Publication No. W E. Service Manual. Overload Prevention Device AML-LIIA. Model TADANO LTD.

Transcription

1 Publication No. W E Service Manual 01 Overload Prevention Device Model AML-LIIA TADANO LTD.

2 Foreword Foreword This service manual (this document) is compiled to provide information on the AML-LIIA (overload prevention device) that is mounted on the Rough Terrain Crane GR-300N-1, TR-250M-7, GR-250N-1, GR-350N-1, and GR-160N-1, Tower reach Rough Terrain Crane GR-120F-1, and All Terrain Crane GA-700N-1. "Diagram of the AML-LIIA System" (Page 9, 36, 50, and 64) and "Input/Output Signals of the AML-LIIA System" (Page 10 to 35, 37 to 49, 51 to 63, and 65 to 86) in this document offers the general description on the electrical circuit of cranes GR-300N-1, TR-250M-7, GR-250N-1, GR-350N-1, GR-160N-1, GR-120F-1, and GA-700N-1. For the detailed electrical circuit, refer to the service manual (electrical circuit diagrams) of each model. For the actual works, perform appropriate repair and service with referring to the separate operation and maintenance manual, parts catalog, and service manual for each model. When part replacement is needed, refer to the parts catalog first to check the disassembly unit as well as the parts sales unit. 1. Applicable Spec. No. / Crane Model February, 2008 Rough terrain crane GR-250N-1 Spec. No.: (1) GR-250N (2) GR-250N (3) GR-250N (4) GR-250N (5) GR-250N (6) GR-250N (7) GR-250N (8) GR-250N (9) GR-250N (10) GR-250N (11) GR-250N (12) GR-250N (13) GR-250N (14) GR-250N (15) GR-250N (16) GR-250N Rough terrain crane GR-350N-1 Spec. No.: (1) GR-350N (2) GR-350N (3) GR-350N (4) GR-350N Rough terrain crane GR-160N-1 Spec. No.: (1) GR-160N (2) GR-160N Tower reach rough terrain crane GR-120F-1 Spec. No.: (1) GR-120F All terrain crane GA-700N-1 Spec. No.: (1) GA-700N (2) GA-700N Use this manual for machines with the AML-LIIA even if the crane model is other than the above. Crane model applicable of this service manual Rough terrain crane GR-300N-1 Spec. No.: (1) GR-300N (2) GR-300N Rough terrain crane TR-250M-7 Spec. No.: (1) TR-250M (2) TR-250M (3) TR-250M (4) TR-250M Please note that, for product improvement, some changes may have been incorporated in the machine that are not covered in this manual. 1 W E

3 Foreword 2. Contents Foreword Applicable Spec. No. / Crane Model Contents... 2 Components of the AML-LIIA Main Unit Panel Internal View and Name Plate Internal Block Diagram... 8 Diagram of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/ GR-350N-1)... 9 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/ GR-350N-1) Diagram of the AML-LIIA System (GR-160N-1) Input/Output Signals of the AML-LIIA System (GR-160N-1) Diagram of the AML-LIIA System (GR-120F-1) Input/Output Signals of the AML-LIIA System (GR-120F-1) Diagram of the AML-LIIA System (GA-700N-1) Input/Output Signals of the AML-LIIA System (GA-700N-1) [OPERATION] Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/ GR-350N-1) Mode Structure Configuration and Functions of the AML System.. 88 Names and Functions of the Parts Registering Operating Conditions Pre-operational Inspection on the AML...98 How to Use the Working Area Limiting Function...99 How to Use the Boom Elevating Speed Adjusting Function Functions of and How to Use User Mode (GR-160N-1) Mode Structure Configuration and Functions of the AML System 104 Names and Functions of the Parts Registering Operating Conditions Pre-operational Inspection on the AML How to Use the Working Area Limiting Function.115 How to Use the Boom Elevating Speed Adjusting Function Functions of and How to Use User Mode (GR-120F-1) Mode Structure Configuration and Functions of the AML System 120 Names and Functions of the Parts Registering Operating Conditions Pre-operational Inspection on the AML How to Use the Working Area Limiting Function.130 How to Use the Jib Tilt Speed Adjusting Function Functions of and How to Use User Mode (GA-700N-1) Mode Structure Configuration and Functions of the AML System 135 Names and Functions of the Parts Registering Operating Conditions Pre-operational Inspection on the AML How to Use the Working Area Limiting Function.146 How to Use the Boom Elevating Speed Adjusting Function [ADJUSTMENT AND MAINTENANCE] Outline of Adjustment Mode and Maintenance Mode Keys and Switches for Adjustment and Maintenance Mode Structure and Menu Method of Shifting Modes W E

4 Foreword 4. Method of Menu Selection Required Adjustment After AML System Parts Replacement Functions of and How to Use Adjustment Mode Adjustment Procedures Adjustment Initialization Procedure of "Conversion Factors Resetting" Procedure of "Moment Adjustment Resetting" Boom Length Adjustment Boom Angle Adjustment Swing Angle Adjustment Outrigger Extension Width Adjustment Jib Angle Adjustment Jib Length Adjustment Moment Adjustment Moment Zero-point Adjustment Moment Span Preliminary Adjustment Moment Zero-point Check and Fine Adjustment Load Radius Adjustment Moment Span Fine Adjustment Moment Zero-point Recheck Clock Adjustment Swing Output Adjustment Procedure of "AO Offset Value Resetting" Swing output (AO offset ) Boom Elevating Output Adjustment Procedure of "Boom Elevating Characteristic Value Resetting" Boom Elevating Output Adjustment (Boom Elevating Characteristic Adjustment) Telescoping/retraction Output Adjustment Procedure of "Retraction Characteristic Value Resetting" Telescoping/retraction Output Adjustment (Retraction Characteristic Adjustment) Language Overload History Display Erasing the Overload History Functions of and How to Use Maintenance Mode Program Version Display Data ID Number Display Di Check Ai Check Elevating Cylinder Oil Pressure Monitor Do Check MDT (Multiplex Data Transmitter) Monitor Key Switch Check Display Unit Check Error Data Display Erasing the Error Data Option (OP) Board Check Ao Check Sio Check Adjust Monitor Overload History Display Erasing the Overload History Clock Error Message Display of Error Message How to Read the Error Message How to Read the Error History Troubleshooting Table Group Code Group Code Group Code Group Code For GR-120F-1 Only (Group Code 0) Disassembly of AML Main Unit Removing Front Panel/Display Board Removing Rear Panel/Connector Board/ Current Output Board Removing CPU Board/Analog Board / Power Board Notes on ROM/EEPROM Replacement..220 Other Functions and How to Use Them W E

5 Foreword [INFORMATION AND DATA] Adjustment Value Table Specification No.: GR-300N Specification No.: GR-300N Specification No.: TR-250M Specification No.: GR-250N , Specification No.: GR-250N , Setting before Detector Slow stop Setting after Specification No.: TR-250M Specification No.: GR-250N , Specification No.: GR-250N , Setting before Detector Slow stop Setting after Specification No.: TR-250M Specification No.: TR-250M Specification No.: GR-250N , Specification No.: GR-250N , Specification No.: GR-250N , Specification No.: GR-250N , Setting before Detector Slow stop Setting after Specification No.: GR-350N Specification No.: GR-350N Setting before Detector Slow stop Setting after Specification No.: GR-350N Specification No.: GR-350N Setting before Detector Slow stop Setting after Specification No.: GR-160N Specification No.: GR-160N Setting before Detector Slow stop Setting after Specification No.: GR-120F Setting before Detector Slow stop Speed Setting after GR-120F-1 (Pythagoras) speed procedure Specification Number: GA-700N Setting before Detector Slow stop Setting after Specification Number: GA-700N Setting before Detector Slow stop Setting after Checking the Detectors (GR-300N-1) Boom Length Detector Boom Angle Detector Swing Angle Detector Outrigger Extension Width Detector Pressure Sensor for Moment Detection Jib Angle Detector Checking the Detectors (TR-250M-7) Boom Length Detector Boom Angle Detector Swing Angle Detector Outrigger Extension Width Detector Pressure Sensor for Moment Detection Jib Angle Detector Checking the Detectors (GR-250N-1/ GR-350N-1) Boom Length Detector Boom Angle Detector Swing Angle Detector Outrigger Extension Width Detector Pressure Sensor for Moment Detection Jib Angle Detector W E

6 Foreword Checking the Detectors (GR-160N-1) Boom Length Detector Boom Angle Detector Swing Angle Detector Outrigger Extension Width Detector Pressure Sensor for Moment Detection Checking the Detectors (GR-120F-1) Boom Length Detector Boom Angle Detector Swing Angle Detector Outrigger Extension Width Detector Pressure Sensor for Moment Detection Jib Length Detector Jib Angle Detector Checking the Detectors (GA-700N-1) Boom Length Detector Boom Angle Detector Swing Angle Detector Outrigger Extension Width Detector Pressure Sensor for Moment Detection Jib Length Detector Jib Angle Detector Fuse Replacing Clock Battery In the Case of CPU Board Employing BR1225 Battery In the Case of CPU Board Employing CR2032 Battery W E

7 Components of the AML-LIIA Main Unit Components of the AML-LIIA Main Unit 1. Panel RLY3, 4 fuse (3A) RLY1, 2 fuse (3A) Main fuse (3A) RLY5, 6 fuse (3A) RLY7, 8 fuse (3A) SIF1 fuse (2A) SIF2 fuse (2A) Moment input short-circuit switch (Not functioning) Protect switch (Selects to "OFF position at adjusting mode) Top view Abnormality display LED (CPU abnormality) Moment zero adjuster (Adjusted by AML maker. Do not touch.) Boom lift symbol Boom angle symbol Upper boom angle limit symbol Boom length symbol Jib angle display Scroll-up key Scroll-down key Lifting height limit symbol Lifting height symbol Boom length display Lower boom angle limit symbol Boom angle display Counterweight condition symbol Load radius display LCD panel Moment display Jib length symbol Jib angle symbol Jib lift symbol Single top lift symbol Actual load display Rated lifting capacity display Load radius symbol Load radius limit symbol Lifting height limit indicator lamp Upper boom angle limit indicator lamp Lower boom angle limit indicator lamp Lower boom angle limit key Upper boom angle limit key Front position symbol Front jack condition symbol Outrigger condition symbol On-rubber condition symbol Suspension lock condition symbol Rear jack condition symbol Increase key Swing position display Decrease key Inspection key Lift status selector key Front view Load radius limit key Display alteration key Set key Right swing limit key Outrigger condition selector key Left swing limit key Lifting height limit key Load radius limit indicator lamp Right swing limit indicator lamp Left swing limit indicator lamp 6 W E

8 Components of the AML-LIIA Main Unit 2. Internal View and Name Plate Swing stop Elevation slow stop Fuse Swing stop (Swing free) Telescoping/retraction slow stop Swing right Swing left Elevation raising CAL/CLOCK Battery Elevation Lowering Swing free Telescoping/ retraction Connector terminal Nos. Right side view (Name plate) Output adjuster (Adjusted by maker. Do not touch). CPU board Moment display contrast adjuster LCD panel contrast adjuster Current output board (for slow stop) Connector board SOL1, 2, fuse (2A) Swing stop CN1 connector SOL3, 4, fuse (2A) Elevation slow stop CN2 connector SOL5, 6, fuse (2A) Swing stop (Swing free) Telescoping/retraction slow stop CN3 connector CN4 connector (Not used) Power board Analog board CPU board Display board Output adjuster (Adjusted by maker. Do not touch). Right side view 7 W E

9 Components of the AML-LIIA Main Unit 3. Internal Block Diagram CONNECTOR BOARD CURRENT OUTPUT BOARD Fuses Fuses Latch Di SW input block Current amplification circuit CAL/CLOCK Fuses CPU BOARD Relay CAL/CLOCK POWER BOARD BUZZER DC power block DISPLAY BOARD Current loop circuit CHR display Latch KEY input O.C. Tr. output block Latch LCD panel (1) LCD panel (2) Di SW input block LCD SW. backlights ANALOG BOARD Buffer Latch Latch Buffer Analog multiplexer A/D converter Pressure sensor analog detector power supply 8 W E

10 Diagram of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) Diagram of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) Boom angle detector CONNECTOR BOARD Boom length detector Swing angle detector Pressure sensor (Main) Pressure sensor (Accumulator) Stop cancel input (*1): These connectors are not used in TR-250M-7, GR-250N-1, GR-350N-1. (*2): Not mounted on TR-250M-7, GR-250N-1, GR-350N-1 with jib and without power tilting. (*3): Not mounted on TR-250M-7, GR-250N-1, GR-350N-1. Working condition input Jib angle detector Stop cancel input Pressure sensor for moment detection (elevating cylinder) (*4): GR-300N-1: From FC5114 TR-250M-7: From FB4054 GR-250N-1: From FB4054 GR-350N-1: From Jib remote control operation signal input Jib remote control output Automatic stop output (AML vent) Working condition input Transmitter Hook-in control output Automatic stop output (remote control pressure vent) Telescoping control output Alarm output (buzzer) Lever operation detection input Outrigger extension width detector (4 locations) Outrigger retracting operation detection input Combination meter Lower unit Upper unit MDT (Multiplex Data Transmitter) Swing stop Elevating slow stop 2 : GR-300N-1 From FC5113 GR-250N-1 FB4064, FB4073, FB4083, from FB4134 GR-350N , , from AML external indicator (Option) Winch high-speed hoist-down output Jib remote control operation output Swing stop (swing free) Telescoping/retraction slow stop Working condition input Jib operation detection input 9 W E

11 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) As shown in the "Diagram of the AML-LIIA System" on the previous page, the inside of the AML-LIIA is composed of the display board, CPU board, analog board, power board, current output board, and connector board. All the input/output signals go through the connector board. Below are the names of the signals that are input to/output from the CN1, CN2, and CN3 connectors, and the descriptions of their functions. Names and functions of signals input to/output from CN1 connector are shown below: CN 1 connector Pin No. Name 1 DET1GND 2 DET1SRC 3 ANAIN A Signal names and functions Signal name: Ground for boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Input voltage: DC 0 V Signal name: Impressed voltage output to boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Output voltage: DC 4.5 V Signal name: Boom length detector input Analog input to detect the boom length. Input voltage: DC 0 to 4.5 V Reference data With GR-300N-1 Input voltage at boom full retraction (7.7 m): 0.45 V (Ai check A/D conversion value: 203) Input voltage at boom full extension (32 m): V (Ai check A/D conversion value 1337) With TR-250M-7, GR-250N-1 Input voltage at boom full retraction (9.5 m): 0.45 V (Ai check A/D conversion value: 203) Input voltage at boom full extension (30.5 m): 2.65 V (Ai check A/D conversion value: 1205) With GR-350N-1 Input voltage at boom full retraction (9.5 m): 0.45 V (Ai check A/D conversion value: 203) Input voltage at boom full extension (36.3 m): V (Ai check A/D conversion value: 1249) 10 W E

12 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 1 connector Pin No. Name 4 ANAIN B Signal names and functions Signal name: Boom angle detector input Analog input to detect the boom angle. Input voltage: DC 0 to 4.5 V Reference data With GR-300N-1 Input voltage at boom angle of -8 : 0.37 V (Ai check A/D conversion value: 167) Input voltage at boom angle of 83 : 3.79 V (Ai check A/D conversion value: 1724) With TR-250M-7, GR-250N-1 Input voltage at boom angle of 0 : 0.49 V (Ai check A/D conversion value: 220) Input voltage at boom angle of 83 : 3.59 V (Ai check A/D conversion value: 1632) With GR-350N-1 Input voltage at boom angle of 0 : 0.45 V (Ai check A/D conversion value: 203) Input voltage at boom angle of 83.5 : V (Ai check A/D conversion value: 1621) Signal name: Swing angle detector 1 input Analog input from the swing angle detector 1 to detect the swing angle. Input voltage: DC 0 to 4.5 V 5 ANAIN C Reference data With GR-250N-1, GR-350N-1 Input voltage at swing angle of 0 : 1.09 V (Ai check A/D conversion value: 495) Input voltage at swing angle of 180 : 3.41 V (Ai check A/D conversion value: 1552) 6 DET1SLD 7 DET2GND 8 DET2SRC 9 ANAIN D Signal name: Shield of boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Input voltage: DC 0 V Signal name: Ground for main hydraulic pressure sensor and accumulator pressure sensor Input voltage: DC 0 V Signal name: Impressed voltage output to main hydraulic pressure sensor and accumulator pressure sensor Output voltage: DC 4.5 V Signal name: Swing angle detector 2 input Analog input from the swing angle detector 2 to detect the swing angle. Input voltage: DC 0 to 4.5 V Reference data With GR-250N-1, GR-350N-1 Input voltage at swing angle of 0 : 3.41 V (Ai check A/D conversion value: 1552) Input voltage at swing angle of 180 : 1.09 V (Ai check A/D conversion value: 495) 11 W E

13 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 1 connector Pin No. Name 10 ANAIN E 11 ANAIN F 12 DET2SLD 13 Di1 14 Di2 Signal names and functions Signal name: Main hydraulic pressure sensor input Analog input to detect the main hydraulic pressure. Input voltage: DC 0 to 4.5 V Reference data Input voltage at main hydraulic pressure of 0 MPa: 0.45 V Input voltage at main hydraulic pressure of 29.4 MPa: 4.05 V Signal name: Accumulator pressure sensor input Analog input to detect the accumulator pressure. Input voltage: DC 0 to 4.5 V Reference data Input voltage at accumulator pressure of 0 MPa: 0.45 V Input voltage at accumulator pressure of 29.4 MPa: 4.05 V Signal name: Shield of main hydraulic pressure sensor and accumulator pressure sensor Input voltage: DC 0 V Signal name: Overwind detection switch input Switch input to detect the overwinding of hook block. Switch ON (DC 0 V): The hook block is in normal status. Switch OFF (DC 24 V): The hook block is in overwinding status. With GR-300N-1 Signal name: 2nd/3rd boom sections full retraction detection switch input Switch input to detect that the 2nd/3rd boom sections are fully retracted. Switch ON (DC 0 V): 2nd/3rd boom sections are in full retraction status. Switch OFF (DC 24 V): 2nd/3rd boom sections are not in full retraction status. Reference data In the case (1) or (2) below, the AML judges that the boom full retraction detection switch is abnormal, and the error message [ ゼンシュク SW4 イジョウ ] is displayed. (1) When the boom length detection value is 7.3 m or less, the boom full retraction detection switch does not detect the boom full retraction status. (2) When the boom length detection value is 8.1 m or more, the boom full retraction detection switch detects the boom full retraction status. With TR-250M-7, GR-250N-1, GR-350N-1 Not used 12 W E

14 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 1 connector Pin No. Name 15 Di3 Signal names and functions With GR-300N-1 Signal name: 4th/5th/top boom sections full retraction detection switch input Switch input to detect that the 4th/5th/top boom sections are fully retracted. Switch ON (DC 0 V): 4th/5th/top boom sections are in full retraction status. Switch OFF (DC 24 V): 4th/5th/top boom sections are not in full retraction status. Reference data In the case (1) or (2) below, the AML judges that the boom full retraction detection switch is abnormal, and the error message [ ゼンシュク SW1 イジョウ ] is displayed. (1) When the boom length detection value is 17.3 m or less, the boom full retraction detection switch does not detect the boom full retraction status. (2) When the boom length detection value is 18.1 m or more, the boom full retraction detection switch detects the boom full retraction status. With TR-250M-7, GR-250N-1 Signal name: 3rd/top boom sections full retraction detection switch input Switch input to detect that the 3rd/top boom sections are fully retracted. Switch ON (DC 0 V): 3rd/top boom sections are in full retraction status. Switch OFF (DC 24 V): 3rd/top boom sections are not in full retraction status. Reference data In the case (1) or (2) below, the AML judges that the boom full retraction detection switch is abnormal, and the error message [ ゼンシュク SW1 イジョウ ] is displayed. (1) When the boom length detection value is 16.1 m or less, the boom full retraction detection switch does not detect the boom full retraction status. (2) When the boom length detection value is 16.9 m or more, the boom full retraction detection switch detects the boom full retraction status. With GR-350N-1 Signal name: 3rd/4th/top boom sections full retraction detection switch input Switch input to detect that the 3rd/4th/top boom sections are fully retracted. Switch ON (DC 0 V): 3rd/4th/top boom sections are in full retraction status. Switch OFF (DC 24 V): 3rd/4th/top boom sections are not in full retraction status. Reference data In the case (1) or (2) below, the AML judges that the boom full retraction detection switch is abnormal, and the error message [ ゼンシュク SW1 イジョウ ] is displayed. (1) When the boom length detection value is 15.8 m or less, the boom full retraction detection switch does not detect the boom full retraction status. (2) When the boom length detection value is 16.6 m or more, the boom full retraction detection switch detects the boom full retraction status. 13 W E

15 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 1 connector Pin No. Name Signal names and functions With GR-300N-1 Signal name: Jib stowed detection switch input Switch input to detect that the jib is stowed. Switch ON (DC 0 V): The jib is in stowed status. Switch OFF (DC 24 V): The jib is not in stowed status. 16 Di4 17 MB 18 MB 19 RB 20 RB 2 21 TC 22 ACC 24 Di5 25 Di6 With TR-250M-7, GR-250N-1, GR-350N-1 Signal name: Jib automatic pin detection switch input Switch input to detect that the jib is stowed into the lower area of the boom and locked to the jib lock device (automatic pin). Switch ON (DC 0 V): The jib is locked to the lower area of the boom. Switch OFF (DC 24 V): The jib is not locked to the lower area of the boom. Signal name: Power for circuit from battery Input voltage: DC 24 V Signal name: Power for relay from battery Input voltage: DC 24 V Signal name: Attachment operation input Switch input not to detect the elevation retracting pressure error (E2023) after the PTO switch is set to "ON (II)." Input voltage: DC 24 V Switch ON (DC 24 V): Elevation retracting pressure error (E2023) is not detected. Switch OFF (DC 0 V): Elevation retracting pressure error (E2023) is detected. Signal name: Automatic swing stop cancel switch input Power input to detect that the automatic swing stop function is canceled. Input voltage: DC 24 V Switch ON (DC 24 V): The automatic swing stop function is canceled. Switch OFF (DC 0 V): The automatic swing stop function works. Signal name: Overwind cutout release switch input Switch input to detect that the overwind cutout function of the hook block is canceled. Switch ON (DC 0 V): Crane stop status due to detection of overwinding of the hook block and alarm buzzer are canceled. Switch OFF (DC 24 V): The overwind cutout function of the hook block works. Signal name: AML emergency switch input Switch input to detect that the AML automatic stop function is canceled. Switch ON (DC 0 V): The automatic stop function of the AML is canceled. At the same time, the diode circuit outside the AML main unit works together, and the overwind cutout function of the hook block is also canceled. Switch OFF (DC 24 V): The automatic stop function of the AML works. 14 W E

16 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 1 connector Pin No. Name 26 Di7 27 Di8 28 Di9 Signal names and functions Signal name: Boom elevation slow stop cancel switch input Switch input to detect that the elevation slow stop function is canceled. Switch ON (DC 0 V): The elevation slow stop function is canceled. Switch OFF (DC 24 V): The elevation slow stop function works. With GR-300N-1 Signal name: Jib stowing pin insertion detection switch input Switch input to detect that the jib stowing pin is inserted. Switch ON (DC 0 V): The jib stowing pin is in inserted status. Switch OFF (DC 24 V): The jib stowing pin is not in inserted status. With TR-250M-7, GR-250N-1, GR-350N-1 Signal name: Jib lock pin insertion detection switch input Switch input to detect that the jib connecting pin (E) (jib lock pin) is inserted. Switch ON (DC 0 V): The jib connecting pin (E) (jib lock pin) is in inserted status. Switch OFF (DC 24 V): The connecting pin (E) (jib lock pin) is not in inserted status. Signal name: Over-front area detection switch input Switch input to detect the swing position (within 2 forward) Switch ON (DC 0 V): The swing position is in the front side. Switch OFF (DC 5 V): The swing position is in the direction other than front. 29 Di10 30 GND 31 GND Signal name: Swing angle detector 1, 2 selection (swing dead angle detection) switch input Switch input to detect the swing position (left lateral side). Switch ON (DC 0 V): The swing position is in the left lateral side. Switch OFF (DC 5 V): The swing position is in the right lateral side. Signal name: Electrical ground Output voltage: DC 0 V MOGND/ DET3GND MOSRC/ DET3SRC MOINP/ ANAING Signal name: Ground for pressure sensor for moment detection Input voltage: DC 0 V Signal name: Impressed voltage output to pressure sensor for moment detection Output voltage: DC 5 V Signal name: Input for pressure sensor for moment detection (extension side) Analog input to detect the extension side pressure of the elevating cylinder. Input voltage: DC 0 to 5 V MOINN/ ANAINH MOSLD/ DET3SLD Signal name: Input for pressure sensor for moment detection (retraction side) Analog input to detect the retraction side pressure of the elevating cylinder. Input voltage: DC 0 to 5 V Signal name: Shield of pressure sensor for moment detection Input voltage: DC 0 V 15 W E

17 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 1 connector Pin No. Name 39 SIF1GND 40 SIF1SRC 41 SIF1TXD+ Signal name: Ground for serial port 1 Input voltage: DC 0 V Signal name: Power for serial port 1 Output voltage: DC 24 V Signal names and functions Signal name: Serial port 1 transmission (+) output signal Signal name: Serial port 1 transmission (-) output 42 SIF1TXDsignal (*1): Transmission signal name With GR-300N-1 Relay output for controlling jib remote control RLY1 to 8 RLY1 to 6 RLY7 RLY8 Conditions with which transmitter relay outputs RLY1 to 8 turn ON (DC 24 V) Transmission data to transmitter at the top end of the boom (*1) When the basic conditions and operation condition (1) below are satisfied, these relay outputs corresponding to each operation (pivot pin, jib rotation, connecting pin) turn ON. When the basic conditions and operation condition (2) below are satisfied, this relay output turns ON. When the basic conditions below are satisfied, this relay output turns ON. However, in the following 2 cases, this relay output turns OFF, and the operable lamp on the remote control for jib operation goes out. Each operation (tilt, pivot pin, jib rotation, connecting pin) is performed with the trigger switch on the jib operation remote control pulled by operating each control switch simultaneously not individually. The AML automatic stop 1 (AML vent) relay output RLY1 is OFF. Basic conditions For the AML operation status, "jib set operation" is registered. The jib remote control switch is "ON." The POWER switch on the jib operation remote control is pressed. (The operable lamp lights.) Operation conditions (1) With the trigger switch on the jib operation remote control pulled, each operation other than tilt operation (pivot pin, jib rotation, connecting pin) is performed. However, each control switch is operated individually. (Simultaneous operation is prohibited.) (2) Tilt operation is not performed. With TR-250M-7, GR-250N-1, GR-350N-1 Not used 16 W E

18 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 1 connector Pin No. Name 43 SIF1RXD+ 44 SIF1RXD- Signal names and functions Signal name: Serial port 1 reception (+) input signal Signal name: Serial port 1 reception (-) input signal Received data from transmitter at the top end of the boom (*1) (*1): Received signal name With GR-300N-1 Ai1 Jib angle (*2) Di1 to 9 Jib remote control operation Di11 Pivot pin full extension detection Di12 Connecting pin full extension detection With TR-250M-7, GR-250N-1, GR-350N-1 Jib angle (*3) (*2): Reference data With GR-300N-1 Input voltage when jib offset angle is minimum (5 ): 2.75 V Input voltage when jib offset angle is maximum (60 ): 4.03 V (*3): Reference data With TR-250M-7, GR-250N-1, GR-350N-1 Input voltage when jib offset angle is minimum (5 ): V (Ai check A/D conversion value: 337) Input voltage when jib offset angle is maximum (45 ): 3.97 V (Ai check A/D conversion value: 1625) 45 SIF1SLD Signal name: Serial port 1 shield Input voltage: DC 0 V 17 W E

19 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) Names and functions of signals input to/output from CN2 connector are shown below: CN 2 connector Pin No. Name Signal names and functions Signal name: Automatic stop 1 (AML vent) relay output When the crane is overloaded, when the hook block is overwound, or when the AML main unit is out of order, this relay contact turns OFF and crane operation is stopped. When the boom elevating operation is being stopped, the slow stop function works at the same time. (Current for slow stop is output from the boom raising solenoid proportional valve output CNTL3P or boom lowering solenoid proportional valve output CNTL4P.) However, when the boom elevation slow stop cancel switch is set to " 解除," the slow stop function does not work together. An exception is a case at the backward stable stop, and the slow stop function works together in this case. Relay ON (DC 24 V): Normal status Relay OFF (DC 0 V): Crane stop status 1 RLY 1 When the AML emergency switch is set to " 非常用 " and the PTO switch is set to "ON (II)," this relay output is changed from OFF to ON, and the automatic stop function of the AML is canceled. (*1) At the same time, the diode circuit outside the AML main unit works together, and the overwind cutout function of the hook block is also canceled. (*1) : The stop function for backward stability alone is not deactivated, and permanently operates to stop boom raising operation slowly and stop boom retracting operation (*2). (*2) : Except for boom retracting operation in the case of TR-250M-7, GR-250N-1, GR-350N-1. Relay output ON Moment load factor < 90% Crane operation status 90% Moment load factor < 100% 18 W E

20 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name 1 RLY 1 Relay output OFF Signal names and functions Crane operation status Moment load factor 100% The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering, jib tilt down (*1) ) is stopped. (*1) : Only for power tilt jib specification While the boom lift is performed with the jib mounted, the relay output turns OFF when the moment load factor becomes as follows: Moment load factor 90% Also, under the condition below, the AML judges that the jib is mounted. With GR-300N-1 The jib stowing pin is not inserted. With TR-250M-7, GR-250N-1, GR-350N-1 The jib connecting pin (E) (jib lock pin) is not inserted. When the hook block is overwound The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering, jib tilt down (*1) ) is stopped. (*1) : Only for power tilt jib specification If the overwind cutout release switch is pressed in this status, the relay output is changed from OFF to ON, and the overwind cutout function is canceled. When the working area limit has been registered and the crane operation other than swinging goes beyond the limit area The crane operation which goes beyond the limit area is stopped. When the AML main unit is out of order All the crane operations other than swinging are stopped. 19 W E

21 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name 1 RLY 1 Relay output OFF Signal names and functions Crane operation status When the backward stability control is activated, the crane operation toward critical side (boom raising or boom retracting) is stopped. With GR-300N-1 The backward stability control is activated in the on-rubber operation only. In the case (1) or (2) below, boom raising and retracting operations are stopped. (1) The boom angle becomes 55 or more with the suspension free. (2) The AML calculates the backward stability and judges as dangerous with the suspension locked. (Example 1): The boom angle becomes 78 or more with the boom fully retracted (7.7 m). (Example 2): The boom angle becomes 82 or more with the boom length 12.7 m. With TR-250M-7, GR-250N-1 The backward stability control is activated in the on-rubber operation only. In the case (1) or (2) below, boom raising operation is stopped. (1) The boom angle becomes 55 or more with the suspension free. (2) The boom angle becomes 77 or more with the suspension locked. With GR-350N-1 The backward stability control is activated in the on-rubber operation only. In the case (1) or (2) below, boom raising operation is stopped. (1) The boom angle becomes 55 or more with the suspension free. (2) The boom angle becomes 76 or more with the suspension locked. 20 W E

22 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name Relay output Signal names and functions Other control functions When the moment is abnormal When the actual load value calculated inside the AML becomes negative, the crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering, jib tilt down (*1) ) is stopped. However, it is not stopped while the boom is retracted to the traveling posture. When all the conditions below are satisfied, the AML judges that the boom is being retracted to the traveling posture. With GR-300N-1 (1) The boom angle is 0 or less. (2) The boom length is 7.8 m or less. (3) The swing position is in the range of front ±5. With TR-250M-7, GR-250N-1, GR-350N-1 (1) The boom angle is 5 or less. (2) The boom length is 9.6 m or less. (3) The swing position is in the range of front ±5. (*1) : Only for power tilt jib specification 1 RLY 1 OFF Functions in GR-300N-1 only When the hook-in operation is performed When all the conditions below are satisfied, this relay output turns OFF, and the hook-in control relay output RLY8 turns ON. (1) The PTO switch is "ON (I)." (2) For the AML operation status, "boom lift" or "single top lift" is registered. (3) The boom is fully retracted (*1). (4) The boom angle is 0 or less. (5) The overwind cutout release switch is "pressed." (*1) : When the contact of 2nd/3rd boom sections full retraction detection switch is "closed," the AML judges that the boom is fully retracted. 21 W E

23 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name 1 RLY 1 Relay output OFF Signal names and functions Other control functions When the boom reaches the elevation stroke end When the boom deviates from the boom angle range in which the extension/retraction side pressure of the elevating cylinder can be properly detected (GR-300N-1: -6 to 82.6, TR-250M-7, GR-250N-1: up to 82.5, GR-350N-1: up to 83.5 ), the boom elevating operation is stopped. However, it is not stopped while the boom is retracted to the traveling posture. When all the conditions below are satisfied, the AML judges that the boom is being retracted to the traveling posture. With GR-300N-1 (1) The boom angle is -6 or less. (2) The boom length is 7.8 m or less. (3) The swing position is in the range of front ±5. In the boom angle range between 82.6 and 83, when the extension/retraction side pressure of the elevating cylinder cannot be properly detected and the moment load factor becomes 100% or more, the automatic stop function by overloading (stop of boom lowering operation) is canceled. With TR-250M-7, GR-250N-1 (1) The boom angle is 5 or less. (2) The boom length is 9.6 m or less. (3) The swing position is in the range of front ±5. In the boom angle range between 82.5 and 83, when the extension/retraction side pressure of the elevating cylinder cannot be properly detected and the moment load factor becomes 100% or more, the automatic stop function by overloading (stop of boom lowering operation) is canceled. With GR-350N-1 (1) The boom angle is 5 or less. (2) The boom length is 9.6 m or less. (3) The swing position is in the range of front ±5. In the boom angle range of 83.5 or more, when the extension/retraction side pressure of the elevating cylinder cannot be properly detected and the moment load factor becomes 100% or more, the automatic stop function by overloading (stop of boom lowering operation) is canceled. Relay output OFF Jib remote control functions in GR-300N-1 only Pivot pin retracting operation prohibition function When the jib is not stowed (*1), the pivot pin cylinder does not retract even if the pivot pin retraction operation is performed. At the same time, the following error message is displayed. [ シテンピンソウサキンシ!] (Error code 0107) (*1) : When the jib stowed detection switch contact is "open," the AML judges that the jib is not stowed. 22 W E

24 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name 1 RLY 1 Relay output OFF Signal names and functions Jib remote control functions in GR-300N-1 only Jib rotation mounting operation prohibition function When the jib is stowed (*1), the jib rotation cylinder does not extend even if the jib rotation mounting operation is performed. At the same time, the following error message is displayed. [ カイドウソウサキンシ!] (Error code 0108) (*1) : When the jib stowed detection switch contact is "closed," the AML judges that the jib is stowed. Jib tilt cylinder retracting operation prohibition function When the pivot pin cylinder is not fully extended, the jib tilt cylinder does not retract even if jib tilt cylinder retracting operation is performed. At the same time, the following error message is displayed. [ チルトソウサキンシ!] (Error code 0109) Connecting pin retracting operation prohibition function When the pivot pin cylinder is not fully extended, the connecting pin cylinder does not retract even if connecting pin retracting operation is performed. At the same time, the following error message is displayed. [ レンケツピンソウサキンシ!] (Error code 0119) Jib fall prevention function When the jib is not stowed (*1), or when the jib stowing pin is not inserted, if both the pivot pin cylinder and the connecting pin cylinder are not fully retracted, all the crane operations other than swing operation are stopped. (*2) At the same time, the following error message is displayed. [ ジブジョウタイガキケン ] (Error code 0103) (*1) : When the jib stowed detection switch contact is "open," the AML judges that the jib is not stowed. (*2) : When the boom status other than "jib set operation" has been registered in the AML, the crane operation is not stopped. Monitoring function of abnormal operation select solenoid With the jib remote control switch "OFF," when jib tilt operation is detected even if the telescoping/jib operation select switch has been set to "boom telescoping," all the crane operations are stopped. At the same time, the following error message is displayed. [ ソウサキリカエ SOL イジョウ ] (Error code 0111) OFF Monitoring function of abnormal remote control operation solenoid With the jib remote control switch "ON," when jib tilt operation is detected even if the jib has not been operated with the remote control, all the crane operations are stopped. At the same time, the following error message is displayed. [ リモコンソウサ SOL イジョウ ] (Error code 0112) 23 W E

25 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name 1 RLY 1 Relay output OFF Signal names and functions Jib control functions in TR-250M-7, GR-250N-1, GR-350N-1 only When the jib fall prevention function is activated during jib mounting operation When all the conditions below are satisfied, boom extending operation is stopped. (1) The jib is extended from the boom side and stowed into the lower area of the boom (*1). (2) The jib connecting pin (E) (jib lock pin) is pulled out. (3) The boom angle is less than 73. (*1) : When the contact of jib automatic pin detection switch is "closed," the AML judges that jib is stowed into the lower area of the boom. When the jib fall prevention function is activated during stowing of the jib When all the conditions below are satisfied, boom extending operation is stopped. (1) The jib is stowed into the lower area of the boom (*1). (2) The jib connecting pin (E) (jib lock pin) is inserted. (3) The boom angle exceeds 5. (*1) : When the contact of jib automatic pin detection switch is "closed," the AML judges that jib is stowed into the lower area of the boom. When the jib tension rod buckling prevention function is activated (*1) With the jib connecting pin (E) (jib lock pin) inserted, that is, when the jib is not mounted, the jib tilt cylinder does not retract even if jib tilt down operation is performed. (*1) : Only for power tilt jib specification 2 RLY 2 Signal name: Automatic stop 2 (remote control pressure vent) relay output With GR-300N-1 When the PTO switch is set to "ON (I)," this relay contact turns ON. (The relay turns OFF on the program.) However, when the jib remote control switch is turned ON, this relay contact is changed from ON to OFF, and the crane operation from the cab is stopped. Relay ON (DC 0 V): Crane stop status (Remote control operation for jib is selected.) Relay OFF (DC 24 V): Normal status With TR-250M-7, GR-250N-1, GR-350N-1 When the PTO switch is set to "ON (I)," this relay contact turns ON. (The relay turns OFF on the program.) Relay ON (DC 0 V): Crane stop status Relay OFF (DC 24 V): Normal status 24 W E

26 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name 3 RLY 3 Signal names and functions Signal name: Accumulator low-pressure alarm relay output This relay contact turns ON, and the buzzer sounds when the accumulator pressure value becomes as follows: With GR-300N-1 Approx. 8.8 MPa (90 kgf/cm 2 ) or less With TR-250M-7, GR-250N-1, GR-350N-1 Approx. 9.3 MPa (95 kgf/cm 2 ) or less Relay ON (DC 24 V): The alarm buzzer sounds. Relay OFF (DC 0 V): Normal status Signal name: AML alarm relay output When the crane is overloaded, this relay contact turns ON, and the buzzer sounds. Relay ON (DC 24 V): The alarm buzzer sounds. Relay OFF (DC 0 V): The alarm buzzer does not sound. Relay output OFF Moment load factor < 90% Conditions for alarming 4 RLY 4 ON/OFF ON 90% Moment load factor < 100% While the boom lift is performed with the jib mounted, the relay output turns ON/OFF when the moment load factor becomes as follows: 80% Moment load factor < 90% Also, under the condition below, the AML judges that the jib is mounted. With GR-300N-1 The jib stowing pin is not inserted. With TR-250M-7, GR-250N-1, GR-350N-1 The jib lock pin is not inserted. Moment load factor 100% While the boom lift is performed with the jib mounted, the relay output turns ON when the moment load factor becomes as follows: Moment load factor 90% Also, under the condition below, the AML judges that the jib is mounted. With GR-300N-1 The jib stowing pin is not inserted. With TR-250M-7, GR-250N-1, GR-350N-1 The jib connecting pin (E) (jib lock pin) is not inserted. 25 W E

27 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name 5 RLY 5 Signal names and functions Signal name: Telescoping control relay output With GR-300N-1 When the boom length becomes the specified value (17.45 m) or more/less, this relay contact turns ON/OFF, and the 4th/5th/top boom or 2nd/3rd boom sections telescope. Relay ON (DC 24 V): 4th/5th/top boom sections telescope. Relay OFF (DC 0 V): 2nd/3rd boom sections telescope. With TR-250M-7, GR-250N-1 When the boom length becomes the specified value (16.3 m) or more/less, this relay contact turns ON/OFF, and the 3rd/top boom or 2nd boom section telescopes. Relay ON (DC 24 V): (3rd/top boom) sections telescope. Relay OFF (DC 0 V): 2nd boom section telescopes. With GR-350N-1 When the boom length becomes the specified value (15.93 m) or more/less, this relay contact turns ON/OFF, and the (3rd/4th/top boom) or 2nd boom section telescopes. Relay ON (DC 24 V): (3rd/4th/top boom) sections telescope. Relay OFF (DC 0 V): 2nd boom section telescopes. (Note): For the 4-section boom, indication in ( ) changes to 3rd/top boom. 7 RLY 7 8 RLY 8 Signal name: Overwinding alarm relay output When the hook block is overwound, this relay contact turns ON and the buzzer sounds. Relay ON (DC 24 V): The alarm buzzer sounds. Relay OFF (DC 0 V): Normal status With GR-300N-1 Signal name: Hook-in control relay output When the hook-in operation is performed, this relay contact turns ON, the automatic stop 1 (AML vent) relay output RLY1 turns OFF, and the set pressure of the winch hydraulic circuit is changed to the lower pressure. Relay ON (DC 24 V): The set pressure of the winch hydraulic circuit is changed to the low pressure. Relay OFF (DC 0 V): Normal status When all the conditions below are satisfied, the AML judges that the hook-in operation is being performed. (1) The PTO switch is "ON (I)." (2) For the AML operation status, "boom lift" or "single top lift" is registered. (3) The boom is fully retracted (*1). (4) The boom angle is 0 or less. (5) The overwind cutout release switch is "pressed." (*1) : When the contact of 2nd/3rd boom sections full retraction detection switch is "closed," the AML judges that the boom is fully retracted. 26 W E

28 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name 8 RLY 8 9 Di11 10 Di12 11 Di13 12 Di14 13 CNTL 1P Signal names and functions With TR-250M-7, GR-250N-1, GR-350N-1 Not used Signal name: Main winch hoist-up operation detection switch input Input from the switch detecting hoist-up operation of the main winch. Switch ON (DC 0 V): No hoist-up operation of the main winch is detected. Switch OFF (DC 5 V): Hoist-up operation of the main winch is detected. With GR-300N-1 Signal name: Main winch hoist-down operation detection switch input Input from the switch detecting hoist-down operation of the main winch. Switch ON (DC 0 V): No hoist-down operation of the main winch is detected. Switch OFF (DC 5 V): Hoist-down operation of the main winch is detected. With TR-250M-7, GR-250N-1, GR-350N-1 Not used Signal name: Auxiliary winch hoist-up operation detection switch input Input from the switch detecting hoist-up operation of the auxiliary winch. Switch ON (DC 0 V): No hoist-up operation of the auxiliary winch is detected. Switch OFF (DC 5 V): Hoist-up operation of the auxiliary winch is detected. With GR-300N-1 Signal name: Auxiliary winch hoist-down operation detection switch input Input from the switch detecting hoist-down operation of the auxiliary winch. Switch ON (DC 0 V): No hoist-down operation of the auxiliary winch is detected. Switch OFF (DC 5 V): Hoist-down operation of the auxiliary winch is detected. With TR-250M-7, GR-250N-1, GR-350N-1 Not used Signal name: Swing right proportional valve output When the right swing operation is stopped by the automatic swing stop function, controlled current is output from the AML to the swing right proportional valve. However, in the 3 cases below, the automatic swing stop function does not work. (1) The automatic swing stop cancel switch is set to " 解除." (2) On-rubber operation (3) The AML emergency switch is set to " 非常用," and the PTO switch is set to "ON (II)." Output voltage: Square wave 0 to 24 V 27 W E

29 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name 13 CNTL 1P 14 CNTL 1N 15 CNTL 2P 16 CNTL 2N 17 Di15 Signal names and functions Crane operation status in which automatic swing stop function is enabled The outrigger extension width differs in the front/rear/left/right, and if the right swing operation is continued further, the status enters an operation range in which the moment load factor becomes 100% or more. While the boom lift is performed with the jib mounted, the automatic swing stop function works when the status enters an operation range in which the moment load factor becomes 90% or more, not 100% or more. Also, under the condition below, the AML judges that the jib is mounted. With GR-300N-1 The jib stowing pin is not inserted. With TR-250M-7, GR-250N-1, GR-350N-1 The jib connecting pin (E) (jib lock pin) is not inserted. The swing limit has been registered, and the crane operation goes beyond the right swing limit area. Signal name: Ground terminal of swing right proportional valve Input voltage: DC 0 V Signal name: Swing left proportional valve output When the left swing operation is stopped by the automatic swing stop function, controlled current is output from the AML to the swing left proportional valve. However, in the 3 cases below, the automatic swing stop function does not work. (1) The automatic swing stop cancel switch is set to " 解除." (2) On-rubber operation (3) When the AML emergency switch is set to " 非常用," and the PTO switch is set to "ON (II). Output voltage: Square wave 0 to 24 V Crane operation status in which automatic swing stop function is enabled The outrigger extension width differs in the front/rear/left/right, and if the left swing operation is continued further, the status enters an operation range in which the moment load factor becomes 100% or more. While the boom lift is performed with the jib mounted, the automatic swing stop function works when the status enters an operation range in which the moment load factor becomes 90% or more, not 100% or more. Also, under the condition below, the AML judges that the jib is mounted. With GR-300N-1 The jib stowing pin is not inserted. With TR-250M-7, GR-250N-1, GR-350N-1 The jib connecting pin (E) (jib lock pin) is not inserted. The swing limit has been registered, and the crane operation goes beyond the left swing limit area. Signal name: Ground terminal of swing left proportional valve Input voltage: DC 0 V Signal name: Boom extending operation detection switch input Input from the switch detecting boom extending operation. Switch ON (DC 0 V): No boom extending operation is detected. Switch OFF (DC 5 V): Boom extending operation is detected. 28 W E

30 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name 18 Di16 19 Di17 20 Di18 Signal names and functions With GR-300N-1 Signal name: Boom retracting operation detection switch input Input from the switch detecting boom retracting operation. Switch ON (DC 0 V): No boom retracting operation is detected. Switch OFF (DC 5 V): Boom retracting operation is detected. With TR-250M-7, GR-250N-1, GR-350N-1 Not used Signal name: Boom raising operation detection switch input Input from the switch detecting boom raising operation. Switch ON (DC 0 V): No boom raising operation is detected. Switch OFF (DC 5 V): Boom raising operation is detected. Signal name: Boom lowering operation detection switch input Input from the switch detecting boom lowering operation. Switch ON (DC 0 V): No boom lowering operation is detected. Switch OFF (DC 5 V): Boom lowering operation is detected. 21 Di19 22 Di20 23 CNTL 3P 24 CNTL 3N 25 CNTL 4P Signal name: Right swing operation detection switch input Input from the switch detecting right swing operation. Switch ON (DC 0 V): No right swing operation is detected. Switch OFF (DC 5 V): Right swing operation is detected. Signal name: Left swing operation detection switch input Input from the switch detecting left swing operation. Switch ON (DC 0 V): No left swing operation is detected. Switch OFF (DC 5 V): Left swing operation is detected. Signal name: Boom raising proportional valve output When the boom raising operation is slowly stopped by the slow stop function, controlled current is output from the AML to the boom raising proportional valve. However, when the boom elevation slow stop cancel switch is set to " 解除," the slow stop function does not operate. (*1) Output voltage: Square wave 0 to 24 V (*1) : An exception is a case at the backward stable stop, and the slow stop function is operated in this case. For the crane operation status in which the slow stop function is activated, refer to the automatic stop 1 (AML vent) relay output RLY1. Signal name: Ground terminal of boom raising proportional valve Input voltage: DC 0 V Signal name: Boom lowering proportional valve output When the boom lowering operation is slowly stopped by the slow stop function, controlled current is output from the AML to the boom lowering proportional valve. However, when the boom elevation slow stop cancel switch is set to " 解除," the slow stop function does not operate. Output voltage: Square wave 0 to 24 V For the crane operation status in which the slow stop function is activated, refer to the automatic stop 1 (AML vent) relay output RLY1. 29 W E

31 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name 26 CNTL 4N 30 SIF2TXD+ 31 SIF2TXD- Signal names and functions Signal name: Ground terminal of boom lowering proportional valve Input voltage: DC 0 V Signal name: Serial port 2 transmission (+) output signal Signal name: Serial port 2 transmission (-) output signal Transmission data to MDT (*1) (*1): Transmission signal name GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1 Do1 AML cancellation (AML warning indicator lamp) Do2 Jib lock display 1 (jib lock lamp) Do3 Hook-in (hook-in indicator lamp) Do4 Fixing jib (boom telescoping operation indicator lamp/jib tilt operation indicator lamp) Do5 Emergency suspension free conditions (*2) Do6 Outrigger retracting operation detection response Do7 Jib lock display 2 (jib lock lamp) (*2): Conditions GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1 For the AML operation status, "boom lift" or "single top lift" is registered. For GR-300N-1, TR-250M-7, and GR-250N-1, the actual load is 0.5 t or less. For GR-350N-1, it is 0.7 t or less. For GR-300N-1, the boom length is 8 m or less. For TR-250M-7, GR-250N-1, and GR-350N-1, it is 9.8 m or less. The boom angle is 55 or less. 30 W E

32 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 2 connector Pin No. Name 32 SIF2RXD+ 33 SIF2RXD- Signal names and functions Signal name: Serial port 2 reception (+) input signal Signal name: Serial port 2 reception (-) input signal Received data from MDT (*3) (*3): Received signal name GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1 ANIN2 O/R (FL) (*4) ANIN3 O/R (FR) (*4) ANIN4 O/R (RL) (*4) ANIN5 O/R (RR) (*4) Di1 Outrigger retracting operation detection (monitor signal of relay output RY6 from MDT lower unit) Di2 Emergency suspension free detection (*4): Reference data With GR-300N-1 H-type outrigger Input voltage when outrigger extension width is minimum: 0.62 V (Ai check A/D conversion value: 253) Input voltage when outrigger extension width is maximum: 4.23 V (Ai check A/D conversion value: 1732) With TR-250M-7, GR-250N-1 X-type outrigger Input voltage when outrigger extension width is minimum: V (Ai check A/D conversion value: 357) Input voltage when outrigger extension width is maximum: 3.98 V (Ai check A/D conversion value: 1630) H-type outrigger Input voltage when outrigger extension width is minimum: 0.85 V (Ai check A/D conversion value: 347) Input voltage when outrigger extension width is maximum: 3.97 V (Ai check A/D conversion value: 1625) With GR-350N-1 X-type outrigger Input voltage when outrigger extension width is minimum: V (Ai check A/D conversion value: 366) Input voltage when outrigger extension width is maximum: V (Ai check A/D conversion value: 1733) 34 SIF2SLD Signal name: Serial port 2 shield Input voltage: DC 0 V 31 W E

33 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) Names and functions of signals input to/output from CN3 connector are shown below: CN 3 connector Signal names and functions Pin No. Name Signal name: Less than 90% (safety) output When the moment load factor is less than 90%, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating less than 90% lights. OC output OFF (DC 24 V): The external indicator lamp indicating less than 90% goes out. 1 TR1 While the boom lift is performed with the jib mounted, the OC output turns ON when the moment load factor is less than 80%. Also, under the condition below, the AML judges that the jib is mounted. With GR-300N-1 The jib stowing pin is not inserted. With TR-250M-7, GR-250N-1, GR-350N-1 The jib connecting pin (E) (jib lock pin) is not inserted. 2 TR2 Signal name: 90% alarm output When the moment load factor is 90% or more and less than 100%, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 90% lights. OC output OFF (DC 24 V): The external indicator lamp indicating 90% goes out. While the boom lift is performed with the jib mounted, the OC output turns ON when the moment load factor is 80% or more and less than 90%. Also, under the condition below, the AML judges that the jib is mounted. With GR-300N-1 The jib stowing pin is not inserted. With TR-250M-7, GR-250N-1, GR-350N-1 The jib connecting pin (E) (jib lock pin) is not inserted. Signal name: 100% alarm output When the moment load factor is 100% or more, or when the automatic stop function is canceled, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 100% lights. OC output OFF (DC 24 V): The external indicator lamp indicating 100% goes out. Conditions under which the OC output turns ON Moment load factor 100% 3 TR3 While the boom lift is performed with the jib mounted, the OC output turns ON when the moment load factor becomes as follows: Moment load factor 90% Also, under the condition below, the AML judges that the jib is mounted. With GR-300N-1 The jib stowing pin is not inserted. With TR-250M-7, GR-250N-1, GR-350N-1 The jib connecting pin (E) (jib lock pin) is not inserted. 32 W E

