Tadano AML-C Service Manual Download Page 10 | Manualshive

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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

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Summary of Contents for AML-C

Page 1: ...W301 0411E 01 Load Moment Indicator AML C Model...

Page 2: ...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 d...

Page 3: ...Function 49 4 4 Fuel Consumption Indicator 50 4 5 User Adjustment Menu 51 B 5 Action against AML System Error 58 B 6 Do Output Control 59 6 1 Cause for AML Automatic Stop Output 59 6 2 Do Output Abno...

Page 4: ...ent Characteristics Measurement Method 168 3 4 Elevating Telescoping Output Adjustment 170 3 5 Function of Slow Stop 171 D 4 Performance Setup 172 D 5 Operation History Erase 174 D 6 Option Select 175...

Page 5: ...ure 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 Standardizati...

Page 6: ...Foreword v W301 0411E 4 International Standard ISO 4306 1 Only description in English is shown here Cranes Vocabulary Part 1 General Fourth edition 2007 10 15...

Page 7: ...ing attachment s m FA Hook assembly Hook assembly Bottom block Bottom block Bottom block Non fixed load lifting attachment s m NA Skip and chain Net Rope slings Electromagnet and chain Grab Gross load...

Page 8: ...Foreword vii W301 0411E 5 Crane Performance...

Page 9: ...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 w...

Page 10: ...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 Connec...

Page 11: ...ut 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 t...

Page 12: ...ng 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 re...

Page 13: ...lay 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 sta...

Page 14: ...ndicator 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 in...

Page 15: ...of the icons 12 Swing position display Shows the current swing position The display is graduated in 45 13 Front position symbol Appears when the boom is directed to the front of the vehicle 14 On rub...

Page 16: ...Chapter A Chapter A Components of AML System 6 W301 0411E 1 2 2 LED Display...

Page 17: ...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 se...

Page 18: ...tem 8 W301 0411E 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 7 CON2 circuit board 8 Case 2 9 Display board 10 CPU b...

Page 19: ...Chapter A Chapter A Components of AML System 9 W301 0411E 1 3 2 Panel outside view CN1 CN9 0 361 933 41030 Front Rear...

Page 20: ...L System 10 W301 0411E 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 cabl...

Page 21: ...Connector 8 Pin CN1 connector Pin No Name Signal names and functions 1 MBGND Signal name Ground Output voltage DC 0 V 2 MBGND Signal name Ground Output voltage DC 0 V 3 DOPOW Signal name Power for ci...

Page 22: ...i twoblock cancel Cancels the anti twoblock function of the hook Stop disabled Stop enabled 5 Di5 17206 7 Signal name Anti twoblock cancel indication Detects the indication of anti twoblock cancel Can...

Page 23: ...Detects the boom extending operation No operation Operation 14 Di14 17202 10 Signal name Boom retraction detection Detects the boom retraction operation No operation Operation 15 Di15 17202 11 Signal...

Page 24: ...Europe spec Not over unwind Over unwind 5 FG Frame ground Connected with ground on circuit board 6 P3 Spare 7 P2A P2 Signal name Drum indicator input Aux Detects the rotation of auxiliary winch drum...

Page 25: ...12 Di28 17202 36 Signal name Twoblocking detection Detects the twoblocking Not twoblocking Twoblocking 13 FG Frame ground Connected with ground on circuit board 14 PSRC Spare 15 P2B Signal name Drum...

Page 26: ...ignal 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 7 5V Signal name 5 V impressed voltage po...

Page 27: ...tions 1 FG Spare 2 5V Signal name 5 V impressed voltage power for detector Impressed voltage to main pressure detector 3 Ai7 Signal name Main pressure Input voltage to main pressure detector 4 Ai8 Spa...

Page 28: ...ength 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 detectio...

Page 29: ...name Main winch high speed hoist down Output to drive the high speed hoist down valve of main winch 10 Do10 Spare GR 750XL 2 17802 149 GR 1000XL 2 Signal name Auxiliary winch high speed hoist down Out...

Page 30: ...ess than 77 Less than 83 Middle extension 1 Less than 70 Less than 82 Output when condition is met OFF output 15 Do15 17802 10 Signal name External indicator lamp 90 to 100 yellow When the moment load...

