Tadano AML-C Service Manual

資料番号 W301-0411E

01

Load Moment Indicator

Model

AML-C

Foreword

Foreword

This service manual (this document) is compiled to

provide information on the AML-C that is equipped on

the crane.

"Input/Output Signals of the AML System" in this

document offers the general description on the

electrical circuit of the crane. For the detailed electrical

circuit, refer to the service manual (Circuit diagrams

and Data) of each model.

For the actual works, perform appropriate repair and

service with referring to the separate operation and

maintenance manual, parts catalog, and service

manual of the applicable model.

When part replacement is needed, refer to the parts

catalog first to check the disassembly unit as well as

the parts sales unit.

1. Applicable Crane Model / Spec. No.

Crane model

GR-1000XL-2

Spec. No. GR-1000-2-00101

GR-1000-2-00103

GR-750XL-2

Spec. No. GR-750-2-00101

With the crane models not shown in the above table,
refer to this service manual when the document
number of this manual is noted in the service manual
for each model.

Figures and contents in this manual are subject to

change depending on improvements, etc.

i

W301-0411E

Foreword

2. Table of Contents

Foreword

1. Applicable Crane Model / Spec. No................... i

2. Table of Contents...............................................ii

3. Acronyms and Abbreviations............................iv

4. International Standard ...................................... v

5.Crane Performance ......................................... vii

6.Reduction of Rated Capacity.......................... viii

Chapter A

(Component of AML System)

A-1 Components of the AML System ............... 1

A-2 Input/Output Signals

of the AML System ....................... 11

2.1 AML Control Unit (Pin Assignment)

CN1 – CN9

B-6 Do Output Control.................................... 59

6.1 Cause for AML Automatic Stop

Output .......................................... 59

6.2 Do Output Abnormality Processing.... 64

6.3 Drum Indicator Control Function........ 65

6.4 Output of warning .............................. 66

B-7 AML Control............................................. 67

7.1 Backward Stability Stop Function ...... 67

7.2 Working Range Limit Stop Function .. 67

7.3 Output of Interference Prevention

Warning .................................. 70

7.4 Winch Drum Position Selection

Function ....................................... 71

B-8 Proportional Control Function.................. 75

B-9 AML Cancel Function .............................. 76

Chapter C

(Maintenance Mode)

Chapter B

(User Mode)

B-1 Functions and How to use

the User Mode.............................. 26

B-2 Registration of Operating State and AML

Function Check ............................ 28

B-3 Alarm and Recovery Operation ............... 38

3.1 Type of Warning Codes and Buzzer .. 38

3.2 Warning Code and Crane Model

Comparison Table ........................ 39

3.3 Warning code and Remedy List......... 40

B-4 Other Functions ....................................... 43

4.1 Working Range Limit Function........... 43

4.2 TARE Function................................... 49

4.3 Mute Alarm Function .......................... 49

4.4 Fuel Consumption Indicator............... 50

4.5 User Adjustment Menu ...................... 51

Outline of Maintenance Mode......................... 80

C-1 Operation Keys and Menu ....................... 81

C-2 Individual Main Menu Functions .............. 85

C-3 Integrated Information Display Screen ...117

C-4 Error Code............................................. 122

4.1 Classification of Error Code ....................122

4.2 Error History............................................122

4.3 Error Notification .....................................123

4.4 Error Code Table.....................................124

4.5 CPU State Indicator LED ........................133

C-5 Required Adjustment after AML System

Part Replacement ...................... 134

C-6 Disassembly and Assembly................... 135

B-5 Action against AML System Error ............ 58

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W301-0411E

Foreword

Chapter D

(Adjustment Mode)

Outline of Adjustment Mode.......................... 150

D-1 Operation Keys and Menu ..................... 151

D-2 Detector Adjustment .............................. 156

D-3 Valve Adjustment ................................... 166

3.1 Adjustment Sub Menu ............................ 166

3.2 Swing Output Adjustment

(Offset Method) ................................ 167

3.3 Swing Output Adjustment

(Characteristics Measurement Method) ....... 168

3.4 Elevating / Telescoping

Output Adjustment............................ 170

3.5 Function of Slow Stop............................. 171

Chapter E

(Information and Data)

E-1 AML Adjustment Value List.................... 180

E-2 Detector Check...................................... 184

E-3 AML Control Function List ..................... 190

E-4 AML Input/Output List............................ 192

A

B

C

D

E

D-4 Performance Setup................................ 172

D-5 Operation History Erase ........................ 174

D-6 Option Select ......................................... 175

D-7 AML Emergency / Override Switch

History Erase.............................. 178

D-8 Outrigger Emergency Setting

History Erase.............................. 179

iii

W301-0411E

Foreword

3. Acronyms and Abbreviations

The following list contains some of the acronyms and

abbreviations used in this manual.

AML: Load Moment Indicator
AML override: Refer to Chapter B-9
Actuator: A mechanical device which converts

supplied energy into mechanical work

(Ex. hydraulic motor, hydraulic cylinder)
Ai: Analog Input
A/D conversion: Analog/Digital conversion
Ao: Analog Output
Aux.: Auxiliary
ASME: American Society of Mechanical Engineers
CAN: Controller Area Network (SAE1939)
CHG: Charge
CPU: Central Processing Unit
C/W: Counter weight
D/A: Digital/ Analog conversion
DCU: Display Control Unit (Meter controller)
Di: Digital Input
Do: Digital Output
Eco mode: Environmental communication mode
ECU: Engine Control Unit
FET: Field-effect Transistor
F.B.: Feed back
Fig.: Figure
Flash memory:

A Semiconductor memory device which can

be electrically erased and rewritten.
FMI: Failure Mode Identifier
FLJ: Full auto Luffing Jib
F/J: Front Jack
F/R: Front Right
F/L: Front Left
ICF: Information Controller for Telematics
ID: Identification
ISO: International Organization for Standardization
J/S: Joystick
LCD: Liquid Crystal Display
LED: Light Emitting Diode
MDT: Multiplex Data Transmitter
MMT: Moment
OE: Output Enable signal

(Fail-safe is active when the signal is ON.)

O/R: Outrigger

PC: Personal Computer
Pi: Pulse input
Pin Assignment:

Assignment of signals to the pins of

connectors
PT: Power Tilt
PTO: Power Take-off
RAM: Random Access Memory
ROM: Read Only Memory
rpm: Revolution per minute
RY: Relay
R/J: Rear Jack
SAE: Society of Automotive Engineers
Si: Serial input
SOL: Solenoid
SPN: Suspect Parameter Number

(Data Classification Number)
STM: Signal Transmitter (D, E type)
SW: Switch
S/T: Single Top
Tr: Transistor
T/C: Torque Converter
T/M: Transmission
USB: Universal Serial Bus
VCU: Vehicle Control Unit (node)
WDT: Watched dog timer
3S: 3 Second
20ms: 20 millisecond (20/1000 second)

Rated capacity = Max. Hoist medium load

Hoist medium load = _Net load + Hook Assy

_Net load = Payload + Sling

iv

W301-0411E

Foreword

4. International Standard

ISO 4306-1

(Only description in English is shown here.)

Cranes – Vocabulary - Part 1: General

Fourth edition 2007.10.15

v

W301-0411E

Foreword

(Only description in English is shown here.)

m

Hoist medium

Fixed load-lifting attachment(s)

Non-fixed load-lifting

attachment(s)

HM

Hoist rope hanging down from jib head Hoist rope hanging down from crab

m

FA

Hook assembly Hook assembly Bottom block Bottom block Bottom block

m

NA

Skip and chain Net Rope slings

Electromagnet

and chain

Grab

m

Net load + Hook

Hoist medium load =

Gross load

GL mHL mNL

Net load =

Payload + Slings

Payload

PL

Contents of

skip

Contents of net

m

Box and
contents

Scrap iron

Contents of

grab

Table 1

vi

W301-0411E

5. Crane Performance

Foreword

vii

W301-0411E

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.

Single Top Lift and Jib Lift

The rated capacities for single top lift or jib lift assume that the main winch is used. If you perform single top lift
or jib lift using the auxiliary winch, subtract the mass of the main hook block from the rated lifting capacity
values.

(ex. : GR-750XL-2)

1

343-979-01200
343-979-01190

△
△

1

viii

W301-0411E

A

Chapter A

Components of AML System

Contents

A-1 Components of the AML System.... 1

1.1 System configuration ................................. 1

1.1.1 Diagram of the Main System ...................... 1

1.1.2 AML-C Block diagram.............................. 2

1.2 Display Unit................................................ 3

1.2.1 Display panel.............................................. 4

1.2.2 LED Display................................................ 6

1.2.3 Control switches......................................... 7

1.3 AML Main Unit ........................................... 8

1.3.1 Construction ............................................... 8

1.3.2 Panel outside view (CN1 – CN9)................ 9

1.3.3 Boards and Inner connectors ................... 10

A-2 Input/Output Signals of the

AML System ...........................11

2.1 AML Control Unit (Pin Assignment) ..........11

2.1.1 CN1 Connector (8-Pin) ............................. 11

2.1.2 CN2-1 Connector (20-Pin) ........................12

2.1.3 CN2-2 Connector (16-Pin) ........................14

2.1.4 CN3 Connector (12-Pin) ...........................16

2.1.5 CN4 Connector (6-Pin) .............................17

2.1.6 CN5 Connector (16-Pin) ...........................18

2.1.7 CN6 Connector (14-Pin) ...........................22

2.1.8 CN7 Connector (20-Pin) ...........................23

2.1.9 CN8 Connector (8-Pin) .............................24

2.1.10 CN9 (USB) Connector (4-Pin)................25

2.1.11 Explanation of the Signals (Di, Do) ........25

i

Chapter A Chapter A

Components of AML System

A-1 Components of the AML System

1.1 System configuration

1.1.1 Diagram of the Main System

(Overwind detector)

(Overwind)

1. Load

2. Anti-twoblock (overwind) stop

3. Backward stability stop:

4. Working range limit stop:

moment ratio ≥ 100%

AML vent / compulsory unload of the main relief valve.

٠If an overload occurs, the AML stops the 24-V output from Do1. Thus the solenoid valve for VENT is

returned to neutral by the spring and vents the oil in the spring side of the balance piston in the main-circuit
safety valve into the tank circuit. The whole oil discharged by the pump is unloaded into the tank, making
crane operation toward critical sides impossible.

٠When crane operation toward non-critical sides (hoisting down, boom raising, boom retraction) is detected,

no oil is vented from the safety valve into the tank. Thus the crane operation becomes available.

:

If operation toward critical sides (hoisting up, boom lowering, boom extension) is attempted while the hook
block is over wound, 24-V output from Do1 stops. Thus the crane operation toward critical sides becomes
impossible due to AML vent (compulsory unload) in the same way as overload.
When operation toward non-critical sides is detected, the operation becomes available.

When the boom is raised over the specified angle, the output from Do1 stops and the crane operation stops
automatically due to AML vent. Recovery from the automatic stop is possible only by boom raising.

When the boom head approaches a pre-registered limit of the working range, slow stop function works and
the AML energizes the corresponding proportional solenoid valve. It slowly closes the pilot pressure circuit
for the main control valve to decelerate crane operation until the main control valve becomes neutral and
the output from Do1 stops to make AML vent disable crane operation. For swing limit, however, the
proportional solenoid valve makes the main control valve immediately to stop the crane. In this case the
crane does not swing beyond the limit even if the AML override is activated, and it swings only toward within
of the limit.

1

W301-0411E

Chapter A Chapter A

Components of AML System

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.

2. The signal transmitter (STM-E) is common to all GR model.

For details of the data, refer to the "N-1 STM-E" section in the service manual for the corresponding model.

3. Communication between STM-E and ECU on the machine with Mitsubishi engine (GR-750XL-2,

GR-1000XL-2) is sent via K-LINE.

2

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Chapter A Chapter A

Components of AML System

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.

(LCD)

2. AML startup

When the PTO switch is set to "ON," the AML starts.

3

W301-0411E

E

Chapter A Chapter A

Components of AML System

1.2.1 Display panel

NOTIC

• 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. The hoist medium load
indication is a reference value, and not a
correct mass of the lifted load.

(1) Load moment ratio display

Shows the load moment ratio with a bar graph.

(2) Load moment ratio index

Serves as an index how critical the load moment ratio is by the bar graph; safe (green), warning (yellow),

orcritical (red).

(3) Jib lift indicator symbol

Appears when the jib lift is registered.

Flashes when the jib set state is registered to the load moment indicator.

4

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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

(7) Crane status indicator (A-2

(8) Crane status indicator (A-3) Jib dismount

(9) Crane status indicator (A-4) Winch selection

(10) Crane status indicator (B-1) Boom telescoping or Auxiliary winch Control

(11) Crane status indicator (B-2)

The indicator (icon) shows a crane state.

Refer to "Operation Indicator Display" (Chapter B-1) for the meaning of the icons.

(12) Swing position display

Shows the current swing position.

The display is graduated in 45°.

Components of AML System

) Jib lock

Hydraulic oil temperature, Outrigger switch out of neutral or Outrigger state emergency registration

(13) Front position symbol

Appears when the boom is directed to the front of the vehicle.

(14) On-rubber status indicator symbol

Flashes during on-rubber creep operation, and turns on steadily during on-rubber stationary operation.

(15) Outrigger status indicator symbol

Indicates the extension width of outriggers.

The outer frames of the symbol represent the maximum available steps of the outrigger extension, and the

inner frames (black-filled segments) represent the current step of outrigger extension.

(16) Boom Lift Indicator Symbol

Appears when the boom lift is registered to the AML.

