Publication No. W E. Load Moment Indicator AML-L E. Model PRINTED IN JAPAN 0606 E

Transcription

1 Publication No. W E 01 Load Moment Indicator Model AML-L E c2006 PRINTED IN JAPAN 0606 E

2 Foreword Foreword This service manual covers the load moment indicator (AML-L E) installed on the TADANO cranes in the chart below. In undertaking repair, refer to the separate operation and maintenance manual, parts catalog, and crane-covering service manual for pertinent information. If the parts replacement is required, check the disassembly and order units from the applicable parts catalog. 1. Applicable spec. No Applicable crane model TT-300XL-1 Specification numbers: (1) TT Use this manual for machines with the AML (AML-L E) even if the crane model is other than the above. Please note that, for product Improvement, some changes may have been incorporated in the machine that are not covered in this manual. 1 W E

3 Foreword 2. Contents 3. Method of Shifting Modes Method of Menu Selection...35 Foreword Applicable spec. No Contents... 2 Required Adjustment After AML System Parts Replacement...36 Components of the AML (AML-L E) Main Unit Panel Internal view and name plate Internal block diagram... 6 Diagram of the AML System (TT-300XL-1)...7 Input/Output Signals of the AML System (TT-300XL-1)...8 [OPERATION]...13 Functions of and How to Use User Mode (TT-300XL-1)...13 Mode Structure Configuration and Functions of the AML System Names and Functions of AML Main Unit Parts Selecting Operational Status AML Pre-operational Inspection How to Use the Working Range Limit Function Display Alteration [ADJUSTMENT AND MAINTENANCE]..31 Functions of and How to Use Adjustment Mode...37 Adjustment Procedures Adjustment Initialization Procedure of Conversion Factors Resetting Procedures of Moment Adjustment Resetting Capacity Setting Procedure of Head-off Capacity Setting Procedure of Jib Selection Procedure of Single Top Selection Procedure of Winch Drum Posirion Setting Boom Length Adjustment Boom Angle Adjustment Swing Angle Adjustment Outrigger Extension Width 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...51 Other Functions and How to Use Them Language Overload History Display Erasing the Overload History...53 General:Adjustment Mode and Maintenance Mode Keys and Switches for Adjustment and Maintenance Mode Structure and Menu W E

4 Foreword 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 Monitor (Multiplex Data Transmitter Monitor) Key Switch Check Display Check Error Data Display Erasing the Error Data OP (Option) Board Check Ao Check Sio Check Adjust Monitor Overload History Display Erasing the Overload History Clock Adjustment Checking the Detectors (TT-300XL-1) Boom Length Detector Boom Angle Detector Swing Angle Detector Outrigger Extension Width Detector Pressure Sensor for Moment Detection...82 Fuses...83 Replacing the Clock Battery...84 Error Display of Error How to Read the Error How to Read the Error History Troubleshooting Table Group Code Group Code Group Code Group Code Disassembly of AML Main Unit Removing Front Panel/Display Board Removing Rear Panel/Connector Board Removing CPU Board/Analog Board /Power Board Notes on ROM/EEPROM Replacement Adjustment Value Table...78 Specification No. : GR (2M2D-specification) W E

5 Components of the AML(AML-L E) Main Unit Components of the AML(AML-L E) Main Unit 1. Panel 4 W E

6 Components of the AML(AML-L E) Main Unit 2. Internal view and name plate 5 W E

7 Components of the AML(AML-L E) Main Unit 3. Internal block diagram 6 W E

8 Diagram of the AML System (TT-300XL-1) Diagram of the AML System (TT-300XL-1) 7 W E

9 Input/output Signals of the AML System (TT-300XL-1) Input/output Signals of the AML System (TT-300XL-1) As shown in the Diagram of the AML System on the previous page, the display board, CPU board, analog board, power board and connector board consist inside the AML. The following lists describe the names and functions of the input/output signals on CN1, CN2 and CN3 cnnectors. CN1 connector signals and functions are shown below: CN 1 connector Pin No. Name 3 ANAIN A 4 ANAIN B 5 ANAIN C 9 ANAIN D 10 ANAIN E 11 ANAIN F 13 Di1 14 Di2 24 Di5 Signal names and functions Signal name: Boom length detector input Analog input representing detected boom length. Input voltage: DC 0 to 4.5 V Signal name: Boom angle detector input Analog input representing detected boom angle. Input voltage: DC 0 to 4.5 V Signal name: Swing angle detector 1 input Analog input from the swing angle detector 1 representing detected swing angle. Input voltage: DC 0 to 4.5 V Signal name: Swing angle detector 2 input Analog input from the swing angle detector 2 representing detected swing angle. Input voltage: DC 0 to 4.5 V Signal name: Main hydraulic pressure sensor input Analog input representing detected main hydraulic pressure. Input voltage: DC 0 to 4.5 V Signal name: Accumulator pressure sensor input Analog input representing detected accumulator pressure. Input voltage: DC 0 to 4.5 V Signal name: Two-blocking detection switch input Switch input representing whether two-blocking condition exists. Switch ON (DC0V): The hook currently in use is in normal state. Switch OFF (DC24V): The hook currently in use is two-blocking. Signal name: 3rd/top boom sections full retraction detection switch input Switch input representing whether the 3rd/top boom sections are fully retracted. Switch ON (DC0V): 3rd/top boom sections in fully retracted state. Switch OFF (DC24V): 3rd/top boom sections are not fully retracted. Signal name: Auti-two block disable switch input Switch input representing whether automatic stop caused by two-blocking is overridden. Switch ON (DC0V): Automatic stop caused by two-blocking is cancelled and the alarm buzzer does not sound. Switch OFF (DC24V): Auti-two block function is ready. 8 W E

10 Input/output Signals of the AML System (TT-300XL-1) CN 1 connector Pin No. Name 25 Di6 27 Di8 29 Di10 34 ANAING 35 ANAINH Signal name: Override key switch input Signal names and functions Switch input representing whether automatic stop caused by overloading is overridden. Switch ON (DC0V): Automatic stop caused by overloading is cancelled. Switch OFF (DC24V): Automatic stop function is ready. Signal name: Jib stowed detection switch input Switch input representing whether the jib is stowed. Switch ON (DC0V): The jib is stowed. Switch OFF (DC5V): The jib is not stowed. Signal name: Swing position check switch input Switch input representing whether the swing position is over-left-side. Switch ON (DC0V): The swing position is over-left-side. Switch OFF (DC5V): The swing position is not over-left-side. Signal name: Input for pressure sensor for moment detection (extension side) Analog input to detect the elevating cylinder extension pressure. Input voltage: DC 0 to 5 V Signal name: Input for pressure sensor for moment detection (retraction side) Analog input to detect the elevating cylinder retraction pressure. Input voltage: DC 0 to 5 V 9 W E

11 Input/output Signals of the AML System (TT-300XL-1) CN2 connector signals and functions are shown below: CN 2 connector Pin No. name Signal names and functions Signal name: Automatic stop (AML vent) relay output This relay contact turns OFF and stops crane operation when the crane is overloaded, the hook is two-blocking or the AML main unit is out of order. Relay ON (DC24V): Normal operation is available. Relay OFF (DC0V): The crane operation is stopped. Relay output Crane condition 1 RLY 1 ON Moment ratio < 90% ON 90% Moment ratio < 100% OFF OFF OFF Moment ratio 100% While the boom lift with the jib mounted is performed, the relay output turns OFF when the moment ratio becomes as follows: Moment ratio 85 % Two-blocking. Failure in the AML unit. 3 RLY3 Signal name: Two-blocking alarm relay output This relay contact turns ON and the alarm buzzer is output when the hook block is two-blocking. Relay ON (DC24V): Alarm buzzer is output. Relay OFF (DC0V): Alarm buzzer is not output. Signal name: AML alarm relay output This relay contact turns ON and outputs alarm buzzer when the crane is overloaded. Relay ON (DC24V): Alarm buzzer is output. Relay OFF (DC0V): Alarm buzzer is not output. Relay output Moment condition OFF Moment ratio < 90% OFF Moment ratio < 75% (with the jib mounted) 4 RLY 4 90% Moment ratio < 100% ON/OFF While the boom lift with the jib mounted is performed, the relay output turns ON/OFF when the moment ratio becomes as follows: below. 75% Moment ratio < 85% Moment ratio 100% 5 RLY 5 ON While the boom lift with the jib mounted is performed, the relay output turns ON when the moment ratio becomes as follows: Moment ratio 85% Signal name: Telescoping control relay output < Extension > The relay turns ON (DC24V) and 4th/top boom sections extend under either of following condition. 1. The boom length is 12.5m or more. < Retraction > The relay turns OFF (DC0V) and 2nd/3rd boom section retracts under either of following condition. 1. The boom length is 12.48m or less. 10 W E

