Tadano Faun MDT-8 Multiplex Data Transmitter Service Manual W303-0251E - PDF DOWNLOAD

Publication No. W303-0251E

01 Multiplex Data Transmitter Model

MDT-8

Introduction This service manual covers the multiplex data transmitter (MDT) system installed on the TADANO cranes.

The crane models to which this manual is applicable are listed in the table below.

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

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

2001.11.

Applicable crane model TR-450XL-4

Even when the model of your crane is not listed here, use this manual if the publication No. of this manual is specified in the service manual for that crane.

The contents of this manual are subject to change without notice due to modification.

1

W303-0251E

Contents Contents

2.

Introduction...................................................... 1 Contents

...................................................... 2

Error code list.......................................... 16 2.1

Error code detected in upper MDT ...........16

2.2

Error code detected in lower MDT ............23

Construction and function ................................ 4

3.

1.

System Configuration................................ 4

Disassembly and reassembly......................... 64

2.

Construction of MDT ................................. 5

1.

2.1

Upper MDT ................................................. 5

2.2

Lower MDT ................................................. 6

MDT main unit......................................... 64 1.1

2.

3.

Check chart............................................. 60

Check functions ........................................ 7

Disassembly and reassembly ...................64

Connector ............................................... 64 2.1

Removing and attaching the connector

3.1

System runaway prevention circuit ............ 7

contact ................................................64

3.2

Memory check function .............................. 7

2.1.1 AMP.070 Multi-lock connector (MarkⅠ)....65

3.3

ROM check function ................................... 7

2.1.2 AMP.040 Multi-lock connector (MarkⅠ)....68

3.4

Transfer data check function

2.1.3 AMP.040 Multi-lock connector (MarkⅡ)....71

(transfer line failure detecting function)..... 7

2.1.4 AMP.040Ⅱ Multi-lock connector (MarkⅡ)

3.5

Lower unit output check function................ 7

3.6

Power supply voltage check function ......... 7

3.7

Manual check function................................ 7

............................................................74 2.2

Crimping receptacle contact .....................76

Connection diagram for connectors................ 77 4.

Display function ........................................ 8 4.1

Display........................................................ 8

4.2

Software identification (ID)/version nos.

1. Upper MDT ...................................................77 2. Lower MDT ...................................................80

display .................................................. 9

Input/output signal lists................................... 84

4.3

Error display ............................................... 9

1. Upper I/O signal lists ....................................84

4.4

Error history display.................................... 9

2. Lower I/O signal lists ....................................87

4.5

Error history erasure................................... 9

4.6

Check mode display ................................. 10

Data table .................................................... 89

4.7

Priority of display function ........................ 10

1. One-to-one input/output system ...................89

4.8

Input and output transmission to AML...... 10

2. Parking lamp.................................................90

4.9

Port/bit Nos., input/output signal Nos. and

3. Parking Alarm ...............................................91 4. CHG lamp .....................................................92

corresponding signals .........................11

5. Head lamp ....................................................92

5.

Fail-safe function .................................... 13 5.1

6. Rear center lamp ..........................................93 7. Outriggers .....................................................94

Fail-safe state ........................................... 13

8. Outrigger switch neutral position detection ..95

Troubleshooting ............................................. 14

9. Outrigger retraction operation detection.......96 10. Exhaust brake...............................................97

1.

Check procedures................................... 14

11. Hi/Lo and 2-wheel/4-wheel drive mode selector ............................................................98

2

W303-0251E

Contents 12. Engine revolution detection.......................... 99 13. Speed warning and overrun warning ......... 100 14. PTO limiter ................................................. 101 15. T/C low pressure warning .......................... 102 16. Air heater.................................................... 103 17. Hydraulic Oil Temperature Indication......... 104 18. Low fuel level warning................................ 105 19. Jib lock lamp .............................................. 106 20. Air pressure detection ................................ 107 21. Torque converter pressure detection ......... 108 22. Steering...................................................... 109 23. Spring lock ..................................................110 24. Transmission...............................................112 25. PTO/travel speed warning lamp..................116

3

W303-0251E

Construction and function Construction and function 1. System Configuration The multiplex data transmitter (MDT) system consists of various blocks as shown in the configuration diagram below.

AML

Input Di1-64 (switches) Ai1-8 (sensors)

Pi1, Pi2 (main speed, tachometer)

RXD2 TXD2 Display LED1-4 LED5, 6

Control SW1, SW2

TXD3 Po4, Po5, Ao1 ＊Po1, Po2

Combination meter Output

Upper MDT

Tr1-24 (relays, lamps, buzzer) TXD1

RXD1

Rotary joint

Input

＊Po1, Po2

＊Pi1, Pi2, Pi4 (main speed, tachometer sensor)

Input Di1-32 (switches) Ai1-11 (sensors) Pi3 (sub speed sensor) CHG (alternator)

RXD1 TXD1 Display LED1, 2 ＊LED3, 4

Output

MSOL1, 2

Tr1-4 (relays)

Lower MDT PMONI1-16

RY1-56 (actuators)

MONI1-56

Communication channel Input/output channel ＊ : Only for hardware IW303-0251E10

1. PMONI1 to PMONI16 : Signals representing monitored voltage of power supplies RPOW1-RPOW16 for the lower unit relay output 2. MONI1 to MONI56 : Signals representing monitored output voltage of lower unit outputs RY1-RY56 3. MSOL1 : Signal of relay cutting the output power supply of lower unit outputs RY41 and 42 4. MSOL2 : Signal of relay cutting the output power supply of lower unit outputs RY43-48

4

W303-0251E

Construction and function 2. Construction of MDT [NOTE] There is a case that the appearance and so on differ from the parts for this crane. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this crane and the parts sales unit described in the parts catalog before starting disassembling operations.

2.1 Upper MDT

1

2

3

CN6

CN1

CN2

4

4

LED6 LED2 LED3 LED5 LED1

CN7

Error code display (LED4) CN8

SW2

SW1

5

CN3

CN9

6

CN4 MODEL SER.No. TYPE CODE No.

CN10

DATE

CN5

MADE IN JAPAN

7

3 8

IW303-0251E11

1. Base

3. Screw

5. Display panel

7. CPU board

2. Cover

4. Screw

6. Name plate

8. Screw

5

W303-0251E

Construction and function 2.2 Lower MDT

2

1

CN7

CN1

CN8

CN2

LED1

LED2

3

CN3 CN9

LED4

LED3

CN4 CN10

CN11

CN5

CN6

4 MODEL SER.No. TYPE CODE No. DATE MADE IN JAPAN

7

6

5

1

8 9 10 IW303-0251E12

1. Screw

4. Name plate

7. CPU board

2. Screw

5. Cover

8. Screw

3. Display sheet

6. Relay board

9. Spacer

6

W303-0251E

10. Base

Construction and function 3.7 Manual check function

3. Check functions

When the system automatically shuts off or does

3.1 System runaway prevention circuit

not operate properly due to unknown malfunction,

The system software is designed to generate a

press the externally added-on system check

pulse within the laps of a certain preset time after

switch, and the system is reset and restarts itself.

the orderly execution of programs.

The pulse is monitored by an external hardware unit so as to stop the system in the fail-safe state, when the program runs out of order.

3.2 Memory check function This function is for checking the correct data reading from and writing into the RAM in the CPU, and for stopping the system in the fail-safe state if faults are found.

3.3 ROM check function This function checks if the data in the ROM (flash memory) is normal. If an error occurs, the system stops in the fail-safe state.

3.4 Transfer data check function (transfer line failure detecting function) This function is for detecting failure of the receiving data to secure correct transfer of data even when data is affected by noise. The faulty data would not replace the former data.

If faulty communication from upper to lower unit continues for 600 ms, the system assumes that the wire is broken and stops in the fail-safe state.

3.5 Lower unit output check function The output signal from the lower unit is monitored, and if the signal does not match the intended output the system is stopped in the fail-safe state.

3.6 Power supply voltage check function The system automatically shuts off in the fail-safe state when power supply voltage transiently drops below about 17 volts at the time of the engine start-up, etc. In addition, when the power supply voltage is regained, the system is reset automatically, and restarts itself.

7

W303-0251E

Construction and function 4. Display function

4. Error code display (LED4) This displays the error code when failure occurs in

4.1 Display

the system.

This is also used to display the software

4.1.1 Upper MDT

ID/version, error history, error history erasure and check mode.

5. LED5 (green)

LED6 LED2 LED3 LED5 LED1

This lights up when the constant-voltage regulated power supply circuit (5V circuit) in the upper MDT operates normally, and goes out when trouble occurs.

6. LED6 (red)

Error code display (LED4)

This lights up when the system is being reset.

SW1

(e.g., when the system check switch is pressed, or

SW2

when the power supply voltage is approx. 17V or less)

IW303-0251E13

4.1.2 Lower MDT 1. LED1 (red) After the system is reset, this stays off until the data from the lower MDT is received normally.

After the data is received, this flashes for a cycle of 0.8 seconds.

This flashes for a cycle of 0.2 seconds while the

LED2

error 31 or 32 occurs.

LED1

2. LED2 (red) After the system is reset or the PTO switch is turned on, this stays off until the data from AML is

LED4

received normally. After the data is received, this

LED3 IW303-0251E14

flashes for a cycle of 0.8 seconds.

This flashes for a cycle of 0.2 seconds while the error 33 or 35 occurs. (Not lit when the PTO

1. LED1 (red)

switch is off.)

After the sysyem is reset, this stays off until the data from the upper MDT is received normally.

3. LED (red)

After the data is received, this flashes for a cycle

After the system is reset or the data from the

of 0.8 seconds.

lower MDT is normally received, this stays off until

This flashes for a cycle of 0.2 seconds when the

the transmission feedback to the combination

error 36 or 37 occurs.

meter is normally completed.

2. LED2 (red)

After the feedback, this flashes for a cycle of 0.8 seconds.

Not lit (Not used)

This flashes for a cycle of 0.2 seconds when the error 38 occurs.

8

W303-0251E

Construction and function will appear.Then, consecutive one-second display

3. LED3 (green) This lights up when the constant-voltage regulated

of each error code will appear in reverse

power supply circuit (5V circuit) in the lower MDT

chronological order. After the last error code is

operates normally, and goes out when trouble

displayed, this mode terminates automatically.

occurs.

3. Conditions Parking switch : ON

4. LED4 (red)

Gearshift lever : N

This lights up when the system is being reset. (e.g., when the system check switch is pressed, or

4. Display example

when the power supply voltage is approx. 17V or

When five error codes 25, FC, 01, 25 and F0 are

less)

stored in chronological order:

4.2 Software identification (ID)/version nos. display

Press SW1 for 1 second or more.

Number of errors

→ Not shown → 05 → Not shown → 0.5 seconds

When the power supply is turned on or the system check switch is pressed, identification and version

Error Code

1 1 1 1 1 second second second second second

error code display as shown below.

Version No. of upper MDT

0.5 1 seconds second

0.5 seconds IW303-0251E18

Version No. of lower MDT

Reset→4A→Not shown→52→Not shown→L2→Not shown→end 1 second

0.5 seconds

F0 → 25 → 01 → FC → 25 → Not shown → End

nos. of upper and lower MDT are displayed on the

ID

1 second

0.5 second

1 second

When no stored error code exist:

0.5 second

Press SW1 for 1 second or more.

IW303-0251E17

Number of errors

→ Not shown → 00 → Not shown →End 0.5 seconds

1 second

4.3 Error display

0.5 seconds IW303-0251E19

1. When failure is detected in upper/lower MDT, error code is displayed on the error code display.

4.5 Error history erasure

2. Once the error code is displayed, it remains on

1. Operation

the display until the system is reset (when the

Press SW1 and SW2 on the upper MDT

system check switch is pressed) even after the

simultaneously for 5 seconds or more, and the

system goes back to normal. The error code will

system will enter the error history erasure mode.

be displayed again when trouble occurs.

When all error codes are erased, “00” will appear

Error codes 01 and 02 will automatically

for 1 second, and the error history erasure mode

disappear when the system goes back to normal.

terminates automatically.

3. When two or more errors occur, each error code is

2. Conditions

displayed for 1 second in sequence repeatedly.

Parking switch : ON Gearshift lever : N

4.4 Error history display

3. Display example

1. Error codes are stored up to max. 60.

Press SW1 and SW2 simultaneously for → Not shown → 00 → Not shown →End 5 seconds or more.

0.5 1 0.5

2. Operation Press SW1 on upper MDT for 1 second or more,

seconds

second

seconds

and the number of errors stored in the memory IW303-0251E20

9

W303-0251E

Construction and function 4.6 Check mode display

4.7 Priority of display function

1. Press SW2 on the upper MDT twice within 2

Display function is prioritized as follows:

seconds, and the system enters check mode to let

1. Check mode display

all the segments mark up for 1 second.

2. Error history erasure, error history display 3. Error display

2. The LED in the left of the error code display displays port Nos; and right side LED, bit Nos.

You can change the display of lower priority into

The indication of “.” (decimal point) explains the

that of higher priority, but the reverse alternation is

condition of the corresponding signal.

unavailable. The alternation between error history

(Refer to “Port/bit Nos. and corresponding signals”

erasure and error history displays is available.

list.)

Lit (both decimal points) : ON

(Ex. “1.0.”)

Not lit

(Ex. “1 0 ”)

: OFF

4.8 Input and output transmission to AML The condition of the signal corresponding to the input and output number (0-255) received from

3. Press SW2 once to go to the next bit number.

When you are through all the bit in one port, you

AML is transmitted to AML.

will go to the next port by pressing the switch.

For digital input and output, 1 (ON) or 0 (OFF) is transmitted. Analog input and output is transmitted

4. The order of indication, as shown in “Port/bit Nos.

after being converted into 0-225.

and corresponding signals” list, is upper unit input

The condition of the signal corresponding to the

(port 1-8), upper unit output (port 1-3), lower unit

input and output number can be checked by “MDT

input (port 1-6) and lower unit output (port 1-8).

monitor” display function in the AML maintenance mode.

5. Before each input and output display, display of Ui,

(Refer to the “Input/output signal Nos. and

Uo, Li or Lo comes on first, and then port and bit

corresponding signals” list.)

nos. display follow.

6. Keep pressing SW2 for 1 second or longer, and port No. and bit No. display will progress one by one at every 0.2 seconds and will stop when SW2 is released.

7. Press SW1 once to go back to the previous bit.

Keep pressing SW1 for 1 second or longer, and port No. and bit No. display will progress in reverse order one by one at every 0.2 seconds and will stop when SW1 is released.

8. To terminate check mode, keep pressing SW2 or press the system check switch.

9. Display example → : SW2 is pressed once. ⇒ : SW1 is pressed once.

After all the segments mark up (for 1 second): Ui → 1.0. → 1 1 → ･･･ → Uo → 1 0 ⇒ Uo ⇒ 8 7 → Uo → ･･･ → Li → 1.0. → ･･･ → Lo → 1 0 ⇒ Lo ⇒ 6 7 → Lo → ･･･ → 8 7 → End

10

W303-0251E

Construction and function 4.9 Port/bit Nos., input/output signal Nos. and corresponding signals For the name of signal, refer to “Input/output signal lists”.

1. PMONI1 to PMONI16 : Signals representing monitored voltage of power supplies RPOW1-RPOW16 for the lower unit relay output 2. MONI1 to MONI56 : Signals representing monitored output voltage of lower unit outputs RY1-RY56 3. MSOL1 : Signal of relay cutting the output power supply of lower unit outputs RY41 and 42 4. MSOL2 : Signal of relay cutting the output power supply of lower unit outputs RY43-48 4.9.1 Port/bit Nos. and corresponding signals (MDT check mode display function) Upper input

Upper output

Lower input

Port Bit Port Bit Port Bit Port Bit Port Bit Signal Signal Signal Signal No. No. No. No. No. No. No. No. No. No.

1

2

3

4

Lower output Signal

Port Bit No. No.

Signal

Port Bit No. No.

Signal

0

Di1

0

Di33

0

Tr1

0

Di1

0

PMONI1

0

MONI1

0

MONI33

1

Di2

1

Di34

1

Tr2

1

Di2

1

PMONI2

1

MONI2

1

MONI34

2

Di3

2

Di35

2

Tr3

2

Di3

2

PMONI3

2

MONI3

2

MONI35

3

Di4

3

Di36

3

Tr4

3

Di4

3

PMONI4

3

MONI4

3

MONI36

4

Di5

4

Di37

4

Tr5

4

Di5

4

PMONI5

4

MONI5

4

MONI37

5

Di6

5

Di38

5

Tr6

5

Di6

5

PMONI6

5

MONI6

5

MONI38

6

Di7

6

Di39

6

Tr7

6

Di7

6

PMONI7

6

MONI7

6

MONI39

7

Di8

7

Di40

7

Tr8

7

Di8

7

PMONI8

7

MONI8

7

MONI40

0

Di9

0

Di41

0

Tr9

0

Di9

0

PMONI9

0

MONI9

0

MONI41

1

Di10

1

Di42

1

Tr10

1

Di10

1 PMONI10

1

MONI10

1

MONI42

2

Di11

2

Di43

2

Tr11

2

Di11

2

2

MONI11

2

MONI43

3

Di12

3

Di44

3

Tr12

3

Di12

3

MONI12

3

MONI44

4

Di13

4

Di45

4

Tr13

4

Di13

4

MONI13

4

MONI45

5

Di14

5

Di46

5

Tr14

5

Di14

5 PMONI14

5

MONI14

5

MONI46

5

6

1

2

1

2

5

6

1

PMONI11

3 PMONI12 4 PMONI13

2

5

6

6

Di15

6

Di47

6

Tr15

6

Di15

6 PMONI15

6

MONI15

6

MONI47

7

Di16

7

Di48

7

Tr16

7

Di16

7 PMONI16

7

MONI16

7

MONI48

0

Di17

0

Di49

0

Tr17

0

Di17

0

MONI17

0

MONI49

1

Di18

1

Di50

1

Tr18

1

Di18

1

MONI18

1

MONI50

2

Di19

2

Di51

2

Tr19

2

Di19

2

MONI19

2

MONI51

3

Di20

3

Di52

3

Tr20

3

Di20

3

MONI20

3

MONI52

4

Di21

4

Di53

4

Tr21

4

Di21

4

MONI21

4

MONI53

5

Di22

5

Di54

5

Tr22

5

Di22

5

MONI22

5

MONI54

6

Di23

6

Di55

6

Tr23

6

Di23

6

MONI23

6

MONI55

7

Di24

7

Di56

7

Tr24

7

Di24

7

MONI24

7

MONI56

0

Di25

0

Di57

0

Di25

0

MONI25

0

Tr1

1

Di26

1

Di58

1

Di26

1

MONI26

1

Tr2

2

Di27

2

Di59

2

Di27

2

MONI27

2

Tr3

3

Di28

3

Di60

3

Di28

3

MONI28

4

Di29

4

Di61

4

Di29

4

MONI29

5

Di30

5

Di62

5

Di30

5

7

8

3

3

4

3

4

7

3

Tr4

4

MSOL1

MONI30

5

MSOL2

8

6

Di31

6

Di63

6

Di31

6

MONI31

6

7

Di32

7

Di64

7

Di32

7

MONI32

7

11

W303-0251E

Construction and function 4.9.2 Input/output signal Nos. and corresponding signals (AML’s “MDT monitor” display function) 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.

