Engine-specific faults and their remedy are given in the operating manual of the engine manufacturer. Fault Possible cause Rectification

Transcription

1 Simple troubleshooting D2-1.1 Engine Engine-specific faults and their remedy are given in the operating manual of the engine manufacturer. Fault Possible cause Rectification The superstructure cannot be started. (For other possible causes, see the Electrical equipment section.) No electrical connection between the battery and the consumer. The switch in the superstructure (OW) is at an incorrect switch position. The battery main switch (rocker switch) is not switched on. Actuate the rocker switch on the superstructure instrument panel. Toggle the switch. The ignition starter switch is defective or the electrical plug connection is loose. Replace the switch. Check the plug connections. The engine is running irregularly or the power is too less. The air cleaner is contaminated. Replace the filter inserts and clean the filter head. (Follow the maintenance indicator) Air-inlet pipes are leaky. Check the inlet system for leak tightness. Tighten the hose clamps. The function of the injection system is defective. Get it checked in a specialist workshop. Excessive coolant temperature even if the engine is not loaded (indicator on the CGC display lights up). Cooler fins are contaminated or the V-belts of the fan are ripped. Cooling system is leaky. Clean the fins or blow out using compressed air; replace V-belts if required. Check the system for leak tightness. Coolant level is too low (indicator on the CGC display lights up). Cooling water hose connections are leaky. Tighten the hose clamps. The pressure relief valve of the expansion tank is defective. Check the functioning of the pressure relief valve and replace it if required. Porous cooling water hoses. Replace all hoses. 1/ Engine

2 Simple troubleshooting D2-1.1 Fault Possible cause Rectification Drain plug loosened or leaky. Tighten the drain plug and replace the sealing tape if required. Fill the remaining volume of cooling water. The engine cannot be stopped. Electrical connections are loose or the switch is defective. Insert the cable lugs or replace the switch. 2/ Engine

3 Simple troubleshooting D2-1.2 Superstructure hydraulic system general Fault Possible cause Rectification The hydraulic system does not deliver the complete output. Air in the system. Pilot pressure is too low (control oil supply). Bleed the hydraulic system. pressure limiting valve: Check the pressure setting and reset it if required. Check the pressure at the measuring connection. The pump control signal is not available or is only partially available. Measure the current of the pump controller. The pressure limiting setting is not correct. Check the pressure and reset it if required. The replenishing valve is contaminated. Clean the valve. The pump controller or hydraulic pumps are defective. Check the pumps and the controller setting and repair them if required. The oil viscosity is incorrect. Fill in the prescribed oil depending on the ambient temperature. Excessive noises of hydraulic pumps. Hydraulic pumps are sucking air. Stop the hydraulic pumps immediately. Check the leak tightness and the oil level of the hydraulic system and top up oil if required. Hydraulic pumps are defective. Repair or replace the hydraulic pumps. The stopcock is closed. Open the stopcock. The superstructure hydraulic system is not functioning. The left is not folded down completely. Fold-down the armrest to release the switch functions. The switch is defective. Replace the switch. Hydraulic pumps are defective. Repair or replace the hydraulic 1/ Superstructure hydraulic system general

4 Simple troubleshooting D2-1.1 Fault Possible cause Rectification pumps. The mechanical connection with the pumps has loosened. Check the screw joints. AML switch off. Select the correct AML program. The pilot signal is missing. Check the control unit. The hydraulic oil temperature is too high. The oil cooler is contaminated. (For other possible causes, see the Electrical system section.) Cleaning the oil cooler. 2/ Superstructure hydraulic system general

5 Simple troubleshooting D2-1.3 Swing mechanism Fault Possible cause Rectification The swing mechanism moves very slowly. Control oil pressure is too low. Check the pressure at the test connection. The crane control lever is defective. Replace the crane control lever. The axial piston engine is defective. Repair or replace it. The swing mechanism pump is defective. Repair or replace it. The pump control valve is defective. Replace the valve. The swing mechanism slews only in one direction. The crane control lever is defective. Replace the crane control lever. The non-return valve in the 3-stage control unit is defective. Replace the valve. The swing mechanism cannot be braked. Discs are worn out. The solenoid valve is defective. Replace the complete disc set. Replace the solenoid valve. The swing mechanism does not function even after actuating the crane control lever. The brake does not open. The crane control lever is defective. Check the hydraulic pressure. Replace the crane control lever. The "Swing mechanism locked" pilot lamp does not light up even if the superstructure lock is actuated. Proximity switch in the carrier is defective. Replace the proximity switch. The slewing gear brake cannot be released. Hydraulic pressure is too low. Check the pressure at the test connection. 1/ Swing mechanism

6 Simple troubleshooting D2-1.4 Telescoping system Fault Possible cause Rectification The boom extends and retracts in a jerky motion. No lubrication of the boom sliding surfaces and slide coverings. Lubricate as per the greasing chart, reset the slide coverings or replace them if required. Air in the cylinder. Bleed the cylinder. The telescope section does not extend or retract any longer. Fuses of the tele-control are defective. Replace the fuses. The relay of the tele-control is defective. Replace the relay The solenoid valve is defective. Replace the solenoid valve (see electric circuit diagrams). No fast run while extending. The fast run valve in the valve block is defective. Replace the valve. The switch in the crane control lever is defective. Replace the switch. 1/ Telescoping system

