SERVICE MANUAL MS-10C.1.PREFACE This Manual has been compiled as a handbook for servicing “Compuload”, the new automatic digital overload prevention device which is fitted to KATO cranes. Unlike the conventional analog ACS device, the new digital ACS system with its built — in microprocessor has a self ~ diagnosis function for servicing in addition to its function as an overload prevention device. Consequently, while the conventional analog ACS device requires a service bag for data collection, this can now be performed by the digital ACS system with its self — diagnostic function. Furthermore, it has become possible to automatically monitor the status of the overload prevention device itself during routine crane operations, resulting in improved reliability. However, even the most advanced electronics cannot provide adequate crane control performance unless the procedure is correctly followed by service engineers. It is therefore recommended that this Manual be read thoroughly so that the appropriate service techniques can be mastered.TABLE OF CONTENTS PREFACE. SYMBOLS AND TERMS 1, STRUCTURE AND FUNCTION 1-1 Composition «+ 12 Block diagram (hardware) -- 1-3 Computing system (software) 14 Display - 15 Display unit 16 Main unit 17 L@—detector unit 18 Optical cable reel - 19 Boom top terminal -- : 1-10 Luffing jib angle detector unit’ +10 LIL Power jib angle detector unit ------+++++++ sreeeteeeeeeeees TL 112 Luffing jib AV detector unit 12 1-13 AV Detector unit ------- sreseees 13 114 Accumulator pressure detector unit 14 2. CHECK AND ADJUSTMENT 21 Input and output of each unit-+++++++-+++° () Layout of adjusting variable resistors of main unit (2) Layout of connectors and terminals of main unit --- (3) Layout of main unit connector terminals (B) - (4) Layout of main unit connector terminals (C) -- (5) Layout of main unit connector terminals (D) ©) Layout of adjusting variable resistors of L@ —detector (7) Layout of L @-detector cab tire connector terminals --- (8) Layout of power jib connection connector terminals :~ (9) Layout of luffing jib connection connector terminals ----~ (10) Layout of boom top terminal adjustment variable resistors -+++- oo (AW) Craneside circuits (only those related to ACS) 22 Troubleshooting : (1) Steps in the event of abnormal conditions (2) Error code table - : (8) Description of display table f8S8R8 23 Adjustment ----- (1) Before adjustment - . (2) Adjustment of power supply (3) Adjustment of boom angle (4) Adjustment of boom length -(5) Adjustment of pressure detector unit--- (6) Adjustment of slewing angle ( Conformation of load display selector switch and illumination changeover «------++++* . (8) Adjustment of boom top angle « (9) Adjustment of jibto-ground angle ---- (10) Confirmation of off-set angle of power jib --- (11) Adjustment of luffing jib AV detector (12) Adjustment of ACC sensor 45 +46 3. REPLACEMENT 3-1 Replacement of ROM 32 Replacement of optical cable reel and optical fiber cabler +53SYMBOLS AND TERMS L 6 P, : P, oJ B eT a oP WR WA R H Le : Software : Hardware cPU ROM RAM Vo A/D LED LcD Stop | Stop Il JS Voice Serial transmission : ACC COR ADJ (ADJUST) SW OH VR t TT : Boom length Boom angle Derrick cylinder head pressure Derrick cylinder rod pressure Jib angle (luffing jib or power jib) Boom top angle Slewing angle Operating status Reference overall load Actual overall load Working radius Maximum lift Boom length . boom angle Sequence and content of system operation Stored in ROM Concrete electronic circuits and their elements IC for program interpretation and execution Read only memory Random access memory Input and output circuits and ICs IC for converting analog signals (such as sensor signal) into digital signals (signal which CPU can process) Light emitting diode display Liquid crystal display Trouble lamp Check according to ACS pre — operation check guide Automatic stop due to increase of moment (Automatic) Stop due to derricking beyond upper limit angle Jib set Voice synthesized from memory chip by digital pulse Each information bit is transmitted linearly Accumulator Crane control computer system Adjustment Switch Overhoisting Adjusting variable resistor Boom top terminal1. Structure and functionStructure and function 1-1 Composition [Power jib specifications] Boom top terminal Power jib angle detector unit Overhoisting detector unit [Luffing jib specifications] eo Luffing AV detector unit ——=_—_ Sy Luffing jib angle 7 Kant unit ~Boom top terminal L.@—detector unit Overhoisting detector unit Optical cord reel Cord real Load display selector Switch, speaker, etc. Display panel Automatic stopper ompuload main unit AV detector unit Slewing angle detector Over front area detector unit Accumulator pressure detector unitStructure and function 1-2 Block diagram (hardware) | Boom top angle co Or j [detector |Amplifier| oH [Poaceae £70 conor | [ateae|}—| = [istectr rrr ie senor L 6 ~ detector ae Load detector Optical cable reel Boom top terminal Guffing unit) Lutfing jib anole detector (Power jib angle detector) Heater control Panel 1 circuit board (Display unit) circuit board (optional) Opwaven] —[Ossaten : ‘tatus ‘status Brive Ls Ostia | A $5 | [mcrae Panel 2 [| ie | Le # acatt board | | i 3] iL] ic -—t Heater ll 5S Ve vo | . Main. circuit T - ‘Analog circuit z Ie board gam | neat cpu i vo I from] fram|frimer) | [tock Tae LH I Computer i ma) 8 | |] Sever unt | [ROMY Vee, vo ‘|| g8 3 He Pel (eee . . u t U Breaker |-. + — a - ; —. rani Sarah = | ie i Output signal * [Perens] fe = Preseure detector jowmnon |Structure and function 1-3 Computing system (software) The CPU performs the computation shown in the flow chart below according to commands stored in the ROM, and thereby controls the crane. Power switch ON Tera Initialization | RAM, ROM check Sj Operating status signal acquisition check { Sensor signal acquisition check +————+({ cor Data | transfer Calculation of WA and R | Calculation of WR ee Computation of safety | Computation of sequential control | Display selection i Display { Output to crane a Voice output {eee cere rrrStructure and function 1-4 Display Joyeoipur ejBue woog Jo1eo1pul_ peo} 40}201pu! Yyoums snyeis Bunyes 4@861RNO Epis — 1YBIY due} \ due soveoipu_smeis soyeoipul_snyeis pasnun 4866u1NG, yous smyers Bunies 498610 pls — 487 YoUMs snes Bunzes 496610 Apis — By eae, \ esta om due} ae \ aS 1 youms smieys Bunies J86613n0 apis — 1407 20,201pu aj6ue yesyyo gir dwie| s0xe0!pu snyeys uoneledo woog wnwixew /s0xe01pul ur6ua}_woog due} Aejdsip kale BumalS, Youms smers uoneiedo woogStructure and function 1-5 Display unit euim Bulpunoi6 sisseyo seg, joueg a1e|d eBueyosip yee}1-6 Main unit Cover Structure and functionStructure and function 1-7 L@- detector unit Jayewonusjod Gunes [woog 40 apis 1YBU UO payUNoW oq oF JorDeIEP — 971 Jo SI WesBeIg) ui6ua]_wWooq wnwixeyy J0}WONUEIOd uonssiep yi6ua} woog \ aed pedeys ue. J9a1 aiqeo jeondo Buyeag =~ ( dating Bu —9 4e}oWONUE}Od_UoNDE}8p aj6ue woog joy Gunma yun uleVy Taneaig ay eseg Bio sseooe Suu jae e1geo ondoStructure and function 1-8 Optical cable reel Power source cable | | | O-ring g Optical sensor ¢ ; / E-ring Air breather. t 3 Bearing an) (do not disassemble) & ae ; AKG oa Amplifier circuit board ——— Cord reel case Packing Relay rod — Optical fiber connection area Reel Base plate Qptical fiber end connector 7 & (For both left-hand operated