(17) Fuel consumption indicator

The fuel consumption rate during crane operation is indicated.

(18) Eco mode indicator

Lights up when Eco mode switch is on and displays current mode such as Eco mode 1 or Eco mode 2.

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Chapter A Chapter A

Components of AML System

1.2.2 LED Display

6

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Chapter A Chapter A

Components of AML System

1.2.3 Control switches

Table 1.2.3

No. Name Description

0 Preset menu key Used for go to the preset menu.

1 F1 key Used to select the function shown as “F1” in the pop-up window.

2 F2 key Used to select the function shown as “F2” in the pop-up window.

3 F3 key Used to select the function shown as “F3” in the pop-up window.

4 F4 key Used to select the function shown as “F4” in the pop-up window.

5 Working range limit key Used to register/cancel the working range limit.

6 Counterweight set key Used to select the mass of the mounted counterweight on AML.

7 Rope part line key Used to select the number of part lines on AML.

8 Lift state select key

9 Outrigger state select key Used to select the outrigger extension width on AML.

Used to select the lift state (boom, jib in various length and offset angle)

on AML.

10 Exit key Used to close the pop-up window.

11 Display change key Used to change the display content.

12 Set key Used to confirm (register) the selected state.

13 Check key Used during pre-operational inspection.

7

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Chapter A Chapter A

Components of AML System

1.3 AML Main Unit

1.3.1 Construction

1. Case assembly

2. Case assembly

3. Bracket

4. Case 1

5. Dustproof sponge assembly

6. CON1 board

LED (3 pcs)

7. CON2 circuit board

8. Case 2

9. Display board

10. CPU board

11. Surface sheet assembly

8

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Chapter A Chapter A

Components of AML System

1.3.2 Panel outside view (CN1 – CN9)

Front

Rear

0

361-933-41030

9

W301-0411E

△

Chapter A Chapter A

Components of AML System

1.3.3 Boards and Inner connectors

Jumper lead

CON2 board

CON1 board

CON1 + CON2 boards

Cable assembly for CN11

DISP board

CPU board

CPU + DISP boards

Jumper lead

LCD connection cable

Graphic liquid crystal display

(LCD)

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Chapter A Chapter A

Components of AML System

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. (Refer to 1.3.2 Panel outside view, from the back)

2.1.1 CN1 Connector (8-Pin)

CN1 connector

Pin No. Name

1 MBGND Signal name: Ground Output voltage: DC 0 V

Signal names and functions

2 MBGND Signal name: Ground Output voltage: DC 0 V

3 DOPOW Signal name: Power for circuit Output voltage: DC 24 V

4 MBGND Signal name: Ground Output voltage: DC 0 V

5 MBGND Signal name: Ground Output voltage: DC 0 V

6 MBPOW Signal name: Power for AML main body Input voltage: DC 24 V

7 DOPOW Signal name: Power for circuit Output voltage: DC 24 V

8 DOPOW Signal name: Power for circuit Output voltage: DC 24 V

11

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Chapter A Chapter A

Components of AML System

2.1.2 CN2-1 Connector (20-Pin)

CN2-1 connector SW status in AML

Pin No. Name

1 Di1+

2 Di2+

- Signal name: Boom telescoping / Aux. winch operation

Detects whether boom telescoping or auxiliary winch
operation is selected.

- Signal name:2nd boom section full retraction detection
Detects that 2nd boom section is fully retracted.

Signal names and functions

selection

(Data No. #---)

(#17206-21)

(#17204-11)

ON (0) OFF (1)

Aux. winch

operation

selected

Full

retraction

Boom

telescoping

selected

No full

retraction

3 Di3+

4 Di4+

5 Di5+

6 Di6+

7 Di7+

8 Di8+

9 Di9+

- Signal name:3rd—top boom section full retraction detection
Detects that 3rd, 4th and top boom sections are fully
retracted.

- Signal name: Swing free detection
Detects swing free/lock status.

- Signal name: Anti-twoblock cancel
Cancels the anti-twoblock function of the hook.

- Signal name: Anti-twoblock cancel indication
Detects the indication of anti-twoblock cancel.

- Signal name: 100% stop cancel (AML cancel)
Cancels the overload stop function.

- Signal name: 100% stop cancel indication
Detects the indication of 100% stop cancel.

- Signal name: Jib connecting (lock) pin insertion detection
Detects that the jib connecting (lock) pin is inserted when the
jib is stowed.

- Signal name: Jib extension detection
Detects the jib extension status.

- Signal name: Swing over-front detection
Detects the swing position is in over-front (within 2°
over-front).

- Signal name: Main hoist-up detection
Detects the main winch hoist-up operation.

(#17204-12)

(#17204-31)

(#17206-3)

(#17206-7)

(#17206-2)

(#17206-6)

(#17204-24)

(#17204-33)

(#17204-23)

(#17202-1)

Full

retraction

Swing free Swing lock

Stop disabled Stop enabled

Cancel

indication

Stop disabled Stop enabled

Cancel

indication

Inserted

(fixed)

Jib stowed Jib extension

Over-front

position

No operation Operation

No full

retraction

No cancel

indication

No cancel

indication

Not inserted

Other than

over-front

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Chapter A Chapter A

CN2-1 connector SW status in AML

Pin No. Name

Components of AML System

(Data No. #---)

Signal names and functions

ON (0) OFF (1)

(#17202-2)

10 Di10+

- Signal name: Main hoist-down detection
Detects the main winch hoist-down operation.

No operation Operation

(#17202-3)

11 Di11+

- Signal name: Auxiliary hoist-up detection
Detects the auxiliary winch hoist-up operation.

No operation Operation

(#17202-4)

12 Di12+

- Signal name: Auxiliary hoist-down detection
Detects the auxiliary winch hoist-down operation.

No operation Operation

(#17202-9)

13 Di13+

- Signal name: Boom extension detection
Detects the boom extending operation.

No operation Operation

(#17202-10)

14 Di14+

- Signal name: Boom retraction detection
Detects the boom retraction operation.

No operation Operation

(#17202-11)

15 Di15+

- Signal name: Boom raising detection
Detects the boom raising operation.

No operation Operation

(#17202-12)

16 Di16+

- Signal name: Boom lowering detection
Detects the boom lowering operation.

No operation Operation

(#17202-17)

17 Di17+

- Signal name: Swing right detection
Detects the swing operation to the right.

No operation Operation

(#17202-18)

18 Di18+

19 Di19+

- Signal name: Swing left detection
Detects the swing operation to the left.

- Signal name: Outrigger emergency setting
Detects the selection of outrigger emergency setting.

(#17206-41)

No operation Operation

Normal

setting

Emergency

setting

20 Di20+ (Spare)

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Chapter A Chapter A

Components of AML System

2.1.3 CN2-2 Connector (16-Pin)

CN2-2 connector SW status in AML

Pin No. Name

1 Di21+ (Spare)

2 Di22+

3 Di23+

- Signal name: Counterweight fitting detection
Detects fitting status of the counterweight.

- Signal name: Main over-unwind detection
Detects the over-unwinding status of the main winch drum.

Signal names and functions

(Europe spec.)

- Signal name: Aux. winch over-unwind detection

4 Di24+

Detects the over-unwinding status of the auxiliary winch
drum.

(Europe spec.)

(Data No. #---)

(#17204-3)

(#17202-37)

(#17202-38)

ON (0) OFF (1)

Mounted Not mount

Not

over-unwind

Not

over-unwind

Over-unwind

Over-unwind

5 FG Frame ground (Connected with ground on circuit board)

6 P3 (Spare)

7

8

P2A（P2）

P1A（P1）

Signal name: Drum indicator input (Aux.)
Detects the rotation of auxiliary winch drum.

Signal name: Drum indicator input (Main)
Detects the rotation of main winch drum.

(#17204-9)

9 Di25+

- Signal name: Jib removal detection
Detects removal of the jib from the crane boom.

Mounted Removed

(#17206-64)

- Signal name: Deactivation of over-unwinding cutout

10 Di26+

Deactivates stop due to over-unwinding only among the
automatic stop functions of the AML.

Over-unwinding

stop deactivated

Over-unwinding

stop activated

(Europe spec.)

11 Di27+

- Signal name:3rd—top boom section extension switch
Shifting operation of boom telescoping cylinder (from No. 1 to
No. 2)

(#17206-55)

Extension

Not

extension

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Chapter A Chapter A

CN2-2 connector SW status in AML

Pin No. Name

12 Di28+

13 FG Frame ground (Connected with ground on circuit board)

14 PSRC (Spare)

15 P2B

16 P1B

- Signal name: Twoblocking detection
Detects the twoblocking.

Signal name: Drum indicator input (Aux.)
Detects the rotation of auxiliary winch drum.

Signal name: Drum indicator input (Main)
Detects the rotation of main winch drum.

Components of AML System

(Data No. #---)

Signal names and functions

(#17202-36)

ON (0) OFF (1)

Not

twoblocking

Twoblocking

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Chapter A Chapter A

Components of AML System

2.1.4 CN3 Connector (12-Pin)

CN3 connector

Pin No. Name

1 +5V

2 Ai1

3 Ai2

4 Ai3

- 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)

- Signal name: Boom angle
Input voltage of boom angle detector (DC 0 to 5 V)

- Signal name: Swing angle detector 1
Input voltage of 2-potentiometer type swing angle detector 1 (DC 0 to 5 V)

Signal names and functions

5 AGND

6 SHIELD

7 +5V

8 Ai4

9 Ai5

10 Ai6

11 AGND

12 SHIELD

- Signal name: Analog ground
Ground for boom length detector, boom angle detector, swing angle detector 1, and swing
angle detector 2

Signal name: Shield (Connected with ground on circuit board)
Shield for boom length detector, boom angle detector, swing angle detector 1, and swing
angle detector 2

- Signal name: 5-V impressed voltage power output for detector
Impressed voltage output to elevating cylinder pressure sensor

Signal name: Swing angle detector 2
Input voltage of 2-potentiometer type swing angle detector 2 (DC 0 to 5 V)

- Signal name: Elevating cylinder extension side pressure
Detects the pressure of elevating cylinder tube side chamber (elevation raising).
Usage: Used for moment detection

- Signal name: Elevating cylinder retraction side pressure
Detects the pressure of elevating cylinder rod side chamber (elevation lowering).
Usage: Used for moment detection

- Signal name: Analog ground
Ground for elevating cylinder pressure sensor

- Signal name: Shield (Connected with ground on circuit board)
Shield for elevating cylinder pressure sensor

16

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Chapter A Chapter A

Components of AML System

2.1.5 CN4 Connector (6-Pin)

CN4 connector

Pin No. Name

1 FG

2 +5V

3 Ai7

4 Ai8

5 AGND

Signal names and functions

(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
Ground for main pressure detector

6 SHIELD

Signal name: Shield
Shield for main pressure detector

17

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Chapter A Chapter A

Components of AML System

2.1.6 CN5 Connector (16-Pin)

CN5 connector

Pin No. Name

1 Do1+

2 Do2+

Signal names and functions

- Signal name: AML stop output (AML vent / compulsory unload)
Controls the unload solenoid valve, and performs the automatic stop output.

- Signal name: Lever non-operation output
Shifts the flow volume in the hydraulic circuit from the stand-by status to large-volume status
when a control lever is operated.

(Data No. #---)

(#17802-1)

(#17802-147)

- Signal name: Telescoping control output 1
Output of telescoping cylinder change solenoid valve

3 Do3+

The values for (A) and (B) are as follows:

Applied to special telescoping mode (Tel. mode II)

- Signal name: Telescoping control output 2
Output of No.2 telescoping cylinder retraction prevention solenoid valve

4 Do4+

(A), (B) data is/are as follows.

(#17802-142)

Output (ON) condition: (1) or (2) or (3)
(1) Boom length is (B) or more.
(2) Boom length is between (A) and (B), and the next boom section extension input is ON.
(3) Boom length is between (A) and (B), and the boom full retraction 2 detection is OFF.

Output (OFF) condition: (4) or (5)
(4) Boom length is (A) or less.
(5) Boom length is between (A) and (B), and the boom full retraction 2 detection is ON.

GR-750XL-2 : (A) 18.60m, (B):19.40m - for tel. mode I (#20586)
GR-1000XL-2 : (A) 20.35m, (B):21.15m - for tel. mode I

(#17802-143)

Output (ON) condition: (1) or (2)
(1) Boom length is(B) or more.
(2) Boom length is between (A) and (B), and the extension input of next boom section is

ON.

Output (OFF) condition: (3) or (4)
(3) Boom length is (A) or less.
(4) Boom length is between (A) and (B), and

the boom full retraction 2 detection is ON and the next boom section extension input is
OFF.

GR-750XL-2 : (A) 34.60m, (B) :35.40m (

#20584)

GR-1000XL-2 : (A)37.85m, (B) : 38.65m

18

W301-0411E

Chapter A Chapter A

CN5 connector

Pin No. Name

5 Do5+

6 Do6+

- Signal name: Tactile type drum indicator (Main)
Interlocked with the drum indicator LED, output is performed to the tactile type drum indicator.

- Signal name: Tactile type drum indicator (Aux.)
Interlocked with the drum indicator LED, output is performed to the tactile type drum indicator.

Components of AML System

(Data No. #---)

Signal names and functions

(#17802-122)

(#17802-123)

(#17802-132)

7 Do7+

8 Do8+

9 Do9- (Spare)

- Signal name: Jib set output
Improves the winch capacity when in the jib set status.

(#17802-124)

-Signal name: AML normal output (Normal: 24V output, Abnormal: 0V)
Detects the reckless driving of task, and outputs the result.