7 Simple troubleshooting D2-1.5 Derrick Fault Possible cause Rectification The derrick cylinder sinks. Air in the cylinder. Bleed the cylinder. The brake valve is defective. Replace the valve. The upward and downward derrick movements are very slow. Control pressure is too low. The control piston in the 2-stage control unit is defective. Reset the control pressure. Replace the valve. The brake valve is defective. Replace the brake valve. The sintered filter in the brake valve is clogged. Replace the filter. The derrick cannot be lowered. The brake valve is defective. Replace the valve. The pressure limiting valve is defective. Replace the valve. The sintered filter is clogged. Replace the filter. No fast run while raising. The fast run valve in the valve block is defective. Replace the valve. The switch in the crane control lever is defective. Replace the switch. 1/ Derrick

8 Simple troubleshooting D2-1.6 Hoisting gear Fault Possible cause Rectification The load is lowered slowly or in a jerky motion when the hand control lever is set to the middle position. The hydro-multi-disc brake is worn out. The free run is defective. Replace the complete disc set. Replace the free run. The hoisting gear turns very slowly. Control oil pressure is too low. Check the pressure at the test connection. The sintered filter is contaminated. Replace the filter. The hoisting gear is too slow while lowering. The replenishing valve is leaky. Replace the valve. The hoisting gear does not function. AML has switched off. The anti-twoblock device is switched off or is defective. Re-actuate the AML. Release the cylinder and/or replace the switch. The crane control lever is defective. Replace the crane control lever. The valve in the 1-stage control unit is defective. Replace the valve. The hoist gear motor is defective. Replace the hoist gear motor. No fast run. The fast run valve in the valve block is defective. Replace the valve. The switch in the manual control valve is defective. Replace the switch. 1/ Hoisting gear

9 Simple troubleshooting D2-1.7 Counterweight Fault Possible cause Rectification Weights automatically lower slowly. The counterweight cylinder is leaky. Replace the cylinder seals and replace the cylinder if required. Air in the cylinder. Bleed the cylinder. The load retaining valve is defective. Replace the valve. Weights cannot be locked or unlocked. The valve in the 3-stage control unit is defective. Replace the valve. The slew motor of the cylinder is defective. Replace the slew motor. Counterweight cylinders are not extended completely. Extend the cylinders completely; the pilot lamp must remain lit up. Counterweight cylinders lower unevenly. The nozzle in the flow divider is clogged. Clean the nozzle. Weights cannot be lowered or lifted. The valve in the 3-stage control unit is defective. Replace the valve. Counterweight cylinders are retracted or extended very slowly. Hydraulic pressure is too low. Check the pressure at the measuring connection. Pilot pressure is too low. Check the pressure at the measuring connection. 1/ Counterweight

10 Simple troubleshooting D2-1.8 Electrical system Fault Possible cause Rectification No current when the ignition is switched on. No connection between the earth and the battery. Switch on the battery main switch. The battery relay is defective or the cables are loose. Replace the battery relay and/or fix the cables. The ground strap is loose. Tighten the strap. The superstructure engine cannot be started. The fuse is defective. The starter is defective. Replace the fuse. Repair or replace the starter. The ignition starter switch is defective. Replace the switch. Hydraulic oil temperature is too high (the symbol on the CGC display lights up). The temperature switch of the cooler motor is defective. The cooler controller relay is defective. Replace the switch. Replace the relay (also see the Relay chart, chapter C Maintenance and repair of superstructure). The cooler motor or the fuse is defective. Replace the motor or the fuse (also see Fuses, chapter C Maintenance and repair of superstructure). 1/ Electrical system

11 Emergency operation D2-2.1 Crane control WARNING Risk of accident while resetting! The lack of circumspection when resetting may lead to accidents. a) If the superstructure is moved using emergency controls, unauthorized persons may not be present in the movement range. b) The operator must be able to see the movement range. If this is not the case, the operator must work with another person, i.e. a marshaler. CAUTION In case of a failure or malfunctions in different control or actuating elements or faults in the electric system, failed functions can sometimes be executed using emergency controls. These emergency controls must however be used only for stopping the crane movements and dismantling the crane. The cause of the damage must then be determined immediately and rectified. See the following graphics for the position of solenoid valves. Prerequisite: The engine is in the idling mode. The mobile crane is supported. 1/ Crane control

12 Emergency operation D2-2.1 Counterweight: Counterweights up/down; lock/unlock A A 1 = lock counterweight 2 = counterweight up, 6 = counterweight down, 7 = unlock counterweight, For this, press 2 = activate counterweight. Driving direction Driving direction Slewing the superstructure: Before actuating control valves 8 and 9, the plugs must be disconnected and connected again after actuation. 5 = release the slewing gear brake For this, 8 = turn to the right or 9 = turn to the left and 4 = arm rest override must be actuated 2/ Crane control