and right — hand operated vehicles)Structure and function 1-9 Boom top terminal ‘Jepow siyy yo eBew! sow ey, S} S9]IYBA payesedo pueY — 148) Joy JeuIWIE doy WOdg ey) (@pIs 148 Uo payunow aq o} JeuIWE, dor Woog yo si WesBEIQ) 40}98UU09 4oyoeuU0d = yndul aueds sosues 9|Sue air (Buyy3N1) soMog eounos 4amod yz + 4epioy |oyoauuos jeo"dQ Bum asIoUsen9 49plOY P1POq HINDU) wsiueyoows Omeg_| | Q 2 \ 7 aa Ao pieog ynoo yy HI padeus "y veyoeiq ssiowonueiog \ & if ‘reyyesiq sy J9}eWORUa}Od UODSIep ae e[6ue doy woogStructure and function 1-10 Luffing jib angle detector unit (Se|o1yen pereiedo puey —i4Y8U pue pereiedo puey— 149] YI0q 404) 4oye1ep_9|6ue reuse AY at Buyin dor woog a) qs sanog oo wsiueysow 481d pedeys ues _* sune0g | —S Suu — seyeuonuerod PUNO wonosiep 2/6ue air seyresig. ay eseg 10-Structure and function 1-11 Power jib angle detector unit epow siyy 4o eBew! sot aun SI SejaIyen peyeiedo puey — 148) 40} y1UN JoxONI9p ay [so1oIyeA pereredo puey — 2481 105] reuusey do woog (om 49009 wisjueyoou! : re seyyeeig ay ayeid padeys uey Jay@WORUS}Od 4oxoaiap ajoue gir asegStructure and function 1-12 Luffing jib AV detector unit Protector Pressure sensor (PT-W-5) eee HolderStructure and function 1-13 AV detector unit aeStructure and function 1-14 Accumulator pressure detector unit 3 fe -14-2. CHECK AND ADJUSTMENTCheck and adjustment 2-1 Input and output of each unit (1) Layout of adjusting variable resistors of main unit Program ROM Compuload main unit span “Os ZERO ADJUST © OT] OTe eae) of symbols Pore etre © 7 eo eo 8 OAR eo ® ©® 980 © © | O'ER cistor RE 8 OT a BP OF ae ‘ADJUST ZERO VOICE SPAN ee a switch [eassel ® ©] ©--monitor temp ° ®o Connector Voice adjusting Circuit board variable resistor @ oe (Description of variable resistor adjustment] VOICE For adjustment of voice volume (do not touch this as it is pre —adjusted prior to. shipment). a slewing angle zero P, ZERO zero point of P, pressure detector P; ZERO zero point of P; pressure detector P, SPAN ‘Adjusts span of P, pressure detector (do not touch) P, SPAN ‘Adjusts span of Ps pressure detector (do not touch) @ “Adjusts boom angle zero L ‘Adjusts boom length zero ACC ZERO ----Adjusts accumulator pressure detector zero ACC SPAN ---Adjusts accumulator pressure detector span (do not move) 83 of 8 JL “Adjusts jib ~ to ~ ground angle zero eT “Adjusts boom top angle zero [Conditions for lighting monitor lamp] @ STOP 1 automatic stop signal is being output @a - sequential control signal A is being output @ B sequential control signal B is being output @ + jib side up signal is being output ® there is no spare wire ® other than luffing operation @ sTOP I- jib reference stop signal is being output ® on overhoist cut signal is being outputCheck and adjustment (2) Layout of connectors and terminal of main unit (A) L.@~detector unit P, pressure detector connector connector ACC connector Slewing angle detector unit P, pressure detector Breaker connector: nnector 4 a a Input“output] Input/output COR 2 connector/ connector connector __ \Crane_connector (13P) (1P) (7p) (gp) 171882-1 172038-1 171366-1 171894-1 Xv" Crane connector Input /output connector oowHD FOOT) Pin, sly View from layout) View tom View from cable side 171894-1 ¥71366-1 1| exp [OUTI Automatic Stop 1 24 when Stop 2] tlumination +24 [OUTS Jib side up 24V when L> specified lenth 3] Heater +24 [OUT Luffing 24V ‘for other than luting operation | 4) Speaker © [OUTS Overhoisting 1 GND when ib set, GND for other than overhoisting 3 | Ratio © IN 4 Stack noisting detector switch GND for other than sack hoisting 6| +24V (crane) iw 2, ———_— 7] +24V (ACS) IN 5 Front jack detector switch GND for front 8 Speaker © IN 7 Telo~extension