34 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 3 connector Pin No. Name 3 TR3 4 TR4 5 TR5 7 TR7 Overwind cutout release switch: "Press" Signal names and functions Automatic swing stop cancel switch: " 解除 " AML emergency switch: " 非常用 " + PTO switch: "ON (II)" With GR-300N-1 Signal name: Auxiliary winch high-speed hoist-down output When the actual load is less than the specified value (300 kg) and the hoist-down operation of the auxiliary winch is detected, the OC (open collector) output turns ON. When the auxiliary winch high-speed hoist-down switch is set to ON, high-speed hoist-down operation works. OC output ON (DC 0 V): High-speed hoist-down operation works. OC output OFF (DC 24 V): Normal-speed hoist-down operation works. With TR-250M-7, GR-250N-1, GR-350N-1 Not used With GR-300N-1 Signal name: Main winch high-speed hoist-down output When the actual load is less than the specified value (500 kg) and the hoist-down operation of the main winch is detected, the OC (open collector) output turns ON. When the main winch high-speed hoist-down switch is set to ON, high-speed hoist-down operation works. OC output ON (DC 0 V): High-speed hoist-down operation works. OC output OFF (DC 24 V): Normal-speed hoist-down operation works. With TR-250M-7, GR-250N-1, GR-350N-1 Not used With GR-300N-1 Signal name: Remote control operation SOL (tilt up) output When all the conditions below are satisfied, the OC (open collector) output turns ON. (1) For the AML operation status, "jib set operation" is registered. (2) The jib remote control switch is "ON." (3) The POWER switch on the jib operation remote control is pressed. (The operable lamp lights.) (4) With the trigger switch on the jib operation remote control pulled, operations other than jib tilt cylinder extension (jib tilt cylinder retraction, pivot pin, jib rotation, connecting pin) are performed. However, each control switch is operated individually. (Simultaneous operation is prohibited.) OC output ON (DC 0 V): Operations other than jib tilt cylinder extension (jib tilt cylinder retraction, pivot pin, jib rotation, connecting pin) are performed. OC output OFF (DC 24 V): All the conditions above are not satisfied. With TR-250M-7, GR-250N-1, GR-350N-1 Not used 33 W E

35 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 3 connector Pin No. Name 8 TR8 Signal names and functions With GR-300N-1 Signal name: Remote control operation SOL (tilt down) output When all the conditions below are satisfied, the OC (open collector) output turns ON. (1) For the AML operation status, "jib set operation" is registered. (2) The jib remote control switch is "ON." (3) The POWER switch on the jib operation remote control is pressed. (The operable lamp lights.) (4) With the trigger switch on the jib operation remote control pulled, the jib tilt cylinder is extended. OC output ON (DC 0 V): The jib tilt cylinder is being extended. OC output OFF (DC 24 V): All the conditions above are not satisfied. With TR-250M-7, GR-250N-1, GR-350N-1 Not used 10 Di25 11 Di26 12 Di27 13 Di28 With GR-300N-1 Signal name: Jib remote control switch input Switch input to detect that the remote control operation for jib is selected. Switch ON (DC 0 V): Remote control operation is selected. Switch OFF (DC 5 V): Remote control operation is not selected. With TR-250M-7, GR-250N-1, GR-350N-1 Not used With GR-300N-1 Signal name: Telescoping/jib operation select switch input Switch input to detect that the boom telescoping operation is selected. Switch ON (DC 0 V): Boom telescoping operation is selected. Switch OFF (DC 5 V): Jib tilt operation is selected. With TR-250M-7, GR-250N-1, GR-350N-1 Not used Signal name: Jib tilt up operation detection switch input Input from the switch detecting jib tilt up operation. Switch ON (DC 0 V): No jib tilt up operation is detected. Switch OFF (DC 5 V): Jib tilt up operation is detected. Signal name: Jib tilt down operation detection switch input Input from the switch detecting jib tilt down operation. Switch ON (DC 0 V): No jib tilt down operation is detected. Switch OFF (DC 5 V): Jib tilt down operation is detected. 34 W E

36 Input/Output Signals of the AML-LIIA System (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) CN 3 connector Pin No. Name 16 CNTL 5P 17 CNTL 5N Signal names and functions Signal name: Swing relief proportional valve output In the swing free status, when the swing movement is stopped by the automatic swing stop function, controlled current is output from the AML to the swing relief proportional valve. However, in the 3 cases below, the automatic swing stop function does not work. (1) The automatic swing stop cancel switch is set to " 解除." (2) On-rubber operation (3) The AML emergency switch is set to " 非常用," and the PTO switch is set to "ON (II)." Output voltage: Square wave 0 to 24 V Crane operation status in which automatic swing stop function is enabled The outrigger extension width differs in the front/rear/left/right, and if the swing free operation is continued further, the status enters an operation range in which the moment load factor becomes 100% or more. While the boom lift is performed with the jib mounted, the automatic swing stop function works when the status enters an operation range in which the moment load factor becomes 90% or more, not 100% or more. Also, under the condition below, the AML judges that the jib is mounted. With GR-300N-1 The jib stowing pin is not inserted. With TR-250M-7, GR-250N-1, GR-350N-1 The jib connecting pin (E) (jib lock pin) is not inserted. The swing limit has been registered, and the swing free operation goes beyond the right swing or left swing limit area. Signal name: Ground terminal of swing relief proportional valve Input voltage: DC 0 V 18 CNTL 6P 19 CNTL 6N 21 Di21 With GR-300N-1 Signal name: Telescoping retraction proportional valve output When the 2nd/3rd boom sections are fully retracted and when the 4th/5th/top boom sections are fully retracted, controlled current is output from the AML to the telescoping retraction proportional valve. Each of them stops slowly at the stroke end. Output voltage: Square wave 0 to 24 V With TR-250M-7, GR-250N-1, GR-350N-1 Not used With GR-300N-1 Signal name: Ground terminal of telescoping retraction proportional valve Input voltage: DC 0 V With TR-250M-7, GR-250N-1, GR-350N-1 Not used Signal name: Swing free switch input Switch input to detect that the swing free is selected. Switch ON (DC 0 V): Swing free is selected. Contact OFF (DC 5 V): Swing free is canceled. 35 W E

37 Input/Output Signals of the AML-LIIA System (GR-160N-1) : Applicable Serial No: From Diagram of the AML-LIIA System (GR-160N-1) 2 (*1): Applicable Serial No: From Boom angle detector CONNECTOR BOARD Boom length detector Swing angle detector Pressure sensor (main) Stop cancel input Stop cancel input Working condition input Pressure sensor for moment detection (elevating cylinder) Automatic stop output (AML vent) Hook-in control output Telescoping control output Alarm output (buzzer) Swing stop Lever operation detection input Combination meter Elevation slow stop Outrigger extension length detector (4 locations) Outrigger retracting operation detection input Lower unit Upper unit MDT (Multiplex Data Transmitter) Winch high-speed hoist-down output AML external indicator lamp output (option) 4th/5th/top boom sections telescoping operation detection input Swing stop (swing free) Working condition input 36 W E

38 Input/Output Signals of the AML-LIIA System (GR-160N-1) Input/Output Signals of the AML-LIIA System (GR-160N-1) As shown in the "Diagram of the AML-LIIA System" on the previous page, the inside of the AML-LIIA is composed of the display board, CPU board, analog board, power board, current output board, and connector board. All the input/output signals go through the connector board. Below are the names of the signals that are input to/output from the CN1, CN2, and CN3 connectors, and the descriptions of their functions. Names and functions of signals input to/output from CN1 connector are shown below: CN 1 connector Signal names and functions Pin No. Name 1 DET1GND 2 DET1SRC 3 ANAIN A Signal name: Ground for boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Input voltage: DC 0 V Signal name: Impressed voltage output to boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Output voltage: DC 4.5 V Signal name: Boom length detector input Analog input to detect the boom length. Input voltage: DC 0 to 4.5 V Reference data Input voltage at boom full retraction (6.5 m): 0.45 V (Ai check A/D conversion value: 203) Input voltage at boom full extension (27.5 m): 2.61 V (Ai check A/D conversion value: 1187) Signal name: Boom angle detector input Analog input to detect the boom angle. Input voltage: DC 0 to 4.5 V 4 ANAIN B Reference data Input voltage at boom angle of 0 : 0.7 V (Ai check A/D conversion value: 307) Input voltage at boom angle of 80 : 3.7 V (Ai check A/D conversion value: 1671) 5 ANAIN C Signal name: Swing angle detector 1 input Analog input from the swing angle detector 1 to detect the swing angle. Input voltage: DC 0 to 4.5 V Reference data Input voltage at swing angle of 0 : 1.09 V (Ai check A/D conversion value: 495) Input voltage at swing angle of 180 : 3.41 V (Ai check A/D conversion value: 1552) 6 DET1SLD 7 DET2GND 8 DET2SRC 9 ANAIN D Signal name: Shield of boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Input voltage: DC 0 V Signal name: Ground for main hydraulic pressure sensor Input voltage: DC 0 V Signal name: Impressed voltage output to main hydraulic pressure sensor Output voltage: DC 4.5 V Signal name: Swing angle detector 2 input Analog input from the swing angle detector 2 to detect the swing angle. Input voltage: DC 0 to 4.5 V 37 W E

39 Input/Output Signals of the AML-LIIA System (GR-160N-1) CN 1 connector Pin No. Name 10 ANAIN E 12 DET2SLD 13 Di1 14 Di2 15 Di3 16 Di4 17 MB 18 MB 19 RB 20 RB Signal names and functions Reference data Input voltage at swing angle of 0 : 3.41 V (Ai check A/D conversion value: 1552) Input voltage at swing angle of 180 : 1.09 V (Ai check A/D conversion value: 495) Signal name: Main hydraulic pressure sensor input Analog input to detect the main hydraulic pressure. Input voltage: DC 0 to 4.5 V Reference data Input voltage at main hydraulic pressure of 0 MPa: 0.45 V Input voltage at main hydraulic pressure of 29.4 MPa: 4.05 V Signal name: Shield of main hydraulic pressure sensor Input voltage: DC 0 V Signal name: Overwind detection switch input Switch input to detect the overwinding of hook block. Switch ON (DC 0 V): The hook block is in normal status. Switch OFF (DC 24 V): The hook block is in overwinding status. Signal name: 2nd/3rd boom sections full retraction detection switch input Switch input to detect that the 2nd/3rd boom sections are fully retracted. Switch ON (DC 0 V): 2nd/3rd boom sections are in full retraction status. Switch OFF (DC 24 V): 2nd/3rd boom sections are not in full retraction status. Reference data In the case (1) or (2) below, the AML judges that the boom full retraction detection switch is abnormal, and the error message [ ゼンシュク SW4 イジョウ ] is displayed. (1) When the boom length detection value is 6.1 m or less, the boom full retraction detection switch does not detect the boom full retraction status. (2) When the boom length detection value is 6.9 m or more, the boom full retraction detection switch detects the boom full retraction status. Signal name: 4th/5th/top boom sections full retraction detection switch input Switch input to detect that the 4th/5th/top boom sections are fully retracted. Switch ON (DC 0 V): 4th/5th/top boom sections are in full retraction status. Switch OFF (DC 24 V): 4th/5th/top boom sections are not in full retraction status. Reference data In the case (1) or (2) below, the AML judges that the boom full retraction detection switch is abnormal, and the error message [ ゼンシュク SW1 イジョウ ] is displayed. (1) When the boom length detection value is 14.5 m or less, the boom full retraction detection switch does not detect the boom full retraction status. (1) When the boom length detection value is 15.3 m or more, the boom full retraction detection switch detects the boom full retraction status. Signal name: Jib lock pin stowed detection switch input Switch input to detect that the jib (jib lock pin) is stowed. Switch ON (DC 0 V): The jib is in stowed status. Switch OFF (DC 24 V): The jib is not in stowed status. Signal name: Power for circuit from battery Input voltage: DC 24 V Signal name: Power for relay from battery Input voltage: DC 24 V 38 W E

40 Input/Output Signals of the AML-LIIA System (GR-160N-1) CN 1 connector Pin No. Name 2 21 TC 22 ACC 24 Di5 25 Di6 26 Di7 27 Di8 28 Di9 30 GND 31 GND MOGND/ DET3GND MOSRC/ DET3SRC Signal names and functions Signal name: Attachment operation input Switch input not to detect the elevation retracting pressure error (E2023) after the PTO switch is set to "ON (II)." Input voltage: DC 24 V Switch ON (DC 24 V): Elevation retracting pressure error (E2023) is not detected. Switch OFF (DC 0 V): Elevation retracting pressure error (E2023) is detected. Signal name: Automatic swing stop cancel switch input Power input to detect that the automatic swing stop function is canceled. Input voltage: DC 24 V Switch ON (DC 24 V): The automatic swing stop function is canceled. Switch OFF (DC 0 V): The automatic swing stop function works. Signal name: Overwind cutout release switch input Switch input to detect that the overwind cutout function of the hook block is canceled. Switch ON (DC 0 V): Crane stop status due to detection of overwinding of the hook block and alarm buzzer are canceled. Switch OFF (DC 24 V): The overwind cutout function of the hook block works. Signal name: AML emergency switch input Switch input to detect that the AML automatic stop function is canceled. Switch ON (DC 0 V): The automatic stop function of the AML is canceled. At the same time, the diode circuit outside the AML main unit works together, and the overwind cutout function of the hook block is also canceled. Switch OFF (DC 24 V): The automatic stop function of the AML works. Signal name: Boom elevation slow stop cancel switch input Switch input to detect that the elevation slow stop function is canceled. Switch ON (DC 0 V): The elevation slow stop function is canceled. Switch OFF (DC 24 V): The elevation slow stop function works. Signal name: Jib set pin insertion detection switch input Switch input to detect that the jib set pin is inserted. Switch ON (DC 0 V): The jib set pin is in inserted status. Switch OFF (DC 24 V): The jib set pin is not in inserted status. Signal name: Over-front area detection switch input Switch input to detect the swing position (within 2 forward) Switch ON (DC 0 V): The swing position is in the front side. Switch OFF (DC 5 V): The swing position is in the status other than front. Signal name: Electrical ground Output voltage: DC 0 V Signal name: Ground for pressure sensor for moment detection Input voltage: DC 0 V Signal name: Impressed voltage output to pressure sensor for moment detection Output voltage: DC 5 V 39 W E

41 Input/Output Signals of the AML-LIIA System (GR-160N-1) CN 1 connector Pin No Name MOINP/ ANAING MOINN/ ANAINH MOSLD/ DET3SLD Signal names and functions Signal name: Input for pressure sensor for moment detection (extension side) Analog input to detect the extension side pressure of the elevating cylinder. Input voltage: DC 0 to 5 V Signal name: Input for pressure sensor for moment detection (retraction side) Analog input to detect the retraction side pressure of the elevating cylinder. Input voltage: DC 0 to 5 V Signal name: Shield of pressure sensor for moment detection Input voltage: DC 0 V 40 W E

42 Input/Output Signals of the AML-LIIA System (GR-160N-1) Names and functions of signals input to/output from CN2 connector are shown below: CN 2 connector Pin No. Name 1 RLY 1 Signal names and functions Signal name: Automatic stop 1 (AML vent) relay output When the crane is overloaded, when the hook block is overwound, or when the AML main unit is out of order, this relay contact turns OFF and crane operation is stopped. When the boom elevating operation is being stopped, the slow stop function works at the same time. (Current for slow stop is output from the boom raising solenoid proportional valve output CNTL3P or boom lowering solenoid proportional valve output CNTL4P.) However, when the boom elevation slow stop cancel switch is set to " 解除," the slow stop function does not work together. Relay ON (DC 24 V): Normal status Relay OFF (DC 0 V): Crane stop status When the AML emergency switch is set to " 非常用 " and the PTO switch is set to "ON (II)," this relay output is changed from OFF to ON, and the automatic stop function of the AML is canceled. At the same time, the diode circuit outside the AML main unit works together, and the overwind cutout function of the hook block is also canceled. Relay output Crane operation status Moment load factor < 90% ON 90% Moment load factor < 100% Moment load factor 100% The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering) is stopped. While the boom lift is performed with the jib mounted, the relay output turns OFF when the moment load factor becomes as follows: Moment load factor 90% Also, when the jib set pin is not inserted, the AML judges that the jib is mounted. When the hook block is overwound The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom OFF lowering) is stopped. If the overwind cutout release switch is pressed in this status, the relay output is changed from OFF to ON, and the overwind cutout function is canceled. When the working area limit has been registered and the crane operation other than swinging goes beyond the limit area The crane operation which goes beyond the limit area is stopped. When the AML main unit is out of order All the crane operations other than swinging are stopped. 41 W E

43 Input/Output Signals of the AML-LIIA System (GR-160N-1) CN 2 connector Pin No. Name 1 RLY 1 Relay output OFF Signal names and functions Other control functions When the moment is abnormal When the actual load value calculated inside the AML becomes negative, the crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering) is stopped. However, it is not stopped while the boom is retracted to the traveling posture. When all the conditions below are satisfied, the AML judges that the boom is being retracted to the traveling posture. (1) The boom angle is -5 or less. (2) The boom length is 6.6 m or less. (2) The swing position is within front ±5. When the hook-in operation is performed When all the conditions below are satisfied, this relay output turns OFF, and the hook-in control relay output RLY8 turns ON. (1) The PTO switch is "ON (I)." (2) For the AML operation status, "boom lift" or "single top lift" is registered. (3) The boom is fully retracted (*1). (4) The boom angle is 0 or less. (5) The overwind cutout release switch is "pressed." (*1) : When the contact of 2nd/3rd boom sections full retraction detection switch is "closed," the AML judges that the boom is fully retracted. When the boom reaches the elevation stroke end When the boom deviates from the boom angle range in which the extension/retraction side pressure of the elevating cylinder can be properly detected (-5.3 to 82.5 ), the boom elevating operation is stopped. However, it is not stopped while the boom is retracted to the traveling posture. When all the conditions below are satisfied, the AML judges that the boom is being retracted to the traveling posture. (1) The boom angle is -5.3 or less. (2) The boom length is 6.6 m or less. (3) The swing position is within front ±5. In the boom angle range of 82.6 or more, when the extension/retraction side pressure of the elevating cylinder cannot be properly detected and the moment load factor becomes 100% or more, the automatic stop function by overloading (stop of boom lowering operation) is canceled. 42 W E

44 Input/Output Signals of the AML-LIIA System (GR-160N-1) CN 2 connector Pin No. Name 1 RLY 1 Relay output OFF Signal names and functions Other control functions When the jib fall prevention function is activated during jib mounting operation When all the conditions below are satisfied, boom extending operation is stopped. The jib (jib lock pin) is stowed. The jib set pin is not inserted. The boom angle is less than 75. When the upper boom angle limit function is activated during jib mounting/stowing operation When the boom angle becomes 80 at jib set, boom raising operation is stopped. Signal name: AML alarm relay output When the crane is overloaded, this relay contact turns ON, and the buzzer sounds. Relay ON (DC 24 V): The alarm buzzer sounds. Relay OFF (DC 0 V): The alarm buzzer does not sound. Relay output Conditions for alarming OFF Moment load factor < 90% 90% Moment load factor < 100% 4 RLY 4 ON/OFF While the boom lift is performed with the jib mounted, the relay output turns ON/OFF when the moment load factor becomes as follows: 80% Moment load factor < 90% Also, when the jib set pin is not inserted, the AML judges that the jib is mounted. 5 RLY 5 7 RLY 7 ON Moment load factor 100% While the boom lift is performed with the jib mounted, the relay output turns ON when the moment load factor becomes as follows: Moment load factor 90% Also, when the jib set pin is not inserted, the AML judges that the jib is mounted. Signal name: Telescoping control relay output When the boom length becomes the specified value (15.1 m) or more/less, this relay contact turns ON/OFF, and the 4th/5th/top boom or 2nd/3rd boom sections telescope. Relay ON (DC 24 V): 4th/5th/top boom sections telescope. Relay OFF (DC 0 V): 2nd/3rd boom sections telescope. Signal name: Overwinding alarm relay output When the hook block is overwound, this relay contact turns ON and the buzzer sounds. Relay ON (DC 24 V): The alarm buzzer sounds. Relay OFF (DC 0 V): Normal status 43 W E

45 Input/Output Signals of the AML-LIIA System (GR-160N-1) CN 2 connector Pin No. Name 8 RLY 8 9 Di11 10 Di12 11 Di13 Signal names and functions Signal name: Hook-in control relay output When the hook-in operation is performed, this relay contact turns ON, the automatic stop 1 (AML vent) relay output RLY1 turns OFF, and the set pressure of the winch hydraulic circuit is changed to the lower pressure. Relay ON (DC 24 V): The set pressure of the winch hydraulic circuit is changed to the low pressure. Relay OFF (DC 0 V): Normal status When all the conditions below are satisfied, the AML judges that the hook-in operation is being performed. (1) The PTO switch is "ON (I)." (2) For the AML operation status, "boom lift" or "single top lift" is registered. (3) The boom is fully retracted (*1). (4) The boom angle is 0 or less. (5) The overwind cutout release switch is "pressed." (*1) : When the contact of 2nd/3rd boom sections full retraction detection switch is "closed," the AML judges that the boom is fully retracted. Signal name: Main winch hoist-up operation detection switch input Input from the switch detecting hoist-up operation of the main winch. Switch ON (DC 0 V): No hoist-up operation of the main winch is detected. Switch OFF (DC 5 V): Hoist-up operation of the main winch is detected. Signal name: Main winch hoist-down operation detection switch input Input from the switch detecting hoist-down operation of the main winch. Switch ON (DC 0 V): No hoist-down operation of the main winch is detected. Switch OFF (DC 5 V): Hoist-down operation of the main winch is detected. Signal name: Auxiliary winch hoist-up operation detection switch input Input from the switch detecting hoist-up operation of the auxiliary winch. Switch ON (DC 0 V): No hoist-up operation of the auxiliary winch is detected. Switch OFF (DC 5 V): Hoist-up operation of the auxiliary winch is detected. 12 Di14 Signal name: Auxiliary winch hoist-down operation detection switch input Input from the switch detecting hoist-down operation of the auxiliary winch. Switch ON (DC 0 V): No hoist-down operation of the auxiliary winch is detected. Switch OFF (DC 5 V): Hoist-down operation of the auxiliary winch is detected. 44 W E

46 Input/Output Signals of the AML-LIIA System (GR-160N-1) CN 2 connector Pin No. Name 13 CNTL 1P 14 CNTL 1N 15 CNTL 2P 16 CNTL 2N Signal names and functions Signal name: Swing right proportional valve output When the right swing operation is stopped by the automatic swing stop function, controlled current is output from the AML to the swing right proportional valve. However, in the 3 cases below, the automatic swing stop function does not work. (1) The automatic swing stop cancel switch is set to " 解除." (2) On-rubber operation (3) The AML emergency switch is set to " 非常用," and the PTO switch is set to "ON (II)." Output voltage: Square wave 0 to 24 V Crane operation status in which automatic swing stop function is enabled The outrigger extension width differs in the front/rear/left/right, and if the right swing operation is continued further, the status enters an operation range in which the moment load factor becomes 100% or more. While the boom lift is performed with the jib mounted, the automatic swing stop function works when the status enters an operation range in which the moment load factor becomes 90% or more, not 100% or more. Also, when the jib set pin is not inserted, the AML judges that the jib is mounted. The swing limit has been registered, and the crane operation goes beyond the right swing limit area. Signal name: Ground terminal of swing right proportional valve Input voltage: DC 0 V Signal name: Swing left proportional valve output When the left swing operation is stopped by the automatic swing stop function, controlled current is output from the AML to the swing left proportional valve. However, in the 3 cases below, the automatic swing stop function does not work. (1) The automatic swing stop cancel switch is set to " 解除." (2) On-rubber operation (3) The AML emergency switch is set to " 非常用," and the PTO switch is set to "ON (II)." Output voltage: Square wave 0 to 24 V Crane operation status in which automatic swing stop function is enabled The outrigger extension width differs in the front/rear/left/right, and if the left swing operation is continued further, the status enters an operation range in which the moment load factor becomes 100% or more. While the boom lift is performed with the jib mounted, the automatic swing stop function works when the status enters an operation range in which the moment load factor becomes 90% or more, not 100% or more. Also, when the jib set pin is not inserted, the AML judges that the jib is mounted. The swing limit has been registered, and the crane operation goes beyond the left swing limit area. Signal name: Ground terminal of swing left proportional valve Input voltage: DC 0 V 45 W E

47 Input/Output Signals of the AML-LIIA System (GR-160N-1) CN 2 connector Pin No. Name 17 Di15 Signal names and functions Signal name: Boom extending operation detection switch input Input from the switch detecting boom extending operation. Switch ON (DC 0 V): No boom extending operation is detected. Switch OFF (DC 5 V): Boom extending operation is detected. (*1) : Only for power tilt jib specification 19 Di17 20 Di18 21 Di19 22 Di20 23 CNTL 3P 24 CNTL 3N 25 CNTL 4P Signal name: Boom raising operation detection switch input Input from the switch detecting boom raising operation. Switch ON (DC 0 V): No boom raising operation is detected. Switch OFF (DC 5 V): Boom raising operation is detected. Signal name: Boom lowering operation detection switch input Input from the switch detecting boom lowering operation. Switch ON (DC 0 V): No boom lowering operation is detected. Switch OFF (DC 5 V): Boom lowering operation is detected. Signal name: Right swing operation detection switch input Input from the switch detecting right swing operation. Switch ON (DC 0 V): No right swing operation is detected. Switch OFF (DC 5 V): Right swing operation is detected. Signal name: Left swing operation detection switch input Input from the switch detecting left swing operation. Switch ON (DC 0 V): No left swing operation is detected. Switch OFF (DC 5 V): Left swing operation is detected. Signal name: Boom raising proportional valve output When the boom raising operation is slowly stopped by the slow stop function, controlled current is output from the AML to the boom raising proportional valve. However, when the boom elevation slow stop cancel switch is set to " 解除," the slow stop function does not operate. Output voltage: Square wave 0 to 24 V For the crane operation status in which the slow stop function is activated, refer to the automatic stop 1 (AML vent) relay output RLY1. Signal name: Ground terminal of boom raising proportional valve Input voltage: DC 0 V Signal name: Boom lowering proportional valve output When the boom lowering operation is slowly stopped by the slow stop function, controlled current is output from the AML to the boom lowering proportional valve. However, when the boom elevation slow stop cancel switch is set to " 解除," the slow stop function does not operate. Output voltage: Square wave 0 to 24 V For the crane operation status in which the slow stop function is activated, refer to the automatic stop 1 (AML vent) relay output RLY1. 46 W E

48 Input/Output Signals of the AML-LIIA System (GR-160N-1) CN 2 connector Pin No. Name Signal names and functions 26 CNTL 4N Signal name: Ground terminal of boom lowering proportional valve Input voltage: DC 0 V 30 SIF2TXD+ 31 SIF2TXD- Signal name: Serial port 2 transmission (+) output signal Signal name: Serial port 2 transmission (-) output signal (*1): Transmission signal name Do1 AML cancellation (AML warning indicator lamp) Do2 Jib lock display 1 (jib lock lamp) Do3 Hook-in (hook-in indicator lamp) Do4 Fixing jib (boom telescoping operation indicator lamp) Do6 Outrigger retracting operation detection response Do7 Jib lock display 2 (jib lock lamp) 32 SIF2RXD+ 33 SIF2RXD- Signal name: Serial port 2 reception (+) input signal Signal name: Serial port 2 reception (-) input signal Transmission data to MDT (*1) Received data from MDT (*2) (*2): Received signal name ANIN2 O/R (FL) (*3) ANIN3 O/R (FR) (*3) ANIN4 O/R (RL) (*3) ANIN5 O/R (RR) (*3) Di1 Outrigger retracting operation detection (monitor signal of relay output RY6 from MDT lower unit) (*3): Reference data X-type outrigger Input voltage when outrigger extension width is minimum: V (Ai check A/D conversion value: 334) Input voltage when outrigger extension width is maximum: 3.40 V (Ai check A/D conversion value: 1392) H-type outrigger Input voltage when outrigger extension width is minimum: V (Ai check A/D conversion value: 333) Input voltage when outrigger extension width is maximum: V (Ai check A/D conversion value: 1387) 34 SIF2SLD Signal name: Serial port 2 shield Input voltage: DC 0 V 47 W E

49 Input/Output Signals of the AML-LIIA System (GR-160N-1) Names and functions of signals input to/output from CN3 connector are shown below: CN 3 connector Signal names and functions Pin No. Name 1 TR1 2 TR2 3 TR3 4 TR4 Signal name: Less than 90% (safety) output When the moment load factor is less than 90%, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating less than 90% lights. OC output OFF (DC 24 V): The external indicator lamp indicating less than 90% goes out. While the boom lift is performed with the jib mounted, the OC output turns ON when the moment load factor is less than 80%. Also, when the jib set pin is not inserted, the AML judges that the jib is mounted. Signal name: 90% alarm output When the moment load factor is 90% or more and less than 100%, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 90% lights. OC output OFF (DC 24 V): The external indicator lamp indicating 90% goes out. While the boom lift is performed with the jib mounted, the OC output turns ON when the moment load factor is 80% or more and less than 90%. Also, when the jib set pin is not inserted, the AML judges that the jib is mounted. Signal name: 100% alarm output When the moment load factor is 100% or more, or when the automatic stop function is canceled, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 100% lights. OC output OFF (DC 24 V): The external indicator lamp indicating 100% goes out. Moment load factor 100% Conditions under which the OC output turns ON While the boom lift is performed with the jib mounted, the OC output turns ON when the moment load factor becomes as follows: Moment load factor 90% Also, when the jib set pin is not inserted, the AML judges that the jib is mounted. Overwind cutout release switch: "Press" Automatic swing stop cancel switch: " 解除 " AML emergency switch: " 非常用 " + PTO switch: "ON (II)" Signal name: Auxiliary winch high-speed hoist-down output When the actual load is less than the specified value (300 kg) and the hoist-down operation of the auxiliary winch is detected, the OC (open collector) output turns ON. When the auxiliary winch high-speed hoist-down switch is set to ON, high-speed hoist-down operation works. OC output ON (DC 0 V): High-speed hoist-down operation works. OC output OFF (DC 24 V): Normal-speed hoist-down operation works. 48 W E

50 Input/Output Signals of the AML-LIIA System (GR-160N-1) CN 3 connector Pin No. Name 5 TR5 13 Di28 Signal names and functions Signal name: Main winch high-speed hoist-down output When the actual load is less than the specified value (350 kg) and the hoist-down operation of the main winch is detected, the OC (open collector) output turns ON. When the main winch high-speed hoist-down switch is set to ON, high-speed hoist-down operation works. OC output ON (DC 0 V): High-speed hoist-down operation works. OC output OFF (DC 24 V): Normal-speed hoist-down operation works. Signal name: 4th/5th/top boom sections telescoping operation detection switch input Input from the switch detecting 4th/5th/top boom sections telescoping operation. Switch ON (DC 0 V): No 4th/5th/top boom sections telescoping operation is detected. Switch OFF (DC 5 V): 4th/5th/top boom sections telescoping operation is detected. 16 CNTL 5P 17 CNTL 5N 21 Di21 Signal name: Swing relief proportional valve output In the swing free status, when the swing movement is stopped by the automatic swing stop function, controlled current is output from the AML to the swing relief proportional valve. However, in the 3 cases below, the automatic swing stop function does not work. (1) The automatic swing stop cancel switch is set to " 解除." (2) On-rubber operation (3) The AML emergency switch is set to " 非常用," and the PTO switch is set to "ON (II)." Output voltage: Square wave 0 to 24 V Crane operation status in which automatic swing stop function is enabled The outrigger extension width differs in the front/rear/left/right, and if the swing free operation is continued further, the status enters an operation range in which the moment load factor becomes 100% or more. While the boom lift is performed with the jib mounted, the automatic swing stop function works when the status enters an operation range in which the moment load factor becomes 90% or more, not 100% or more. Also, when the jib stowing pin is not inserted, the AML judges that the jib is mounted. The swing limit has been registered, and the swing free operation goes beyond the right swing or left swing limit area. Signal name: Ground terminal of swing relief proportional valve Input voltage: DC 0 V Signal name: Swing free switch input Switch input to detect that the swing free is selected. Switch ON (DC 0 V): Swing free is selected. Contact OFF (DC 5 V): Swing free is canceled. 49 W E

51 Diagram of the AML-LIIA System (GR-120F-1) Diagram of the AML-LIIA System (GR-120F-1) Boom angle detector CONNECTOR Connector board BOARD Boom length detector Swing angle detector Pressure sensor (main) Stop cancel input Stop cancel input Working condition input Pressure sensor for moment detection (elevating cylinder) Jib length detector Jib angle detector Jib-related Transmitter Automatic stop output (AML vent) Alarm output (buzzer) Hook-in control output Swing stop Lever operation detection input Outrigger extension length detector (4 locations) Outrigger retracting operation detection input Jib indicator lamp output Combination meter Lower unit Upper unit MDT (Multiplex Data Transmitter) Elevation slow stop AML external indicator lamp output (option) Telescoping slow stop Working condition input Jib length limit (option) 50 W E

52 Input/Output Signals of the AML-LIIA System (GR-120F-1) Input/Output Signals of the AML-LIIA System (GR-120F-1) As shown in the "Diagram of the AML-LIIA System" on the previous page, the inside of the AML-LIIA is composed of the display board, CPU board, analog board, power board, current output board, and connector board. All the input/output signals go through the connector board. Below are the names of the signals that are input to/output from the CN1, CN2, and CN3 connectors, and the descriptions of their functions. Names and functions of signals input to/output from CN1 connector are shown below: CN 1 connector Signal names and functions Pin No. Name 1 DET1GND Signal name: Ground for boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Input voltage: DC 0 V 2 DET1SRC Signal name: Impressed voltage output to boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Output voltage: DC 4.5 V Signal name: Boom length detector input Analog input to detect the boom length. Input voltage: DC 0 to 4.5 V 3 4 ANAIN A ANAIN B Reference data Input voltage at boom full retraction (5.5 m): 0.45 V (Ai check A/D conversion value: 203) Input voltage at boom full extension (15.0 m): 1.42 V (Ai check A/D conversion value: 644) Signal name: Boom angle detector input Analog input to detect the boom angle. Input voltage: DC 0 to 4.5 V Reference data Input voltage at boom angle of -2.7 : 0.57 V (Ai check A/D conversion value: 261) Input voltage at boom angle of 82.4 : 3.76 V (Ai check A/D conversion value: 1712) Signal name: Swing angle detector 1 input Analog input from the swing angle detector 1 to detect the swing angle. Input voltage: DC 0 to 4.5 V 5 ANAIN C Reference data Input voltage at swing angle of 0 : 1.09 V (Ai check A/D conversion value: 495) Input voltage at swing angle of 180 : 3.41 V (Ai check A/D conversion value: 1552) 6 DET1SLD 7 DET2GND 8 DET2SRC 9 ANAIN D Signal name: Shield of boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Input voltage: DC 0 V Signal name: Ground for main hydraulic pressure sensor Input voltage: DC 0 V Signal name: Impressed voltage output to main hydraulic pressure sensor Output voltage: DC 4.5 V Signal name: Swing angle detector 2 input Analog input from the swing angle detector 2 to detect the swing angle. Input voltage: DC 0 to 4.5 V Reference data Input voltage at swing angle of 0 : 3.41 V (Ai check A/D conversion value: 1552) Input voltage at swing angle of 180 : 1.09 V (Ai check A/D conversion value: 495) 51 W E

53 Input/Output Signals of the AML-LIIA System (GR-120F-1) CN 1 connector Pin No. Name 10 ANAIN E 12 DET2SLD 13 Di1 14 Di2 16 Di4 17 MB 18 MB 19 RB 20 RB 21 TC 22 ACC Signal names and functions Signal name: Main hydraulic pressure sensor input Analog input to detect the main hydraulic pressure. Input voltage: DC 0 to 4.5 V Reference data Input voltage at main hydraulic pressure of 0 MPa: 0.45 V Input voltage at main hydraulic pressure of 29.4 MPa: 4.05 V Signal name: Shield of main hydraulic pressure sensor Input voltage: DC 0 V Signal name: Overwind detection switch input Switch input to detect the overwinding of hook block. Switch ON (DC 0 V): The hook block is in normal status. Switch OFF (DC 24 V): The hook block is in overwinding status. Signal name: Boom full retraction detection switch input Switch input to detect that the boom is fully retracted. Switch ON (DC 0 V): The boom is in full retraction status. Switch OFF (DC 24 V): The boom is not in full retraction status. Reference data In the case (1) or (2) below, the AML judges that the boom full retraction detection switch is abnormal, and the error message [ ゼンシュク SW1 イジョウ ] is displayed. (1) When the boom length detection value is 5.12 m or less, the boom full retraction detection switch does not detect the boom full retraction status. (2) When the boom length detection value is 5.92 m or more, the boom full retraction detection switch detects the boom full retraction status. Signal name: Jib lock pin stowed detection switch input Switch input to detect that the jib (jib lock pin) is stowed. (Used for the input condition at hook-in operation.) Switch ON (DC 0 V): The jib is in stowed status. Switch OFF (DC 24 V): The jib is not in stowed status. Signal name: Power for circuit from battery Input voltage: DC 24 V Signal name: Power for relay from battery Input voltage: DC 24 V Signal name: Attachment operation input Switch input not to detect the elevation retracting pressure error (E2023) after the PTO switch is set to "ON (II)." Input voltage: DC 24 V Switch ON (DC 24 V): Elevation retracting pressure error (E2023) is not detected. Switch OFF (DC 0 V): Elevation retracting pressure error (E2023) is detected. Signal name: Automatic swing stop cancel switch input Power input to detect that the automatic swing stop function is canceled. Input voltage: DC 24 V Switch ON (DC 24 V): The automatic swing stop function is canceled. Switch OFF (DC 0 V): The automatic swing stop function works. 52 W E

54 Input/Output Signals of the AML-LIIA System (GR-120F-1) CN 1 connector Pin No. Name 24 Di5 25 Di6 26 Di7 28 Di9 30 GND 31 GND MOGND/ DET3GND MOSRC/ DET3SRC MOINP/ ANAING MOINN/ ANAINH MOSLD/ DET3SLD 39 SIF1GND Signal names and functions Signal name: Overwind cutout release switch input Switch input to detect that the overwind cutout function of the hook block is canceled. Switch ON (DC 0 V): Crane stop status due to detection of overwinding of the hook block and alarm buzzer are canceled. Switch OFF (DC 24 V): The overwind cutout function of the hook block works. Signal name: AML emergency switch input Switch input to detect that the AML automatic stop function is canceled. Switch ON (DC 0 V): The automatic stop function of the AML is canceled. At the same time, the diode circuit outside the AML main unit works together, and the overwind cutout function of the hook block is also canceled. Switch OFF (DC 24 V): The automatic stop function of the AML works. Signal name: Boom elevation slow stop cancel switch input Switch input to detect that the elevation slow stop function is canceled. Switch ON (DC 0 V): The elevation slow stop function is canceled. Switch OFF (DC 24 V): The elevation slow stop function works. Signal name: Over-front area detection switch input Switch input to detect the swing position (within 2 forward) Switch ON (DC 0 V): The swing position is in the front side. Switch OFF (DC 5 V): The swing position is in the status other than front. Signal name: Electrical ground Output voltage: DC 0 V Signal name: Ground for pressure sensor for moment detection Input voltage: DC 0 V Signal name: Impressed voltage output to pressure sensor for moment detection Output voltage: DC 5 V Signal name: Input for pressure sensor for moment detection (extension side) Analog input to detect the extension side pressure of the elevating cylinder. Input voltage: DC 0 to 5 V Signal name: Input for pressure sensor for moment detection (retraction side) Analog input to detect the retraction side pressure of the elevating cylinder. Input voltage: DC 0 to 5 V Signal name: Shield of pressure sensor for moment detection Input voltage: DC 0 V Signal name: Ground for serial port 1 Input voltage: DC 0 V Signal name: Power for serial port 1 Output voltage: DC 24 V 40 SIF1SRC 53 W E

55 Input/Output Signals of the AML-LIIA System (GR-120F-1) CN 1 connector Pin No. Name 41 SIF1TXD+ 42 SIF1TXD- Signal names and functions Signal name: Serial port 1 transmission (+) output signal Signal name: Serial port 1 transmission (-) output signal (*1): Transmission signal name: Jib rotation stowing, connecting pin retraction Jib rotation mounting, connecting pin extension 43 SIF1RXD+ 44 SIF1RXD- Signal name: Serial port 1 reception (+) input signal Signal name: Serial port 1 reception (-) input signal Transmission data to transmitter at the top end of the boom (*1) Received data from transmitter at the top end of the boom (*2) (*2): Received signal name: Jib angle, jib length, jib full retraction, jib tilt down (maximum), reverse retraction, reverse mounting, connecting pin full extension, connecting pin full retraction 45 SIF1SLD Signal name: Serial port 1 shield Input voltage: DC 0 V 54 W E

56 Input/Output Signals of the AML-LIIA System (GR-120F-1) Names and functions of signals input to/output from CN2 connector are shown below: CN 2 connector Pin No. Name Signal names and functions Signal name: Automatic stop 1 (AML vent) relay output When the crane is overloaded, when the hook block is overwound, or when the AML main unit is out of order, this relay contact turns OFF and crane operation is stopped. When the boom raising and jib raising operation are being stopped, the slow stop function works at the same time. (Current for slow stop is output from the boom raising solenoid proportional valve output CNTL3P.) However, when the boom elevation slow stop cancel switch is set to " 解除," the slow stop function does not work together. Relay ON (DC 24 V): Normal status Relay OFF (DC 0 V): Crane stop status When the AML emergency switch is set to " 非常用 " and the PTO switch is set to "ON (II)," this relay output is changed from OFF to ON, and the automatic stop function of the AML is canceled. At the same time, the diode circuit outside the AML main unit works together, and the overwind cutout function of the hook block is also canceled. Relay output Crane operation status 1 RLY 1 ON OFF Moment load factor < 90% 90% Moment load factor < 100% Moment load factor 100% The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering, jib extending, jib lowering) is stopped. When the hook block is overwound The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, jib extending, jib lowering) is stopped. If the overwind cutout release switch is pressed in this status, the relay output is changed from OFF to ON, and the overwind cutout function is canceled. When the working area limit has been registered and the crane operation other than swinging goes beyond the limit area The crane operation which goes beyond the limit area is stopped. When the AML main unit is out of order All the crane operations other than swinging are stopped. 55 W E

57 Input/Output Signals of the AML-LIIA System (GR-120F-1) CN 2 connector Pin No. Name Relay output OFF Signal names and functions Other control functions When the moment is abnormal When the actual load value calculated inside the AML becomes negative, the crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering, jib extending, jib lowering) is stopped. However, it is not stopped while the boom is retracted to the traveling posture. When all the conditions below are satisfied, the AML judges that the boom is being retracted to the traveling posture. (1) The boom angle is 2 or less. (2) The boom length is 5.65 m or less. (3) The swing position is within front ±5. 1 RLY 1 OFF When the hook-in operation is performed When all the conditions below are satisfied, this relay output turns OFF, and the hook-in control relay output RLY8 turns ON. (1) For the AML status setting, "jib set" is registered. (2) The boom is fully retracted (*1) (Di2: Boom full retraction detection). (3) The jib is fully retracted (Jib transmitter Di1: Jib full retraction detection). (4) The jib is in stowed status (Di4: Jib lock pin stowed detection). (*1) : When the contact of boom full retraction detection switch is "closed," the AML judges that the boom is fully retracted. When the jib is mounted and stowed When an improper operation is performed, this relay output turns OFF, and interlock is activated. When the boom reaches the elevation stroke end When the boom deviates from the boom angle 81.9 at which the extension side pressure of the elevating cylinder can be properly detected, the boom elevating operation is stopped. However, it is not stopped while the boom is retracted to the traveling posture. When all the conditions below are satisfied, the AML judges that the boom is being retracted to the traveling posture. (1) The boom length is 5.65 m or less. (2) The swing position is within front ±5. At the boom angle 80.4 or more, when the extension/retraction side pressure of the elevating cylinder cannot be properly detected and the moment load factor becomes 100% or more, the automatic stop function by overloading (stop of boom lowering operation) is canceled. 3 RLY 3 Signal name: Alarm (high-frequency buzzer) relay output (not used) 56 W E

58 Input/Output Signals of the AML-LIIA System (GR-120F-1) CN 2 connector Pin No. Name 4 RLY 4 5 RLY 5 6 RLY 6 7 RLY 7 Signal names and functions Signal name: AML alarm relay output When the crane is overloaded, this relay contact turns ON, and the buzzer sounds. Relay ON (DC 24 V): The alarm buzzer (low frequency) sounds. Relay OFF (DC 0 V): The alarm buzzer (low frequency) does not sound. Relay output OFF Moment load factor < 90% Conditions for alarming ON/OFF 90% Moment load factor < 100% ON Moment load factor 100% Signal name: Jib warning indicator relay output When the combination of operation selection is abnormal, when the jib set error occurs (when the jib is not fully retracted), and when the combination of operation selecting status and connection/rotation, maximum jib tilt down detection is abnormal, this relay contact turns ON, and the jib warning lamp lights. Relay ON (DC 24 V): The jib warning lamp lights. Relay OFF (DC 0 V): The jib warning lamp goes out. Signal name: Jib tilt operation indicator relay output When jib operation is selected, this relay contact turns ON, and the jib tilt operation indicator lamp lights. Relay ON (DC 24 V): The jib tilt operation indicator lamp lights. Relay OFF (DC 0 V): The jib tilt operation indicator lamp goes out. When boom lift or jib set operation is selected with "jib set" selected by the AML status setting, if the jib tilt down angle is not maximum, the jib tilt indicator lamp flashes. Signal name: Overwinding alarm relay output When the hook block is overwound, this relay contact turns ON and the buzzer sounds. Relay ON (DC 24 V): The alarm buzzer sounds. Relay OFF (DC 0 V): Normal status 8 RLY 8 Signal name: Hook-in control relay output When the hook-in operation is performed, this relay contact turns ON, the automatic stop 1 (AML vent) relay output RLY1 turns OFF, and the set pressure of the winch hydraulic circuit is changed to the lower pressure. Relay ON (DC 24 V): The set pressure of the winch hydraulic circuit is changed to the low pressure. Relay OFF (DC 0 V): Normal status When all the conditions below are satisfied, the AML judges that the hook-in operation is being performed. (1) For the AML status setting, "jib set" is registered. (2) The boom is fully retracted (*1) (Di2: Boom full retraction detection). (3) The jib is fully retracted (Jib transmitter Di1: Jib full retraction detection). (4) The jib is in stowed status (Di4: Jib lock pin stowed detection). (*1) : When the contact of boom full retraction detection switch is "closed," the AML judges that the boom is fully retracted. 57 W E

59 Input/Output Signals of the AML-LIIA System (GR-120F-1) CN 2 connector Pin No. Name 9 Di11 Signal names and functions Signal name: Main winch hoist-up operation detection switch input Input from the switch detecting hoist-up operation of the main winch. Switch ON (DC 0 V): No hoist-up operation of the main winch is detected. Switch OFF (DC 5 V): Hoist-up operation of the main winch is detected. 11 Di13 Signal name: Auxiliary winch hoist-up operation detection switch input Input from the switch detecting hoist-up operation of the auxiliary winch. Switch ON (DC 0 V): No hoist-up operation of the auxiliary winch is detected. Switch OFF (DC 5 V): Hoist-up operation of the auxiliary winch is detected. 13 CNTL 1P Signal name: Swing right proportional valve output When the right swing operation is stopped by the automatic swing stop function, controlled current is output from the AML to the swing right proportional valve. However, in the 2 cases below, the automatic swing stop function does not work. (1) The automatic swing stop cancel switch is set to " 解除." (2) The AML emergency switch is set to " 非常用," and the PTO switch is set to "ON (II)." Output voltage: Square wave 0 to 24 V 14 CNTL 1N Crane operation status in which automatic swing stop function is enabled The outrigger extension width differs in the front/rear/left/right, and if the right swing operation is continued further, the status enters an operation range in which the moment load factor becomes 100% or more. The swing limit has been registered, and the crane operation goes beyond the right swing limit area. Signal name: Ground terminal of swing right proportional valve Input voltage: DC 0 V 15 CNTL 2P Signal name: Swing left proportional valve output When the left swing operation is stopped by the automatic swing stop function, controlled current is output from the AML to the swing left proportional valve. However, in the 2 cases below, the automatic swing stop function does not work. (1) The automatic swing stop cancel switch is set to " 解除." (2) The AML emergency switch is set to " 非常用," and the PTO switch is set to "ON (II)." Output voltage: Square wave 0 to 24 V Crane operation status in which automatic swing stop function is enabled The outrigger extension width differs in the front/rear/left/right, and if the left swing operation is continued further, the status enters an operation range in which the moment load factor becomes 100% or more. The swing limit has been registered, and the crane operation goes beyond the left swing limit area. 58 W E

60 Input/Output Signals of the AML-LIIA System (GR-120F-1) CN 2 connector Pin No. Name 16 CNTL 2N Signal names and functions Signal name: Ground terminal of swing left proportional valve Input voltage: DC 0 V 17 Di15 18 Di16 19 Di17 20 Di18 21 Di19 22 Di20 23 CNTL 3P 24 CNTL 3N 25 CNTL 4P Signal name: Boom/jib extending operation detection switch input Input from the switch detecting boom extending/jib tilt down operation. Switch ON (DC 0 V): No boom/jib extending operation is detected. Switch OFF (DC 5 V): Boom/jib extending operation is detected. (*1) : Only for power tilt jib specification Signal name: Boom/jib retracting operation detection switch input Input from the switch detecting boom retracting/jib tilt up operation. Switch ON (DC 0 V): No boom/jib retracting operation is detected. Switch OFF (DC 5 V): Boom/jib retracting operation is detected. (*1) : Only for power tilt jib specification Signal name: Boom/jib raising operation detection switch input Input from the switch detecting boom raising operation. Switch ON (DC 0 V): No boom/jib raising operation is detected. Switch OFF (DC 5 V): Boom/jib raising operation is detected. Signal name: Boom/jib lowering operation detection switch input Input from the switch detecting boom lowering operation. Switch ON (DC 0 V): No boom/jib lowering operation is detected. Switch OFF (DC 5 V): Boom/jib lowering operation is detected. Signal name: Right swing operation detection switch input Input from the switch detecting right swing operation. Switch ON (DC 0 V): No right swing operation is detected. Switch OFF (DC 5 V): Right swing operation is detected. Signal name: Left swing operation detection switch input Input from the switch detecting left swing operation. Switch ON (DC 0 V): No left swing operation is detected. Switch OFF (DC 5 V): Left swing operation is detected. Signal name: Boom raising proportional valve output When the boom and jib raising operation is slowly stopped by the slow stop function, or when the jib raising speed is limited, controlled current is output from the AML to the boom raising proportional valve. However, when the boom elevation slow stop cancel switch is set to " 解除," the slow stop function does not operate. Output voltage: Square wave 0 to 24 V For the crane operation status in which the slow stop function is activated, refer to the automatic stop 1 (AML vent) relay output RLY1. Signal name: Ground terminal of boom raising proportional valve Input voltage: DC 0 V Signal name: Boom lowering proportional valve output When the jib lowering speed is limited, controlled current is output from the AML to the boom lowering proportional valve. Output voltage: Square wave 0 to 24 V 59 W E

61 Input/Output Signals of the AML-LIIA System (GR-120F-1) CN 2 connector Pin No. Name 26 CNTL 4N 30 SIF2TXD+ 31 SIF2TXD- Signal names and functions Signal name: Ground terminal of boom lowering proportional valve Input voltage: DC 0 V Signal name: Serial port 2 transmission (+) output signal Signal name: Serial port 2 transmission (-) output signal (*1): Transmission signal name Do1 AML cancellation (AML warning indicator lamp) Do2 Jib lock display 1 (jib lock lamp) Do3 Hook-in (hook-in indicator lamp) Do6 Outrigger retracting operation detection response Do7 Jib lock display 2 (jib lock lamp) 32 SIF2RXD+ 33 SIF2RXD- Signal name: Serial port 2 reception (+) input signal Signal name: Serial port 2 reception (-) input signal Transmission data to MDT (*1) Received data from MDT (*2) (*2): Received signal name ANIN2 O/R (FL) (*3) ANIN3 O/R (FR) (*3) ANIN4 O/R (RL) (*3) ANIN5 O/R (RR) (*3) Di1 Outrigger retracting operation detection (monitor signal of relay output RY6 from MDT lower unit) (*3): Reference data H-type outrigger Input voltage when outrigger extension width is minimum: 0.89 V (Ai check A/D conversion value: 336) Input voltage when outrigger extension width is maximum: 3.11 V (Ai check A/D conversion value: 1274) 34 SIF2SLD Signal name: Serial port 2 shield Input voltage: DC 0 V 60 W E