Page 31: ...exceeds 100 2 100 cancel indication Di6 is Canceled status 3 Twoblocking cancel indication Di5 is Canceled status When in the boom operation with jib elected during main operation with jib elected the...

Page 32: ...ve COM Output return terminal 5 Ao3 17804 9 Signal name Boom raising proportional solenoid valve Drives the proportional reducing valve for boom raising 6 Ao3 Signal name Boom raising proportional sol...

Page 33: ...smission output signal Transmission data to MDT Multiplex Data Transmitter 6 SHIELD Signal name Serial port 2 shield Input voltage DC 0 V 7 DGND 8 CAN1_L 9 CAN1_H 10 SHIELD 11 RX1 12 RX1 13 SHIELD Spa...

Page 34: ...oot Boot mode activation with GND connection For maintenance data readout and rewriting 4 TXD RS232C communication For maintenance data readout and rewriting 5 FG Spare 6 DGND Digital ground For maint...

Page 35: ...are 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 sig...

Page 36: ...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 Li...

Page 37: ...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 7...

Page 38: ...rm 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 re...

Page 39: ...control selector switch is set to Boom telescoping Auxiliary Winch Control B 1 The boom telescoping auxiliary hoist control selector switch is set to Auxiliary winch Hydraulic oil temperature 50 C Fla...

Page 40: ...o 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 1Registrat...

Page 41: ...er state symbol are as shown in the illustration on the right GR 750XL 2 GR 1000XL 2 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 Minimum extension...

Page 42: ...play 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 6 Take out the ma...

Page 43: ...l 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 stat...

Page 44: ...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 high...

Page 45: ...play 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 ov...

Page 46: ...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...

Page 47: ...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 s...

Page 48: ...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...

Page 49: ...f part lines 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 regis...

Page 50: ...s 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...

Page 51: ...r boom angle limit restriction W0028 Stopped at lifting height restriction W0029 Stopped at load radius restriction W0034 Stopped by main winch over unwinding prevention device Europe spec W0035 Stopp...

Page 52: ...Overload occurs during the swing operation Swing in the opposite direction or retract or raise the boom W0025 Backward stability decreases and the crane can overturn Lower or extend the boom W0034 Rem...

Page 53: ...again and insert the pin Then register the outrigger state again W0013 The state of front position detector switch and actual swing angle do not agree Inspect and maintain the crane W0016 W0017 Crane...

Page 54: ...beeps repeat for 3 seconds When the power is turned on the battery for the AML built in clock is low Replace the battery W0106 The elevation slow stop function is activated and boom elevating operatio...

Page 55: ...le 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...

Page 56: ...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...

Page 57: ...oom jib within the limit range The indicator lamp turns to staying lit When the state of the crane reaches the registered limit the indicator lamp flashes The corresponding operation of the boom jib a...

Page 58: ...es 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...

Page 59: ...ork range limit The illustration on the right shows an example of display in which swing limit is registered NOTICE Registration of swing range limit is the function to set the allowable swing range R...

Page 60: ...ximately 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 stat...

Page 61: ...ated 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 sou...

Page 62: ...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...

Page 63: ...stment 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...

Page 64: ...ction 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...

Page 65: ...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 high...

Page 66: ...creen 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...

Page 67: ...ified 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 i...

Page 68: ...to the normal display When you want to cancel the registration push the key exit The pop up window closes and the AML returns to the status before start of the registrati When the AML PTO switch is tu...

Page 69: ...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 operat...

Page 70: ...e 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...

Page 71: ...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...

Page 72: ...ion 1 5 5m 80 or more 92 or more 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 boo...

Page 73: ...as follows data No 10722 10724 to 10733 10736 Model Stop angle Remark 11 00m Boom angle of 76 or more 19 00m Boom angle of 80 or more Boom lift Single top lift GR 750XL 2 Boom length 11 00m Boom angle...

Page 74: ...elevation Jib telescoping Jib tilt Swing Jib mounting Up Down Up Down Ext Ret Rse Lwr Ext Ret Rse Lwr Right Left Ext Stw 6 1 6 Lifting Height Limit Stop Restriction is implemented to the operations ex...

Page 75: ...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 U...

Page 76: ...al 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 outpu...

