Tadano AML-C Service Manual
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Tadano AML-C Service Manual

Tadano AML-C Service Manual

Load moment indicator
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W301-0411E
資料番号
01
Load Moment Indicator
AML-C
Model

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Summary of Contents for Tadano AML-C

  • Page 1 W301-0411E 資料番号 Load Moment Indicator AML-C Model...

  • Page 2: Applicable Crane Model / Spec. No

    1. Applicable Crane Model / Spec. No. Crane model This service manual (this document) is compiled to GR-1000XL-2 provide information on the AML-C that is equipped on the crane. Spec. No. GR-1000-2-00101 GR-1000-2-00103 "Input/Output Signals of the AML System" in this...

  • Page 3: Table Of Contents

    Foreword 2. Table of Contents B-6 Do Output Control........59 6.1 Cause for AML Automatic Stop Output .......... 59 Foreword 6.2 Do Output Abnormality Processing..64 1. Applicable Crane Model / Spec. No....i 6.3 Drum Indicator Control Function..65 2.
  • Page 4 Foreword Chapter D Chapter E (Adjustment Mode) (Information and Data) Outline of Adjustment Mode......150 E-1 AML Adjustment Value List ....180 D-1 Operation Keys and Menu ..... 151 E-2 Detector Check........184 D-2 Detector Adjustment ......156 E-3 AML Control Function List ..... 190 D-3 Valve Adjustment ........

  • Page 5: Acronyms And Abbreviations

    Foreword 3. Acronyms and Abbreviations PC: Personal Computer Pi: Pulse input The following list contains some of the acronyms and Pin Assignment: abbreviations used in this manual. Assignment of signals to the pins of connectors PT: Power Tilt AML: Load Moment Indicator PTO: Power Take-off AML override: Refer to Chapter B-9 RAM: Random Access Memory...

  • Page 6: International Standard

    Foreword 4. International Standard ISO 4306-1 (Only description in English is shown here.) Cranes – Vocabulary - Part 1: General Fourth edition 2007.10.15 W301-0411E...
  • Page 7 Foreword (Only description in English is shown here.) Hoist medium Hoist rope hanging down from jib head Hoist rope hanging down from crab Fixed load-lifting attachment(s) Hook assembly Hook assembly Bottom block Bottom block Bottom block Non-fixed load-lifting Electromagnet Skip and chain Rope slings Grab attachment(s)

  • Page 8: Crane Performance

    Foreword 5. Crane Performance W301-0411E...

  • Page 9: Reduction Of Rated Capacity

    Foreword 6. Reduction of Rated Capacity Boom Lift The rated capacities for boom lift assume that the jib is stowed in the specified position and the main winch is used. When the jib is attached to the boom end during boom lift, subtract the value in the table below from the rated capacity.

  • Page 10: Chapter A

    1.1 System configuration ......... 1 2.1 AML Control Unit (Pin Assignment) ..11 1.1.1 Diagram of the Main System ...... 1 1.1.2 AML-C Block diagram......2 2.1.1 CN1 Connector (8-Pin) ......11 2.1.2 CN2-1 Connector (20-Pin) ......12 1.2 Display Unit..........3 2.1.3 CN2-2 Connector (16-Pin) ......14...

  • Page 11: Components Of The Aml System

    Components of AML System Chapter A Chapter A A-1 Components of the AML System 1.1 System configuration 1.1.1 Diagram of the Main System (Overwind detector) (Overwind) 1. Load ratio ≥ 100% moment AML vent / compulsory unload of the main relief valve. ٠If an overload occurs, the AML stops the 24-V output from Do1.

  • Page 12: Aml-C Block Diagram

    Chapter A 1.1.2 AML-C Block diagram 1. While the PTO switch is ON, AML-C and DCU give and take the data on the version No. of the DCU and error occurring in the DCU. For details of the data, refer to the "N-1 DCU" section in the service manual for the corresponding model.

  • Page 13: Display Unit

    Components of AML System Chapter A Chapter A 1.2 Display Unit Composition of the display Unit 1. The LED display indicates the limit state of each working range, rotation state of the winch drum, and AML control state. The display panel indicates the moment ratio, crane state, outrigger state, swing position, and error code.

  • Page 14: Display Panel

    Components of AML System Chapter A Chapter A 1.2.1 Display panel NOTICE • Load moment ratio is not a ratio of the hoist medium load to the rated capacity. Find the correct hoist medium load from the rated capacity. • The AML is not a hoist medium load indicator.
  • Page 15 Components of AML System Chapter A Chapter A (4) Single top lift indicator symbol Appears when the single top lift is registered. (5) Counterweight indicator Indicates the state of the mounted counterweight. (6) Crane status indicator (A-1) Boom telescope Jib lock (7) Crane status indicator (A-2 (8) Crane status indicator (A-3) Jib dismount...

  • Page 16: Led Display

    Components of AML System Chapter A Chapter A 1.2.2 LED Display W301-0411E...

  • Page 17: Control Switches

    Components of AML System Chapter A Chapter A 1.2.3 Control switches Table 1.2.3 Name Description Preset menu key Used for go to the preset menu. F1 key Used to select the function shown as “F1” in the pop-up window. F2 key Used to select the function shown as “F2”...

  • Page 18: Aml Main Unit

    Components of AML System Chapter A Chapter A 1.3 AML Main Unit 1.3.1 Construction LED (3 pcs) 1. Case assembly 4. Case 1 7. CON2 circuit board 10. CPU board 2. Case assembly 5. Dustproof sponge assembly 8. Case 2 11.

  • Page 19: Panel Outside View (Cn1 - Cn9)

    Components of AML System Chapter A Chapter A 1.3.2 Panel outside view (CN1 – CN9) Front Rear △ 361-933-41030 W301-0411E...

  • Page 20: Boards And Inner Connectors

    Components of AML System Chapter A Chapter A 1.3.3 Boards and Inner connectors Jumper lead CON2 board CON1 board CON1 + CON2 boards Cable assembly for CN11 CPU board DISP board CPU + DISP boards Jumper lead LCD connection cable Graphic liquid crystal display (LCD) W301-0411E...

  • Page 21: Input/Output Signals

    Components of AML System Chapter A Chapter A A-2 Input/Output Signals of the AML System 2.1 AML Control Unit (Pin Assignment) Below are the names of the signals that are input to/output from the connectors, and the descriptions of their functions.

  • Page 22: Cn2-1 Connector (20-Pin)

    Components of AML System Chapter A Chapter A 2.1.2 CN2-1 Connector (20-Pin) CN2-1 connector SW status in AML (Data No. #---) Signal names and functions Pin No. Name ON (0) OFF (1) (#17206-21) - Signal name: Boom telescoping / Aux. winch operation Aux.
  • Page 23 Components of AML System Chapter A Chapter A CN2-1 connector SW status in AML (Data No. #---) Signal names and functions Pin No. Name ON (0) OFF (1) #17202-2) Di10+ No operation Operation - Signal name: Main hoist-down detection Detects the main winch hoist-down operation. #17202-3) Di11+ No operation...

  • Page 24: Cn2-2 Connector (16-Pin)

    Components of AML System Chapter A Chapter A 2.1.3 CN2-2 Connector (16-Pin) CN2-2 connector SW status in AML (Data No. #---) Signal names and functions Pin No. Name ON (0) OFF (1) Di21+ (Spare) #17204-3) Mounted Not mount Di22+ - Signal name: Counterweight fitting detection Detects fitting status of the counterweight.
  • Page 25 Components of AML System Chapter A Chapter A CN2-2 connector SW status in AML (Data No. #---) Signal names and functions Pin No. Name ON (0) OFF (1) #17202-36) Di28+ Twoblocking - Signal name: Twoblocking detection twoblocking Detects the twoblocking. Frame ground (Connected with ground on circuit board) PSRC (Spare)

  • Page 26: Cn3 Connector (12-Pin)

    Components of AML System Chapter A Chapter A 2.1.4 CN3 Connector (12-Pin) CN3 connector Signal names and functions Pin No. Name - Signal name: 5-V impressed voltage power output for detectors Impressed voltage output to boom length detector, boom angle detector, swing angle detector 1, and swing angle detector 2 - Signal name: Boom length Input voltage of boom length detector (DC 0 to 5 V)

  • Page 27: Cn4 Connector (6-Pin)

    Components of AML System Chapter A Chapter A 2.1.5 CN4 Connector (6-Pin) CN4 connector Signal names and functions Pin No. Name (Spare) Signal name: 5-V impressed voltage power for detector Impressed voltage to main pressure detector Signal name: Main pressure Input voltage to main pressure detector (Spare) Signal name: Analog ground...