12 Input/output Signals of the AML System (TT-300XL-1) CN 2 connector Pin No. name 6 RLY 6 8 RLY 8 9 Di11 11 Di13 17 Di15 19 Di17 20 Di18 Signal names and functions Signal name: Aux. winch select indicator lamp relay output [For (2M2D)] This relay contact turns ON and the indicator lamp is lit when the winch selector switch is set to the aux. winch side. Relay ON (DC24V): Aux. winch select indicator lamp is lit. Relay OFF (DC0V): Aux. winch select indicator lamp goes on. Signal name: Accumulator low pressure alarm relay output This relay contact turns ON and the alarm buzzer is output when the accumulator pressure is 10.3MPa (1494psi) or less. Relay ON (DC24V): Alarm buzzer is output. Relay OFF (DC0V): Alarm buzzer is not output. Signal name: Main winch hoist-up operation detection switch input Input from the switch detecting hoist-up operation of the main winch. Switch ON (DC0V): No hoist-up operation of the main winch is detected. Switch OFF (DC5V): Hoist-up operation of the main winch is detected. Signal name: Aux. winch hoist-up operation detection switch input Input from the switch detecting hoist-up operation of the auxiliary winch. Switch ON (DC0V): No hoist-up operation of the auxiliary winch is detected. Switch OFF (DC5V): Hoist-up operation of the auxiliary winch is detected. Signal name: Boom extending operation detector switch input Input from the switch detecting boom extending operation. Switch ON (DC0V): No boom extending operation is detected. Switch OFF (DC5V): Boom extending operation is detected. Signal name: Boom raising operation detector switch input Input from the switch detecting boom raising operation. Switch ON (DC0V): No boom raising operation is detected. Switch OFF (DC5V): Boom raising operation is detected. Signal name: Boom lowering operation detector switch input Input from the switch detecting boom lowering operation. Switch ON (DC0V): No boom lowering operation is detected. Switch OFF (DC5V): Boom lowering operation is detected. 11 W E

13 Input/output Signals of the AML System (TT-300XL-1) CN3 connector signals and functions are shown below: CN 3 connector Pin No. Name 2 TR2 3 TR3 4 TR4 21 Di21 22 Di22 23 Di23 Signal name: AML 90% alarm output Signal names and functions OC (Open collector) output turns ON when the Load moment ratio is between 90% and 100%. OC output ON (DC0V): External indicator lamp indicating 90% is lit. OC output OFF (DC24V): External indicator lamp indicating 90% goes out. While the boom lift with the jib mounted is performed, OC output turns ON when the moment ratio reaches the range below: 75% Moment ratio < 85% Signal name: AML 100% alarm output OC (Open collector) output turns ON when the load moment ratio exceeds 100% or automatic stop function is cancelled. OC output ON (DC0V): External indicator lamp indicating 100% is lit. OC output OFF (DC24V): External indicator lamp indicating 100% goes out. Condition to turn ON OC output Moment ratio 100% While the boom lift with the jib mounted is performed, OC output turns ON when the moment ratio reaches the range below: Moment ratio 85% Anti-twoblock disable switch: pressed Override key switch ON position and PTO switch in OVERRIDE position. Signal name: Front jack overload warning output OC (Open collector) output turns ON when the front jack overload detection switch is ON. OC output ON (DC0V): The horn sounds. OC output OFF (DC24V): The horn does not sound. Signal name: Winch selector switch (SN50) onput [For (2M2D)] Switch input representing whether Auxiliary winch is employed. Switch ON (DC0V): Auxiliary winch is employed. Switch OFF (DC5V): Main winch is employed. Signal name: Outrigger state emergency register switch (SN51) input Switch input representing whether emergency registration of outrigger extension width to the AML during malfunction of the outrigger extension detector system is available. Switch ON (DC0V): Emergency registration of outrigger extension width is available. Switch OFF (DC5V): No emergency registration is available. Signal name: 3rd/top boom section extending switch (SN16) input Switch input to extend the 3rd/top boom sections. Switch ON (DC0V): The boom secondary extending switch is pressed. Switch OFF (DC5V): The boom secondary extending switch is not pressed. 12 W E

14 Functions of and How to Use User Mode (TT-300XL-1) [OPERATION] Functions of and How to Use User Mode (TT-300XL-1) Mode Structure 2. Maintenance Mode: Used to make functional checks of AML. See the ADJUSTMENT AND MAINTENANCE section. 3. Adjustment Mode: Used to make detector adjustment. See the ADJUSTMENT AND MAINTENANCE section. The AML device has three modes and AML functions are allotted for these models. POWER ON Protect switch ON USER MODE MAINTENANCE MODE Protect switch OFF ADJUSTMENT MODE POWER ON IW E05 1. User Mode: Used to indicate moment ratio or to perform AML pre-opetational inspection (Normally used). In normal use, turn ON the protect switch mounted on the adjustment window on the top of AML. AML will go to the user mode when the power turns on. The abnormality display LED lights when the AML is in abnormal conditions (to indicate that the CPU is faulty). MOMENT SHORT PROTECT ZERO WDT HALT ON OFF Top view Protect switch Abnormality display LED IW E35 13 W E

15 Functions of and How to Use User Mode (TT-300XL-1) Configuration and Functions of the AML System The AML system is a safety device provided to prevent overloading of the crane which may cause it to overturn or be damaged. The AML system has various kinds of functions, including the following typical functions. Based on the registered work conditions by operator selection and the signals from various sensors, the crane operations are controlled. (2) Automatic stop function to prevent two-blocking when two-blocking occurs, failure message is shown, alarm buzzer sounds, and the crane operation toward the critical side stops. (3)Working range limit functions When the crane reaches the registered boom angle (upper or lower), lifting height, or load radius, the relevant restriction indicator lamp flashes and the alarm buzzer soumds to warn the operator. (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. Automatic stop by overloading : Stop Hoisting up Boom lowering Boom extension On-outrigger operation 14 W E

