Tadano AML-C Automatic Moment Limiter Service Manual – PDF DOWNLOAD
FILE DETAILS:
Tadano AML-C Automatic Moment Limiter Service Manual – PDF DOWNLOAD
Language : English
Pages : 349
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Tadano AML-C Automatic Moment Limiter Service Manual – PDF DOWNLOAD
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.
TABLE OF CONTENTS:
Tadano AML-C Automatic Moment Limiter Service Manual – PDF DOWNLOAD
W301-0432E 1
Foreword 2
1 Applicable Crane Model / Spec No 2
2 Table of Contents 3
3 Acronyms and Abbreviations 5
(A)_Components of AML System 6
A-1 Components of the AML System 7
1 1 System configuration 7
1 1 1 Diagram of the Main System 7
1 1 2 AML-C Block Diagram 8
1 2 Display Unit 9
1 2 1 Display panel 10
1 2 2 LED Display 12
1 2 3 Control switches 13
1 3 AML Main Unit 14
1 3 1 Construction 14
1 3 2 Panel outside view (CN1 – CN9) 15
1 3 3 Boards and Inner connectors 16
A-2 Input/output Signals of the AML System 17
2 1 AML Control Unit (Pin Assignment) 17
2 1 1 Explanation of the Signals (Di, Do) 17
2 1 2 CN1 Connector (8-Pin) 18
2 1 3 CN2-1 Connector (20-Pin) 18
2 1 4 CN2-2 Connector (16-Pin) 21
2 1 5 CN3 Connector (12-Pin) 24
2 1 6 CN4 Connector (6-Pin) 25
2 1 7 CN5 Connector (16-Pin) 26
2 1 8 CN6 Connector (14-Pin) 30
2 1 9 CN7 Connector (20-Pin) 31
2 1 10 CN8 Connector (8-Pin) 33
2 1 11 CN9 (USB) Connector (4-Pin) 33
A-3 ESP Boom controller (applicable to GR-1450EX-2) 34
3 1 Controller (Pin Assignment) 34
3 1 1 CN1 Connector (8-Pin) 34
3 1 2 CN2-1 Connector (20-Pin) 35
3 1 3 CN2-2 Connector (16-Pin) 37
3 1 4 CN3 Connector (12-Pin) 39
3 1 5 CN4 Connector (6-Pin) 40
3 1 6 CN5 Connector (16-Pin) 41
3 1 7 CN6 Connector (14-Pin) 42
3 1 8 CN7 Connector (20-Pin) 43
3 1 9 CN8 Connector (8-Pin) 44
3 1 10 CN9 (USB) Connector (4-Pin) 44
(B)_User Mode 45
B-1 Functions and How to use the User Mode 47
1 1 Mode Structure 47
1 2 Display Selection 47
1 3 Operation Indicator Display 48
1 3 1 GR-300EX-2, GR-500EX-2, GR-600EX-2, GR-800EX-2 48
1 3 2 GR-1450EX-2 49
1 3 3 GT-600EX-1 50
B-2 Registration of Operating State and AML Function Check 52
2 1 GR-300EX-2, GR-500EX-2, GR-600EX-2, GR-800EX-2, GR-1450EX-2 52
2 1 1 Registration of Outrigger State 52
2 1 2 Registration of Crane State 55
2 1 3 Registration of counterweight state (Applicable to GR-1450EX-2) 57
2 1 4 Registration of Number of Part-lines of Wire Rope 58
2 1 5 Pre-operational Inspection on AML 60
2 2 GT-600EX-1 62
2 2 1 Registration of Outrigger State 63
2 2 2 Registration of Crane State 66
2 2 3 Registration of Number of Part-lines of Wire Rope 68
2 2 4 Pre-operational Inspection on AML 70
B-3 Alarm and Recovery Operation 72
3 1 Type of Warning Codes and Buzzer 72
3 2 Warning Code 74
3 3 Warning code and Remedy List 75
3 3 1 Stop warning code 75
3 3 2 Warning Code 77
B-4 Other Functions 80
4 1 Working Range Limit Function 80
4 1 1 Display of Limit Function State 81
4 1 2 Registering Boom Slewing Angle, Lifting Height, and Load Radius Limit 81
4 1 3 Registration of Slewing Range Limit Function 83
4 1 4 Alarm for Work Range Limit and Recovery Operation 85
4 2 TARE Function 86
4 3 Mute Alarm Function 86
4 4 Fuel Consumption Indicator 87
