Tadano Faun Load Moment Indicator AML- LK Service Manual - PDF DOWNLOAD

Publication No.

04 Load Moment Indicator Model

AML- LK

W301-0234E

Foreword Foreword

1. Applicable Spec. No. 2007.11.

This service manual covers the load moment indicator

Applicable crane model

(AML-LK) installed on the TADANO cranes in the chart below.

TR-600XL-4

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

Specification numbers:

crane-covering service manual for pertinent

(1) GR-600-1-00101 (2M2D-specification)

information.

TR-600XXL-4

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

Specification numbers:

catalog.

(1) GR-600-1-00103 (2M2D-specification) TR-800XXL-4 Specification numbers: (1) GR-800-1-00101 (2M2D-specification) TT-600XL-1 Specification numbers: (1) GT-600-1-90102 (2M2D-specification) TT-800XXL-1 Specification numbers: (1) GT-800-1-90102 (2M2D-specification) Use this manual for machines with the load moment indicator (AML-LK) 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.

1

W301-0234E

Foreword 2. Contents

1. Applicable Spec. No.......................................... 1 2. Contents............................................................ 2

Selecting Winch Condition....................................42 Selecting Jib Mounted Condition ..........................42 Load Moment Indicator Pre-operational Inspection............................................43 How to Use the Working Range Limit Function....44 Display Alteration ..................................................48

Components of the Load Moment Indicator (AML-LK) Main Unit........................ 5

Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1)......... 49

Foreword

....................................................... 1

Mode Structure .....................................................49 Configuration and Functions of the Load Moment Indicator System (TT-600XL-1)...........50 Configuration and Functions of the Load Moment Indicator System (TT-800XXL-1) ........53 Names and Functions of Load Moment Indicator Main Unit Parts ...................................56 Selecting Operational Status ................................62 Selecting Winch Condition....................................66 Selecting Jib Mounted Condition ..........................66 Load Moment Indicator Pre-operational Inspection............................................67 How to Use the Working Range Limit Function....68 Display Alteration ..................................................72

Diagram of the Load Moment Indicator (AML-LK) System (TR-600XL-4/TR-600XXL-4/ TR-800XXL-4) ................................ 6

Diagram of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) ........... 7

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TR-600XL-4/TR-600XXL-4/ TR-800XXL-4) ................................ 8

[ADJUSTMENT AND MAINTENANCE].......... 73

General: Adjustment Mode and Maintenance Mode ............................................ 73

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) ......... 17

1. Keys and Switches for Adjustment and Maintenance .......................................73 2. Mode Structure and Menu ...............................74 3. Method of Shifting Modes................................76 4. Method of Menu Selection...............................77

[OPERATION]................................................. 26

Functions of and How to Use User Mode (TR-600XL-4/TR-600XXL-4/ TR-800XXL-4) .............................. 26

Required Adjustment After AML System Parts Replacement................................ 78

Mode Structure ..................................................... 26 Configuration and Functions of the Load Moment Indicator System................................. 27 Names and Functions of Load Moment Indicator Main Unit Parts................................... 31 Selecting Operational Status................................ 37

2

W301-0234E

Foreword Functions of and How to Use Adjustment Mode .................. 79

5. Elevating Cylinder Oil Pressure Monitor........102 6. Do Check .......................................................103 7. MDT (Multiplex Data Transmitter) Monitor.....103 8. Key Switch Check..........................................105 9. Display Check................................................105 10. Error Data Display .........................................105 11. Erasing the Error Data ...................................106 12.OP (Option) Board Check..............................106 13. Ao Check .......................................................106 14. Sio Check ......................................................107 15.Adjust Monitor................................................107 16. Overload History Display ...............................107 17.Erasing the Overload History.........................107 18. Clock Adjustment...........................................107

1. Adjustment Initialization .................................. 80 1.1 Procedure of Conversion Factors Resetting ............................... 80 1.2 Procedures of Moment Adjustment Resetting ......................... 80 2. Capacity Setting .............................................. 81 2.1 Procedure of Head-off Capacity Setting... 81 2.2 Procedure of Jib Selection ....................... 82 2.3 Procedure of Single Top Selection ........... 82 2.4 Procedure of Winch Drum Position Setting .................................. 83 3. Boom Length Adjustment................................ 84 4. Boom Angle Adjustment.................................. 85 5. Swing Angle Adjustment ................................. 86 6. Outrigger Extension Width Adjustment ........... 87 7. Moment Adjustment ........................................ 88 7.1 Moment Zero-point Adjustment ................ 89 7.2 Moment Span Preliminary Adjustment ..... 90 7.3 Moment Zero-point Check and Fine Adjustment.................................. 90 7.4 Load Radius Adjustment .......................... 91 7.5 Moment Span Fine Adjustment ................ 91 7.6 Moment Zero-point Recheck .................... 92 8. Clock Adjustment ............................................ 93 9. Adjustment of Swing Output ........................... 94 9.1 Procedure of Resetting Ao Offset Value... 94 9.2 Adjustment of Swing Output (Ao offset adjustment) ........................ 94 10.Adjustment of Elevation Output ...................... 96 10.1 Procedure of Resetting Elevation Data .... 96 10.2 Adjustment of Elevation Output (elevation speed adjustment) ............. 96 Other Functions and How to Use Them ............ 98 1.Language........................................................ 98 2.Overload History Display ................................ 98 3.Erasing the Overload History.......................... 99

Error Message .............................................. 108 1. Display of Error Message ..............................108 2. How to Read the Error Message ...................108 3. How to Read the Error History.......................108 4. Troubleshooting Table ...................................109 4.1 Group Code 0 .........................................109 4.2 Group Code 1 .........................................118 4.3 Group Code 2 .........................................120 4.4 Group Code 3 .........................................123

Disassembly of AML Main Unit..................... 124 1. Removing Front Panel/Display Board/CPU board .............................125 1.1 Notes on ROM/EEPROM Replacement.....................................125 2. Removing Rear Panel/Connector Board/Option board ..........................126 3. Removing Analog Board/Power board ..........126

Functions of and How to Use Maintenance Mode..................... 100 1. Program Version Display .............................. 101 2. Data ID Number Display ............................... 101 3. Di Check........................................................ 101 4. Ai Check........................................................ 102

3

W301-0234E

Foreword [INFORMATION AND DATA] ....................... 127

Adjustment Value Table................................ 127 Specification No. : GR-600-1-00101 (2M2D-specification) ........................ 127 Specification No. : GR-600-1-00103 (2M2D-specification) ........................ 129 Specification No. : GR-800-1-00101 (2M2D-specification) ........................ 131 Specification No. : GT-600-1-90102 (2M2D-specification) ........................ 132 Specification No. : GT-800-1-90102 (2M2D-specification) ........................ 135

Checking the Detectors (TR-600XL-4/TR-600XXL-4/ TR-800XXL-4) ............................ 137 1. Boom Length Detector .................................. 137 2. Boom Angle Detector .................................... 137 3. Swing Angle Detector.................................... 138 4. Outrigger Extension Width Detector ............. 138 5. Pressure Sensor for Moment Detection........ 139

Checking the Detectors (TT-600XL-1/TT-800XXL-1) ....... 140 1. Boom Length Detector .................................. 140 2. Boom Angle Detector .................................... 140 3. Swing Angle Detector.................................... 141 4. Outrigger Extension Width Detector ............. 141 5. Pressure Sensor for Moment Detection........ 142

Fuses

................................................... 143

Replacing the Clock Battery ......................... 144

4

W301-0234E

Components of the Load Moment Indicator (AML-LK) Main Unit Components of the Load Moment Indicator (AML-LK) Main Unit RLY3, 4 fuse (3A) RLY1, 2 fuse (3A) MAIN fuse (3A)

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

CN1

SIF2 fuse (2A)

ZERO CNTL 6 SPAN

HALT

WDT

ZERO

SPAN

PROTECT

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

ZERO CNTL 5 SPAN

SIF1 fuse (2A)

Abnormality display LED (CPU abnormality.)

Moment input short-circuit switch (Not used.)

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

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

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

Top view Boom lift indicative symbol

Moment display

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

MBGND MBGND MOGND MOSRC MOINP MOINN MOSLD NC NC SIF1GND SIF1SRC SIF1TXD+ SIF1TXDSIF1RXD+ SIF1RXDSIF1SLD

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

(CNTL3P) (CNTL3N) (CNTL4P) (CNTL4N) (CNTLSLD) SIF2GND SIF2SRC SIF2TXD+ SIF2TXDSIF2RXD+ SIF2RXDSIF2SLD

16 17 18 19 20 21 22 23 24

(RE1GND) (RE1SRC) (RE1INA) (RE1INB) (RE1SLD) DI 21 DI 22 DI 23 DI 24

7 8 9

RTS CTS

Boom angle indicative symbol Jib angle indicative symbol

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

17 18 19 20 21 22 23 24 25 26 27 28 29

MBPW MBPW RLYPW RLYPW TC ACC NC DI 5 DI 6 DI 7 DI 8 DI 9 DI 10

CN2 13 14 15 16 17 18 19 20 21 22

(CNTL1P) (CNTL1N) (CNTL2P) (CNTL2N) DI 15 DI 16 DI 17 DI 18 DI 19 DI 20

CN3 10 11 12 13 14 15

(RE1GND) (RE1SRC) (RE1INA) (RE1INB) (RE1SLD) NC

CN4 4 5 6

RD SG

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

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

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

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

1 2 3 4 5 6 7 8 9

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

1 2 3

FG DSR TD

Single-top lift indicative symbol

Jib angle display

Swing

SOL3, 4 FUSE: 250V 2A

Elevating

PWMFREQ CNTL 1

CNTL 2

CNTL 3

CNTL 4

ZERO SPAN

Real load display

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

Rated lifting capacity display

Lifting height indicative symbol

Load radius limit restriction indicative symbol

SPAN ZERO SPAN

Left swing

Lower boom angle limit restriction symbol

ZERO SPAN

Boom lower

Right side view (Name plate)

Output adjustment trimmer (Adjusted by AML maker.

Do not touch.)

CN2 CN3

CPU board

Moment display contrast adjuster LCD panel contrast adjuster Option board (for Ai,Do extension) Connector board

CN1 Connector

Lower boom angle limit restriction indicator lamp

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

Load radius display

Lower boom angle limit restriction key

CN2 Connector

LCD panel

Upper boom angle limit restriction key

% deg

Over-front position symbol

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

Lifting height restriction key

CN3 Connector

Load radius restriction indicator lamp

Outrigger state indicative symbol

Right swing restriction indicator lamp

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

CN4 Connector (Not used.)

Left swing restriction indicator lamp Load radius restriction key

Suspension lock state indicative symbol

Display alteration key

Increase key

Register key

Boom position indicator

Right swing restriction key

Decrease key

Number of part-lines of rope select key Check key

Outrigger mode select key

Left swing restriction key

Front view 5

ROM 1 ROM 0

CPU

Upper boom angle limit restriction indicator lamp

Lift mode select key

EEPROM

CN1

Boom raise

Lifting height restriction indicator lamp

m deg

Boom angle display

CAL/CLOCK

ZERO

Load radius indicative symbol

Boom length display

Battery

Right swing

Connector terminal Nos.

Jib lift indicative symbol

Boom length indicative symbol

SOL1, 2 FUSE: 250V 2A

W301-0234E

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

Power board Analog board CPU board Display board

Right side view IW301-0231E01

5

Diagram of the Load Moment Indicator (AML-LK) System (TR-600XL-4/TR-600XXL-4/TR-800XXL-4) Diagram of the Load Moment Indicator (AML-LK) System (TR-600XL-4/TR-600XXL-4/TR-800XXL-4) Boom angle detector

CONNECTOR BOARD A C B D E

Boom length detector

Pressure sensor (Main)

Swing free input Auto. stop override signal input

Working condition input

Auto. stop override signal input

24(V)

Pressure sensor for moment detection (Elevating)

Auto.stop signal output SOL.

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

Outrigger extension width detector (4 peace)

Slow stop(Elevating)

MDT (multiplex data transmitter) lower unit

Outrigger retraction operation detection input

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

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

Latch

Fuses

Di SW. input block

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

Fuses

Current Amplifier Circuit

SOL5, 6 (2A)

CPU BOARD

SIF 1 (2A)

SIF 2 (2A) MAIN (3A)

POWER BOARD

EEPROM

RAM

CAL/CLOCK

DISPLAY BOARD

CPU

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

Relay

DC power block

Key input

+12V -12V +5V

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

SCI

+20V

LCD panel (1)

Serial input/output circuit LCD panel (2)

LCD SW . backlights

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

Buzzer

CHR display

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

ROM

O.C.Tr. output block

Latch

ANALOG BOARD

Di SW. input block

Latch

Buffer

Buffer

Analog multiplexer

A/D converter

CN3

MDT (multiplex data transmitter) upper unit Jib set output

90 - 100% 100% -

AML external indicator output

Indicator lamp Telescoping system select input (*1)

Slow stop (Swing free)

Working condition input

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

CN1

Swing angle detector

Alarm signal output

CURRENT OUTPUT BOARD

Counterweight equipped detection input (*1)

6

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

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

Pressure sensor analog detector power supply

(*1) .....TR-800XXL-4 model only

IW301-0231E02

W301-0234E

6

Diagram of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) Diagram of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) CONNECTOR BOARD

Boom angle detector A C B D E

Boom length detector

Pressure sensor (Main)

Swing free input Auto. stop override signal input

Working condition input

Auto. stop override signal input

24(V)

Pressure sensor for moment detection (Elevating)

Auto.stop signal output SOL.

BUZZER Indicator lamp

Top cyl. select output SOL.

Lever manipulation detection input Slow stop(Swing)

Outrigger extension width detector (4 peace)

F/J extension and F/J overload detection input

Slow stop(Elevating)

Transmitter (Type 2) AML external indicator output

Outrigger and F/J retraction operation detection input

90 - 100% 100% -

F/J overload warning output 24(V)

Jib set output Indicator lamp

Telescoping system select input (*1)

Slow stop (Swing free)

Working condition input

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

CN1

Swing angle detector

Alarm signal output

CURRENT OUTPUT BOARD

Counterweight equipped detection (1) input

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

Latch

Fuses

Di SW. input block

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

Fuses

Current Amplifier Circuit

SOL 5, 6 (2A)

CPU BOARD

SIF 1 (2A)

SIF 2 (2A) MAIN (3A)

ROM

POWER BOARD

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

Buzzer

DISPLAY BOARD

CPU RAM

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

Relay

DC power block

SCI Key input

+12V -12V +5V

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

CAL/CLOCK

+20V

LCD panel (1)

Serial input/output circuit LCD panel (2)

LCD SW. backlights

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

EEPROM

CHR display

CN2

O.C.Tr. output block

Latch

ANALOG BOARD

Di SW. input block

Latch

Buffer

Buffer

Analog multiplexer

A/D converter

CN3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Counterweight equipped detection (2)(3) input (*1)

7

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

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

Pressure sensor analog detector power supply

(*1) ..... TT-800XXL-1 model only

IW301-0232E01

W301-0234E

7

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Input/Output Signals of the Load Moment Indicator (AML-LK) System (TR-600XL-4/TR-600XXL-4/TR-800XXL-4) As shown in the “Diagram of the AML (AML-LK) System” on the previous page, the display board, CPU board, analog board, power board, option 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 connectors.

