Tadano GT-550E-2 Operation And Maintenance Manual Download Page 63

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AML System Configuration

T038300E

AML (Overload Prevention Device)

Boom length signal

Outrigger extension
width detector

Boom angle signal

Moment ratio signal

Swing angle signal

Crane control position
signal

Working range limit
signal output

Alarm buzzer

External warning
lamps

AML unit

Boom
extension
halted

Boom lowering
halted

Hoisting up
halted

Upper boom angle
restricted
Lower boom angle
restricted

Lifting height
restricted

Load radius
restricted

Outrigger status

Lift status

Working range limits

Operator selection

Stop output when:

Moment ratio exceeds 100%
Overwinding occurs
Moment exceeding limit for
boom with jib mounted

Boom raising
halted
Boom retracting
halted

Boom upper
angle
restriction

T24085E

Number of part-lines of rope

Swinging
halted toward
critical side

Swing restricted

AML system error occurs

Display panel

Summary of Contents for GT-550E-2

Page 1: ...RQ DQG G 0DLQWHQDQFH 0DQXDO 7UXFN UDQH 0RGHO 7 SSOLFDEOH 6HULDO 1R 7 4 7 12 7 87 21 5HDG WKLV PDQXDO EHIRUH RSHUDW W 6DYH WKLV PDQXDO IRU IXWXUH UHIH H 2 S H U D W L R Q D Q G 0 D L Q W H Q D Q F H 0...

Page 2: ...dentified as DANGER WARNING CAUTION or NOTICE These terms are defined as follows NOTICE NOTICE indicates an important operational or maintenance procedure or condition which if not strictly observed c...

Page 3: ...labels on the machine contain instructions and must be followed to ensure safe operation Read and understand all DANGER WARNING and CAUTION labels Neglecting these instructions and warnings can resul...

Page 4: ...r alcohol the probability of an accident event is greatly increased since atten tiveness and judgment are impaired Maintain proper physical fitness for crane operation Keep All Footings and Shoes Clea...

Page 5: ...emedy it and only then start operation Do Not Operate a Machine Being Inspected or Serviced Operating the machine while it is undergoing in spection or maintenance work can cause damage or an accident...

Page 6: ...decrease in service life of the machine or malfunctions In win ter run the engine for at least five minutes for proper warm up Then run the engine at low speed without a load to warm up the hydraulic...

Page 7: ...The signal person and the operator should commu nicate with each other using mobile transceiver phones Hold Work Site Meetings with Concerned All Personnel Lack of sufficient communications with conc...

Page 8: ...ators must proceed cautiously strictly observ ing all instructions of the signal person Rules for Operation Setting Outriggers Set the Crane on Firm Level Ground The machine should not be located on s...

Page 9: ...les for Operation General Observe Working Conditions Operating the crane under conditions outrigger beam length boom length load radius etc other than specified in the rated lifting capacity table can...

Page 10: ...ng properly The wire rope has no entanglement or disorderly winding on the drum Rig the Load Securely Improper rigging procedure can result in the lifted load being dropped Rig the load securely payin...

Page 11: ...mmedi ate personnel of crane startup During crane operations fence off or barricade the work area to prevent unauthorized persons from ap proaching the machine Be Extremely Careful When Raising the Lo...

Page 12: ...the winch drum Operate the Crane Carefully Operating the controls too abruptly can result in an accident a swaying load can hit an object or dam age the machine Operate all control levers and pedals s...

Page 13: ...ely extended boom decreases the rated lifting capacity and also can cause overswing of the load or lower working efficiency Keep the length of the boom as short as possible during operation Be Careful...

Page 14: ...ult the line can unwind off the winch drum causing the wire rope to be damaged or broken When lowering a very light load or a bare hook block the rope will unwind off the winch drum at a faster rate T...

Page 15: ...achine or cause the machine to overturn to the rear owing to decreased rearward stability Never install or place a counterweight s or equiva lent other than those specified Do Not Position Any Part of...

