RRO/R Ls] display Left-front outrigger : Adjust [LFO/R Ls] display Left-rear outrigger : Adjust [LRO/R Ls] display

[NOTICE] Refer to “Adjustment Value Table” in the INFORMATION AND DATA section since the conditions and values for outrigger extension width adjustment vary depending on the specification number.

1. Select the main manu [• Adjust ] in the

11.Fully retract all the outrigger beams again.

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

12.Press the scroll-up or scroll-down key until the right-front outrigger extension width zero-point adjustment display [RFO/R Lz] appears.

2. When [: Adjust L&A ] is displayed, press the register key to select the menu.

13.Does the right-front outrigger extension width zero-point adjustment display [RFO/R Lz] conform to the zero-point adjustment value in “Adjustment Value Table” ? And does each display for the right-rear outrigger [RRO/R Lz], for the left-front outrigger [LFO/R Lz], and for the left-rear outrigger [LRO/R Lz] conform to the zero-point adjustment value in “Adjustment Value Table” ?

3. Fully retract all the outrigger beams.

4. Press the scroll-up or scroll-down key until the right-front outrigger extension width zero-point adjustment display [RFO/R Lz] appears.

5. Press the increase or decrease key so that the value of the right-front outrigger extension width zero-point adjustment display [RFO/R Lz] conforms to the zero-point adjustment value in “Adjustment Value Table”. Press the register key for registration.

NO

YES

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

6. Adjust and register the values of the right-rear, left-front and left-rear outrigger extension width zero-point adjustment in the same manner as the one of the right-front outrigger extension width zero-point adjustment.

Right-rear outrigger : Adjust [RRO/R Lz] display Left-front outrigger : Adjust [LFO/R Lz] display Left-rear outrigger : Adjust [LRO/R Lz] display 7. Fully extend all the outrigger beams.

8. Press the scroll-up or scroll-down key until the right-front outrigger extension width span adjustment display [RFO/R Ls] appears.

9. Press the increase or decrease key so that value of the right-front outrigger extension width span adjustment display [RFO/R Ls] conforms to span adjustment value in “Adjustment Value Table”.

Press the register key for registration.

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Functions of and How to Use Adjustment Mode 7. Moment Adjustment WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety.

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

Refer to “Adjustment Value Table” in the INFORMATION AND DATA section since the conditions and values for moment adjustment vary depending on the specification number.

If the moment zero-point value is not within the tolerance at “7.6 Moment Zero-point Recheck”, follow the fine adjustment steps of the broken line process order.

The procedure to adjust moment is as follows: 7.1 Moment Zero-point Adjustment 7.2 Moment Span Preliminary Adjustment 7.3 Moment Zero-point Check and Fine Adjustment 7.4 Load Radius Adjustment 7.5 Moment Span Fine Adjustment 7.6 Moment Zero-point Recheck NO YES End of moment adjustment

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Functions of and How to Use Adjustment Mode 7.1 Moment Zero-point Adjustment

0.00 to 0.99 klbs: “000” to “099” -0.99 to -0.01 klbs: “-99” to “-01”

[NOTICE] For the conditions and adjustment value of the moment zero-point adjustment, refer to the moment zero-point adjustment item in the “Adjustment Value Table”.

Set the crane as follows: (1)Outriggers mode: Fully extended (2)Lift mode: Boom lift (Stow jib and single top) (3)Boom length: Fully retracted (4)Boom angle: Raise boom until it almost reaches to maximum point, and then lower it until boom angle display corresponds to condition of zero-point adjustment.(Refer to “Adjustment Value Table”.)

(5)Hook block position: Hoisted down just clear of ground surface or vehicle structure (6)Actual status and registered status of number of parts of line: Standard number of parts of line when main boom is fully extended (7)Hook block: Refer to “Adjustment Value Table”.

(Stow auxiliary hook block.)

(8)Refer to “Adjustment Value Table” according to the crane model, there might be a condition besides above.

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

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

1. Select the main menu [• Adjust ] in the adjustment mode, and press the register key to select the menu.

2. When [:Adjust L&A ] is displayed, press the scroll-down key until the display [:Adjust MMT] appears. Press the register key to select the menu.

3. While the moment zero-point adjustment is displayed, adjust the value indicated in the actual load value indicator finely with the increase or decrease key to conform it to the adjustment value of the zero-point adjustment.

Moment zero-point adjustment display: Display [X.XXX z . % ] Moment ratio(%) Shows zero-point adjustment state Moment detector input(mV) The actual load value less than 1 klbs is shown as follows:

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

7.3 Moment Zero-point Check and Fine Adjustment

[NOTICE]

[NOTICE]

For the conditions and adjustment value of the moment span preliminary adjustment, refer to the moment span preliminary adjustment item in the “Adjustment Value Table”.

For the conditions and adjustment value of the moment zero-point check and fine adjustment, refer to the moment zero-point adjustment item in the “Adjustment Value Table”.

1. Continued from “7.1 Moment Zero-point Adjustment”.

1. Continued from “7.2 Moment Span Preliminary Adjustment”.

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

2. Raise the boom until it almost reaches to the

condition of the span preliminary adjustment.

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

maximum point, and then lower it until the boom angle display corresponds to the condition of the zero-point adjustment. (Hoist down the hook block until it almost touches the ground surface or chassis.)

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

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

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

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

Moment ratio(%) Shows span adjustment state

Moment ratio(%)

Moment detector input(mV)

Shows zero-point adjustment

4. Adjust the value indicated in the actual load value indicator finely with the increase or decrease key to conform it to the adjustment value of the span preliminary adjustment.

The actual load value less than 1 klbs is shown as follows: 0.00 to 0.99 klbs: “000” to “099” -0.99 to -0.01 klbs: “-99” to “-01”

state Moment detector input(mV) 4. Has the indicated value become the zero-point adjustment value?

The actual load value less than 1 klbs is shown as follows: 0.00 to 0.99 klbs: “000” to “099” -0.99 to -0.01 klbs: “-99” to “-01”

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

YES

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

NO

5. Make an adjustment with the increase or

Fine Adjustment”.

decrease key so that the result becomes the zero-point adjustment value. Then, press the register key to save the adjusted value.

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

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Functions of and How to Use Adjustment Mode 7.4 Load Radius Adjustment

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

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

(6)Actual status and registered status of number of parts of line: Standard number of parts of line when main boom is fully extended.

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

(Stow auxiliary hook block.)

(8)Refer to “Adjustment Value Table” according to the crane model, there might be a condition besides above.