4 5 User Adjustment Menu 88
4 5 1 Adjustment menu/model comparison table 88
4 5 2 User Adjustment Menu 88
4 5 3 Eco mode selection 89
4 5 4 Activating/Deactivating the Winch Drum Rotation Buzzer Function 90
4 5 5 Fuel Consumption History Display 91
4 5 6 Selection of Winch to be used 92
4 5 7 Adjustment of Display Panel Contrast 95
4 5 8 Telematics On-demand data Transmission Function 96
4 5 9 Maintenance Telescoping Mode (Applicable to GR-300EX-2) 97
4 5 10 Selection of Elevation Slow Stop/Cancel (Applicable to GT-600EX-1) 99
4 5 11 Setting of Anemometer Alarm Threshold Value (Applicable to GR-1450EX-2) 100
4 6 Back light On (Off) Function 101
B-5 Action Against AML System Error 102
5 1 GR-300EX-2, GR-500EX-2, GR-600EX-2, GR-800EX-2, GR-1450EX-2, 102
5 2 GT-600EX-1 103
B-6 Do Output Control 104
6 1 Cause for AML Automatic Stop Output 104
6 1 1 100% Lifting Performance Stop 105
6 1 2 Anti-two-block Stop 106
6 1 3 Backward Stability Stop 106
6 1 4 Boom Upper Limit Stop 107
6 1 5 Boom Lower Limit Stop 107
6 1 6 Lifting Height Limit Stop 107
6 1 7 Load radius Limit Stop 108
6 1 8 Elevation Lower Limit 108
6 1 9 Elevation Upper Limit 109
6 2 Drum Indicator Control Function 110
6 2 1 Outline of Drum Indicator Control Function 110
6 2 2 Input 110
6 2 3 Output 110
6 2 4 Panel LED Control 110
6 2 5 Drum Indicator Do Output Control 111
6 2 6 Drum Indicator Do Output Restriction 111
6 3 Output of warning 111
6 3 1 Safety signal 111
6 3 2 90% warning 111
6 3 3 100% warning 111
B-7 AML Control 112
7 1 Backward Stability Stop Function 112
7 1 1 Outline of Function 112
7 1 2 Restriction Contents 112
7 2 Working Range Limit Stop Function 112
7 2 1 Outline of Function 112
7 2 2 Restriction Contents 113
7 2 3 Cancel Condition 114
7 2 4 Storing of Setting Condition 114
7 3 Output of Interference Prevention Warning 115
7 3 1 Function 115
7 3 2 Data Specification 115
7 3 3 Input 115
7 3 4 Warning Condition 115
7 3 5 Warning Code 115
7 4 Front Jack Extension Processing 116
7 4 1 Function 116
7 4 2 Processing Effective Condition 116
7 4 3 Input 116
7 4 4 Output 116
B-8 Proportional Control Function 117
8 1 Factors for Control 117
8 2 Elevation Slow Stop 117
8 3 Slewing Slow Stop 117
B-9 AML Cancel Function 118
9 1 Introduction 118
9 2 Canceling Method 119
9 2 1 Cancel Status Judgment 119
9 2 2 Cancel Switch Abnormality Judgment 119
9 3 Interlock Stop 120
9 3 1 Cancel Contents 120
9 4 Overload Cancel 120
9 4 1 Cancel Contents 120
9 5 Detector Abnormality 121
9 5 1 Stop Processing at Detector Abnormality (Compulsory unload output) 121
(C)_Maintenance Mode 124
Outline of Maintenance Mode 126
C-1 Operation Keys and Menu 127
1 1 Operation Keys 127
1 2 Structure of Maintenance Mode Menu 128
1 3 Mode Shift and Menu Structure 129
1 3 1 Shift to Maintenance Mode 129
1 3 2 Menu Selection 129
1 3 3 Maintenance Main Menu Functions 130
C-2 Individual Main Menu Functions 131
2 1 ROM ID check 131
2 2 Di Check 132
2 3 Ai Check 133
2 4 Pi Check 134
2 5 Si Check 135
2 6 Do Check 137
2 7 Ao Check 138
2 8 MDT Check 139
2 8 1 Description of Display Contents 139
2 8 2 Operation Method 139
2 8 3 Selection of MDT Check Menu Item 140