13 Emergency operation D2-2.1 Hydraulic pumps for crane control: CAUTION If the pump controller fails, the hydraulic pumps can be activated via emergency control. Crane movements are then possible. Before actuating control valves 1 and 2, the plugs must be disconnected and connected again after actuation. Pump actuation B 1 = hydraulic pump 1 2 = hydraulic pump 2 Driving direction 3/ Crane control

14 Emergency operation D2-2.2 Drive unit Emergency start/stop: CAUTION Risk of burns! The engine and lines are hot when the engine is running. a) Do not touch hot parts when operating the emergency start/stop function of the engine. CAUTION The emergency start/stop function of the engine may be used only for completing the crane movement and supporting the mobile crane. Other operations are not allowed under load. 1 Engine start pushbutton 2 Engine stop pushbutton Pushbuttons for the emergency start/stop function are provided at the side of the engine. Prerequisites: Parking brake is engaged. Secure the mobile crane using wheel chocks if required. The ignition in the superstructure has been switched on. The engine cover has been opened. 1/ Drive unit

15 Emergency operation D2-2.2 a) Starting the engine: Press the engine start pushbutton (1). The engine will start and run at the idling speed. b) Stopping the engine: Press the engine stop pushbutton (2) or press the engine start pushbutton (1) again. The engine will stop. Starting the engine and increasing the engine speed: a) Press the engine start pushbutton (1) and keep it pressed. The engine will start and run in the idle mode. The speed increases to the maximum within three seconds of starting the engine. b) Release the engine start pushbutton (1) after reaching the required engine speed. The engine will continue to run at the current engine speed. 2/ Drive unit

16 Emergency operation D2-2.2 Fuel hand pump fuel filter with a water separator The fuel filter with a water separator and a built-in hand pump are provided on the right side of the vehicle. If dirt and/or air enter the fuel system, replace the filter element, clean the fuel system and bleed it. The system needs to be bled and fuel needs to be fed using the hand pump after the fuel tank was empty, if leakages develop in the fuel system, after replacing the fuel filter. Bleeding the system and feeding the fuel: Prerequisite: Adequate fuel has been topped up. Leakages have been rectified. Filter cartridge has been replaced as described in Part "Servicing and maintenance of superstructure". a) Loosen the bleed screw (1). b) Actuate the pump tappet (2) until the fuel emerging is free of air bubbles (collect the overflowing fuel in a suitable container and pour it in the fuel tank). c) Then tighten the vent screw (1) firmly. d) Start the engine. In case of starting troubles, ask an assistant to actuate the pump tappet until the engine starts running. 3/ Drive unit

17 Emergency operation D2-2.2 Overheated drive unit Filling the coolant: WARNING Risk of injuries! The cooling system is under excess pressure. Hot coolant can gush out when opening and scald your skin and eyes. The coolant tank may be opened only when the coolant temperature drops below 90 C (219,6 F). a) Loosen the cap slowly using safety gloves or a cloth and release the excess pressure completely before opening. a) Remove the cap (1) of the coolant tank. If the coolant level is too low, fill the coolant in the coolant tank up to the 'Half' mark. b) Check whether the coolant is flowing out of the engine. Check whether the V-belt is damaged and the radiator is clogged. Other problems may occur. NOTICE Cold shock due to excessively cold coolant! If excessively cold water is filled in the overheated engine too quickly, the engine may get damaged. Always fill the cooling water gradually. If the coolant is not available, tap water can also be used temporarily. The tap water must be replaced with a regular coolant and, if required, the cooling system must be cleaned in the nearest workshop. 4/ Drive unit

18 Emergency operation D2-2.2 Using the shunt cables NOTICE Overvoltage! Erroneous execution of these processes may damage the generator. The repair vehicle must be equipped with a 24 V system whose power must be equivalent to at least the broken down vehicle (i.e. the discharged battery). Do not touch the bare parts of cable clamps and ensure that the plus cable (+) does not come in contact with any metal part of the vehicle body. If the engine does not start owing to the discharged battery, you can start the engine using the batteries of another vehicle and jump leads. Only the specially designed jump leads having an adequate cross-section must however be used. Batteries of the superstructure are provided on the right side of the vehicle. Receiver: vehicle that cannot be started owing to the discharged starter battery. Donor: vehicle that can be started owing to the charged battery. Connect the batteries to the system in the vehicle as prescribed. An interruption may damage the generator rectifier. Both vehicles must be equipped with 24 V systems. The total capacity (Ah) of batteries of the donor vehicle may not be considerably less than that of the receiver. Bring the batteries closer to each other. Vehicle bodies should not touch. There should not be any connection between the vehicles in order to avoid a possible current flow. a) Open the access to the batteries (battery cover, pole protection caps). b) Switch off the radio and other devices that consume energy (in the donor and receiver vehicles). 5/ Drive unit