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

Set the crane as follows: (1)Outriggers mode: Fully extended (2)Lift mode: Boom lift (Stow jib and single top) (3)Boom length: Fully extended (4)Actual status and registered status of number of parts of line: Standard number of parts of line when main boom is fully extended (5)Hook block: Refer to “Adjustment Value Table”.

(Stow auxiliary hook block.)

(6)Load radius: After lifting rated lifting capacity of load radius adjustment condition, set actual load radius to meet load radius adjustment condition (load radius) by boom lowering operation. (Cancel AML stop function when overload hinders boom lowering.)

(7)Refer to “Adjustment Value Table” according to the crane model, there might be a condition besides above.

1. Select the main menu [• Adjust ] in the adjustment mode, and press the register key to select the menu.

2. When [: Adjust L&A ] is displayed, press the scroll-down key until the display [:Adjust MMT] appears. Press the register key to select the menu.

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

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

1. Select the main menu [• Adjust ] in the adjustment mode, and press the register key to select the menu.

Moment ratio(%)

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

Shows span adjustment state

adjustment display [: Adj. work rad ] appears.

Then, press the register key to select the menu.

Moment detector input(mV)

3. Press the increase or decrease key so that the

4. Using the increase or decrease key, adjust the

load radius adjustment display [Rad. 1s] becomes the load radius adjustment value. Press the register key for that registration.

indicated value so that it becomes the span fine adjustment value. Then, press the register key to save the adjusted value.

The actual load value less than 1 klbs is shown as follows: 0.00 to 0.99 klbs: “000” to “099” -0.99 to -0.01 klbs: “-99” to “-01”

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

7.5 Moment Span Fine Adjustment [NOTICE]

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

For the conditions and adjustment value of the moment span fine adjustment, refer to the moment span fine adjustment item in the “Adjustment Value Table”.

Set the crane as follows: (1)Outriggers mode: Fully extended (2)Lift mode: Boom lift (Stow jib and single top) (3)Boom length: Fully extended

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Functions of and How to Use Adjustment Mode 7.6 Moment Zero-point Recheck [NOTICE] For the conditions and adjustment value of the moment zero-point recheck, refer to the moment zero-point adjustment item in the “Adjustment Value Table”.

6. Make fine adjustment as shown below. (The following fine adjustment procedures are extracted from “7.3 Moment Zero-point Check and Fine Adjustment”.)

1. Continued from “7.5 Moment Span Fine Adjustment”.

(1)Make an adjustment with the increase or decrease key so that the result becomes the zero-point adjustment value. Then, press the register key to save the adjusted value.

2. Retract the boom fully.

3. Raise the boom until it almost reaches to the maximum point, and then lower the boom until the boom angle display corresponds to the zero-point adjustment condition. (Hoist down the hook block until it almost touches the ground surface or chassis.)

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

7. Perform “7.5 Moment Span Fine Adjustment”.

Perform “7.6 Moment Zero-point Recheck”.

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

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

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

The moment adjustment is completed.

Moment ratio(%) Shows zero-point adjustment state Moment detector input(mV) 5. Has the indicated value become the zero-point adjustment value?

The actual load value less than 1 klbs is shown as follows: 0.00 to 0.99 klbs: “000” to “099” -0.99 to -0.01 klbs: “-99” to “-01” YES

NO

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Functions of and How to Use Adjustment Mode 8. Clock Adjustment AML has calender and clock IC inside, which is used for recording errors. Adjust the clock in the following procedure. Adjust the clock in the maintenance mode.

1. Select the main menu [• Adjust clock] in the maintenance mode, and press the register key to select the menu.

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

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

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

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

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

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

Display: [:Disp. Late data ]

1. Language

[:Disp. Max. data]

The menu [Language] is used to change the

3. Display of latest overload data

language for message appearing on the moment display. The message on the menu [Language] is always displayed in English.

The selection of [:Disp. Late data ] results in the latest registered overload history data being displayed. The time when overload history data has been registered is indicated in the moment display.

To view the next data on record (up to 50 items), press the scroll-down key.

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

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

Display example: [= Japanese ] Press the scroll-down key. [: English] The sign “=” at the left side of the message shows that the language is currently set to be used.

Moment display Display example: [99. 01. 23 12:35 ]

3. When the aimed language is displayed, press the register key. After the registration, the sign “:” at the left side of message changes to “=”.

Display example: [: English] Press the register key. [=English] 4. Press the display alteration key to exit the menu.

After this, the messages on the moment display are switched to the newly set language.

2. Overload History Display The records of crane operations beyond overloading limit are displayed. You can choose between the displays of latest overload data and of the greatest overload data.

1. Select the main menu [• Disp. O/L data ] in the adjustment mode, and press the register key to select the menu.

2. Use the scroll-up or scroll-down key until the menu of latest overload ratio or peak overload ratio appears. Select it by pressing the register key.

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Functions of and How to Use Adjustment Mode 3. Erasing the Overload History

4. Display of greatest overload data The selection of [:Disp. Max. data] results in the registered greatest overload history data being displayed.

The time when overload history data has been registered is indicated in the moment display.

Press the scroll-down key, and load ratio, jib length, and jib angle will be displayed (jib length and jib angle are displayed only during the jib lift).

Further press the scroll-down key, and the display will change into the next information (up to 10 items).

[NOTICE] When the AML main unit or EEPROM is replaced for repair and all adjustment is completed, erase-protect the overload history.

Before delivering the machine to an user, erase-protect the overload history by erasing the latest history data three times.

You can erase the overload history data (record of crane operation when moment load ratio exceeds the set limit). Note that if the latest history data are erased three times, the menu will not appear, disabling the history data to be erased. At the time of the third erasure, the records of the greatest overload values will also be erased.

Moment display Display example: [99. 01. 23 12:35 ]

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

[125% 14.5f 45.0° ]

2. Use the scroll-up or scroll-down key to display the overload history data item to be erased. Select it by pressing the register key.

Display: [:Erase Late dat ] [:Erase Max. data] 3. When the message [Erase OK?] appears, press the register key to erase the data.

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

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

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

(5)Revision date display: Indicates the date of data revision.

Display example:[96, 01, 23]

1. Program Version Display

3. Di Check

ROM program version is displayed.

The input state of Di (external contact switch) is 1. Select the main menu [• Maintenance ] in the

displayed.

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

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

2. When [:Prog. version ] is displayed, press the register key to select the menu.

2. Press the scroll-up or scroll-down key until the display [:Di check ] appears, and then press the register key to select the menu.