2 8 4 MDT Check, Display of Upper Section Di Check State 141
2 8 5 MDT Check, Display of Upper Section Ai Check State 142
2 8 6 MDT Check, Display of Upper Section Do Check State 143
2 8 7 MDT Check, Display of Lower Section Di Check State 144
2 8 8 MDT Check, Display of Lower Section Ai Check State 145
2 8 9 MDT Check, Display of Lower Section Do Power Check State 146
2 8 10 MDT Check, Display of Lower Section Do Check State 147
2 8 11 MDT Check, Display of Lower Section Ao Check State 148
2 8 12 MDT Check, Display of Pi Check State 149
2 9 ESP Check (Applicable to GR-1450EX-2) 150
2 9 1 Description of Display Contents 150
2 9 2 Operation Method 150
2 9 3 Selection of ESP Check Menu Item 151
2 9 4 ESP Check, Controller ID Check 152
2 9 5 ESP Check, Display of Di Check State 153
2 9 6 ESP Check, Display of Ai Check State 154
2 9 7 ESP Check, Display of Do Check State 155
2 9 8 ESP Check, Display of Ao Check State 156
2 9 9 ESP Check, Display of System Power Check State 157
2 10 System Voltage Check 158
2 11 Error History Display 159
2 12 Erasing Error History 160
2 13 AML Emergency Switch History Display 161
2 14 Latest Overload History Display 162
2 15 Maximum Overload History Display 163
2 17 C/W Emergency Setting History (Applicable to GR-1450EX-2) 165
2 18 Telematics Check (Not applicable to GT-600EX-1) 166
2 19 Clock Adjustment 167
2 20 Meter Adjustment (Not applicable to GT-600EX-1) 169
2 21 Unit Selection 170
2 22 Language Selection 171
C-3 Integrated Information Display Screen 172
3 1 Crane Information Display Screen 172
3 2 Vehicle Information Display Screen 172
3 3 Display Contents 173
3 4 Vehicle Error Information 177
C-4 Error Code 178
4 1 Classification of Error Code 178
4 2 Error History 178
4 3 Error Notification 179
4 4 Error Code Table 180
4 4 1 Communication Device Error (Transmitter, etc ) 180
4 4 2 Detector Abnormality or Abnormal Combination of Detectors 183
4 4 3 AML Internal Abnormality (System Abnormality) 191
4 5 CPU State Indicator LED 193
C-5 Required Adjustment after AML System Part Replacement 194
C-6 Disassembly and Assembly 195
6 1 Disassembly of AML Main Unit 195
6 2 Replacing the Clock Battery 196
(D)_Adjustment Mode 197
Outline of Adjustment Mode 199
D-1 Operation Keys and Menu 200
1 1 Operation Keys 200
1 2 Structure of Adjustment Mode Menu 201
1 3 Mode Shift 202
1 3 1 Shift to Maintenance Mode 202
1 3 2 Menu Selection 202
1 3 3 Shift to Adjustment Mode 203
1 3 4 Adjustment Main Menu 204
D-2 Detector Adjustment 206
2 1 Length and Angle Adjustment Screen 206
2 2 Boom Length Adjustment 207
2 2 1 Boom Length Zero Adjustment 207
2 2 2 Boom Length Span Adjustment 207
2 2 3 Adjustment Check 207
2 3 Boom Angle Adjustment 208
2 3 1 Boom Angle Zero Adjustment 208
2 3 2 Boom Angle Span Adjustment 208
2 3 3 Adjustment Check 208
2 4 Slewing Angle Adjustment 209
2 4 1 Slewing Angle 1 Zero Adjustment 209
2 4 2 Slewing Angle 2 Zero Adjustment 209
2 4 3 Slewing Angle 1 Span Adjustment 210
2 4 4 Slewing Angle 2 Span Adjustment 210
2 4 5 Adjustment Check 210
2 5 Outrigger Length Adjustment 211
2 5 1 Outrigger Length Zero Adjustment 211
2 5 2 Outrigger Length Span Adjustment 212
2 5 3 Adjustment Check 212
2 6 Jib Length Detector Adjustment 213