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

4

5

9

10

13

14

15

16

Name

Signal names and functions

ANAIN A

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

Input voltage: DC 0 to 4.5 V

ANAIN B

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

Input voltage: DC 0 to 4.5 V

ANAIN C

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

Input voltage: DC 0 to 4.5 V

ANAIN D

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

Input voltage: DC 0 to 4.5 V

ANAIN E

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

Input voltage: DC 0 to 4.5 V

Di1

Signal name: Two-blocking detection switch (L4) input Switch input representing whether two-blocking condition exists.

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

Switch OFF (DC24V): The hook currently in use is two-blocking.

Di2

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

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

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

Di3

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

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

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

Di4

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

Switch ON (DC0V): Boom swing lock device is free.

Switch OFF (DC24V): Boom swing lock device is locked.

8

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) CN 1 connector Pin No.

Name

Signal names and functions

ACC

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

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

Switch OFF (DC0V): Swing stop is functioning.

Di5

Signal name: Auti-two block disable switch (S3) input Switch input representing whether automatic stop caused by two-blocking is overridden.

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

Switch OFF (DC24V): Auti-two block function is ready.

Di6

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

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

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

Di7

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

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

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

Di8

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

Switch ON (DC0V): The jib is stowed.

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

Di9

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

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

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

29

Di10

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

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

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

34

ANAING

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

Input voltage: DC 0 to 5 V

ANAINH

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

Input voltage: DC 0 to 5 V

22

24

25

26

27

28

35

9

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) CN2 connector signals and functions are shown below: CN 2 connector Pin No.

Signal names and functions

name

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

Relay ON (DC24V): Normal operation is available.

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

Relay output

Crane condition

ON

Moment ratio < 90%

ON

90%

Moment ratio < 100%

Moment ratio 1

RLY 1 OFF

100%

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

Maximum (23’7-1/2”) (7.2m)

Moment ratio

93%

Middle (21’11-3/4”) (6.7m)

Moment ratio

92%

Middle (18’1/2”) (5.5m)

Moment ratio

91%

OFF

Two-blocking.

OFF

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

OFF

Failure in the AML unit.

OFF

Operated to critical side when backward stability control activated.

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

Relay ON (DC24V): Alarm buzzer is output.

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

Relay output OFF

Moment condition Moment ratio < 90% 90%

4

RLY 4

ON/OFF

Moment ratio < 100%

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

Maximum (23’7-1/2”) (7.2m)

84%

Moment ratio < 94%

Middle (21’11-3/4”) (6.7m)

84%

Moment ratio < 94%

Middle (18’1/2”) (5.5m)

82%

Moment ratio < 92%

Moment ratio

ON

100%

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

Maximum (23’7-1/2”) (7.2m)

Moment ratio

94%

Middle (21’11-3/4”) (6.7m)

Moment ratio

94%

Middle (18’1/2”) (5.5m)

Moment ratio

92%

10

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) CN 2 connector Pin No.

name

Signal names and functions Signal name: Telescoping control relay output [For TR-600XL-4] <3rd•top boom sections telescope> The relay turns ON (DC24V) under either of following condition and 3rd•top boom sections telescope.

1. The boom length is 19.1m or more.

2. The boom length is 18.3 -- 19.1m and 3rd•top boom extension switch is "ON" (Di28 / 0V).

3. The boom length is 18.3 -- 19.1m and 3rd•top boom full retraction detection switch is "OFF" (Di3 / 24V). <2nd boom section telescopes> The relay turns OFF (DC0V) (under either of following condition) and 2nd boom section telescopes.

1. The boom length is 18.3m or less.

2. The boom length is 18.3 -- 19.1m and 3rd•top boom full retraction detector switch is "ON" (Di3 / DC0V).

Relay ON (DC24V): 3rd•top boom sections telescope.

Relay OFF (DC0V): 2nd boom section telescopes.

5

RLY 5

[For TR-600XXL-4] <3rd / top boom sections telescope> The relay turns ON (DC24V) under either of following conditions and 3rd / top boom sections telescole.

1. The boom length is 19.23 m or more.

2. The boom length is 18.43 m -- 19.23 m and 3rd / top boom extension switch is “ON” (Di28/0V).

3. The boom length is 18.43 m -- 19.23 m and 3rd / top boom full retraction detection switch is “OFF” (Di3/24V). <2nd boom section telescopes> The relay turns OFF (DC0V) under either of following conditions and 2nd boom section telescoles.

1. The boom length is 18.43 m or less.

2. The boom length is 18.43 m -- 19.23 m and 3rd / top boom full retraction detection switch is “ON” (Di3/0V).

Relay ON (DC24V): 3rd / top boom sections telescope.

Relay OFF (DC0V): 2nd boom section telescopes.

[For TR-800XXL-4] (2nd boom section primary extending mode) (A) The telescoping mode <3rd / top boom sections telescope> The relay turns ON (DC24V) under either of following conditions and 3rd / top boom sections telescope.

1. The boom length is 20.03 m or more.

2. The boom length is 19.23 m -- 20.03 m and 3rd / top boom extension switch is “ON” (Di28/0V).

3. The boom length is 19.23 m -- 20.03 m and 3rd / top boom full retraction detection switch is “OFF” (Di3/24V). <2nd boom section telescopes> The relay turns OFF (DC0V) under either of following conditions and 2nd boom section telescopes.

1. The boom length is 19.23 m or less.

2. The boom length is 19.23 m -- 20.03 m and 3rd / top boom full retraction detection switch is “ON” (Di3/0V).

Relay ON (DC24V): 3rd / top boom sections telescope.

Relay OFF (DC0V): 2nd boom section telescopes.

11

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) CN 2 connector Pin No.

5

name

RLY 5

Signal names and functions (B) The telescoping mode (3rd / top boom sections primary extending mode) <2nd boom section telescopes> The relay turns ON (DC24V) under either of following conditions and 2nd boom section telescopes.

1. The boom length is 36.28 m or more.

2. The boom length is 35.48 m -- 36.28 m and 2nd boom extension switch is “ON” (Di28/0V).

3. The boom length is 35.48 m -- 36.28 m and 2nd boom full retraction detection switch is “OFF” (Di3/24V). <3rd / top boom sections telescope> The relay turns OFF (DC0V) under either of following conditions and 3rd / top boom sections telescole.

1. The boom length is 35.48 m or less.

2. The boom length is 35.48 m -- 36.28 m and 2nd boom full retraction detection switch is “ON” (Di3/0V).

Relay ON (DC24V): 2nd boom section telescopes.

Relay OFF (DC0V): 3rd / top boom sections telescope.

7

9

11

RLY 7

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

Relay ON (DC24V): Alarm buzzer is output.

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

Di11

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

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

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

Di13

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

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

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

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

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

(2) Outriggers are not extended.

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

Output voltage: Square wave 0 to 24V

13

CNTL 1P

Crane condition that causes the automatic swing stop The moment ratio exceeds 100% due to right swing while the extension widths of four outriggers are different.

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

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

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

14

CNTL 1N

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

12

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) CN 2 connector Pin No.

15

name

CNTL 2P

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

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

(2) Outriggers are not extended.

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

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

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

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

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

16

17

18

19

20

21

22

CNTL 2N

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

Di15

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

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

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

Di16

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

Input from the switch detecting boom retracting operation.

Switch ON (DC0V): Auxiliary winch is employed.

Switch OFF (DC5V): Main winch is employed.

Di17

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

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

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

Di18

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

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

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

Di19

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

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

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

Di20

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

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

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

13

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) CN 2 connector Pin No.

Signal names and functions

name

23

CNTL 3P

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

Output voltage: Square wave 0 to 24V

24

CNTL 3N

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

25

CNTL 4P

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

Output voltage: Square wave 0 to 24V

26

CNTL 4N

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

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

Signal names and functions

Name

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

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

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

2

TR2

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

Maximum (23’7-1/2”) (7.2m)

84%

Moment ratio < 94%

Middle (21’11-3/4”) (6.7m)

84%

Moment ratio < 94%

Middle (18’1/2”) (5.5m)

82%

Moment ratio < 92%

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

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

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

Condition to turn ON OC output Moment ratio 3

TR3

100%

Anti-twoblock disable switch: pressed.

Swing stop cancel switch: “OFF”.

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

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

Maximum (23’7-1/2”) (7.2m)

Moment ratio

93%

Middle (21’11-3/4”) (6.7m)

Moment ratio

92%

Middle (18’1/2”) (5.5m)

Moment ratio

91%

14

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) CN 3 connector Pin No.

5

6

10

12

Name

Signal names and functions

TR5

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

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

TR6

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

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

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

Di25

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

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

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

Di27

Signal name: Telescoping mode / switch (S31) input Switch input to select the telescoping mode or .

Switch ON (DC0V): The telescoping mode is selected.

Switch OFF (DC5V): The telescoping mode is selected. (Only for TR-800XXL-4) Signal name: Boom secondary extending switch (S7) input [For TR-600XL-4] Switch input to extend the 3rd/top boom sections.

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

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

13

Di28

[For TR-800XXL-4] • For the telescoping mode (2nd boom section primary extending mode) Switch to extend the 3rd/top boom sections after the 2nd boom section extend fully.

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

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

• For the telescoping mode (3rd/top boom sections primary extending mode) Switch to extend the 2nd boom section after the 3rd/top boom sections extend fully.

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

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

16

CNTL 5P

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

17

CNTL 5N

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

15

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) CN 3 connector Pin No.

21

22

Name

Signal names and functions

Di21

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

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

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

Di22

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

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

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

16

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) Input/Output Signals of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) As shown in the “Diagram of the AML (AML-LK) System” on the previous page, the display board, CPU board, analog board, power board, option 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 connectors.

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

4

5

9

10

13

14

15

16

Name

Signal names and functions

ANAIN A

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

Input voltage: DC 0 to 4.5 V

ANAIN B

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

Input voltage: DC 0 to 4.5 V

ANAIN C

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

Input voltage: DC 0 to 4.5 V

ANAIN D

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

Input voltage: DC 0 to 4.5 V

ANAIN E

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

Input voltage: DC 0 to 4.5 V

Di1

Signal name: Two-blocking detection switch (L4) input Switch input representing whether two-blocking condition exists.

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

Switch OFF (DC24V): The hook currently in use is two-blocking.

Di2

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

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

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

Di3

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

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

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

Di4

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

Switch ON (DC0V): Boom swing lock device is free.

Switch OFF (DC24V): Boom swing lock device is locked.

17

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) CN 1 connector Pin No.

22

24

25

26

27

29

34

35

Name

Signal names and functions

ACC

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

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

Switch OFF (DC0V): Swing stop is functioning.

Di5

Signal name: Auti-two block disable switch (S3) input Switch input representing whether automatic stop caused by two-blocking is overridden.

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

Switch OFF (DC24V): Auti-two block function is ready.

Di6

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

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

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

Di7

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

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

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

Di8

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

Switch ON (DC0V): The jib is stowed.

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

Di10

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

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

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

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

18

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) CN2 connector signals and functions are shown below: CN 2 connector Pin No.

Signal names and functions

name

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

Relay ON (DC24V): Normal operation is available.

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

Relay output

Crane condition

ON

Moment ratio < 90%

ON

90%

Moment ratio < 100%

Moment ratio

1

RLY 1

OFF

100%

While boom lift with the jib mounted is performed, the crane operation stops automatically when the load moment ratio reaches the ranges listed below.

TT-600XL-1

Moment ratio

90%

TT-800XXL-1

Moment ratio

85%

OFF

Two-blocking.

OFF

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

OFF

Failure in the AML unit.

Operated to critical side when backward stability control activated.

OFF

While the extension width of outriggers is minimum and the crane is operating in the over-side area, the crane operation stops automatically when the boom is raised to 71°

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

Relay ON (DC24V): Alarm buzzer is output.

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

Relay output OFF

Moment condition Moment ratio < 90% 90%

4

RLY 4

ON/OFF

Moment ratio < 100%

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

TT-600XL-1

80%

Moment ratio < 90%

TT-800XXL-1

75%

Moment ratio < 85%

Moment ratio ON

100%

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

TT-600XL-1

Moment ratio

90%

TT-800XXL-1

Moment ratio

85%

19

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) CN 2 connector Pin No.

name

Signal names and functions Signal name: Telescoping control relay output [For TT-600XL-1] <3rd•top boom sections telescope> The relay turns ON (DC24V) under either of following condition and 3rd•top boom sections telescope.

1. The boom length is 19.1m or more.

2. The boom length is 18.3 -- 19.1m and 3rd•top boom extension switch is "ON" (Di28 / 0V).

3. The boom length is 18.3 -- 19.1m and 3rd•top boom full retraction detection switch is "OFF" (Di3 / 24V). <2nd boom section telescopes> The relay turns OFF (DC0V) (under either of following condition) and 2nd boom section telescopes.

1. The boom length is 18.3m or less.

2. The boom length is 18.3 -- 19.1m and 3rd•top boom full retraction detector switch is "ON" (Di3 / DC0V).

Relay ON (DC24V): 3rd•top boom sections telescope.

Relay OFF (DC0V): 2nd boom section telescopes.

5

RLY 5

[For TT-800XXL-1] (2nd boom section primary extending mode) (A) The telescoping mode <3rd / top boom sections telescope> The relay turns ON (DC24V) under either of following conditions and 3rd / top boom sections telescope.

1. The boom length is 20.03 m or more.

2. The boom length is 19.23 m -- 20.03 m and 3rd / top boom extension switch is “ON” (Di28/0V).

3. The boom length is 19.23 m -- 20.03 m and 3rd / top boom full retraction detection switch is “OFF” (Di3/24V). <2nd boom section telescopes> The relay turns OFF (DC0V) under either of following conditions and 2nd boom section telescopes.

1. The boom length is 19.23 m or less.

2. The boom length is 19.23 m -- 20.03 m and 3rd / top boom full retraction detection switch is “ON” (Di3/0V).

Relay ON (DC24V): 3rd / top boom sections telescope.

Relay OFF (DC0V): 2nd boom section telescopes.

(3rd / top boom sections primary extending mode) (B) The telescoping mode <2nd boom section telescopes> The relay turns ON (DC24V) under either of following conditions and 2nd boom section telescopes.

1. The boom length is 36.28 m or more.

2. The boom length is 35.48 m -- 36.28 m and 2nd boom extension switch is “ON” (Di28/0V).

3. The boom length is 35.48 m -- 36.28 m and 2nd boom full retraction detection switch is “OFF” (Di3/24V). <3rd / top boom sections telescope> The relay turns OFF (DC0V) under either of following conditions and 3rd / top boom sections telescole.

1. The boom length is 35.48 m or less.

2. The boom length is 35.48 m -- 36.28 m and 2nd boom full retraction detection switch is “ON” (Di3/0V).

Relay ON (DC24V): 2nd boom section telescopes.

Relay OFF (DC0V): 3rd / top boom sections telescope.

20

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) CN 2 connector Pin No.

6

7

9

11

13

name

Signal names and functions

RLY 6

Signal name: Jib lock lamp relay output When the jib slides out of the center support on the boom, this relay contact turns ON and the indicator lamp is lit.

