Overload Prevention Device Manual

Publication No.
W301-0213E
Service Manual
(AML-L B)
03
Overload Prevention Device

Model
AML-L B
W301-0213E
ｃ
◯2005
PRINTED IN JAPAN
0505 K
Foreword
Foreword 1. Applicable Spec. No.

2005.5.
This service manual covers the overload prevention
Applicable crane model
device (AML-L B) installed on the TADANO cranes in
the chart below.
GT-550E-1
In undertaking repair, refer to the separate operation
and maintenance manual, parts catalog, and Specification numbers:
crane-covering service manual for pertinent (1) GT-550E-1-10102
information. (2) GT-550E-1-10202
If the parts replacement is required, check the
disassembly and order units from the applicable parts GR-120N-1
catalog.
Specification numbers:
(1) GR-120N-1-00103
GR-700EXL-1
(1) GR-700E-1-00101 (Europe:2M2D)
(2) GR-700E-1-00102 (General Export:2M2D)
GR-300EX-1
(1) GR-300E-1-00201 (Europe:2M2D,4+2)
(2) GR-300E-1-00202 (General Export:2M2D,4+2)
(3) GR-300E-1-00203 (General Export:1M1D,4+0)
Use this manual for machines with the overload

prevention device (AML-L B) even if the crane
model is other than the above.
Please note that, for product Improvement, some

changes may have been incorporated in the machine
that are not covered in this manual.
1 W301-0213E
Foreword
2. Contents Display Alteration ...............................................62
1. Applicable Spec. No.................................. 1 Functions of and How to Use User Mode

(GR-120N-1)................................ 63
2. Contents ................................................... 2 Mode Structure...................................................63
Configuration and Functions of the
Components of the AML (AML-L B) AML System........................................64
Main Unit ....................................... 5 Names and Functions of
AML Main Unit Parts...........................67
Diagram of the AML System Selecting Operational Status..............................73
(GT-550E-1) .................................. 6 AML Pre-operational Inspection.........................77
How to Use the Working Range
Input/Output Signals of the AML System Limit Function .....................................77
(GT-550E-1) .................................. 7 How to Use the Elevation Speed Adjustment
Function ..............................................79
Diagram of the AML System Display Alteration ...............................................81
(GR-120N-1)................................ 13
Functions of and How to Use User Mode
Input/Output Signals of the AML System (GR-700EXL-1)............................ 82
(GR-120N-1)................................ 14 Mode Structure...................................................82
Diagram of the AML System AML System........................................83
(GR-700EXL-1) ........................... 27 Names and Functions of
AML Main Unit Parts...........................87
Input/Output Signals of the AML System Selecting Operational Status..............................93
(GR-700EXL-1) ........................... 28 Selecting Winch Condition .................................97
Selecting Jib Mounted Condition........................97
Diagram of the AML System AML Pre-operational Inspection.........................98
(GR-300EX-1) ............................. 36 How to Use the Working Range
Limit Function .....................................99
Input/Output Signals of the AML System Display Alteration .............................................103
(GR-300EX-1) ............................. 37
[OPERATION]................................................ 44 (GR-300EX-1)............................ 104
Mode Structure.................................................104
Functions of and How to Use User Mode Configuration and Functions of the
(GT-550E-1) ................................ 44 AML System......................................105
Mode Structure .................................................. 44
Names and Functions of
AML Main Unit Parts.........................109
AML System ....................................... 45
Selecting Operational Status............................ 115
Names and Functions of
Selecting Winch Condition ............................... 119
AML Main Unit Parts .......................... 48
Selecting Jib Mounted Condition...................... 119
Selecting Operational Status ............................. 54
AML Pre-operational Inspection.......................120
AML Pre-operational Inspection ........................ 57
Limit Function ...................................121
Limit Function ..................................... 58
Display Alteration .............................................125
2 W301-0213E
Foreword
[ADJUSTMENT AND MAINTENANCE] ........126 10. Adjustment of Elevation Output .....................149

10.1 Procedure of Resetting Elevation Data...149
General: Adjustment Mode and 10.2 Adjustment of Elevation Output
Maintenance Mode .....................126 (elevation speed adjustment)............149
1. Keys and Switches for Adjustment and Other Functions and How to Use Them .............151
Maintenance..................................... 126 1. Language.......................................................151
2. Mode Structure and Menu ............................ 127 2. Overload History Display ...............................151
3. Method of Shifting Modes ............................. 129 3. Erasing the Overload History.........................152
4. Method of Menu Selection ............................ 130
Functions of and How to Use
Required Adjustment After AML System Maintenance Mode .................... 153
Parts Replacement .....................131 1. Program Version Display ...............................153
2. Data ID Number Display................................153
Functions of and How to Use 3. Di Check ........................................................153
Adjustment Mode .......................132 4. Ai Check ........................................................154
Adjustment Procedures ...................................... 132 5. Elevating Cylinder Oil Pressure Monitor........154
1. Adjustment Initialization ................................ 133 6. Do Check .......................................................155
1.1 Procedure of Conversion 7. MDT Monitor (Multiplex Data Transmitter
Factors Resetting ............................. 133 Monitor).............................................155
1.2 Procedures of Moment 8. Key Switch Check..........................................155
Adjustment Resetting ....................... 133 9. Display Check................................................156
2. Capacity Setting ............................................. 134 10. Error Data Display .........................................156
2.1 Procedure of Head-off 11. Erasing the Error Data ...................................156
Capacity Setting ............................... 134 12. OP (Option) Board Check..............................157
2.2 Procedure of Jib Selection ..................... 135 13. Ao Check .......................................................157
2.3 Procedure of Single Top Selection ......... 135 14. Sio Check ......................................................158
2.4 Procedure of Winch Drum 15. Adjust Monitor................................................158
Position Setting ................................ 136 16. Overload History Display ...............................158
3. Boom Length Adjustment.............................. 137 17. Erasing the Overload History.........................158
4. Boom Angle Adjustment ............................... 138 18. Clock Adjustment...........................................158
5. Swing Angle Adjustment ............................... 139
6. Outrigger Extension Width Adjustment ......... 140 Error Message ............................................. 159
7. Moment Adjustment ...................................... 141 1. Display of Error Message ..............................159
7.1 Moment Zero-point Adjustment.............. 142 2. How to Read the Error Message ...................159
7.2 Moment Span Preliminary Adjustment... 143 3. How to Read the Error History.......................159
7.3 Moment Zero-point Check and 4. Troubleshooting Table ...................................160
Fine Adjustment ............................... 143 4.1 Group Code 0 .........................................160
7.4 Load Radius Adjustment ........................ 144 4.2 Group Code 1 .........................................169
7.5 Moment Span Fine Adjustment.............. 144 4.3 Group Code 2 .........................................170
7.6 Moment Zero-point Recheck .................. 145 4.4 Group Code 3 .........................................174
8. Clock Adjustment .......................................... 146
9. Adjustment of Swing Output ......................... 147 Disassembly of AML Main Unit .................... 175
9.1 Procedure of Resetting Ao 1. Removing Front Panel/Display Board ...........175
Offset Value ...................................... 147 2. Removing Rear Panel/Connector
9.2 Adjustment of Swing Output Board /Current Output Board............175
(Ao offset adjustment) ...................... 147
3 W301-0213E
Foreword
3. Removing CPU Board/Analog Fuses .................................................. 195

Board /Power Board ......................... 176
3.1 Notes on ROM/EEPROM Replacing the Clock Battery......................... 196
Replacement .................................... 176
[INFORMATION AND DATA]........................177
Adjustment Value Table ................................177

Specification No. : GT-550E-1-10102.............. 177
Specification No. : GT-550E-1-10202.............. 177
Specification No. : GR-120N-1-00103 ............. 179
Specification No. : GR-700E-1-00101 ............. 181
MDT (Multiplex Data Transmitter)

Input/Output Nos. and
Corresponding Signals ...............185
Checking the Detectors

(GT-550E-1) ...............................186
1. Boom Length Detector .................................. 186
2. Boom Angle Detector .................................... 186
3. Swing Angle Detector.................................... 187
4. Outrigger Extension Width Detector ............. 187
5. Pressure Sensor for Moment Detection........ 188
Check the Detectors

(GR-120N-1/GR-700EXL-1) .......189
Check the Detectors

(GR-300EX-1) ............................192
4 W301-0213E
Components of the AML (AML-L B) Main Unit
Components of the AML (AML-L B) Main Unit
CN1
RLY3, 4 fuse (3A) RLY5, 6 fuse (3A) 30 MBGND 17 MBPW 1 DET1GND
SOL1, 2
FUSE: Swing
31 MBGND 18 MBPW 2 DET1SRC
RLY1, 2 fuse (3A) RLY7, 8 fuse (3A) 32 MOGND/ANGND 19 RLYPW 3 ANAINA
250V 2A
33 MOSRC/+5V 20 RLYPW 4 ANAINB
MAIN fuse (3A) 34 MOINP/ANAING 21 TC 5 ANAINC
SOL3, 4
FUSE: Elevating
35 MOINN/ANAINH 22 ACC 6 DET1SLD
250V 2A
36 MOSLD/ANSLD 23 7 DET2GND
37 24 Di-5 8 DET2SRC SOL 6
SOL5,
38 25 Di-6 9 ANAIND FUSE: Swing free
39 SiF1GND 26 Di-7 10 ANAINE 250V 2A (GR-120N-1: Not used.)
SIF1 fuse (2A) 40 SiF1SRC 27 Di-8 11 ANAINF
41 SiF1TXD+ 28 Di-9 12 DET2SLD Fuse
42 SiF1TXD- 29 Di-10 13 Di-1
SIF2 fuse (2A) 43 SiF1RXD+ 14 Di-2
PWMFREQ
44 SiF1RXD- 15 Di-3
45 SiF1SLD 16 Di-4 ZERO
CN2 CNTL Right
1 Swing
23 CNTL3P 13 CNTL1P 1 RLY 1 SPAN
PROTECT
MOMENT
24 CNTL3N 14 CNTL1N 2 RLY 2
SHORT
ZERO
25 CNTL4P 15 CNTL2P 3 RLY 3 ZERO
HALT
Left
WDT
CNTL
26 CNTL4N 16 CNTL2N 4 RLY 4 2 Swing
27 CNTLSLD 17 Di-15 5 RLY 5 SPAN
28 SiF2GND 18 Di-16 6 RLY 6
29 SiF2SRC 19 Di-17 7 RLY 7 ZERO
CNTL Boom
30 SiF2TXD+ 20 Di-18 8 RLY 8
31 SiF2TXD- 21 Di-19 9 Di-11
3
SPAN Raise Battery
32 SiF2RXD+ 22 Di-20 10 Di-12
ZERO
CAL/CLOCK
33 SiF2RXD- 11 Di-13 CNTL Boom
34 SiF2SLD 12 Di-14 4 Lower
SPAN CN1
Moment input short-circuit switch (Not used.) Abnormality display LED CN3 EEPROM
16 CNTL5P 1 TR-1 ZERO
Protect switch (CPU abnormality.) 17 CNTL5N 10 Di-25 2 TR-2 CNTL Swing
5 Free CN4 PLD
18 CNTL6P 11 Di-26 3 TR-3 SPAN
(Selects to "OFF" position at adjusting mode.) Moment zero adjuster 19 CNTL6N 12 Di-27 4 TR-4
(GR-120N-1: Not used.)
20 CNTLSLD 13 Di-28 5 TR-5 ZERO ROM 1
(Adjusted by AML maker. Do not touch.) 21 Di-21 14 6 TR-6
CNTL Boom
6 Retraction CPU
22 Di-22 15 7 TR-7 SPAN
Top view
(Not used.)
23 Di-23 8 TR-8 ROM 0
24 Di-24 9
Output adjustment trimmer
CN4 CN2
(Adjusted by AML maker.
7 RTS 4 RD 1 FG CN3
Boom lift symbol Moment display 8 CTS 5 SG 2 DSR Do not touch.)
Right side view

9 6 3 TD
Boom angle symbol Connector terminal Nos.

Number of parts of line symbol Jib angle symbol (Name plate) CPU board
Upper boom angle limit symbol Jib lift symbol
Moment display contrast adjuster
Boom length symbol Single-top lift symbol
LCD panel contrast adjuster
Jib angle display Actual load display
Current output board (for Slow stop)
Scroll-up key Rated lifting capacity display
Scroll-down key Connector board
Load radius symbol
Lifting height limit symbol
Lifting height symbol Load radius limit symbol
SOL1, 2 fuse (2A)
Boom length display Lifting height restriction indicator lamp Slow stop (Swing)
m
Lower boom angle limit symbol Upper boom angle restriction indicator lamp CN1 Connector
m t
Boom angle display
SOL3, 4 fuse (2A)
%
max t Lower boom angle restriction indicator lamp Slow stop (Elevating)
Load radius display m Lower boom angle restriction key CN2 Connector
LCD panel Upper boom angle restriction key SOL5, 6 fuse (2A)
Over-front position symbol Slow stop (Swing free)
Lifting height restriction key (GR-120N-1: Not used.)
Front jack symbol
Load radius restriction indicator lamp CN3 Connector
Outrigger state symbol
Right swing restriction indicator lamp
"On-rubber" (Outrigger-not-in-use) CN4 Connector (Not used.)
state symbol Left swing restriction indicator lamp
Suspension lock state symbol Load radius restriction key

Output adjustment trimmer
Increase key Display alteration key (Adjusted by AML maker. Do not touch.)
Register key Power board
Boom position indicator
Right swing restriction key Analog board
Decrease key
Number of parts of line select key CPU board
Outrigger mode select key
Check key Display board
Lift mode select key
Left swing restriction key
Right side view
Front view
IW301-0213E01
5 W301-0213E
Diagram of the AML System (GT-550E-1)
Diagram of the AML System (GT-550E-1)

3 (B)
2 (W)
Boom angle detector
1 (R)
B B
CONNECTOR BOARD CURRENT OUTPUT BOARD
A SOL5, 6 (2A)
3 (B) R R
C SOL1, 2 (2A)
2 (W) W W CN1 SOL3, 4 (2A)
Boom length detector 1 (R) G
B
B Latch
D 1 DET1GND
E 2 DET1SRC Fuses
3 R R
3 ANAINA
SOL1, 2 (2A)
Di SW.
2 W W
4 ANAINB input block
5 ANAINC
CUP1 1
6 DET1SLD
Swing angle detector SOL3, 4 (2A)
3
7 DET2GND Current
8 DET2SRC
2 G G
9 ANAIND Amplifier Circuit
CUP2 1 B B
10 ANAINE
Fuses SOL5, 6 (2A)
11 ANAINF
R R
12 DET2SLD
SIF 1 (2A)
CPU BOARD
13 Di1
W W
Pressure sensor (Main) B B
14 Di2
15 Di3 SIF 2 (2A)
16 Di4
17 MB
18 MB MAIN (3A)
ROM EEPROM Buzzer
19
20
RB
RB DISPLAY BOARD
21 TC
Working condition input Auto. stop override signal input 22
23
ACC
NC
POWER BOARD CPU
24 Di5 CHR display
Auto. stop override signal input 25 Di6
26 Di7
27 Di8 RAM CAL/CLOCK SCI
28 Di9 Fuses +20V
29 Di10
30 GND RLY1, 2 (3A) +12V
Key input
31 GND DC power
32 DET3GND
RLY3, 4 (3A) block -12V
33 DET3SRC
34 ANAING +5V
35 ANAINH Relay RLY5, 6 (3A) LCD panel (1)
24(V)
36 DET3SLD
37 NC RLY7, 8 (3A)
Pressure sensor for moment detection 38 NC Serial input/output circuit
(Elevating) R R 39 SIF1GND
W W 40 SIF1SRC
B B 41 SIF1TXD+
LCD panel (2)
42 SIF1TXD-
R R 43 SIF1RXD+
W W 44 SIF1RXD-
B B 45 SIF1SLD
LCD SW .
Alarm signal output Latch backlights
Auto.stop signal output CN2
SOL. 1 RLY1
Buzzer 2 RLY2
3 RLY3
Telescoping control output 4 RLY4
SOL. 5 RLY5
O.C.Tr.
Lever manipulation detection input 6 RLY6
output Latch
7
8
RLY7
RLY8 block ANALOG BOARD
9 Di11
Slow stop(Swing) 10 Di12
11 Di13
12 Di14
13 CNTL1P
14 CNTL1N
15 CNTL2P Di SW. Latch
16 CNTL2N
17 Di15
input block
Working condition signal input (Outrigger) 18 Di16
19 Di17
20 Di18
21 Di19
22 Di20
Slow stop(Elevating) 23 CNTL3P
24 CNTL3N
25 CNTL4P
Buffer
26 CNTL4N
27 CNTLSLD
28 SIF2GND
29 SIF2SRC
30 SIF2TXD+
31 SIF2TXD- Buffer Analog
32 SIF2RXD+ multiplexer A/D
33 SIF2RXD- converter
Outrigger extension width 34 SIF2SLD
detector (4 peace)
Transmitter
(Type2) CN3
1 TR1
90 - 100% 2 TR2
Pressure sensor
3 TR3 analog detector
24(V) 100% - power supply
4 TR4
AML external indicator
5 TR5
output 6 TR6
7 TR7
Working condition input
8 TR8
9 NC
10 Di25
11 Di26
12 Di27
13 Di28
14 NC
15 NC
16 (CNTL5P)
17 (CNTL5N)
Slow stop (Swing free) 18 (CNTL6P)
19 (CNTL6N)
20 CNTLSLD
21 Di21
22 Di22
IW301-0211E02
23 Di23
24 Di24
6 W301-0213E
Input/Output Signals of the AML System (GT-550E-1)

As shown in the “Diagram of the AML System” on the previous page, the display board, CPU board, analog
board, power board, current output board and connector board consist inside the AML. The following lists
describe the names and functions of the input/output signals on CN1, CN2 and CN3 cnnectors.
CN1 connector signals and functions are shown below:
CN 1 connector
Signal names and functions
Pin No. Name
Signal name: Boom length detector input
3 ANAIN A Analog input representing detected boom length.
Input voltage: DC 0 to 4.5 V
Signal name: Boom angle detector input
4 ANAIN B Analog input representing detected boom angle.
Signal name: Swing angle detector 1 input
5 ANAIN C Analog input from the swing detector 1 representing detected swing angle.
9 ANAIN D Analog input from the swing detector 2 representing detected swing angle.
Signal name: Main hydraulic pressure sensor input
10 ANAIN E Analog input representing detected main hydraulic pressure.
Signal name: Overwind detection switch (L4) 137input
Switch input representing whether overwinding condition exists.
13 Di1
Switch ON (DC0V): The hook currenty in use is in normal state.
Switch OFF (DC24V): The hook currently in use is overwinding.
Signal name: 2nd boom full-retraction detection switch (L8) 135 input
Switch input used detecting the boom state.
14 Di2
Switch ON (DC0V): 2nd boom is fully retracted.
Switch OFF (DC24V): 2nd boom is extended.
Signal name: 3rd-top boom full-retraction detection switch (L7) 136 input
Switch input used detecting the boom state.
15 Di3
Switch ON (DC0V): 3rd-top boom are fully retracted.
Switch OFF (DC24V): 3rd-top boom are extended.
Signal name: Swing free/lock selector switch (S15) 140 input
Switch input used detecting the swing free, lock state.
16 Di4
Switch ON (DC0V): Swing lock device; Free.
Switch OFF (DC24V): Swing lock device; Lock.
Signal name: Swing slow stop release switch (S14) 142 input
When release a crane motion stop state caused by a swing slow stop, make this
switch “ON”.
22 ACC Switch ON (DC24V): Release a swing slow stop state.
Switch OFF (DC0V): Not cancel a swing slow stop state.
7 W301-0213E
CN 1 connector
Pin No. Name
Signal name: Overwind cutout disable switch (S3) 143 input
When release a crane motion stop state caused by a hook overwind detection, make
24 Di5 this switch “ON”.
Switch ON (DC0V): Release a hook overwind cutout state and buzzer alarm.
Switch OFF (DC24V): A hook overwind cutout state.
Signal name: AML cutout release switch (SK1) (S19) 149, 150 input
When release a crane motion stop state caused by a hook over-wind detection,
25 Di6 make this switch “ON”.
Switch ON (DC0V): Release a overload stop state.
Switch OFF (DC24V): Not cancel a overload stop state.
Signal name: Elevating slow stop release switch (S22) 141 input
When release a crane motion stop state caused by a elevating slow stop, make this
26 Di7 switch “ON”.
Switch ON (DC0V): Release a elevating slow stop state.
Switch OFF (DC24V): Not cancel a elevating slow stop state.
Signal name: Jib set pin detection (Jib extension detection) switch (L1) 144 input
This signal represents extended or retracted state of the jib.
27 Di8
Switch ON (DC0V): Jib in retracted state.
Switch OFF (DC24V): Jib in extended state.
Signal name: Jib automatic lock pin detection switch (CS10) 145 input
This signal represents locked or unlocked state to the jib.
28 Di9
Switch ON (DC0V): Jib in automatic lock state.
Switch OFF (DC5V): Jib in automatic unlock state.
Signal name: Swing angle detector 1,2 selection switch (CS11) 146 input
This signal represents the boom swing position (Swing blind corner).
29 Di10
Switch ON (DC0V): Boom in left over-side area.
Switch OFF (DC5V): Boom in right over-side area.
Signal name: Input for pressure sensor for moment detection (extension side)
34 ANAING Analog input to detect the elevating cylinder extension pressure.
Input voltage: DC 0 to 5 V
Signal name: Input for pressure sensor for moment detection (retraction side)
35 ANAINH Analog input to detect the elevating cylinder retraction pressure.
8 W301-0213E

CN 2 connector
Pin No. Name
Signal name: Automatic stop 1 relay output
When a overload or a hook overwind is detected, or when AML is in failure, or in any
likewise situation, this relay output goes “OFF” and stops the crane motion.
Relay ON (DC24V): The crane motion is normal.
Relay OFF (DC0V): The crane motion is auto. Stopped.
Crane work operation Relay output
Moment load ratio < 90% ON
90% Moment load ratio < 100% ON
1 RLY 1 Moment load ratio 100% OFF
Overwinding occurred. OFF
Crane movement exceeded any registered working range limit. OFF
Failure in the AML unit. OFF
Operated to critical side when rearward stability control
OFF
activated.
Boom lift with jib mounted on boom.
80% Moment load ratio < 90% ON
Moment load ratio 90% OFF
Signal name: AML alarm relay output
On occurrence of an overload, this output energizes the relay to turn on the buzzer 3
(280Hz Low).
Relay ON (DC24V): Alarm buzzer sounds.
Relay OFF (DC0V): Alarm buzzer does not sound.
Raising alarm conditions Relay output
4 RLY 4
Moment ratio < 90% OFF
90% Moment ratio < 100% ON/OFF
Moment ratio 100% ON
Boom lift with jib mounted on boom.
80% Moment ratio < 90% ON/OFF
Moment ratio 90% ON
Signal name: Telescoping control relay output
Output for switch between 3rd-top boom telescoping and 2nd boom telescoping.
5 RLY 5
Relay ON (DC24V): 3rd-top boom sections are telescoped.
Relay OFF (DC0V): 2nd boom sections are telescoped.
Signal name: Jib lock lamp relay output
When the jib set pin is extracted, this output energizes lamp lights up.
6 RLY 6
Relay ON (DC24V): Jib lock lamp lights up when the jib set pin is extracted.
Relay OFF (DC0V): Normal condition.
Signal name: Overwind alarm relay output
When an overwind state is detected, this output energizes the relay to turn on the
7 RLY 7 buzzer.
Relay ON (DC24V): Overwind alarm buzzer sounds.
Relay OFF (DC0V): Normal condition.
9 W301-0213E
CN 2 connector
Pin No. Name
Signal name: Main winch hoist-up detection switch (PS1) 29 input
Input from the main winch hoist-up detection switch.
9 Di11
Switch ON (DC0V): Main winch hoist-up operation is not detected.
Switch OFF (DC5V): Main winch hoist-up operation is detected.
Signal name: Auxiliary winch wind detection switch (PS2) 35 input
Input from the aux. winch hoist-up detection switch.
11 Di13
Switch ON (DC0V): Aux. winch hoist-up operation is not detected.
Switch OFF (DC5V): Aux. winch hoist-up operation is detected.
Signal name: Swing right proportional valve output
When swing to clockwise, over the deviation angle start point, AML outputs the
controlled to the right proportional valve (PRP3) 65-1.
13 CNTL 1P
Swing will be stopped at specified position where calculated in the AML-L B.
Output value when starts the deceleration is 56% × 800mA, 24V rectangular wave.
Output voltage: Square wave 0 to 24V
Signal name: Swing right proportional valve COM (-)
14 CNTL 1N
Input voltage: DC0V
Signal name: Swing left proportional valve output
When swing to clockwise, over the deviation angle start point, outputs the controlled
15 CNTL 2P to the left proportional valve (PRP4) 65-2.
Swing will be stopped same as above.
Signal name: Swing left proportional valve COM (-)
16 CNTL 2N
Input voltage: DC0V
Signal name: Boom extension detection switch (PS3) 2M2D 31,1M1D 43 input
Input from the boom extension operation detection switch.
17 Di15
Switch ON (DC0V): Boom extension operation is not detected.
Switch OFF (DC5V): Boom extension operation is detected.
Signal name: Boom retraction detection switch (PS4) 2M2D 33,1M1D 44 input
Input from the boom retraction operation detection switch.
18 Di16
Switch ON (DC0V): Boom retraction operation is not detected.
Switch OFF (DC5V): Boom retraction operation is detected.
Signal name: Boom raising operation detection switch (PS5) 26 input
Input from the boom raising operation detection switch.
19 Di17
Switch ON (DC0V): Boom raising operation is not detected.
Switch OFF (DC5V): Boom raising operation is detected.
Signal name: Boom lowering operation detection switch (PS6) 22 input
Input from the boom lowering operation detection switch.
20 Di18
Switch ON (DC0V): Boom lowering operation is not detected.
Switch OFF (DC5V): Boom lowering operation is detected.
Signal name: Boom right operation detection switch (PS9) 38 input
Input from the right swing operation detection switch.
21 Di19 Switch ON (DC0V): Swing right operation is not detected.
Switch OFF (DC5V): Swing right operation is detected.
10 W301-0213E
CN 2 connector
Pin No. Name
Signal name: Boom left operation detection switch (PS10) 39 input
Input from the left swing operation detection switch.
22 Di20
Switch ON (DC0V): Swing left operation is not detected.
Switch OFF (DC5V): Swing left operation is detected.
Signal name: Boom raising proportional valve output
When raise the boom to nearly elevating cylinder stroke end, AML outputs the
controlled current to the boom raising proportional valve (PRP1) 27-2. Raising the
23 CNTL3 P
boom will be stopped at 0.5° lower than elevating cylinder stroke end due to the
protection of the shock.
Signal name: Boom raising proportional valve common pat (-)
24 CNTL 3N
Input voltage: DC0V
Signal name: Boom lowering proportional valve output
When lower the boom to nearly elevating cylinder stroke end, AML outputs the
controlled current to the boom lowering proportional valve (PRP2) 27-1. Lowering the
25 CNTL 4P
boom will be stopped at 0.5° higher than elevating cylinder stroke end due to the
protection of the shock.
Signal name: Boom lowering proportional valve common pat (-)
26 CNTL 4N
Input voltage: DC0V
11 W301-0213E

CN 3 connector
Pin No. Name
1
Signal name: AML 90% (80%)* alarm output
1
Outputs if the load moment is in a range between 90% (80%)* and 100%
1
(90%)* .
1
90% and 100% not inclusive (80% and 90% not inclusive)* .
2 TR 2
OC (Open collector) output “ON” (DC0V):
1
The external indicator 90% (80%)* turns on.
OC (Open collector) output “OFF” (DC24V):
1
The external indicator 90% (80%)* turns off.
1
Signal name: AML 100% (90%)* alarm output
1
Outputs if the load moment is 100% (90%)* or more.
3 TR 3 OC (Open collector) output “ON” (DC0V):
1
The external indicator 100% (90%)* turns on.
1
The external indicator 100% (90%)* turns off.
Signal name: Front jack overload warning output
OC (Open collector) output “ON” (DC0V):
Buzzer [130] sounds when the front jack overload detection switch
4 TR 4 is ON.
Buzzer [130] does not sound when the front jack overload detection switch
is OFF.
Signal name: Outrigger stowing operation detection switch input
10 Di25 Switch ON (DC0V): The outrigger stowing operation is detected.
Switch OFF (DC5V): The outrigger stowing operation is not detected.
Signal name: Telescoping method selector switch (S31) 157 input
12 Di27 Switch ON (DC0V): Special telescoping method.
Switch OFF (DC5V): Sequential telescoping method.
Signal name: Head-end boom sections (3rd, 4th and top) extension switch (S7)
[158] input
Switch ON (DC0V):
13 Di28
Head-end boom sections (3rd, 4th and top) extend first.
Switch OFF (DC5V):
Head-end boom sections (3rd, 4th and top) do not extend first.
Signal name: Proportional valve (For swing relief) input
16 CNTL5P Used to control swing slow stop while free swing mode is active.
Signal name: Proportional valve (For swing relief) common pat (-)
17 CNTL5N
Input voltage: DC0V
1
*1: For the boom lift mode with the jib mounted on the boom, apply the values marked with * .
(The alarm and automatic stop function at the values lower than the ones they do in the boom lift mode with
no jib mounted on the boom.)
12 W301-0213E
Diagram of the AML System (GR-120N-1)
Diagram of the AML System (GR-120N-1)
Boom angle detector CONNECTOR BOARD CURRENT OUTPUT BOARD

SOL5, 6 (2A)
A
SOL1, 2 (2A)
C
CN1 SOL3, 4 (2A) Latch
B
Boom length detector D 1 DET1GND
E 2 DET1SRC Fuses
3 ANAINA
SOL1, 2 (2A)
Di SW.
5 ANAINC
6 DET1SLD
Swing angle detector 7 DET2GND
SOL3, 4 (2A) Current
8 DET2SRC Amplifier Circuit
9 ANAIND Fuses SOL5, 6 (2A)
10 ANAINE
Pressure sensor (Main) 11
12
ANAINF
DET2SLD
SIF 1 (2A)
CPU BOARD
13 Di1
14 Di2
15 Di3 SIF 2 (2A)
16 Di4
17 MB
18 MB MAIN (3A)
ROM EEPROM Buzzer
19
20
RB
RB DISPLAY BOARD
Pressure sensor (Accumulator) 24(V) 21 TC
Auto. stop 22 ACC POWER BOARD
override signal input 23 NC CPU
Auto. stop 24 Di5 CHR display
25 Di6
override signal input 26 Di7
RAM CAL/CLOCK SCI
27 Di8
Working condition input 28 Di9 Fuses +20V
29 Di10
30 GND RLY1, 2 (3A) +12V
Key input
31 GND DC power
Pressure sensor for moment detection 32 DET3GND
RLY3, 4 (3A) block -12V
(Elevating) 33 DET3SRC
34 ANAING
Relay +5V
35 ANAINH RLY5, 6 (3A) LCD panel (1)
36 DET3SLD
Jib angle detector 37 NC RLY7, 8 (3A)
38 NC Serial input/output circuit
39 SIF1GND
40 SIF1SRC
41 SIF1TXD+
LCD panel (2)
42 SIF1TXD-
43 SIF1RXD+
44 SIF1RXD-
45 SIF1SLD
LCD SW .
Auto.stop signal output backlights
CN2 Latch
Transmitter SOL.
1 RLY1
2 RLY2
Hook-in control output Telescoping control output 3 RLY3
Alarm signal output SOL.
SOL. 4 RLY4
5 RLY5
6 RLY6
O.C.Tr.
BUZZER output Latch
7
8
RLY7
9 Di11
10 Di12
12 Di14
13 CNTL1P
14 CNTL1N
15 CNTL2P
16 CNTL2N
Di SW. Latch
Lever manipulation detection input 17 Di15
input block
18 Di16
19 Di17
20 Di18
21 Di19
22 Di20
Slow stop(Elevating) 23 CNTL3P
24 CNTL3N
Combination meter 25 CNTL4P
Buffer
26 CNTL4N
27 CNTLSLD
Outrigger extension width detector 28 SIF2GND
29 SIF2SRC
(4 peace) 30 SIF2TXD+
34 SIF2SLD
CN3
- 90% 1 TR1
90 - 100% 2 TR2 Pressure sensor
lower unit upper unit 100% - 3 TR3 analog detector
Outrigger retraction operation MDT (multiplex data 4 TR4 power supply
AML external indicator 5 TR5
detection input transmitter) output (option) 6 TR6
7 TR7
8 TR8
9 NC
10 Di25
11 Di26
Output for high-speed hoist down 12 Di27
13 Di28
14 NC
15 NC
16 (CNTL5P)
17 (CNTL5N)
18 (CNTL6P)
19 (CNTL6N)
20 CNTLSLD
21 Di21
22 Di22
23 Di23
24 Di24
Working condition input IW301-0211E36
13 W301-0213E
Input/Output Signals of the AML System (GR-120N-1)