16 Functions of and How to Use User Mode (TT-300XL-1) AML System Configuration 15 W E

17 Functions of and How to Use User Mode (TT-300XL-1) Automatic Stop Functions Causes of automatic stop Moment ratio exceeds 100% (*1) Two-blocking AML system error Operation Boom lift Jib lift Halted movement Hoisting up Boom lowering Boom extension (*1):For the boom lift with the jib mounted, automatic stop will work when the moment is 85% or more. Alarm Functions Condition Winch is overwound A control is moved toward critical side (hoist up, boom lowering or boom extension) while two-brocking condition exists. Alarm Buzzer:Sounds continuously. Moment display: Displays [Warning:0024]. Buzzer: Sounds continuously. Anti-twoblock function is Moment display: Displays deactivated while the [Warning:0015]. hook block two-brocking. External warning lamps: Red lamp is lit. Buzzer: Sounds continuously. Moment ratio is 90% to 99%. Moment ratio is 100% or more A control is moved toward critical side while moment ratio is 100% or more. AML system errer Working range limit function activated. Moment display: Yellow segment is lit. External warning lamps: Orange lamp is lit. Buzzer: Sounds intermittently. Moment display: Red segment(s) is lit while ratio is up to 110%, and all segments are lit when 110% is exceeded. External warning lamps: Red lamp is lit. Buzzer: Sounds continuously. Moment display: Displays [Warning:0023]. External warning lamps: Red lamp is it. Buzzer: Sounds continuously. Moment display: Displays failure messages. AML Buzzer: Sounds 3 seconds. Associated restriction indicator lamp flashes. Buzzer: Sounds continuously. Boom lift with jib mounted on boom Moment ratio is between Moment display: Applicable 75% to 85%. segment is lit. External warning lamps : Orange lamp is lit. Buzzer: Sounds intermittently. Moment ratio is 85% or more. Moment display: Displays [Warning:0088]. External warning lamps : Red lamp is lit. Buzzer: Sounds continuously. In the above table, "Buzzer" is the device outside the AML unit, outputting buzzing sound. "AML buzzer" is the device inside the AML unit, outputting beeping sound. The AML buzzer sounds for 3 seconds every time a message appears. 16 W E

18 Functions of and How to Use User Mode (TT-300XL-1) Names and Functions of AML Main Unit Parts 17 W E

19 Functions of and How to Use User Mode (TT-300XL-1) Bargraph Display Usually on or more than that Each frame representing 10% Each frame representing 2.5% Each frame representing 2.5% IW E57 1. Moment ratio mark The moment ratios on the bargraph are color coded as follows: safe (green), notice (yellow) and limit (red). 2. Moment display Normally displays a moment ratio on a bargraph. Displays the main-circuit pressure when the display alteration key is pressed. Also displays error messages when an operational or system error occurs. 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. 18 W E

20 Functions of and How to Use User Mode (TT-300XL-1) Display Panel 1 1. Jib angle display When jib lift is selected, the jib offset angle is displayed. When the number of parts of line select key or the display alteration key is pressed, the number of parts of line is displayed. Also, when an upper boom angle limit has been registered, the registered upper boom angle limit value is displayed while the register key is pressed. 2. Number of parts of line symbol This symbol indicates that the jib angle display [1] is showing the number of parts of line. 3. Boom length symbol This symbol indicates that the boom length display [13] is showing the boom length. 5. Jib angle symbol This symbol indicates that the jib angle display [1] is showing the jib offset angle. 6. Jib lift symbol This symbol indicates that the jib lift is selected. Its also indicates the condition of the jib. 7. Actual load display Displays the actual load. 8. Rated lifting capacity display Displays the rated lifting capacity. 9. Load radius limit symbol This symbol indicates that the load radius display [11] is showing the registered load radius limit value. The load radius symbol [10] is also displayed at the same time. 10. Load radius symbol This symbol indicates that the load radius display [11] is showing the load radius. 11. Load radius display Normally displays the crane's load radius. Displays the boom swing angle while the display alteration key is pressed. When a load radius limit has been registered, the registered load radius limit value is displayed while the register key is pressed. 13. Boom length display Normally displays the boom length. Displays the lifting height while the display alteration key is pressed. When a lifting height limit has been registered, the registered lifting height limit value is displayed while the register key is pressed. 14. Lifting height symbol This symbol indicates the boom length display [13] is showing the lifting height. 19 W E

21 Functions of and How to Use User Mode (TT-300XL-1) 15. Lifting height limit symbol This symbol indicates that the boom length display [13] is showing the registered lifting height limit value. The lifting height symbol [14] is also displayed at the same time. 16. Upper boom angle limit symbol This symbol indicates that the jib angle display [1] is showing the registered upper boom angle limit value. 17. Boom angle symbol This symbol indicates that the boom angle display [19] is showing the boom angle. 19. Boom angle display Normally displays the boom angle. Displays the moment ratio when the display alteration key is pressed. When a lower boom angle limit has been registered, the registered lower boom angle limit value is displayed while the register key is pressed. 20. Boom lift symbol This symbol indicates that the boom lift is selected. 18. Lower boom angle limit symbol This symbol indicates that the boom angle display [19] is showing the registered lower boom angle limit value. 20 W E

22 Functions of and How to Use User Mode (TT-300XL-1) Controls 1. Increase key Used to increase the selected value. 2. Decrease key Used to decrease the selected value. 3. Lifting height restriction key Used to activate and release the lifting height limiting function. 4. Lifting height restriction indicator lamp Lights up when lifting height limiting function is activated. 5. Upper boom angle restriction indicator lamp Lights up when the uppermost boom angle limiting function is activated. 6. Lower boom angle restriction indicator lamp Lights up when the lowermost boom angle limiting function is activated. 7. Upper boom angle restriction key Used to activate and release the uppermost boom angle limiting function. 8. Lower boom angle restriction key Used to activate and release the lowermost boom angle limiting function. 9. Load radius restriction indicator lamp Lights up when the load radius limiting function is activated. 10.Load radius restriction key Used to activate and release the load radius limiting function. 11.Display alteration key Used to alter the displays on display panel Register key Used to register a selected status. 13.Check key Used to check the AML system functions. 14.Lift mode select key Used to select the lift status. 15.On-rubber mode select key Not used for this machine. If the key is pressed by mistake, the on-rubber state is registered (the state symbol flashes). In this case, press the display alteration key to restore the outrigger state registration. 16.Right outrigger status select key 17.Left outrigger status select key Used to select the outrigger status. 18.Number of parts of line select key Used to select the a number of parts of line. 21 W E

23 Functions of and How to Use User Mode (TT-300XL-1) Display Panel 2 1. Front jack When the front jack is set, the symbol lights to indicate that the front jack is set. 2. Outrigger state symbol Indicates the way the outriggers are extended. Flashes while an outrigger state is in process of being registered, and lights up when the registration is completed. 3. "on-rubber" state symbol When power is supplied (PTO switch is turned ON), the symbol lights to indicate that the outriggers are not set. 4. Boom position indicator Indicates the boom position in 10 increments. 22 W E

24 Functions of and How to Use User Mode (TT-300XL-1) Selecting Operational Status WARNING Should the operational status be incorrectly registered, the crane may overturn or be damaged, leading to a serious accident. Prior to every operation, check that the registered status corresponds to the actual status of the crane. Selecting Outrigger Status When power is supplied (PTO switch is turned ON), the on-rubber status is automatically selected ( on-rubber state symbol lights). Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power has been last turned off, enter the settings all over again. If an outrigger or the front jack is stowed after registration of outrigger status, the registered status is automatically switched to the on-rubber status. In this case, register the outrigger status again before starting crane operation. When the outrigger or left outrigger status select key is pressed, the outrigger state symbol (and the front jack symbol) flashes in accordance with the status that the load moment indicator detects. After making sure that the display conforms to the actual outrigger and front jack conditions, press the register key. The outrigger state symbol (and the front jack symbol) will change from flashing to continuous lighting and the moment display, rated lifting capacity display and actual load display will return to normal display conditions, meaning that the state has been registered. Register the outrigger state using the right or left outrigger status select key and the register key. 23 W E

25 Functions of and How to Use User Mode (TT-300XL-1) Selecting Lift Status The boom lift status is the default status and is automatically selected (the boom lift symbol lights up) when the power supply is turned on (the PTO switch is placed in the ON position). Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power has been last turned off, enter the settings all over again. After selecting the intended lift status, press the register key to register the status. The corresponding indicative symbols will change from flashing to lighting and the moment display, rated lifting capacity display and actual load display will return to normal display conditions, meaning that the state has been registered. (When the jib set status is selected, the jib lift symbol will remain flashing.) Register the lift status using the lift mode select key and the register key. Each time the lift mode select key is pressed, the mode changes in numerical sequence, from (1) to (4). The display returns to (1) if you press the switch while the status (4) is displayed on the screen. Select the status that corresponds to the actual lift status. 24 W E