  • Page 28: Cn5 Connector (16-Pin)

    Components of AML System Chapter A Chapter A 2.1.6 CN5 Connector (16-Pin) CN5 connector (Data No. #---) Signal names and functions Pin No. Name (#17802-1) - Signal name: AML stop output (AML vent / compulsory unload) Do1+ Controls the unload solenoid valve, and performs the automatic stop output. #17802-147) - Signal name: Lever non-operation output Do2+...
  • Page 29 Components of AML System Chapter A Chapter A CN5 connector (Data No. #---) Signal names and functions Pin No. Name (#17802-122) - Signal name: Tactile type drum indicator (Main) Do5+ Interlocked with the drum indicator LED, output is performed to the tactile type drum indicator. (#17802-123) - Signal name: Tactile type drum indicator (Aux.) Do6+...
  • Page 30 Components of AML System Chapter A Chapter A CN5 connector (Data No. #---) Signal names and functions Pin No. Name #17802-9) - Signal name: External indicator lamp (up to 90%, green) When the moment load factor is less than 90%, the green external indicator lamp lights. Output condition: (1) and (2) and (3) (1): Load moment ratio is less than 90%.
  • Page 31 Components of AML System Chapter A Chapter A CN5 connector (Data No. #---) Signal names and functions Pin No. Name #17802-11) - Signal name: External indicator lamp (100% or more, red) When the load moment ratio is 100% or more, the red external indicator lamp lights. Output condition: (1) or (2) or (3) (1): Load factor exceeds 100%.

  • Page 32: Cn6 Connector (14-Pin)

    Components of AML System Chapter A Chapter A 2.1.7 CN6 Connector (14-Pin) CN6 connector (Data No. #---) Signal names and functions Pin No. Name #17804-1) Ao1+ - Signal name: Swing right proportional solenoid valve Drives the proportional reducing valve for right swing. - Signal name: Swing right proportional solenoid valve COM Ao1- (Output return terminal)

  • Page 33: Cn7 Connector (20-Pin)

    Components of AML System Chapter A Chapter A 2.1.8 CN7 Connector (20-Pin) CN7 connector Signal names and functions Pin No. Name TX1+ TX1- (Spare) SHIELD - Signal name: Serial port 2 transmission (+) output signal TX2+ [Transmission data to MDT (Multiplex Data Transmitter)] Signal name: Serial port 2 transmission (-) output signal TX2- [Transmission data to MDT (Multiplex Data Transmitter)]...

  • Page 34: Cn8 Connector (8-Pin)

    Components of AML System Chapter A Chapter A 2.1.9 CN8 Connector (8-Pin) CN8 connector Signal names and functions Pin No. Name (Spare) (Spare) Boot (Boot mode activation with GND connection) BOOT For maintenance (data readout and rewriting) RS232C communication For maintenance (data readout and rewriting) (Spare) Digital ground DGND...

  • Page 35: Cn9 (Usb) Connector (4-Pin)

    Components of AML System Chapter A Chapter A 2.1.10 CN9 (USB) Connector (4-Pin) CN9 connector Signal names and functions Pin No. Name VBUS (Spare) DGND 2.1.11 Explanation of the Signals (Di, Do) [NOTICE] For the detailed electrical circuit, refer to the service manual (circuit diagrams) for each model. 1.

  • Page 36: Chapter B

    Chapter B U s e r M o d e Contents B-1 Functions and How to use 3.3 Warning code and Remedy List....40 the User Mode......26 3.3.1 Stop warning code ........40 3.3.2 Warning Code (ex.: GR-750XL-2, 1.1 Mode Structure ........26 GR-1000XL-2) ........41 1.2 Display Selection ........
  • Page 37 B-5 Action against AML 7.3 Output of Interference Prevention System Error ......58 Warning ........70 7.3.1 Function ............70 7.3.2 Data Specification ........70 B-6 Do Output Control......59 7.3.3 Input ............70 7.3.4 Warning Condition........70 6.1 Cause for AML Automatic Stop Output ..59 7.3.5 Warning Code ...........70 6.1.1 100% Lifting Performance Stop....

  • Page 38: Mode Structure

    User Mode Chapter B Chapter B B-1 Functions and How to use the User Mode 1.1 Mode Structure The AML has the following three basic operation modes. This chapter describes the operation method in user mode. • User Mode: Used by the operator to operate the crane. •...

  • Page 39: Operation Indicator Display

    User Mode Chapter B Chapter B 1.3 Operation Indicator Display The crane state is displayed by the indicator (icon). Operation indicators and displayed contents are as follows. Icon Designation Position Display condition The boom telescoping mode I is selected. Telescoping mode I The boom telescoping mode II is selected.

  • Page 40: Registration Of Operating State And Aml Function Check

    User Mode Chapter B Chapter B B-2 Registration of Operating State and AML Function Check WARNING Before you start the crane operation, make sure that correct operation state is registered and the AML system functions normally. If you register the operation state incorrectly or the AML system does not operate normally, the machine can overturn or suffer damage, and this can cause a fatal injury.
  • Page 41 User Mode Chapter B Chapter B 4. Make sure that the display agrees with the actual outrigger state. • The meanings of each indication of the outrigger state symbol are as shown in the illustration on the right. GR-750XL-2 GR-1000XL-2 Maximum extension 23' 11-3/8"...
  • Page 42 User Mode Chapter B Chapter B 5. If the display agrees with the actual condition, push the < > key (set) to register the state. • After registration is completed, the pop-up window closes and the AML returns to the crane operation state.

  • Page 43: Registration Of Crane State

    User Mode Chapter B Chapter B 2.2 Registration of Crane State 7. Push the < > key (lift state select) to register the lift state (single top/jib/boom). • The pop-up window for the outrigger state registration is shown on the display panel. Each time you push the<...
  • Page 44 User Mode Chapter B Chapter B 8. Push the < > key (set). • When the booms are fully retracted, the popup window for boom telescoping mode selection appears on the display panel. When a boom is extended, the boom telescoping modes cannot be selected.

  • Page 45: Registration Of Counterweight State

    User Mode Chapter B Chapter B 2.3 Registration of counterweight state 11. Push the counterweight state select key. • The pop-up window for counterweight state registration appears on the display panel. 12. Check that the value of the counterweight indicated on the AML agrees with the actual crane state.

  • Page 46: Registration Of Number Of Part-Lines

    User Mode Chapter B Chapter B 2.4 Registration of Number of Part-lines of Wire Rope 14. Push the < > key (rope part line) to register the number of part lines to be used. • The pop-up window for rope part line registration appears on the display panel.
  • Page 47 User Mode Chapter B Chapter B 15. Push the < > key (set) to register the setting. • After registration is completed, the pop-up window closes and the AML returns to the crane operation state. 16. Set the jib status switch to register the jib state. •...

  • Page 48: Pre-Operational Inspection On Aml

    User Mode Chapter B Chapter B 2.5. Pre-operational Inspection on AML 17. Push the < > key (inspeciton) and make sure that the AML is in the condition below. • LED Display : All lit • Display Panel : All highlighted •...
  • Page 49 User Mode Chapter B Chapter B 20. Make sure that the items on the display panel listed below agree with the actual state. (1) Hoist medium load Make sure that approximate main hook mass is shown under a no-load condition. (2) Swing position display (3) Front position symbol (only when the boom is directed toward the front...

  • Page 50: Alarm And Recovery Operation

    User Mode Chapter B Chapter B B-3 Alarm and Recovery Operation NOTICE Repair/recovery is necessary if any of the events below occurs: • The warning code other than given here is/are shown. • The warning code remains even after you register the state that corresponds to the warning code or perform the recovery operation.

  • Page 51: Warning Code And Crane Model

    User Mode Chapter B Chapter B 3.2 Warning Code and Crane Model Comparison Table ● Table 3.2.1 ：Stop Warning Code, ：Warning Code Code Cause GR-750XL-2 GR-1000XL-2 W0001 Right front outrigger beam retraction ○ ○ W0002 Right rear outrigger beam retraction ○...

  • Page 52: Warning Code And Remedy List

    User Mode Chapter B Chapter B 3.3 Warning code and Remedy List 3.3.1 Stop warning code [Warning code] Buzzer Cause Remedy Ordinary bar graph display Load moment ratio is (no warning code) 100% or more. Unwind the winch, Alarm buzzer: retract or raise the Continuous sound boom, or swing to the...
  • Page 53 User Mode Chapter B Chapter B 3.3.2 Warning Code (ex.: GR-750XL-2, GR-1000XL-2) [Warning code] Buzzer Cause Remedy Ordinary bar graph display Alarm buzzer: Load moment ratio is Carefully monitor the (no warning code) Intermittent sound 90% or more and less load ratio.
  • Page 54 User Mode Chapter B Chapter B [Warning code] Buzzer Cause Remedy AML built-in buzzer: When the boom (or jib) Carefully lower or swing beep-beep-beep may touch the engine a boom. [W0197] (Short beeps repeat cover or the mirror. for 3 seconds. ) When the power is Replace the battery.