19 Emergency operation D2-2.2 Connecting the jump lead: Follow the sequence for connecting the jump lead. 1 Plus pole (+) of the receiver battery 4 Minus pole (-) of the receiver battery 2 Plus pole (+) of the donor battery 5 Donor battery 3 Minus pole (-) of the donor battery 6 Receiver battery a) Connect the red clamp (+) of the jump lead to the plus pole (+) of the receiver battery. b) Connect the other red clamp (+) to the plus pole (+) of the donor battery. c) Connect the black clamp (-) of the jump lead to the minus pole (-) of the donor battery. d) Connect the other black clamp (-) to the minus pole (-) of the receiver battery. e) Start the engine of the donor vehicle and let it run. f) Attempt to start the receiver: switch on the battery main switch, switch on the ignition and start the engine. g) After starting the engine successfully, let it run for a few minutes. Observe the following sequence in order to avoid damage to the generator. Current-receiving vehicle The ignition is switched off. The main switch of the battery is switched off. Current-supplying vehicle The ignition is switched off. The main switch of the battery is switched off. 1. Connect the external current cable. 2. Connect the external current cable. 3. Switch on the battery main switch. 4. Switch on the ignition. 5. Start the engine and let it run. 6. Switch on the battery main switch. 7. Switch on the ignition. 8. Start the engine and let it run for a few minutes. 6/ Drive unit

20 Emergency operation D Stop the engine, switch off the ignition and switch off the main switch of the battery. 10. Disconnect the external current cable. 11. Disconnect the external current cable. 7/ Drive unit

21 AML-B Warning and Error Codes D2-3.1 AML-B Warning and Error Codes AML-B_ErrorCodeList_06 1/17

22 AML-B Warning and Error Codes D2-3.1 W---- shows information of crane state in correct condition. Table-4.1: Warning messages Message Description Remedy W0007 W0012 W0015 W0016 W0017 Stopped due to a further swing operation that will result in overloading (or overloading has already occurred) with the outrigger extension widths different between the right and left. Crane is in insufficient backward stability condition. Overwind. When overwind cancel switch is on. Crane capacity is not in defined condition. (wrong combination of counterweight and outrigger are selected) Crane capacity is not in defined condition. (wrong boom configuration is selected) Swing in the opposite direction, retract the boom, or raise the boom. Operate to increase backward stability (ex. lower boom or extend the boom). Wind down hook. Register the operating condition correctly. Change crane condition to correct condition. Register the operating condition correctly. Change crane condition to correct condition. W0023 Stopped due to overload. Make crane to safe posture (ex: elevating up boom) W0024 Stopped due to overwind. Wind down hook. W0025 W0026 W0027 W0028 W0029 W0034 Stopped due to insufficient backward stability condition. *Not installed the outrigger length detectors: This message appears only in undefined crane capacity condition. *Installed the outrigger length detectors: This message appears in the outrigger extension widths different condition between the right and left. Stopped due to working area limit (upper boom angle limit). Stopped due to working area limit (lower boom angle limit). Stopped due to working area limit (height limit). Stopped due to working area limit (work radius limit). Stopped due to main winch rope reserve condition. Operate to increase backward stability (ex. lower boom) *Not installed the outrigger length detectors: Change to correct counterweight and outrigger combination. Cancel work range function, or lower the boom. Cancel work range function, or elevation up the boom. Cancel work range function, or lower the boom. Cancel work range function, or elevate the boom ( up ). Wind up main winch rope AML-B_ErrorCodeList_06 2/17

23 AML-B Warning and Error Codes D2-3.1 Message Description Remedy W0035 Stopped due to aux. winch rope reserve condition. Wind up aux. winch rope W0039 Armrest is up. Armrest is lowered. W0040 W0042 W0043 W0045 Emergency operation mode (Emergency telescopic switch is on). Stopped due to working area limit (right swing limit). Stopped due to working area limit (left swing limit). During telescopic operation in manual mode, telescopic cylinder reaches its limit. It is necessary to operate carefully. Cancel work range function, or swing to left. Cancel work range function, or swing to right. Retract telescopic cylinder. W0054 W0055 W0056 Stopped due to elevating cylinder lower stroke end Stopped due to elevating cylinder upper stroke end A further swing operation will result in overloading (or overloading has already occurred) with the outrigger extension widths different between the right and left. *Under canceled slow swing stop conditions. Elevate the boom ( up ). Elevate the boom ( down ). W0057 Front-right outrigger is retracted. Extend outrigger again W0058 Rear-right outrigger is retracted. Extend outrigger again W0059 Front-left outrigger is retracted. Extend outrigger again W0060 Rear-left outrigger is retracted. Extend outrigger again W0093 W0094 W0095 W0097 Boom connection pins (B-pin) or telescope cylinder connection pins (C-pin) are uncontrollable. (B-pin or C-pin lock-out-sensor and lock-sensor = '0FF' on both side.) Telescope cylinder connection pin (C-pin) is uncontrollable. Automatic telescope is impossible, because the boom connection pin (B-pin) speed is very slow. The maximum instantaneous (i.e. gust) wind speed exceeds the limit for working safely. Swing in the opposite direction, retract the boom, or raise the boom. Return the joystick to neutral at once. Then retry. Boom angle should be over 70 degree in boom condition. In jib condition, boom angle should be over 75 degree. Return the joystick to neutral at once. Then retry. Boom angle should be over 70 degree in boom condition. In jib condition, boom angle should be over 75 degree. Retry again with full joystick and full engine revolution. If the temperature is more than 0 degree centigrade, it is possible to use Slow telescoping mode cancel function (see operation manual). Stop crane operation and stow the boom. AML-B_ErrorCodeList_06 3/17