[GR-1000XL-2]

- Signal name: Main winch high-speed hoist-down

10 Do10-

11 D o 11 -

12 Do12-

Output to drive the high-speed hoist-down valve of main winch

(Spare) [GR-750XL-2]

[GR-1000XL-2]

- Signal name: Auxiliary winch high-speed hoist-down
Output to drive the high-speed hoist-down valve of auxiliary winch

(Spare) [GR-750XL-2]

- Signal name: Buzzer output (AML warning)
Controls the external buzzer depending on the load moment ratio.
There are two outputs: intermittent output for when notice is made and continuous output for
when limit is reached.

Output when condition(s) is/are met: OFF output

(#17802-148)

(#17802-149)

(#17802-12)

Output condition: Load moment ratio of 90% or more and less than 100%; intermittent

output with 0.8 s interval

Load moment ratio of 100% or more: Continuous output

13 Do13-

- Signal name: Buzzer output (twoblocking warning)
Twoblocking warning buzzer sounds when the twoblocking status is reached.
Output when in twoblocking status: ON output

19

W301-0411E

(#17802-38)

Chapter A Chapter A

CN5 connector

Pin No. Name

Components of AML System

(Data No. #---)

Signal names and functions

(#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%.
(2): 100% cancel indication (Di6) is "Not canceled" status.
(3): Twoblocking cancel indication (Di5) is "Not canceled" status.

When in the boom operation with jib elected
(during main operation with jib elected), the green
external indicator lamp lights when the load
moment ratio described below is reached.

14 Do14-

Output when condition is met: OFF output

Outrigger
extension
width
Maximum
extension
Middle
extension 2
Middle
extension 1

Output

GR-750XL-2 GR-1000XL-2

Less than 78％ Less than 84％

Less than 77％ Less than 83％

Less than 70％ Less than 82％

(#20803)

- Signal name: External indicator lamp (90% to 100%, yellow)
When the moment load factor is 90% or more and less than 100%, the yellow external
indicator lamp lights.
Output condition:

When in the boom operation with jib
(during main operation with jib
yellow external indicator lamp lights when the

load moment ratio described below is reached.

15 Do15-

Output when condition is met: OFF output

(1) and (2) and (3)
(1): Load moment ratio is 90% or more and 100% or less.
(2) 100% cancel indication (Di6) is "Not canceled" status.
(3): Twoblocking cancel indication (Di5) is "Not canceled" status.

elected

elected), the

Outrigger
extension
width
Maximum
extension
Middle
extension 2
Middle
extension 1

GR-750XL-2 GR-1000XL-2

78％ or more

Less than 88％

77％ or more

Less than 87％

70％ or more

Less than 80％

Output

(#17802-10)

(#20803)

84％ or more

Less than 94％

83％ or more

Less than 93％

82％ or more

Less than 92％

20

W301-0411E

Chapter A Chapter A

CN5 connector

Pin No. Name

Components of AML System

(Data No. #---)

Signal names and functions

(#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:

When in the boom operation with jib
(during main operation with jib elected), the
red external indicator lamp lights when the

load moment ratio described below is

16 Do16-

reached.

Output when condition is met: OFF output

(1) or (2) or (3)
(1): Load factor exceeds 100%.
(2) 100% cancel indication (Di6) is "Canceled" status.
(3): Twoblocking cancel indication (Di5) is "Canceled" status.

Outrigger
extension

width

Maximum
extension

Middle

extension 2

Middle

extension 1

elected

(#20803)

Output

GR-750XL-2 GR-1000XL-2

88％ or more 94％ or more

87％ or more 93％ or more

80％ or more 92％ or more

21

W301-0411E

Chapter A Chapter A

Components of AML System

2.1.7 CN6 Connector (14-Pin)

CN6 connector

Pin No. Name

1 Ao1+

2 Ao1-

3 Ao2+

4 Ao2-

Signal names and functions

- Signal name: Swing right proportional solenoid valve
Drives the proportional reducing valve for right swing.

- Signal name: Swing right proportional solenoid valve COM
(Output return terminal)

- Signal name: Swing left proportional solenoid valve
Drives the proportional reducing valve for left swing.

- Signal name: Swing left proportional solenoid valve COM
(Output return terminal)

(Data No. #---)

(

#17804-1)

(

#17804-2)

5 Ao3+

6 Ao3-

7 FG

8 Ao4+

9 Ao4-

10 Ao5+

11 Ao5-

12 AO6+

- Signal name: Boom raising proportional solenoid valve
Drives the proportional reducing valve for boom raising.

- Signal name: Boom raising proportional solenoid valve COM
(Output return terminal)

Frame ground

- Signal name: Boom lowering proportional solenoid valve
Drives the proportional reducing valve for boom lowering.

- Signal name: Boom lowering proportional solenoid valve COM
(Output return terminal)

- Signal name: Swing relief proportional solenoid valve
Drives the proportional reducing valve for swing relief.

- Signal name: Swing relief proportional solenoid valve COM
(Output return terminal)

(Spare)

(

#17804-9)

(

#17804-10)

(

#17804-16)

13 AO6-

14 FG

(Spare)

Frame ground

22

W301-0411E

Chapter A Chapter A

Components of AML System

2.1.8 CN7 Connector (20-Pin)

CN7 connector

Pin No. Name

1 TX1+

2 TX1-

3 SHIELD

4 TX2+

5 TX2-

(Spare)

- Signal name: Serial port 2 transmission (+) output signal
[Transmission data to MDT (Multiplex Data Transmitter)]

Signal name: Serial port 2 transmission (-) output signal
[Transmission data to MDT (Multiplex Data Transmitter)]

Signal names and functions

6 SHIELD

- Signal name: Serial port 2 shield
Input voltage: DC 0 V

7 DGND

8 CAN1_L

9 CAN1_H

10 SHIELD

(Spare)

11 RX1 +

12 RX1-

13 SHIELD

14 RX2+

15 RX2-

- Signal name: Serial port 2 reception (+) input signal
[Reception data from MDT (Multiplex Data Transmitter)]

- Signal name: Serial port 2 reception (-) input signal
[Reception data from MDT (Multiplex Data Transmitter)]

16 SHIELD

(Spare)

17 DGND

18 CAN2_L

19 CAN2_H

20 SHIELD

CAN communication

CAN communication

Shield

23

W301-0411E

Chapter A Chapter A

Components of AML System

2.1.9 CN8 Connector (8-Pin)

CN8 connector

Pin No. Name

1 FG

2 FG

3 BOOT

4 TXD

Signal names and functions

(Spare)

(Spare)

Boot (Boot mode activation with GND connection)
For maintenance (data readout and rewriting)

RS232C communication
For maintenance (data readout and rewriting)

5 FG

6 DGND

7 DGND

8 RXD

(Spare)

Digital ground
For maintenance (data readout and rewriting)

Digital ground
For maintenance (data readout and rewriting)

RS232C communication
For maintenance (data readout and rewriting)

24

W301-0411E

Chapter A Chapter A

Components of AML System

2.1.10 CN9 (USB) Connector (4-Pin)

CN9 connector

Pin No. Name

1 VBUS

2 D-

(Spare)

3 D+

8 DGND

Signal names and functions

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. Di signals

Di (+) and Di (-) indicate the digital input signal with the connection status shown in the figure below.

2. Do signals

Do (+) and Do (-) indicate the digital output signal with the connection status shown in the figure below.

25

W301-0411E

Chapter B

B

Contents

B-1 Functions and How to use

the User Mode........................ 26

1.1 Mode Structure ........................................ 26

1.2 Display Selection ..................................... 26

1.3 Operation Indicator Display ..................... 27

B-2 Registration of Operating State and

AML Function Check............. 28

2.1 Registration of Outrigger State ................ 28

2.2 Registration of Crane State...................... 31

User Mode

3.3 Warning code and Remedy List............... 40

3.3.1 Stop warning code ....................................40

3.3.2 Warning Code (ex.: GR-750XL-2,

GR-1000XL-2) ....................................41

B-4 Other Functions .............................43

4.1 Working Range Limit Function ................ 43

4.1.1 Display of Limit Function State .................44

4.1.2 Registering Boom Angle, Lifting Height,

and Load Radius Limit ........................44

4.1.3 Registration of Swing Range

Limit Function .....................................46

4.1.4 Alarm for Work Range Limit

and Recovery Operation.....................48

2.3 Registration of counterweight state.......... 33

2.4 Registration of Number of Part-lines

of Wire Rope ................................ 34

2.5. Pre-operational Inspection on AML.......... 36

B-3 Alarm and Recovery Operation ....38

3.1 Type of Warning Codes and Buzzer ........ 38

3.2 Warning Code and
Crane Model Comparison Table ... 39

4.2 TARE Function ........................................ 49

4.3 Mute Alarm Function................................ 49

4.4 Fuel Consumption Indicator..................... 50

4.5 User Adjustment Menu ............................ 51

4.5.1 Adjustment menu/model

comparison table.................................51

4.5.2 User Adjustment Menu..............................51

4.5.3 Eco mode selection...................................52

4.5.4 Activating/Deactivating the Winch Drum

Rotation Buzzer Function ...................53

4.5.5 Fuel Consumption History Display............54

4.5.6 Selection of Winch to be used ..................55

4.5.7 Adjustment of Display Panel Contrast ......57

4.5.8 Transmission of Telematics alarm data.....57

i

B-5 Action against AML

System Error.......................... 58

B-6 Do Output Control.......................... 59

6.1 Cause for AML Automatic Stop Output .... 59

6.1.1 100% Lifting Performance Stop................ 60

6.1.2 Anti-twoblock Stop.................................... 61

6.1.3 Backward Stability Stop............................ 61

6.1.4 Boom Upper Limit Stop ............................ 62

6.1.5 Boom Lower Limit Stop ............................ 62

6.1.6 Lifting Height Limit Stop............................ 62

6.1.7 Load radius Limit Stop.............................. 62

6.1.8 Elevation Lower Limit ............................... 63

6.1.9 Elevation Upper Limit ............................... 63

6.2 Do Output Abnormality Processing .......... 64

6.3 Drum Indicator Control Function.............. 65

6.3.1 Outline of Drum Indicator Control Function65

6.3.2 Input.......................................................... 65

6.3.3 Output....................................................... 65

6.3.4 Panel LED Control.................................... 65

6.3.5 Drum Indicator Do Output Control............ 65

6.3.6 Drum Indicator Do Output Restriction ...... 65

7.3 Output of Interference Prevention

Warning .................................. 70

7.3.1 Function ....................................................70

7.3.2 Data Specification .....................................70

7.3.3 Input ..........................................................70

7.3.4 Warning Condition.....................................70

7.3.5 Warning Code ...........................................70

7.4 Winch Drum Position Selection Function 71

7.4.1 Function ....................................................71

7.4.2 Processing Effective Condition .................72

7.4.3 Information Relevant to

Winch Drum Position Selection ..........73

7.4.4 Output .......................................................73

7.4.5 Processing Contents.................................73

7.4.6 Special Notes............................................74

B-8 Proportional Control Function ......75

8.1 Factors for Control................................... 75

8.2 Elevation Slow Stop................................. 75

8.3 Swing Slow Stop...................................... 75

6.4 Output of warning .................................... 66

6.4.1 Safety signal............................................. 66

6.4.2 90% warning............................................. 66

6.4.3 100% warning........................................... 66

B-7 AML Control ...................................67

7.1 Backward Stability Stop Function............. 67

7.1.1 Outline of Function ................................... 67

7.1.2 Restriction Contents ................................. 67

7.2 Working Range Limit Stop Function......... 67

7.2.1 Outline of Function ................................... 67

7.2.2 Restriction Contents ................................. 68

7.2.3 Cancel Condition...................................... 69

7.2.4 Storing of Setting Condition...................... 69

B-9 AML Cancel Function ....................76

9.1 Introduction.............................................. 76

9.2 Canceling Method.................................... 77

9.2.1 Cancel Status Judgment...........................77

9.2.2 Cancel Switch Abnormality Judgment ......77

9.3 Interlock Stop........................................... 78

9.3.1 Cancel Contents .......................................78

9.4 Overload Cancel...................................... 78

9.4.1 Cancel Contents .......................................78

9.5 Detector Abnormality ............................... 79

9.5.1 Stop Processing at Detector Abnormality

(Compulsory unload output) ...............79

ii

Chapter B Chapter B

User Mode

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.

• Maintenance Mode: Used to perform the AML operation check, reference of history information, etc.

Also, some adjustment functions such as clock adjustment are included in the

maintenance mode.

For operation method of maintenance mode, refer to "Chapter C, Maintenance

Mode."

• Adjustment Mode: Used to adjust detectors, actuators, etc.

For operation method of adjustment mode, refer to "Chapter D, Adjustment Mode."

1.2 Display Selection

When the display change key < > is pushed during normal state, the content of the display panel changes

as shown below.

26

W301-0411E

Chapter B Chapter B

User Mode

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

Telescoping mode I

Telescoping mode II

Jib lock

Jib dismount

Winch selection

(Main winch)

A-1

A-2

A-3

The boom telescoping mode I is selected.

The boom telescoping mode II is selected.

Under the jib set state, the jib extension/retraction switch is set to "Ext".
and the jib offset cylinder is fully extended.

The jib is dismounted from the boom, and the jib status switch is set to
"REMOVED".

The main winch is selected.

A-4

Winch selection

(Auxiliary winch)

Boom telescoping

control

Auxiliary Winch

Control

Hydraulic oil

temperature 50°C

B-1

The auxiliary winch is selected during single top lift or jib lift.

The boom telescoping/auxiliary hoist control selector switch is set to
"Boom telescoping".