  • Page 55: Other Functions

    User Mode Chapter B Chapter B Other Functions There are other 5 functions as shown below. 1. Working range limit function 2. TARE function 3. Mute alarm function 4. Fuel consumption display function 5. User control menu • Eco mode selection (Eco1, Eco2) •...

  • Page 56: Display Of Limit Function State

    User Mode Chapter B Chapter B 4.1.1 Display of Limit Function State You can monitor the registered state of the work range limit by the limit indicator lamps on the LED display. The limit indicator lamp representing the work range limit currently activated lights up. When the crane reaches the limit and stops automatically, the condition of the limit indicator lamp changes from "staying lit"...
  • Page 57 User Mode Chapter B Chapter B 2. After you operate the boom (jib) to the desired boom angle, height, and load radius, push the < > key (set). • The corresponding limit indicator flashes in the LED display, and the work range limit is registered. •...
  • Page 58 User Mode Chapter B Chapter B 4.1.3 Registration of Swing Range Limit Function 1. Push the < > key (working range limit) repeatedly and select the item (left swing limit or right swing limit) to be registered. • The symbol for the selected item flashes. •...

  • Page 59: Registration Of Swing Range

    User Mode Chapter B Chapter B 2. After you swing the boom to the desired position where the limit is to be set, push the < > key (set). • The corresponding limit indicator lamp flashes, and the swing limit is registered. •...

  • Page 60: Alarm For Work Range Limit And Recovery Operation

    User Mode Chapter B Chapter B 4. To cancel the limit function, push the < > key (working range limit) to select the item to be canceled. • The pop-up window for work range limit registration appears on the display panel. 5.

  • Page 61: Tare Function

    User Mode Chapter B Chapter B 4.2 TARE Function The mass of the load only is shown on the hoist medium load display. 1. Before you lift a load, push the < > key (TARE). • The indication of the hoist medium load display turns to "0", and the TARE indicator lamp lights up.

  • Page 62: Fuel Consumption Indicator

    User Mode Chapter B Chapter B 4.4 Fuel Consumption Indicator CAUTION When you check the fuel consumption indicator, be careful that a crane operation is not hindered. Distraction can cause a serious accident. This function shows the fuel consumption during a crane operation or standby. Checking the indication enables you to operate a crane in a environmentally friendly way.

  • Page 63: User Adjustment Menu

    User Mode Chapter B Chapter B 4.5 User Adjustment Menu 4.5.1 Adjustment menu/model comparison table The following functions are available as the user adjustment menu. Table 4.5.1 GR-750XL-2 GR-1000XL-2 1. Eco mode selection ○ ○ 2. Activating/Deactivating the Winch Drum Rotation Buzzer Function ○...

  • Page 64: Eco Mode Selection

    User Mode Chapter B Chapter B 4.5.3 Eco mode selection Select a crane operation mode when Eco mode switch is "ON". ・Eco mode 1 : In this mode, a crane restricts the maximum engine speed, consumes less fuel and makes less noise compared with when Eco mode is "OFF".

  • Page 65: Activating/Deactivating The Winch Drum Rotation Buzzer Function

    User Mode Chapter B Chapter B 4.5.4 Activating/Deactivating the Winch Drum Rotation Buzzer Function This is the function to sound the buzzer according to the rotation speed of the winch drum. Select whether or not to sound the buzzer. The buzzer sounds only while the winch drum turns at a low speed. When the winch drum rotation speed increases, the buzzer stops sounding.

  • Page 66: Fuel Consumption History Display

    User Mode Chapter B Chapter B 4.5.5 Fuel Consumption History Display The fuel consumption history is displayed. 1. Hoist down a load and set each operation lever and pedal to the neutral position. 2. Select the fuel consumption history icon, and then push the <...

  • Page 67: Selection Of Winch To Be Used

    User Mode Chapter B Chapter B 4.5.6 Selection of Winch to be used WARNING If the selection of the winch to be used does not agree with the actual state of the crane, the AML does not indicate the correct value of the load. If you operate the crane in this state, the crane may overturn or be damaged, resulting in an accident.
  • Page 68 User Mode Chapter B Chapter B Push the < > key (set). • After registration is completed, the pop-up window closes and the AML returns to the normal display. When you want to cancel the registration, push the < > key (exit). The pop-up window closes and the AML returns to the status before start of the registrati When the AML (PTO switch) is turned off, the registered information is not retained.

  • Page 69: Adjustment Of Display Panel Contrast

    User Mode Chapter B Chapter B 4.5.7 Adjustment of Display Panel Contrast 1. Select the contrast adjustment menu icon, and push the set key. • The pop-up window for contrast adjustment appears on the display panel. 2. Push the < >...

  • Page 70: Action Against Aml System Error

    User Mode Chapter B Chapter B B-5 Action against AML System Error DANGER When override key switch is turned to "ON" and the PTO switch is turned to "OVERRIDE", load moment indicator automatic stop function is canceled. Never operate the crane in this condition.

  • Page 71: Do Output Control

    User Mode Chapter B Chapter B B-6 Do Output Control 6.1 Cause for AML Automatic Stop Output The AML automatic stop output is an output to drive the solenoid of unload valve for main pumps circuit. ON is output during crane operation, and OFF is output while the operation is being stopped. Once the operation is stopped, in order to prevent the repetition of detection signal (stop <=>...

  • Page 72: Output

    User Mode Chapter B Chapter B 6.1.1 100% Lifting Performance Stop When the load moment ratio (load ratio) exceeds 100%, the operation in the load ratio-increasing direction is stopped. However, for the main boom operation with jib, the automatic stop is performed when the load moment ratio (load ratio) becomes as follows: (#20803) Outrigger extension width...

  • Page 73: Anti-Twoblock Stop

    User Mode Chapter B Chapter B 6.1.2 Anti-twoblock Stop In the case of twoblocking, the operation in the hook block hoist-up direction is stopped. However, while the jib is being set, anti-twoblock stop is not performed. Code at stop: W0024 Cancel: Twoblocking cancel (Di5: ON) Stop operation: (×: Stop operation) Boom...

  • Page 74: Boom Upper Limit Stop

    User Mode Chapter B Chapter B 6.1.4 Boom Upper Limit Stop Restriction is implemented to the operations exceeding the boom angle that is set with the area limit. Code at stop: W0026 Cancel: 100% stop cancel (Di6: ON) Stop operation: (×: Stop operation) Boom Boom M winch...

  • Page 75: Elevation Lower Limit

    User Mode Chapter B Chapter B 6.1.8 Elevation Lower Limit As for the cranes whose moment detection is the differential pressure detection type, the moment detection becomes no longer possible when the elevating stroke end is reached. This function stops the elevation before the lowering stroke end is reached.

  • Page 76: Do Output Abnormality Processing

    User Mode Chapter B Chapter B 6.2 Do Output Abnormality Processing The block diagram below shows the Do highside output. +24V (Field Effect Transistor) Do0 output signal RY(Relay) Do highside output Do output power monitor Do output signal Output monitor Output monitor signal circuit (1) Do output power abnormality...

  • Page 77: Drum Indicator Control Function

    Auxiliary 6.3.4 Panel LED Control According to the rotation of displayed drum, the LED indicators (Fig. 6.3.1) in the AML-C body upper section are sequentially illuminated. However with models that winch drum position is selected in the user preset menu, the illumination switching timing is calculated based on the information described in the table below (Table 6.3.1) according to the selected...

  • Page 78: Output Of Warning

    User Mode Chapter B Chapter B 6.4 Output of warning The aim of this output is to give information to operators via external warning lamps and buzzer. 6.4.1 Safety signal This output controls the external warning lamps. (data No.:#17802-9) Condition of output: (1), (2) and (3) exist. (1)The load moment ratio is less than 90%.

  • Page 79: Aml Control

    User Mode Chapter B Chapter B B-7 AML Control 7.1 Backward Stability Stop Function 7.1.1 Outline of Function The backward stability stop function prevents the overturning of crane to the direction opposite to the boom side (backward) by the weight of counterweight (C/W) and other components. Unlike the overload stop and anti-twoblock stop, the stop cannot be canceled with this function.

  • Page 80: Restriction Contents

    User Mode Chapter B Chapter B 7.2.2 Restriction Contents When the stored stop set value or higher is reached, the crane stop output is performed while the crane is operated toward to the critical side. Even after the stop output condition is canceled, the stop output is maintained for 2 seconds.

  • Page 81: Cancel Condition

    User Mode Chapter B Chapter B 7.2.3 Cancel Condition Regarding the range limit functions other than the swing, they can be canceled by the AML emergency (override) switch. With the swing limit, swing motion differs depending on the re-stop setting status. The swing range limit cancel conditions are shown in Table 7.2.1.