Relay ON (DC24V): Jib lock indicator lamp is lit.

Relay OFF (DC0V): Jib lock indicator lamp goes out..

RLY 7

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

Relay ON (DC24V): Alarm buzzer is output.

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

Di11

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

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

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

Di13

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

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

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

CNTL 1P

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

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

(2) Outriggers are not extended.

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

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

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

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

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

14

CNTL 1N

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

21

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) CN 2 connector Pin No.

15

name

CNTL 2P

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

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

(2) Outriggers are not extended.

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

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

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

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

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

16

17

18

19

20

21

22

CNTL 2N

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

Di15

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

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

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

Di16

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

Input from the switch detecting boom retracting operation.

Switch ON (DC0V): Auxiliary winch is employed.

Switch OFF (DC5V): Main winch is employed.

Di17

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

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

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

Di18

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

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

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

Di19

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

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

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

Di20

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

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

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

22

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) CN 2 connector Pin No.

Signal names and functions

name

23

CNTL 3P

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

Output voltage: Square wave 0 to 24V

24

CNTL 3N

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

25

CNTL 4P

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

Output voltage: Square wave 0 to 24V

26

CNTL 4N

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

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

2

Signal names and functions

Name

TR2

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.

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.

3

TR3

Condition to turn ON OC output Moment ratio

100%

Anti-twoblock disable switch: pressed.

Swing stop cancel switch: “OFF”.

AML override key switch : “ON”. and AML override switch : “ON”.

4

5

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.

TR5

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

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

23

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) CN 3 connector Pin No.

6

10

12

Name

Signal names and functions

TR6

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

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

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

Di25

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

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

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

Di27

Signal name: Telescoping mode / switch (S31) input Switch input to select the telescoping mode or .

Switch ON (DC0V): The telescoping mode is selected.

Switch OFF (DC5V): The telescoping mode is selected. (Only for TT-800XXL-1) Signal name: Boom secondary extending switch (S7) input [For TT-600XL-1] Switch input to extend the 3rd/top boom sections.

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

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

13

Di28

[For TT-800XXL-1] • For the telescoping mode (2nd boom section primary extending mode) Switch to extend the 3rd/top boom sections after the 2nd boom section extend fully.

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

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

• For the telescoping mode (3rd/top boom sections primary extending mode) Switch to extend the 2nd boom section after the 3rd/top boom sections extend fully.

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

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

16

CNTL 5P

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

17

CNTL 5N

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

21

22

Di21

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

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

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

Di22

Signal name: C/W mount detection switch (CS18) input Switch input representing whether the C/W is mounted.

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

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

24

W301-0234E

Input/Output Signals of the Load Moment Indicator (AML-LK) System (TT-600XL-1/TT-800XXL-1) CN 3 connector Pin No.

23

24

Name

Signal names and functions

Di23

Signal name: C/W mount detection switch (CS19) input (Only for TT-800XXL-1) Switch input representing whether the C/W is mounted.

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

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

Di24

Signal name: C/W mount detection switch (CS20) input (Only for TT-800XXL-1) Switch input representing whether the C/W is mounted.

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

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

25

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4)

HALT

WDT

SPAN

ZERO

ON

OFF

MOMENT SHORT

Functions of and How to Use User Mode(TR-600XL-4/TR-600XXL-4/ TR-800XXL-4)

PROTECT

[OPERATION]

Mode Structure

Protect switch Abnormality display LED Top view

The AML device has three modes and AML

IW301-0231E03

functions are allotted for these models.

2. Maintenance Mode:

Power ON

Protect switch ON

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

MAINTENANCE MODE

USER MODE

Protect switch OFF

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

ADJUSTMENT MODE

Power ON

IW301-0233E01

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

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

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

26

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Configuration and Functions of the Load Moment Indicator System

(3) Working range limit functions When any working range limit is registered to the load moment indicator, the crane is controlled so that the crane work posture does not exceed this registered working range limit. When the boom reaches the previously registered restriction, buzzer sounds, and the crane operation stops.

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

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

(4) Slow stop function In the following cases, the boom elevation speed or the swing speed gradually decreases to stop before the boom reaches the stoppage position.

• When the automatic stop is caused by overloading (Boom lowering will stop.)

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

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

• When the automatic stop is caused by working range limit function (Boom raising/lowering will stop.)

• When the automatic stop is caused by backward instability during on-rubber operation (Boom raising will stop.)

(2) Automatic stop function by backward instability When the boom is raised to [77°:TR-600XL-4 and TR-600XXL-4 (69°:TR-800XXL-4)] in an over-side area with on-rubber operation.

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

Automatic stop by overloading Stop by backward instability Stop at stroke end Stop by working range restriction : Slow stop

: Stop

Hoisting up Boom lowering Boom extension Swing Boom raising Boom raising/lowering Boom raising/lowering Boom extension Swing

×: Not stop

On-outrigger operation

On-rubber operation

– –

×

×

–: Not relevant

27

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Load Moment Indicator System Configuration Boom length signal

Boom angle signal

Moment ratio signal

L

Over-front area signal

Crane control position signal

W

θ

Outrigger extension width detector

Swing angle signal

Operator selection

Outrigger status

L

Lift status

θ

Working range limits Number of part-lines of rope Jib status Winch selection (single top and jib lift only)

Load moment indicator unit (AML unit) External warning lamps

Alarm buzzer Display panel

°

Stop output when: °

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

Backward stability control activated

Swing restricted

Working range limit signal output

Boom extension halted

Boom lowering halted

Hoisting up halted

Boom raising halted

Upper boom angle restricted Lower boom angle restricted

Lifting height restricted

Load radius restricted

θu

H θL R IW301-0231E04

28

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Alarm Functions

Automatic Stop Functions Causes of automatic stop

Operation

• Moment ratio

Halted movement • Hoisting up • Boom lowering

exceeds 100% (*1)

• Boom extension

• Two-blocking • AML system error Upper boom angle Working range limit

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

Anti-twoblock function is Moment display: Displays deactivated while [Warning:0015]. two-brocking codition exists. External warning lamps: Red lamp is lit.

Buzzer: Sounds continuously.

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

External warning lamps: Orange lamp is lit.

Buzzer: Sounds intermittently.

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

Buzzer: Sounds continuously.

Moment display: Displays AML system errer failure messages.

AML Buzzer: Sounds 3 seconds.

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

Associated restriction indicator lamp flashes.

Buzzer: Sounds continuously.

AML Buzzer: Sounds 3 seconds.

Operated to critical side Moment display: Displays [Warning:0025]. when backward stability control activated.

AML Buzzer: Sounds 3 seconds.

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

AML Buzzer: Sounds 3 seconds.

Boom lift with jib mounted on boom (1) Moment ratio is between Moment display: 84% and 94%.

Corresponding segment is lit.

(2) Moment ratio is between External warning lamps : 84% and 94%.

Orange lamp is lit.

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

Moment display: Displays (1) Moment ratio exceeds [Warning:0088].

94% or more.

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

94%.

Buzzer: Sounds continuously.

(3) Moment ratio exceeds 92%.

restricted

• Boom raising • Boom lift

Lower boom angle • Single top lift restricted

• Boom lowering

• Jib lift

Lifting height

• Boom raising

restricted

• Boom extension

Load radius

• Boom lowering

restricted

• Boom extension • Swing • Boom raising

Swing restricted • Backward instability (*2)

• Boom lift • Single top lift

IW301-0232E11

(*1): For the boom lift with the jib mounted, automatic stop will work when the moment exceeds the value listed below, according to the outrigger extension width: Outrigger extension width

Moment

Maximum (23' 7-1/2"[7.2 m]) Middle (21' 11-3/4"[6.7 m])

93% or more

Middle (18' 1/2" [5.5 m])

91% or more

92% or more IW301-0231E06

Buzz

(1) is applicable when the outriggers are extended to maximum (23’ 7-1/2” [7.2m]).

(2) is applicable when the outriggers are extended to middle (21’ 11-3/4” [6.7m]).

(3) is applicable when the outriggers are extended to middle (18’ 1/2” [5.5m]).

IW301-0131E54

(*2): Automatic stop will work when the boom is raised to [77° :TR-600XL-4 and TR-600XXL-4 (69° :TR-800XXL-4)] in an over-side area with on-rubber operation.

29

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4)

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

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

The AML buzzer sounds for 3 seconds every time a message appears. It outputs long sounds when slow stop control is activated and outputs short sounds when other controls are activated.

30

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Names and Functions of Load Moment Indicator Main Unit Parts Bargraph display

Display panel 1 ゜ m

゜ ・

Display panel 2 Control

IW301-0231E08

31

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4)

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 messages displayed on the moment display.

Normally displays a moment ratio on a bargraph.

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

Also displays error messages when the load moment indicator or any of its associated devices fails.

32

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Display Panel 1 1

2

3

17

20

5

゜ m

15

16

14

21

18

13

6

゜ ・

19

7

17

12 8

11

10

9

IW301-0231E09

8. Rated lifting capacity display

1. Jib angle display

Displays the rated lifting capacity.

When jib lift is selected, the jib angle offset is displayed. When the number of part-lines of rope select key is pressed, or the display alteration key is held down, the number of part-lines of ropes is displayed. Also, when the upper boom angle restriction function is registered, the registered upper boom angle restricted value is displayed as long as the register key is pressed on.

9. Load radius limit restriction indicative symbol This symbol, while marked up, means the value shown in the load radius display (11) represents the load radius limit. Note that the load radius indicative symbol (10) is also displayed at the same time.

10.Load radius indicative symbol This symbol, while marked up, means the value shown in the load radius display (11) represents the load radius.

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

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

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

Displays the boom swing angle while the display alteration key is held down.

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

5. Jib angle indicative symbol This symbol, while marked up, means the value shown in the jib angle display (1) represents the offset angle.

12. Counterweight state indicative symbol (Only for

6. Jib lift indicative symbol

TR-800XXL-4) Marked up when the operation with the counterweight mounted is selected, indicating its mounting state.

Is marked up when the jib lift is selected, indicating the condition of the jib.

7. Real load display Displays the real load.

33

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4)

17.Boom angle indicative symbol

13.Boom length display

Indicates that the boom angle display (19) displays the boom angle.

Usually displays boom length.

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

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

18.Lower boom angle limit restriction symbol This symbol, while marked up, means the boom angle display (19) displays the registered lower boom angle restricted value.

14.Lifting height indicative symbol

19.Boom angle display Normally displays the boom angle.

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

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

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

The lifting height symbol (14) is marked up simultaneously.

20.Boom lift indicative symbol Is marked up when the boom lift is selected.

16.Upper boom angle limit restriction symbol

21.Single-top lift indicative symbol

Indicates that the jib angle display (1) displays the registered boom angle upper restricted value.

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

34

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Controls 14 13 12 11

15

10 16 17 18

9

19 8

20

7 6

1

2

3

4

5

IW301-0131E59

11. Lower boom angle limit restriction indicator lamp

1. Increase key

Lights up when the lower most boom angle limiting function is activated.

Used to increase the selected value.

2. Decrease key

12.Upper boom angle limit restriction key

Used to decrease the selected value.

Used to activate and release the upper most boom angle limiting function.

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

13.Upper boom angle limit restriction indicator lamp Lights up when the upper most boom angle limiting function is activated.

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

5. Check key

14.Lifting height restriction key

Used to check the AML system functions.

Used to activate and release the lifting height limiting function.

6. Register key Used to register a selected state.

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

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

16.Right swing restriction key Used to activate and release the right swing limiting function.

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

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

17.Right swing restriction indicator lamp

10.Lower boom angle limit restriction key

18.Left swing restriction key

Lights up when the right swing limiting function is activated.

Used to activate and release the left swing limiting function.

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

35

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4)

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

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

Display Panel 2 5 1 3 2 4

2

3

3

2 3

IW301-0231E10

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

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

5. Boom position indicator

2. Outrigger state indicative symbol

Displays the boom position in 10° increments.

Displays the way the outriggers are extended.

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

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

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

36

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Selecting Operational Status

(1) On-outrigger operation When the outrigger mode select key is pressed, the outrigger state indicative symbol flashes in accordance with the status that the load moment indicator detects on.

After making sure that the display conforms to the actual outrigger conditions, press the register key.

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

WARNING Should the operational status be incorrectly registered, the crane might overturn or be damaged, leading to a serious accident.

Prior to every operation, check that the registered status corresponds to the actual status of the crane.

Selecting Outrigger Status (TR-600XL-4/ TR-600XXXL-4) [NOTICE] The "on-rubber stationary" status is the default status and is automatically selected when the power supply is turned on (the PTO switch is placed in the "ON" position).

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

Actual outrigger extension condition

Register the outrigger state using the outrigger

Displayed outrigger status

IW301-0231E12

mode select key and the register key.

Fully extended (23' 7-1/2" (7.2m))

Mid. extended (21' 11-3/4" (6.7m)) ゜ m

Mid. extended (18' 1/2" (5.5m)) ゜ ・

Min. extended (9' 2-1/4" (2.8m)) IW301-0231E13

Register key

Outrigger mode select key IW301-0231E11

37

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Selecting Outrigger Status (TR-800XXL-4)

(2) On-rubber operation Press the outrigger mode select key repeatedly until the display conforms to the actual condition (on-rubber stationary operation or on-rubber creep operation). Then press the register key. The moment display, rated lifting capacity display and real load display will return to normal display conditions, meaning that the on-rubber state has been registered.

On-rubber stationary operation

[NOTICE] The "on-rubber stationary" status is the default status and is automatically selected when the power supply is turned on (the PTO switch is placed in the "ON" position).

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

On-rubber creep operation

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

Marked up

Flashing

Marked up

Marked up

゜ m

IW301-0131E64

゜ ・

[NOTICE] The outrigger status automatically changes to a on-rubber creep status when an operation is made for stowing the outrigger after the registration of the outrigger status. Be sure to again register the outrigger status, when necessary.

Register key

Outrigger mode select key IW301-0231E11

[NOTICE] Crane operation is prohibited without full counterweigth (17,400lbs.) installed.

Counterweigth state indicative symbol is marked up as shown below:

38

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4)

Dismounting the Counterweight

Mounting the Counterweight Fully extended (23' 7-1/2" (7.2m))

Mid. extended (21' 11-3/4" (6.7m))

Mid. extended (18' 1/2" (5.5m))

Min. extended (9' 2-1/4" (2.8m)) IW301-0231E14 IW301-0231E13

(1) On-outrigger operation When the outrigger mode select key is pressed, the outrigger state indicative symbol and counterweight state indicative symbol flashes in accordance with the status that the load moment indicator detects on.

After making sure that the display conforms to the actual outrigger conditions, press the register key.

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

Actual outrigger extension condition

(2) On-rubber operation Press the outrigger mode select key repeatedly until the display conforms to the actual condition (on-rubber stationary operation or on-rubber creep operation). Then press the register key. The moment display, rated lifting capacity display and real load display will return to normal display conditions, meaning that the on-rubber state has been registered.

On-rubber stationary operation

On-rubber creep operation

Marked up

Flashing

Marked up

Marked up

Displayed outrigger status

IW301-0131E64

[NOTICE] The outrigger status automatically changes to a on-rubber creep status when an operation is made for stowing the outrigger after the registration of the outrigger status. Be sure to again register the outrigger status, when necessary.