3. When the below program version appears, press the display alteration key to exit the menu.

Display example: [AML-L L0204 ]

3. Di input state is displayed. Display changes by scroll-up or scroll-down key.

Press the display alteration key to exit the menu.

Display example (Di1): [ 01 Over-wind of ]

program version number

2. Data ID Number Display Information of ROM data is displayed.

Indicates switch state

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

on : active of : not active Switch name

2. Find the display [:Data ID. number ] by the scroll-up or scroll-down key, and then press the register key to select the menu.

Indicates Di input terminal number.

01 to 28 : Di 1 to Di 28 T : TC A : ACC No indication: Serial port input (Di from multiplex data transmitter and signal transmitter)

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

Press the display alteration key to exit the menu.

The ROM data is displayed as follows: (1)ID number display: Indicates ROM ID number (revision number included).

Display example:[750200 ]

[NOTICE] Switch state means on/off state which the AML program judges logically.

Usually, this matches to the physical condition of switch. However, if “r” is added in front of the displayed “on” or “of”, these have different meanings as below. ron: Logically switch is active, but physical contact is off. rof: Logically switch is not active, but physical contact is on.

Only the Di switch used for input in the program can be displayed. Since the display sequence of Di switch input states depends on the contents of the

(2)Specification number display: Indicates crane spec. number.

Display example:[TR-500-3-00101 ] (3)Code number display: Indicates parts code number of AML. Display example:[361-175-02000 ] (4)Data date display: Indicates the date of making up data.

Display example:[95, 12, 27 ]

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W301-0351E

Functions of and How to Use Maintenance Mode program, the Di switch input states may not be indicated in the numerical order of Di switch input numbers.

[NOTICE] Only the Ai used for input in the program can be displayed. Since the display sequence of Ai input states depends on the contents of the program, the Ai input states may not be indicated in the numerical order of Ai input numbers.

4. Ai Check The input state of Ai (analog detector input) is

5. Elevating Cylinder Oil Pressure Monitor

displayed.

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

The cylinder extension lateral pressure and retraction lateral pressure which are detected for moment calculation are displayed.

2. Press the scroll-up or scroll-down key until the display [:Ai check ] appears, and then press the register key to select the menu.

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

3. Ai input state is displayed. Display changes by scroll-up or scroll-down key.

Press the display alteration key to exit the menu.

Display example (ANAiNB): [ 02 Boom A 1201 ok ]

2. Press the scroll-up or scroll-down key until the display [:Disp ELEV PRES ] appears, and then press the register key to select the menu.

3. The elevating cylinder extension lateral pressure

When detected input is within

and retraction lateral pressure are displayed.

Press the display alteration key to exit the menu.

Display example: [E . R . Mpa ]

the normal input range, “ok” appears; when it is out of the range, then “ng” appears at this portion.

Unit

A/D converted value of analog input.

Retraction oil pressure

Analog detector name

Extension oil pressure

Logical number of analog input in the program.

00:Moment input (MOINP, MOINN) 01:ANAiNA 02:ANAiNB 03:ANAiNC 04:ANAiND 05:ANAiNE 06:ANAiNF 07:Analog detector source (DET1SRC, DET2SRC) 08:Pressure input (ANAING) 09:Pressure input (ANAINH) 11 to 15:Serial port-1 analog input 1 to 5 (Ai from signal transmitter) 21 to 25:Serial port-2 analog input 1 to 5 (Ai from multiplex data transmitter)

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Functions of and How to Use Maintenance Mode 7. MDT Monitor (Multiplex Data Transmitter Monitor)

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

Also, you can invert the current state of selected output.

The input/output state of the MDT (multiplex data transmitter) is displayed.

1. Select the main menu [• Maintenance ] in the

1. Select the main menu [• Maintenance ] in the

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

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

2. Press the scroll-up or scroll-down key until the display [:MDT Monitor ] appears, and then press the register key to select the menu.

2. Press the scroll-up or scroll-down key until the display [:Do check ] appears, and then press the register key to select the menu.

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

transmitter) is displayed. Display changes by increase or decrease key. Press the display alteration key to exit the menu.

Display example: [ No.123 Val. 1]

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

Display example (RLY1): [ 00 Stoppage of ] Current output state

Input/output state Digital input/output: 1:ON 0:OFF Analog input/output: represented in numerals from 0 through 255.

Output name Logical output port number 00 to 07:RLY1 to PLY8 (relay output) 10 to 17:TR1 to TR8 (open collector output)

Input/output number

[NOTICE]

[NOTICE]

Output state means on/off state which the AML program judges logically (same as the Di). Usually, this matches to the physical condition of switch.

However, if “r” is added in front of the displayed “on” or “of”, these have different meanings as below. ron: Logically switch is active, but physical contact is off. rof: Logically switch is not active, but physical contact is on.

For the signal represented by the displayed input/output No., see the “MDT (Multiplex Data Transmitter) Input/Output Nos. and Corresponding Signals” in the INFORMATION AND DATA section.

8. Key Switch Check Check the key switch on the AML front panel whether it works normally or not.

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

4. During the above Do output monitoring procedure, output state will be inverted while you are pressing the check key.

2. Press the scroll-up or scroll-down key until the display [:key SW check ] appears, and then press the register key to select the menu.

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Functions of and How to Use Maintenance Mode Display example: [ Error:2003 ]

3. The display [– – – – – – – – – • – – – – – –] appears. Press any key other than the display alteration key, and the corresponding portion of display changes from “-“ to “ ” while you are pressing the key. Press the display alteration key to exit the menu.

(3)The mark “ ” on the error code display shows the another errors exist.

Press the scroll-down key to display the next error code.

9. Display Check The segments of LCD panels and LEDs of the AML indicator repeat to go on and off.

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

2. Press the scroll-up or scroll-down key until the display [:Display check ] appears, and then press the register key to select the menu.

3. The segments of LCD panels and LEDs of the AML indicator repeat to go on and off. Press the display alteration key to exit the menu and return to the ordinary display state.

10. Error Data Display Error data registered in the AML are displayed on the moment indicator and display panel 1.

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

11. Erasing the Error Data

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

Use this menu to erase the registered error data

display [:Disp. err data ] appears, and then press the register key to select the menu.

information.

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

3. The error codes are displayed on the moment indicator and display panel. Press the display alteration key to exit the menu and return to the ordinary display state.

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

(1)The moment indicator displays the time when

display [:Erase err data ] appears, and then press the register key to select the menu.

error occurred.