  • Page 82: Output Of Interference Prevention

    User Mode Chapter B Chapter B 7.3 Output of Interference Prevention Warning 7.3.1 Function With cranes whose boom or stowed jib may contact the carrier side-mirror or engine cover, a warning code is displayed to alert the operator when the boom or others approach an obstacle (stop is not performed). 7.3.2 Data Specification In order to enable this function, the data below is required.

  • Page 83: Winch Drum Position Selection Function

    User Mode Chapter B Chapter B 7.4 Winch Drum Position Selection Function NOTICE The crane operations other than those shown in the illustrations below are prohibited. Use the specified combinations only. (A) When boom lift or S/T lift or Jib lift is registered following conditions, Main winch should be selected. (Memorized in the AML with Main winch used.) Fig.

  • Page 84: Processing Effective Condition

    User Mode Chapter B Chapter B 7.4.2 Processing Effective Condition (1) Specification selection When a lifting capacity setting winch position selection (#17200-53) is 1 "With setting" and winch drum selection effective (#17200-79) is 1 "Changeover possible": Select the winch drum position in the user preset menu. Fig.

  • Page 85: Information Relevant To

    When the adjustment value is set as "Front," by Tadano, therefore, the selection can be made by the winch drum position selection menu of user preset menu.

  • Page 86: Special Notes

    User Mode Chapter B Chapter B 7.4.6 Special Notes When the winch drum front-and-rear position changeover setting is performed in the user preset menu, an inconsistency occurs with the information that is used to calculate the hook movement as indicated in the table below (Table 7.4.1, 7.4.2).

  • Page 87: Proportional Control Function

    User Mode Chapter B Chapter B B-8 Proportional Control Function This section describes the deceleration and slow stop controls by the hydraulic pilot pressure restriction using the solenoid proportional valve. 8.1 Factors for Control Factors for deceleration and slow stop include the conditions below. The slow stop function can be canceled by the switch input or software setting.

  • Page 88: Aml Cancel Function

    User Mode Chapter B Chapter B B-9 AML Cancel Function 9.1 Introduction This function aims to prevent an occurrence of accident caused by the canceling of AML. However, depending on circumstances, because a returning to normal status is not possible unless the stop function is cancelled, the specification for such circumstances are described below.

  • Page 89: Canceling Method

    User Mode Chapter B Chapter B 9.2 Canceling Method 9.2.1 Cancel Status Judgment The cancel status is judged by the level detection of momentary type cancel switch. Therefore, the canceling of interlock stop is effective only while the cancel switch is ON. 9.2.2 Cancel Switch Abnormality Judgment As the cancel switch trouble judgment, if the cancel switch is ON when PTO is ON, a warning code (W0191)

  • Page 90: Interlock Stop

    User Mode Chapter B Chapter B 9.3 Interlock Stop 9.3.1 Cancel Contents The table below shows the relationship between the automatic stop function and cancel availability described in "6.1 Cause for AML Automatic Stop Output." (Including items that are not applicable depending on models) Table 9.3.1 Relationship between automatic stop function and cancel availability Stop function at AML Stop function name...

  • Page 91: Detector Abnormality

    User Mode Chapter B Chapter B Chapter B 9.5 Detector Abnormality 9.5.1 Stop Processing at Detector Abnormality (Compulsory unload output) When a failure occurs with a detector that is needed to calculate the load moment ratio (load ratio) (error code Nos. of 1000s and 2000s), the automatic stop cannot be performed by the "re-stop condition." Therefore, in the AML cancel status at detector abnormality, all the stop functions are canceled.

  • Page 92: Chapter C

    Chapter C M a i n t e n a n c e M o d e Contents Outline of Maintenance Mode....80 2.8 MDT Check..........93 2.8.1 Description of Display Contents....93 2.8.2 Operation Method ........93 C-1 Operation Keys and Menu..... 81 2.8.3 Selection of MDT Check Menu Item ..94 2.8.4 MDT Check, Display of 1.1 Operation Keys ........
  • Page 93 C-5 Required Adjustment after AML 2.14 Maximum Overload History Display ..109 System Part Replacement...134 2.15 Outrigger Emergency Setting History Display ......110 C-6 Disassembly and Assembly ..135 2.16 Telematics Check ........111 6.1 Disassembly of AML Main Unit ....135 2.17 Clock Adjustment .........

  • Page 94: Outline Of Maintenance Mode

    Maintenance Mode Chapter C Chapter C Outline of Maintenance Mode The AML has the following three basic operation modes. This chapter describes the operation method in maintenance mode. User Mode: Used by the operator to operate the crane. For the operation method of User mode, refer to "Chapter B, User Mode." Maintenance Mode: Used to perform the AML maintenance menu (operation check, reference of history information, etc).

  • Page 95: Operation Keys And Menu

    Maintenance Mode Chapter C Chapter C C-1 Operation Keys and Menu 1.1 Operation Keys Liquid crystal display (LCD) Fig. 1.1.1 AML display control panel Operation keys The following keys are used in the maintenance and adjustment mode. On and after, < > in the descriptions indicates the operation key.

  • Page 96: Structure Of Maintenance Mode Menu

    Maintenance Mode Chapter C Chapter C 1.2 Structure of Maintenance Mode Menu 1. ID ROM Check (Adjustment mode) Length/angle 2. Adjust ID code input adjustment 3. Di Check 4. Ai Check Maintenance 5. Pi Check mode main menu 6. Si Check 7.

  • Page 97: Mode Shift And Menu Structure

    Maintenance Mode Chapter C Chapter C 1.3 Mode Shift and Menu Structure 1.3.1 Shift to Maintenance Mode In the user mode, when all the three keys of the < > key, the < > key, and the < > key are pressed and held simultaneously for 0.5 seconds or more, the mode shifts to the maintenance mode.

  • Page 98: Maintenance Main Menu Functions

    Maintenance Mode Chapter C Chapter C 1.3.3 Maintenance Main Menu Functions Table 1.3.1 shows the maintenance main menu functions. Table 1.3.1 Maintenance main menu functions Displayed menu Menu function 1. ID ROM Check For checking the ROM ID. Displays the program ID, data ID, etc. 2.

  • Page 99: Individual Main Menu Functions

    - Making date of data. (From left, year, month, day.) - RC ChartMask ID (only for FAUN specification) - STM-D ID (Refer to Chapter A 1.1.2 AML-C Block diagram) Fig. 2.1.1 AML ID check screen Fig. 2.1.2 Connected device ID check screen...

  • Page 100: Di Check

    Maintenance Mode Chapter C Chapter C 2.2 Di Check Displays the status of digital input. In the maintenance main menu of Fig. 1.3.1, select "Di Check," and press the < > key to display the Di check screen shown in Fig. 2.2.1. Pressing the <...

  • Page 101: Ai Check

    Maintenance Mode Chapter C Chapter C 2.3 Ai Check Displays the status of analog input. In the maintenance main menu of Fig. 1.3.1, select "Ai Check," and press the < > key to display the Ai check screen shown in Fig. 2.3.1. Pressing the <...

  • Page 102: Pi Check

    Maintenance Mode Chapter C Chapter C 2.4 Pi Check Displays the status of pulse input. In the maintenance main menu of Fig. 1.3.1, select "Pi Check," and press the < > key to display the Pi check screen shown in Fig. 2.4.1. To go back to the maintenance main menu, press the <...

  • Page 103: Si Check

    Maintenance Mode Chapter C Chapter C 2.5 Si Check Displays the status of serial port. In the maintenance main menu of Fig. 1.3.1, select "Si Check," and press the < > key to display the Si check screen shown in Fig. 2.5.1. To go back to the maintenance main menu, press the <...
  • Page 104 Maintenance Mode Chapter C Chapter C When a node is connected to the CAN, the state of each node is also displayed as shown in Fig. 2.5.2. Fig. 2.5.2 Si check screen including CAN node state <Description of display contents> Port CAN1 to CAN2: CAN communication port...

  • Page 105: Do Check

    Maintenance Mode Chapter C Chapter C 2.6 Do Check Displays the status of digital output. In the maintenance main menu of Fig. 1.3.1, select "Do Check," and press the < > key to display the Do check screen shown in Fig. 2.6.1. Pressing the <...

  • Page 106: Ao Check

    Maintenance Mode Chapter C Chapter C 2.7 Ao Check Displays the status of analog output. In the maintenance main menu of Fig. 1.3.1, select "Ao Check," and press the < > key to display the Ao check screen shown in Fig. 2.7.1. To perform the test output, select the set value of item (highlighted) using the <...

  • Page 107: Mdt Check

    Maintenance Mode Chapter C Chapter C 2.8 MDT Check Displays the input/output status of MDT (Multiplex Data Transmitter). In the maintenance main menu of Fig. 1.3.1, select "MDT Check," and press the < > key to display the MDT check menu selection screen shown in Fig.