IW301-0231E12

39

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) that the state has been registered.

(When the jib set status is selected, the jib lift indicative symbol will remain flashing.)

Select the boom lift status when lifting a load on the boom with the jib mounted.

Select the jib lift status when lifting a single load using both the boom and jib.

Selecting Lift Status [NOTICE] The boom lift status is the default status and is automatically selected (the boom lift indicative symbol is marked up) when the power supply is turned on (the PTO switch is placed in the ON position).

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

(1) Boom lift

(2) Single top lift

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

(3) Jib set (mounting or stowage)

° m

(4) Jib lift : 32.5 ft (9.9m) jib, 3.5° offset

° %

(5) Jib lift : 32.5 ft (9.9m) jib, 25° offset

Register key (6) Jib lift : 32.5 ft (9.9m) jib, 45° offset

Lift mode select key IW301-0131E65

(7) Jib lift : 58.1 ft (17.7m) jib, 3.5° offset

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

(8) Jib lift : 58.1 ft (17.7m) jib, 25° offset

[NOTICE]

(9) Jib lift : 58.1 ft (17.7m) jib, 45° offset

After selecting the intended lift status, press the register key to register the status. The corresponding indicative symbols will stop flashing and become marked up and the moment display, rated lifting capacity display and real load display will return to normal display conditions, meaning

IW301-0231E15

40

W301-0234E

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) When the power supply is turned on (i.e. PTO switch ON), the standard number of part-lines of rope corresponding to a work condition is selected.

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

Similarly, a process takes place on the basis of the standard number of part-lines of rope if the registered number is larger than the standard number.

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

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

°

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

Register key

IW301-0131E67

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

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

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

set, press the register key and register the number.

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

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

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

[NOTICE] When the increase or the decrease key is pressed, a numeral showing the number of rope stops flashing and becomes continuously marked up, showing a fixed value for the increase or decrease.

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

41

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Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Selecting Winch Condition

Selecting Jib Mounted Condition

WARNING

WARNING

Select the correct winch according to the actual crane condition; otherwise the load moment indicator will show wrong moment ratio, leading you to damage or overturn the crane.

If the jib mounting/dismounting state is set improperly, the load moment indicator can not detect the actual load precisely. The crane operation in this condition could create hazard.

The lifting capacities vary depending on the

The jib can be dismounted from the crane body

operating condition. Register the winch selection using the winch selector switch so that the winch selection indicator lamp is as shown in the table below according to the operating condition.

when it is not used. The reduced mass of the crane body after jib removal will influence the precision of the load moment indicator. Use this switch to set the jib mounting /dismounting state to the load moment indicator.

[NOTICE]

When main winch is employed : Main Winch

When auxiliary winch is employed

The key can be inserted in/removed from either “REMOVED” or “EQUIPPED” position.

: Auxiliary Winch

(1) “REMOVED” Select this position when the jib is dismounted. The jib removed indicator lamp will light up.

Winch selector switch

(2) “EQUIPPED” Select this position when the jib is mounted. The jib removed indicator lamp will go off.

: Main Winch

: Auxiliary Winch

Jib removed indicator lamp

IW301-0231E16 2B

D E F

COOL

HO

MODE 3B-

The winch selection alternates between main winch and auxiliary winch each time the winch selector switch is pressed. When auxiliary winch is selected, the winch selection indicator lamp lights up.

Jib state switch

[NOTICE] For boom lift, always employ the main winch.

42

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IW301-0231E17

Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Load Moment Indicator Pre-operational Inspection

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

WARNING

3. Make sure that the display on the display panels

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

conforms to the actual crane conditions.

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

Before starting operation, check that the load

(4) Real load……Make sure that the approximately mass of the hook block while no load is on the hook block

moment indicator works in good condition, as follows: 1. Press the check key and make sure that the load moment indicator is in the following conditions: • Moment display……All segments are marked up.

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

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

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

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

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

(5) Outrigger state indicative symbol (6) Boom position indicator (7) Over-front position symbol ……shown while the boom is in over-front area (8) Counterweigth state indicative symbol (Only for TR-800XXL-4)

Buzz

3 2 1

Bargraph display

4 8

Display panel 1 ゜

° m

Display panel 2

6

° %

7

5 IW301-0231E18

IW301-0131E68

43

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Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) How to Use the Working Range Limit Function

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

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

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

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

The working range restricting function makes the boom automatically stop at the previously registered boom angles (upper and lower), lifting height, load radius and swing angle, The function is useful for handling a load in a confined place because it defines the area in which the boom can operate.

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

Upper boom angle restricted Lower boom angle restricted

Upper boom angle limit restriction indicator lamp

Lifting height restricted °

Lower boom angle limit restriction indicator lamp

θu H

Lower boom angle limit restriction key

θL

Load radius restricted

Upper boom angle limit restriction key

Swing restricted

IW301-0131E71

R IW301-0131E70

44

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Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Swing Limit

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

Swing the boom to the desired position, and press

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

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

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

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

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

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

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

[NOTICE]

°

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

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

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

Lifting height restriction indicator lamp

Lifting height restriction key

IW301-0131E72

Left swing restriction indicator lamp °

Right swing restriction indicator lamp

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

45

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Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Load Radius Limit Move the boom to the desired load radius, and press the load radius restriction key. The load radius restriction indicator lamp will flash and the buzzer will sound continuously, indicating that the limit load radius has been stored in the memory.

When the boom is moved back toward the non-critical side, the load radius restriction indicator lamp stops flashing, and stays lit and the buzzer stops.

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

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

°

Load radius restriction indicator lamp Load radius restriction key

IW301-0131E74

46

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Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Display of Working Range Restriction Values Press in the register key while working range restricting functions are registered.

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

[NOTICE] This display is not available when preoperational load moment indicator check is made and when working state is registered.

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

Upper boom angle limit restriction values

Working range

Lower boom angle limit restriction values

Lifting height restriction values

Load radius restriction values Boom position indicator

Register key Swing limit restriction values

IW301-0131E75

47

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Functions of and How to Use User Mode (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Display Alteration Displays on the moment display and the display panel 1 can be altered, as shown below in the figures, while the display alteration key is being pushed. The indicative symbols are displayed, too.

Moment Display

M＊＊＊＊

psi Unit

Main-circuit pressure Meaning main circuit pressure

IW301-0131E76

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

Number of part-lines of rope M＊＊＊＊

psi

Lifting height

Moment ratio Real load

%

Rated lifting capacity Swing angle

Display alteration key IW301-0131E77

48

W301-0234E

Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1)

2. Maintenance Mode:

Mode Structure

3. Adjustment Mode:

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

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

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

Power ON

Protect switch ON

MAINTENANCE MODE

USER MODE

Protect switch OFF

ADJUSTMENT MODE

Power ON

IW301-0233E01

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

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

The abnormality display LED lights when the AML

HALT

WDT

SPAN

ZERO

PROTECT ON

OFF

MOMENT SHORT

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

Protect switch Abnormality display LED Top view

IW301-0231E03

49

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Configuration and Functions of the Load Moment Indicator System (TT-600XL-1)

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

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

The load moment indicator 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.

Hoisting up

Automatic stop by overloading

Boom lowering

Stop at stroke end

Boom raising/lowering

Stop by working range restriction :Slow stop

Boom extension Boom raising/lowering Boom extension Swing :Stop

[NOTICE]

(1) Automatic stop function for overloading

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

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

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

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

(3) Slow stop function In the following cases, the boom elevation speed or the swing speed gradually decreases to stop before the boom reaches the stoppage position.

• When the automatic stop is caused by overloading (Boom lowering will stop.)

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

• When the automatic stop is caused by working range limit function (Boom raising/lowering will stop.)

50

W301-0234E

Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Load Moment Indicator System Configuration (TT-600XL-1) Boom length signal

Boom angle signal

Moment ratio signal

L

Swing angle signal

Crane control position signal

W

Outrigger extension width detector Operator selection

Outrigger status Lift status Working range limits Number of part-lines of rope Jib state

L

Winch selection (single top and jib lift only) Load moment indicator unit (AML unit) Alarm buzzer Display panel

External warning lamps

m

m

t %

Stop output when:

max t

m

Moment ratio exceeds 100% Two-blocking occurs Moment exceeding limit for boom with jib mounted

Swing restricted

Load moment indicator system error occurs

Working range limit signal output

Boom extension halted

Boom lowering halted

Hoisting up halted

Upper boom angle restricted Lower boom angle restricted

Lifting height restricted

Load radius restricted

u

H L

R

IW301-0232E02

51

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Automatic Stop Functions Causes of automatic stop

Operation

• Moment ratio

Condition A control is moved toward critical side (hoist up, boom lowering or boom extension) while twoblocking condition exists.

Anti-twoblock function is deactivated while twoblocking condition exists.

Halted movement • Hoisting up •Boom lowering

exceeds 100% (*1)

•Boom extension

• Two-blocking • AML system error Upper boom angle Working range limit

Alarm Functions

Moment display: Displays [Warning:0015].

External warning lamps: Red lamp is lit.

Buzzer: Sounds continuously.

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

External warning lamps : Orange lamp is lit.

Buzzer: Sounds intermittently.

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

Buzzer: Sounds continuously.

AML system error Moment display: Displays failure messages.

AML buzzer: Sounds 3 seconds.

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

Associated restriction indicator lamp flashes.

AML buzzer: Sounds 3 seconds.

Buzzer: Sounds continuously.

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

Boom lift with jib mounted on boom*

• Boom raising

restricted

• Boom lift

Lower boom angle

• Single top lift

restricted

• Jib lift

• Boom lowering

Lifting height

• Boom raising

restricted

• Boom extension

Load radius restricted

• Boom lowering • Boom extension

Swing restricted

• Swing

Alarm Moment display: Displays [Warning:0024].

Buzzer: Sounds continuously.

IW301-0231E05

(*1): For the boom lift with the jib mounted, automatic stop will work when the moment exceeds 90%.

Buzz

(1)Moment ratio is Moment display: Corresponding between 80% and 90%. segment is lit.

External warning lamps Orange lamp is lit.

Buzzer: Sounds intermittently.

(1)Moment ratio exceeds Moment display: Displays 90%.

[Warning:0088].

External warning lamps : Red lamp is lit.

Buzzer: Sounds continuously.

IW301-0131E54

IW301-0234E01

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

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

The AML buzzer sounds for 3 seconds every time a message appears. It outputs long sounds when slow stop control is activated and outputs short sounds when other controls are activated.

52

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Configuration and Functions of the Load Moment Indicator System (TT-800XXL-1)

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

• When the automatic stop is caused by working range limit function (Boom raising/lowering will stop.)

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

The load moment indicator 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.

• When the automatic stop is caused by backward stability (Boom raising will stop.)

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

Automatic stop by overloading

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

Boom lowering Boom extension

Stop by backward instability

Boom raising

Stop at stroke end

Boom raising/lowering

Stop by working range restriction :Slow stop

(2) Automatic stop function by backward instability When the boom is raised to 71° in an over-side area with the outriggers extended to minimum,a message and an output and boom raising is halted.

Hoisting up

Boom raising/lowering Boom extension Swing :Stop

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

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

(3) Working range limit functions When any working range limit is registered to the load moment indicator, the crane is controlled so that the crane work posture does not exceed this registered working range limit. When the boom reaches the previously registered restriction, buzzer sounds, and the crane operation stops.

(4) Slow stop function In the following cases, the boom elevation speed or the boom swing speed gradually decreases to stop before the boom reaches the stoppage position.

• When the automatic stop is caused by overloading (Boom lowering will stop.)

53

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Load Moment Indicator System Configuration (TT-800XXL-1) Boom length signal

Boom angle signal

Moment ratio signal

L

Swing angle signal

Crane control position signal

W

Outrigger extension width detector Operator selection

Outrigger status Lift status Working range limits Number of part-lines of rope Jib state

L

Winch selection (single top and jib lift only) Load moment indicator unit (AML unit) Alarm buzzer Display panel

External warning lamps

m

m

t %

Stop output when:

max t

m

Moment ratio exceeds 100% Two-blocking occurs Moment exceeding limit for boom with jib mounted

Back ward stability control activated Swing restricted

Load moment indicator system error occurs

Working range limit signal output

Boom extension halted

Boom lowering halted

Hoisting up halted

Boom raising halted

Upper boom angle restricted Lower boom angle restricted

Lifting height restricted

Load radius restricted

u

H L

R

IW301-0232E04

54

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Alarm Functions

Automatic Stop Functions Causes of automatic stop

Operation

• Moment ratio

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

Anti-twoblock function is Moment display: Displays [Warning:0015]. deactivated while twoblocking condition exists. External warning lamps: Red lamp is lit.

Buzzer: Sounds continuously.

Moment display:Yellow segment Moment ratio exceeds is lit.

90% External warning lamps: Orange lamp is lit.

Buzzer: Sounds intermittently.

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

Buzzer: Sounds continuously.

Moment display: Displays failure AML system error messages.

AML buzzer: Sounds 3 seconds.

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

Associated restriction indicator lamp flashes.

Buzzer: Sounds continuously.

AML buzzer: Sounds 3 seconds.

Operated to cirtical side Moment display: Displays when backward stability [Warning:0025] Buzzer: Sounds 3 seconds. control activoted.

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

Boom lift with jib mounted on boom* (1) Moment ratio is Moment display: Corresponding between 75% and 85%. segment is lit.

External warning lamps Orange lamp is lit.

Buzzer: Sounds intermittently.

(1) Moment ratio exceeds Moment display: Displays 85%.

[Warning:0088].

External warning lamps : Red lamp is lit.

Buzzer: Sounds continuously.

Halted movement • Hoisting up • Boom lowering

exceeds 100% (*1)

• Boom extension

• Two-blocking • AML system error

Working range limit

Upper boom angle restricted

• Boom raising • Boom lift

Lower boom angle • Single top lift restricted

• Boom lowering

• Jib lift

Lifting height

• Boom raising

restricted

• Boom extension

Load radius

• Boom lowering

restricted

• Boom extension • Swing • Boom raising

Swing restricted • Backward instability (*2)

• Boom lift • Single top lift

IW301-0232E11

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

Buzz

IW301-0131E54

(*2): Automatic stop will work when the boom raised

IW301-0234E02

to 71° in an over-side area whith the outriggers extended to minimum.

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

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

The AML buzzer sounds for 3 seconds every time a message appears. It outputs long sounds when slow stop control is activated and outputs short sounds when other controls are activated.

55

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Names and Functions of Load Moment Indicator Main Unit Parts Bargraph display

Display panel 1 ° m

° %

Display panel 2 Control

IW301-0131E56

56

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1)

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 messages displayed on the moment display.

Normally displays a moment ratio on a bargraph.

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

Also displays error messages when the load moment indicator or any of its associated devices fails.

57

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Display Panel 1 1

2

3

17

20

5

゜ m

15

16

14

21

18

13

6

゜ ・

19

7

17

12 8

11

10

9

IW301-0231E09

8. Rated lifting capacity display

1. Jib angle display

Displays the rated lifting capacity.

When jib lift is selected, the jib angle offset is displayed. When the number of part-lines of rope select key is pressed, or the display alteration key is held down, the number of part-lines of ropes is displayed. Also, when the upper boom angle restriction function is registered, the registered upper boom angle restricted value is displayed as long as the register key is pressed on.