Page 16: ...all brakes Place all control levers in their neutral positions Shut off the engine and remove the starter key Lock the crane operator s cab door Never Allow Anyone to Ride on the Machine Except the O...

Page 17: ...should be avoided if possible If conditions require such a lift observe the instruc tions given in the AML section of the manual and perform the operation with the utmost care and at tention Mount an...

Page 18: ...anger The table below lists wind speed ranges and the ground conditions for each range Note that the wind speeds in the table are those at a point 10 m above open level ground Stop All Operation If Th...

Page 19: ...bution lines implement the following preventive measures Meet with the power company concerned to devel op a relevant safety plan Require that working personnel wear approved insulating shoes Keep the...

Page 20: ...A 19 Safety Rules Safety Rules...

Page 21: ...settings for the boom length boom an gle and number of rope parts Lift the load so that the wire rope s of each crane are only subjected to vertical line pulls Attempt to rig the load so that all the...

Page 22: ...k and boom in position and lock the outrigger beams etc in posi tion if lock pins are available Give a traveling configuration to the machine by referring to the manual Do Not Travel with Any Cargo on...

Page 23: ...A 22 Safety Rules Safety Rules...

Page 24: ...tion and maintenance work requiring handling of potentially flammable substances observe the following in structions Use a non flammable cleaning liquid to wash parts and components Store fuel and oil...

Page 25: ...Inspection or Maintenance Work If any unauthorized person starts the engine during inspection or maintenance work the machine may be damaged or injury or even death may result When performing inspecti...

Page 26: ...nd footing Walk on the non slip strips if provided on the machine Cautions for Working at Heights Working at heights involves the possibility of falling To reduce this risk remove all obstacles and an...

Page 27: ...ausing hands or a leg to be caught and injured If an inspection hole cover or access door or the operator s cab door must remain open secure in po sition Do Not Allow Tools and Parts to Drop When work...

Page 28: ...ting the battery cable can cause the wiring to be shortcircuited possibly damaging the electrical and electronic systems Before inspecting or maintaining the electrical sys tem disconnect the battery...

Page 29: ...A 28 Safety Rules Safety Rules...

Page 30: ...A 29 Warning Labels Warning Labels...

Page 31: ...WARNING ON STOWING THE SINGLE TOP 6 JIB HANDLING INSTRUCTIONS 7 CAUTION TO BOOM SWING 8 CAUTION IN JIB OFFSET 9 WARNING ON TOP JIB 10 CAUTION IN HANDLING JIB 11 CAUTION TO OVERRIDE FUNCTION 12 CAUTION...

Page 32: ...A 31 Warning Labels Warning Labels 1 2 3 JIB PIN STATUS...

Page 33: ...A 32 Warning Labels Warning Labels 4 WARNING IN JIB OFFSET 5 WARNING ON STOWING THE SINGLE TOP 6 JIB HANDLING INSTRUCTIONS 7...

Page 34: ...IN OVERRIDE THE SYMBOL LIGHTS UP ALL SAFETY STOP FUNCTION WILL BE DISABLED WITH THIS LIGHT ON CONTINOUS SAFE OPERATION IS CONTRLED ONLY BY THE OPERATOR 12 13 CAUTION IN HANDLING OVERRIDE KEY SWITCH WA...

Page 35: ...ARNING PULL THE CONTROL CONSOLE BACKWARD TO THE STOWING POSITION WHEN TRAVELING OR GETTING OUT OF THE CAB 2 83 7 505 67 25 867 1 7 1 2 21752 2162 7 5 72 26 7 225 1 7 21752 2162 6 835 7 16 CAUTION IN H...

Page 36: ...1 Contents Contents...

Page 37: ...2 Contents Contents...

Page 38: ......