CN 1 connector
Pin No. Name
Signal name: Ground for analog detector 1
1 DET1GND
Input voltage: DC0V
Signal name: Applied voltage output for analog detector 1
2 DET1SRC
Output voltage: DC4.5V
Analog input representing detected boom length.
3 ANAIN A Date for reference
Input voltage when the boom is fully retracted (5.3 m):
0.45 V (The A/D value converted by Ai check is 203.)
Input voltage when the boom is fully extended (23.8 m):
2.07 V (The digital value converted by Ai check is 944.)
Analog input representing detected boom angle.
4 ANAIN B Date for reference
Input voltage when the boom angle is –2.7°:
Input voltage when the boom angle is 82.4°:
3.76 V (The digital value converted by Ai check is 1712.)
Analog input from the swing angle detector 1 representing detected swing
5 ANAIN C
angle.
Signal name: Shield for analog detector 1
6 DET1SLD
Input voltage: DC0V
Signal name: Ground for analog detector 2
7 DET2GND
Input voltage: DC0V
Signal name: Applied voltage output for analog detector 2
8 DET2SRC
Output voltage: DC4.5V
9 ANAIN D
angle.
Analog input representing detected main hydraulic pressure.
10 ANAIN E Input voltage: DC 0 to 4.5 V
Date for reference
Input voltage when the main hydraulic pressure is 0 MPa.: 0.45 V.
14 W301-0213E
CN 1 connector
Pin No. Name
Signal name: Accumulator pressure sensor input
Analog input representing detected accumulator pressure.
11 ANAIN F Input voltage: DC 0 to 4.5 V
Date for reference
Input voltage when the accumulator pressure is 0 MPa.: 0.45 V.
Signal name: Shield for analog detector 2
12 DET2SLD
Input voltage: DC0V
Signal name: Overwinding detection switch input
13 Di1
Switch ON (DC0V): The hook currently in use is in normal state.
Signal name: 2nd/3rd boom sections full retraction detection switch input
Switch input representing whether the 2nd/3rd boom sections are fully
retracted.
Switch ON (DC0V): 2nd/3rd boom sections are fully retracted.
Switch OFF (DC24V): 2nd/3rd boom sections are not fully retracted.
14 Di2 Data for reference
If the following (1) or (2) condition exists, the AML assumes that the boom full
retraction detector switch is faulty and displays the error message “Error: 0021”.
(1) The boom full retraction detector switch does not detect the fully retracted
state when the boom length detector input is 4.9 m or less.
(2) The boom full retraction detector switch detects the fully retracted state
when the boom length detector input is 5.7m or more.
Signal name: 4th/5th/top boom sections full retraction detection switch input
Switch input representing whether the 4th/5th/top boom sections are fully
retracted.
Switch ON (DC0V): 4th/5th/top boom sections are fully retracted.
Switch OFF (DC24V): 4th/5th/top boom sections are not fully retracted.
15 Di3 Data for reference

If the following (1) or (2) condition exists, the AML assumes that the boom full
retraction detector switch is abnormal and displays the error message “Error:
0018”.
(1) The boom full retraction detector switch does not detect the fully retracted
state when the boom length detector input is 12.3 m or less.
(2) The boom full retraction detector switch detects the fully retracted state
when the boom length detector input is 13.1 m or more.
Signal name: Jib lock pin detection switch input
Switch input representing whether the jib is stowed.
16 Di4
Switch ON (DC0V): The jib is in stowed condition.
Switch OFF (DC24V): The jib is out of stowed condition.
17 MB Signal name: DC power supply from battery for circuit
18 MB Input voltage: DC24V
19 RB Signal name: DC power supply from battery for relay
20 RB Input voltage: DC24V
15 W301-0213E
CN 1 connector
Pin No. Name
Signal name: Swing stop/override switch input
Switch input representing whether the swing stop is cancelled.
22 ACC Input voltage: DC24V
Switch ON (DC24V): Swing stop is cancelled.
Switch OFF (DC0V): Swing stop is functioning.
Signal name: Overwind cutout disable switch input
Switch input representing whether automatic stop caused by overwinding is
overridden.
24 Di5
Switch ON (DC0V): Automatic stop caused by overwinding is cancelled and the
alarm buzzer does not sound.
Switch OFF (DC24V): Overwind cutout function is ready.
Signal name: AML emergency switch input
Switch input representing whether automatic stop caused by overloading is
25 Di6 overridden.
Switch ON (DC0V): Automatic stop caused by overloading is cancelled.
Switch OFF (DC24V): Automatic stop function is ready.
Signal name: Elevation slow stop/override switch input
Switch input representing whether elevation slow stop is cancelled.
26 Di7
Switch ON (DC0V): Slow stop function is cancelled.
Switch OFF (DC24V): Slow stop function is ready.
Signal name: Jib set pin inserted condition detector switch input
Switch input representing whether the jib set pin is inserted.
27 Di8
Switch ON (DC0V): The jib set pin is in inserted condition.
Switch OFF (DC24V): The jib set pin is out of inserted condition.
Signal name: Over-front detection switch input
Switch input representing whether the boom is in the over-front area.
28 Di9
Switch ON (DC0V): The boom is in the over-front area.
Switch OFF (DC5V): The boom is out of the over-front area.
Signal name: Swing angle detector 1,2 selection (swing dead angle detection)
switch input
29 Di10 Switch input representing whether the boom is in the over-left area.
Switch ON (DC0V): The boom is in the over-left.
Switch OFF (DC5V): The boom is in the over-right.
30 GND Signal name: Electric ground
31 GND Output voltage: DC0V
MOGND/ Signal name: Ground for pressure sensor (moment detection)
32
DET3GND Input voltage: DC0V
MOSRC/ Signal name: Applied voltage output for pressure sensor (moment detection)
33
DET3SRC Output voltage: DC5V
Analog input to detect the elevating cylinder extension pressure.
MOINP/
34 Input voltage: DC 0 to 5 V
ANAING
16 W301-0213E
CN 1 connector
Pin No. Name
MOINN/
35 Analog input to detect the elevating cylinder retraction pressure.
ANAINH
MOSLD/ Signal name: Shield for pressure sensor (moment detection)
36
DET3SLD Input voltage: DC0V
Signal name: Ground for serial port 1
39 SIF1GND
Input voltage: DC0V
Signal name: Power supply for serial port 1
40 SIF1SRC
Output voltage: DC24V
Signal name: Receiving (+) input signal for serial
43 SIF1RXD+ The received data from the
port 1
transmitter on the boom
Signal name: Receiving (-) input signal for serial head
(*1)
44 SIF1RXD-
port 1
(*1): Received signal name
Jib angle
Signal name: Shield for serial port 1
45 SIF1SLD
Input voltage: DC0V

CN 2 connector
Pin No. Name
Signal name: Automatic stop relay output
This relay contact turns OFF and stops crane operation when the crane is
overloaded, the hook is overwound or the AML main unit is out of order.
When the boom elevation stops, the slow stop function activates
simultaneously. (The current controlled by the AML is output from the boom
raising proportional valve output CNTL3P or the boom lowering proportional
valve input CNTL4P to activate the slow stop function.)
However, the slow stop function is not activated when the elevation slow
stop/override switch is set to “OVERRIDE”.
Relay ON (DC24V): Normal operation is available.
Relay OFF (DC0V): The crane operation is stopped.
When the AML emergency switch is set to “Emergency” and the PTO switch is
1 RLY 1 set to “OVERRIDE”, this relay output is shifted from OFF to ON and the AML
automatic stop function is cancelled. The overwind cutout function is also
cancelled by the diode circuit.
Relay output Crane condition
Moment ratio < 90%
90% Moment ratio < 100%
ON
17 W301-0213E
CN 2 connector
Pin No. Name
Moment ratio 100%
The crane operation toward the critical side (main winch
hoist-up, auxiliary winch hoist-up, boom extension, boom
(*1)
lowering or jib tilt lowering ) is stopped.
(*1): Only for machines with power-tilt jib
While the boom lift with the jib mounted is performed, the
relay output turns OFF when the moment ratio becomes as
follows:
Moment ratio 90 %
While the jib set pin is out of the inserted condition, the AML
assumes that the jib is mounted.
When the hook block is overwound:
OFF
The crane operation toward the critical side (main winch
hoist-up, auxiliary winch hoist-up, boom extension, boom
(*1)
lowering or jib tilt lowering ) is stopped.
When the overwind cutout disable switch is pressed in this
state, the relay output is shifted from OFF to ON and the
overwind cutout function is cancelled.
The crane operations except boom swing exceed the limit
while the working range limit is registered.
Crane operations beyond the limit are stopped.
1 RLY 1 Failure in the AML unit.
All the crane operations except the boom swing are stopped.
Relay output Other control functions
When the moment is abnormal
When the actual load value calculated in the AML becomes
negative, the crane operation toward the critical side (main
winch hoist-up, auxiliary winch hoist-up, boom extension,
(*1)
boom lowering or jib tilt lowering ) is stopped. However, the
operation does not stop while the boom is being stowed to the
traveling configuration.
When all the following conditions are satisfied, the AML
assumes that the boom is in process of the stowage to the
traveling configuration.
(*2)
(1) Boom angle is 2°or less.
OFF
(2) Boom length is 5.4 m or less.
(3) The swing position is within 10° in over-front area.
(*1): For machines with power-tilt jib only

(*2): For machines up to FD0126, the boom angle is –1.7° or
less
18 W301-0213E
CN 2 connector
Pin No. Name
Relay output Other control functions
When the HOOK-IN operation is performed:
When the following conditions are satisfied, this relay output
turns OFF and the HOOK-IN control relay output RLY8 turns
ON.
(1) PTO switch is ON (I).
(2) Boom lift or single top lift status is registered in the AML.
(*1)
(3) Boom is fully retracted.
(4) Boom angle is 2°or less.
(5) Overwind cutout disable switch is pressed.
(*1): When the 2nd/3rd boom section full retraction detector

switch contact is closed, the AML assumes that the
boom is fully retracted.
When the boom reaches its elevation stroke end:
When the boom is out of the boom angle range (–1.7° to
81.9°) where the pressure of the elevation cylinder on the
extension and retraction side can be detected normally, the
boom elevation stops. However, the operation does not stop
while the boom is being stowed to the traveling configuration.
When all the following conditions are satisfied, the AML
assumes that the boom is in process of the stowage to the
1 RLY 1 traveling configuration.
OFF
(1) Boom angle is –1.7°or less.
(2) Boom length is 5.4 m or less.
(3) The swing position is within 10° in over-front area.
If the pressure on the extension and retraction sides of the
elevation cylinder cannot be normally detected and the
moment ratio becomes 100% or more while the boom angle is
between 81.9° and 83°, the automatic stop halting (boom
lowering operation) due to overloading is cancelled.
Jib fall prevention while the jib is being mounted or stowed
When all the following conditions are satisfied, the boom
extension stops.
Jib (jib lock pin) is stowed; jib set pin is out of inserted
condition; the boom angle is 75° or less.
Upper boom angle restriction while the jib is being mounted or
stowed
The boom angle becomes 78° while the jib is mounted or
stowed, the boom raising operation stops.
(*1)
When the jib tension rod buckling prevention activates
While the jib set pin is inserted into the boom bottom surface,
i.e. the jib is stowed, the jib tilt cylinder is not retracted even if
jib tilt lowering is attempted.
19 W301-0213E
CN 2 connector
Pin No. Name
Signal name: Accumulator low pressure alarm relay output
This relay contact turns ON and outputs alarm buzzer when the accumulator
2
3 RLY 3 pressure is approx. 8.8 MPa (90 kgf/cm ) or less.
Relay ON (DC24V): Alarm buzzer is output.
Relay OFF (DC0V): Alarm buzzer is not output.
This relay contact turns ON and outputs alarm buzzer when the crane is
overloaded.
Relay output Moment condition
OFF Moment ratio < 90%
relay output turns ON/OFF when the moment ratio reaches
4 RLY 4
ON/OFF the range below.
When the jib set pin is out of inserted condition, the AML
Moment ratio 100%
relay output turns ON when the moment ratio reaches the
ON range below.
Moment ratio 90%
When the jib set pin is out of inserted condition, the AML
When the boom length is extended or retracted beyond the specified length
(12.5 m), this relay contact turns ON/OFF and the 4th/5th/top boom sections or
5 RLY 5 2nd/3rd boom sections extend or retract.
Relay ON (DC24V): 4th, 5th and top boom sections extend or retract.
Relay OFF (DC0V): 2nd and 3rd boom sections extend or retract.
Signal name: Overwinding alarm relay output
This relay contact turns ON and the alarm buzzer is output when the hook block
is overwinding.
7 RLY 7
20 W301-0213E
CN 2 connector
Pin No. Name
Signal name: HOOK-IN control relay output
When the HOOK-IN operation is performed, this relay contact turns ON,
automatic stop 1 (AML vent) relay output RLY1 turns OFF, and the pressure in
the winch hydraulic circuit drops.
Relay ON (DC24V): The pressure in the winch hydraulic circuit drops.
Relay OFF (DC0V): The pressure in the winch hydraulic circuit is normal.
When all the following conditions are satisfied, the AML assumes that the
HOOK-IN operation is performed.
8 RLY 8 (1) PTO switch is ON (I).
(2) Boom lift or single top lift status is registered in the AML.
(*1)
(3) Boom is fully retracted.
(4) Boom angle is 2° or less.
(5) Overwind cutout disable switch is pressed.
(*1): When the 2nd/3rd boom section full retraction detection switch contact is
closed, the AML assumes that the boom is fully retracted.
Signal name: Main winch hoist-up operation detector switch input
Input from the switch detecting hoist-up operation of the main winch.
9 Di11
Switch ON (DC0V): No hoist-up operation of the main winch is detected.
Switch OFF (DC5V): Hoist-up operation of the main winch is detected.
Signal name: Main winch hoist-down operation detector switch input
Input from the switch detecting hoist-down operation of the main winch.
10 Di12
Switch ON (DC0V): No hoist-down operation of the main winch is detected.
Switch OFF (DC5V): Hoist-down operation of the main winch is detected.
Signal name: Aux. winch hoist-up operation detector switch input
Input from the switch detecting hoist-up operation of the auxiliary winch.
11 Di13
Switch ON (DC0V): No hoist-up operation of the auxiliary winch is detected.
Switch OFF (DC5V): Hoist-up operation of the auxiliary winch is detected.
Signal name: Aux. winch hoist-down operation detector switch input
Input from the switch detecting hoist-down operation of the auxiliary winch.
Switch ON (DC0V): No hoist-down operation of the auxiliary winch is detected.
Switch OFF (DC5V): Hoist-down operation of the auxiliary winch is detected.
12 Di14
21 W301-0213E
CN 2 connector
Pin No. Name
Signal name: Right swing proportional control valve output
Current controlled by the AML is output from the AML to the right swing
proportional control valve when the right swing is stopped by automatic swing
stop. However, in the following conditions, the automatic swing stop does not
activate.
(1) Swing stop/override switch is set to “OVERRIDE”.
(2) Outriggers are not extended.
(3) AML emergency switch is set to “Emergency” and the PTO switch is set to
“OVERRIDE”.
13 CNTL 1P Output voltage: Square wave 0 to 24V
Crane condition that causes the automatic swing stop
The moment ratio exceeds 100% due to right swing while the extension widths
of four outriggers are different.
The moment ratio reaches 90% or more (not 100%) while the boom lift with the
jib mounted is performed.
When the jib set pin is out of inserted condition, the AML assumes that the jib is
mounted.
The crane operation exceeds the right swing limit when the swing stop limit is
registered.
Signal name: Ground terminal for right swing proportional control valve
14 CNTL 1N
Input voltage: DC0V
Signal name: Left swing proportional control valve output
Current controlled by the AML is output from the AML to the left swing
proportional control valve when the left swing is stopped by automatic swing
stop. However, in the following conditions, the automatic swing stop is not
activated.
“OVERRIDE”.
15 CNTL 2P Output voltage: Square wave 0 to 24V
The moment ratio exceeds 100% due to left swing while the extension widths of
four outriggers are different.
The moment ratio reaches 90% or more (not 100%) while the boom lift with the
jib mounted is performed.
mounted.
The crane operation exceeds the left swing limit when the swing stop limit is
registered.
Signal name: Ground terminal for left swing proportional control valve
Input voltage: DC0V
16 CNTL 2N
22 W301-0213E
CN 2 connector
Pin No. Name
(*1)
Signal name: Boom extending/jib tilt lowering operation detector switch input
Input from the switch detecting boom extending/jib tilt lowering operation.
17 Di15 Switch ON (DC0V): No boom extending/jib tilt lowering operation is detected.
Switch OFF (DC5V): Boom extending/jib tilt lowering operation is detected.
(*1)
Signal name: Boom retracting/jib tilt raising operation detector switch input
Input from the switch detecting boom retracting/jib tilt raising operation.
18 Di16 Switch ON (DC0V): No boom retracting /jib tilt raising operation is detected.
Switch OFF (DC5V): Boom retracting /jib tilt raising operation is detected.
Signal name: Boom raising operation detector switch input
Input from the switch detecting boom raising operation.
19 Di17
Switch ON (DC0V): No boom raising operation is detected.
Signal name: Boom lowering operation detector switch input
Input from the switch detecting boom lowering operation.
20 Di18
Switch ON (DC0V): No boom lowering operation is detected.
Signal name: Right swing operation detector switch input
Input from the switch detecting right swing operation.
21 Di19
Switch ON (DC0V): No right swing operation is detected.
Switch OFF (DC5V): Right swing operation is detected.
Signal name: Left swing operation detector switch input
Input from the switch detecting left swing operation.
22 Di20
Switch ON (DC0V): No left swing operation is detected.
Switch OFF (DC5V): Left swing operation is detected.
Signal name: Boom raising proportional control valve output
Current controlled by the AML is output from the AML to the boom raising
proportional control valve when the boom raising is stopped by elevation slow
stop. However, when the elevation slow stop/override switch is set to
23 CNTL 3P “OVERRIDE”, the elevation slow stop is not activated.
For the crane conditions that cause the elevation slow stop, refer to the
automatic stop 1 (AML vent) relay output RLY1.
Signal name: Ground terminal for boom raising proportional control valve
24 CNTL 3N
Input voltage: DC0V
Signal name: Boom lowering proportional control valve output
Current controlled by the AML is output from the AML to the boom lowering
proportional control valve when the boom lowering is stopped by elevation slow
stop. However, when the elevation slow stop/override switch is set to
25 CNTL 4P “OVERRIDE”, the elevation slow stop is not activated.
For the crane conditions that cause the elevation slow stop, refer to the
automatic stop 1 (AML vent) relay output RLY1.
23 W301-0213E
CN 2 connector
Pin No. Name
Signal name: Ground terminal for boom lowering proportional control valve
26 CNTL 4N
Input voltage: DC0V
Signal name: Transmitting (+) output signal for
30 SIF2TXD+
serial port 2 Transmitting data to MDT
(*1)
Signal name: Transmitting (-) output signal for
31 SIF2TXD-
serial port 2
(*1): Transmitting signal name
Do1 AML override (AML warning indicator lamp)
Do2 Jib lock indicator 1 (Jib lock lamp)
Do3 HOOK-IN (HOOK IN indicator lamp)
Do4 Fixed jib (boom extension indicator lamp/jib tilt indicator lamp)
Do6 Outrigger stowing control detection return transmitting
Do7 Jib lock indicator 2 (Jib lock lamp)
Signal name: Receiving (+) input signal for serial
32 SIF2RXD+
port 2 Receiving data from MDT
(*2)
Signal name: Receiving (-) input signal for serial
33 SIF2RXD-
port 2
(*2): Received signal name
(*3)
ANIN2 O/R(FL)
(*3)
ANIN3 O/R(FR)
(*3)
ANIN4 O/R(RL)
(*3)
ANIN5 O/R(RR)
Di1 Outrigger retracting control detection (Monitoring signal for relay output RY6 of the MDT lower unit)
(*3): Data for reference
X-type outriggers
Input voltage at the minimum outrigger extension width:
Input voltage at the maximum outrigger extension width:
H-type outriggers
Input voltage at the minimum outrigger extension width:
Input voltage at the maximum outrigger extension width:
Signal name: Shield for serial port 2
34 SIF2SLD
Input voltage: DC0V
24 W301-0213E

CN 3 connector
Pin No. Name
Signal name: AML 90% or less (safety) output
OC (Open collector) output turns ON when the moment ratio is less than 90%.
OC output “ON” (DC0V): External indicator lamp indicating 90% is lit.
OC output “OFF” (DC24V): External indicator lamp indicating 90% goes out.
1 TR1
While the boom lift with the jib mounted is performed, OC output turns ON when
the moment ratio is 80% or less.
mounted.
Signal name: AML 90% alarm output
OC (Open collector) output turns ON when the moment ratio is between 90%
and 100%.
2 TR2
While the boom lift with the jib mounted is performed, OC output turns ON when
the moment ratio reaches the range below:
mounted.
OC (Open collector) output turns ON when the moment ratio exceeds 100% or
automatic stop function is cancelled.
Condition to turn ON OC output
Moment ratio 100%
3 TR3 While the boom lift with the jib mounted is performed, OC output turns ON when
the moment ratio reaches the range below:
Moment ratio 90%
mounted.
Overwind cutout disable switch: Pressed
Swing stop/override switch: “OVERRIDE”
AML emergency switch: “Emergency” + PTO switch: “OVERRIDE”
Signal name: Auxiliary winch high-speed hoist-down operation output
OC (Open collector) output turns ON when the auxiliary winch hoist-down
operation is detected with the actual load less than the specified value (200kg).
4 TR4 High-speed hoist-down operation is performed when the auxiliary winch
high-speed down hoisting switch is set to ON.
OC output ON (DC0V): High-speed hoist-down operation is performed.
OC output OFF (DC24V): Normal hoist-down operation is performed.
25 W301-0213E
CN 3 connector
Pin No. Name
Signal name: Main winch high-speed hoist-down operation output
OC (Open collector) output turns ON when the main winch hoist-down operation
is detected with the actual load less than the specified value (300kg).
5 TR5 High-speed hoist-down operation is performed when the main winch high-speed
down hoisting switch is set to ON.
OC output ON (DC0V): High-speed hoist-down operation is performed.
OC output OFF (DC24V): Normal hoist-down operation is performed.
Signal name: Boom telescoping/jib operation selector switch input
Switch input representing whether the jib operation is detected.
21 Di21
Switch ON (DC0V): Jib operation is selected.
Switch OFF (DC5V): Boom telescoping condition is selected.
26 W301-0213E
Diagram of the AML System (GR-700EXL-1) Applicable serial No. △
3 ：545593 - -
Diagram of the AML System (GR-700EXL-1)
Boom angle detector

A SOL 5, 6 (2A)
C SOL 1, 2 (2A)
B CN1 SOL 3, 4 (2A) Latch
E 2 DET1SRC Fuses
3 ANAINA
SOL 1, 2 (2A)
Di SW.
5 ANAINC
6 DET1SLD
Swing angle detector SOL 3, 4 (2A)
7 DET2GND Current
8 DET2SRC
Amplifier Circuit
9 ANAIND Fuses SOL 5, 6 (2A)
10 ANAINE
11
12
ANAINF
DET2SLD
SIF 1 (2A)
CPU BOARD
13 Di1
Pressure sensor (Main) 14 Di2
15 Di3 SIF 2 (2A)
16 Di4
17 MB
18 MB MAIN (3A)
Swing free input ROM EEPROM Buzzer
19
20
RB
RB DISPLAY BOARD
21 TC
Auto. stop
Working condition input override signal input
22
23
ACC
NC
POWER BOARD CPU
Auto. stop
24 Di5 CHR display
25 Di6
CAL/CLOCK
27 Di8
RAM SCI
28 Di9 Fuses +20V
29 Di10
30 GND RLY 1, 2 (3A) +12V
Key input
3 31 GND DC power
24(V)
32 DET3GND
RLY 3, 4 (3A) block -12V
33 DET3SRC
34 ANAING
Relay +5V
35 ANAINH RLY 5, 6 (3A) LCD panel (1)
36 DET3SLD
37 NC RLY 7, 8 (3A)
(Elevating) 39 SIF1GND
40 SIF1SRC
41 SIF1TXD+
LCD panel (2)
42 SIF1TXD-
43 SIF1RXD+
44 SIF1RXD-
45 SIF1SLD
LCD SW .
Alarm signal output Auto.stop signal output Latch backlights
CN2
SOL. 1 RLY1
BUZZER 2 RLY2
3 RLY3
Top cyl. select output 4 RLY4
SOL. 5 RLY5
O.C.Tr.
6 RLY6
Lever manipulation detection input output Latch
7
8
RLY7
9 Di11
10 Di12
12 Di14
13 CNTL1P
14 CNTL1N
15 CNTL2P
16 CNTL2N
Di SW. Latch
17 Di15
input block
18 Di16
19 Di17
20 Di18
Outrigger extension width detector 21 Di19
22 Di20
(4 peace) Slow stop(Elevating) 23 CNTL3P
24 CNTL3N
25 CNTL4P
MDT (multiplex data 26 CNTL4N
Buffer
transmitter) lower unit 27 CNTLSLD
28 SIF2GND
29 SIF2SRC
30 SIF2TXD+
34 SIF2SLD
Outrigger retraction operation
detection input CN3
1 TR1
MDT (multiplex data transmitter) 90 - 100% 2 TR2
Pressure sensor
upper unit 100% - 3 TR3 analog detector
4 TR4 power supply
output (option) 6 TR6
Jib set output 7 TR7
8 TR8
9 NC
Indicator lamp 10 Di25
11 Di26
12 Di27
13 Di28
14 NC
15 NC
16 (CNTL5P)
17 (CNTL5N)
18 (CNTL6P)
Slow stop (Swing free) 19 (CNTL6N)
20 CNTLSLD
21 Di21
22 Di22
23 Di23
Counterweight equipped 24 Di24
Working condition input detection input
IW301-0213E02
Over - unwind detection input
27 W301-0213E
Input/Output Signals of the AML System (GR-700EXL-1)

CN 1 connector
Pin No. Name
5 ANAIN C
angle.
9 ANAIN D
angle.
Signal name: Overwinding detection switch (L4) input
13 Di1
Signal name: 2nd boom section full retraction detection switch (L8) input
Switch input representing whether the 2nd boom section is fully retracted.
14 Di2
Switch ON (DC0V): 2nd boom section is fully retracted.
Switch OFF (DC24V): 2nd boom section is not fully retracted.
Signal name: 3rd/top boom sections full retraction detection switch (L7) input
Switch input representing whether the 3rd/top boom sections are fully retracted.
15 Di3
Switch ON (DC0V): 3rd/top boom sections are fully retracted.
Switch OFF (DC24V): 3rd/top boom sections are not fully retracted.
Signal name: Swing free/lock selector switch (S15) input
Switch input representing whether the swing is free/lock state.
16 Di4
Switch ON (DC0V): Swing lock device is free.
Switch OFF (DC24V): Swing lock device is lock.
28 W301-0213E
CN 1 connector
Pin No. Name
Signal name: Swing stop cancel switch (S14) input
Switch input representing whether the swing stop is cancelled.
22 ACC Input voltage: DC24V
Switch ON (DC24V): Swing stop is cancelled.
Switch OFF (DC0V): Swing stop is functioning.
Signal name: Overwind cutput disable switch (S3) input
overridden.
24 Di5
Signal name: Override key switch (SK1) input
25 Di6 overridden.
Signal name: Elevation slow stop cancel switch (S22) input
Switch input representing whether elevation slow stop is cancelled.
26 Di7
Switch ON (DC0V): Slow stop function is cancelled.
Switch OFF (DC24V): Slow stop function is ready.
Signal name: Jib stowed detection switch (CS10) input
27 Di8
Switch ON (DC0V): The jib is stowed.
Switch OFF (DC24V): The jib is not stowed.
Signal name: Over-front detection switch (CS12) input
28 Di9
Signal name: Swing angle detector 1,2 selection (swing dead angle detection)
switch (CS11) input
3
Di10 Switch input representing whether the boom is in the swing dead angle.
29
Switch ON (DC0V): The boom is in the over-left.
Switch OFF (DC5V): The boom is in the over-right.
3 : Pin No. 29 is not applied (serial No. 545593-)
29 W301-0213E