9. Load radius limit restriction indicative symbol This symbol, while marked up, means the value shown in the load radius display (11) represents the load radius limit. Note that the load radius indicative symbol (10) is also displayed at the same time.

10.Load radius indicative symbol This symbol, while marked up, means the value shown in the load radius display (11) represents the load radius.

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

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

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

Displays the boom swing angle while the display alteration key is held down.

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

5. Jib angle indicative symbol This symbol, while marked up, means the value shown in the jib angle display (1) represents the offset angle.

12. Counterweight state indicative symbol (Only for

6. Jib lift indicative symbol

TT800XXL-1) Marked up when the operation with the counterweight mounted is selected, indicating its mounting state.

Is marked up when the jib lift is selected, indicating the condition of the jib.

7. Real load display Displays the real load.

58

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1)

17.Boom angle indicative symbol

13.Boom length display

Indicates that the boom angle display (19) displays the boom angle.

Usually displays boom length.

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

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

18.Lower boom angle limit restriction symbol This symbol, while marked up, means the boom angle display (19) displays the registered lower boom angle restricted value.

14.Lifting height indicative symbol

19.Boom angle display Normally displays the boom angle.

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

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

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

The lifting height symbol (14) is marked up simultaneously.

20.Boom lift indicative symbol Is marked up when the boom lift is selected.

16.Upper boom angle limit restriction symbol

21.Single-top lift indicative symbol

Indicates that the jib angle display (1) displays the registered boom angle upper restricted value.

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

59

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Controls 14 13 12 11

15

10 16 17 18

9

19 8

20

7 6

1

2

3

4

5

IW301-0131E59

11. Lower boom angle limit restriction indicator lamp

1. Increase key

Lights up when the lower most boom angle limiting function is activated.

Used to increase the selected value.

2. Decrease key

12.Upper boom angle limit restriction key

Used to decrease the selected value.

Used to activate and release the upper most boom angle limiting function.

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

13.Upper boom angle limit restriction indicator lamp Lights up when the upper most boom angle limiting function is activated.

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

5. Check key

14.Lifting height restriction key

Used to check the AML system functions.

Used to activate and release the lifting height limiting function.

6. Register key Used to register a selected state.

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

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

16.Right swing restriction key Used to activate and release the right swing limiting function.

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

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

17.Right swing restriction indicator lamp

10.Lower boom angle limit restriction key

18.Left swing restriction key

Lights up when the right swing limiting function is activated.

Used to activate and release the left swing limiting function.

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

60

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1)

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

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

Display Panel 2 4

1

3 2

2

3 2

2

3

3 IW301-0211E09

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

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

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

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

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

61

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Selecting Operational Status

When the outrigger mode select key is pressed, the outrigger state indicative symbol, front jack symbol and counterweight state indicative symbol flash in accordance with the status that the AML detects on.

After making sure that the display conforms to the actual crane conditions, press the register key. The outrigger state indicative symbol, front jack symbol and counterweitht state indicative symbol will change from flashing into being marked up continuously and the moment display, rated lifting capacity display and real load display will return to normal display conditions, meaning that the state has been registered.

WARNING Should the operational status be incorrectly registered, the crane might overturn or be damaged, leading to a serious accident.

Prior to every operation, check that the registered status corresponds to the actual status of the crane.

Selecting Outrigger and Counterweight Status Before turning on the load moment indicator, make sure that the switches below are in the following positions:

[NOTICE] • In carrier driver’s cab:

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

Outrigger state indicative symbol is marked up as shown below:

Key-actuated switch “chassis-superstructure”… “1” Rocker switch “PTO”…………………………… “ON” • In crane operator’s cab: Starter switch…………………………………… “ON” All of the switches above must satisfy the above conditions to turn on the power supply.

Fully extended (23' 7 1/2'' (7.2m))

[NOTICE] The "on-rubber stationary" status is the default status and is automatically selected when the power supply is turned on (The outrigger state indicative symbols and front jack symbol remain off.)

Turning the power off automatically erases all the previous settings stored in memory. To resume the operation, enter the settings all over again.

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

Mid. extended (15' 9''(4.8m))

Min. extended (6' 9 7/8"(2.08m)) IW301-0232E06

° m

° %

Register key

Outrigger mode select key IW301-0131E61

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1)

[NOTICE] Counterweight state indicative symbol is marked up as shown below: (TT-600XL-1) 0 lbf (0kg)

8000 lbf (3630kg)

IW301-0232E07

(TT-800XXL-1) 0 lbf (0kg)

3700 lbf (1680kg)

7700 lbf (3495kg)

15700 lbf (7125kg)

IW301-0232E08

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) meaning that the state has been registered.

(When the jib set status is selected, the jib lift indicative symbol will remain flashing.)

Select the boom lift status when lifting a load on the boom with the jib mounted.

Select the jib lift status when lifting a single load using both the boom and jib.

Selecting Lift Status [NOTICE] The boom lift status is the default status and is automatically selected (the boom lift indicative symbol is marked up) when the power supply is turned on (the PTO switch is placed in the ON position).

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

(1) Boom lift

(2) Single top lift

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

(3) Jib set (mounting or stowage)

° m

(4) Jib lift : 32.5 ft (9.9m) jib, 3.5° offset

° %

(5) Jib lift : 32.5 ft (9.9m) jib, 25° offset

Register key (6) Jib lift : 32.5 ft (9.9m) jib, 45° offset

Lift mode select key IW301-0131E65

(7) Jib lift : 58.1 ft (17.7m) jib, 3.5° offset

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

(8) Jib lift : 58.1 ft (17.7m) jib, 25° offset

[NOTICE]

(9) Jib lift : 58.1 ft (17.7m) jib, 45° offset

After selecting the intended lift status, press the register key to register the status.

The corresponding indicative symbols will stop flashing and become marked up and the moment display, rated lifting capacity display and real load display will return to normal display conditions,

IW301-0231E15

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) When the power supply is turned on (i.e. PTO switch ON), the standard number of part-lines of rope corresponding to a work condition is selected.

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

Similarly, a process takes place on the basis of the standard number of part-lines of rope if the registered number is larger than the standard number.

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

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

°

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

Register key

IW301-0131E67

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

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

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

set, press the register key and register the number.

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

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

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

[NOTICE] When the increase or the decrease key is pressed, a numeral showing the number of rope stops flashing and becomes continuously marked up, showing a fixed value for the increase or decrease.

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

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Selecting Winch Condition

Selecting Jib Mounted Condition

WARNING

WARNING

Select the correct winch according to the actual crane condition; otherwise the load moment indicator will show wrong moment ratio, leading you to damage or overturn the crane.

If the jib mounting/dismounting state is set improperly, the load moment indicator can not detect the actual load precisely. The crane operation in this condition could create hazard.

The lifting capacities vary depending on the

The jib can be dismounted from the crane body

operating condition. Register the winch selection using the winch selector switch so that the winch selection indicator lamp is as shown in the table below according to the operating condition.

when it is not used. The reduced mass of the crane body after jib removal will influence the precision of the load moment indicator. Use this switch to set the jib mounting /dismounting state to the load moment indicator.

[NOTICE]

When main winch is employed : Main Winch

When auxiliary winch is employed

The key can be inserted in/removed from either “REMOVED” or “EQUIPPED” position.

: Auxiliary Winch

(1) “REMOVED” Select this position when the jib is dismounted. The jib removed indicator lamp will light up.

Winch selector switch

(2) “EQUIPPED” Select this position when the jib is mounted. The jib removed indicator lamp will go off.

: Main Winch

: Auxiliary Winch

Jib removed indicator lamp

IW301-0231E16 2B

D E F

COOL

HO

MODE 3B-

The winch selection alternates between main winch and auxiliary winch each time the winch selector switch is pressed. When auxiliary winch is selected, the winch selection indicator lamp lights up.

Jib state switch

[NOTICE] For boom lift, always employ the main winch.

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IW301-0231E17

Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Load Moment Indicator Pre-operational Inspection

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

WARNING

3. Make sure that the display on the display panels

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

conforms to the actual crane conditions.

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

Before starting operation, check that the load

(4) Real load……Make sure that the approximately mass of the hook block while no load is on the hook block

moment indicator works in good condition, as follows: 1. Press the check key and make sure that the load moment indicator is in the following conditions: • Moment display……All segments are marked up.

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

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

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

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

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

(5) Outrigger state indicative symbol (6) Front jack state indicator symbol (7) Boom position indicator (8) Counterweigth state indicative symbol 3 2

Buzz 1

4

Bargraph display

8

゜

Display panel 1 7

° m

Display panel 2 ° %

6

5 IW301-0232E09

[NOTICE] If the load moment indicator does not work properly, have it checked and repaired by the nearest TADANO distributor or dealer.

IW301-0131E68

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) How to Use the Working Range Limit Function

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

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

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

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

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

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

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

Upper boom angle restricted Lower boom angle restricted

Upper boom angle limit restriction indicator lamp

Lifting height restricted °

Lower boom angle limit restriction indicator lamp

θu H

Lower boom angle limit restriction key

θL

Load radius restricted

Upper boom angle limit restriction key

Swing restricted

IW301-0131E71

R IW301-0131E70

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Swing Limit

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

Swing the boom to the desired position, and press

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

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

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

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

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

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

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

[NOTICE]

°

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

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

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

Lifting height restriction indicator lamp

Lifting height restriction key

IW301-0131E72

Left swing restriction indicator lamp °

Right swing restriction indicator lamp

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

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Load Radius Limit Move the boom to the desired load radius, and press the load radius restriction key. The load radius restriction indicator lamp will flash and the buzzer will sound continuously, indicating that the limit load radius has been stored in the memory.

When the boom is moved back toward the non-critical side, the load radius restriction indicator lamp stops flashing, and stays lit and the buzzer stops.

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

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

°

Load radius restriction indicator lamp Load radius restriction key

IW301-0131E74

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Display of Working Range Restriction Values Press in the register key while working range restricting functions are registered.

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

[NOTICE] This display is not available when preoperational load moment indicator check is made and when working state is registered.

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

Upper boom angle limit restriction values

Working range

Lower boom angle limit restriction values

Lifting height restriction values

Load radius restriction values Boom position indicator

Register key Swing limit restriction values

IW301-0131E75

71

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Functions of and How to Use User Mode (TT-600XL-1/TT-800XXL-1) Display Alteration Displays on the moment display and the display panel 1 can be altered, as shown below in the figures, while the display alteration key is being pushed. The indicative symbols are displayed, too.

Moment Display

psi

M＊＊＊＊

Unit

Main-circuit pressure Meaning main circuit pressure

IW301-0131E76

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

Number of part-lines of rope M＊＊＊＊

psi

Lifting height

Moment ratio Real load

%

Rated lifting capacity Swing angle

Display alteration key IW301-0131E77

72

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

HALT

WDT

ZERO

SPAN

PROTECT ON

OFF

MOMENT SHORT

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

7. Check key 4. Increase key 3. Register key 5. Decrease key 6. Display alteration key

8. Moment input short-circuit switch 9. Protect switch 10. Moment span adjuster 11. Moment zero adjuster Top view 12. Abnormality display LED IW301-0231E19

IW301-0131E01

the maintenance mode.

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

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

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

9. Protect switch 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.

3. Register key Used to register the selected state and write the adjustment value in EEPROM.

10.Moment span adjuster

4. Increase key

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

Used to increase the adjustment value.

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

5. Decrease key Used to decrease the adjustment value.

6. Display alteration key

12.Abnormality display LED

Used to change the display to the upper menu.

Lights when the AML is in abnormal conditions or when the AML adjustment is initialized.

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

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

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

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

MAIN MENU

Power ON

Protect switch ON Protect switch OFF

[• Maintenance] MAINTENANCE MODE

USER MODE

[• Adjust clock]

ADJUSTMENT MODE

Power ON

IW301-0233E01

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

HALT

WDT

ZERO

ZERO

PROTECT ON

OFF

MOMENT SHORT

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

ON Protect switch

Top view

IW301-0231E20

74

W301-0234E

SUB-MENU [: Prog. version] [: Data ID. number] [: Di check] [: Ai check] [: Disp ELEV PRES] [: Do check] [: MDT Monitor] [: Key SW check] [: Display check] [: Disp. err data] [: Erase err data] [: Disp. O/L data] [: Erase O/L data] [: OP board check] [: Ao check] [: Sio check] [: Adjust Monitor]

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

SUB-MENU [: Adjust L&A]

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

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

[• Language]

(*1)

[: Adj. ELV speed]

*Boom length zero-point adjustment *Boom length span-point adjustment *Boom angle zero-point adjustment *Boom angle span-point adjustment *Swing angle zero-point adjustment *Swing angle span-point adjustment *Outrigger length zero-point adjustment *Outrigger length span-point adjustment *Load radius span adjustment *Moment zero-point adjustment *Moment span-point adjustment [Adjust ELV UP] [Correct ELV UP] [Adjust ELV DN] [Correct ELV DN]

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

[: Head-OFF Capac] [: Jib Select]] [: S/T Select] [: Winch drum PSN]

: This menu is prohibited to be used.

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W301-0234E

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

Moment display

HALT

WDT

ZERO

ZERO

ON

OFF

MOMENT SHORT

PROTECT

Scroll-down key

OFF Protect switch ON

Top view

IW301-0231E20

POWER ON

Protect switch ON Protect switch OFF

1 MAINTENANCE MODE

USER MODE 2 3

5

4 ADJUSTMENT MODE

Register key Display alteration key

POWER ON

IW301-0131E04

IW301-0232E12

4. “Adjustment mode” → “User mode”

1. “User mode” → “Maintenance mode”

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

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

5. “Maintenance mode” → “Adjustment mode”

2. “Maintenance mode” → “User mode”

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

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

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

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W301-0234E

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

Moment display Scroll-down key

Register key Display alteration key IW301-0131E04

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

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

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

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

and “ ”.

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

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

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

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

Replaced part

Required adjustment

Boom length detector

Boom length adjustment

Boom angle detector

Boom angle adjustment

Swing angle detector

Swing angle adjustment

Outrigger extension width detector

Outrigger extension width adjustment

Pressure sensor for moment detection

Moment adjustment

Display board

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

CPU board

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

AML unit ROM

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

None

Analog board

Boom length adjustment Boom angle adjustment Swing angle adjustment Moment adjustment

Power board

None

Current output board (Option board)

Adjustment of swing output Adjustment of elevation output

Connector board

None

Right swing proportional control valve Proportional control valve for Slow stop

Clock adjustment

Left swing proportional control valve Boom raising proportional control valve Boom lowering proportional control valve

78

Adjustment of swing output

Adjustment of elevation output

W301-0234E

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

Erasing the Overload History

[NOTICE] For how to shift to the adjustment mode and select from the adjustment menu, refer to “Method of Shifting Modes” and “Method of Menu Selection” in “General: Adjustment Mode and Maintenance Mode”.

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

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

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

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

The adjustment items and procedures are as follows: 1. Adjustment Initialization 2. Capacity Setting 3. Boom Length Adjustment 4. Boom Angle Adjustment 5. Swing Angle Adjustment 6. Outrigger Extension Width Adjustment 7. Moment Adjustment (Including load radius adjustment) 8. Clock Adjustment 9. Adjustment of Swing Output 10.Adjustment of Elevation Output Adjustment completed

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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.