Page 39: ...ring Parts When contacting the TADANO distributor or dealer for repairs or to order parts please specify the following information 1 Specification number 2 Production serial number 3 Year of productio...

Page 40: ...used in this manual are defined with reference to the driver s position when seated in the carrier driver s cab Their definitions remain the same even when the crane s upper structure is turned The il...

Page 41: ...6 Layout of Controls Layout of Controls of Controls Layo out...

Page 42: ...load prevention device 29 16 Winch drum rotation indicator option 72 17 Overwind cutout release switch 52 72 18 AML override switch 29 19 Swing brake switch 84 20 Swing stop override switch 84 21 Slow...

Page 43: ...h 75 46 3rd 4th top boom emergency telescoping switch 75 47 Air conditioner control panel option 119 48 Cab lamp 126 49 Seat 66 50 Fan switch option 126 51 Override key switch 29 52 Swing lock lever 1...

Page 44: ...h Jib Offset Angle Jib length refers to the center to center distance as il lustrated in the figure below Jib offset angle refers to the angle formed by the cen terline of an extended jib and the cent...

Page 45: ...respectively 360 degree Capacity 360 degree capacity means that the lifting capacities are the same regardless of the area in which the load is lifted Outrigger Extension Widths Outrigger extension w...

Page 46: ...H000450E OPERATION...

Page 47: ...ummary Carrier Traveling Procedure Summary WARNING This summary describes briefly the essential steps for traveling the crane For detailed informa tion on the individual procedures refer to the approp...

Page 48: ...e swing lock pin before applying the swing brake Observe the specified boom elevation angle For detailed information refer to the Weight Distribution Chart in the INFORMATION AND DATA section To preve...

Page 49: ...rming Up the Machine P 57 7 Fully extend the outriggers and level the crane Outriggers P 58 8 Extend the front jack Outriggers P 58 Crane Operation Procedure Summary T038280E 13 Crane Operation Proced...

Page 50: ...p sheave system or the jib is installed AML Overload Prevention Device P 24 During Operation 1 Follow the rated lifting capacity table to eliminate any possibility of overloading How to Read Performan...

Page 51: ...arter switch in the crane operator s cab Starting and Stopping the Engine P 54 8 Get out of the crane operator s cab and lock the door Crane Operator s Cab P 66 9 Retract the front jack Outriggers P 5...

Page 52: ...fferent boom lengths jib lengths and boom angles jib offset angles Use the chart in conjunction with the rated lifting capacity table when making an operation plan While points A and B in the figure a...

Page 53: ...ends first during boom extension and the telescoping mode II the 3rd through top boom sections extend first during boom extension are available When the boom length is any of the values listed in the...

Page 54: ...the rated lifting capacity table the values above the blue line are based on the structural strength of the crane whereas the values below that line are based on the stability of the crane The stabili...

Page 55: ...0 19 300 19 100 15 700 16 700 10 800 13 000 8 000 8 000 8 000 8 0 18 300 17 900 17 600 15 200 15 800 10 200 12 500 8 000 8 000 8 000 9 0 15 200 14 600 14 200 14 300 14 200 9 300 11 300 7 600 8 000 8 0...

Page 56: ...offset 25 offset 45 offset 5 offset 25 offset 45 offset 80 3500 2500 1400 2300 1150 750 75 3500 2330 1380 2100 1040 670 72 3300 2250 1350 1950 1000 630 70 3000 2100 1320 1750 950 610 65 2300 1900 1250...

Page 57: ...or an over side area to the over front area The mass of load handling devices such as hook blocks and slings shall be considered part of the load and must be deducted from rated lifting capacities Jib...

Page 58: ...nsion F Rated lifting capacity capacity with outriggers at mid dle extension G Rated lifting capacity capacity with outriggers at full extension H Minimum extension width of outriggers I Middle extens...

Page 59: ...gers at full extension 4 Over left area 200 340 capacities with outriggers at middle extension If the outrigger extension is as shown below the lifting capacity turns from the one with outriggers at...