The boom telescoping/auxiliary hoist control selector switch is set to
"Auxiliary winch".

Flashes when the hydraulic oil temperature is between 122° F (50°C) and
185°F (85°C).
(If more than one icon are to appear in this area, they appear alternately
at each 3 seconds. )

Flashes when the hydraulic oil temperature exceeds 185°F (85°C).
(If more than one icon are to appear in this area, they appear alternately
at each 3 seconds. )

temperature 85°C

Hydraulic oil

B-2

Flashes when the extend/retract selector switch or jack/slide selector

Outrigger switch out of

neutral

Outrigger state

emergency
registration

switch is set to the positions other than neutral position.
(If more than one icon are to appear in this area, they appear alternately
at each 3 seconds. )

Flashes when the emergency outrigger control switch is set to "ON".
(If more than one icon are to appear in this area, they appear alternately
at each 3 seconds. )

27

W301-0411E

Chapter B Chapter B

User Mode

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.

Before the crane operation, observe the steps below to register the operation state and be sure to do the AML

function check.

1. Set the PTO switch to "ON".

• The PTO indicator lights up, and the power is

supplied to the AML.

2. Set up the outriggers.

2.1 Registration of Outrigger State

3. Push the < > key (outrigger state select).

• The pop-up window for the outrigger state

registration is shown on the display panel.

Each time the <

pushed, the display changes as shown below..

> key (outrigger state select) is

When the power for the AML is turned on, the "On-rubber (creep) operation" state is automatically set.

Instead of the outrigger state select key, you can use the < > key (backward) or < > key (forward)to

change the display of the outrigger state.

28

W301-0411E

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.

Maximum extension 23' 11-3/8" (7.3m)

Middle extension 2 21' 11-3/4" (6.7m)

Middle extension 1 18' 1/2" (5.5m)

GR-750XL-2

GR-1000XL-2

User Mode

Minimum extension 8' 10-1/4" (2.7m)

When you want to stop registration, push the < > key (EXT).

The pop-up window closes and the AML returns to the state before start of the registration.

29

W301-0411E

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.

User Mode

6. Take out the main and auxiliary hook blocks from the

stowing positions.

30

W301-0411E

Chapter B Chapter B

User Mode

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< > key (lift state select),

the display changes as shown in the illustration.

When the power of the AML is turned on, the boom lift state is automatically set.

Instead of the lift state select key, you can use the

< > key (backward) or < > key (forward) to

change the display of the lift state.

When you want to stop registration, push the < >

key (EXT). The pop-up window closes and the AML

returns to the state before start of the registration.

31

W301-0411E

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.

9. Push the< > key (backward) or < > key (forward)

to select one of the telescoping mode icons.

• The selected icon is highlighted.

User Mode

10. 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.

32

W301-0411E

Chapter B Chapter B

User Mode

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.

WARNING

If the indication on the AML and actual
counterweight state does not agree, an
overturning accident or a crane damage can
occur.

13. Push the < > key (set) to register the setting.

• After the registration is completed, the pop-up

window closes, and the AML returns to the crane

operation state.

33

W301-0411E

Chapter B Chapter B

User Mode

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.

Each time you push the < > key (rope part line),

the number of part lines changes.

The hook block is automatically selected and shown

according to the registered lift state. If the displayed

hook block symbol is not the one you want to register,

push the < > key (main hook block) to change the

indication.

You can register only the number of part lines specified for each model.

Instead of the rope part line key, you can use the < > key (backward) or < > key (forward) to

change the display of the number of part lines.

When you want to stop registration, push the < > key (EXT).

The pop-up window closes and the AML returns to the state before the start of the registration.

34

W301-0411E

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.

User Mode

16. Set the jib status switch to register the jib state.

• REMOVED: Jib dismounted

• EQUIPPED: Jib mounted

When the switch is set to "REMOVED", the jib
dismount icon appears on the display panel of the
AML.

WARNING

Make sure that the switch position
corresponds to the actual jib mounting
state. Otherwise, the calculation base of
the AML is inaccurate, and the machine
can overturn or be damaged.

When the jib is dismounted, the reduction of the

mass affects the measurement of the AML.

You can insert/remove the switch key either in the

"REMOVED" or "EQUIPPED" position.

35

W301-0411E

Chapter B Chapter B

User Mode

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

• Alarm buzzer : Continuously sounds.

18. Attempt hoist-up, boom extension, and boom

lowering operations to make sure that the crane does

not operate.

19. Push the < > key (inspeciton) again to return the

AML to the crane operation state.

36

W301-0411E

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

of the vehicle)

(4) Boom angle

(5) Outrigger status indicator symbol

(6) Boom length

(7) Number of part lines

User Mode

(8) Jib length (When jib lift is registered)

(9) Jib offset angle (When jib lift is registered)

The hook block mass shown varies depending

on the crane configuration, etc.

Now, operation state registration and AML function check are completed.

You can start crane operation.

Even after you turn off the AML, the registered information is retained for approximately 2 hours.

When the AML is turned on, the operation starts with the retained information.

The registered information is erased approximately 2 hours after the AML is turned off. In this case, it is

necessary to register the operation state from the beginning.

37

W301-0411E

E

Chapter B Chapter B

User Mode

B-3 Alarm and Recovery Operation

NOTIC

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.

• The crane stops and you cannot operate it.

When any failure occurs or improper operation is performed during crane operation, the buzzer sounds and an

warning code is/are shown to ensure safety and to prevent damage to the machine. Examine the contents of the

warning code, and perform the recovery operation.

3.1 Type of Warning Codes and Buzzer

The warning codes appear on the display panel.

There are 3 types of buzzers, and each buzzer sounds differently according to the cause of the alarm.

Warning codes appear on the display panel.

While the warning code(s) is/are displayed, pushing the < > key opens the pop-up window and displays

the code(s) individuality.

F1 key

38

W301-0411E

Chapter B Chapter B

User Mode

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
W0003 Left front outrigger beam retraction
W0004 Left rear outrigger beam retraction
W0005 Boom angle value becomes out of specified range
W0006 Improperly inserted jib lock pin
W0007 Stop at swing angle limit
W0012 Rear stability auto. stop range
W0013 Over-front detection switch is defective

W0015

W0016

W0017

Twoblocking condition
(When Anti-twoblock stop function is cancelled)
State 1 is not applied
(Outrigger, Swing angle, C/W, combinations)
State 2 is not applied

(Boom and Jib combination)
W0018 Boom full retraction switch 1 faulty
W0019 Boom full retraction switch 2 faulty
W0020 Boom full retraction switch 3 faulty
W0021 Boom full retraction switch 4 faulty
W0022 Jib full retraction switch 1 faulty
W0023 Stopped at 100% of crane performance
W0024 Stop due to twoblocking (overwind)
W0025 Stopped due to backward stability
W0026 Stopped at upper boom angle limit restriction
W0027 Stopped at lower boom angle limit restriction
W0028 Stopped at lifting height restriction
W0029 Stopped at load radius restriction

W0034

W0035

Stopped by main winch over-unwinding

prevention device (Europe spec.)

Stopped by aux. winch over-unwinding

prevention device (Europe spec.)
W0040 AML override sw “ON” condition (EN13000 spec.)
W0042 Right swing restriction limit
W0043 Left swing restriction limit
W0044 Jib stowed condition
W0054 Stopped by elevating cylinder stroke end (Ret.)
W0055 Stopped by elevating cylinder stroke end (Ext.)
W0056 Swing operation is dangerous
W0057 Right front outrigger state change
W0058 Right rear outrigger state change
W0059 Left front outrigger state change
W0060 Left rear outrigger state change
W0078 Altered counterweight state
W0106 Elevating speed is reducing
W0107 Telescoping speed is reducing
W0108 Swing speed is reducing
W0121 Stopped at elevating cylinder stroke end
W0122 Out of working range
W0123 During jib stowing
W0124 Stopped at limit range of boom with jib
W0189 Boom angle out of specified range for hook-in
W0190 Auto. stopped at critical range
W0191 Auto. stop override sw is defective (STD spec.)
W0197 Boom interference condition
W0198 Special lifting performance
W0214 Stopped due to Tension rod interference
W0215 Boom length detection is inconsistent
W0219 Stopped due to boom full extension
W0999 Back-up battery running down

○ ○
○ ○
○ ○
○ ○

● ●

○ ○

○ ○

○ ○

○ ○

○ ○
○ ○

● ●

● ●

● ●

● ●

● ●

● ●

● ●

● ●

● ●

● ●

● ●

● ●

● ●
○ ○
○ ○
○ ○
○ ○
○ ○
○ ○
○ ○

○ ○

● ●

● ●

○ ○

○ ○

39

W301-0411E

Chapter B Chapter B

User Mode

3.3 Warning code and Remedy List

3.3.1 Stop warning code

[Warning code] Buzzer Cause Remedy
Ordinary bar graph display
(no warning code)

Load moment ratio is
100% or more.

[W0023]

[W0024]

[W0007]

[W0025]

[W0034]

[W0035]

Alarm buzzer:
Continuous sound
(low tone)

Overwind
(twoblocking) alarm
buzzer:
Tremolo sound

AML built-in buzzer:

beep-beep-beep

(Short beeps repeat

for 3 seconds. )

Crane is operated
toward a critical side
while the load moment
ratio is 100% or more.

Crane is operated
toward a critical side
while the hook block is
overwound
(twoblocking).
Overload occurs during
the swing operation.

Backward stability
decreases and the
crane can overturn.

Remaining wire rope on
the main winch drum is
short.

Remaining wire rope on
the auxiliary winch drum
is short.

Unwind the winch,
retract or raise the
boom, or swing to the
non-critical side.

Unwind the winch or
retract the boom to
lower the hook block.

Swing in the opposite
direction, or retract or
raise the boom.

Lower or extend the
boom.

Wind up the winch.

[W0054]

[W0055]

[W0121]

[W0124]

Boom is lowered at
elevation lower limit
stroke end.

During the elevation
slow stop cancel, the
boom is raised at the
elevation upper limit
stroke end.

Boom is raised at
elevation upper limit
stroke end when the
elevation slow stop is
activated.

Load moment ratio
exceeds 80% during
the boom lift with the jib
extended.

Raise the boom.

Lower the boom.

• Unwind the winch, or
retract or raise the
boom.

• Stow the jib.

40

W301-0411E

Chapter B Chapter B

User Mode

3.3.2 Warning Code (ex.: GR-750XL-2, GR-1000XL-2)

[Warning code] Buzzer Cause Remedy
Ordinary bar graph display
(no warning code)

Alarm buzzer:
Intermittent sound
(low tone)

Load moment ratio is
90% or more and less
than 100%.

Carefully monitor the
load ratio.

[W0015]

[W0001]

[W0002]

[W0003]

[W0004]

[W0057]

[W0058]

[W0059]

[W0060]

[W0013]

Overwind
(twoblocking) alarm
buzzer:
Tremolo sound

AML built-in buzzer:
beep-beep-beep
(Short beeps repeat
for 3 seconds. )

The stop function is
canceled with the
anti-twoblock disable
switch while the hook
block is overwound
(twoblocking).
Outrigger beams
are retracted
during crane
operation

An outrigger beam
retracts during crane
operation, and the
performance (lifting
capacity) changes to
the one with smaller
extension width of
outriggers.

The state of front
position detector switch
and actual swing angle
do not agree.

R/F

R/R

L/F

L/R

Unwind the winch or
retract the boom to
lower the hook block.

Extend the outrigger
again, and insert the pin.
Then, register the
outrigger state again.

Inspect and maintain the
crane.

[W0016]

[W0017]

[W0018]

[W0019]

[W0056]

[W0078]

• Crane operation state
goes out of the states
that are registered to
the AML.

• An operation state
with no capacity rated
is registered to the
AML.

The state of the boom
full retraction detector
switch and actual boom
length do not agree.

The outriggers are
unequally extended,
and further swing
operation causes
overloading.
The state of the
counterweight mounted
on the crane does not
agree with the state of
registration on the AML.

• Register the operation
state again.

• For on-rubber
operation, retract the
boom to the capacity
range.

Inspect and maintain the
crane.

Swing in the opposite
direction, or retract or
raise the boom.

• Register the state of
counterweight on the
AML.

• Never operate a crane
while counterweight is
dismounted.

41

W301-0411E

Chapter B Chapter B

[Warning code] Buzzer Cause Remedy

AML built-in buzzer:

[W0197]

[W0999]

beep-beep-beep
(Short beeps repeat
for 3 seconds. )

User Mode

When the boom (or jib)
may touch the engine
cover or the mirror.

When the power is
turned on, the battery
for the AML built-in
clock is low.

Carefully lower or swing
a boom.

Replace the battery.

[W0106]

[W0108]

AML built-in buzzer:
beep-beep-beep
(Long beeps repeat
for 3 seconds. )

The elevation slow stop
function is activated
and boom elevating
operation is
decelerating.

The swing stop function
is activated and swing
operation is
decelerating.

The crane is
approaching the stop
position.
Operate with care.

42

W301-0411E

E

Chapter B Chapter B

User Mode

B-4 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)

• Winch drum rotation buzzer selection

• Fuel consumption history display

• Selection of the winch to be used

• Adjustment of display panel contrast

• Transmission of Telematics alarm data

Each function is as follows:

4.1 Working Range Limit Function

NOTIC

If the work range limit is registered too close to an obstacle, the machine can hit the
obstacle depending on the crane configuration and operation methods.
Consider a sufficient allowance when you register the limit.

The work range limit function restricts the operation of

the crane to the pre-registered boom angle (upper

limit, lower limit), lifting height, load radius, and swing

angle (left, right). Use this function when operating the

machine in a place where there are obstacles around

the machine or when requiring the working range limit

of the boom.