  • Page 108: Selection Of Mdt Check Menu Item

    Maintenance Mode Chapter C Chapter C 2.8.3 Selection of MDT Check Menu Item Table 2.8.1 shows the MDT check items. Table 2.8.1 MDT check item Menu item Menu item content 1. Upper Di check Displays the upper Di signal state (refer to 2.8.4). 2.
  • Page 109 Maintenance Mode Chapter C Chapter C 2.8.4 MDT Check, Display of Upper Section Di Check State Displays the input/output status of MDT. In the MDT check selection menu of Fig. 2.8.1, select "Upper Di Check," and press the < > key to display the MDT check upper Di signal state display screen shown in Fig. 2.8.2. To go back to the MDT check selection menu, press the <...
  • Page 110 Maintenance Mode Chapter C Chapter C 2.8.5 MDT Check, Display of Upper Section Ai Check State Displays the input/output status of MDT. In the MDT check selection menu of Fig. 2.8.1, select "Upper Ai Check," and press the < > key to display the MDT check upper Ai signal state display screen shown in Fig. 2.8.3. To go back to the MDT check selection menu, press the <...
  • Page 111 Maintenance Mode Chapter C Chapter C 2.8.6 MDT Check, Display of Upper Section Do Check State Displays the input/output status of MDT. In the MDT check selection menu of Fig. 2.8.1, select "Upper Do Check," and press the < > key to display the MDT check upper Do signal state display screen shown in Fig.
  • Page 112 Maintenance Mode Chapter C Chapter C 2.8.7 MDT Check, Display of Lower Section Di Check State Displays the input/output status of MDT. In the MDT check selection menu of Fig. 2.8.1, select "Lower Di Check," and press the < > key to display the MDT check lower Di signal state display screen shown in Fig. 2.8.5. To go back to the MDT check selection menu, press the <...
  • Page 113 Maintenance Mode Chapter C Chapter C 2.8.8 MDT Check, Display of Lower Section Ai Check State Displays the input/output status of MDT. In the MDT check selection menu of Fig. 2.8.1, select "Lower Ai Check," and press the < > key to display the MDT check lower Ai signal state display screen shown in Fig. 2.8.6. To go back to the MDT check selection menu, press the <...
  • Page 114 Maintenance Mode Chapter C Chapter C 2.8.9 MDT Check, Display of Lower Section Do Power Check State Displays the input/output status of MDT. In the MDT check selection menu of Fig. 2.8.1, select "Lower Do Power Check," and press the < >...
  • Page 115 Maintenance Mode Chapter C Chapter C 2.8.10 MDT Check, Display of Lower Section Do Check State Displays the input/output status of MDT. In the MDT check selection menu of Fig. 2.8.1, select "Lower Do Check," and press the < > key to display the MDT check lower Do signal state display screen shown in Fig.
  • Page 116 Maintenance Mode Chapter C Chapter C 2.8.11 MDT Check, Display of Lower Section Ao Check State Displays the input/output status of MDT. In the MDT check selection menu of Fig. 2.8.1, select "Lower Ao Check," and press the < > key to display the MDT check lower Ao signal state display screen shown in Fig.
  • Page 117 Maintenance Mode Chapter C Chapter C 2.8.12 MDT Check, Display of Pi Check State Displays the input/output status (pulse) of MDT. In the MDT check selection menu of Fig. 2.8.1, select "Pi Check," and press the < > key to display the MDT check Pi signal state display screen shown in Fig. 2.8.10. To go back to the MDT check selection menu, press the <...

  • Page 118: System Voltage Check

    Maintenance Mode Chapter C Chapter C 2.9 System Voltage Check Displays the system voltage state. In the maintenance main menu of Fig. 1.3.1, select "System Voltage," and press the < > key to display the system voltage check screen shown in Fig. 2.9.1. To go back to the maintenance main menu, press the <...

  • Page 119: Error History Display

    Maintenance Mode Chapter C Chapter C 2.10 Error History Display Displays the error history of AML. In the maintenance main menu of Fig. 1.3.1, select "Error History," and press the < > key to display the error history display screen shown in Fig. 2.10.1. Pressing the < >...

  • Page 120: Erasing Error History

    Maintenance Mode Chapter C Chapter C 2.11 Erasing Error History Erases the error history of AML. In the maintenance main menu of Fig. 1.3.1, select "Error Erase," and press the < > key to display the error history erase screen shown in Fig. 2.11.1. Pressing the < >...

  • Page 121: Aml Emergency Switch History Display107

    Maintenance Mode Chapter C Chapter C 2.12 AML Emergency Switch History Display Displays the AML emergency switch history. In the maintenance main menu of Fig. 1.3.1, select "Emergency History," and press the < > key to display the AML emergency switch history display shown in Fig. 2.12.1. The items are displayed in the order starting with the one of which changeover time is the newest.

  • Page 122: Latest Overload History Display

    Maintenance Mode Chapter C Chapter C 2.13 Latest Overload History Display Displays the latest overload history that is stored in the AML. In the maintenance menu of Fig. 1.3.1, select "New History," and press the < > key to display the latest overload history shown in Fig. 2.13.1. Pressing the <...

  • Page 123: Maximum Overload History Display

    Maintenance Mode Chapter C Chapter C 2.14 Maximum Overload History Display Displays the maximum overload history that is stored in the AML. In the maintenance menu of Fig. 1.3.1, select "Max History," and press the < > key to display the maximum overload history shown in Fig. 2.14.1. Pressing the <...

  • Page 124: Outrigger Emergency Setting

    Chapter C Maintenance Mode Chapter C 2.15 Outrigger Emergency Setting History Display Displays the outrigger emergency setting history information. In the maintenance main menu of Fig. 1.3.1, select "O/R Emergency History," and press the < > key to display the outrigger emergency setting history display shown in Fig.

  • Page 125: Telematics Check

    Chapter C Maintenance Mode Chapter C 2.16 Telematics Check To check various information of current Telematics status, select "Telematics Check" on the maintenance main menu shown in the Fig. 1.3.1 and press the < > key. The display will go to the Telematics check screen shown in Fig.

  • Page 126: Clock Adjustment

    Chapter C Maintenance Mode Chapter C 2.17 Clock Adjustment Adjusts the clock and calendar that are integrated in the AML. In the maintenance menu of Fig. 1.3.1, select "Clock Adjust," and press the < > key to display the clock adjustment screen shown in Fig. 2.17.1. When the clock information is obtained from the ICF via CAN port, the clock adjustment screen of Fig.
  • Page 127 Maintenance Mode Chapter C Chapter C <Operation method> Move the " _ " (cursor) to the right using the < > key (forward) or to the left using the < > key (back). With the forward movement, the cursor moves as shown in the Fig. below. (With the backward movement, the cursor movement becomes reversed.) Year Month...

  • Page 128: Meter Adjustment

    Chapter C Maintenance Mode Chapter C 2.18 Meter Adjustment [NOTICE] When replacing the DCU (display control unit), adjust the meters in the following procedure. ･ Adjust the meters to the values shown on the combination meter. ･ In the case that the combination meter has been replaced, adjust the meters shown by HELLO-NET. Case Value to be refered to DCU is replaced.

  • Page 129: Unit Selection

    Chapter C Maintenance Mode Chapter C 2.19 Unit Selection Sets the unit that is used commonly in all of the user mode, adjustment mode, and maintenance mode. In the maintenance main menu of Fig. 1.3.1, select "Unit Select," and press the < >...

  • Page 130: Language Selection

    Maintenance Mode Chapter C Chapter C 2.20 Language Selection This is a function to change the displayed language. In the maintenance main menu of Fig. 1.3.1, select "Language," and press the < > key to display the language selection screen shown in Fig. 2.20.1. To go back to the maintenance main menu, press the < >...

  • Page 131: Integrated Information Display Screen

    Chapter C Maintenance Mode Chapter C C-3 Integrated Information Display Screen This is a screen for checking the current operation status in the maintenance screen or in the adjustment screen. 3.1 Crane Information Display Screen In the maintenance screen and adjustment screen, pressing the < >...

  • Page 132: Display Contents

    Maintenance Mode Chapter C Chapter C 3.3 Display Contents The crane information contents displayed in the integrated information screen are shown in Fig. 3.3.1, and the vehicle information contents are shown in Fig. 3.3.2. For the function specific display (slow stop adjustment, over-front special performance, etc.), refer to the corresponding function specification.
  • Page 133 Chapter C Maintenance Mode Chapter C [12 ]: Load ratio ( EN13000 spec.) [13 ]: Outrigger state display [14 ]: Maintenance mode display icon [15 ]: Oil temperature 50°C icon There is no display of 85°C icon. [16 ]: Hook-in icon (Only for hook-in specification) [17 ]: Tilt cylinder full retraction icon (Only for SACO-Jib specification) [18 ]: Jib lock pin unlock icon [19 ]: Boom elevation slow stop cancel icon...
  • Page 134 Chapter C Maintenance Mode Chapter C [10] [13] [11] [12] Fig. 3.3.2 Vehicle information display screen (Display contents) [1]: Vehicle speed [2]: Odometer [3]: Hour meter [4]: Remaining fuel rate [5]: Accumulated fuel consumption [6]: Engine speed [7]: Torque converter pressure [8]: Engine coolant temperature [9]:...