Display example: [ 96. 01. 23 12:35 ]

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

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

(2)When the scroll-down key, the time display changes to the error code display.

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

12. Option Board Check The state of the incorporated option board (analog

The Ao (analog output) state is displayed with an

output, wire detection) is indicated.

output value of the specified percentage.

1. Select the main menu [• Maintenance ] in the

1. Select the main menu [• Maintenance ] in the

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

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

2. Press the scroll-up or scroll-down key until the display [:OP board check ] appears, and then press the register key to select the menu.

2. Press the scroll-up or scroll-down key until the display [:Ao check ] appears, and then press the register key to select the menu.

3. The sort of the incorporated option board is

3. Ao output state is displayed as below.

displayed (Up to two option boards can be incorporated). Display changes by scroll-up or scroll-down key. Press the display alteration key to exit the menu.

Display example: [ 1 Valve control ]

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

Press the display alteration key to exit the menu.

Display example (CNTL1P•CNTL1N): [ 41 SWG RV 0 0 ] Output level for checking indicates at what percentage of the maximum level the value is to be output.

Option board name (1 valve control : Circuit board for analog output) (2 Rope LGTH DET : Circuit board for detecting wire rope movement to indicate hook block position)

Output level indicates at what percentage of the maximum level the value is being output.

Output name Ao output terminal number 11-19:Output to serial port 1 (Signal transmitter) 21-29:Output to serial port 2 (Multiplex data transmitter) 41-49:Output to option board (41:CNTL1P • CNTL1N) (42:CNTL2P • CNTL2N) (43:CNTL3P • CNTL3N) (44:CNTL4P • CNTL4N) [NOTICE] Only the Ao used for output in the program can be displayed. Since the display sequence of Ao output states depends on the contents of the program, the Ao output states may not be indicated in the numerical order of Ao output numbers.

4. How to see the output values for checking Using the increase or decrease key while the Ao output state is displayed, set up an output level for

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Functions of and How to Use Maintenance Mode 15. Adjust Monitor

checking. Every time you press the key, the level is increased or decreased by 1%. When the key is held down for more than one second, the level is increased or decreased by 10% for the increase key and by 5% for the decrease key. When the level exceeds 100%, it returns to 0% (conversely, when the level reaches 0%, it returns to 100%.)

The same items as shown in the [• Adjust ] menu of the main menu of the adjustment mode appears. However, adjustment is not available.

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

5. How to output the output values for checking While the output level for checking is indicated, press the check key; output level for checking will be output while the key is held down. The displayed output level value blinks.

2. Press the scroll-up or scroll-down key until the display [:Adjust Monitor ] appears, and then press the register key to select the menu.

3. The same items as shown in the [• Adjust ] menu

14. Sio Check

of the main menu of the adjustment mode are displayed.

Press the display alteration key to exit the menu.

The Sio (serial port) state is indicated.

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

16. Overload History Display The overload history display in the maintenance mode has the same function as that of in the adjustment mode.

See the “Overload History Display” in the “Functions of and How to Use Adjustment Mode” section.

2. Press the scroll-up or scroll-down key until the display [:Sio check ] appears, and then press the register key to select the menu.

3. Serial port state is displayed. Display changes by scroll-up or scroll-down key. Press the display alteration key to exit the menu.

Display example: [Serial port1 OK ]

17. Erasing the Overload History Erasing the overload history in the maintenance mode has the same function as that of in the adjustment mode.

See the “Erasing the Overload History” in the “Functions of and How to Use Adjustment Mode” section.

Serial port state OK : Normal NG : Abnormal NU : Not used

18. Clock Adjustment

Serial port name

Clock adjustment is included in the functions of

(Serial port 1:serial communication circuit to signal transmitter) (Serial port 2:serial communication circuit to multiplex data transmitter)

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

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Error Message Error Message

2. How to Read the Error Message 1. Error code in the error message is represented by

1. Display of Error Message

four-digit codes.

[NOTICE]

Error code: E1 E2 E3 E4

The language (English or Japanese) of error message is selected at the [• Language] menu in the adjustment mode.

lndividual code Group code 0:Alarm 1:Abnormal communication 2:Abnormal detector 3:Abnormality inside AML

Displays a failure message

2. The highest rank (E1 in the above figure) indicates error groups. The each next three digit figure (E2 through E4 above) indicates individual error code under error groups.

IW301-0131E09

3. Since group code “0” indicates a warning condition, it does not always mean that there is a problem in the system when an error message is displayed.

1. If AML system detects the trouble in ordinary use (user mode), it makes beep sound as well as displays error message on the moment display.

Display example: [Error:2001]

4. For this reason, warning-related error messages are not registered in the system’s error history memory. Warning-related error messages are shown in the moment display in the same way as message for other group codes.

Shows that an error of error code 2001 has occurred.

2. This error message display continues till the cause is eliminated.

3. How to Read the Error History

3. While the adjustment or maintenance mode is 1. Error history records 50 errors, maximum, of the

being used, only beep sound informs the operator of the occurrence of trouble. The display on the moment display, however, does not change to the error message display automatically. Current message keeps displayed.

group code, in order of occurrence. Those beyond 50 will be made to disappear in the order of occurrence.

2. See the “Error Data Display” in the “Functions of and How to Use Maintenance Mode” section for reading the error history.

4. To confirm the error message in the adjustment or maintenance mode, press the lift height limit key.

While you are pressing the key, the error message is shown on the moment display. (It may take some seconds for the display to change.)

5. If trouble remains even when you return to the user mode after exiting adjustment or maintenance mode, corresponding error message appears on the moment display.

61

W301-0351E

Error Message 4. Troubleshooting Table 4.1 Group Code 0 Message

Description

Warning : 0001 Warning : 0002 Warning : 0003 Warning : 0004

Right front outrigger beam retraction Right rear outrigger beam retraction Left front outrigger beam retraction Left rear outrigger beam retraction

Situation: Cause: Action:

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

Outrigger beam(s) have just retracted.

Extend the outrigger beam again.

Message

Description

Error : 0005

Boom angle value becomes out of specified range

Situation:

Boom extension automatically stops during setting of the side-up jib.

(Only applicable to the machines with side-up jib)

Cause: Action:

Boom angle is smaller than that required for jib setting.

Raise the boom till safety angle for jib setting.

Message

Description

Error : 0006

Improperly inserted jib lock pin

Situation: Cause: Action:

Boom extending operation automatically stops during setting or stowing of the side-up jib.

(Only applicable to the machines with side-up jib) Jib lock pins are in incorrect states.