detector switch GND for operation Pin 9) Radio @ IN © Auxiiary winch hoisting detector switch GND for operation No.9] JOUT2 Sequential control A 24V for L > specified lenath u OUTS Sequential control B_ 24V for L> specified lenath 12 ours. ——___ 13 (OUT? Automatic stop I 24V for jib reference stop | Ins 15 {iN 1 Display selector switch GND for operation 16| INN 6 Derrick lowering detector switch GND for operation 7 InN 8 Main winch hoisting detector switch GND for operation -16-Check and adjustment (3) Layout of main unit connector terminals (B) Name ] Input/output connector (11P) | COR —2 connector 3B) (aT Tose 716[5]4/3[2h1 a 6/5/4/3[2/ 1] [ ae view from cable side | vne ae 2088 - 172038-1 ton 1 [IN 10 Derrick initiation detector switch GND for operation | Data communication line 2 JIN 11 Tele~retraction detector switch GND for operation 3. JIN 12 Main winch lowering detector switch GND for operation line 4 JIN 14 Jib tilt down detector switch GND for operation OUT 2’ Warming light green relay output GND for operation | Data communication line 6 }OUT 3° ——— GND vin|? [PS 2 sua wo er crs GD rain a ni NO.l5 Jin is = ————— |GnD 10 four 1” warning taht yetow relay ouput GND for operation | Data communiaton tne li1 Jour 4° over noistine 2 GND during safety sie operation [pata communication ne [12 GND 8 Data communication tine -17-Check and adjustment (4) Layout of main unit connector terminals (C) Optical cable reel GND Optical cable reel power source (av) Boom angle reference voltage (Hii level) Boom angle reference voltage Gow level) ‘Boom angle input signal Pressure detector | ACC pressure detector L @ detector connector panna Pees @@O Pin © ©® GOO GOO layout ([cYoro) O®@ ©® SRCN2A- 16-108 SRCN2A- 13-58 SRCN2A-13-5S 1 frterence votase for boom | +8 <5 length (i lve |2|petence wats for beam foons ACC Presure input sina |"Jingin" (Low ive © |] boom tength input sent [Pressure input sina] ACC Pressure input sina ( | 4 | Data communication input (+) )-5V COM 5|Data communication input (—) | Shield Shield SSCheck and adjustment (5) Layout of main unit connector terminals (D) Name] Slewing angle detection (unit) connector Pin @@O layout ©@ +5.0V Slewing angle signal 1 Slewing angle signal 2 GND z Ei Waneene 3S © \9 (9 19~-Check and adjustment (6) Layout of adjusting variable resistors of L 6 — detector 408/891 ajgeueA Bunsnipe NvdS ei6ue woog Jajujod @jBuy aield 4oysise1 aigeuen Bunsnipe oe 9 snipe \ gus — ue NvdS wisue] woog wooq Sunseyep 40} sajawonuarog soqoarep — 97 yyBue}_woog wnwixew ajSue woog Bunoarep Bunies 40} s8,WORUaIOg 40} Je,eWONUEI0g -20Check and adjustment (7) Layout of L @— detector cab tire connector terminals L 6 ~ cable °— (§}-——=c1 viewing direction Compuload main unit side pono] —a—A viewing direction L 6-side D@® (OOOO) Pin OO” Pin layout layout View from direction of arrow B SRCN6A~ 16- 10P ; = 1 |Reference voltage for boom 1 length (Hi level) 2 |Reference voltage for boom 2 length (Low level) 3 3 |Boom length input signal 4 |Data communication input 4 () 5 |Data communication input 5 Pin] |(-) Pin| § No. | G No. | 6 Optical cable reel GND 7 Optical cable reel, power source (+ 8V) | 8 [Reference voltage for boom | | Jangle (Hi level) 9 [Reference voltage for boom | Jangie (Low level) |10|Boom angle input signal Mark View from direction of arrow A 1-171822-6 Reference voltage for boom length (Low level) Boom length input signal Reference voltage for boom length (Hi level) Reference voltage for boom length (Low level) Boom angle input signal Reference voltage for boom angle (Hi level) Sine:Check and adjustment (8) Layout of power jib connection connector terminals Boom top terminal cable © —— D=——$cn Viewing