Page 77: ...low 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 Se...

Page 78: ...t 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 t...

Page 79: ...nting at performance limit hysteresis is considered in the boom elevation angle judgment 7 2Working Range Limit Stop Function 7 2 1 Outline of Function The working range limit stop function specifies...

Page 80: ...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 Eleva...

Page 81: ...able 7 2 1 Cancel condition of swing range limit Re stop data Setting 813 AML emergency 17206 2 Swing stop cancel 17206 5 Result Cancel Without stop Set No cancel With stop Emergency Override Without...

Page 82: ...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 Co...

Page 83: ...ual hoist medium road 7 4 1 Function For the machine whose performance is determined on the assumption that the only main winch drum position front 1 is employed Use the winch position selection funct...

Page 84: ...g 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...

Page 85: ...ting 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 men...

Page 86: ...wire rope For auxiliary hook Hook 2 Table 7 4 2 Information used for hook movement calculation with winch drum position selection menu available in user preset menu Selected specification 17200 96 Li...

Page 87: ...wing 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 dup...

Page 88: ...hout cancel With detector abnormality Operation impossible due to vent in this status No detector abnormality U 5 Mixed Cancel Stop Cancel Stop Stop User mode Cancel status With detector abnormality U...

Page 89: ...s sounded In the cancel status the cancel indicator LED of AML display panel lights up The external indicator lamp for cancel shall be red 1 The warning code and beep sound are maintained for 120 seco...

Page 90: ...e 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...

Page 91: ...bled even when cancel is performed while abnormal BM Boom S T Single top JB Jib PJ Power tilt jib JS Jib set FLJ Full auto Luff Jib Stop condition 100 lifting performance stop Anti twoblock stop Backw...

Page 92: ...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 Sectio...

Page 93: ...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 A...

Page 94: ...to operate the crane For the operation method of User mode refer to Chapter B User Mode Maintenance Mode Used to perform the AML maintenance menu operation check reference of history information etc...

Page 95: ...n with F1 2 Function 2 Used for functions displayed on the adjustment mode screen with F2 3 Function 3 Used for functions displayed on the adjustment mode screen with F3 4 Function 4 Used for function...

Page 96: ...ck 5 Pi Check 6 Si Check 7 Do Check 8 Ao Check 9 MDT Check Applicable to GR series 10 System Voltage 11 Error History 12 Error Erase 13 Emergency History 14 New History 15 Max History ID code input Le...

Page 97: ...ntered the liquid crystal display LCD shows the maintenance main menu as shown in Fig 1 3 1 Fig 1 3 1 Maintenance main menu display 1 3 2 Menu Selection Pressing the key scroll up or the key scroll do...

Page 98: ...est output 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 ite...

Page 99: ...splay returns to the maintenance main menu Displayed items are listed below When the transmitter STM D is connected pressing the key or the key displays the connected device ID check screen shown in F...

Page 100: ...f 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 si...

Page 101: ...t page changes the pages To go back to the maintenance main menu press the key Fig 2 3 1 Ai check screen Description of display contents Port Ai 1 to Ai 8 Input to AML As11 to As14 Input from serial p...

Page 102: ...heck and press the key to display the Pi check screen shown in Fig 2 4 1 To go back to the maintenance main menu press the key Fig 2 4 1 Pi check screen Description of display contents Port PiA1 to Pi...

Page 103: ...ey Fig 2 5 1 Si check screen Description of display contents Port Si1 to Si2 Communication port with transmitter Signal Name JIB Transmitter for jib Lower Lower transmitter State Reception state R Tra...

Page 104: ...scription of display contents Port CAN1 to CAN2 CAN communication port Signal Name ICF Node name of information controller for Telematics VCU Node name of controller for vehicle Reference Represents t...

Page 105: ...1 Do check screen Description of display contents Port Do1 to Do16 Output from AML Os11 to Os18 Transmitter output via serial port 1 Os21 to Os28 Transmitter output via serial port 2 Out Current outp...

Page 106: ...e key or the key To quit the continuous test output press any of the key the key the key scroll up or the key scroll down Fig 2 7 1 Ao check screen Description of display contents Set Set value for te...