CN 2 connector
Pin No. name
ON Moment ratio < 90%
ON 90% Moment ratio < 100%
Moment ratio 100%
While boom lift with the jib mounted is performed, the crane
1 RLY 1 operation stops autmatically when the load moment ratio
reaches the ranges listed below, depending on the outrigger
OFF extension width.
Maximum (7.2m) Moment ratio 93%
Middle (6.7m) Moment ratio 92%
OFF Overwinding.
The crane movement going beyond the restriction while working
OFF
range limit is registered.
OFF Failure in the AML unit.
OFF Operated to critical side when backward stability control activated.
This relay contact turns ON and outputs alarm buzzer when the crane is overloaded.
While boom lift with the jib mounted is performed, the alarm
buzzer is output when the load moment ratio reaches the
ON/OFF ranges listed below, depending on the outrigger extension width.
4 RLY 4
Maximum (7.2m) 84% Moment ratio < 94%
Middle (6.7m) 84% Moment ratio < 94%
Moment ratio 100%
ON ranges listed below, depending on the outrigger extension width.
30 W301-0213E
CN 2 connector
Pin No. name
< Extension >
The relay turns ON (DC24V) and 3rd-top boom sections extend under either of
following condition.
1. The boom length is 20.03m or more.
2. The boom length is 19.23 - 20.03m and 3rd-top boom extension switch is "ON"
(Di28 / 0V).
5 RLY 5 3. The boom length is 19.23 - 20.03m and 3rd-top boom full retraction detector
switch is "OFF" (Di3 / 24V).
< Retraction >
The relay turns OFF (DC0V) and 2nd boom section retracts under either of following
condition.
1. The boom length is 19.23m or less.
2. The boom length is 19.23 - 20.03m and 3rd-top boom full retraction detector
switch is "ON" (Di3 / DC0V).
This relay contact turns ON and the alarm buzzer is output when the hook block is
7 RLY 7 overwinding.
9 Di11 Switch ON (DC0V): No hoist-up operation of the main winch is detected.
10 Di12 Switch ON (DC0V): No hoist-down operation of the main winch is detected.
11 Di13 Switch ON (DC0V): No hoist-up operation of the auxiliary winch is detected.
12 Di14 Switch ON (DC0V): No hoist-down operation of the auxiliary winch is detected.
Current controlled by the AML is output from the AML to the right swing proportional
control valve when the right swing is stopped by automatic swing stop. However, in
the following conditions, the automatic swing stop does not activate.
“OVERRIDE”.
13 CNTL 1P Crane condition that causes the automatic swing stop
The moment ratio exceeds 100% due to right swing while the extension widths of
The moment ratio reaches 90% or more (not 100%) while the boom lift with the jib
mounted is performed.
mounted.
registered.
31 W301-0213E
CN 2 connector
Pin No. name
14 CNTL 1N
Input voltage: DC0V
Current controlled by the AML is output from the AML to the left swing proportional
control valve when the left swing is stopped by automatic swing stop. However, in
the following conditions, the automatic swing stop is not activated.
“OVERRIDE”.
15 CNTL 2P
The moment ratio exceeds 100% due to left swing while the extension widths of four
outriggers are different.
mounted.
registered.
16 CNTL 2N
Input voltage: DC0V
Signal name: Boom extending operation detector switch (PS3) input
Input from the switch detecting boom extending operation.
17 Di15
Switch ON (DC0V): No boom extending operation is detected.
Switch OFF (DC5V): Boom extending operation is detected.
Signal name: Winch selector switch (S32) input
Switch input representing whether Auxiliary wiche is employed.
18 Di16 Input from the switch detecting boom retracting operation.
Switch ON (DC0V): Auxiliary winch is employed.
Switch OFF (DC5V): Main winch is employed.
Signal name: Boom raising operation detector switch (PS5) input
19 Di17
Signal name: Boom lowering operation detector switch (PS6) input
20 Di18
Signal name: Right swing operation detector switch (PS9) input
21 Di19
32 W301-0213E
CN 2 connector
Pin No. name
Signal name: Left swing operation detector switch (PS10) input
22 Di20
23 CNTL 3P
proportional control valve when the boom raising is stopped by elevation slow stop.
24 CNTL 3N
Input voltage: DC0V
25 CNTL 4P proportional control valve when the boom lowering is stopped by elevation slow
stop.
26 CNTL 4N
Input voltage: DC0V
33 W301-0213E

CN 3 connector
Pin No. Name
OC (Open collector) output turns ON when the Load moment ratio is between 90%
and 100%.
2 TR2 While boom lift with the jib mounted is performed, OC output turns ON when the
load moment ratio reaches the ranges listed below, depending on the outrigger
extension width.
OC (Open collector) output turns ON when the load moment ratio exceeds 100% or
Moment ratio 100%
Overwind cutout disable switch: pressed.
3 TR3
Swing stop cancel switch: “OFF”.
Override key switch ON position and PTO switch in OVERRIDE position.
While boom lift with the jib mounted is performed, OC output turns ON when the
extension width.
Signal name: Jib set output
OC (Open collector) output turns ON when setting to the jib set with the boom state
5 TR5 selection key of AML.
OC output “ON” (DC0V): The jib set pin can be pulled out.
OC output “OFF” (DC24V): The jib set pin cannot be pulled out.
Signal name: Auxiliary winch employed output
OC (Open collector) output turns ON when the the auxiliary winch employed is
selected
6 TR6 The winch selection indicator lamp is lit when the winch selection switch is set to the
auxiliary winch side.
OC output “ON” (DC0V): The winch selection indicator lamp is lit.
OC output “OFF” (DC24V): Normally, the winch selection indicator lamp goes out.
34 W301-0213E
CN 3 connector
Pin No. Name
Signal name: Outrigger state emergency register switch (SK2) input
Switch input representing whether emergency registration of outrigger extension
width to the AML during malfunction of the outrigger extension detector system is
10 Di25 available.
Switch ON (DC0V): Emergency registration of outrigger extension width is available.
Switch OFF (DC5V): No emergency registration is available.
Signal name: Rope run-out release switch (S20) input.
Switch input to release the rope run-out.
11 Di26
Switch ON (DC0V): The rope run-out release switch is pressed.
Switch OFF (DC5V): The rope run-out release switch is not pressed.
Signal name: Boom secondary extending switch (S7) input
Switch input to extend the 3rd/top boom sections.
13 Di28
Switch ON (DC0V): The boom secondary extending switch is pressed.
Switch OFF (DC5V): The boom secondary extending switch is not pressed.
Signal name: Swing relief proportional control valve output
16 CNTL 5P Current controlled by the AML is output from the AML to the swing relief proportional
control valve when boom swing is stopped by swing slow stop while swing free
condition is selected.
Signal name: Ground terminal for swing relief proportional control valve output
17 CNTL 5N
Input voltage: DC0V
Signal name: Jib state switch (SK4) input
Switch input to select the state of jib-mounted or jib-unmounted.
21 Di21
Switch ON (DC0V): Jib-unmounted is selected.
Switch OFF (DC5V): Jib-mounted is selected.
Signal name: C/W mount detection switch (CS18) input (Only for TR-800XXL-4)
Switch input representing whether the C/W is mounted.
22 Di22
Switch ON (DC0V): C/W is mounted.
Switch OFF (DC5V): C/W is not mounted.
Signal name: Main rope run-out detection switch (LS17) input
Switch input representing whether main rope is over-unwind.
23 Di23
Switch ON (DC0V): Main rope is not over-unwind.
Switch OFF (DC5V): Main rope is over-unwind.
Signal name: Aux. rope run-out detection switch (LS18) input
Switch input representing whether Aux. rope is over-unwind.
24 Di24
Switch ON (DC0V): Aux. rope is not over-unwind.
Switch OFF (DC5V): Aux. rope is over-unwind.
35 W301-0213E
Diagram of the AML System (GR-300EX-1)
Diagram of the AML System (GR-300EX-1)
Boom angle detector

A SOL 5, 6 (2A)
C SOL 1, 2 (2A)
B CN1 SOL 3, 4 (2A)
Latch
E 2 DET1SRC Fuses
3 ANAINA
SOL 1, 2 (2A)
Di SW.
5 ANAINC
6 DET1SLD
Swing angle detector SOL 3, 4 (2A)
7 DET2GND Current
8 DET2SRC
Amplifier Circuit
9 ANAIND Fuses SOL 5, 6 (2A)
10 ANAINE
11
12
ANAINF
DET2SLD
SIF 1 (2A)
CPU BOARD
13 Di1
Pressure sensor (Main) 14 Di2
15 Di3 SIF 2 (2A)
16 Di4
17 MB
18 MB MAIN (3A)
Swing free input ROM EEPROM Buzzer
19
20
RB
RB DISPLAY BOARD
21 TC

22
23
ACC
NC
POWER BOARD CPU
Auto. stop
24 Di5 CHR display
25 Di6
CAL/CLOCK
27 Di8
RAM SCI
28 Di9 Fuses +20V
29 Di10
30 GND RLY 1, 2 (3A) +12V Key input
24(V) 31 GND DC power
32 DET3GND
RLY 3, 4 (3A) block -12V
33 DET3SRC
34 ANAING +5V
35 ANAINH
Relay RLY 5, 6 (3A) LCD panel (1)
36 DET3SLD
37 NC RLY 7, 8 (3A)
(Elevating) 39 SIF1GND
40 SIF1SRC
41 SIF1TXD+
LCD panel (2)
42 SIF1TXD-
43 SIF1RXD+
44 SIF1RXD-
45 SIF1SLD
LCD SW .
Alarm signal output Auto.stop signal output Latch backlights
CN2
SOL. 1 RLY1
BUZZER 2 RLY2
3 RLY3
Top cyl. select output 4 RLY4
SOL. 5 RLY5
O.C.Tr.
6 RLY6
Lever manipulation detection input output Latch
7
8
RLY7
9 Di11
10 Di12
12 Di14
13 CNTL1P
14 CNTL1N
15 CNTL2P
16 CNTL2N
Di SW. Latch
17 Di15
input block
18 Di16
19 Di17
20 Di18
Outrigger extension width detector 21
22
Di19
Di20
(4 peace) Slow stop(Elevating) 23 CNTL3P
24 CNTL3N
25 CNTL4P
MDT (multiplex data 26 CNTL4N
Buffer
transmitter) lower unit 27 CNTLSLD
28 SIF2GND
29 SIF2SRC
30 SIF2TXD+
34 SIF2SLD
Outrigger retraction operation
detection input CN3
1 TR1
MDT (multiplex data transmitter) 90 - 100% 2 TR2 Pressure sensor
upper unit 100% - 3 TR3 analog detector
4 TR4 power supply
output (option) 6 TR6
7 TR7
8 TR8
9 NC
Indicator lamp 10 Di25
11 Di26
12 Di27
13 Di28
14 NC
15 NC
16 (CNTL5P)
17 (CNTL5N)
18 (CNTL6P)
Slow stop (Swing free) 19 (CNTL6N)
20 CNTLSLD
21 Di21
22 Di22
23 Di23
24 Di24
IW301-0213E03
Over - unwind detection input
36 W301-0213E
Input/Output Signals of the AML System (GR-300EX-1)

CN 1 connector
Pin No. Name
5 ANAIN C
angle.
9 ANAIN D
angle.
Signal name: Overwinding detection switch input
13 Di1
Signal name: 3rd/top boom sections full retraction detection switch input
Switch input representing whether the 3rd/top boom sections are fully retracted.
15 Di3
Switch ON (DC0V): 3rd/top boom sections are fully retracted.
Switch OFF (DC24V): 3rd/top boom sections are not fully retracted.
Signal name: Swing free/lock selector switch input
Switch input representing whether the swing is free/lock state.
16 Di4
Switch ON (DC0V): Swing lock device is free.
Switch OFF (DC24V): Swing lock device is lock.
Signal name: Overwind cutput disable switch input
overridden.
24 Di5
37 W301-0213E
CN 1 connector
Pin No. Name
Signal name: Override key switch input
25 Di6 overridden.
Signal name: Jib stowed detection switch input
27 Di8
Switch ON (DC0V): The jib is stowed.
Switch OFF (DC24V): The jib is not stowed.
Signal name: Over-front detection switch input
28 Di9
38 W301-0213E

CN 2 connector
Pin No. name
ON Moment ratio < 90%
ON 90% Moment ratio < 100%
Moment ratio 100%
While boom lift with the jib mounted is performed, the crane
1 RLY 1 operation stops autmatically when the load moment ratio
reaches the ranges listed below, depending on the outrigger
OFF extension width.
OFF Overwinding.
The crane movement going beyond the restriction while working
OFF
range limit is registered.
OFF Failure in the AML unit.
OFF Operated to critical side when backward stability control activated.
This relay contact turns ON and outputs alarm buzzer when the crane is overloaded.
ON/OFF ranges listed below, depending on the outrigger extension width.
4 RLY 4
Moment ratio 100%
ON ranges listed below, depending on the outrigger extension width.
39 W301-0213E
CN 2 connector
Pin No. name
< Extension >
The relay turns ON (DC24V) and 3rd-top boom sections extend under either of
following condition.
1. The boom length is 17.2m or more.
2. The boom length is 16.4 - 17.2m and 3rd-top boom extension switch is "ON"
(Di28 / 0V).
5 RLY 5 3. The boom length is 16.4 - 17.2m and 3rd-top boom full retraction detector
switch is "OFF" (Di3 / 24V).
< Retraction >
The relay turns OFF (DC0V) and 2nd boom section retracts under either of following
condition.
1. The boom length is 16.4m or less.
2. The boom length is 16.4 - 17.2m and 3rd-top boom full retraction detector
switch is "ON" (Di3 / DC0V).
This relay contact turns ON and the alarm buzzer is output when the hook block is
7 RLY 7 overwinding.
9 Di11 Switch ON (DC0V): No hoist-up operation of the main winch is detected.
10 Di12 Switch ON (DC0V): No hoist-down operation of the main winch is detected.
11 Di13 Switch ON (DC0V): No hoist-up operation of the auxiliary winch is detected.
12 Di14 Switch ON (DC0V): No hoist-down operation of the auxiliary winch is detected.
Current controlled by the AML is output from the AML to the right swing proportional
control valve when the right swing is stopped by automatic swing stop. However, in
the following conditions, the automatic swing stop does not activate.
“OVERRIDE”.
13 CNTL 1P Crane condition that causes the automatic swing stop
The moment ratio exceeds 100% due to right swing while the extension widths of
mounted.
registered.
40 W301-0213E
CN 2 connector
Pin No. name
14 CNTL 1N
Input voltage: DC0V
Current controlled by the AML is output from the AML to the left swing proportional
control valve when the left swing is stopped by automatic swing stop. However, in
the following conditions, the automatic swing stop is not activated.
“OVERRIDE”.
15 CNTL 2P
The moment ratio exceeds 100% due to left swing while the extension widths of four
outriggers are different.
mounted.
registered.
16 CNTL 2N
Input voltage: DC0V
Signal name: Boom extending operation detector switch (PS3) input
Input from the switch detecting boom extending operation.
17 Di15
Switch ON (DC0V): No boom extending operation is detected.
Switch OFF (DC5V): Boom extending operation is detected.
Signal name: Boom raising operation detector switch (PS5) input
19 Di17
Signal name: Boom lowering operation detector switch (PS6) input
20 Di18
Signal name: Right swing operation detector switch (PS9) input
21 Di19
Signal name: Left swing operation detector switch (PS10) input
22 Di20
41 W301-0213E
CN 2 connector
Pin No. name
23 CNTL 3P
proportional control valve when the boom raising is stopped by elevation slow stop.
24 CNTL 3N
Input voltage: DC0V
25 CNTL 4P proportional control valve when the boom lowering is stopped by elevation slow
stop.
26 CNTL 4N
Input voltage: DC0V

CN 3 connector
Pin No. Name
OC (Open collector) output turns ON when the Load moment ratio is between 90%
and 100%.
2 TR2 While boom lift with the jib mounted is performed, OC output turns ON when the
extension width.
OC (Open collector) output turns ON when the load moment ratio exceeds 100% or
Moment ratio 100%
Overwind cutout disable switch: pressed.
3 TR3
Swing stop cancel switch: “OFF”.
Override key switch ON position and PTO switch in OVERRIDE position.
While boom lift with the jib mounted is performed, OC output turns ON when the
extension width.
42 W301-0213E
CN 3 connector
Pin No. Name
Signal name: Outrigger state emergency register switch (SK2) input
Switch input representing whether emergency registration of outrigger extension
width to the AML during malfunction of the outrigger extension detector system is
10 Di25 available.
Switch ON (DC0V): Emergency registration of outrigger extension width is available.
Switch OFF (DC5V): No emergency registration is available.
Signal name: Rope run-out release switch (S20) input.
Switch input to release the rope run-out.
11 Di26
Switch ON (DC0V): The rope run-out release switch is pressed.
Switch OFF (DC5V): The rope run-out release switch is not pressed.
Signal name: Boom secondary extending switch (S7) input
Switch input to extend the 3rd/top boom sections.
13 Di28
Switch ON (DC0V): The boom secondary extending switch is pressed.
Switch OFF (DC5V): The boom secondary extending switch is not pressed.
Signal name: Swing relief proportional control valve output
16 CNTL 5P Current controlled by the AML is output from the AML to the swing relief proportional
control valve when boom swing is stopped by swing slow stop while swing free
condition is selected.
Signal name: Ground terminal for swing relief proportional control valve output
17 CNTL 5N
Input voltage: DC0V
Signal name: Jib state switch (SK4) input
Switch input to select the state of jib-mounted or jib-unmounted.
21 Di21
Switch ON (DC0V): Jib-unmounted is selected.
Switch OFF (DC5V): Jib-mounted is selected.
Signal name: Main rope run-out detection switch (LS17) input
Switch input representing whether main rope is over-unwind.
23 Di23
Switch ON (DC0V): Main rope is not over-unwind.
Switch OFF (DC5V): Main rope is over-unwind.
Signal name: Aux. rope run-out detection switch (LS18) input
Switch input representing whether Aux. rope is over-unwind.
24 Di24
Switch ON (DC0V): Aux. rope is not over-unwind.
Switch OFF (DC5V): Aux. rope is over-unwind.
43 W301-0213E
Functions of and How to Use User Mode (GT-550E-1)
[OPERATION]
2. Maintenance Mode:
Used to make functional checks of AML. See the
Functions of and How to Use User Mode “ADJUSTMENT AND MAINTENANCE” section.
(GT-550E-1) 3. Adjustment Mode:
Used to make detector adjustment. See the
Mode Structure
“ADJUSTMENT AND MAINTENANCE” section.
The AML device has three modes and AML
functions are allotted for these models.
POWER ON
Protect USER MODE MAINTENANCE MODE

switch
ON
Protect
switch
OFF ADJUSTMENT MODE
POWER ON
IW301-0212E05
1. User Mode:
Used to indicate moment ratio or to perform AML
pre-opetational inspection (Normally used).
In normal use, turn ON the protect switch

mounted on the adjustment window on the top of
AML. AML will go to the user mode when the
power turns on.
The abnormality display LED lights when the AML

is in abnormal conditions (to indicate that the CPU
is faulty).
PROTECT
MOMENT
SHORT
ZERO
HALT
WDT
OFF
ON
Protect switch
Abnormality display LED
Top view IW301-0132E35
44 W301-0213E
Configuration and Functions of the AML System

(4)Slow stop function
The AML (Automatic Moment Limiter) system is a
safety device provided to prevent overloading of In the following cases, the boom elevation spead
the crane which may cause it to overturn or be gradually decreases to stop before theboom
damaged. reaches the stoppage position.
The AML system has various kinds of functions, • When the automatic stop si caused by
including the following four typical functions. overloading (Boom lowering will stop.)
Based on the registered work conditions by
operator selection and the signals from various • When the elevating cylinder reaches its storoke
sensors, the crane operations are controlled. end (Boom raising/lowering will stop.)
(1)Automatic stop function to prevent overloading • When the automatic stop is caused by working
range limit function (Boom raising/lowering will
The AML calculates and compares the working stop.)
and rated moment values and displays their ratio.
When the working moment exceeds the rated • When the automatic stop is caused by boom
moment (100% or more), failure message is upper angle restriction (Boom raising and boom
shown, alarm buzzer sounds, and the crane retraction will stop.)
operation toward the critical side stops.
The situation of automatic stop due to automatic
(2)Automatic stop function by boom upper angle stop function and working range limit function is
restriction as listed below, depending on the working
condition:
To prevent jib from contacting the hook block or : Slow stop : Stop
wire rope during boom lift or single top lift, a
Hoisting up
message and an alarm is output and boom raising
Automatic stop by Boom lowering
and boom retraction are halted in the following overloading Boom extension
conditions:
Swing
The boom is raised over approx. 76° while the Boom upper angle Boom raising
boom extension is less than approx. 2 m. restriction Boom retraction
Stop at stroke end Boom raising/lowering
The boom extension is reduced less than approx.
Boom raising/lowering
2 m while the boom angle is over approx. Stop by working
Boom extension
76°. range restriction
Swing
(3)Working range limit functions
[NOTICE]
When any working range limit is registered to the While the elevation slow stop cancel switch is in
AML, the crane is controlled so that the crane “OFF” position, the slow stop function for boom
elevation is deactivated.
work posture does not exceed this registered
While the swing stop cancel swich is in “OFF”
working range limit. When the crane reaches the
position, swing does not stop automatically.
registered limit, failure message is shown, alarm
buzzer sounds, and the crane operation stops.
45 W301-0213E
AML System Configuration
Boom length signal Boom angle signal Moment ratio signal Swing angle signal Crane control
position signal
L
W
Outrigger extension
width detector
Outrigger status
Operator selection
Lift status
Working range limits

L
Number of pars of
line
AML unit
Alarm buzzer External warning

Display panel lamps
%
t
Stop output when:
m ax t
Moment ratio exceeds Boom upper

100% angle
Overwinding occurs restriction
Moment exceeding limit Swing restricted
for boom with jib
mounted
AML system error occurs
Working range limit
signal output
Boom Boom Hoisting up Swinging Boom raising Upper boom Lifting height Load radius
extension lowering halted halted toward halted angle restricted restricted restricted
halted halted critical side Boom Lower boom
retracting angle restricted
halted
L
R
IW301-0213E04
46 W301-0213E
Automatic Stop Functions Condition Alarm

Causes of Halted Moment ratio exceeds Moment display:
Operation
automatic stop movement 100% Displays [Warning:0023].
Moment ratio Hoisting up External warning lamps:
exceeds 100% Red lamp is lit.
(*1) Boom lowering
Buzzer:
Overwinding Boom extension
Sounds continuously.
AML system error Boom swing AML system error Moment display:
Displays failure
Upper boom
Boom lift Boom raising messages.
angle restricted Buzzer:
Working range limit
Lower boom Single top lift

Boom lowering Sounds 3 seconds.
angle restricted Jib lift
Working range limit Moment display:
Lifting height Boom raising function activated. Displays failure
restricted Boom extension messages.
Load radius Boom lowering Associated restriction
indicator lamp flashes.
restricted Boom extension
Buzzer:
Swing
Swing Sounds continuously.
restricted
AML buzzer:
Boom upper angle Boom lift Boom raising Sounds 3 seconds.
restriction (*2) Single top lift Boom retraction
Operated to critical side Moment display:
when boom angle Displays [Warning:0026]
(*1):For the boom lift with the jib mounted, automatic
exceeds the upper limit Buzzer:
stop will work when the moment exceeds 85%. Sounds 3 seconds.
(*2):To avoid the main hook block contacting the jib, Slow stop control Moment display:
this function prevents the concurrence of the Displays [Warning:0081]
boom angle exceeding 76° and boom retraction or [0082].
Buzzer:
beyond the boom length of 11.3 m. Sounds intermittently.
Boom lift with jib mounted on boom
(1) Moment ratio is Moment display:
Alarm Functions
between 75%and Green segment(s) is lit.
Condition Alarm 85% External warning lamps:
Orange lamp is lit.
Winch lever is moved Moment display:
Buzzer:
toward critical side (hoist Displays [Warning:0024].
Sounds intermittently.
up, boom lowering or Buzzer:
boom extension) while Sounds continuously. (2) Moment ratio Moment display:
overwinding condition exceeds 85% Displays [Warning:0088].
exists. External warning lamps:
Red lamp is lit.
Overwind cutout function Moment display:
Buzzer:
is released with the while Displays [Warning:0015].
Sounds continuously.
overwinding condition External warning lamps:
exists. Red lamp is lit.
Buzzer: [NOTICE]
Sounds continuously. ◆In the above table, "Buzzer" is the device outside
the AML unit, outputting buzzing sound.
"AML buzzer" is the device inside the AML unit,
Moment ratio exceeds Moment display:
outputting beeping sound.
90% Yellow segment(s) is lit.
External warning lamps: ◆The AML buzzer sounds for 3 seconds every time a
Orange lamp is lit. message appears. It outputs long sounds when
Buzzer: slow stop control is activated and outputs short
Sounds intermittently. sounds when other controls are activated.
47 W301-0213E
Names and Functions of AML Main Unit Parts
Bargraph display
Display panel 1
m t
%
max t
Display panel 2
m
Control
IW301-0211E05
48 W301-0213E
Bar graph Display
3 1 2
Usually on 0-89 90-99 100-109 110 or more

than that
Each frame representing 10% Each frame representing 2.5%
Each frame representing 2.5%

IW301-0211E06
1. Moment ratio mark 3. Scroll-up key

The moment ratios on the bargraph are color Used to see the previous lines of message
coded as follows: displayed on the moment display.
safe (green), notice (yellow) and limit (red).
4. Scroll-down key
2. Moment display Used to see the next lines of message displayed
Normally displays a moment ratio on a bargraph. on the moment display.
Displays the main-circuit pressure when the
display alteration key is pressed.
Also displays error messages when an
operational or system error occurs.
49 W301-0213E
Display Panel 1
1 2 3 5
m
15
14 16 17 20 21
6
m 18 t
13
O
%
max t 7
17
m 8
19 11 10 9
IW301-0211E07
1. Jib angle display 9. Load radius limit symbol

When jib lift is selected, the jib offset angle is This symbol indicates that the load radius display
displayed. [11] is showing the registered load radius limit
When the number of parts of line select key or the value.
display alteration key is pressed, the number of The load radius symbol [10] is also displayed at
parts of line is displayed. Also, when an upper the same time.
boom angle limit has been registered, the
10. Load radius symbol
registered upper boom angle limit value is
This symbol indicates that the load radius display
displayed while the register key is pressed.
[11] is showing the load radius.
2. Number of parts of line symbol
11. Load radius display
This symbol indicates that the jib angle display [1]
Normally displays the crane's load radius.
is showing the number of parts of line.
Displays the boom swing angle while the display
3. Boom length symbol alteration key is pressed.
This symbol indicates that the boom length When a load radius limit has been registered, the
display [13] is showing the boom length. registered load radius limit value is displayed
while the register key is pressed.
5. Jib angle symbol
This symbol indicates that the jib angle display [1] 13. Boom length display
is showing the jib offset angle. Normally displays the boom length.
Displays the lifting height while the display
6. Jib lift symbol
alteration key is pressed.
This symbol indicates that the jib lift is selected.
When a lifting height limit has been registered, the
It also indicates the condition of the jib.
registered lifting height limit value is displayed
7. Actual load display while the register key is pressed.
Displays the actual load.
14. Lifting height symbol
8. Rated lifting capacity display This symbol indicates the boom length display
Displays the rated lifting capacity. [13] is showing the lifting height.
50 W301-0213E
15. Lifting height limit symbol 19. Boom angle display

This symbol indicates that the boom length Normally displays the boom angle.
display [13] is showing the registered lifting height Displays the moment ratio when the display
limit value. alteration key is pressed.
The lifting height symbol [14] is also displayed at When a lower boom angle limit has been
the same time. registered, the registered lower boom angle limit
value is displayed while the register key is
16. Upper boom angle limit symbol
pressed.
is showing the registered upper boom angle limit 20. Boom lift symbol
value. This symbol indicates that the boom lift is
selected.
17. Boom angle symbol
This symbol indicates that the boom angle display 21. Single-top lift symbol
[19] is showing the boom angle. This symbol indicates that the single-top lift is
selected.
18. Lower boom angle limit symbol
This symbol indicates that the boom angle display
[19] is showing the registered lower boom angle
limit value.
51 W301-0213E
Controls
15 14 13 12 11
10
16 17 9
19
18 8
20
7
1 2 3 4 5
IW301-0211E08
1. Increase key 11. Lower boom angle restriction indicator lamp

Used to increase the selected value. Lights up when the lowermost boom angle limiting
function is activated.
2. Decrease key
Used to decrease the selected value. 12.Upper boom angle restriction key
Used to activate and release the uppermost boom
3. Outrigger mode select key
angle limiting function.
Used to select the outrigger status.
13.Upper boom angle restriction indicator lamp
4. Lift mode select key
Lights up when the uppermost boom angle limiting
Used to select the lift status.
5. Check key
14.Lifting height restriction key
Used to check the AML system functions.
Used to activate and release the lifting height
6. Register key limiting function.
Used to register a selected status.
15.Lifting height restriction indicator lamp
7. Display alteration key Lights up when lifting height limiting function is
Used to alter the displays on display panel 1. activated.
8. Load radius restriction key 16.Right swing restriction key

Used to activate and release the load radius Used to activate and release the right swing
limiting function. limiting function.
9. Load radius restriction indicator lamp 17.Right swing restriction indicator lamp
Lights up when the load radius limiting function is Lights up when the right swing limiting function is
activated. activated.
10.Lower boom angle restriction key 18.Left swing restriction key

Used to activate and release the lowermost boom Used to activate and release the left swing limiting
angle limiting function. function.
52 W301-0213E
19.Left swing restriction indicator lamp

Lights up when the left swing limiting function is
activated.
20.Number of parts of line select key

Used to select the a number of parts of line.
Display Panel 2
4 1
2 2
3
2 2
3
3
IW301-0211E09
1. Front jack symbol

Indicates that the front jack is used.
2. Outrigger state symbol

Indicates the way the outriggers are extended.
3. "On-rubber" (Outrigger-not-in-use) state symbol

Indicates that the starter switch in the crane
operator’s cab is turned “ON”.
4. Boom position indicator

Indicates the boom position in 10 ° increments.
53 W301-0213E
Selecting Operational Status

When the outrigger mode select key is pressed,
WARNING the outrigger state symbols and front jack symbol
Should the operational status be incorrectly flash in accordance with the status that the AML
registered, the crane may overturn or be detects.
damaged, leading to a serious accident. Prior to
every operation, check that the registered status After making sure that the display conforms to the
corresponds to the actual status of the crane.
actual outrigger conditions, press the register key.
The outrigger state symbol will change from
flashing to continuous lighting and the moment
Selecting Outrigger Status
display, rated lifting capacity display and actual
[NOTICE] load display will return to normal display
◆The "on-rubber" state symbol lights up when the conditions, meaning that the state has been
power supply is turned on (the PTO switch in the registered.
carrier driver’s cab is turned ON after the engine is
started). (The outrigger state symbols and front jack
Actual outrigger status Representation of outrigger
symbol remain off.) status on the AML
◆Turning the power off (PTO switch: OFF)
automatically erases all the previous settings stored
in memory after approximately 2 hours. To resume
the operation more than 2 hours after the power has
been last turned off, enter the settings all over again.
Register the outrigger status using the outrigger

mode select key and register key.
IW301-0211E11
m Fully extended (6.8m)
m t
Front
jack ％
m ax t Mid. extended (4.6m)
symbol
m
Min. extended (2.39m)

Register key
IW301-0211E12
[NOTICE]
◆If an outrigger or the front jack is stowed after
registration of outrigger status, the registered status
Outrigger state symbol Outrigger mode select key
is erased. In this case, register the outrigger status
IW301-0213E05 again before starting crane operation.
54 W301-0213E
Selecting Lift Status has been registered.