62 Input/Output Signals of the AML-LIIA System (GR-120F-1) Names and functions of signals input to/output from CN3 connector are shown below: CN 3 connector Pin No. Name 1 TR1 2 TR2 3 TR3 6 TR6 Signal names and functions Signal name: Less than 90% (safety) output When the moment load factor is less than 90%, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating less than 90% lights. OC output OFF (DC 24 V): The external indicator lamp indicating less than 90% goes out. Signal name: 90% alarm output When the moment load factor is 90% or more and less than 100%, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 90% lights. OC output OFF (DC 24 V): The external indicator lamp indicating 90% goes out. Signal name: 100% alarm output When the moment load factor is 100% or more, or when the automatic stop function is canceled, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 100% lights. OC output OFF (DC 24 V): The external indicator lamp indicating 100% goes out. Moment load factor 100% Conditions under which the OC output turns ON Overwind cutout release switch: "Press" Automatic swing stop cancel switch: " 解除 " AML emergency switch: " 非常用 " + PTO switch: "ON (II)" Signal name: Jib telescoping operation indicator output When jib operation is selected, the OC (open collector) turns ON. OC output ON (DC 0 V): The jib telescoping operation indicator lamp lights. OC output OFF (DC 24 V): The jib telescoping operation indicator lamp goes out. When boom lift, jib set operation (rotation stowing), or jib set operation (connecting pin retraction) is selected and the jib is not fully retracted with "jib set" selected by the AML status setting, the jib telescoping indicator lamp flashes. 7 TR7 Signal name: Connecting pin indicator output When detected status of the connecting pin is normal, the OC (open collector) output turns ON. OC output ON (DC 0 V): The connecting pin indicator lamp lights. OC output OFF (DC 24 V): The connecting pin indicator lamp goes out. When detection is abnormal, or when the jib connecting pin position is not detected properly, the connecting pin indicator lamp flashes. 61 W E

63 Input/Output Signals of the AML-LIIA System (GR-120F-1) Applicable Serial No. 1 : From FD1149 CN 3 connector Pin No. Name 8 TR8 Signal names and functions Signal name: Jib rotation indicator output When detected status of the jib rotation mounting and stowing is normal, the OC (open collector) output turns ON. OC output ON (DC 0 V): The jib rotation indicator lamp lights. OC output OFF (DC 24 V): The jib rotation indicator lamp goes out. When detection is abnormal, or when the jib is being rotated, the jib rotation indicator lamp flashes. 10 Di25 11 Di26 12 Di27 13 Di28 16 CNTL5P 17 CNTL5T Signal name: Jib rotating operation select switch input Switch input to detect that the jib rotating operation is selected. Switch ON (DC 0 V): Jib rotating operation is selected. Switch OFF (DC 5 V): Jib rotating operation is not selected. Signal name: Connecting pin operation select switch input Switch input to detect that the connecting pin operation is selected. Switch ON (DC 0 V): Connecting pin operation is selected. Switch OFF (DC 5 V): Connecting pin operation is not selected. Signal name: Jib set operation select switch input Switch input to detect that the jib set operation is selected. Switch ON (DC 0 V): Jib set operation is selected. Switch OFF (DC 5 V): Jib set operation is not selected. Signal name: Jib operation select switch input Switch input to detect that the jib operation is selected. Switch ON (DC 0 V): Jib operation is selected. Switch OFF (DC 5 V): Jib operation is not selected. Signal name: Boom and jib telescoping extension proportional valve output When the boom and jib extending speed is limited, controlled current is output from the AML to the telescoping extension proportional valve. Output voltage: Square wave 0 to 24 V Signal name: Ground terminal of boom and jib telescoping extension proportional valve Input voltage: DC 0 V 18 CNTL6P 19 CNTL6N Signal name: Boom and jib telescoping retraction proportional valve output When the boom and jib retracting speed is limited, controlled current is output from the AML to the telescoping retraction proportional valve. Output voltage: Square wave 0 to 24 V Signal name: Ground terminal of boom and jib telescoping retraction proportional valve Input voltage: DC 0 V 1 21 Di21 Signal name: Jib length limit switch input (option) Switch input to detect that jib length is limited. Switch ON (DC 0 V): When the jib is extended, jib length is limited. Switch OFF (DC 5 V): When the jib is extended, jib length is not limited. 62 W E

64 Input/Output Signals of the AML-LIIA System (GR-120F-1) CN 3 connector Pin No. Name 22 Di22 23 Di23 Signal names and functions Signal name: Jib mounting operation selector switch input Switch input to detect that the jib mounting operation is selected. Switch ON (DC 0 V): Jib mounting operation is selected. Switch OFF (DC 5 V): Jib mounting operation is not selected. Signal name: Jib stowed operation selector switch input Switch input to detect that the jib stowing operation is selected. Switch ON (DC 0 V): Jib stowing operation is selected. Switch OFF (DC 5 V): Jib stowing operation is not selected. 63 W E

65 Diagram of the AML-LIIA System (GA-700N-1) Diagram of the AML-LIIA System (GA-700N-1) Boom angle detector Connector board CONNECTOR BOARD Boom length detector Swing angle detector Pressure sensor (main) Pressure sensor (accumulator) Swing free input Telescoping lever control selector switch input Working condition input Jib angle detector Pressure sensor for moment detection (elevating cylinder) Jib length detector Jib control output Working condition input Transmitter Automatic stop output (AML vent) Accumulator abnormal pressure warning lamp output Alarm output (buzzer) 4th/top boom sections telescoping control output Jib tilt warning lamp output Hydraulic removal output for jib connecting pin and jib pivot pin operation Swing stop Lever operatiaon detection input Elevation slow stop Outrigger extension length detector (4 locations) Outrigger retraction detection input Front jack ground detection input Transmitter AML external indicator lamp output (option) Boom and jib connecting pin lock warning lamp output 3rd boom section telescoping control output 2nd boom section telescoping control output Swing stop (swing free) Telescoping retraction slow stop Working condition input Stop cancel input 64 W E

66 Input/Output Signals of the AML-LIIA System (GA-700N-1) Input/Output Signals of the AML-LIIA System (GA-700N-1) As shown in the "Diagram of the AML-LIIA System" on the previous page, the inside of the AML-LIIA is composed of the display board, CPU board, analog board, power board, current output board, and connector board. All the input/output signals go through the connector board. Below are the names of the signals that are input to/output from the CN1, CN2, and CN3 connectors, and the descriptions of their functions. Names and functions of signals input to/output from CN1 connector are shown below: CN 1 connector Signal names and functions Pin No. Name 1 DET1GND Signal name: Ground for boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Input voltage: DC 0 V 2 DET1SRC Signal name: Impressed voltage output to boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Output voltage: DC 4.5 V Signal name: Boom length detector input Analog input to detect the boom length. Input voltage: DC 0 to 4.5 V 3 ANAIN A Reference data Input voltage at boom full retraction (11.5 m): 0.45 V (Ai check A/D conversion value: 203) Input voltage at boom full extension (44 m): 3.77 V (Ai check A/D conversion value: 1714) 4 ANAIN B Signal name: Boom angle detector input Analog input to detect the boom angle. Input voltage: DC 0 to 4.5 V Reference data Input voltage at boom angle of -2 : 0.6 V (Ai check A/D conversion value: 272) Input voltage at boom angle of 83 : 3.78 V (Ai check A/D conversion value: 1722) 5 ANAIN C 6 DET1SLD 7 DET2GND 8 DET2SRC 9 ANAIN D Signal name: Swing angle detector 1 input Analog input from the swing angle detector 1 to detect the swing angle. Input voltage: DC 0 to 4.5 V Signal name: Shield of boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 Input voltage: DC 0 V Signal name: Ground for main hydraulic pressure sensor and accumulator pressure sensor Input voltage: DC 0 V Signal name: Impressed voltage output to main hydraulic pressure sensor and accumulator pressure sensor Output voltage: DC 4.5 V Signal name: Swing angle detector 2 input Analog input from the swing angle detector 2 to detect the swing angle. Input voltage: DC 0 to 4.5 V 65 W E

67 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 1 connector Pin No. Name 10 ANAIN E 11 ANAIN F 12 DET2SLD 13 Di1 14 Di2 Signal names and functions Signal name: Main hydraulic pressure sensor input Analog input to detect the main hydraulic pressure. Input voltage: DC 0 to 4.5 V Reference data Input voltage at main hydraulic pressure of 0 MPa: 0.45 V Input voltage at main hydraulic pressure of 29.4 MPa: 4.05 V Signal name: Accumulator pressure sensor input Analog input to detect the accumulator pressure. Input voltage: DC 0 to 4.5 V Reference data Input voltage at accumulator pressure of 0 MPa: 0.45 V Input voltage at accumulator pressure of 29.4 MPa: 4.05 V Signal name: Shield of main hydraulic pressure sensor and accumulator pressure sensor Input voltage: DC 0 V Signal name: Overwind detection switch input Switch input to detect the overwinding of hook block. Switch ON (DC 0 V): The hook block is in normal status. Switch OFF (DC 24 V): The hook block is in overwinding status. Signal name: 4th/top boom sections full retraction detection switch input Switch input to detect that the 4th/top boom sections are fully retracted. Switch ON (DC 0 V): 4th/top boom sections are in full retraction status. Switch OFF (DC 24 V): 4th/top boom sections are not in full retraction status. Reference data With boom telescoping system I (2nd/3rd boom sections end extending system) In the case (1) or (2) below, the AML judges that the 4th/top boom sections full retraction detection switch is abnormal, and the error message [ ゼンシュク SW2 イジョウ ] is displayed. (1) When the boom length detection value is 27.4 m or less, the 4th/top boom sections full retraction detection switch does not detect the full retraction status. (2) When the boom length detection value is 28.2 m or more, the 4th/top boom sections full retraction detection switch detects the full retraction status. With boom telescoping system II (3rd boom section end extending system) In the case (1) or (2) below, the AML judges that the 4th/top boom sections full retraction detection switch is abnormal, and the error message [ ゼンシュク SW2 イジョウ ] is displayed. (1) When the boom length detection value is 19.2 m or less, the 4th/top boom sections full retraction detection switch does not detect the full retraction status. (2) When the boom length detection value is 20 m or more, the 4th/top boom sections full retraction detection switch detects the full retraction status. 66 W E

68 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 1 connector Pin No. Name 15 Di3 16 Di4 17 MB 18 MB 19 RB 20 RB 22 ACC Signal names and functions Signal name: 2nd to top boom sections (all sections) full retraction detection switch input Switch input to detect that the 2nd to top boom sections are fully retracted. Switch ON (DC 0 V): 2nd to top boom sections are in full retraction status. Switch OFF (DC 24 V): 2nd to top boom sections are not in full retraction status. Reference data In the case (1) or (2) below, the AML judges that the 2nd/3rd boom sections full retraction detection switch and the 4th/top boom sections full retraction detection switch are abnormal, and the error message [ ゼンシュク SW1 イジョウ ] is displayed. (1) When the boom length detection value is 11.3 m or less, the 2nd/3rd boom sections full retraction detection switch and the 4th/top boom sections full retraction detection switch do not detect the full retraction status. (2) When the boom length detection value is 11.7 m or more, the 2nd/3rd boom sections full retraction detection switch and the 4th/top boom sections full retraction detection switch detect the full retraction status. Signal name: 2nd boom section full retraction detection switch input Switch input to detect that the 2nd boom section is fully retracted. Switch ON (DC 0 V): 2nd boom section is in full retraction status. Switch OFF (DC 24 V): 2nd boom section is not in full retraction status. Reference data With boom telescoping system I (2nd/3rd boom sections end extending system) Not used With boom telescoping system II (3rd boom section end extending system) In the case (1) or (2) below, the AML judges that the 2nd boom section full retraction detection switch is abnormal, and the error message [ ゼンシュク SW3 イジョウ ] is displayed. (1) When the boom length detection value is 35.5 m or less, the 2nd boom section full retraction detection switch does not detect the full retraction status. (2) When the boom length detection value is 36.3 m or more, the 2nd boom section full retraction detection switch detects the full retraction status. Signal name: Power for circuit from battery Input voltage: DC 24 V Signal name: Power for relay from battery Input voltage: DC 24 V Signal name: Swing free/lock selector switch input Power input to detect that the swing free is selected. Input voltage: DC 24 V Switch ON (DC 24 V): Swing free is selected. Switch OFF (DC 0 V): Swing lock is selected. 67 W E

69 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 1 connector Pin No. Name 24 Di5 25 Di6 26 Di7 27 Di8 28 Di9 29 Di10 30 GND 31 GND MOGND/ DET3GND MOSRC/ DET3SRC MOINP/ ANAING Signal names and functions Signal name: Jib operation select 1 switch input Switch input to detect the position of the telescoping lever control selector switch. Switch ON (DC 0 V): The telescoping lever control selector switch is at the position of either jib tilt operation or jib set operation. Switch OFF (DC 24 V): The telescoping lever control selector switch is at the position of either boom telescoping operation or jib telescoping operation. Signal name: Jib operation select 2 switch input Switch input to detect the position of the telescoping lever control selector switch. Switch ON (DC 0 V): The telescoping lever control selector switch is at the position of either jib telescoping operation or jib set operation. Switch OFF (DC 24 V): The telescoping lever control selector switch is at the position of either boom telescoping operation or jib tilt operation. Signal name: Jib tilt down/extending operation detection switch input Input from the switch detecting the jib tilt down or jib extending operation. Switch ON (DC 0 V): Jib tilt down or jib extending operation is not detected. Switch OFF (DC 24 V): Jib tilt down or jib extending operation is detected. Signal name: Jib tilt up/retracting operation detection switch input Input from the switch detecting the jib tilt up or jib retracting operation. Switch ON (DC 0 V): Jib tilt up or jib retracting operation is not detected. Switch OFF (DC 24 V): Jib tilt up or jib retracting operation is detected. Signal name: Jib stowed detection switch input Switch input to detect that the jib is stowed. Switch ON (DC 0 V): The jib is in stowed status. Switch OFF (DC 5 V): The jib is not in stowed status. Signal name: Swing angle detector 1, 2 selector (swing dead angle detection) switch input Switch input to detect the swing position (left lateral side). Switch ON (DC 0 V): The swing position is in the left lateral side. Switch OFF (DC 5 V): The swing position is in the right lateral side. Signal name: Electrical ground Output voltage: DC 0 V Signal name: Ground for pressure sensor for moment detection Input voltage: DC 0 V Signal name: Impressed voltage output to pressure sensor for moment detection Output voltage: DC 5 V Signal name: Input for pressure sensor for moment detection (extension side) Analog input to detect the extension side pressure of the elevating cylinder. Input voltage: DC 0 to 5 V 68 W E

70 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 1 connector Pin No Name MOINN/ ANAINH MOSLD/ DET3SLD 39 SIF1GND 40 SIF1SRC 41 SIF1TXD+ Signal names and functions Signal name: Input for pressure sensor for moment detection (retraction side) Analog input to detect the retraction side pressure of the elevating cylinder. Input voltage: DC 0 to 5 V Signal name: Shield of pressure sensor for moment detection Input voltage: DC 0 V Signal name: Ground for serial port 1 Input voltage: DC 0 V Signal name: Power for serial port 1 Output voltage: DC 24 V Signal name: Serial port 1 transmission (+) output signal Signal name: Serial port 1 transmission (-) output 42 SIF1TXDsignal (*1): Transmission signal name Jib control outputs SOL No. 1, SOL No. 2, SOL No. 3 Transmission data to transmitter at the top end of the boom (*1) Depending on the ON (DC 0 V)/OFF (DC 24 V) status of the jib operation select 1 switch input Di5 and jib operation select 2 switch input Di6 of the AML, the jib control outputs SOL No. 1, SOL No. 2, and SOL No. 3 of the transmitter turn ON (DC 24 V). Position of telescoping Jib operation select 1, 2 Jib control output of transmitter lever control selector switch input of AML switch Di5 Di6 SOL No. 2 SOL No. 3 SOL No. 1 Boom telescoping operation OFF OFF ON OFF OFF Jib tilt operation ON OFF OFF OFF OFF Jib telescoping operation OFF ON ON ON OFF Jib set operation ON ON ON OFF ON (*2) (*2): Turned ON when the jib mounting/retracting operation is performed. Jib control outputs SOL No. 4, SOL No. 5 When the jib connecting pin/jib pivot pin operation detection switch input Di7 of the transmitter turns ON (DC 0 V), the jib control outputs SOL No. 4 and SOL No. 5 of the transmitter turn ON (DC 24 V). Jib connecting pin/jib pivot pin operation detection switch input of transmitter Jib control output of transmitter Di7 SOL No. 4 SOL No. 5 ON ON ON 69 W E

71 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 1 connector Pin No. Name 43 SIF1RXD+ Signal names and functions Signal name: Serial port 1 reception (+) input signal Signal name: Serial port 1 reception (-) input 44 SIF1RXDsignal (*1): Received signal name Jib angle (*2) Jib length (*3) Di1 Jib full retraction detection (*4) Di2 Jib tilt detection Di6 Jib connecting pin/jib pivot pin insertion detection Received data from transmitter at the top end of the boom (*1) Di7 When jib connecting pin/jib pivot pin operation is detected (when this input Di7 is ON (DC 0 V), the jib connecting pin/jib pivot pin hydraulic removal relay output RLY7 of AML turns ON (DC 24 V). (*2): Reference data Input voltage when jib offset angle is minimum (5 ): 3.64 V Input voltage when jib offset angle is maximum (60 ): 1.57 V (*3): Reference data With GA-700N Input voltage at jib full retraction (9.7 m): 0.45 V Input voltage at jib full extension (16 m): 3.23 V With GA-700N Input voltage at jib full retraction (10.7 m): 0.45 V Input voltage at jib full extension (18 m): 1.75 V (*4): Reference data With GA-700N In the case (1) or (2) below, the AML judges that the jib full retraction detection switch is abnormal, and the error message [ ジブスイッチ 1 イジョウ ] is displayed. (1) When the jib length detection value is 9.5 m or less, the jib full retraction detection switch does not detect the full retraction status. (2) When the jib length detection value is 9.9 m or more, the jib full retraction detection switch detects the full retraction status. With GA-700N In the case (1) or (2) below, the AML judges that the jib full retraction detection switch is abnormal, and the error message [ ジブスイッチ 1 イジョウ ] is displayed. (1) When the jib length detection value is 10.5 m or less, the jib full retraction detection switch does not detect the full retraction status. (2) When the jib length detection value is 10.9 m or more, the jib full retraction detection switch detects the full retraction status. 45 SIF1SLD Signal name: Serial port 1 shield Input voltage: DC 0 V 70 W E

72 Input/Output Signals of the AML-LIIA System (GA-700N-1) Names and functions of signals input to/output from CN2 connector are shown below: CN 2 connector Pin No. Name Signal names and functions Signal name: Automatic stop 1 (AML vent) relay output When the crane is overloaded, when the hook block is overwound, or when the AML main unit is out of order, this relay contact turns OFF and crane operation is stopped. When the boom elevating operation is being stopped, the slow stop function works at the same time. (Current for slow stop is output from the boom raising solenoid proportional valve output CNTL3P or boom lowering solenoid proportional valve output CNTL4P.) However, when the boom elevation slow stop cancel switch is set to "ON ( 解除 )," the slow stop function does not work together. An exception is a case at the backward stable stop, and the slow stop function works together in this case. Relay ON (DC 24 V): Normal status Relay OFF (DC 0 V): Crane stop status When the AML emergency switch is retained at the position of automatic stop cancel (ON), this relay output is changed from OFF to ON only for a duration while the switch is retained, and the automatic stop function of the AML becomes canceled. (*1) (*1) : The stop function for backward stability alone is not deactivated, and permanently operates to stop boom raising operation slowly. Relay output Crane operation status 1 RLY 1 ON OFF Moment load factor < 90% 90% Moment load factor < 100% Moment load factor 100% The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, jib extending, boom lowering, jib tilt down) is stopped. While the boom lift is performed with the jib mounted, the relay output turns OFF when the moment load factor becomes as follows: Outrigger extension width: Moment load factor 90% Maximum (7.8 m) Outrigger extension width: Middle (7.2 m) Moment load factor 85% Outrigger extension width: Middle (5.3 m) When the jib stowed detection switch contact is "open," the AML judges that the jib is mounted. When the hook block is overwound The crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, jib extending, boom lowering, jib tilt down) is stopped. 71 W E

73 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 2 connector Pin No. Name 1 RLY 1 Relay output OFF Relay output OFF Signal names and functions Crane operation status If the overwinding stop cancel switch is pressed in this status, the relay output is changed from OFF to ON, and the overwind cutout function is canceled. When the working area limit has been registered and the crane operation other than swinging goes beyond the limit area The crane operation which goes beyond the limit area is stopped. When the AML main unit is out of order All the crane operations other than swinging are stopped. When the backward stability control is activated, the crane operation toward critical side (boom raising) is stopped. The backward stability control is the function which works when at least one outrigger is in the minimum extension status (2.23 m). In the swing position range of 130 on left/right lateral side, when the boom angle becomes 67 or more, boom raising operation is stopped. Other control functions When the moment is abnormal When the actual load value calculated inside the AML becomes negative, the crane operation toward critical side (main winch hoisting up, auxiliary winch hoisting up, boom extending, boom lowering, jib extending, boom lowering, jib tilt down) is stopped. However, it is not stopped while the boom is retracted into the boom rest. When all the conditions below are satisfied, the AML judges that the boom is being retracted into the boom rest. (1) The boom angle is 1 or less. (2) The boom length is 11.9 m or less. (3) The swing position is in the range of front ±5. When the boom reaches the elevation stroke end When the boom deviates from the boom angle range in which the extension/retraction side pressure of the elevating cylinder can be properly detected (-2.4 to 83.5 ), the boom elevating operation is stopped. In the boom angle range between 83.5 and 84, when the extension/retraction side pressure of the elevating cylinder cannot be properly detected and the moment load factor becomes 100% or more, the automatic stop function by overloading (stop of boom lowering operation) is canceled. 72 W E

74 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 2 connector Pin No. Name 1 RLY 1 Relay output OFF Signal names and functions Jib control functions Abnormal position of telescoping lever control selector switch When all the conditions below are satisfied, this relay output turns OFF. At the same time, the following error message is displayed. Error message: [ シンシュクセンタクイジョウ ] (1) The telescoping lever control selector switch is at the position other than "Jib set operation." (2) The jib connecting pin switch or jib pivot pin switch is being controlled. Boom telescoping limit function in jib stowed status When all the conditions below are satisfied, this relay output turns OFF. At the same time, the following error message is displayed. Error message: [ ジブチルトデテイシ!] (1) The jib is in stowed status (*1). (2) The jib tilt angle is not 0 (*2). (3) The boom length is 12.3 m or less. (4) The boom extending or retracting operation is detected. (*1) : When the jib stowed detection switch contact is "closed," the AML judges that the jib is stowed. (*2) : When the jib tilt detection switch contact is "open," the AML judges that the jib tilt angle is not 0. Jib tilt down limit function in jib stowed status (Jib tilt warning lamp/alarm) When all the conditions below are satisfied, this relay output turns OFF, and jib tilt warning lamp/alarm relay output RLY6 turns ON. At the same time, the following error message is displayed. Error message: [ ジブガチルトシテイマス!] (1) The jib is in stowed status (*1). (2) The jib tilt angle is not 0 (*2). (3) The jib tilt down or extending operation is detected. (*1) : When the jib stowed detection switch contact is "closed," the AML judges that the jib is stowed. (*2) : When the jib tilt detection switch contact is "open," the AML judges that the jib tilt angle is not W E

75 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 2 connector Pin No. Name Relay output Signal names and functions Jib control functions Jib extending limit function in jib stowed status (Jib tilt warning lamp/alarm) When all the conditions below are satisfied, this relay output turns OFF, and jib tilt warning lamp/alarm relay output RLY6 turns ON. At the same time, the following error message is displayed. Error message: [ ジブガノビテイマス!] (1) The jib is in stowed status (*1). (2) The jib is not fully retracted (*2). (3) The jib tilt down or extending operation is detected. (*1) : When the jib stowed detection switch contact is "closed," the AML judges that the jib is stowed. (*2) : When the jib full retraction detection switch contact is "open," the AML judges that the jib is not fully retracted. 1 RLY 1 OFF Jib tilt up limit function during jib lift (Alarm for abnormal jib tilt) When all the conditions below are satisfied during jib lift, this relay output turns OFF, and the abnormal jib tilt/jib set alarm relay output RLY8 turns ON. At the same time, the following error message is displayed. Error message: [ ジブチルトカクサイショウ!] [ チルトサイショウデテイシ!] (1) The jib is in mounted status (*1). (2) The jib tilt angle is 3.5 or less. (3) The jib tilt up operation is detected. (*1) : When the jib stowed detection switch contact is "open," the AML judges that the jib is mounted. Jib tilt down limit function during jib lift (Alarm for abnormal jib tilt) When all the conditions below are satisfied during jib lift, this relay output turns OFF, and the abnormal jib tilt/jib set alarm relay output RLY8 turns ON. At the same time, the following error message is displayed. Error message: [ ジブチルトカクサイダイ!] [ チルトサイダイデテイシ!] (1) The jib is in mounted status (*1). (2) The jib tilt angle is 61 or more. (3) The jib tilt down operation, main winch hoist-up operation, or auxiliary winch hoist-up operation is detected. (*1) : When the jib stowed detection switch contact is "open," the AML judges that the jib is mounted. 74 W E

76 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 2 connector Pin No. Name 1 RLY 1 Relay output OFF Signal names and functions Jib control functions Jib extending limit function during jib set (Alarm for abnormal jib set) When all the conditions below are satisfied during jib set operation, this relay output turns OFF, and the abnormal jib tilt/jib set alarm relay output RLY8 turns ON. At the same time, the following error message is displayed. Error message: [ ジブナガサオーバー!] (1) The jib is in mounted status (*1). (2) The jib length is specified length (*2) or more. (3) The jib extending operation is detected. (*1) : When the jib stowed detection switch contact is "open," the AML judges that the jib is mounted. (*2) : 9.9 m (GA-700N ) 10.9 m (GA-700N ) 2 RLY 2 Signal name: Accumulator abnormal pressure alarm relay output When the accumulator pressure deviates from the normal range described below, this relay contact turns ON (relay OFF on the program), and the accumulator abnormal pressure warning lamp lights. Normal range: 2.2 to 5.9 MPa (22 to 60 kgf/cm 2 ) Relay ON (DC 0 V): Normal status Relay OFF (DC 24 V): Accumulator abnormal pressure warning lamp lights. Signal name: Overwinding alarm relay output When the hook block is overwound, this relay contact turns ON and the buzzer sounds. Relay ON (DC 24 V): The alarm buzzer sounds. Relay OFF (DC 0 V): Normal status 3 RLY 3 75 W E

77 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 2 connector Pin No. Name Signal names and functions Signal name: AML alarm relay output When the crane is overloaded, this relay contact turns ON, and the buzzer sounds. Relay ON (DC 24 V): The alarm buzzer sounds. Relay OFF (DC 0 V): The alarm buzzer does not sound. Relay output Conditions for alarming OFF Moment load factor < 90% 4 RLY 4 ON/OFF ON 90% Moment load factor < 100% While the boom lift is performed with the jib mounted, the relay output turns ON/OFF when the moment load factor becomes as follows: Outrigger extension width: Maximum (7.8 m) Outrigger extension width: Middle (7.2 m) Outrigger extension width: Middle (5.3 m) 80% Moment load factor < 90% 75% Moment load factor < 85% When the jib stowed detection switch contact is "open," the AML judges that the jib is mounted. Moment load factor 100% While the boom lift is performed with the jib mounted, the relay output turns ON when the moment load factor becomes as follows: Outrigger extension width: Maximum (7.8 m) Outrigger extension width: Middle (7.2 m) Moment load factor 90% Moment load factor 85% Outrigger extension width: Middle (5.3 m) When the jib stowed detection switch contact is "open," the AML judges that the jib is mounted. 76 W E

78 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 2 connector Pin No. Name 5 RLY 5 6 RLY 6 7 RLY 7 Signal names and functions Signal name: Telescoping control relay output With boom telescoping system I (2nd/3rd boom sections end extending system) In the case (1) or (2) below, this relay contact turns ON, and 4th/top boom sections telescope. (1) With the 2nd/3rd boom sections extended to the specified length (27.4 m) or more, the next boom section extension switch is pressed. (2) With the 2nd/3rd boom sections extended to the specified length (27.4 m) or more, the contact of 4th/top boom sections full retraction detection switch becomes "open." Relay ON (DC 24 V): 4th/top boom sections telescope. Relay OFF (DC 0 V): 2nd/3rd boom sections telescope. With boom telescoping system II (3rd boom section end extending system) In the case (1) or (2) below, this relay contact turns ON, and 4th/top boom sections telescope. In the case (3) or (4) below, this relay contact turns OFF, and 2nd boom section telescopes. (1) With the 3rd boom section extended to the specified length (19.2 m) or more, the next boom section extension switch is pressed. (2) With the 3rd boom section extended to the specified length (19.2 m) or more, the contact of 4th/top boom sections full retraction detection switch becomes "open." (3) With the 3rd/4th/top boom sections extended to the specified length (35.5 m) or more, the next boom section extension switch is pressed. (4) With the 3rd/4th/top boom sections extended to the specified length (35.5 m) or more, the contact of 2nd boom section full retraction detection switch becomes "open." Relay ON (DC 24 V): 4th/top boom sections telescope. Relay OFF (DC 0 V): 2nd boom section telescopes. Signal name: Jib tilt warning lamp/alarm relay output When the jib is tilted (*2) or extended (*3) with the jib stowed (*1), this relay contact turns ON, the jib tilt warning lamp lights, and the alarm buzzer sounds. At the same time, the automatic stop 1 (AML vent) relay output RLY1 turns OFF. Relay ON (DC 24 V): The jib tilt warning lamp lights and the alarm buzzer sounds. Relay OFF (DC 0 V): Normal status (*1) : When the jib stowed detection switch contact is "closed," the AML judges that the jib is stowed. (*2) : When the jib tilt detection switch contact is "open," the AML judges that the jib is tilted. (*3) : When the jib full retraction detection switch contact is "open," the AML judges that the jib is extended. Signal name: Jib connecting pin/jib pivot pin hydraulic removal relay output When the jib connecting pin or jib pivot pin is operated, the jib connecting pin/jib pivot pin operation detection switch input Di7 of the transmitter at the top end of the boom turns ON (DC 0 V), and this relay contact turns ON. Relay ON (DC 24 V): The jib connecting pin or jib pivot pin is operated. Relay OFF (DC 0 V): The jib connecting pin or jib pivot pin is not operated. 77 W E

79 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 2 connector Pin No. Name 8 RLY 8 9 Di11 10 Di12 11 Di13 Signal names and functions Signal name: Abnormal jib tilt/jib set alarm relay output Alarm for abnormal jib tilt When the jib offset angle deviates from the range between 3.5 and 61 during jib lift, this relay contact turns ON, and the buzzer sounds. At the same time, the automatic stop 1 (AML vent) relay output RLY1 turns OFF. Relay ON (DC 24 V): The alarm buzzer sounds. Relay OFF (DC 0 V): The alarm buzzer does not sound. Alarm for abnormal jib set When the jib length becomes to the following specified length or more during jib set operation, this relay contact turns ON, and the buzzer sounds. At the same time, the automatic stop 1 (AML vent) relay output RLY1 turns OFF. GA-700N : Specified length 9.9 m GA-700N : Specified length 10.9 m Relay ON (DC 24 V): The alarm buzzer sounds. Relay OFF (DC 0 V): The alarm buzzer does not sound. Signal name: Main winch hoist-up operation detection switch input Input from the switch detecting hoist-up operation of the main winch. Switch ON (DC 0 V): No hoist-up operation of the main winch is detected. Switch OFF (DC 5 V): Hoist-up operation of the main winch is detected. Signal name: Main winch hoist-down operation detection switch input Input from the switch detecting hoist-down operation of the main winch. Switch ON (DC 0 V): No hoist-down operation of the main winch is detected. Switch OFF (DC 5 V): Hoist-down operation of the main winch is detected. Signal name: Auxiliary winch hoist-up operation detection switch input Input from the switch detecting hoist-up operation of the auxiliary winch. Switch ON (DC 0 V): No hoist-up operation of the auxiliary winch is detected. Switch OFF (DC 5 V): Hoist-up operation of the auxiliary winch is detected. Signal name: Auxiliary winch hoist-down operation detection switch input Input from the switch detecting hoist-down operation of the auxiliary winch. Switch ON (DC 0 V): No hoist-down operation of the auxiliary winch is detected. Switch OFF (DC 5 V): Hoist-down operation of the auxiliary winch is detected. 12 Di14 78 W E

80 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 2 connector Pin No. Name 13 CNTL 1P Signal names and functions Signal name: Swing right proportional valve output When the right swing operation is stopped by the automatic swing stop function, controlled current is output from the AML to the swing right proportional valve. However, in the 2 cases below, the automatic swing stop function does not work. (1) The automatic swing stop cancel switch is set to "ON ( 解除 )." (2) The AML emergency switch is retained at the position of automatic stop cancel (ON). Output voltage: Square wave 0 to 24 V Crane operation status in which automatic swing stop function is enabled The outrigger extension width differs in the front/rear/left/right, and if the right swing operation is continued further, the status enters an operation range in which the moment load factor becomes 100% or more. While the boom lift is performed with the jib mounted, the automatic swing stop function works when the status enters either of followings, not when enters an operation range in which the moment load factor becomes 100% or more. Outrigger extension width: Maximum (7.8 m) Outrigger extension width: Middle (7.2 m) Outrigger extension width: Middle (5.3 m) When status enters an operation range in which the moment load factor becomes 90% or more When status enters an operation range in which the moment load factor becomes 85% or more When the jib stowed detection switch contact is "open," the AML judges that the jib is mounted. The swing limit has been registered, and the crane operation goes beyond the right swing limit area. 14 CNTL 1N Signal name: Ground terminal of swing right proportional valve Input voltage: DC 0 V 79 W E

81 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 2 connector Pin No. Name 15 CNTL 2P 16 CNTL 2N 17 Di15 18 Di16 19 Di17 20 Di18 Signal names and functions Signal name: Swing left proportional valve output When the left swing operation is stopped by the automatic swing stop function, controlled current is output from the AML to the swing left proportional valve. However, in the 2 cases below, the automatic swing stop function does not work. (1) The automatic swing stop cancel switch is set to "ON ( 解除 )." (2) The AML emergency switch is retained at the position of automatic stop cancel (ON). Output voltage: Square wave 0 to 24 V Crane operation status in which automatic swing stop function is enabled The outrigger extension width differs in the front/rear/left/right, and if the left swing operation is continued further, the status enters an operation range in which the moment load factor becomes 100% or more. While the boom lift is performed with the jib mounted, the automatic swing stop function works when the status enters either of followings, not when enters an operation range in which the moment load factor becomes 100% or more. Outrigger extension width: Maximum (7.8 m) Outrigger extension width: Middle (7.2 m) Outrigger extension width: Middle (5.3 m) When status enters an operation range in which the moment load factor becomes 90% or more When status enters an operation range in which the moment load factor becomes 85% or more When the jib stowed detection switch contact is "open," the AML judges that the jib is mounted. The swing limit has been registered, and the crane operation goes beyond the left swing limit area. Signal name: Ground terminal of swing left proportional valve Input voltage: DC 0 V Signal name: Boom extending operation detection switch input Input from the switch detecting boom extending operation. Switch ON (DC 0 V): No boom extending operation is detected. Switch OFF (DC 5 V): Boom extending operation is detected. Signal name: Boom retracting operation detection switch input Input from the switch detecting boom retracting operation. Switch ON (DC 0 V): No boom retracting operation is detected. Switch OFF (DC 5 V): Boom retracting operation is detected. Signal name: Boom raising operation detection switch input Input from the switch detecting boom raising operation. Switch ON (DC 0 V): No boom raising operation is detected. Switch OFF (DC 5 V): Boom raising operation is detected. Signal name: Boom lowering operation detection switch input Input from the switch detecting boom lowering operation. Switch ON (DC 0 V): No boom lowering operation is detected. Switch OFF (DC 5 V): Boom lowering operation is detected. 80 W E

82 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 2 connector Pin No. Name 21 Di19 22 Di20 23 CNTL 3P 24 CNTL 3N 25 CNTL 4P Signal names and functions Signal name: Right swing operation detection switch input Input from the switch detecting right swing operation. Switch ON (DC 0 V): No right swing operation is detected. Switch OFF (DC 5 V): Right swing operation is detected. Signal name: Left swing operation detection switch input Input from the switch detecting left swing operation. Switch ON (DC 0 V): No left swing operation is detected. Switch OFF (DC 5 V): Left swing operation is detected. Signal name: Boom raising proportional valve output When the boom raising operation is slowly stopped by the slow stop function, controlled current is output from the AML to the boom raising proportional valve. However, when the boom elevation slow stop cancel switch is set to "ON ( 解除 )," the slow stop function does not operate. (*1) Output voltage: Square wave 0 to 24 V (*1) : An exception is a case at the backward stable stop, and the slow stop function is operated in this case. For the crane operation status in which the slow stop function is activated, refer to the automatic stop 1 (AML vent) relay output RLY1. Signal name: Ground terminal of boom raising proportional valve Input voltage: DC 0 V Signal name: Boom lowering proportional valve output When the boom lowering operation is slowly stopped by the slow stop function, controlled current is output from the AML to the boom lowering proportional valve. However, when the boom elevation slow stop cancel switch is set to "ON ( 解除 )," the slow stop function does not operate. Output voltage: Square wave 0 to 24 V For the crane operation status in which the slow stop function is activated, refer to the automatic stop 1 (AML vent) relay output RLY1. Signal name: Ground terminal of boom lowering proportional valve Input voltage: DC 0 V 26 CNTL 4N 81 W E

83 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 2 connector Pin No. Name 32 SIF2RXD+ Signal names and functions Signal name: Serial port 2 reception (+) input signal Signal name: Serial port 2 reception (-) input 33 SIF2RXDsignal (*1): Received signal name Ai1 O/R (FR) (*2) Ai2 O/R (FL) (*2) Ai3 O/R (RR) (*2) Ai4 O/R (RL) (*2) Di3 Outrigger retracting operation detection Di4 Front jack ground detection Received data from lower part of the transmitter (*1) (*2): Reference data H-type outrigger Input voltage when outrigger extension width is minimum: 0.5 V (Ai check A/D conversion value: 203) Input voltage when outrigger extension width is maximum: 4.13 V (Ai check A/D conversion value: 1690) 34 SIF2SLD Signal name: Serial port 2 shield Input voltage: DC 0 V Names and functions of signals input to/output from CN3 connector are shown below: CN 3 connector Pin No. Name 1 TR1 Signal names and functions Signal name: 100% alarm output When the moment load factor is 100% or more, or when the automatic stop function is canceled, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 100% lights. OC output OFF (DC 24 V): The external indicator lamp indicating 100% goes out. Conditions under which the OC output turns ON Moment load factor 100% While the boom lift is performed with the jib mounted, the OC output turns ON when the moment load factor becomes as follows: Outrigger extension width: Maximum (7.8 m) Outrigger extension width: Middle (7.2 m) Outrigger extension width: Middle (5.3 m) Moment load factor 90% Moment load factor 85% When the jib stowed detection switch contact is "open," the AML judges that the jib is mounted. Overwinding stop cancel switch: "Press" (2) AML emergency switch: "Retain at the position of automatic stop cancel (ON)." 82 W E

84 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 3 connector Pin No. Name 2 TR2 5 TR5 6 TR6 Signal names and functions Signal name: 90% alarm output When the moment load factor is 90% or more and less than 100%, the OC (open collector) output turns ON. OC output ON (DC 0 V): The external indicator lamp indicating 90% lights. OC output OFF (DC 24 V): The external indicator lamp indicating 90% goes out. While the boom lift is performed with the jib mounted, the OC output turns ON when the moment load factor becomes as follows: Outrigger extension width: Maximum (7.8 m) Outrigger extension width: Middle (7.2 m) Outrigger extension width: Middle (5.3 m) When the moment load factor is 80% or more and less than 90% When the moment load factor is 75% or more and less than 85% When the jib stowed detection switch contact is "open," the AML judges that the jib is mounted. Signal name: Boom and jib connecting pin lock warning lamp output When the jib connecting pin/jib pivot pin insertion detection input Di6 of the transmitter at the top end of the boom turns ON (DC 0 V), the OC (open collector) output turns OFF. OC output ON (DC 0 V): Boom and jib connecting pin lock warning lamp lights. OC output OFF (DC 24 V): Boom and jib connecting pin lock warning lamp goes out. Signal name: 3rd boom section telescoping control output With boom telescoping system I (2nd/3rd boom sections end extending system) This OC (open collector) output is normally OFF. With boom telescoping system II (3rd boom section end extending system) In the case (1) or (2) below, this OC (open collector) output turns OFF, and 4th/top boom sections telescope. (1) With the 3rd boom section extended to the specified length (19.2 m) or more, the next boom section extension switch is pressed. (2) With the 3rd boom section extended to the specified length (19.2 m) or more, the contact of 4th/top boom sections full retraction detection switch becomes "open." OC output ON (DC 0 V): 3rd boom section telescopes. OC output OFF (DC 24 V): 4th/top boom sections telescope. 83 W E

85 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 3 connector Pin No. Name 7 TR7 10 Di25 11 Di26 Signal names and functions Signal name: 2nd boom section telescoping control output With boom telescoping system I (2nd/3rd boom sections end extending system) This OC (open collector) output is normally OFF. With boom telescoping system II (3rd boom section end extending system) In the case (1) or (2) below, this OC (open collector) output turns ON, and 2nd boom section telescopes. (1) With the 3rd/4th/top boom sections extended to the specified length (35.5 m) or more, the next boom section extension switch is pressed. (2) With the 3rd/4th/top boom sections extended to the specified length (35.5 m) or more, the contact of 2nd boom section full retraction detection switch becomes "open." OC output ON (DC 0 V): 2nd boom section telescopes. OC output OFF (DC 24 V): 4th/top boom sections telescope. Signal name: Next boom section extension switch input With boom telescoping system I (2nd/3rd boom sections end extending system) Switch input to extend 4th/top boom sections after 2nd/3rd boom sections are fully extended. Switch ON (DC 0 V): The next boom section extension switch is pressed. Switch OFF (DC 5 V): The next boom section extension switch is not pressed. With boom telescoping system II (3rd boom section end extending system) Switch input to extend 4th/top boom sections after 3rd boom section is fully extended. Or, switch input to extend 2nd boom section after 4th/top boom sections are fully extended. Switch ON (DC 0 V): The next boom section extension switch is pressed. Switch OFF (DC 5 V): The next boom section extension switch is not pressed. Signal name: Boom telescoping system selector switch input Switch input to select the boom telescoping system I and II. Switch ON (DC 0 V): Boom telescoping system I is selected. Switch OFF (DC 5 V): Boom telescoping system II is selected. Signal name: Counterweight mount detection switch input Switch input to detect that the counterweight is mounted. Switch ON (DC 0 V): The counterweight is mounted. Switch OFF (DC 5 V): The counterweight is not mounted. 12 Di27 84 W E

86 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 3 connector Pin No. Name 16 CNTL 5P 17 CNTL 5N 18 CNTL 6P 19 CNTL 6N 21 Di21 22 Di22 Signal names and functions Signal name: Swing relief proportional valve output In the swing free status, when the swing movement is stopped by the automatic swing stop function, controlled current is output from the AML to the swing relief proportional valve. However, in the 2 cases below, the automatic swing stop function does not work. (1) The automatic swing stop cancel switch is set to "ON ( 解除 )." (2) The AML emergency switch is retained at the position of automatic stop cancel (ON). Output voltage: Square wave 0 to 24 V Crane operation status in which automatic swing stop function is enabled The outrigger extension width differs in the front/rear/left/right, and if the swing free operation is continued further, the status enters an operation range in which the moment load factor becomes 100% or more. While the boom lift is performed with the jib mounted, the automatic swing stop function works when the status enters either of followings, not when enters an operation range in which the moment load factor becomes 100% or more. Outrigger extension width: Maximum (7.8 m) Outrigger extension width: Middle (7.2 m) Outrigger extension width: Middle (5.3 m) When status enters an operation range in which the moment load factor becomes 90% or more When status enters an operation range in which the moment load factor becomes 85% or more When the jib stowed detection switch contact is "open," the AML judges that the jib is mounted. The swing limit has been registered, and the swing free operation goes beyond the right swing or left swing limit area. Signal name: Ground terminal of swing relief proportional valve Input voltage: DC 0 V Signal name: Telescoping retraction proportional valve output When the 2nd boom section is fully retracted, when the 3rd boom section is fully retracted, and when the 4th/top boom sections are fully retracted, controlled current is output from the AML to the telescoping retraction proportional valve. Each of them stops slowly at the stroke end. Output voltage: Square wave 0 to 24 V Signal name: Ground terminal of telescoping retraction proportional valve Input voltage: DC 0 V Signal name: Overwinding stop cancel switch input Switch input to detect that the overwind cutout function of the hook block is canceled. Switch ON (DC 0 V): Crane stop status due to detection of overwinding of the hook block and alarm buzzer are canceled. Switch OFF (DC 5 V): The overwind cutout function of the hook block works. Signal name: AML emergency switch input Switch input to detect that the AML automatic stop function is canceled. Switch ON (DC 0 V): The automatic stop function of the AML is canceled. Switch OFF (DC 5 V): The automatic stop function of the AML works. 85 W E

87 Input/Output Signals of the AML-LIIA System (GA-700N-1) CN 3 connector Pin No. Name 23 Di23 24 Di24 Signal names and functions Signal name: Boom elevation slow stop cancel switch input Switch input to detect that the elevation slow stop function is canceled. Switch ON (DC 0 V): The elevation slow stop function is canceled. Switch OFF (DC 5 V): The elevation slow stop function works. Signal name: Automatic swing stop cancel switch input Switch input to detect that the automatic swing stop function is canceled. Switch ON (DC 0 V): The automatic swing stop function is canceled. Switch OFF (DC 0 V): The automatic swing stop function works. 86 W E

88 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) [OPERATION] Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1 /GR-350N-1) Mode Structure 2. Maintenance Mode: Used to make functional checks of the AML. Refer to the "ADJUSTMENT AND MAINTENANCE" section. 3. Adjustment Mode: Used to make detector. Refer to the "ADJUSTMENT AND MAINTENANCE" section. The AML device has three modes and the AML functions are allotted for these models. POWER 電源 ON プロテクト Protect スイッチ switch ON ON ユーザーモード USER MODE 保守モード MAINTENANCE MODE プロテクト Protect スイッチ switch OFF 調整モード ADJUSTMENT MODE POWER 電源 ON ON IW J03 1. User Mode: Used to indicate moment load factor or to perform AML pre-operational inspection (Normally used). In normal use, turn ON the protect switch mounted on the window on the top of the AML. The AML will go to the user mode when the power turns on. The abnormality display LED lights when the AML is in abnormal conditions (to indicate that the CPU is faulty). MOMENT SHORT PROTECT ZERO WDT HALT ON OFF Top 上面 view Protect 異常表示 Abnormality LED プロテクトスイッチ switch display LED IW J35 87 W E

89 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) Configuration and Functions of the AML System The AML system has various kinds of functions, including the following five typical functions. Based on the work conditions registered in the AML and the signals from various sensors, these functions control the crane operations. 1. Automatic stop function to prevent overloading The AML calculates and compares the working and rated moment values and displays their ratio. When the working moment exceeds the rated moment (100% or more), failure message is shown, alarm buzzer sounds, and the crane operation toward the critical side stops. If the backward stability is getting worse, failure message is shown, alarm buzzer sounds, and the operation toward the critical side stops. 2. Working area limit functions When any working area limit is registered to the AML, the crane is controlled so that the crane work posture does not exceed this registered working area limit. When the crane reaches the registered limit, failure message is shown, alarm buzzer sounds, and the crane operation stops. 3. Slow stop function When the crane boom elevation is stopped as shown in 1 and 2 above, at the boom elevation stroke end, or at the boom retracting stroke end (*1) (when all the booms are fully retracted or the top boom is fully retracted), the operation speed goes down gradually and then the operation stops slowly. (*1) : For TR-250M-7, GR-250N-1, and GR-350N-1, there is no slow stop function at the boom retracting stroke end. The availability of the above described automatic stop function, working area limit functions, and slow stop function is as shown in the table below depending on the individual operation. Be careful that turning the AML emergency switch to " 非常用," and the PTO switch to "ON (II)" will change the center warning lamp to "AML warning" state and deactivate all the above AML stop functions (the troubleshooting function of the system). However, the stop function for backward stability alone is not deactivated, and permanently operates. On-outrigger operation On-rubber operation Automatic stop Hoisting up by overloading Boom lowering Boom extension Swing Jib lowering (*1) No jib lift Stop for backward Boom raising - stability Boom retraction (*2) - Stop at the stroke end Boom raising/lowering Boom retraction (*2) Stop by working area Boom raising/lowering limit Swing Boom extension Jib raising/lowering (*1) No jib lift : Slow stop : Stop : No stop -: Not related (*1) : For TR-250M-7, GR-250N-1, and GR-350N-1 with jib and without power tilt, there is no stop function. (*2) : For TR-250M-7, GR-250N-1, and GR-350N-1, there is no stop function. 88 W E

90 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) When the automatic swing stop cancel switch is set to " 解除," the swing does not stop automatically. When the boom elevation slow stop cancel switch is set to " 解除," the slow stop function of the boom raising/lowering is deactivated. An exception is a case of stopping for backward stability, and the slow stop function is not deactivated. 解除 Automatic 旋回自動停止解除 swing stop canceled 解除 Elevation 起伏緩停止解除 slow stop canceled 旋停 Automatic 旋回自動停止 swing stop 起伏停 Elevation 起伏緩停止 slow stop Swing 旋回停止 stop IW J50 Elevation 起伏緩停止 slow stop IW J51 4. Alarm Functions Condition Alarm Overwinding Buzzer: Tremolo sound Moment load factor Moment display: Applicable bargraph is lit yellow. 90% or more, and less than 100% Buzzer: Sounds intermittently. Moment load factor 100% or more Moment display: Applicable bargraph is lit until the moment load factor is up to 110%. When 110% is exceeded, all the bargraphs are lit. Crane operation control required Working area limit function activated AML system error Buzzer: Sounds continuously. Moment display: Displays the control message. Buzzer: Beep (only for 3 seconds)(*1) The corresponding limit indicator lamp flashes. Buzzer: Beep (only for 3 seconds)(*1) Moment display: Displays an error message. Buzzer: Beep (only for 3 seconds)(*1) (*1): There are two types of buzzer sounds and those are classified as follows: Slow stop control: Beep in long cycle Other controls: Beep in short cycle 5. Boom elevating speed adjusting function This function adjusts the maximum speed when the boom is extended. 89 W E

91 メッセージ 調整 点検 ブーム 揚程制限 旋回左限 O / R 起伏上限 旋回右限 起伏下限 半径制限 表示切替 セット Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) ブーム長さ検出 Boom length detection ブーム角度検出 Boom angle detection モーメント検出 Moment load factor Front 前方位置検出 position detection Crane クレーン操作検出 operation detection detection L θ W Swing 旋回角度検出 angle detection アウトリガ張出幅検出 Outrigger extension width detection (*1) ジブ Jib offset オフセangle ット角度検出 detection Operator input オペレータ入力アウトリガ状態登録 Registration of the outrigger condition Registration of the boom ブーム ジブ状態登録 and jib lift Registration of the 作業範囲制限登録 working area limits AML 本体 unit 表示パネル Display panel 警報ブザー Alarm buzzer AML AML 外部表示ランプ external indicator lamps (option) ( オプション ) An automatic 自動停止出力 stop is output when: モーメント Moment load 100% factor 以上 is 100% or more. 巻過ぎ Overwinding occurs. 作業範囲 The working area limit 制限出力 signal is output. 後方安定 Stop for backward 停止出力 stability signal is output. ブーム上げ停止 Boom raising halted (*1) ジブチルト下げ停止 Jib tilting down halted Boom retraction ブーム縮小停止 halted (*2) ブーム伸長 Boom extension 停止 halted ブーム下げ Boom lowering 停止 halted ウインチ Hoisting up halted 巻上げ停止 危険側への旋回 Swing toward critical side 停止 halted (except ( アウトリガ for outrigger fully extended) 最大張出を除く ) 左旋回制限 Left swing restricted 右旋回制限 Right swing restricted ブーム角度 Upper boom angle restricted 上限制限ブーム角度 Lower boom angle restricted 下限制限 揚程制限 Lifting height restricted 作業半径制限 Load radius restricted θ u H θ L R (*1): For TR-250M-7, GR-250N-1, and GR-350N-1 with jib and without power tilting, there is no stop function. (*2): For TR-250M-7, GR-250N-1, and GR-350N-1, there is no stop function. IW J04 90 W E

92 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) Names and Functions of the Parts AML (Main Unit) A. Bargraph display 3 1 A メッセージ Message メッセージ B 4 2 IW J54 1. Load factor mark D 揚程制限 起伏上限起伏下限 C The moment load factors on the bargraph are color coded as follows: safe (green), notice (yellow) and limit (red) A. Bargraph display B. Display panel 1 C. Controls section 調整 点検 旋回左限旋回右限半径制限表示切替ブーム O / R セット IW J53 2. Moment display Normally displays a moment load factor on a bargraph and in value. Displays the main hydraulic pressure and accumulator pressure when the display alteration key is pressed. Displays the boom elevating speed value when the increase key or decrease key is pressed. Also displays error messages when detects an error in a detector or others. D. Display panel 2 3. Scroll-up key ( ) Used to see the previous lines of message displayed on the moment display. 4. Scroll-down key ( ) Used to see the next lines of message displayed on the moment display. 91 W E