Signal

Input/ output No.

Lower output

Analog input

Signal

Input/ output No.

Signal

Input/ output Signal 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

12

W303-0251E

Upper Ao1 Lower Ao1 Lower Ao2 Lower Ao3

Construction and function 5. Fail-safe function 5.1 Fail-safe state When a failure occurs, non-critical operation is maintained to avoid hazard.

Circuit Designation Spring lock check release solenoid valve

State ・If a failure occurs, the valve maintains the existing state. ・If a failure still exists, the valve maintains existing state even after the system check switch is pressed.

Headlamp (low beam)

・If a failure occurs, the lamp maintains the existing state. ・The lamp lights up when system check switch is pressed.

The lamp stays lit if a failure still exists, even after the system is reset.

Circuit other than the above circuit

・If a fault occurs, system assumes OFF state.

13

W303-0251E

Troubleshooting Troubleshooting

LED3 (red) : Communication with combination meter

The multiplex data transmitter (MDT) system includes various blocks interconnected by many

Normal : Flashing (in a 0.8-second cycle)

wires and connectors as shown in “System

Faulty

: Not lit (Flashes in a 0.2-second cycle when error 38 occurs.)

configuration”. When the system does not operate normally, follow the procedures below to check the

Error code display (LED4)

system, understanding the faulty conditions precisely

Check the display

to identify the faulty block and component.

LED5 (green) : 5V power supply Normal : Lit

1. Check procedures

Faulty

1. Press the sysyem check switch.

: Not lit

LED6 (red) : Resetting Normal : Not lit (Lit while the system check

System check switch location:

switch is being pressed.)

Inside the upper relay box

Faulty : Lit [when the system is being reset (e.g.,

2. Check the conditions of LEDs on the upper and

when the system check switch is pressed, or when the power supply voltage is

lower MDT and the upper MDT error code display.

approx. 17V or less)]

2.1 Upper MDT

2.2 Lower MDT

LED6 LED2 LED3 LED5 LED1

LED2

LED1

Error code display (LED4) SW1

SW2 LED4

IW303-0251E13

LED1 (red) : Communication with lower MDT

LED1 (red) : Communication with upper MDT

Normal : Flashing (in a 0.8-second cycle) Faulty

Normal : Flashing (in a 0.8-second cycle)

: Not lit (Flashes in a 0.2-second cycle

Faulty

when error 31 or 32 occurs.)

: Not lit (Flashes in a 0.2-second cycle when error 36 or 37 occurs.)

LED2 (red) : Communication with AML

LED2 (red) : Not used

Normal : Flashing (in a 0.8-second cycle)

Not lit

(Not lit when PTO switch is off) Faulty

LED3 IW303-0251E14

LED3 (green) : 5V power supply

: Not lit (Flashes in a 0.2-second cycle

Normal : Lit

when error 33 or 35 occurs.)

Faulty

14

: Not lit

W303-0251E

Troubleshooting

6. When the faulty block is found in the upper or

LED4 (red) : Resetting

lower MDT, replace the board, referring to the

Normal : Not lit (Lit while the system check

“Disassembly and reassembly” section. To

switch is being pressed.)

remove the terminals of the connector, follow the

Faulty : Lit [when the system is being reset (e.g., when the system check switch is pressed,

removing instructions in the “Disssembly and

or when the power supply voltage is

resassembly” section.

approx. 17V or less)] 3. When the error code is displayed or the LED shows the faulty state, follow the procedures below to check the system.

When the error code is not displayed on the error code display, perform the same operation as that on the faulty condition to check the system operates normally. If the error code is displayed or the system does not operate normally consequently, follow the procedures below to check the system.

4. Check the input and output signals on the MDT which seems to be faulty according to the error code lists and faulty conditions. Find the faulty circuit or parts and repair or replace them, referring to the “Data table” at the end of this manual or electrical circuit diagram in “Service Manual” for your model.

For checking MDT input and output signals, use the following functions: 1. MDT check mode display function To check digital signal condition 2. “MDT monitor” display function in the AML maintenance mode To check digital and analog signal condition When the input power supply seems to be faulty, check the voltage according to “Initial conditions before checking” in the check chart.

5. If the cause can not be identified after the above check in accordance with the check chart.

15

W303-0251E

Troubleshooting 2. Error code list 1. When two or more errors exist, each error code is repeatedly displayed every one second.

2. Once the error code is displayed, it remains on the display until the system is reset (When the system check switch is pressed) even after the system goes back to normal. The error code will be displayed again if the error remains.

Error code 01 and 02 will automatically disappear when the system goes back to normal.

For the error codes marked with ＊, the MDT action will remain until the system is reset. The error code will be displayed again if the error remains.

3. Short circuit may occur in ground and power supply circuits.

2.1 Error code detected in upper MDT Error codes vary depending on the machine models. Check the error code to be detected with the table below.

○ : Error code to be detected － : Error code not to be detected Error code

TR-450XL -4

01

○

02

○

03

○

04

○

05

○

06

○

07

○

08

○

09

○

13

○

15

○

18

○

24

○

25

○

27

○

30

○

31

○

32

○

33

○

34

○

35

○

38

○

16

W303-0251E

Troubleshooting

Error code

Error (Details)

01

1.Gears in transmission are not shifted with the gearshift lever in “D”.

2.Speedometer does not work. (remains to indicate a low value) (Failure in the main speed sensor)

The main speed is 1km/h or less and the sub-speed is 4km/h or more.

Failure is not detected in the following conditions: Gearshift is in N or R. For 1.5 seconds after changing the gearshift from N to D Emergency transmission input is ON.

Error 03 occurs.

Unavailable to downshift (Failure in the sub-speed sensor)

Remarks

Countermeasure

The main speed becomes higher/lower than the last time by 4km/h or more.

02

Cause

Condition

The main speed is 4km/h or more and the sub-speed is 1km/h or less.

Failure is not detected in the following conditions:

1.Failure in main speed sensor on the transmission output shaft 2.Broken or short-circuited wires between the main speed sensor, lower unit connector (terminals (7) and (8) of CN4), rotary joint or upper unit input connector (terminal (4) of CN 7) 3.Failure in vehicle speed detection circuit in the upper unit 4.Failure in vehicle speed input/output circuit in the lower unit 5.Failure in 12V power supply (voltage at terminal (9) of CN4) in the lower unit

Downshift becomes unavailable.

Main speed sensor : Installed on the transmission output side Sub-speed sensor : Installed on the transmission input side

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the upper or lower unit CPU board.

1.Failure in sub-speed sensor on the transmission input shaft or on the torque converter output shaft 2.Broken or short-circuited wires between the sub-speed sensor and the lower unit input connector (terminals (1) and (2) of CN4)

Gearshift is in N and the main speed is less than 35km/h.

3.Failure in vehicle speed detection circuit in the lower unit

Gearshift is in R.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Emergency transmission input is ON.

MDT action:

Repair the lower unit CPU board.

The main speed becomes higher/lower than the last time by 4km/h or more.

Error 03 occurs.

17

W303-0251E

MDT action: Downshift becomes unavailable.

Main speed sensor : Installed on the transmission output side Sub-speed sensor : Installed on the transmission input side

Troubleshooting

Error code

Error (Details)

＊ 03

Failure in main speed sensor (When gearshift is in N)

Cause

Condition

Remarks

Countermeasure While the gearshift is in N and the emergency transmission input is OFF, the main speed becomes higher/lower than the last time by 14km/h or more.

1.Failure in main speed sensor on the transmission output shaft 2.Broken or short-circuited wires between the main speed sensor, lower unit connector (terminals (7) and (8) of CN4), rotary joint or upper unit input connector (terminal (4) of CN 7) 3.Failure in vehicle speed detection circuit in the upper unit 4.Failure in vehicle speed input/output circuit in the lower unit

MDT action: The gearshift input and the transmission output are set to N. Main speed sensor : Installed on the transmission output side

5.Failure in 12V power supply (voltage at terminal (9) of CN4) in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the upper or lower unit CPU board.

04

Failure in outrigger FL data

The rate of outrigger length input data to the power supply voltage (5V) is 5% or less or 95% or more, and this state continues for 600 ms.

Failure is not detected for 2 seconds after the system is reset, or when the PTO switch is turned off.

1.Failure in potentiometer of outrigger extension length detector 2.Broken or short-circuited wires between the outrigger extension length detector and lower unit

MDT action: Only the error code is displayed.

3.Failure in the A/D conversion circuit for the outrigger extension length detection in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the potentiometer of outrigger extension length detector.

Repair the lower unit CPU board.

05

Failure in Ditto outrigger FR data

Ditto

Ditto

06

Failure in Ditto outrigger RL data

Ditto

Ditto

07

Failure in Ditto outrigger RR data

Ditto

Ditto

18

W303-0251E

Troubleshooting

Error code

Error (Details)

08

Abnormal torque converter pressure

Cause

Condition

Remarks

Countermeasure The rate of torque converter pressure input data to the power supply voltage (5V) is 5% or less or 95% or more, and this state continues for 600 ms.

Failure is not detected for 2 seconds after the system is reset.

1.Failure in torque converter pressure sensor 2.Broken or short-circuited wires between the torque converter pressure sensor and lower unit input connector (terminal (31) of CN6)

MDT action: Only the error code is displayed.

3.Failure in the A/D conversion circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the torque converter pressure sensor.

Repair the lower unit CPU board.

09

Abnormal air pressure sensor

The rate of air pressure input data to the power supply voltage (5V) is 5% or less or 95% or more, and this state continues for 600 ms.

Failure is not detected for 2 seconds after the system is reset.

1.Failure in air pressure sensor 2.Broken or short-circuited wires between the air pressure sensor and the upper unit input connector (terminal (9) of CN8)

MDT action: Only the error code is displayed.

3. Failure in the A/D conversion circuit in the upper unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the air pressure sensor.

Replace the upper unit CPU board.

13

Failure in the upper A/D conversion

Upper unit A/D conversion is not completed within the set time.

Failure in the upper A/D converter

Replace the upper unit CPU board.

19

W303-0251E

MDT action: A/D conversion data would not replace the former ones.

Troubleshooting

Error code

Error (Details)

＊ 15

Upper unit RAM check error

Cause

Condition

Remarks

Countermeasure Failure in the upper unit RAM

Replace the upper unit CPU board.

MDT action: Upper unit output stops.

[Sets the all OE (output enable signal) to ON.] Upper unit system operation stops.

＊ 18

Upper unit ROM check error

Failure in the upper unit ROM

Replace the upper unit CPU board.

MDT action: Upper unit output stops.

[Sets the all OE (output enable signal) to ON.] Upper unit system operation stops.

24

25

27

Actual transmission and gearshift lever position are not matched.

(Failure in the transmission input signal combination)

Two or more transmission input signals (N, 1st, 2nd, 3rd, D and R) remains on for 1 second or longer.

Actual transmission and gearshift lever position are not matched.

(Failure in the transmission input signal)

All transmission input signals (N, 1st, 2nd, 3rd, D and R) remains off for 2 seconds or longer.

Failure in steering mode input signal combination

Two or more steering mode input signals (of 2-wheel steering, 4-wheel steering and crab steering) remains on for 1 second or longer.

Failure in the transmission input signals from the gearshift lever (terminals (3), (4), (5), (6), (7) and (8) of CN4)

MDT action: Gearshift stays in the same position.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the upper unit CPU board.

Failure in the transmission input signals from the gearshift lever (terminals (3), (4), (5), (6), (7) and (8) of CN4)

MDT action: Gearshift stays in the same position.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the upper unit CPU board.

Failure in the steering input signals (terminals (1), (2) and (3) of CN5)

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the upper unit CPU board.

20

W303-0251E

MDT action: Follows the treatment by the steering system.

(Refer to the steering function in the “Data table”.)

Troubleshooting

Error code

Error (Details)

30

1.Speedometer indicates abnormally high speed.

Cause

Condition

Remarks

Countermeasure Vehicle speed of the main speed sensor is 70km/h or more.

2.Over speed warning buzzer sounds continuously.

(Input value from the main speed sensor is unusually high.)

1.Failure in main speed sensor on the transmission output shaft 2.Broken or short-circuited wires between the main speed sensor, lower unit connector (terminals (7) and (8) of CN4), rotary joint or upper unit input connector (terminal (4) of CN 7) 3.Failure in vehicle speed detection circuit in the upper unit

MDT action: Only the error code is displayed.

Main speed sensor : Installed on the transmission output side

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the upper unit CPU board.

31

Interrupted communication from lower to upper unit

Lower unit communication data does not flow into the upper unit for 600 ms.

Failure is not detected for 3.2 seconds after the system is reset.

1.Broken communication cable (cables between terminals (1) and (2) of the upper unit CN2 and terminals (1) and (2) of the lower unit CN3)

MDT action: Upper unit output stops.

2.Failure in lower unit system (system operation stops) 3.Failure in upper or lower unit communication circuit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the upper or lower unit CPU board.

32

Faulty communication from lower to upper unit

Reception error of lower unit data to the upper unit for three consecutive times

1.Unconductive or short-circuited communication cable 2.Failure in communication circuit on the upper or lower unit CPU board.

Repair or replace the faulty part referring to the crane electrical circuit diagram Replace the upper or lower unit CPU board.

21

W303-0251E

MDT action: Data from the lower unit do not replace the former ones.

Troubleshooting

Error code

Error (Details)

33

Interrupted communication from AML to upper unit

Cause

Condition

Remarks

Countermeasure AML data does not flow into the upper unit for 4 seconds.

1.Broken cable between AML and upper unit input connector (terminals (5) and (6) of CN2)

Failure is not detected when the PTO switch is turned off.

2.Failure in upper unit receiving circuit

MDT action: Data from AML do not replace the former ones.

3.Failure in AML Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the upper unit CPU board or AML board.

34

35

Failure in RAM for main speed data

Main speed data stored in another memory does not match to that in RAM.

Faulty communication from AML to upper unit

Reception error of AML data to the upper unit for three consecutive times Failure is not detected when the PTO switch is turned off, or for 4 seconds after the switch is changed from OFF to ON.

38

Faulty communication between upper unit and combination meter

Reception error of upper unit data to the combination meter for three consecutive times

Failure in RAM for main speed data Replace the upper unit CPU board.

1.Unconductive or short-circuited communication cable 2.Failure in communication circuit on upper unit CPU board or AML board

MDT action: Transmission output state is maintained.

MDT action: Data from AML do not replace the former ones.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the upper unit CPU board or AML board.

1.Unconductive or short-circuited communication cable.

2.Failure in communication circuit on upper unit CPU board or combination meter board Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the upper unit CPU board or combination meter board.

22

W303-0251E

MDT action: Only the error code is displayed.

Troubleshooting 2.2 Error code detected in lower MDT Error codes vary depending on the machine models. Check the error code to be detected with the table below.

○ : Error code to be detected － : Error code not to be detected

Error code

TR450XL -4

16

Error code

TR450XL -4

○

9d

○

17

○

9E

○

19

○

9F

－

36

○

A0

－

37

○

A1

－

61

○

A2

－

62

○

A3

－

63

○

A4

－

64

－

A5

－

65

－

A6

－

66

○

A7

－

67

○

A8

－

68

－

A9

－

69

－

AA

－

70

－

Ab

－

71

－

AC

－

72

－

Ad

－

73

○

AE

－

74

○

AF

－

75

○

b0

○

76

○

b1

－

80

○

b2

－

90

○

b3

－

91

○

b4

○

92

○

b5

○

93

○

b6

○

94

○

b7

－

95

○

b8

○

96

○

b9

－

97

－

bA

－

98

○

bb

－

99

○

bC

○

9A

○

bd

○

9b

○

bE

○

9C

○

bF

－

Reference note

－

Note 2, 4

－

Note 3, 4, 5

Note 1, 2, 3, 4

23

W303-0251E

Reference note

Note 1, 2, 3, 4

Note 3, 4

Note 1, 2, 3, 4

Note 3, 4

Note 1, 2, 3, 4

Troubleshooting

Error code

TR450XL -4

Error code

TR450XL -4

C0

－

EA

○

C1

－

Eb

○

C2

－

EC

○

C3

－

Ed

○

C4

－

EE

○

C5

－

EF

○

C6

－

F0

○

C7

－

F1

○

C8

－

F2

－

C9

－

F3

○

CA

－

F4

○

Cb

－

F5

○

CC

－

F6

－

Cd

－

F7

－

CE

－

F8

○

CF

－

F9

○

d0

－

FA

－

d1

－

Fb

○

d2

－

FC

○

d3

－

Fd

○

d4

－

FE

－

d5

－

FF

－

d6

－

d7

－

d8

－

d9

－

dA

－

db

－

dC

－

dd

－

dE

－

Errors 61-76, 98-9F, A8-AF, b8-bF, C8-CF, d8-dF,

dF

－

E8-EF and F8-FF are not detected for 3 seconds

E0

－

after the lower unit Di25 (engine start) is shifted

E1

○

from “0(0V)” to “1(24V)”.

E2

○

Note 3.

E3

○

E4

○

E5

○

corresponding byte, or when the corresponding

E6

○

OE (output enable signal) is ON .

E7

○

(The byte and OE correspond to RY1-8, RY9-16,

E8

－

E9

○

Reference note

Note 3, 4

Note 1, 2, 3, 4

Note 3, 4

Reference note

Note 1, 2, 3, 4

Note 3, 4

Note 1, 2, 3, 4

Note 1.

Errors 98-9F, A8-AF, b8-bF, C8-CF, d8-dF, E8-EF and F8-FF are not detected for 100 ms after the interrupted communication from the upper unit recovers, and are not detected for 3 seconds after the power supply is turned on.

Note 1, 2, 3, 4

Note 2.

Errors 90-FF are not detected when the error 80 is

Note 3, 4

detected through the monitored data of the

RY17-24, RY25-32, RY33-40, RY41-48 and

Note 1, 2, 3, 4

RY49-56.)

24

W303-0251E

Troubleshooting Note 4.

Errors 61-76 and 90-FF are not detected for 100 ms after any changes of OE (output enable signal)1-7, and are not detected for 100 ms after any changes of RY1-56 and Tr1-4.

Note 5. [Not applicable to TR-450XL-4] Errors 90-97 are not detected when the lower unit input Di26 (outrigger switch in neutral) is “1”, or for 100 ms after it is shifted from “1” to “0”. (Only applicable to the machine models detecting Di26)

25

W303-0251E

Troubleshooting

Error code

Error (Details)

＊ 16

Lower unit RAM check error

Cause

Condition

Remarks

Countermeasure Failure in the lower unit RAM

Replace the lower unit CPU board.

MDT action: Lower unit output stops.

[Sets the all OE (output enable signal) to ON.] Lower unit system operation stops.

17

＊ 19

Failure in the lower A/D conversion

Lower unit A/D conversion is not completed within the set time.