Page 60: ...buzzer sounds and the moment ratio indication on the AML exceeds 100 while a load is swung stop swinging immediately Then lower the load or swing the boom back For the specified values which trigger...

Page 61: ...gle is over approx 76 3 Working range limit functions When any working range limit is registered to AML the crane is controlled so that the crane work posture does not exceed this registered working r...

Page 62: ...stop automatically T038300E 26 AML Overload Prevention Device AML Overload Prevention Device Hoisting up Automatic stop Boom lowering by overloading Boom extension Swing Boom upper Boom raising angle...

Page 63: ...sion halted Boom lowering halted Hoisting up halted Upper boom angle restricted Lower boom angle restricted Lifting height restricted Load radius restricted Outrigger status Lift status Working range...

Page 64: ...ously Moment ratio exceeds 90 Moment display Yellow segment s is lit External warning lamps Orange lamp is lit Buzzer Sounds intermittently Moment ratio exceeds 100 Moment display Displays Warning 002...

Page 65: ...stow the boom when failure occurs in the AML system For details see the Disposition of System Troubles section Emergency Outrigger Control Switch This switch is used to enable registering outrigger e...

Page 66: ...mes and Functions of AML Main Unit Parts T038300E 30 AML Overload Prevention Device AML Overload Prevention Device T23984E t m max t m m Bargraph display Display panel 1 Control Display panel 2 AML LI...

Page 67: ...l pressure and torque con verter oil pressure when the display alteration key is held down Also displays error messages when the AML or any of its associated devices fail s 3 Scroll up key Used to see...

Page 68: ...istered jib status 7 Real load display Displays the real load 8 Rated lifting capacity display Displays the rated lifting capacity 9 Load radius limit restriction indicative symbol Comes on to indicat...

Page 69: ...oom angle 18 Lower boom angle limit restriction symbol Indicates that the boom angle display 19 displays the registered lower boom angle restricted value 19 Boom angle display Normally displays the bo...

Page 70: ...ction key Used to activate and cancel the lower most boom angle limiting function 11 Lower boom angle limit restriction indicator lamp Lights up when the lowermost boom angle limiting func tion is act...

Page 71: ...Number of part lines of rope select key Used to register a number of part lines of rope Display Panel 2 1 Front jack symbol Indicates that the front jack is used 2 Outrigger state indicative symbol Di...

Page 72: ...ions press the register key The outrig ger state indicative symbol will change from flashing into being marked up continuously and the moment display rated lifting capacity display and real load displ...

Page 73: ......

Page 74: ...e number of part lines of rope select key The number of part lines of rope symbol will flash and the number of part lines of rope will be shown on the jib angle display in a flashing mode 2 Press the...

Page 75: ...Jib angle shown while jib lift is selected 4 Real load Make sure that the approximate mass of the hook block while no load is on the hook block The real load is not shown correctly if the lift status...

Page 76: ...to the desired angle and press the boom upper or lower limit restriction key The corre sponding limit restriction indicator lamp will flash and the buzzer will sound continuously indicating that the l...

Page 77: ...t the swing restriction lamp stops flashing and stays illuminated and the buzzer stops Thereafter a swing restriction indicator lamp flashes the swinging boom stops automatically and the buzzer sounds...

Page 78: ...restriction indicator lamp stops flashing and stays illumi nated and the buzzer stops The load radius restriction indicator lamp flashes and the buzzer sounds continuously whenever the limit previous...

Page 79: ...ot available when preoperational AML check is made and when working state is registered When working range restricting functions are not reg istered the message will be displayed T038300E 43 AML Overl...

Page 80: ...isplay Display Panel 1 Displays on the real load display and the rated lifting capacity display do not alter even when the display al teration key is pressed in T038300E 44 AML Overload Prevention Dev...