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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. For the models other than TR-600XL-4, TR-800XXL-4 refer to the Service Manual specified for each crane model.

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

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

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

The crane capacity data normally does not need this setting.

[: Head-Off Capac ], and then press the register key to select the menu.

For the capacity setting, select one of the four

3. The currently registered head-off capacity value is

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

indicated on the moment display.

Display example: [Capacity 132.3 kp] (TR-600XL-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.

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

2.3 Procedure of Single Top Selection

[NOTICE]

[NOTICE]

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

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

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

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

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

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

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

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

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

3. The currently registered single top capacity 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.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

NO

YES

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

[NOTICE] Refer to “Adjustment Value Table” in the INFORMATION AND DATA section since the conditions and values for boom length adjustment vary depending on the specification number. For the models other than TR-600XL-4, TR-800XXL-4 refer to the Service Manual specified for each crane model.

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

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

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

3. Fully retract the boom.

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

Press the register key for registration.

5. Fully extend the boom.

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

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

8. Fully retract the boom again.

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

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Functions of and How to Use Adjustment Mode 4. Boom Angle Adjustment 8. Press the increase or decrease key so that the

WARNING

value of boom angle span adjustment display [Boom As] becomes the span adjustment value in “Adjustment Value Table”. Press the register key for registration.

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

[NOTICE]

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

Refer to “Adjustment Value Table” in the INFORMATION AND DATA section since the conditions and values for boom angle adjustment vary depending on the specification number. For the models other than TR-600XL-4, TR-800XXL-4 refer to the Service Manual specified for each crane model.

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

adjustment value in “Adjustment Value Table” again.

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

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

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.

NO

YES

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

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

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

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

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

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

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

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

Press the register key for registration.

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

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

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

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

Press the register key for registration.

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

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

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

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

SW AG 1z：0 ± 0.6° SW AG 2z：360 ± 0.6°

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

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

NO

YES

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

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

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

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

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

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

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

Press the register key for registration.

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

[NOTICE]

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

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

Refer to “Adjustment Value Table” in the INFORMATION AND DATA section since the conditions and values for outrigger extension width adjustment vary depending on the specification number. For the models other than TR-600XL-4, TR-800XXL-4 refer to the Service Manual specified for each crane model.

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

11.Fully retract all the outrigger beams again.

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

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

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

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

3. Fully retract all the outrigger beams.

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

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

NO

YES

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

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

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

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

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

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

[NOTICE] Before starting moment adjustment, raise the hydraulic oil temperature to approx.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. For the models other than TR-600XL-4, TR-800XXL-4 refer to the Service Manual specified for each crane model.

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

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

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

-0.99 to -0.01 klbs: “-99” to “-01”

[NOTICE]

4. After the adjustment, press the register key to

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: Two-blocking status (6)Actual status and registered status of number of part-lines: Standard number of part-lines when main boom is fully extended (7)Hook block: Refer to “Adjustment Value Table”.

(Stow auxiliary hook block.)

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

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: 0.00 to 0.99 klbs: “000” to “099”

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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. (Hook block position: Two-blocking status)

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 state

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”

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

YES

save the adjusted value.

NO

5. Make an adjustment with the increase or

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

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

Fine Adjustment”.

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 part-lines: Standard number of part-lines when main boom is fully extended.

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

(Stow auxiliary hook block.)

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

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

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

(Stow auxiliary hook block.)

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

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

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]

6. Make fine adjustment as shown below. (The

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”.

following fine adjustment procedures are extracted from “7.3 Moment Zero-point Check and Fine Adjustment”.)

(1)Make an adjustment with the increase or

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

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.

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

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. (Hook block position: Two-blocking status)

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 9. Adjustment of Swing Output

3. Press the scroll-up or scroll-down key until the right swing output adjustment display [41 SWG RV] (the left swing output adjustment display [42 SWG LV] for the left swing output adjustment) appears and a cursor comes on under the output value.

Display example: [41 SWG RV 0 0 ]

[NOTICE] Always reset the Ao offset value before adjustment of swing output (Ao offset adjustment).

9.1 Procedure of Resetting Ao Offset Value 1. Select the main menu [• Adjust AO ] in the

Actual output value

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

Output value

2. When [:Adjust AO Ofs. ] is displayed, press the scroll-down key until the display [:Reset AO Ofs.] appears. Press the register key to select the menu.

4. Press the increasse or decrease key to conform the output value of the right swing output adjustment display [41 SWG RV] to the standard value of the swing output. Remember that actual output value will also change in this situation.

Display example: [41 SWG RV 35 35 ]

3. When [Reset OK?] appears, reset the Ao offset value by pressing the register key.

4. When the message [Done] appears, the Ao offset

Actual output value

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

Output value

9.2 Adjustment of Swing Output (Ao offset adjustment)

5. Press the scroll-down key to move the cursor to under the actual output value.

Display example: [41 SWG RV 35 35 ]

[NOTICE] Refer to “Adjustment Value Table” in the INFORMATION AND DATA section since the standard value of the swing output varies depending on the specification number. For the models other than TR-600XL-4, TR-800XXL-4 refer to the Service Manual specified for each crane model.

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

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

(5)Hook block position: Hoisted up as much as possible (6)Hydraulic oil temperature: Approx.122° F(50°C)

Actual output value Output value 6. While keeping the swing control lever fully to the right swing side, raise the engine speed to maximum. Then press the increase or decrease key so that the boom swing will stop under this condition.

Display example: [41 SWG RV 35 37 ] Actual output value Output value 7. Press the register key to save the adjusted value

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

in EEPROM. Now the adjustment of the right swing output is completed.

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

2. When [: Adjust AO Ofs. ] is displayed, press the register key to select the menu.

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Functions of and How to Use Adjustment Mode

8. Adjust and save the left swing output in the same manner as the right swing output adjustment.

Then press the display alteration key to exit the menu. (For the left swing output adjustment, substitute “left swing output adjustment display [42 SWG LV]” for “right swing output adjustment display [41 SWG RV]”.)

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Functions of and How to Use Adjustment Mode 10. Adjustment of Elevation Output

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

This message does not appear if the boom is already retracted fully.

[NOTICE] Always reset the elevation data before adjustment of elevation output (elevation speed adjustment).

5. When [Boom A

10.1 Procedure of Resetting Elevation Data

.

° ] appears, lower the

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

This message does not appear if the boom is already lowered to or below the specified angle.

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

2. When [: Adj. ELV speed ] is displayed, press the scroll-down key until the display [:Reset ELV data] appears. Press the register key to select the menu.

6. When the following messages appear, press the register key to select the menu.

Display: [Start CNT Adj. ] [JS neutral ] [Push reg. key]

3. When [Reset OK?] appears, reset the elevation data by pressing the register key.

7. When the following messages appear, shift the boom elevating control lever fully to the boom raising side while keeping the engine revolution at the maximum. Maintain this situation until the end of the measurement.

Display: [ELV Ope. MAX ] [Engine MAX]

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

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

10.2 Adjustment of Elevation Output (elevation speed adjustment) [NOTICE] Set the crane as follows: (1)Outriggers mode: Fully extended (2)Lift mode: Boom lift (Stow jib and single top.)

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

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

8. The following message will appear during measurement.

Display example: [pi= . CV= ] Elevating cylinder velocity Output pilot pressure If the elevating cylinder rod moves almost all the

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

way to its stroke end during measurement, it stops automatically and the following messages will appear. Reattempt from the step 5.

Display example: [Stroke end ] [Boom A . °]

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

2. When [: Adj. ELV speed ] is displayed, press the register key to select the menu.

3. Press the scroll-up or scroll-down key until the boom raising measurement display [Adjust ELV UP ] appears and press the register key to select the menu. (The boom lowering measurement display is [Adjust ELV DN ].)

To cancel the measurement, return the boom elevating control lever to the neutral position and press the display alteration key to exit the menu.

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Functions of and How to Use Adjustment Mode 9. The measurement is completed when the elevating cylinder rod stops and the following messages appear.

Display: [Adjustment done ] [JS neutral] 10.Return the boom elevating control lever to the neutral position.

When [Push reg. key ] appears, press the register key to store the measured value into the EEPROM. You can see the measurement result as shown below if you press the scroll-down key while [Push reg. key ] is displayed.

Display example: [ N P= . C= ] Elevating cylinder velocity Output pilot pressure Indicating that the displayed data are Nth in sequence.

11.The measurement of the boom raising is completed when [Data recorded] appears. Press the display alteration key to return to the submenu [:Adj. ELV speed ].

12.Measure the boom lowering and store the measured value in the same manner described for boom raising. Press the display alteration key to exit the menu.

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

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.

Display: [:Disp. Late data ]

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

[:Disp. Max. data] 3. Display of latest overload data

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

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.

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

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

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

Moment display Display example: [99. 01. 23 12:35 ] Shows the number of registered items.

(50 items maximum.)

3. When the aimed language is displayed, press the

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

register key. After the registration, the sign “:” at the left side of message changes to “=”.

Display example: [: English] Press the register key. [=English]

Shows the overload ratio.

(Max. 400%)

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.

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

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

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

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

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

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

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

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

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

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

[125% 14.5f 45.0° ] Indicates boom length.

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

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

Indicates boom angle.

Indicates load radius.

Indicates lift status.

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.

Indicates swing position.

Indicates outrigger status.

Indicates actual load.

Indicates rated lifting capacity.

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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 [NOTICE] For how to shift to the maintenance mode and select from the maintenance menu, refer to “Method of Shifting Modes” and “Method of Menu Selection” in “General: Adjustment Mode and Maintenance Mode”

Maintenance Menus

MAIN MENU [• Maintenance] [• Adjust clock]

SUB-MENU [: Prog. version] [: Data ID. number] [: Di check] [: Ai check] [: Disp ELEV PRES] [: Do check] [: MDT Monitor] [: Key SW check] [: Display check] [: Disp. err data] [: Erase err data] [: Disp. O/L data] [: Erase O/L data] [: OP board check] [: Ao check] [: Sio check] [: Adjust Monitor]

[NOTICE] This menu includes “MDT (Multiplex Date Transmitter) Monitor”, which makes the input/output state of the MDT (Multiplex Date Transmitter) appear.

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Functions of and How to Use Maintenance Mode 1. Program Version Display

3. Di Check

ROM program version is displayed.

The input state of Di (external contact switch) 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. 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

Indicates switch state on : active of : not active

Information of ROM data is displayed.

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

Switch name

maintenance mode, and 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)

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.

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:

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

(1)ID number display: Indicates ROM ID number (revision number included).

Display example:[750200 ] (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 ] (5)Revision date display: Indicates the date of data revision.

Display example:[96, 01, 23]

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Functions of and How to Use Maintenance Mode 4. Ai Check

[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.

The input state of Ai (analog detector input) is displayed.

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 [:Ai check ] appears, and then press the register key to select the menu.

5. Elevating Cylinder Oil Pressure Monitor The cylinder extension lateral pressure and retraction lateral pressure which are detected for moment calculation are displayed.

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 ]

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

When detected input is within

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.

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

3. The elevating cylinder extension lateral pressure and retraction lateral pressure are displayed.

Press the display alteration key to exit the menu.

Display example: [E . R . psi ]

A/D converted value of analog input.

Analog detector name Logical number of analog input in the program.

Unit

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)

Retraction oil pressure Extension oil pressure

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Functions of and How to Use Maintenance Mode 7. MDT (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.

[NOTICE]

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

For the signal represented by the displayed input/output No., see the “MDT (Multiplex Data Transmitter) Input/Output Nos. and Corresponding Signals” on the next page.

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

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

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

3. Do output state is displayed. Display changes by 2. Press the scroll-up or scroll-down key until the

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

Display example (RLY1): [ 00 Stoppage of ]

display [:MDT Monitor ] appears, and then press the register key to select the menu.

3. The input/output state of the MDT (multiplex data transmitter) is displayed. Display changes by increase or decrease key. Press the display alteration key to exit the menu.

Display example: [ No.123 Val. 1]

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

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

Input/output number

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

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Functions of and How to Use Maintenance Mode MDT (multiplex data transmitter ) input/output nos. and corresponding signals Upper input

Upper output

Lower input

Input/ Input/ Input/ Input/ Input/ output Signal output Signal output Signal output Signal output No. No. No. No. No.

Lower output

Analog input

Signal

Input/ Input/ Input/ output Signal output Signal output Signal No. No. No. Upper Ai1 Upper Ai2 Upper Ai3 Upper Ai4 Upper Ai5 Upper Ai6 Upper Ai7 Upper Ai8 Upper Ai9 Upper Ai10 Lower Ai1 Lower Ai2 Lower Ai3 Lower Ai4 Lower Ai5 Lower Ai6 Lower Ai7 Lower Ai8 Lower Ai9 Lower Ai10 Lower Ai11 Lower Ai12

1

Di1

33

Di33

65

Tr1

89

Di1

121

PMONI1

137

MONI1

169

MONI33

201

2

Di2

34

Di34

66

Tr2

90

Di2

122

PMONI2

138

MONI2

170

MONI34

202

3

Di3

35

Di35

67

Tr3

91

Di3

123

PMONI3

139

MONI3

171

MONI35

203

4

Di4

36

Di36

68

Tr4

92

Di4

124

PMONI4

140

MONI4

172

MONI36

204

5

Di5

37

Di37

69

Tr5

93

Di5

125

PMONI5

141

MONI5

173

MONI37

205

6

Di6

38

Di38

70

Tr6

94

Di6

126

PMONI6

142

MONI6

174

MONI38

206

7

Di7

39

Di39

71

Tr7

95

Di7

127

PMONI7

143

MONI7

175

MONI39

207

8

Di8

40

Di40

72

Tr8

96

Di8

128

PMONI8

144

MONI8

176

MONI40

208

9

Di9

41

Di41

73

Tr9

97

Di9

129

PMONI9

145

MONI9

177

MONI41

209

10

Di10

42

Di42

74

Tr10

98

Di10

130

PMONI10

146

MONI10

178

MONI42

210

11

Di11

43

Di43

75

Tr11

99

Di11

131

PMONI11

147

MONI11

179

MONI43

211

12

Di12

44

Di44

76

Tr12

100

Di12

132

PMONI12

148

MONI12

180

MONI44

212

13

Di13

45

Di45

77

Tr13

101

Di13

133

PMONI13

149

MONI13

181

MONI45

213

14

Di14

46

Di46

78

Tr14

102

Di14

134

PMONI14

150

MONI14

182

MONI46

214

15

Di15

47

Di47

79

Tr15

103

Di15

135

PMONI15

151

MONI15

183

MONI47

215

16

Di16

48

Di48

80

Tr16

104

Di16

136

PMONI16

152

MONI16

184

MONI48

216

17

Di17

49

Di49

81

Tr17

105

Di17

153

MONI17

185

MONI49

217

18

Di18

50

Di50

82

Tr18

106

Di18

154

MONI18

186

MONI50

218

19

Di19

51

Di51

83

Tr19

107

Di19

155

MONI19

187

MONI51

219

20

Di20

52

Di52

84

Tr20

108

Di20

156

MONI20

188

MONI52

220

21

Di21

53

Di53

85

Tr21

109

Di21

157

MONI21

189

MONI53

221

22

Di22

54

Di54

86

Tr22

110

Di22

158

MONI22

190

MONI54

222

23

Di23

55

Di55

87

Tr23

111

Di23

159

MONI23

191

MONI55 Analog output

24

Di24

56

Di56

88

Tr24

112

Di24

160

MONI24

192

MONI56 Input/

25

Di25

57

Di57

113

Di25

161

MONI25

193

Tr1

output Signal No.