(When the jib set status is selected, the jib lift
symbol will remain flashing.)
[NOTICE]
Select the boom lift status when lifting a load on the
The boom lift status is the default status and is
boom with the jib mounted.
automatically selected (the boom lift symbol lights
up) when the power supply is turned on (the PTO Select the jib lift status when lifting a single load
switch is placed in the ON position). using both the boom and jib.
Turning the power off (PTO switch: OFF)
automatically erases all the previous settings stored (1) Boom lift
been last turned off, enter the settings all over
again.
(2) Single top lift
Register the lift status using the lift mode select
key and the register key.
(3) Jib set (mounting or stowage)
(4) Jib lift: 9.0m jib, 5 dgrees offset

m t
%
m ax t

Register key

IW301-0211E13

Each time the lift mode select key is pressed, the
mode changes in numerical sequence, from (1) to
(9). The display returns to (1) if you press the
switch while the status (9) is displayed on the (8) Jib lift: 14.6m jib, 25 dgrees offset
screen. Select the status that corresponds to the
actual lift status.
[NOTICE]
After selecting the intended lift status, press the (9) Jib lift: 14.6m jib, 45 dgrees offset
register key to register the status. The
corresponding lift symbols will change from flashing
to lighting and the moment display, rated lifting
capacity display and actual load display will return
to normal display conditions, meaning that the state IW301-0211E14
55 W301-0213E
Selecting Number of Parts of Line

1. Press the number of parts of line select key. The
[NOTICE] number of parts of line symbol will flash, and the
If the registered number of pars of line is smaller number of parts of line will be shown on the jib
than the standard number, a maximum allowable angle display in a flashing mode.
lifting load is limited, depending on the registered
number. If zero(0) is registered, however, the AML 2. Press the increase or the decrease key to set the
performs as if the standard number were registered. number to the actual number of parts of line.
Similarly, the AML works on the basis of the
standard number of parts of line if the registered [NOTICE]
number is larger than the standard number or other When the increase or the decrease key is pressed,
than the values specified for your model. a numeral showing the number of parts of line
When the power supply is turned on (i.e. PTO changes from flashing to lighting, and increases or
switch ON), the standard number of pars of line decreases.
corresponding to the work condition is selected. When the increase or the decrease key is kept
pressed, the number of parts of line continuously
Register the number of parts of line by use of the increases or decreases.
number of parts of line select key and the register
key, as follows: 3. Once the intended number of parts of line is set,
press the register key to register the number.
Number of parts of
Then, the number of parts of line symbol will be
line symbol
turned off and the jib angle display will return to a
normal status.
Number of [NOTICE]
parts of line
The number of parts of line can be confirmed by
pressing the display alteration key.
m t
max t Number of
parts of
m line select
key
Decrease
key Register key
Increase
key
IW301-0213E06
56 W301-0213E
AML Pre-operational Inspection 2. Press either the register key, display alteration key
or check key to return the display to the normal
WARNING
condition.
Operating the crane with a malfunctioning AML
could cause the crane to overturn or be 3. Make sure that the display on the display panels
damaged. Be sure to perform the pre-operational
inspection on the AML system and start the conforms to the actual crane conditions.
crane only after ensuring that the system is
operating properly. (1) Boom length
(2) Boom angle
Before starting operation, check that the AML (3) Jib angle ......shown while jib lift is selected
works in good condition, as follows:
(4) Actual load...With no load on hook, make sure
1. Press the check key and make sure that the AML that an approximate mass of the
is in the following conditions: hook block is shown.
Moment display ................... All segments light up. [NOTICE]

The actual load is not shown correctly if the lift
Display panel (1 and 2) status is not registered correctly.
.................... All segments light up.
(5) Outrigger state symbol
Working range restriction indicator lamp
.....................All six lamps light up. (6) Front jack symbol
Alarm buzzer .................... Sounds continuously. (7) Boom position indicator
Movement toward critical sides 3

...................... Automatically halted
2
1
Buzz
4
Bargraph display 7
m t
o
max t
Display panel 1
m
m
Display panel 2
m t
%
m ax t
5
Check key
IW301-0211E17
IW301-0211E16
57 W301-0213E
How to Use the Working Range Limit Function Boom Angle Limit
[NOTICE] Raise or lower the boom to the desired angle, and

◆If the working range limit is registered very close to press the upper or lower boom angle restriction
an obstacle, there is a risk of the crane colliding
with the obstacle, depending on the operational key. The corresponding restriction indicator lamp
status and the manner in which the load is handled. will flash and the buzzer will sound continuously,
When registering a range limit, allow a sufficient indicating that the boom angle limit has been
clearance to avoid collision. registered in the memory. When the boom is
moved back to an angle within the set limit, the
The working range restricting function makes the
restriction indicator lamp stops flashing and stays
boom automatically stop at the previously
lit and the buzzer stops.
registered boom angles (upper and lower), lifting
Thereafter, the upper or lower boom angle
height and load radius.
restriction indicator lamp flashes and the buzzer
If makes the alarm sound when the boom reaches sounds continuously whenever the upper or lower
the previously registered swing restriction. limit previously registered is reached. (Boom
raising or lowering stops automatically.)
The function is useful for handling a load in a
To cancel the boom angle limit function, press the
confined place because it defines the area in
boom angle restriction key again. The
which the boom can operate.
corresponding boom angle restriction indicator
[NOTICE] lamp will go off.
◆Turning the power off (PTO switch: OFF)
again.
Upper boom angle
restriction indicator
lamp
Upper boom angle restricted Lifting height restricted m t
Lower boom angle restricted

m ax t
Lower boom angle

m restriction indicator
u lamp
L Lower boom angle

restriction key
Load radius restricted Swing restricted Upper boom angle

restriction key
IW301-0213E07
IW301-0211E18
58 W301-0213E
Lifting Height Limit Swing Limit
Move the boom to the desired height, and press Swing the boom to the desired position, and press
the lifting height restriction key. The lifting height a swing restriction key. The corresponding swing
restriction indicator lamp will flash and the buzzer restriction indicator will flash and the buzzer will
will sound continuously, indicating that the height sound continuously, indicating that the swing
limit has been registered in the memory. When the angle limit has been registered in the memory.
boom is moved back to a height within the set limit, When the boom is swung back to an angle within
the lifting height restriction indicator lamp stops the set limit, the swing restriction lamp stops
flashing and stays lit and the buzzer stops. flashing and stays lit and the buzzer stops.
Thereafter, the lifting height restriction indicator Thereafter, the swing restriction indicator lamp will
lamp flashes and the buzzer sounds continuously flash and the buzzer will sound whenever the limit
whenever the height limit previously registered is previously registered is reached. (Boom swinging
reached. (Boom raising and extending stop stops automatically.)
automatically.) To cancel the restriction function, press the
To cancel the height limit function, press the lifting corresponding swing restriction key again. The
height restriction key again. The lifting height corresponding swing restriction indicator lamp will
restriction indicator lamp will go off. go off.
[NOTICE]
When registering a swing angle limit, register both
the right and left swing limits, one-side registering is
dangerous because an automatic stop is not made
when the boom approaches the limit position from
Lifting height restriction the opposite direction.
m t
indicator lamp
While the swing stop cancel switch is set to OFF,
m ax t
the automatic stop does not work even if the boom
m Lifting height restriction
key
is swung to the limit. In this case, the corresponding
swing restriction indicator lamp flashes, a message
appears and the AML buzzer beeps for 3 seconds.
Take care when swinging the boom.
IW301-0211E20
Left swing restriction

m t indicator lamp
m ax t
Right swing restriction

m
indicator lamp

key

key
IW301-0211E21
59 W301-0213E
Load Radius Limit
Move the boom to the desired load radius, and

press the load radius restriction key. The load
radius restriction indicator lamp will flash and the
buzzer will sound continuously, indicating that the
load radius limit has been registered in the
memory. When the boom is moved back toward
the non-critical side, the load radius restriction
indicator lamp stops flashing, and stays lit and the
buzzer stops.
The load radius restriction indicator lamp flashes
and the buzzer sounds continuously whenever the
limit previously registered is reached. (Boom
extending and lowering stop automatically.)
To cancel the load radius limit function, press the
load radius restriction key again. The
corresponding load radius restriction indicator
lamp will go off.
m t
m ax t
Load radius restriction

indicator lamp
Load radius
restriction key
IW301-0211E22
60 W301-0213E
Display of Working Range Limit Values
Press the register key while working range limits

have been registered.
While the key is being pressed, the registered
working range limit values are displayed. On the
moment display will be displayed a message
"Working range".
[NOTICE]
This display is not made during a preoperational
check of the AML and when a working state is being
registered.
When working range limits are not registered, the
message "- - -" will be displayed.
Upper boom angle limit values Working range
Lifting height limit values Lower boom angle limit values
m t
Load radius limit values
m ax t
m
Register key
Swing limit values
IW301-0213E08
61 W301-0213E
Display Alteration
Displays on the moment display and the display

panel 1 can be altered, as shown below in the
figures, by pressing the display alteration key.
The indicative symbols are displayed, too.
Moment Display
M* * *. * MPa Unit
Main circuit pressure
IW301-0211E24
Display Panel 1
[NOTICE]
◆Displays on the actual load display and the rated
lifting capacity display do not alter even when the
Number of parts of line

M * * *. * MPa
Lifting height Moment ratio
Actual load
m
%
m ax t
Rated lifting capacity
Swing angle
Display alteration key

IW301-0213E09
62 W301-0213E
Functions of and How to Use User Mode (GR-120N-1)

(GR-120N-1) Used to make functional checks of AML. See the
Mode Structure
3. Adjustment Mode:
POWER ON

switch
ON
Protect
switch
OFF ADJUSTMENT MODE
POWER ON
IW301-0212E05
1. User Mode:

power turns on.

is faulty).
PROTECT
MOMENT
SHORT
ZERO
HALT
WDT
OFF
ON
Protect switch
63 W301-0213E
Configuration and Functions of the AML System

(2) Working range limit functions
When any working range limit is registered to AML,
The AML system has various kinds of functions,
the crane is controlled so that the crane work
including the following four typical functions. Based posture does not exceed this registered working
on the registered work conditions by operator range limit. When the boom reaches the
selection and the signals from various sensors, the previously registered restriction, failure message
crane operations are controlled. is shown, alarm buzzer sounds, and the crane
operation stops.
(1) Automatic stop function for overloading
(3) Slow stop function
The AML calculates and compares the working
When the boom elevation stops in the above (1)
and rated moment values and displays them as a
or (2) case or reaches the stroke ends, the
percentage. When the working moment exceeds
elevating speed slows down before the boom
the rated moment (100% or more), failure
elevation stops.
message is shown, alarm buzzer sounds, and the
crane operation toward the critical side stops.
The above automatic stop, working range restricting
and slow stop functions are available depending on
the conditions shown in the following table:
On-outrigger operation On-rubber operation

Hoisting up
Automatic stop Boom lowering
by overloading Boom extension
Swing ×
Stop by working range
Swing ×
restriction
Boom extension
：Slow stop ：Stop ×：Not stop
[NOTICE] [NOTICE]
When swing stop/override switch is shifted to When elevation slow stop/override switch is shifted
"Override" side, swing stop does not activate. to "Override" side, boom elevation slow stop does
not activate.
Override
Override
Stop Stop
SWING STOP ELEV. SLOW STOP OVERRIDE

OVERRIDE IW301-0211E37
IW301-0211E38
64 W301-0213E
(4) Alarm function (5) Elevation speed adjustment function

The maximum elevation speed with the boom
Condition Alarm extended can be adjusted.
Overwinding Buzzer: Sounds continuously.
Moment ratio is Moment display: Associated
between 90% and yellow segments are lit.
100% Buzzer: Sounds intermittently.
Moment ratio Moment display: Associated
exceeds 100% segments are lit until the
moment reaches 110%; all
segments are lit when moment
exceeds 110%.
Buzzer: Sounds continuously.
Crane operation Moment display: Displays
needs to be control messages.
controlled Buzzer: Beeps 3 seconds.
(*1)
Working range Associated restriction indicator

restricting function lamp flashes.
activated Buzzer: Beeps 3 seconds.
(*1)
AML system error Moment display: Displays

failure messages.
(*1)
Buzzer: Beeps 3 seconds.
(*1): There are two types of buzzer sounds as

follows:
When slow stop control is activated: Long sounds
When other controls are activated: Short sounds
65 W301-0213E
Boom length signal Elevation angle signal Moment signal Over-front area signal Crane control signal
L
W
θ
Swing angle signal Outrigger status
Operator input
Outrigger extension
Lift status
signal
AML unit
AML external
Alarm buzzer warning lamps
Display panel (option)
Automatic stop signal output
Moment ratio Work area

100% or higher limit signal
Overwinding output
Boom Boom Hoisting up Swinging Left swing Upper boom Lifting height Load radius
extension lowering halted halted toward restricted angle restricted restricted restricted
halted halted critical side Right swing Lower boom
restricted angle restricted
L
R
IW301-0213E10
66 W301-0213E
Bargraph display
Display panel 1
m t
%
max t
Display panel 2
m
Control
IW301-0211E05
67 W301-0213E
Bar graph Display
3 1 2

than that

IW301-0211E06

4. Scroll-down key
68 W301-0213E
Display Panel 1
1 2 3 22 5
m
15
14 16 17 20 21
6
m 18 t
13
O
%
max t 7
17
m 8
19 11 10 9
IW301-0212E03

5. Jib angle symbol
6. Jib lift symbol
7. Actual load display registered lifting height limit value is displayed
Displays the actual load. while the register key is pressed.
8. Rated lifting capacity display 14. Lifting height symbol

Displays the rated lifting capacity. This symbol indicates the boom length display
[13] is showing the lifting height.
69 W301-0213E

pressed.
selected.
selected.
This symbol indicates that the boom angle display 22. Jib length symbol
[19] is showing the registered lower boom angle This symbol shows that the jib angle display [1]
limit value. indicates the jib length.
70 W301-0213E
Controls
15 14 13 12 11
10
16 17 9
19
18 8
20
7
1 2 3 4 5
IW301-0211E08

2. Decrease key
5. Check key


71 W301-0213E

activated.

Display Panel 2
5
3
2
4
2 3
3 2
3
IW301-0231E10
1. Over-front position symbol 4. Suspension lock state symbol

Indicates that the boom is swung into the Lights up the suspensions are locked up.
over-front position.
2. Outrigger state symbol Indicates the boom position in 10° increments.
Flashes while an outrigger state is in process of
being registered, and lights up when the
registration is completed.
3. "on-rubber" (Outrigger-not-in-use) state symbol

Indicates that the on-rubber operation
(non-outrigger operation) is selected.
Lights up when the stationary on-rubber operation
is selected, and flashes when the traveling
on-rubber (creep) operation is selected.
72 W301-0213E

(1)On-outrigger operation
WARNING Press the outrigger mode selector key. The AML
Incorrectly entering the operation status into the automatically detects the current outrigger
AML can result in a serious accident such as the position and displays the detected position by
crane falling over or being damaged. Before flashing the corresponding outrigger state
starting a crane operation, make sure that the
operation status stored in the AML matches the symbols.
actual operation status. Check that the outrigger state symbols flashing on
the display match the actual outrigger position. If
they do, press the register key to store the
Selecting Outrigger Status outrigger position to the AML memory. The
outrigger state symbols will light when the
[NOTICE]
outrigger position is registered.
The on-rubber status is automatically set when the
AML is turned on.
Even when you turn the AML off (by setting the
PTO switch to OFF), the currently registered
operation status is retained in the AML. The stored
data is available next time you turn on the AML.
Note, however, that the data is erased after 2 hours.
If you have interrupted the operation for more than
2 hours, register the operation status again into the
AML before resuming the operation.
Use the outrigger mode selector key to register IW301-0211E46
the outrigger position into the AML. Then follow

the procedure described in the following The outrigger positions are displayed as follows.
paragraphs.
X-type outrigger
Max. extension (4.7 m)
Middle extension (4.3 m)

Outrigger state
symbol Middle extension (2.5 m)
Min. extension (1.7 m)
IW301-0211E47
Register key
H-type outrigger
Max. extension (4.7 m)

On-rubber symbol Outrigger mode
selector key IW301-0211E45
Min. extension (1.64 m)
IW301-0211E48
73 W301-0213E
(2)On-rubber stationary operation Selecting Lift Status

Press the outrigger mode selector key. At this time,
the outrigger state symbols flash. Press the [NOTICE]
outrigger mode selector key again. At this time, The single top lift status is automatically selected
when the power supply is turned on.
the outrigger state symbols go out and the
on-rubber symbol becomes marked up. The
PTO switch to OFF), the currently registered
on-rubber status is now registered in the AML operation status is retained in the AML. The
memory. registered data is available next time you turn on
the AML. Note, however, that the data is erased
after 2 hours. If you have interrupted the operation
for more than 2 hours, register the operation status
again into the AML before resuming the operation.
Lighting
Jib lift symbol
Single top lift symbol
IW301-0211E49
Boom lift symbol
(3)On-rubber creep operation

Press the outrigger mode selector key to flash the
tire part of the on-rubber symbol becomes lit up. Register key
The on-rubber status is now registered in the AML

memory.
Flashing
Lift mode selector key
IW301-0213E11
Lighting The lift mode selector key is used to register the

lift status. Each time the lift mode selector key is
pressed, the lift status changes. The status
Flashing changes in numerical sequence as shown in the
following table. The display returns to (1) if you
IW301-0211E50
press the switch when status (9) is displayed on
the screen. Register the status that corresponds
to the actual lift status.
74 W301-0213E
Display Type of lift
Single top lift (1)
Flashing
Jib set (mounting or stowage) (2)
Jib lift (3)

Jib length: 3.6 m, Jib offset angle: 5°
Jib lift
(4)
Jib lift
Jib length: 3.6 m, Jib offset angle: 45° (5)
Jib lift (6)

Jib lift (7)

Jib lift (8)

Boom lift (9)
IW301-0211E52
75 W301-0213E
Selecting Number of Parts of Line

1. Press the number of parts of line select key. The
[NOTICE] number of parts of line symbol will flash, and the
If the registered number of pars of line is smaller number of parts of line will be shown on the jib
than the standard number, a maximum allowable angle display in a flashing mode.
lifting load is limited, depending on the registered
number. If zero(0) is registered, however, the AML 2. Press the increase or the decrease key to set the
performs as if the standard number were registered. number to the actual number of parts of line.
standard number of parts of line if the registered [NOTICE]
number is larger than the standard number or other When the increase or the decrease key is pressed,
than the values specified for your model. a numeral showing the number of parts of line
When the power supply is turned on (i.e. PTO changes from flashing to lighting, and increases or
switch ON), the standard number of pars of line decreases.
corresponding to the work condition is selected. When the increase or the decrease key is kept
Register the number of parts of line by use of the increases or decreases.
number of parts of line select key and the register
key, as follows: 3. Once the intended number of parts of line is set,
press the register key to register the number.
Number of parts of
Then, the number of parts of line symbol will be
line symbol
turned off and the jib angle display will return to a
normal status.
Number of [NOTICE]
parts of line
pressing the display alteration key.
m t
max t Number of
parts of
m line select
key
Decrease
key Register key
Increase
key
IW301-0213E06
76 W301-0213E
AML Pre-operational Inspection How to Use the Working Range Limit Function
WARNING [NOTICE]
Operating the crane with a malfunctioning AML Do not register a limit position into the AML with the
could cause the crane to overturn or be boom positioned very close to an obstacle. If you do,
damaged. Be sure to perform the pre-operational a collision with the obstacle may occur under some
inspection on the AML system and start the operating conditions or with certain control
crane only after ensuring that the system is procedures. Provide enough clearance between
operating properly. limit positions and obstacles.
The working range restricting function

Before starting operation, check that the AML
automatically stop the boom telescoping,
elevation, or swing operation when the preset
1. Press the check key and make sure that the AML elevation angle (upper/lower limits), lifting height,
is in the following conditions: load radius, or swing angle (right/left) is reached.
・Display panel (1 and 2) ….. The working range limit function is useful for
…..All segments light up. handling a load in a confined place because it
・Moment display….. defines the area in which the boom can operate.
…..All segments light up. Elevation angle upper limit
・Working range restriction indicator lamp….. Elevation angle lower limit
…..All six lamps light up. Lifting height limit Automatic stop and
warning buzzer
・Alarm buzzer….. Load radius limit (3-second beeping)
…..Sounds continuously. Left swing limit
・Movement toward critical sides….. Right swing limit
…..Automatically halted.
[NOTICE]
2. Press either the register key, display alteration key When the swing stop/override switch is set to the
or check key to return the display to the normal override position, the warning buzzer sounds, but
condition. (Bar graphs are indicated on the the swing limit function does not automatically stop
the swing operation.
moment display.)
3. Make sure that the display on the display panels PTO switch to OFF), the limit position data is
retained in the AML. The stored data is available
conforms to the actual crane conditions.
next time you turn on the AML. Note, however, that
(1) Boom length the data is erased after 2 hours. If you have
(2) Boom angle interrupted the operation for more than 2 hours,
(3) Jib angle (Jib length) ….. register the limit position again into the AML before
resuming the operation.
…..shown while jib lift is selected.
(4) Actual load …..With no load on hook, Indicator lamps
Working range
make sure that the approximate mass of restriction keys
the hook block is shown. Swing limit range
[NOTICE]
status is not registered correctly.
(5) Outrigger state position

(6) Boom position indicater
(7) Over-front position symbol …shown while the
boom is over-front ared. IW301-0211E54
77 W301-0213E
Working Range Limit Values Lifting Height Limit
Press the register key while the working range Move the boom to the desired height, and press
limits have been registered. While the key is being the lifting height limit key. The lifting height symbol
pressed, the registered working range limit values will flash, indicating that the current lifting height
are displayed. On the moment ratio display will be has been registered in the memory as the lifting
displayed a message "Working range". height limit.
When the boom is moved back to a height within
Upper the set limit, the lifting height restriction indicator
boom angle
limit value lamp stops flashing and stays lit. When the lifting
Working range
Lower boom height again reaches the set limit, the indicator
angle limit lamp flashes. At the same time, the boom
value
Lifting height m
movement (raising or extending) automatically
t
limit value
max t
Load radius
stops, and the warning buzzer sounds (3-second
m limit value beeping). To cancel the registered limit, press the
lifting height limit key again. The lifting height
Swing symbol will go off.
limit
value
Load Radius Limit
Register key Move the boom to the desired load radius, and
IW301-0213E12 press the load radius limit key. The load radius
limit symbol will flash, indicating that the current
Boom Angle Limit load radius has been registered in the memory as
the load radius limit. When the boom is moved
Raise or lower the boom to the desired angle, and
back to a load radius within the set limit, the load
press the elevation angle upper or lower key. The
radius restriction indicator lamp stops flashing and
corresponding limit symbol will flash, indicating
stays lit. When the load radius again reaches the
that the current boom angle has been registered
set limit, the indicator lamp flashes. At the same
in the memory as the boom angle upper or lower
time, the boom movement (lowering or extending)
limit.
automatically stops, and the warning buzzer
When the boom is moved back to an angle within
sounds (3-second beeping).
the set limit, the restriction indicator lamp stops
To cancel the registered limit, press the load
flashing and stays lit. When the boom angle again
radius limit key again. The load radius limit symbol
reaches the set limit, the indicator lamp flashes. At
will go off.
the same time, the boom movement (raising or
lowering) automatically stops, and the warning
buzzer sounds (3-second beeping). To cancel the
registered limit, press the elevation angle upper or
lower key again. The corresponding elevation
angle limit symbol will go off.
78 W301-0213E
Swing Limit How to Use the Elevation Speed Adjustment

Function
To register a swing limit, swing to the desired
The elevation speed adjustment function works to
angle, and press the right or left swing limit key. At
adjust the maximum elevation speed with the
this time, the corresponding swing limit indicator
boom extended.
lamp flashes and the buzzer sounds (3-second
beeping). The current swing angle is registered as
the right or left swing angle. When you swing back Registering the Elevation Speed
to an angle within the limit, the buzzer (3-second
beeping) stops, and the swing angle limit indicator
lamp stops flashing and stays lit. When you swing
again to the limit angle, the swing operation
automatically stops and the buzzer sounds
(3-second beeping).
To cancel the registered limit, press the right or
left swing limit key again. Then the corresponding
swing limit indicator lamp will go off.
Decrease key
[NOTICE] Increase key
Use the swing limit function with both the right and
left swing limits defined. The swing limit function
may not warn you when it should if used with only
one of the swing limits defined.
IW301-0211E56
The swing limit function does not automatically stop
the swing operation when the swing stop/override
switch is set to the override position. When the
Use the increase and decrease keys to adjust the
preset limit is reached, the swing restriction
indicator lamp flashes, a warning message appears, elevation speed limit. When the increase or
and the warning buzzer of the AML unit sounds decrease key is pressed, the indication on the bar
(3-second beeping), but the automatic stop function graph display will go out, and the elevation speed
is not available. Perform swing operations carefully.
adjustment rate will appear as follows:
Up 100% Dwn 100%
Maximum speed
for boom lowering
Maximum speed
for boom raising
IW301-0211E57
To change the elevation speed adjustment rate,

press the increase or decrease key while the
elevation speed adjustment rate is displayed on
the bar graph display. The adjustment rate can be
adjusted from 0% (stop) to 100% (normal speed)
in 10% increments.
79 W301-0213E
To adjust the boom raising and lowering speeds Actual Elevation Speed When Registering the
individually, press the increase or decrease key Elevation Speed Adjustment
during the boom elevating operation.
The elevation speed adjustment rate (%) is based
・While raising the boom:
on the elevation speed with the boom fully
Boom raising speed is adjusted.
extended. Therefore, the boom moves at the
・While lowering the boom: normal speed (shown on the display) when the
Boom lowering speed is adjusted. boom is fully retracted.
The relation between the elevation speed
・While the boom elevating operation is not adjustment rate and the actual elevation speed is
performed: as follows:
Boom raising and lowering speeds are adjusted (1) When setting the adjustment value to 0%
simultaneously. Fully retracted…..
…..Moves at the normal speed
[NOTICE]
Extended to the middle…..
If the increase and decrease keys are not left
unpressed at least for approx. 10 seconds, the …..Moves at half normal speed
indication on the bar graph display is returned to the Fully extended…..
normal state (bar graphs are displayed on the …..Stops (Hardly moves at all)
moment ratio display) even if the registration is not
(2) When setting the adjustment value to 50%
completed.
Fully retracted…..
Even if you turned the AML off (by setting the PTO
switch to OFF), the adjustment rate data is stored in …..Moves at the normal speed
the AML. The stored data is available next time you Extended to the middle…..
turn on the AML. When the AML is turned on, all the …..Moves at 75% of the normal speed
segments on the moment ratio display become
Fully extended…..
marked up, the elevation speed adjustment rate
appears for 2 or 3 seconds, and then the display …..Moves at half normal speed
returns to the normal state (bar graphs are (3) When setting the adjustment value to 100%
displayed on the moment ratio display). Fully retracted…..
Extended to the middle…..
Fully extended…..
Maximum elevation speed
Normal speed 100%
75%
50% 50%
25%
0%
Stop Boom length
Fully Extended to Fully
retracted the middle extended
IW301-0211E58
80 W301-0213E
Display Alteration

Moment ratio Display
M ***. * A ***. * MPa Unit
Accumulator pressure
Main oil pressure
IW301-0211E61
Display Panel 1
[NOTICE]

M * * *. * MPa
Actual load
m
%
m ax t
Swing angle

IW301-0213E09
81 W301-0213E
Functions of and How to Use User Mode (GR-700EXL-1)
Functions of and How to Use User

Mode (GR-700EXL-1)
Mode Structure 3. Adjustment Mode:

POWER ON

switch
ON
Protect
switch
OFF ADJUSTMENT MODE
POWER ON
IW301-0212E05
1. User Mode:

power turns on.

is faulty).
PROTECT
MOMENT
SHORT
ZERO
HALT
WDT
OFF
ON
Protect switch
82 W301-0213E
Configuration and
Functions of the AML System When any working range limit is registered to the
AML, the crane is controlled so that the crane
The AML(Automatic Moment Limiter) system is a
safety device provided to prevent overloading of
the crane which may cause it to overturn or be
damaged.
including the following typical functions. Based on (4) Slow stop function
the registered work conditions by operator In the following cases, the boom elevation speed
selection and the signals from various sensors, gradually decreases to stop before the boom
the crane operations are controlled. reaches the stoppage position.
(1) Automatic stop function to prevent overloading • When the automatic stop is caused by overloading
The AML calculates and compares the working (Boom lowering will stop.)
When the working moment exceeds the rated • When the elevating cylinder reaches its stroke end
moment (100% or more), failure message is (Boom raising/lowering will stop.)
shown, alarm buzzer sounds, and the crane • When the automatic stop is caused by working
operation toward the critical side stops. range limit function (Boom raising/lowering will
(2) Automatic stop function by backward instability stop.)
When the boom is raised to 69°: in an over-side • When the automatic stop is caused by backward
area with on-rubber operation. instability during on-rubber operation (Boom
raising will stop.)
The situation of automatic stop due to automatic

stop function and working range limit function is as
listed below, depending on the working condition.

Hoisting up
overloading Boom extension
Swing ×
Stop by backward instability Boom raising -
Boom extension
restriction
Swing ×
: Slow stop : Stop × : Not stop - : Not relevant
83 W301-0213E
AML System Configuration
Boom length signal Boom angle signal Moment ratio signal Over-front area signal Crane control position
signal
L
θ W
Outrigger extension Outrigger status Swing angle signal

width detector
Lift status
Operator selection
θ
L Jib status
Winch selection
(single top and jib lift only)
AML unit

lamps
Display panel
Stop output when:
Backward
Moment ratio exceeds 100 % stability
Overwinding occurs control
Moment exceeding limit for activated Swing restricted
boom with jib mounted
AML system error occurs
Working range limit

signal output
Boom Boom lowering Hoisting up Swinging Boom raising Upper boom Lifting height Load radius
extension halted halted halted toward halted angle restricted restricted restricted
halted critical side Lower boom
angle restricted
H
L
R
IW301-0213E13
84 W301-0213E
Automatic Stop Functions Alarm Functions

Causes of Condition Alarm
Operation Halted movement A control is moved toward Moment display: Displays
automatic stop
critical side (hoist up, boom [Warning:0024].
• Moment ratio • Hoisting up
lowering or boom extension) Buzzer: Sounds continuously.
exceeds 100%(*1) • Boom lowering while overwinding condition
• Overwinding • Boom extension exists.
• AML system error • Swing Overwind cutout function is Moment display: Displays
deactivated while [Warning:0015].
Upper boom • Boom raising
overwinding codition exists. External warning lamps: Red
angle restricted • Boom lift
lamp is lit.
Working range limit
Lower boom • Single top lift • Boom lowering Buzzer: Sounds continuously.
angle restricted • Jib lift Moment ratio exceeds 90% Moment display: Yellow
Lifting height • Boom raising segment is lit.
restricted • Boom extension External warning lamps:
Orange lamp is lit.
Load radius • Boom lowering
restricted • Boom extension A control is moved toward Moment display: Displays
Swing restricted • Swing critical side while moment [Warning:0023].
• Backward instability • Boom lift • Boom raising ratio exceeds 100% External warning lamps: Red
(*2) lamp is lit.
• Single top lift
AML system errer Moment display: Displays
(*1): For the boom lift with the jib mounted,
failure messages.
automatic stop will work when the moment AML Buzzer: Sounds 3
exceeds the value listed below, according to the seconds.
outrigger extension width: Working range limit function Moment display: Displays
activated. failure messages.
Associated restriction
Outrigger extension width Moment indicator lamp flashes.
Maximum 7.2m 93% or more AML Buzzer: Sounds 3
seconds.
Middle 6.7m 92% or more
A control is moved toward Moment display: Displays
Middle 5.5m 91% or more critical side when backward [Warning:0025].
stability control activated AML Buzzer: Sounds 3
seconds.
Slow stop control Moment display: Displays
[Warning:0081] or [0082]
Buzz
AML Buzzer: Sounds 3
seconds.
Boom lift with jib mounted on boom (*1)
(1) Moment ratio is between Moment display:
84% and 94%. Corresponding segment is lit.
(2) Moment ratio is between External warning lamps :
84% and 94%. Orange lamp is lit.
(3) Moment ratio is between Buzzer: Sounds
82% and 92%. intermittently.
(1) Moment ratio exceeds Moment display: Displays
IW301-0131E54
94% [Warning:0088].
(2) Moment ratio exceeds External warning lamps : Red
94% lamp is lit.
(*2): Automatic stop will work when the boom is (3) Moment ratio exceeds Buzzer: Sounds continuously.
raised to 69° in an over-side area with 92%
on-rubber operation.
85 W301-0213E
(*1)(1) is applicable when the outriggers are extended

to maximum 7.2m.
(2) is applicable when the outriggers are extended
to middle 6.7m.
(3) is applicable when the outriggers are extended
to middle 5.5m.
[NOTICE]
In the above table, "Buzzer" is the device outside
The AML buzzer sounds for 3 seconds every time a
message appears. It outputs long sounds when
slow stop control is activated and outputs short
sounds when other controls are activated.
86 W301-0213E
Bargraph display
Display panel 1
゜
m
゜
・
Display panel 2
Control
IW301-0231E08
87 W301-0213E
Bar graph Display
3 1 2

than that

IW301-0211E06

4. Scroll-down key
88 W301-0213E
Display Panel 1
1 2 3 5
゜
m
15 16
17 21
14 20
18 6
13
゜
・
7
19 17
12
8
11 10 9 IW301-0231E09

5. Jib angle symbol
This symbol indicates that the jib angle display [1] 12.Counterweight state indicative symbol
is showing the jib offset angle. Iights up when the operation with the counterwight
mounted is selected, indicating its mounting state.
6. Jib lift symbol
7. Actual load display

8. Rated lifting capacity display

Displays the rated lifting capacity.
89 W301-0213E
13. Boom length display 18. Lower boom angle limit symbol
Normally displays the boom length. This symbol indicates that the boom angle display
Displays the lifting height while the display [19] is showing the registered lower boom angle
alteration key is pressed. limit value.
19. Boom angle display
Normally displays the boom angle.
Displays the moment ratio when the display
14. Lifting height symbol alteration key is pressed.
This symbol indicates the boom length display When a lower boom angle limit has been
[13] is showing the lifting height. registered, the registered lower boom angle limit
15. Lifting height limit symbol
pressed.
This symbol indicates that the boom length
display [13] is showing the registered lifting height 20. Boom lift symbol
limit value. This symbol indicates that the boom lift is
The lifting height symbol [14] is also displayed at selected.
the same time.
21. Single-top lift symbol
16. Upper boom angle limit symbol This symbol indicates that the single-top lift is
This symbol indicates that the jib angle display [1] selected.
is showing the registered upper boom angle limit
value.