Page 81: ...zzer sounds continuously 2 When the limit moment for the boom lift with the jib mounted is exceeded Moment display Warning 0088 Buzzer sounds continuously T038300E 45 AML Overload Prevention Device AM...

Page 82: ...rearward stability control function works Moment display Warning 0025 T038300E 46 AML Overload Prevention Device AML Overload Prevention Device Hoist down the winch Retract the boom slowly T23993E Buz...

Page 83: ...t display Warning 0028 is shown Buzzer Continuous Lifting height restric tion indicator lamp flashes 8 When load radius restriction function works Moment display Warning 0029 is shown Buzzer Continuou...

Page 84: ...cutout function deactivated wound excessively or auxiliary winch Warning 0024 Stops by overwinding Error 0016 Operational status not Wrong registration of operational Register operational status agai...

Page 85: ...ns inserted in jib Jib connecting pin and jib set pin Set the pins on the jib to normal inserted conditions Warning 0011 Connecting pin uninserted Jib connecting pin is not inserted Warning 0077 Front...

Page 86: ...igger state into AML and the indicator lamp will light up 1 Set the emergency outrigger control switch to ON The emergency outrigger control indicator lamp will light up and the outrigger state on the...

Page 87: ...s and front jack status press the register key to register the status The outrigger state indicative symbol will stop flashing and become marked up 4 Register the lift status See Selecting Lift Status...

Page 88: ...ect the leads of the overwind cutout device correctly If the leads are not connected the AML assumes an overwind condition and all actions toward the critical condition are automatically stopped Once...

Page 89: ...ted 1 Overwind cutout function 2 Swing stop function 3 Automatic stop by the AML caused by the moment exceeding 100 working range limit etc T038310E 53 Other Safety Devices Other Safety Devices The ho...

Page 90: ...r Neutral 2 Swing brake switch ON 3 Swing stop override switch Activated 4 Slow elevation stop switch Activated 5 Emergency outrigger control switch OFF Starting and Stopping the Engine T038320E 54 St...

Page 91: ...n the starter switch to the START position to crank the engine Starting Engine from Crane Operator s Cab When the engine is cold use the starter switch in the carrier driver s cab 1 Turn the starter s...

Page 92: ...Engine from the Carrier Driver s Cab For a detailed explanation of how to stop the engine see the separate Crane Carrier Operation and Maintenance Manual 1 Make sure that the PTO switch is in the OFF...

Page 93: ...warming up the engine and ma chine highly viscous oils may cause damage to the engine and hydraulic system For this machine the hydraulic oil temperature should be within the range of 30 C to 60 C Ope...

Page 94: ...stone pavement 3 Areas that have been filled in after excavation 4 Reclaimed land 5 Areas near the shoulder of a road or the edge of a pit Preparing the Ground When it is unavoidable to set the crane...

Page 95: ...t 9 Individual control lever right front 10 Individual control lever left rear 11 Individual control lever right rear T038330E 59 Outriggers Outriggers Controls The illustration shows the right side o...

Page 96: ...times remain level even when it is supported on only three jacks Operating the machine in such a condition is very dangerous After extending the outriggers make sure that all outrigger floats are in c...

Page 97: ...he extend retract control lever and all the individual con trol levers to the neutral position 8 Use the bubble levels to make sure that the crane is level If the crane is not level refer to the Level...

Page 98: ...e direction of the bubble is higher Example A bubble in the glass level is off center and to the right The crane is listing to the left Adjustment The crane should be adjusted to a level position by r...

Page 99: ...he extend retract control lever toward EXT for approx 3 seconds after the front jack float has reached the ground Then return the extend retract con trol lever and front jack lever to the neutral posi...

Page 100: ...your side to EXTENSION Then move the extend retract control lever toward RET to retract the outrigger beams fully The figure below shows an outrigger on the right side of the carrier 5 After all four...

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Tadano GT-550E-2, Operation And Maintenance Manual

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