93 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) B. Display panel m m % 14 m 13 8 t max t 1. Boom length symbol This symbol indicates that the boom length display [19] is showing the boom length IW J55 2. Jib length symbol This symbol indicates that the jib angle display [22] is showing the jib length. 3. Jib angle symbol This symbol indicates that the jib angle display [22] is showing the jib offset angle. 4. Jib lift symbol This symbol lights when the jib operation is selected. 5. Actual load display Displays the actual load. 6. Rated lifting capacity display Displays the rated lifting capacity. 7. Load radius limit symbol This symbol indicates that the load radius display [9] is showing the registered load radius limit value. The load radius symbol [8] is also lit at the same time when this symbol is lit. 8. Load radius symbol This symbol indicates that the load radius display [9] is showing the load radius. 9. Load radius display Normally displays the crane s load radius. Displays the boom swing angle while the display alteration key is pressed. When the load radius limit function is activated, the registered load radius limit value is displayed while the set key is pressed. 10. Boom angle display Normally displays the boom angle. Displays the moment load factor (%) while the display alteration key is pressed. When the lower limit function of boom angle is activated, the registered limit value is displayed while the set key is pressed. 11, 12. Boom angle symbols This symbol indicates that the boom angle display [10] is showing the boom angle. 13. Single top lift symbol This symbol indicates that the single top performance is selected. 14. Boom lift symbol This symbol indicates that the boom lift is selected. 15, 16. Lower boom angle limit symbols This symbol indicates that the boom angle display [10] is showing the registered lower boom angle limit value. 17, 18. Upper boom angle limit symbols This symbol indicates that the jib angle display [22] is showing the registered upper boom angle limit value. 19. Boom length display Normally displays the boom length. Displays the lifting height while the display alteration key is pressed. When the lifting height limit function is activated, the registered limit value is displayed while the set key is pressed. 20. Lifting height symbol This symbol indicates that the boom length display [19] is showing the lifting height. 92 W E

94 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) 21. Lifting height limit symbol This symbol indicates that the boom length display [19] is showing the registered lifting height limit value. The lifting height symbol [20] is lit at the same time when this symbol is lit. 22. Jib angle display The jib offset angle is displayed when the jib operation is selected, and the jib length is displayed while the display alteration key is pressed. Also, when the upper boom angle limit function is activated, the upper boom angle limit value is displayed while the set key is pressed. C. Controls section 6. Set key Used to register a selected condition. 7. Display alteration key Used to alter the displays on display panel Left swing limit key Used to activate and release the left swing limiting function. 9. Right swing limit key Used to activate and release the right swing limiting function. 10. Load radius limit key Used to activate and release the load radius limiting function 揚程制限 旋回左限旋回右限 起伏上限起伏下限 半径制限 Lifting height limit key Used to activate and release the lifting height limiting function. 12. Upper boom angle limit key Used to activate and release the uppermost boom angle limiting function. 1 2 調整 3 4 点検 5 ブーム 15 9 O / R 表示切替 セット Lower boom angle limit key Used to activate and release the lowermost boom angle limiting function. IW J56 1. Increase key Used to increase the selected value. Also, used to adjust the elevating speed. 2. Decrease key Used to decrease the selected value. Also, used to adjust the elevating speed. 14 to 19. Limit indicator lamps Lights when the corresponding limiting function is activated. If the crane operation reaches the limit area while the working area limit function is activated, the indicator lamp changes from "being lit" to "flashing." 3. Inspection key Used to perform the pre-operational inspection of the AML system. 4. Lift status selector key Used to select the boom lift status. 5. Outrigger condition selector key Used to select the on-outrigger or on-rubber status. 93 W E

95 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) D. Display panel IW J57 1. Front position symbol Lights to indicate that the swing position comes to the front position. 2. Swing position display Indicates the swing position in 10 increments by flashing. 3. Outrigger condition symbol Indicates the outrigger extension status by symbol. Flashes while the outrigger condition is being registered, and stays lit after the registration is completed. 4. On-rubber condition symbol Indicates that the performance in the on-rubber condition is selected using the symbol. Lights when the performance in the "on-rubber stationary" condition is selected, and flashes when that in the "on-rubber creep" condition is selected. 5. Suspension lock condition symbol Indicates the suspension lock condition using the symbol. When the suspension lock performance is selected, the symbol lights. 94 W E

96 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) Registering Operating Conditions WARNING Should the operational status be incorrectly registered, the crane may overturn or be damaged, leading to a serious accident. Prior to every operation, check that the registered status corresponds to the actual status of the crane. the AML by flashing the outrigger condition symbol. Check whether it matches the actual outrigger extension status, and if it is OK, press the set key to register. The outrigger condition symbol changes to "being lit" to indicate that the condition has been successfully registered. Registration of Outrigger Condition [NOTICE] When the power supply is turned on, the "on-rubber creep" condition is automatically selected. Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the registered operation condition. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again. To register the outrigger condition, press the outrigger condition selector key to enable the outrigger condition selector function, and follow the procedure below. IW J59 The outrigger condition symbol by the outrigger extension width is as follows: Example for GR-300N-1 最大 Fully (6.7m) extended 張出し (6.7 m) 中間 Mid. (6.3m) extended 張出し (6.3 m) 中間 Mid. (5.2m) extended 張出し (5.2 m) 中間 Mid. (3.8m) extended 張出し (3.8 m) メッセージ 最小 Min. (2.08m) extended 張出し (2.08 m) IW J60 Outrigger アウトリガ condition 状態シンボル symbol Suspension サスペンション lock ロック状態シンボル condition symbol 揚程制限起伏上限起伏下限旋回左限旋回右限半径制限表示切替調整点検ブーム O / R セット On-rubber オンタイヤ condition 状態シンボル symbol セットキー Set key Outrigger アウトリガ状態 condition selector 選択キー key IW J58 2. On-rubber stationary status Pressing the outrigger condition selector key makes the outrigger condition symbol flash. From this status, press the outrigger condition selector key again. Ensure that the outrigger condition symbol disappears and the on-rubber condition symbol lights. Now, the condition is automatically registered. 1. Outrigger fully extended Pressing the outrigger condition selector key indicates the outrigger extension width entered in 95 W E

97 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) Registration of Lift Status Lights. 点灯 IW J61 3. On-rubber creep (suspension locked) status Press the outrigger condition selector key to make the on-rubber condition symbol flash. Now, the condition is automatically registered. [NOTICE] When the power supply is turned on, the single top lift is automatically selected. Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation condition. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again. Flashes. 点滅 メッセージ Jib lift symbol ジブ状態シンボル 点灯 Lights. 点滅 Flashes. 揚程制限 起伏上限起伏下限 シングルトップ状態 Single top lift シンボル symbol ブーム状態シンボル Boom lift symbol IW J62 旋回左限旋回右限 半径制限 表示切替 4. On-rubber creep (suspension not locked) status When the on-rubber creep or stationary status is registered, if the emergency suspension free switch is set to " 非常用," the suspension lock condition symbol disappears and the condition is automatically registered. Flashes. 点滅点滅 Flashes. 調整点検ブーム O / R セット Lift status selector key ブーム状態選択キー IW J64 To register the lift status, use the lift status selector key. Each time the lift status selector key is pressed, the display changes in numerical sequence in the table on the next page. The display returns to (1) if you press the key when the last status is shown on the display. Select the status that corresponds to the actual lift status. The status is automatically registered. IW J63 96 W E

98 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) The following display pattern shows in the case of GR-300N-1. Display 表示 Lift status ブーム状態 シングルトップ作業 Single top lift (1) Flashes. 点滅 Jib ジブセット作業 set (2) Jib lift: 6.5 m jib, 5 offset 6.5mジブ 5 オフセット作業 (3) Jib lift: 11.0 m jib, 5 offset 11.0mジブ 5 オフセット作業 (4) Boom ブーム作業 lift (5) IW J65 97 W E

99 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) Pre-operational Inspection on the AML WARNING Operating the crane with a malfunctioning AML could cause the crane to overturn or be damaged. Be sure to perform the pre-operational inspection on the AML system and start the crane only after ensuring that the system is operating properly. [NOTICE] Before starting operation, check that the AML system works in good condition, as follows: 1. Press the inspection key and make sure that the AML is in the following conditions: Display panel (1 and 2) Moment display All segments light. Working area limit indicator lamp Alarm buzzer Sounds continuously. Movement toward critical sides Automatically halted. 2. Press the set key, display alteration key, or inspection key to return the display to the normal condition (a bargraph must be shown on the moment display). 3. Visually check that values and symbols shown on the display panel 1 and 2 represent the actual crane conditions, particularly on the following items. (1) Boom length (2) Boom angle (3) Jib angle (jib length) (shown while jib lift is selected) (4) Actual load With no load on hook, make sure that an approximate mass of the hook block is shown. [NOTICE] The actual load is not shown correctly if the lift status of the AML is not registered correctly. (5) Outrigger condition symbol (6) Swing position display (7) Front position symbol (when the swing position is in the front position) 98 W E

100 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) How to Use the Working Area Limiting Function Working area Swing limit 作業範囲制限キー limit keys area 旋回制限領域 Indicator 表示ランプ lamps [NOTICE] If the working area limit is registered very close to an obstacle, there is a risk of the crane colliding with the obstacle, depending on the operational status and the manner in which the load is handled. When registering an area limit, allow a sufficient clearance to avoid collision. The working area limit function limits operation of the boom and swing movement to the pre-registered boom angle (upper limit, lower limit), lifting height, load radius, and swing angle (left, right). Use this function when performing operation in a place where there are obstacles around the machine, requiring the working-area limitation of the boom. Upper boom angle limit Lower boom angle limit Lifting height limit Load radius limit Left swing limit Right swing limit Automatic stop and alarm buzzer (Beep for 3 seconds) [NOTICE] When the automatic swing stop cancel switch is set to " 解除," the swing does not stop automatically, even if the swing limit area is reached. Only the alarm buzzer sounds. Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation condition. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again. 調整 Working Area Limit Value While the working area limit function is activated, as long as the set key is pressed, the working area limit values registered in the indicator shown below are displayed. Also the message " ハンイセイゲンチヒョウジ " appears on the moment display. Upper boom ブーム上限 angle limit 角度制限値 value Lifting 揚程制限値 height limit value Boom Angle Limit メッセージ 調整 点検 m 点検 ブーム ブーム m 揚程制限 O / R 揚程制限 旋回左限 ハンイセイゲンチヒヨウジ 半径制限 セット Raise or lower the boom to a desired limit angle, and press the upper or lower boom angle limit key. The corresponding limit indicator lamp will flash, indicating that the boom angle limit has been registered in the memory. When the boom is moved back to an angle within the set limit, the boom angle limit indicator lamp stops flashing and stays lit. Thereafter, the upper t max t 旋回左限旋回右限 O / R 起伏上限起伏下限 半径制限 表示切替 セット 起伏上限 旋回右限 起伏下限 表示切替 IW J66 Lower ブーム下限 boom angle 角度制限値 limit value 作業半径 Load radius 制限値 limit value Set key セットキー IW J67 99 W E

101 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) or lower boom angle limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the upper or lower limit previously registered is reached. (Boom raising or lowering stops automatically.) To cancel the boom angle limits, press the upper or lower boom angle limit key again. The corresponding boom angle limit indicator lamp will go out. Lifting Height Limit Move the boom or jib (*1) to a desired limit height, and press the lifting height limit key. The lifting height limit indicator lamp will flash, indicating that the lifting height limit has been registered in the memory. When the boom or jib is moved back to a height within the set limit, the lifting height limit indicator lamp stops flashing and stays lit. Thereafter, the height limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the height limit previously registered is reached. (Boom or jib raising and boom extending stop automatically.) To cancel the height limit, press the lifting height limit key again. The lifting height limit indicator lamp will go out. (*1) : Not apply to TR-250M-7, GR-250N-1, and GR-350N-1 with jib and without power tilt. Load Radius Limit Move the boom or jib (*1) to a desired limit load radius, and press the load radius limit key. The load radius limit indicator lamp will flash, indicating that the load radius limit has been registered in the memory. When the boom or jib is moved back to a load radius within the set limit, the load radius limit indicator lamp stops flashing and stays lit. Thereafter, the load radius limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the load radius previously registered is reached. (Boom or jib lowering and boom extending stop automatically.) To cancel the load radius limit, press the load radius limit key again. The load radius limit indicator lamp will go out. (*1) : Not apply to TR-250M-7, GR-250N-1, and GR-350N-1 with jib and without power tilt. Swing Limit Swing to a desired limit swing position, and press the left swing limit key or right swing limit key. The corresponding swing limit indicator lamp will flash and the buzzer (beep) sounds for 3 seconds, indicating that the swing limit has been registered in the memory. When the boom is moved back to a swing position within the set limit, the swing limit indicator lamp stops flashing and stays lit. Thereafter, the swing limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the swing angle previously registered is reached. (Swing stops automatically.) To cancel the swing limit, press the left swing limit key or right swing limit key again. The corresponding swing limit indicator lamp will go out. [NOTICE] Ensure to register both the right swing and left swing limit positions. If either right or left limit position only is set, the alarm does not sound correctly. When the automatic swing stop cancel switch is set to " 解除," the swing does not stop automatically, even if the swing limit area is reached. Be extremely careful of the operation, because the machine does not stop automatically but only the swing limit indicator lamp flashes, the message appears, and the AML buzzer (beep) sounds for 3 seconds. 100 W E

102 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) How to Use the Boom Elevating Speed Adjusting Function The boom elevating speed adjusting function is a function to adjust the maximum speed when the boom is extended. How to Register Boom Elevating Speed Adjustment Increase 減キー key Decrease 増キー key メッセージ 調整 点検 揚程制限起伏上限起伏下限 Use the increase or decrease key to register the boom elevating speed. Pressing the increase or decrease key changes the bargraph display to the following elevating speed values. While the elevating speed values are shown on the bargraph display, pressing the increase or decrease key again enables to set each boom elevating speed value to 0% (stop) to 100% (standard speed) in 10% increments. In addition, pressing the increase or decrease key during a boom elevating operation enables to adjust the boom raising and boom lowering speeds separately. ブーム 旋回左限旋回右限 メッセージアゲ 100% サゲ 100% O / R 半径制限 表示切替 セット IW J68 Boom ブーム下げ側の最高速度 lowering max. speed ブーム上げ側の最高速度 Boom raising max. speed IW J69 During boom raising operation: Only raising speed can be changed During boom lowering operation: Only lowering speed can be changed No boom elevating operation: Both the raising and lowering speeds can be changed at the same time. [NOTICE] If the increase key or decrease key is not pressed for approx. 10 seconds, the bargraph display returns to the normal condition (a bargraph must be shown on the moment display), and the registration of boom elevating has been completed. Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation condition. When the power supply is turned on again, all the segments of the bargraph display light, and the boom elevating values are shown only for 2 to 3 seconds. After that, the display returns to the normal condition (a bargraph must be shown on the moment display). Operating Speed on Registration of Boom Elevating Speed Adjustment The percentage value shown by the boom elevating speed adjusting function is a speed limit value when the boom is fully extended. On the contrary, when the boom is fully retracted, it always elevates at the standard speed. The relation between the value and boom elevating speed is as follows: 1. When value is 0% Fully retracted Standard speed In between fully retracted and fully extended (1/2) 1/2 of standard speed Fully extended Stop (almost no movement) 2. When value is 50% Fully retracted Standard speed In between fully retracted and fully extended (1/2) 3/4 of standard speed Fully extended 1/2 of standard speed 101 W E

103 Functions of and How to Use User Mode (GR-300N-1/TR-250M-7/GR-250N-1/GR-350N-1) 3. When value is 100% Fully retracted Standard speed In between fully retracted and fully extended (1/2) Standard speed Fully extended Standard speed Boom 起伏最高速度 elevating max. speed Standard 標準速度 100% 3/4 速度 1/2 速度 50% 1/4 速度 0% Stop 停止 Fully 全縮中間 Mid. Fully 全伸ブーム長さ Boom length retracted extended IW J70 IW J W E

104 Functions of and How to Use User Mode (GR-160N-1) Functions of and How to Use User Mode (GR-160N-1) Mode Structure The AML device has three modes and the AML functions are allotted for these models. POWER 電源 ON 2. Maintenance Mode: Used to make functional checks of the AML. Refer to the "ADJUSTMENT AND MAINTENANCE" section. 3. Adjustment Mode: Used to make detector. Refer to the "ADJUSTMENT AND MAINTENANCE" section. プロテクト Protect スイッチ switch ON ON ユーザーモード USER MODE 保守モード MAINTENANCE MODE プロテクト Protect スイッチ switch OFF 調整モード ADJUSTMENT MODE POWER 電源 ON ON IW J03 1. User Mode: Used to indicate moment load factor or to perform AML pre-operational inspection (Normally used). In normal use, turn ON the protect switch mounted on the window on the top of the AML. The AML will go to the user mode when the power turns on. The abnormality display LED lights when the AML is in abnormal conditions (to indicate that the CPU is faulty). MOMENT SHORT PROTECT ZERO WDT HALT ON OFF Top view 上面 Protect 異常表示 Abnormality LED switch プロテクトスイッチ display LED IW J W E

105 Functions of and How to Use User Mode (GR-160N-1) Configuration and Functions of the AML System The AML system has various kinds of functions, including the following five typical functions. Based on the work conditions registered in the AML and the signals from various sensors, these functions control the crane operations. 1. Automatic stop function to prevent overloading The AML calculates and compares the working and rated moment values and displays their ratio. When the working moment exceeds the rated moment (100% or more), failure message is shown, alarm buzzer sounds, and the crane operation toward the critical side stops. 2. Working area limit functions When any working area limit is registered to the AML, the crane is controlled so that the crane work posture does not exceed this registered working area limit. When the crane reaches the registered limit, failure message is shown, alarm buzzer sounds, and the crane operation stops. 3. Slow stop function When the crane boom elevation is stopped as shown in 1 and 2 above, at the boom elevation stroke end, the operation speed goes down gradually and then the operation stops slowly. The availability of the above described automatic stop function, working area limit functions, and slow stop function is as shown in the table below depending on the individual operation. Be careful that turning the AML emergency switch to " 非常用," and the PTO switch to "ON (II)" will change the center warning lamp to "AML warning" state and deactivate all the above AML stop functions (the troubleshooting function of the system). On-outrigger operation On-rubber operation Automatic stop Hoisting up by overloading Boom lowering Boom extension Swing Stop at the stroke end Boom raising/lowering Stop by working area limit Boom raising/lowering Swing Boom extension : Slow stop : Stop : No stop When the automatic swing stop cancel switch is set to " 解除," the swing does not stop automatically. When the boom elevation slow stop cancel switch is set to " 解除," the slow stop function of the boom raising/lowering is deactivated. 解除 Automatic 旋回自動停止解除 swing stop canceled 解除 Elevation 起伏緩停止解除 slow stop canceled 旋停 Automatic 旋回自動停止 swing stop 起伏停 Elevation 起伏緩停止 slow stop Swing 旋回停止 stop IW J50 Elevation slow stop 起伏緩停止 IW J W E

106 Functions of and How to Use User Mode (GR-160N-1) 4. Alarm Functions Condition Alarm Overwinding Buzzer: Tremolo sound Moment load factor 90% or more, and less than 100% Moment load factor 100% or more Moment display: Applicable bargraph is lit yellow. Buzzer: Sounds intermittently. Moment display: Applicable bargraph is lit until the moment load factor is up to 110%. When 110% is exceeded, all the bargraphs are lit. Crane operation control required Working area limit function activated AML system error Buzzer: Sounds continuously. Moment display: Displays the control message. Buzzer: Beep (only for 3 seconds)(*1) The corresponding limit indicator lamp flashes. Buzzer: Beep (only for 3 seconds)(*1) Moment display: Displays an error message. Buzzer: Beep (only for 3 seconds)(*1) (*1): There are two types of buzzer sounds and those are classified as follows: Slow stop control: Beep in long cycle Other controls: Beep in short cycle 5. Boom elevating speed adjusting function This function adjusts the maximum speed when the boom is extended. 105 W E

107 メッセージ 調整 点検 ブーム 揚程制限起伏上限起伏下限 旋回左限旋回右限半径制限 O / R 表示切替 セット Functions of and How to Use User Mode (GR-160N-1) Boom ブーム長さ検出 length detection Boom ブーム角度検出 angle detection モーメント検出 Moment load factor Front 前方位置検出 position detection クレーン操作検出 Crane operation detection detection L θ W Swing 旋回角度検出 angle detection Outrigger extension アウトリガ張出幅検出 width detection Operator input オペレータ入力Registration アウトリガ状態登録 of the outrigger condition Registration of the boom and ブーム ジブ状態登録 jib lift Registration of the working 作業範囲制限登録 area limits AML 本体 unit 表示パネル Display panel 警報ブザー Alarm buzzer AML AML 外部表示ランプ external indicator ( lamps オプション (option) ) An automatic stop is output when: 自動停止出力 モーメント Moment load 100% factor 以上 is 100% or more. 巻過ぎ Overwinding occurs. The 作業範囲 working area 制限出力 limit signal is output. ブーム伸長 Boom 停止 extension halted ブーム下げ Boom 停止 lowering halted ウインチ Hoisting up 巻上げ停止 halted 危険側への旋回 Swing toward critical side 停止 halted (except ( アウトリガ for outrigger fully extended) 最大張出を除く ) 左旋回制限 Left swing 右旋回制限 restricted Right swing restricted ブーム角度 Upper boom 上限制限 angle restricted ブーム角度 Lower boom 下限制限 angle restricted 揚程制限 Lifting height restricted 作業半径制限 Load radius restricted θ u H θ L R 106 W E IW J07

108 Functions of and How to Use User Mode (GR-160N-1) Names and Functions of the Parts AML (Main Unit) A. Bargraph display 3 1 A メッセージ B メッセージ Message 4 2 IW J54 1. Load factor mark D 揚程制限起伏上限起伏下限旋回左限旋回右限半径制限 C The moment load factors on the bargraph are color coded as follows: safe (green), notice (yellow) and limit (red) A. Bargraph display B. Display panel 1 C. Controls section D. Display panel 2 調整 点検 ブーム O / R 表示切替セット IW J53 2. Moment display Normally displays a moment load factor on a bargraph and in value. Displays the main hydraulic pressure and accumulator pressure when the display alteration key is pressed. Displays the boom elevating speed value when the increase key or decrease key is pressed. Also displays error messages when detects an error in a detector or others. 3. Scroll-up key ( ) Used to see the previous lines of message displayed on the moment display. 4. Scroll-down key ( ) Used to see the next lines of message displayed on the moment display. 107 W E

109 Functions of and How to Use User Mode (GR-160N-1) B. Display panel m m deg Boom length symbol This symbol indicates that the boom length display [19] is showing the boom length. 2. Jib length symbol This symbol indicates that the jib angle display [22] is showing the jib length. 3. Jib angle symbol This symbol indicates that the jib angle display [22] is showing the jib offset angle. 4. Jib lift symbol This symbol lights when the jib operation is selected. 5. Actual load display Displays the actual load % deg 6. Rated lifting capacity display Displays the rated lifting capacity Load radius limit symbol This symbol indicates that the load radius display [9] is showing the registered load radius limit value. The load radius symbol [8] is also lit at the same time when this symbol is lit. 8. Load radius symbol This symbol indicates that the load radius display [9] is showing the load radius m 13 ton max ton IW J55 9. Load radius display Normally displays the crane s load radius. Displays the boom swing angle while the display alteration key is pressed. When the load radius limit function is activated, the registered load radius limit value is displayed while the set key is pressed. 10. Boom angle display Normally displays the boom angle. Displays the moment load factor (%) while the display alteration key is pressed. When the lower limit function of boom angle is activated, the registered limit value is displayed while the set key is pressed. 11, 12. Boom angle symbols This symbol indicates that the boom angle display [10] is showing the boom angle. 13. Single top lift symbol This symbol indicates that the single top performance is selected. 14. Boom lift symbol This symbol indicates that the boom lift is selected. 15, 16. Lower boom angle limit symbols This symbol indicates that the boom angle display [10] is showing the registered lower boom angle limit value. 17, 18. Upper boom angle limit symbols This symbol indicates that the jib angle display [22] is showing the registered upper boom angle limit value. 19. Boom length display Normally displays the boom length. Displays the lifting height while the display alteration key is pressed. When the lifting height limit function is activated, the registered limit value is displayed while the set key is pressed. 20. Lifting height symbol This symbol indicates that the boom length display [19] is showing the lifting height. 108 W E

110 Functions of and How to Use User Mode (GR-160N-1) 21. Lifting height limit symbol This symbol indicates that the boom length display [19] is showing the registered lifting height limit value. The lifting height symbol [20] is lit at the same time when this symbol is lit. 22. Jib angle display The jib offset angle is displayed when the jib operation is selected, and the jib length is displayed while the display alteration key is pressed. Also, when the upper boom angle limit function is activated, the upper boom angle limit value is displayed while the set key is pressed. C. Controls section 6. Set key Used to register a selected condition. 7. Display alteration key Used to alter the displays on display panel Left swing limit key Used to activate and release the left swing limiting function. 9. Right swing limit key Used to activate and release the right swing limiting function. 10. Load radius limit key Used to activate and release the load radius limiting function 揚程制限 旋回左限旋回右限 起伏上限起伏下限 半径制限 Lifting height limit key Used to activate and release the lifting height limiting function. 12. Upper boom angle limit key Used to activate and release the uppermost boom angle limiting function. 1 2 調整 3 4 点検 5 ブーム 15 9 O / R 表示切替 セット Lower boom angle limit key Used to activate and release the lowermost boom angle limiting function. IW J56 1. Increase key Used to increase the selected value. Also, used to adjust the elevating speed. 2. Decrease key Used to decrease the selected value. Also, used to adjust the elevating speed. 14 to 19. Limit indicator lamps Light when the corresponding limiting function is activated. If the crane operation reaches the limit area while the working area limit function is activated, the indicator lamp changes from "being lit" to "flashing." 3. Inspection key Used to perform the pre-operational inspection of the AML system. 4. Lift status selector key Used to select the boom lift status. 5. Outrigger condition selector key Used to select the on-outrigger or on-rubber status. 109 W E

111 Functions of and How to Use User Mode (GR-160N-1) D. Display panel Front position symbol IW J57 Lights to indicate that the swing position comes to the front position. 2. Swing position display Indicates the swing position in 10 increments by flashing. 3. Outrigger condition symbol Indicates the outrigger extension status by symbol. Flashes while the outrigger condition is being registered, and stays lit after the registration is completed. 4. On-rubber condition symbol Indicates that the performance in the on-rubber condition is selected using the symbol. Lights when the performance in the "on-rubber stationary" condition is selected, and flashes when that in the "on-rubber creep" condition is selected. 5. Spring (suspension) lock condition symbol Indicates the spring (suspension) lock condition. When the "on-rubber" condition is selected, the symbol lights. 110 W E

112 Functions of and How to Use User Mode (GR-160N-1) Registering Operating Conditions WARNING Should the operational status be incorrectly registered, the crane may overturn or be damaged, leading to a serious accident. Prior to every operation, check that the registered status corresponds to the actual status of the crane. Registration of Outrigger Condition [NOTICE] When the power supply is turned on, the "on-rubber creep" condition is automatically selected. Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the registered operation condition. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again. To register the outrigger condition, press the outrigger condition selector key to enable the outrigger condition selector function, and follow the procedure below. 1. Outrigger fully extended Pressing the outrigger condition selector key indicates the outrigger extension width entered in the AML by flashing the outrigger condition symbol. Check whether it matches the actual outrigger extension status, and if it is OK, press the set key to register. The outrigger condition symbol changes to "being lit" to indicate that the condition has been successfully registered. IW J59 The outrigger condition symbol by the outrigger extension width is as follows: X 型アウトリガ X-type outrigger H 型アウトリガ H-type outrigger 最大 Fully (5.2m) extended 張出し (5.2 m) 最大 (5.2m) Fully extended 張出し (5.2 m) 中間 Mid. (4.8m) extended 張出し (4.8 m) 中間 (4.8m) Mid. extended 張出し (4.8 m) 中間 Mid. (4.4m) extended 張出し (4.4 m) 中間 (4.4m) Mid. extended 張出し (4.4 m) 中間 Mid. (3.2m) extended 張出し (3.2 m) 中間 (3.2m) Mid. extended 張出し (3.2 m) Outrigger condition symbol 最小 Min. (2.7m) extended 張出し (2.7 m) 最小 (1.79m) Min. extended 張出し (1.79 m) IW J08 On-rubber condition symbol Outrigger condition selector key Set key 2. On-rubber stationary status Pressing the outrigger condition selector key makes the outrigger condition symbol flash. From this status, press the outrigger condition selector key again. Ensure that the outrigger condition symbol disappears and the on-rubber condition symbol lights. Now, the condition is automatically registered. 111 W E

113 Functions of and How to Use User Mode (GR-160N-1) Registration of Lift Status 点灯 Lights. IW J02 3. On-rubber creep Press the outrigger condition selector key to make the on-rubber condition symbol flash. Now, the condition is automatically registered. [NOTICE] When the power supply is turned on, the single top lift is automatically selected. Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation condition. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again. Flashes 点滅 メッセージ Lights. 点灯 Flashes 点滅 IW J62 揚程制限起伏上限起伏下限旋回左限旋回右限半径制限 ジブ状態シンボル Jib lift symbol シングルトップ状態 Single top lift symbol シンボルブーム状態シンボル Boom lift symbol 表示切替 調整 点検 ブーム O / R セット ブーム状態選択キー Lift status selector key IW J64 To register the lift status, use the lift status selector key. Each time the lift status selector key is pressed, the display changes in numerical sequence in the following table. The display returns to (1) if you press the key when the last status is shown on the display. Select the status that corresponds to the actual lift status. The status is automatically registered. 112 W E

114 Functions of and How to Use User Mode (GR-160N-1) The following table shows the display pattern. Display Boom status Single top lift Flashes. Jib set Jib lift, 5 offset operation Jib lift, 25 offset operation Jib lift, 45 offset operation Boom lift 113 W E

115 Functions of and How to Use User Mode (GR-160N-1) Pre-operational Inspection on the AML WARNING Operating the crane with a malfunctioning AML could cause the crane to overturn or be damaged. Be sure to perform the pre-operational inspection on the AML system and start the crane only after ensuring that the system is operating properly. [NOTICE] Before starting operation, check that the AML system works in good condition, as follows: 1. Press the inspection key and make sure that the AML is in the following conditions: Display panel (1 and 2) Moment display All segments light. Working area limit indicator lamp Alarm buzzer Sounds continuously. Movement toward critical sides Automatically halted. 2. Press the set key, display alteration key, or inspection key to return the display to the normal condition (a bargraph must be shown on the moment display). 3. Visually check that values and symbols shown on the display panel 1 and 2 represent the actual crane conditions, particularly on the following items. (1) Boom length (2) Boom angle (3) Jib angle (jib length) (shown while jib lift is selected) (4) Actual load With no load on hook, make sure that an approximate mass of the hook block is shown. [NOTICE] The actual load is not shown correctly if the lift status of the AML is not registered correctly. (5) Outrigger condition symbol (6) Swing position display (7) Front position symbol (when the swing position is in the front position) 114 W E

116 Functions of and How to Use User Mode (GR-160N-1) How to Use the Working Area Limiting Function Working area 作業範囲制限キー Swing limit limit keys area 旋回制限領域 Indicator 表示ランプ lamps [NOTICE] If the working area limit is registered very close to an obstacle, there is a risk of the crane colliding with the obstacle, depending on the operational status and the manner in which the load is handled. When registering an area limit, allow a sufficient clearance to avoid collision. The working area limit function limits operation of the boom and swing movement to the pre-registered boom angle (upper limit, lower limit), lifting height, load radius, and swing angle (left, right). Use this function when performing operation in a place where there are obstacles around the machine, requiring the working-area limitation of the boom. Upper boom angle limit Lower boom angle limit Lifting height limit Load radius limit Left swing limit Right swing limit Automatic stop and alarm buzzer (Beep for 3 seconds) [NOTICE] When the automatic swing stop cancel switch is set to " 解除," the swing does not stop automatically, even if the swing limit area is reached. Only the alarm buzzer sounds. Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation condition. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again. 調整 Working Area Limit Value While the working area limit function is activated, as long as the set key is pressed, the working area limit values registered in the indicator shown below are displayed. Also the message " ハンイセイゲンチヒョウジ " appears on the moment display. Upper boom ブーム上限 angle 角度制限値 limit value 揚程制限値 Lifting height limit value Boom Angle Limit メッセージ 調整 点検 m 点検 ブーム ブーム m 揚程制限 揚程制限 旋回左限 ハンイセイゲンチヒヨウジ deg deg 半径制限 セット Raise or lower the boom to a desired limit angle, and press the upper or lower boom angle limit key. The corresponding limit indicator lamp will flash, indicating that the boom angle limit has been registered in the memory. When the boom is moved back to an angle within the set limit, the boom angle limit indicator lamp stops flashing and stays lit. Thereafter, the upper or lower boom angle limit indicator lamp flashes O / R ton max ton 旋回左限旋回右限 O / R 起伏上限起伏下限 半径制限 表示切替 セット 起伏上限 旋回右限 起伏下限 表示切替 IW J66 Lower ブーム下限 boom angle limit 角度制限値 value 作業半径 Load radius 制限値 limit value Set key セットキー IW J W E

117 Functions of and How to Use User Mode (GR-160N-1) and the alarm buzzer (beep) sounds for 3 seconds whenever the upper or lower limit previously registered is reached. (Boom raising or lowering stops automatically.) To cancel the boom angle limits, press the upper or lower boom angle limit key again. The corresponding boom angle limit indicator lamp will go out. Lifting Height Limit Move the boom to a desired limit height, and press the lifting height limit key. The lifting height limit indicator lamp will flash, indicating that the lifting height limit has been registered in the memory. When the boom or jib is moved back to a height within the set limit, the lifting height limit indicator lamp stops flashing and stays lit. Thereafter, the height limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the height limit previously registered is reached. (Boom or jib raising and boom extending stop automatically.) To cancel the height limit, press the lifting height limit key again. The lifting height limit indicator lamp will go out. Load Radius Limit Move the boom to a desired limit load radius, and press the load radius limit key. The load radius limit indicator lamp will flash, indicating that the load radius limit has been registered in the memory. When the boom or jib is moved back to a load radius within the set limit, the load radius limit indicator lamp stops flashing and stays lit. Thereafter, the load radius limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the load radius previously registered is reached. (Boom or jib raising and boom extending stop automatically.) To cancel the load radius limit, press the load radius limit key again. The load radius limit indicator lamp will go out. Swing Limit Swing to a desired limit swing position, and press the left swing limit key or right swing limit key. The corresponding swing limit indicator lamp will flash and the buzzer (beep) sounds for 3 seconds, indicating that the swing limit has been registered in the memory. When the boom is moved back to a swing position within the set limit, the swing limit indicator lamp stops flashing and stays lit. Thereafter, the swing limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the swing angle previously registered is reached. (Swing stops automatically.) To cancel the swing limit, press the left swing limit key or right swing limit key again. The corresponding swing limit indicator lamp will go out. [NOTICE] Ensure to register both the right swing and left swing limit positions. If either right or left limit position only is set, the alarm does not sound correctly. When the automatic swing stop cancel switch is set to " 解除," the swing does not stop automatically, even if the swing limit area is reached. Be extremely careful of the operation, because the machine does not stop automatically but only the swing limit indicator lamp flashes, the message appears, and the AML buzzer (beep) sounds for 3 seconds. 116 W E

118 Functions of and How to Use User Mode (GR-160N-1) How to Use the Boom Elevating Speed Adjusting Function The boom elevating speed adjusting function is a function to adjust the maximum speed when the boom is extended. How to Register Boom Elevating Speed Adjustment Increase key 減キー Decrease 増キー key メッセージ 調整 揚程制限起伏上限起伏下限 Use the increase or decrease key to register the boom elevating speed. Pressing the increase or decrease key changes the bargraph display to the following elevating speed values. 点検 While the elevating speed values are shown on the bargraph display, pressing the increase or decrease key again enables to set each boom elevating speed value to 0% (stop) to 100% (standard speed) in 10% increments. In addition, pressing the increase or decrease key during a boom elevating operation enables to adjust the boom raising and boom lowering speeds separately. ブーム メッセージアゲ 100% サゲ 100% 旋回左限旋回右限 O / R 半径制限 表示切替 セット IW J68 Boom ブーム下げ側の最高速度 lowering max. speed ブーム上げ側の最高速度 Boom raising max. speed IW J69 During boom raising operation: Only raising speed can be changed During boom lowering operation: Only lowering speed can be changed No boom elevating operation: Both the raising and lowering speeds can be changed at the same time. [NOTICE] If the increase key or decrease key is not pressed for approx. 10 seconds, the bargraph display returns to the normal condition (a bargraph must be shown on the moment display), and the registration of boom elevating has been completed. Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation condition. When the power supply is turned on again, all the segments of the bargraph display light, and the boom elevating values are shown only for 2 to 3 seconds. After that, the display returns to the normal condition (a bargraph must be shown on the moment display). Operating Speed on Registration of Boom Elevating Speed Adjustment The percentage value shown by the boom elevating speed adjusting function is a speed limit value when the boom is fully extended. On the contrary, when the boom is fully retracted, it always elevates at the standard speed. The relation between the value and boom elevating speed is as follows: 1. When value is 0% Fully retracted Standard speed In between fully retracted and fully extended (1/2) 1/2 of standard speed Fully extended Stop (almost no movement) 2. When value is 50% Fully retracted Standard speed In between fully retracted and fully extended (1/2) 3/4 of standard speed Fully extended 1/2 of standard speed 117 W E

119 Functions of and How to Use User Mode (GR-160N-1) 3. When value is 100% Fully retracted Standard speed In between fully retracted and fully extended (1/2) Standard speed Fully extended Standard speed Boom 起伏最高速度 elevating max. speed Standard 標準速度 100% 3/4 速度 1/2 速度 50% 1/4 速度 0% Stop 停止 Fully 全縮 Mid. 中間 Fully 全伸ブーム長さ Boom length retracted extended IW J70 IW J W E

120 Functions of and How to Use User Mode (GR-120F-1) Functions of and How to Use User Mode (GR-120F-1) Mode Structure The AML device has three modes and the AML functions are allotted for these models. 2. Maintenance Mode: Used to make functional checks of the AML. Refer to the "ADJUSTMENT AND MAINTENANCE" section. 3. Adjustment Mode: Used to make detector. Refer to the "ADJUSTMENT AND MAINTENANCE" section. POWER 電源 ON ON プロテクト Protect スイッチ switch ON ON ユーザーモード USER MODE 保守モード MAINTENANCE MODE プロテクト Protect スイッチ switch OFF 調整モード ADJUSTMENT MODE POWER 電源 ON ON IW J03 1. User Mode: Used to indicate moment load factor or to perform AML pre-operational inspection (Normally used). In normal use, turn ON the protect switch mounted on the window on the top of the AML. The AML will go to the user mode when the power turns on. The abnormality display LED lights when the AML is in abnormal conditions (to indicate that the CPU is faulty). MOMENT SHORT PROTECT ZERO WDT HALT ON OFF Top 上面 view Protect 異常表示 Abnormality LED プロテクトスイッチ switch display LED IW J W E

121 Functions of and How to Use User Mode (GR-120F-1) Configuration and Functions of the AML System The AML system has various kinds of functions, including the following six typical functions. Based on the work conditions registered in the AML and the signals from various sensors, these functions control the crane operations. 1. Automatic stop function to prevent overloading The AML calculates and compares the working and rated moment values and displays their ratio. When the working moment exceeds the rated moment (100% or more), failure message is shown, alarm buzzer sounds, and the crane operation toward the critical side stops. 2. Working area limit functions When any working area limit is registered to the AML, the crane is controlled so that the crane work posture does not exceed this registered working area limit. When the crane reaches the registered limit, failure message is shown, alarm buzzer sounds, and the crane operation stops. The availability of the above described automatic stop function, working area limit functions, and slow stop function is as shown in the table below depending on the individual operation. On-outrigger operation Automatic Hoisting up stop by Boom lowering overloading Boom extension Swing Jib lowering Jib extension Stop at the Boom raising stroke end Boom lowering Jib raising Jib lowering Stop by working area limit Boom raising/lowering Swing Boom extension Jib raising/lowering : Slow stop : Stop 3. Slow stop function When the stroke end of the boom raising or jib raising is reached, the operation speed goes down gradually and then the operation stops slowly. 120 W E

122 Functions of and How to Use User Mode (GR-120F-1) [NOTICE] When the boom elevation slow stop cancel switch is set to " 解除," the slow stop function of the boom raising/lowering is deactivated. 解除 起伏停 Elevation 起伏緩停止 slow stop Elevation 起伏緩停止解除 slow stop canceled Elevation 起伏緩停止 slow stop IW J51 4. Automatic swing stop status Because the performance range of the crane operation is different depending on the extended width of the outriggers, the crane operation will stop at the boundary area of the performance range if the overloading occurs during swing operation. [NOTICE] When the swing stop switch is set to " 解除," the swing does not stop automatically. 5. Alarm Functions Condition Alarm Overwinding Buzzer: Tremolo sound Moment load factor 90% or more, and less than 100% Moment load factor 100% or more Crane operation control required Working area limit function activated AML system error Moment display: Applicable bargraph is lit yellow. Buzzer: Sounds intermittently. Moment display: Applicable bargraph is lit until the moment load factor is up to 110%. When 110% is exceeded, all the bargraphs are lit. Buzzer: Sounds continuously. Moment display: Displays the control message. Buzzer: Beep (only for 3 seconds)(*1) The corresponding limit indicator lamp flashes. Buzzer: Beep (only for 3 seconds)(*1) Moment display: Displays an error message. 解除旋停 Swing 旋回停止 stop Automatic 旋回自動停止解除 swing stop canceled Automatic 旋回自動停止 swing stop IW J50 Buzzer: Beep (only for 3 seconds)(*1) (*1): There are two types of buzzer sounds and those are classified as follows: Slow stop control: Beep in long cycle Other controls: Beep in short cycle 6. Elevating speed adjusting function This function adjusts the maximum speed when the jib is extended. 121 W E

123 Functions of and How to Use User Mode (GR-120F-1) Boom length detection Boom angle detection Moment load factor detection Swing angle detection Crane operation detection Outrigger extension width detection Display panel Outrigger status registration Jib offset angle detection Jib length detection Operator input Main, auxiliary status registration Registration of the working area limits AML unit Display panel Alarm buzzer AML external indicator lamps (option) An automatic stop is output when: Jib extension stop Jib lowering stop Moment load factor is 100% or more. Overwinding occurs. The working area limit signal is output. Boom extension halted Boom lowering halted Hoisting up halted Swing toward critical side halted Left swing restricted Right swing restricted Upper boom angle restricted Lower boom angle restricted Lifting height restricted Load radius restricted 122 W E

124 Functions of and How to Use User Mode (GR-120F-1) Names and Functions of the Parts A. Bargraph display AML (Main Unit) 3 1 A メッセージ B メッセージ Message 4 2 IW J54 1. Load factor mark D 揚程制限起伏上限起伏下限旋回左限旋回右限半径制限 C The moment load factors on the bargraph are color coded as follows: safe (green), notice (yellow) and limit (red) A. Bargraph display B. Display panel 1 C. Controls section D. Display panel 2 調整 点検 ブーム O / R 表示切替セット IW J53 2. Moment display Normally displays a moment load factor on a bargraph and in value. Displays the main hydraulic pressure and accumulator pressure when the display alteration key is pressed. Displays the boom elevating speed value when the increase key or decrease key is pressed. Also displays error messages when detects an error in a detector or others. 3. Scroll-up key ( ) Used to see the previous lines of message displayed on the moment display. 4. Scroll-down key ( ) Used to see the next lines of message displayed on the moment display. 123 W E

125 Functions of and How to Use User Mode (GR-120F-1) B. Display panel 1 8. Load radius symbol This symbol indicates that the load radius display [9] is showing the load radius. 9. Load radius display Normally displays the crane s load radius. Displays the boom swing angle while the display alteration key is pressed. When the load radius limit function is activated, the registered load radius limit value is displayed while the set key is pressed. 1. Boom length symbol This symbol indicates that the boom length display [19] is showing the boom length. 2. Jib length symbol This symbol indicates that the jib angle display [22] is showing the jib length. 3. Jib angle symbol This symbol indicates that the jib angle display [22] is showing the jib offset angle. 4. Auxiliary hoisting condition symbol Lights when the auxiliary hoisting operation is selected. Flashes when the jib set operation is selected. 5. Actual load display Displays the actual load. 6. Rated lifting capacity display Displays the rated lifting capacity. 7. Load radius limit symbol This symbol indicates that the load radius display [9] is showing the registered load radius limit value. The load radius symbol [8] is also lit at the same time when this symbol is lit. 10. Boom angle display Normally displays the boom angle. Displays the moment load factor (%) while the display alteration key is pressed. When the lower limit function of boom angle is activated, the registered limit value is displayed while the set key is pressed. 11, 12. Boom angle symbols This symbol indicates that the boom angle display [10] is showing the boom angle. 13. Main hoisting condition symbol Lights when the main hoisting operation is selected. 14. Boom lift symbol Not used. 15, 16. Lower boom angle limit symbols This symbol indicates that the boom angle display [10] is showing the registered lower boom angle limit value. 17, 18. Upper boom angle limit symbols This symbol indicates that the boom angle display [22] is showing the registered upper boom angle limit value. 19. Boom length display Normally displays the boom length. Displays the lifting height while the display alteration key is pressed. When the lifting height limit function is activated, the registered limit value is displayed while the set key is pressed. 124 W E

126 Functions of and How to Use User Mode (GR-120F-1) 20. Lifting height symbol This symbol indicates that the boom length display [19] is showing the lifting height. 21. Lifting height limit symbol This symbol indicates that the boom length display [19] is showing the registered lifting height limit value. The lifting height symbol [20] is lit at the same time when this symbol is lit. 22. Jib angle display The jib offset angle is displayed when the jib operation is selected, and the jib length is displayed while the display alteration key is pressed. Also, when the upper boom angle limit function is activated, the upper boom angle limit value is displayed while the set key is pressed. C. Controls section 5. Outrigger condition selector key Used to select the on-outrigger or on-rubber status. 6. Set key Used to register a selected condition. 7. Display alteration key Used to alter the displays on display panel Left swing limit key Used to activate and release the left swing limiting function. 9. Right swing limit key Used to activate and release the right swing limiting function. 10. Load radius limit key Used to activate and release the load radius limiting function 揚程制限 旋回左限旋回右限 起伏上限起伏下限 半径制限 Lifting height limit key Used to activate and release the lifting height limiting function. 12. Upper boom angle limit key Used to activate and release the uppermost boom angle limiting function. 1 2 調整 3 4 点検 5 ブーム 15 9 O / R 表示切替 セット Lower boom angle limit key Used to activate and release the lowermost boom angle limiting function. IW J56 1. Increase key Used to increase the selected value. Also, used to adjust the elevating speed. 2. Decrease key Used to decrease the selected value. Also, used to adjust the elevating speed. 14 to 19. Limit indicator lamps Light when the corresponding limiting function is activated. If the crane operation reaches the limit area while the working area limit function is activated, the indicator lamp changes from "being lit" to "flashing." 3. Inspection key Used to perform the pre-operational inspection of the AML system. 4. Lift status selector key Used to select the boom lift status. 125 W E

127 Functions of and How to Use User Mode (GR-120F-1) D. Display panel IW J57 1. Front position symbol Lights to indicate that the swing position comes to the front position. 2. Swing position display Indicates the swing position in 10 increments by flashing. 3. Outrigger condition symbol Indicates the outrigger extension status by symbol. Flashes while the outrigger condition is being registered, and stays lit after the registration is completed. 4. On-rubber condition symbol Indicates that the performance in the on-rubber condition is selected using the symbol. Lights when the performance in the "on-rubber stationary" condition is selected, and flashes when that in the "on-rubber creep" condition is selected. 5. Spring (suspension) lock condition symbol (Not used in this machine) Indicates the spring (suspension) lock condition using the symbol. When the "on-rubber" condition is selected, the symbol lights. 126 W E

128 Functions of and How to Use User Mode (GR-120F-1) Registering Operating Conditions WARNING Should the operational status be incorrectly registered, the crane may overturn or be damaged, leading to a serious accident. Prior to every operation, check that the registered status corresponds to the actual status of the crane. Registration of Outrigger Condition Pressing the outrigger condition selector key indicates the outrigger extension width entered in the AML by flashing the outrigger condition symbol. Check whether it matches the actual outrigger extension status, and if it is OK, press the set key to register. The outrigger condition symbol changes to "being lit" to indicate that the condition has been successfully registered. [NOTICE] When the power supply is turned on, the "on-rubber creep" condition is automatically selected. Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the registered operation condition. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again. To register the outrigger condition, press the outrigger condition selector key to enable the outrigger condition selector function, and follow the procedure below. IW J59 The outrigger condition symbol by the outrigger extension width is as follows: H-type outrigger Fully extended (4.7 m) Mid. extended (4.3 m) Mid. extended (3.5 m) Mid. extended (2.5 m) Outrigger condition symbol Min. extended (1.64 m) Set key On-rubber condition symbol Outrigger condition selector key 127 W E

129 Functions of and How to Use User Mode (GR-120F-1) Registration of Lift Status [NOTICE] When the power supply is turned on, the auxiliary hoisting operation is selected if the jib is extended, and the jib set operation is selected if other operations are selected. Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation condition. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again. To register the lift status, use the lift status selector key. Each time the lift status selector key is pressed, the display changes in numerical sequence in the table shown below. The display returns to (1) if you press the key when the last status is shown on the display. Select the status that corresponds to the actual lift status. Auxiliary hoisting condition symbol Main hoisting condition symbol Lift status selector key The following table shows the display pattern. Display Boom status Flashes. Jib set operation Main hoisting operation Auxiliary hoisting operation 128 W E

130 Functions of and How to Use User Mode (GR-120F-1) Pre-operational Inspection on the AML WARNING Operating the crane with a malfunctioning AML could cause the crane to overturn or be damaged. Be sure to perform the pre-operational inspection on the AML system and start the crane only after ensuring that the system is operating properly. (8) Front position symbol (when the swing position is in the front position) [NOTICE] Before starting operation, check that the AML system works in good condition, as follows: 1. Press the inspection key and make sure that the AML is in the following conditions: Display panel (1 and 2) Moment display All segments light. Working area limit indicator lamp Alarm buzzer Sounds continuously. Movement toward critical sides Automatically halted. 2. Press the set key, display alteration key, or inspection key to return the display to the normal condition (a bargraph must be shown on the moment display). 3. Visually check that values and symbols shown on the display panel 1 and 2 represent the actual crane conditions, particularly on the following items. (1) Boom length (2) Boom angle (3) Jib offset angle (4) Jib length (5) Actual load With no load on hook, make sure that an approximate mass of the hook block is shown. [NOTICE] The displayed mass varies depending on the working posture. The actual load is not shown correctly if the lift status of the AML is not registered correctly. (6) Outrigger condition symbol (7) Swing position display 129 W E

131 Functions of and How to Use User Mode (GR-120F-1) How to Use the Working Area Limiting Function [NOTICE] If the working area limit is registered very close to an obstacle, there is a risk of the crane colliding with the obstacle, depending on the operational status and the manner in which the load is handled. When registering an area limit, allow a sufficient clearance to avoid collision. When the crane is stopped automatically by the working area limit, the slow stop function does not work. Some shocks may be experienced at the time of crane stopping. The working area limit function limits operation of the boom and swing movement to the pre-registered boom angle (upper limit, lower limit), lifting height, load radius, and swing angle (left, right). Use this function when performing operation in a place where there are obstacles around the machine, requiring the working-area limitation of the boom. Upper boom angle limit Lower boom angle limit Lifting height limit Load radius limit Left swing limit Right swing limit Automatic stop and alarm buzzer (Beep for 3 seconds) [NOTICE] When the automatic swing stop cancel switch is set to " 解除," the swing does not stop automatically, even if the swing limit area is reached. Only the alarm buzzer sounds. Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation condition. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again. Working area Swing limit 作業範囲制限キー limit keys area 旋回制限領域 調整 点検 Working Area Limit Value ブーム 揚程制限 旋回左限 Indicator 表示ランプ lamps 半径制限 セット While the working area limit function is activated, as long as the set key is pressed, the working area limit values registered in the indicator shown below are displayed. Also the message " ハンイセイゲンチヒョウジ " appears on the moment display. [NOTICE] When the crane reaches the position close to the registered working area value, the message " セイゲンハンイフキン " appears on the moment display. Upper boom ブーム上限 angle 角度制限値 limit value Lifting 揚程制限値 height limit value メッセージ 調整 ハンイセイゲンチヒヨウジ m 点検 deg ブーム deg m ton max ton O / R 揚程制限起伏上限起伏下限 旋回左限旋回右限 O / R 半径制限 表示切替 セット 起伏上限 旋回右限 起伏下限 表示切替 IW J66 Lower ブーム下限 boom angle 角度制限値 limit value 作業半径 Load radius 制限値 limit value Set key セットキー IW J W E