26 Functions of and How to Use User Mode (TT-300XL-1) Selecting Number of Parts of line If the registered number of parts of line is smaller than the standard number, a maximum allowable lifting load is limited, depending on the registered number. If zero(0) is registered, however, the AML performs as if the standard number were registered. Similarly, the AML works on the basis of the standard number of parts of line if the registered number is larger than the standard number, or other than the values specified for your model. When the power supply is turned on (i.e. PTO switch ON), the standard number of parts of line corresponding to the work condition is selected. Register the number of parts of line by use of the number of parts of line select key and the register key, as follows: 1. Press the number of parts of line select key. The number of parts of line symbol will flash, and the number of parts of line will be shown on the jib angle display in a flashing mode. 2. Press the increase or the decrease key to set the number to the actual number of parts of line. When the increase or the decrease key is pressed, a numeral showing the number of parts of line changes from flashing to lighting, and increases or decreases. When the increase or the decrease key is kept pressed, the number of parts of line continuously increases or decreases. 3. Once the intended number of parts of line is set, press the register key to register the number. Then, the number of parts of line symbol will be turned off and the jib angle display will return to a normal status. The number of parts of line can be confirmed by pressing the display alteration key. 25 W E

27 Functions of and How to Use User Mode (TT-300XL-1) AML Pre-operational Inspection 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. Before starting operation, check that the AML works in good condition, as follows: 1. Press the check key and make sure that the AML is in the following conditions: Moment display All segments light up. Display panel (1 and 2) All segments light up. Working range restriction indicator lamp All four lamps light up. Alarm buzzer Sounds continuously. Movement toward critical sides Automatically halted 2. Press either the register key, display alteration key or check key to return the display to the normal condition. 3. Make sure that the display on the display panels conforms to the actual crane conditions. (1) Boom length (2) Boom angle (3) Jib angle 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 The actual load is not shown correctly if the lift status is not registered correctly. (5) Outrigger state symbol (6) Front jack symbol (7) Boom position indicator 26 W E

28 Functions of and How to Use User Mode (TT-300XL-1) How to Use the Working Range Limit Function If the working range limit is registered very close to an obstacle, there is a risk of the crane colliding with the obstacle, depending on the operational status and the manner in which the load is handled. When registering a range limit, allow a sufficient clearance to avoid collision. The working range limit function gives warning only, and does not automatically stop crane motions. When the alarm buzzer sounds, immediately halt the crane motion. The working range limit function gives warning when the crane reaches the previously registered boom angles (upper and lower), lifting height or load radius. The function is useful for handling a load in a confined place because it defines the area in which the boom can operate. Boom Angle Limit Raise or lower the boom to the desired angle, and press the upper or lower boom angle restriction key. The corresponding restriction indicator lamp will flash and the buzzer will sound continuously, indicating that the boom angle limit has been registered in the memory. When the boom is moved back to an angle within the set limit, the restriction indicator lamp stops flashing and stays lit and the buzzer stops. Thereafter, the upper or lower boom angle restriction indicator lamp flashes and the buzzer sounds continuously whenever the upper or lower limit previously registered is reached. To cancel the boom angle limit function, press the boom angle restriction key again. The corresponding boom angle restriction indicator lamp will go off. Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power has been last turned off, enter the settings all over again. 27 W E

29 Functions of and How to Use User Mode (TT-300XL-1) Lifting Height Limit Move the boom to the desired height, and press the lifting height restriction key. The lifting height restriction indicator lamp will flash and the buzzer will sound continuously, indicating that the height limit has been registered in the memory. When the boom is moved back to a height within the set limit, the lifting height restriction indicator lamp stops flashing and stays lit and the buzzer stops. Thereafter, the lifting height restriction indicator lamp flashes and the buzzer sounds continuously whenever the height limit previously registered is reached. To cancel the height limit function, press the lifting height restriction key again. The lifting height restriction indicator lamp will go off. Load Radius Limit Move the boom to the desired load radius, and press the load radius restriction key. The load radius restriction indicator lamp will flash and the buzzer will sound continuously, indicating that the load radius limit has been registered in the memory. When the boom is moved back toward the non-critical side, the load radius restriction indicator lamp stops flashing, and stays lit and the buzzer stops. The load radius restriction indicator lamp flashes and the buzzer sounds continuously whenever the limit previously registered is reached. To cancel the load radius limit function, press the load radius restriction key again. The corresponding load radius restriction indicator lamp will go off. 28 W E

30 Functions of and How to Use User Mode (TT-300XL-1) Display of Working Range Limit Values Press the register key while working range limits have been registered. While the key is being pressed, the registered working range limit values are displayed. On the moment display will be displayed a message "Working range". This display is not made during a preoperational check of the AML and when a working state is being registered. When working range limits are not registered, the message "---" will be displayed. 29 W E

31 Functions of and How to Use User Mode (TT-300XL-1) Display Alteration Displays on the moment display and the display panel 1 can be altered, as shown below in the figures, by pressing the display alteration key. The indicative symbols are displayed, too. Display Panel 1 Displays on the actual load display and the rated load display do not alter even when the display alteration key is pressed. 30 W E

32 General: Adjustment Mode and Maintenance Mode [ADJUSTMENT AND MAINTENANCE] General: Adjustment Mode and Maintenance Mode 1. Keys and Switches for Adjustment and Maintenance MOMENT SHORT PROTECT ZERO WDT HALT ON OFF 8. Moment input short-circuit switch 9. Protect switch 10. Moment zero adjuster 11. Abnormality display LED Top view IW E02 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 messages displayed on the moment display. 3. Register key Used to register the selected state and write the adjustment value in EEPROM. 4. Increase key Used to increase the adjustment value. 5. Decrease key Used to decrease the adjustment value. 6. Display alteration key Used to change the display to the upper menu. 7. Check 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 adjustment mode. With this switch OFF, data in the EEPROM becomes rewritable. 10.Moment zero adjuster This adjuster is for adjustment by the AML manufacturer s service personnel. Do not tamper. 11.Abnormality display LED Lights when the AML is in abnormal conditions or when the AML adjustment is initialized. 31 W E

33 General: Adjustment Mode and Maintenance Mode 2. Mode Structure and Menu The AML device has three modes and AML functions are allotted for these models. 2. Maintenance Mode: Used to make functional checks of AML. This mode has the following menus: Protect switch ON Protect switch OFF 1. User Mode: POWER ON USER MODE ADJUSTMENT MODE POWER ON MAINTENANCE MODE IW E05 Used to indicate moment ratio or to perform AML pre-opetational inspection (Normally used). In normal use, turn ON the protect switch mounted on the adjustment window on the top of AML. AML will go to the user mode when the power turns on. MAIN MENU [ Maintenance] [ Adjust clock] SUB-MENU [: Prog. version] [: Data ID. number] [: Di check] [: Ai check] [: Disp ELEV PRES] [: Do check] [: MDT Monitor] [: Key SW check] [: Display check] [: Disp. err data] [: Erase err data] [: Disp. O/L data] [: Erase O/L data] [: OP board check] [: Ao check] [: Sio check] [: Adjust Monitor] MOMENT SHORT PROTECT ZERO WDT HALT ON OFF Top view ON Protect switch IW E03 32 W E