2 6 1 Jib Length Zero Adjustment 213
2 6 2 Jib Length Span Adjustment 213
2 6 3 Adjustment Check 213
2 7 Jib offset Angle Adjustment (Offset angle to Boom) 214
2 7 1 Jib offset angle Zero Adjustment 214
2 7 2 Jib offset angle Span Adjustment 214
2 7 3 Adjustment Check 214
2 8 ESP Telescoping Cylinder Length Adjustment 215
2 8 1 ESP Telescoping Cylinder Length Zero Adjustment 215
2 8 2 ESP Telescoping Cylinder Length Span Adjustment 215
2 8 3 Adjustment Check 215
2 9 Moment / Load Radius Adjustment 216
2 9 1 Moment Zero Adjustment 217
2 9 2 Moment Span Preliminary / Load Radius Adjustment 217
2 9 3 Moment Span Adjustment 218
2 9 4 Moment Adjustment Check 218
D-3 Valve Adjustment 219
3 1 Adjustment Sub Menu 219
3 2 Slewing Output Adjustment (Offset Method) 220
3 3 Slewing Output Adjustment (Characteristics Measurement Method) 221
3 3 1 Adjustment Procedure 221
3 4 Elevating / Telescoping Output Adjustment 223
3 5 Function of Slow Stop 224
3 5 1 Elevation Slow Stop 224
3 5 2 Slewing Slow Stop 224
D-4 Performance Setup 225
4 1 Winch drum position selection (Not applicable to GR-300EX-2) 225
D-5 Operation History Erase 227
5 1 Operation Procedure 227
D-6 Option Select 228
6 1 Operation Procedure 228
6 2 Processing Depending on Setting Status 228
6 3 Processing at Setting without Detector 229
6 4 Processing at Setting without Function 229
D-7 AML Emergency / Override Switch History Erase 230
7 1 Operation Procedure 230
7 2 Operating Conditions 230
D-8 Outrigger Emergency Setting History Erase 231
8 1 Operation Procedure 231
8 2 Operating Conditions 231
D-9 Telematics Setup 232
9 1 Method 232
9 2 Process According to the Registered Configuration 233
9 2 1 Allowing / prohibiting Communication Via communication terminal: “Terminal Communication” 233
9 2 2 Operation data forcible exclusion setting: “Unsent data -> Sent data” 233
D-10 ESP Valve Adjustment (Applicable to GR-1450EX-2) 234
10 1 Adjustment Sub Menu 234
10 2 Telescoping Cylinder Output Adjustment 235
D-11 ESP Telescoping Reset (Applicable to GR-1450EX-2) 236
(E)_Information and Data 237
E-1 AML Adjustment Value List 239
1 1 Applicable Model: GR-300EX-2 239
1 1 1 Initial Adjustment 239
1 1 2 Detector Adjustment 239
1 1 3 Slow Stop Adjustment 240
1 1 4 Setting Item after Adjustment 240
1 1 5 Option Setting 240
1 2 Applicable Model: GR-500EX-2 241
1 2 1 Initial Adjustment 241
1 2 2 Detector Adjustment 241
1 2 3 Slow Stop Adjustment 242
1 2 4 Setting Item after Adjustment 242
1 2 5 Option Setting 242
1 2 6 Engine (E/G) Setting 242
1 3 Applicable Model: GR-600EX-2 243
1 3 1 Initial Adjustment 243
1 3 2 Detector Adjustment 243
1 3 3 Slow Stop Adjustment 244
1 3 4 Setting Item after Adjustment 244
1 3 5 Option Setting 244
1 3 6 Engine (E/G) Setting 244
1 4 Applicable Model: GR-800EX-2 245
1 4 1 Initial Adjustment 245
1 4 2 Detector Adjustment 245
1 4 3 Slow Stop Adjustment 246
1 4 4 Setting Item after Adjustment 246
1 4 5 Option Setting 246
1 4 6 Engine (E/G) Setting 246
1 5 Applicable Model: GR-1450EX-2 247
1 5 1 Initial Adjustment 247
1 5 2 Detector Adjustment 247
1 5 3 Telescoping Cylinder Length Correction 248
1 5 4 Slow Stop Adjustment 249