132 Functions of and How to Use User Mode (GR-120F-1) Boom Angle Limit Raise or lower the boom to a desired limit angle, and press the upper or lower boom angle limit key. The corresponding limit indicator lamp will flash, indicating that the boom angle limit has been registered in the memory. When the boom is moved back to an angle within the set limit, the boom angle limit indicator lamp stops flashing and stays lit. Thereafter, the upper or lower boom angle limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the upper or lower limit previously registered is reached. (Boom raising or lowering stops automatically.) To cancel the boom angle limits, press the upper or lower boom angle limit key again. The corresponding boom angle limit indicator lamp will go out. Lifting Height Limit Move the boom or jib to a desired limit height, and press the lifting height limit key. The lifting height limit indicator lamp will flash, indicating that the height limit has been registered in the memory. When the boom or jib is moved back to a height within the set limit, the lifting height limit indicator lamp stops flashing and stays lit. Thereafter, the lifting height limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the height limit previously registered is reached. (Boom or jib raising and boom or jib extending stop automatically.) To cancel the height limit, press the lifting height limit key again. The lifting height limit indicator lamp will go out. Load Radius Limit Move the boom or jib to a desired limit load radius, and press the load radius limit key. The load radius limit indicator lamp will flash, indicating that the load radius limit has been registered in the memory. When the boom or jib is moved back to a load radius within the set limit, the load radius limit indicator lamp stops flashing and stays lit. Thereafter, the load radius limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the load radius previously registered is reached. (Boom or jib lowering and boom or jib extending stop automatically.) To cancel the load radius limit, press the load radius limit key again. The load radius limit indicator lamp will go out. Swing Limit WARNING When setting the swing area, do not set the automatic swing stop cancel switch to " 解除." It is dangerous to cancel the swing stop function because an automatic stop is not made even if the crane reaches the swing limit position. Ensure to register both the right swing and left swing limit positions. If either right or left limit position only is set, the swing does not stop automatically if the operation is performed in the opposite direction. Example: With the swing limit set only on the left side, the crane does not stop automatically when it reaches the set position in swinging from the right side. Swing to a desired limit swing position, and press the left swing limit key or right swing limit key. The corresponding swing limit indicator lamp will flash and the buzzer (beep) sounds for 3 seconds, indicating that the swing limit has been registered in the memory. When the boom is moved back to a swing position within the set limit, the swing limit indicator lamp stops flashing and stays lit. Thereafter, the swing limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the swing angle previously registered is reached. (Swing stops automatically.) To cancel the swing limit, press the left swing limit key or right swing limit key again. The corresponding swing limit indicator lamp will go out. 131 W E

133 Functions of and How to Use User Mode (GR-120F-1) How to Use the Jib Tilt Speed Adjusting Function The jib tilt speed adjusting function is a function to adjust the maximum jib tilt speed when the jib is extended. How to Register Jib Tilt Speed Adjustment During jib raising operation: Only raising speed can be changed During jib lowering operation: Only lowering speed can be changed No jib tilt operation: Both the raising and lowering speeds can be changed at the same time. [NOTICE] Decrease 減キー key Increase 増キー key メッセージ 調整 点検 揚程制限起伏上限起伏下限旋回左限旋回右限半径制限表示切替ブーム O / R セット IW J68 If the increase key or decrease key is not pressed for approx. 10 seconds, the bargraph display returns to the normal condition (a bargraph must be shown on the moment display), and the registration of jib tilt speed has been completed. Even after the power supply is turned off (PTO switch: OFF), the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation condition. When the power supply is turned on again, all the segments of the bargraph display light, and the jib tilt speed values are shown only for 2 to 3 seconds. After that, the display returns to the normal condition (a bargraph must be shown on the moment display). Use the increase or decrease key to register the jib tilt speed. Pressing the increase or decrease key changes the bargraph display to the following jib tilt speed values. Jib lowering max. speed Jib raising max. speed While the jib tilt speed values are shown on the bargraph display, pressing the increase or decrease key again enables to set each jib tilt speed value to 0% (stop) to 100% (standard speed) in 10% increments. In addition, pressing the increase or decrease key during jib tilt operation enables to adjust the jib raising and jib lowering speeds separately. Operating Speed on Registration of Jib Tilt Speed Adjustment The percentage value shown by the jib tilt speed adjusting function is a speed limit value when the jib is fully extended. On the contrary, when the jib is fully retracted, it always operates at the standard speed. The relation between the value and jib tilt speed is as follows: 1. When value is 0% Fully retracted Standard speed In between fully retracted and fully extended (1/2) 1/2 of standard speed Fully extended Stop (almost no movement) 2. When value is 50% Fully retracted Standard speed In between fully retracted and fully extended (1/2) 3/4 of standard speed Fully extended 1/2 of standard speed 132 W E

134 Functions of and How to Use User Mode (GR-120F-1) 3. When value is 100% Fully retracted Standard speed In between fully retracted and fully extended (1/2) Standard speed Fully extended Standard speed Jib tilt max. speed Standard Stop Fully retracted Mid. Fully Jib length extended T28220J 133 W E

135 Functions of and How to Use User Mode (GA-700N-1) Functions of and How to Use User Mode (GA-700N-1) Mode Structure The AML device has three modes and the AML functions are allotted for these models. 2. Maintenance Mode: Used to make functional checks of the AML. Refer to the "ADJUSTMENT AND MAINTENANCE" section. 3. Adjustment Mode: Used to make detector. Refer to the "ADJUSTMENT AND MAINTENANCE" section. POWER 電源 ON ON プロテクト Protect スイッチ switch ON ON ユーザーモード USER MODE 保守モード MAINTENANCE MODE プロテクト Protect スイッチ switch OFF 調整モード ADJUSTMENT MODE POWER 電源 ON IW J03 1. User Mode: Used to indicate moment load factor or to perform AML pre-operational inspection (Normally used). In normal use, turn ON the protect switch mounted on the window on the top of the AML. The AML will go to the user mode when the power turns on. The abnormality display LED lights when the AML is in abnormal conditions (to indicate that the CPU is faulty). MOMENT SHORT PROTECT ZERO WDT HALT ON OFF Top 上面 view Protect 異常表示 Abnormality LED switch display LED プロテクトスイッチ IW J W E

136 Functions of and How to Use User Mode (GA-700N-1) Configuration and Functions of the AML System The AML system has various kinds of functions, including the following five typical functions. Based on the work conditions registered in the AML and the signals from various sensors, these functions control the crane operations. 1. Automatic stop function to prevent overloading The AML calculates and compares the working and rated moment values and displays their ratio. When the working moment exceeds the rated moment (100% or more), failure message is shown, alarm buzzer sounds, and the crane operation toward the critical side stops. If the backward stability is getting worse, failure message is shown, alarm buzzer sounds, and the operation toward the critical side stops. 2. Working area limit functions When any working area limit is registered to the AML, the crane is controlled so that the crane work posture does not exceed this registered working area limit. When the crane reaches the registered limit, failure message is shown, alarm buzzer sounds, and the crane operation stops. 3. Slow stop function When the crane boom elevation is stopped as shown below, the slow stop function works, and the machine stops slowly. Boom lowering stop for the overloading automatic stop function Boom raising stop for the backward stability stop function Boom elevation stop for the elevating cylinder reaching the stroke end Boom retraction stop for the telescoping cylinder reaching the stroke end Boom elevation stop for the working area limit stop function The availability of the above described automatic stop function and working area limit functions is as shown in the table below depending on the individual operation. However, if the AML emergency switch is held at the automatic stop cancel "ON" position, the AML emergency warning lamp lights while the AML emergency switch is held, and all these stop functions of the AML are canceled (remedy for system error). Note that only the function for stop by backward stability is not canceled, and still continues working. : Slow stop : Stop Automatic stop Hoisting up by overloading Boom lowering Boom extension Swing Jib lowering Jib extension Stop for Boom raising backward stability Stop at the stroke Boom raising/lowering end Boom retraction Stop by working Boom raising/lowering area limit Swing Boom extension Jib raising/lowering Jib extension When the automatic swing stop cancel switch is set to "ON ( 解除 )," the swing does not stop automatically. When the boom elevation slow stop cancel switch is set to "ON ( 解除 )," the slow stop function of the boom raising/lowering is deactivated. An exception is a case of stopping for backward stability, and the slow stop function is not deactivated. 135 W E

137 ACCUM AML JIB TILT UNLOCK 85 Functions of and How to Use User Mode (GA-700N-1) Automatic swing stop cancel warning lamp 旋回自動停止解除警告灯 Elevation 起伏緩停止解除警告灯 slow stop cancel warning lamp 起伏緩停止解除スイッチ Boom elevation slow ( stop 解除時 cancel : 警告灯点灯 switch ) (Cancel: Warning lamp lights.) AML 50 ON OFF Elevation 旋回自動停止解除スイッチ automatic stop cancel switch (Cancel: ( 解除時 Warning : 警告灯点灯 lamp lights.) ) IW J71 4. Alarm Functions Condition Alarm Overwinding Buzzer: Tremolo sound Moment load factor 90% or more and less than 100% Moment load factor 100% or more Crane operation control required Working area limit function activated AML system error Moment display: Applicable bargraph is lit yellow. Buzzer: Sounds intermittently. Moment display: Applicable bargraph is lit until the moment load factor is up to 110%. When 110% is exceeded, all the bargraphs are lit. Buzzer: Sounds continuously. Moment display: Displays the control message. Buzzer: Beep (only for 3 seconds)(*1) The corresponding limit indicator lamp flashes. Buzzer: Beep (only for 3 seconds)(*1) Moment display: Displays an error message. Buzzer: Beep (only for 3 seconds)(*1) (*1): There are two types of buzzer sounds and those are classified as follows: Slow stop control: Beep in long cycle Other controls: Beep in short cycle 5. Boom elevating speed adjusting function This function adjusts the maximum speed when the boom is extended. 136 W E

138 メッセージ 調整 点検 ブーム 揚程制限起伏上限起伏下限 旋回左限旋回右限半径制限 O / R 表示切替 セット Functions of and How to Use User Mode (GA-700N-1) Boom ブーム長さ検出 length detection Boom ブーム角度検出 angle detection Jib ジブ長さ検出 length detection Jib ジブ角度検出 angle detection Moment モーメント検出 load factor Width アウトリガ張出幅検出 of outrigger Swing 旋回角度検出 angle detection detection extension F/J 状態検出 detection F/J status detection θ クレーン操作検出 Crane operation detection L θ L θ W L Counterweight カウンタウエイト condition 状態検出 detection オペレ タ入力 Operator input Registration アウトリガ状態登録 of the outrigger condition Registration of the boom ブーム ジブ状態登録 and jib condition Registration 作業範囲制限登録 of the working area limits AML 本体 unit 警報ブザー Alarm buzzer AML 外部表示灯 external indicator ( オプション lamps ) (option) 表示パネル Display panel An automatic stop 自動停止出力 is output when: Jib ジブ伸長停止 extension halted Moment load factor モーメント100% 以上 is 100% or more. 巻過ぎ Overwinding occurs. The 作業範囲 working area 制限出力 limit signal is output. Stop 後方安定 for backward stability 停止出力 signal is output. Boom raising ブーム上げ停止 halted Boom ブーム縮小停止 retraction halted ジブチルト下げ停止 Jib tilting down halted ブーム伸長 Boom 停止 extension halted ブーム下げ Boom 停止 lowering halted ウインチ Hoisting up 巻上げ停止 halted 危険側への旋回 Swing toward 停止 critical side halted 左旋回制限 Left swing 右旋回制限 restricted Right swing restricted ブーム角度 Upper boom 上限制限 angle restricted ブーム角度 Lower boom 下限制限 angle restricted Lifting 揚程制限 height restricted 作業半径制限 Load radius restricted θ u H θ L R 137 W E IW J72

139 Functions of and How to Use User Mode (GA-700N-1) Names and Functions of the Parts AML (Main Unit) A. Bargraph display 3 1 A メッセージ メッセージ Message B 4 2 IW J54 1. Load factor mark D 揚程制限起伏上限起伏下限旋回左限旋回右限半径制限 C The moment load factors on the bargraph are color coded as follows: safe (green), notice (yellow) and limit (red) A. Bargraph display B. Display panel 1 C. Controls section D. Display panel 2 調整 点検 ブーム O / R 表示切替セット IW J53 2. Moment display Normally displays a moment load factor on a bargraph and in value. Displays the main hydraulic pressure and accumulator pressure when the display alteration key is pressed. Displays the boom elevating speed value when the increase key or decrease key is pressed. Also displays error messages when detects an error in a detector or others. 3. Scroll-up key ( ) Used to see the previous lines of message displayed on the moment display. 4. Scroll-down key ( ) Used to see the next lines of message displayed on the moment display. 138 W E

140 Functions of and How to Use User Mode (GA-700N-1) B. Display panel m Boom length symbol This symbol indicates that the boom length display [20] is showing the boom length. 2. Jib length symbol This symbol indicates that the jib angle display [23] is showing the jib length. 3. Jib angle symbol This symbol indicates that the jib angle display [23] is showing the jib offset angle. 4. Jib lift symbol This symbol lights when the jib operation is selected. m 5. Actual load display Displays the actual load % 6. Rated lifting capacity display Displays the rated lifting capacity. 7. Load radius limit symbol This symbol indicates that the load radius display [9] is showing the registered load radius limit value. The load radius symbol [8] is also lit at the same time when this symbol is lit. 8. Load radius symbol This symbol indicates that the load radius display [9] is showing the load radius m 13 8 t max t IW J73 9. Load radius display Normally displays the crane s load radius. Displays the boom swing angle while the display alteration key is pressed. When the load radius limit function is activated, the registered load radius limit value is displayed while the set key is pressed. 10. Boom angle display Normally displays the boom angle. Displays the moment load factor (%) while the display alteration key is pressed. When the lower limit function of boom angle is activated, the registered limit value is displayed while the set key is pressed. 11, 12. Boom angle symbols This symbol indicates that the boom angle display [10] is showing the boom angle. 13. Single top lift symbol This symbol indicates that the single top performance is selected. 14. Boom lift symbol This symbol indicates that the boom lift is selected. 15, 16. Lower boom angle limit symbols This symbol indicates that the boom angle display [10] is showing the registered lower boom angle limit value. 17, 18. Upper boom angle limit symbols This symbol indicates that the jib angle display [23] is showing the registered upper boom angle limit value. 19. Counterweight condition symbol Indicates that the performance of the counterweight operation is selected, and displays the status for the operation. 20. Boom length display Normally displays the boom length. Displays the lifting height while the display alteration key is pressed. When the lifting height limit function is activated, the registered limit value is displayed while the set key is pressed. 139 W E

141 Functions of and How to Use User Mode (GA-700N-1) 21. Lifting height symbol This symbol indicates that the boom length display [20] is showing the lifting height. 22. Lifting height limit symbol This symbol indicates that the boom length display [20] is showing the registered lifting height limit value. The lifting height symbol [21] is lit at the same time when this symbol is lit. 23. Jib angle display The jib offset angle is displayed when the jib operation is selected, and the jib length is displayed while the display alteration key is pressed. Also, when the upper boom angle limit function is activated, the upper boom angle limit value is displayed while the set key is pressed. C. Controls section 5. Outrigger condition selector key Used to select the outrigger extension status. 6. Set key Used to register a selected condition. 7. Display alteration key Used to alter the displays on display panel Left swing limit key Used to activate and release the left swing limiting function. 9. Right swing limit key Used to activate and release the right swing limiting function. 10. Load radius limit key Used to activate and release the load radius limiting function 揚程制限 旋回左限旋回右限 起伏上限起伏下限 半径制限 Lifting height limit key Used to activate and release the lifting height limiting function. 12. Upper boom angle limit key Used to activate and release the uppermost boom angle limiting function. 1 2 調整 3 4 点検 5 ブーム 15 9 O / R 表示切替 セット Lower boom angle limit key Used to activate and release the lowermost boom angle limiting function. IW J56 1. Increase key Used to increase the selected value. Also, used to adjust the elevating speed. 2. Decrease key Used to decrease the selected value. Also, used to adjust the elevating speed. 14 to 19. Limit indicator lamps Light when the corresponding limiting function is activated. If the crane operation reaches the limit area while the working area limit function is activated, the indicator lamp changes from "being lit" to "flashing." 3. Inspection key Used to perform the pre-operational inspection of the AML system. 4. Lift status selector key Used to select the boom lift status. 140 W E

142 Functions of and How to Use User Mode (GA-700N-1) D. Display panel IW J74 1. Front position symbol Not used in this machine. 2. Swing position display Indicates the swing position in 10 increments by flashing. 3. Outrigger condition symbol Indicates the outrigger extension status by symbol. Flashes while the outrigger condition is being registered, and stays lit after the registration is completed. 4. On-rubber condition symbol Lights when the power is turned on or outrigger is retracted. 5. Suspension lock condition symbol Not used in this machine. 6. Front jack condition symbol Automatically lights when the front jack is used. 7. Rear jack condition symbol Not used in this machine. 141 W E

143 Functions of and How to Use User Mode (GA-700N-1) Registering Operating Conditions WARNING Should the operational status be incorrectly registered, the crane may overturn or be damaged, leading to a serious accident. Prior to every operation, check that the registered status corresponds to the actual status of the crane. Registration of Outrigger Condition フロントジャッキ Front jack 状態シンボル condition symbol Outrigger アウトリガ condition symbol 状態シンボル メッセージ [NOTICE] When the power supply is turned on, the on-rubber condition symbol is lit. Press the outrigger condition selector key and set key to register the actual outrigger condition. Also, when the outrigger is retracted, the on-rubber condition symbol lights. Register the outrigger condition again. Even after the power supply is turned off, the registered data is stored, and when the power supply is turned on again, the system is resumed with the registered operation condition. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again. To register the outrigger condition, press the outrigger condition selector key to enable the outrigger condition selector function, and follow the procedure below. 揚程制限起伏上限起伏下限旋回左限旋回右限半径制限表示切替調整点検ブーム O / R セット セットキー Set key Outrigger アウトリガ状態 condition selector 選択キー key IW J75 Pressing the outrigger condition selector key after the setting of the outriggers indicates the outrigger extension width entered in the AML by flashing the outrigger condition symbol. Check whether it matches the actual outrigger extension status, and if it is OK, press the set key to register. The outrigger condition symbol changes to "being lit" to indicate that the condition has been successfully registered. [NOTICE] Front jack condition and counterweight condition are registered by the automatic detection function together with the registration of the outrigger condition. Check the status on the display. -Example- When the outrigger status is registered in the following conditions after the setting of the outriggers. (1) Counterweight: 5.6 t (2) Extension width of outrigger: Maximum (3) Front jack: Mounted 142 W E

144 Functions of and How to Use User Mode (GA-700N-1) Power 電源投入時 ON The symbol display by the mass of the counterweight is as follows: カウンタウエイト Counterweight: t t カウンタウエイト Counterweight: t t Front jack: No フロント display ジャッキ表示無し On-rubber display オンタイヤ表示 After アウトリガ registration of 状態登録後 outrigger condition 2 個点灯 Two symbols light. IW J78 Front フロント jack display ジャッキ表示 最大張出 Maximum 表示 extension display IW J76 The outrigger condition symbol by the outrigger extension width is as follows: 最大張出 Fully extended (7.8m)(7.8 m) 中間張出 Mid. extended (7.2m)(7.2 m) 中間張出 Mid. extended (5.3m)(5.3 m) 中間張出 Mid. extended (4.1m)(4.1 m) 最小張出 Min. extended (2.23m)(2.23 m) IW J W E

145 Functions of and How to Use User Mode (GA-700N-1) Registration of Lift Status [NOTICE] When the power supply is turned on, the boom lift is automatically selected. Even after the power supply is turned off, the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation condition. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again. To register the lift status, use the lift status selector key. (1) (1) ブーム作業 Boom lift (2) (2) シングルトップ作業 Single top lift (3) (3) ジブセット作業 Jib set operation メッセージ ジブ状態シンボル Jib lift symbol (4) (4) ジブ作業 Jib lift シングルトップ状態 Single top lift symbol シンボル IW J79 ブーム状態シンボル Boom lift symbol 揚程制限起伏上限起伏下限 旋回左限旋回右限 半径制限 表示切替 調整 点検 ブーム O / R セット Lift ブーム状態選択キー status selector key IW J64 Each time the lift status selector key is pressed, the display changes in numerical sequence from (1) to (4) as shown in the right table. The display returns to (1) if you press the key when (4) is shown on the display. Select the status that corresponds to the actual lift status. The status is automatically registered. [NOTICE] When performing the boom lift with the jib mounted, register the boom lift. Before lifting one piece of load with the boom and jib, register the jib lift. 144 W E

146 Functions of and How to Use User Mode (GA-700N-1) Pre-operational Inspection on the AML WARNING Operating the crane with a malfunctioning AML could cause the crane to overturn or be damaged. Be sure to perform the pre-operational inspection on the AML system and start the crane only after ensuring that the system is operating properly. [NOTICE] Before starting operation, check that the AML system works in good condition, as follows: 1. Press the inspection key and make sure that the AML is in the following conditions: Bargraph display Display panel (1 and 2) Working area limit indicator lamp (6) Alarm buzzer: Sounds continuously Movement toward critical sides: Automatically halted All segments light. 3. Visually check that values and symbols shown on the display panel 1 and 2 represent the actual crane conditions, particularly on the following items. (1) Boom length (2) Boom angle (3) Jib angle (jib length) (shown while jib lift is selected) (4) Actual load With no load on hook, make sure that an approximate mass of the hook block is shown. [NOTICE] The actual load is not shown correctly if the lift status of the AML is not registered correctly. (5) Outrigger condition symbol (6) Front jack condition symbol (7) Counterweight condition symbol (8) Swing position display バーグラフ表示部 Bargraph display メッセージ 表示パネル1 Display panel 1 m 表示パネル2 Display panel 2 m % t max t Boo ブー m 揚程制限 起伏上限 起伏下限 旋回左限 旋回右限 半径制限 表示切替 調整 点検 ブーム O / R セット IW J80 2. Press the set key, display alteration key, or inspection key to return the display to the normal condition (a bargraph must be shown on the moment display). 145 W E

147 Functions of and How to Use User Mode (GA-700N-1) How to Use the Working Area Limiting Function WARNING When the automatic swing stop cancel switch is set to " 解除," the swing does not stop automatically, even if the swing limit area is reached. Only the alarm buzzer sounds. Therefore, great attention must be paid. [NOTICE] If the working area limit is registered very close to an obstacle, there is a risk of the crane colliding with the obstacle, depending on the operational status and the manner in which the load is handled. When registering an area limit, allow a sufficient clearance to avoid collision. Upper boom angle limit Lower boom angle limit Lifting height limit Load radius limit Left swing limit Right swing limit Upper boom angle limit ブーム角度上限制限 Lower boom angle limit ブーム角度下限制限 θu θl Automatic stop and alarm buzzer (Beep for 3 seconds) Lifting height limit 揚程制限 H The working area limit function limits operation of the boom and swing movement to the pre-registered boom angle (upper limit, lower limit), lifting height, load radius, and swing angle (left, right). Use this function when performing operation in a place where there are obstacles around the machine, requiring the working-area limitation of the boom. Load 作業半径制限 radius limit R Swing 旋回制限 limit IW J81 [NOTICE] Even after the power supply is turned off, the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation condition. However, the maximum storage period is 2 hours. If 2 hours or more have passed before the next power on, the registered data is erased. To resume the operation, register the settings all over again. 146 W E

148 Functions of and How to Use User Mode (GA-700N-1) Working Area Limit Value While the working area limit function is activated, as long as the set key is pressed, the working area limit values registered in the indicator shown below are displayed. Also the message " ハンイセイゲンチヒョウジ " appears on the moment display. Upper boom ブーム上限 angle limit 角度制限値 value Lifting 揚程制限値 height limit value メッセージ ハンイセイゲンチヒヨウジ m m 揚程制限 t max t 旋回左限旋回右限 起伏上限起伏下限 半径制限 Lower ブーム下限 boom angle 角度制限値 limit value 作業半径 Load radius 制限値 limit value Boom Angle Limit Raise or lower the boom to a desired limit angle, and press the upper or lower boom angle limit key. The corresponding limit indicator lamp will flash, indicating that the boom angle limit has been registered in the memory. When the boom is moved back to an angle within the set limit, the boom angle limit indicator lamp stops flashing and stays lit. Thereafter, the upper or lower boom angle limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the upper or lower limit previously registered is reached. (Boom raising or lowering stops automatically.) To cancel the boom angle limits, press the upper or lower boom angle limit key again. The corresponding boom angle limit indicator lamp will go out. 表示切替 調整 点検 ブーム O / R セット Set セットキー key IW J67 メッセージ m t max t Upper ブーム角度上限 boom angle limit indicator 制限ランプ lamp Lower ブーム角度下限 boom angle limit indicator 制限ランプ lamp m 揚程制限 起伏上限 起伏下限 旋回左限 旋回右限 半径制限 調整 点検 ブーム O / R 表示切替 セット Lower ブーム角度下限 boom angle limit key 制限キー Upper boom angle limit ブーム角度上限 key 制限キー IW J W E

149 Functions of and How to Use User Mode (GA-700N-1) Lifting Height Limit Move the boom or jib to a desired limit height, and press the lifting height limit key. The lifting height limit indicator lamp will flash, indicating that the height limit has been registered in the memory. When the boom or jib is moved back to a height within the set limit, the lifting height limit indicator lamp stops flashing and stays lit. Thereafter, the lifting height limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the height limit previously registered is reached. (Boom or jib raising and extending stop automatically.) To cancel the height limit, press the lifting height limit key again. The lifting height limit indicator lamp will go out. Load Radius Limit Move the boom or jib to a desired limit load radius, and press the load radius limit key. The load radius limit indicator lamp will flash, indicating that the load radius limit has been registered in the memory. When the boom or jib is moved back to a load radius within the set limit, the load radius limit indicator lamp stops flashing and stays lit. Thereafter, the load radius limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the load radius previously registered is reached. (Boom or jib lowering and extending stop automatically.) To cancel the load radius limit, press the load radius limit key again. The load radius limit indicator lamp will go out. メッセージ Lifting height limit indicator lamp 揚程制限ランプ メッセージ m t max t m 揚程制限起伏上限起伏下限 m t max t Load radius limit indicator 作業半径 lamp 制限ランプ m 旋回左限 旋回右限 半径制限 揚程制限 起伏上限 起伏下限 表示 切替 調整 点検 ブーム O / R セット 旋回左限 旋回右限 半径制限 Lifting height limit key 揚程制限キー 調整 点検 ブーム O / R 表示切替 セット IW J83 Load radius 作業半径 limit key 制限キー IW J W E

150 Functions of and How to Use User Mode (GA-700N-1) Swing Limit Swing to a desired limit swing position, and press the left swing limit key or right swing limit key. The corresponding swing limit indicator lamp will flash and the buzzer (beep) sounds for 3 seconds, indicating that the swing limit has been registered in the memory. When the boom is moved back to a swing position within the set limit, the swing limit indicator lamp stops flashing and stays lit. Thereafter, the swing limit indicator lamp flashes and the alarm buzzer (beep) sounds for 3 seconds whenever the swing angle previously registered is reached. (Swing stops automatically.) To cancel the swing limit, press the left swing limit key or right swing limit key again. The corresponding swing limit indicator lamp will go out. [NOTICE] Ensure to register both the right swing and left swing limit positions. If either right or left limit position only is set, the alarm does not sound correctly. When the automatic swing stop cancel switch is set to " 解除," the swing does not stop automatically, even if the swing limit area is reached. Be extremely careful of the operation, because the machine does not stop automatically but only the swing limit indicator lamp flashes, the message appears, and the AML buzzer (beep) sounds for 3 seconds. メッセージ m t max t Left 旋回左制限ランプ swing limit indicator lamp Right 旋回右制限ランプ swing limit indicator lamp m 揚程制限 起伏上限 起伏下限 旋回左限 旋回右限 半径制限 表示切替 調整 点検 ブーム O / R セット Right swing limit indicator key 旋回右制限ランプ Left swing limit indicator key 旋回左制限ランプ IW J W E

151 Functions of and How to Use User Mode (GA-700N-1) How to Use the Boom Elevating Speed Adjusting Function The boom elevating speed adjusting function is a function to adjust the maximum speed when the boom is extended. How to Register Boom Elevating Speed Adjustment Decrease 減キー key Increase 増キー key メッセージ 調整 揚程制限起伏上限起伏下限 Use the increase or decrease key to register the boom elevating speed. Pressing the increase or decrease key changes the bargraph display to the following elevating speed values. 点検 While the elevating speed values are shown on the bargraph display, pressing the increase or decrease key again enables to set each boom elevating speed value to 0% (stop) to 100% (standard speed) in 10% increments. In addition, pressing the increase or decrease key during a boom elevating operation enables to adjust the boom raising and boom lowering speeds separately. ブーム 旋回左限旋回右限 メッセージアゲ 100% サゲ 100% O / R 半径制限 表示切替 セット IW J68 Boom ブーム下げ側の最高速度 lowering max. speed ブーム上げ側の最高速度 Boom raising max. speed IW J69 During boom raising operation: Only raising speed can be changed During boom lowering operation: Only lowering speed can be changed No boom elevating operation: Both the raising and lowering speeds can be changed at the same time. [NOTICE] If the increase key or decrease key is not pressed for approx. 10 seconds, the bargraph display returns to the normal condition (a bargraph must be shown on the moment display), and the registration of boom elevating has been completed. Even after the power supply is turned off, the registered data is stored, and when the power supply is turned on again, the system is resumed with the stored operation condition. When the power supply is turned on again, all the segments of the bargraph display light, and the boom elevating values are shown only for 2 to 3 seconds. After that, the display returns to the normal condition (a bargraph must be shown on the moment display). Operating Speed on Registration of Boom Elevating Speed Adjustment The percentage value shown by the boom elevating speed adjusting function is a speed limit value when the boom is fully extended. On the contrary, when the boom is fully retracted, it always elevates at the standard speed. The relation between the value and boom elevating speed is as follows: 1. When value is 0% Fully retracted Standard speed In between fully retracted and fully extended (1/2) 1/2 of standard speed Fully extended Stop (almost no movement) 2. When value is 50% Fully retracted Standard speed In between fully retracted and fully extended (1/2) 3/4 of standard speed Fully extended 1/2 of standard speed 150 W E

152 Functions of and How to Use User Mode (GA-700N-1) 3. When value is 100% Fully retracted Standard speed In between fully retracted and fully extended (1/2) Standard speed Fully extended Standard speed Boom elevating max. speed 起伏最高速度 Standard 標準速度 100% 3/4 速度 1/2 速度 50% 1/4 速度 0% Stop 停止 Fully 全縮中間 Mid. Fully 全伸ブーム長さ Boom length retracted extended IW J70 IW J W E

153 Outline of Adjustment Mode and Maintenance Mode [ADJUSTMENT AND MAINTENANCE] Outline of Adjustment Mode and Maintenance Mode 1. Keys and Switches for Adjustment and Maintenance 1. スクロールアップキー 1. Scroll-up key モーメント表示器 Moment display 2. スクロールダウンキー 2. Scroll-down key m m t % max t m MOMENT SHORT PROTECT ZERO WDT HALT ON OFF Inspection 7. 点検キー key 4. Increase 4. 増キー key セットキー Set key 5. Decrease 5. 減キー key Display 表示切替えキー alteration key IW J01 8. Moment input short-circuit switch 8. モーメント入力短絡スイッチ 9. プロテクトスイッチ 9. Protect switch Moment モーメント零調整器 zero adjuster 11. 異常表示 LED Top 上面 View IW J Abnormality display LED 1. Scroll-up key Used to see the previous lines of message displayed on the moment display. 2. Scroll-down key Used to see the next lines of message displayed on the moment display. 3. Set key Used to confirm the selected menu item and write the value in EEPROM. 4. Increase key Used to increase the value. 5. Decrease key Used to decrease the value. 6. Display alteration key Used to change the display to the upper menu. 7. Inspection key Used for "Do Check" and "Ao Check" functions in the maintenance mode. 8. Moment input short-circuit switch Not used for this machine. 9. Protect switch Set this switch to OFF when changing the mode from user mode to mode. With this switch OFF, data can be written in the EEPROM. 10. Moment zero adjuster Do not touch. This adjuster is for by the AML manufacturer's service personnel. 11. Abnormality display LED Lights when the AML is in abnormal conditions or when the AML is initialized (reset). 152 W E

154 Outline of Adjustment Mode and Maintenance Mode 2. Mode Structure and Menu The AML device has three modes and the AML functions are allotted for these models. Protect プロテクトスイッチ switch ON Protect プロテクトスイッチ switch OFF POWER 電源 ON ユーザーモード USER MODE 1. User Mode: Used to indicate moment load factor or to perform AML pre-operational inspection (Normally used). In normal use, turn ON the protect switch mounted on the window on the top of the AML. The AML will go to the user mode when the power turns on. Top 上面 View 調整モード ADJUSTMENT MODE POWER 電源 ON ON MOMENT SHORT ON PROTECT 保守モード MAINTENANCE MODE ON OFF ZERO IW J03 WDT HALT プロテクトスイッチ Protect switch IW J03 2. Maintenance Mode: Used to make functional checks of the AML. This mode has the following menus: MAIN MENU SUB-MENU [ ホシュ] [: プログラムバージョン ] トケイチョウセイ ] [: データシュベツ ] [:DI チェック ] [:AI チェック ] [: キフクアツリョクモニタ ] [:DO チェック ] [:MDT モニタ ] (*1) [: キースイッチチェック ] [: ヒョウジキチェック ] [: エラーリレキヒョウジ ] [: エラーリレキショウキョ ] [: ウンテンリレキヒョウジ ] [: ウンテンリレキショウキョ ] [:OP ボードチェック ] [:AO チェック ] [:SIO チェック ] [: チョウセイモニタ ] (*1) : Not apply to the model (GA-700N-1) without MDT (Multiplex Data Transmitter). 3. Adjustment Mode: Used to make detector. This mode has the following menus: MAIN MENU SUB-MENU [ チョウセイ] [ セイギョデータチョウセイ ] [ AO チョウセイ ] [ ケイスウリセット ] [ モーメントチョウセイリセット ] [ ウンテンリレキヒョウジ ] [ ウンテンリレキショウキョ ] [ セイドシュウセイ ] (*2) [ Language] [: ナガサカクドチョウセイ ] [: サギョウハンケイチョウセイ ] [: モーメントチョウセイ ] [: キフクトクセイチョウセイ ] [: キフクトクセイリセット ] [: チヂミトクセイチョウセイ ] (*1) [: チヂミトクセイリセット ] (*1) [:AO オフセットチョウセイ ] [:AO オフセットリセット ] [: タワミケイスウリセット ] [: ゼロ スパンリセット ] [: セイドデータリセット ] (*2) (*1) : Not apply to TR-250M-7, GR-250N-1, GR-350N-1, GR-160N-1, and GR-120F-1. (*2) : Do not use. 153 W E

155 Outline of Adjustment Mode and Maintenance Mode 3. Method of Shifting Modes Scroll-up key スクロールアップキーモーメント表示器 Moment display スクロールダウンキー Scroll-down key MOMENT SHORT PROTECT ZERO WDT HALT m m t ON OFF OFF ON プロテクトスイッチ Protect switch % max t Top 上面 View IW J03 m 電源 ON POWER ON + - プロテクト Protect スイッチ switch ON プロテクト Protect スイッチ switch OFF ユーザーモード USER MODE 調整モード ADJUSTMENT MODE 保守モード MAINTENANCE MODE セットキー Set key Display 表示切替えキー alteration key IW J04 POWER 電源 ON IW J05 1. "User mode" "Maintenance mode" Press the scroll-up key, scroll-down key, and set key at the same time. Then, the moment display changes from the bargraph to [ ホシュ]. This display denotes the "Maintenance mode." 2. "Maintenance mode" "User mode" Press the display alteration key. Then, the moment display changes to the bargraph. This display denotes the "User mode." 4. "Adjustment mode" "User mode" While the main menu of the mode is displayed, turn ON the protect switch. Then, the moment display changes to the bargraph. This display denotes the "User mode." 5. " Maintenance mode " " Adjustment mode " While the main menu of the maintenance mode is displayed, turn OFF the protect switch. Then, the moment display changes to [ チョウセイ ]. This display denotes the "Adjustment mode." 3. "User mode" "Adjustment mode" Turn OFF the protect switch at the window on the top of the AML. Then, the moment display changes from the bargraph to [ チョウセイ]. This display denotes the "Adjustment mode." 154 W E

156 Outline of Adjustment Mode and Maintenance Mode 4. Method of Menu Selection Scroll-up key スクロールアップキーモーメント表示器 Moment display スクロールダウンキー Scroll-down key m m t % max t m + - セットキー Set key Display 表示切替えキー alteration key IW J04 1. When the AML enters "Maintenance mode" or "Adjustment mode," first the main menu is displayed on the moment display. Displayed main menu item can be changed by means of the scroll-up or scroll-down key. Press the set key to select the displayed item. 2. If the selected item in the main menu has any sub-menus, the sub-menus are displayed on the moment display. You can select a desired item in the sub-menu in the same way as in the main menu by means of the scroll-up, scroll-down, and set keys. 4. The following marks displayed in the menu: "," ":," and " " When a main menu is displayed, the mark " " stands before the menu name. (Ex. [ チョウセイ ]) When a sub-menu is displayed, the mark ":" stands before the menu name. (Ex. [: モーメントチョウセイ ]) The " " mark after the menu name indicates that the depression of the scroll-down key calls for another menu. 3. By pressing the display alteration key, the display changes to the upper menu. 155 W E

157 Required Adjustment After AML System Parts Replacement Required Adjustment After AML System Parts Replacement [NOTICE] EEPROM stores the values for each specification number. When replacing the CPU board, remove the EEPROM from the broken CPU board and reuse it. Then, all works except the clock can be omitted. Visually check that the values such as the boom length and boom angle, and the symbols displayed on the display panels 1 and 2 on the AML correspond to the actual crane conditions. Replaced part Required Boom length detector Boom length Boom angle detector Boom angle Swing angle detector Swing angle Outrigger extension width detector Outrigger extension width Jib angle detector (*1) Jib angle (*1) Jib length detector (*2) Jib length (*2) Pressure sensor for moment detection Moment Display board None CPU board only (When reusing EEPROM removed Clock from the broken CPU board) AML unit Solenoid proportional valve for slow stop CPU board Analog board Power board CPU board (When EEPROM is not to be reused) EEPROM ROM Current output board (optional board) Connector board Swing right proportional valve Swing left proportional valve Perform initialization and take every step of the. For the items and procedure, refer to "Adjustment Procedures" on the subsequent page in the "Functions of and How to Use Adjustment Mode" section. None Boom length Boom angle Swing angle Jib angle (*1) Jib length (*2) Moment None Swing output Boom elevating output Telescoping/retraction output (*3) None Swing output Boom raising proportional valve Boom elevating output Boom lowering proportional valve Telescoping/retraction proportional valve (*3) Telescoping/retraction output (*3) (*1): Not apply to TR-250M-7, GR-250N-1, and GR-350N-1 with jib and without power tilt. Not apply to GR-160N-1, because it is with standard jib. (*2): Not apply to GR-300N-1, TR-250M-7, GR-250N-1, GR-350N-1, and GR-160N-1. (*3): Not apply to TR-250M-7, GR-250N-1, GR-350N-1, GR-160N-1, and GR-120F W E

158 Functions of and How to Use Adjustment Mode Functions of and How to Use Adjustment Mode [NOTICE] For how to shift to the mode and how to select the menu, refer to "Method of Shifting Modes" and "Method of Menu Selection" in the "General: Adjustment Mode and Maintenance Mode" section. Adjustment Procedures Adjustment Procedures WARNING Before making an, extend the outriggers fully and set the crane on firm ground for safety. The items and procedures are as follows: 1. Adjustment Initialization 2. Boom Length Adjustment 3. Boom Angle Adjustment 4. Swing Angle Adjustment 5. Outrigger Extension Width Adjustment 6. Jib Angle Adjustment (*1) 7. Jib Length Adjustment (*2) 8. Moment Adjustment (including load radius ) 9. Clock Adjustment [NOTICE] You can adjust the boom length, boom angle, swing angle, outrigger extension width, jib angle, and jib length in random order. You can adjust the swing output, elevation output, and telescoping/retraction output in random order. After whole is completed, erase-protect the overload history, referring to "Erasing the Overload History" in the "Functions of How to Use Adjustment Mode" section. 10. Swing Output Adjustment 11. Boom Elevating Output Adjustment 12. Telescoping/retraction Output Adjustment (*3) Adjustment Completed Erasing the Overload History (*1) : Not apply to TR-250M-7, GR-250N-1, and GR-350N-1 with jib and without power tilt. Not apply to GR-160N-1, because it is with standard jib. (*2) : Not apply to GR-300N-1, TR-250M-7, GR-250N-1, GR-350N-1, and GR-160N-1. (*3) : Not apply to TR-250M-7, GR-250N-1, GR-350N-1, GR-160N-1, and GR-120F W E

159 Functions of and How to Use Adjustment Mode 1. Adjustment Initialization [NOTICE] Adjustment initialization should be performed only when EEPROM is replaced. When the CPU board is replaced, if the EEPROM removed from the faulty CPU board is to be reused, no initialization is required. By the initialization, the conversion factors (specification for each specification number) stored within the AML program that convert detected voltage input from the detectors into physical volumes are read out from the P-ROM and written onto the EEPROM. Perform the initialization only once before the first takes place. If this initialization is done while s are being made, you must restart the from the very beginning. For the initialization, you have to execute the following two menu items. [ ケイスウリセット ]: Initializes the conversion factors that convert into physical volumes in the program for the boom length, angle, and deflection. [ モーメントチョウセイリセット ]: Initializes the conversion factors that convert into physical volumes in the program for the moment. 5. When [: タワミケイスウリセット ] appears, press the scroll-down key to display [: ゼロ スパンリセット ], and then press the set key to reset the zero span factor. 6. When the message [ ケイスウヲリセットシマシタ ] appears, the zero span factor resetting is completed. Press the display alteration key to return to the main menu. 1.2 Procedure of "Moment Adjustment Resetting" 1. Select the item [ モーメントチョウセイリセット ] in the main menu of the mode, and press the set key to confirm. 2. When [ モーメントゼロチョウリセット ] appears, reset the moment by pressing the set key. 3. When the message [ モーメントヲリセットシマシタ ] appears, the moment resetting is completed. Press the display alteration key to return to the main menu. 1.1 Procedure of "Conversion Factors Resetting" 1. Select the item [ ケイスウリセット ] in the main menu of the mode, and press the set key to confirm. 2. When [: タワミケイスウリセット ] appears, reset the deflection factor by pressing the set key. 3. When the message [ ケイスウヲリセットシマシタ ] appears, the deflection factor resetting is completed. Press the display alteration key to return to the main menu. 4. Select the item [ ケイスウリセット ] in the main menu of the mode, and press the set key again to confirm. 158 W E

160 Functions of and How to Use Adjustment Mode 2. Boom Length Adjustment WARNING Before making an, extend the outriggers fully and set the crane on firm ground for safety. [NOTICE] The conditions and values for boom length vary depending on the specification number. Refer to "Adjustment Value Table" in the INFORMATION AND DATA section. For your information, "Adjustment Value Table" for models other than GR-300N-1, TR-250M-7, GR-250N-1, GR-350N-1, GR-160N-1, GR-120F-1, GA-700N-1 is described on the service manual of the applicable model. When the length detector has been just installed and its cord has not yet been unwound or wound, go through the entire boom telescoping cycle to have the cord naturally wound up onto the drum. 9. Press the scroll-up key until the boom length zero-point display [ ブーム Lz] appears. 10. Has the boom length zero-point display [ ブーム Lz] become the zero-point value in "Adjustment Value Table"? NO YES 11. Press the display alteration key to exit the menu item. 1. Select the item [ チョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [: ナガサカクドチョウセイ ] is displayed, press the set key to select the menu item. 3. Retract the boom fully. 4. Press the increase or decrease key so that the value of boom length zero-point display [ ブーム Lz] becomes the zero-point value in "Adjustment Value Table." Press the set key for registration. 5. Extend the boom fully. 6. Press the scroll-down key until the boom length span display [ ブーム Ls] appears. 7. Press the increase or decrease key so that the value of boom length span display [ ブーム Ls] becomes the span value in "Adjustment Value Table." Press the set key for registration. 8. Retract the boom fully again. 159 W E

161 Functions of and How to Use Adjustment Mode 3. Boom Angle Adjustment WARNING Before making an, extend the outriggers fully and set the crane on firm ground for safety. [NOTICE] The conditions and values for boom angle vary depending on the specification number. Refer to "Adjustment Value Table" in the INFORMATION AND DATA section. For your information, "Adjustment Value Table" for models other than GR-300N-1, TR-250M-7, GR-250N-1, GR-350N-1, GR-160N-1, GR-120F-1, GA-700N-1 is described on the service manual of the applicable model. When setting the boom angle to "Adjustment condition," always perform the setting by lowering the boom. Use a spirit level goniometer to measure the actual boom angle. 1. Select the item [ チョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [: ナガサカクドチョウセイ ] is displayed, press the set key to select the menu item. boom angle span display [ ブームカク s] appears. 8. Press the increase or decrease key so that the value of boom angle span display [ ブームカク s] becomes the span value in "Adjustment Value Table." Press the set key for registration. 9. Bring the actual boom angle to the zero-point value in "Adjustment Value Table" again. 10. Press the scroll-up or scroll-down key until the boom angle zero-point display [ ブームカク z] appears. 11. Has the value of boom angle zero-point display [ ブームカク z] become the zero-point value in "Adjustment Value Table"? NO YES 12. Press the display alteration key to exit the menu item. 3. Set the actual boom angle to the condition of the zero-point specified in "Adjustment Value Table" by lowering the boom. 4. Press the scroll-up or scroll-down key until the boom angle zero-point display [ ブームカク z] appears. 5. Press the increase or decrease key so that the value of boom angle zero-point display [ ブームカク z] becomes the zero-point value in "Adjustment Value Table." Press the set key for registration. 6. Raise the boom to a point just before the upper stroke end of the elevating cylinder, and then adjust the actual boom angle to the condition of the span specified in "Adjustment Value Table" by lowering the boom. 7. Press the scroll-up or scroll-down key until the 160 W E

162 Functions of and How to Use Adjustment Mode 4. Swing Angle Adjustment WARNING Before making an, extend the outriggers fully and set the crane on firm ground for safety. [NOTICE] Since the swing angles involve a hysteresis, always make after a stop from clockwise movement. 1. Select the item [ チョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [: ナガサカクドチョウセイ ] is displayed, press the set key to select the menu item. 3. Set the boom to the zero-point reference position (on the front centerline) by swinging it clockwise. 4. Press the scroll-up or scroll-down key until the swing angle 1 zero-point display [ センカイカク 1z] appears. 5. Press the increase or decrease key so that the value of swing angle 1 zero-point display [ センカイカク 1z] becomes 0±0.3. Press the set key for registration. 10. Press the increase or decrease key so that the value of swing angle 1 span display [ センカイカク 1s] becomes 180±0.3. Press the set key for registration. 11. With the swing position unchanged, press the scroll-up or scroll-down key until the swing angle 2 span display [ センカイカク 2s] appears. 12. Press the increase or decrease key so that the value of swing angle 2 span display [ センカイカク 2s] becomes 180±0.3. Press the set key for registration. 13. Set the boom again to the zero-point reference position (on the front centerline) by swinging it clockwise. 14. Check the swing angle 1 and 2 zero-point displays [ センカイカク 1z] and [ センカイカク 2z] by pressing the scroll-up or scroll-down key. Does each display indicate the angle below? センカイカク 1z: 0±0.6 センカイカク 2z: 360±0.6 NO YES 15. Press the display alteration key to exit the menu item. 6. With the swing position unchanged, press the scroll-up or scroll-down key until the swing angle 2 zero-point display [ センカイカク 2z] appears. 7. Press the increase or decrease key so that the value of swing angle 2 zero-point display [ センカイカク 2z] becomes 360±0.3. Press the set key for registration. 8. Set the boom to the span-point reference position (on the rear centerline) by swinging it clockwise. 9. Press the scroll-up or scroll-down key until the swing angle 1 span display [ センカイカク 1s] appears. 161 W E

163 Functions of and How to Use Adjustment Mode 5. Outrigger Extension Width Adjustment [NOTICE] The conditions and values for outrigger extension width vary depending on the specification number. Refer to "Adjustment Value Table" in the INFORMATION AND DATA section. For your information, "Adjustment Value Table" for models other than GR-300N-1, TR-250M-7, GR-250N-1, GR-350N-1, GR-160N-1, GR-120F-1, GA-700N-1 is described on the service manual of the applicable model. 1. Select the item [ チョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [: ナガサカクドチョウセイ ] is displayed, press the set key to select the menu item. 3. Fully retract all the outrigger beams. 4. Press the scroll-up or scroll-down key until the front right outrigger extension width zero-point display [RFO/R Lz] appears. 5. Press the increase or decrease key so that the value of front right outrigger extension width zero-point display [RFO/R Lz] becomes the zero-point value in "Adjustment Value Table." Press the set key for registration. 6. Adjust and register the values of the rear right, front left and rear left outrigger extension width zero-point in the same manner as the front right outrigger extension width zero-point. Rear right outrigger : [RRO/R Lz] Front left outrigger : [LFO/R Lz] Rear left outrigger : [LRO/R Lz] display [RFO/R Ls] becomes the span value in "Adjustment Value Table." Press the set key for registration. 10. Adjust and register the values of the rear right, front left and rear left outrigger extension width span in the same manner as the front right outrigger extension width span. Rear right outrigger : [RRO/R Ls] Front left outrigger : [LFO/R Ls] Rear left outrigger : [LRO/R Ls] 11. Fully retract all the outrigger beams again. 12. Press the scroll-up or scroll-down key until the front right outrigger extension width zero-point display [RFO/R Lz] appears. 13. Has the front right outrigger extension width zero-point display [RFO/R Lz] become the zero-point value in "Adjustment Value Table"? Check the values of the rear right, front left and rear left outrigger extension width zero-point in the same manner as the front right outrigger extension width zero-point check. Rear right outrigger : [RRO/R Lz] Front left outrigger : [LFO/R Lz] Rear left outrigger : [LRO/R Lz] NO YES 14. Press the display alteration key to exit the menu item. 7. Fully extend all the outrigger beams. 8. Press the scroll-up or scroll-down key until the front right outrigger extension width span display [RFO/R Ls] appears. 9. Press the increase or decrease key so that the value of front right outrigger extension width span 162 W E

164 Functions of and How to Use Adjustment Mode 6. Jib Angle Adjustment [NOTICE] The conditions and values for jib angle vary depending on the specification number. Refer to "Adjustment Value Table" in the INFORMATION AND DATA section. For your information, "Adjustment Value Table" for models other than GR-300N-1, TR-250M-7, GR-250N-1, GR-350N-1, GR-120F-1, GA-700N-1 is described on the service manual of the applicable model. 1. Mount the jib. WARNING Before making an, extend the outriggers fully and set the crane on firm ground for safety. 2. Select the item [ チョウセイ ] in the main menu of the mode, and press the set key to confirm. 3. When [: ナガサカクドチョウセイ ] is displayed, press the set key to select the menu item. 4. Set the jib offset angle to the minimum. (And only for GR-300N-1, set the boom angle to 35 or below.) If the jib tilt cylinder cannot reach the stroke end (in case of GA-700N-1), raise the jib until the jib tilt cylinder reaches the stroke end, and then set the actual jib offset angle to the condition of the zero-point specified in "Adjustment Value Table" by tilting down the jib. angle to the condition of the span specified in "Adjustment Value Table" by tilting down the jib. 8. Press the scroll-up or scroll-down key until the jib angle span display [B ジブカク S] appears. 9. Press the increase or decrease key so that the value of jib angle span display [B ジブカク S] becomes the span value in "Adjustment Value Table." Press the set key for registration. 10. Set the jib offset angle to the minimum again. (And only for GR-300N-1, set the boom angle to 35 or below.) If the jib tilt cylinder cannot reach the stroke end (in case of GA-700N-1), raise the jib until the jib tilt cylinder reaches the stroke end, and then set the actual jib offset angle to the condition of the zero-point specified in "Adjustment Value Table" by tilting down the jib. 11. Press the scroll-up or scroll-down key until the jib angle zero-point display [B ジブカク Z] appears. 12. Has the value of jib angle zero-point display [B ジブカク Z] become the zero-point value in "Adjustment Value Table"? NO YES 13. Press the display alteration key to exit the menu item. 5. Press the scroll-up or scroll-down key until the jib angle zero-point display [B ジブカク Z] appears. 6. Press the increase or decrease key so that the value of jib angle zero-point display [B ジブカク Z] becomes the zero-point value in "Adjustment Value Table." Press the set key for registration. 7. Set the jib offset angle to the maximum. If the jib tilt cylinder cannot reach the stroke end (in case of GA-700N-1), set the actual jib offset 163 W E