When the crane reaches the registered working range,

the limit function works as shown below:

Working range limit

function
Boom angle upper limit
Boom angle lower limit
Lifting height limit

Load radius limit
Left swing limit
Right swing limit

Crane state

• Crane stops
automatically.

• AML built-in buzzer

beep-beep-beep

(Short beeps repeat for

3 seconds. )

43

W301-0411E

Chapter B Chapter B

User Mode

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" to "flashing".

4.1.2 Registering Boom Angle, Lifting Height, and Load Radius Limit

1. Push the < > key (working range limit) to select the

item to be registered.

• The pop-up window for work range limit registration

appears on the display panel.

• Every time you push the < > key (working range

limit), the item to be selected changes in the

following sequence.

1. Lifting height limit

2. Load radius limit

3. Boom angle upper limit

4. Boom angle lower limit

5. Left swing limit

6. Right swing limit

• The illustration on the right shows an example of

display where "load radius limit" is registered and

"boom angle upper limit" is selected.

Instead of the< > key (working range limit), you

can use the < > key (backward) or < > key

(forward) to change the display of the item to be

selected.

When you want to stop registration, push the < >

key (EXT). The pop-up window closes and the AML

returns to the state before start of the registration.

44

W301-0411E

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.

• After registration is completed, the pop-up window

closes and the AML returns to the crane operation

state.

If you select the item with the limit value already

registered, remember that pushing the < > key

(set) cancels the registration of the work range limit.

3. Move the boom (jib) within the limit range.

• The indicator lamp turns to staying lit.

User Mode

• When the state of the crane reaches the registered

limit, the indicator lamp flashes.

The corresponding operation of the boom (jib)

automatically stops, and the warning code is shown

on the display panel. The AML built-in buzzer

repeats short beeps for 3 seconds.

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. Push the < > key (set).

• The corresponding limit indicator lamp goes out.

• The pop-up window closes and the AML returns to

the basic display.

When you push the < > key (clear), all the work

range limits are canceled.

45

W301-0411E

Chapter B Chapter B

User Mode

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.

• Every time you push the< > key (working range

limit), the item to be selected changes in the

following sequence.

1. Lifting height limit

2. Load radius limit

3. Boom angle upper limit

4. Boom angle lower limit

5. Left swing limit

6. Right swing limit

• The illustration on the right shows an example of

the display where "left swing limit" is selected.

Instead of the < > key (working range limit), you

can use the < > key (backward) or < > key

(forward) to change the display of the item to be

selected.

When you want to stop registration, push the < >

key (EXT). The pop-up window closes and the AML

returns to the state before start of the registration.

46

W301-0411E

E

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.

• After registration is completed, the pop-up window

closes and the AML returns to the crane operation

state.

If you select the item with the limit value

already registered, remember that pushing the

< > key (set) cancels the registration of the

work range limit.

User Mode

• The illustration on the right shows an example of

display, in which "swing limit" is registered.

Registration of swing range limit is the
function to set the allowable swing range.
Register it for both the left swing and right
swing.

NOTIC

3. Move the boom (jib) within the limit range.

• The indicator lamp turns to staying lit.

• When the boom reaches a registered swing limit, the indicator lamp flashes.

The swing operation automatically stops, and warning code appears on the display panel.

The AML built-in buzzer repeats short beeps for 3 seconds.

If you register the swing range limit only for one side (right or left), the crane does not operate

properly.

47

W301-0411E

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. Push the < > key (set).

• The corresponding limit indicator lamp goes out.

• The pop-up window closes and the AML returns

to the crane operation state.

When you push the < > key (clear), all

the work range limits are canceled.

User Mode

Even after you turn off the AML, the registered information is retained for approximately 2 hours.

When the AML is turned on, the operation starts with the retained information.

The registered information is erased approximately 2 hours after the AML is turned off. In this case, it is

necessary to register the operation state from the beginning.

4.1.4 Alarm for Work Range Limit and Recovery Operation

When the crane state reaches the registered limit value, the AML buzzer sounds, and the warning code

appears on the display panel.

Examine the meaning of the warning code, and perform recovery operation.

[Warning code] Buzzer Cause Remedy

[W0026]

[W0027]

[W0028]

[W0029]

[W0042]

[W0043]

AML built-in buzzer:
"Beep-beep-beep"
(Long beeps repeat
for 3 seconds)

The boom angle reaches
the upper limit.

The boom angle reaches
the lower limit.

The boom head or jib
head reaches the lifting
height limit.

The load radius reaches
the limit.

The boom is swung to the
swing limit.

Lower the boom.

Raise the boom.

Retract or lower the
boom.

Retract or raise the
boom.

Swing the boom in the
opposite direction.

48

W301-0411E

E

Chapter B Chapter B

User Mode

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.

2. Perform hoist-up operation to lift up the load.

• The mass of the load is shown on the hoist medium load

display.

3. To cancel the TARE function, push the < > key (TARE) again.

• The hoist medium load display returns to the normal hoist medium load display, and the TARE

indicator lamp goes out.

4.3 Mute Alarm Function

NOTIC

If the mute alarm function is activated, only the error code(s) and warning lamp indicate an
error, and the buzzer does not sound.
Be sure to deactivate the mute alarm function.

The following alarm buzzers can be muted.

• Alarm buzzer that sounds when the load moment ratio reaches or exceeds 90% (intermittent sound)

•

Alarm buzzer that sounds when the load moment ratio reaches or exceeds 100% (continuous sound)

To activate the function, push the< > key (mute alarm) while the alarm buzzer sounds.

• The mute alarm warning lamp lights up, and the buzzer

stops sounding.

To deactivate the function, push the < > key (mute alarm)

again.

• The mute alarm warning lamp goes out, and the alarm

buzzer sounds.

In the cases below, the mute alarm function is automatically deactivated.

• The AML is turned off.

• The alarm buzzer is necessary for other causes.

• The causes to sound buzzer no longer exist.

49

W301-0411E

Chapter B Chapter B

User Mode

4.4 Fuel Consumption Indicator

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.

The fuel consumption is displayed when the PTO is "ON", the following items are shown.

The fuel consumption includes the moment when outriggers are not used (when traveling).

1.Current Fuel Consumption.................

The current fuel consumption (hour/gallon)

during a crane operation is shown.

The max. value in a bargraph is 1.0 hour/gallon.

2.Average Fuel Consumption...............

The average fuel consumption (hour/gallon)

during a crane operation is shown as a bargraph.

The average fuel consumption is reset during

standby or when PTO switch is turned to "OFF".

3.Fuel Consumption during Standby.....

The fuel consumption (gallon) during standby is

shown.

4.Standby Period.................................

The crane standby period (min) is shown.

The crane standby period is the period when each operation lever and pedal are in neutral position.

Fuel Consumption during Standby and Standby Period are displayed when a crane has been in

standby mode for a specified period.

The displayed data may be different from the actual data depending on work conditions.

Check the fuel gauge to see the remaining fuel amount.

The fuel consumption history during a crane operation and standby is displayed.

Refer to ”4.5 User Adjustment Menu”.

50

W301-0411E

g

Chapter B Chapter B

User Mode

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

3. Fuel Consumption History Display

4. Selection of Winch to be used

5. Adjustment of Display Panel Contrast

6. Transmission of Telematics alarm data

More details, refer to each model’s Operation and Maintenance Manual.

4.5.2 User Adjustment Menu

1. Push the < > key (User preset menu).

• The pop-up window for the preset menu selection

appears on the display panel.

○ ○
○ ○
○ ○
○ ○
○ ○
○ ○

2. Push the < > key (backward) key or < > key

(forward) to select the preset icon..

• The selected preset icon is highlighted.

Push < > key (EXT) to exit the preset

menu. The pop-up window closes, and the

crane operation state before the

adjustment is restored.

3. Push the < > key (set).

• The selected preset screen appears.

Fi

. 4.5.1

51

W301-0411E

Chapter B Chapter B

User Mode

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".

・Eco mode 2 :

In this mode, a crane consumes further less fuel and makes

further less noise compared with when Eco mode 1 is

selected.

A crane operation becomes slower by restricting the maximum

engine speed. Select a suitable Eco mode depending on

crane operation.

1. Select the Eco mode selection icon, and then push

the < > key (set).

• The pop-up window for Eco mode selection

appears on the display panel.

2. Push the < > key (backward) or < > key

(forward) to select one of the Eco mode icons.

• The selected icon is highlighted.

3. Push the < > key (set).

• After the registration is completed, the pop-up

window closes and the AML returns to the crane

operation state.

• When Eco mode switch is turned "ON", Eco mode

indicator (Eco mode 1 or Eco mode 2) is

displayed.

Fig. 4.5.2

When you want to cancel the selection, push the

< > key (EXT). The pop-up window closes

and the AML returns to the crane operation state

without changing registration.

Even after the AML is turned off, the registered

information is retained. When the AML is turned

on, the operation starts with the retained

information.

52

W301-0411E

Chapter B Chapter B

User Mode

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.

1. Select the winch drum rotation buzzer selection menu

icon, and push the < > key (set).

• The pop-up window for winch drum rotation buzzer

selection appears on the display panel.

2. Push the < > key (backward) or < > key (forward)

to select one of the rotation buzzer icons.

• The selected icon is highlighted.

3. Push the < > key (set).

• After the registration is completed, the pop-up

window closes and the AML returns to the crane

operation state.

When you want to cancel the registration, push the

< > key (exit). The pop-up window closes and the

AML returns to the crane operation state without

changing registration.

Even after the AML is turned off, the registered

information is retained. When the AML is turned on,

the operation starts with the retained information.

Fig. 4.5.3

53

W301-0411E

Chapter B Chapter B

User Mode

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 < > key (set).

• The screen for fuel consumption history appears.

Fig. 4.5.4

3. The display changes when the < > key (display

change) is pushed.

• The fuel consumption history is shown in either a

bargraph or number.

• The items shown on the numeric display screen are

as follows.

G(N) ......... Fuel consumption during standby (gallon)

G(D) ......... Fuel consumption during crane operation

(gallon)

h/G ......... Fuel consumption ratio during crane

operation (hour/gallon) You can change

the unit of fuel consumption ratio in h/G

(hour/ gallon) or G/h (gallon/hour) by

pushing F2 (unit change) key.

The measurements restart when < > key

(reset) is pushed. The previous records are

moved down by pushing < > key (reset). 6

previous records including the current rate

are displayed.

Push < > key (exit) to exit the history display. The pop-up window closes and the AML returns to the

crane operation state.

The fuel consumptions of G(N) and G(D) include when the crane is operated without outriggers (when

traveling).

54

W301-0411E

Chapter B Chapter B

User Mode

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.
Make sure that the state of actual crane operation and the selection of the winch for use
agree before starting operation.

NOTICE

The crane operations other than those shown in the illustrations below are prohibited. Use the
specified combinations only.

Select the winch (main winch/auxiliary winch) to be used.

<Standard>Main winch should be selected when boom lift, S/T lift or Jib lift is registered following

conditions.(Memorized in the AML with main winch used)

When S/T lift or Jib lift status is registered following conditions, should be selected Aux. winch (Rear side

used by user adjustment menu). Then, subtract the mass of the main hook from the Rated capacity, gives

actual hoist medium load. (Refer to "Reduction of Rated Capacity" Foreword 6. Viii )

1. Select the winch select icon, and then push the < > key

(set).

• The pop-up window for winch selection appears on

the display panel.

2. Push the < > key (backward) or < > key (forward) to

select one of the winch icons.

• The selected icon (Aux. winch) is highlighted.

55

Fig. 4.5.5

W301-0411E

Chapter B Chapter B

3. Push the < > key (set).

• After registration is completed, the pop-up window

closes and the AML returns to the normal display.

User Mode

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.

When the AML (PTO switch) is turned on, the operation starts with "main winch" automatically.

56

W301-0411E

Chapter B Chapter B

User Mode

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 < > key (-) or < > key (+) to adjust the

contrast.

• Push the < > key (+) to increase contrast and the

< > key (-) to decrease contrast.

3. Push the < > key (set).

Fig. 4.5.6

• When registration is completed, the pop-up

window closes and the AML returns to the crane

operation state.

When you want to stop registration, push the

< > key (EXT). The pop-up window closes and

the AML returns to the crane operation state
without changing registration.

If you push the < > key (EXT) for 3 seconds or

more, the contrast returns to the initial setting.

Even after the AML is turned off, the registered

information is retained. When the AML is turned

on, the operation starts with the retained
information.

4.5.8 Transmission of Telematics alarm data

(Refer to Chapter C "2.16 Telematics Check)

57

W301-0411E

R

E

Chapter B Chapter B

User Mode

B-5 Action against AML System Error

DANGE

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. The crane can overturn or suffer damage, and this can cause a serious accident.

NOTIC

The person having supervisory or management duties of the machine or the job shall keep

the key for the override key switch.

When the load moment indicator system is in error, the crane may not operate normally.

In this case, stow the crane by the following procedure.

1. When a load is suspended, unwind the winch to

lower the load to the ground.

2. Insert the key into the override key switch, and

turn it to "ON".

3. Set the PTO switch to "OVERRIDE".

The emergency operation warning lamp on the

load moment indicator will light up.

When the switch is release, it will

automatically return to "ON".

4. Stow the crane.

5. Return the override key switch to "OFF", and

remove the key.

6. Set the PTO switch to "OFF".

58

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Chapter B Chapter B

User Mode

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 <=> operation), the unload

status is maintained for 2 seconds even after the stop condition is resolved.