1 5 5 Setting Item after Adjustment 249
1 5 6 Option Setting 250
1 5 7 Adjustment Item at AML Replacement 250
1 6 Applicable Model: GT-600EX-1 251
1 6 1 Initial Adjustment 251
1 6 2 Detector Adjustment 251
1 6 3 Slow Stop Adjustment 252
1 6 4 Setting Item after Adjustment 252
E-2 Detector Check 253
2 1 Applicable Model: GR-300EX-2 253
2 1 1 Boom Length Detector 253
2 1 2 Boom Angle Detector 254
2 1 3 Slewing Angle Detector 254
2 1 4 Outrigger Extension Length Detector 255
2 1 5 Pressure Sensor for Moment Detection 255
2 2 Applicable Model: GR-500EX-2 256
2 2 1 Boom Length Detector 256
2 2 2 Boom Angle Detector 257
2 2 3 Slewing Angle Detector 257
2 2 4 Outrigger Extension Length Detector 258
2 2 5 Pressure Sensor for Moment Detection 258
2 3 Applicable Model: GR-600EX-2 259
2 3 1 Boom Length Detector 259
2 3 2 Boom Angle Detector 260
2 3 3 Slewing Angle Detector 260
2 3 4 Outrigger Extension Length Detector 261
2 3 5 Pressure Sensor for Moment Detection 261
2 4 Applicable Model: GR-800EX-2 262
2 4 1 Boom Length Detector 262
2 4 2 Boom Angle Detector 263
2 4 3 Slewing Angle Detector 263
2 4 4 Outrigger Extension Length Detector 264
2 4 5 Pressure Sensor for Moment Detection 264
2 5 Applicable Model: GR-1450EX-2 265
2 5 1 Telescoping Cylinder Stroke Detector 265
2 5 2 Boom Angle Detector 265
2 5 3 Slewing Angle Detector 266
2 5 4 Outrigger Extension Length Detector 266
2 5 5 Pressure Sensor for Moment Detection 267
2 5 6 Jib Angle Detector 267
2 6 Applicable Model: GT-600EX-1 268
2 6 1 Boom Length Detector 268
2 6 2 Boom Angle Detector 269
2 6 3 Slewing Angle Detector 269
2 6 4 Outrigger Extension Length Detector 270
2 6 5 Pressure Sensor for Moment Detection 270
E-3 AML Control Function List 271
3 1 Applicable Model: GR-300EX-2 271
3 1 1 Setting of operation status No 271
3 1 2 Subtraction load at single top 271
3 1 3 Section range setting 271
3 1 4 Data specifying boom telescoping No and telescoping sequence 271
3 1 5 Number of part-lines of wire rope and limit load 271
3 1 6 Hysteresis data 271
3 1 7 Stroke end stop 272
3 1 8 Backward stability 272
3 1 9 Warning and stop % during boom lift with jib extended 272
3 1 10 Hoist medium load check 272
3 1 11 Fuel consumption monitor 273
3 1 12 Eco mode 273
3 1 13 Self diagnosis 273
3 1 14 Telematics 273
3 1 15 Setting of allowable value for overload stop cancel 273
3 2 Applicable Model: GR-500EX-2 274
3 2 1 Setting of operation status No 274
3 2 2 Subtraction load at single top 274
3 2 3 Section range setting 274
3 2 4 Data specifying boom telescoping No and telescoping sequence 274
3 2 5 Number of part-lines of wire rope and limit load 274
3 2 6 Hysteresis data 275
3 2 7 Stroke end stop 275
3 2 8 Backward stability 275
3 2 9 Condition for boom extension warning during jib set status 275
3 2 10 Interference prevention area 276
3 2 11 Warning and stop % during boom lift with jib extended 276
3 2 12 Hoist medium load check 276
3 2 13 Fuel consumption monitor 277
3 2 14 Eco mode 277
3 2 15 Self diagnosis 277
3 2 16 Telematics 277
3 3 Applicable Model: GR-600EX-2 278
3 3 1 Setting of operation status No 278
3 3 2 Subtraction load at single top 278
3 3 3 Section range setting 278