165 Functions of and How to Use Adjustment Mode 7. Jib Length Adjustment WARNING Before making an, extend the outriggers fully and set the crane on firm ground for safety. [NOTICE] The conditions and values for jib length vary depending on the specification number. Refer to "Adjustment Value Table" in the INFORMATION AND DATA section. For your information, "Adjustment Value Table" for models other than GR-120F-1 and GA-700N-1 is described on the service manual of the applicable model. 11. Press the scroll-up or scroll-down key until the jib length zero-point display [ テレジブ LZ] appears. 12. Has the jib length zero-point display [ テレジブ LZ] become the zero-point value in "Adjustment Value Table"? NO YES 13. Press the display alteration key to exit the menu item. 1. Mount the jib. 2. Select the item [ チョウセイ ] in the main menu of the mode, and press the set key to confirm. 3. When [: ナガサカクドチョウセイ ] is displayed, press the set key to select the menu item. 4. Fully retract the jib. 5. Press the scroll-up or scroll-down key until the jib length zero-point display [ テレジブ LZ] appears. 6. Press the increase or decrease key so that the value of jib length zero-point display [ テレジブ LZ] becomes the zero-point value in "Adjustment Value Table." Press the set key for registration. 7. Fully extend the jib. 8. Press the scroll-up or scroll-down key until the jib length span display [ テレジブ LS] appears. 9. Press the increase or decrease key so that the value of jib length span display [ テレジブ LS] becomes the span value in "Adjustment Value Table." Press the set key for registration. 10. Fully retract the jib again. 164 W E

166 Functions of and How to Use Adjustment Mode 8. Moment Adjustment WARNING Before making an, extend the outriggers fully and set the crane on firm ground for safety. [NOTICE] Before starting moment, raise the hydraulic oil temperature to approx. 50 C by alternately raising and lowering the boom. The conditions and values for moment vary depending on the specification number. Refer to "Adjustment Value Table" in the INFORMATION AND DATA section. For your information, "Adjustment Value Table" for models other than GR-300N-1, TR-250M-7, GR-250N-1, GR-350N-1, GR-160N-1, GR-120F-1, GA-700N-1 is described on the service manual of the applicable model. If the moment zero-point value is not within the tolerance at "8.6 Moment Zero-point Recheck," return to "8.3 Moment Zero-point Check and Fine Adjustment," and follow the order shown by the broken line to make a fine. The procedure to adjust the moment is as follows: 8.1 Moment Zero-point Adjustment 8.2 Moment Span Preliminary Adjustment 8.3 Moment Zero-point Check and Fine Adjustment 8.4 Load Radius Adjustment 8.5 Moment Span Fine Adjustment 8.6 Moment Zero-point Recheck YES NO End of moment 165 W E

167 Functions of and How to Use Adjustment Mode 8.1 Moment Zero-point Adjustment [NOTICE] For the conditions and values for moment zero-point, refer to the moment zero-point value in "Adjustment Value Table." Set the crane as follows: (1) Actual and registered statuses of outriggers: Fully extended (2) Actual and registered statuses of boom: Main boom (Jib and single top stowed) (3) Boom length: Fully retracted (4) Boom angle: Raise boom to an angle just before the maximum boom angle, and then adjust the value of boom angle display to the condition of the zero-point specified in "Adjustment Value Table" by lowering the boom. (5) Hook block position: Hoisted down just clear of ground surface or vehicle structure (For GA-700N-1, GR-250N-1 (from #FB3729), GR-350N-1, GR-160N-1, and GR-120F-1, set the hook block position to the overwinding stop position.) (6) Number of part lines: Standard number of part lines when the main boom is fully extended (7) Hook block: Refer to "Adjustment Value Table." (Auxiliary hook block stowed) (8) There may be other conditions in addition to those described above depending on the crane model. Refer to "Adjustment Value Table" for details. 1. Select the item [ チョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [: ナガサカクドチョウセイ ] is displayed, press the scroll-down key until the display [: モーメントチョウセイ ] appears. Press the set key to select the menu item. 3. While the moment zero-point is displayed, fine adjust the value shown on the actual load display to the zero-point value in "Adjustment Value Table," using the increase or decrease key. Moment zero-point display: Display [X.XXXz***.*% ] Moment load factor (%) Shows zero-point state. Detection distortion voltage (mv) The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t "000" to "099" to t "-99" to "-01" 4. After the, press the set key to register the adjusted value. 5. Proceed to "8.2 Moment Span Preliminary Adjustment." 8.2 Moment Span Preliminary Adjustment [NOTICE] For the conditions and values for moment span preliminary, refer to the moment span preliminary value in "Adjustment Value Table." 1. Continued from "8.1 Moment Zero-point Adjustment." 2. Set the value shown on the boom angle display to the condition of the span preliminary specified in "Adjustment Value Table" by lowering the boom. (Hoist down the hook block to a position just clear of ground surface.) 3. Press the scroll-up or scroll-down key until the moment span display appears. Moment span display: Display [X.XXXs***.*% ] Moment load factor (%) Shows span state. Detection distortion voltage (mv) 166 W E

168 Functions of and How to Use Adjustment Mode 4. Fine adjust the value shown on the actual load display to the span preliminary value in "Adjustment Value Table," using the increase or decrease key. The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t "000" to "099" to t "-99" to "-01" 5. After the, press the set key to register the adjusted value. 6. Proceed to "8.3 Moment Zero-point Check and Fine Adjustment." 8.3 Moment Zero-point Check and Fine Adjustment [NOTICE] For the conditions and values for moment zero-point check and fine, refer to the moment zero-point value in "Adjustment Value Table." 1. Continued from "8.2 Moment Span Preliminary Adjustment." 2. Raise the boom to an angle just before the maximum boom angle, and then adjust the value of boom angle display to the condition of the zero-point specified in "Adjustment Value Table" by lowering the boom. (Hoist down the hook block to a position just clear of ground surface or chassis.) (For GR-700N-1, GR-250N-1 (from #FB3729), GR-350N-1, GR-160N-1, and GR-120F-1, set the hook block position to the overwinding stop position.) 3. Press the scroll-up or scroll-down key until the moment zero-point display appears. Moment zero-point display: Display [X.XXXz***.*% ] Moment load factor (%) Shows zero-point state. Detection distortion voltage (mv) 4. Has the value shown on the actual load display become the zero-point value in "Adjustment Value Table"? The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t "000" to "099" to t "-99" to "-01" YES NO 5. Fine adjust the value shown on the actual load display to the zero-point value in "Adjustment Value Table," using the increase or decrease key. Press the set key for registration. 6. Press the display alteration key to exit the menu item. 167 W E

169 Functions of and How to Use Adjustment Mode 8.4 Load Radius Adjustment [NOTICE] For the conditions and values for load radius, refer to the load radius value in "Adjustment Value Table." Set the crane as follows: (1) Actual and registered statuses of outriggers: Fully extended (2) Actual and registered statuses of boom: Main boom (Jib and single top stowed) (3) Boom length: Fully extended (4) Number of part lines: Standard number of part lines when the main boom is fully extended (5) Hook block: Refer to "Adjustment Value Table." (Auxiliary hook block stowed) (6) Load radius: After lifting the rated lifting capacity of load radius condition, set the actual load radius to the value of load radius condition (load radius) in "Adjustment Value Table" by lowering the boom. (Cancel AML automatic stop function when overload hinders boom lowering.) (7) There may be other conditions in addition to those described above depending on the crane model. Refer to "Adjustment Value Table" for details. 1. Select the item [ チョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [: ナガサカクドチョウセイ ] is displayed, press the scroll-down key until the display [: サギョウハンケイチョウセイ ] appears. Press the set key to select the menu item. 3. Press the increase or decrease key so that the value of load radius display [ ハンケイ 1s] becomes the load radius value in "Adjustment Value Table." Press the set key for registration. 4. Press the display alteration key to exit the menu item. 168 W E

170 Functions of and How to Use Adjustment Mode 8.5 Moment Span Fine Adjustment [NOTICE] For the conditions and values for moment span fine, refer to the moment span fine value in "Adjustment Value Table." Set the crane as follows: (1) Actual and registered statuses of outriggers: Fully extended (2) Actual and registered statuses of boom: Main boom (Jib and single top stowed) (3) Boom length: Fully extended (4) Boom angle: Set the value shown on the boom angle display to the condition of the span fine specified in "Adjustment Value Table" by lowering the boom. (5) Hook block position: Hoist down the hook block to a position just clear of ground surface. (6) Number of part lines: Standard number of part lines when the main boom is fully extended (7) Hook block: Refer to "Adjustment Value Table." (Auxiliary hook block stowed) (8) There may be other conditions in addition to those described above depending on the crane model. Refer to "Adjustment Value Table" for details. The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t "000" to "099" to t "-99" to "-01" 5. Proceed to "8.6 Moment Zero-point Recheck." 1. Select the item [ チョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [: ナガサカクドチョウセイ ] is displayed, press the scroll-down key until the display [: モーメントチョウセイ ] appears. Press the set key to select the menu item. 3. Press the scroll-down key until the moment span display appears. Moment span display: Display [X.XXXs***.*% ] Moment load factor (%) Shows span state. Detection distortion voltage (mv) 4. Press the increase or decrease key so that the value shown on the actual load display becomes the span fine value in "Adjustment Value Table." Press the set key for registration. 169 W E

171 Functions of and How to Use Adjustment Mode 8.6 Moment Zero-point Recheck [NOTICE] For the conditions and values for moment zero-point recheck, refer to the moment zero-point value in "Adjustment Value Table." 1. Continued from "8.5 Moment Span Fine Adjustment." 2. Retract the boom fully. 3. Raise boom to an angle just before the maximum boom angle, and then adjust the value of boom angle display to the condition of the zero-point specified in "Adjustment Value Table" by lowering the boom. (Hoist down the hook block to a position just clear of ground surface or chassis.) (For GA-700N-1, GR-250N-1 (from #FB3729), GR-350N-1, GR-160N-1, and GR-120F-1, set the hook block position to the overwinding stop position.) (1) Fine adjust the value shown on the actual load display to the zero-point value in "Adjustment Value Table," using the increase or decrease key. Press the set key for registration. (2) Press the display alteration key to exit the menu item. 7. Perform "8.5 Moment Span Fine Adjustment." Perform "8.6 Moment Zero-point Recheck." 8. Press the display alteration key to exit the menu item. End of moment 4. Press the scroll-up or scroll-down key until the moment zero-point display appears. Moment zero-point display: Display [X.XXXz***.*% ] Moment load factor (%) Shows zero-point state Detection distortion voltage (mv) 5. Has the value shown on the actual load display become the zero-point value in "Adjustment Value Table"? The actual load value less than 1 t is shown as follows: 0.00 to 0.99 t "000" to "099" to t "-99" to "-01" YES NO 6. Make the moment zero-point fine as shown below. (The following moment zero-point fine procedure is extracted from "8.3 Moment Zero-point Check and Fine Adjustment.") 170 W E

172 Functions of and How to Use Adjustment Mode 9. Clock Adjustment The AML has a calendar and clock IC inside, which is used to record errors. Adjust the clock in the following procedure. The clock is included in the maintenance mode. 1. Select the item [ トケイチョウセイ] in the main menu of the maintenance mode, and press the set key to confirm. 2. When the time is displayed on the moment display, press the scroll-up or scroll-down key to bring the cursor to the place to be adjusted. Time is displayed in the 24-hour basis. The cursor lies under a numeral. Display example: [ :30] Cursor 3. Press the increase key or decrease key to change the value to be adjusted. 4. After the, press the set key to write the adjusted value onto the IC. If there are plural places, move the cursor for in order. Finally press the set key. 5. Press the display alteration key to exit the menu item. 171 W E

173 Functions of and How to Use Adjustment Mode 10. Swing Output Adjustment [NOTICE] Before adjusting the swing output (AO offset ), ensure to reset the AO offset value to zero Procedure of "AO Offset Value Resetting" 1. Select the item [ AO チョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [:AO オフセットチョウセイ ] is displayed, press the scroll-down key until the display [:AO オフセットリセット ] appears. Press the set key to select the menu item. 3. When [ リセット OK?] appears, reset the AO offset value by pressing the set key. 4. When the message [ オフセットヲリセットシマシタ ] appears, the AO offset value resetting is completed. Press the display alteration key to return to the main menu Swing output (AO offset ) [NOTICE] The specification for swing output varies depending on the specification number. Refer to "Adjustment Value Table" in the INFORMATION AND DATA section. For your information, "Adjustment Value Table" for models other than GR-300N-1, TR-250M-7, GR-250N-1, GR-350N-1, GR-160N-1, GA-700N-1 is described on the service manual of the applicable model. Set the crane as follows: (1) Actual and registered statuses of outriggers: Fully extended (2) Actual and registered statuses of boom: Main boom (Jib and single top stowed) (3) Boom length: Fully retracted (4) Boom angle: Upright position, if possible (If the boom angle is low, it is dangerous during swing operation.) (5) Hook block position: Wound up as possible. (6) Hydraulic oil temperature: Approx. 50 C 1. Select the item [ AO チョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [:AO オフセットチョウセイ ] is displayed, press the set key to select the menu item. 3. Press the scroll-up or scroll-down key until the right swing output display [41 センカイ RV] (to adjust the left swing output, the left swing output display [42 センカイ LV]) and a cursor under the output value appear. Display example: [41センカイ RV 0 0 ] Actual output value Output value 4. Press the increase or decrease key so that the output value of right swing output display [41 センカイ RV] becomes the specification of swing output. At this time, the actual output value also changes. Display example: [41センカイ RV ] Actual output value Output value 5. Press the scroll-down key to bring the cursor to under the actual output value. Display example: [41センカイ RV ] Actual output value Output value 6. With the swing lever being at the right swing full stroke end, raise the engine speed to the maximum. With the operations above continued, press the increase or decrease key until the swing operation stops. Display example: [41センカイ RV ] Actual output value Output value 172 W E

174 Functions of and How to Use Adjustment Mode 7. Press the set key to register the adjusted value to EEPROM. End of right swing output 8. For the left swing output, adjust following the right swing output procedure. After the registration, press the display alteration key to exit the menu item. (For the left swing output, the right swing output display [41 センカイ RV] shall be replaced with the left swing output display [42 センカイ LV].) 173 W E

175 Functions of and How to Use Adjustment Mode 11. Boom Elevating Output Adjustment [NOTICE] Before adjusting the boom elevating output (boom elevating characteristic ), ensure to reset the boom elevating characteristic value to zero Procedure of "Boom Elevating Characteristic Value Resetting" 1. Select the item [ セイギョデータチョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [: キフクトクセイチョウセイ ] is displayed, press the scroll-down key until the display [: キフクトクセイリセット ] appears. Press the set key to select the menu item. 3. When [ リセット OK?] appears, reset the boom elevating characteristic value by pressing the set key. 4. When the message [ トクセイヲリセットシマシタ ] appears, the boom elevating characteristic value resetting is completed. Press the display alteration key to return to the main menu Boom Elevating Output Adjustment (Boom Elevating Characteristic Adjustment) [NOTICE] Set the crane as follows: (1) Actual and registered statuses of outriggers: Fully extended (2) Actual and registered statuses of boom: Main boom (Jib and single top stowed) (3) Boom length: Fully retracted (4) Hook block position: Wound up as possible. But no overwinding shall occur during operation. (5) Hydraulic oil temperature: Approx. 50 C 1. Select the item [ セイギョデータチョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [: キフクトクセイチョウセイ ] is displayed, press the set key to select the menu item. 3. Press the scroll-up or scroll-down key until the boom raising measurement display [ キフクアゲケイソク ] appears. Press the set key to select the menu item. (The boom lowering measurement display: [ キフクサゲケイソク ]) 4. When [ ゼンシュクニシテクダサイ ] appears, fully retract the boom. When the boom has already been fully retracted, this message will not appear. 5. When [ ブームカク **.* イカ ] appears, make the boom angle equal to or lower than the angle shown in the message. The rod of the boom elevating cylinder shall not reach the stroke end. If the boom angle has already been the angle shown in the message, the message will not appear. 6. When the following message is displayed, press the set key to select the menu item. Display [ ケイソクヲカイシシマス ] [JS ヲチュウリツニシテ ] [ セットキーヲオシテクダサイ ] 7. When the following message is displayed, with the maximum engine speed maintained, operate the boom elevating lever toward the boom raising full stroke. Maintain the state until the measurement is completed. Display [ キフク JS サイダイソウサ ] [ エンジン Max ニ ] [ シテクダサイ ] 8. During the measurement, the following display appears. Display example [pi = **.* cv = ***] Boom elevating cylinder speed Output pilot pressure If, during the measurement, the rod of boom elevating cylinder is about to reach the stroke end, the rod is automatically stops and the following message is displayed. Return to step 5 and repeat the procedure. 174 W E

176 Functions of and How to Use Adjustment Mode Display example [ ストロークエンドシマス ] [ ブームカク **.* イカニ ] [ シテクダサイ ] To stop the measurement before it is completed, return the boom elevating lever to the neutral position, and press the display alteration key to exit the menu item. 9. When the rod of the boom elevating cylinder stops and the following display appears, the measurement is completed. Display [ ケイソクシュウリョウ ] [ キフク JS ヲチュウリツニ ] [ モドシテクダサイ ] 10. Return the boom elevating lever to the neutral position. When [ セットキーヲオシテキオク ] is displayed, press the set key to register the measured value to EEPROM. With [ セットキーヲオシテキオク ] displayed, press the scroll-down key to display the measurement result as follows: Display example [N p = **.* c = *** ] Boom elevating cylinder speed Output pilot pressure Indicates that it is Nth data. 11. When [ トクセイヲキオクシマシタ ] is displayed, the boom elevating measurement is completed. Press the display alteration key to return to the item [: キフクトクセイチョウセイ ] in the sub menu. 12. For the boom lowering measurement, measure following the boom raising measurement procedure. After the registration, press the display alteration key to exit the menu item. 175 W E

177 Functions of and How to Use Adjustment Mode 12. Telescoping/retraction Output Adjustment [NOTICE] Before adjusting the telescoping/retraction output (retraction characteristic ), ensure to reset the retraction characteristic value to zero Procedure of "Retraction Characteristic Value Resetting" 1. Select the item [ セイギョデータチョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [: キフクトクセイチョウセイ ] is displayed, press the scroll-down key until the display [: チヂミトクセイリセット ] appears. Press the set key to select the menu item. 3. When [ リセット OK?] appears, reset the retraction characteristic value by pressing the set key. 4. When the message [ トクセイヲリセットシマシタ ] appears, the retraction characteristic value resetting is completed. Press the display alteration key to return to the main menu Telescoping/retraction Output Adjustment (Retraction Characteristic Adjustment) [NOTICE] Set the crane as follows: (1) Actual and registered statuses of outriggers: Fully extended (2) Actual and registered statuses of boom: Main boom (Jib and single top stowed) (3) Boom angle: Approx. 50 to 70 (4) Hook block position: Wound up as possible. If, during the operation, the hook block is about to contact the ground surface, hoist up the hook block. (5) Hydraulic oil temperature: Approx. 50 C "No. 1 boom telescoping cylinder" in the following text indicates the boom telescoping cylinder closer to the boom bottom. 1. Select the item [ セイギョデータチョウセイ ] in the main menu of the mode, and press the set key to confirm. 2. When [: キフクトクセイチョウセイ ] is displayed, press the scroll-down key until the display [: チヂミトクセイチョウセイ ] appears. Press the set key to select the menu item. 3. When [No.1 チヂミケイソク ] is displayed, press the set key to select the menu item. 4. When [ キフクカクド 50 イジョウ ] is displayed, set the boom angle to approx. 70. When the boom angle has already been 50 or more, this message will not appear. 5. When [ ナガサ **.*m イジョウ ] is displayed, set the boom length to the value shown in the message or higher. The rod of No. 1 boom telescoping cylinder shall not reach the stroke end. If the boom length has already been the value shown in the message or higher, this message will not appear. 6. When the following message is displayed, press the set key to select the menu item. Display [ ケイソクヲカイシシマス ] [JS ヲチュウリツニシテ ] [ セットキーヲオシテクダサイ ] 7. When the following message is displayed, with the maximum engine speed maintained, operate the boom elevating lever toward the boom lowering full stroke. Maintain the state until the measurement is completed. Display [ チヂミ JS サイダイソウサ ] [ エンジン Max ニ ] [ シテクダサイ ] 8. During the measurement, the following display appears. Display example [pi = **.* bv = ***] No. 1 boom telescoping cylinder speed Output pilot pressure If, during the measurement, the rod of No. 1 boom telescoping cylinder is about to reach the stroke end, the rod is automatically stops and the 176 W E

178 Functions of and How to Use Adjustment Mode following message is displayed. Return to step 5 and repeat the procedure. Display example [ ストロークエンドシマス ] [ ナガサ **.*m イジョウニ ] [ シテクダサイ ] To stop the measurement before it is completed, return the boom telescoping lever to the neutral position, and press the display alteration key to exit the menu item. 9. When the rod of No. 1 boom telescoping cylinder stops and the following display appears, the measurement is completed. Display [ ケイソクシュウリョウ ] [ チヂミ JS ヲチュウリツニ ] [ モドシテクダサイ ] 10. Return the boom telescoping lever to the neutral position. When [ セットキーヲオシテキオク ] is displayed, press the set key to register the measured value to EEPROM. With [ セットキーヲオシテキオク ] displayed, press the scroll-down key to display the measurement result as follows: Display example [N p = **.* b = *** ] No. 1 boom telescoping cylinder speed Output pilot pressure Indicates that it is Nth data. 11. When [ トクセイヲキオクシマシタ ] is displayed, the boom retraction measurement is completed. Press the display alteration key to exit the menu item. 177 W E

179 Functions of and How to Use Adjustment Mode Other Functions and How to Use Them 1. Language The menu item [Language] is used to change the language for messages appearing on the moment display. The message on the menu item [Language] is always displayed in English. 1. Select the item [Language] in the main menu of the mode, and press the set key to confirm. 2. When the language selection display appears, press the scroll-up or scroll-down key to display the aimed language. Display example [= Japanese ] Press the scroll-down key. [: English] The symbol "=" at the left of the displayed language indicates that the language is set at present. 3. When the aimed language is displayed, press the set key to set. After the setting, the symbol ":" at the left of the set language changes to "=," indicating that the setting is completed. Display example [: English] Press the set key. [= English] 4. Press the display alteration key to exit the menu item. The messages appear in the newly set language after that. 1. Select the item [ ウンテンリレキヒョウジ ] in the main menu of the mode, and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu items of the latest overload data or maximum overload data appear. Select either of them with the set key. Display [: サイシンチヒョウジ ] [: サイダイチヒョウジ ] 3. Display of latest overload data Selecting [: サイシンチヒョウジ ] shows the latest data registered in the overload history. The time when the overload history data has been registered is indicated in the moment display. Press the scroll-down key to show the next record. (up to 50 items) Moment display Display example [ :35 ] Serial 1からの連番 number (means ( 何番目の運転履歴かを示す Nth overload history data.) ) Shows 登録数を示す the number of Shows そのときのオーバロード the overload factor. registered ( 最大 50 項目まで items. ) 状態を示す (Max. 400%) (Max. 50 items) ( 最大 400% まで ) % 2. Overload History Display The records of crane operations (with the moment load factor exceeding the overloading limit) registered in the AML are displayed. You can choose between the displays of latest overload data and of the maximum overload data. + - IW J W E

180 Functions of and How to Use Adjustment Mode 4. Display of maximum overload data Selecting [: サイダイチヒョウジ ] shows the maximum data registered in the overload history. The time when the overload history data has been registered is indicated in the moment display. Press the scroll-down key to show the load factor, jib length, and jib angle. (The jib length and jib angle are displayed only during the jib lift.) Press the scroll-down key again to show the next record. (up to 10 items) Moment display Display example [ :35 ] [125% 14.5m45.0 ] Serial 1からの連番 number ((means 何番目の運転履歴かを示す Nth overload history data) ) Indicates ブーム角度を示す boom angle. Indicates ブーム長さを示す boom length. Indicates 作業半径を示す load radius. ブーム状態を示す Indicates lift status. m t 3. Erasing the Overload History [NOTICE] When the AML main unit or EEPROM is replaced for repair and all is completed, erase-protect the overload history. Before delivering the machine to a user, erase-protect the overload history by erasing the latest history data three times. You can erase the overload history data (the record of crane operation when the moment load factor exceeds the set limit). Note that if the latest history data are erased three times, the menu will not appear, disabling the history data to be erased. At the time of the third erasure, the records of the maximum overload values will also be erased. 1. Select the item [ ウンテンリレキショウキョ ] in the main menu of the mode, and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item on which the overload history is to be erased appears. Select either of them with the set key. Display [: サイシンチショウキョ ] [: サイダイチショウキョ ] m max t 3. When [ ショウキョ OK?] appears, erase the overload history by pressing the set key When the message [ リレキヲショウキョシマシタ ] appears, the overload history data is now erased. Press the display alteration key to exit the menu item. Indicates 旋回位置を示す swing position. Indicates 実荷重を示す actual load. Indicates アウトリガ状態を示す outrigger condition. Indicates 定格総荷重を示す rated lifting capacity. IW J06 5. Press the display alteration key to exit the menu item. 179 W E

181 Functions of and How to Use Maintenance Mode Functions of and How to Use Maintenance Mode [NOTICE] For how to shift to the maintenance mode and how to select the maintenance menu, refer to "Method of Shifting Modes" and "Method of Menu Selection" in "General: Adjustment Mode and Maintenance Mode" section. 1. Maintenance mode menu Used to make functional checks of the AML. This mode has the following menus: MAIN MENU SUB MENU [ ホシュ ] [ トケイチョウセイ ] [: プログラムバージョン ] [: データシュベツ ] [:DI チェック ] [:AI チェック ] [: キフクアツリョクモニタ ] [:DO チェック ] [:MDT モニタ ] (*1) [: キースイッチチェック ] [: ヒョウジキチェック ] [: エラーリレキヒョウジ ] [: エラーリレキショウキョ ] [: ウンテンリレキヒョウジ ] [: ウンテンリレキショウキョ ] [:OP ボードチェック ] [:AO チェック ] [:SIO チェック ] [: チョウセイモニタ ] (*) : Not apply to the model (GA-700N-1) without MDT (Multiplex Data Transmitter). [NOTICE] This menu includes "MDT (Multiplex Data Transmitter) monitoring" function, showing the input status of MDT. 1. Program Version Display ROM program version is displayed. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. When [: プログラムバージョン ] is displayed, press the set key to select the menu item. 3. The program version is displayed. Press the display alteration key to exit the menu item. Display example [AML-L L0204 ] Program version 2. Data ID Number Display Information of ROM data is displayed. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [: データシュベツ ] appears. Press the set key to select the menu item. 3. The ROM data is displayed as follows: Press the scroll-up or scroll-down key until the desired ROM data is displayed. Press the display alteration key to exit the menu item. (1) ROM ID number display: Indicates ROM ID number (revision number included). Display example [ ] (2) Specification number display: Indicates crane spec. number. Display example [TR ] (3) Code number display: Indicates parts code number of the AML. Display example [ ] (4) Data date display: Indicates the date of making up data. Display example [95, 12, 27 ] (5) Revision date display: Indicates the date of data revision. Display example [96, 01, 23] 180 W E

182 Functions of and How to Use Maintenance Mode 3. Di Check The input state of Di (external contact switch) is displayed. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [:DI チェック ] appears. Press the set key to select the menu item. 3. Di (external contact switch) input state is displayed. Press the scroll-up or scroll-down key until the desired data is displayed. Press the display alteration key to exit the menu item. Display example (Di1) [01 カマキケンシュツ of ] Switch name Switch state on: Active of: Not active Di input terminal number 01 to 28: Di1 to Di28 T: TC input A: ACC input No indication: Serial port input (Di from multiplex data transmitter and signal transmitter) [NOTICE] Switch state means ON/OFF state which the AML program judges logically. Usually, this matches to the physical condition of switch. However, if "r" is added as shown in the example below, the meaning differs. ron: Switch is active. (Physical contact is OFF.) rof: Switch is not active. (Physical contact is ON.) Only the Di switch used for input in the program can be displayed. Since the display sequence of Di switch input states depends on the contents of the program, the Di switch input states may not be indicated in the numerical order of Di switch input numbers. 4. Ai Check The input state of Ai (analog detector input) is displayed. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [:AI チェック ] appears. Press the set key to select the menu item. 3. The input state of Ai (analog detector input) is displayed. Press the scroll-up or scroll-down key until the desired data is displayed. Press the display alteration key to exit the menu item. Display example (ANAiNB) [02 ブームカク 1201 ok ] When analog detector input value is within the normal input range, "ok" appears; when it is out of the range, then "ng" appears. Analog detector input value (A/D converted value) Detector name Logical number in the program 00: Moment input (MOINP, MOINN) 01: ANAiNA 02: ANAiNB 03: ANAiNC 04: ANAiND 05: ANAiNE 06: ANAiNF 07: Analog detector source (DET1SRC, DET2SRC) 08: Pressure input (ANAING) 09: Pressure input (ANAINH) 11 to 15: Serial port-1 analog input 1 to 5 (Ai from signal transmitter) 21 to 25: Serial port-2 analog input 1 to 5 (Ai from MDT) 181 W E

183 Functions of and How to Use Maintenance Mode [NOTICE] Only the Ai used for input in the program can be displayed. Since the display sequence of Ai input states depends on the contents of the program, the Ai input states may not be indicated in the numerical order of Ai input numbers. 5. Elevating Cylinder Oil Pressure Monitor The cylinder extension lateral pressure and retraction lateral pressure which are detected for the moment calculation are displayed. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [: キフクアツリョクモニタ ] appears. Press the set key to select the menu item. 3. The elevating cylinder extension lateral pressure and retraction lateral pressure are displayed. Press the display alteration key to exit the menu item. Display example [E**.* R**.* MPa] Extension oil pressure Unit Retraction oil pressure 6. Do Check The output state of Do (Digital output: Relay output and open collector output) is displayed. Also, you can invert the current state of selected output. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [:DO チェック ] appears. Press the set key to select the menu item. 3. The output state of Do (digital output) is displayed. Press the scroll-up or scroll-down key until the desired data is displayed. Press the display alteration key to exit the menu item. Display example (PLY1) [00 AML テイシ of ] Output name Present output state Output port number 00 to 07: RLY1 to PLY8 (relay contact output) 10 to 17: TR1 to TR8 (open collector output) [NOTICE] Output state means ON/OFF state which the AML program judges logically (same as the Di). Usually, this matches to the physical condition of switch. However, if "r" is added as shown in the example below, the meaning differs. ron: Switch is active. (Physical contact is OFF.) rof: Switch is not active. (Physical contact is ON.) 4. During the above Do output monitoring procedure, output state will be inverted while you are pressing the inspection key. 182 W E

184 Functions of and How to Use Maintenance Mode 7. MDT (Multiplex Data Transmitter) Monitor The input/output state of the MDT (Multiplex Data Transmitter) is displayed. [NOTICE] For the signal represented by the displayed input/output No., refer to the "MDT Input/Output Nos. and Corresponding Signals" on the following page. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [:MDT モニタ ] appears. Press the set key to select the menu item. 3. The input/output state of the MDT is displayed. Press the increase or decrease key until the desired data is displayed. Press the display alteration key to exit the menu item. Display example [No.123 Val.1] Input/output number Input/output state Digital input/output: 1: ON 0: OFF Analog input/output: represented in numerals from 0 through W E

185 Functions of and How to Use Maintenance Mode MDT Input/Output Nos. and Corresponding Signals The following table does not apply to the model (GA-700N-1) without MDT (Multiplex Data Transmitter). Upper input Upper output Lower input Lower output Analog input Input/output Signal Input/output Signal Input/output Signal Input/output Signal Input/output Signal name Input/output Signal Input/output Signal Input/output Signal number name number name number name number name number number name number name number name 1 Di1 33 Di33 65 Tr1 89 Di1 121 PMONI1 137 MONI1 169 MONI Upper Ai1 2 Di2 34 Di34 66 Tr2 90 Di2 122 PMONI2 138 MONI2 170 MONI Upper Ai2 3 Di3 35 Di35 67 Tr3 91 Di3 123 PMONI3 139 MONI3 171 MONI Upper Ai3 4 Di4 36 Di36 68 Tr4 92 Di4 124 PMONI4 140 MONI4 172 MONI Upper Ai4 5 Di5 37 Di37 69 Tr5 93 Di5 125 PMONI5 141 MONI5 173 MONI Upper Ai5 6 Di6 38 Di38 70 Tr6 94 Di6 126 PMONI6 142 MONI6 174 MONI Upper Ai6 7 Di7 39 Di39 71 Tr7 95 Di7 127 PMONI7 143 MONI7 175 MONI Upper Ai7 8 Di8 40 Di40 72 Tr8 96 Di8 128 PMONI8 144 MONI8 176 MONI Upper Ai8 9 Di9 41 Di41 73 Tr9 97 Di9 129 PMONI9 145 MONI9 177 MONI Upper Ai9 10 Di10 42 Di42 74 Tr10 98 Di PMONI MONI MONI Upper Ai10 11 Di11 43 Di43 75 Tr11 99 Di PMONI MONI MONI Lower Ai1 12 Di12 44 Di44 76 Tr Di PMONI MONI MONI Lower Ai2 13 Di13 45 Di45 77 Tr Di PMONI MONI MONI Lower Ai3 14 Di14 46 Di46 78 Tr Di PMONI MONI MONI Lower Ai4 15 Di15 47 Di47 79 Tr Di PMONI MONI MONI Lower Ai5 16 Di16 48 Di48 80 Tr Di PMONI MONI MONI Lower Ai6 17 Di17 49 Di49 81 Tr Di MONI MONI Lower Ai7 18 Di18 50 Di50 82 Tr Di MONI MONI Lower Ai8 19 Di19 51 Di51 83 Tr Di MONI MONI Lower Ai9 20 Di20 52 Di52 84 Tr Di MONI MONI Lower Ai10 21 Di21 53 Di53 85 Tr Di MONI MONI Lower Ai11 22 Di22 54 Di54 86 Tr Di MONI MONI Lower Ai12 23 Di23 55 Di55 87 Tr Di MONI MONI55 Analog output 24 Di24 56 Di56 88 Tr Di MONI MONI56 25 Di25 57 Di Di MONI Tr1 Input/output number 26 Di26 58 Di Di MONI Tr Di27 59 Di Di MONI Tr Di28 60 Di Di MONI Tr Di29 61 Di Di MONI MSOL Di30 62 Di Di MONI MSOL2 31 Di31 63 Di Di MONI31 32 Di32 64 Di Di MONI32 Signal name Upper Ao1 Lower Ao1 Lower Ao2 Lower Ao3 184 W E

186 Functions of and How to Use Maintenance Mode 8. Key Switch Check The key input on the AML control is checked. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [: キースイッチチェック ] appears. Press the set key to select the menu item. 3. The following display appears. Press any key other than the display alteration key, and the corresponding portion of display changes from "-" to " " while you are pressing the key. Press the display alteration key to exit the menu item. Display [ ] 9. Display Unit Check The segments of LCD panels and LEDs of the AML display repeat to go on and off. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [: ヒョウジキチェック ] appears. Press the set key to select the menu item. 10. Error Data Display Error data registered in the AML are displayed on the moment display and display panel Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [: エラーリレキヒョウジ ] appears. Press the set key to select the menu item. 3. The error codes are displayed on the moment display and display panel 1. Press the display alteration key to exit the menu item and return to the ordinary display state. (1) The moment display displays the time when the error occurred. Display example [ :35 ] (2) When the scroll-down key is pressed, the time display changes to the error code display. Display example [ ブームナガサイジョウ ] (3) The mark " " on the error code display shows that another error exists. Press the scroll-down key to display the next error code. Total 記憶総数 number of stored items Serial 1からの連番 number ((means 何番目のエラーであるかを示す Nth error.) ) 3. The segments of LCD panels and LEDs of the AML display repeat to go on and off. Press the display alteration key to exit the menu item and return to the ordinary display state. + - この部分に If "C" "C が表示されている場合は現在 is displayed here, 発生中のエラーであることを示している the error is present now. Error code エラーコード This この例はエラーコード example shows error 2003 code 2003 [ [ ブームナガサイジョウ ] を示す ]. IW J W E

187 Functions of and How to Use Maintenance Mode 11. Erasing the Error Data Use this menu item to erase the error information registered in the AML. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [: エラーリレキショウキョ ] appears. Press the set key to select the menu item. 3. When [ ショウキョ OK?] appears, erase the error data information by pressing the set key. 4. When the message [ リレキヲショウキョシマシタ ] appears, the error data is now erased. Press the display alteration key to exit the menu item. 12. Option (OP) Board Check The type of the incorporated option board (analog output, wire detection) is indicated. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [:OP ボードチェック ] appears. Press the set key to select the menu item. 3. The type of the incorporated option board is displayed. (Up to two option boards can be incorporated.) Press the scroll-up or scroll-down key until the desired data is displayed. Press the display alteration key to exit the menu item. Display example [1 セイギョキバン ] Option board name (1 セイギョバン : Analog output board) (2 ワイヤーケンシュツ : Wire rope movement detection board to indicate hook block position) 13. Ao Check The Ao (analog output) state is displayed with an output value of the specified percentage. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [:AO チェック ] appears. Press the set key to select the menu item. 3. The state of Ao (analog output) is displayed. Press the scroll-up or scroll-down key until the desired data is displayed. Press the display alteration key to exit the menu item. Display example (CNTL1P CNTL1N) [41 センカイ RV 0 0 ] Output name Output level for checking indicates at what percentage of the maximum level the value is to be output. Output level indicates at what percentage of the maximum level the value is being output. Ao output terminal number 11-19: Output to serial port 1 (Signal transmitter) 21-29: Output to serial port 2 (MDT) 41-49: Output to option board (41: CNTL1P, CNTL1N) (42: CNTL2P, CNTL2N) (43: CNTL3P, CNTL3N) (44: CNTL4P, CNTL4N) [NOTICE] Only the Ao used for output in the program can be displayed. Since the display sequence of Ao output states depends on the contents of the program, the Ao output states may not be indicated in the numerical order of Ao output numbers. 4. How to set the output values for checking With the Ao output state displayed, use the increase or decrease key to set up an output level for checking. Every time the key is pressed, the level is increased or decreased by 1%. When the key is held down for one second or longer, the level is increased by 10% for the increase key and decreased by 5% for the decrease key. When the level exceeds 100%, it returns to 0% (conversely, when the level reaches 0%, it returns to 100%.) 186 W E

188 Functions of and How to Use Maintenance Mode 5. How to output the output values for checking With the output level for checking indicated, press the inspection key; the output level for checking will be output while the key is held down. The displayed output value for checking blinks. 14. Sio Check The Sio (serial port) state is displayed. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [:SIO チェック ] appears. Press the set key to select the menu item. 3. The serial port state is displayed. Press the scroll-up or scroll-down key until the desired data is displayed. Press the display alteration key to exit the menu item. Display example [ シリアルポート 1 OK ] Serial port state OK : Normal NG : Abnormal NU : Not used appears. Press the display alteration key to exit the menu item. 16. Overload History Display The overload history display in the maintenance mode has the same functions as those in the mode. Refer to the "Overload History Display" in the "Functions of and How to Use Adjustment Mode" section. 17. Erasing the Overload History Erasing the overload history in the maintenance mode has the same functions as those in the mode. Refer to the "Erasing the Overload History" in the "Functions of and How to Use Adjustment Mode" section. 18. Clock Clock is included in the functions of the maintenance mode. However, for how to adjust the clock, refer to the "Clock Adjustment" in the "Functions of and How to Use Adjustment Mode" section. Serial port name (Serial port 1: Serial communication circuit to signal transmitter) (Serial port 2: Serial communication circuit to MDT) 15. Adjust Monitor The same items as shown in the [ チョウセイ ] menu of the main menu of the mode appears. However, no is available. 1. Select the menu item [ ホシュ ], and press the set key to confirm. 2. Press the scroll-up or scroll-down key until the menu item [: チョウセイモニタ ] appears. Press the set key to select the menu item. 3. The same items as shown in the [ チョウセイ ] menu of the main menu of the mode 187 W E

189 Error Message Error Message 1. Display of Error Message [NOTICE] The language (English or Japanese) of error message can be selected in the [ Language] menu of the mode. When English is selected, only the error codes are displayed. +- エラーメッセージを表示 Displays error message. 1. If the program detects an abnormality in ordinary operation state (user mode), it generates beep sound as well as displays the error message on the moment display. Display example [ キフクヒズミセンサイジョウ ] [(2001)] Shows that an error of error code 2001 has occurred. IW J09 2. This error message display continues until the cause is eliminated. 3. While an operation in the or maintenance mode is being made, only beep sound informs the operator of occurrence of an abnormality. The moment display, however, does not show the error message automatically. The present message remains displayed. 4. To confirm the error message in this state, press the lift height limit key. While the key is pressed and held, the error message is shown on the moment display. (It may take some seconds for the display to show the error message.) mode is resumed after exiting the or maintenance mode, the corresponding error message appears on the moment display. 2. How to Read the Error Message 1. An error code in the error message is represented by four-digit codes. Error code E1 E2 E3 E4 Individual code Group code 0: Alarm 1: Abnormal communication 2: Abnormal detector 3: Abnormality inside the AML 2. The highest rank (E1 in the above figure) indicates an error group. The each next three digit figure (E2 through E4 above) indicates individual error code under the error group. 3. Since the group code "0" indicates just an alarm condition, no error code is included in the error message. When the error message is displayed, it does not always mean that there is an abnormality in the system. 4. For this reason, no alarm-related error message is registered in the system's error history memory. However, such an error message is displayed in the moment display as the messages for other group codes. 3. How to Read the Error History 1. Error data records up to 50 errors of the group codes 1, 2, and 3 only, in order of occurrence. After 50th error is registered, the oldest one is erased every time a new one is registered. 2. For reading the error history, refer to the "Error Data Display" in the "Functions of and How to Use Maintenance Mode" section. 5. If the abnormality remains even when the user 188 W E

190 Error Message 4. Troubleshooting Table 4.1 Group Code 0 Error code Message Name Status: Cause: Action: ミギマエ O/R チヂミミギウシロ O/R チヂミヒダリマエ O/R チヂミヒダリウシロ O/R チヂミ Front right outrigger beam retraction Rear right outrigger beam retraction Front left outrigger beam retraction Rear left outrigger beam retraction The outrigger extension width detection value decreases, close to the lifting capacity change over point. The machine does not stop automatically. The outrigger slide is retracted. Extend the outrigger slide again. Error code Message Name 0005 ブームカクドハンイガイ Boom angle value becomes out of specified range. Displayed only for the machines with side-up jib. Status: Cause: Action: Boom extension automatically stops during setting of the side-up jib. Boom angle is smaller than that required for jib setting. Raise the boom until a safety angle for jib setting is secured. Error code Message Name 0007 センカイセイノウゲンド! Swing capacity limit Displayed only for the machines with the swing slow stop function. (Displayed only during a left or right swing operation.) Status: Cause: Action: The boom enters a range beyond the capacity due to a swing operation. If the machine has the automatic swing stop function, it automatically stops. The machine enters a range with limited capacity due to the outrigger extension width and the moment load factor exceeds 100%. Swing to an opposite direction. Retract or raise the boom to bring it within the capacity range. Error code Message Name 0010 センカイセイゲンカクフキン! Close to the swing angle limit Displayed only for the machines with the swing slow stop function. However, displayed only when the swing slow stop function is canceled (no automatic swing stop). (Displayed as long as the boom is in close to the limit for both a left and right swing operation.) Status: The status in which the swing limit area is reached in any additional swing. The machine does not stop automatically. Cause: The swing area limit function is active, and the boom has been swung to a point just close to the limit. Action: Swing the boom away from the swing-limited side. Cancel the swing area limit function. Error code Message Name 0011 ジブピンミソウニュウ The jib pin has not been inserted. Status: Cause: Action: The pin status of a jib is incorrect. The machine automatically stops by an operation toward the critical side (boom extension) from this status. Both the connecting and setting pins of the jib have been inserted. The connecting pin of the jib has not been inserted. Bring the jib pins to the normal state. 189 W E

191 Error Message Error code Message Name 0013 ゼンポウスイッチイジョウ Abnormal over-front detection switch Status: Cause: Action: The swing position does not conform with the status detected by the over-front detection switch. No automatic stop is made. The over-front detection switch has detected "Front" when the boom does not face to the front. (At this time, obtain the capacity with the over-front detection switch being "Not in Front.") Over-front detection switch is abnormal or its cable is open. Swing angle detector is abnormal or incorrectly adjusted. Investigate the possible causes described above. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. Error code Message Name 0015 カマキジョウタイデス Overwinding condition (when the stop function by overwinding is canceled) Displayed when an overwinding condition is detected when the stop function by overwinding is canceled. Status: The overwinding detection switch has been turned OFF. The machine does not stop automatically though the error code is displayed when overwinding is canceled. Cause: Main or auxiliary hook block has been wound up excessively. Overwinding detection switch is abnormal or its cable is open. Action: Hoist down the main or auxiliary winch. Investigate the overwinding detection switch and its wiring. Error code Message Name Status: Cause: Action: セイノウガアリマセンセイノウガアリマセン Crane is out of capacity 1. Crane is out of capacity 2. The crane is in out-of-capacity status. The machine automatically stops by an operation toward the critical side from this status. The set operation status is not achieved. Set each operation status correctly. Operate the crane to bring it to the operation status within capacity. 190 W E

192 Error Message Error code Message Name Status: Cause: Action: ゼンシュク SW1 イジョウゼンシュク SW4 イジョウ Abnormal boom full retraction switch 1 Abnormal boom full retraction switch 4 At a specific boom section, the boom is fully retracted, but the boom full retraction detection switch does not detect the "Fully retracted" status. On the contrary, at a specific boom section, the boom is not fully retracted, but the boom full retraction detection switch detects the "Fully retracted" status. The machine automatically stops by an operation toward the critical side from this status. Boom full retraction detection switch is abnormal or its cable is open. Boom length detector is abnormal or incorrectly adjusted. AML main unit is abnormal. (Analog board is faulty.) Investigate the possible causes described above. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. Replace any faulty parts and adjust as necessary. Error code Message Name 0022 ジブスイッチ 1 イジョウ Abnormal jib full retraction detection switch Status: The jib is fully retracted, but the jib full retraction detection switch is OFF (detects the "Not fully retracted" status.) On the contrary, the jib is not fully retracted, but the jib full retraction detection switch is ON (detects the "Fully retracted" status.) The machine automatically stops by an operation toward the critical side from this status. Cause: Jib full retraction detection switch is abnormal or its cable is open. Jib length detector is abnormal or incorrectly adjusted. Action: Investigate the jib full retraction detection switch. ([Di Check] related item:[ ジブカマキ ]) Investigate the jib length detector. ([Ai Check] related item:[ テレジブ L]) The input status from a detection switch and detector can be checked in [Di Check] or [Ai Check] of the "Maintenance" menu. The judgment result of [Di Check] is shown by "on" or "of," and that of [Ai Check] is shown by "ok" when it is completed successfully. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. Replace any faulty parts and adjust as necessary. Error code Message Name % デテイシ! Stop by 100% Status: Cause: Action: The machine stops automatically due to an operation toward the critical side (winch hoisting-up, boom lowering, boom extension). Out of capacity Operate the machine on the safe side (winch hoisting-down, boom raising, boom retraction). 191 W E

193 Error Message Error code Message Name 0024 カマキデテイシ! Stop by overwinding Status: Cause: Action: Overwinding detection switch is OFF. The machine automatically stops by an operation toward the critical side from this status. Main or auxiliary hook block has been wound up excessively. Overwinding detection switch is abnormal or its cable is open. Hoist down the main or auxiliary winch. Investigate the overwinding switch and its wiring. Error code Message Name 0026 ブームカクドセイゲン! Stop by upper boom angle limit Status: Cause: Action: The boom angle exceeds the upper limit. The machine automatically stops by an operation toward the critical side from this status. The upper boom angle limit function has been set and the boom angle exceeds the limit value. Lower the boom. Cancel the upper boom angle limit function. Error code Message Name 0027 ブームカクドセイゲン! Stop by lower boom angle limit Status: Cause: Action: The boom angle exceeds the lower limit. The machine automatically stops by an operation toward the critical side from this status. The lower boom angle limit function has been set and the boom angle exceeds the limit value. Raise the boom. Cancel the lower boom angle limit function. Error code Message Name 0028 ヨウテイセイゲンデテイシ! Stop by upper lifting height limit Status: Cause: Action: The top end of the boom exceeds the lifting height limit. The machine automatically stops by an operation toward the critical side from this status. The lifting height limit function has been set and the top end of the boom exceeds the limit value. Lower or retract the boom. Cancel the lifting height limit function. Error code Message Name 0029 ハンケイセイゲンデテイシ! Stop by load radius limit Status: Cause: Action: The load radius is out of the limit area. The machine automatically stops by an operation toward the critical side from this status. The load radius limit function has been set and the load radius exceeds the limit value. Raise or retract the boom. Cancel the load radius limit function. 192 W E

194 Error Message Error code Message Name 0037 アキュムレータアツイジョウ Accumulator pressure abnormality Status: The value detected by the accumulator hydraulic pressure detector is abnormal. The machine does not stop automatically. (Not directly related to the AML control.) Cause: Action: The accumulator hydraulic pressure lowers. Hydraulic pressure detector is abnormal or its cable is open. AML main unit (analog board) is abnormal. Investigate the possible causes described above. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. (Normal: "ok" is displayed.) Replace any faulty parts, and adjust as necessary. Error code Message Name Status: Cause: Action: ミギセンカイゲンド! ヒダリセンカイゲンド! Right swing limit Left swing limit The swing position is out of the limit area. If the machine has the automatic swing stop function, it automatically stops. The swing area limit function has been set and the swing position exceeds the limit value. Swing the boom away from the swing-limited side. Cancel the swing area limit function. Error code Message Name 0044 ジブカクノウジョウタイ! Jib is in retracted status. Displayed only for the machines with the jib mounting status detected. Status: Cause: Action: The machine stops automatically due to an operation toward the critical side (jib telescoping/extension, jib tilt down). An operation toward the critical side with the jib retracted may buckle the tension rod or bracket. Stop an operation toward the critical side. Error code Message Name 0046 ジョウタイヲサイセッテイ! Condition setting altered Status: The crane state has changed. The machine does not stop automatically. Cause: Outrigger jack has been retracted. (Unexpected outrigger jack retraction movement) Action: Set the operation status again. Error code Message Name 0056 センカイソウサハキケン! The swing operation is dangerous. Status: Cause: Action: An additional swing will make out-of-capacity status. The machine does not stop automatically. (Displayed only during a left or right swing operation.) The machine with the swing slow stop function displays only when the swing slow stop function is canceled. (At this time, displayed only during the swing angle change.) The boom has been swung to a point just close to the limited capacity range, due to the outrigger extension width. Swing to an opposite direction. Retract or raise the boom to bring it within the capacity range. 193 W E

195 Error Message Error code Message Name Status: Cause: Action: ミギマエ O/R ヘンカミギウシロ O/R ヘンカヒダリマエ O/R ヘンカヒダリウシロ O/R ヘンカ Front right outrigger status change Rear right outrigger status change Front left outrigger status change Rear left outrigger status change The outrigger status has changed and the capacity decreases to a smaller outrigger extension width. The machine does not stop automatically. The outrigger extension width decreases unintentionally. If a reduced capacity does not matter, continue to use the machine without change. If an out-of-capacity status is expected, re-extend the outrigger further and register the working area again. Error code Message Name 0062 ブームカクドオーバー! Boom angle is exceeded. Status: Cause: Action: The machine stops automatically by an operation toward the critical side (boom raising). With the jib retraction pin detached and the pivot pin (a pin at the left) among the jib connection pins only inserted, the boom is raised too high. Operate in the safe side (boom lowering). Insert the jib retraction pin. Insert the jib connection pins at the left and right (both the pivot pin and connecting pin). Error code Message Name モーメントイジョウモーメントイジョウ Abnormal moment [Distortion detection type] Does not stop. Abnormal moment [Hydraulic pressure detection type] Can not operate toward the critical side. This alarm is triggered when the actual load value calculated inside the AML shows a negative value. Abnormal negative load value range varies depending on the boom status. Status: Cause: Action: The actual load value calculated inside the AML shows a negative value due to abnormal moment detector. Therefore, re- of the detector is required. (Error code 0067: The alarm is triggered without automatic stop, error code 0113: The machine stopped by an operation toward the critical side.) Detector is abnormal. (Abnormal boom length detector, boom angle detector, moment detector, or elevating cylinder pressure detector) Detector is incorrectly adjusted. AML main unit is abnormal. (Analog board is faulty.) The moment value cannot be detected correctly because the elevating cylinder has retracted to the stroke end. (In case of error code 0113) Readjust the corresponding detector. Investigate the detector which seems to be faulty. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu or "Elevating Cylinder Oil Pressure Monitor." In "Ai Check," if it is normal, "ok" is displayed. ([Ai Check] related items: [ ブーム L], [ ブームカク ], [ モーメント V], [ キフクノビ ], [ キフクチヂミ ], etc.) For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. Raise the boom. (In case of error code 0113) 194 W E