34 General: Adjustment Mode and Maintenance Mode 3. Adjustment Mode: Used to make detector adjustment. This mode has the following menus: MAIN MENU SUB-MENU [ Adjust] [: Adjust L & A] *Boom length zero-point adjustment *Boom length span-point adjustment *Boom angle zero-point adjustment *Boom angle span-point adjustment *Swing angle zero-point adjustment *Swing angle span-point adjustment *Outrigger length zero-point adjustment *Outrigger length span-point adjustment [: Adj. work rad] *Load radius span adjustment [: Adjust MMT] *Moment zero-point adjustment *Moment span-point adjustment [ Adjust CNT dat] [: Adj. ELV speed] (*2) [: Reset ELV data] (*2) [ Adjust AO] [: Adjust AO Ofs.] (*2) [: Reset AO Ofs.] (*2) [ Initialize L & A] [: Reset DEF. FCT] [ Initialize MMT] [: Reset zero. span] [ Disp. O/L data] [: Reset PCSN] (*1) [ Erase O/L data] [ Adjust PCSN] (*1) [ Reg. Capac.] [: Head-OFF Capac] (*2) [ Language] [: Jib Select]] (*2) [: S/T Select] [: Winch drum PSN] (*1) : This menu is prohibited to be used. (*2) :In case of TT-300XL, This menu is not applied. 33 W E

35 General: Adjustment Mode and Maintenance Mode 3. Method of Shifting Modes MOMENT SHORT PROTECT ZERO WDT HALT ON OFF Protect switch Top view IW E03 POWER ON Protect switch ON Protect switch OFF 1 USER MODE MAINTENANCE MODE ADJUSTMENT MODE POWER ON IW E12 1. User mode Maintenance mode Press the scroll-up key, scroll-down key, and register key at the same time. Then, the moment display changes from the bargraph to [ Maintenance]. This display denotes the Maintenance mode. 2. Maintenance mode User mode Press the display alteration key. When the bargraph shows up on the moment display, AML goes back to the User mode. 4. Adjustment mode User mode While the main menu of the adjustment mode is displayed, turn ON the protect switch. Then AML will go back to User mode and bargraph will be displayed on the moment display. 5. Maintenance mode Adjustment mode While the main menu of the maintenance mode is displayed, turn OFF the protect switch. The moment display will change to [ Adjust], and will denote Adjustment mode. 3. User mode Adjustment mode Turn OFF the protect switch at the adjustment window on the top of AML. Then, the moment display will change to [ Adjust], and will denote Adjustment mode. 34 W E

36 General: Adjustment Mode and Maintenance Mode 4. Method of Menu Selection 1. When AML is in Maintenance mode or Adjustment mode, the main menu is displayed on the moment display of bargraph display portion. Displayed menu changes by means of the scroll-up or scroll-down key. Press the register key to select the displayed item. 2. If the selected item in the main menu has any sub-menus, the sub-menus are displayed on the moment display of bargraph display portion. You can select the sub-menu in the same way sa main menu selection. 4. The following marks displayed in the menu:, : and. When a main menu is displayed, the mark stands before the menu name. (Ex. Adjust ) When a sub-menu is displayed, the mark : stands before the menu name. (Ex. :Adjust MMT ) The mark after the menu name indicates that the depression of the scroll-down key calls for another menu. 3. By pressing the display alteration key, the display changes to the upper menu. 35 W E

37 Required Adjustment After AML System Parts Replacement Required Adjustment After AML System Parts Replacement NOTICE] EEPROM stores the adjustment values for each specification number. When replacing the CPU board, remove the EEPROM after removing it from the broken CPU board to dispense with adjustment work other than clock adjustment. Visually check that the value displays such as boom length and boom angle and symbol display on the display panels 1 and 2 on the AML conform the actual crane condition. Replaced part Required adjustment Boom length detector Boom angle detector Swing angle detector Outrigger extension width detector Pressure sensor for moment detection Boom length adjustment Boom angle adjustment Swing angle adjustment Outrigger extension width adjustment Moment adjustment AML unit Display board CPU board only (When reusing EEPROM removed from the broken CPU board) CPU board Analog board Power board Connector board CPU board (When EEPROM is not to be reused) EEPROM ROM None Clock adjustment Perform adjustment initialization and take every step of adjustment. For adjustment items and procedure, see Adjustment Procedures on the subsequent page in the Function of and How to Use Adjustment Mode section. None Boom length adjustment Boom angle adjustment Swing angle adjustment Moment adjustment None None 36 W E

38 Functions of and How to Use Adjustment Mode Functions of and How to Use Adjustment Mode Adjustment Procedures WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety. You can adjust boom length, boom angle, swing angle, and outrigger extension width in random order. You can adjust swing output and elevation output in random order. After all adjustment is completed, erase-protect the overload history, referring to Erasing the Overload History in the Functions of How to Use Adjustment Mode section. The adjustment items and procedures are as follows: 1. Adjustment Initialization 2. Capacity Setting 3. Boom Length Adjustment 4. Boom Angle Adjustment 5. Swing Angle Adjustment 6. Outrigger Extension Width Adjustment 7. Moment Adjustment (Including load radius adjustment) 8. Clock Adjustment Adjustment completed Erasing the Overload History 37 W E

39 Functions of and How to Use Adjustment Mode 1. Adjustment Initialization Adjustment initialization should be performed only when EEPROM is replaced. If the EEPROM removed from the faulty CPU board is reused when the CPU board is replaced, adjustment initialization is not required. By the adjustment initialization, the conversion factors (standard values specified for each specification) stored within the AML program that convert detected voltage input from the detectors into physical volumes is read out from the P-ROM and written onto the EEPROM. Perform the initialization only once before the first adjustment takes place. If this initialization is done while adjustments are being made, you must restart the adjustment from the very beginning. For adjustment initialization, you have to execute the following two menus. [ Initialize L&A] : Initialize the conversion factors for boom length, angle, and deflection. [ Initialize MMT] : Initialize the conversion factors for moment. 1.1 Procedure of Conversion Factors Resetting 1. Select the main menu [ Initialize L&A ] in the adjustment mode, and press the register key to select the menu. 2. When [: Reset DEF. FCT ] appears, reset the deflection factor by pressing the register key. 3. When the message [Done] appears, the deflection factor resetting is completed. Press the display alteration key to return to the main menu. 4. Press the register key again to select the main menu [ Initialize L&A ] in the adjustment mode. 5. When [: Reset DEF. FCT ] appears, press the scroll-down key to display [:Reset zero. span], and then press the register key to reset the zero span factor. 6. When the message [Done] appears, the zero span factor resetting is completed. Press the display alteration key to return to the main menu. 1.2 Procedures of Moment Adjustment Resetting 1. Select the main menu [ Initialize MMT ] in the adjustment mode, and press the register key to select the menu. 2. When [Reset MMT] appears, reset the moment factor by pressing the register key. 3. When the message [Done] appears, the moment adjustment resetting is completed. Press the display alteration key to return to the main menu. 38 W E

40 Functions of and How to Use Adjustment Mode 2. Capacity Setting Check the specification number of Adjustment Value Table in the INFORMATION AND DATA section whether your crane needs to perform this setting. The crane capacity data is stored in the ROM. This setting is performed to partially change the crane capacity data in the ROM. The crane capacity data normally does not need this setting. For the capacity setting, select one of the four sub-menus indicated below. [: Head-Off Capac] : Used to set the maximum rated lifting capacity to the specified value. [: Jib Select] : Used to change the capacity for jib-mounted condition to the capacity for jib-unmounted condition. [: S/T Select] : Used to change the capacity for single-top-mounted condition to the capacity for single-top unmounted condition. [: Winch drum PSN] : Used to specify the mounting position of winch drum for capacity adjustment. 2.1 Procedure of Head-off Capacity Setting A head-off capacity value defined with this function is compared with the capacity (rated lifting capacity) data stored in the ROM, and the value whichever smaller is set as the capacity. Note that if the head-off capacity value is zero, the capacity data stored in the ROM is used. 1. Select the main menu [ Reg. Capac. ] in the adjustment mode, and press the register key to select the menu. 2. Press the scroll-up or scroll-down key to display [: Head-Off Capac ], and then press the register key to select the menu. 3. The currently registered head-off capacity value is indicated on the moment display. Display example: [Capacity 99.2 kp] (TR-450XL-4) 4. Press the increase or decrease key to adjust the head-off capacity value as desired. Every time you press the increase or decreace key, the head-off capacity value increases or decreases in steps of 0.1 klbs. If the key is held down, the value increases or decreases in steps of 10klbs. 5. When the desired head-off capacity value is reached, press the register key to save it. 6. Press the display alteration key to exit the menu. 39 W E