[19] is showing the boom angle.
90 W301-0213E
Controls
15 14 13 12 11
10
16 17 9
19
18 8
20
7
1 2 3 4 5 IW301-0131E59

2. Decrease key
5. Check key


91 W301-0213E

activated.

Display Panel 2
5
3
2
4
2 3
3 2
3
IW301-0231E10


92 W301-0213E

[NOTICE]
Crane operation is prohibited without full
WARNING counterweigth installed.
Should the operational status be incorrectly Counterweigth state indicative symbol is marked up
registered, the crane may overturn or be as shown below:
damaged, leading to a serious accident.
Prior to every operation, check that the Dismounting the Counterweight Mounting the Counterweight
registered status corresponds to the actual
status of the crane.
Selecting Outrigger Status
[NOTICE]
The "on-rubber stationary" status is the default
status and is automatically selected when the power
supply is turned on (the PTO switch is placed in the IW301-0231E14
"ON" position).
Turning the power off (PTO switch: OFF) (1) On-outrigger operation
automatically erases all the previous settings stored When the outrigger mode select key is pressed,
in memory after approximately 2 hours. To resume the outrigger state symbols and counterweight
the operation more than 2 hours after the power has state symbol flashe in accordance with the status
again. that the AML detects.
After making sure that the display conforms to the
Register the outrigger status using the outrigger actual outrigger conditions, press the register key.
mode select key and the register key. The outrigger state symbols and counterweight
state symbol will change from flashing to
continuous lighting and the moment display, rated
lifting capacity display and actual load display will
return to normal display conditions, meaning that
the state has been registered.
゜
m
Actual outrigger
extension Displayed outrigger status
゜ condition
・
Register key
IW301-0231E12

IW301-0231E11
93 W301-0213E
Fully extended (23' 7-1/2" (7.2m))
Mid. extended (21' 11-3/4" (6.7m))
Mid. extended (18' 1/2" (5.5m))
Min. extended (9' 2-1/4" (2.8m))
IW301-0231E13
(2) On-rubber operation

Press the outrigger mode select key repeatedly
until the display conforms to the actual condition
(on-rubber stationary operation or on-rubber creep
operation). Then press the register key. The
moment display, rated lifting capacity display and
actual load display will return to normal display
conditions, meaning that the on-rubber state has
been registered.
[NOTICE]
The outrigger status automatically changes to
on-rubber creep status when an operation is made
for stowing the outrigger after the registration of the
outrigger status. Be sure to again register the
outrigger status, when necessary.
94 W301-0213E

[NOTICE]
Turning the power off (PTO switch: OFF) (1) Boom lift
again. (2) Single top lift

(3) Jib set (mounting or stowage)
m
(4) Jib lift : 32.5 ft (9.9m) jib, 3.5° offset
m t
%
m ax t
(5) Jib lift : 32.5 ft (9.9m) jib, 25° offset
Register key

IW301-0211E13
(7) Jib lift : 58.1 ft (17.7m) jib, 3.5° offset

switch while the status (9) is displayed on the
actual lift status.
[NOTICE] (9) Jib lift : 58.1 ft (17.7m) jib, 45° offset
After selecting the intended lift status, press the

capacity display and actual load display will return IW301-0231E15
to normal display conditions, meaning that the state
95 W301-0213E
Selecting Number of Parts of Line When the power supply is turned on (i.e. PTO
switch ON), the standard number of pars of line
corresponding to the work condition is selected.
[NOTICE]
If the registered number of pars of line is smaller
Register the number of parts of line by use of the
than the standard number, a maximum allowable
lifting load is limited, depending on the registered number of parts of line select key and the register
number. If zero(0) is registered, however, the AML key, as follows:
performs as if the standard number were registered.
standard number of parts of line if the registered
number is larger than the standard number or other
than the values specified for your model.
Number of parts of line symbol

Number of parts of line select key
Decrease key
Increase key Register key
IW301-0134E11
1. Press the number of parts of line select key. The 3. Once the intended number of parts of line is set,
number of parts of line symbol will flash, and the press the register key to register the number.
number of parts of line will be shown on the jib Then, the number of parts of line symbol will be
angle display in a flashing mode. turned off and the jib angle display will return to a
normal status.
2. Press the increase or the decrease key to set the
number to the actual number of parts of line. [NOTICE]
[NOTICE] pressing the display alteration key.
When the increase or the decrease key is pressed,
a numeral showing the number of parts of line
changes from flashing to lighting, and increases or
decreases.
When the increase or the decrease key is kept
increases or decreases.
96 W301-0213E
Functions of and How to Use User Mode (GR700EXL-1)
Selecting Winch Condition Selecting Jib Mounted Condition
WARNING WARNING
Select the correct winch according to the actual If the jib mounted/dismounted state is set
crane condition; otherwise the AML will show improperly, the AML does not function
wrong moment ratio, and damage to or overturn accurately. The crane operation in this condition
of the crane can be caused. could create hazard.
The lifting capacities vary depending on the The jib can be dismounted from the crane body
operating condition. Register the winch selection when it is not used. The reduced mass of the
using the winch selector switch so that the winch crane body after jib removal will influence the
selection indicator lamp is as shown in the table accuracy of the AML. Use this switch to set the jib
below according to the operating condition. mounted /dismounted state to the AML.
[NOTICE]
The key can be inserted in and removed from
When main winch is employed When auxiliary winch is employed either “REMOVED” or “EQUIPPED” position.
: Main Winch : Auxiliary Winch (1) “REMOVED” Select this position when the jib is
dismounted. The jib removed indicator lamp will
light up.
Winch selector switch
(2) “EQUIPPED” Select this position when the jib is
mounted. The jib removed indicator lamp will go
: Main Winch off.
Jib removed indicator lamp
: Auxiliary Winch
HO
D E F COOL
IW301-0231E16 2B
MODE
3B-
The winch selection alternates between main

winch and auxiliary winch each time the winch
selector switch is pressed. When auxiliary winch Jib state switch
IW301-0231E17
is selected, the winch selection indicator lamp
lights up.
[NOTICE]
For boom lift, always employ the main winch.
97 W301-0213E
AML Pre-operational Inspection 2. Press either the register key, display alteration
key or check key to return the display to the
WARNING normal condition.
Operating the crane with a malfunctioning AML 3. Make sure that the display on the display panels
could cause the crane to overturn or be
damaged. Be sure to perform the conforms to the actual crane conditions.
pre-operational inspection on the AML system
and start the crane only after ensuring that the (1) Boom length
system is operating properly.
(2) Boom angle
(3) Jib angle ......shown while jib lift is selected

(4) Actual load…With no load on hook, make
sure that an approximate mass
1. Press the check key and make sure that the AML of the hook block is shown.
is in the following conditions:
[NOTICE]
Moment display ................... All segments light up. The actual load is not shown correctly if the lift
status is not registered correctly.
Display panel (1 and 2)
.................... All segments light up. (5) Outrigger state symbol
Working range restriction indicator lamp (6) Boom position indicator

.....................All six lamps light up.
(7) Over-front position symbol
Alarm buzzer .................... Sounds continuously. ……shown while the boom is in over-front area
Movement toward critical sides (8) Counterweigth state indicative symbol

...................... Automatically halted
3
Buzz 2
1
Bargraph display
4
8
Display panel 1
゜
m
6
Display panel 2
m t
%
m ax t
m
7
Check key
5
IW301-0231E18
IW301-0211E16
98 W301-0213E
How to Use the Working Range Limit Boom Angle Limit

Function
Raise or lower the boom to the desired angle,
[NOTICE] and press the upper or lower boom angle
If the working range limit is registered very close restriction key. The corresponding restriction
to an obstacle, there is a risk of the crane colliding indicator lamp will flash and the buzzer will sound
with the obstacle, depending on the operational continuously, indicating that the boom angle limit
status and the manner in which the load is handled.
has been registered in the memory. When the
When registering a range limit, allow a sufficient
clearance to avoid collision. boom is moved back to an angle within the set
limit, the restriction indicator lamp stops flashing
The working range restricting function makes the and stays lit and the buzzer stops.
boom automatically stop at the previously Thereafter, the upper or lower boom angle
registered boom angles (upper and lower), lifting restriction indicator lamp flashes and the buzzer
height, load radius and swing angle, sounds continuously whenever the upper or lower
The function is useful for handling a load in a limit previously registered is reached. (Boom
confined place because it defines the area in raising or lowering stops automatically.)
which the boom can operate. To cancel the boom angle limit function, press the
[NOTICE]
lamp will go off.
automatically erases all the previous settings
stored in memory after approximately 2 hours. To
resume the operation more than 2 hours after the
power was last turned off, enter the settings all over
again.
Upper boom angle restricted Lifting height restricted Upper boom angle
Lower boom angle restricted restriction indicator
m t
lamp
m ax t
θu
Lower boom angle
H
lamp
θL
Lower boom angle

Load radius restricted Swing restricted restriction key
Upper boom angle

restriction key
IW301-0213E07
R
IW301-0131E70
99 W301-0213E
[NOTICE]
m t
indicator lamp
m ax t
key
IW301-0211E20

m t indicator lamp
m ax t

m
indicator lamp

key

key
IW301-0211E21
100 W301-0213E
Load Radius Limit

buzzer stops.
lamp will go off.
m t
m ax t

indicator lamp
Load radius
restriction key
IW301-0211E22
101 W301-0213E

"Working range".
[NOTICE]
check of the AML and when a working state is being
registered.
m t
m ax t
m
Register key
Swing limit values
IW301-0213E08
102 W301-0213E
Display Alteration
Moment Display
M* * *. * MPa Unit
IW301-0211E24
Display Panel 1
[NOTICE]

M * * *. * MPa
Actual load
m
%
m ax t
Swing angle

IW301-0213E09
103 W301-0213E
Functions of and How to Use User Mode (GR-300EX-1)
Functions of and How to Use User

Mode (GR-300EX-1)
Mode Structure 3. Adjustment Mode:

POWER ON

switch
ON
Protect
switch
OFF ADJUSTMENT MODE
POWER ON
IW301-0212E05
1. User Mode:

power turns on.

is faulty).
PROTECT
MOMENT
SHORT
ZERO
HALT
WDT
OFF
ON
Protect switch
104 W301-0213E
Configuration and
Functions of the AML System When any working range limit is registered to the
AML, the crane is controlled so that the crane
The AML(Automatic Moment Limiter) system is a
safety device provided to prevent overloading of
the crane which may cause it to overturn or be
damaged.
including the following typical functions. Based on (4) Slow stop function
the registered work conditions by operator In the following cases, the boom elevation speed
selection and the signals from various sensors, gradually decreases to stop before the boom
the crane operations are controlled. reaches the stoppage position.
(1) Automatic stop function to prevent overloading • When the automatic stop is caused by overloading
The AML calculates and compares the working (Boom lowering will stop.)
When the working moment exceeds the rated • When the elevating cylinder reaches its stroke end
moment (100% or more), failure message is (Boom raising/lowering will stop.)
shown, alarm buzzer sounds, and the crane • When the automatic stop is caused by working
operation toward the critical side stops. range limit function (Boom raising/lowering will
(2) Automatic stop function by backward instability stop.)
When the boom is raised to 72°: in an over-side • When the automatic stop is caused by backward
area with on-rubber operation. instability during on-rubber operation (Boom
raising will stop.)
The situation of automatic stop due to automatic stop
function and working range limit function is as listed
below, depending on the working condition.

Hoisting up
overloading Boom extension
Swing ×
Stop by backward instability Boom raising -
Boom extension
restriction
Swing ×
: Slow stop : Stop × : Not stop - : Not relevant
105 W301-0213E
Load Moment Indicator System Configuration
Boom length signal Boom angle signal Moment ratio signal Over-front area signal Crane control position
signal
L
q W
Outrigger extension Swing angle signal

Outrigger status
width detector
Operator selection
Lift status
q

L
Jib status
AML unit

Display panel lamps
m
Stop output when:
% Moment ratio exceeds 100% Backward

Overwinding occurs stability
Moment exceeding limit for control
boom with jib mounted activated Swing restricted
AML system error occurs (Except for on-rubber
operation)
Working range limit

signal output
Boom Boom lowering Hoisting up Swing halted Boom raising Upper boom angle Lifting height Load radius
extension halted halted in critical side halted restricted restricted restricted
halted (Except for on-rubber Lower boom angle
operation) restricted
qu
qL
R
IW301-0213E14
106 W301-0213E
Automatic Stop Functions Alarm Functions

Causes of Condition Alarm
Operation Halted movement A control is moved toward Moment display: Displays
automatic stop
critical side (hoist up, boom [Warning:0024].
• Moment ratio • Hoisting up
lowering or boom extension) Buzzer: Sounds continuously.
exceeds 100%(*1) • Boom lowering while overwinding condition
• Overwinding • Boom extension exists.
• AML system error • Swing Overwind cutout function is Moment display: Displays
deactivated while [Warning:0015].
Upper boom • Boom raising
overwinding codition exists. External warning lamps: Red
angle restricted • Boom lift
lamp is lit.
Working range limit
Lower boom • Single top lift • Boom lowering Buzzer: Sounds continuously.
angle restricted • Jib lift Moment ratio exceeds 90% Moment display: Yellow
Lifting height • Boom raising segment is lit.
restricted • Boom extension External warning lamps:
Orange lamp is lit.
Load radius • Boom lowering
restricted • Boom extension A control is moved toward Moment display: Displays
Swing restricted • Swing critical side while moment [Warning:0023].
• Backward instability • Boom lift • Boom raising ratio exceeds 100% External warning lamps: Red
(*2) lamp is lit.
• Single top lift
AML system errer Moment display: Displays
(*1): For the boom lift with the jib mounted,
failure messages.
automatic stop will work when the moment AML Buzzer: Sounds 3
exceeds the value listed below, according to the seconds.
outrigger extension width: Working range limit function Moment display: Displays
activated. failure messages.
Associated restriction
Outrigger extension width Moment indicator lamp flashes.
Maximum 6.3m 94% or more AML Buzzer: Sounds 3
seconds.
Middle 5.9m 93% or more
A control is moved toward Moment display: Displays
Middle 5.0m 91% or more critical side when backward [Warning:0025].
stability control activated AML Buzzer: Sounds 3
seconds.
Slow stop control Moment display: Displays
[Warning:0081] or [0082]
Buzz
AML Buzzer: Sounds 3
seconds.
Boom lift with jib mounted on boom (*1)
(1) Moment ratio is between Moment display:
84% and 94%. Corresponding segment is lit.
(2) Moment ratio is between External warning lamps :
83% and 93%. Orange lamp is lit.
(3) Moment ratio is between Buzzer: Sounds
81% and 91%. intermittently.
(1) Moment ratio exceeds Moment display: Displays
IW301-0131E54
94% [Warning:0088].
(2) Moment ratio exceeds External warning lamps : Red
93% lamp is lit.
(*2): Automatic stop will work when the boom is (3) Moment ratio exceeds Buzzer: Sounds continuously.
raised to 72° in an over-side area with 91%
on-rubber operation.
107 W301-0213E
(*1)
(1) is applicable when the outriggers are extended to
maximum 6.3m.
middle 5.9m.
middle 5.0m.
[NOTICE]
In the above table, "Buzzer" is the device outside
The AML buzzer sounds for 3 seconds every time a
message appears. It outputs long sounds when
slow stop control is activated and outputs short
sounds when other controls are activated.
108 W301-0213E
Bargraph display
Display panel 1
゜
m
゜
・
Display panel 2
Control
IW301-0231E08
109 W301-0213E
Bar graph Display
3 1 2

than that

IW301-0211E06

4. Scroll-down key
110 W301-0213E
Display Panel 1
1 2 3 5
m
15
14 16 17 20 21
6
m 18 t
13
O
%
max t 7
17
m 8
19 11 10 9
IW301-0211E07

5. Jib angle symbol
6. Jib lift symbol
It also indicates the condition of the jib.
7. Actual load display while the register key is pressed.
14. Lifting height symbol
8. Rated lifting capacity display This symbol indicates the boom length display
Displays the rated lifting capacity. [13] is showing the lifting height.
111 W301-0213E

pressed.
selected.
selected.
[19] is showing the registered lower boom angle
limit value.
112 W301-0213E
Controls
15 14 13 12 11
10
16 17 9
19
18 8
20
7
1 2 3 4 5 IW301-0131E59

2. Decrease key
5. Check key


angle limiting function. functio
113 W301-0213E

activated.

Display Panel 2
5
3
2
4
2 3
3 2
3
IW301-0231E10


114 W301-0213E

(1) On-outrigger operation
When the outrigger mode select key is pressed,
WARNING the outrigger state symbols flash in accordance
Should the operational status be incorrectly with the status that the AML detects.
registered, the crane may overturn or be
After making sure that the display conforms to the
damaged, leading to a serious accident.
Prior to every operation, check that the actual outrigger conditions, press the register key.
registered status corresponds to the actual The outrigger state symbols will change from
status of the crane.
flashing to continuous lighting, and the moment
display, rated lifting capacity display and actual
Selecting Outrigger Status load display will return to normal display
conditions, meaning that the state has been
[NOTICE] registered.
The "on-rubber stationary" status is the default
status and is automatically selected when the power Actual outrigger
supply is turned on (the PTO switch is placed in the extension Displayed outrigger status
"ON" position). condition

again.
Register the outrigger status using the outrigger

IW301-0231E12
mode select key and the register key.
゜
m
゜
・
Register key

IW301-0231E11
115 W301-0213E
(2) On-rubber operation

Press the outrigger mode select key repeatedly
until the display conforms to the actual condition
(on-rubber stationary operation or on-rubber creep
operation). Then press the register key. The
moment display, rated lifting capacity display and
actual load display will return to normal display
conditions, meaning that the on-rubber state has
been registered.
[NOTICE]
The outrigger status automatically changes to
on-rubber creep status when an operation is made
for stowing the outrigger after the registration of the
outrigger status. Be sure to again register the
outrigger status, when necessary.
116 W301-0213E

[NOTICE]
again.

m t
%
m ax t
Register key

IW301-0211E13

switch while the status (9) is displayed on the
actual lift status.
[NOTICE]
After selecting the intended lift status, press the
capacity display and actual load display will return
to normal display conditions, meaning that the state
117 W301-0213E
Selecting Number of Parts of Line When the power supply is turned on (i.e. PTO
switch ON), the standard number of pars of line
corresponding to the work condition is selected.
[NOTICE]
If the registered number of pars of line is smaller
Register the number of parts of line by use of the
than the standard number, a maximum allowable
lifting load is limited, depending on the registered number of parts of line select key and the register
number. If zero(0) is registered, however, the AML key, as follows:
performs as if the standard number were registered.
standard number of parts of line if the registered
number is larger than the standard number or other
than the values specified for your model.
Number of parts of line symbol

Number of parts of line select key
Decrease key
Increase key Register key
IW301-0134E11
1. Press the number of parts of line select key. The 3. Once the intended number of parts of line is set,
number of parts of line symbol will flash, and the press the register key to register the number.
number of parts of line will be shown on the jib Then, the number of parts of line symbol will be
angle display in a flashing mode. turned off and the jib angle display will return to a
normal status.
2. Press the increase or the decrease key to set the
number to the actual number of parts of line. [NOTICE]
[NOTICE] pressing the display alteration key.
When the increase or the decrease key is pressed,
a numeral showing the number of parts of line
changes from flashing to lighting, and increases or
decreases.
When the increase or the decrease key is kept
increases or decreases.
118 W301-0213E
Selecting Jib Mounted Condition
WARNING
If the jib mounted/dismounted state is set
improperly, the AML does not function
accurately. The crane operation in this condition
could create hazard.
The jib can be dismounted from the crane body

when it is not used. The reduced mass of the
crane body after jib removal will influence
accuracy of the AML. Use this switch to set the jib
mounted /dismounted state to the AML.
[NOTICE]
The key can be inserted in and removed from either
“REMOVED” or “EQUIPPED” position.
(1) “REMOVED” Select this position when the jib is

dismounted. The jib removed indicator lamp will
light up.
(2) “EQUIPPED” Select this position when the jib is

mounted. The jib removed indicator lamp will go
off.
Jib removed indicator lamp
HO
D E F COOL
2B
MODE
3B-
Jib state switch

IW301-0231E17
119 W301-0213E
AML Pre-operational Inspection

2. Press either the register key, display alteration key
or check key to return the display to the normal
WARNING condition.
Operating the crane with a malfunctioning AML
could cause the crane to overturn or be 3. Make sure that the display on the display panels
damaged. Be sure to perform the conforms to the actual crane conditions.
pre-operational inspection on the AML system
and start the crane only after ensuring that the
(1) Boom length
system is operating properly.
(2) Boom angle
(3) Jib angle……shown while jib lift is selected

works in good condition, as follows: (4) Actual load…With no load on hook, make sure
1. Press the check key and make sure that the AML that an approximate mass of the
is in the following conditions: hook block is shown
• Moment display……All segments light up.
[NOTICE]
• Display panel (1 and 2)
………………………All segments light up. status is not registered correctly.
• Working range restriction indicator lamp
………………………………All six lamps light up. (5) Outrigger state symbol
• Alarm buzzer………………Sounds continuously.
(6) Boom position indicator
• Movement toward critical sides
………………………………Automatically halted (7) Over-front position symbol
……shown while the boom is in over-front area
Buzz
Bargraph display 3
2
1
Display panel 1
4
m
Display panel 2
m t 7
m t
% o
m ax t
max t
m
m
Check key
IW301-0211E17
IW301-0211E16
120 W301-0213E
How to Use the Working Range Limit Boom Angle Limit

Function
Raise or lower the boom to the desired angle, and
[NOTICE] press the upper or lower boom angle restriction
If the working range limit is registered very close to key. The corresponding restriction indicator lamp
an obstacle, there is a risk of the crane colliding will flash and the buzzer will sound continuously,
with the obstacle, depending on the operational indicating that the boom angle limit has been
status and the manner in which the load is handled.
registered in the memory. When the boom is
When registering a range limit, allow a sufficient
clearance to avoid collision. moved back to an angle within the set limit, the
restriction indicator lamp stops flashing and stays
The working range restricting function makes the lit and the buzzer stops.
boom automatically stop at the previously Thereafter, the upper or lower boom angle
registered boom angles (upper and lower), lifting restriction indicator lamp flashes and the buzzer
height, load radius and swing angle, sounds continuously whenever the upper or lower
The function is useful for handling a load in a limit previously registered is reached. (Boom
confined place because it defines the area in raising or lowering stops automatically.)
which the boom can operate. To cancel the boom angle limit function, press the
[NOTICE]
lamp will go off.
the operation more than 2 hours after the power
was last turned off, enter the settings all over again.
Upper boom angle restricted Lifting height restricted

Lower boom angle restricted Upper boom angle
restriction indicator
m t
lamp
θu
m ax t
H Lower boom angle

θL lamp
Load radius restricted Swing restricted

Lower boom angle
restriction key
Upper boom angle

restriction key
IW301-0213E07
R
IW301-0131E70
121 W301-0213E
[NOTICE]
m t
indicator lamp
m ax t
key
IW301-0211E20

m t indicator lamp
m ax t

m
indicator lamp

key

key
IW301-0211E21
122 W301-0213E
Load Radius Limit

buzzer stops.
lamp will go off.
m t
m ax t

indicator lamp
Load radius
restriction key
IW301-0211E22
123 W301-0213E

"Working range".
[NOTICE]
check of the AML (load moment indicator) and
when a working state is being registered.
m t
m ax t
m
Register key
Swing limit values
IW301-0213E08
124 W301-0213E
Display Alteration
Moment Display
M* * *. * MPa Unit
IW301-0211E24
Display Panel 1
[NOTICE]

M * * *. * MPa
Actual load
m
%
m ax t
Swing angle

IW301-0213E09
125 W301-0213E
General: Adjustment Mode and Maintenance Mode
[ADJUSTMENT AND MAINTENANCE]

1. Keys and Switches for Adjustment and Maintenance

1. Scroll-up key Moment display
2. Scroll-down key
m t
max t
PROTECT
MOMENT
SHORT
ZERO
HALT
WDT
OFF
ON
8. Moment input short-circuit switch
7. Check key 9. Protect switch
4. Increase key 3. Register key 10. Moment zero adjuster
5. Decrease key 6. Display alteration key 11. Abnormality display LED
IW301-0211E26 Top view IW301-0131E02
1. Scroll-up key 7. Check key

Used to see the previous lines of message Used for ”Do Check” and ”Ao Check” functions in
displayed on the moment display. the maintenance mode.
2. Scroll-down key 8. Moment input short-circuit switch

Used to see the next lines of messages displayed Not used for this machine.
on the moment display.
9. Protect switch
3. Register key Set this switch to OFF when changing the mode
Used to register the selected state and write the from user mode to adjustment mode. With this
adjustment value in EEPROM. switch OFF, data in the EEPROM becomes
rewritable.
4. Increase key
Used to increase the adjustment value. 10.Moment zero adjuster
This adjuster is for adjustment by the AML
5. Decrease key
manufacturer’s service personnel. Do not tamper.
Used to decrease the adjustment value.
11.Abnormality display LED
6. Display alteration key
Lights when the AML is in abnormal conditions or
Used to change the display to the upper menu.
when the AML adjustment is initialized.
126 W301-0213E
2. Mode Structure and Menu 2. Maintenance Mode:

Used to make functional checks of AML. This
The AML device has three modes and AML mode has the following menus:
MAIN MENU SUB-MENU

POWER ON
[• Maintenance] [: Prog. version]
[: Data ID. number]
[• Adjust clock] [: Di check]
switch
ON [: Ai check]
[: Disp ELEV PRES]
Protect [: Do check]
switch
OFF ADJUSTMENT MODE [: MDT Monitor]
[: Key SW check]
[: Display check]
POWER ON [: Disp. err data]
IW301-0212E05
[: Erase err data]
1. User Mode: [: Disp. O/L data]
Used to indicate moment ratio or to perform AML [: Erase O/L data]
pre-opetational inspection (Normally used). [: OP board check]
[: Ao check]
In normal use, turn ON the protect switch [: Sio check]
mounted on the adjustment window on the top of [: Adjust Monitor]
power turns on.
PROTECT
MOMENT
SHORT
ZERO
HALT
WDT
OFF
ON
ON
Protect switch
127 W301-0213E
3. Adjustment Mode:
Used to make detector adjustment. This mode has the following menus:
MAIN MENU SUB-MENU
[• Adjust] [: Adjust L&A] *Boom length zero-point adjustment

*Boom length span-point adjustment
*Boom angle zero-point adjustment
*Boom angle span-point adjustment
*Swing angle zero-point adjustment
*Swing angle span-point adjustment
*Outrigger length zero-point adjustment
*Outrigger length span-point adjustment
*Jib length zero-point adjustment
*Jib length span-point adjustment
*Jib angle zero-point adjustment
*Jib angle span-point adjustment
[: Adj. work rad] *Load radius span adjustment
[: Adjust MMT] *Moment zero-point adjustment
*Moment span-point adjustment
[• Adjust CNT dat] [: Adj. ELV speed] [Adjust ELV UP]
[Correct ELV UP]
[Adjust ELV DN]
[Correct ELV DN]
[: Reset ELV data]
[• Adjust AO] [: Adjust AO Ofs.]
[: Reset AO Ofs.]
[• Initialize L&A] [: Reset DEF. FCT]
[• Initialize MMT] [: Reset zero. span]
(*1)
[• Disp. O/L data] [: Erase PCSN]
[• Erase O/L data]
(*1)
[• Adjust PCSN]
[• Reg. Capac.] [: Head-OFF Capac]
[• Language] [: Jib Select]]
[: S/T Select]
[: Winch drum PSN]
(*1)
: This menu is prohibited to be used, except for Europe.
128 W301-0213E
3. Method of Shifting Modes

Scroll-up key Moment display
Scroll-down key
PROTECT
MOMENT
SHORT
ZERO
HALT
WDT
OFF
ON
OFF
m t
max t ON Protect switch

m
POWER ON
1
switch 2
ON
3 5
4
Protect
switch
OFF ADJUSTMENT MODE
Register key
Display alteration key POWER ON
IW301-0211E28 IW301-0232E12
1. “User mode” → “Maintenance mode” 4. “Adjustment mode” → “User mode”

Press the scroll-up key, scroll-down key, and While the main menu of the adjustment mode is
register key at the same time. Then, the moment displayed, turn ON the protect switch. Then AML
display changes from the bargraph to will go back to “User mode” and bargraph will be
[• Maintenance]. This display denotes the displayed on the moment display.
“Maintenance mode”.
5. “Maintenance mode” → “Adjustment mode”
2. “Maintenance mode” → “User mode” While the main menu of the maintenance mode is
Press the display alteration key. When the displayed, turn OFF the protect switch. The
bargraph shows up on the moment display, AML moment display will change to [•Adjust], and will
goes back to the “User mode”. denote “Adjustment mode”.
3. “User mode” → “Adjustment mode”

Turn OFF the protect switch at the adjustment
window on the top of AML. Then, the moment
display will change to [•Adjust], and will denote
“Adjustment mode”.
129 W301-0213E
4. Method of Menu Selection