26

Di26

58

Di58

114

Di26

162

MONI26

194

Tr2

231

27

Di27

59

Di59

115

Di27

163

MONI27

195

Tr3

241

28

Di28

60

Di60

116

Di28

164

MONI28

196

Tr4

242

29

Di29

61

Di61

117

Di29

165

MONI29

197

MSOL1

243

30

Di30

62

Di62

118

Di30

166

MONI30

198

MSOL2

31

Di31

63

Di63

119

Di31

167

MONI31

32

Di32

64

Di64

120

Di32

168

MONI32

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Upper Ao1 Lower Ao1 Lower Ao2 Lower Ao3

Functions of and How to Use Maintenance Mode 8. Key Switch Check

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

Check the key switch on the AML front panel 3. The error codes are displayed on the moment

whether it works normally or not.

indicator and display panel. Press the display alteration key to exit the menu and return to the ordinary display state.

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

(1)The moment indicator displays the time when 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.

error occurred.

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

3. The display

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

Display example: [ Error:2003 ]

[– – – – – – – – – • – – – – – –] 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

Total number of stored items.

Serial number. (signifies what number the error is.)

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

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

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

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

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

If "C" mark is seen here, this is the living error.

Error code. This example shows the error code 2003.

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

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

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

11. Erasing the Error Data Use this menu to erase the registered error data

The Ao (analog output) state is displayed with an

information.

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 [:Erase err data ] 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. When the message [Erase OK? ]appears, press

3. Ao output state is displayed as below.

the register key.

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 ]

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

Output level for checking indicates at what percentage of the maximum level the value is to be output.

12. OP (Option) Board Check The state of the incorporated option board (analog output, wire detection) is indicated.

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

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

Output name

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

Ao output terminal number

display [:OP board check ] appears, and then press the register key to select the menu.

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)

3. The sort of the incorporated option board is 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 ] Option board name

[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.

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

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Functions of and How to Use Maintenance Mode 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 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%.)

15. Adjust Monitor 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.

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.

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.

3. The same items as shown in the [• Adjust ] menu of the main menu of the adjustment mode are displayed.

Press the display alteration key to exit the menu.

14. Sio Check

16. Overload History Display

The Sio (serial port) state is indicated.

The overload history display in the maintenance

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

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.

17. Erasing the Overload History

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 ]

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

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

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

18. Clock Adjustment

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

107

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

W301-0234E

Error Message Error Message

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

1. Display of Error Message

four-digit codes.

[NOTICE]

Error code: E1 E2 E3 E4

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

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

Displays a failure message

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

IW301-0131E09

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

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

Display example: [Error:2001]

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

Shows that an error of error code 2001 has occurred.

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

3. How to Read the Error History

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

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

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

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

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

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

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

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Error Message 4. Troubleshooting Table 4.1 Group Code 0 Message

Description

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

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

Situation: Cause: Action:

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

Outrigger beam(s) have just retracted.

Extend the outrigger beam again.

Message

Description

Error : 0005

Boom angle value becomes out of specified range

Situation:

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

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

Cause: Action:

Boom angle is smaller than that required for jib setting.

Raise the boom till safety angle for jib setting.

Message

Description

Error : 0006

Improperly inserted jib lock pin

Situation: Cause: Action:

Boom extending operation 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 : 0007

Situation: Cause: Action:

Stop at swing angle limit

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

(Error code is displayed only during either left or right swing operation is peformed.)

Lifting capacity is exceeded by swing operation.

Crane is automatically stopped if swing automatic stop function is provided.

The boom is swung into an area where the capacity is reduced due to outrigger extension width and the moment ratio has exceeded 100%.

Swing the boom in the opposite direction.

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

Message

Description

Warning : 0010

Close to the swing angle restriction

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

Situation: Cause:

Action:

The boom is just close to the swing restriction angle.

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

Cancel the swing area restriction function.

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Error Message

Message

Description

Warning : 0012

Rear stability auto. stop range

Situation: Cause: Action:

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

The boom is raised too high.

The outrigger extension width is insufficient.

Lower the boom.

Increase the outrigger extention width.

Message

Description

Error : 0013 Error : 0014

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

Situation:

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

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

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

Cause:

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

Swing angle detector is defective or maladjusted.

Investigate the possible causes described above.

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

Action:

Message

Description

Warning : 0015

Two-blocking condition (When two-blocking stop function is cancelled)

Situation:

Cause: Action:

Two-blocking detection switch has been turned off (two-blocking status).

A crane does not stop automatically though the error code is displayed when two-blocking is cleared.

Main or auxiliary hook block has been wound up excessively.

Hoist down the main or auxiliary winch.

Message

Description

Error : 0016 Error : 0017

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

Situation: Cause: Action:

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

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

Register the operation status again.

110

W301-0234E

Error Message

Message

Description

Error : 0018

Boom full retraction switch 1 faulty (2nd boom): TR-600XL-4, TR-600XXL-4, TR-800XXL-4, TT-600XL-1, TT-800XXL-1 Boom full retraction switch 2 faulty (3rd -- top boom): TR-600XL-4, TR-600XXL-4, TR-800XXL-4, TT-600XL-1, TT-800XXL-1 Boom full retraction switch 3 faulty (No use) Boom full retraction switch 4 faulty (No use)

Error : 0019 Error : 0020 Error : 0021

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.

111

W301-0234E

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.

112

W301-0234E

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.

113

W301-0234E

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.

114

W301-0234E

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).

115

W301-0234E

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.

116

W301-0234E

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:

117

W301-0234E

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.

118

W301-0234E

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.

119

W301-0234E

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:

120

W301-0234E

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.

121

W301-0234E

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:

122

W301-0234E

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:

123

W301-0234E

Disassembly of AML Main Unit Disassembly of AML Main Unit Exploded view

124

W301-0234E

Disassembly of AML Main Unit Connector disassembling

1. Removing Front Panel/Display Board/CPU board [NOTICE] Do not touch the two surfaces of the boards during disassembly processes.

1. Remove the front panel, desplay board and CPU board as an assembly from the unit case by unscrewing screw a.

Connectors CN•A, CN•B, CN•C, and CN•D come

2. Unplug connectors CN•A and CN•B.

off when the retaining levers are pushed open.

When replugging, be sure to push them until they click.

3. Remove the CPU board by pulling off connector CN•H and unscrewing screw b.

4. Separate the display board by unscrewing screw c.

1.1 Notes on ROM/EEPROM Replacement CALENDER/CLOCK BATTERY CN1

EEPROM

ROM 1

CPU

ROM 0

CN2 CN3

CPU Board IW301-0231E22

When replacing ROM and EEPROM, make sure that the concavities of IC and socket meet each other.

[NOTICE] EEPROM stores the adjustment values for each specification number. When replacing the CPU board, reuse the EEPROM after removing it from the broken CPU board.

125

W301-0234E

Disassembly of AML Main Unit 2. Removing Rear Panel/Connector Board/Option board [NOTICE] Do not touch the two surfaces of the boards during disassembly processes.

1. Remove the rear panel, connector board and option boad as an assembly from the unit case by unscrewing screw d.

2. Unplug connectors CN•C and CN•D. 3. Remove screw i, connectors CN•G and CN•I and disconnect the option board.

4. Remove screw and disconnect the connector board.

3. Removing Analog Board/Power board [NOTICE] Do not touch the two surfaces of the boards during disassembly processes.

1. Remove the front panel, display board and CPU board as an assembly by unscrewing screw a.

2. Unplug connectors CN•A and CN•B. 3. Remove the rear panel, connectors bord and option board as an asembly by unscrewing screw d.

4. Unplug connectors CN•C and CN•D. 5. Remove the analog and power boards as an assembly by unscrewing screw e.

6. Remove connectors CN•E and CN•F as well as screws f and g, and disconnect the analog and power boards.

126

W301-0234E

Adjustment Value Table [INFORMATION AND DATA] Adjustment Value Table Specification No. : GR-600-1-00101 (2M2D-specification) AML model

: AML-LK

AML code No.

: 361-907-20000

1. Setting before adjustment Capacity setting Head-off capacity setting

Jib selection

Single top selection

Winch drum position setting

Not set

Not set

Not set

Set to “R” (rear)

2. Adjustment the detector Precautions for adjustment (*1) Adjust the center of dispersion to coincide to the adjusting value. (*2) Adjust the boom angle and the moment in the elevating lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) When adjusting the moment, make the number of part-lines of rope to the standard number (four part-lines) that is when boom fully extended, and set the AML as Boom status: Boom and Number of part-lines of rope:4.

Adjustment item

Condition Boom length: Fully retracted

36.09ft (11.0m)

±0.12ft (±0.26ft for zero-point check)

Span adjustment

Boom length: Fully extended

111.88ft (34.1m)

±0.13ft

Zero-point adjustment

Boom angle: 0° (actual value)

0°

±0.1° (±0.2°for zero-point check)

Span adjustment

Boom angle: 78° (actual value)

78°

±0.1°

Zero-point adjustment

Swing angle1:0°

Swing position : front (Right swing)

Swing angle2:360°

Swing angle (*3) Span adjustment

Outrigger extension width

Tolerance

Zero-point adjustment Boom length

Boom angle (*2)

Adjustment value

Swing angle1:180° Swing angle2:180°

Swing position : rear (Right swing)

±0.3° (±0.6°for zero-point check) ±0.3° (±0.6°for zero-point check) ±0.3° ±0.3°

Zero-point adjustment

Outrigger extension width: MIN.

4.593ft (1.4m)

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

Span adjustment

Outrigger extension width: MAX.

11.811ft (3.6m)

±0.02ft

127

W301-0234E

Adjustment Value Table

Adjustment item

Condition

Adjustment value

Boom length: Fully retracted Zero-point adjustment

Boom angle: 80±0.1° (indicated value) Load : Without load (0.476t hook only) Hook : Two-blocking status

Tolerance

0.85klbf (0.385t) Hook block mass minus Wire rope mass

±0.64klbf

Boom length: Fully retracted Span preliminary adjustment Moment (*2) (*4)

Boom angle: 10±0.1° (indicated value) Load : Without load (0.476t hook only) Hook : Hoisting-down until immediately before the ground plane

1.05klbf (0.476t)

±0.11klbf

Hook block mass

Boom length: Fully extended Load radius adjustment

Load radius: 25ft (7.62m) (actual value) Rated lifting capacity: 27.8klbf (12.61t)

25ft (7.62m)

±0.19ft

1.05klbf (0.476t)

±0.04klbf

Boom length: Fully extended Span fine adjustment

Boom angle: 10±0.1° (indicated value) Load : Without load (0.476t hook only) Hook : Hoisting-down until immediately before the ground plane

Hook block mass

3. Slow stop adjustment 1. Standard value of the swing output : 217 2. Measurement of elevating up and down characteristic 4. Setting after adjustment 1. Number of part-line : 1 line 2. Language switch : English

[NOTICE] Refer to “terminal No.5 (RLY5) of CN2 connector (page 11)” for the telescoping control relay output of the AML.

128

W301-0234E

Adjustment Value Table Specification No. : GR-600-1-00103 (2M2D-specification) AML model

: AML-LK

AML code No.

: 361-922-30000

1. Setting before adjustment Capacity setting Head-off capacity setting

Jib selection

Single top selection

Winch drum position setting

Not set

Not set

Not set

Set to “R” (rear)

2. Adjustment the detector Precautions for adjustment (*1) Adjust the center of dispersion to coincide to the adjusting value. (*2) Adjust the boom angle and the moment in the elevating lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) When adjusting the moment, make the number of part-lines of rope to the standard number (four part-lines) that is when boom fully extended, and set the AML as Boom status: Boom and Number of part-lines of rope:4.

The adjusting value is for 0.40 ton hook installed, and the value in the { } is for 0.47 ton hook installed.

Adjustment item

Condition Boom length: Fully retracted

36.42ft (11.1m)

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

Span adjustment

Boom length: Fully extended

137.80ft (42m)

±0.13ft

Zero-point adjustment

Boom angle: 0°(actual value)

0°

±0.1° (±0.2°for zero-point check)

Span adjustment

Boom angle: 80°(actual value)

80°

±0.1°

Zero-point adjustment

Swing angle1:0°

Swing position : front (Right swing)

Swing angle2:360°

Swing angle (*3) Span adjustment

Outrigger extension width

Tolerance

Zero-point adjustment Boom length

Boom angle (*2)

Adjustment value

Swing angle1:180° Swing angle2:180°

Swing position : rear (Right swing)

±0.3° (±0.6°for zero-point check) ±0.3° (±0.6°for zero-point check) ±0.3° ±0.3°

Zero-point adjustment

Outrigger extension width: MIN.

4.593ft (1.4m)

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

Span adjustment

Outrigger extension width: MAX.

11.811ft (3.6m)

±0.02ft

129

W301-0234E

Adjustment Value Table

Adjustment item

Condition

Adjustment value

Boom length: Fully retracted Zero-point adjustment

Boom angle: 80±0.1° (indicated value) Load : Without load (0.4t {0.47t} hook only) Hook : Two-blocking status

Tolerance

0.67klbf (0.30t) {0.82klbf (0.37t)} Hook block mass minus Wire rope mass

±0.68klbf

Boom length: Fully retracted Span preliminary adjustment Moment (*2) (*4)

Boom angle: 10±0.1° (indicated value) Load : Without load (0.4t {0.47t} hook only) Hook : Hoisting-down until immediately before the ground plane

0.88klbf (0.40t) {1.05klbf (0.47t)}

±0.11klbf

Hook block mass

Boom length: Fully extended Load radius adjustment

Load radius: 29.99ft (9.14m) (actual value) Rated lifting capacity: 17.6klbf (7.98t)

29.99ft (9.14m)

±0.24ft

Boom length: Fully extended Span fine adjustment

Boom angle: 30±0.1° (indicated value) Load : Without load (0.4t {0.47t} hook only) Hook : Hoisting-down until immediately before the ground plane

0.88klbf (0.40t) {1.05klbf (0.47t)}

±0.04klbf

Hook block mass

3. Slow stop adjustment 1. Standard value of the swing output : 217 2. Measurement of elevating up and down characteristic 4. Setting after adjustment 1. Number of part-line : 1 line 2. Language switch : English

[NOTICE] Refer to “terminal No.5 (RLY5) of CN2 connector (page 11)” for the telescoping control relay output of the AML.

130

W301-0234E

Adjustment Value Table Specification No. : GR-800-1-00101 (2M2D-specification) AML model

: AML-LK

AML code No.

: 361-908-90000

1. Setting before adjustment Capacity setting Head-off capacity setting

Jib selection

Single top selection

Winch drum position setting

Not set

Not set

Not set

Set to “R” (rear)

2. Adjustment the detector Precautions for adjustment (*1) Adjust the center of dispersion to coincide to the adjusting value. (*2) Adjust the boom angle and the moment in the elevating lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) When adjusting the moment, make the number of part-lines of rope to the standard number (four part-lines) that is when boom fully extended, and set the AML as Boom status: Boom and Number of part-lines of rope:4.