Page 107: ...2 8 1 Description of Display Contents No MDT check item No 1 to 9 Item Name of the item to which MDT check is performed 2 8 2 Operation Method Pressing the key back or the key forward moves the select...

Page 108: ...heck Displays the upper Do signal state refer to 2 8 6 4 Lower Di check Displays the lower Di signal state refer to 2 8 7 5 Lower Ai check Displays the lower Ai signal state refer to 2 8 8 6 Lower Do...

Page 109: ...ate display screen shown in Fig 2 8 2 To go back to the MDT check selection menu press the key Fig 2 8 2 Display screen of MDT check upper Di signal state Description of display contents No Input outp...

Page 110: ...k to the MDT check selection menu press the key Fig 2 8 3 Display screen of MDT check upper Ai signal state Description of display contents No Input output number of upper Di signal state display 201...

Page 111: ...te display screen shown in Fig 2 8 4 To go back to the MDT check selection menu press the key Fig 2 8 4 Display screen of MDT check upper Do signal state Description of display contents No Input outpu...

Page 112: ...te display screen shown in Fig 2 8 5 To go back to the MDT check selection menu press the key Fig 2 8 5 Display screen of MDT check lower Di signal state Description of display contents No Input outpu...

Page 113: ...k to the MDT check selection menu press the key Fig 2 8 6 Display screen of MDT check lower Ai signal state Description of display contents No Input output number of lower Ai signal state display 211...

Page 114: ...state display screen shown in Fig 2 8 7 To go back to the MDT check selection menu press the key Fig 2 8 7 Display screen of MDT check lower Do power signal state Description of display contents No In...

Page 115: ...8 8 To go back to the MDT check selection menu press the key Fig 2 8 8 Display screen of MDT check lower Do signal state Description of display contents No Input output number of lower Do signal state...

Page 116: ...the MDT check lower Ao signal state display screen shown in Fig 2 8 9 To go back to the MDT check selection menu press the key Fig 2 8 9 Display screen of MDT check lower Ao signal state Description...

Page 117: ...display the MDT check Pi signal state display screen shown in Fig 2 8 10 To go back to the MDT check selection menu press the key Fig 2 8 10 Display screen of MDT check Pi signal state Description of...

Page 118: ...1 System voltage check screen Description of display contents Signal Name Battery Voltage Input power supply voltage Voltage after the internal rectification and it is several volts lower than the bat...

Page 119: ...es To go back to the maintenance main menu press the key Fig 2 10 1 Error history display screen Description of display contents Maximum of 50 error items can be stored and the items are displayed in...

Page 120: ...rase screen shown in Fig 2 11 1 Pressing the key erases the error history After the history is erased the display of Fig 2 11 2 appears To go back to the maintenance main menu press the key When not e...

Page 121: ...the pages To go back to the maintenance main menu press the key However when the number of displayed items is 8 or less any input of key previous page or the key next page is disabled Fig 2 12 1 AML e...

Page 122: ...the operation status and operation posture with which the operation was performed Storing condition During a period starting from when Load moment ratio calculated by the AML becomes 110 or more until...

Page 123: ...y Fig 2 14 1 Latest overload history display Description of display contents With the maximum overload history information the maximum of 100 items are stored in the order starting from the largest cl...

Page 124: ...any input of the key or the key is disabled When there is no stored emergency setting history data the history screen without data will be displayed as shown in Fig 2 15 2 Fig 2 15 1 Outrigger emerge...

Page 125: ...on the maintenance main menu shown in the Fig 1 3 1 and press the key The display will go to the Telematics check screen shown in Fig 2 16 1 When the key is pressed the menu is quitted and the mainten...

Page 126: ...1 3 1 select Clock Adjust and press the key to display the clock adjustment screen shown in Fig 2 17 1 When the clock information is obtained from the ICF via CAN port the clock adjustment screen of...

Page 127: ...ical setting is completed press the key to register the set value Immediately after the registration the display returns to the maintenance main menu To go back to the maintenance main menu press the...

Page 128: ...ed the calculated data is reset and the data cumulating from the day when the DCU is replaced is shown Adjusts the hour meter and odometer when the meter information is being received from the CAN por...

Page 129: ...ig 1 3 1 select Unit Select and press the key to display the displayed unit selection screen shown in Fig 2 19 1 Fig 2 19 1 Displayed unit selection screen Operation method The current setting is high...