Scroll-up key Moment display
Scroll-down key
m t
max t
Register key
IW301-0211E28
1. When AML is in “Maintenance mode” or 4. The following marks displayed in the menu: “•”, “:”
“Adjustment mode”, the main menu is displayed and “ ”.
on the moment display of bargraph display portion. When a main menu is displayed, the mark “•”
Displayed menu changes by means of the stands before the menu name. (Ex. “•Adjust ”)
scroll-up or scroll-down key. Press the register key When a sub-menu is displayed, the mark “:”
to select the displayed item. stands before the menu name.
(Ex. “:Adjust MMT”)
2. If the selected item in the main menu has any
The “ ” mark after the menu name indicates that
sub-menus, the sub-menus are displayed on the
the depression of the scroll-down key calls for
moment display of bargraph display portion. You
another menu.
can select the sub-menu in the same way sa main
menu selection.
3. By pressing the display alteration key, the display

changes to the upper menu.
130 W301-0213E
Required Adjustment After AML System Parts Replacement
Required Adjustment After AML System Parts Replacement
[NOTICE]
EEPROM stores the adjustment values for each specification number. When replacing the CPU board,
remove the EEPROM after removing it from the broken CPU board to dispense with adjustment work other
than clock adjustment. Visually check that the value displays such as boom length and boom angle and
symbol display on the display panels 1 and 2 on the AML conform the actual crane condition.
Replaced part Required adjustment
Boom length detector Boom length adjustment
Boom angle detector Boom angle adjustment
Swing angle detector Swing angle adjustment
Outrigger extension width detector Outrigger extension width adjustment
Pressure sensor for moment detection Moment adjustment
Display board None

CPU board only
(When reusing EEPROM removed Clock adjustment
from the broken CPU board)
Perform adjustment initialization and
CPU board take every step of adjustment. For
CPU board (When EEPROM is not to be reused) adjustment items and procedure, see
“Adjustment Procedures” on the
subsequent page in the “Function of
EEPROM and How to Use Adjustment Mode”
AML unit section.
ROM None
Boom length adjustment
Boom angle adjustment
Analog board
Swing angle adjustment
Moment adjustment
Power board None
Adjustment of swing output
Current output board (Option board)
Adjustment of elevation output
Connector board None
Right swing proportional control valve

Adjustment of swing output
Proportional Left swing proportional control valve
control valve
for Slow stop Boom raising proportional control valve
Adjustment of elevation output
Boom lowering proportional control valve
131 W301-0213E
Functions of and How to Use Adjustment Mode
Functions of and
How to Use Adjustment Mode
Adjustment Procedures
WARNING
Before making an adjustment, extend the
outriggers fully and set the crane on firm ground
for safety.
[NOTICE]
You can adjust boom length, boom angle, swing
angle, and outrigger extension width in random
order.
You can adjust swing output and elevation output in
random order.
After all adjustment is completed, erase-protect the
overload history, referring to “Erasing the Overload
History” in the “Functions of How to Use Adjustment
Mode” section.
The adjustment items and procedures are as follows:
1. Adjustment Initialization
2. Capacity Setting
3. Boom Length Adjustment

4. Boom Angle Adjustment
5. Swing Angle Adjustment
6. Outrigger Extension Width Adjustment
7. Moment Adjustment
(Including load radius adjustment)
8. Clock Adjustment
9. Adjustment of Swing Output

10.Adjustment of Elevation Output
Adjustment completed
Erasing the Overload History
132 W301-0213E
1. Adjustment Initialization 1.1 Procedure of Conversion Factors Resetting
1. Select the main menu [ • Initialize L&A ] in the

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

factor by pressing the register key.
3. When the message [Done] appears, the moment

adjustment resetting is completed.
Press the display alteration key to return to the
main menu.
133 W301-0213E
2. Capacity Setting 2.1 Procedure of Head-off Capacity Setting
[NOTICE]
[NOTICE]
A head-off capacity value defined with this function
Check the specification number of “Adjustment
is compared with the capacity (rated lifting capacity)
Value Table” in the INFORMATION AND DATA
data stored in the ROM, and the value whichever
section whether your crane needs to perform this
smaller is set as the capacity. Note that if the
setting. For the models other than GT-550E-1,
head-off capacity value is zero, the capacity data
GR-120N-1 and GR-700EXL-1, GR-300EX-1 refer
stored in the ROM is used.
to the Service Manual specified for each crane
model.
1. Select the main menu [• Reg. Capac. ] in the
The crane capacity data is stored in the ROM. adjustment mode, and press the register key to
This setting is performed to partially change the select the menu.
crane capacity data in the ROM.
2. Press the scroll-up or scroll-down key to display
The crane capacity data normally does not need [: Head-Off Capac ], and then press the register
this setting. key to select the menu.
For the capacity setting, select one of the four 3. The currently registered head-off capacity value is
sub-menus indicated below. indicated on the moment display.
[: Head-Off Capac] : Display example:
Used to set the maximum rated lifting capacity to [Capacity 45.00t]
the specified value.
4. Press the increase or decrease key to adjust the
[: Jib Select] :
head-off capacity value as desired.
Used to change the capacity for jib-mounted
Every time you press the increase or decreace
condition to the capacity for jib-unmounted
key, the head-off capacity value increases or
condition.
decreases in steps of 0.01t. If the key is held
[: S/T Select] :
down, the value increases or decreases in steps
Used to change the capacity for
of 1t.
single-top-mounted condition to the capacity for
single-top unmounted condition. 5. When the desired head-off capacity value is
[: Winch drum PSN] : reached, press the register key to save it.
Used to specify the mounting position of winch
6. Press the display alteration key to exit the menu.
drum for capacity adjustment.
134 W301-0213E
2.2 Procedure of Jib Selection 2.3 Procedure of Single Top Selection
[NOTICE] [NOTICE]
When the jib-unmounted (detached) condition is When the single-top-unmounted (detached)
selected, the jib capacity data stored in the ROM condition is selected, the single top capacity data
becomes unusable and also the jib mass is stored in the ROM becomes unusable and also the
excluded from capacity calculation. single top mass is excluded from capacity
calculation.
adjustment mode, and press the register key to 1. Select the main menu [• Reg. Capac. ] in the
select the menu. adjustment mode, and press the register key to
2. Press the scroll-up or scroll-down key to display select the menu.
[: Jib Select ], and then press the register key to
select the menu.
[: S/T Select ], and then press the register key to
3. The currently registered jib capacity condition is select the menu.
indicated on the moment display. Using the
3. The currently registered single top capacity
scroll-up or scroll-down key, adjust it to the
condition is indicated on the moment display.
desired condition .
Using the scroll-up or scroll-down key, adjust it to
Display example:
the desired condition.
[Jib = Mounted ]
Display example:
Press the scroll-up key.
[S/T=Mounted ]
[Jib : Not Mounted]
When “ = ” is indicated, it means that the
[S/T : Not Mounted]
displayed condition is registered currently.
When “ = ” is indicated, it means that the
4. When the desired condition is displayed, press the displayed condition is registered currently.
register key for confirmation. When the setting is
4. When the desired condition is displayed, press the
completed, “:” in the Jib condition display changes
register key for confirmation. When the setting is
to “ = ”.
completed, “:” in the single top condition display
Display example:
changes to “ = ”.
[Jib：Not Mounted]
Display example：
Press the register key.
[S/T : Not Mounted]
[Jib = Not Mounted]
5. Press the display alteration key to exit the menu. [S/T = Not Mounted]
135 W301-0213E
2.4 Procedure of Winch Drum Position Setting
[NOTICE]
The center of gravity of winch drum can be changed
by adjusting the winch drum position. The
calculation is performed according to the winch
drum position setting by this function.

select the menu.

[: Winch drum PSN], and then press the register
key to select the menu.
3. The currently registered jib capacity condition is

indicated on the moment display. Using the
scroll-up or scroll-down key, adjust it to the
desired condition.
Display example:
[Winch drum = FR ]
[Winch drum : F ]
[Winch drum : R]
In the above examples, “F” means the condition
with single winch mounted at the front. “R” means
the condition with single winch mounted at the
rear. “FR” means the condition with double
winches mounted at the front and rear.
The conditions with “ = ” is the currently registered
condition.
4. When the desired condition is displayed, press the

register key for confirmation. When the setting has
been completed, “:” in the winch drum condition
display changes to “ = ”.
Display example:
[Winch drum : F ]
[Winch drum = F ]
136 W301-0213E
3. Boom Length Adjustment 10.Has the boom length zero-point adjustment

display [Boom Lz] become the zero-point
WARNING adjustment value in “Adjustment Value Table” ?
NO YES
for safety.
11.Press the display alteration key to exit the menu.
[NOTICE]
Refer to “Adjustment Value Table” in the
INFORMATION AND DATA section since the
conditions and values for boom length adjustment
vary depending on the specification number. For the
models other than GT-550E-1, GR-120N-1 and
GR-700EXL-1, GR-300EX-1 refer to the Service
Manual specified for each crane model.
When the length detector has only been installed
and its cord has not yet been unwound on the drum,
set the code wound naturally on the boom through
the entire length during the boom telescopic
operation.
1. Select the main menu [• Adjust ] in the

select the menu.
2. When [: Adjust L&A ] is displayed, press the

register key to select the menu.
3. Fully retract the boom.
4. Press the increase or decrease key so that the

value of boom length zero-point adjustment
display [Boom Lz] becomes the zero-point
adjustment value in “Adjustment Value Table”.
Press the register key for registration.
5. Fully extend the boom.
6. Press the scroll-down key until the boom length

span adjustment display [Boom Ls] appears.

value of boom length span adjustment display
[Boom Ls] becomes the span adjustment value in
“Adjustment Value Table”. Press the register key
for registration.
8. Fully retract the boom again.
9. Press the scroll-up key until the boom length

zero-point adjustment display [Boom Lz] appears.
137 W301-0213E
4. Boom Angle Adjustment

WARNING
value of boom angle span adjustment display
[Boom As] becomes the span adjustment value in
for safety. “Adjustment Value Table”. Press the register key
for registration.
[NOTICE]
9. Bring the actual boom angle to the zero-point
INFORMATION AND DATA section since the adjustment value in “Adjustment Value Table”
conditions and values for boom angle adjustment again.
vary depending on the specification number. For the
models other than GT-550E-1, GR-120N-1 and 10.Press the scroll-up or scroll-down key until the
GR-700EXL-1, GR-300EX-1 refer to the Service boom angle zero-point adjustment display [Boom
Manual specified for each crane model. Az] appears.
Always perform the boom lowering operation when
adjusting the boom angle to the adjustment 11.Has the value of boom angle zero-point
condition. Measure the boom angle with a level adjustment display [Boom Az] become the
angle meter.
zero-point adjustment value in “Adjustment Value
1. Select the main menu [• Adjust ] in the Table” ?
adjustment mode, and press the register key to NO YES
select the menu.
2. When [: Adjust L&A ] is displayed, press the 12.Press the display alteration key to exit the menu.
3. Set the actual boom angle to the condition of the

zero-point adjustment specified in “Adjustment
Value Table” by lowering the boom.
4. Press the scroll-up or scroll-down key until the

boom angle zero-point adjustment display [Boom
Az] appears.

value of boom angle zero-point adjustment display
[Boom Az] becomes the zero-point adjustment
value in “Adjustment Value Table”. Press the
register key for registration.
6. Raise the boom to just before the upper stroke

end, and then adjust the actual boom angle to the
condition of the span-point adjustment specified in
“Adjustment Value Table” by lowering the boom.

boom angle span adjustment display [Boom As]
appears.
138 W301-0213E
5. Swing Angle Adjustment 10.Press the increase or decrease key so that the
value of swing angle 1 span-point adjustment
WARNING display [SW AG 1s] will become 180 ± 0.3°.
Before making an adjustment, extend the Press the register key for registration.
for safety. 11.With the swing position unchanged, press the
scroll-up or scroll-down key until the swing angle 2
[NOTICE] span-point adjustment display [SW AG 2s]
Since the swing angles involve a hysteresis, always appears.
make adjustment after a stop from rightward
movement. 12.Press the increase or decrease key so that the
value of swing angle 2 span-point adjustment
display [SW AG 2s] will become 180 ± 0.3°.
select the menu.
13.Set the boom again to the zero-point adjustment
2. When [: Adjust L&A ] is displayed, press the
reference position (on the front centerline) by
swinging it clockwise.
14.Check the swing angle 1 and 2 zero-point

3. Set the boom to the zero-point adjustment adjustment displays [SW AG 1z] and [SW AG 2z]
reference position (on the front centerline) by by pressing the scroll-up or scroll-down key. Does
swinging it rightward. each display indicate the angle below?
SW AG 1z：0 ± 0.6°
4. Press the scroll-up or scroll-down key until the SW AG 2z：360 ± 0.6°
swing angle 1 zero-point adjustment display [SW
AG 1z] appears. NO YES
5. Adjust the increase or decrease key so that the 15.Press the display alteration key to exit the menu.
value of swing angle 1 zero-point adjustment
display [SW AG 1z] will become 0 ± 0.3°. Press
the register key for registrarion.
6. With the swing position unchanged, press the

scroll-up or scroll-down key until the swing angle 2
zero-point adjustment display [SW AG 2z]
appears.
7. Adjust the increase or decrease key so that the

value of swing angle 2 zero-point adjustment
display [SW AG 2z] will become 360 ± 0.3°. Press
the register key for registration.
8. Set the boom to the span- point adjustment

reference position (on the rear centerline) by
swinging it rightward.

swing angle 1 span-point adjustment display [SW
AG 1s] appears.
139 W301-0213E
6. Outrigger Extension Width Adjustment adjustment value in “Adjustment Value Table”.

[NOTICE]
Refer to “Adjustment Value Table” in the 10.Adjust and register the values of the right-rear,
INFORMATION AND DATA section since the left-front and left-rear outriggers extension width
conditions and values for outrigger extension width span adjustment in the same manner as the one
adjustment vary depending on the specification
of the right-front outrigger extension width span
number. For the models other than GT-550E-1,
GR-120N-1 and GR-700EXL-1, GR-300EX-1 refer adjustment.
to the Service Manual specified for each crane Right-rear outrigger : Adjust [RRO/R Ls] display
model. Left-front outrigger : Adjust [LFO/R Ls] display
Left-rear outrigger : Adjust [LRO/R Ls] display
1. Select the main manu [• Adjust ] in the
adjustment mode, and press the register key to 11.Fully retract all the outrigger beams again.
select the menu.
12.Press the scroll-up or scroll-down key until the
2. When [: Adjust L&A ] is displayed, press the right-front outrigger extension width zero-point
register key to select the menu. adjustment display [RFO/R Lz] appears.
13.Does the right-front outrigger extension width

zero-point adjustment display [RFO/R Lz] conform
3. Fully retract all the outrigger beams.
to the zero-point adjustment value in “Adjustment
4. Press the scroll-up or scroll-down key until the Value Table” ? And does each display for the
right-front outrigger extension width zero-point right-rear outrigger [RRO/R Lz], for the left-front
adjustment display [RFO/R Lz] appears. outrigger [LFO/R Lz], and for the left-rear
outrigger [LRO/R Lz] conform to the zero-point
5. Press the increase or decrease key so that the adjustment value in “Adjustment Value Table” ?
value of the right-front outrigger extension width
zero-point adjustment display [RFO/R Lz] NO YES
conforms to the zero-point adjustment value in
14.Press the display alteration key to exit the menu.
“Adjustment Value Table”. Press the register key
for registration.
6. Adjust and register the values of the right-rear,

left-front and left-rear outrigger extension width
zero-point adjustment in the same manner as the
one of the right-front outrigger extension width
zero-point adjustment.
Right-rear outrigger : Adjust [RRO/R Lz] display
Left-front outrigger : Adjust [LFO/R Lz] display
Left-rear outrigger : Adjust [LRO/R Lz] display
7. Fully extend all the outrigger beams.

right-front outrigger extension width span
adjustment display [RFO/R Ls] appears.
9. Press the increase or decrease key so that value

of the right-front outrigger extension width span
adjustment display [RFO/R Ls] conforms to span
140 W301-0213E
7. Moment Adjustment
WARNING
for safety.
[NOTICE]
Before starting moment adjustment, raise the
hydraulic oil temperature to approx.50°C by
alternate raising and lowering the boom.
conditions and values for moment adjustment vary
depending on the specification number. For the
GR-700EXL-1, GR-300EX-1 refer to the Service
If the moment zero-point value is not within the
tolerance at “7.6 Moment Zero-point Recheck”,
follow the fine adjustment steps of the broken line
process order.
The procedure to adjust moment is as follows:
7.1 Moment Zero-point Adjustment
7.2 Moment Span Preliminary Adjustment
7.3 Moment Zero-point Check and Fine Adjustment
7.4 Load Radius Adjustment
7.5 Moment Span Fine Adjustment
7.6 Moment Zero-point Recheck

YES NO
End of moment adjustment
141 W301-0213E
7.1 Moment Zero-point Adjustment 0.00 to 0.99 t: “000” to “099”

-0.99 to -0.01 t: “-99” to “-01”
[NOTICE]
For the conditions and adjustment value of the 4. After the adjustment, press the register key to
moment zero-point adjustment, refer to the moment save the adjusted value.
zero-point adjustment item in the “Adjustment Value
Table”. 5. Proceed to “7.2 Moment Span Preliminary
Set the crane as follows: Adjustment”.
(1)Outriggers mode: Fully extended
(2)Lift mode: Boom lift (Stow jib and single top)
(3)Boom length: Fully retracted
(4)Boom angle: Raise boom until it almost reaches to
maximum point, and then lower it until boom angle
display corresponds to condition of zero-point
adjustment.(Refer to “Adjustment Value Table”.)
(5)Hook block position: Hoisted down just clear of
ground surface or vehicle structure
(6)Actual status and registered status of number of
part-lines: Standard number of part-lines when main
boom is fully extended
(7)Hook block: Refer to “Adjustment Value Table”.
(Stow auxiliary hook block.)
(8)Refer to “Adjustment Value Table” according to the
crane model, there might be a condition besides
above.

select the menu.
2. When [:Adjust L&A ] is displayed, press the

scroll-down key until the display [:Adjust MMT]
appears. Press the register key to select the
menu.
3. While the moment zero-point adjustment is

displayed, adjust the value indicated in the actual
load value indicator finely with the increase or
decrease key to conform it to the adjustment
value of the zero-point adjustment.
Moment zero-point adjustment display:
Display [X.XXX z . % ]
Moment ratio(%)
Shows zero-point adjustment

state
Moment detector input(mV)
The actual load value less than 1 klbs is shown as

follows:
142 W301-0213E
7.2 Moment Span Preliminary Adjustment 7.3 Moment Zero-point Check and
Fine Adjustment
[NOTICE]
For the conditions and adjustment value of the [NOTICE]
moment span preliminary adjustment, refer to the For the conditions and adjustment value of the
moment span preliminary adjustment item in the moment zero-point check and fine adjustment, refer
“Adjustment Value Table”. to the moment zero-point adjustment item in the
“Adjustment Value Table”.
1. Continued from “7.1 Moment Zero-point
Adjustment”. 1. Continued from “7.2 Moment Span Preliminary
Adjustment”.
2. Lower the boom to set the boom angle to the
condition of the span preliminary adjustment. 2. Raise the boom until it almost reaches to the
(Hook block position:Hoisted down until it almost maximum point, and then lower it until the boom
touches ground surface) angle display corresponds to the condition of the
zero-point adjustment. (Hoist down the hook block
3. Press the scroll-up or scroll-down key until the until it almost touches the ground surface or
moment span adjustment display appears. chassis.)
Moment span adjustment display:
Display [X.XXX s . %] 3. Press the scroll-up or scroll-down key until the
moment zero-point adjustment display appears.
Moment ratio(%) Moment zero-point adjustment display:
Shows span adjustment state Display [X.XXX z . % ]
Moment detector input(mV) Moment ratio(%)
4. Adjust the value indicated in the actual load value Shows zero-point adjustment
indicator finely with the increase or decrease key state
to conform it to the adjustment value of the span Moment detector input(mV)
preliminary adjustment.
The actual load value less than 1 t is shown as 4. Has the indicated value become the zero-point
follows: adjustment value?
0.00 to 0.99 t: “000” to “099” The actual load value less than 1 t is shown as
-0.99 to -0.01 t: “-99” to “-01” follows:
0.00 to 0.99 t: “000” to “099”
5. After the adjustment, press the register key to -0.99 to -0.01 t: “-99” to “-01”
save the adjusted value.
YES NO
6. Proceed to “7.3 Moment Zero-point Check and
Fine Adjustment”. 5. Make an adjustment with the increase or
decrease key so that the result becomes the
zero-point adjustment value. Then, press the
register key to save the adjusted value.
143 W301-0213E
7.4 Load Radius Adjustment (4)Boom angle: Lower boom until the boom angle
display corresponds to condition of span fine
[NOTICE] adjustment.
For the conditions and adjustment value of the load (5)Hook block position: Hoisted down until it almost
radius adjustment, refer to the load radius touches ground surface or vehicle structure.
adjustment item in the “Adjustment Value Table”. (6)Actual status and registered status of number of
Set the crane as follows: parts of line: Standard number of pars of line when
(1)Outriggers mode: Fully extended main boom is fully extended.
(2)Lift mode: Boom lift (Stow jib and single top) (7)Hook block: Refer to “Adjustment Value Table”.
(3)Boom length: Fully extended
(8)Refer to “Adjustment Value Table” according to the
(4)Actual status and registered status of number of
part-lines: Standard number of parts of line when
above.
main boom is fully extended
(5)Hook block: Refer to “Adjustment Value Table”. 1. Select the main menu [• Adjust ] in the
(6)Load radius: After lifting rated lifting capacity of
load radius adjustment condition, set actual load select the menu.
radius to meet load radius adjustment condition
(load radius) by boom lowering operation. (Cancel 2. When [: Adjust L&A ] is displayed, press the
AML stop function when overload hinders boom scroll-down key until the display [:Adjust MMT]
lowering.) appears. Press the register key to select the
(7)Refer to “Adjustment Value Table” according to the menu.
above. 3. Press the scroll-down key until the moment span
adjustment display appears.
1. Select the main menu [• Adjust ] in the Moment span adjustment display:
adjustment mode, and press the register key to Display [X.XXX s . %]
select the menu.
Moment ratio(%)
2. Press the scroll-down key until the load radius
adjustment display [: Adj. work rad ] appears. Shows span adjustment state
Then, press the register key to select the menu.
4. Using the increase or decrease key, adjust the
load radius adjustment display [Rad. 1s] becomes
indicated value so that it becomes the span fine
the load radius adjustment value. Press the
adjustment value. Then, press the register key to
register key for that registration.
save the adjusted value.
4. Press the display alteration key to exit the menu. The actual load value less than 1 t is shown as
follows:
0.00 to 0.99 t: “000” to “099”
7.5 Moment Span Fine Adjustment
-0.99 to -0.01 t: “-99” to “-01”
[NOTICE]
5. Proceed to “7.6 Moment Zero-point Recheck”.
For the conditions and adjustment value of the
moment span fine adjustment, refer to the moment
span fine adjustment item in the “Adjustment Value
Table”.
Set the crane as follows:
(2)Lift mode: Boom lift (Stow jib and single top)
(3)Boom length: Fully extended
144 W301-0213E
7.6 Moment Zero-point Recheck
[NOTICE]
For the conditions and adjustment value of the
moment zero-point recheck, refer to the moment 6. Make fine adjustment as shown below. (The
zero-point adjustment item in the “Adjustment Value following fine adjustment procedures are
Table”. extracted from “7.3 Moment Zero-point Check and
Fine Adjustment”.)
1. Continued from “7.5 Moment Span Fine
Adjustment”. (1)Make an adjustment with the increase or
decrease key so that the result becomes the
2. Retract the boom fully.
zero-point adjustment value. Then, press the
3. Raise the boom until it almost reaches to the register key to save the adjusted value.
maximum point, and then lower the boom until the
(2)Press the display alteration key to exit the menu.
boom angle display corresponds to the zero-point
adjustment condition. (Hoist down the hook block
until it almost touches the ground surface or
chassis.) 7. Perform “7.5 Moment Span Fine Adjustment”.
Perform “7.6 Moment Zero-point Recheck”.
moment zero-point adjustment display appears.
Moment zero-point adjustment display: 8. Press the display alteration key to exit the menu.
Display [X.XXX z . % ]
The moment adjustment is completed.
Moment ratio(%)
Shows zero-point adjustment

state
5. Has the indicated value become the zero-point

adjustment value?
The actual load value less than 1 t is shown as
follows:
0.00 to 0.99 t: “000” to “099”
-0.99 to -0.01 t: “-99” to “-01”
YES NO
145 W301-0213E
8. Clock Adjustment
AML has calender and clock IC inside, which is
used for recording errors. Adjust the clock in the
following procedure. Adjust the clock in the
maintenance mode.
1. Select the main menu [• Adjust clock] in the

maintenance mode, and press the register key to
select the menu.
2.When the time is displayed on the moment display,

press the scroll-up or scroll-down key to bring the
cursor to the place to be adjusted.
Time is displayed in the 24-hour basis. The cursor
lies under a numeral.
Display example:[ 99. 8. 23 16:30]
Cursor
3. Press the increase or decrease key to change the

value to be adjusted.
4. After the adjustment, press the register key to put

the adjustment value onto the IC. If there are
plural adjustment places, move the cursor for
adjustment in order. Finally press the register key.
5. press the display alteration key to exit the menu.
146 W301-0213E
9. Adjustment of Swing Output 3. Press the scroll-up or scroll-down key until the
right swing output adjustment display [41 SWG
[NOTICE] RV] (the left swing output adjustment display [42
Always reset the Ao offset value before adjustment SWG LV] for the left swing output adjustment)
of swing output (Ao offset adjustment).
appears and a cursor comes on under the output
value.
9.1 Procedure of Resetting Ao Offset Value
Display example:
1. Select the main menu [• Adjust AO ] in the [41 SWG RV 0 0 ]
adjustment mode, and press the register key to Actual output value
select the menu. Output value
2. When [:Adjust AO Ofs. ] is displayed, press the 4. Press the increasse or decrease key to conform
scroll-down key until the display [:Reset AO Ofs.] the output value of the right swing output
appears. Press the register key to select the adjustment display [41 SWG RV] to the standard
menu. value of the swing output. Remember that actual
3. When [Reset OK?] appears, reset the Ao offset output value will also change in this situation.
value by pressing the register key. Display example:
[41 SWG RV 35 35 ]
4. When the message [Done] appears, the Ao offset
value resetting is completed. Press the display Actual output value
alteration key to return to the main menu. Output value
9.2 Adjustment of Swing Output 5. Press the scroll-down key to move the cursor to
(Ao offset adjustment) under the actual output value.
Display example:
[NOTICE]
[41 SWG RV 35 35 ]
Actual output value
standard value of the swing output varies
depending on the specification number. For the
Output value
GR-700EXL-1, GR-300EX-1 refer to the Service 6. While keeping the swing control lever fully to the
right swing side, raise the engine speed to
Set the crane as follows:
maximum. Then press the increase or decrease
key so that the boom swing will stop under this
(2)Lift mode: Boom lift (Stow jib and single top.)
condition.
Display example:
(4)Boom angle: As high as possible (Lowered boom
can constitute a hazard when swung.) [41 SWG RV 35 37 ]
(5)Hook block position: Hoisted up as much as Actual output value
possible
(6)Hydraulic oil temperature: Approx. 50°C Output value
1. Select the main menu [• Adjust AO ] in the 7. Press the register key to save the adjusted value
adjustment mode, and press the register key to in EEPROM. Now the adjustment of the right
select the menu. swing output is completed.
2. When [: Adjust AO Ofs. ] is displayed, press the

147 W301-0212E
8. Adjust and save the left swing output in the same

manner as the right swing output adjustment.
Then press the display alteration key to exit the
menu. (For the left swing output adjustment,
substitute “left swing output adjustment display
[42 SWG LV]” for “right swing output adjustment
display [41 SWG RV]”.)
148 W301-0212E
10. Adjustment of Elevation Output 4. When [Retract Boom] appears, retract the boom
fully.
[NOTICE] This message does not appear if the boom is
Always reset the elevation data before adjustment already retracted fully.
of elevation output (elevation speed adjustment).
5. When [Boom A . ° ] appears, lower the boom
10.1 Procedure of Resetting Elevation Data to or below the displayed angle. However, do not
retract the elevating cylinder to its stroke end.
1. Select the main menu [• Adjust CNT dat ] in the
This message does not appear if the boom is
already lowered to or below the specified angle.
select the menu.
6. When the following messages appear, press the
2. When [: Adj. ELV speed ] is displayed, press the
scroll-down key until the display [:Reset ELV data]
Display:
appears. Press the register key to select the
[Start CNT Adj. ]
menu.
[JS neutral ]
3. When [Reset OK?] appears, reset the elevation [Push reg. key]
data by pressing the register key.
7. When the following messages appear, shift the
4. When the message [Done] appears, the elevation boom elevating control lever fully to the boom
data resetting is completed. raising side while keeping the engine revolution at
Press the display alteration key to return to the the maximum. Maintain this situation until the end
main menu. of the measurement.
Display:
10.2 Adjustment of Elevation Output [ELV Ope. MAX ]
(elevation speed adjustment) [Engine MAX]
[NOTICE] 8. The following message will appear during

Set the crane as follows: measurement.
(1)Outriggers mode: Fully extended Display example:
(2)Lift mode: Boom lift (Stow jib and single top.) [pi= . CV= ]
(4)Hook block position: Hoisted up as much as Elevating cylinder velocity
possible (Take care not to overwind during
adjustment work.) Output pilot pressure
(5)Hydraulic oil temperature: Approx. 50°C If the elevating cylinder rod moves almost all the
way to its stroke end during measurement, it stops
1. Select the main menu [• Adjust CNT dat ] in the
automatically and the following messages will
appear. Reattempt from the step 5.
select the menu.
Display example:
2. When [: Adj. ELV speed ] is displayed, press the [Stroke end ]
register key to select the menu. [Boom A . °]
3. Press the scroll-up or scroll-down key until the To cancel the measurement, return the boom
boom raising measurement display [Adjust ELV elevating control lever to the neutral position and
UP ] appears and press the register key to select press the display alteration key to exit the menu.
the menu. (The boom lowering measurement
display is [Adjust ELV DN ].)
149 W301-0212E
9. The measurement is completed when the

elevating cylinder rod stops and the following
messages appear.
Display:
[Adjustment done ]
[JS neutral]
10.Return the boom elevating control lever to the

neutral position.
When [Push reg. key ] appears, press the
register key to store the measured value into the
EEPROM.
You can see the measurement result as shown
below if you press the scroll-down key while [Push
reg. key ] is displayed.
Display example:
[ N P= . C= ]
Elevating cylinder velocity
Output pilot pressure
Indicating that the displayed data are Nth in

sequence.
11.The measurement of the boom raising is

completed when [Data recorded] appears. Press
the display alteration key to return to the submenu
[:Adj. ELV speed ].
12.Measure the boom lowering and store the

measured value in the same manner described for
boom raising. Press the display alteration key to
exit the menu.
150 W301-0212E
Other Functions and How to Use Them Display:

[:Disp. Late data ]
1. Language
[:Disp. Max. data]
The menu [Language] is used to change the
3. Display of latest overload data
language for message appearing on the moment
The selection of [:Disp. Late data ] results in the
display. The message on the menu [Language] is
latest registered overload history data being
always displayed in English.
displayed. The time when overload history data
1. Select the main menu [• Language] in the has been registered is indicated in the moment
adjustment mode, and press the register key to display.
select the menu. To view the next data on record (up to 50 items),
press the scroll-down key.
2. When message for language selection appears,
operate the scroll-up or scroll-down key to display Moment display
the aimed language. Display example:
Display example: [99. 01. 23 12:35 ]
[= Japanese ] Shows the number of registered items.
Press the scroll-down key. (50 items maximum.)
[: English] Serial number.
(of overload data in order of lateness.)
The sign “=” at the left side of the message shows
Shows the overload ratio.
that the language is currently set to be used. (Max. 400%)
3. When the aimed language is displayed, press the

register key. After the registration, the sign “:” at
the left side of message changes to “=”.
Display example:
[: English]
[=English]
%
After this, the messages on the moment display
are switched to the newly set language.
2. Overload History Display
The records of crane operations beyond
overloading limit are displayed. You can choose
between the displays of latest overload data and
of the greatest overload data.
1. Select the main menu [• Disp. O/L data ] in the

IW301-0211E30
select the menu.
2. Use the scroll-up or scroll-down key until the

menu of latest overload ratio or peak overload
ratio appears. Select it by pressing the register
key.
151 W301-0212E
3. Erasing the Overload History

4. Display of greatest overload data
The selection of [:Disp. Max. data] results in the [NOTICE]
registered greatest overload history data being When the AML main unit or EEPROM is replaced
displayed. for repair and all adjustment is completed,
The time when overload history data has been erase-protect the overload history.
registered is indicated in the moment display. Before delivering the machine to an user,
erase-protect the overload history by erasing the
Press the scroll-down key, and load ratio, jib
latest history data three times.
length, and jib angle will be displayed (jib length
and jib angle are displayed only during the jib lift). You can erase the overload history data (record of
Further press the scroll-down key, and the display crane operation when moment load ratio exceeds
will change into the next information (up to 10 the set limit). Note that if the latest history data are
items). erased three times, the menu will not appear,
disabling the history data to be erased. At the time
Moment display
of the third erasure, the records of the greatest
Display example:
overload values will also be erased.
[99. 01. 23 12:35 ]
1. Select the main menu [• Erase O/L data ] in the
[125% 14.5f 45.0° ] adjustment mode, and press the register key to
Indicates boom length.
select the menu.
Serial number.
(of overload data in order of greatness.) 2. Use the scroll-up or scroll-down key to display the
Indicates boom angle. overload history data item to be erased. Select it
Indicates load radius. by pressing the register key.
Indicates lift status.
Display:
[:Erase Late dat ]
[:Erase Max. data]
3. When the message [Erase OK?] appears, press

the register key to erase the data.
t
m
4. When the message [Done] appears, the overload
max t record data is now erased. Press the display
alteration key to exit the menu.
m
Indicates swing position. Indicates actual load.