196 Error Message Error code Message Name 0068 センカイカクドイジョウ Abnormal swing angle Status: Cause: Action: The difference in the detected values between two swing angle detectors is out of the tolerance. (The alarm is triggered without stop. For error codes 2016 through 2019, and 2021, the machine stops.) Detector is abnormal. (Swing angle detector) Detector is incorrectly adjusted. AML main unit (analog board) is faulty. The AML continuously checks the detected values of the swing angle. The AML judges that the tolerance is exceeded during the check operation. Readjust the corresponding detector. Investigate the swing angle detector. Error code Message Name 0069 ブームナガサイジョウ Abnormal boom length Status: Cause: Action: The detected value of the boom length exceeds the upper or lower limit of the tolerance. (The alarm is triggered without stop. For error codes 2007 and 2008, the machine stops.) Detector is abnormal. (Boom length detector) Detector is incorrectly adjusted. AML main unit (analog board) is faulty. The AML continuously checks the detected values of the boom length. The AML judges that the upper or lower limit of the tolerance is exceeded during the check operation. Readjust the corresponding detector. Investigate the boom length detector. Error code Message Name 0070 ブームカクドイジョウ Abnormal boom angle Status: Cause: Action: The detected value of the boom angle exceeds the upper or lower limit of the tolerance. (The alarm is triggered without stop. For error code 2004, the machine stops.) Detector is abnormal. (Boom length/angle detector) Detector is incorrectly adjusted. AML main unit (analog board) is faulty. The AML continuously checks the detected values of the boom angle. The AML judges that the upper or lower limit of the tolerance is exceeded during the check operation. Readjust the corresponding detector. Investigate the boom angle detector. 195 W E

197 Error Message Error code Message Name Status: Cause: Action: ミギマエ O/R イジョウミギウシロ O/R イジョウヒダリマエ O/R イジョウヒダリウシロ O/R イジョウ Abnormal extension width of the front right outrigger Abnormal extension width of the rear right outrigger Abnormal extension width of the front left outrigger Abnormal extension width of the rear left outrigger The detected value of the outrigger width exceeds the upper or lower limit of the tolerance. (The alarm is triggered without stop. For error codes 2009 through 2012, the machine stops.) Detector is abnormal. (Outrigger extension width detector) Detector is incorrectly adjusted. MDT (Multiplex Data Transmitter) main unit is faulty. The AML continuously checks the detected values of the outrigger width. The AML judges that the upper or lower limit of the tolerance is exceeded during the check operation. Readjust the corresponding detector. Investigate the corresponding detector. Error code Message Name 0075 スプリングロックヘンカ Spring lock state has changed. Status: The spring lock state has changed from "Locked" to "Not locked." The machine does not stop automatically. Cause: Spring lock has been released unintentionally. Spring lock has been released by mistake. Action: If a reduced capacity does not matter, continue to use the machine without change. If the actual capacity is exceeded, engage the spring lock and set the status again. Error code Message Name 0081 ブームキフクゲンソクチュウ! Boom elevating operation is slowing down. Displayed only for the machines with the boom elevation slow stop function. (Displayed only during a boom elevating operation.) Status: The boom elevation slow stop function is activated, slowing down the boom operation. Cause: The boom has been elevated close to a stop angle (stop by 100%, by area limit, by stroke end, or for rear stability), the elevation slow stop function has been activated, and the elevation speed is reduced. Action: Stop the operation. Elevate the boom toward the opposite direction. Cancel the working area limit function. Operate on the safe side. 196 W E

198 Error Message Error code Message Name 0082 センカイゲンソクチュウ! Swing operation is slowing down. Displayed only for the machines with the automatic swing stop function. (Displayed only during a left or right swing operation.) Status: The swing slow stop function is activated, slowing down the swing operation. Cause: The boom has swung close to a stop angle (stop by 100%, by area limit), the swing slow stop function has been activated, and swing speed is reduced. Action: Stop the operation. Swing to an opposite direction. Retract or raise the boom to bring it within the capacity range. Cancel the swing area limit function. Error code Message Name 0085 キフクストロークエンドデス Elevation stopped at stroke end Displayed only for [Hydraulic pressure detection type]. Status: Cause: Action: The boom reaches the upper stroke end. (The boom has been elevated to the available limit.) The machine automatically stops because an operation toward the critical side is attempted in this situation. When the moment is detected in the hydraulic pressure in the elevating cylinder, the correct moment cannot be detected if the boom elevating cylinder reaches the stroke end. Therefore, the automatic stop function intervenes in the boom elevating operation just before the boom elevating cylinder reaches the stroke end. Stop the operation which has caused the stop. Operate the boom in the opposite direction which has caused the stop. Error code Message Name 0088 ジブツキゲンカイテイシ Stopped at jib limit Displayed only for the machines with the jib mounting status detected. Status: Cause: Action: The crane automatically stops because an operation toward the critical side (winch hoisting-up, boom lowering, boom extension) is attempted when the moment has exceeded the specified value. The moment load factor during the boom lift with the jib mounted exceeds the specified limit. (The actual capacity varies depending on various conditions such as the outrigger extension width.) Operate the machine on the safe side (winch hoisting-down, boom raising, boom retraction). Error code Message Name 0090 フックインキンシリョウイキ! Hook-in prohibited area Status: Cause: Action: No hook-in operation is possible. (Stops due to overwinding.) If a hook-in is attempted, the hook block and boom lower part may contact. Hoist down the main or auxiliary winch. Adjust the boom status so that a hook-in operation is possible. 197 W E

199 Error Message Error code Message Name 0091 ジブセットセッテイミス! Wrong jib setting Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type. Status: Cause: Action: The combination of the AML boom status setting and an operation select switch *1 selection is as follows: AML boom status setting: Select other than the jib set. Operation select switch *1 : Select the jib set position. The machine automatically stops by an operation toward the critical side from this status. Either the AML boom status setting or operation select switch *1 selection is wrong. Operation select switch *1 is abnormal. Select the jib set in the AML boom status setting. Select the boom position or jib position using an operation select switch *1. Investigate the operation select switch *1. ([Di Check] related item: [JB ソウサキリカエ 1] to [JB ソウサキリカエ 4]) The input status from the switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Operation select switch *1 : Boom/jib operation select switch (boom, jib, jib set) Jib set operation select switch (pivot pin, mounting/retraction cylinder, connecting pin) Mounting/retraction select switch (mounting, retraction) Error code Message Name 0092 ジブハリカクキケンソウサ Jib extension/retraction dangerous operation Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type. Status: Cause: Action: The machine automatically stops due to a dangerous operation that may lead damage to the boom or jib during the jib mounting/retraction operation. Not-allowed operation was made. (Allowed operations: Hoist-up and down of the auxiliary winch, left and right swing, boom retraction (jib mounting/retraction)) The allowed operations only shall be made. Change the AML boom status setting or operation select switch *1 selection. Operation select switch *1 : Boom/jib operation select switch (boom, jib, jib set) Jib set operation select switch (pivot pin, mounting/retraction cylinder, connecting pin) Mounting/retraction select switch (mounting, retraction) 198 W E

200 Error Message Error code Message Name 0093 ジブセットカノウカクド! Allowable boom angle for jib set Displayed for the jib types (such as TR-200M-5 jib) that allows the jib-side roller to be mounted/retracted along the boom-side guide without using an additional rope. Status: The crane operation automatically stops because the boom reaches the allowable angle for jib mounting/retraction. Cause: With the jib set operation selected by the AML status setting, the boom has raised to the allowable angle for jib mounting/retraction. Allowable angle for jib mounting/retraction Mounting: The boom angle in which the jib does not swing largely and does not interfere the revolving structure when the jib-side roller is detached from the boom-side guide during a boom extension operation. Retraction: The boom angle in which the jib-side roller engages the boom-side guide to allow the jib to be retracted during a boom retraction operation. Action: Jib mounting: Extend the boom and then mount the jib. Jib retraction: Retract the boom and then retract the jib. Others: Stop the boom raising operation. Shift the AML status setting to an item other than the jib set. Error code Message Name 0094 ソウサキリカエセンタクエラー Operation select error Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type. Status: Cause: The combination of the operation select switch *1 inputs is implausible. Therefore, the automatic stop function intervenes in all operations. Operation select switch *1 is abnormal. Action: Investigate the operation select switch *1. ([Di Check] related item: [JB ソウサキリカエ 1] to [JB ソウサキリカエ 4]) The input status from the switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Operation select switch *1 : Boom/jib operation select switch (boom, jib, jib set) Jib set operation select switch (pivot pin, mounting/retraction cylinder, connecting pin) Mounting/retraction select switch (mounting, retraction) 199 W E

201 Error Message Error code Message Name 0095 フックインケンシュツエラー Hook-in detection error Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type. Status: Cause: Action: The combination of the auxiliary overwinding detection and auxiliary hook-in detection is implausible. ([Auxiliary not in overwound status] and [Auxiliary hook-in status] are detected.) Therefore, the automatic stop function intervenes in all operations. Auxiliary overwinding detection switch is abnormal or its wiring is shorted. Auxiliary hook-in detection switch is abnormal or its wiring is shorted. Investigate the auxiliary overwinding detection switch. ([Di Check] related item: [ ジブカマキ ]) Investigate the auxiliary hook-in detection switch. ([Di Check] related item: [S フックフックイン ]) The input status from the detection switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Error code Message Name 0096 シテンピンケンシュツエラー Pivot pin detection error Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type. Status: Cause: Action: The combination of the pivot pin full retraction detection and full extension detection is implausible. ([Pivot pin fully retracted] and [Pivot pin fully extended] are detected.) Therefore, the automatic stop function intervenes in all operations. Pivot pin full retraction detection switch is abnormal or its wiring is shorted. Pivot pin full extension detection switch is abnormal or its wiring is shorted. Investigate the pivot pin full retraction detection switch. ([Di Check] related item: [ シテンピンヌケ ]) Investigate the pivot pin full extraction detection switch. ([Di Check] related item: [ レンケツピンシテン ]) The input status from the detection switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") 200 W E

202 Error Message Error code Message Name 0098 サブウインチガイジョウ Abnormal auxiliary winch Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type. Status: Cause: Action: (a) A high pressure is detected in the auxiliary winch motor. (b) The auxiliary winch brake is not released. The machine automatically stops by an operation toward the critical side from this status. (a) The auxiliary high pressure detection switch is abnormal. Auxiliary hoisting/unhoisting SOL or auxiliary unhoisting SOL is abnormal. (Sticking, foreign matter is caught, the coil is open, the signal wiring is open, etc.) (b) Auxiliary negative brake release pressure switch is abnormal. Auxiliary automatic hoisting SOL or auxiliary winch brake release SOL is abnormal. (Sticking, foreign matter is caught, the coil is open, the signal wiring is open, etc.) Auxiliary brake release hydro-valve or clutch valve is abnormal. Operate the boom at slow speed so that no high pressure is accumulated in the auxiliary winch motor. Investigate various switches, SOLs, and valves. ([Di Check] related item: [S ウインチコウアツ ]) ([Do Check] related item: [SW テイアツキリカエ ] Auxiliary hoisting/unhoisting SOL [S テイアツクリダシ ] Auxiliary unhoisting SOL [S ウインチマキコミ ] Auxiliary automatic hoisting SOL [SWBRK カイジョ ] Auxiliary winch brake release SOL) The input status from various switches and output status to SOL can be checked in [Di Check] or [Do Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Error code Message Name 0099 メインカマキデテイシ! Stop by main overwinding Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type. Status: Cause: Action: The main overwinding detection switch has been turned off. The machine automatically stops by an operation toward the critical side from this status. The main winch is overwound. Main overwinding detection switch is abnormal or its cable is open. Hoist down the main winch. Investigate the main overwinding detection switch. ([Di Check] related item: [ カマキケンシュツ ]) The input status from the detection switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") 201 W E

203 Error Message Error code Message Name 0100 メインカマキジョウタイ! Main overwinding condition (when the stop function by overwinding is canceled) Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type. This message is displayed if the main winch overwinding condition is detected when the stop function by overwinding is canceled. Status: The main overwinding detection switch has been turned off. The machine does not stop automatically. Cause: The main winch is overwound. Main overwinding detection switch is abnormal or its cable is open. Action: Hoist down the main winch. Investigate the main overwinding detection switch. ([Di Check] related item: [ カマキケンシ ュツ ]) The input status from the detection switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Error code Message Name 0101 サブカマキデテイシ! Stop by auxiliary overwinding Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type. Status: Cause: Action: The auxiliary overwinding detection switch has been turned off. The machine automatically stops by an operation toward the critical side from this status. The auxiliary winch is overwound. Auxiliary overwinding detection switch is abnormal or its cable is open. The conditions for the automatic tensioning control are not met. Hoist down the auxiliary winch. Investigate the auxiliary overwinding detection switch. ([Di Check] related item: [ ジブカマキ ]) The input status from the detection switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Check the inputs related to the automatic tensioning control. Error code Message Name 0102 サブカマキジョウタイ! Auxiliary overwinding condition (when the stop function by overwinding is canceled) Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type. This message is displayed if the auxiliary winch overwinding condition is detected when the stop function by overwinding is canceled. Status: The auxiliary overwinding detection switch has been turned off. The machine does not stop automatically. Cause: The auxiliary winch is overwound. Auxiliary overwinding detection switch is abnormal or its cable is open. Action: Hoist down the auxiliary winch. Investigate the auxiliary overwinding detection switch. ([Di Check] related item: [ ジブカマ キ ]) The input status from the detection switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") 202 W E

204 Error Message Error code Message Name 0103 ジブジョウタイガキケン The jib status is dangerous. Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type and those with the jib upward mounting remote control function. Status: Moving the crane may allow the jib to drop due to unstable jib status. The machine automatically stops by an operation toward the critical side from this status. Cause: Action: A pin to fix the jib (the jib retraction pin, jib anchor pin, pivot pin, connecting pin, fixing pin, etc.) is not completely inserted. Insert each pin to prevent the jib to drop even when the crane is moved. Error code Message Name 0105 マキコミイジョウデテイシ! Stop by hoisting error Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type. Status: Cause: Action: The auxiliary winch has been wound regardless of the command from the AML. Therefore, the automatic stop function intervenes in all operations. Auxiliary winch automatic hoisting SOL is abnormal. (Sticking, foreign matter is caught, the coil is open, the signal wiring is open, etc.) Investigate the auxiliary winch automatic hoisting SOL. ([Do Check] related item: [S ウインチマキコミ ]) The output status to SOL can be checked in [Do Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Error code Message Name 0106 ドウジソウサハキンシ! Simultaneous operation is prohibited. Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type. Status: Cause: Action: The machine stops automatically due to a simultaneous operation prohibited during the jib mounting/retraction. The automatic tensioning control has performed the auxiliary winch winding operation and unwinding operation at the same time. Stop either operation. (The operation shall be done individually.) Error code Message Name 0107 シテンピンソウサキンシ! Pivot pin operation is prohibited. Displayed only for the machines with the jib upward mounting remote control function. Status: Cause: Action: If the jib pivot pin is extracted in the present crane status, the jib may drop. Therefore, the machine stops automatically. The pivot pin is extracted with the jib not retracted. Stop extracting the pivot pin. Investigate the jib retraction detection switch. ([Di Check] related item: [JIB カクノウピン ]) The input status from the detection switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") 203 W E

205 Error Message Error code Message Name 0108 カイドウソウサキンシ! Cylinder extraction/retraction is prohibited. Displayed only for the machines with the jib upward mounting remote control function. Status: Cause: If the cylinder is extracted/retracted in the present crane status, the jib support and main boom may contact each other. Therefore, the machine automatically stops. The cylinder is extended/retracted with the jib retracted. Action: Stop extracting/retracting the cylinder. Investigate the jib retraction detection switch. ([Di Check] related item: [JIB カクノウピン ]) The input status from the detection switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Error code Message Name 0109 チルトソウサキンシ! Tilt operation is prohibited. Displayed only for the machines with the jib upward mounting remote control function. Status: Cause: If the jib is tilted in the present crane status, the jib support and main boom may contact each other. Therefore, the machine automatically stops. The jib is tilted (up) with the pivot pin not inserted. Action: Stop tilting the jib. Investigate the pivot pin full extension detection switch. ([Di Check] related item: [ レンケツピンシテン ]) The input status from the detection switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Error code Message Name 0111 ソウサキリカエ SOL イジョウ Abnormal operation select solenoid Displayed only for the machines with the jib upward mounting remote control function. Status: Cause: Action: When the telescoping operation is selected by the telescoping/tilt operation select switch and the lever operation within cab by the remote control select switch, the tilt (up/down) operation is detected. Therefore, the automatic stop function intervenes in all operations. Telescoping/tilt select SOL is abnormal. (Sticking, foreign matter is caught, the coil is open, the signal wiring is open, etc.) Investigate the telescoping/tilt select SOL. Investigate the telescoping/tilt operation select switch, remote control select switch, and tilt operation detection switch. ([Di Check] related item: [ レバーキリカエ 1], [ リモコンキリカエ SW], [ ジブアゲ ], [ ジブサゲ ]) The input status from the select switch and detection switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") 204 W E

206 Error Message Error code Message Name 0112 リモコンソウサ SOL イジョウ Abnormal remote control operation solenoid Displayed only for the machines with the jib upward mounting remote control function. Status: Cause: When the remote control operation is selected by the remote control select switch, even if the remote control is not operated, the tilt (up/down) operation is detected. Therefore, the automatic stop function intervenes in all operations. Remote control operation SOL (1) or (2) is abnormal. (Sticking, foreign matter is caught, the coil is open, the signal wiring is open, etc.) Action: Investigate the remote control operation SOLs (1) and (2). ([Di Check] related item: Remote control operation SOL (1) [ リモコンチルトアゲ ] Remote control operation SOL (2) [ リモコンチルトサゲ ]) Investigate the tilt operation detection switch. ([Do Check] related item: [ ジブアゲ ], [ ジブサゲ ]) Investigate each operation switch on the remote control. ([Di Check] related item: Pivot pin (insertion) SW operation [ シテンピンサシ SW] Pivot pin (extraction) SW operation [ シテンピンヌキ SW] Extension/retraction cylinder (extension) SW operation [ ハリカク CL ハリ SW] Extension/retraction cylinder (retraction) SW operation [ ハリカク CL カク SW] Connecting pin (insertion) SW operation [ レンケツ P サシ SW] Connecting pin (extraction) SW operation [ レンケツ P ヌキ SW]) The input status from various switches and output status to SOL can be checked in [Di Check] or [Do Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Error code Message Name 0114 サスペンションフリー! Suspension free! Status: Cause: Action: The suspension state has changed from "Locked" to "Not locked." The machine does not stop automatically. The suspension becomes free unintentionally. If a reduced capacity does not matter, continue to use the machine without change. If the actual capacity is exceeded, engage the suspension lock and set the status again. Error code Message Name 0115 キフクテイシカクドフキン! Close to the boom elevating stop angle Status: Cause: Action: A further boom elevating operation will stop the crane. (Preliminary alarm) The boom angle comes just before stopping by boom upper stroke end or a working area limit (boom angle limit, load radius limit, lifting height limit). Stop elevating the boom. Move the boom toward the safe side. 205 W E

207 Error Message Error code Message Name 0116 シンシュクゲンソクチュウ! Telescoping operation is slowing down. Displayed only for the machines with the boom telescoping/retraction slow stop function. (Displayed only during a boom retraction operation.) Status: The boom telescoping/retraction slow stop function is activated, slowing down the boom operation. Cause: Because the boom comes close to the stroke end during the telescoping/retraction operation, the telescoping/retraction slow stop function is activated, slowing down the retracting operation. Action: None Error code Message Name 0117 ブームセッショクチュウイ! Be careful of boom contact! Status: Cause: Action: The boom comes close to the mirror or engine cover. The machine does not stop automatically. The boom or retracted jib comes close to the mirror of the carrier or engine cover, and an additional boom lowering operation or swing operation may allow the boom or jib to contact these components. Be careful of an obstacle during a boom lowering operation or swing operation. Error code Message Name 0118 リモコンソウサセンタクチュウ Remote control operation is being selected. Displayed only for the machines with the jib upward mounting remote control function. Status: Cause: Action: The remote control operation is selected by the remote control select switch. The lever within the cab cannot be operated. The input from the remote control select switch changes to the remote control operation side. When the lever is used for operation, select the lever operation by the remote control select switch. If this message is displayed, even though the lever operation is selected, investigate the harnesses. ([Di Check] related item: [ リモコンキリカエ SW]) With this message displayed, if the lever operation is possible, investigate the remote control pressure vent SOL. ([Do Check] related item: [ リモコンアツキリカエ ]) The input status from the switch and output status to SOL can be checked in [Di Check] or [Do Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Error code Message Name 0119 レンケツピンソウサキンシ! Connecting pin operation is prohibited! Displayed only for the machines with the jib upward mounting remote control function. Status: Cause: Action: If the connecting pin is extracted in the present crane status, the jib may drop. Therefore, the machine stops automatically. The connecting pin is extracted (retracted) with the pivot pin not inserted correctly. Stop extracting the connecting pin. Investigate the pivot pin full extension detection switch. ([Di Check] related item: [ レンケツピンシテン ]) The input status from the detection switch can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") 206 W E

208 Error Message Error code Message Name 0120 シンシュクセンタクイジョウ Telescoping select error Displayed only for the machines with the jib mounting control function of GA-700N-1 type. Status: Cause: Action: Because the jib mounting/retraction has not been operated correctly, the jib may be malfunctioning. Therefore, the automatic stop function intervenes in all operations. With the boom/jib select switch in a position other than the jib set position, the connecting pin is operated. Move the connecting pin operation switch to the neutral position. Move the boom/jib select switch to the correct position. Investigate the inputs from the boom/jib select switch and connecting pin operation switch. ([Di Check] related item: [ ジブキリカエ 1], [ ジブキリカエ 2], [ レンケツピンソウサ ]) The input status from the various switches can be checked in [Di Check] of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Error code Message Name 0121 チルトゲンソクチュウ! Tilt operation is slowing down. Displayed only for the machines with the jib mounting/retraction control function in TR-250F-1 type and tilt slow stop function. (Displayed only during a jib tilt operation.) Status: The jib tilt operation slow stop function is activated, slowing down the tilt operation. Cause: Action: Because the jib offset angle comes close to the stroke end or angle to ground of 0 during a jib tilt operation, the jib tilt slow stop function is activated, slowing down the tilt operation. None 207 W E

209 Error Message 4.2 Group Code 1 Error code Message Name Status: Cause: Action: トランスミッタ 1 イジョウトランスミッタ 2 イジョウ The transmitter cannot receive any signals from the AML at all. Therefore, all operations except boom swing are unavailable. Serial port 1 transmission line open Serial port 2 transmission line open A part of wiring to the transmitter is open. The connector pins of wiring to the transmitter are in poor contact. The receiving circuit of the transmitter or the transmitting circuit of the AML is faulty. Check the wiring to the transmitter for continuity. If no continuity exists, repair or replace the wiring. Replace the transmitter or AML power board. Error code Message Name Status: Cause: Action: トランスミッタ 1 イジョウトランスミッタ 2 イジョウ Serial port 1 receiving line open Serial port 2 receiving line open The signals from the transmitter cannot be received at all. Therefore, all operations except boom swing are unavailable. A part of wiring from the transmitter is open or in poor contact. No transmitter is connected. (The connector is disconnected.) The receiving circuit of the AML or the transmitting circuit of the transmitter is faulty. The serial port fuse (SIF1, 2) of the AML has blown. Check the wiring to the transmitter for continuity. If no continuity exists, repair or replace the wiring. Replace the transmitter or AML power board. Replace the serial port fuse of the AML. Error code Message Name Status: Cause: Action: トランスミッタ 1 イジョウトランスミッタ 2 イジョウ Abnormal transmitter 1 Abnormal transmitter 2 An abnormality is detected in the transmitter. Therefore, all operations except boom swing are unavailable. The internal circuit of the transmitter is abnormal. Replace the transmitter. Error code Message Name Status: Cause: Action: トランスミッタ 1 イジョウトランスミッタ 2 イジョウトランスミッタ 1 イジョウトランスミッタ 2 イジョウ Serial port 1 transmitting data error Serial port 2 transmitting data error Serial port 1 receiving data error Serial port 2 receiving data error The data transmitted (received) by the AML and that received (transmitted) by the transmitter are different. Therefore, all operations except boom swing are unavailable. The data has been garbled due to noise (external radio wave). The signal wire connection is in poor contact. Turn off any device which is emitting strong noise. Check the signal line for poor contact. Repair or replace the wiring. 208 W E

210 Error Message Error code Message Name Status: Action: トランスミッタ 1 イジョウトランスミッタ 2 イジョウ A wrong transmitter is connected to the serial port. Therefore, all operations except boom swing are unavailable. Connect the approved transmitter to the serial port. Transmitter 1 type improper Transmitter 2 type improper 209 W E

211 Error Message 4.3 Group Code 2 Error code Message Name 2001 キフクヒズミセンサイジョウ Abnormal moment detector Status: Cause: Action: The input values detected by the moment detector are implausible. Therefore, all operations except boom swing are unavailable. Moment detector is abnormal or its cable is open. The moment is not adjusted correctly by the AML. AML main unit is abnormal. (Analog board is faulty.) Investigate the possible causes described above. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. Replace any faulty parts and adjust as necessary. Error code Message Name 2003 ブームナガサイジョウ Abnormal boom length detector Status: Cause: Action: The input values from the boom length detector are implausible. Therefore, all operations except boom swing are unavailable. Boom length detector is abnormal or its cable is open. AML main unit is abnormal. (Analog board is faulty.) Investigate the possible causes described above. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. Replace any faulty parts and adjust as necessary. Error code Message Name 2004 ブームカクドイジョウ Abnormal boom angle detector Status: Cause: Action: The input values from the boom angle detector are implausible. Therefore, all operations except boom swing are unavailable. Boom angle detector is abnormal or its cable is open. AML main unit is abnormal. (Analog board is faulty.) Investigate the possible causes described above. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. Replace any faulty parts and adjust as necessary. Error code Message Name 2005 ジブナガサイジョウ Abnormal jib length detector Status: Cause: Action: The input values from the jib length detector are implausible. Therefore, all operations except boom swing are unavailable. Jib length detector is abnormal or its cable is open. Transmitter unit is abnormal. Investigate the possible causes described above. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. Replace any faulty parts and adjust as necessary. 210 W E

212 Error Message Error code Message Name 2006 ジブカクドイジョウ Abnormal jib angle detector Status: Cause: Action: The input values from the jib angle detector are implausible. Therefore, all operations except boom swing are unavailable. Jib angle detector is abnormal or its cable is open. Transmitter unit is abnormal. Investigate the possible causes described above. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. Replace any faulty parts and adjust as necessary. Error code Message Name Status: Cause: Action: ミギマエ O/R イジョウミギウシロ O/R イジョウヒダリマエ O/R イジョウヒダリウシロ O/R イジョウ Abnormal front right O/R length detector Abnormal rear right O/R length detector Abnormal front left O/R length detector Abnormal rear left O/R length detector The input values from the outrigger length detector are implausible. The machine does not stop automatically. Outrigger length detector is abnormal or its cable is open. Outrigger length detector of the AML has not been adjusted correctly. Transmitter unit is abnormal. Investigate the possible causes described above. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. Replace any faulty parts and adjust as necessary. Error code Message Name Status: Cause: Action: センカイカクドイジョウセンカイカクドイジョウ Abnormal swing angle detector 1 (swing dead angle switch OFF) Abnormal swing angle detector 2 (swing dead angle switch ON) The relation between the input values from the swing angle detector and swing dead angle detection switch is abnormal. Therefore, all operations except boom swing are unavailable. Swing angle detector is abnormal or incorrectly adjusted, or its cable is open. Swing dead angle detection switch is abnormal or incorrectly adjusted, or its cable is open. AML main unit is abnormal. (Analog board is faulty.) Investigate the possible causes described above. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. The input status from the detection switch can be checked in "Di Check" item of the "Maintenance" menu. (The judgment result is indicated by "on" or "of.") Replace any faulty parts, and adjust as necessary. 211 W E

213 Error Message Error code Message Name 2021 センカイカクドイジョウ Abnormal swing angle detector Status: Cause: Action: The offset of the swing angle detectors 1 or 2 is abnormal. Therefore, all operations except boom swing are unavailable. The swing angle detectors 1 or 2 is wrongly mounted or incorrectly adjusted. AML main unit is abnormal. (Analog board is faulty.) Investigate the possible causes described above. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. Replace any faulty parts and adjust as necessary. Error code Message Name Status: Cause: Action: キフクノビアツイジョウキフクチヂミアツイジョウ Abnormal boom elevating cylinder extension pressure detector Abnormal boom elevating cylinder retraction pressure detector The input values from the hydraulic pressure detector in the boom elevating cylinder's extension (retraction) chamber are implausible. Therefore, all operations except boom swing are unavailable. Hydraulic pressure detector is abnormal or its cable is open. AML main unit is abnormal. Investigate the possible causes described above. The input status from a detector can be checked in "Ai Check" item of the "Maintenance" menu. ([Ai Check] related item: [ キフクノビ ], [ キフクチヂミ ]) If it is normal, "ok" is displayed. For the specifications of the detector, refer to the "Detector Check" in the INFORMATION AND DATA section. Replace any faulty parts and adjust as necessary. 212 W E

214 Error Message 4.4 Group Code 3 Error code Message Name 3003 システムイジョウ (3003) System error (sum check error) Status: Cause: Action: An error is found in ROM as a result of sum check. Therefore, all operations except boom swing are unavailable. AML main unit is abnormal. (CPU board is faulty.) ROM is abnormal. Replace the AML main unit. (Replace the CPU board.) Replace ROM. Error code Message Name 3006 システムイジョウ (3006) System error (EEPROM error) Status: Cause: Action: AML cannot write on its nonvolatile memory (EEPROM). Therefore, all operations except boom swing are unavailable. AML main unit is abnormal (CPU board is abnormal) or EEPROM is abnormal. Replace the AML main unit (replace the CPU board) or replace EEPROM. Error code Message Name Status: Cause: Action: システムイジョウ (3007) システムイジョウ (3008) システムイジョウ (3009) システムイジョウ (3011) システムイジョウ (3012) システムイジョウ (3013) システムイジョウ (3017) The software program cannot run normally. Therefore, all operations except boom swing are unavailable. AML main unit is abnormal. (Abnormal CPU circuit board) System error (RAM error) System error (RAM error) System error (CPU error) System error (bus error) System error (address error) System error (unauthorized command) System error (privilege violation) Replace the AML main unit. (Replace the CPU board.) If this error has occurred, the relevant error message is displayed and the AML stops processing. (There is a continuous beep and two LEDs in the window light.) When such a state occurs, the cause may exist in the AML itself. At first, check for an abnormality such as loose connector within the AML unit. Error code Message Name 3010 システムイジョウ (3010) System error (A/D converter error) Status: Cause: Action: The input status of the A/D converter is abnormal. Therefore, all operations except boom swing are unavailable. AML main unit is abnormal. (CPU board or analog board is faulty.) Replace the AML main unit. (Replace the CPU board or analog board.) 213 W E

215 Error Message 4.5 For GR-120F-1 Only (Group Code 0) Error code: 0049 Message: [ シ フ カ チルトシテイマス ] Name: Jib tilt not fully lowered Status: The extension/retraction operation is prohibited in the status other than jib tilt fully lowered. (Prevention of an interference between the set horn and jib lock pin) Cause: The jib mounting/retraction operation is performed with the tilt full lowering detection OFF. When the connecting pin full extension is OFF and jib rotation retraction is ON, the boom retraction operation is performed with the tilt full lowering detection OFF. The tilt full lowering detector is faulty or incorrectly adjusted. Action: Perform the tilt lowering operation until relief is reached. If the error still exists, replace or readjust the tilt full lowering detector. Error code: 0097 Message: [ レンケツヒ ンケンシュツエラー ] Name: Connecting pin detection error [ レンケツヒ ンケンシュツ Di] [ クミアワセイシ ョウ ] Status: Abnormal connecting pin status in rotation operation (The rotation operation is prohibited with the connecting pin extended. Prevention of damage to the connecting pin.) Cause: The jib rotation operation is performed in the status other than "the connecting pin full extension detection OFF and connecting pin full extension detection ON." The connecting pin detector is faulty or incorrectly adjusted. Action: Perform the connecting pin retraction operation until relief is reached. If the error still exists, check the detector status in the Di check, and replace or readjust the abnormal detector. Error code: 0103 Message: [ シ フ シ ョウタイカ キケン ] Name: Jib not stowed completed [ シ フ ノシ ョウタイカ ] [ キケンナタメテイシ ] Status: Any operations not toward the retraction operation direction are prohibited when the connecting pin is off. Prevention of damage to the jib rotation motor. Cause: The major cause is the connecting pin full extension detection OFF, but the operation to be prohibited varies depending on the machine status. The connection pin is retracted unintentionally, or the connecting pin full extension detector is faulty or incorrectly adjusted. (1) When the boom operation is selected: (a) AML boom status "jib set" is selected - With the rotation retraction detection OFF and in the jib-extendable/retractable range, the swing operation is prohibited. (b) AML boom status "main hook" or "auxiliary hook" is selected - Main winch hoisting up, auxiliary winch hoisting up, boom elevation, boom extension, and swing operations are prohibited. (However, if the connecting pin full extension detection is turned OFF during swing operation, no stop is made. When the swing lever once returns to the neutral position, the swing operation is additionally prohibited.) (2) When the jib operation is selected: (a) AML boom status "jib set" is selected - With the rotation retraction detection OFF, the jib extension, jib raising, and swing operations are prohibited. - With the rotation retraction detection ON, the jib extension and jib raising operations are prohibited. (b) AML boom status "main hook" or " auxiliary hook" is selected - Main winch hoisting up, auxiliary winch hoisting up, jib raising and lowering, jib extension, and 214 W E

216 Error Message swing operations are prohibited. (However, if the connecting pin full extension detection is turned OFF during swing operation, no stop is made. When the swing lever once returns to the neutral position, the swing operation is additionally prohibited.) Action: Perform the connecting pin extension operation until relief is reached. If the error still exists, replace or readjust the connecting pin full extension detector. Error code: 0110 Message: [ シ フ カクノウフカンセ ン ] Name: Jib not retracted completely [ シ フ カ カンセ ンニ ] [ カクノウサレテイマセン ] Status: The boom operation is prohibited before the jib rotation retraction is completed (Prevention of an interference between the set horn and jib lock pin.) Prevention of damage to the jib rotation motor Cause: The major cause is the connecting pin full extension detection OFF, but the operation to be prohibited varies depending on the machine status. The connection pin is retracted unintentionally, or the connecting pin full extension detector is faulty or incorrectly adjusted. (1) When the boom operation is selected: (a) AML boom status "jib set" is selected - With the jib rotation retraction detection OFF and in the jib-extendable/retractable boom length or below, the boom retraction and swing operations are prohibited. - With the jib lock pin detection OFF and at the boom-extendable/retractable boom angle or below, the boom lowering operation is prohibited. However, this interlock can operate with the AML canceled. (2) When all operations are selected and the AML is canceled - With the jib lock pin detection OFF and at the boom-extendable/retractable boom angle or below, the boom lowering operation is prohibited. Action: Perform the rotation retraction operation until relief is reached. If the error still exists, replace or readjust the jib rotation retraction detector. Replace or readjust the jib lock pin detector. Error code: 0123 Message: [ ソウサニュウリョクイシ ョウ ] Name: Abnormal operation input Status: Abnormal operation select switch Cause: Both the switch operation input 1 (Di28) and switch operation input 2 (Di27) are turned ON. Both the switch operation input 3 (Di25) and switch operation input 4 (Di26) are turned ON. Both the jib mounting/retraction (extension) (Di22) and jib mounting/retraction (retraction) (Di23) are turned ON. Action: Replace or readjust the faulty switch. Error code: 0124 Message: [ ケンシュツイシ ョウ 1] [ シ フ ハリカクケンシュツ ] [ クミアワセイシ ョウ ] Status: Faulty jib mounting/retraction detector Cause: Action: Replace or readjust the abnormal detector. Name: Both the jib mounting detector and jib retraction detector are turned ON. Abnormal combination of jib extension/retraction detection 215 W E

217 Error Message Error code: 0125 Message: [ シ フ インターロックテイシ 1] [ ヘイヨウソウサキンシ ] Status: Cause: Action: Name: Simultaneous operation is prohibited in jib mounting operation Simultaneous operation is prohibited when the jib mounting/retraction operation is selected. Simultaneous operation other than main winch hoisting up and down, auxiliary winch hoisting up and down is performed when the jib mounting/retraction operation is selected. Abnormal operation detection switch If the error still exists when all the levers are engaged in the neutral position, replace the abnormal operation select switch. Error code: 0126 Message: [ シ フ セットエラー ] Name: Jib set error Status: Cause: Action: The jib mounting/retraction operation is prohibited with the jib full retraction detection OFF. (Because the extension/retraction is performed using the jib telescoping circuit as a power source) The jib is extended unintentionally, or the jib full retraction detector is faulty or incorrectly adjusted. Perform the jib retraction operation until relief is reached. If the error still exists, replace or readjust the jib full retraction detector. Error code: 0127 Message: [ シ フ インターロックテイシ 2] [ ハリタ シケンシュツエラー ] Status: Cause: Action: Name: Jib extension detection error The connecting pin extension operation is prohibited before the jib rotation extension is completed (Prevention of damage to the connecting pin.) The connecting pin extension operation is prohibited with the jib rotation extension detection OFF. The jib rotation extension detector is faulty and incorrectly adjusted. Perform the jib rotation extension operation until relief is reached. If the error still exists, replace or readjust the jib rotation extension detector. Error code: 0128 Message: [ シ フ インターロックテイシ 3] [ シ フ ノソウサキンシ ] Name: Extension operation prohibited at jib set Status: The jib extension operation is prohibited with the AML status "jib set." (Because the extension/retraction is performed using the jib telescoping circuit as a power source) Cause: Action: The jib extension operation is prohibited with the jib operation selection: AML status "jib set." If the error still exists when the lever is engaged in the neutral position, replace the operation detection switch. 216 W E

218 Error Message Error code: 0129 Message: [ シ フ インターロックテイシ 4] [ シ フ セットハンイカ イ ] Status: Cause: Action: Name: Jib set is out of range The jib extension/retraction operation is prohibited outside the jib rotation motor capacity range. The jib extension/retraction operation is prohibited outside the connecting pin status visible range. The jib extension/retraction operation is prohibited in the jib lock pin detected status. The boom operation is prohibited toward outside of the jib extension/retraction range with the jib set not completed. Prevention of damage to the jib rotation motor. The major cause is the operation outside the jib set range, but the operation to be prohibited varies depending on the machine status. The connection pin full extension detector is faulty or incorrectly adjusted. The jib lock pin detector is faulty or incorrectly adjusted. (1) When the boom operation is selected: (a) AML boom status "jib set" is selected - With the connecting pin full extension detection OFF and in the jib-extendable/retractable range length above, the boom extension operation is prohibited. - With the connecting pin full extension detection OFF, jib lock pin detection ON, and at the jib-retractable range angle or below, the boom extension operation is prohibited. However, this automatic stop disables the AML cancel. (2) When the jib rotation retraction, jib rotation extension, connecting pin extension, and connecting pin retraction operations are performed. - The jib extension/retraction operation is prohibited outside the extension/retraction range. (3) In all the statues of operation selected when the AML is canceled - With the connecting pin full extension detection OFF, jib lock pin detection ON, and at the jib-retractable range angle or below, the boom extension operation is prohibited. Perform the connecting pin extension operation until relief is reached. If the error still exists, replace or readjust the connecting pin full extension detector. Replace or readjust the jib lock pin detector. Error code: 0132 Message: [ ケンシュツイシ ョウ 3] [ カクノウシ ケンシュツキ ] [ クミアワセイシ ョウ ] Status: Abnormal detector status on retraction Cause: Action: Name: Abnormal combination of detectors on retraction When the jib lock pin is detected, the statuses other than the "tilt full lowering detection ON, jib rotation extension OFF, and jib rotation retraction ON" The jib lock pin detector is faulty or incorrectly adjusted. The tilt full lowering detector is faulty or incorrectly adjusted. The jib rotation extension detector is faulty or incorrectly adjusted. The jib rotation retraction detector is faulty or incorrectly adjusted. Replace or readjust the jib lock pin detector. Replace or readjust the tilt full lowering detector. Replace or readjust the jib rotation extension detector. Replace or readjust the jib rotation retraction detector. 217 W E

219 Error Message Error code: 0133 Message: [ ケンシュツイシ ョウ 4] [ シ ト ウヒ ンレンケツヒ ン ] [ クミアワセイシ ョウ ] Status: Cause: Action: Name: Abnormal combination of jib lock pin and connecting pin Abnormal combination of the jib automatic pin (jib lock pin) and connecting pin full extension detection. (Simultaneous detection of the jib retraction status and jib mounting status) Both the jib lock pin detection and connecting pin full extension detection are turned ON. The jib lock pin detector is faulty or incorrectly adjusted. The connecting pin full extension detector is faulty or incorrectly adjusted. Replace or readjust the detector different from the actual machine status. Error code: 0134 Message: [ ケンシュツイシ ョウ 2] [ レンケツヒ ンケンシュツ ] [ クミアワセイシ ョウ ] Status: Abnormal connecting pin detector Cause: Action: Name: Abnormal combination of connecting pin detection Both the connecting pin full extension detection and connecting pin full retraction detection are turned ON. The connecting pin full extension detector is faulty or incorrectly adjusted. The connecting pin full retraction detector is faulty or incorrectly adjusted. Replace or readjust the detector different from the actual machine status. Error code: 0135 Message: [ サフ フックカンショウ ] Name: Auxiliary hook block interference Status: Cause: Action: The auxiliary hook block interference is prevented. The jib raising, jib retraction, and boom elevation operations are prohibited in the auxiliary hook block interference range. Operate outside the auxiliary hook block interference range. Error code: 0136 Message: [ シ フ インターロックテイシ 5] [ フ ームキフクカケ ン ] Status: Cause: Action: Name: Elevation lower limit on jib setting The boom lowering operation is limited when the jib is set in the upper limit of the jib extendable/retractable range length or above. The boom lowering operation is performed in the jib extendable/retractable range length or above and at the jib extendable/retractable range angle or below. Operate at the jib extendable/retractable range angle or above. 218 W E

220 Disassembly of AML Main Unit Disassembly of AML Main Unit 1. Removing Front Panel/Display Board 2. Removing Rear Panel/Connector Board/Current Output Board [NOTICE] Do not touch each front and rear face of the boards by hand when removing the boards. [NOTICE] Do not touch each front and rear face of the boards by hand when removing the boards. 1. Remove the screws (c) and take off the rear panel, connector board, and current output board as an assembly from the main unit case. 1. Remove the screws (a) and take off the front panel and display board as an assembly from the main unit case. Connector board コネクタ基板 Current電流出力基板 output board Main unit case 本体ケース board 表示基板 Front panel Display 前面パネル 本体ケース unit case a Main IW J19 Rear panel 後面パネル c IW J21 2. Remove the screws (b) and separate the display board. 2. Remove the screws (d) and separate the current output board. Remove the spacers (e) and separate the connector board. コネクタ基板 Connector board 電流出力基板 output board e Current d b 表示基板 Display board IW J22 IW J W E

221 Disassembly of AML Main Unit 3. Removing CPU Board/Analog Board /Power Board [NOTICE] Do not touch each front and rear face of the boards by hand when removing the boards. 1. Remove the screws (a) and take off the front panel and display board as an assembly from the main unit case. Remove the screws (c) and take off the rear panel, connector board, and current output board as an assembly from the main unit case. Connector コネクタ基板 board Current 電流出力基板 output board Rear 後面パネル panel c 3.1 Notes on ROM/EEPROM Replacement [NOTICE] EEPROM stores the values for each specification number. When replacing the CPU board, remove the EEPROM from the broken CPU board and reuse it. When replacing ROM or EEPROM, make sure that the concavities of the IC and socket meet each other. Calendar/clock カレンダ / 時計 EEPROM ROM 1 Batteries 電池 CN4 PLD CN1 ROM 0 CPU CN2 CN3 a Main 本体ケース unit case 前面パネル Front panel Display 表示基板 board IW J23 CPU 基板 CPU board IW J25 2. Remove the screws (f) and separate the CPU board. Then, remove the spacers (h) and take off the analog board and power board as an assembly from the main unit case. Remove the nuts (g) and separate the analog board. Analog アナログ基板 board Power 電源基板 board Main 本体ケース unit case h g f CPU CPU board 基板 IW J W E

222 Adjustment Value Table [INFORMATION AND DATA] Adjustment Value Table Specification No.: GR-300N Specification No.: GR-300N Precautions for 1 Any shall be done with the single top extended and the auxiliary hook block mounted. AML model: AML-LIIA AML code No.: Adjustment item Boom length Boom angle Swing angle Outrigger extension width Jib angle Moment (A hook block with 30 t capacity is to be used.) Standard for swing output 217 Zero-point Span Zero-point Span Zero-point Span Zero-point Span Zero-point Span Zero-point Preliminary span Load radius Span fine Adjustment condition Boom length: Fully retracted Adjustment value 7.70 m Boom length: Fully extended m ±0.04 m Tolerance ±0.04 m (±0.08 m for zero-point check) Boom angle: 0.0 (actual ± value) (±0.2 for zero-point check) Boom angle: 80.0 (actual value) 80.0 ±0.1 Swing angle 1: ±0.3 Swing position: Front (right 0.0 (±0.6 ) swing) Swing angle 2: ± (±0.6 ) Swing position: Rear (right Swing angle 1: ±0.3 swing) Swing angle 2: ±0.3 Outrigger extension width: Min. Outrigger extension width: Max. Jib offset angle: Min. (Adjust the boom angle to 35.0 or lower.) m m ±0.006 m -5.0 Jib offset angle: Max ±0.2 Boom length: Fully retracted Boom angle: 80.0±0.1 (indicated value) Boom length: Fully retracted Boom angle: 10.0±0.1 (indicated value) Boom length: Fully extended Load radius: 7.00 m (actual value) Rated lifting capacity: 7.00 t Boom length: Fully extended Boom angle: 15.0±0.1 (indicated value) 0.26 t (Hook block mass) 0.26 t (Hook block mass) ±0.006 m (±0.012 m for zero-point check) ±0.2 (±0.4 for zero-point check) ±0.12 t ±0.04 t 7.00 m ±0.05 m 0.26 t (Hook block mass) ±0.01 t [NOTICE] For the AML telescoping control relay output, refer to "CN2 connector terminal No. 5" (page 26). 221 W E

223 Adjustment Value Table Specification No.: TR-250M Specification No.: GR-250N , Specification No.: GR-250N , AML model: AML-LIIA AML code No.: Setting before Head-off capacity setting Jib selection Capacity setting Single top selection Winch drum position setting Not set Not set Not set Not set 2. Detector Precautions for (*1) Adjust the center of dispersion to coincide with the value. (*2) Adjust the boom angle and the moment in the boom lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) Before adjusting the moment, set the number of parts of line to the standard number (four parts of line) for fully-extended boom, and set the boom status in the AML setting to "Boom." Adjustment item Zero-point Boom length Span Zero-point Boom angle (*2) Span Swing angle (*3) X-type outrigger extension width Power tilt jib angle Zero-point Span Zero-point Span Zero-point Span Adjustment condition Boom length: Fully retracted Adjustment value 9.50 m Boom length: Fully extended m ±0.04 m Boom angle: 0.0 (actual 0.0 value) Boom angle: 80.0 (actual value) Swing angle 1: Swing position: Front (right 0.0 swing) Swing angle 2: Swing angle 1: Swing position: Rear (right swing) Swing angle 2: Outrigger extension width: Min. Outrigger extension width: Max ± m Jib offset angle: Min Tolerance ±0.04 m (±0.08 m for zero-point check) ±0.1 (±0.2 for zero-point check) ±0.3 (±0.6 for zero-point check) ±0.3 (±0.6 for zero-point check) ±0.3 ± m ±0.006m Jib offset angle: Max ±0.1 ±0.006 m (±0.012 m for zero-point check) ±0.1 (±0.2 for zero-point check) 222 W E

224 Adjustment Value Table 1 Specification No.: TR-250M (260-kg main hook block) 1 Specification No.: GR-250N , (--FB3721, 260-kg main hook block) Boom length: Fully retracted Boom angle: 81.0±0.1 Zero-point (indicated value) 0.26 t Load: Without load (0.26 t hook (Hook block block only) mass) Hook block: Hoisted down close to the ground surface. Boom length: Fully retracted 1 Moment (A hook block with 25 t capacity is to be used.) (*2)(*4) Preliminary span Load radius Span fine Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.26 t hook block only) Hook block: Hoisted down close to the ground surface. Boom length: Fully extended Load radius: 8.00 m (actual value) Rated lifting capacity: 7 t Boom length: Fully extended Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.26 t hook block only) Hook block: Hoisted down close to the ground surface. 1 Specification No.: GR-250N , (FB3729--, 220-kg main hook block) 0.26 t (Hook block mass) ±0.13 t ±0.03 t 8.00 m ±0.05 m 0.26 t (Hook block mass) 1 Specification No.: GR-250N , (FB3752--, 220-kg main hook block) Boom length: Fully retracted 0.17 t Boom angle: 81.0±0.1 Hook block Zero-point (indicated value) mass Load: Without load (0.22 t hook minus block only) Wire rope Hook block: At the stop by mass overwinding Boom length: Fully retracted Moment (A hook block with 25 t capacity is to be used.) (*2)(*4) Preliminary span Load radius Span fine Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.22 t hook block only) Hook block: Hoisted down close to the ground surface. Boom length: Fully extended Load radius: 8.00 m (actual value) Rated lifting capacity: 7.00 t Boom length: Fully extended Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.22 t hook block only) Hook block: Hoisted down close to the ground surface t (Hook block mass) ±0.01 t ±0.13 t ±0.03 t 8.00 m ±0.05 m 0.22 t (Hook block mass) ±0.01 t 223 W E

225 Adjustment Value Table 3. Slow stop - Adjustment specification for swing control output: Boom raising and lowering characteristic measurement: Set - Telescoping/retraction characteristic measurement: Not set 4. Setting after - Setting of number of parts of line: Not set - Language variation: Not set [NOTICE] For the AML telescoping control relay output, refer to "CN2 connector terminal No. 5" (page 26). 224 W E

226 Adjustment Value Table Specification No.: TR-250M Specification No.: GR-250N , Specification No.: GR-250N , AML model: AML-LIIA AML code No.: Setting before Head-off capacity setting Jib selection Capacity setting Single top selection Winch drum position setting Not set Not set Not set Not set 2. Detector Precautions for (*1) Adjust the center of dispersion to coincide with the value. (*2) Adjust the boom angle and the moment in the boom lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) Before adjusting the moment, set the number of parts of line to the standard number (four parts of line) for fully-extended boom, and set the boom status in the AML setting to "Boom." Adjustment item Adjustment condition Adjustment value Tolerance ±0.04 m Zero-point Boom length: Fully retracted 9.50 m (±0.08 m for zero-point Boom length check) Boom angle (*2) Swing angle (*3) H-type outrigger extension width Power tilt jib angle Span Zero-point Span Zero-point Span Zero-point Span Zero-point Span Boom length: Fully extended Boom angle: 0.0 (actual value) Boom angle: 80.0 (actual value) Swing position: Front (right swing) m ±0.04 m ±0.1 Swing angle 1: 0.0 ±0.1 (±0.2 for zero-point check) ±0.3 (±0.6 for zero-point check) ±0.3 Swing angle 2: (±0.6 for zero-point check) Swing angle 1: ±0.3 Swing position: Rear (right swing) Swing angle 2: ±0.3 Outrigger extension width: Min. Outrigger extension width: Max m Jib offset angle: Min m ±0.006 m Jib offset angle: Max ±0.1 ±0.006 m (±0.012 m for zero-point check) ±0.1 (±0.2 for zero-point check) 225 W E

227 Adjustment Value Table 1 Specification No.: TR-250M (260-kg main hook block) 1 Specification No.: GR-250N , (--FB3728, 260-kg main hook block) Boom length: Fully retracted Boom angle: 81.0±0.1 (indicated value) 0.26 t Zero-point Load: Without load (0.26 t hook (Hook block block only) mass) Hook block: Hoisted down close to the ground surface. ±0.13 t 1 Moment (A hook block with 25 t capacity is to be used.) (*2)(*4) Preliminary span Load radius Span fine Boom length: Fully retracted Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.26 t hook block only) Hook block: Hoisted down close to the ground surface. Boom length: Fully extended Load radius: 8.00 m (actual value) Rated lifting capacity: 7.00 t Boom length: Fully extended Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.26 t hook block only) Hook block: Hoisted down close to the ground surface t (Hook block mass) ±0.03 t 8.00 m ±0.05 m 0.26 t (Hook block mass) ±0.01 t 1 Specification No.: GR-250N , (FB3746--, 220-kg main hook block) 1 Specification No.: GR-250N , (FB3751--, 220-kg main hook block) Boom length: Fully retracted 0.17 t Boom angle: 81.0±0.1 Hook block Zero-point (indicated value) mass Load: Without load (0.22 t hook minus block only) Wire rope Hook block: At the stop by mass overwinding Boom length: Fully retracted Moment (A hook block with 25 t capacity is to be used.) (*2)(*4) Preliminary span Load radius Span fine Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.22 t hook block only) Hook block: Hoisted down close to the ground surface. Boom length: Fully extended Load radius: 8.00 m (actual value) Rated lifting capacity: 7.00 t Boom length: Fully extended Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.22 t hook block only) Hook block: Hoisted down close to the ground surface t (Hook block mass) ±0.13 t ±0.03 t 8.00 m ±0.05 m 0.22 t (Hook block mass) ±0.01 t 226 W E