41 Functions of and How to Use Adjustment Mode 2.2 Procedure of Jib Selection When the jib-unmounted (detached) condition is selected, the jib capacity data stored in the ROM becomes unusable and also the jib mass is excluded from capacity calculation. 1. Select the main menu [ Reg. Capac. ] in the adjustment mode, and press the register key to select the menu. 2. Press the scroll-up or scroll-down key to display [: Jib Select ], and then press the register key to select the menu. 3. The currently registered jib capacity condition is indicated on the moment display. Using the scroll-up or scroll-down key, adjust it to the desired condition. Display example: [Jib = Mounted ] Press the scroll-up key. [Jib : Not Mounted] When = is indicated, it means that the displayed condition is registered currently. 4. When the desired condition is displayed, press the register key for confirmation. When the setting is completed, : in the Jib condition display changes to =. Display example: [Jib:Not Mounted] Press the register key. [Jib = Not Mounted] 5. Press the display alteration key to exit the menu. 2.3 Procedure of Single Top Selection When the single-top-unmounted (detached) condition is selected, the single top capacity data stored in the ROM becomes unusable and also the single top mass is excluded from capacity calculation. 1. Select the main menu [ Reg. Capac. ] in the adjustment mode, and press the register key to select the menu. 2. Press the scroll-up or scroll-down key to display [: S/T Select ], and then press the register key to select the menu. 3. The currently registered single top capacity condition is indicated on the moment display. Using the scroll-up or scroll-down key, adjust it to the desired condition. Display example: [S/T=Mounted ] Press the scroll-up key. [S/T : Not Mounted] When = is indicated, it means that the displayed condition is registered currently. 4. When the desired condition is displayed, press the register key for confirmation. When the setting is completed, : in the single top condition display changes to =. Display example: [S/T : Not Mounted] Press the register key. [S/T = Not Mounted] 5. Press the display alteration key to exit the menu. 40 W E

42 Functions of and How to Use Adjustment Mode 2.4 Procedure of Winch Drum Position Setting The center of gravity of winch drum can be changed by adjusting the winch drum position. The calculation is performed according to the winch drum position setting by this function. 1. Select the main menu [ Reg. Capac. ] in the adjustment mode, and press the register key to select the menu. 2. Press the scroll-up or scroll-down key to display [: Winch drum PSN], and then press the register key to select the menu. 3. The currently registered jib capacity condition is indicated on the moment display. Using the scroll-up or scroll-down key, adjust it to the desired condition. Display example: [Winch drum = FR ] Press the scroll-up key. [Winch drum : F ] Press the scroll-up key. [Winch drum : R] In the above examples, F means the condition with single winch mounted at the front. R means the condition with single winch mounted at the rear. FR means the condition with double winches mounted at the front and rear. The conditions with = is the currently registered condition. 4. When the desired condition is displayed, press the register key for confirmation. When the setting has been completed, : in the winch drum condition display changes to =. Display example: [Winch drum : F ] Press the register key. [Winch drum = F ] 5. Press the display alteration key to exit the menu. 41 W E

43 Functions of and How to Use Adjustment Mode 3. Boom Length Adjustment WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety. 10.Has the boom length zero-point adjustment display [Boom Lz] become the zero-point adjustment value in Adjustment Value Table? NO YES 11.Press the display alteration key to exit the menu. Refer to Adjustment Value Table in the INFORMATION AND DATA section since the conditions and values for boom length adjustment vary depending on the specification number. When the length detector has only been installed and its cord has not yet been unwound on the drum, set the code wound naturally on the boom through the entire length during the boom telescopic operation. 1. Select the main menu [ Adjust ] in the adjustment mode, and press the register key to select the menu. 2. When [: Adjust L&A ] is displayed, press the register key to select the menu. 3. Fully retract the boom. 4. Press the increase or decrease key so that the value of boom length zero-point adjustment display [Boom Lz] becomes the zero-point adjustment value in Adjustment Value Table. Press the register key for registration. 5. Fully extend the boom. 6. Press the scroll-down key until the boom length span adjustment display [Boom Ls] appears. 7. Press the increase or decrease key so that the value of boom length span adjustment display [Boom Ls] becomes the span adjustment value in Adjustment Value Table. Press the register key for registration. 8. Fully retract the boom again. 9. Press the scroll-up key until the boom length zero-point adjustment display [Boom Lz] appears. 42 W E

44 Functions of and How to Use Adjustment Mode 4. Boom Angle Adjustment WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety. Refer to Adjustment Value Table in the INFORMATION AND DATA section since the conditions and values for boom angle adjustment vary depending on the specification number. Always perform the boom lowering operation when adjusting the boom angle to the adjustment condition. Measure the boom angle with a level angle meter. 1. Select the main menu [ Adjust ] in the adjustment mode, and press the register key to select the menu. 2. When [: Adjust L&A ] is displayed, press the register key to select the menu. Adjustment Value Table. Press the register key for registration. 9. Bring the actual boom angle to the zero-point adjustment value in Adjustment Value Table again. 10.Press the scroll-up or scroll-down key until the boom angle zero-point adjustment display [Boom Az] appears. 11.Has the value of boom angle zero-point adjustment display [Boom Az] become the zero-point adjustment value in Adjustment Value Table? NO YES 12.Press the display alteration key to exit the menu. 3. Set the actual boom angle to the condition of the zero-point adjustment specified in Adjustment Value Table by lowering the boom. 4. Press the scroll-up or scroll-down key until the boom angle zero-point adjustment display [Boom Az] appears. 5. Press the increase or decrease key so that the value of boom angle zero-point adjustment display [Boom Az] becomes the zero-point adjustment value in Adjustment Value Table. Press the register key for registration. 6. Raise the boom to just before the upper stroke end, and then adjust the actual boom angle to the condition of the span-point adjustment specified in Adjustment Value Table by lowering the boom. 7. Press the scroll-up or scroll-down key until the boom angle span adjustment display [Boom As] appears. 8. Press the increase or decrease key so that the value of boom angle span adjustment display [Boom As] becomes the span adjustment value in 43 W E

45 Functions of and How to Use Adjustment Mode 5. Swing Angle Adjustment WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety. Since the swing angles involve a hysteresis, always make adjustment after a stop from rightward movement. 1. Select the main menu [ Adjust ] in the adjustment mode, and press the register key to select the menu. 2. When [: Adjust L&A ] is displayed, press the register key to select the menu. 3. Set the boom to the zero-point adjustment reference position (on the front centerline) by swinging it rightward. 4. Press the scroll-up or scroll-down key until the swing angle 1 zero-point adjustment display [SW AG 1z] appears. 5. Adjust the increase or decrease key so that the value of swing angle 1 zero-point adjustment display [SW AG 1z] will become 0 ± 0.3. Press the register key for registrarion. 10.Press the increase or decrease key so that the value of swing angle 1 span-point adjustment display [SW AG 1s] will become 180 ± 0.3. Press the register key for registration. 11.With the swing position unchanged, press the scroll-up or scroll-down key until the swing angle 2 span-point adjustment display [SW AG 2s] appears. 12.Press the increase or decrease key so that the value of swing angle 2 span-point adjustment display [SW AG 2s] will become 180 ± 0.3. Press the register key for registration. 13.Set the boom again to the zero-point adjustment reference position (on the front centerline) by swinging it clockwise. 14.Check the swing angle 1 and 2 zero-point adjustment displays [SW AG 1z] and [SW AG 2z] by pressing the scroll-up or scroll-down key. Does each display indicate the angle below? SW AG 1z:0 ± 0.6 SW AG 2z:360 ± 0.6 NO YES 15.Press the display alteration key to exit the menu. 6. With the swing position unchanged, press the scroll-up or scroll-down key until the swing angle 2 zero-point adjustment display [SW AG 2z] appears. 7. Adjust the increase or decrease key so that the value of swing angle 2 zero-point adjustment display [SW AG 2z] will become 360 ± 0.3. Press the register key for registration. 8. Set the boom to the span- point adjustment reference position (on the rear centerline) by swinging it rightward. 9. Press the scroll-up or scroll-down key until the swing angle 1 span-point adjustment display [SW AG 1s] appears. 44 W E