Indicates outrigger status. Indicates rated lifting capacity.
IW301-0211E31
152 W301-0212E
Functions of and How to Use Maintenance Mode
Functions of and (5)Revision date display:

How to Use Maintenance Mode Indicates the date of data revision.
1. Program Version Display Display example:[96, 01, 23]
3. Di Check
ROM program version is displayed.
The input state of Di (external contact switch) is
1. Select the main menu [• Maintenance ] in the displayed.
select the menu. 1. Select the main menu [• Maintenance ] in the
2. When [:Prog. version ] is displayed, press the select the menu.
3. When the below program version appears, press display [:Di check ] appears, and then press the
the display alteration key to exit the menu. register key to select the menu.
Display example:
[AML-L L0204 ] 3. Di input state is displayed. Display changes by
scroll-up or scroll-down key.
program version number Press the display alteration key to exit the menu.
2. Data ID Number Display Display example (Di1):
[ 01 Over-wind of ]
Information of ROM data is displayed.
Indicates switch state
1. Select the main menu [• Maintenance ] in the
on : active
of : not active
select the menu.
Switch name
2. Find the display [:Data ID. number ] by the
scroll-up or scroll-down key, and then press the Indicates Di input terminal number.
register key to select the menu. 01 to 28 : Di 1 to Di 28
T : TC
3. Display changes by scroll-up or scroll-down key.
A : ACC
Press the display alteration key to exit the menu.
No indication: Serial port input (Di from multiplex
The ROM data is displayed as follows:
data transmitter and signal
(1)ID number display: transmitter)
Indicates ROM ID number (revision number
[NOTICE]
included).
Switch state means on/off state which the AML
Display example:[750200 ] program judges logically.
(2)Specification number display: Usually, this matches to the physical condition of
switch. However, if “r” is added in front of the
Indicates crane spec. number.
displayed “on” or “of”, these have different
Display example:[TR-500-3-00101 ] meanings as below.
ron:
(3)Code number display: Logically switch is active, but physical contact is off.
Indicates parts code number of AML. rof:
Display example:[361-175-02000 ] Logically switch is not active, but physical contact is
on.
(4)Data date display: Only the Di switch used for input in the program can
Indicates the date of making up data. be displayed. Since the display sequence of Di
Display example:[95, 12, 27 ] switch input states depends on the contents of the
153 W301-0213E
program, the Di switch input states may not be [NOTICE]

indicated in the numerical order of Di switch input
Only the Ai used for input in the program can be
numbers.
displayed. Since the display sequence of Ai input
4. Ai Check states depends on the contents of the program, the
Ai input states may not be indicated in the
The input state of Ai (analog detector input) is numerical order of Ai input numbers.
displayed. 5. Elevating Cylinder Oil Pressure
1. Select the main menu [• Maintenance ] in the Monitor
The cylinder extension lateral pressure and
select the menu.
retraction lateral pressure which are detected for
2. Press the scroll-up or scroll-down key until the moment calculation are displayed.
display [:Ai check ] appears, and then press the
3. Ai input state is displayed. Display changes by select the menu.
scroll-up or scroll-down key.
display [:Disp ELEV PRES ] appears, and then
Display example (ANAiNB):
press the register key to select the menu.
[ 02 Boom A 1201 ok ]
3. The elevating cylinder extension lateral pressure
When detected input is within
and retraction lateral pressure are displayed.
the normal input range, “ok”
appears; when it is out of the
Display example:
range, then “ng” appears at this
[E . R . MPa ]
portion.
Unit
A/D converted value of analog input.
Retraction oil pressure
Analog detector name
Extension oil pressure
Logical number of analog input in the program.
00:Moment input (MOINP, MOINN)
01:ANAiNA
02:ANAiNB
03:ANAiNC
04:ANAiND
05:ANAiNE
06:ANAiNF
07:Analog detector source
(DET1SRC, DET2SRC)
08:Pressure input
(ANAING)
09:Pressure input
(ANAINH)
11 to 15:Serial port-1 analog input 1 to 5
(Ai from signal transmitter)
21 to 25:Serial port-2 analog input 1 to 5
(Ai from multiplex data transmitter)
154 W301-0213E
6. Do Check 7. MDT Monitor

(Multiplex Data Transmitter
The output state of Do (Digital output: relay output
and open collector transistor output) is displayed. Monitor)
Also, you can invert the current state of selected
The input/output state of the MDT (multiplex data
output.
transmitter) is displayed.
select the menu.
select the menu.
display [:Do check ] appears, and then press the
display [:MDT Monitor ] appears, and then press
the register key to select the menu.
3. Do output state is displayed. Display changes by
3. The input/output state of the MDT (multiplex data
scroll-up or scroll-down key. Press the display
transmitter) is displayed. Display changes by
increase or decrease key. Press the display
Display example (RLY1):
[ 00 Stoppage of ]
Display example:
Current output state [ No.123 Val. 1]
Output name Input/output state

Digital input/output:
Logical output port number 1:ON
00 to 07:RLY1 to PLY8 0:OFF
(relay output) Analog input/output:
10 to 17:TR1 to TR8 represented in numerals from 0
(open collector output) through 255.
[NOTICE] Input/output number
Output state means on/off state which the AML
program judges logically (same as the Di). Usually, [NOTICE]
this matches to the physical condition of switch. For the signal represented by the displayed
However, if “r” is added in front of the displayed “on” input/output No., see the “MDT (Multiplex Data
or “of”, these have different meanings as below. Transmitter) Input/Output Nos. and Corresponding
ron: Signals” in the INFORMATION AND DATA section.
Logically switch is active, but physical contact is off.
rof: 8. Key Switch Check
Logically switch is not active, but physical contact is
on. Check the key switch on the AML front panel
whether it works normally or not.
4. During the above Do output monitoring procedure,
output state will be inverted while you are 1. Select the main menu [• Maintenance ] in the
pressing the check key. maintenance mode, and press the register key to
select the menu.

display [:key SW check ] appears, and then
155 W301-0213E
3. The display [ Error:2003 ]

[– – – – – – – – – • – – – – – –]
(3)The mark “ ” on the error code display shows the
appears. Press any key other than the display
another errors exist.
alteration key, and the corresponding portion of
Press the scroll-down key to display the next error
display changes from “-“ to “ ” while you are
code.
pressing the key. Press the display alteration key
to exit the menu. Total number of stored items.
9. Display Check Serial number.

(signifies what number the error is.)
The segments of LCD panels and LEDs of the

AML indicator repeat to go on and off.

select the menu.

display [:Display check ] appears, and then press
the register key to select the menu.
3. The segments of LCD panels and LEDs of the

AML indicator repeat to go on and off. Press the
display alteration key to exit the menu and return
to the ordinary display state.
10. Error Data Display
Error data registered in the AML are displayed on
the moment indicator and display panel 1.
1. Select the main menu [• Maintenance ] in the If "C" mark is seen here, this is the living error.
Error code. This example shows the error code 2003.
maintenance mode, and press the register key to IW301-0211E32
select the menu.

11. Erasing the Error Data
display [:Disp. err data ] appears, and then press Use this menu to erase the registered error data
the register key to select the menu. information.
3. The error codes are displayed on the moment 1. Select the main menu [• Maintenance ] in the
indicator and display panel. Press the display maintenance mode, and press the register key to
alteration key to exit the menu and return to the select the menu.
ordinary display state.
(1)The moment indicator displays the time when display [:Erase err data ] appears, and then
error occurred. press the register key to select the menu.
Display example:
[ 96. 01. 23 12:35 ] 3. When the message [Erase OK? ]appears, press
the register key.
(2)When the scroll-down key, the time display
changes to the error code display. 4. When the message [Done] is displayed, the error
Display example: data is now erased. Press the display alteration
156 W301-0213E
key to exit the menu. 13. Ao Check

12. OP (Option) Board Check
The Ao (analog output) state is displayed with an
The state of the incorporated option board (analog output value of the specified percentage.
output, wire detection) is indicated.
1. Select the main menu [• Maintenance ] in the maintenance mode, and press the register key to
maintenance mode, and press the register key to select the menu.
select the menu.
2. Press the scroll-up or scroll-down key until the display [:Ao check ] appears, and then press the
display [:OP board check ] appears, and then register key to select the menu.
3. Ao output state is displayed as below.
3. The sort of the incorporated option board is Display changes by scroll-up or scroll-down key.
displayed (Up to two option boards can be Press the display alteration key to exit the menu.
incorporated). Display changes by scroll-up or Display example (CNTL1P•CNTL1N):
scroll-down key. Press the display alteration key [ 41 SWG RV 0 0 ]
to exit the menu.
Output level for checking
Display example:
indicates at what percentage of
[ 1 Valve control ]
the maximum level the value is to
Option board name be output.
(1 valve control : Circuit board for analog output)
Output level indicates at what
(2 Rope LGTH DET : Circuit board for detecting
percentage of the maximum level
wire rope movement to indicate hook block
the value is being output.
position)
Output name
Ao output terminal number

11-19:Output to serial port 1
(Signal transmitter)
21-29:Output to serial port 2
(Multiplex data transmitter)
41-49:Output to option board
(41:CNTL1P • CNTL1N)
[NOTICE]
Only the Ao used for output in the program can be
displayed. Since the display sequence of Ao output
states depends on the contents of the program, the
Ao output states may not be indicated in the
numerical order of Ao output numbers.
4. How to see the output values for checking

Using the increase or decrease key while the Ao
output state is displayed, set up an output level for
157 W301-0213E
checking. Every time you press the key, the level 15. Adjust Monitor
is increased or decreased by 1%. When the key is
held down for more than one second, the level is The same items as shown in the [• Adjust ] menu
increased or decreased by 10% for the increase of the main menu of the adjustment mode
key and by 5% for the decrease key. When the appears. However, adjustment is not available.
level exceeds 100%, it returns to 0% (conversely, 1. Select the main menu [• Maintenance ] in the
when the level reaches 0%, it returns to 100%.) maintenance mode, and press the register key to
5. How to output the output values for checking select the menu.
While the output level for checking is indicated, 2. Press the scroll-up or scroll-down key until the
press the check key; output level for checking will
display [:Adjust Monitor ] appears, and then
be output while the key is held down. The
displayed output level value blinks.
14. Sio Check 3. The same items as shown in the [• Adjust ] menu
of the main menu of the adjustment mode are
The Sio (serial port) state is indicated. displayed.
maintenance mode, and press the register key to 16. Overload History Display
select the menu. The overload history display in the maintenance
2. Press the scroll-up or scroll-down key until the mode has the same function as that of in the
display [:Sio check ] appears, and then press the adjustment mode.
register key to select the menu. See the “Overload History Display” in the
“Functions of and How to Use Adjustment Mode”
3. Serial port state is displayed. Display changes by section.
scroll-up or scroll-down key. Press the display 17. Erasing the Overload History
Display example: Erasing the overload history in the maintenance
[Serial port1 OK ] mode has the same function as that of in the
adjustment mode.
Serial port state
See the “Erasing the Overload History” in the
OK : Normal
“Functions of and How to Use Adjustment Mode”
NG : Abnormal
section.
NU : Not used
18. Clock Adjustment
Serial port name
Clock adjustment is included in the functions of
(Serial port 1:serial communication circuit to signal
the maintenance mode. However, see the “Clock
transmitter)
Adjustment” in the “Functions of and How to Use
(Serial port 2:serial communication circuit to
Adjustment Mode” section for how to adjust the
multiplex data transmitter)
clock.
158 W301-0213E
Error Message
Error Message 2. How to Read the Error Message

1. Error code in the error message is represented by
1. Display of Error Message four-digit codes.
[NOTICE] Error code: E1 E2 E3 E4

The language (English or Japanese) of error
message is selected at the [• Language] menu in lndividual code
the adjustment mode.
Group code
Displays a failure message 0:Alarm
1:Abnormal communication
2:Abnormal detector
3:Abnormality inside AML
2. The highest rank (E1 in the above figure)

indicates error groups. The each next three digit
figure (E2 through E4 above) indicates individual
IW301-0131E09 error code under error groups.
3. Since group code “0” indicates a warning

1. If AML system detects the trouble in ordinary use condition, it does not always mean that there is a
(user mode), it makes beep sound as well as problem in the system when an error message is
displays error message on the moment display. displayed.
Display example:
4. For this reason, warning-related error messages
[Error:2001]
are not registered in the system’s error history
Shows that an error of error code 2001 has memory. Warning-related error messages are
occurred. shown in the moment display in the same way as
message for other group codes.
2. This error message display continues till the
cause is eliminated.
3. How to Read the Error History
3. While the adjustment or maintenance mode is
being used, only beep sound informs the operator 1. Error history records 50 errors, maximum, of the
of the occurrence of trouble. The display on the group code, in order of occurrence. Those beyond
moment display, however, does not change to the 50 will be made to disappear in the order of
error message display automatically. Current occurrence.
message keeps displayed.
2. See the “Error Data Display” in the “Functions of
4. To confirm the error message in the adjustment or and How to Use Maintenance Mode” section for
maintenance mode, press the lift height limit key. reading the error history.
While you are pressing the key, the error message
is shown on the moment display. (It may take
some seconds for the display to change.)
5. If trouble remains even when you return to the

user mode after exiting adjustment or
maintenance mode, corresponding error message
appears on the moment display.
159 W301-0213E
Error Message
4. Troubleshooting Table
4.1 Group Code 0
Message Description
Warning : 0001 Right front outrigger beam retraction
Warning : 0002 Right rear outrigger beam retraction
Warning : 0003 Left front outrigger beam retraction
Warning : 0004 Left rear outrigger beam retraction
Situation: Outrigger beam has retracted and O/R extended width decreases, close to the lifting
capacity change over point.
Cause: Outrigger beam(s) have just retracted.
Action: Extend the outrigger beam again.
Message Description
Error : 0005 Boom angle value becomes out of specified range
Situation: Boom extension automatically stops during setting of the side-up jib.
(Only applicable to the machines with side-up jib)
Cause: Boom angle is smaller than that required for jib setting.
Action: Raise the boom till safety angle for jib setting.
Message Description
Error : 0006 Improperly inserted jib lock pin
Situation: Boom extending operation automatically stops during setting or stowing of the side-up jib.
(Only applicable to the machines with side-up jib)
Cause: Jib lock pins are in incorrect states.
(Jib lock, jib set and automatic lock pins have been inserted)
Action: Correct the lock pins property inserted.
Message Description
Warning : 0010 Close to the swing angle restriction
* The error code is applicable only to models with the slow swing stop function.
Situation: The boom is just close to the swing restriction angle.
Cause: The swing area restriction function is active, and the boom has been swung to a point just
close to the limit. (The error code will remain displayed as long as the boom is in close to
the limit for both left and right swing operation)
Error code is displayed only when the slow swing stop function is canceled. (swing is not
automatically stopped)
Action: Swing the boom away from the swing restriction point.
Cancel the swing area restriction function.
160 W301-0213E
Error Message
Message Description
Warning : 0012 Rear stability auto. stop range
Situation: The rearward tipping load limit lowers below the current lifting load as the boom is swung.
Cause: The boom is raised too high.
The outrigger extension width is insufficient.
Action: Lower the boom.
Increase the outrigger extention width.
Message Description
Error : 0013 Over-front detection switch is defective
Error : 0014 Over-front or over-rear detection switch is/are defective
Situation: The swing angle does not conform with the condition detected by the over-front detection
switch.
Over-front switch has detected as front though boom doesnot turn front.
(Obtains capacity of over-front detection switch as not in front.)
Cause: Over-front detection switch is defective, over-front and/or over-rear detection switch is/are
defective, or its wiring is open.
Swing angle detector is defective or maladjusted.
Action: Investigate the possible causes described above.
The input status can be checked with “Ai & Di check” function from the “Maintenance”
menu.
Message Description
Warning : 0015 Overwinding condition (When overwinding stop function is cancelled)
Situation: Overwinding detection switch has been turned off (overwinding status).
A crane does not stop automatically though the error code is displayed when overwinding
is cleared.
Cause: Main or auxiliary hook block has been wound up excessively.
Action: Hoist down the main or auxiliary winch.
Message Description
Error : 0016 State 1 is not applied (Outrigger, Swing angle, CW, combinations)
Error : 0017 State 2 is not applied (Boom and Jib combination)
Situation: Crane is automatically stopped while the outrigger, boom, jib and counterweight settings
are out of the allowable condition, and operation toward a critical conditions is attempted.
Cause: The outrigger, boom, jib and counterweight settings are improper.
Action: Register the operation status again.
161 W301-0213E
Error Message
Message Description
Error : 0018 Boom (3rd-top boom sections for GR-300EX-1,GR-120N-1) full retraction
switch 1 faulty
Error : 0019 Boom (3rd-top boom sections for GT-550E-1,GR-700EXL-1) full retraction
switch 2 faulty
Error : 0020 Boom full retraction switch 3 faulty
nd
Error : 0021 Boom (2 boom section for GR-120N-1) full retraction switch 4 faulty
Situation: Crane is automatically stopped when operation toward a critical condition is performed,
when the specified boom section full retraction detector switch does not detect full
retraction while the specified boom section is fully retracted, or vice versa.
Cause: Boom full retraction detection switch is faulty, or its wiring is open.
Boom length sensor is defective or maladjusted.
The AML itself is defective.
Action: Perform inspection for the possible causes listed above.
The input status can be checked with “Ai & Di check” function from the “Maintenance”
menu.
Message Description
Warning : 0023 Stopped at 100% of crane performance
Situation: Because the crane performance has exceeded 100%, a crane is automatically stopped
when hoisting-up, boom lowering or boom extending is performed.
Cause: The allowable lifting capacity is exceeded.
Action: Perfrom either of hoisting-down, boom raising, or boom retracting.
Message Description
Warning : 0024 Stop due to overwinding
Situation: Crane is automatically stopped when operation toward a critical condition is performed
while the overwinding detection switch is turned off (Overwinding status).
Cause: Main or auxiliary winch hook block has been wound up excessively.
Action: Hoist down the main or auxiliary winch.
Message Description
Warning : 0025 Stopped due to backward stability
Situation: The crane is in a state where the backward stability is not assured, boom raising/retracting
operation should be stopped automatically.
Cause: The boom angle is too large, or the boom length is insufficient.
The outrigger extension width is too small.
Action: Lower the boom, extend the boom, or increases the extension width of outriggers.
162 W301-0213E
Error Message
Message Description
Warning : 0026 Stopped at upper boom angle limit restriction
Situation: Crane operation is automatically stopped when operation toward a critical condition is
attempted while boom angle exceeds the upper limit.
Cause: The upper boom angle limit restriction is set, and the boom angle has exceeded the limit.
Action: Lower the boom.
Cancel the upper boom angle limit restriction.
Message Description
Warning : 0027 Stopped at lower boom angle limit restriction
attempted while boom angle exceeds the lower limit.
Cause: The lower boom angle limit restriction is set, and the boom angle has exceeded the limit.
Action: Raise the boom.
Cancel the lower boom angle limit restriction.
Message Description
Warning : 0028 Stopped at lifting height restriction
attempted while lifting height exceeds the limit.
Cause: The lifting height limit restriction is set, and the top boom head’s height has exceeded the
limit.
Action: Lower or retract the boom.
Cancel the lifting height restriction function.
Message Description
Warning : 0029 Stopped at load radius restriction
attempted while the load radius exceeds the limit.
Cause: The load radius restriction is set, and the load radius has exceeded the limit.
Action: Raise or retract the boom.
Cancel the load radius restriction function.
163 W301-0213E
Error Message
Message Description
Warning : 0034 Stopped by main winch over-unwinding prevention device
Warning : 0035 Stopped by aux. winch over-unwinding prevention device
Situation: Hoisting-down is automatically stopped by over-unwinding prevention device as the
main/aux. wire rope on the winch drum is drawing to the end.
Cause: The number of wire rope part line on the hook block is wrong.
The hook block position is too low.
Action: Adjust the number of part line as specified, or perform winch winding operation.
Message Description
Error : 0037 Defective accumulator pressure (sensor)
Situation: Abnormal accumulator pressure is detected. (Only for models with accumlator pressure
detector)
(This message does not relate to the control by the AML)
Cause: Accumulator pressure is too low.
Accumulator pressure detector is defective, or its wiring is open.
AML (analog circuit board) is defective.
The status of any input from the detector can be checked using the “Ai check” function
from the “Maintenance” menu.
Message Description
Error : 0041 Wrong counterweight state registered
Warning : 0078 Altered counterweight state
attempted when the detected counterweight status is different from the registered one.
(Applicable only to the error code 0041) (Crane does not stop automatically when
“Warning:0078” is displayed)
Cause: Defective counterweight state detector, improper installation or adjustment of the detector,
open wiring of the detector circuit.
Altered combination of the counterweight.
Action: Search for the cause of the detector defect. The status of any input from the detector can
be checked using the “Di check” function from the “Maintenance” menu.
Register the counterweight state again.
Message Description
Warning : 0042 Right swing restriction limit
Warning : 0043 Left swing restriction limit
Situation: Boom is swing to a point exceeding the swing restriction limit setting. Crane is
automatically stopped if swing automatic stop function is provided.
Cause: The swing restriction limit function is set, and swing position has been exceeded the limit.
Action: Swing the boom in the opposite direction to the setting.
Cancel the swing restriction function.
164 W301-0213E
Error Message
Message Description
Warning : 0046 Condition setting altered
Situation: Crane state has changed.
Cause: Outrigger jacks have been retracted.
Action: Register operation status again.
Message Description
Warning : 0047 Hook block contacts to the elevating cylinder
Situation: Hook block approaches the space where it can hit the elevation cylinder rod.
Cause: Boom raised too high while it is almost fully retracted.
Action: Extend or lower the boom.
Message Description
Warning : 0056 Swing operation is dangerous
Situation: The lifting capacity will be exceeded if the boom is swung further.
Cause: The boom has been swung to a point just before the region where the capacity is reduced
in retraction with outrigger extension width.
Action: Swing the boom in the opposite direction.
Retract or raise the boom so that the lifting capacity will not be exceeded.
Message Description
Warning : 0057 Right front outrigger state change
Warning : 0058 Right rear outrigger state change
Warning : 0059 Left front outrigger state change
Warning : 0060 Left rear outrigger state change
Situation: Outrigger state has changed as to decrease extension. Crane performance shifted to that
with a smaller outrigger extension width.
A crane does not stop automatically.
Cause: Outrigger extension width has decreased unintentionally.
Action: If reduced capacity does not matter, continue to use the crane. If the capacity is expected
to be exceeded, re-extend the outrigger further and register working state again.
165 W301-0213E
Error Message
Message Description
Error : 0067 Abnormal moment [Strain gauge detector]
Does not stop
Warning : 0113 Abnormal moment [Pressure sensor detector]
Can not operate to dangerous direction
Situation: Actual lifting load display value calculated in the AML becomes a minus value because of
an abnormal moment detector.
Therefore, re-adjustment of the moment detector is required.
(0067: Only warning, automatic stop does not work)
(0113: Crane operation is stopped when operation toward a critical condition is
attempted)
Cause: Abnormal detectors (Boom length detector, strain gauge type and/or pressure sensor
type moment detector).
Maladjusted detector.
Abnormal AML main body (Analog board).
[Warning : 0113] Moment value can not be detected because the elevating cylinder has
retracted to the stroke end.
* This warning (0113) is output when actual lifting load display value that calculate in the
AML becomes a minus value. Abnormal minus load value is difference due to the boom
condition.
Action: Readjust the corresponding detector (pressure sensor).
Investigate the detector which seems to be defective.
Input status from the detector can be confirmed by “Ai” check of “Maintenance” menu and
“Elevating cylinder pressure monitor”.
(“Ai” check related items: [Boom L], [Boom A], [MMT V], [DRC EXT], [DRC RTR] etc.)
Raise the boom. (error code: In case of 0113)
Message Description
Error : 0068 Abnormal swing angle
Error : 0069 Abnormal boom length
Error : 0070 Abnormal boom angle
Error : 0071 Abnormal extension width of the right front outrigger
Error : 0072 Abnormal extension width of the right rear outrigger
Error : 0073 Abnormal extension width of the left front outrigger
Error : 0074 Abnormal extension width of the left rear outrigger
Situation: The detected value from the corresponding detector is out of the normal range and the
detector requires readjustment.
Alarm is output but automatic stop does not work. For the errors which cause
automatic stop, see the fllowing ones.
Abnormal swing angle Message : 2016 - 2019, 2021
Abnormal boom length Message : 2007, 2008
Abnormal boom angle Message : 2004
Abnormal outrigger extension width Message : 2009 – 2012
Cause: Misadjastment or misalignment.
Improper installation of the detector.
The AML itself is defective. (Analog board is defective)
Action: Readjust the corresponding detector.
Insrall the corresponding detector properly and readjust it.
If the detectors are not defective, replace the AML main unit (analog board).
166 W301-0213E
Error Message
Message Description
Warning : 0075 Spring lock state has changed
Situation: Spring lock state has changed.
(Only for models with spring lock state detection)
Cause: Spring lock released unintentionally.
Spring lock has been released by mistake.
Action: Set spring lock again.
Message Description
Warning : 0077 Altered front or rear jack state
Situation: The actual front or rear jack state has changed from the registered one.
(Only for models with spring lock state detection)
Cause: Front or rear jack has operated.
Defective detector.
The AML itself is defective. (Analog board is defective)
Action: Return the front or rear jack to the original condition.
Check the detector using “Di check” function on “Maintenance” menu.
Message Description
Warning : 0078 Altered counterweight state (refer to 0041)
Message Description
Warning : 0081 Elevation motion slowing down
* This error code is applicable only to models with the slow elevation stop function.
Situation: The boom elevation slow stop function is activated, slowing down boom elevation motion.
Cause: The boom has been elevated close to a stop angle (100% stop, restriction limit stop,
stroke end stop, or rear stability stop), and the elevation slow stop function has been
activated, and the elevation speed is reduced. (The error code is displayed only when the
boom is being elevated)
Action: Stop operating the boom.
Operate the boom in the opposite direction, whether it is rising or lowering.
Cancel the boom angle limit restriction function.
Move the boom to the non-critical side.
Message Description
Warning : 0082 Swing motion slowing down
* This error code is applicable only to models with the slow swing stop function.
Situation: The slow swing stop function is activated, slowing down boom swing motion.
Cause: The boom has swung close to a stop angle (either 100% stop or range limit stop) and the
slow swing stop function has been activated, and swing speed is reduced. (The error
code is displayed only when the boom is being swung to the left or right)
Action: Stop the swing operation.
Swing away from the limit.
Retract or raise the boom so that the lifting capacity will not be exceeded.
Cancel the swing limit restriction function.
167 W301-0213E
Error Message
Message Description
Warning : 0085 Elevation stopped at stroke end
* Applicable to the models with the oil pressure detection method.
attempted while boom elevating operation is stopped due to elevation stroke end.
Cause: Boom elevating is automatically stopped just before the elevating cylinder stroke end
because the moment cannot be detected correctly by the oil pressure in the elevating
cylinder if the cylinder is reached/extended to stroke end.
Action: Stop operation which has caused automatic stop.
Operate the boom in the opposite direction which has caused automatic stop.
Message Description
Warning : 0088 Stopped at jib limit
* This error code is applicable only to models with jib extension status monitoring.
Situation: Crane operation is automatically stopped when operation toward a critical condition such
as hoisting-up, lowering or extending the boom is attempted.
Cause: In the state of AML setting to boom while extending the jib, is exceeding the lifting
capacity.
Action: Perform operation toward non-critical condition, such as hoisting-down, raising or
retracting the boom.
Message Description
Warning : 0113 Abnormal moment [Pressure senser detector] (refer to 0067)
Message Description
Warning : 0117 Boom contact warning
Situation: The boom approaches the mirror or engine cover, etc.
Cause: The boom, stowing jib and/or elevating cylinder approach (es) the mirror or engine cover
etc. of the carrier, there is a possibility to come in contact if operating the boom lowering
or swinging further.
Action: Operate watching the obstacles when operating the boom lowering or swinging.
168 W301-0213E
Error Message
4.2 Group Code 1
Message Description
Error : 1001 Serial port transmission line 1 open
Error : 1002 Selial port transmission line 2 open
Situation: All operations except boom swing are unavailable because the transmitter cannot receive
any signal from the AML.
Cause: A part of wiring to the transmitter is open.
The connector pins of wiring to the transmitter are in poor contact.
The receiving circuit of transmitter or the transmitting circuit of AML is defective.
Action: Check the wiring to the transmitter for continuity. If no continuity exists, replace or repair
the wiring.
Replace the transmitter or AML’s power circuit board.
Message Description
Error : 1003 Serial port receiving line 1 open
Error : 1004 Serial port receiving line 2 open
Situation: All operations except boom swing are unavailable because the AML cannot receive any
signal from the transmitter.
Cause: The line from the transmitter includes open wiring or poorly contacting connection.
The transmitter is not connected (the connector is disconnected).
The receiving circuit of AML or the transmitting circuit of transmitter is defective.
The serial port fuse (SIF1, 2) of AML has blown.
Action: Check the wiring to the transmitter for continuity. If no continuity exists, replace or repair
the wiring.
Replace the transmitter or AML’s power circuit board.
Replace the serial port fuse of AML.
Message Description
Error : 1005 Transmitter 1 defect
Error : 1006 Transmitter 2 defect
Situation: All operations except boom swing are unavailable due to the faulty transmitter.
Cause: The internal circuit of transmitter is defective.
Action: Replace the defective transmitter.
169 W301-0213E
Error Message
Message Description
Error : 1007 Transmitting data error at serial port 1
Error : 1008 Transmitting data errot at serial port 2
Error : 1009 Receiving data error at serial port 1
Error : 1010 Receiving data error at serial port 2
Situation: All operations except boom swing are unavailable due to a discrepancy between the data
transmitted/received by the AML and the data received/transmitted by the transmitter.
Cause: The data has been garbled due to noise (external radio wave interference).
The signal wire connection is in poor contact.
Action: Turn off any device which is emitting strong noise.
Check the signal wire for poor connection. Repair or replace the wiring as appropriate.
Message Description
Error : 1011 Transmitter type improper (serial port 1)
Error : 1012 Transmitter type improper (serial port 2)
Situation: All operations except boom swing are unavailable due to the wrong transmitter connected
to the serial port.
Action: Connect a proper transmitter to the serial port.
170 W301-0213E
Error Message
4.3 Group Code 2
Message Description
Error : 2001 Moment detector trouble
Situation: All operations except boom swing are unavailable due to the abnormal input value from
the moment detector.
Cause: The moment detector is defective, or its wiring is open.
Message Description
Error : 2003 Boom length detector trouble
the boom length detector.
Cause: The boom length detector is defective, or its wiring is open.
Message Description
Error : 2004 Boom angle detector trouble
the boom angle detector.
Cause: The boom angle detector is defective, or its wiring is open.
Message Description
Error : 2005 Jib length detector trouble
the jib length detector.
Cause: The jib length detector is defective, or its wiring is open.
The transmitter unit is defective.
171 W301-0213E
Error Message
Message Description
Error : 2006 Jib angle detector trouble
the jib angle detector.
Cause: The jib angle detector is defective, or its wiring is open.
Message Description
Error : 2009 Right front outrigger length detector trouble
Error : 2010 Right rear outrigger length detector trouble
Error : 2011 Left front outrigger length detector trouble
Error : 2012 Left rear outrigger length detector trouble
Situation: The input data from the outrigger length detector are abnormal.
Cause: The outrigger length detector is defective, or its wiring is open.
The AML outrigger length detector is maladjusted. (For multiplex data transmitter)
Message Description
Error : 2017 Swing angle detector 1 trouble (swing dead angle switch OFF)
Error : 2019 Swing angle detector 2 trouble (swing dead angle switch ON)
(same as swing angle detector 1,2 select switch)
Situation: All operations except boom swing are unavailable due to the input data from the swing
angle detector inconsistent with the swing dead angle detector switch position.
Cause: Swing angle detector is faulty or maladjusted, or its wiring is open.
Swing dead angle detector switch is faulty or maladjusted, or its wiring is open.
The status of any input from the detector can be checked using the “Ai & Di check”
function from the “Maintenance” menu.
172 W301-0213E
Error Message
Message Description
Error : 2021 Swing angle detector offset trouble
Situation: All operations except boom swing are unavailable due to the abnormal offset value of the
swing angle detector 1 or 2.
Cause: The swing angle detector is faulty.
Message Description
Error : 2022 Boom elevation cylinder extension pressure detector trouble
Error : 2023 Boom elevation cylinder retraction pressure detector trouble
the oil pressure detector in the boom elevating cylinder’s extension/retraction chamber.
Cause: The pressure detector is defective, or its wiring is open.
( “Ai check” related items : [DRC EXT], [DRC RTR]
173 W301-0213E
Error Message
4.4 Group Code 3
Message Description
Error : 3003 System trouble (sum check error)
Situation: All operations except boom swing are unavailable because ROM has been found
abnormal as a result of sum check.
Cause: The AML‘s CPU board is defective.
ROM defective.
Action: Replace the AML’s CPU board.
Replace ROM.
Message Description
Error : 3006 System trouble (EEPROM defect)
Situation: All operations except boom swing are unavailable because AML cannot write on its
nonvolatile memory (EEPROM).
Cause: The AML’s CPU board is defective.
EEPROM is defective.
Action: Replace the AML’s CPU board or EEPROM.
Message Description
Error : 3007 System trouble (RAM trouble)
Error : 3008 System trouble (RAM trouble)
Error : 3009 System trouble (CPU trouble)
Error : 3011 System trouble (bus error)
Error : 3012 System trouble (address error)
Error : 3013 System trouble (unauthorised instruction)
Error : 3017 System trouble (privilege violation)
Situation: All operations except boom swing are unavailable because software program cannot run
normally.
Cause: The AML’s CPU board is defective.
Action: Replace the AML’s CPU board.
If this error has occurred, the relevant error message is displayed and the AML stops
processing. (There is a continuous beep and two LEDs in the adjustment window
illuminate)
While the AML’s CPU board is suspected to be defective, check the inside of the AML for
any abnormality such as loose connectors.
Message Description
Error : 3010 System trouble (A/D converter trouble)
Situation: All operations except boom swing are unavailable due to abnormal input to the A/D
converter.
Cause: AML’s CPU board and/or analog board are defective.
Wiring for the analog defector is abnormal (short-circuit).
Action: Replace the AML’s CPU board and/or analog board.
Check the connection (resistance) of analog detectors (one connected with AML itself).
174 W301-0213E
Disassembly of AML Main Unit
Disassembly of AML Main Unit 2. Removing Rear Panel/Connector Board