direction Compuload main unit Base side Pin Layout View from arrow B T 1 2 | Red Reference voltage for power jib angle (Hi level) 3| Green | Power jib angle input signal 4 | Yellow | Reference voltage for power jib angle (Low level) 5 in| 6| Be 8| 9 | 10} Black |—— 11) Black 12] Shield |-—Jumper —22Check and adjustment (9) Layout of luffing jib connection connector terminal Boom top terminal cable -— cab Viewing direction Compuload main unit Base side Pin layout View from arrow B 1 2| Blue Reference voltage for luffing jib angle (Hi level) 3|Green |Luffing jib angle input signal 4 | Yellow |Refference voltage for luffing jib angle (Low level) 5 | Orange |Jib AV detection pressure sensor input signal 6 | Brown Reference voltage for jib AV detection pressure sensor Pin (Hi level) No. | 7 | White Reference voltage for jib AV detection pressure sensor (Low level) 8 | Red | Jiv AV detection pressure sensor ground 9 10 u 12 Shield -23Check and adjustment (10) Layout of boom top terminal adjustment variable resistors TT circuit board Variable resistor VRE Screw sp| Name of variable i resistors Usage @) +5v Adjustment of top terminal power source @| 63 span Adjustment of luffing power jib angle span @| @T span Adjustment of boom top angle span @| PJ span Adjustment of jib AVdetection pressure sensor span @| VW span Adjustment of wind velocity indicator span ®| 64 Zero Zero adjustment of luffing power jib angle @| @T Zero Zero adjustment of boom top angle ®| PJ Zero Zero adjustment of AV detector pressure sensor ®| VW Zero Zero adjustment of wind velocity indicator @| A/D Zero @| A/D Full scale 24Check and adjustment (11) Crane side circuit 1 Work lamp _switch 9 2 6 8 _ Illumination 8 Heater) & Speaker (-) 8 Radio (-) 2 +24V (crane) & +24v (ACS) + 24v S Speaker (+) PTO switch Radio (+) Automatic stop 1 (Stop + 24V) Jib side up (L in excess of specified length) © Luffing (other than tuffing ~ 24v) Overhoisting 1 (other than overhoisting GND) (Slack hoisting detection) (other than slack hoisting cutoff GND) ‘ACS emergency switch ete Sescenin solv Zmsoton Front jack detection (front GND) Tele — extension detection (operation GND) Auxiliary winch hoisting detection (operation GND) Sequential control A (L in excess of specified length 24V) Sequential control 8 (L in excess of specified length 24V) FP, ick wnch’ OP Automatic stop (Stop 24V) Input//output connector Display change over (change over GND) Derrick lowering detection (operation GND) Main winch hoisting detection (operation GND) Derrick erection detection (operation GND) © Tele ~ retraction detection (operation GND) © Main winch lowering detection (operation GND) © Jib tilt lowering detection (warning light: green) © Auxiliary winch lowering detection (operation GND) Input connector (Warning light: Yellow) Overhoisting (safe side operation GND) Note : Luffing jib specification only : Power jib specification only (Standard jib specification) [Luffing jib specification, power jib specification] Cord reel iS 3 noone, jx Cord ree! main J Rooster Top terminal Main TTL, Rooster fs], ib ESL, (Lutting jib) Hoveeeisting 1 an ‘Gvericstna t ‘Speaker Radio vib side_door ‘stop_switch vib swing See, caren Bei Automatic stop “\ Free fall ‘olay Tele — change over Tele — extension detection switch Auxiliary winch hoisting switch Derrick lowering switch Main winch hoisting switch Derrick erection switch Tele - retraction switch Main winch lowering switch Jib tilt down switch Auxiliary winch lowering switchCheck and adjustment Crane side circuit 2 Option : Extention indicator (warning lamp) circuit Be worn tort can FS 33 (ON: GND)| 3 I © aig tte o|_p-———t eal (ON: GNp)| 10 + 2ay 4 = mr mat Overhoisting 