Lower unit ROM check error

Failure in the lower A/D converter

Replace the lower unit CPU board.

Failure in the lower unit ROM

Replace the lower unit CPU board.

MDT action: A/D conversion data do not replace the former ones.

MDT action: Lower unit output stops.

[Sets the all OE to ON.] Lower unit system operation stops.

36

Interrupted communication from upper to lower unit

Upper unit communication data does not flow into the lower unit, or reception error continues for 600ms.

1.Broken communication cable (Cable between terminal (1) of the upper unit CN2 and terminal (2) of the lower unit CN3) 2.Failure in upper unit communication circuit

MDT action: Lower unit output stops.

[Sets the all OE (output enable signal) to ON.]

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the upper or lower unit CPU board.

37

Faulty communication from upper to lower unit

Reception error of upper unit data to the lower unit for three consecutive times

1.Unconductive or short-circuited communication cable 2.Failure in communication circuit on upper or lower unit CPU board Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the upper or lower unit CPU board.

26

W303-0251E

MDT action: Data from upper do not replace the former ones.

Troubleshooting

Error code

Error (Details)

61

Failure in lower unit output power supply 1

Cause

Condition

Remarks

Countermeasure Monitored data on the lower unit output power supply 1 stays off for 100ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (3) of the lower unit CN11

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

62

Failure in lower unit output power supply 2

Monitored data on the lower unit output power supply 2 stays off for 100ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (4) of the lower unit CN11

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

63

Failure in lower unit output power supply 3

Monitored data on the lower unit output power supply 3 stays off for 100ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (1) of the lower unit CN11

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

64

Failure in lower unit output power supply 4

Monitored data on the lower unit output power supply 4 stays off for 100ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (2) of the lower unit CN11

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

65

Failure in lower unit output power supply 5

Monitored data on the lower unit output power supply 5 stays off for 100ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (2) of the lower unit CN10 Repair or replace the faulty part referring to the crane electrical circuit diagram.

27

W303-0251E

MDT action: Only the error code is displayed.

Troubleshooting

Error code

Error (Details)

66

Failure in lower unit output power supply 6

Cause

Condition

Remarks

Countermeasure Monitored data on the lower unit output power supply 6 stays off for 100ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (1) of the lower unit CN10

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

67

Failure in lower unit output power supply 7

Monitored data on the lower unit output power supply 7 stays off for 100ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (3) of the lower unit CN10

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

68

Failure in lower unit output power supply 8

Monitored data on the lower unit output power supply 8 stays off for100ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (1) of the lower unit CN9

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

69

Failure in lower unit output power supply 9

1.Other than the case of type (0, 0, 1) : [TR-450XL] The state of monitored data of the lower output power supply 9 stays off for 100ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (2) of the lower unit CN9 Repair or replace the faulty part referring to the crane electrical circuit diagram.

2.In the case of type (0, 0, 1) : ON or OFF state of the monitored data of the lower unit output power supply 9 is contrary to the normal state, and this state continues for 100ms.

(In the normal state, when the lower unit output Tr4 state is ON [OFF], the monitored data is ON [OFF].)

MDT action: Only the error code is displayed.

The type mentioned here represents the type fo the lower unit software and varies depending on the machine model.

[Type] TR-450XL : (0, 1, 0)

28

W303-0251E

Troubleshooting

Error code

Error (Details)

70

Failure in lower unit output power supply 10

Cause

Condition

Remarks

Countermeasure Monitored data on the lower unit output power supply 10 stays off for 100 ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (1) of the lower unit CN8

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

71

Failure in lower unit output power supply 11

Monitored data on the lower unit output power supply 11 stays off for 100 ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (2) of the lower unit CN8

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

72

Failure in lower unit output power supply 12

Monitored data on the lower unit output power supply 12 stays off for 100 ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (3) of the lower unit CN8

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

73

Failure in lower unit output power supply 13

Monitored data on the lower unit output power supply 13 stays off for 100 ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (4) of the lower unit CN8

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

74

Failure in lower unit output power supply 14

ON or OFF state of the monitored data of the lower unit output power supply 14 is contrary to the normal state, and this state continues for 100ms.

(In the normal state, when the emergency transmission state is 0 [1], the monitored data is ON [OFF].)

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (5) of the lower unit CN8 Repair or replace the faulty part referring to the crane electrical circuit diagram.

29

W303-0251E

MDT action: Only the error code is displayed.

Troubleshooting

Error code

Error (Details)

75

Failure in lower unit output power supply 15

Cause

Condition

Remarks

Countermeasure Monitored data on the lower unit output power supply 15 stays off for 100 ms.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (1) of the lower unit CN7

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

76

＊ 80

＊ 90

Failure in lower unit output power supply 16

Monitored lower unit output data is unstable.

Faulty RY1 output

ON or OFF state of the monitored data of the lower unit output power supply 16 is contrary to the normal state, and this state continues for 100ms.

(In the normal state, when the lower unit output Tr3 state is ON [OFF], the monitored data is ON [OFF].)

The sample monitored data of the lower unit output (RY1-RY56) at every 10ms do not match the latest data 50 consecutive times.

The monitored data continue ON for 100ms while RY1 output data is OFF.

1.Blowout of the corresponding fuse 2.Broken wire or failure in circuit connecting to terminal (2) of the lower unit CN7

MDT action: Only the error code is displayed.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Failure in the relay output monitor circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

1.Circuit connected with terminal (5) of lower unit CN11 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

30

W303-0251E

MDT action: Sets the corresponding OE (output enable signal) to ON. MDT action: RY1-RY8 is set are OFF.

Troubleshooting

Error code

Error (Details)

＊ 91

Faulty RY2 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON for 100ms while RY2 output data is OFF.

1.Circuit connected with terminal (6) of lower unit CN11 is short-circuited with the 24-V circuit.

MDT action: RY1-RY8 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ 92

Faulty RY3 output

The monitored data continue ON for 100ms while RY3 output data is OFF.

1.Circuit connected with terminal (7) of lower unit CN11 is short-circuited with the 24-V circuit.

MDT action: RY1-RY8 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ 93

Faulty RY4 output

The monitored data continue ON for 100ms while RY4 output data is OFF.

1.Circuit connected with terminal (8) of lower unit CN11 is short-circuited with the 24-V circuit 2.Failure in relay output circuit in the lower unit.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

31

W303-0251E

MDT action: RY1-RY8 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ 94

Faulty RY5 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON for 100ms while RY5 output data is OFF.

1.Circuit connected with terminal (9) of lower unit CN11 is short-circuited with the 24-V circuit.

MDT action: RY1-RY8 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ 95

Faulty RY6 output

The monitored data continue ON for 100ms while RY6 output data is OFF.

1.Circuit connected with terminal (10) of lower unit CN11 is short-circuited with the 24-V circuit.

MDT action: RY1-RY8 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ 96

Faulty RY7 output

The monitored data continue ON for 100ms while RY7 output data is OFF.

1.Circuit connected with terminal (11) of lower unit CN11 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

32

W303-0251E

MDT action: RY1-RY8 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ 97

Faulty RY8 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON for 100ms while RY8 output data is OFF.

1.Circuit connected with terminal (12) of lower unit CN11 is short-circuited with the 24-V circuit

MDT action: RY1-RY8 are set to OFF.

2.Failure in relay output circuit in the lower unit.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

98

99

Faulty RY1 output

Faulty RY2 output

The monitored data continue OFF while RY1 output data is ON.

Failure in relay output circuit in the lower unit

Failure is not detected when the output power supply 1 is OFF.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

The monitored data continue OFF while RY2 output data is ON.

Failure in relay output circuit in the lower unit

Failure is not detected when the output power supply 1 is OFF. 9A

Faulty RY3 output

The monitored data continue OFF while RY3 output data is ON. Failure is not detected when the output power supply 2 is OFF.

9b

Faulty RY4 output

The monitored data continue OFF while RY4 output data is ON. Failure is not detected when the output power supply 2 is OFF.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

33

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

Troubleshooting

Error code

Error (Details)

9C

Faulty RY5 output

Faulty RY6 output

The monitored data continue OFF while RY5 output data is ON.

The monitored data continue OFF while RY6 output data is ON. Failure is not detected when the output power supply 3 is OFF.

9E

Faulty RY7 output

The monitored data continue OFF while RY7 output data is ON. Failure is not detected when the output power supply 3 is OFF.

9F

Faulty RY8 output

The monitored data continue OFF while RY8 output data is ON. Failure is not detected when the output power supply 3 is OFF.

＊ A0

Faulty RY9 output

Remarks

Countermeasure

Failure is not detected when the output power supply 3 is OFF. 9d

Cause

Condition

The monitored data continue ON while RY9 output data is OFF.

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

1.Circuit connected with terminal (13) of lower unit CN11 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

34

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: RY9-RY16 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ A1

Faulty RY10 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY10 output data is OFF.

1.Circuit connected with terminal (14) of lower unit CN11 is short-circuited with the 24-V circuit.

MDT action: RY9-RY16 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ A2

Faulty RY11 output

The monitored data continue ON while RY11 output data is OFF.

1.Circuit connected with terminal (15) of lower unit CN11 is short-circuited with the 24-V circuit.

MDT action: RY9-RY16 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ A3

Faulty RY12 output

The monitored data continue ON while RY12 output data is OFF.

1.Circuit connected with terminal (16) of lower unit CN11 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

35

W303-0251E

MDT action: RY9-RY16 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ A4

Faulty RY13 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY13 output data is OFF.

1.Circuit connected with terminal (17) of lower unit CN11 is short-circuited with the 24-V circuit.

MDT action: RY9-RY16 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ A5

Faulty RY14 output

The monitored data continue ON while RY14 output data is OFF.

1.Circuit connected with terminal (4) of lower unit CN10 is short-circuited with the 24-V circuit.

MDT action: RY9-RY16 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ A6

Faulty RY15 output

The monitored data continue ON while RY15 output data is OFF.

1.Circuit connected with terminal (5) of lower unit CN10 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

36

W303-0251E

MDT action: RY9-RY16 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ A7

Faulty RY16 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY16 output data is OFF.

1.Circuit connected with terminal (6) of lower unit CN10 is short-circuited with the 24-V circuit.

MDT action: RY9-RY16 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

A8

Faulty RY9 output

The monitored data continue OFF while RY9 output data is ON. Failure is not detected when the output power supply 4 is OFF.

A9

Faulty RY10 output

The monitored data continue OFF while RY10 output data is ON. Failure is not detected when the output power supply 4 is OFF.

AA

Faulty RY11 output

The monitored data continue OFF while RY11 output data is ON. Failure is not detected when the output power supply 4 is OFF.

Ab

Faulty RY12 output

The monitored data continue OFF while RY12 output data is ON. Failure is not detected when the output power supply 4 is OFF.

Failure in relay output circuit in the lower unit.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

37

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

Troubleshooting

Error code

Error (Details)

AC

Faulty RY13 output

Faulty RY14 output

The monitored data continue OFF while RY13 output data is ON.

The monitored data continue OFF while RY14 output data is ON. Failure is not detected when the output power supply 5 is OFF.

AE

Faulty RY15 output

The monitored data continue OFF while RY15 output data is ON. Failure is not detected when the output power supply 5 is OFF.

AF

Faulty RY16 output

The monitored data continue OFF while RY16 output data is ON. Failure is not detected when the output power supply 5 is OFF.

＊ b0

Faulty RY17 output

Remarks

Countermeasure

Failure is not detected when the output power supply 5 is OFF. Ad

Cause

Condition

The monitored data continue ON while RY17 output data is OFF.

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

1.Circuit connected with terminal (7) of lower unit CN10 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

38

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: RY17 is set to OFF.

Troubleshooting

Error code

Error (Details)

＊ b1

Faulty RY18 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY18 output data is OFF.

1.Circuit connected with terminal (8) of lower unit CN10 is short-circuited with the 24-V circuit.

MDT action: RY18 is set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ b2

Faulty RY19 output

The monitored data continue ON while RY19 output data is OFF.

1.Circuit connected with terminal (9) of lower unit CN10 is short-circuited with the 24-V circuit.

MDT action: RY19 is set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ b3

Faulty RY20 output

The monitored data continue ON while RY20 output data is OFF.

1.Circuit connected with terminal (10) of lower unit CN10 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

39

W303-0251E

MDT action: RY20 is set to OFF.

Troubleshooting

Error code

Error (Details)

＊ b4

Faulty RY21 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY21 output data is OFF.

1.Circuit connected with terminal (11) of lower unit CN10 is short-circuited with the 24-V circuit.

MDT action: RY21 is set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ b5

Faulty RY22 output

The monitored data continue ON while RY22 output data is OFF.

1.Circuit connected with terminal (12) of lower unit CN10 is short-circuited with the 24-V circuit.

MDT action: RY22 is set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ b6

Faulty RY23 output

The monitored data continue ON while RY23 output data is OFF.

1.Circuit connected with terminal (13) of lower unit CN10 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

40

W303-0251E

MDT action: RY23 is set to OFF.

Troubleshooting

Error code

Error (Details)

＊ b7

Faulty RY24 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY24 output data is OFF.

1.Circuit connected with terminal (3) of lower unit CN9 is short-circuited with the 24-V circuit.

MDT action: RY24 is set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

b8

Faulty RY17 output

The monitored data continue OFF while RY17 output data is ON. Failure is not detected when the output power supply 6 is OFF.

b9

Faulty RY18 output

The monitored data continue OFF while RY18 output data is ON. Failure is not detected when the output power supply 6 is OFF.

bA

Faulty RY19 output

The monitored data continue OFF while RY19 output data is ON. Failure is not detected when the output power supply 6 is OFF.

bb

Faulty RY20 output

The monitored data continue OFF while RY20 output data is ON. Failure is not detected when the output power supply 6 is OFF.

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

41

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

Troubleshooting

Error code

Error (Details)

bC

Faulty RY21 output

Faulty RY22 output

The monitored data continue OFF while RY21 output data is ON.

The monitored data continue OFF while RY22 output data is ON. Failure is not detected when the output power supply 7 is OFF.

bE

Faulty RY23 output

The monitored data continue OFF while RY23 output data is ON. Failure is not detected when the output power supply 7 is OFF.

bF

Faulty RY24 output

The monitored data continue OFF while RY24 output data is ON. Failure is not detected when the output power supply 7 is OFF.

＊ C0

Faulty RY25 output

Remarks

Countermeasure

Failure is not detected when the output power supply 6 is OFF. bd

Cause

Condition

The monitored data continue ON while RY25 output data is OFF.

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

1.Circuit connected with terminal (4) of lower unit CN9 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

42

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: RY25-RY27 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ C1

Faulty RY26 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY26 output data is OFF.

1.Circuit connected with terminal (5) of lower unit CN9 is short-circuited with the 24-V circuit.

MDT action: RY25-RY27 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ C2

Faulty RY27 output

The monitored data continue ON while RY27 output data is OFF.

1.Circuit connected with terminal (6) of lower unit CN9 is short-circuited with the 24-V circuit.

MDT action: RY25-RY27 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ C3

Faulty RY28 output

The monitored data continue ON while RY28 output data is OFF.

1.Circuit connected with terminal (7) of lower unit CN9 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

43

W303-0251E

MDT action: RY28-RY32 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ C4

Faulty RY29 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY29 output data is OFF.

1.Circuit connected with terminal (8) of lower unit CN9 is short-circuited with the 24-V circuit.

MDT action: RY28-RY32 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ C5

Faulty RY30 output

The monitored data continue ON while RY30 output data is OFF.

1.Circuit connected with terminal (9) of lower unit CN9 is short-circuited with the 24-V circuit.

MDT action: RY28-RY32 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ C6

Faulty RY31 output

The monitored data continue ON while RY31 output data is OFF.

1.Circuit connected with terminal (14) of lower unit CN9 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

44

W303-0251E

MDT action: RY28-RY32 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ C7

Faulty RY32 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY32 output data is OFF.

1.Circuit connected with terminal (15) of lower unit CN9 is short-circuited with the 24-V circuit.

MDT action: RY28-RY32 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

C8

Faulty RY25 output

The monitored data continue OFF while RY25 output data is ON. Failure is not detected when the output power supply 8 is OFF.

C9

Faulty RY26 output

The monitored data continue OFF while RY26 output data is ON. Failure is not detected when the output power supply 8 is OFF.

CA

Faulty RY27 output

The monitored data continue OFF while RY27 output data is ON. Failure is not detected when the output power supply 8 is OFF.

Cb

Faulty RY28 output

The monitored data continue OFF while RY28 output data is ON. Failure is not detected when the output power supply 9 is OFF.

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

45

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

Troubleshooting

Error code

Error (Details)

CC

Faulty RY29 output

Faulty RY30 output

The monitored data continue OFF while RY29 output data is ON.

The monitored data continue OFF while RY30 output data is ON. Failure is not detected when the output power supply 9 is OFF.

CE

Faulty RY31 output

The monitored data continue OFF while RY31 output data is ON. Failure is not detected when the output power supply 9 is OFF.

CF

Faulty RY32 output

The monitored data continue OFF while RY32 output data is ON. Failure is not detected when the output power supply 9 is OFF.

＊ d0

Faulty RY33 output

Remarks

Countermeasure

Failure is not detected when the output power supply 9 is OFF. Cd

Cause

Condition

The monitored data continue ON while RY33 output data is OFF.

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

1.Circuit connected with terminal (16) of lower unit CN9 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

46

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: RY33-RY36 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ d1

Faulty RY34 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY34 output data is OFF.

1.Circuit connected with terminal (17) of lower unit CN9 is short-circuited with the 24-V circuit.

MDT action: RY33-RY36 are set to OFF.

2.Failure in relay output circuit inc the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ d2

Faulty RY35 output

The monitored data continue ON while RY35 output data is OFF.

1.Circuit connected with terminal (18) of lower unit CN9 is short-circuited with the 24-V circuit.

MDT action: RY33-RY36 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ d3

Faulty RY36 output

The monitored data continue ON while RY36 output data is OFF.

1.Circuit connected with terminal (19) of lower unit CN9 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

47

W303-0251E

MDT action: RY33-RY36 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ d4

Faulty RY37 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY37 output data is OFF.

1.Circuit connected with terminal (7) of lower unit CN8 is short-circuited with the 24-V circuit.

MDT action: RY37 and RY38 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ d5

Faulty RY38 output

The monitored data continue ON while RY38 output data is OFF.

1.Circuit connected with terminal (8) of lower unit CN8 is short-circuited with the 24-V circuit.

MDT action: RY37 and RY38 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ d6

Faulty RY39 output

The monitored data continue ON while RY39 output data is OFF.

1.Circuit connected with terminal (9) of lower unit CN8 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

48

W303-0251E

MDT action: RY39 and RY40 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ d7

Faulty RY40 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY40 output data is OFF.

1.Circuit connected with terminal (10) of lower unit CN8 is short-circuited with the 24-V circuit.