24 AML-B Warning and Error Codes D2-3.1 Message Description Remedy W0102 W0106 W0108 This message appears when Slow telescoping mode cancel is selected. Elevating speed is reduced due to slow stop function. Swing motion speed is reduced due to slow stop function. W0113 Crane posture is in elevating capacity limit Elevating up, or retract boom. W0121 W0173 W0179 Stopped due to elevating cylinder stroke end. Counterweight cylinder extends but swing operation is selected. AML detects superstructure lock at not rear side of swing angle sensor. Set counterweight correctly. Check superstructure lock pin and swing angle sensor. W0180 Hook block may touch the boom. Elevate the boom ( down ). W0183 1: The counterweight lock sensor as well as the counterweight unlock sensor issues signal = sensor faulty. 2: The counterweight has sunk down and the function "Slewing superstructure" has been selected. Eliminate the fault. Retract counterweight cylinders. NOTE : Watch the AML display to find out whether fault 1 or 2 is present. W0184 W0185 Radio control operation is active. The superstructure swings through 180 (just behind) with maximum C/W cylinder length in mounting the C/W. Stop swinging, and swing to the opposite direction. Any tele-section-detector (Tele-ID sensor) does not work normally. W0188 W0231 Note: Tele-control goes on without stopping, because a tele-sections-common-detector which detects at all tele-sections is working normally. (If the tele-sections-common-detector does not work normally at the same time, telecontrol will stop with any error-code.) Remote control operation (for mounting / dismounting the main boom) is active. (Boom mounting/dismounting mode is selected.) Then operation by Joysticks is unacceptable. Any tele-section-detector fault.. AML-B_ErrorCodeList_06 4/17

25 AML-B Warning and Error Codes D2-3.1 Message Description Remedy W0999 AML back-up battery power is low. This message only appears at power on. Replace back-up battery by a new one. AML-B_ErrorCodeList_06 5/17

26 AML-B Warning and Error Codes D2-3.1 E1--- shows communication error between display unit or transmitter and control unit. If this group error occurs, crane operation stops. But crane operation is possible via the AML override key. Table-4.2: Communication Errors Code Description Remedy E1003 E1004 E1005 AML cannot receive information from Jib state transmitter. AML cannot receive information from Outrigger state transmitter. Jib state transmitter internal error. Communication line between Transmitter and AML is interrupted. Jib state transmitter fault. Communication line between Transmitter and AML is interrupted. Outrigger state transmitter fault. Jib state transmitter fault. E1006 E1009 E1010 E1011 E1012 E1021 Outrigger state transmitter internal error. AML detects data error in data received from Jib state transmitter. AML detects data error in data received from Outrigger state transmitter. Jib state transmitter type in data received is wrong. Outrigger state transmitter type in data received is wrong. AML detects data error in data received from Display Unit Outrigger state transmitter fault. Communication line between Transmitter and AML is interrupted or connected incorrectly. AML receive circuit fault. Transmitter's transmit circuit fault. Communication line between Transmitter and AML is interrupted or connected incorrectly. AML receive circuit fault. Transmitter's transmit circuit fault. Jib state transmitter fault Wrong connection of communication line. Outrigger state transmitter fault Wrong connection of communication line. Display Unit fault Wrong connection of communication line. E1022 E1023 Display Unit cannot receive information from main unit. Display Unit type error Main Unit is not working. Main Unit fault. Wrong connection of communication line. Display Unit fault Wrong connection of communication line. E1024 Display Unit internal error Display Unit fault E1025 Main Unit cannot receive information from Display Unit. Display Unit is not working. Wrong connection of communication line. AML-B_ErrorCodeList_06 6/17

27 AML-B Warning and Error Codes D2-3.1 E2--- shows detectors, operating joysticks, or hydraulic valve error. If this group error occurs, crane operation stops. Crane operation is basically possible via AML override key. But in case of some errors, crane operation is not possible via AML override key before the correct condition exists. Table-4.3: Detector Errors Code Description Remedy E2003 E2004 E2006 E2009 E2010 E2011 Boom length detector error The input value from detector is out of normal range. Normal range is mA (Inside of AML convert to voltage V). Boom angle detector error The input value from detector is out of normal range. Normal range is mA (Inside of AML convert to voltage V). Jib-offset angle detector error The input value from detector is out of normal range. Normal range is voltage V. Front right outrigger length detector error The input value from detector is out of normal range. *Current detective type: Normal range is mA (Inside of transmitter convert voltage V). *Voltage detective type: Normal range is V. Rear right outrigger length detector error The input value from detector is out of normal range. *Current detective type: Normal range is mA (Inside of transmitter convert voltage V). *Voltage detective type: Normal range is V. Front left outrigger length detector error The input value from detector is out of normal range. *Current detective type: Normal range is mA (Inside of transmitter convert voltage V). *Voltage detective type: Normal range is V. Detector fault Detector wire interrupted or short-circuit Detector fault Detector wire interrupted or short-circuit Detector fault Detector wire interrupted or short-circuit Detector fault Detector wire interrupted or short-circuit. Outrigger state transmitter circuit fault Detector fault Detector wire interrupted or short-circuit. Outrigger state transmitter circuit fault Detector fault Detector wire interrupted or short-circuit. Outrigger state transmitter circuit fault AML-B_ErrorCodeList_06 7/17