Page 130: ...o display the language selection screen shown in Fig 2 20 1 To go back to the maintenance main menu press the key The currently selected language is highlighted enclosed by a square frame Press the ke...

Page 131: ...3 1 2 Integrated information screen Crane information units in ft klb 3 2 Vehicle Information Display Screen When the vehicle information is obtained from the CAN port pressing the key again while th...

Page 132: ...he corresponding function specification Fig 3 3 1 Integrated information screen Display contents 1 Number of part lines 2 Hook movement 3 Jib length Displayed only when jib operation is selected 4 Jib...

Page 133: ...n showing that user adjustment is effective 27 Indication showing that range limit setting is effective 28 Indication showing that C W setting is effective 29 Indication showing that number of part li...

Page 134: ...gine coolant temperature 9 Intake air temperature 10 Torque converter oil temperature 11 Vehicle error code e g M0103 Indication of the internal error of the meter ECU 12 Vehicle error SPN Suspect Par...

Page 135: ...t the vehicle error information is displayed cyclically in the bottom section of sub screen shown in Fig 3 4 1 At this time pressing the key displays the error code table of Fig 3 4 2 Fig 3 4 1 Integr...

Page 136: ...ion device transmitter etc error Group 2 Detector abnormality or abnormal combination of detectors Group 3 AML internal abnormality system abnormality When this abnormality occurs the execution of con...

Page 137: ...ed while the error exists Fig 4 3 1 Error code display screen When Japanese is selected for the language when the key is pressed while the error code is being displayed a sub window appears in the LCD...

Page 138: ...vice malfunction Remedy Check the wiring to the transmitter for conductivity If no conductivity exists replace or repair the wiring Replace the transmitter or AML s power circuit board Serial port rec...

Page 139: ...Radio wave interference device malfunction Remedy Turn off any device which is emitting strong noise Check the signal wire for poor connection Repair or replace the wiring as appropriate Receiving dat...

Page 140: ...CAN port 1 reception trouble The data on the bus connected with the CAN port 1 cannot be acquired correctly Reception abnormality E1101 Cause Bus connected with CAN1 is open or short Device malfunctio...

Page 141: ...nspection for the above possible cause The status of any input from the detector can be checked using the Ai check function from the Maintenance menu Jib angle detector trouble The detection value of...

Page 142: ...e above possible cause The status of any input from the detector can be checked using the Ai Di check function from the Maintenance menu Swing angle detector 2 trouble swing dead angle switch ON same...

Page 143: ...tion Remedy Perform inspection for the above possible cause 2nd boom length detector abnormality The detection value of 2nd boom length detector is out of the normal range Normal range 5 to 95 0 25 to...

Page 144: ...output monitor incorrectly becomes ON E2207 Cause Signal line short circuit board malfunction Remedy Perform inspection for the above possible cause Do8 output OFF abnormality Although the Do8 output...

Page 145: ...form inspection for the above possible cause Do6 output ON abnormality Although the Do6 output is ON the output monitor incorrectly becomes OFF E2214 Cause Signal line short to ground board malfunctio...

Page 146: ...en activated which is not executed in normal cases Cause Runaway due to noise and others board malfunction However even in the normal status this may be stored at turning ON OFF of power Remedy Perfor...

Page 147: ...Indication priority Small High In normal processing LED 2 and 3 light up alternately 7 In power ON initialization processing Under execution of program change System abnormality CPU exception etc LED...

Page 148: ...ctor Outrigger extension length detector adjustment Swing angle detector Swing angle detector adjustment Boom length detector Boom length detector adjustment Boom angle detector Boom angle detector ad...

Page 149: ...oiding adhesion of water dust exposure of ultraviolet rays and static electricity 6 1 Disassembly of AML Main Unit 1 Remove the pan head screws a 10 positions and slightly open the upper case from the...

Page 150: ...411 5760 2 715131 1 The part Nos of the contact extraction tools are designated by AMP 2 1 1 AMP 070 Multi lock connector Mark Insertion of Contact 1 Insert the receptacle properly with its seam side...