MDT action: RY39 and RY40 are set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

d8

Faulty RY33 output

The monitored data continue OFF while RY33 output data is ON. Failure is not detected when the output power supply 10 is OFF.

d9

Faulty RY34 output

The monitored data continue OFF while RY34 output data is ON. Failure is not detected when the output power supply 10 is OFF.

dA

Faulty RY35 output

The monitored data continue OFF while RY35 output data is ON. Failure is not detected when the output power supply 10 is OFF.

db

Faulty RY36 output

The monitored data continue OFF while RY36 output data is ON. Failure is not detected when the output power supply 10 is OFF.

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

49

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

Troubleshooting

Error code

Error (Details)

dC

Faulty RY37 output

Faulty RY38 output

The monitored data continue OFF while RY37 output data is ON.

The monitored data continue OFF while RY38 output data is ON. Failure is not detected when the output power supply 11 is OFF.

dE

Faulty RY39 output

The monitored data continue OFF while RY39 output data is ON. Failure is not detected when the output power supply 12 is OFF.

dF

Faulty RY40 output

Remarks

Countermeasure

Failure is not detected when the output power supply 11 is OFF. dd

Cause

Condition

The monitored data continue OFF while RY40 output data is ON. Failure is not detected when the output power supply 12 is OFF.

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

50

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

Troubleshooting

Error code

Error (Details)

＊ E0

Faulty RY41 output

Faulty RY42 output

The monitored data continue ON for 100ms while RY41 output data is OFF.

The monitored data continue ON for 100ms while RY42 output data is OFF. Failure is not detected when the emergency transmission state is “1”, or for 100 ms after it is shifted from “1” to “0”.

＊ E2

Faulty RY43 output

Remarks

Countermeasure

Failure is not detected when the emergency transmission state is “1”, or for 100 ms after it is shifted from “1” to “0”.

＊ E1

Cause

Condition

The monitored data continue ON for 100ms while RY43 output data is OFF. Failure is not detected when the emergency transmission state is “1”, or for 100 ms after it is shifted from “1” to “0”.

1.Circuit connected with terminal (11) of lower unit CN8 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit

MDT action: RY41-RY48 and MSOL1-MSOL2 are set to OFF.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

1.Circuit connected with terminal (3) of lower unit CN7 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit

MDT action: RY41-RY48 and MSOL1-MSOL2 are set to OFF.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

1.Circuit connected with terminal (4) of lower unit CN7 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

51

W303-0251E

MDT action: RY41-RY48 and MSOL1-MSOL2 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ E3

Faulty RY44 output

Faulty RY45 output

The monitored data continue ON for 100ms while RY44 output data is OFF.

The monitored data continue ON for 100ms while RY45 output data is OFF. Failure is not detected when the emergency transmission state is “1”, or for 100 ms after it is shifted from “1” to “0”.

＊ E5

Faulty RY46 output

Remarks

Countermeasure

Failure is not detected when the emergency transmission state is “1”, or for 100 ms after it is shifted from “1” to “0”.

＊ E4

Cause

Condition

The monitored data continue ON for 100ms while RY46 output data is OFF. Failure is not detected when the emergency transmission state is “1”, or for 100 ms after it is shifted from “1” to “0”.

1.Circuit connected with terminal (5) of lower unit CN7 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit

MDT action: RY41-RY48 and MSOL1-MSOL2 are set to OFF.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

1.Circuit connected with terminal (6) of lower unit CN7 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit

MDT action: RY41-RY48 and MSOL1-MSOL2 are set to OFF.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

1.Circuit connected with terminal (8) of lower unit CN7 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

52

W303-0251E

MDT action: RY41-RY48 and MSOL1-MSOL2 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ E6

Faulty RY47 output

Faulty RY48 output

The monitored data continue ON for 100ms while RY47 output data is OFF.

The monitored data continue ON for 100ms while RY48 output data is OFF. Failure is not detected when the emergency transmission state is “1”, or for 100 ms after it is shifted from “1” to “0”.

E8

Faulty RY41 output

The monitored data continue OFF while RY41 output data is ON. Failure is not detected when the output power supply 13 is OFF.

E9

Faulty RY42 output

Remarks

Countermeasure

Failure is not detected when the emergency transmission state is “1”, or for 100 ms after it is shifted from “1” to “0”.

＊ E7

Cause

Condition

The monitored data continue OFF while RY42 output data is ON. Failure is not detected when the output power supply 13 is OFF.

1.Circuit connected with terminal (8) of lower unit CN7 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit

MDT action: RY41-RY48 and MSOL1-MSOL2 are set to OFF.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

1.Circuit connected with terminal (9) of lower unit CN7 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit

MDT action: RY41-RY48 and MSOL1-MSOL2 are set to OFF.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

53

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

Troubleshooting

Error code

Error (Details)

EA

Faulty RY43 output

Faulty RY44 output

The monitored data continue OFF for 100ms while RY43 output data is ON.

The monitored data continue OFF for 100ms while RY44 output data is ON. Failure is not detected when the output power supply 14 is OFF.

EC

Faulty RY45 output

The monitored data continue OFF for 100ms while RY45 output data is ON. Failure is not detected when the output power supply 14 is OFF.

Ed

Faulty RY46 output

The monitored data continue OFF for 100ms while RY46 output data is ON. Failure is not detected when the output power supply 14 is OFF.

EE

Faulty RY47 output

Remarks

Countermeasure

Failure is not detected when the output power supply 14 is OFF. Eb

Cause

Condition

The monitored data continue OFF for 100ms while RY47 output data is ON. Failure is not detected when the output power supply 14 is OFF.

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

54

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

Troubleshooting

Error code

Error (Details)

EF

Faulty RY48 output

Faulty RY49 output

Remarks

Countermeasure The monitored data continue OFF for 100ms while RY48 output data is ON. Failure is not detected when the output power supply 14 is OFF.

＊ F0

Cause

Condition

The monitored data continue ON while RY49 output data is OFF.

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

1.Circuit connected with terminal (10) of lower unit CN7 is short-circuited with the 24-V circuit.

MDT action: Only the error code is displayed.

MDT action: RY49 is set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ F1

Faulty RY50 output

The monitored data continue ON while RY50 output data is OFF.

1.Circuit connected with terminal (11) of lower unit CN7 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

55

W303-0251E

MDT action: RY50 is set to OFF.

Troubleshooting

Error code

Error (Details)

＊ F2

Faulty RY51 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY51 output data is OFF.

1.Circuit connected with terminal (12) of lower unit CN7 is short-circuited with the 24-V circuit.

MDT action: RY51 is set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ F3

Faulty RY52 output

The monitored data continue ON while RY52 output data is OFF.

1.Circuit connected with terminal (13) of lower unit CN7 is short-circuited with the 24-V circuit.

MDT action: RY52 is set to OFF.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

＊ F4

Faulty RY53 output

The monitored data continue ON while RY53 output data is OFF.

1.Circuit connected with terminal (14) of lower unit CN7 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

56

W303-0251E

MDT action: RY53-RY56 and Tr3 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ F5

Faulty RY54 output

Cause

Condition

Remarks

Countermeasure The monitored data continue ON while RY54 output data is OFF.

1.Circuit connected with terminal (15) of lower unit CN7 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit

MDT action: RY53-RY56 and Tr3 are set to OFF.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.) ＊ F6

Faulty RY55 output

The monitored data continue ON while RY55 output data is OFF.

1.Circuit connected with terminal (16) of lower unit CN7 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit

MDT action: RY53-RY56 and Tr3 are set to OFF.

Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.) ＊ F7

Faulty RY56 output

The monitored data continue ON while RY56 output data is OFF.

1.Circuit connected with terminal (17) of lower unit CN7 is short-circuited with the 24-V circuit.

2.Failure in relay output circuit in the lower unit Repair or replace the faulty part referring to the crane electrical circuit diagram.

Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

57

W303-0251E

MDT action: RY53-RY56 and Tr3 are set to OFF.

Troubleshooting

Error code

Error (Details)

F8

Faulty RY49 output

Faulty RY50 output

The monitored data continue OFF while RY49 output data is ON.

The monitored data continue OFF while RY50 output data is ON. Failure is not detected when the output power supply 15 is OFF.

FA

Faulty RY51 output

The monitored data continue OFF while RY51 output data is ON. Failure is not detected when the output power supply 15 is OFF.

Fb

Faulty RY52 output

The monitored data continue OFF while RY52 output data is ON. Failure is not detected when the output power supply 15 is OFF.

＊ FC

Faulty RY53 output

Remarks

Countermeasure

Failure is not detected when the output power supply 15 is OFF. F9

Cause

Condition

The monitored data continue OFF for 100ms while RY53 output data is ON. Failure is not detected when the output power supply 16 is OFF.

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

58

W303-0251E

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: Only the error code is displayed.

MDT action: RY53-RY56 and Tr3 are set to OFF.

Troubleshooting

Error code

Error (Details)

＊ Fd

Faulty RY54 output

Faulty RY55 output

The monitored data continue OFF for 100ms while RY54 output data is ON.

The monitored data continue OFF for 100ms while RY55 output data is ON. Failure is not detected when the output power supply 16 is OFF.

＊ FF

Faulty RY56 output

Remarks

Countermeasure

Failure is not detected when the output power supply 16 is OFF. ＊ FE

Cause

Condition

The monitored data continue OFF for 100ms while RY56 output data is ON. Failure is not detected when the output power supply 16 is OFF.

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

Failure in relay output circuit in the lower unit Replace the lower unit relay board.

(Replace the CPU board, if the failure is not recovered even after the relay board is replaced.)

59

W303-0251E

MDT action: RY53-RY56 and Tr3 are set to OFF.

MDT action: RY53-RY56 and Tr3 are set to OFF.

MDT action: RY53-RY56 and Tr3 are set to OFF.

Troubleshooting 3. Check chart Initial conditions before checking 1. Stop the engine.

2. Set the starter switch to ON. 3. Make sure that the emergency transmission switch is OFF. 4. Check that the upper and lower MDTs are energized.

4.1 Upper MDT Each voltage between power supply terminals (1), (2), (3) and ground terminals (4), (5), (6) respectively of CN1 is approx. 24V. Voltage between power supply terminal (1) and ground terminals (9), (10) of CN7 is approx. 12V. 4.2 Lower MDT Each voltage between power supply terminal (1), (2), (3) and ground terminals (4), (5), (6) respectively of CN2 is approx. 24V. Voltage between power supply terminal (9) and ground terminals (16) of CN4 is approx. 12V.

Go to the applicable check procedures according to failure state.

Signals from upper structure to lower structure of crane are faulty.

Signals from lower structure to upper structure of crane are faulty.

All signals are faulty.

Signals in both directions are all faulty.

All signals are faulty.

Some of the signals are faulty.

Some of the signals are faulty.

Go to check chart 1.

Go to check chart 2.

60

W303-0251E

Go to check chart 3.

Troubleshooting Check chart 1 [Some of the signals from the crane upper structure to the lower structure are faulty.]

[NOTE] Measure voltage between the terminal in the connector on the upper electric circuit side and the chassis.

Do not disconnect irrelevant connectors.

Operate the switches, levers, etc. according to the failure conditions, referring to the “Data table” at the end of this manual. Note that in the “Data table”, check circuits are denoted by signal names. Find the terminal Nos. by referring to the “Connection diagram for connectors”.

1. With the MDT check mode display function or the AML’s “MDT monitor” display function, check the condition of the input and output signals to find the faulty signals, and measure the followings: 1.1 When the faulty signal circuit is Di1-Di48: After disconnecting only connector containing the circuit for faulty signal among the upper MDT connectors (CN4,CN5 or CN10), try to operate the control, and measure the voltage between the terminal in faulty signal circuit and the chassis.

1.2 When the faulty signal circuit is Di49-Di64: After disconnecting only the connector CN10 on the upper MDT side, try to operate the control, and measure the conductivity between the terminal in faulty signal circuit and the chassis.

2. Compare the results from the above measurements with the correct input state in the “Data table” at the end of this manual.

OK

Faulty

Fault in upper electric circuit Check related switches and wiring (connectors and wires).

[NOTE] Measure voltage between the connector terminal on the lower MDT side and the chassis.

Measure voltage without disconnecting the connector.

Operate the switches, levers, etc. according to the failure conditions, referring to the “Data table” at the end of this manual. Note that in the “Data table”, check circuits are denoted by signal names. Find the terminal Nos. by referring to the “Connection diagram for connectors”.

Reconnect the disconnected connector to the upper MDT, and measure the voltage between the terminal in faulty signal circuit in the connector on the lower MDT and the chassis in the same way as above operation and compare the result with the correct state given in the “Data table”.

OK

Faults in the lower electric circuit.

Faulty

[NOTE]

Check related components, connectors and wiring.

Replacement order of the board depends on the faulty condition.

Failure in the MDT Check operation after replacing the CPU board in the upper MDT. If operation is still faulty, replace the CPU board in the lower MDT. If still faulty, replace the relay board in the lower MDT.

61

W303-0251E

Troubleshooting

Check chart 2 [Some of the signals from the crane lower structure to the upper structure are faulty.]

[NOTE] The check circuits are denoted by the signal names in the “Data table”. Find the terminal Nos. by referring to the “connection diagram for connectors”.

1. With the MDT check mode display function or the AML’s “MDT monitor” display function, check the condition of the input and output signals to find the faulty signals, and perform the followings: 1.1 When the faulty signal circuit is Di1-Di24: Disconnect the connector CN1 on the lower MDT side, and short the terminal in the corresponding faulty signal circuit (lower MDT side) to the chassis.

1.2 When the faulty signal circuit is Di25-Di32: Disconnect the connector CN1 on the lower MDT side, and connect the terminal corresponding to the faulty signal circuit (lower MDT side) to the 24-V power supply.

2. Compare the condition of the indicator lamp and buzzer on the crane upper structure with the correct state in the data table at the end of this manual.

OK

Faulty

Faults in lower electric circuit Check the related components, connectors and wires.

[NOTE] The check circuits are denoted by the signal names in the “Data table”. Find the terminal Nos. by referring to the “Connection diagram for connectors”.

With connector CN3 or CN9 on the upper MDT disconnected, short the terminal for the faulty signal circuit (upper electric circuit side) to the chassis, and check that the indicator lamp, buzzer, etc. on the crane upper structure operate normally.

OK

Faulty

Faults in the upper electric circuit

[NOTE]

Check related indicator lamp, buzzer, connectors and wiring.

Replacement order of the board depends on the faulty condition.

Failure in the MDT Check the operation after replacing the CPU board in the lower MDT. If the failure is still detected, replace the CPU board in the upper MDT.

62

W303-0251E

Troubleshooting

Check chart 3 All signals from the lower to the upper or all signals from the upper to the lower structure are faulty, or all signals in both directions are faulty.

With all the connectors on the upper and the lower MDT connected, disconnect the connectors from the upper and the lower MDT to the rotary joint, and connect the upper and the lower MDT with the special checking harness shown below. Check operation again.

OK

Faulty

Rotary joint is faulty.

Check the electric part of the rotary joint in section B shown below and the connectors and the wires.

Check the conductivity between the connectors and wires in sections A and B shown below.

All circuit are OK.

Some circuits have no conductivity.

Wiring (connector or wire) is faulty.

[NOTE] Replacement order of the board depends on the faulty condition.

Failure in the MDT Check operation after replacing the CPU board in the upper MDT. If operation is still faulty, replace the CPU board in the lower MDT. If still faulty, replace the relay board in the lower MDT.

A

B

C Connector

Connector

Rotary joint 7

Upper MDT

[ 5 ] CY [ 3 ] WR

11 25 23

Lower [ 5 ] CY

MDT

[ 3 ] WR

26 Harness for checking Connector

Transfer line

Connector IW303-0251E51

63

W303-0251E

Disassembly and reassembly 2. Connector

Disassembly and reassembly 1. MDT main unit

2.1 Removing and attaching the connector contact

If you find the MDT main unit faulty after checking it

【NOTICE】 The connector contacts are fixed to the connectors by double-locking mechanism.

according to the "Troubleshooting", replace the faulty board.

Follow the procedure below when removing and

【NOTICE】 Remove or install the MDT after turning the starter switch of the crane to OFF.

attaching the connector contacts.

Do not touch the two surfaces of the boards with uncovered hands when dismounting and remounting them.

manufacturer AMP's instruction sheet.

The following description is based on the

Insert the connectors securely taking care not to contaminate them with water, dust, etc.

AMP connector type

1.1 Disassembly and reassembly When disassembling and reassembling, refer to “Construction of MDT”.

Documentation Part No. of No. of AMP contact instruction extraction tool sheet

.070 Multi-lock connector (MarkⅠ)

412-5520

755430-2

.040 Multi-lock connector (MarkⅠ)

411-5883

755430-1

.040 Multi-lock connector (MarkⅡ)

412-5475-1

.040Ⅱ Multi-lock connector (MarkⅡ)

411-5760-2

715131-1

The part Nos. of the contact extraction tools are designated by AMP.

64

W303-0251E

Disassembly and reassembly 2.1.1 AMP.070 Multi-lock connector (MarkⅠ)

Insertion of Contact

Confirmation of Locking: Please make certain of the complete of locking

1. Insert the receptacle properly with its seam side

by checking the hooks and the locks on both

up (for both upper and lower cavities) into the

sides.

housing with its locking side up. Please do not force to insert; make sure the direction is correct.

2. Increase of Contact Keeping Strength can be expected by doublelocking.

2. Please make sure that the contact is perfectly locked with the housing until it clicks. Please

3. Releasing Doublelock:

make it a rule to check the locking by gently

Refer to contact extraction tool(755430-2)

pulling forward the contact after insertion.

instruction sheet.

"Please obey the authorized instruction to

3. In case the contact must be pulled out again,

release,otherwise the housing could be damaged.

please care about the deformation of contact.

Please release it properly."

[Refer to contact extraction tool(755430-2) instruction sheet.]

Harness Checker

4. Doublelock immediately after insertion of contact.

1. Please refer to the figure below to check the

Otherwise it might be damaged in carrying the

current running of assembled harness.

harness due to doublelock catching things.

Doublelock 1. After the insertion of contact into the housing, doublelock it (hinge type). There are eight places to lock. Please make sure to lock all of them.

“Use of Current Checker of Spring Pin is preferable.”

65

W303-0251E

Disassembly and reassembly

1.INTRODUCTION: AMP Extraction Tool, P/N 755430-2 has been designed to extract 070 Series contacts from double lock housing.

Read this instruction sheet carefully, before you start operation.

2.UNLOCKING HINGE-LOCKING DEVICE: The loaded contacts are locked by the double locking hinge device. It is necessary to unlock the hinge locking device, before to start removal of contacts from the housing.

Opening of hinges should be performed carefully, not to damage them during handling. Open one after one, gradually.

Releasing Side Locking Device: 1.Insert tip end of the tool into the gap between the double-lock hinge and side wall of housing as shown in Fig.2.

2.Tilt the tool so that the tip end digs up the double-lock plate with the side wall partially bending outside to release locking device as shown in Fig.3.

Note: Care must be taken not to apply an excessive force, lest it should result damage of housing wall etc.

66

W303-0251E

Disassembly and reassembly

Releasing Center Locking Device: 3.Insert tip end of the tool into the gap of locking device with its flat sides facing aside as shown in Fig.4.