28 AML-B Warning and Error Codes D2-3.1 Code Description Remedy E2012 E2022 E2023 E2030 E2031 E2041 E2042 Rear left outrigger length detector error The input value from detector is out of normal range. *Current detective type: Normal range is mA (Inside of transmitter convert voltage V). *Voltage detective type: Normal range is V. Telescopic cylinder length detector error. The input value from detector is out of normal range. Normal range is mA (Inside of AML convert to voltage V). Moment Error. Calculated load (weight) becomes negative ( minus ). Note: Crane operation which reduces load moment is possible. Error log is not recorded. Elevating cylinder's rod pressure detector error The input value from detector is out of normal range. Normal range is mA (Inside of AML convert to voltage V). Elevating cylinder's tube pressure detector error The input value from detector is out of normal range. Normal range is mA (Inside of AML convert to voltage V). Crane control joystick left/front-rear error (analogue) The input value from joystick left/frontrear is out of normal range. Normal range is V. Note: joystick left/front-rear operation is not possible. Another operation is possible via AML override key. Crane control joystick left/left-right error (analogue) The input value from joystick left/left-right is out of normal range. Normal range is V. Note: joystick left/left-right operation is not possible. Another operation is possible via AML override key. Detector fault Detector wire interrupted or short-circuit. Outrigger state transmitter circuit fault Detector fault Detector wire interrupted or short-circuit Pressure sensor of elevation cylinder fault Detector wire interrupted or short-circuit Adjustment is effected incorrectly Pressure sensor of elevation cylinder fault Detector wire interrupted or short-circuit Adjustment is effected incorrectly Pressure sensor of elevation cylinder fault Detector wire interrupted or short-circuit Adjustment is effected incorrectly Joystick fault, Wire-fault (interrupted or short-circuit) Joystick fault, Wire-fault (interrupted or short-circuit) AML-B_ErrorCodeList_06 8/17

29 AML-B Warning and Error Codes D2-3.1 Code Description Remedy E2043 E2044 E2048 E2049 E2050 Crane control joystick right/front-rear error (analogue) The input value from joystick right/frontrear is out of normal range. Normal range is V. Note: joystick right/front-rear operation is not possible. Another operation is possible via AML override key. Crane control joystick right/left-right error (analogue) The input value from joystick right/leftright is out of normal range. Normal range is V. Note: joystick right/left-right operation is not possible. Another operation is possible via AML override key. Crane control joystick left/front-rear error (mismatch) When operation detect switch of joystick left/front-rear is off, analog input value from crane control joystick left/front-rear is not in neutral range. Note: joystick left/front-rear operation is not possible. Another operation is possible via AML override key. Crane control joystick left/left-right error (mismatch) When operation detect switch of joystick left/left-right is off, analog input value from crane control joystick left/left-right is not in neutral range. Note: joystick left/left-right operation is not possible. Another operation is possible via AML override key. Crane control joystick right/front-rear error (mismatch) When operation detect switch of joystick right/front-rear is off, analog input value from crane control joystick right/front-rear is not in neutral range. Note: joystick right/front-rear operation is not possible. Another operation is possible via AML override key. Joystick fault, Wire-fault (interrupted or short-circuit) Joystick fault, Wire-fault (interrupted or short-circuit) Joystick fault, Wire-fault (interrupted or short-circuit) Joystick fault, Wire-fault (interrupted or short-circuit) Joystick fault, Wire-fault (interrupted or short-circuit) AML-B_ErrorCodeList_06 9/17

30 AML-B Warning and Error Codes D2-3.1 Code Description Remedy E2051 E2061 E2062 E2063 E2064 E2065 E2067 E2068 E2081 Crane control joystick right/left-right error (mismatch) When operation detect switch of joystick right/left-right is off, analog input value from crane control joystick right/left-right is not in neutral range. Note: joystick right/left-right operation is not possible. Another operation is possible via AML override key. Swing control output error AML detect the swing control current flow, when controlled current output is off. Note: Swing operation is not possible. Another operation is possible via AML override key. Main winch control output error AML detects current flow when controlled current output is off. Note: All operations are not possible. Aux. winch control output error AML detects current flow when controlled current output is off. Note: All operations are not possible. Telescopic cylinder control output error AML detects current flow when controlled current output is off. Note: All operations are not possible. Elevating cylinder control output error AML detects current flow when controlled current output is off. Note: All operations are not possible. Pump1 control output error AML detects current flow when controlled current output is off. Note: All operations are not possible. Pump2 control output error AML detects current flow when controlled current output is off. Swing motion error When AML does not activate the swing valve, swing motion (to right) is detected. Note: Swing right operation is not possible. Another operation is possible via AML override key. Joystick fault, Wire-fault (interrupted or short-circuit) Wire-fault Wire-fault Wire-fault Wire-fault Wire-fault Wire-fault Wire-fault Hydraulic circuit fault. Solenoid fault. Swing angle detector fault. AML-B_ErrorCodeList_06 10/17