Page 151: ...ing by checking the hooks and the locks on both sides 2 Increase of Contact Keeping Strength can be expected by doublelocking 3 Releasing Doublelock Refer to contact extraction tool 755430 2 instructi...

Page 152: ...g device before to start removal of contacts from the housing Opening of hinges should be performed carefully not to damage them during handling Open one after one gradually Releasing Side Locking Dev...

Page 153: ...d bending walls excessively to prevent from damage during operation 3 EXTRACTION OF CONTACTS Insert tip end of the tool into the housing cavity from the mating side of housing so as to raise the locki...

Page 154: ...eformation of contact Refer to contact extraction tool 755430 1 instruction sheet 4 Doublelock immediately after insertion of contact Otherwise it might be damaged in carrying the harness due to doubl...

Page 155: ...he hinge locking device before to start removal of contacts from the housing Opening of hinges should be performed carefully not to damage them during handling Open one after one gradually 1 Insert ti...

Page 156: ...ke contact unlocking Proceed as follows Fig 4 1 Push back the contact into the housing in the direction A This will result relaxing of locking tension prior to unlocking 2 Insert extraction tool into...

Page 157: ...that it is going in the right direction Terminals forced in backwards can accidentally scrape the housing lance off 2 Verify that the terminal has been firmly locked to the housing lance If the crimp...

Page 158: ...sure it is locked by lightly pulling the wire outward The conditions shown in Figs 4 and 5 will be seen if the retainer behaves correctly If any contacts are not completely fixed the retainer does not...

Page 159: ...m the connector fitting side to lift up the connector housing lance 1 Depress the contact in the direction of the arrow 2 Insert jig 3 Lift up the lance 4 Remove the contact NOTICE Do not insert the r...

Page 160: ...ts is not completely inserted Press both ends of the retainer to assemble it Removing the retainer From the finally assembled position to the pre assembled position 1 To remove the contacts from the h...

Page 161: ...Chapter C Chapter C Maintenance Mode 147 W301 0411E Extract the contact in accordance with following procedure...

Page 162: ...nd hand tools are designated by AMP 2 Nomenclature 3 Crimping condition 040 series 070 series 040 series No Item 175062 1 175062 2 175027 1 175027 2 179417 1 179418 2 1 Cut off tab 0 25mm Max 0 3mm Ma...

Page 163: ...When removing the battery remove while holding the battery upper positive side because the battery may pop up The built in clock battery longevity is usually about 10 years If the built in clock batt...

Page 164: ...3 3 Adjustment Check 158 2 4 Swing Angle Adjustment 159 2 4 1 Swing Angle 1 Zero Adjustment 159 2 4 2 Swing Angle 2 Zero Adjustment 159 2 4 3 Swing Angle 1 Span Adjustment 160 2 4 4 Swing Angle 2 Span...

Page 165: ...74 D 6 Option Select 175 6 1 Operation Procedure 175 6 2 Processing Depending on Setting Status 176 6 3 Processing at Setting without Detector 176 6 4 Processing at Setting without Function 177 D 7 AM...

Page 166: ...sed to perform the AML maintenance menu operation check history information reference etc Also some adjustment functions such as clock adjustment are included in the maintenance mode For the operation...

Page 167: ...screen with F2 3 Function 3 Used with functions displayed on the adjustment mode screen with F3 4 Function 4 Used with functions displayed on the adjustment mode screen with F4 5 Range limit Used whe...

Page 168: ...eeded Operation history erase AML emergency SW History Erase Boom length TAP correction Adjustment not needed Option selection O R Emergency History Erase Slow stop adjustment Boom length adjustment B...

Page 169: ...ered the maintenance main menu appears on the LCD as shown in Fig 1 3 1 Fig 1 3 1 Maintenance main menu display 1 3 2 Menu Selection Pressing the key scroll up or the key scroll down changes the selec...

Page 170: ...adjustment main menu of Fig 1 3 3 Note 2 Fig 1 3 2 ID code input display Input the ID code 6 digits according to the steps below A numerical value is displayed only for the digit that is being input A...

Page 171: ...e control output Precision Adjustment Precision correction adjustment of displayed load and load radius precision Length Detector Correction Adjustment value setting of boom length detection value Opt...