4.Tilt the tool in the arrowed direction to raise the hinge with the locking arm bending out.

Repeat the steps from 1 to 4 to release on both sides in the same manner, so that all the locking devices are unlocked and hinges become free for raising up.

Avoid bending walls excessively to prevent from damage during operation.

3.EXTRACTION OF CONTACTS: Insert tip end of the tool into the housing cavity from the mating side of housing, so as to raise the locking lance of housing. This will make contact unlocking.

Proceed as follows (Fig.5): 1. Push back the contact into the housing in the direction "A". This will result relaxing of locking tension prior to unlocking.

2. Insert extraction tool into the housing cavity.

3. Raise the locking lance in housing.

4. Pull back the contact from the housing.

Note: Avoid inserting tool tip from reaching the contact leaf area for prevention from contact deformation and damage.

67

W303-0251E

Disassembly and reassembly 2.1.2 AMP.040 Multi-lock connector (MarkⅠ)

2. Increase of Contact Keeping Strength can be expected by doublelocking.

3. Releasing Doublelock: Refer to contact extraction tool(755430-1) instruction sheet.

Insertion of Contact

"Please obey the authorized instruction to 1. Insert the receptacle properly with its seam side

release,otherwise the housing could be damaged.

up (for both upper and lower cavities) into the

Please release it properly."

housing with its locking side up. Please do not Harness Checker

force to insert; make sure the direction is correct.

2. Please make sure that the contact is perfectly

1. Please refer to the figure below to check the

locked with the housing until it clicks. Please

current running of assembled harness.

make it a rule to check the locking by gently pulling forward the contact after insertion.

3. In case the contact must be pulled out again, please care about the deformation of contact.

[Refer to contact extraction tool(755430-1) instruction sheet.]

4. Doublelock immediately after insertion of contact.

Otherwise it might be damaged in carrying the harness due to doublelock catching things.

“Use of Current Checker of Spring Pin is preferable.”

Doublelock 1. After the insertion of contact into the housing, doublelock it (hinge type). Please make sure to lock all of them.

68

W303-0251E

Disassembly and reassembly

1.INTRODUCTION: AMP Extraction Tool, P/N 755430-1 has been designed to extract 040 Series contacts from double lock housing.

Read this instruction sheet carefully, before you start operation.

2.UNLOCKING HINGE-LOCKING DEVICE: The loaded contacts are locked by the double locking hinge device. It is necessary to unlock the hinge locking device, before to start removal of contacts from the housing.

Opening of hinges should be performed carefully, not to damage them during handling. Open one after one, gradually.

1.Insert tip end of the tool into the gap between the double-lock hinge and side wall of housing as shown in Fig.2.

2.Tilt the tool so that the tip end digs up the double-lock plate with the side wall partially bending outside to release locking device as shown in Fig.3.

Note: Care must be taken not to apply an excessive force, lest it should result damage of housing wall etc.

69

W303-0251E

Disassembly and reassembly 3.EXTRACTION OF CONTACTS: Insert tip end of the tool into the housing cavity from the mating side of housing, so as to raise the locking lance of housing. This will make contact unlocking.

Proceed as follows (Fig.4): 1. Push back the contact into the housing in the direction "A". This will result relaxing of locking tension prior to unlocking.

2. Insert extraction tool into the housing cavity.

3. Raise the locking lance in housing.

4. Pull back the contact from the housing.

Note: Avoid inserting tool tip from reaching the contact leaf area for prevention from contact deformation and damage.

70

W303-0251E

Disassembly and reassembly 2.1.3 AMP.040 Multi-lock connector (MarkⅡ)

2. Verify that the terminal has been firmly locked to the housing lance. If the crimp is located at the center of the retainer during contact mounting as shown in Fig.2, contact locking is not engaged rightly, causing the contact to slip out. Push the contact into the lance as shown in Fig.3. Locking it to the housing lance correctly will make a clicking sound.

After inserting the contact in place, check it by pulling the wire backward. Whenever the contact has to be removed for remounting, use the specified pulling tools.

Insertion of Contact 1. Before loading contacts into the housing, verify that there are no incomplete crimps and then place the contact with the locking lever facing upward as shown in Fig.1 and insert the contact straight until it stops at the end of housing cavity.

If the contact is not easily seated in housing, do not force it, but make sure that it is going in the right direction.

Terminals forced in backwards can accidentally scrape the housing lance off.

71

W303-0251E

Disassembly and reassembly

Double Lock Ratchet 1. A double lock ratchet is used to reinforce contact support. The insulation barrel is supported at the retainer type double lock area. See Fig.4.

2. If contacts are not mounted correctly inside the housing, double lock may not completely lock or effectively lock. See Figs.2 and 6.

3. Verify that the double lock is firmly locked. When completing and verifying steps 1 and 2 above, press the retainer press area. The retainer moves downward and the ratchet clicks to be released.

Make sure it is locked by lightly pulling the wire Unlocking the double lock ratchet

outward. The conditions shown in Figs.4 and 5 will be seen if the retainer behaves correctly.

Unlock the detent lock

If any contacts are not completely fixed, the retainer does not work properly resulting in the

1. Insert the jig into the insertion slot.

condition shown in Fig.6, in which the retainer is

2. Release the ratchet teeth by turning the jig in the

effective only on one side and the ratchet teeth

direction of the arrow so that the housing wall

are lifted on one side. If this happens, remount the

bends to allow you to lift the retainer press area

contact in the correct position using a removing

upward. Repeat the same procedure for the other

jig.

side as well.

72

W303-0251E

Disassembly and reassembly

Note: Bending the wall excessively may damage it.

Extracting Contacts Remove contacts by inserting the jig from the connector fitting side to lift up the connector housing lance.

1. Depress the contact in the direction of the arrow.

2. Insert jig.

3. Lift up the lance.

4. Remove the contact.

Note: Do not insert the removing jig into the contacting area of receptacle contacts (in order to prevent the contact leaf from deforming).

73

W303-0251E

Disassembly and reassembly 2.1.4 AMP.040Ⅱ Multi-lock connector (MarkⅡ)

Removing the retainer (From the finally assembled position to the pre-assembled position) 1. To remove the contacts from the housing the retainer must be at pre-assembled position. The

Insertion of Contact

contact can not be removed from the retainer if it

1. Confirm the proper orientation and insert the

is finally assembled position. Insert the end of

contact into the retainer until a click sound is

Extraction Tool (AMP part No.715131-1) into the

noted. Confirm that the contact is inserted fully

retainer extraction hole and pull up the retainer.

into the retainer. Then, lightly pull the wire to

Set the retainer to the pre-assembled position by

confirm that it will not come off.

aligning the alignment marks if it is dislocated from the pre-assembled position.

2. Orientation of the contact

How to extract the contacts

Orient the dimple provided on the contact so that it faces the retainer side of the housing.

1. Set the retainer to the pre-assembled position.

The contacts can not be removed with the retainer set to the finally assembled position.

Be sure to use the Extraction Tool (AMP part No.715131-1) to remove the contact.

Insert the tool horizontally into the housing. Never allow the tool to face downward to interfere with the contact as shown in the improper example below.

Securing the retainer (From pre-assembled position to the finally assembled position) 1. Note that the retainers provided on the connector are pre-assembled. Thus, they need to be finally assembled as shown in the figure below after inserting the contacts into them. The retainers can not be pushed in if any one of the contacts is not completely inserted. Press both ends of the retainer to assemble it.

74

W303-0251E

Disassembly and reassembly

Extract the contact in accordance with following procedure.

75

W303-0251E

Disassembly and reassembly 2.2 Crimping receptacle contact 1. Applicable contact Contact part No.

Finish

175062-1

Tin-plated

175062-2

Gold-plated

175027-1

Tin-plated

175027-2

Gold-plated

179417-1

Tin-plated

AMP connector type

.040 series .070 series .040Ⅱseries

Applicable wire size (nominal)

Hand tool Part No.

2

911738-1

0.5-1.25mm

2

911788-2

0.3-0.85mm

2

934192-1

0.3-0.5mm

The part Nos. of contacts and hand tools are designated by AMP.

2. Nomenclature

3. Crimping condition No.

Item

1

Cut-off tab

2

Bellmouth

3

.040 series

.070 series

.040Ⅱseries

175062-1

175027-1

179417-1

175062-2

175027-2

179418-2

0.25mm Max.

0.3mm Max.

0.5mm Max.

Front

0.4mm Max.

0.5mm Max.

Rear

0.15-0.65mm

0.5mm Max.

Allowable

Bending

limit of

Twisting

3° Max.

5.5° Max.

deformation

Rolling

5° Max.

10° Max.

4

Wire end protrusion length

5

Insulation stripping length (ref.)

-4°～+2° Max.

-3°～+3° Max.

0-1.5mm 4.0-4.5mm

-4°～+5° Max.

0-1.0mm 3.5-4.5mm

4.0-4.5mm

Seam must be neatly closed.

6

Wire barrel seam

(A slight gap is allowable on condition where no strand looses out of the seam.)

76

W303-0251E

Connection diagram for connectors Connection diagram for connectors 1.

CN1 (power supply) No. 1 2 3 4 5 6

Upper MDT CN1 (.070MKI) 6 5 4 3 2 1

CN6 (.040MKII) 1 2 3 4

CN7 (.040IIMKII)

12 11 10 9 8 7

6 5 4 3 2 1

CN3 (.040MKII) 20 19 18 17 16 15 14 13 12 11

10 9 8 7 6 5 4 3 2 1

1 2 3

9 8 7 6 5

4 5

CN5 (.070MKI) 14 13 12 11 10 9 8 7

6 5 4

3 2 1

9 10 11 12 13 14 15 16 23 24 25 26 27 28

CN9 (.070MKI)

CN4 (.070MKI)

4 3 2 1

No. Signal 1 TXD1

CN8 (.040MKII) 1 2 3 4 5 6 7 8 17 18 19 20 21 22

6 7 8 9 10 11 12

2

RXD1

3

TXD2(+)

4

TXD2(-)

5 6 7

RXD2(+) RXD2(-) TXD3

8 9 10 11 12

GND GND Pi3 Pi4 DPOW

CN10 (.040IIMKII) 1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 25 26

Signal name 24V power supply 24V power supply 24V power supply GND GND GND

Wire color (No.)

WB (213) WB (213) WB (213) B (0) B (0) B (0)

CN2

6 7 8 9 10

1 2 3 4 5

CN2 (.040MKII)

20 19 18 17 16 15 14 13 12 11 10

5 6 7 8

Signal MPOW MPOW MPOW GND GND GND

9 10 11 12 13 14 15 16 27 28 29 30 31 32 33 34 35 36

IW303-0251E15

Note: Inside the parentheses in the connector arrangement are AMP connector type.

77

W303-0251E

Signal name Wire color (No.) Upper/lower unit WR (3) serial output Upper/lower unit LY (5) serial input AML serial R (198) output(+) AML serial G (199) output(-) AML serial input(+) W (196) AML serial input(-) B (197) Combination meter W (191) serial output GND B (192) GND B (0) Unusable Unusable Unusable

Connection diagram for connectors CN3 (OUT) No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Signal Tr1 Tr2 Tr3 Tr4 Tr5 Tr6 Tr7 Tr8 GND GND Tr9 Tr10 Tr11 Tr12 Tr13 Tr14 Tr15

18

Tr16

19 20

GND GND

CN5 (IN) Wire color (No.) Signal name Alarm buzzer V (212) High beam lamp BL (239) Glow lamp WR (211) Spare output 12 Spare output 11 Spare output 10 Spare output 9 Spare output 8 GND B (0) GND B (0) Two-wheel steering RW (73) Four-wheel steering LG (74) Crab steering GL (75) Spare output 7 Spare output 6 Spare output 5 Spring lock state WL (309) detection Engine revolution YB (559) detection GND B (0) GND B (0)

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Di2(+) Di3(+) Di4(+) Di5(+) Di6(+) Di7(+) Di8(+) Di9(+) Di10(+) Di11(+) Di12(+) Di13(+) Di14(+) Di15(+) Di16(+) Di17(+) Di18(+) Di19(+)

Signal name GND Emergency transmission 1st 2nd 3rd D N R ALL FL FR RL RR Ext. Ret. Jack Slider Spare intput(+) 17 Lock (spring lock) Free (spring lock)

Signal Di20(+) Di21(+) Di22(+) Di23(+) Di24(+) Di25(+) Di26(+)

8 9 10 11 12 13 14

Di27(+) Di28(+) Di29(+) Di30(+) Di31(+) Di32(+) GND

Wire color (No.) Signal name Two-wheel steering L (29) Four-wheel steering LR (48) Crab steering LB (47) Spare intput(+) 16 Spare intput(+) 15 High/low shift YB (51) 2-wheel/4-wheel YL (50) drive shift Spare intput(+) 14 Spare intput(+) 13 Spare intput(+) 12 Headlamp A BrR (36) Headlamp B BrY (37) Clearance lamp Br (35) GND B (0)

CN6 No. 1 2 3 4 5 6 7 8

CN4 (IN) No. Signal 1 GND 2 Di1(+)

No. 1 2 3 4 5 6 7

Wire color (No.)

B (0) YG (20)

Signal TXD RXD BOOT GND GND GND GND GND

Signal name

Wire color (No.)

LR (800) LW (801) LG (802) LB (803) Br (804) Br (804) Br (804) Br (804)

CN7 RY (31) RB (32) RW (33) O (34) RL (30) R (40) Sb (72) PB (45) WY (44) WR (42) W (41) WB (43) Y (62) WL (46) GY (60)

No. Signal 1 SPOW 2 Pi1 3

Po1

4 5 6 7

Pi2 Po2 Po3 CHK

8

Ao1

9 10

GND GND

Lg (39) LgR (38)

78

W303-0251E

Wire color (No.) Signal name 12V IN WY (915) Tachometer sensor P (907) input Tachometer sensor LgW(908) output Main speed input WL (911) Main speed output LgY (912) Unusable MDT system check YW (4) input Unusable (fuel gauge output) GND B (0) GND B (0)

Connection diagram for connectors CN8

CN10 (IN)

No. Signal

Signal name

Wire color (No.)

1 2 3 4 5

AVCC AVCC AVCC AVCC AGND

R (227)

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

AGND AGND AGND Ai1 Ai2 Ai3 Ai4 SLD SLD SLD SLD AVCC AVCC AVCC AVCC AGND AGND AGND AGND Ai5 Ai6 Ai7 Ai8

5V (for air pressure) 5V (for spare 1) 5V (for spare 2) 5V (for spare 3) GND (for air pressure) GND (for spare 1) GND (for spare 2) GND (for spare 3) Air pressure input Spare analog input 1 Spare analog input 2 Spare analog input 3 GND (for shield) GND (for shield) GND (for shield) GND (for shield) 5V (for spare 4) 5V (for spare 5) 5V (for spare 6) 5V (for spare 7) GND (for spare 4) GND (for spare 5) GND (for spare 6) GND (for spare 7) Spare analog input 4 Spare analog input 5 Spare analog input 6 Spare analog input 7

B (229)

W (228)

Shield

CN9 No. 1 2 3 4 5 6 7 8 9 10 11

Signal Tr17 Tr18 Tr19 Tr20 Tr21 Tr22 Tr23 Tr24 Po4 Po5 Tr25

12

GND

Signal name Spare output 4 Spare output 3 Spare output 2 Spare output 1 Unusable Unusable Unusable Unusable Air pressure T/C pressure Unusable (MDT CPU output) GND

Wire color (No.)

No. 1 2 3

Signal Di49(-) Di50(-) Di51(-)

4 5 6 7 8 9 10 11

Di52(-) Di53(-) Di54(-) Di55(-) Di56(-) Di57(-) Di58(-) Di59(-)

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

Di60(-) Di61(-) Di62(-) Di63(-) Di64(-) Di33(+) Di34(+) Di35(+) Di36(+) Di37(+) Di38(+) Di39(+) Di40(+) Di41(+) Di42(+) GND GND GND GND Di43(+) Di44(+) Di45(+) Di46(+) Di47(+) Di48(+)

Y (143) YB (24)

B (0)

79

W303-0251E

Wire color (No.) Signal name Over-front detection BW (333) Spare intput(-) 13 Hydraulic oil temp.

YG (298) 50°C Spare intput(-) 12 Spare intput(-) 11 Spare intput(-) 10 Spare intput(-) 9 Spare intput(-) 8 Spare intput(-) 7 Spare intput(-) 6 Hydraulic oil temp.

Y (296) 85°C Spare intput(-) 5 Spare intput(-) 4 Spare intput(-) 3 Spare intput(-) 2 Spare intput(-) 1 Exhaust brake Y (52) Air heater LO (54) Working lamp YG (167) PTO G (22) Parking brake WG (19) Spare intput(+) 11 Spare intput(+) 10 Spare intput(+) 9 Spare intput(+) 8 Spare intput(+) 7 GND B (0) GND B (0) GND B (0) GND B (0) Spare intput(+) 6 Spare intput(+) 5 Spare intput(+) 4 Spare intput(+) 3 Spare intput(+) 2 Spare intput(+) 1

Connection diagram for connectors 2.

Lower MDT

CN1 (IN) No. Signal 1 Di1(-)

CN1 (.040IIMKII) CN7 (.070MKI) 18 17 16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1

CN8 (.070MKI) 12 11 10 9 8 7 6

5 4

9 8 7 6 5

4 3 2 1

CN10 (.070MKI) 14 13 12 11 10 9 8 7

6 5 4 3 2 1

CN11 (.070MKI) 18 17 16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1

Relay board

26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1

CN2 (.070MKI) 6 5 4 3 2 1

3 2 1

CN9 (.070MKI) 20 19 18 17 16 15 14 13 12 11 10

36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9

CN3 (.040MKII) 6 5 4 3 2 1

12 11 10 9 8 7

CN4 (.040MKI) 16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1

CN5 (.040MKII) 8 7 6 5

4 3 2 1

CN6 (.040MKII) 36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9

26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1

CPU board IW303-0251E16

2

Di2(-)

3

Di3(-)

4 5 6

Di4(-) Di5(-) Di6(-)

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

Di7(-) Di8(-) Di9(-) Di10(-) Di11(-) Di12(-) Di13(-) Di14(-) GND GND Di15(-) Di16(-) Di17(-) Di18(-) Di19(-) Di20(-) Di21(-) Di22(-) Di23(-) Di24(-) Di25(+) Di26(+) Di27(+) Di28(+) Di29(+) Di30(+) Di31(+) Di32(+) GND GND

Wire color (No.) Signal name Brake fluid level BW (82) detection Engine oil BR (85) low-pressure Air low-pressure BL (83) (parking brake) Spare intput(-) 17 Spare intput(-) 16 Straight ahead Y (78) detection Fuel level detection YO (244) 4WD detection GB (70) Air low-pressure GW (175) Spare intput(-) 15 Spare intput(-) 14 Spare intput(-) 13 Spare intput(-) 12 Spare intput(-) 11 GND B (0) GND B (0) Spare intput(-) 10 Spare intput(-) 9 Spare intput(-) 8 Spare intput(-) 7 Spare intput(-) 6 Spare intput(-) 5 Spare intput(-) 4 Spare intput(-) 3 Spare intput(-) 2 Spare intput(-) 1 Engine start LG (21) Spare intput(+) 7 Spare intput(+) 6 Spare intput(+) 5 Spare intput(+) 4 Spare intput(+) 3 Spare intput(+) 2 Spare intput(+) 1 GND B (0) GND B (0)

CN2 (power supply) No. 1 2 3 4 5 6

Note: Inside the parentheses in the connector arrangement are AMP connector type.