31 AML-B Warning and Error Codes D2-3.1 Code Description Remedy E2082 E2083 E2084 E2085 E2086 E2087 E2088 Main winch motion error When AML does not activate the main winch valve, but winch motion (up) is detected. Note: Main winch up operation is not possible. Another operation is possible via AML override key. Aux. winch motion error When AML does not activate the aux. winch valve, but winch motion (up) is detected. Note: Aux. winch up operation is not possible. Another operation is possible via AML override key. Telescope motion error When AML does not activate the telescopic valve, but telescopic motion is detected. Note: Telescope cylinder extension operation is not possible. Another operation is possible via AML override key. Elevating motion error When AML does not activate the elevating valve, but elevating up motion is detected. Note: Elevation "up" operation is not possible. Another operation is possible via AML override key. Jib-offset motion error When AML does not activate the Jib-offset valve, but Jib-offset "up motion is detected. Note: Jib-offset "up" operation is not possible. Another operation is possible via AML override key. Boom section detector error Plural boom section detectors are turned on at the same time. Note: Telescope operation is not possible. Another operation is possible via AML override key. Tele section 2 detector (ID-sensor) does not work. Tele section 3(1) detector (ID-sensor) works after tele 1(3) without tele 2. Note: Telescope operation is not possible. Another operation is possible via AML override key. Hydraulic circuit fault. Solenoid fault. Main winch position sensor fault. Hydraulic circuit fault. Solenoid fault. Aux. winch position sensor fault. Hydraulic circuit fault. Solenoid fault. Telescopic cylinder length detector fault. Hydraulic circuit fault. Solenoid fault. Boom angle detector fault. Hydraulic circuit fault. Solenoid fault. Jib-offset angle detector fault. Jib state transmitter circuit fault. Boom section detector fault.. Tele section 1 or 2 or 3 detector fault.. AML-B_ErrorCodeList_06 11/17

32 AML-B Warning and Error Codes D2-3.1 Code Description Remedy E2089 E2090 E2091 E2092 E2093 E2094 E2095 Boom section detector error. While telescopic cylinder is not connected to the boom, telescopic cylinder length value exceeds the normal range when boom section detector becomes on. Cylinder length and boom section detector status does not match. Note: Telescope operation is not possible. Another operation is possible via AML override key. B-pin Error. Cannot lock or unlock B-pin B-pin lock status detector and unlock status detector are both turned on. Note: Telescope operation is not possible. Another operation is possible. C-pin Error. Cannot lock or unlock C-pin C-pin lock status detector and unlock status detector are both turned on. Note: Telescope operation is not possible. Another operation is possible. B,C pin error B-pin and C-pin detectors are both unlocked state. Note: Telescope operation is not possible. Another operation is possible. Boom section detector and C-pin status error C-pin unlock detector goes off when boom section detector is not turned on. If this state continues more than 1 sec, AML issues this error. Note: Telescope operation is not possible. Another operation is possible. joystick left/front-rear operation detect switches are both turned on. Cylinder length detector fault or incorrect adjustment. Boom section detector fault or incorrect adjustment.. or wrong memorization of boom status. B-pin lock/unlock detector fault,, C-pin lock/unlock detector fault,, B-pin, C-pin lock/unlock detector fault Boom section detector or C-pin lock/unlock detector fault Note: Telescope operation is not possible. Another operation is possible. Tele-reset is necessary. This error appears after AML exchange or battery inside AML is at low power. Execute tele-reset menu. Note: joystick left/front-rear operation is not possible. Another operation is possible. joystick left/front-rear fault AML-B_ErrorCodeList_06 12/17

33 AML-B Warning and Error Codes D2-3.1 Code Description Remedy E2096 E2097 E2098 E2103 E2104 E2105 E2106 joystick left/left-right operation detect switches are both turned on. Note: joystick left/left-right operation is not possible. Another operation is possible. joystick right/front-rear operation detect switches are both turned on. Note: joystick right/front-rear operation is not possible. Another operation is possible. joystick right/left-right operation detect switches are both turned on. Note: joystick right/left-right operation is not possible. Another operation is possible. Swing motion error When AML does not activate the swing valve, swing motion (to the left) is detected. Note: Swing left operation is not possible. Another operation is possible. via AML override key Main winch motion error When AML does not activate the main winch valve, but winch motion (down) is detected. Note: Main winch down operation is not possible. Another operation is possible via AML override key. Aux. winch motion error When AML does not activate the aux. winch valve, but winch motion (down) is detected. Note: Aux. winch down operation is not possible. Another operation is possible via AML override key. Telescope motion error When AML does not activate the telescopic valve, but retract motion is detected. Note: Telescope cylinder retract operation is not possible. Another operation is possible via AML override key. joystick left/left-right fault joystick right/front-rear fault joystick right/left-right fault Hydraulic circuit fault Swing angle detector fault. Hydraulic circuit fault. Solenoid fault. Main winch position sensor fault. Hydraulic circuit fault. Solenoid fault. Aux. winch position sensor fault. Hydraulic circuit fault. Solenoid fault. Telescopic cylinder length detector fault. AML-B_ErrorCodeList_06 13/17