  • Page 135: Vehicle Error Information

    Maintenance Mode Chapter C Chapter C 3.4 Vehicle Error Information When the vehicle error information is obtained from the CAN port, the vehicle error information is displayed cyclically in the bottom section of sub screen shown in Fig. 3.4.1. At this time, pressing the < >...

  • Page 136: Error Code

    Chapter C Maintenance Mode Chapter C C-4 Error Code 4.1 Classification of Error Code The error code is displayed with the numerical value having four digits. The first digit (E1) indicates the error group. The following three-digit number indicates the individual code within the error group. Individual code Group code Group 0: Warning (Refer to Chapter B 3.2 Warning Code and Model Comparison Table)

  • Page 137: Error Notification

    Maintenance Mode Chapter C Chapter C 4.3 Error Notification When the AML detects an error, it displays the error code on the LCD and, at the same time, it outputs the beep sound to notify that an error has occurred. The error code continues to be displayed while the error exists. Fig.

  • Page 138: Error Code Table

    Chapter C Maintenance Mode Chapter C 4.4 Error Code Table 4.4.1 Communication Device Error (Transmitter, etc.) - Crane operation : All the operations are possible. : All the operations are stopped. Port 1: Serial port connected with signal transmitter (for jib) Port 2: Serial port connected with MDT (Multiplex Data Transmitter) Error Crane...
  • Page 139 Chapter C Maintenance Mode Chapter C Error Crane Error name Description code operation Transmitter connected with port 2 has detected an internal Transmitter 2 defect abnormality. E1006 Cause: Transmitter malfunction. Refer to transmitter repair manual. Remedy: Replace the defective transmitter. Transmitting data Transmitter connected with port 1 issued a notification that an error at serial port 1...
  • Page 140 Maintenance Mode Chapter C Chapter C Error Crane Error name Description code operation Transmitter type The type of transmitter connected with port 2 is incorrect. improper (serial port 2) E1012 Cause: Transmitter malfunction, incorrect connection Remedy: Connect a proper transmitter to the serial port. The data on the bus connected with the CAN port 1 cannot be CAN port 1 reception trouble...

  • Page 141: Detector Abnormality Or Abnormal Combination Of Detectors

    Chapter C Maintenance Mode Chapter C 4.4.2 Detector Abnormality or Abnormal Combination of Detectors Error Crane Error name Description code operation The detection value of boom length detector is out of the normal Boom length range. detector trouble Normal range: 5 to 95% (0.25 to 4.75 V) E2003 Cause: Detector malfunction, signal line open/short circuit, board malfunction...
  • Page 142 Maintenance Mode Chapter C Chapter C Error Crane Error name Description code operation Left front outrigger The detection value of front left outrigger length detector is out of the length detector normal range. trouble Normal range: 5 to 95% (0.25 to 4.75 V) E2011 Cause: Detector malfunction, signal line open/short circuit, board malfunction...
  • Page 143 Chapter C Maintenance Mode Chapter C Error Crane Error name Description code operation The detection value of elevating cylinder's rod side pressure detector Elevating rod is out of the normal range, and the status continues for 5 seconds in pressure abnormality low pressure side or for 1 second in high pressure side.
  • Page 144 Maintenance Mode Chapter C Chapter C Error Crane Error name Description code operation Although the Do4 output is OFF, the output monitor incorrectly Do4 output OFF abnormality becomes ON. E2204 Cause: Signal line short circuit, board malfunction Remedy: Perform inspection for the above possible cause. Do5 output OFF Although the Do5 output is OFF, the output monitor incorrectly abnormality...
  • Page 145 Maintenance Mode Chapter C Chapter C Error Crane Error name Description code operation Do4 output ON Although the Do4 output is ON, the output monitor incorrectly abnormality becomes OFF. E2212 Cause: Signal line short to ground, board malfunction Remedy: Perform inspection for the above possible cause. Do5 output ON Although the Do5 output is ON, the output monitor incorrectly abnormality...

  • Page 146: Aml Internal Abnormality

    Maintenance Mode Chapter C Chapter C 4.4.3 AML Internal Abnormality (System Abnormality) : All the operations are stopped. (AML automatic stop output OFF) Error Crane Description Error name code operation ROM check sum An abnormality has occurred to the ROM check sum. abnormality Cause: Incorrect flash memory writing, memory malfunction...

  • Page 147: Cpu State Indicator Led

    Maintenance Mode Chapter C Chapter C 4.5 CPU State Indicator LED The AML has three LEDs on the circuit board whose illumination is controlled by software. Depending on the lighting status of each LED, the AML operating status can be checked. Table 4.5.1 CPU state indicator LED Indication priority Description...

  • Page 148: Required Adjustment After Aml System Part Replacement

    Proportional sol. valve for elevation Valve output adjustment for elevating control 1): Refer to "Data Readout/Rewriting with Maintenance Tool" (Can be found in service section of TADANO INTRANET in Japan only) For the adjustment work, refer to Chapter D, Adjustment Mode. W301-0411E...

  • Page 149: Disassembly And Assembly

    Maintenance Mode Chapter C Chapter C C-6 Disassembly and Assembly 3. With the upper case, remove the board fixing pan head screws, and remove the display board and [NOTICE] CPU board together. Before mounting or dismounting the AML, be sure to turn OFF the starter switch of the crane.

  • Page 150: Connector

    Maintenance Mode Chapter C Chapter C 6.2 Connector 2.1.1 AMP.070 Multi-lock connector (Mark ) 6.2.1 Removing and attaching the connector contact NOTICE The connector contacts are fixed to the connectors by double-locking mechanism. Follow the procedure below when removing and attaching the connector contacts.
  • Page 151 Maintenance Mode Chapter C Chapter C Double lock Harness Checker 1. After the insertion of contact into the housing, 1. Please refer to the Fig. below to check the current doublelock it (hinge type). There are eight places running of assembled harness. to lock.
  • Page 152 Maintenance Mode Chapter C Chapter C 1.INTRODUCTION: AMP Extraction Tool, P/N 755430-2 has been designed to extract 070 Series contacts from double lock housing. Read this instruction sheet carefully, before you start operation. 2.UNLOCKING HINGE-LOCKING DEVICE: The loaded contacts are locked by the double locking hinge device.
  • Page 153 Maintenance Mode Chapter C Chapter C Releasing Center Locking Device: 3. Insert tip end of the tool into the gap of locking device with its flat sides facing aside as shown in Fig.4. 4.Tilt the tool in the arrowed direction to raise the hinge with the locking arm bending out.
  • Page 154 Chapter C Maintenance Mode Chapter C 2.1.2 AMP.040 Multi-lock connector (Mark ) 2. Increase of Contact Keeping Strength can be expected by doublelocking. Insertion of Contact 3. Releasing Doublelock: Refer to contact extraction tool(755430-1) 1. Insert the receptacle properly with its seam side instruction sheet.
  • Page 155 Chapter C Maintenance Mode Chapter C 1.INTRODUCTION: AMP Extraction Tool, P/N 755430-1 has been designed to extract 040 Series contacts from double lock housing. Read this instruction sheet carefully, before you start operation. 2.UNLOCKING HINGE-LOCKING DEVICE: The loaded contacts are locked by the double locking hinge device.
  • Page 156 Chapter C Maintenance Mode Chapter C 3.EXTRACTION OF CONTACTS: Insert tip end of the tool into the housing cavity from the mating side of housing, so as to raise the locking lance of housing. This will make contact unlocking. Proceed as follows (Fig.4): 1.
  • Page 157 Maintenance Mode Chapter C Chapter C 2.1.3 AMP.040 Multi-lock connector (Mark ) 2. Verify that the terminal has been firmly locked to the housing lance. If the crimp is located at the center of the retainer during contact mounting as shown in Fig.2, contact locking is not engaged rightly, causing the contact to slip out.
  • Page 158 Chapter C Maintenance Mode Chapter C Double Lock Ratchet 1. A double lock ratchet is used to reinforce contact support. The insulation barrel is supported at the retainer type double lock area. See Fig.4. 2. If contacts are not mounted correctly inside the housing, double lock may not completely lock or effectively lock.
  • Page 159 Chapter C Maintenance Mode Chapter C Extracting Contacts Remove contacts by inserting the jig from the connector fitting side to lift up the connector housing lance. 1. Depress the contact in the direction of the arrow. 2. Insert jig. 3. Lift up the lance. 4.
  • Page 160 Maintenance Mode Chapter C Chapter C 2.1.4 AMP.040 Multi-lock connector (Mark ) Removing the retainer (From the finally assembled position to the pre-assembled position) 1. To remove the contacts from the housing the retainer must be at pre-assembled position. The Insertion of Contact contact can not be removed from the retainer if it is finally assembled position.
  • Page 161 Chapter C Maintenance Mode Chapter C Extract the contact in accordance with following procedure. W301-0411E...