Page 172: ...djustment screen Table 2 1 1 shows the list of adjustment items Table 2 1 1 Detector adjustment item list Adjustment item Detector to be adjusted Boom Length Boom Angle Swing Angle1 Swing Angle2 RFron...

Page 173: ...lue is adjusted the span adjustment is needed because the span adjusted value changes automatically 2 2 2 Boom Length Span Adjustment Fully extend the boom Until Boom Length and Span adjustment value...

Page 174: ...ract the boom While measuring the boom angle using the sprit level type angle meter set the boom by the boom lowering operation to the span adjustment condition Until Boom Angle and Span adjustment va...

Page 175: ...tment angle is reached press the key to register the adjustment value After the adjustment value is registered is shown at the left of zero adjustment value 2 4 2 Swing Angle 2 Zero Adjustment Keep th...

Page 176: ...ment value 2 4 4 Swing Angle 2 Span Adjustment Keep the swing positions same as 2 4 3 Until Swing Angle2 and Zero adjustment value become highlighted on the LCD Fig 2 1 1 press the key backward or the...

Page 177: ...o that the detected Right Front outrigger length becomes the zero adjustment value When the adjustment length is reached press the key to register the adjustment value After the adjustment value is re...

Page 178: ...is shown at the left of span adjustment value Also for the outrigger length of Left Front Right Rear and Left Rear operate the key backward and the key forward to show the span point adjustment displ...

Page 179: ...ent adjustment be sure to set the boom angle by the boom lowering operation and always wait until the distortion voltage becomes stable before starting the adjustment Under the moment adjustment statu...

Page 180: ...a becomes the adjustment value press the key to register the adjustment value 2 6 2 Moment Span Preliminary Load Radius Adjustment Fully extend the boom Lift the rated capacity Max Hoist medium load f...

Page 181: ...he ground In the LCD Fig 2 6 1 press the key backward or the key forward until both of Wa and Span become highlighted Wa 0 34 t_ F 1 345 mV Zero 0 000 0 000 _Span 3 000 3 000_ Wa Actual hoist medium l...

Page 182: ...leted The subjected crane operations are described below Swing right left operation Elevation raising lowering operation 3 1 Adjustment Sub Menu When Valve Adjustment is selected in the adjustment mai...

Page 183: ...justment is necessary depending on every serial No In the valve adjustment item selection screen shown in Fig 3 1 1 select Swing right or Swing left and then press the key to display the swing output...

Page 184: ...d stops boom swing on the basis of these measured characteristics Applicable model GR 750XL 2 GR 1000XL 2 Reference data E 4 AML Input Output List 1 Digital input 1 17200 No 80 In the valve adj item s...

Page 185: ...speed is decelerated with specified time intervals When Slew velocity in the screen of Fig 3 3 3 becomes zero the measurement is completed Then the screen changes to the one shown in Fig 3 3 4 Fig 3 3...

Page 186: ...se the engine speed to the maximum and perform a boom up full lever operation The measurement will start automatically When the control lever is not in the neutral position the message JS neutral appe...

Page 187: ...r and elevation cylinder when the elevation is continued to be lowered above the engine hood cover set with the by models data 12792 shall be the stop lower limit angle 3 5 2 Swing Slow Stop The swing...

Page 188: ...y starts the selected menu To go back to the adjustment main menu press the key Fig 4 1 1 Set up performance menu screen 4 1 Winch drum position selection When Winch drum position select is selected i...

Page 189: ...oom jib lift state and the winch position cannot be selected in the user preset menu The position for boom lift state is fixed in the front position The position for S T and jib lift states is fixed i...

Page 190: ...here three times 5 1 Operation Procedure In the adjustment main menu of Fig 1 3 3 select History Erase to display the operation history erase screen as shown in Fig 5 1 1 Under the status shown in Fi...

Page 191: ...nt main menu of Fig 1 3 3 select Option Select then press the key to display the option selection screen as shown in Fig 6 1 1 Fig 6 1 1 Option selection screen The current setting status is displayed...

Page 192: ...function Out 6 3Processing at Setting without Detector When swing angle detector is not present Swing Angle 1 Swing angle related error check will not be performed 2 Setting of swing angle limit is di...

Page 193: ...ith each of the lifting height limit load radius limit boom angle upper limit and boom angle lower limit a warning will be issued but no stop will be performed For the swing range limit a stop is alwa...