80

Signal MPOW MPOW MPOW GND GND GND W303-0251E

Signal name 24V power supply 24V power supply 24V power supply GND GND GND

Wire color (No.)

W (105) W (105) W (105) B (0) B (0) B (0)

Connection diagram for connectors CN3

CN6

No. Signal 1 TXD1

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Signal AVCC AVCC AVCC AVCC AVCC AGND AGND AGND AGND AGND Ai6 Ai7 Ai8 Ai9 Ai10 SLD AVCC

18

AVCC

19

AVCC

20

AVCC

21

AVCC

22

AGND

23

AGND

24

AGND

25

AGND

26

AGND

27 28 29 30 31 32 33 34 35 36

Ai1 Ai2 Ai3 Ai4 Ai5 SLD SLD SLD SLD SLD

Wire color (No.) Signal name Upper/lower unit LY (5) output 2 RXD1 Upper/lower unit WR (3) input 3 TXD2 Spare serial output 4 RXD2 Spare serial input 5 GND GND B (0) 6 CHK MDT system check YW (4) input 7 Ai12 (CHG) Charging lamp BG (86) 8 Tr1 PTO limiter YR (245) 9 Tr2 Clearance lamp Br (35) 10 Tr3 Steering power supply GB (247) 11 Tr4 Spare output 12 GND GND B (0)

CN4 (IN) No. 1 2 3

Signal Pi3(+) Pi3(-) Pi4(+)

4 5 6 7 8 9 10 11 12 13 14 15

Pi4(-) Pi1 Po1 Pi2 Po2 SPOW GND Po3 Ao1 Ao2 Ao3 Ai11

16

GND

Signal name Wire color (No.) Sub-speed input(+) W (135) Sub-speed input(-) B (129) Tachometer W (203) input(+) Tachometer input(-) B (204) Unusable Tachometer output P (907) Main speed input WG (913) Main speed output WL (911) 12V (for main speed) WR (914) GND Unusable Spare analog output 1 Spare analog output 2 Spare analog output 3 Unusable (fuel sender input) GND B (0)

CN5 No. 1 2 3 4 5 6 7 8

Signal TXD RXD BOOT GND GND GND GND GND

Signal name

Wire color (No.)

LR (800) LW (801) LG (802) LB (803) Br (804) Br (804) Br (804) Br (804)

81

W303-0251E

Wire color (No.) Signal name 5V (for spare 1) 5V (for spare 2) 5V (for spare 3) 5V (for spare 4) 5V (for spare 5) GND (for spare 1) GND (for spare 2) GND (for spare 3) GND (for spare 4) GND (for spare 5) Spare analog input 1 Spare analog input 2 Spare analog input 3 Spare analog input 4 Spare analog input 5 GND (for shield) 5V R (for O/R length FL) 5V R (for O/R length FR) 5V R (for O/R length RL) 5V R (for O/R length RR) 5V R (220) (for T/C pressure) GND B (for O/R length FL) GND B (for O/R length FR) GND B (for O/R length RL) GND B (for O/R length RR) GND B (222) (for T/C pressure) O/R length FL input W O/R length FR input W O/R length RL input W O/R length RR input W T/C pressure input W (221) GND (for shield) Shield GND (for shield) Shield GND (for shield) Shield GND (for shield) Shield GND (for shield) Shield

Connection diagram for connectors CN7

CN9

Wire color (No.) No. Signal Signal name 1 RPOW15 Output power sourse GW (93) [CN7(10-13)] 2 RPOW16 Output power sourse GL (248) [CN7(14-17)] 3 RY42 Lock up LgY (58) 4 RY43 F1 RY (31) 5 RY44 F2 RB (32) 6 RY45 F3 RW (33) 7 RY46 Hi O (34) 8 RY47 Lo RL (30) 9 RY48 R R (40) 10 RY49 Headlamp B BrY (37) 11 RY50 Spring lock check LgR (38) release 12 RY51 Spare output 3 13 RY52 Spring lock Lg (39) 14 RY53 4-wheel steering LR (48) 15 RY54 Crab steering LB (47) 16 RY55 Spare output 2 17 RY56 Spare output 1 18 GND GND B (0)

No. Signal 1 RPOW8

CN8 No. Signal 1 RPOW10 2

RPOW11

3

RPOW12

4

RPOW13

5

RPOW14

6 7 8 9 10 11 12

GND RY37 RY38 RY39 RY40 RY41 GND

2

RPOW9

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

RY24 RY25 RY26 RY27 RY28 RY29 RY30 GND GND GND GND RY31 RY32 RY33 RY34 RY35 RY36 GND

Wire color (No.) Signal name Output power sourse [CN9(4-6)] Output power sourse [CN9(7-9,14,15)] Spare output 21 Spare output 20 Spare output 19 Spare output 18 Spare output 17 Spare output 16 Spare output 15 GND B (0) GND B (0) GND B (0) GND B (0) Spare output 14 Spare output 13 Spare output 12 Spare output 11 Spare output 10 Spare output 9 GND B (0)

CN10

Signal name Wire color (No.) Output power sourse [CN9(16-19)] Output power sourse [CN8(7-8)] Output power sourse [CN8(9-10)] Output power sourse GY (88) [CN8(11),CN7(3)] Output power sourse GB (89) [CN7(4-9)] GND B (0) Spare output 8 Spare output 7 Spare output 6 Spare output 5 Spare output 4 GND B (0)

No. Signal 1 RPOW6

82

2

RPOW5

3

RPOW7

4 5 6 7

RY14 RY15 RY16 RY17

8 9 10 11 12 13 14

RY18 RY19 RY20 RY21 RY22 RY23 GND

W303-0251E

Signal name Wire color (No.) Output power sourse RL (95) [CN10(7-10)] Output power sourse [CN11(17),CN10(4-6)] Output power sourse Gr (79) [CN10(10-13),CN9(3)] Spare output 27 Spare output 26 Spare output 25 2-wheel/4-wheel YL (50) drive shift Spare output 24 Spare output 23 Spare output 22 Exhaust brake Y (52) Headlamp A BrR (36) Air heater LO (54) GND B (0)

Connection diagram for connectors CN11 No. Signal 1 RPOW3 2

RPOW4

3

RPOW1

4

RPOW2

5 6 7 8 9 10 11 12 13 14 15 16 17 18

RY1 RY2 RY3 RY4 RY5 RY6 RY7 RY8 RY9 RY10 RY11 RY12 RY13 GND

Wire color (No.) Signal name Output power sourse GO (91) [CN11(9-12)] Output power sourse [CN11(13-16)] Output power sourse GR (90) [CN11(5-6)] Output power sourse P (87) [CN11(7-8)] FL PB (45) FR WY (44) RL WR (42) RR W (41) Ext. WB (43) Ret. Y (62) Jack/slider selector WL (46) Spare output 33 Spare output 32 Spare output 31 Spare output 30 Spare output 29 Spare output 28 GND B (0)

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Input/output signal lists Input/output signal lists

Signal Signal name Di11(+) RL

Di signal Di(+) or Di(-) means a digital input signal in the following conditions.

Di12(+) RR

Di(+) MDT

24V Switch contact

Di(+) Voltmeter

Switch Di contact signal

Measured voltage

Di13(+) Ext.

Open

0

L (0 V)

Di14(+) Ret.

Closed

1

H (24V)

Di15(+) Jack Di16(+) Slider

Di(-)

MDT Switch contact

Di(-) Voltmeter

Switch Di contact signal

Measured voltage

Open

0

H (Approx.12V)

Closed

1

L (0 V)

Di17(+) Spare input(+) Di18(+) Lock (spring lock) Di19(+) Free (spring lock)

Di20(+) 2-wheel steering Di21(+) 4-wheel steering Di22(+) Crab steering

IW303-0251E52

1.

Upper I/O signal lists

Upper unit input Signal Signal name Di1(+) Emergency transmission

Di2(+)

1st

Di3(+)

2nd

Di4(+)

3rd

Di5(+)

D

Di6(+)

N

Di7(+)

R

Di8(+)

ALL

Di9(+)

FL

Di10(+) FR

Signal detail 0[L(0V)]: Emergency transmission OFF 1[H(24V)]: Emergency transmission ON 0[L(0V)]: Gearshift lever “1st” OFF 1[H(24V)]: Gearshift lever “1st” ON 0[L(0V)]:Gearshift lever “2nd” OFF 1[H(24V)]:Gearshift lever “2nd” ON 0[L(0V)]: Gearshift lever “3rd” OFF 1[H(24V)]:Gearshift lever “3rd” ON 0[L(0V)]: Gearshift lever “D” OFF 1[H(24V)]: Gearshift lever “D” ON 0[L(0V)]: Gearshift lever “N” OFF 1[H(24V)]: Gearshift lever “N” ON 0[L(0V)]: Gearshift lever “R” OFF 1[H(24V)]: Gearshift lever “R” ON 0[L(0V)]: All O/R control OFF 1[H(24V)]: All O/R control ON 0[L(0V)]: Front left O/R control OFF 1[H(24V)]: Front left O/R control ON 0[L(0V)]: Front right O/R control OFF 1[H(24V)]: Front right O/R control ON

Di23(+) Spare input(+) Di24(+) Spare input(+) Di25(+) High/low shift

Signal detail 0[L(0V)]: Rear left O/R control OFF 1[H(24V)]: Rear left O/R control ON 0[L(0V)]: Rear right O/R control OFF 1[H(24V)]: Rear right O/R control ON 0[L(0V)]: O/R extension OFF 1[H(24V)]: O/R extension ON 0[L(0V)]: O/R retraction OFF 1[H(24V)]: O/R retraction ON 0[L(0V)]: O/R jack OFF 1[H(24V)]: O/R jack ON 0[L(0V)]: O/R slider OFF 1[H(24V)]: O/R slider ON 0[L(0V)]: Spring lock OFF 1[H(24V)]: Spring lock ON 0[L(0V)]: Spring lock release OFF 1[H(24V)]: Spring lock release ON 0[L(0V)]: 2-wheel steering OFF 1[H(24V)]: 2-wheel steering ON 0[L(0V)]: 4-wheel steering OFF 1[H(24V)]: 4-wheel steering ON 0[L(0V)]: Crab steering OFF 1[H(24V)]: Crab steering ON

0[L(0V)]: Hi 1[H(24V)]: Low Di26(+) 2-wheel/4-wheel 0[L(0V)]: 2-wheel drive drive shift 1[H(24V)]: 4-wheel drive Di27(+) Spare input(+) Di28(+) Spare input(+) Di29(+) Spare input(+) Di30(+) Headlamp A 0[L(0V)]: Headlamp OFF 1[H(24V)]: High beam ON Di31(+) Headlamp B 0[L(0V)]: Headlamp OFF 1[H(24V)]: Low beam ON Di32(+) Clearance lamp 0[L(0V)]: Clearance lamp OFF 1[H(24V)]: Clearance lamp ON Di33(+) Exhaust brake 0[L(0V)]: Exhaust brake switch OFF 1[H(24V)]: Exhaust brake switch ON Di34(+) Air heater 0[L(0V)]: Air heater operation OFF 1[H(24V)]: Air heater operation ON Di35(+) Working lamp 0[L(0V)]: Not lit 1[H(24V)]: Lit

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Input/output signal lists Signal Signal name Di36(+) PTO Di37(+) Parking brake Di38(+) Spare input(+) Di39(+) Spare input(+) Di40(+) Spare input(+) Di41(+) Spare input(+) Di42(+) Spare input(+) Di43(+) Spare input(+) Di44(+) Spare input(+) Di45(+) Spare input(+) Di46(+) Spare input(+) Di47(+) Spare input(+) Di48(+) Spare input(+) Di49(-) Over-front detection Di50(-) Spare input(-) Di51(-) Hydraulic oil temp. 50°C Di52(-) Di53(-) Di54(-) Di55(-) Di56(-) Di57(-) Di58(-) Di59(-)

Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-) Hydraulic oil temp. 85°C

Di60(-) Di61(-) Di62(-) Di63(-) Di64(-)

Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-)

Signal detail 0[L(0V)]: PTO OFF 1[H(24V)]: PTO ON 0[L(0V)]: Applied 1[H(24V)]: Released

Serial signal input from AML Signal Do1 Do2 Do3 Do4 Do5 Do6

Signal detail 0: AML functioning 1: AML cancelled 0: Jib lock pin removed 1: Jib lock pin inserted

Response to 0: No O/R retraction detected outrigger retraction 1: O/R retraction detected operation detection

Do7 Do8

Spare Spare

Upper unit output 0[H(approx. 12V)]: Not detecting 1[L(0V)]: Detecting

Signal Tr1

0[H(approx. 12V)]: Temp. 50°C not detected 1[L(0V)]: Temp. 50°C detected

Tr2 Tr3 Tr4 Tr5 Tr6 Tr7 Tr8 Tr9

0[H(approx. 12V)]: Temp. 85°C not detected 1[L(0V)]: Temp. 85°C detected

Tr10 Tr11 Tr12 Tr13 Tr14 Tr15

Upper unit input Signal Ai1 Ai2 Ai3 Ai4 Ai5 Ai6 Ai7 Ai8 Pi1 Pi2 Pi3 Pi4

Signal name AML cancellation Jib lock indicator 1 Spare Spare Spare

Signal name Air pressure input Spare analog input Spare analog input Spare analog input Spare analog input Spare analog input Spare analog input Spare analog input Tachometer sensor input Main speed input Unusable Unusable

Signal detail

Tr16 Tr17 Tr18 Tr19 Tr20 Tr21 Tr22 Tr23 Tr24 Ao1 Po4 Po5

85

Signal name Alarm buzzer

Signal detail 0[H(24V)]: No sound 1[L(0V)]: Sound output High beam lamp 0[H(24V)]: Indicator not lit 1[L(0V)]: Indicator lit Glow lamp 0[H(24V)]: Indicator not lit 1[L(0V)]: Indicator lit Spare output Spare output Spare output Spare output Spare output 2-wheel steering 0[H(24V)]: Indicator not lit 1[L(0V)]: Indicator lit 4-wheel steering 0[H(24V)]: Indicator not lit 1[L(0V)]: Indicator lit Crub steering 0[H(24V)]: Indicator not lit 1[L(0V)]: Indicator lit Spare output Spare output Spare output Spring lock state 0[H(24V)]: Not energizing relay detection 1[L(0V)]: Energizing relay Engine revolution 0[H(24V)]: Not energizing relay detection 1[L(0V)]: Energizing relay Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output Unusable (fuel gauge output) Air pressure gauge T/C pressure gauge

W303-0251E

Input/output signal lists Serial signal output to AML

Serial signal output to combination meter

Signal Signal name Signal detail ANIN1 Spare ANIN2 FL ANIN3 FR ANIN4 RL ANIN5 RR Outrigger retraction 0: No O/R retraction operation Di1 operation detection 1: O/R retraction operation performed Di2 Spare Di3 Spare Di4 Spare Di5 Spare Di6 Spare Di7 Spare Di8 Spare

Signal Do1 Do2 Do3 Do4 Do5 Do6 Do7 Do8 Do9 Do10 Do11 Do12 Do13 Do14 Do15 Do16 Do17 Do18 Do19 Do20 Do21 Do22 Do23 Do24 Do25 Do26 Do27 Do28 Do29 Do30 Do31 Do32 Do33 Do34 Do35 Do36 Do37 Do38 Do39 Do40

86

Signal name Spare SUS LOCK LOW 4WD Spare Rear center Spare Exhaust brake Parking brake Lock up PTO/travel Spare WORK LAMP PTO Jib lock Hydraulic oil temp. 50°C Spare Spare Shift 1st Shift 2nd Shift 3rd Shift N Shift D Shift R Spare Air low-pressure warning Engine oil low-pressure warning T/C low-pressure warning Hydraulic oil temp. 85°C CHG Speed warning Engine overrun warning Low fuel level warning MDT failure Outrigger switch neutral position Spare Spare AML alarm Spare Spare

W303-0251E

Signal detail

0: not lit 1: lit

Input/output signal lists 2.

Lower I/O signal lists

Lower unit input

Lower unit input Signal Di1(-)

Signal name Brake fluid level detection

Di2(-)

Engine oil low-pressure

Di3(-)

Air low-pressure (parking brake)

Di4(-) Di5(-) Di6(-)

Spare input(-) Spare input(-) Straight ahead detection

Di7(-)

Di8(-)

Di9(-)

Signal Signal name Ai1 FL Ai2 FR Ai3 RL Ai4 RR Ai5 T/C pressure input Ai6 Spare analog input Ai7 Spare analog input Ai8 Spare analog intput Ai9 Spare analog input Ai10 Spare analog input Ai11 Unusable (fuel sender input) Ai12 (CHG) Charging lamp Pi3 Sub-speed input

Signal detail 0[H(approx. 12V)]: Sufficient fluid 1[L(0V)]: Insufficient fluid 0[H(approx. 12V)]: Normal pressure 1[L(0V)]: Low pressure 0[H(approx. 12V)]: Parking brake released 1[L(0V)]: Parking brake applied

0[H(approx. 12V)]: Straight wheels not detected 1[L(0V)]: Straight wheels detected Fuel level 0(approx. 12V): detection Warning detection OFF 1[L(0V)]: Warning detection ON 4WD detection 0[H(approx. 12V)]: 4WD not detected 1[L(0V)]: 4WD detected Air low-pressure 0[H(approx. 12V)]: Normal pressure 1[L(0V)]: Low pressure Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-) Spare input(-)

Di10(-) Di11(-) Di12(-) Di13(-) Di14(-) Di15(-) Di16(-) Di17(-) Di18(-) Di19(-) Di20(-) Di21(-) Di22(-) Di23(-) Di24(-) Spare input(-) Di25(+) Engine start

Signal detail

Lower unit output Signal RY1

Signal name FL

RY2

FR

RY3

RL

RY4

RR

RY5

Ext.

RY6

Ret.