(Jib lock, jib set and automatic lock pins have been inserted) Correct the lock pins property inserted.

Message

Description

Warning : 0010

Close to the swing angle restriction

Situation: Cause:

Action:

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

The boom is just close to the swing restriction angle.

The swing area restriction function is active, and the boom has been swung to a point just close to the limit. (The error code will remain displayed as long as the boom is in close to the limit for both left and right swing operation) Error code is displayed only when the slow swing stop function is canceled. (swing is not automatically stopped) Swing the boom away from the swing restriction point.

Cancel the swing area restriction function.

62

W301-0351E

Error Message

Message

Description

Warning : 0012

Rear stability auto. stop range

Situation: Cause: Action:

The rearward tipping load limit lowers below the current lifting load as the boom is swung.

The boom is raised too high.

The outrigger extension width is insufficient.

Lower the boom.

Increase the outrigger extention width.

Message

Description

Error : 0013 Error : 0014

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

Situation:

The swing angle does not conform with the condition detected by the over-front detection switch.

Over-front switch has detected as front though boom doesnot turn front.

(Obtains capacity of over-front detection switch as not in front.)

Cause:

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

Swing angle detector is defective or maladjusted.

Investigate the possible causes described above.

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

Action:

Message

Description

Warning : 0015

Overwinding condition (When overwinding stop function is cancelled)

Situation:

Cause: Action:

Overwinding detection switch has been turned off (overwinding status).

A crane does not stop automatically though the error code is displayed when overwinding is cleared.

Main or auxiliary hook block has been wound up excessively.

Hoist down the main or auxiliary winch.

Message

Description

Error : 0016 Error : 0017

State 1 is not applied (Outrigger, Swing angle, CW, combinations) State 2 is not applied (Boom and Jib combination)

Situation: Cause: Action:

Crane is automatically stopped while the outrigger, boom, jib and counterweight settings are out of the allowable condition, and operation toward a critical conditions is attempted.

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

Register the operation status again.

63

W301-0351E

Error Message

Message

Description

Error : 0018 Error : 0019 Error : 0020 Error : 0021

Boom (3rd-top boom sections for TR-300XL-4) full retraction switch 1 faulty Boom full retraction switch 2 faulty Boom full retraction switch 3 faulty Boom full retraction switch 4 faulty

Situation:

Cause:

Action:

Crane is automatically stopped when operation toward a critical condition is performed, when the specified boom section full retraction detector switch does not detect full retraction while the specified boom section is fully retracted, or vice versa.

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

Boom length sensor is defective or maladjusted.

The AML itself is defective.

Perform inspection for the possible causes listed above.

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

Message

Description

Warning : 0023

Stopped at 100% of crane performance

Situation:

Because the crane performance has exceeded 100%, a crane is automatically stopped when hoisting-up, boom lowering or boom extending is performed.

Cause: Action:

The allowable lifting capacity is exceeded.

Perfrom either of hoisting-down, boom raising, or boom retracting.

Message

Description

Warning : 0024

Stop due to two-blocking

Situation: Cause: Action:

Crane is automatically stopped when operation toward a critical condition is performed while the two-blocking detection switch is turned off (Two-blocking status).

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

Hoist down the main or auxiliary winch.

Message

Description

Warning : 0025

Stopped due to backward stability

Situation: Cause: Action:

The crane is in a state where the backward stability is not assured, boom raising/retracting operation should be stopped automatically.

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

The outrigger extension width is too small.

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

64

W301-0351E

Error Message

Message

Description

Warning : 0026

Stopped at upper boom angle limit restriction

Situation: Cause: Action:

Crane operation is automatically stopped when operation toward a critical condition is attempted while boom angle exceeds the upper limit.

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

Lower the boom.

Cancel the upper boom angle limit restriction.

Message

Description

Warning : 0027

Stopped at lower boom angle limit restriction

Situation:

Crane operation is automatically stopped when operation toward a critical condition is attempted while boom angle exceeds the lower limit.

Cause: Action:

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

Raise the boom.

Cancel the lower boom angle limit restriction.

Message

Description

Warning : 0028

Stopped at lifting height restriction

Situation: Cause: Action:

Crane operation is automatically stopped when operation toward a critical condition is attempted while lifting height exceeds the limit.

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

Lower or retract the boom.

Cancel the lifting height restriction function.

Message

Description

Warning : 0029

Stopped at load radius restriction

Situation: Cause: Action:

Crane operation is automatically stopped when operation toward a critical condition is attempted while the load radius exceeds the limit.

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

Raise or retract the boom.

Cancel the load radius restriction function.

65

W301-0351E

Error Message

Message

Description

Warning : 0034 Warning : 0035

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

Situation: Cause: Action:

Hoisting-down is automatically stopped by over-unwinding prevention device as the main/aux. wire rope on the winch drum is drawing to the end.

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

The hook block position is too low.

Adjust the number of part line as specified, or perform winch winding operation.

Message

Description

Error : 0037

Defective accumulator pressure (sensor)

Situation:

Abnormal accumulator pressure is detected. (Only for models with accumlator pressure detector) (This message does not relate to the control by the AML)

Cause:

Accumulator pressure is too low.

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

AML (analog circuit board) is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Action:

Message

Description

Error : 0041 Warning : 0078

Wrong counterweight state registered Altered counterweight state

Situation:

Cause:

Action:

Crane operation is automatically stopped when operation toward a critical condition is attempted when the detected counterweight status is different from the registered one.

(Applicable only to the error code 0041) (Crane does not stop automatically when “Warning:0078” is displayed) Defective counterweight state detector, improper installation or adjustment of the detector, open wiring of the detector circuit.

Altered combination of the counterweight.

Search for the cause of the detector defect. The status of any input from the detector can be checked using the “Di check” function from the “Maintenance” menu.

Register the counterweight state again.

Message

Description

Warning : 0042 Warning : 0043

Right swing restriction limit Left swing restriction limit

Situation: Cause: Action:

Boom is swing to a point exceeding the swing restriction limit setting. Crane is automatically stopped if swing automatic stop function is provided.

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

Swing the boom in the opposite direction to the setting.

Cancel the swing restriction function.

66

W301-0351E

Error Message

Message

Description

Warning : 0046

Condition setting altered

Situation: Cause: Action:

Crane state has changed.

Outrigger jacks have been retracted.

Register operation status again.

Message

Description

Warning : 0047

Hook block contacts to the elevating cylinder

Situation:

Hook block approaches the space where it can hit the elevation cylinder rod.