  • Page 162: Crimping Receptacle Contact

    Maintenance Mode Chapter C Chapter C 6.2.2 Crimping receptacle contact 1. Applicable contact Contact Applicable wire size Hand tool AMP connector Finish part No. (nominal) Part No. type 175062-1 Tin-plated .040 series 0.3-0.5mm 911738-1 175062-2 Gold-plated 175027-1 Tin-plated .070 series 0.5-1.25mm 911788-2 175027-2...

  • Page 163: Replacing The Clock Battery

    Chapter C Maintenance Mode Chapter C 6.3 Replacing the Clock Battery (Procedure) 1. Remove the upper case (CPU board) from the [NOTICE] AML main unit. When the clock battery is worn out, the adjustment values, error codes and driving history cannot be backed up (saving data at power OFF).
  • Page 164 Chapter D A d j u s t m e n t M o d e Contents Outline of Adjustment Mode....150 2.4 Swing Angle Adjustment ......159 2.4.1 Swing Angle 1 Zero Adjustment....159 2.4.2 Swing Angle 2 Zero Adjustment....159 D-1 Operation Keys and Menu...
  • Page 165 3.5 Function of Slow Stop ......171 3.5.1 Elevation Slow Stop........ 171 3.5.2 Swing Slow Stop........171 D-4 Performance Setup ...... 172 4.1 Winch drum position selection ....172 D-5 Operation History Erase....174 5.1 Operation Procedure ......174 D-6 Option Select........ 175 6.1 Operation Procedure ......

  • Page 166: Chapter D

    Chapter D Adjustment mode Chapter D Outline of Adjustment Mode The AML has the following three basic operation modes. This chapter describes the operation method in adjustment mode. User Mode: Used by the operator to operate the crane. For the operation method of user mode, refer to "Chapter B, User Mode." Maintenance Mode: Used to perform the AML maintenance menu (operation check, history information reference, etc).

  • Page 167: Operation Keys And Menu

    Chapter D Adjustment mode Chapter D D-1 Operation Keys and Menu 1.1 Operation Keys Operation keys Fig. 1.1 AML display control panel The following keys are used in the adjustment mode. On and after, < > in the descriptions indicates the operation key.

  • Page 168: Structure Of Adjustment Mode Menu

    Chapter D Adjustment mode Chapter D 1.2 Structure of Adjustment Mode Menu In the maintenance mode and adjustment mode, a menu having a hierarchical structure is used. Use the < > key to go back to the previous hierarchical level. Adjustment mode menu (Maintenance mode menu) Boom angle adjustment...

  • Page 169: Mode Shift

    Chapter D Adjustment mode Chapter D 1.3 Mode Shift 1.3.1 Shift to Maintenance Mode In the user mode, when all the three keys of the < > key, the < > key, and the < > key are pressed and held simultaneously for 0.5 seconds or more, the mode shifts to the maintenance mode.

  • Page 170: Shift To Adjustment Mode

    > key to confirm the input value. Note 1: ID code is changed daily based on the date. (If you need the ID code, contact to Tadano Overseas Div. in Tokyo) Adjustments of calendar and clock must be done in advance before inputting the ID code.

  • Page 171: Adjustment Main Menu

    Chapter D Adjustment mode Chapter D 1.3.4 Adjustment Main Menu When the ID code is correctly input, the adjustment main menu is displayed as shown in Fig. 1.3.3. (The items differ depending on the model.) Fig. 1.3.3 Adjustment main menu display Perform the selection of adjustment menu as described below.

  • Page 172: Detector Adjustment

    Chapter D Adjustment mode Chapter D D-2 Detector Adjustment 2.1 Length and Angle Adjustment Screen When "Detector Adjustment" is selected in the adjustment main menu, the detector adjustment screen appears on the LCD as shown in Fig. 2.1.1. Fig. 2.1.1 Detector adjustment screen Table 2.1.1 shows the list of adjustment items.

  • Page 173: Boom Length Adjustment

    Chapter D Adjustment mode Chapter D 2.2 Boom Length Adjustment Span 2.2.1 Boom Length Zero Adjustment - Fully retract the boom. Zero V(v) - Until "Boom Length" and "Zero adjustment value" become highlighted on the LCD (Fig. 2.1.1), press the < >...

  • Page 174: Adjustment Check

    Chapter D Adjustment mode Chapter D 2.3 Boom Angle Adjustment 2.3.1 Boom Angle Zero Adjustment - Fully retract the boom. - While measuring the boom angle using the sprit level type angle meter, set the boom by the boom lowering operation to the zero adjustment condition. - Until "Boom Angle"...

  • Page 175: Swing Angle Adjustment

    Chapter D Adjustment mode Chapter D 2.4 Swing Angle Adjustment 2.4.1 Swing Angle 1 Zero Adjustment - By the right (clockwise) swing operation, set the swing angle to the over-front. - Until "Swing Angle1" and "Zero adjustment value" become highlighted on the LCD (Fig. 2.1.1), press the <...

  • Page 176: Swing Angle 1 Span Adjustment

    Chapter D Adjustment mode Chapter D 2.4.3 Swing Angle 1 Span Adjustment - By the right (clockwise) swing operation, set the swing angle to the over-rear. - Until "Swing Angle1" and "Span adjustment value" become highlighted on the LCD (Fig. 2.1.1), press the <...

  • Page 177: Outrigger Length Adjustment

    Chapter D Adjustment mode Chapter D 2.5 Outrigger Length Adjustment The outrigger adjustment can be performed with four outriggers at the same time, or separately with each outrigger. 2.5.1 Outrigger Length Zero Adjustment - Fully retract all four outrigger beams. - Until "RFront O/R"...

  • Page 178: Outrigger Length Span Adjustment

    Chapter D Adjustment mode Chapter D 2.5.2 Outrigger Length Span Adjustment - Fully extend all four outrigger beams. - Until "RFront O/R" and "Span adjustment value" become highlighted on the LCD (Fig. 2.1.1), press the < > key (backward) or the < >...

  • Page 179: Moment / Load Radius Adjustment

    Chapter D Adjustment mode Chapter D 2.6 Moment / Load Radius Adjustment Perform the moment adjustment / load radius adjustment according to the description below. Measurement condition: 1. Perform all the adjustments with the outrigger becomes fully extended. 2. The number of part-lines shall be the standard number of part-lines for boom full extension.

  • Page 180: Moment Zero Adjustment

    Chapter D Adjustment mode Chapter D 2.6.1 Moment Zero Adjustment - Fully retract the boom, and lower the boom to the specified boom angle. - With no load (Main hook block only), set the hook to the twoblocking status. - In the LCD (Fig. 2.6.1), press the < >...

  • Page 181: Moment Span Preliminary / Load Radius

    Chapter D Adjustment mode Chapter D - In the LCD (Fig. 2.6.1), press the < > key (backward) or the < > key (forward) until "Radius, K=" becomes highlighted. _Radius 6.78 m K=1.00_ Load radius Deflection coefficient adjustment multiplication - Operate the < >...

  • Page 182: Valve Adjustment

    Chapter D Adjustment mode Chapter D D-3 Valve Adjustment The characteristics of actuator operation speed necessary for the slow stop to AML valve control output (D/A command value) are stored as the valve output adjustment value. Note: Slow stop function corresponding to the proportional solenoid valve does not work until the valve adjustment is completed.

  • Page 183: Swing Output Adjustment (Offset Method)

    Chapter D Adjustment mode Chapter D 3.2 Swing Output Adjustment (Offset Method) By the adjustment of swing output (current) Ao1, Ao2, (CN6-pin1, pin3), the stop point is adjusted. The current value to the proportional solenoid valve that controls the pilot pressure given to the swing control valve’s spool is increased by the F2 key.

  • Page 184: Swing Output Adjustment (Characteristics Measurement Method)

    Chapter D Adjustment mode Chapter D 3.3 Swing Output Adjustment (Characteristics Measurement Method) The offset method keeps only the stop points in memory, so it may fail to decelerate the crane smoothly in some direction clockwise and counterclockwise. To achieve smooth deceleration, characteristics measurement method is used for adjustment of the outputs.
  • Page 185 Chapter D Adjustment mode Chapter D Fig. 3.3.3 Screen during swing output measurement When the measurement is started, the swing speed is gradually increased. After the maximum swing speed is reached, the speed is decelerated with specified time intervals. When "Slew velocity" in the screen of Fig. 3.3.3 becomes zero, the measurement is completed.