228 Adjustment Value Table 3. Slow stop - Adjustment specification for swing control output: Boom raising and lowering characteristic measurement: Set - Telescoping/retraction characteristic measurement: Not set 4. Setting after - Setting of number of parts of line: Not set - Language variation: Not set [NOTICE] For the AML telescoping control relay output, refer to "CN2 connector terminal No. 5" (page 26). 227 W E

229 Adjustment Value Table Specification No.: TR-250M Specification No.: TR-250M Specification No.: GR-250N , Specification No.: GR-250N , Specification No.: GR-250N , Specification No.: GR-250N , AML model: AML-LIIA AML code No.: Setting before Head-off capacity setting Jib selection Capacity setting Single top selection Winch drum position setting Not set Not set Not set Not set 2. Detector Precautions for (*1) Adjust the center of dispersion to coincide with the value. (*2) Adjust the boom angle and the moment in the boom lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) Before adjusting the moment, set the number of parts of line to the standard number (four parts of line) for fully-extended boom, and set the boom status in the AML setting to "Boom." Adjustment item Adjustment condition Adjustment value Tolerance ±0.04 m Zero-point Boom length: Fully retracted 9.50 m (±0.08 m for zero-point check) Boom length Boom angle (*2) Swing angle (*3) X-type outrigger extension width Span Zero-point Span Zero-point Span Zero-point Span Boom length: Fully extended m ±0.04 m Boom angle: 0.0 (actual value) Boom angle: 80.0 (actual value) Swing position: Front (right swing) ±0.1 Swing angle 1: 0.0 ±0.1 (±0.2 for zero-point check) ±0.3 (±0.6 for zero-point check) ±0.3 Swing angle 2: (±0.6 for zero-point check) Swing angle 1: ±0.3 Swing position: Rear (right swing) Swing angle 2: ±0.3 Outrigger extension width: Min. Outrigger extension width: Max m m ±0.006 m ±0.006 m (±0.012 m for zero-point check) 228 W E

230 Adjustment Value Table 1 Specification No.: TR-250M , (260-kg main hook block) 1 Specification No.: GR-250N , 00203, 00107, 00207, 00108, (--FB3724, 260-kg main hook block) 1 Specification No.: GR-250N , (--FB3722, 260-kg main hook block) Boom length: Fully retracted Boom angle: 81.0±0.1 (indicated value) 0.26 t Zero-point Load: Without load (0.26 t hook (Hook block block only) mass) Hook block: Hoisted down close to the ground surface. 1 Moment (A hook block with 25 t capacity is to be used.) (*2)(*4) Preliminary span Load radius Span fine Boom length: Fully retracted Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.26 t hook block only) Hook block: Hoisted down close to the ground surface. Boom length: Fully extended Load radius: 8.00 m (actual value) Rated lifting capacity: 7.00 t Boom length: Fully extended Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.26 t hook block only) Hook block: Hoisted down close to the ground surface t (Hook block mass) ±0.13 t ±0.03 t 8.00 m ±0.05 m 0.26 t (Hook block mass) ±0.01 t 229 W E

231 Adjustment Value Table 1 Specification No.: GR-250N , 00203, 00107, 00207, 00108, (--FB3743, 220-kg main hook block) 1 Specification No.: GR-250N , (FB3745--, 220-kg main hook block) Boom length: Fully retracted 0.17 t Boom angle: 81.0±0.1 Hook block (indicated value) Zero-point mass Load: Without load (0.22 t hook minus block only) Wire rope Hook block: At the stop by mass overwinding Moment (A hook block with 25 t capacity is to be used.) (*2)(*4) Preliminary span Load radius Span fine Boom length: Fully retracted Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.22 t hook block only) Hook block: Hoisted down close to the ground surface. Boom length: Fully extended Load radius: 8.00 m (actual value) Rated lifting capacity: 7.00 t Boom length: Fully extended Boom angle: 10.0 ±0.1 (indicated value) Load: Without load (0.22 t hook block only) Hook block: Hoisted down close to the ground surface t (Hook block mass) ±0.13 t ±0.03 t 8.00 m ±0.05 m 0.22 t (Hook block mass) ±0.01 t 3. Slow stop - Adjustment specification for swing control output: Boom raising and lowering characteristic measurement: Set - Telescoping/retraction characteristic measurement: Not set 4. Setting after - Setting of number of parts of line: Not set - Language variation: Not set [NOTICE] For the AML telescoping control relay output, refer to "CN2 connector terminal No. 5" (page 26). 230 W E

232 Adjustment Value Table Specification No.: GR-350N Specification No.: GR-350N AML model: AML-LIIA AML code No.: Setting before Head-off capacity setting Jib selection Capacity setting Single top selection Winch drum position setting Not set Not set Not set Not set 2. Detector Precautions for (*1) Any shall be done with the single top extended and the auxiliary hook block mounted. (*2) Adjust the center of dispersion to coincide with the value. (*3) Adjust the boom angle and the moment in the boom lowering operation. (*4) Adjust the swing angle in the clockwise swing operation. (*5) Before adjusting the moment, set the number of parts of line to the standard number (four parts of line) for fully-extended boom under the intermediate hook status with the removable sheave removed, and set the boom status in the AML setting to "Boom." Boom length Boom angle (*3) Swing angle (*4) Adjustment item Adjustment condition Adjustment value Tolerance Zero-point Span Zero-point Span Zero-point Span Boom length: Fully retracted 9.50 m Boom length: Fully extended m ±0.04 m Boom angle: 0.0 (actual value) 0.0 Boom angle: 80.0 (actual value) 80.0 ±0.1 Swing position: Front (right swing) Swing angle 1: 0.0 Swing angle 2: Swing angle 1: Swing position: Rear (right swing) Swing angle 2: ±0.04 m (±0.08 m for zero-point check) ±0.1 (±0.2 for zero-point check) ±0.3 (±0.6 for zero-point check) ±0.3 (±0.6 for zero-point check) ±0.3 ± W E

233 Adjustment Value Table Outrigger extension width Power tilt jib angle Zero-point Span Zero-point Span Outrigger extension width: Min m Outrigger extension width: Max m ±0.006 m Jib offset angle: Min Jib offset angle: Max ±0.1 ±0.006 m (±0.012 m for zero-point check) ±0.1 (±0.2 for zero-point check) 232 W E

234 Adjustment Value Table Moment (*1)(*3)(*5) Adjustment item Adjustment condition Adjustment value Tolerance Zero-point Preliminary span Load radius Span fine Boom length: Fully retracted Boom angle: 80.0±0.1 (indicated value) Load: Without load (0.21 t hook block ± 0.07 t hook block) Intermediate hook and auxiliary hook block: At the stop by overwinding Boom length: Fully retracted 0.16 t Hook block weight minus Wire rope mass ±0.16 t Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.21 t hook block t hook block) 0.28 t Auxiliary hook block: At the (Hook block mass) ±0.04 t stop by overwinding Intermediate hook: Hoisted down close to the ground surface. Boom length: Fully extended Load radius: 8.00 m (actual value) Rated gross weight: 7.00 t Boom length: Fully extended 8.00 m ±0.06 m Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.21 t hook block t hook block) 0.28 t Auxiliary hook block: At the (Hook block mass) ±0.01 t stop by overwinding Intermediate hook: Hoisted down close to the ground surface. 3. Slow stop - Adjustment specification for swing control output: Boom raising and lowering characteristic measurement: Set - Telescoping/retraction characteristic measurement: Not set 4. Setting after - Setting of number of parts of line: Not set - Language variation: Not set [NOTICE] For the AML telescoping control relay output, refer to "CN2 connector terminal No. 5" (page 26). 233 W E

235 Adjustment Value Table Specification No.: GR-350N Specification No.: GR-350N AML model: AML-LIIA AML code No.: Setting before Capacity setting Head-off capacity setting Jib selection Single top selection Winch drum position setting Not set Not set Not set Not set 2. Detector Precautions for (*1) Any shall be done with the single top retracted and the auxiliary hook block dismounted. (*2) Adjust the center of dispersion to coincide with the value. (*3) Adjust the boom angle and the moment in the boom lowering operation. (*4) Adjust the swing angle in the clockwise swing operation. (*5) Before adjusting the moment, set the number of parts of line to the standard number (four parts of line) for fully-extended boom, and set the boom status in the AML setting to "Boom." Adjustment item Adjustment condition Adjustment value Tolerance Zero-point Boom length Span Zero-point Boom angle (*3) Span Swing angle (*4) Outrigger extension width Zero-point Span Zero-point Span Boom length: Fully retracted 9.50 m Boom length: Fully extended m ±0.04 m ±0.04 m (±0.08 m for zero-point check) Boom angle: 0.0 (actual ±0.1 value) 0.0 (±0.2 for zero-point check) Boom angle: 80.0 (actual value) 80.0 ±0.1 Swing angle 1: ±0.3 Swing position: Front (right 0.0 (±0.6 for zero-point check) swing) Swing angle 2: ± (±0.6 for zero-point check) Swing angle 1: Swing position: Rear (right ±0.3 swing) Swing angle 2: ±0.3 ±0.006 m Outrigger extension width: m Min. (±0.012 m for zero-point check) Outrigger extension width: Max m ±0.006 m 234 W E

236 Adjustment Value Table Moment (*1)(*3)(*5) Adjustment item Adjustment condition Adjustment value Tolerance Boom length: Fully retracted 0.21 t Boom angle: 80.0±0.1 Hook block Zero-point (indicated value) weight Load: Without load (0.33 t ±0.16 t minus hook block) Wire rope Main hook block: At the stop by mass overwinding Load radius Span fine Boom length: Fully extended Load radius 7.00 m (actual value) Rated gross weight: t Boom length: Fully extended Boom angle: 10.0±0.1 (indicated value) Load: Without load (0.33 t hook block) Main hook block: Hoisted down close to the ground surface m ±0.05 m 0.33 t (Hook block mass) ±0.02 t 3. Slow stop - Adjustment specification for swing control output: Boom raising and lowering characteristic measurement: Set - Telescoping/retraction characteristic measurement: Not set 4. Setting after - Setting of number of parts of line: Not set - Language variation: Not set [NOTICE] For the AML telescoping control relay output, refer to "CN2 connector terminal No. 5" (page 26). 235 W E

237 Adjustment Value Table Specification No.: GR-160N Specification No.: GR-160N AML model: AML-LIIA AML Code No.: , Setting before Capacity setting Head-off capacity setting Jib selection Single top selection Winch drum position setting Not set Not set Not set Not set 2. Detector Precautions for (*1) Adjust the center of dispersion to coincide with the value. (*2) Adjust the boom angle and the moment in the boom lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) Before adjusting the moment, set the number of parts of line to the standard number (four parts of line) for fully-extended boom, and set the boom status in the AML setting to "Boom." Adjustment Adjustment item Adjustment condition Tolerance value ±0.04 m Zero-point Boom length: Fully retracted 6.50 m (±0.08 m for zero-point Boom length check) Span Boom length: Fully extended m ±0.04 m Zero-point Boom angle (*3) Span Swing angle (*4) X-type outrigger extension width H-type outrigger extension width Zero-point Span Zero-point Span Zero-point Span Boom angle: 0.0 (actual ± value) (±0.2 m for zero-point check) Boom angle: 80.0 (actual value) 80.0 ±0.1 Swing angle 1: ±0.3 Swing position: Front (right 0.0 (±0.6 for zero-point check) swing) Swing angle 2: ± (±0.6 for zero-point check) Swing angle 1: Swing position: Rear (right ±0.3 swing) Swing angle 2: ±0.3 ±0.006 m Outrigger extension width: m Min. (±0.012 m for zero-point check) Outrigger extension width: Max m ±0.006 m Outrigger extension width: Min. Outrigger extension width: Max m m ±0.006 m ±0.006 m (±0.012 m for zero-point check) 236 W E

238 Adjustment Value Table Moment (*3)(*5) Zero-point Preliminary span Load radius Span fine Boom length: Fully retracted Boom angle: 80.0±0.1 (indicated value) Load: Without load Hook block: At the stop by overwinding Boom length: Fully retracted Boom angle: 10.0±0.1 (indicated value) Load: Without load Hook block: Hoisted down close to the ground surface. Boom length: Fully extended Load radius: 7.00 m (actual value) Rated lifting capacity: 3.50 t Boom length: Fully extended Boom angle: 20.0±0.1 (indicated value) Load: Without load Hook block: Hoisted down close to the ground surface t Hook block weight minus Wire rope mass 0.14 t (Hook block mass) ±0.07 t ±0.03 t 7.00 m ±0.05 m 0.14 t (Hook block mass) ±0.01 t 3. Slow stop - Adjustment specification for swing control output: Boom raising and lowering characteristic measurement: Set - Telescoping/retraction characteristic measurement: Not set 4. Setting after - Setting of number of parts of line: Not set - Language variation: Not set [NOTICE] For the AML telescoping control relay output, refer to "CN2 connector terminal No. 5" (page 43). 237 W E

239 Adjustment Value Table Specification No.: GR-120F AML model: AML-LIIA AML code No.: Setting before Capacity setting Head-off capacity setting Jib selection Single top selection Winch drum position setting Not set Not set Not set Not set 2. Detector Precautions for 1 (*1) Adjust the center of dispersion to coincide with the value. (*2) Adjust the boom angle and the moment in the boom lowering operation. (*3) Adjust the boom angle with the AML boom status setting being "jib set." (If the AML boom status setting is other than "jib set," when the jib angle to ground is horizontal or below, the boom elevation is no longer lowered.) (*4) Adjust the swing angle in the clockwise swing operation. (*5) Adjust the jib length within the tilt angle range of 25 to 26. (With the tilt angle being in the range of 7.3 to 25, the jib will not be lowered to 5.0 m or below.) (*6) Adjust the power tilt jib with the boom fully retracted, jib length being 5.0 m, boom elevating angle being 80, and the AML boom status setting being "jib set," and follow the procedure below. (1) Install a digital goniometer onto the base jib and raise the jib until the jib tilt cylinder reaches the stroke end. In this state, adjust the AML zero-point and reset the digital goniometer. (2) Lower the tilt until the digital goniometer indicates 67.7 (= ) and adjust the AML span point. (*7) Before adjusting the moment, set the number of parts of line to four parts of line and set the AML boom status setting to "main operation." Boom length Adjustment item Zero-point Span Boom Zero-point angle (*2)(*3) Span Swing angle (*4) Zero-point Span Adjustment condition Boom length: Fully retracted Adjustment value 5.52 m Boom length: Fully extended m ±0.04 m Tolerance ±0.04 m (±0.08 m for zero-point check) Boom angle: 3.0 (actual ± value) (±0.2 for zero-point check) Boom angle: 80.0 (actual value) 80.0 ±0.1 Swing angle 1: ±0.3 Swing position: Front (right 0.0 (±0.6 for zero-point check) swing) Swing angle 2: ± (±0.6 for zero-point check) Swing angle 1: Swing position: Rear (right ±0.3 swing) Swing angle 2: ± W E

240 Adjustment Value Table H-type outrigger extension width Adjustment item Zero-point Span Zero-point Jib length (*5) Span Zero-point Power tilt Jib angle (*6) Moment (*2)(*7) Span Zero-point Load radius Span fine Adjustment condition Outrigger extension width: Min. Outrigger extension width: Max. Jib length: Fully retracted Adjustment value m m ±0.006 m m Jib length: Fully extended m ±0.04 m Jib offset angle: Min Jib offset angle: Max ±0.1 Boom length: Fully retracted Jib length: (5.0 m) Tilt angle (Min. 7.3 ) Boom angle: 80.0±0.1 (indicated value) Load: Without load Hook block: At the stop by overwinding Boom length: Fully extended Jib length: (5.0 m) Tilt angle (Min. 7.3 ) Load radius: 3.50 m (actual value) Rated lifting capacity: 4.30 t (M Hook block mass: 0.07 t) Boom length: Fully extended Jib length: (5.0 m) Tilt angle (Min. 7.3 ) Boom angle: 45.0±0.1 (indicated value) Load: Without load Hook block: Hoisted down close to the ground surface t Hook block mass minus Wire rope mass Tolerance ±0.006 m (±0.012 m for zero-point check) ±0.04 m (±0.08 m for zero-point check) ±0.1 (±0.2 m for zero-point check) ±0.03 t 3.50 m ±0.04 m 0.07 t ±0.01 t 239 W E

241 Adjustment Value Table 3. Slow stop - Adjustment specification for swing control output: Boom raising and lowering characteristic measurement: Set Adjust the boom raising and lowering characteristic measurement with the boom fully retracted, jib length being 5.0 m, and tilt angle being the minimum. In addition, before setting the AML boom status, set it to "jib set" first and cancel the AML. - Telescoping/retraction characteristic measurement: Not set 4. Speed - Adjust it according to the GR-120F-1 (Pythagoras) speed procedure. 5. Setting after - Setting of number of parts of line: Not set - Language variation: Not set 240 W E

242 Adjustment Value Table GR-120F-1 (Pythagoras) speed procedure The GR-120F1-1 (Pythagoras) speed consists of the following five menu items. [ シ フ ソクト チョウセイ ]: Jib telescoping speed (adjusts the telescoping speed on jib 4th to 6th sections.) [ ヒレイ V セ ロチョウセイ ]: Proportional valve zero-point (adjusts all the throttle point of proportional valve for jib telescoping.) [ チルトサイコウソクチョウセイ ]: Jib tilt maximum speed (adjusts to 100% speed in tilt speed mode.) [ フ ームソクト チョウセイ ]: Boom telescoping speed (adjusts the speed around the switch point on boom 2nd and 3rd sections.) [ センカイソクト チョウセイ ]: Swing speed (adjusts the swing limit speed on the jib mounting/retraction.) 1. Operation method - When you press the <+> key or <-> key, the value increases or decreases. When you press once, the value will increase or decrease by 1%. When you press and hold the corresponding key, the value will increase or decrease by 10%. If you press the <+> key or <-> key while moving the control lever toward the desired operating direction, the value of each operating direction can be adjusted individually. (The proportional valve zero-point is excluded.) - To confirm the adjusted value, press the <set> key to reflect and save the value, and then the display returns to the menu. To cancel the adjusted value, press the <display alternation> key to cancel the value, and then the display returns to the menu. 2. Adjustment procedures The GR-120F1-1 (Pythagoras) speed is performed as follows: (1) Proportional valve zero-point (2) Jib telescoping speed (3) Tilt maximum speed (* shall be performed after the boom elevation measurement.) (4) Boom telescoping speed (* Initial set value: Shall be checked "Extend 20% Retract 20%" only.) (5) Swing speed (* Initial set value: Shall be checked "Right 78% Left 78%" only.) [Notice] * The order of (1) (2) shall be strictly observed, but (3) can be performed earlier. (If the order of (1) (2) is not observed, the cannot be performed correctly.) * (4) Boom telescoping speed shall be basically a fixed value according to the data setting. If impact is larger, adjust it. * (5) Swing speed shall be basically a fixed value according to the data setting. 1) Proportional valve zero-point procedure This operation adjusts the border point of the proportional valve on which the jib telescoping starts moving. 241 W E

243 Adjustment Value Table (1) Operation configuration Boom length: Fully retracted Boom angle: 70 Jib length: 9 to 10 m (* Shall be in this range.) Tilt angle: 30 Selected operation: Jib AML status: Auxiliary winch operation (2) Jib telescoping speed setting Set the telescoping speed on the jib 4th to 6th sections to 0% so that the output to the proportional valve is set to full throttle. On the menu, select [ シ フ ソクト チョウセイ ] to set the value to 0%. [ シ フ ソクト チョウセイ ] Press the <set> key to select. [Extend 40% Retract 40%] Press the <-> key to set the value to 0%. (Initial value: 40%) When both Extend and Retract are set to 0%, press the <set> key to confirm. [Extend 0% Retract 0%] Press the <set> key to confirm. (3) Proportional valve zero-point On the menu, select [ ヒレイ V セ ロチョウセイ ]. [ ヒレイ V セ ロチョウセイ ] Press the <set> key to select. Set the value by pressing the <+> key or <-> key. [Zero-point 40%] Press the <+> key or <-> key to increase or decrease the value, and press the <set> key to confirm. (* The value is an example.) Perform the jib telescoping operation and check that the jib 4th to 6th sections do not move. If the section(s) move, select [ ヒレイ V セ ロチョウセイ ] again to change the value. Repeat this operation to find the value (in increments of 1%) in which the jib does not move. When you find the border between the value in which the jib moves and that in which the jib does not move, set to the value in which the jib does not move, and exit from the operation. 2) Jib telescoping speed This operation adjusts the telescoping speed on the jib 4th to 6th sections. (1) Operation configuration Boom length: Fully retracted Boom angle: Maximum Jib length: 5 m Tilt angle: Minimum Selected operation: Jib AML status: Auxiliary winch operation 242 W E

244 Adjustment Value Table (2) Jib telescoping speed On the menu, select the jib telescoping speed. [ シ フ ソクト チョウセイ ] Press the <set> key to select. Set the value for each of Extend and Retract. [Extend 30% Retract 30%] Press the <+> key or <-> key to increase or decrease the value, and press the <set> key to confirm. (* The value is an example.) [Notice] If you want to set the value for each operation individually, press the <+> key or <-> key while moving the control lever toward the desired operating direction. The machine moves at this time, but the value being set now is not reflected. Pressing the <set> key enables the set value. If the operation configuration changes depending on the operation, return to the configuration specified above. (3) Jib telescoping speed measurement With the maximum engine speed, measure the duration of jib movement from length of 5 m to fully extended status and also that from fully extended status to 5 m. If one of the measured values is out of the standard value range, return to (2) Jib telescoping speed, correct the deviated value, and measure it again. Repeat this operation until the jib telescoping duration enters the standard value range. However, if the extending value is less than Extend 15%, set with Extend 15%. And if the retracting value is less than Retract 20%, set with Retract 20%. [Notice] The auxiliary winch hook block position changes with telescoping movement. Be extremely careful during the operation. If the auxiliary winch hook block is in overwinding condition or about to contact the ground, operate the winch to avoid such conditions. [Standard values] Jib extension duration: 28.5±1.5 s (27.0 to 30.0 s) Jib retraction duration: 36.0±4.0 s (32.0 to 40.0 s) 3) Jib tilt maximum speed This operation adjusts the jib tilt maximum speed. (1) Operation configuration Boom length: Fully retracted Boom angle: 75 Jib length: 5 m Tilt angle: 75 Selected operation: Jib 243 W E

245 Adjustment Value Table AML status: Auxiliary winch operation * The boom elevation slow stop shall be canceled in advance. (2) Jib tilt maximum speed On the menu, select the jib tilt maximum speed. [ チルトサイコウソクチョウセイ ] Press the <set> key to select. Set the value for each of up and down operation. (Initial value: 100% for both Up and Down) [UP 50% Down 90%] Press the <+> key or <-> key to increase or decrease the value, and press the <set> key to confirm. (* The value is an example.) [Notice] If you want to set the value for each operation individually, press the <+> key or <-> key while moving the control lever toward the desired operating direction. The machine moves at this time, but the value being set is not reflected. Pressing the <set> key enables the set value. If the operation configuration changes depending on the operation, return to the configuration specified above. (3) Tilt speed measurement With the maximum engine speed, measure the duration of jib tilt movement from the horizontal position (tilt lower limit stop angle) to the minimum tilt angle and also that from the minimum tilt angle to the horizontal position (tilt lower limit stop angle). If one of the measured values is out of the standard value range, return to (2) Jib tilt maximum speed, correct the deviated value, and measure it again. Repeat this operation until the jib tilt duration enters the standard value range. [Notice] The hook block position changes with tilt movement. Be extremely careful during the operation. In addition, be extremely careful not to hit the main hook block to the tilt cylinder during the operation. [Standard values] Tilt up duration: 19.0±1.0 s (18.0 to 20.0 s) Tilt down duration: 24.0±4.0 s (20.0 to 28.0 s) 244 W E

246 Adjustment Value Table Specification Number: GA-700N AML model: AML-LIIA AML code No.: Setting before Capacity setting Head-off capacity setting Jib selection Single top selection Winch drum position setting Not set Not set Not set Not set 2. Detector Precautions for (*1) Adjust the center of dispersion to coincide with the value. (*2) Adjust the boom angle and the moment in the boom lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) Before adjusting the moment, set the number of parts of line to the standard number (four parts of line) for fully-extended boom. (*5) Adjust the power tilt jib angle to the actual measured angle by the tilt lowering operation. (When adjusting at a point other than the stroke end) Boom length Adjustment item Adjustment condition Adjustment value Tolerance ±0.04 m Zero-point Boom length: Fully retracted m (±0.08 m for zero-point check) Boom angle (*2) Swing angle (*3) Outrigger extension width Jib length Span Zero-point Span Zero-point Span Zero-point Span Zero-point Span Boom length: Fully extended m ±0.04 m Boom angle: 0.0 (actual value) 0.0 ±0.1 (±0.2 m for zero-point check) Boom angle: 80.0 (actual value) 80.0 ±0.1 Swing position: Front (right Swing angle 1: 0.0 ±0.3 (±0.6 for zero-point check) swing) Swing angle 2: ± (±0.6 for zero-point check) Swing angle 1: Swing position: Rear (right ±0.3 swing) Swing angle 2: ±0.3 ±0.01 m Outrigger extension width: m Min. (±0.02 m for zero-point check) Outrigger extension width: Max m ±0.01 m ±0.02 m Jib length: Fully retracted 9.70 m (±0.04 m for zero-point check) Jib length: Fully extended m ±0.02 m 245 W E

247 Adjustment Value Table Power tilt Jib angle Moment (A hook block with 50 t capacity is to be used.) (A counterweight of 5.6 t is mounted.) (A front jack is used.) Zero-point Span Zero-point Preliminary span Load radius Span fine Jib offset angle: 5.0 (actual value) (The jib tilt cylinder shall not be fully extended.) Jib offset angle: 60.0 (actual value) (The jib tilt cylinder shall not be fully retracted.) Boom length: Fully retracted Boom angle: 80.0±0.1 (indicated value) Load: Without load (50 t hook block only) Hook block: At the stop by overwinding Boom length: Fully retracted Boom angle: 10.0±0.1 (indicated value) Load: Without load (50 t hook block only) Hook block: Hoisted down close to the ground surface. Boom length: Fully extended Load radius: m (actual value) Rated lifting capacity: 8 t Boom length: Fully extended Boom angle: 45.0±0.1 (indicated value) Load: Without load (50 t hook block only) Hook block: Hoisted down close to the ground surface ±0.1 (±0.2 for zero-point check) ± t Hook block weight minus Wire rope mass 0.50 t (Hook block mass) ±0.24 t ±0.05 t m ±0.08 m 0.50 t (Hook block mass) ±0.02 t 3. Slow stop - Adjustment specification for swing control output: Boom raising and lowering characteristic measurement: Set - Telescoping/retraction characteristic measurement: Set 4. Setting after - Setting of number of parts of line: Not set - Language variation: Not set [NOTICE] For the AML telescoping control relay output, refer to "CN2 connector terminal No. 5" (page 77). 246 W E

248 MDT Input/Output Nos. and Corresponding Signals Specification Number: GA-700N AML model: AML-LIIA AML code No.: Setting before Capacity setting Head-off capacity setting Jib selection Single top selection Winch drum position setting Not set Not set Not set Not set 2. Detector Precautions for (*1) Adjust the center of dispersion to coincide with the value. (*2) Adjust the boom angle and the moment in the boom lowering operation. (*3) Adjust the swing angle in the clockwise swing operation. (*4) Before adjusting the moment, set the number of parts of line to the standard number (four parts of line) for fully-extended boom. (*5) Adjust the power tilt jib angle to the actual measured angle by the tilt lowering operation. (When adjusting at a point other than the stroke end) Boom length Adjustment item Adjustment condition Adjustment value Tolerance Boom angle (*2) Swing angle (*3) Outrigger extension width Jib length Zero-point Span Zero-point Span Zero-point Span Zero-point Span Zero-point Span Boom length: Fully retracted m Boom length: Fully extended m ±0.04 m Boom angle: 0.0 (actual value) Boom angle: 80.0 (actual value) Swing position: Front (right swing) ±0.1 ±0.04 m (±0.08 m for zero-point check) ±0.1 (±0.2 for zero-point check) ±0.3 Swing angle 1: 0.0 (±0.6 for zero-point check) ±0.3 Swing angle 2: (±0.6 for zero-point check) Swing angle 1: ±0.3 Swing position: Rear (right swing) Swing angle 2: ±0.3 Outrigger extension width: Min. Outrigger extension width: Max. Jib length: Fully retracted m m ±0.01 m m Jib length: Fully extended m ±0.02 m ±0.01 m (±0.02 m for zero-point check) ±0.02 m (±0.04 m for zero-point check) 247 W E

249 MDT Input/Output Nos. and Corresponding Signals Power tilt Jib angle Moment (A hook block with 50 t capacity is to be used.) (A counterweight of 5.6 t is mounted.) (A front jack is used.) Zero-point Span Zero-point Preliminary span Load radius Span fine Jib offset angle: 5.0 (actual value) (The jib tilt cylinder shall not be fully extended.) Jib offset angle: 60.0 (actual value) (The jib tilt cylinder shall not be fully retracted.) Boom length: Fully retracted Boom angle: 80.0±0.1 (indicated value) Load: Without load (50 t hook block only) Hook block: At the stop by overwinding Boom length: Fully retracted Boom angle: 10.0±0.1 (indicated value) Load: Without load (50 t hook block only) Hook block: Hoisted down close to the ground surface. Boom length: Fully extended Load radius: m (actual value) Rated lifting capacity: 8.00 t Boom length: Fully extended Boom angle: 45.0±0.1 (indicated value) Load: Without load (50 t hook block only) Hook block: Hoisted down close to the ground surface ± t Hook block mass minus Wire rope mass 0.50 t (Hook block mass) ±0.1 (±0.2 m for zero-point check) ±0.24 t ±0.05 t m ±0.08 m 0.50 t (Hook block mass) ±0.02 t 3. Slow stop - Adjustment specification for swing control output: Boom raising and lowering characteristic measurement: Set - Telescoping/retraction characteristic measurement: Set 4. Setting after - Setting of number of parts of line: Not set - Language variation: Not set [NOTICE] For the AML telescoping control relay output, refer to "CN2 connector terminal No. 5" (page 77). 248 W E

250 Checking the Detectors (GR-300N-1) Checking the Detectors (GR-300N-1) 1. Boom Length Detector 1. Retract the boom fully, set the boom angle to 0, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector. Then pull out the CN1 connector and measure resistance of the potentiometer. The specified resistance values are as follows: Resistance value 2-1: 833±167 Ω 3-1: 458±92 Ω Boom angle detector Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: Applicable serial No. Resistance value Up to FC5113 C-D: 833±167 Ω B-D: 458±92 Ω Boom length detector Boom ブーム角度検出器 angle detector DET1SLD 6 E DET1SRC 2 C A E ANAINB 4 A B C D ANAINA 3 DET1GND 1 B D Boom length detector ブーム長さ検出器 IW J10 Applicable serial No. Resistance value From FC5114 R-G: 833±167 Ω W-G: 458±92 Ω Shield Boom angle detector Plug Shield Boom length detector 249 W E

251 Checking the Detectors (GR-300N-1) 2. Boom Angle Detector 1. Retract the boom fully, set the boom angle to 0, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: Applicable serial No. Resistance value Up to FC5113 C-D: 833±167 Ω A-D: 146±29 Ω Boom ブーム角度検出器 angle detector Resistance value 2-1: 833±167 Ω 4-1: 146±29 Ω Boom angle detector DET1SLD 6 DET1SRC 2 E C Boom length detector A E ANAINB 4 A B C D ANAINA 3 DET1GND 1 B D Boom length detector ブーム長さ検出器 IW J10 Applicable serial No. Resistance value From FC5114 R-G: 833±167 Ω B-G: 146±29 Ω Boom angle detector Shield Plug Shield Boom length detector 250 W E

252 Checking the Detectors (GR-300N-1) 3. Swing Angle Detector 1. Swing the boom to over-left-side and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 500±75 Ω W-B: 0-15 Ω 4. Outrigger Extension Width Detector 1. Stow the outriggers and set the starter switch to "OFF." 2. The potentiometer may be damaged if the detector wire is further wound, therefore move the hoisting prevention fitting to the guide hole of the detector and fix it there. Then remove the wire from the outrigger and hold the wire, letting it protruding by 630 mm from the guide hole of the detector. G プラグ Plug W DET1SLD 6 DET1SRC 2 ANAINC 5 シールド Shield R W Winding prevention fitting 巻込み防止金具 R Shield シールド B ANAIND 9 DET1GND 1 G B IW J11 Checking at the CN1 connector of the AML Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 500±75 Ω 5-1: 0-15 Ω 630 mm IW J12 3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 2000±100 Ω W-B: 200±30 Ω 5V AVCC R W B R Input 入力 Ai1 W FL GND AGND B IW J DET1SLD 6 DET1SRC 2 Shield シールド R ANAINC 5 W ANAIND 9 DET1GND 1 G B 30 1 IW J W E

253 Checking the Detectors (GR-300N-1) 5. Pressure Sensor for Moment Detection 1. Set the PTO switch to "ON." (5-V DC will be applied between R and B of the pressure sensor connector.) 2. Measure the output voltage between W and B of the pressure sensor connector. 6. Jib Angle Detector 1. Stow the jib and set the PTO switch to "OFF." 2. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D: 1000±150 Ω B-D: In the range between 52 and 58% of the value measured between C and D. DET3SRC 33 R W B R ANAING 34 SPS3 W (ANAINH 35) (SPS4) DET3GND 32 B IW E14 3. The output voltage between W and B is proportional to the pressure in the elevating cylinder. The specified value is as shown below. E D B C Shield AGND シールド (FG) Ai1 AVCC E D A B C IW J26 Output 出力電圧 voltage (V (V DC) DC) Pressure 圧力 (MPa) 35 IW J W E

254 Checking the Detectors (TR-250M-7) Checking the Detectors (TR-250M-7) 1. Boom Length Detector 1. Retract the boom fully, set the boom angle to 0, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: Resistance value 2-1: 833±167 Ω 3-1: 458±92 Ω Boom angle detector Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: Applicable serial No. Resistance value Up to FB4053 C-D: 833±167 Ω A-D: 458±92 Ω Boom ブーム角度検出器 angle detector Boom length detector DET1SLD 6 E DET1SRC 2 C A E ANAINB 4 A B C D ANAINA 3 DET1GND 1 B D Boom ブーム長さ検出器 length detector IW J10 Applicable serial No. Resistance value From FB4054 R-G: 833±167 Ω W-G: 458±92 Ω Shield Boom angle detector Plug Shield Boom length detector 253 W E

255 Checking the Detectors (TR-250M-7) 2. Boom Angle Detector 1. Retract the boom fully, set the boom angle to 0, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: Applicable serial No. Resistance value Up to FB4053 C-D: 833±167 Ω A-D: 146±29 Ω Boom ブーム角度検出器 angle detector Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: Resistance value 2-1: 833±167 Ω 4-1: 146±29 Ω Boom angle detector DET1SLD 6 DET1SRC 2 E C Boom length detector A E ANAINB 4 A B C D ANAINA 3 DET1GND 1 B D Boom ブーム長さ検出器 length detector IW J10 Applicable serial No. Resistance value From FB4054 R-G: 833±167 Ω B-G: 146±29 Ω Boom angle detector Shield Plug Shield Boom length detector 254 W E

256 Checking the Detectors (TR-250M-7) 3. Swing Angle Detector 1. Swing the boom to over-left-side and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 500±75 Ω W-B: 0-15 Ω 4. Outrigger Extension Width Detector 1. Stow the outriggers and set the starter switch to "OFF." 2. Remove the wire for the detector from the outrigger and hold the wire, letting it protruding by 80 mm from the guide hole of the detector. G R プラグ Plug Shield シールド W B DET1SLD 6 DET1SRC 2 ANAINC 5 ANAIND 9 DET1GND 1 シールド Shield R W Checking at the CN1 connector of the AML Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 500±75 Ω 5-1: 0-15 Ω G B IW J11 3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 2000±100 Ω W-B: 200±30 Ω W B R 80 mm 5V AVCC Input 入力 Ai1 GND AGND IW J27 R W B FL IW J DET1SLD 6 DET1SRC 2 Shield シールド R ANAINC 5 W ANAIND 9 DET1GND 1 G B 30 1 IW J W E

257 Checking the Detectors (TR-250M-7) 5. Pressure Sensor for Moment Detection 1. Set the PTO switch to "ON." (5-V DC will be applied between R and B of the pressure sensor connector.) 2. Measure the output voltage between W and B of the pressure sensor connector. W B R DET3SRC 33 ANAING 34 (ANAINH 35) DET3GND The output voltage between W and B is proportional to the pressure in the elevating cylinder. The specified value is as shown below. R W B SPS3 (SPS4) IW E14 6. Jib Angle Detector 1. Mount the jib. 2. Minimize the jib offset angle and set the PTO switch to "OFF." 3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: A-D: 1000±50 Ω C-D: 165±20 Ω E D C A A B C E D IW J28 Output 出力電圧 voltage (V (V DC) DC) Pressure 圧力 (MPa) 35 IW J W E

258 Checking the Detectors (GR-250N-1/GR-350N-1) Checking the Detectors (GR-250N-1/GR-350N-1) 1. Boom Length Detector 1. Retract the boom fully, set the boom angle to 0, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: Applicable serial No. Resistance value GR-250N-1 (Up to FB4053) GR-350N-1 (Up to ) C-D: 833±167 Ω B-D: 458±92 Ω Boom ブーム角度検出器 angle detector Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: Resistance value 2-1: 833±167 Ω 3-1: 458±92 Ω Boom angle detector Boom length detector DET1SLD 6 E DET1SRC 2 C A E ANAINB 4 A B C D ANAINA 3 DET1GND 1 B D ブーム長さ検出器 IW J10 Boom length detector Applicable Serial No. Resistance value GR-250N-1 (From FB4054) GR-350N-1 (From ) R-G: 833±167 Ω W-G: 458±92 Ω Boom angle detector Shield Plug Shield Boom length detector 257 W E

259 Checking the Detectors (GR-250N-1/GR-350N-1) 2. Boom Angle Detector 1. Retract the boom fully, set the boom angle to 0, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: Applicable serial No. Resistance value GR-250N-1 (Up to FB4053) GR-350N-1 (Up to ) C-D: 833±167 Ω A-D: 146±29 Ω Boom ブーム角度検出器 angle detector Resistance value 2-1: 833±167 Ω 4-1: 146±29 Ω Boom angle detector DET1SLD 6 DET1SRC 2 E C Boom length detector A E ANAINB 4 A B C D ANAINA 3 DET1GND 1 B D ブーム長さ検出器 IW J10 Boom length detector Applicable serial No. Resistance value GR-250N-1 (From FB4054) GR-350N-1 (From ) R-G: 833±167 Ω B-G: 146±29 Ω Boom angle detector Shield Plug Shield Boom length detector 258 W E

260 Checking the Detectors (GR-250N-1/GR-350N-1) 3. Swing Angle Detector 1. Swing the boom to front and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 2500±375 Ω W-B: 1062±160 Ω G-B: 2354±353 Ω 4. Outrigger Extension Width Detector 1. Stow the outriggers and set the starter switch to "OFF." 2. Remove the wire for the detector from the outrigger and hold the wire, letting it protruding by 80 mm from the guide hole of the detector. DET1SLD 6 Shield シールド DET1SRC 2 R 80 mm ANAINC 5 W IW J27 ANAIND 9 DET1GND 1 Checking at the CN1 connector of the AML Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 2500±375 Ω 5-1: 1062±160 Ω 9-1: 2354±353 Ω G B IW J02 3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 2000±100 Ω W-B: 200±30 Ω W B R 5V AVCC Input 入力 Ai1 GND AGND R W B FL IW J DET1SLD 6 DET1SRC 2 シールド Shield R ANAINC 5 W ANAIND 9 DET1GND 1 G B 30 1 IW J W E

261 Checking the Detectors (GR-250N-1/GR-350N-1) 5. Pressure Sensor for Moment Detection 1. Set the PTO switch to "ON." (5-V DC will be applied between R and B of the pressure sensor connector.) 2. Measure the output voltage between W and B of the pressure sensor connector. W B R DET3SRC 33 ANAING 34 (ANAINH 35) DET3GND The output voltage between W and B is proportional to the pressure in the elevating cylinder. The specified value is as shown below. R W B SPS3 (SPS4) IW E14 6. Jib Angle Detector 1. Mount the jib. 2. Minimize the jib offset angle and set the PTO switch to "OFF." 3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: A-D: 1000±50 Ω C-D: 165±20 Ω E D C A A B C E D IW J28 Output 出力電圧 voltage (V (V DC) DC) 圧力 (MPa) Pressure 35 IW J W E

262 Checking the Detectors (GR-160N-1) Checking the Detectors (GR-160N-1) 1. Boom Length Detector 1. Retract the boom fully, set the boom angle to 0, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D: 833±167 Ω B-D: 458±92 Ω Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 833±167 Ω 3-1: 458±92 Ω Resistance value 2-1: 833±167 Ω 3-1: 458±92 Ω Boom angle detector Applicable serial No. Resistance value Up to C-D: 833±167 Ω B-D: 458±92 Ω Boom ブーム角度検出器 angle detector Boom length detector DET1SLD 6 E DET1SRC 2 C A E ANAINB 4 A B C D ANAINA 3 DET1GND 1 B D Boom length detector ブーム長さ検出器 IW J10 Applicable serial No. Resistance value From R-G: 833±167 Ω W-G: 458±92 Ω Shield Boom angle detector Plug Shield Boom length detector 261 W E

263 Checking the Detectors (GR-160N-1) 2. Boom Angle Detector 1. Retract the boom fully, set the boom angle to 0, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: Applicable serial No. Resistance value Up to C-D: 833±167 Ω A-D: 146±29 Ω Boom ブーム角度検出器 angle detector Resistance value 2-1: 833±167 Ω 4-1: 146±29 Ω Boom angle detector DET1SLD 6 DET1SRC 2 E C Boom length detector A E ANAINB 4 A B C D ANAINA 3 DET1GND 1 B D ブーム長さ検出器 IW J10 Boom length detector Applicable serial No. Resistance value From R-G: 833±167 Ω B-G: 146±29 Ω Boom angle detector Shield Plug Shield Boom length detector 262 W E

264 Checking the Detectors (GR-160N-1) 3. Swing Angle Detector 1. Swing the boom to front and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 500±75 Ω W-B: 224±34 Ω G-B: 474±71 Ω 4. Outrigger Extension Width Detector 1. Stow the outriggers and set the starter switch to "OFF." 2. Remove the wire for the detector from the outrigger and hold the wire, letting it protruding by 80 mm from the guide hole of the detector. G R プラグ Plug Shield シールド W B DET1SLD 6 DET1SRC 2 ANAINC 5 ANAIND 9 DET1GND 1 シールド Shield R W Checking at the CN1 connector of the AML Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 500±75 Ω 5-1: 224±34 Ω 9-1: 474±71 Ω G B IW J11 80 mm IW J27 3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 2000±100 Ω W-B: 200±30 Ω W B R 5V AVCC Input 入力 Ai1 GND AGND R W B FL IW J DET1SLD 6 DET1SRC 2 Shield シールド R ANAINC 5 W ANAIND 9 DET1GND 1 G B 30 1 IW J W E

265 Checking the Detectors (GR-160N-1) 5. Pressure Sensor for Moment Detection 1. Set the PTO switch to "ON." (5-V DC will be applied between R and B of the pressure sensor connector.) 2. Measure the output voltage between W and B of the pressure sensor connector. W B R DET3SRC 33 ANAING 34 (ANAINH 35) DET3GND 32 R W B SPS3 (SPS4) IW E14 3. The output voltage between W and B is proportional to the pressure in the elevating cylinder. The specified value is as shown below. Output 出力電圧 voltage (V (V DC) DC) 圧力 (MPa) Pressure 35 IW J W E

266 Checking the Detectors (GR-120F-1) Checking the Detectors (GR-120F-1) 1. Boom Length Detector 1. Retract the boom fully, set the boom angle to 0, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-G: 833±167 Ω W-G: 458±92 Ω 2. Boom Angle Detector 1. Retract the boom fully, set the boom angle to 0, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-G: 833±167 Ω B-G: 146±29 Ω Boom angle detector Shield Boom angle detector Plug Shield Shield Plug Shield Boom length detector Boom length detector Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 833±167 Ω 3-1: 458±92 Ω Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 833±167 Ω 4-1: 146±29 Ω Boom angle detector Boom angle detector Boom length detector Boom length detector 265 W E

267 Checking the Detectors (GR-120F-1) 3. Swing Angle Detector 1. Swing the boom to front and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 500±75 Ω W-B: 224±34 Ω G-B: 474±71 Ω G R プラグ Plug Shield シールド W B DET1SLD 6 DET1SRC 2 ANAINC 5 ANAIND 9 DET1GND 1 シールド Shield R W Checking at the CN1 connector of the AML Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 500±75 Ω 5-1: 224±34 Ω 9-1: 474±71 Ω G B IW J11 4. Outrigger Extension Width Detector 1. Stow the outriggers and set the starter switch to "OFF." 2. Remove the wire for the detector from the outrigger and hold the wire, letting it protruding by 80 mm from the guide hole of the detector. 80 mm W B R IW J27 5V AVCC Input 入力 Ai1 GND AGND 3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 2000±100 Ω W-B: 200±30 Ω R W B FL IW J DET1SLD 6 DET1SRC 2 Shield シールド R ANAINC 5 W ANAIND 9 DET1GND 1 G B 30 1 IW J W E

268 Checking the Detectors (GR-120F-1) 5. Pressure Sensor for Moment Detection 1. Set the PTO switch to "ON." (5-V DC will be applied between R and B of the pressure sensor connector.) 2. Measure the output voltage between W and B of the pressure sensor connector. W B R 3. The output voltage between W and B is proportional to the pressure in the elevating cylinder. The specified value is as shown below. Output 出力電圧 voltage (V (V DC) DC) DET3SRC 33 ANAING 34 (ANAINH 35) DET3GND 32 Pressure 圧力 (MPa) R W B 35 SPS3 (SPS4) IW E14 IW J15 6. Jib Length Detector 1. Mount the jib. 2. Retract the jib fully and set the PTO switch to "OFF." 3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D: 5000±250 Ω B-D: 500±85 Ω 7. Jib Angle Detector 1. Mount the jib. A D B C Shield GND V in 4.5V シールド 2. Maximize the jib offset angle and set the PTO switch to "OFF." 3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: A-D: 1000±150 Ω C-D: In the range of 86%±4 Ω of the value measured between A and D. A B C E D IW J31 E D C A Shield 4.5V シールド V in GND A B E D C IW J W E

269 Checking the Detectors (GA-700N-1) Checking the Detectors (GA-700N-1) 1. Boom Length Detector 1. Retract the boom fully, set the boom angle to 0, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D: 833±167 Ω B-D: 458±92 Ω DET1SLD 6 DET1SRC 2 E C Boom ブーム角度検出器 angle detector 2. Boom Angle Detector 1. Retract the boom fully, set the boom angle to 0, and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: C-D: 833±167 Ω A-D: 146±29 Ω Boom ブーム角度検出器 angle detector A E DET1SLD 6 DET1SRC 2 ANAINB 4 E C A A E ANAINB 4 A B C D ANAINA 3 DET1GND 1 B D B C D ANAINA 3 DET1GND 1 B D Boom ブーム長さ検出器 length detector IW J10 Boom ブーム長さ検出器 length detector IW J10 Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 833±167 Ω 3-1: 458±92 Ω Boom ブーム角度検出器 angle detector DET1SLD 6 E DET1SRC 2 C Checking at the CN1 connector of the AML Pull out the connector of the swing angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 833±167 Ω 4-1: 146±29 Ω Boom ブーム角度検出器 angle detector DET1SLD 6 DET1SRC 2 ANAINB 4 E C A ANAINB 4 A 30 1 ANAINA 3 DET1GND 1 B D Boom ブーム長さ検出器 length detector 30 1 ANAINA 3 DET1GND 1 B D Boom ブーム長さ検出器 length detector IW J33 IW J W E

270 Checking the Detectors (GA-700N-1) 3. Swing Angle Detector 1. Swing the boom to over-left-side and set the PTO switch to "OFF." 2. Measure the resistance of the potentiometer. Checking at the connector of the detector Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 500±75 Ω W-B: 0-15 Ω G R プラグ Plug Shield シールド W B DET1SLD 6 DET1SRC 2 ANAINC 5 ANAIND 9 DET1GND 1 シールド Shield R W Checking at the CN1 connector of the AML Pull out the connector of the boom length and angle detector. Then pull out the CN1 connector of the AML and measure resistance of the potentiometer. The specified resistance values are as follows: 2-1: 500±75 Ω 5-1: 0-15 Ω G B IW J11 4. Outrigger Extension Width Detector 1. Stow the outriggers, and set the PTO switch to "OFF." 2. Remove the wire for the detector from the outrigger and hold the wire, letting it protruding by 600 mm from the guide hole of the detector. 600mm IW J29 3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: R-B: 2000±100 Ω W-B: 200±10 Ω W B R AVCC Ai1 AGND R W B IW J30 Front 右前 right DET1SLD 6 DET1SRC 2 Shield シールド R ANAINC 5 W ANAIND 9 DET1GND 1 G B 30 1 IW J W E

271 Checking the Detectors (GA-700N-1) 5. Pressure Sensor for Moment Detection 1. Set the PTO switch to "ON." (5-V DC will be applied between R and B of the pressure sensor connector.) 2. Measure the output voltage between W and B of the pressure sensor connector. 6. Jib Length Detector 1. Mount the jib. 2. Retract the jib fully and set the PTO switch to "OFF." 3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: W B R DET3SRC 33 ANAING 34 (ANAINH 35) DET3GND 32 R W B SPS3 (SPS4) Specifications for GA-700N C-D: 2000±100 Ω B-C: 200±24 Ω 3. The output voltage between W and B is proportional to the pressure in the elevating cylinder. The specified value is as shown below. Output 出力電圧 voltage (V (V DC) DC) 圧力 (MPa) Pressure IW E14 35 IW J15 Specifications for GA-700N C-D: 5000±250 Ω B-D: 500±60 Ω 7. Jib Angle Detector 1. Mount the jib. A D B C シールド Shield GND V in 4.5V A B E D C IW J31 2. Set the jib offset angle to 0 and set the PTO switch to "OFF." 3. Pull out the connector of the detector and measure resistance of the potentiometer. The specified resistance values are as follows: A-D: 1000±150 Ω C-D: In the range of between 84 and 86% of the value measured between A and D. E D Shield シールド 4.5V A E C A V in GND B D C IW J W E

272 Fuse Fuse RLY1, 2 RLY3, 4 RLY5, 6 RLY7, 8 MAIN SIF2 SIF1 SOL1, 2 SOL3, 4 SOL5, 6 IW J16 MAIN fuse (3A) AML main fuse for whole unit. RLY1, 2 fuse (3A) Common, with relay output 1 and 2. RLY3, 4 fuse (3A) Common, with relay output 3 and 4. RLY5, 6 fuse (3A) Common, with relay output 5 and 6. SIF2 fuse (2A) For SIF2SRC power supply output terminal. SOL1, 2 fuse (2A) Common, with current output 1 and 2. SOL3, 4 fuse (2A) Common, with current output 3 and 4. SOL5, 6 fuse (2A) Common, with current output 5 and 6. RLY7, 8 fuse (3A) Common, with relay output 7 and 8. SIF1 fuse (2A) For SIF1SRC power supply output terminal. 271 W E

273 Replacing Clock Battery Replacing Clock Battery [NOTICE] When the built-in clock battery is worn out, the values, error codes, and driving history cannot be backed up (saving data at power OFF). Also, when the error code or overload history is recorded in the AML, an accurate date and time cannot be recorded. The built-in clock battery life is usually about 10 years. If the built-in clock batteries are worn out, replace them according to the following procedure. 1. In the Case of CPU Board Employing BR1225 Battery 1. Remove the CPU board from the AML main unit. 2. Remove the batteries from the battery holder on the CPU board by pressing them diagonally. 3. Set new batteries on the CPU board by pressing them diagonally. (Refer to the figure below.) The battery positive side must face upward. Lithium battery (PANASONIC BR1225) [NOTICE] Two built-in clock batteries are on CPU board of the AML main unit. Replace both 2 pieces when you replace the battery. 4. Install the CPU board in the AML main unit. 5. Reconnect the connector to the board. 2. In the Case of CPU Board Employing CR2032 Battery [NOTICE] One built-in clock battery is on CPU board of the AML main unit. When removing the battery, remove while holding the battery upper (positive) side because the battery may pop up. Do not use a conductive tool such as a metal screwdriver for replacing the batteries. In addition, do not handle the batteries with bare hands. The board may be damaged due to a short circuit. Use a tool made of non-conductive materials such as wood or plastic (ex. wooden spatula). 272 W E

274 Replacing Clock Battery When removing the battery or setting a new one, do not handle it with a conductive tool and/or bare hands. The board may be damaged due to a short circuit. Use a tool made of non-conductive materials. 4. Put on a new battery. [NOTICE] Ensure to prevent any dust or oil from attaching to the battery surface. 1. Raise the battery and remove it from the lock. Lock 5. Push the battery into the holder. 2. Slide the battery forward. [NOTICE] Ensure to prevent battery s positive and negative terminals from being short-circuited. 3. Remove the battery. 6. Check that the battery is locked. 273 W E