However, during this period of 2 seconds, when an operation is performed only to return to the safe side,

the on-load output is performed immediately to allow the return operation to be performed.

In the stop status, a warning is given using the AML built-in buzzer. At the same time, an warning code is

displayed on the graphic display.

The causes for stop are as follows:

Stop item Warning code

1 100% lifting performance stop

2 Anti-twoblock stop W0024

3 Backward stability stop W0025

4 Boom upper limit stop (When area limit is set) W0026

5 Boom lower limit stop (When area limit is set) W0027

6 Lifting height limit stop W0028

7 Load radius limit stop W0029

8 Elevation lower limit (At cylinder stroke end) W0054

9 Elevation upper limit (At cylinder stroke end) W0055

W0023 or
W0124 (In the case of main winch used for jib)

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Chapter B Chapter B

User Mode

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)

Maximum extension 7.3m 88% or more 94% or more

Middle extension 2 6.7m 87% or more 93% or more

Middle extension 1 5.5m 80% or more 92% or more

Outrigger extension width Output

GR-750XL-2 GR-1000XL-2 GR-750XL-2 GR-1000XL-2

Main boom with jib judgment: (1) and (2)

(1) Jib extension detection is in "extension" status (Di7: OFF).

(2) "Boom operation" is set with AML.

Code at stop: W0023

W0124 (For the main boom with jib)

Cancel: 100% stop cancel (Di6: ON)

Stop operation: (×: Stop operation)

M winch A winch

Up Down Up Down Ext. Ret. Rse. Lwr. Ext. Ret. Rse. Lwr. Right Left Ext. Stw.

× × × × × × ×

Boom

telescoping

Boom

elevation

Jib

telescoping

Jib tilt Swing

mounting

Jib

Special note: The load ratio exceeds 100% when the boom raising stroke end is reached.

Therefore, when the boom angle is A° or more, the automatic stop will not be performed for the boom

lowering operation even when the load ratio is 100% or more.

GR-750XL-2 GR-1000XL-2

Angle A°

80.1 80.1

(#2782)

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Chapter B Chapter B

User Mode

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)

M winch A winch

Up Down Up Down Ext. Ret. Rse. Lwr. Ext. Ret. Rse. Lwr. Right Left Ext. Stw.

× × × × × × ×

Boom

telescoping

Boom

elevation

Jib

telescoping

Jib tilt Swing

Jib

mounting

6.1.3 Backward Stability Stop

When the backward stability is lost, the operations that reduce the backward stability are stopped.

Stop condition: During on-rubber operation, the boom angle becomes as follows:

(data No.: #10722, #10724 to 10733, #10736)

GR-750XL-2

GR-1000XL-2

Model

Boom length

Boom length

11.00 m

19.00m

11.00 m

12.00m

20.75m

29.50m

12.00m

Stop angle Remark

Boom angle of 76° or
more

Boom angle of 80° or
more
Boom angle of 40° or
more
Boom angle of 68° or
more
Boom angle of 75° or
more
Boom angle of 78° or
more
Boom angle of 40° or
more

Boom lift

Jib lift

Boom lift
Single top lift

Jib lift

Single top lift

Stop condition: While either of the outriggers is at minimum extension, the boom angle becomes as follows:

Model

GR-750XL-2

GR-1000XL-2 Boom length 12.00m

---

Stop angle Remark

---

Boom angle of 78° or

more

Boom lift
Single top lift

Code at stop: W0025

Cancel: None (Not allowed)

Stop operation: (×: Stop operation)

M winch A winch

Up Down Up Down Ext. Ret. Rse. Lwr. Ext. Ret. Rse. Lwr. Right Left Ext. Stw.

× ×

Boom

telescoping

Boom

elevation

Jib

telescoping

Jib tilt Swing

Jib

mounting

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Chapter B Chapter B

User Mode

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)

M winch A winch

Up Down Up Down Ext. Ret. Rse. Lwr. Ext. Ret. Rse. Lwr. Right Left Ext. Stw.

×

Boom

telescoping

Boom

elevation

Jib

telescoping

Jib tilt Swing

Jib

mounting

6.1.5 Boom Lower Limit Stop

Restriction is implemented to the operations falling short of the boom angle that is set with the area limit.

Code at stop: W0027

Cancel: 100% stop cancel (Di6: ON)

Stop operation: (×: Stop operation)

M winch A winch

Up Down Up Down Ext. Ret. Rse. Lwr. Ext. Ret. Rse. Lwr. Right Left Ext. Stw.

×

Boom

telescoping

Boom

elevation

Jib

telescoping

Jib tilt Swing

6.1.6 Lifting Height Limit Stop

Restriction is implemented to the operations exceeding the lifting height that is set with the area limit.

Code at stop: W0028

Cancel: 100% stop cancel (Di6: ON)

Stop operation: (×: Stop operation)

M winch A winch

Up Down Up Down Ext. Ret. Rse. Lwr. Ext. Ret. Rse. Lwr. Right Left Ext. Stw.

× × × ×

Boom

telescoping

Boom

elevation

Jib

telescoping

Jib tilt Swing

6.1.7 Load radius Limit Stop

Jib

mounting

Jib

mounting

Restriction is implemented to the operations exceeding the load radius that is set with the area limit.

Code at stop: W0029

Cancel: 100% stop cancel (Di6: ON)

Stop operation: (×: Stop operation)

M winch A winch

Up Down Up Down Ext. Ret. Rse. Lwr. Ext. Ret. Rse. Lwr. Right Left Ext. Stw.

× × × ×

Boom

telescoping

Boom

elevation

Jib

telescoping

Jib tilt Swing

62

W301-0411E

Jib

mounting

Chapter B Chapter B

User Mode

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. However, to achieve the traveling configuration, when the swing

angle and boom length condition (#2784) are satisfied, the lowering can be performed to the stroke end

without a stop.

Stop condition: Boom angle

≤ Boom lowering stop angle (#2784), and in the crane status other than the one

specified by data (#2784)

GR-750XL-2 GR-1000XL-2

Angle A°

-30.0 -30.0

Cancel: 100% stop cancel

Code at stop: W0054

Stop operation:

M winch A winch

Up Down Up Down Ext. Ret. Rse. Lwr. Ext. Ret. Rse. Lwr. Right Left Ext. Stw.

×

Boom

telescoping

Boom

elevation

Jib

telescoping

Jib tilt Swing

Jib

mounting

The crane status (traveling retraction) specified by (#2784) is as follows:

Boom length (m) Left swing limit (°) Right swing limit (°) Boom angle (°)

GR-750XL-2 11.10 355.0 5.0 3.5

GR-1000XL-2 12.10 355.0 5.0 3.5

6.1.9 Elevation Upper Limit

With 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 raising stroke end is reached.

When the raising stroke end is reached, an overload status is reached, and then the lowering operation

becomes prohibited, making the stowing impossible. Therefore, at the angle (#2783) or more than the ones

specified in the table below, the elevation lowering is allowed even when the moment value is 100% or more.

Stop condition: Detected boom angle

≥ Boom raising stop angle (#16719)

GR-750XL-2 GR-1000XL-2

Angle A° 80.8 81.0

Cancel: 100% stop cancel (Di6: ON)

Code at stop: W0055

Stop operation:

M winch A winch

Up Down Up Down Ext. Ret. Rse. Lwr. Ext. Ret. Rse. Lwr. Right Left Ext. Stw.

×

Boom

telescoping

Boom

elevation

Jib

telescoping

Jib tilt Swing

Jib

mounting

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Chapter B Chapter B

User Mode

6.2 Do Output Abnormality Processing

The block diagram below shows the Do highside output.

Do0 output signal

Do output power monitor

Do output signal

Output monitor signal

(1) Do output power abnormality

- In case of Do0 operation failure (Do output power monitor is 18 V or less), an error is displayed.

At the Do0 operation failure, the Do highside ON output abnormality is not displayed.

- As for the Do highside output abnormality processing of (2), the error will not be displayed when Do0 is turned

OFF.

- As for Di, when PTO ON/OFF changeover is possible and PTO is OFF, the abnormality detection is not

performed.

(2) Do highside output abnormality

- When an output abnormality (a contradiction between Do output signal and output monitor signal) occurs to the

Do highside output (Do1 to 8), an error is displayed.

- When the Do output signal is OFF and the output monitor signal is ON, in order to prevent the dangerous

operation caused by the Do highside output clinging (such as FET output short, etc.), the output voltage of Do

highside output (Do1 to 8) is cut by turning OFF Do0.

+24V

RY(Relay)

FET

(Field Effect Transistor)

Do highside output

Output monitor

circuit

The table below shows the output status of Do0 output signal with each output abnormality.

Table 6.2.1 Output status of Do0 output signal for each output abnormalities

Do No. Do output signal Output monitor signal Do0 output signal status

Do1

.
.

Do8

- When the Do0 output signal is OFF, the abnormality is not detected for Do output signal ON and output

monitor signal OFF.

- To restore from the output voltage cutoff of Do highside output (Do1 to 8), turn OFF the machine main power

and then ON again because the error status is retained.

On (H) Off (H) ---

Off (L) On (L) Off

.
.

On (H) Off (H) ---

Off (L) On (L) Off

.
.

.
.

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Chapter B Chapter B

User Mode

6.3 Drum Indicator Control Function

6.3.1 Outline of Drum Indicator Control Function

The panel LED changes depending on the drum rotation speed of displayed drum. According to the main drum

rotation and auxiliary drum rotation, the Do output (20 ms = 20/1000 second) is performed.

6.3.2 Input

1). #17216-1 Main drum rotation

2). #17216-2

Auxiliary drum rotation

6.3.3 Output

1). #17802-122 Main drum indicator Do output

2). #17708-123

Auxiliary drum indicator Do output

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

winch drum, and the control is performed.

Fig. 6.3.1 Panel drum indicator LED

Table 6.3.1 Models with user preset menu selection, illumination switching timing

(Selection of adjustment method: " Front " ←→ "Front/rear")

Operation status Winch drum position status

Boom lift Front

Other than

boom lift

(Refer to Chapter B, 4.5.6 “Selection of Winch to be use”)

Front

Rear

Rotation detector

Main winch

Main winch

Auxiliary winch

(pulse)

drum

drum

drum

Frequency dividing

Number of main wire

part-lines

Number of auxiliary

wire part-lines

6.3.5 Drum Indicator Do Output Control

The Do (#17802-122) output control corresponding to main drum rotation speed (#17216-1) and the Do

(#17802-123) output control corresponding to auxiliary drum rotation speed (#17216-2) are performed

concurrently. ON is output for 20 ms, and then OFF is output.

6.3.6 Drum Indicator Do Output Restriction

The drum output exceeding the frequency of 7 Hz is stopped, and the output stop status will be maintained until

the frequency becomes to 5 Hz or less.

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Chapter B Chapter B

User Mode

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%. (When boom lift is performed with the jib mounted on the boom,

the ratio is below the value specified in #20803.)

(2)100% stop cancel input (#19206-6) is "no cancel display".

(3)Anti-twoblock stop cancel input (#17206-7) is "no-cancel display".

When the condition is fulfilled, "OFF" is output.

6.4.2 90% warning

This output controls the external warning lamps. (data No.:#17802-10)

Condition of output: (1), (2) and (3) exist.

(1)The load moment ratio is 90% or over and less than 100%. (When boom lift is performed with the jib

mounted on the boom, the ratio is in the range specified in #20803.)

(2)100% stop cancel input (#17206-6) is "no-cancel display".

(3) Anti-twoblock stop cancel input(#17206-7) is "no-cancel display".

When the condition is fulfilled, "OFF" is output.

6.4.3 100% warning

This output controls the external warning lamps. (data No.:#17802-11)

Condition of output: ①, ② or ③ exists.

①The load moment ratio is over 100%. (When boom lift is performed with the jib mounted on the boom, the

ratio is over the value specified in #20803.)

②100% stop cancel input (#17206-6) is "cancel display".

③Anti-twoblock stop cancel input (#17206-7) is "cancel display".

When the condition is fulfilled, "OFF" is output.

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Chapter B Chapter B

User Mode

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.

7.1.2 Restriction Contents

When the boom elevation angle goes over the backward stability performance, a warning code "W0012" is

displayed regardless of the operation. Also, the crane stop output is performed while the crane is operated

toward the critical side exceeding the stability performance.

The critical side operations are as follows:

(1) Boom retraction

(2) Elevation raising

During the stop output, the code "W0025" is displayed.

Even after the stop output condition is canceled, the stop output is maintained for 2 seconds. In order to

suppress the hunting at performance limit, hysteresis is considered in the boom elevation angle judgment.

7.2 Working Range Limit Stop Function

7.2.1 Outline of Function

The working range limit stop function specifies the working range where the crane entry by operator is prohibited,

and performs the crane stop output when the crane is operated to enter the specified area. The area is specified

by the copying method (the crane is actually operated to before the entry prohibition area, and then the range

limit position is set at the position). The following 6 working range limit stops are performed.

(1) Boom height (lifting height)

(2) Boom upper limit angle

(3) Boom lower limit angle

(4) Load radius

(5) Right swing limit (Note)

(6) Left swing limit (Note)

Note: The swing hydraulic circuit adopts a route different from that of other operations, and no stop is performed

with the main pumps relief valve’s unload. Consequently, the stop is performed by the output of solenoid

proportional valve that is connected to the pilot pressure line for swing operation. Therefore, the swing range

limit works only the models equipped with the solenoid proportional valve for swing operation.

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Chapter B Chapter B

User Mode

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. In order to suppress the hunting, hysteresis is used in the range limit judgment.