RY7

Jack/slider selector Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output

RY8 RY9 RY10 RY11 RY12 RY13 RY14 RY15 RY16 RY17 RY18 RY19 RY20 RY21

0[L(0V)]: Engine start OFF 1[H(24V)]: Engine start ON

Di26(+) Spare input(+) Di27(+) Spare input(+) Di28(+) Spare input(+) Di29(+) Spare input(+) Di30(+) Spare input(+) Di31(+) Spare input(+) Di32(+) Spare input(+)

87

Signal detail 0[L(0V)]: O/R FL output OFF 1[H(24V)]: O/R FL output ON 0[L(0V)]: O/R FR output OFF 1[H(24V)]: O/R FR output ON 0[L(0V)]: O/R RL output OFF 1[H(24V)]: O/R RL output ON 0[L(0V)]: O/R RR output OFF 1[H(24V)]: O/R RR output ON 0[L(0V)]: O/R Ext. output OFF 1[H(24V)]: O/R Ext. output ON 0[L(0V)]: O/R Ret. output OFF 1[H(24V)]: O/R Ret. output ON 0[L(0V)]: O/R slider 1[H(24V)]: O/R jack

Spare output 2-wheel/4-wheel 0[L(0V)]: 2-wheel drive shift 1[H(24V)]: 4-wheel Spare output Spare output Spare output Exhaust brake

RY22

Headlamp A

RY23

Air heater

W303-0251E

0[L(0V)]: Exhaust brake not activated 1[H(24V)]: Exhaust brake activated 0[L(0V)]: High beam OFF 1[H(24V)]: High beam ON 0[L(0V)]: Air heater relay not energized 1[H(24V)]: Air heater relay energized

Input/output signal lists Signal RY24 RY25 RY26 RY27 RY28 RY29 RY30 RY31 RY32 RY33 RY34 RY35 RY36 RY37 RY38 RY39 RY40 RY41 RY42

Lock up

RY43

F1

RY44

F2

RY45

F3

RY46

Hi

RY47

Lo

RY48

R

RY49

Headlamp B

RY50

Spring lock check release Spare output Spring lock

RY51 RY52

Signal name Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output Spare output

Signal detail

Signal RY53

Signal name 4-wheel steering

RY54

Crab steering

RY55 RY56 Tr1

Spare output Spare output PTO limiter

Signal detail 0[L(0V)]: 4-wheel steering output OFF 1[H(24V)]: 4-wheel steering output ON 0[L(0V)]: Crab steering output OFF 1[H(24V)]: Crab steering output ON

0[H(24V)]: Closed PTO circuit 1[L(0V)]: Open PTO circuit Tr2 Clearance 0[H(24V)]: Not lit lamp 1[L(0V)]: Lit Tr3 Steering power 0[H(24V)]: supply Steering power supply OFF 1[L(0V)]: Steering power supply ON Tr4 Spare output MSOL1 Power supply 0: Power to RY41,42 OFF of RY41,42 1: Power to RY41,42 ON MSOL2 Power supply 0: Power to RY43-48 OFF of RY43-48 1: Power to RY43-48 ON

0[L(0V)]: Lock up OFF 1[H(24V)]: Lock up ON 0[L(0V)]: Transmission sol. F1 OFF 1[H(24V)]: Transmission sol. F1 ON 0[L(0V)]: Transmission sol. F2 OFF 1[H(24V)]: Transmission sol. F2 ON 0[L(0V)]: Transmission sol. F3 OFF 1[H(24V)]: Transmission sol. F3 ON 0[L(0V)]: Transmission sol. Hi OFF 1[H(24V)]: Transmission sol. Hi ON 0[L(0V)]: Transmission sol. Lo OFF 1[H(24V)]: Transmission sol. Lo ON 0[L(0V)]: Transmission sol. R OFF 1[H(24V)]: Transmission sol. R ON 0[L(0V)]: Low beam OFF 1(24V): Low beam ON 0[L(0V)]: Spring lock released 1[H(24V)]: Spring lock activated

Lower unit output Signal Signal name Ao1 Spare analog output Ao2 Spare analog output Ao3 Spare analog output

0[L(0V)]: Spring lock output OFF 1[H(24V)]: Spring lock output ON

88

W303-0251E

Signal detail

Data table Data table 1.

One-to-one input/output system

1. Signal transmitted to combination meter that keeps one-to-one correspondence with upper unit input signal 1. Di33 (exhaust brake) → Do8 (exhaust brake) 2. Di35 (working lamp) → Do13 (WORK LAMP) 3. Di36 (PTO) → Do14 (PTO) 2. Signal transmitted to combination meter that keeps one-to-one correspondence with lower unit input signal 1. Di2 (engine oil low-pressure) → Do27 (engine oil low-pressure) 2. Di8 (4WD detection) → Do4 (4WD) 3. Di9 (air low-pressure)→ Do26 (air low-pressure) 3. Signal transmitted to combination meter that keeps one-to-one correspondence with serial signal received from AML 1. Do1 (AML cancellation) → Do38 (AML alarm) 4. Signal output form lower unit that keeps one-to-one correspondence with upper unit input signal 1. Di32 (clearance lamp) → Tr2 (clearance lamp)

89

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Data table 2.

Parking lamp

1. The parking lamp lights up when the parking brake switch is ON or the parking brake is applied.

2. The parking lamp goes out when the parking brake is released while the parking brake switch is OFF. However, the parking lamp does not go out when the parking brake is released with the brake fluid amount insufficient.

Remarks

Upper unit input status Di37 (parking brake)

Di3 [air low-pressure (parking brake)]

0

1

0

0

1

1

1

0

1：switch contact ･･･closed (H) 0：switch contact ･･･ open (L)

Serial signal output status to combination meter

Lower unit input status Di1 (brake fluid level detection)

Do9 (parking brake)

－

1

1

1

0

0

1：switch contact ･･･ closed (L) 0：switch contact ･･･ open (H)

90

1：level “H” 0：level “L”

W303-0251E

Data table 3.

Parking Alarm

1. The alarm buzzer sounds when the gearshift lever is moved out of the “N” position while the parking brake is applied. (the parking brake input signal is “0” and the air low-pressure (parking brake) input is “1”.)

2. The alarm buzzer sounds if the parking brake does not function when the parking brake switch is turned ON or if the parking brake is not released when the parking brake switch is turned OFF. 3. The alarm buzzer sounds when the parking brake is released while the air pressure is low.

Upper unit input status Gearshift position (N) 1 0

Di37 (parking brake)

Upper unit output status

Di3 Di9 [air low-pressure (air low-pressure) (parking brake)]

Tr1 (alarm buzzer)

0

1

0

0

－

1

1

－

1

0

1：switch contact-closed (H) 0：switch contact-open (L) Remarks

Lower unit input status

－

0 1

－

＊1

1

1

0 1：switch contact･･･closed (L) 0：switch contact･･･open (H)

0 1：Transistor ON 0：Transistor OFF

Note 1：The output status of ＊1 becomes “1”, 2 seconds after the conditions of input status agree.

Note 2：When only one of the gearshift inputs (R, N, D, 3rd, 2nd and 1st) is “1”, the gearshift status is renewed. Otherwise the previous gearshift status remains.

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Data table 4.

CHG lamp

1. The CHG lamp lights up when the power supply voltage on the upper unit is below 23.5V or the alternator is not generating electricity.

Upper unit input status

Lower unit input status

Serial signal output status to combination meter

MPOW (power supply)

CHG (charging lamp)

Do30 (CHG)

V2≧16

0

V1≧23.5

V2＜16 V2≧16

V1＜23.5

1

Remarks

V2＜16

V1：voltage of MPOW〔V〕 V2：voltage of CHG〔V〕

5.

Head lamp

1：level “H” 0：level “L”

1. Signal corresponding to high/low beam is output to the head lamp relay depending on the lighting switch.

2. The high beam lamp lights up while the lighting switch is shifted to the high beam side.

Upper unit input status Di30 (headlamp A) 0

Remarks

1

Di31 (headlamp B) 0 1 0

Upper unit output status

Lower unit output status Remarks

Tr2 (high beam lamp)

RY22 (headlamp A)

RY49 (headlamp B)

0

0

0

No light

1

1

0

High beam

1 0 0 1 Low beam 1：switch contact –closed (H) 1：transistor ON 1：relay contact ON 0：switch contact – open (L) 0：transistor OFF 0：relay contact OFF Note 1：Upper unit output Tr2 is turned ON for 0.5 seconds when the power supply is turned on or the system check switch is pressed.

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Data table 6.

Rear center lamp

1. The rear center lamp does not light while the rear steering is straight and is lit while the rear steering

Remarks

is not straight.

Lower unit input status

Serial signal output status to combination meter

Di6 (straight ahead detection)

Do6 (rear center)

0

1

1

0

1：switch contact ･･･ closed (L) 0：switch contact ･･･ open (H)

1：level “H” 0：level “L”

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Data table 7.

Outriggers

1. Outrigger operation is made unavailable while the spring lock is not completed or the gearshift lever is out of the N position.

2. When ALL or individual operation is performed while Ext./Ret. and Jack/Slider are selected, the signal corresponding to the selected operation is output.

Remarks

Upper unit output Upper unit intput status Lower unit output status status Di6 Di13 Di14 Di15 Di16 Di8 Di9 Di10 Di11 Di12 RY5 RY6 RY7 RY1 RY2 RY3 RY4 Tr15 (FL) (FR) (RL) (RR) (spring (N) (Ext.) (Ret.) (Jack) (Slider) (ALL) (FL) (FR) (RL) (RR) (Ext.) (Ret.) (Jack/ Slider lock state selector) detection) ― 1 ― ― ― ― ― 0 ― ― ― ― ― 0 0 0 0 0 0 0 0 0 0 0 ― ― 1 1 ― ― 1 1 1 0 0 0 0 0 0 0 1 0 0 ― ― ― ― ― 0 0 0 0 1 0 1 0 0 0 0 0 0 1 1 0 1 1 0 1 0 0 1 0 1 1 1 1 1 ― ― ― ― 1 0 1 0 1 0 1 0 1 0 0 1 1 0 1 1 0 0 0 0 1 0 ＊a 0 0 0 0 0 0 0 0 0 1 0 1 0 0 0 1 0 0 1 1 0 1 1 0 1 0 1：transistor 0 1 0 ON ＊1 ＊1 0 0：transistor 1 0 1 0 1 0 1 OFF 0 0 1 1：switch contact ･･･ closed (H) 1：relay contact ON 0：switch contact ･･･ open (L) 0：relay contact OFF ＊1: Di9 and RY1; Di10 and RY2; Di11 and RY3; and Di12 and RY4 keep one-to-one correspondence respectively. However, the correspondence enclosed in ＊a is applied if Di9, Di10, Di11, and Di12 are “0”.

94

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Data table 8.

Outrigger switch neutral position detection

1. The outrigger switch out-of-neutral warning lamp is lit when the Ext./Ret. or Jack/Slider selector switch is out of the neutral positions.

2. Alarm buzzer sounds intermittently if no outrigger operation is performed for 10 seconds while the Ext./Ret. or Jack/Slider selector switch is out of the neutral positions.

Upper unit input status

Serial signal output status to combination meter

Upper unit output status

Di13 (Ext.)

Di14 (Ret.)

Di15 (Jack)

Di16 (Slider)

Do35 (outrigger switch neutral position)

Tr1 (alarm buzzer)

0

0

0

0

0

0

1

＊1

Remarks

Combination other than the above 1：switch contact ･･･ closed (H) 0：switch contact ･･･ open (L)

1：level “H” 0：level “L”

1：transistor ON 0：transistor OFF 1/0：alternates ON and OFF at 0.6-second intervals. ＊1; Output is “1/0” if upper unit input Di8, Di9, Di10, Di11and Di12 remain “0” for more than 10 seconds continuously. Output is “0” if any of above input is “1”.

95

W303-0251E

Data table 9.

Outrigger retraction operation detection

1. Retraction operation signal is output to AML when outrigger retraction operation is detected while the PTO is engaged.

2. Retracted status is stored in the EEPROM when outrigger retraction operation is detected while the PTO is disengaged.

3. Retraction operation signal is output to AML if retracted status is stored in the EEPROM while the PTO is engaged. If a response comes from AML, output of retraction operation signal stops and status stored in the EEPROM is cleared.

Upper unit input status

Lower unit input status

Di36 (PTO)

MONI6 (outrigger retraction operation detection)

0

1

Serial signal input status from AML Do6 (response to outrigger retraction operation detection)

Remarks

Di1 (outrigger retraction operation detection)

0

―

0

1

―

＊1

0

＊2

1

＊3

―

1

1：level “H” 0：level “L”

1：level “H” 0：level “L”

0 1

1：switch contact･･･ closed (H) 0：switch contact･･･ open (L)

Serial signal output status to AML

1：monitor ON (H) 0：monitor OFF (L)

＊1: Output is “0”. Outrigger retraction operation status in EEPROM becomes “1”. ＊2: Output is “0” if outrigger retraction operation status is “0”; is “1” if outrigger retraction operation status is “1”. ＊3: Output is “0”. If outrigger retraction operation status is “1”, however, it turns into “0”.

96

W303-0251E

Data table 10. Exhaust brake 1. Exhaust brake output is ON when the exhaust brake switch is ON and the gearshift is out of N position.

2. Exhaust brake output is OFF when the gearshift lever is in the D position and vehicle speed is below 1 km/h.

Upper unit input status Di33 (exhaust brake) 0 ―

Remarks

1

Gearshift status (D)

(N)

―

―

0

1

1

―

1 0

0

Lower unit output status Pi2 (main speed) ―

RY21 (exhaust brake)

0

Vs＜1 Vs≧1 ―

1

Vs： 1：relay contact ON vehicle speed 0：relay contact OFF (km/h) Note 1：If main speed sensor failure (error 01) occurs, the speed detected by the main speed sensor is assumed as Vs≧1.

Note 2：If any one of gearshift input (R, N, D, 3rd, 2nd, 1st) is “1”, the gearshift status is renewed. Otherwise the gearshift status does not change.

1：switch contact ･･･ closed (H) 0：switch contact ･･･ open (L)

97

W303-0251E

Data table 11. Hi/Lo and 2-wheel/4-wheel drive mode selector 1. “2-wheel Hi” , “4-wheel Hi” or “4-wheel Lo” status is output depending on the drive mode select switch operation. The indicator is lit while “Lo” mode is selected.

2. The LOW indicator is not lit while the emergency transmission is functioning because only “Hi” mode is effective due to external circuits regardless of the select switch position.

3. Drive mode cannot be sifted while the vehicle speed is over 5km/h. However, it is automatically shifted to “Hi” when the emergency transmission functions.

Serial signal output status to combination meter

Upper unit input status Pi2

Di25

(main speed)

(high/low shift)

0

Di26

Do3 (LOW )

Di1

(2-wheel/ (emergency 4-wheel transmission) drive shift)

0 1

1

1

0 1

0

0

1

0

Remarks

Vs: vehicle speed (km/h)

―

―

2-wheel Hi

1

4-wheel Hi

1 Keeps previous status.

4-wheel Hi

1

4-wheel Lo

Hi

Keeps previous status.

1

1：switch contact ･･･ closed (H) 0：switch contact ･･･ open (L)

Remarks

0

1

0 Vs≧5

RY17 (2-wheel/4-wheel drive shift)

―

0 Vs<5

Lower unit output status

0

1：level “H” 0：level “L”

Keeps previous status.

1：relay contact ON 0：relay contact OFF

Hi

Note 1：If main speed sensor failure (error 01) occurs, the speed detected by the main speed sensor is assumed as Vs≧5.

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Data table 12. Engine revolution detection 1. This function energizes the relay to turn off the power supply to the air conditioner while the engine is not running (the engine speed is 400 -1

min or below); turns on the power supply to the air conditioner when the engine speed exceeds -1

500 min .

Upper unit input status

Upper unit output status

Pi1 (tachometer sensor)

Tr16 (engine revolution detection)

Erev≧500

0

Erev＜400

1 1：transistor ON 0：transistor OFF

-1

Remarks

Erev：engine speed (min ) Tr16 (engine revolution detection) -1

Engine speed (min )

400

500

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W303-0251E

Data table 13. Speed warning and overrun warning 1. If vehicle speed or engine speed which will not occur during normal traveling on a flat ground is detected, alarm buzzer sounds and speed warning indicator or overrun warning indicator will light up.

2. For speed warning, the alarm buzzer sounds intermittently or continuously depending on the vehicle speed. For overrun warning, it sounds intermittently.

Upper unit output status

Serial signal output status to combination meter

Pi2 (main speed)

Tr1 (alarm buzzer)

Do31 (speed warning)

57≦Vs＜60

1/0

Vs≧60

1

52＜Vs≦58

1/0

Vs≦52

0

Remarks

Upper unit input status

Vs：vehicle speed (km/h)

1 0

1：transistor ON 0：transistor OFF 1/0：alternates ON and OFF in 0.6-second cycles.

1：level “H” 0：level “L”

Tr1 (alarm buzzer)

Continuous 58

Vehicle speed (km/h)

52

Intermittent

60

No sound

57

Upper unit output status

Serial signal output status to combination meter

Pi1 (tachometer sensor)

Tr1 (alarm buzzer)

Do32 (engine overrun warning)

Erev≧3030

1/0

1

Erev＜2800

0

0

Remarks

Upper unit input status

Erev：engine -1 speed (min )

1：transistor ON 0：transistor OFF 1/0：alternates ON and OFF at 0.6-second intervals

Tr1 (alarm buzzer)

1：level “H” 0：level “L”

Intermittent -1

Engine speed (min )

No sound 2800

3030

100

W303-0251E

Data table 14. PTO limiter 1. To prevent the PTO clutch from engaging while the engine speed is high, this function deenergizes the PTO circuit by energizing the relay when the engine revolution exceeds the specified limit.

Upper unit input status

Lower unit output status

Pi1 (tachometer sensor)

Tr1 (PTO limiter)

Erev≧2350

1

Erev＜1000

0

Remarks

-1

Erev：engine speed (min )

1：transistor ON 0：transistor OFF

Tr1 (PTO limiter) -1

Engine speed (min )

1000

2350

101

W303-0251E

Data table 15. T/C low pressure warning 1. The torque convertor oil pressure warning indicator is lit if the torque converter oil pressure is below the specified value. Alarm buzzer also sounds if the parking brake is released.

2. The torque converter oil pressure drops for a short while when speed is shifted. Alarm buzzer sounds if the pressure remains low for more than 3 seconds.

Upper unit input status

Lower unit input status

Serial signal output status to combination meter

Upper unit output status

Di37 (parking brake)

Ai5 (T/C pressure)

Do28 (T/C low-pressure warning)

Tr1 (alarm buzzer)

P≦0.98 {10.0}

1 (3 seconds delayed)

P≧1.03 {10.5}

0

P≦0.98 {10.0}

1 (3 seconds delayed)

1 (3 seconds delayed)

P≧1.03 {10.5}

0

0

0

Remarks

1 1：switch contact ･･･ closed (H) 0：switch contact ･･･ open (L)

P：pressure 2 [MPa {kgf/cm }]

0

1：level “H” 0：level “L”

3 seconds

1：transistor ON 0：transistor OFF

3 seconds

Lower unit input Ai 5 (T/C pressure)

P≧1.03 MPa P≦0.98 MPa 1 0

Upper unit output Do 28 or Tr 1 (T/C low-puressure warning)

IW303-0251E01

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Data table 16. Air heater 1. A signal to energize the air heater relay is output and the glow lamp lights up as the air heater is operated.

2. The signal output to the air heater relay turns OFF

Remarks

when the specified period of time elapses.