Cause: Action:

Boom raised too high while it is almost fully retracted.

Extend or lower the boom.

Message

Description

Warning : 0056

Swing operation is dangerous

Situation: Cause: Action:

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

The boom has been swung to a point just before the region where the capacity is reduced in retraction with outrigger extension width.

Swing the boom in the opposite direction.

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

Message

Description

Warning : 0057 Warning : 0058 Warning : 0059 Warning : 0060

Right front outrigger state change Right rear outrigger state change Left front outrigger state change Left rear outrigger state change

Situation:

Cause: Action:

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

A crane does not stop automatically.

Outrigger extension width has decreased unintentionally.

If reduced capacity does not matter, continue to use the crane. If the capacity is expected to be exceeded, re-extend the outrigger further and register working state again.

67

W301-0351E

Error Message

Message

Description

Error : 0067

Abnormal moment [Strain gauge detector] Does not stop

Warning : 0113

Abnormal moment [Pressure sensor detector] Can not operate to dangerous direction

Situation:

Cause:

Action:

Actual lifting load display value calculated in the AML becomes a minus value because of an abnormal moment detector.

Therefore, re-adjustment of the moment detector is required.

(0067: Only warning, automatic stop does not work) (0113: Crane operation is stopped when operation toward a critical condition is attempted) Abnormal detectors (Boom length detector, strain gauge type and/or pressure sensor type moment detector).

Maladjusted detector.

Abnormal AML main body (Analog board).

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

Readjust the corresponding detector (pressure sensor).

Investigate the detector which seems to be defective.

Input status from the detector can be confirmed by “Ai” check of “Maintenance” menu and “Elevating cylinder pressure monitor”. (“Ai” check related items: [Boom L], [Boom A], [MMT V], [DRC EXT], [DRC RTR] etc.)

Raise the boom. (error code: In case of 0113)

Message

Description

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

Abnormal swing angle Abnormal boom length Abnormal boom angle Abnormal extension width of the right front outrigger Abnormal extension width of the right rear outrigger Abnormal extension width of the left front outrigger Abnormal extension width of the left rear outrigger

Situation:

The detected value from the corresponding detector is out of the normal range and the detector requires readjustment.

Alarm is output but automatic stop does not work. For the errors which cause automatic stop, see the fllowing ones.

Cause:

Action:

Abnormal swing angle

Message : 2016 - 2019, 2021

Abnormal boom length

Message : 2007, 2008

Abnormal boom angle

Message : 2004

Abnormal outrigger extension width

Message : 2009 – 2012

Misadjastment or misalignment.

Improper installation of the detector.

The AML itself is defective. (Analog board is defective) Readjust the corresponding detector.

Insrall the corresponding detector properly and readjust it.

If the detectors are not defective, replace the AML main unit (analog board).

68

W301-0351E

Error Message Message

Description

Warning : 0075

Spring lock state has changed

Situation: Cause: Action:

Spring lock state has changed.

(Only for models with spring lock state detection) Spring lock released unintentionally.

Spring lock has been released by mistake.

Set spring lock again.

Message

Description

Warning : 0077

Altered front or rear jack state

Situation:

The actual front or rear jack state has changed from the registered one.

(Only for models with spring lock state detection)

Cause:

Front or rear jack has operated.

Defective detector.

The AML itself is defective. (Analog board is defective) Return the front or rear jack to the original condition.

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

Action:

Message

Description

Warning : 0078

Altered counterweight state (refer to 0041)

Message

Description

Warning : 0081

Elevation motion slowing down

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

Situation: Cause:

Action:

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

The boom has been elevated close to a stop angle (100% stop, restriction limit stop, stroke end stop, or rear stability stop), and the elevation slow stop function has been activated, and the elevation speed is reduced. (The error code is displayed only when the boom is being elevated) Stop operating the boom.

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

Cancel the boom angle limit restriction function.

Move the boom to the non-critical side.

Message

Description

Warning : 0082

Swing motion slowing down

Situation: Cause:

Action:

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

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

The boom has swung close to a stop angle (either 100% stop or range limit stop) and the slow swing stop function has been activated, and swing speed is reduced. (The error code is displayed only when the boom is being swung to the left or right) Stop the swing operation.

Swing away from the limit.

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

Cancel the swing limit restriction function.

69

W301-0351E

Error Message

Message

Description

Warning : 0085

Elevation stopped at stroke end

Situation: Cause:

Action:

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

Crane operation is automatically stopped when operation toward a critical condition is attempted while boom elevating operation is stopped due to elevation stroke end.

Boom elevating is automatically stopped just before the elevating cylinder stroke end because the moment cannot be detected correctly by the oil pressure in the elevating cylinder if the cylinder is reached/extended to stroke end.

Stop operation which has caused automatic stop.

Operate the boom in the opposite direction which has caused automatic stop.

Message

Description

Warning : 0088

Stopped at jib limit

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

Situation: Cause: Action:

Crane operation is automatically stopped when operation toward a critical condition such as hoisting-up, lowering or extending the boom is attempted.

In the state of AML setting to boom while extending the jib, is exceeding the lifting capacity.

Perform operation toward non-critical condition, such as hoisting-down, raising or retracting the boom.

Message

Description

Warning : 0113

Abnormal moment [Pressure senser detector] (refer to 0067)

Message

Description

Warning : 0117

Boom contact warning

Situation:

The boom approaches the mirror or engine cover, etc.

Cause:

The boom, stowing jib and/or elevating cylinder approach (es) the mirror or engine cover etc. of the carrier, there is a possibility to come in contact if operating the boom lowering or swinging further.

Operate watching the obstacles when operating the boom lowering or swinging.

Action:

70

W301-0351E

Error Message 4.2 Group Code 1 Message

Description

Error : 1001 Error : 1002

Serial port transmission line 1 open Selial port transmission line 2 open

Situation:

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

Cause:

A part of wiring to the transmitter is open.

The connector pins of wiring to the transmitter are in poor contact.

The receiving circuit of transmitter or the transmitting circuit of AML is defective.

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

Replace the transmitter or AML’s power circuit board.

Action:

Message

Description

Error : 1003 Error : 1004

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

Situation: Cause:

Action:

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

The line from the transmitter includes open wiring or poorly contacting connection.

The transmitter is not connected (the connector is disconnected).

The receiving circuit of AML or the transmitting circuit of transmitter is defective.

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

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

Replace the transmitter or AML’s power circuit board.

Replace the serial port fuse of AML.