The critical side operations of swing limit and displayed warning codes are as shown below. With the swing limit,

the warning code is displayed even when the limit is canceled.

(1) Boom height (lifting height) limit

- Boom extension

- Elevation raising

- Jib extension

- Jib tilt raising

Code at stop: "W0028"

(2) Boom upper limit angle restriction

- Elevation raising

Code at stop: "W0026"

(3) Boom lower limit angle restriction

- Elevation lowering

Code at stop: "W0027"

(4) Load radius limit

- Boom extension

- Elevation lowering

- Jib extension

- Jib tilt lowering

Code at stop: "W0029"

(5) Right swing limit

- Right swing

Code at stop: "W0042"

(6) Left swing limit

- Left swing

Code at stop: "W0043"

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Chapter B Chapter B

User Mode

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.

Table 7.2.1 Cancel condition of swing range limit

Re-stop data

Setting (#813)

Set ---

AML emergency

#17206-2

Swing stop

cancel

#17206-5

Cancel Without stop

No cancel With stop

Result

Emergency

(Override)

None

Normal

--- Without stop

Cancel Without stop

No cancel With stop

7.2.4 Storing of Setting Condition

With the range limit function, the set limit value is stored in the backup RAM, and the value is retained and used

when the machine is restarted within 2 hours. The set value is stored when the range limit value and limit status

are changed.

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Chapter B Chapter B

User Mode

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.

#12785: Interference warning range data

7.3.3 Input

(1) Swing angle …………………. Swing angle calculated with AML

(2) Elevation angle ……………… Elevation angle calculated with AML

(3) Swing angle left limit ……..… "1. Swing angle left limit" of data #12785

(4) Swing angle right limit ……… "2. Swing angle right limit" of data #12785

(5) Elevation angle upper limit … "3. Elevation angle upper limit" of data #12785

Items (3) to (5) can be set concurrently.

7.3.4 Warning Condition

When the condition below is satisfied, the warning code is displayed.

{(3) Swing angle left limit

{(2) Elevation angle

When two or more of (3) to (5) are set concurrently, the warning code is displayed when any of the items

satisfies the above condition.

- The condition is not dependent on the boom status setting. (In any operating status, the warning code is

displayed when the above condition is satisfied.)

≤ (1) Swing angle ≤ (4) Swing angle right limit} and

≤ (5) Elevation angle upper limit}

7.3.5 Warning Code

[W0197]

The automatic stop output or any output to external buzzer and external indicator lamp are not performed.

70

W301-0411E

E

Chapter B Chapter B

User Mode

7.4 Winch Drum Position Selection Function

NOTIC

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. 7.7.1

(B) When S/T lift or Jib lift status is registered following conditions, should be selected Aux. winch (front side

used by user preset menu). Then, subtract the mass of the main hook from the Rated Capacity, gives actual
hoist medium road.

Fig. 7.7.2

7.4.1 Function

For the machine whose performance is determined on the assumption that the only main winch (drum position:

front

position: front and rear

1) is employed. Use the winch position selection function if both of main and auxiliary winches (drum

2) are used.

Select the winch position according to the crane operation status to decrease a lifting capacity reduction

(decrease a back moment by Aux. winch wire rope tension due to loosing the distance from the boom pivot pin).

(

1) Spec. selection flag differs according to #17200-96.

(

2) Spec. selection flag corresponding to setting of front/rear winch selection differs depending on #17200-96.

When the flag indicates " Front ←→ Front/rear (1), the main winch is in front and the aux. winch is in rear.

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Chapter B Chapter B

User Mode

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. 7.7.3 Adjusted working status

(Main winch front position)

Fig. 7.7.4 Normal (memorized) working status

(Aux. winch back position)

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Chapter B Chapter B

User Mode

7.4.3 Information Relevant to Winch Drum Position Selection

(1) Specification selection flag

- A lifting capacity setting, winch position selection (#17200-53)

- Winch drum position selection effective flag (#17200-79)

- Winch drum selection method setting (#17200-96)

(2) By-models data

- Frame adjustment data (#10302)

(3) Winch drum select icon (#17204-62)

When the selection method (1) is employed, the winch selection status toggles between "front/rear" and

"front" every time the F3 or F4 key is pressed.

"Front" represents the condition that the auxiliary hook block is attached on the main wire rope

(i. e., the auxiliary winch is wound up all the way and the main hook block is detached.)

"Front/rear" represents the condition that the main hook block is attached on the main wire

rope and the auxiliary hook block is on the auxiliary wire rope.

(4) User preset menu (Refer to Chapter B, “4-5-6 Selection of winch to be used”)

(5) Boom and jib status setting (Refer to Chapter B, “2-2 Registration of Crane State”)

(6) Winch drum position selection adjustment menu (Refer to Chapter D, “4-1 Winch drum position selection”)

7.4.4 Output

(1) Models using user preset menu for winch position change

- Winch drum position icon display to normal operation status screen (Fig. 7.7.3, Fig. 7.7.4)

- Winch drum position icon display to integrated display screen

7.4.5 Processing Contents

(1) Models using user preset menu for winch position change

The winch drum position adjustment value is set in the adjustment menu. Then, the winch drum position is

determined in accordance with the adjustment value and with the boom and jib operating status, and the

rated capacity is determined. 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.

Adjustment value:

-Winch drum position adjustment value selection method = " Front — Front/Rear" (1)

Winch position = Front and Rear ... Main boom lift status: Front position,

S/T and jib lift status: Rear position

Winch position = Front ……………. Main boom lift status: Front position,

S/T and jib lift status: User preset menu selection

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Chapter B Chapter B

User Mode

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). Therefore, the user preset menu drum position adjustment and hook position

initialization will be required.

Table 7.4.1 Information used for hook movement calculation

(no winch drum position selection menu available in user preset menu)

Hook

position

information

(

1)

For main

hook

For auxiliary

hook

Hook

position

information

(

Paid-out

length of

wire rope

For main

wire rope

For

auxiliary

wire rope

1)

No. of part

For main

auxiliary

Paid-out

length of

wire rope

lines

hook

For

hook

No. of part

Position

adjustment

（

Hook 1

Hook 2

lines

2）

Position

adjustment

2）

（

Selected

specification

(#17200-96)

Winch

Lift status

Boom lift - Main hook

Other than

boom lift

Lift status

drum

position

-

(with winch drum position selection menu available in user preset menu)

Displayed

hook status

Auxiliary

hook

Table 7.4.2 Information used for hook movement calculation

Winch

drum

position

hook status

Displayed

Selecting "Rear"

and "Front/rear"

(0)

(Used)

Selecting "Front"

and "Front/rear"

(1)

(Not used)

(

1) At the calculation of hook movement, the difference between the previous hook position and current hook

position is calculated. This is the information that stores the previous hook position.

(

2) This is the hook that is selected in the drum position adjustment of user preset menu.

Boom lift

Other than

boom lift

(S/T, Jib)

Boom lift Front Main hook

Other than

boom lift

(S/T, Jib)

Front

Rear

Auxiliary

hook

Auxiliary

hook

For main

hook

For auxiliary

hook

For auxiliary

hook

For main

wire rope

For main

wire rope

For

auxiliary

wire rope

For main

hook

For

auxiliary

hook

For

auxiliary

hook

Hook 1

Hook 1

Hook 2

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Chapter B Chapter B

User Mode

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.

- Elevation slow stop

Load moment ratio 100% stop: Elevation lowering

(Load ratio 100% stop)
Backward stability stop: Elevation raising

Working Range limit stop: Elevation raising, elevation lowering

Elevating cylinder stroke end stop: Elevation raising, elevation lowering

Re-stop: Elevation lowering

Boom interference stop: Elevation lowering

- Swing slow stop

Working Range limit stop: Right swing, left swing

Capacity change at O/R beam differential extension: Right swing, left swing

Swing free control: Common with left and right swing

- Speed limit

Elevation speed limit: Elevation raising, elevation lowering

Swing speed limit: Right swing, left swing

- Other

Deceleration processing’s (specific to particular models, etc.)

When there is duplication of two or more control factors, the one with the largest output value is output.

8.2 Elevation Slow Stop

The elevation slow stop functions with the stop positions by load moment ratio (load 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. However, when multiple conditions are met, the control
is implemented for the one having the smallest allowable angle in relation to the stop angle.

8.3 Swing Slow Stop

The swing slow stop functions while adopting the stop positions by working range limit stop, shift to lower

capacity at outrigger (O/R) slide beam differential extension, and boom interference stop as the target
stop angle. However, when multiple conditions are met, the control is implemented for the one having the
smallest allowable angle between the target stop angle and current swing angle.

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Chapter B Chapter B

User Mode

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.

The table below indicates the availability of stop function cancel for each cancel mode defined in this

specification.

- User mode indicates the normal operation status.

Table 9.1.1 Relationship of cancel mode and stop condition

Load

User mode

Cancel mode

Normal

status

(Without

cancel)

Cancel status

Interlock

stop

No detector
abnormality { (Stop)

With detector

abnormality
No detector
abnormality

With detector

abnormality

U 5

(Mixed) ¯ (Cancel)

U 2

(Mixed) ¯ (Cancel)¯ (Cancel)¯ (Cancel) { (Stop)

moment

1

ratio 100%

stop

{

(Stop)

Operation impossible due to vent in this status

Re-stop

4

{

(Stop)

{

(Stop) ¯ (Cancel) { (Stop)

Range

limit

{

(Stop)

{: Stop function effective U: Stop function is effective or disabled depending on condition
¯: Stop function disabled

1: Stop function indicated in Table 9.3.1 Relationship between automatic stop function and cancel

availability.

2: When there is an abnormality with the detector needed for obtaining the machine information that

constitutes the stop condition, all stop functions will be canceled. However, when the detector is
normal which can detect the stop condition, the cancel-prohibited stop functions will not be canceled

even if the cancel status is judged.
4: It is the overload stop with which the stop is performed even during normal cancel status.
5: The details on the availability of stop function cancel are described in Table 9.3.1.

Anti-

twoblock

stop

{

(Stop)

Backward

stability

stop

{

(Stop)

{

(Stop)

U 2

(Mixed)

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Chapter B Chapter B

User Mode

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)

display panel lights up.

The external indicator lamp for cancel shall be red.

1. The warning code and beep sound are maintained for 120 seconds. Even during the warning status, the

warning is stopped when the switch is returned to the neutral.

The sounding of warning beep cannot be muted by the alarm OFF function.

2. If the cancel switch is ON when each of the boom/jib selection setting, outrigger status changeover

setting, and counterweight setting is performed, the warning code and beep sound are maintained for 5

seconds.

is displayed, and beep is sounded. In the cancel status, the cancel indicator LED of AML

Cancel indicator LED

Fig. 9.2.1 Cancel indicator LED

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Chapter B Chapter B

User Mode

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 name

Elevation lower limit
Elevation upper limit

{: Stop function enable ¯: Stop function disable

Stop function at AML

cancel

¯
¯

9.4 Overload Cancel

When the status 1 or 2, specific to large-sized crane, is entered at load moment ratio (load ratio) 100%

stop, this function aims to return the crane to the safe side.

1 During the insertion operation into the indoors, when the lifted load reaches 100% while the boom is being

extended and the lifted load is being adjusted by winch hoist-down, the retraction and hoist-up operation

will need to be performed at the same time for the recovery operation (the winch hoist-up is recognized as

the dangerous operation). Therefore, the overload cancel becomes required.

2 During the operation with the boom raising, when the 100% stop is performed due to a physical contact of

boom top with an obstacle {if the elevation is raised with boom contacted against an obstacle, the

pressure becomes high at the tube (extension) side, resulting in the increase of detected hoist medium

load}, the elevation lowering will be needed for recovery operation (the elevation lowering is recognized

as the dangerous operation). Therefore, the overload cancel is required.

9.4.1 Cancel Contents

In the load moment ratio (load ratio) 100% stop status, the dangerous operation judgment is disabled.

The dangerous operations with load moment ratio (load ratio) 100% stop are as follows:

- Main winch hoist-up

-

Auxiliary winch hoist-up

- Boom elevation lowering

- Boom telescoping extension

- Right and left swing (when a capacity change occurs due to the differential outrigger slide extension

status, the capacity of swing destination is smaller than present hoist medium load)

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A

A

A

A

A

A

A

A

A

A

A

A

Chapter B Chapter B

User Mode

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.

However, when the detector needed for stop function is working normally, the relevant automatic stop function is enabled (only the ones canceling is not allowed).

Chapter B

The list of necessary detectors for automatic stop functions is shown in the table below.

When a detector abnormality exists, compulsory unload is always performed due to the abnormality status but not by an operation.

However, the swing operation shall be permitted.