/Current Output Board
1. Removing Front Panel/Display Board [NOTICE]
[NOTICE] ◆Do not touch each front and rear face of the boards
by hand when removing the boards.
◆Do not touch each front and rear face of the boards
by hand when removing the boards.
1. Take off the rear panel, connector board and
1. Take off the front panel and display board as an current output board as an assembly from the unit
assembly from the unit case by unscrewing case by unscrewing screw(c).
screw(a). Connector board Rear panel
Current output board c
Front panel Display board Unit case
a Unit case
IW301-0131E21
IW301-0131E19
2. Separate the current output board by unscrewing

2. Separate the display board by unscrewing screw(d).
screw(b). Then remove the spacer(e) and separate the
connector board.
e Current output board

Connector board d
b IW301-0131E22
Display board
IW301-0131E20
175 W301-0213E
Disassembly of AML Main Unit
3. Removing CPU Board/Analog Board 3.1 Notes on ROM/EEPROM Replacement

/Power Board
[NOTICE] [NOTICE]
◆Do not touch each front and rear face of the boards ◆EEPROM stores the adjustment values for each
by hand when removing the boards. specification number. When replacing the CPU
board, reuse the EEPROM after removing it from
1. Take off the front panel and display board as an the broken CPU board.
assembly from the unit case by unscrewing
When replacing ROM and EEPROM, make sure
screw(a). Then take off the rear panel, connector
that the concavities of IC and socket meet each
board and current output board as an assembly
other.
from the unit case by unscrewing screw(c).
Connector board Rear panel Battery

Current output board c CAL/CLOCK
EEPROM CN1
CN4 PLD
ROM 1
CPU
ROM 0
CN2
CN3
a Unit case
Front panel Display board IW301-0131E23
CPU board
IW301-0131E25
2. Take off the CPU board by unscrewing screw(f).

Then remove the spacer(h) and take off the
analog board and power board as an assembly
from the unit case. Next, separate the analog
board by removing nut(g).
Analog board Power board Unit case

h
CPU board
IW301-0131E24
176 W301-0213E
Adjustment Value Table
[INFORMATION AND DATA]

Specification No. : GT-550E-1-10102

Specification No. : GT-550E-1-10202
AML model : AML-L B
AML code No. : 361-904-70000
1. Setting before adjustment

Capacity setting
Head-off capacity Winch drum position
Jib selection Single top selection
setting setting
Not set Not set Not set Not set
2. Adjustment the detector
Precautions for adjustment

(*1) Adjust the center of dispersion to coincide to the adjusting value.
(*2) Adjust the boom angle and the moment in the elevating lowering operation.
(*3) Adjust the swing angle in the clockwise swing operation.
(*4) When adjusting the moment, make the number of parts of line to the standard number (four parts of line)
that is when boom fully extended, and set the AML as Boom status: Boom and Number of parts of line:4.
The adjusting value is for 0.57 ton hook installed, and the value in the { } is for 0.4 ton hook installed.
Adjustment
Adjustment item Condition Tolerance
value
± 0.04m
Zero-point adjustment Boom length: Fully retracted 11.10m (± 0.08m for
Boom length zero-point check)
Span adjustment Boom length: Fully extended 42.00m ± 0.04m
± 0.1°
Boom angle Zero-point adjustment Boom angle: 0°(actual value) 0° (± 0.2° for
(*2) zero-point check)
Span adjustment Boom angle: 75°(actual value) 75° ± 0.1°
± 0.3°
Swing
(± 0.6° for
angle1:0°
Swing position : front zero-point check)
Zero-point adjustment
(Right swing) ± 0.3°
Swing
Swing angle (± 0.6° for
angle2:360°
Swing
± 0.3°
Swing position : rear angle1:180°
Span adjustment
(Right swing) Swing
± 0.3°
angle2:180°
± 0.006m
Outrigger Zero-point adjustment Outrigger extension width: MIN. 1.195m (± 0.012m for
extension zero-point check)
width
Span adjustment Outrigger extension width: MAX. 3.400m ± 0.006m
177 W301-0213E
Adjustment item Condition Adjustment value Tolerance
Boom length: Fully retracted 0.50t

Boom angle: 75±0.1° {0.33t}
Zero-point adjustment (indicated value) ± 0.14t
Lifting capacity : Without load Hook block mass
minus
(0.57t {0.4t} hook only)
Wire rope mass
Hook : Overwinding status
Boom length: Fully retracted
Boom angle: 10±0.1°
(indicated value) 0.57t
Span Lifting capacity : Without load {0.40t} ± 0.03t
preliminary adjustment (0.57t {0.4t} hook only)
Hook : Hoisting-down until Hook block mass
Moment immediately before the ground
(*2) (*4) plane
Boom length: Fully extended
Load radius: 10.0m
Load radius adjustment 10.0m ± 0.14m
(actual value)
Rated lifting capacity: 8.00t

Boom angle: 45±0.1° 0.57t
(indicated value) {0.40t}
Span Lifting capacity : Without load ± 0.02t
fine adjustment (0.57t {0.4t} hook only) Hook block mass
Hook : Hoisting-down until
immediately before the ground
plane
3. Slow stop adjustment
1. Standard value of the swing output : 217
2. Measurement of elevating up and down characteristic
4. Setting after adjustment
1. Number of part-line : 4 line
2. Language switch : English
178 W301-0213E
Specification No. : GR-120N-1-00103

AML model : AML-L B
AML code No. : 361-914-50000
Capacity setting
setting setting
Not set Not set Not set Not set

Adjustment
value
± 0.04m
Span adjustment Boom length: Fully extended 23.8m ± 0.04m
± 0.1°
Boom angle Zero-point adjustment Boom angle: 0° (actual value) 0° (± 0.2° for
Span adjustment Boom angle: 80° (actual value) 80° ± 0.1°
± 0.3°
Swing
(± 0.6° for
angle1:0°
Swing
angle2:360°
Swing
± 0.3°
Span adjustment
(Right swing) Swing
± 0.3°
angle2:180°
± 0.006m
width
Span adjustment Outrigger extension width: MAX. 2.350m ±0.006m
179 W301-0213E

0.08t
Zero-point adjustment (indicated value) Hook block mass ± 0.04t
Lifting capacity : minus
Without load (0.09t hook only) Wire rope mass
(indicated value)
Span Lifting capacity : Without load Hook block mass ± 0.02t
preliminary adjustment (0.09t hook only)
(*2) (*4) plane
Load radius: 5.0m
Load radius adjustment 5.00m ± 0.04m
(actual value)

(indicated value) 0.09t
Span Lifting capacity : Without load ± 0.00t
fine adjustment (0.09t hook only) Hook block mass
plane
180 W301-0213E
Specification No. : GR-700E-1-00101 Applicable serial No. △

1 ：545484 ~
Specification No. : GR-700E-1-00102
AML model : AML-L B
AML code No. : 361-915-70000
AML code No. : 361-920-20000

Capacity setting
setting setting
Not set Not set Not set Set to “R” (rear)

1 ：The adjusting value is for 0.47 ton hook installed, and the value in the { } is for 0.85 ton hook installed.
Adjustment
value
± 0.04m
Span adjustment Boom length: Fully extended 44m ± 0.04m
± 0.1°
± 0.3°
Swing
(± 0.6° for
angle1:0°
Swing
angle2:360°
Swing
± 0.3°
Span adjustment
(Right swing) Swing
± 0.3°
angle2:180°
± 0.006m
width
181 W301-0213E

Boom angle: 80±0.1° 1 {0.78t}
Zero-point adjustment (indicated value) Hook block mass ± 0.31t
Lifting capacity : Without load minus
1 (0.47t {0.85t} hook only)
Wire rope mass
(indicated value)
Span 1 {0.85t}
Lifting capacity : Without load ± 0.05t
preliminary adjustment
1 (0.47t {0.85t} hook only) Hook block mass
(*2) (*4) plane
Load radius:14.00m
Load radius adjustment 14.00m ±0.08m
(actual value)

(indicated value)
Span 1 {0.85t}
Lifting capacity : Without load ± 0.02t
fine adjustment
1 (0.47t {0.85t} hook only)
Hook block mass
plane
1 ：The adjusting value is for 0.47 ton hook installed, and the value in the { } is for 0.85 ton hook installed.
182 W301-0213E
Specification No. : GR-300E-1-00201 (2M2D-specification)

Specification No. : GR-300E-1-00202 (2M2D-specification)
Specification No. : GR-300E-1-00203 (1M1D and without jib-specification)
AML model : AML-L B
AML code No. : 361-920-80000

Capacity setting
Head-off capacity
Jib selection Single top selection Winch drum position setting
setting
GR-300E-1-00201
GR-300E-1-00203
Not set Not set Not set GR-300E-1-00202
Not set Set to “R” (rear)

(*4) When adjusting the moment, make the number of parts of line to the standard number
(four parts od line) that is when boom fully extended, and set the AML as Boom status: Boom and
Number of parts of line:4.
Adjustment
value
± 0.04m
Span adjustment Boom length: Fully extended 31m ± 0.04m
± 0.1°
± 0.3°
Swing
(± 0.6° for
angle1:0°
Swing
angle2:360°
Swing
± 0.3°
Span adjustment
(Right swing) Swing
± 0.3°
angle2:180°
± 0.006m
width
183 W301-0213E

Boom angle: 80±0.1° Hook block mass
Zero-point adjustment (indicated value) minus ± 0.12t
Lifting capacity : Without load Wire rope mass
(0.27t hook only)
Load radius:6.5m
Load radius adjustment 6.5m ±0.05m
Moment (actual value)
(*2) (*4)

(indicated value)
Span Lifting capacity : Without load
Hook block mass ± 0.02t
fine adjustment (0.27t hook only)
plane
184 W301-0213E
MDT ( Multiplex Data Transmitter) Input/Output Nos. and Corresponding Signals
MDT (Multiplex Data Transmitter) Input/Output Nos. and Corresponding Signals

The following table does not apply to a machine that is not equipped with a multiplex data transmitter (that is, GT-550E-1 model).
Upper input Upper output Lower input Lower output Analog input
Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/
output Signal output Signal output Signal output Signal output Signal output Signal output Signal output Signal
No. No. No. No. No. No. No. No.
Upper
1 Di1 33 Di33 65 Tr1 89 Di1 121 PMONI1 137 MONI1 169 MONI33 201
Ai1
Upper
Ai2
Upper
Ai3
Upper
Ai4
Upper
Ai5
Upper
Ai6
Upper
Ai7
Upper
Ai8
Upper
Ai9
Upper
Ai10
Lower
Ai1
Lower
Ai2
Lower
Ai3
Lower
Ai4
Lower
Ai5
Lower
Ai6
Lower
17 Di17 49 Di49 81 Tr17 105 Di17 153 MONI17 185 MONI49 217
Ai7
Lower
Ai8
Lower
Ai9
Lower
Ai10
Lower
Ai11
Lower
Ai12
23 Di23 55 Di55 87 Tr23 111 Di23 159 MONI23 191 MONI55 Analog output
24 Di24 56 Di56 88 Tr24 112 Di24 160 MONI24 192 MONI56 Input/
output Signal
25 Di25 57 Di57 113 Di25 161 MONI25 193 Tr1 No.
Upper
26 Di26 58 Di58 114 Di26 162 MONI26 194 Tr2 231
Ao1
Lower
27 Di27 59 Di59 115 Di27 163 MONI27 195 Tr3 241
Ao1
Lower
28 Di28 60 Di60 116 Di28 164 MONI28 196 Tr4 242
Ao2
Lower
29 Di29 61 Di61 117 Di29 165 MONI29 197 MSOL1 243
Ao3
30 Di30 62 Di62 118 Di30 166 MONI30 198 MSOL2
31 Di31 63 Di63 119 Di31 167 MONI31
32 Di32 64 Di64 120 Di32 168 MONI32
185 W301-0213E
Checking the Detectors (GT-550E-1)
Checking the Detectors (GT-550E-1) 2. Boom Angle Detector
1. Retract the boom fully, set the boom angle to 0

1. Boom Length Detector
degree and turn off the PTO switch.
2. Measure resistance of the potentiometer.
Checking at the connector of the detector
Pull out the connector of the detector and
Checking at the connector of the detector measure resistance of the potentiometer. The
Pull out the connector of the detector and specified resistance values are as follows:
measure resistance of the potentiometer. The C-D:833 ± 167Ω
specified resistance values are as follows: A-D:146 ± 29Ω
C-D:833 ± 167Ω
Boom angle detector
B-D:458 ± 92Ω
DET1SLD 6 E
Boom angle detector DET1SRC 2 C
DET1SLD 6 E A E ANAINB 4 A
DET1SRC 2 C
A E ANAINB 4 A
B D
C ANAINA 3 B
DET1GND 1 D
B D
ANAINA 3 B Boom length detector
C IW301-0131E10
DET1GND 1 D
Boom length detector

IW301-0131E10
Checking at the CN1 connector of the AML
Pull out the connector of the swing angle detector.
Checking at the CN1 connector of the AML Then pull out the CN1 connector and measure
Pull out the connector of the swing angle detector. resistance of the potentiometer. The specified
Then pull out the CN1 connector and measure resistance values are as follows:
resistance of the potentiometer. The specified 2-1:833 ± 167Ω
resistance values are as follows: 4-1:146 ± 29Ω
2-1:833 ± 167Ω
Boom angle detector
3-1:458 ± 92Ω
DET1SLD 6 E
DET1SLD 6 E 45 16 ANAINB 4 A
DET1SRC 2 C
45 16 ANAINB 4 A
ANAINA 3 B
DET1GND 1 D
30 1
ANAINA 3 B
IW301-0132E33
DET1GND 1 D
30 1
IW301-0132E33
186 W301-0213E
3. Swing Angle Detector 4. Outrigger Extension Width Detector
1. Swing the boom to over-left and turn off the PTO 1. Stow the outriggers and disengage the PTO.
switch.
2. Remove the wire for the detector from the
2. Measure resistance of the potentiometer. outrigger and hold the wire, letting it protruding by
80mm from the guide hold of the detector.
measure resistance of the potentiometer. The
specified resistance values are as follows:
R-B:500 ± 75Ω
W-B:0 - 15Ω
DET1SLD 6 Shield
DET1SRC 2 R 80 mm
G Plug W ANAINC 5 W IW301-0151J27
R Shield B
ANAIND 9 G
DET1GND 1 B
3. Pull out the connector of the detector and
IW301-0131E11
Checking at the CN1 connector of the AML R-B:2000 ± 100Ω
Pull out the connector of the boom length and W-B:200 ± 30Ω
angle detector. Then pull out the CN1 connector
and measure resistance of the potentiometer. The 5V AVCC R
specified resistance values are as follows: W B R IN Ai1 W FR
2-1:500 ± 75Ω GND AGND B
5-1:0 - 15Ω IW301-0211E34
DET1SLD 6 Shield
45 16
DET1SRC 2 R
ANAINC 5 W
ANAIND 9 G
DET1GND 1 B
30 1
IW301-0132E34
187 W301-0213E
5. Pressure Sensor for Moment Detection
1. Engage the PTO. (5-V DC will be applied between

R and B of the pressure sensor connector.)
2. Measure the output voltage between W and B of

the pressure sensor connector.
DET3SRC 33 R
ANAING 34 SPS3
W B R W (SPS4)
(ANAINH 35)
DET3GND 32 B
IW301-0131E14
3. The output voltage between W and B is

proportional to the pressure in the elevating
cylinder.
The specified value is as shown below.
Output (V DC)
4.5
0.5
0 35
Pressure (MPa) IW301-0131E15
188 W301-0213E
Checking the Detectors (GR-120N-1/GR-700EXL-1)
Checking the Detectors (GR-120N-1) 2. Boom Angle Detector

Checking at the connector of the detector measure resistance of the potentiometer. The
measure resistance of the potentiometer. The C-D:833 ± 167Ω
specified resistance values are as follows: A-D:146 ± 29Ω
C-D:833 ± 167Ω
Boom angle detector
B-D:458 ± 92Ω
DET1SLD 6 E
Boom angle detector
DET1SRC 2 C
DET1SRC 2 C
A E ANAINB 4 A
B D
C ANAINA 3 B
B D DET1GND 1 D
C ANAINA 3 B Boom length detector

DET1GND 1 D IW301-0131E10

IW301-0131E10
resistance of the potentiometer. The specified 2-1:833 ± 167Ω
resistance values are as follows: 4-1:146 ± 29Ω
2-1:833 ± 167Ω
Boom angle detector
3-1:458 ± 92Ω
DET1SLD 6 E
DET1SRC 2 C
45 16 ANAINB 4 A
ANAINA 3 B
DET1GND 1 D
30 1
ANAINA 3 B Boom length detector
DET1GND 1 D IW301-0132E33
30 1
IW301-0132E33
189 W301-0213E
1. Swing the boom to over-left and turn off the PTO 1. Stow the outriggers and turn the starter switch to
switch. OFF.
2. Measure resistance of the potentiometer. 2. Remove the wire for the detector from the
outrigger and hold the wire, letting it protruding by
80mm from the guide hold of the detector.
R-B:500 ± 75Ω
W-B:0 - 15Ω
DET1SLD 6 Shield
DET1SRC 2 R
G Plug W ANAINC 5 W 80 mm
R Shield B IW301-0151J27
ANAIND 9 G
DET1GND 1 B
IW301-0131E11
Checking at the CN1 connector of the AML specified resistance values are as follows:
Pull out the connector of the boom length and R-B:2000 ± 100Ω
angle detector. Then pull out the CN1 connector W-B:200 ± 30Ω
and measure resistance of the potentiometer. The
specified resistance values are as follows: 5V AVCC R
2-1:500 ± 75Ω W B R IN Ai1 W FL
5-1:0 - 15Ω GND AGND B
IW301-0131E13
DET1SLD 6 Shield
45 16
DET1SRC 2 R
ANAINC 5 W
ANAIND 9 G
DET1GND 1 B
30 1
IW301-0132E34
190 W301-0213E
5. Pressure Sensor for Moment Detection
1. Turn ON the PTO switch. (5-V DC will be applied

between R and B of the pressure sensor
connector.)

DET3SRC 33 R
ANAING 34 SPS3
W B R W (SPS4)
(ANAINH 35)
DET3GND 32 B
IW301-0131E14

cylinder.
Output (V DC)
4.5
0.5
0 35
191 W301-0213E
Checking the Detectors (GR-300EX-1)
Checking the Detectors 2. Boom Angle Detector

(GR-300EX-1)
Checking at the cnnector of the detector
Checking at the cnnector of the detector measure resistance of the potentiometer. The
measure resistance of the potentiometer. The C-D:833±167Ω
specified resistance values are as follows: A-D:146±29Ω
C-D:833±167Ω Boom angle detector
B-D:458±92Ω
DET1SLD 6 E
DET1SRC 2 C
A E ANAINB 4 A B D
C ANAINA 3 B
DET1GND 1 D
B D
C ANAINA 3 B
IW301-0131E10
DET1GND 1 D

IW301-0131E10
resistance of the potentiometer. The specified 2-1:833±167Ω
resistance values are as follows: 4-1:146±29Ω
2-1:833±167Ω Boom angle detector
3-1:458±92Ω
DET1SLD 6 E
DET1SRC 2 C
45 16 ANAINB 4 A
ANAINA 3 B
DET1GND 1 D
30 1
ANAINA 3 B
IW301-0132E33
DET1GND 1 D
30 1
IW301-0132E33
192 W301-0213E

1. Swing the boom to over-left and turn off the PTO 1. Stow the outriggers and turn the starter switch to
switch. OFF.
2. Measure resistance of the potentiometer. 2. Remove the wire for the detector from the
outrigger and hold the wire, letting it protruding by
Checking at the cnnector of the detector
3.1 in (80mm) from the guide hold of the detector.
R-B:2500±375Ω
W-B:1062±160Ω
G-B:2354±353Ω
DET1SLD 6 Shield
DET1SRC 2 R 3.1 in (80 mm)
ANAINC 5 W
IW301-0131E12
ANAIND 9 G
DET1GND 1 B
IW301-0134E12
Checking at the CN1 connector of the AML R-B:2000±100Ω
Pull out the connector of the boom length and W-B:200±30Ω
angle detector. Then pull out the CN1 connector
and measure resistance of the potentiometer. The 5V AVCC R
specified resistance values are as follows: W B R IN Ai1 W FL
2-1:2500±375Ω GND AGND B
5-1:1062±160Ω IW301-0131E13
9-1:2354±353Ω
DET1SLD 6 Shield
45 16
DET1SRC 2 R
ANAINC 5 W
ANAIND 9 G
DET1GND 1 B
30 1
IW301-0132E34
193 W301-0213E
5. Pressure Sensor for Moment

Detection
1. Turn ON the PTO switch. (5-V DC will be applied
between R and B of the pressure sensor
connector.)

DET3SRC 33 R
ANAING 34 SPS3
W B R W (SPS4)
(ANAINH 35)
DET3GND 32 B
IW301-0131E14

cylinder.
Output (V DC)
4.5
0.5
0 35
194 W301-0213E
Fuses
Fuses
RLY1, 2 RLY3, 4 RLY5, 6 RLY7, 8
MAIN
SIF2
SIF1
SOL1, 2
t
m
SOL3, 4
max t SOL5, 6
m
IW301-0211E35
MAIN fuse (3A) SOL1,2 fuse (2A)

AML main fuse for whole unit. Common, with current output 1 and 2.
RLY1,2 fuse (3A) SOL3,4 fuse (2A)

Common, with relay output 1 and 2. Common, with current output 3 and 4.
RLY3,4 fuse (3A) SOL5,6 fuse (2A)

Common, with relay output 3 and 4. Common, with current output 5 and 6.
RLY5,6 fuse (3A)

Common, with relay output 5 and 6.
RLY7,8 fuse (3A)

Common, with relay output 7 and 8.
SIF1 fuse (2A)

For SIF1SRC power supply output.
SIF2 fuse (2A)

For SIF2SRC power supply output.
195 W301-0213E
Replacing the Clock Battery
Replacing the Clock Battery

3. Attach a new battery on the CPU board by
[NOTICE] pressing the battery diagonally. (Refer to the
When the clock battery is worn out, the adjusting figure below)
values, error codes and driving history cannot be The battery positive side must be faced up.
backed up (saving data at power OFF).
Also, when the error code or driving history is
recorded in AML, an accurate date and time cannot
be recorded.
Two built-in clock batteries are on CPU board of the
AML main unit.
Replace both 2 pieces when you replace the
battery.
The built-in clock battery longevity is usually about

10 years.
If the built-in clock batteries are worn out, replace
them according to the following procedures.
4. Install the CPU board in the AML main unit.
1. Remove the CPU board from the AML main unit.
5. Reconnect the connector to the board.
2. Remove the battery from the battery holder on
CPU board by pressing the battery diagonally.
[NOTICE]
When removing the battery, remove while holding
the battery upper (positive side) because the battery
may pop up.
196 W301-0213E
Head 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
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Overload Prevention Device Manual

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Overload Prevention Device Manual

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Publication No.

Overload Prevention Device

Foreword 1. Applicable Spec. No.

Use this manual for machines with the overload

Please note that, for product Improvement, some

2. Contents Display Alteration ...............................................62

1. Applicable Spec. No.................................. 1 Functions of and How to Use User Mode

[ADJUSTMENT AND MAINTENANCE] ........126 10. Adjustment of Elevation Output .....................149

3. Removing CPU Board/Analog Fuses .................................................. 195

[INFORMATION AND DATA]........................177

Adjustment Value Table ................................177

MDT (Multiplex Data Transmitter)

Checking the Detectors

Check the Detectors

Check the Detectors

Components of the AML (AML-L B) Main Unit

Right side view

Boom angle symbol Connector terminal Nos.

Suspension lock state symbol Load radius restriction key

Diagram of the AML System (GT-550E-1)

Input/Output Signals of the AML System (GT-550E-1)

CN2 connector signals and functions are shown below:

CN3 connector signals and functions are shown below:

Diagram of the AML System (GR-120N-1)

Boom angle detector CONNECTOR BOARD CURRENT OUTPUT BOARD

Input/Output Signals of the AML System (GR-120N-1)

15 Di3 Data for reference

CN2 connector signals and functions are shown below:

(*1): For machines with power-tilt jib only

(*1): When the 2nd/3rd boom section full retraction detector

CN3 connector signals and functions are shown below:

Diagram of the AML System (GR-700EXL-1)

Boom angle detector

Over - unwind detection input

Input/Output Signals of the AML System (GR-700EXL-1)

CN1 connector signals and functions are shown below:

3 : Pin No. 29 is not applied (serial No. 545593-)

CN2 connector signals and functions are shown below:

13 CNTL 1P Crane condition that causes the automatic swing stop

CN3 connector signals and functions are shown below:

Diagram of the AML System (GR-300EX-1)

Boom angle detector

Working condition input

Over - unwind detection input

Input/Output Signals of the AML System (GR-300EX-1)

CN1 connector signals and functions are shown below:

CN2 connector signals and functions are shown below:

CN3 connector signals and functions are shown below:

Protect USER MODE MAINTENANCE MODE

In normal use, turn ON the protect switch

The abnormality display LED lights when the AML

Configuration and Functions of the AML System

AML System Configuration

Working range limits

Alarm buzzer External warning

Moment ratio exceeds Boom upper

Automatic Stop Functions Condition Alarm

Lower boom Single top lift

Names and Functions of AML Main Unit Parts

Bar graph Display

Usually on 0-89 90-99 100-109 110 or more

Each frame representing 10% Each frame representing 2.5%

Each frame representing 2.5%