Upper unit input status

Upper unit output status

Lower unit output status

Di34 (air heater)

Tr3 (glow lamp)

RY23 (air heater)

0

0

0

1

1 (8 sec. maximum)

1 (8 sec. maximum)

1：switch contact ･･･ 1：relay contact ON closed (H) 1：level “H” 0：relay contact OFF 0：switch contact ･･･ 0：level “L” open (L) Note 1:Upper unit output Tr3 is turned ON for 0.5 seconds when the power supply is turned on or the system check switch is pressed.

8 seconds

8 seconds 1：switch contact ･･･ closed (H)

Upper unit input Di34 (air heater)

0：switch contact ･･･ open (L) 1：transistor ON

Upper unit output Tr3 (glow lamp)

0：transistor OFF 1：relay contact ON

Lower unit output RY23 (air heater)

0：relay contact OFF IW303-0251E02

103

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Data table 17. Hydraulic Oil Temperature Indication 1. This function makes the hydraulic oil temperature o

50 C indicator light up when the hydraulic oil o

tempetature 50 C detection switch is turned ON. o

It makes the 50 C indicator go out and makes the o

85 C indicator light up when the hydraulic oil o

temperature 85 C detection switch is turned ON.

Upper unit input status

Serial signal output status to combination meter Do16 Do29 (hydraulico oil temp. (hydraulico oil temp.

50 C) 85 C)

Di59 (hydraulico oil temp.

85 C)

0

0

0

0

1

0

1

0

－

1

0

1

Remarks

Di51 (hydraulico oil temp.

50 C)

1：switch contact ･･･ closed (L) 0：switch contact ･･･ open (H)

1：level “H” 0：level “L”

104

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Data table 18. Low fuel level warning 1. The low fuel level warning indicator lights up when the low fuel level detection switch is turned ON for 1 second or longer. The indicator does not light when the low fuel level detection switch is turned

Remarks

ON temporarily.

Lower unit input status

Serial signal output status to combination meter

Di7 (fuel level detection)

Do33 (low fuel level warning)

0

0

1

1 (1 sec. delayed)

1：switch contact ･･･ closed (L) 0：switch contact ･･･ open (H)

1：level “H” 0：level “L”

1 second

1 second

Lower unit input Di7 (fuel level detection ) Serial signal output status to combination meter Do33 (low fuel level warning)

1：switch contact

･･･ closed (L)

0：switch contact

･･･ open (H)

1：level “H” 0：level “L”

IW303-0251E03

105

W303-0251E

Data table 19. Jib lock lamp 1. The jib lock indicator lights up when the jib set pin is extracted.

Upper unit input status

Serial signal input status from AML

Serial signal output status to combination meter

Di36 (PTO)

Do2 (jib lock indicator 1)

Do15 (jib lock)

0

0

1

1

－

0

1

Remarks

0 1：switch contact ･･･ closed (H) 0：switch contact ･･･ open (L)

1：level “H” 0：level “L”

1：level “H” 0：level “L”

106

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Data table 20. Air pressure detection 1. This function converts the pressure value detected by the air pressure sensor into frequency according to the characteristics shown below and outputs it to the air pressure gauge.

Upper unit output Po4 [Hz] 275

166 119

0

1.23 1.63

5 Upper unit input Ai1 [V]

2.56

IW303-0251E04

Ai1 < 2.56 [V] Po4 [Hz] = 117.5×Ai1 [V] - 25.53 Ai1≧2.56 [V] Po4 [Hz] = 275

107

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Data table 21. Torque converter pressure detection 1. This function converts the pressure value detected by the torque convertor pressure sensor into frequency according to the characteristics shown below and outputs it to the torque convertor pressure gauge.

Upper unit output Po5 [Hz] 200 190

50

0

0.5

4.5

5 Lower unit input Ai5 [V] IW303-0251E05

Po5 [Hz] = 35×Ai5 [V] + 32.5

108

W303-0251E

Data table 22. Steering 1. The steering mode status (2-wheel, 4-wheel or crab) selected by the steering mode select switch is output.

2. If an error occurs in the steering system, 2-wheel steering mode status is output. In this case the indicator on the 2-wheel steering mode select switch lights up. The indicator on 4-wheel or crab steering mode select switch flashes if the corresponding steering mode is selected.

Upper unit input status Di20

Upper unit output status

Di22

Di21

(2-wheel) (4-wheel)

Tr9

(crab)

Tr10

(2-wheel) (4-wheel)

Lower unit output status Tr3

Remarks

(crab)

(steering power supply)

Tr11

RY53

RY54

(crab)

(4-wheel)

1

0

0

1

0

0

0

0

0

2-wheel steering mode

0

1

0

0

1

0

1

0

1

4-wheel steering mode

0

0

1

0

0

1

0

1

1

Crab steering mode

Combination other than the above

Keeps previous status.

＊1

Remarks

1：switch contact ･･･closed (H) 1：transistor ON 0：transistor OFF 0：switch contact ･･･open (L)

＊2

1：relay contact ･･･ON 1：transistor ON 0：relay contact 0：transistor OFF ･･･OFF

＊1: “0” is output if previous output has been “0”. “1/0” is output if previous output has been “1”. ＊2: “0” is output when lower unit outputs RY53 and RY54 are both “0”, otherwise “1” is output.

Note 1：Previous status is assumed to be 2-wheel steering mode in case that all of the upper unit inputs Di20, Di21 and Di22 are “0” or that 2 or more inputs occur at one time when the power supply is turn on or the system check switch is pressed.

Note 2：If any of the errors F4, F5, FC, Fd, F6, or F7 is detected, the upper unit outputs (Tr9, Tr10, Tr11) become as listed in＊3 and the lower unit outputs (RY53, RY54, Tr3) become “0”.

To reset error, press the system check switch or turn on the power supply.

＊3 Upper unit input status

Upper unit output status

Di20

Di21

Di22

Tr9

Tr10

Tr11

(2-wheel)

(4-wheel)

(crab)

(2-wheel)

(4-wheel)

(crab)

1

0

0

0

0

0

1

0

1/0

0

0

0

1

0

1/0

0

0

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W303-0251E

Combination other than the above

1 1/0

Data table 23. Spring lock

3. While the vehicle speed is over 1 km/h, neither spring lock operation or spring lock release

1. When spring lock operation is performed, the

operation is available.

indicator starts flashing 1 second after lock side of the spring lock switch is turned ON. The lock

4. The spring lock status is assumed free when the

status is output 1 second after that. However, the

indicator does not light; being locked when the

lock status is not output while the engine speed is

indicator is flashing; locked when the indicator is

-1

below 500 min .

lit. When the spring lock status changes, the new

After the lock status is output for 5 seconds,

status is stored in the EEPROM and is recalled

spring lock is assumed to be completed and the

when the power is turned ON.

indicator turns from flashing into being lit.

5. Unless the spring lock is completed, this function

2. When spring lock release operation is performed,

energizes the relay by the output Tr 15 and vents

the free status is output and the lighting indicator

the remote control pressure, making the crane

goes out 1 second after the free side of the spring

operation unavailable. It also makes outrigger

lock switch is turned ON while the over-front

operation unavailable unless the spring lock is

detection switch is ON and the PTO is

completed. (See “Outriggers”.)

disengaged.

Table 1 (PTO)

Serial signal output status to combination meter Do2 (SUS LOCK)

0

0

1

1/0 ＊5

Being locked

－

1/0 ＊6

1

1

Lock

－

1

0

1

Spring lock status

Di36

Free

Upper Tr15 (spring lock state detection)

Lower RY50 (spring lock check release)

1

0

＊5：0.4-second cycle ＊6：0.8-second cycle

Time Chart 1 ・Flashing light turns into being lit after the specified time T (sec.) elapses. ・T：5 seconds, T1：continuous 2 seconds, T2：continuous 1 second. ・T = Ta + Tb = Tc + Td Upper unit input Di18 [lock (spring lock)] Lower unit output RY50 (spring lock check release) Lower unit output RY52 (spring lock) Serial signal output status to combination meter Do2 (SUS LOCK)

switch contact -closed (H) T1

T1

Ta

T

T2

switch contact -open (L)

T1 T1 Tb

T1

Tc

Td

relay contact ON relay contact OFF relay contact ON

T2

T2 Flashing

relay contact OFF level “H” level “L” Erev≧500min-1 Erev＜400min-1

Upper unit input Pi1 (tachometer sensor) (Judged by status of upper unit output Tr 16) Upper unit output Tr15 (spring lock state detection)

transistor ON transistor OFF IW303-0251E07

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W303-0251E

Data table Serial signal output status Upper unit output to combination status meter

Upper unit input status Pi2 (Main speed)

Vs＜1

Vs≧1

Di49 (over-front detection)

Di36 (PTO)

1

0

Pi1 Tr52 Di19 RY50 Di18 Do2 Tr15 (spring [free (tachometer (SUS LOCK) (spring lock (spring [lock lock check lock) (spring (spring sensor) state lock)] lock)] detection) release) 0 ＊3 0 ＊4 1 0 －

1

0

－

1

0

－

0

－

－

－

－

－

－

－

－

Vs: 1：switch vehicle contact speed ･･･closed (L) (km/h) 0：switch contact ･･･open (H)

Lower unit output status

－ 1 0

1：switch contact ･･･closed (H) 0：switch contact ･･･open (L)

＊1

Keeps previous status. ＊2

0

See Time Chart 1.

Engine Speed -1 (min )

＊1

Keeps previous status. ＊2

0

1：level “H” 1：transistor 1：relay contact ON 0：level “L” ON 0：transistor 0：relay contact OFF OFF

＊1: When the combination of spring lock status stored in EEPROM and RY50 monitor data agrees the cases listed in the Table 1, output signal is as shown in the Table 1, according to the Di36 input status . If the combination does not agree, the signal correspondent to the status being lock is output.

Remarks

＊2: “Previous status” means the lock status and the signal as shown in the Table 1 is output if the spring lock status stored in the EEPROM (See Table 1.) is same as the RY50 monitor data when the power supply is turned ON or the system check switch is pressed. If the status in the EEPROM differs from the RY50 monitor data, the signal crrespondent to the status being locked is output. ＊3: It is assumed to be “1” if there is input continuing for 1 second or longer.

Note 1：The case that the main speed sensor detects Vs≧1 is assumed if a failure of the main speed sensor (error 01) or the communication failure between upper and lower units (error 31, 32, 36 or 37) occurs.

Note 2：Lower unit outputs RY50 and RY52 are always monitored as follows； ・The measurement of “T seconds” is started after it is confirmed that the lower unit outputs RY50 and RY52 are “1”. If a failure ( the output data of RY50 and RY52 differ from the monitored data) occurs during measurement, the measurement stops if a failure (the output data of RY50 or RY52 differs from the monitored data) occurs. (It is reset if the data of RY50 is erroneous; is suspended if the data of RY52 is erroneous.) It restarts when a failure is eliminated. ・If a failure of the lower unit output RY50 (output data differ from monitored data) occurs, combination meter output status (SUS LOCK) becomes “1/0” and upper unit output Tr15 becomes “1”. ・For the case marked with “＊4”, combination meter output status (SUS LOCK) becomes “0” after it is confirmed that the monitored data of lower unit output RY50 is “0”.

Note 3：Spring lock status is stored in EEPROM as the status is changed. (the change from free status to status being locked is detected as the upper unit output data of RY52 becomes “1” after the output status to combination meter becomes “1/0”.)

111

W303-0251E

Data table 24. Transmission

While manual transmission is functioning,

1. “1st”, “2nd”, “3rd” and “R” selected by the gearshift

upshifting is available regardless of the vehicle

operation is for manual transmission. “D” acts as

speed；to prevent engine overrun, downshifting is

automatic gear while “Hi” mode is selected and as

unavailable until the speeds detected by the main

manual 4th gear while “Lo” mode is selected.

speed sensor and the sub-speed sensor drop to the specified values.

2. Forward 6 gears (F1 through F6) and reverse 2 gears (R1 and R2) are provided. While “Hi” mode

4. While “Hi” mode is selected, lockup is

is selected, the available gears are F3, F4, F5, F6

activated/deactivated according to the currently

and R2. While “Lo” mode is selected, the available

selected gear and the main speed sensor. Lockup

gears are F1, F2, F3, F4 and R1.

is deactivated for 2 seconds to prevent shocks when upshift/downshift is performed.

3. While automatic transmission is functioning, the gear upshifts when the speed detected by the

5. While emergency transmission is functioning, “N”

main speed sensor reaches the specified speed

status is output and manual transmission is

and downshifts when the speeds detected by the

perfromed via external circuits. However, the

main speed sensor and the sub-speed sensor

gearshift indicator conform to the input from the

drop to the specified values. (See the shift timing.)

input from the gershift lever.

Upper unit input status

Upper unit

Hi/Lo －

Lo

Remarks

Hi

Di1 (emergency transmission) 1

Lower unit output status, applicable shift timing

Gearshift status (1st)

(2nd) (3rd)

(D)

(N)

(R)

－ － － － － － Neutral(N), M SOL1, M SOL2: OFF 0 0 0 0 1 0 Neutral(N), M SOL1, M SOL2: ON 1 0 0 0 0 0 Lo, manual 1st gear (F1) 0 1 0 0 0 0 Lo, manual 2nd gear (F2) 0 0 1 0 0 0 Lo, manual 3rd gear (F3) 0 0 0 1 0 0 Lo, manual 4th gear (F4) 0 0 0 0 0 0 1 Lo, reverse (R1) 1 0 0 0 0 0 Hi, manual 1st gear (F3) 0 1 0 0 0 0 Hi, manual 2nd gear (F4) 0 0 1 0 0 0 Hi, manual 3rd gear (F5) 0 0 0 0 0 1 Hi, reverse (R2) 0 0 0 1 0 0 Hi automatic transmission (F3,F4,F5,F6) 1：switch contact ･･･ closed (H) 0：switch contact ･･･ open (L) Note 1：“Hi/Lo” mode of the upper unit depends on the operation of Hi/Lo and 2-wheel/4-wheel drive mode selector.

Note 2：When only one of the gearshift inputs (R, N, D, 3rd, 2nd and 1st) is “1”, the gearshift status is renewed. Otherwise the previous gearshift status remains.

Note 3：While the speed detected by the main speed sensor is 30km/h or faster, the gearshift status “N” turns into “D”. If the gearshift status is “D”, it cannot turn into “N”.

112

W303-0251E

Data table Shift timing in automatic transmission ("Hi" mode) MSD3 LD4 MSD2 LD3

Hi 4th (F6)

MSD1 LD2 SD3

LD1 SD2

SU2

SU3

Hi 3rd (F5)

LU4

Hi 2nd (F4)

LU3

Hi 1st (F3)

SU1 LU2

0km/h SD1

LU1

Shift timing in manual transmission ("Lo" mode) MSD3

Lo 4th (F4)

MSD2

Lo 3rd (F3)

MSD1

Lo 2nd (F2) Lo 1st (F1)

0km/h

IW303-0251E08

Shift point (km/h) SD 1

MSD 1

SU 1

SD 2

MSD 2

SU 2

SD 3

MSD 3

SU 3

Hi

8

12.5

13.5

17

20.5

21.5

26

31

32

Lo

－

5

－

－

7.5

－

－

12

－

Remarks

Note 1：Upshifting (SU1-3) is available depending on the speed detected by the main speed sensor.

Note 2：Automatic downshifting (SD1-3) and manual downshifting (MSD1-3) is available depending on the speeds detected by the main and sub-speed sensors.

113

W303-0251E

Data table Output of transmission relay Gearshift status

Lower unit output status RY 43 (F1)

RY 44 (F2)

RY 45 (F3)

RY 46 (Hi)

RY 47 (Lo)

RY 48 (R)

N

0

0

0

0

0

0

F1

1

0

0

0

1

0

F2

0

1

0

0

1

0

F3

0

0

1

0

1

0

F4

1

0

0

1

0

0

F5

0

1

0

1

0

0

F6

0

0

1

1

0

0

R1

0

0

0

0

1

1

R2

0

0

0

1

0

1

1：relay contact ON 0：relay contact OFF

Remarks

Gearshift output status and combination meter display Upper unit input status Di1 )

Di2 Di3 Di4 (1st) (2nd) (3rd)

Di5 (D)

Di6 (N)

Di7 (R)

Emergency transmission

0

1

－

－

－

－

－

－

1st

2nd

3rd

N

D

R

N

0

0

0

1

0

0

Manual 1st

1

0

0

0

0

0

Manual 2nd

0

1

0

0

0

0

Manual 3rd Automatic 1st Automatic 2nd Automatic 3rd 4th

0

0

1

0

0

0

1

0

0

0

1

0

0

1

0

0

1

0

0

0

1

0

1

0

0

0

0

0

1

0

Reverse

0

0

0

0

0

1

0

0

0

1

0

0

0

1

0

0

0

0

0

0

1

0

0

0

0

0

0

0

1

0

1

0

0

0

0

0

0

1

0

0

0

0

0

0

1

0

0

0

0

0

0

1

0

0

0

0

0

0

1

0

0

0

0

0

0

1

0

0

0

0

0

1

－

Keeps previous status.

Combination other than the above Remarks

(

Serial signal output status to combination meter

Gearshift output status

1：switch contact ･･･ closed (H) 0：switch contact ･･･ open (L)

1：level “H” 0：level “L”

114

W303-0251E

Data table Lock up control (km/h) 2nd 3rd 4th gear gear gear

Serial signal output status Lower unit to combination meter output status Do10 RY42 (lock up) (lock up)

LU 2 LU 3 LU 4 Hi

15.5

36.5

LD 2 LU 3 LU 4 12

Remarks

25

20.5 29.5

1

1

0

0

(ON)

(OFF)

Note 1：Activating/deactivating lockup depends on the speed detected by the main speed sensor.

Lock up time lag For upshifting (2nd → 3rd → 4th) and downshifting (4th → 3rd → 2nd), time lag is set as shown below.

Shift point 2nd, 3rd or 4th gear

T

Lower unit output RY 42 (Lock up)

relay contact ON relay contact OFF T = 2 seconds IW303-0251E09

115

W303-0251E

Data table 25. PTO/travel speed warning lamp 1. The PTO/travel speed warning lamp flashes when the vehicle speed exceeds 4km/h while the PTO is engaged.

Serial signal output status to combination meter

Upper unit input status Di36 (PTO)

Pi2 (main speed)

Do11 (PTO/travel)

0

－

0

Vs＜4

0

Vs≧4

1/0

Remarks

1

1：switch contact ･･･ 0：level “L” closed (H) Vs：vehicle speed (km/h) 1/0：alternates level “H” and level “L” in 0.8-second 0：switch contact ･･･ cycles. open (L) Note 1：If a failure of the main speed sensor (error 01) occurs, the vehicle speed detected by the main speed sensor is assumed 4 km/h or faster.

116

W303-0251E

Head Office

Ko-34,Sinden-cho,

本社 香川県高松市新田町甲 34 番地

Takamatsu,Japan

History of revision 1 2 3 4 5

改訂履歴

TADANO. LTD

ｃ ◯2001

PRINTED IN JAPAN 0111

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