BM: Boom
S/T: Single top
JB: Jib
PJ: Power tilt jib
JS: Jib set
FLJ: Full auto Luff. Jib

Table 9.5.1 Relationship between detector abnormality and automatic stop function (including items that are not applicable depending on models)

Stop item

Do output control (Refer to P.59)

Stop condition

停止条件 AML状態

100%停止

100% lifting performance stop

nti-twoblock stop

過巻停止 －

Backward stability stop

後方安定停止 －

Boom upper limit stop

ブーム上限停止 －

Boom lower limit stop

ブーム下限停止 －

Lifting height limit stop

揚程制限停止

Load radius limit stop

半径制限停止

Jib tilt lower limit automatic stop

チルト下限自動停止 JB

Jib tilt upper limit automatic stop

チルト上限自動停止 JB

Main winch unwind stop

メインウィンチ捨て巻き停止 －

uxiliary winch unwind stop

サブウィンチ捨て巻き停止 －

utomatic stop by no-insertion of jib fixing pin

ジブ固定ピン未挿入自動停止

Boom retraction automatic stop

ブーム縮自動停止

Jib automatic pin stop

ジブオートピン停止

Jib set pin stop

ジブセットピン停止

utomatic stop by jib set abnormality

ジブセット異常自動停止

utomatic stop by unlock the jib connecting pin

ジブ連結ピン未挿入自動停止

utomatic stop by FLJ angle to ground 0°

FLJ対地角度0°自動停止

Minimum elevating capacity stop

起伏能力最小停止

utomatic stop by pivot side no-insertion of jib connecting pin

ジブ連結ピン支点側未挿入自動停止

Elevating cylinder stroke end stop

起伏シリンダストロークエンド停止

Elevation lower limit

起伏下限

Elevation upper limit

起伏上限 － ○○○○○○○○○○○○○×○○○○○○○○○○○○

ML status

BM,S/T

JB

BM,S/T

JB

BM,S/T

JB

－ ×○×○×○×○×○×○○○○×○○○○○○○○○○
－ ×○×○×○×○×○×○×○○○○○○○○○○○○○
－ ×○×○×○×○×○×○○×○○○○○○○○○○○○
－ ×○×○×○×○×○×○○×○○○○○○○○○○○○

PJ-JS×○×○×○×○×○×○○○×○○○○○○○○○○○

－ ×○×○×○×○×○×○○○○○○○○○○○○○○○
－ ×○×○×○×○×○×○○○○○×○○○○○○○○○
－ ○○○○○○○○○○○○××○○○○○○○○○○○○
－ ×○×○×○×○×○×○○○○○○○○○○○○○○○
－ ○○○○○○○○○○○○○×○○○○○○○○○○○○
－ ○○○○○○○○○○○○○×○○○○○○○○○○○○

E1001 E1002 E1003 E1004 E1005 E1006 E1007 E1008 E1009 E1010 E1011 E1012 E2003 E2004 E2005 E2006 E2007 E2009 E2010 E2011 E2012 E2017 E2019 E2021 E2023 E2030

BM角
度異常ジブ長

さ異常

abnormality

BM angle

Jib length

abnormality

ジブ角
度異
常

Jib angle

abnormality

ジブ角
度異
常

Jib angle

abnormality

右前
O/R
長さ異
常

Front right

O/R length

右後
O/R
長さ異
常

abnormality

左前
O/R
長さ異
常

Rear right

O/R length

abnormality

Front left O/R

length

abnormality

左後
O/R
検出
異常

Rear left O/R

length

abnormality

旋回
角度1
異常

Swing angle 1

abnormality

旋回
角度2
異常

Swing angle 2

abnormality

旋回
角度
異常

Swing angle

abnormality

モーメ
ント異
常

Moment

abnormality

起伏
縮圧
力異
常

Elevation retraction

pressure

AML
送信

ML

断線

AML
AML
送信
断線

communication

line open

AML
受信

ML

断線

transmission

line open

AML
受信

ML

断線

reception line

open

ﾄﾗﾝｽ
ﾐｯﾀ異

ML

常

reception line

open

ﾄﾗﾝｽ
ﾐｯﾀ異
常

Transmitter

abnormality

送信

ﾃﾞｰﾀ

異常

Transmitter

abnormality

AML
送信
ﾃﾞｰﾀ

ML transmission

異常

data abnormality

AML
受信
ﾃﾞｰﾀ

ML transmission

異常

data abnormality

ML reception

AML
受信
ﾃﾞｰﾀ
異常

data abnormality

ML reception

data abnormality

装置タ
イプ異
常

Device type

abnormality

装置タ
イプ異常BM長

さ異常

Device type

abnormality

BM length

abnormality

ЧЧЧЧЧЧЧЧЧЧЧЧЧЧ－－－ЧЧЧЧЧЧЧЧЧ
ЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧ
○○○○○○○○○○○○○○○○○○○○○○○○○○
○Ч○Ч○Ч○Ч○Ч○ЧЧЧ○○○ЧЧЧЧЧЧЧ○○
○○○○○○○○○○○○○Ч○○○○○○○○○○○○
○○○○○○○○○○○○○Ч○○○○○○○○○○○○
○○○○○○○○○○○○ЧЧ○○○○○○○○○○ЧЧ
Ч○Ч○Ч○Ч○Ч○Ч○ЧЧЧЧЧ○○○○○○○ЧЧ
○○○○○○○○○○○○ЧЧ○○○○○○○○○○ЧЧ
Ч○Ч○Ч○Ч○Ч○Ч○ЧЧЧЧЧ○○○○○○○ЧЧ
Ч○Ч○Ч○Ч○Ч○Ч○Ч○○Ч○○○○○○○○○○
Ч○Ч○Ч○Ч○Ч○Ч○Ч○○Ч○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○

abnormality

Canceling of automatic stop is not allowed.

自動停止解除不可
○ 異常時に解除しても停止機能を有効とする
× 異常時に解除すると停止機能が無効となる

Stop function is enabled even when cancel is performed while abnormal.

Stop function is disabled even when cancel is performed while abnormal

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79

Chapter C

C

Maintenance Mode

Contents

Outline of Maintenance Mode................ 80

C-1 Operation Keys and Menu............. 81

1.1 Operation Keys ........................................ 81

1.2 Structure of Maintenance Mode Menu ..... 82

1.3 Mode Shift and Menu Structure ............... 83

1.3.1 Shift to Maintenance Mode....................... 83

1.3.2 Menu Selection......................................... 83

1.3.3 Maintenance Main Menu Functions ......... 84

C-2 Individual Main Menu Functions... 85

2.1 ROM ID check ......................................... 85

2.2 Di Check .................................................. 86

2.3 Ai Check .................................................. 87

2.8 MDT Check.............................................. 93

2.8.1 Description of Display Contents................93

2.8.2 Operation Method .....................................93

2.8.3 Selection of MDT Check Menu Item .........94

2.8.4 MDT Check, Display of

Upper Section Di Check State............95

2.8.5 MDT Check, Display of

Upper Section Ai Check State.............96

2.8.6 MDT Check, Display of

Upper Section Do Check State...........97

2.8.7 MDT Check, Display of Lower

Section Di Check State.......................98

2.8.8 MDT Check, Display of Lower

Section Ai Check State .......................99

2.8.9 MDT Check, Display of Lower

Section Do Power Check State.........100

2.8.10 MDT Check, Display of Lower

Section Do Check State....................101

2.8.11 MDT Check, Display of Lower

Section Ao Check State ....................102

2.8.12 MDT Check, Display of

Pi Check State ..................................103

2.4 Pi Check .................................................. 88

2.5 Si Check .................................................. 89

2.6 Do Check ................................................. 91

2.7 Ao Check ................................................. 92

2.9 System Voltage Check .......................... 104

2.10 Error History Display ............................ 105

2.11 Erasing Error History............................ 106

2.12 AML Emergency Switch History Display107

2.13 Latest Overload History Display........... 108

i

2.14 Maximum Overload History Display ..... 109

2.15 Outrigger Emergency Setting

History Display ........................... 110

2.16 Telematics Check ..................................111

2.17 Clock Adjustment ................................. 112

2.18 Meter Adjustment ................................. 114

2.19 Unit Selection ....................................... 115

2.20 Language Selection ............................. 116

C-3 Integrated Information Display

Screen ..................................117

3.1 Crane Information Display Screen......... 117

3.2 Vehicle Information Display Screen ....... 117

C-5 Required Adjustment after AML

System Part Replacement...134

C-6 Disassembly and Assembly ........135

6.1 Disassembly of AML Main Unit.............. 135

6.2 Connector .............................................. 136

6.2.1 Removing and attaching the connector

contact ..............................................136

6.2.2 Crimping receptacle contact ...................148

6.3 Replacing the Clock Battery .................. 149

3.3 Display Contents.................................... 118

3.4 Vehicle Error Information ....................... 121

C-4 Error Code .................................... 122

4.1 Classification of Error Code ................... 122

4.2 Error History........................................... 122

4.3 Error Notification .................................... 123

4.4 Error Code Table.................................... 124

4.4.1 Communication Device Error (Transmitter,

etc.) .................................................. 124

4.4.2 Detector Abnormality or Abnormal

Combination of Detectors................. 127

4.4.3 AML Internal Abnormality (System

Abnormality) ..................................... 132

4.5 CPU State Indicator LED ....................... 133

ii

Chapter C Chapter C

Maintenance Mode

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).

Also, some adjustment functions such as clock adjustment are included in the

maintenance mode.

 Adjustment Mode: Used to adjust detectors, actuators, etc.

For the operation method of adjustment mode, refer to "Chapter D, Adjustment

Mode."

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Chapter C Chapter C

Maintenance Mode

C-1 Operation Keys and Menu

1.1 Operation Keys

Liquid crystal display (LCD)

Fig. 1.1.1 AML display control panel

The following keys are used in the maintenance and adjustment mode. On and after, < > in the descriptions

indicates the operation key.

Key No. Key name Function

1 <

2 <

3 <

4 <

10 <

11 <

12 <

13 <

Function 1>: Used for functions displayed on the adjustment mode screen with F1.

Function 2>: Used for functions displayed on the adjustment mode screen with F2.

Function 3>: Used for functions displayed on the adjustment mode screen with F3.

Function 4>: Used for functions displayed on the adjustment mode screen with F4.

Cancel>: Used to quit the menu that is running.

Display change>: Used to change the displayed information.

Set>: Used to determine the menu selection or to register the adjustment value.

Inspection>: Used to erase the adjustment value for the precision adjustment.

Operation keys

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Chapter C Chapter C

Maintenance Mode

1.2 Structure of Maintenance Mode Menu

Maintenance

mode

main menu

1. ID ROM Check

2. Adjust

3. Di Check

4. Ai Check

5. Pi Check

6. Si Check

7. Do Check

8. Ao Check

9. MDT Check (Applicable to GR series)

10. System Voltage

11. Er r o r H istory

12. Error Erase

13. Emergency History

14. New History

15. Max History

16. O/R Emergency History

17. Telematics Check

18. Clock Adjust

ID code input

Length/angle

(Adjustment mode)

adjustment

19. Meter Adjust

20. Unit Select

21. Language

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Chapter C Chapter C

Maintenance Mode

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 <

simultaneously for 0.5 seconds or more, the mode shifts to the maintenance mode.

When the maintenance mode is entered, the liquid crystal display (LCD) shows the maintenance main menu as

shown in Fig. 1.3.1.

Maintenance

menu items

> key, the < > key, and the < > key are pressed and held

Fig. 1.3.1 Maintenance main menu display

1.3.2 Menu Selection

Pressing the <

(highlighted).

Pressing the <

With the targeted menu selected, pressing the <

To quit the maintenance mode, press the <

> key (scroll up) or the < > key (scroll down) changes the selected maintenance menu item

> key (previous page) or the < > key (next page) changes the pages.

> key while the maintenance main menu is being displayed.

> key starts the selected menu.

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Chapter C Chapter C

Maintenance Mode

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. Adjust Transition to adjustment mode

3. Di Check Displays the status of digital input.

4. Ai Check Displays the status of analog input.

5. Pi Check Displays the value of pulse input counter.

6. Si Check Displays the status of serial input port.

7. Do Check Performs the digital output value monitoring and ON/OFF test output.

8. Ao Check

9. MDT Check Monitors the MDT internal information.

10. System Voltage Displays the voltage value of internal circuit for AML unit.

11. Error History Displays the error history (maximum of 50 items).

12. Error Erase Erases the error history.

13. Emergency History

14. New History Displays the latest overload history (maximum of 100 items).

15. Max History Displays the maximum overload history (maximum of 100 items).

16. O/R Emergency History

17. Telematics Check Displays various information of Telematics.

18. Clock Adjust Adjusts the built-in calendar and clock of AML.

Performs the analog output value monitoring and the command value
test output.

Displays the history of AML override switch input changeover
(maximum of 100 items).

Displays the history of outrigger emergency setting history (maximum
of 10 items).

19. Meter Adjust Adjusts the hour meter and odometer of DCU.

20. Unit Select Selects the unit of display (m / ton, ft / klb).

21. Language Selects the language to be displayed.

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Chapter C Chapter C

Maintenance Mode

C-2 Individual Main Menu Functions

2.1 ROM ID check

In the maintenance main menu of Fig. 1.3.1, select "ID Code Check," and press the < > key to display the AML

ID check screen shown in Fig. 2.1.1.

Pressing the <

are listed below.

When the transmitter STM-D is connected, pressing the <

ID check screen shown in Fig. 2.1.2.

- ROM Code No.

- Crane Specification code

- Data ID

- Program ID

- 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)

> key quits the menu, and the display returns to the maintenance main menu. Displayed items

> key or the < > key displays the connected device

Fig. 2.1.1 AML ID check screen

Fig. 2.1.2 Connected device ID check screen

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Chapter C Chapter C

Maintenance Mode

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 <

To go back to the maintenance main menu, press the <

> key (previous page) or the < > key (next page) changes the pages.

> key.

Fig. 2.2.1 Di check screen

<Description of display contents>

Port State

Di1 to Di28: Input to AML Close: Contact ON

Ds11 to Ds18: Input to serial port 1 Open: Contact OFF

Ds21 to Ds28: Input to serial port 2

Reading method of Di signal (State)

Di signal “State” shows “Open” and “Close” of the each switch contact.

However, Main and Aux. winch twoblocking detection switch (circuit) contacted with the series circuit.

Therefore when either switch detects the overwound and the switch contact becomes “Open”, then, both

contacts become “Open”. In a word, State of Di5 changes two signals at the same time.

These functions are not provided in other Ai and Pi, etc.

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