Message

Description

Error : 1005 Error : 1006

Transmitter 1 defect Transmitter 2 defect

Situation: Cause: Action:

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

The internal circuit of transmitter is defective.

Replace the defective transmitter.

71

W301-0351E

Error Message

Message

Description

Error : 1007 Error : 1008 Error : 1009 Error : 1010

Transmitting data error at serial port 1 Transmitting data errot at serial port 2 Receiving data error at serial port 1 Receiving data error at serial port 2

Situation: Cause: Action:

All operations except boom swing are unavailable due to a discrepancy between the data transmitted/received by the AML and the data received/transmitted by the transmitter.

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

The signal wire connection is in poor contact.

Turn off any device which is emitting strong noise.

Check the signal wire for poor connection. Repair or replace the wiring as appropriate.

Message

Description

Error : 1011 Error : 1012

Transmitter type improper (serial port 1) Transmitter type improper (serial port 2)

Situation:

All operations except boom swing are unavailable due to the wrong transmitter connected to the serial port.

Action:

Connect a proper transmitter to the serial port.

72

W301-0351E

Error Message 4.3 Group Code 2 Message

Description

Error : 2001

Moment detector trouble

Situation:

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

Cause:

The moment detector is defective, or its wiring is open.

The AML itself is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Action:

Message

Description

Error : 2003

Boom length detector trouble

Situation: Cause: Action:

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

The boom length detector is defective, or its wiring is open.

The AML itself is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Message

Description

Error : 2004

Boom angle detector trouble

Situation: Cause: Action:

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

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

The AML itself is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Message

Description

Error : 2005

Jib length detector trouble

Situation:

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

Cause:

The jib length detector is defective, or its wiring is open.

The transmitter unit is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Action:

73

W301-0351E

Error Message

Message

Description

Error : 2006

Jib angle detector trouble

Situation: Cause: Action:

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

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

The transmitter unit is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Message

Description

Error : 2009 Error : 2010 Error : 2011 Error : 2012

Right front outrigger length detector trouble Right rear outrigger length detector trouble Left front outrigger length detector trouble Left rear outrigger length detector trouble

Situation:

The input data from the outrigger length detector are abnormal.

Cause:

The outrigger length detector is defective, or its wiring is open.

The AML outrigger length detector is maladjusted. (For multiplex data transmitter) The transmitter unit is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Action:

Message

Description

Error : 2017 Error : 2019

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

Situation: Cause:

Action:

All operations except boom swing are unavailable due to the input data from the swing angle detector inconsistent with the swing dead angle detector switch position.

Swing angle detector is faulty or maladjusted, or its wiring is open.

Swing dead angle detector switch is faulty or maladjusted, or its wiring is open.

The AML itself is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai & Di check” function from the “Maintenance” menu.

74

W301-0351E

Error Message

Message

Description

Error : 2021

Swing angle detector offset trouble

Situation: Cause: Action:

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

The swing angle detector is faulty.

The AML itself is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu.

Message

Description

Error : 2022 Error : 2023

Boom elevation cylinder extension pressure detector trouble Boom elevation cylinder retraction pressure detector trouble

Situation:

All operations except boom swing are unavailable due to the abnormal input value from the oil pressure detector in the boom elevating cylinder’s extension/retraction chamber.

Cause:

The pressure detector is defective, or its wiring is open.

The AML itself is defective.

Perform inspection for the possible causes listed above.

The status of any input from the detector can be checked using the “Ai check” function from the “Maintenance” menu. ( “Ai check” related items : [DRC EXT], [DRC RTR]

Action:

75

W301-0351E

Error Message 4.4 Group Code 3 Message

Description

Error : 3003

System trouble (sum check error)

Situation:

All operations except boom swing are unavailable because ROM has been found abnormal as a result of sum check.

Cause:

The AML‘s CPU board is defective.

ROM defective.

Replace the AML’s CPU board.

Replace ROM.

Action:

Message

Description

Error : 3006

System trouble (EEPROM defect)

Situation: Cause: Action:

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

The AML’s CPU board is defective.

EEPROM is defective.

Replace the AML’s CPU board or EEPROM.

Message

Description

Error : 3007 Error : 3008 Error : 3009 Error : 3011 Error : 3012 Error : 3013 Error : 3017

System trouble (RAM trouble) System trouble (RAM trouble) System trouble (CPU trouble) System trouble (bus error) System trouble (address error) System trouble (unauthorised instruction) System trouble (privilege violation)

Situation: Cause: Action:

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

The AML’s CPU board is defective.

Replace the AML’s CPU board.

If this error has occurred, the relevant error message is displayed and the AML stops processing. (There is a continuous beep and two LEDs in the adjustment window illuminate) While the AML’s CPU board is suspected to be defective, check the inside of the AML for any abnormality such as loose connectors.

Message

Description

Error : 3010

System trouble (A/D converter trouble)

Situation:

All operations except boom swing are unavailable due to abnormal input to the A/D converter.

Cause:

AML’s CPU board and/or analog board are defective.

Wiring for the analog defector is abnormal (short-circuit).

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

Check the connection (resistance) of analog detectors (one connected with AML itself).

Action:

76

W301-0351E

Disassembly of AML Main Unit 2.

Disassembly of AML Main Unit 1.

Removing Rear Panel/Connector Board

[NOTICE]

Removing Front Panel/Display Board

◆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. Take off the rear panel and connector board as an assembly from the unit case by unscrewing screw(c).

1. Take off the front panel and display board as an assembly from the unit case by unscrewing screw(a).

2. Remove the spacer(e) and separate the connector board.

2. Separate the display board by unscrewing screw(b).

b Display board IW301-0131E20

77

W301-0351E

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

3.1 Notes on ROM/EEPROM Replacement [NOTICE]

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

◆EEPROM stores the adjustment values for each specification number. When replacing the CPU board, reuse the EEPROM after removing it from the broken CPU board.

1. Take off the front panel and display board as an assembly from the unit case by unscrewing screw(a). Then take off the rear panel and connector board as an assembly from the unit case by unscrewing screw(c).

When replacing ROM and EEPROM, make sure that the concavities of IC and socket meet each other.

CAL/CLOCK

Battery CN1

EEPROM CN4 PLD

ROM 1 CPU

ROM 0

CN2 CN3

CPU board IW301-0131E25

2. Take off the CPU Board by unscrewing screw(f).

Then remove the spacer(h) and take off the analog board and power board as an assembly from the unit case. Next, separate the analog board by removing nut(g).