Page 194: ...as shown in Fig 7 1 1 Pressing the key erases the AML emergency switch history Then the erase confirmation display appears as shown in Fig 7 1 2 To go back to the adjustment main menu of Fig 1 3 3 wi...

Page 195: ...1 1 To go back to the adjustment main menu of Fig 1 3 3 without erasing the outrigger emergency setting history press the key while the screen shown in Fig 8 1 1 is being displayed To go back to the...

Page 196: ...2 Detector Check 184 2 1 Applicable Model GR 750XL 2 184 2 1 1 Boom Length Detector 184 2 1 2 Boom Angle Detector 184 2 1 3 Swing Angle Detector 185 2 1 4 Outrigger Extension Length Detector 185 2 1 5...

Page 197: ...ust the swing angle by the right clockwise swing operation 4 At the moment adjustment set the number of part lines of wire rope to the standard number of part lines for boom full extension 4 part line...

Page 198: ...Full extended Indicated boom angle 20 0 0 1 Load No load 0 47 t main hook block only Hook block Hoist down until just before touching the ground Actual hoist medium load Hook weight 0 47 0 01 t 1 1 3...

Page 199: ...stment set the number of part lines of wire rope to the standard number of part lines for boom full extension 4 part lines and perform the adjustment with AML set to boom status 5 When using the hook...

Page 200: ...angle 20 0 0 1 Load No load 0 47 t main hook block only Hook block Hoist down until just before touching the ground Actual hoist medium load Hook weight 0 47 0 01 t 1 2 3 Slow Stop Adjustment Item Re...

Page 201: ...e potentiometer The specified resistance values are as follows 1 5 833 167 2 5 458 92 2 1 2 Boom Angle Detector 1 Retract the boom fully set the boom angle to 0 and set the PTO switch to OFF 2 Measure...

Page 202: ...dvance Pull out the CN3 connector CN643 of AML and measure the resistance of the potentiometer The specified resistance values are as follows 1 5 2500 375 4 5 1062 160 5 8 2354 353 2 1 4 Outrigger Ext...

Page 203: ...W and B of pressure sensor connector Pressure sensor CN584 of extension side elevating cylinder 361 801 10000 Pressure sensor CN585 of retraction side elevating cylinder 361 801 60000 W B R M R W B 5V...

Page 204: ...ometer The specified resistance values are as follows 1 5 833 167 2 5 458 92 2 2 2 Boom Angle Detector 1 Retract the boom fully set the boom angle to 0 and set the PTO switch to OFF 2 Measure the resi...

Page 205: ...dvance Pull out the CN3 connector CN643 of AML and measure the resistance of the potentiometer The specified resistance values are as follows 1 5 2500 375 4 5 1062 160 5 8 2354 353 2 2 4 Outrigger Ext...

Page 206: ...W and B of pressure sensor connector Pressure sensor CN584 of extension side elevating cylinder 361 801 10000 Pressure sensor CN585 of retraction side elevating cylinder 361 801 60000 W B R M R W B 5V...

Page 207: ...Specifies the boom angle range where the hoist medium load lower limit check is performed Lower limit boom angle deg Upper limit boom angle deg 3 0 83 0 Data No 10837 Specifies the tolerance load rang...

Page 208: ...g 80 1 For North America Specification O R MID2 83 0 93 0 93 0 Data No 838 Hoist medium load to be used with actual load check Data No 16719 Slow stop control data Data No 2784 Boom lowering stroke en...

Page 209: ...ts outrigger emergency status ON Emergency setting OFF Normal setting Di19 19 1 Outrigger emergency setting 41 Among automatic stop functions of AML only stop related to over unwinding is canceled ON...

Page 210: ...oblock control is deactivated during jib set status Detects the reckless driving of task and outputs the result Do8 8 1 Abnormality status output 124 17216 Data that specifies to which Pi terminal the...

Page 211: ...ad Office Ko 34 Sinden cho Takamatsu Japan Overseas Service Group Tadano Ryogoku Bldg 4 12 Kamezawa 2 chome Sumida ku Tokyo Japan Tel 81 3 3621 7765 Tel fax 81 3 3621 7785 History of revision 1 2 3 4...

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