34 AML-B Warning and Error Codes D2-3.1 Code Description Remedy E2107 E2108 E2110 E2111 E2112 E2113 E2115 E2116 E2117 Elevating motion error When AML does not activate the elevating valve, but elevating down motion is detected. Note: Elevation down operation is not possible. Another operation is possible via AML override key. Jib-offset motion error When AML does not activate the Jib-offset valve, but Jib-offset down motion is detected. Note: Jib-offset "down" operation is not possible. Another operation is possible via AML override key. Swing angle detector A Error. Input current from swing angle detector is out of normal range ( mA) Swing angle detector B Error. Input current from swing angle detector is out of normal range ( mA) Swing angle detectors' offset Error. Input current difference between swing angle detector A and B is out of range. Input current from overwind detector is out of normal range ( mA) Tele section 3 detector (ID-sensor) does not work. Tele section 4(2) detector (ID-sensor) works after tele 2(4) without tele 3. Note: Telescope operation is not possible. Another operation is possible via AML override key. Tele section 4 detector (ID-sensor) does not work. Tele section 5(3) detector (ID-sensor) works after tele 3(5) without tele 4. Note: Telescope operation is not possible. Another operation is possible via AML override key. Tele section 5 detector (ID-sensor) does not work. Tele section 6(4) detector (ID-sensor) works after tele 4(6) without tele 5. Note: Telescope operation is not possible. Another operation is possible via AML override key. Hydraulic circuit fault. Solenoid fault. Boom angle detector fault. Hydraulic circuit fault. Solenoid fault. Jib-offset angle detector fault. Jib state transmitter circuit fault. Swing angle detector fault Swing angle detector fault Swing angle detector fault Overwind detector fault Overwind connector is not rigged. Tele 2 or tele 3 or tele 4 section detector fault Tele 3 or tele 4 or tele 5 section detector fault Tele section 4 or 5 or 6 detector fault AML-B_ErrorCodeList_06 14/17

35 AML-B Warning and Error Codes D2-3.1 Code Description Remedy E2119 E2133 E2134 E2135 E2136 E2137 E2138 Boom section detector and B-pin status error B-pin lock detector goes off when C-pin is not locked. When this state continues more than 1 sec, AML issues this error. Note: Telescope operation is not possible. Another operation is possible via AML override key. Tele-ID. Error on one side. Expected ID-combination not defined on one side. Note: Continued automatic mode with error-free side. Tele-ID. Error on both sides. Expected ID-combination not defined on both sides. Note: Automatic mode stopped. Movement only in emergency mode. B-Pin lock-out-sensor and lock-sensor = '0FF' on one side. Note: Continued automatic mode in reduced-speed by tele-cylinder length or error-free pins. B-Pin lock or B-Pin unlock error. Lock-sensor and unlock-sensor = 'ON' on one side or both side. Note: Telescope operation is not possible, movement only in emergency mode. Another operation is possible. C-Pin lock-out-sensor and lock-sensor = '0FF' on one side. Note: Continued automatic mode in reducedspeed by tele-cylinder length or error-free pins. C-Pin lock or C-Pin unlock error. Lock-sensor and unlock-sensor = 'ON' on one side or both side. Note: Telescope operation is not possible, movement only in emergency mode. Another operation is possible. Boom section detector or B-pin lock/unlock detector fault Tele-ID detector fault Tele-ID detector fault B-pin lock/unlock detector fault,, B-pin lock/unlock detector fault,, C-pin lock/unlock detector fault,, C-pin lock/unlock detector fault,, AML-B_ErrorCodeList_06 15/17

36 AML-B Warning and Error Codes D2-3.1 E3--- shows inside of AML error. If this group error occurs, crane operation stop. Crane operation is basically possible, but only in emergency mode Table-4.4: System Errors Code Description Remedy - E3002 E3003 E3004 E3005 E3006 E3007 E3008 During ROM sum check, error is detected. During RAM check, error is detected. CPU or DMAC address error Illegal instruction Undefined exception is called. Applied voltage to analog detector (5V) is out of range. Adjustment data in flash memory is not correct. Input output handling program(s) do(es) not run correctly. Re-write program and data Hardware fault due to external noise. Hardware fault due to external noise. Re-write program and data Circuit fault Hardware fault due to external noise. Note: Erase error log. This message remains until erase error log operation. Re-write program and data, or do re-adjustment Hardware fault due to external noise. AML-B_ErrorCodeList_06 16/17

37 AML-B Warning and Error Codes D2-3.1 E4--- shows Display Unit error. If this group error occurs, crane operation stops. Crane operation is basically possible via AML override key. Table-4.5: Display Unit Detect Errors Code Description Remedy E4001 E4002 E4003 E4004 E4005 During ROM sum check, error is detected. During RAM check, error is detected. CPU or DMAC address error Illegal instruction Undefined exception is called. Memory fault. Re-write program and data Display unit circuit fault Memory fault. Hardware fault due to external noise. Display unit circuit fault. Memory fault. Re-write program and data Hardware fault due to external noise. Display unit circuit fault E4010 E4011 Receive timeout error Cannot receive data from Main Unit Receive data error Cannot receive data from Main Unit. Main Unit is updating flash Display unit or Main unit circuit fault Display unit or Main unit circuit fault AML-B_ErrorCodeList_06 17/17