The adjusting value is for 0.40 ton hook installed, and the value in the { } is for 0.47 ton hook installed.

Adjustment item

Condition Boom length: Fully retracted

36.42ft (11.1m)

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

Span adjustment

Boom length: Fully extended

137.80ft (42m)

±0.13ft

Zero-point adjustment

Boom angle: 0°(actual value)

0°

±0.1° (±0.2°for zero-point check)

Span adjustment

Boom angle: 80°(actual value)

80°

±0.1°

Zero-point adjustment

Swing angle1:0°

Swing position : front (Right swing)

Swing angle2:360°

Swing angle (*3) Span adjustment

Outrigger extension width

Tolerance

Zero-point adjustment Boom length

Boom angle (*2)

Adjustment value

Swing angle1:180° Swing angle2:180°

Swing position : rear (Right swing)

±0.3° (±0.6°for zero-point check) ±0.3° (±0.6°for zero-point check) ±0.3° ±0.3°

Zero-point adjustment

Outrigger extension width: MIN.

4.593ft (1.4m)

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

Span adjustment

Outrigger extension width: MAX.

11.811ft (3.6m)

±0.02ft

131

W301-0234E

Adjustment Value Table

Adjustment item

Condition

Adjustment value

Boom length: Fully retracted Zero-point adjustment

Boom angle: 80±0.1° (indicated value) Load : Without load (0.4t {0.47t} hook only) Hook : Two-blocking status

Tolerance

0.67klbf (0.30t) {0.82klbf (0.37t)} Hook block mass minus Wire rope mass

±0.68klbf

Boom length: Fully retracted Span preliminary adjustment Moment (*2) (*4)

Boom angle: 10±0.1° (indicated value) Load : Without load (0.4t {0.47t} hook only) Hook : Hoisting-down until immediately before the ground plane

0.88klbf (0.40t) {1.05klbf (0.47t)}

±0.11klbf

Hook block mass

Boom length: Fully extended Load radius adjustment

Load radius: 29.99ft (9.14m) (actual value) Rated lifting capacity: 17.6klbf (7.98t)

29.99ft (9.14m)

±0.24ft

Boom length: Fully extended Span fine adjustment

Boom angle: 30±0.1° (indicated value) Load : Without load (0.4t {0.47t} hook only) Hook : Hoisting-down until immediately before the ground plane

0.88klbf (0.40t) {1.05klbf (0.47t)}

±0.04klbf

Hook block mass

3. Slow stop adjustment 1. Standard value of the swing output : 217 2. Measurement of elevating up and down characteristic 4. Setting after adjustment 1. Number of part-line : 1 line 2. Language switch : English

[NOTICE] Refer to “terminal No.5 (RLY5) of CN2 connector (page 11)” for the telescoping control relay output of the AML.

132

W301-0234E

Adjustment Value Table

Specification No. : GT-600-1-90102 (2M2D-specification) AML model

: AML-LK

AML code No.

: 361-912-40000

1. Setting before adjustment Capacity setting Head-off capacity setting

Jib selection

Single top selection

Winch drum position setting

Not set

Not set

Not set

Set to “R” (rear)

2. Adjustment the detector Precautions for adjustment (*1) Adjust the center of dispersion to coincide to the adjusting value. (*2) Adjust the boom angle and the moment in the elevating lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) When adjusting the moment, make the number of part-lines of rope to the standard number (four part-lines) that is when boom fully extended, and set the AML as Boom status: Boom and Number of part-lines of rope:4.

Adjustment item

Condition Boom length: Fully retracted

36.09ft (11.0m)

±0.12ft (±0.26ft for zero-point check)

Span adjustment

Boom length: Fully extended

111.88ft (34.1m)

±0.13ft

Zero-point adjustment

Boom angle: 0° (actual value)

0°

±0.1° (±0.2°for zero-point check)

Span adjustment

Boom angle: 78° (actual value)

80°

±0.1°

Zero-point adjustment

Swing angle1:0°

Swing position : front (Right swing)

Swing angle2:360°

Swing angle (*3) Span adjustment

Outrigger extension width

Tolerance

Zero-point adjustment Boom length

Boom angle (*2)

Adjustment value

Swing angle1:180° Swing angle2:180°

Swing position : rear (Right swing)

±0.3° (±0.6°for zero-point check) ±0.3° (±0.6°for zero-point check) ±0.3° ±0.3°

Zero-point adjustment

Outrigger extension width: MIN.

3.412ft (1.04m)

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

Span adjustment

Outrigger extension width: MAX.

11.811ft (3.6m)

±0.02ft

133

W301-0234E

Adjustment Value Table

Adjustment item

Condition

Adjustment value

Boom length: Fully retracted Zero-point adjustment

Boom angle: 80±0.1° (indicated value) Load : Without load (0.476t hook only) Hook : Two-blocking status

Tolerance

0.85klbf (0.385t) Hook block mass minus Wire rope mass

±0.64klbf

Boom length: Fully retracted Span preliminary adjustment Moment (*2) (*4)

Boom angle: 10±0.1° (indicated value) Load : Without load (0.476t hook only) Hook : Hoisting-down until immediately before the ground plane

1.05klbf (0.476t)

±0.11klbf

Hook block mass

Boom length: Fully extended Load radius adjustment

Load radius: 25ft (7.62m) (actual value) Rated lifting capacity: 27.8klbf (12.61t)

25ft (7.62m)

±0.19ft

1.05klbf (0.476t)

±0.04klbf

Boom length: Fully extended Span fine adjustment

Boom angle: 10±0.1° (indicated value) Load : Without load (0.476t hook only) Hook : Hoisting-down until immediately before the ground plane

Hook block mass

3. Slow stop adjustment 1. Standard value of the swing output : 217 2. Measurement of elevating up and down characteristic 4. Setting after adjustment 1. Number of part-line : 1 line 2. Language switch : English

[NOTICE] Refer to “terminal No.5 (RLY5) of CN2 connector (page 20)” for the telescoping control relay output of the AML.

134

W301-0234E

Adjustment Value Table Specification No. : GT-800-1-90102 (2M2D-specification) AML model

: AML-LK

AML code No.

: 361-907-40000

1. Setting before adjustment Capacity setting Head-off capacity setting

Jib selection

Single top selection

Winch drum position setting

Not set

Not set

Not set

Set to “R” (rear)

2. Adjustment the detector Precautions for adjustment (*1) Adjust the center of dispersion to coincide to the adjusting value. (*2) Adjust the boom angle and the moment in the elevating lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) When adjusting the moment, make the number of part-lines of rope to the standard number (four part-lines) that is when boom fully extended, and set the AML as Boom status: Boom and Number of part-lines of rope:4.

The adjusting value is for 0.40 ton hook installed, and the value in the { } is for 0.47 ton hook installed.

Adjustment item

Condition Boom length: Fully retracted

37.73ft (11.5m)

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

Span adjustment

Boom length: Fully extended

144.36ft (44m)

±0.13ft

Zero-point adjustment

Boom angle: 0°(actual value)

0°

±0.1° (±0.2°for zero-point check)

Span adjustment

Boom angle: 80°(actual value)

80°

±0.1°

Zero-point adjustment

Swing angle1:0°

Swing position : front (Right swing)

Swing angle2:360°

Swing angle (*3) Span adjustment

Outrigger extension width

Tolerance

Zero-point adjustment Boom length

Boom angle (*2)

Adjustment value

Swing angle1:180° Swing angle2:180°

Swing position : rear (Right swing)

±0.3° (±0.6°for zero-point check) ±0.3° (±0.6°for zero-point check) ±0.3° ±0.3°

Zero-point adjustment

Outrigger extension width: MIN.

3.412ft (1.04m)

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

Span adjustment

Outrigger extension width: MAX.

11.811ft (3.6m)

±0.02ft

135

W301-0234E

Adjustment Value Table

Adjustment item

Condition

Adjustment value

Boom length: Fully retracted Zero-point adjustment

Boom angle: 80±0.1° (indicated value) Load : Without load (0.4t {0.47t} hook only) Hook : Two-blocking status

Tolerance

0.68klbf(0.31t) {0.84klbf(0.38t)} Hook block mass minus Wire rope mass

±0.51klbf

Boom length: Fully retracted Span preliminary adjustment Moment (*2) (*4)

Boom angle: 10±0.1° (indicated value) Load : Without load (0.4t {0.47t} hook only) Hook : Hoisting-down until immediately before the ground plane

0.88klbf (0.40t) {1.05klbf (0.47t)}

±0.11klbf

Hook block mass

Boom length: Fully extended Load radius adjustment

Load radius: 45.01ft (13.72m) (actual value) Rated lifting capacity: 17.59klbf(7.98t)

45.01ft (13.72m)

±0.2ft

Boom length: Fully extended Span fine adjustment

Boom angle: 40±0.1° (indicated value) Load : Without load (0.4t {0.47t} hook only) Hook : Hoisting-down until immediately before the ground plane

0.88klbf (0.40t) {1.05klbf (0.47t)}

±0.04klbf

Hook block mass

3. Slow stop adjustment 1. Standard value of the swing output : 217 2. Measurement of elevating up and down characteristic 4. Setting after adjustment 1. Number of part-line : 1 line 2. Language switch : English

[NOTICE] Refer to “terminal No.5 (RLY5) of CN2 connector (page 20)” for the telescoping control relay output of the AML.

136

W301-0234E

Checking the Detectors (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) Checking the Detectors (TR-600XL-4/TR-600XXL-4/ TR-800XXL-4) 1. Boom Length Detector

2. Boom Angle Detector 1. Retract the boom fully, set the boom angle to 0 degree and turn off the PTO switch.

2. Measure resistance of the potentiometer.

1. Retract the boom fully, set the boom angle to 0 degree and turn off the PTO switch.

Checking at the cnnector 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 cnnector 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

B

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

A

DET1SRC 2

C

ANAINB 4

A

ANAINA 3 DET1GND 1

B D

E

B

D C

Boom length detector IW301-0131E10

ANAINA 3 DET1GND 1

B D

Checking at the CN1 connector of the AML

Boom length detector IW301-0131E10

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

16

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

45

30 ANAINA 3 DET1GND 1 30

E

D C

45

DET1SLD 6

1

DET1SLD 6

E

DET1SRC 2

C

ANAINB 4

A

ANAINA 3 DET1GND 1

B D

16

1

Boom length detector IW301-0132E33

B D Boom length detector IW301-0132E33

137

W301-0234E

Checking the Detectors (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) 3. Swing Angle Detector

4. Outrigger Extension Width Detector

1. Swing the boom to over-left and turn off the PTO

1. Stow the outriggers and turn the starter switch to

switch.

OFF.

2. Measure resistance of the potentiometer.

2. Remove the wire for the detector from the outrigger and hold the wire, letting it protruding by 3.1 in (80mm) from the guide hold of the detector.

Checking at the cnnector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B:500±75Ω W-B:0-15Ω DET1SLD 6 G

Plug

W

R

Shield

B

Shield

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B

3.1 in (80 mm) IW301-0131E12

IW301-0131E11

3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B:2000±100Ω W-B:200±30Ω

Checking at the CN1 connector of the AML Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1:500±75Ω 5-1:0-15Ω

W

B

R

5V AVCC

R

IN Ai1

W

GND AGND

B

FL IW301-0131E13

45

30

16

DET1SLD 6

Shield

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B

1 IW301-0132E34

138

W301-0234E

Checking the Detectors (TR-600XL-4/ TR-600XXL-4/ TR-800XXL-4) 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

139

W301-0234E

Checking the Detectors (TT-600XL-1/TT-800XXL-1) Checking the Detectors (TT-600XL-1/TT-800XXL-1)

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 cnnector 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 cnnector 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

140

W301-0234E

Checking the Detectors (TT-600XL-1/TT-800XXL-1) 3. Swing Angle Detector

4. Outrigger Extension Width Detector

1. Swing the boom to over-left and turn off the PTO

1. Stow the outriggers and turn the starter switch to

switch.

OFF.

2. Measure resistance of the potentiometer.

2. Remove the wire for the detector from the outrigger and hold the wire, letting it protruding by 18.9 in (480mm) from the guide hold of the detector.

Checking at the cnnector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B:500±75Ω W-B:0-15Ω DET1SLD 6 G

Plug

W

R

Shield

B

Shield

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B

18.9in (480mm) IW301-0232E10 IW301-0131E11

3. Pull out the connector of the detector and

Checking at the CN1 connector of the AML

measure resistance of the potentiometer. The specified resistance values are as follows: R-B:2000±100Ω W-B:200±30Ω

Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1:500±75Ω 5-1:0-15Ω

W

B

R

5V AVCC

R

IN Ai1

W

GND AGND

B

FL IW301-0131E13

45

30

16

DET1SLD 6

Shield

DET1SRC 2

R

ANAINC 5

W

ANAIND 9 DET1GND 1

G B

1 IW301-0132E34

141

W301-0234E

Checking the Detectors (TT-600XL-1/TT-800XXL-1) 5. Pressure Sensor for Moment Detection 1. Turn ON the PTO switch. (5-V DC will be applied between R and B of the pressure sensor connector.)

2. Measure the output voltage between W and B of the pressure sensor connector.

W

B

R

DET3SRC 33

R

ANAING 34

W

DET3GND 32

B

(ANAINH 35)

SPS3

(SPS4)

IW301-0131E14

3. The output voltage between W and B is

Output (V DC)

proportional to the pressure in the elevating cylinder.

The specified value is as shown below.

4.5

0.5 0

Pressure (MPa)

35 IW301-0131E15

142

W301-0234E

Fuses Fuses RLY1,2 MAIN

RLY3,4

RLY5,6

RLY7,8 SIF2 SIF1 SOL5,6

m deg

SOL1, 2

% deg

SOL3, 4

IW301-0231E23

SOL1,2 fuse (2A)

MAIN fuse (3A)

Common, with current output 1 and 2.

AML main fuse for whole unit.

SOL3,4 fuse (2A)

RLY1,2 fuse (3A) Common, with relay output 1 and 2.

Common, with current output 3 and 4.

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

SOL5,6 fuse (2A) Common, with current output 5 and 6.

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

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

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

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

143

W301-0234E

Replacing the Clock Battery Replacing the Clock Battery

3. Attach a new battery on the CPU board by

[NOTICE] When the clock battery is worn out, the adjusting values, error codes and driving history cannot be backed up (saving data at power OFF).

Also, when the error code or driving history is recorded in AML, an accurate date and time cannot be recorded.

Two built-in clock batteries are on CPU board of the AML main unit.

Replace both 2 pieces when you replace the battery.

pressing the battery diagonally. (Refer to the figure below) The battery positive side must be faced up.

The built-in clock battery longevity is usually about 10 years.

If the built-in clock batteries are worn out, replace them according to the following procedures.

4. Install the CPU board in the AML main unit.

1. Remove the CPU board from the AML main unit.

5. Reconnect the connector to the board.

2. Remove the battery from the battery holder on CPU board by pressing the battery diagonally.

[NOTICE] When removing the battery, remove while holding the battery upper (positive side) because the battery may pop up.

144

W301-0234E

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