46 Functions of and How to Use Adjustment Mode 6. Outrigger Extension Width Adjustment Refer to Adjustment Value Table in the INFORMATION AND DATA section since the conditions and values for outrigger extension width adjustment vary depending on the specification number. 1. Select the main manu [ Adjust ] in the adjustment mode, and press the register key to select the menu. 2. When [: Adjust L&A ] is displayed, press the register key to select the menu. 3. Fully retract all the outrigger beams. 4. Press the scroll-up or scroll-down key until the right-front outrigger extension width zero-point adjustment display [RFO/R Lz] appears. 5. Press the increase or decrease key so that the value of the right-front outrigger extension width zero-point adjustment display [RFO/R Lz] conforms to the zero-point adjustment value in Adjustment Value Table. Press the register key for registration. 10.Adjust and register the values of the right-rear, left-front and left-rear outriggers extension width span adjustment in the same manner as the one of the right-front outrigger extension width span adjustment. Right-rear outrigger : Adjust [RRO/R Ls] display Left-front outrigger : Adjust [LFO/R Ls] display Left-rear outrigger : Adjust [LRO/R Ls] display 11.Fully retract all the outrigger beams again. 12.Press the scroll-up or scroll-down key until the right-front outrigger extension width zero-point adjustment display [RFO/R Lz] appears. 13.Does the right-front outrigger extension width zero-point adjustment display [RFO/R Lz] conform to the zero-point adjustment value in Adjustment Value Table? And does each display for the right-rear outrigger [RRO/R Lz], for the left-front outrigger [LFO/R Lz], and for the left-rear outrigger [LRO/R Lz] conform to the zero-point adjustment value in Adjustment Value Table? NO YES 14.Press the display alteration key to exit the menu. 6. Adjust and register the values of the right-rear, left-front and left-rear outrigger extension width zero-point adjustment in the same manner as the one of the right-front outrigger extension width zero-point adjustment. Right-rear outrigger : Adjust [RRO/R Lz] display Left-front outrigger : Adjust [LFO/R Lz] display Left-rear outrigger : Adjust [LRO/R Lz] display 7. Fully extend all the outrigger beams. 8. Press the scroll-up or scroll-down key until the right-front outrigger extension width span adjustment display [RFO/R Ls] appears. 9. Press the increase or decrease key so that value of the right-front outrigger extension width span adjustment display [RFO/R Ls] conforms to span adjustment value in Adjustment Value Table. Press the register key for registration. 45 W E

47 Functions of and How to Use Adjustment Mode 7. Moment Adjustment WARNING Before making an adjustment, extend the outriggers fully and set the crane on firm ground for safety. Before starting moment adjustment, raise the hydraulic oil temperature to approx.122 F(50 C) by alternate raising and lowering the boom. Refer to Adjustment Value Table in the INFORMATION AND DATA section since the conditions and values for moment adjustment vary depending on the specification number. If the moment zero-point value is not within the tolerance at 7.6 Moment Zero-point Recheck, follow the fine adjustment steps of the broken line process order. The procedure to adjust moment is as follows: 7.1 Moment Zero-point Adjustment 7.2 Moment Span Preliminary Adjustment 7.3 Moment Zero-point Check and Fine Adjustment 7.4 Load Radius Adjustment 7.5 Moment Span Fine Adjustment 7.6 Moment Zero-point Recheck YES End of moment adjustment NO 46 W E

48 Functions of and How to Use Adjustment Mode 7.1 Moment Zero-point Adjustment For the conditions and adjustment value of the moment zero-point adjustment, refer to the moment zero-point adjustment item in the Adjustment Value Table. Set the crane as follows: (1)Outriggers mode: Fully extended (2)Lift mode: Boom lift (Stow jib and single top) (3)Boom length: Fully retracted (4)Boom angle: Raise boom until it almost reaches to maximum point, and then lower it until boom angle display corresponds to condition of zero-point adjustment.(refer to Adjustment Value Table.) (5)Hook block position: Hoisted down just clear of ground surface or vehicle structure (6)Actual status and registered status of number of parts of line: Standard number of parts of line when main boom is fully extended (7)Hook block: Refer to Adjustment Value Table. (Stow auxiliary hook block.) (8)Refer to Adjustment Value Table according to the crane model, there might be a condition besides above to 0.99 klbs: 000 to to klbs: -99 to After the adjustment, press the register key to save the adjusted value. 5. Proceed to 7.2 Moment Span Preliminary Adjustment. 1. Select the main menu [ Adjust ] in the adjustment mode, and press the register key to select the menu. 2. When [:Adjust L&A ] is displayed, press the scroll-down key until the display [:Adjust MMT] appears. Press the register key to select the menu. 3. While the moment zero-point adjustment is displayed, adjust the value indicated in the actual load value indicator finely with the increase or decrease key to conform it to the adjustment value of the zero-point adjustment. Moment zero-point adjustment display: Display [X.XXX z. % ] Moment ratio(%) Shows zero-point adjustment state Moment detector input(mv) The actual load value less than 1 klbs is shown as follows: 47 W E

49 Functions of and How to Use Adjustment Mode 7.2 Moment Span Preliminary Adjustment For the conditions and adjustment value of the moment span preliminary adjustment, refer to the moment span preliminary adjustment item in the Adjustment Value Table. 1. Continued from 7.1 Moment Zero-point Adjustment. 2. Lower the boom to set the boom angle to the condition of the span preliminary adjustment. (Hook block position:hoisted down until it almost touches ground surface) 3. Press the scroll-up or scroll-down key until the moment span adjustment display appears. Moment span adjustment display: Display [X.XXX s. %] Moment ratio(%) Shows span adjustment state Moment detector input(mv) 4. Adjust the value indicated in the actual load value indicator finely with the increase or decrease key to conform it to the adjustment value of the span preliminary adjustment. The actual load value less than 1 klbs is shown as follows: 0.00 to 0.99 klbs: 000 to to klbs: -99 to After the adjustment, press the register key to save the adjusted value. 6. Proceed to 7.3 Moment Zero-point Check and Fine Adjustment. 7.3 Moment Zero-point Check and Fine Adjustment For the conditions and adjustment value of the moment zero-point check and fine adjustment, refer to the moment zero-point adjustment item in the Adjustment Value Table. 1. Continued from 7.2 Moment Span Preliminary Adjustment. 2. Raise the boom until it almost reaches to the maximum point, and then lower it until the boom angle display corresponds to the condition of the zero-point adjustment. (Hoist down the hook block until it almost touches the ground surface or chassis.) 3. Press the scroll-up or scroll-down key until the moment zero-point adjustment display appears. Moment zero-point adjustment display: Display [X.XXX z. % ] Moment ratio(%) Shows zero-point adjustment state Moment detector input(mv) 4. Has the indicated value become the zero-point adjustment value? The actual load value less than 1 klbs is shown as follows: 0.00 to 0.99 klbs: 000 to to klbs: -99 to -01 YES NO 5. Make an adjustment with the increase or decrease key so that the result becomes the zero-point adjustment value. Then, press the register key to save the adjusted value. 6. Press the display alteration key to exit the menu. 48 W E