Analog board

h

Power board

Unit case

g

f CPU board IW301-0131E24

78

W301-0351E

Adjustment Value Table (TL-300E-3) [INFORMATION AND DATA] Adjustment Value Table (TL-300E-3) Specification No. : TL-300E-3-00107 (2M2D-specification) AML model

: AML-L D

AML code No.

: 361-922-00000

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

TL-300E-3-00107

2. Adjustment the detector Precautions for adjustment (*1) Adjust the center of dispersion to coincide to the adjusting value. (*2) Adjust the boom angle and the moment in the elevating lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) When adjusting the moment, make the number of parts of line to the standard number (four parts of line) that is when boom fully extended, and set the AML as Boom status: Boom and Number of parts of line:4.

Adjustment item

Boom length

Boom angle (*2)

Condition

Adjustment value

Tolerance

Zero-point adjustment

Boom length: Fully retracted

10.50 m

±0.04m (±0.08m for zero-point check)

Span adjustment

Boom length: Fully extended

33.00 m

±0.04m

Zero-point adjustment

Boom angle: 0.0° (actual value)

0.0°

±0.1° (±0.2°for zero-point check)

Span adjustment

Boom angle: 80.0° (actual value)

80.0°

±0.1°

Zero-point adjustment

Swing position : front (Right swing)

Span adjustment

Swing position : rear (Right swing)

±0.3° (±0.6°for zero-point check) ±0.3° Swing (±0.6°for angle2:360.0° zero-point check) Swing ±0.3° angle1:180.0° Swing ±0.3° angle2:180.0° Swing angle1:0.0°

Swing angle (*3)

79

W301-0351E

Adjustment Value Table (TL-300E-3)

Adjustment item

Condition Boom length: Fully retracted

Zero-point adjustment

Boom angle: 80.0±0.1° (indicated value) Lifting capacity : Without load (0.28t hook only) Hook : Two-blocking status

Adjustment value

Tolerance

0.23t Hook block mass minus Wire rope mass

±0.15t

8.00m

±0.06m

Boom length: Fully extended Moment (*2) (*4)

Load radius adjustment

Load radius: 8.00m (actual value) Rated lifting capacity: 7.00t Boom length: Fully extended

Span fine adjustment

Boom angle: 20.0±0.1° (indicated value) Lifting capacity : Without load (0.28t hook only) Hook : Hoisting-down until immediately before the ground plane

3. Slow stop adjustment Not set 4. Setting after adjustment 1. Setting of the number of parts of line: not set 2. Language switch : English

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W301-0351E

0.28t Hook block mass

±0.01t

Checking the Detectors (TL-300E-3) Checking the Detectors (TL-300E-3)

2. Boom Angle Detector 1. Retract the boom fully, set the boom angle to 0

1. Boom Length Detector

degree and turn off the PTO switch.

1. Retract the boom fully, set the boom angle to 0 degree and turn off the PTO switch.

2. Measure resistance of the potentiometer.

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D:833±167Ω A-D:146±29Ω

2. Measure resistance of the potentiometer.

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D:833±167Ω B-D:458±92Ω

Boom angle detector

Boom angle detector

A

E

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

A

B

ANAINA 3 DET1GND 1

DET1SRC 2

C

ANAINB 4

A

ANAINA 3 DET1GND 1

B D

D

D C

E

E

C B

DET1SLD 6

Boom length detector

B D

IW301-0131E10

Boom length detector IW301-0131E10

Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector.

Then pull out the CN1 connector and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1:833±167Ω 4-1:146±29Ω

Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector.

Then pull out the CN1 connector and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1:833±167Ω 3-1:458±92Ω

Boom angle detector

Boom angle detector

45

16

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

45

30 ANAINA 3 DET1GND 1 30

1

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

ANAINA 3 DET1GND 1

B D

16

1

B D

Boom length detector IW301-0132E33

Boom length detector IW301-0132E33

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W301-0351E

Checking the Detectors (TL-300E-3) 3. Swing Angle Detector

4. Outrigger Extension Width Detector

1. Swing the boom to over-left-side and turn off the

1. Stow the outriggers and turn the starter switch to

PTO switch.

OFF.

2. Measure resistance of the potentiometer.

2. Remove the wire for the detector from the outrigger and hold the wire, letting it protruding by 3.1 in (80mm) from the guide hold of the detector.

Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D:1--15Ω B-D: 382±20Ω

3.1 in (80 mm) IW301-0131E12

3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B:2000±100Ω W-B:200±30Ω

Checking at the CN1 connector of the AML Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector and measure resistance of the potentiometer. The specified resistance values are as follows: 5-1:1--15Ω 9-1:382±20Ω

W

B

R

5V AVCC

R

IN Ai1

W

GND AGND

B

FL IW301-0131E13

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W301-0351E

Checking the Detectors (TL-300E-3) 5. Pressure Sensor for Moment Detection 1. Turn ON the PTO switch. (5-V DC will be applied between R and B of the pressure sensor connector.)

2. Measure the output voltage between W and B of the pressure sensor connector.

W

B

R

DET3SRC 33

R

ANAING 34

W

DET3GND 32

B

(ANAINH 35)

SPS3

(SPS4)

IW301-0131E14

3. The output voltage between W and B is

Output (V DC)

proportional to the pressure in the elevating cylinder.

The specified value is as shown below.

4.5

0.5 0

Pressure (MPa)

35 IW301-0131E15

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W301-0351E

Fuses Fuses

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.

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

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W301-0351E

Replacing the Clock Battery Replacing the Clock Battery [NOTICE] When the clock battery is worn out, the adjusting values, error codes and driving history cannot be backed up (saving data at power OFF).

Also, when the error code or driving history is recorded in AML, an accurate date and time cannot be recorded.

Two built-in clock batteries are on CPU board of the AML main unit.

Replace both 2 pieces when you replace the battery.

3. Attach a new battery on the CPU board by pressing the battery diagonally. (Refer to the figure below) The battery positive side must be faced up.

The built-in clock battery longevity is usually about 10 years.

If the built-in clock batteries are worn out, replace them according to the following procedures.

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.

[NOTICE] Two built-in clock batteries are on CPU board of the AML main unit.

Replace both 2 pieces when you replace the battery.

4. Install the CPU board in the AML main unit.

5. Reconnect the connector to the board.

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.

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W301-0351E

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

Publication No.

W301-0351E

Service Manual (AML-L D)

01 Overload Prevention Device Model

PRINTED IN JAPAN 0703

E

W301-0351E

ｃ ◯2007

AML-L D