  • Page 186: Elevating / Telescoping Output Adjustment

    Chapter D Adjustment mode Chapter D 3.4 Elevating / Telescoping Output Adjustment The adjustment of elevating output and telescoping output is performed automatically. Perform the operation according to the guidance message. In the screen shown in Fig. 3.1.1, select "Boom up," "Boom down," or "Boom retract,"...

  • Page 187: Function Of Slow Stop

    Chapter D Adjustment mode Chapter D 3.5 Function of Slow Stop 3.5.1 Elevation Slow Stop The elevation slow stop functions with the stop positions by load moment ratio 100% stop, backward stability stop, working range limit stop, elevating cylinder stroke end stop, and boom interference stop adopted as the target stop angle.

  • Page 188: Performance Setup

    Chapter D Adjustment mode Chapter D Performance Setup <Performance setup menu> When "Set up performance" is selected in the adjustment main menu of Fig. 1.3.3, the set up performance screen appears as shown in Fig. 4.1.1. Pressing the < > key (scroll up) or the < >...
  • Page 189 Chapter D Adjustment mode Chapter D <Operation method> The currrent setup stae is enclosed by a frame. Press the < > key (scroll up) or the < > key (scroll down) key to select the state to set up, and press the < >...

  • Page 190: Operation History Erase

    Chapter D Adjustment mode Chapter D D-5 Operation History Erase This section describes the method to erase the registration contents of operation history information {stored data of when the crane operation is performed while the load moment ratio is exceeding the set limit value}. [NOTICE] Before delivery to users, always repeat erasing the operation as described here three times.

  • Page 191: Option Select

    Chapter D Adjustment mode Chapter D D-6 Option Select This function is used to change the detector availability information with the models that detectors are provided as options. However, only the items are displayed whose specification selection flag (#17200-29_32, 37, 49, 54, 94) are set as "Option."...

  • Page 192: Processing At Setting Without Detector

    Chapter D Adjustment mode Chapter D 6.2 Processing Depending on Setting Status In: With detector or with function Out: With no detector or with no function The default setting is as listed in the Table 6.2.1. Table 6.2.1 Default setting of the optional items Optional item Default Swing angle...

  • Page 193: Processing At Setting Without Function

    Chapter D Adjustment mode Chapter D 6.4 Processing at Setting without Function - When work range limit function is not present: "Working Range Limitation" With each of the lifting height limit, load radius limit, boom angle upper limit, and boom angle lower limit, a warning will be issued but no stop will be performed.

  • Page 194: Operation Procedure

    Chapter D Adjustment mode Chapter D D-7 AML Emergency / Override Switch History Erase 7.1 Operation Procedure This section describes the method to erase the registration contents of AML emergency / override switch history information (information on the date and time when the AML emergency / override switch is turned ON/OFF).

  • Page 195: Operation Procedure

    Chapter D Adjustment mode Chapter D D-8 Outrigger Emergency Setting History Erase 8.1 Operation Procedure This section describes how to erase the registration contents of outrigger emergency setting history information. In the adjustment main menu of Fig. 1.3.3, select "O/R Emergency History Erase" to display the outrigger history erase screen as shown in Fig.
  • Page 196 Chapter E I n f o r m a t i o n a n d D a t a Contents E-1 AML Adjustment Value List ..180 E-3 AML Control Function List ..190 1.1 Applicable Model: GR-750XL-2 ..... 180 3.1 Applicable Model: GR-750XL-2 .....

  • Page 197: Information And Data

    Information and Data Chapter E Chapter E E-1 AML Adjustment Value List [NOTICE] For the details of adjustment method, refer to "Adjustment Mode." 1.1 Applicable Model: GR-750XL-2 1.1.1 Initial Adjustment (1) Clock adjustment Select the "clock adjust" menu in the maintenance mode, and adjust the date and time. (2) Use the "Winch drum position"...

  • Page 198: Slow Stop Adjustment

    Information and Data Chapter E Chapter E Adjustment value Item Adjustment condition ( ): Tolerance at inspections Power tilt jib (Zero/Span) Adjustment not needed offset angle - Boom: Fully retracted - Indicated boom angle: 80.0±0.1° Actual hoist medium load (Zero) - Load: No load (Hook weight): 0.47±0.21 t (0.47 t main hook block only)

  • Page 199: Applicable Model: Gr-1000Xl-2

    Information and Data Chapter E Chapter E 1.2 Applicable Model: GR-1000XL-2 1.2.1 Initial Adjustment (1) Clock adjustment Select the "clock adjust" menu in the maintenance mode, and adjust the date and time. (2) Use the "Winch drum position" of adjustment mode to set to "Front." 1.2.2 Detector Adjustment These adjustments are based on condition that crane is set on firm level surface, with outrigger max.

  • Page 200: Slow Stop Adjustment

    Information and Data Chapter E Chapter E Adjustment value Item Adjustment condition ( ): Tolerance at inspections - Boom: Fully retracted - Indicated boom angle: 80.0±0.1° Actual hoist medium load (Zero) - Load: No load (Hook weight): 0.47±0.21 t (0.47 t main hook block only) - Hook block: Twoblocking status - Boom: Full extended Moment...

  • Page 201: Detector Check

    Information and Data Chapter E Chapter E E-2 Detector Check 2.1.2 Boom Angle Detector 1. Retract the boom fully, set the boom angle to 0°, and set the PTO switch to "OFF." 2.1 Applicable Model: GR-750XL-2 2. Measure the resistance of the potentiometer. 2.1.1 Boom Length Detector Checking at the connector of the detector 1.

  • Page 202: Swing Angle Detector

    Information and Data Chapter E Chapter E 2.1.3 Swing Angle Detector 2.1.4 Outrigger Extension Length Detector 1. Swing the boom to the over-front (swing angle: 0°), 1. Stow the outrigger beams, and set the PTO switch and set the PTO switch to "OFF." to "OFF."...

  • Page 203: Pressure Sensor For Moment Detection

    Information and Data Chapter E Chapter E 2.1.5 Pressure Sensor for Moment Detection 1. Set the PTO switch to "ON." (Between R and B of pressure sensor connector, voltage of DC 5 V is impressed.) 2. Measure the output voltage between W and B of pressure sensor connector.

  • Page 204: Applicable Model: Gr-1000Xl-2

    Information and Data Chapter E Chapter E 2.2.2 Boom Angle Detector 2.2 Applicable Model: GR-1000XL-2 1. Retract the boom fully, set the boom angle to 0°, 2.2.1 Boom Length Detector and set the PTO switch to "OFF." 1. Retract the boom fully, set the boom angle to 0°, 2.

  • Page 205: Swing Angle Detector

    Information and Data Chapter E Chapter E 2.2.3 Swing Angle Detector 2.2.4 Outrigger Extension Length Detector 1. Swing the boom to the over-front (swing angle: 0°), 1. Stow the outrigger beams, and set the PTO switch and set the PTO switch to "OFF." to "OFF."...

  • Page 206: Pressure Sensor For Moment Detection

    Information and Data Chapter E Chapter E 2.2.5 Pressure Sensor for Moment Detection 1. Set the PTO switch to "ON." (Between R and B of pressure sensor connector, voltage of DC 5 V is impressed.) 2. Measure the output voltage between W and B of pressure sensor connector.

  • Page 207: Aml Control Function List

    Information and Data Chapter E Chapter E Chapter E 3. AML Control Function List 3.1 Applicable Model: GR-750XL-2 1.Setting of operation status No. 9.Backward stability ① Data No.258 (Status after 2 hours have elapsed) 11.Warning and stop % during boom lift with jib extended ①...

  • Page 208: Applicable Model: Gr-1000Xl-2

    Information and Data Chapter E Chapter E Chapter E 3.2 Applicable Model: GR-1000XL-2 1.Setting of operation status No. 9.Backward stability ① Data No.258 (Status after 2 hours have elapsed) ① Data No.10736 (Backward stability data) 11.Warning and stop % during boom lift with jib extended ②...

  • Page 209: Aml Input/Output List

    Information and Data Chapter E Chapter E Chapter E 4. AML Input/Output List 4.1 Applicable Model: GR-750XL-2 2.Analog input ① 17214 (Data that specifies to which Ai terminal the analog detector is connected. Only the signals are shown with which the terminal is assigned.) 1.Digital input ②...

  • Page 210: Applicable Model: Gr-1000Xl-2

    Information and Data Chapter E Chapter E Chapter E 4.2 Applicable Model: GR-1000XL-2 2.Analog input ① 17214 (Data that specifies to which Ai terminal the analog detector is connected. Only the signals are shown with which the terminal is assigned.) 1.Digital input ②...
  • Page 211 Head Office Ko-34,Sinden-cho, Takamatsu, Japan Overseas Service Group Tadano Ryogoku Bldg. 4-12, Kamezawa 2-chome, Sumida-ku, Tokyo, Japan Tel. 81 (3) 3621-7765 Tel fax 81 (3) 3621-7785 History of revision...

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