50 Functions of and How to Use Adjustment Mode 7.4 Load Radius Adjustment For the conditions and adjustment value of the load radius adjustment, refer to the load radius adjustment item in the Adjustment Value Table. Set the crane as follows: (1)Outriggers mode: Fully extended (2)Lift mode: Boom lift (Stow jib and single top) (3)Boom length: Fully extended (4)Actual status and registered status of number of parts of line: Standard number of parts of line when main boom is fully extended (5)Hook block: Refer to Adjustment Value Table. (Stow auxiliary hook block.) (6)Load radius: After lifting rated lifting capacity of load radius adjustment condition, set actual load radius to meet load radius adjustment condition (load radius) by boom lowering operation. (Cancel AML stop function when overload hinders boom lowering.) (7)Refer to Adjustment Value Table according to the crane model, there might be a condition besides above. 1. Select the main menu [ Adjust ] in the adjustment mode, and press the register key to select the menu. 2. Press the scroll-down key until the load radius adjustment display [: Adj. work rad ] appears. Then, press the register key to select the menu. 3. Press the increase or decrease key so that the load radius adjustment display [Rad. 1s] becomes the load radius adjustment value. Press the register key for that registration. 4. Press the display alteration key to exit the menu. 7.5 Moment Span Fine Adjustment For the conditions and adjustment value of the moment span fine adjustment, refer to the moment span fine adjustment item in the Adjustment Value Table. Set the crane as follows: (1)Outriggers mode: Fully extended (2)Lift mode: Boom lift (Stow jib and single top) (3)Boom length: Fully extended (4)Boom angle: Lower boom until the boom angle display corresponds to condition of span fine adjustment. (5)Hook block position: Hoisted down until it almost touches ground surface or vehicle structure. (6)Actual status and registered status of number of parts of line: Standard number of parts of line when main boom is fully extended. (7)Hook block: Refer to Adjustment Value Table. (Stow auxiliary hook block.) (8)Refer to Adjustment Value Table according to the crane model, there might be a condition besides above. 1. Select the main menu [ Adjust ] in the adjustment mode, and press the register key to select the menu. 2. When [: Adjust L&A ] is displayed, press the scroll-down key until the display [:Adjust MMT] appears. Press the register key to select the menu. 3. Press the scroll-down key until the moment span adjustment display appears. Moment span adjustment display: Display [X.XXX s. %] Moment ratio(%) Shows span adjustment state Moment detector input(mv) 4. Using the increase or decrease key, adjust the indicated value so that it becomes the span fine adjustment value. Then, press the register key to save the adjusted value. The actual load value less than 1 klbs is shown as follows: 0.00 to 0.99 klbs: 000 to to klbs: -99 to Proceed to 7.6 Moment Zero-point Recheck. 49 W E

51 Functions of and How to Use Adjustment Mode 7.6 Moment Zero-point Recheck For the conditions and adjustment value of the moment zero-point recheck, refer to the moment zero-point adjustment item in the Adjustment Value Table. 1. Continued from 7.5 Moment Span Fine Adjustment. 2. Retract the boom fully. 3. Raise the boom until it almost reaches to the maximum point, and then lower the boom until the boom angle display corresponds to the zero-point adjustment condition. (Hoist down the hook block until it almost touches the ground surface or chassis.) 4. Press the scroll-up or scroll-down key until the moment zero-point adjustment display appears. Moment zero-point adjustment display: Display [X.XXX z. % ] Moment ratio(%) 6. Make fine adjustment as shown below. (The following fine adjustment procedures are extracted from 7.3 Moment Zero-point Check and Fine Adjustment.) (1)Make an adjustment with the increase or decrease key so that the result becomes the zero-point adjustment value. Then, press the register key to save the adjusted value. (2)Press the display alteration key to exit the menu. 7. Perform 7.5 Moment Span Fine Adjustment. Perform 7.6 Moment Zero-point Recheck. 8. Press the display alteration key to exit the menu. The moment adjustment is completed. Shows zero-point adjustment state Moment detector input(mv) 5. Has the indicated value become the zero-point adjustment value? The actual load value less than 1 klbs is shown as follows: 0.00 to 0.99 klbs: 000 to to klbs: -99 to -01 YES NO 50 W E

52 Functions of and How to Use Adjustment Mode 8. Clock Adjustment AML has calender and clock IC inside, which is used for recording errors. Adjust the clock in the following procedure. Adjust the clock in the maintenance mode. 1. Select the main menu [ Adjust clock] in the maintenance mode, and press the register key to select the menu. 2. When the time is displayed on the moment display, press the scroll-up or scroll-down key to bring the cursor to the place to be adjusted. Time is displayed in the 24-hour basis. The cursor lies under a numeral. Display example:[ :30] Cursor 3. Press the increase or decrease key to change the value to be adjusted. 4. After the adjustment, press the register key to put the adjustment value onto the IC. If there are plural adjustment places, move the cursor for adjustment in order. Finally press the register key. 5. press the display alteration key to exit the menu. 51 W E

53 Functions of and How to Use Adjustment Mode Other Functions and How to Use Them 1. Language The menu [Language] is used to change the language for message appearing on the moment display. The message on the menu [Language] is always displayed in English. 1. Select the main menu [ Language] in the adjustment mode, and press the register key to select the menu. 2. When message for language selection appears, operate the scroll-up or scroll-down key to display the aimed language. Display example: [= Japanese ] Press the scroll-down key. [: English] The sign = at the left side of the message shows that the language is currently set to be used. Display: [:Disp. Late data ] [:Disp. Max. data] 3. Display of latest overload data The selection of [:Disp. Late data ] results in the latest registered overload history data being displayed. The time when overload history data has been registered is indicated in the moment display. To view the next data on record (up to 50 items), press the scroll-down key. Moment display Display example: [ :35 ] 3. When the aimed language is displayed, press the register key. After the registration, the sign : at the left side of message changes to =. Display example: [: English] Press the register key. [=English] 4. Press the display alteration key to exit the menu. After this, the messages on the moment display are switched to the newly set language. 2. Overload History Display The records of crane operations beyond overloading limit are displayed. You can choose between the displays of latest overload data and of the greatest overload data. 1. Select the main menu [ Disp. O/L data ] in the adjustment mode, and press the register key to select the menu. 2. Use the scroll-up or scroll-down key until the menu of latest overload ratio or peak overload ratio appears. Select it by pressing the register key. 52 W E

54 Functions of and How to Use Adjustment Mode 4. Display of greatest overload data The selection of [:Disp. Max. data] results in the registered greatest overload history data being displayed. The time when overload history data has been registered is indicated in the moment display. Press the scroll-down key, and load ratio, jib length, and jib angle will be displayed (jib length and jib angle are displayed only during the jib lift). Further press the scroll-down key, and the display will change into the next information (up to 10 items). Moment display Display example: [ :35 ] [125% 14.5f 45.0 ] 3. Erasing the Overload History When the AML main unit or EEPROM is replaced for repair and all adjustment is completed, erase-protect the overload history. Before delivering the machine to an user, erase-protect the overload history by erasing the latest history data three times. You can erase the overload history data (record of crane operation when moment load ratio exceeds the set limit). Note that if the latest history data are erased three times, the menu will not appear, disabling the history data to be erased. At the time of the third erasure, the records of the greatest overload values will also be erased. 1. Select the main menu [ Erase O/L data ] in the adjustment mode, and press the register key to select the menu. 2. Use the scroll-up or scroll-down key to display the overload history data item to be erased. Select it by pressing the register key. Display: [:Erase Late dat ] [:Erase Max. data] 3. When the message [Erase OK?] appears, press the register key to erase the data. 4. When the message [Done] appears, the overload record data is now erased. Press the display alteration key to exit the menu. 5. Press the display alteration key to exit the menu. 53 W E