3 3 4 Data specifying boom telescoping No and telescoping sequence 278
3 3 5 Number of part-lines of wire rope and limit load 279
3 3 6 Boom telescoping control 279
3 3 7 Hysteresis data 279
3 3 8 Stroke end stop 279
3 3 9 Backward stability 280
3 3 10 Condition for boom extension warning during jib set status 280
3 3 11 Interference prevention area 280
3 3 12 Warning and stop % during boom lift with jib extended 281
3 3 13 Setting of allowable value for overload stop cancel 281
3 3 14 Hoist medium load check 281
3 3 15 Fuel consumption monitor 281
3 3 16 Eco mode 282
3 3 17 Self diagnosis 282
3 3 18 Telematics 282
3 4 Applicable Model: GR-800EX-2 283
3 4 1 Setting of operation status No 283
3 4 2 Subtraction load at single top 283
3 4 3 Section range setting 283
3 4 4 Data specifying boom telescoping No and telescoping sequence 283
3 4 5 Number of part-lines of wire rope and limit load 284
3 4 6 Boom telescoping control 284
3 4 7 Hysteresis data 284
3 4 8 Stroke end stop 284
3 4 9 Backward stability 285
3 4 10 Condition for boom extension warning during jib set status 286
3 4 11 Interference prevention area 286
3 4 12 Warning and stop % during boom lift with jib extended 286
3 4 13 Setting of allowable value for overload stop cancel 286
3 4 14 Hoist medium load check 286
3 4 15 High speed winch mode 287
3 4 16 Fuel consumption monitor 287
3 4 17 Eco mode 287
3 4 18 Self diagnosis 288
3 4 19 Telematics 288
3 5 Applicable Model: GR-1450EX-2 289
3 5 1 Specification No : GR-1450E-2-00101 289
3 5 2 Specification No : GR-1450E-2-00102 296
3 6 Applicable Model: GT-600EX-1 303
3 6 1 Setting of operation status No 303
3 6 2 Display travel average 303
3 6 3 Subtraction load at single top 303
3 6 4 Section range setting 303
3 6 5 Data specifying boom telescoping No and telescoping method 303
3 6 6 Number of part-lines of wire rope and limit load 304
3 6 7 Hysteresis data 304
3 6 8 Boom telescoping cylinder select boom length range 304
3 6 9 Backward stability 304
3 6 10 Stroke end stop 305
3 6 11 Warning and stop % during boom operation with jib extended 305
3 6 12 Setting of allowable value for overload stop cancel 305
3 6 13 Hook load check 305
E-4 AML Input/Output List 306
4 1 Applicable Model: GR-300EX-2 306
4 1 1 Digital input 306
4 1 2 Analog input 309
4 1 3 Pulse input 309
4 1 4 Digital output 310
4 1 5 Analog output 310
4 2 Applicable Model: GR-500EX-2 311
4 2 1 Digital input 311
4 2 2 Analog input 314
4 2 3 Pulse input 314
4 2 4 Digital output 315
4 2 5 Analog output 315
4 3 Applicable Model: GR-600EX-2 316
4 3 1 Digital input 316
4 3 2 Analog input 319
4 3 3 Pulse input 319
4 3 4 Digital output 320
4 3 5 Analog output 320
4 4 Applicable Model: GR-800EX-2 321
4 4 1 Digital input 321
4 4 2 Analog input 324
4 4 3 Pulse input 325
4 4 4 Digital output 325
4 4 5 Analog output 326
4 5 Applicable Model: GR-1450EX -2 327
4 5 1 Specification No : GR-1450E-2-00101 327
4 5 2 Specification No : GR-1450E-2-00102 335
4 6 Applicable Model: GT-600EX-1 343
4 6 1 Digital input 343
4 6 2 Analog input 347
4 6 3 Pulse input 347
4 6 4 Digital output 348
4 6 5 Analog output 348
History of revision 349
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