1 relay :Check and adjustment 2-2 Troubleshooting (1) Steps in the event of abnormal conditions a) When error number is displayed Under the following conditions, ACS will light up the trouble lamp and display the error number, and the crane will stop automatically. % When an error occurs in ACS during crane operation. * When an error is found in ACS during checking conducted according to the ACS pre~ operation checking guide. Example] 563 Pl or P2 input error (Only for (@) checking) L Display of c. Setting of boom operation error number — ©@US® condition switch (Checking) P,, P., wiring, connector ‘—Checking location (Adjusting) Pressure detector adjustment {Adjust according to appropriate item under Section 2-3, Adjustment (Replacement) P,, P,, analog circuit board ‘When the problem is not rectified by (Checking) or (Adjustment), replace one or more of these items. b) When ACS display is blank or displays “+++”, “OOO”, or an unrecognizable symbol, the following check or replacement should be conducted. 1) Operate the crane within a safe range and check if the monitor lamp of the main unit turns ON or OFF normally. 2) Monitor lamp display is normal : :display unit connector, wiring :display unit, panel circuit board, main circuit board 3) Monitor lamp display is abnormal : : battery, wiring, connector Check by disconnecting connectors in sequence, except for power source of main unit. : main circuit board, chassis, analog circuit board -28@ Check and adjustment Error code table c22 io IS IS : E05 c10 E12 E13 EM C20 E21 E22 Boom operation status switch input error :Check that switch is not set to position not available in crane specification. Jib angle detector connection defect (during power jib only) Connection of connector, wiring : Top terminal circuit board RAM error < Replace > : Main circuit board SL ROM error < Replace > :S1 ROM, main circuit board Defect in stabilization power source :Remove in sequence; battery, connector, wiring and sensor connector : “Power source adjustment” < Replace > : Main circuit board, sensor Note :Sensor indicates L @ ~ detector, pressure detector and slewing angle detector A/D input error :Sensor connector, wiring Remove sensor connectors in sequence. :Sensor, main circuit board Software computation impossible :Sensor connector, wiring < Replace > : Sensor, main circuit board S1, ROM Outrigger setting switch input error :Check that switch is not set to neutral position Indicator connector, wiring, switch wiring < Replace > : Indicator, panel circuit board, main circuit board Boom operation status switch input error :Check that switch is not set at intermediate position Indicator connector, wiring, switch wiring < Replace > : Indicator, panel circuit board, main circuit board SI ROM Slack hoisting switch input error (only for : Switch, wiring Note _: When the specification has no slack hoist, connection is made directly to GND (see P.2 — P.1l) : Switch, main circuit board Jib tilt lowering detection switch input error (only for @} checking) : Switch, wiring : Switch, main circuit board checking) -29-Check and adjustment E30 Derrick lowering detection switch input error (only for (@) checking) : Switch, wiring Note ‘Switch indicator lamp comes ON during lever operation and goes out when lever is in neutral position. Indicator lamp : Switch, main circuit board E31 Tele~ extension detection switch input error (only for @ checking) : Switch, wiring < Replace > : Switch, main circuit board E32 Main hoisting detection switch input error (only for checking) : Switch, wiring : Switch, main circuit board E33 Auxiliary hoisting detection switch input error(only for @ checking) : Switch, wiring : Switch, main circuit board E34 Derrick lowering detection switch input error (only for (@j) checking) : Switch, wiring : Switch, main circuit board E35 Tele — retraction detection switch input error (only for < (Check > Switch, wiring : Switch, main circuit board E36 Main winch lowering detection switch input error (only for [@) checking) ” : Switch, wiring : Switch, main circuit board E37. Auxiliary winch lowering detection switch input error (only for checking) : Switch, wiring < Replace > : Switch, main circuit board E40 Boom length input exceeds extension limit :L6@~wiring, connector, L potentiometer wiring :Boom length adjustment :L @ — mechanism, analog circuit board, chassis, main circuit board E50 Boom angle input exceeds 90° :L @~ wiring, connector, 6 — potentiometer wiring :Boom angle adjustment :L 6 ~ mechanism, analog circuit board, chassis, main circuit board checking) ~30-B52 iy Check and adjustment Boom top angle input exceeds limit (only for luffing jib and power jib) :Top terminal wiring, connector, potentiometer wiring < Adjust > :Boom top angle adjustment < Replace > :L @~ mechanism, top terminal circuit board Jib angle input exceeds limit (only for luffing jib and power jib) :Jib angle indicator wiring, connector, potentiometer wiring : “Jib angle adjustment” : @—J mechanism, top terminal circuit board Jib angle adjusting variable resistors input error (only for luffing jib and power jib) < Adjust >: “Jib angle adjustment” : Analog circuit board of main unit Boom top angle adjusting variable resistor input error (only for luffing jib and power jib) :Boom top angle adjustment : Analog circuit board of main unit Power jib offset exceeds lower limit (only for power jib) :Top terminal, jib angle indicator wiring connector, potentiometer wiring < Adjust > :Boom top angle adjustment”, “Jib angle adjustment” : Top terminal circuit board, @~T mechanism, 6 —J mechanism Power jib offset exceeds top limit (only for power jib) :See E55 < Adjust > :See B55 < Replace > : See B55 Pl or P2 input error :PI, P2 wiring, connector Disconnect Pl and P2 connectors in sequence Note This error occurs when Pl and P2 are connected in reverse. : “Pressure detector adjustment” :P1, P2 analog circuit board, chassis, main circuit board PI input exceeds limit :P1 wiring, connector < Adjust >: “Pressure detector adjustment” :P1 analog circuit board, chassis, main circuit board Pl input zero However error is judged only when at @~-10° or higher : PI wiring, connector < Adjust >: “Pressure detector adjustment” :P1 analog circuit board, chassis, main circuit board aE63 B64 E66 Check and adjustment Pl or P2 input error (only for checking) :Confirm that hook is grounded Confirm that crane is in standard main boom operation status. PI wiring, connector ‘Pressure detectoradjustment”, “Boom angle adjustment” : Pl, P2, analog circuit board, L @ ~ mechanism, chassis, main circuit board ACC input exceeds limit :ACC pressure detector wiring, connector : “ACC sensor adjustment” : ACC pressure detector, analog circuit board, chassis, main circuit board ACC input error (only for checking) :ACC pressure detector wiring, connector ACC hydraulic circuit :See B64 < Replace > : See E64 Luffing jib pressure input is excessively large or small (only for luffing jib) :Luffing jib pressure sensor wiring, connector : “Luffing jib AV detector adjustment” : Luffing jib AV pressure sensor, top terminal circuit board Luffing jib pressure input error (only for :See E66 :See E66 < Replace > : See E66 Pl or P2 input error :See E60 < Adjust > :See E60 : See E60E71 P2 input exceeds limit :P1 wiring, connector : “Pressure detector adjustment” : P2, analog circuit board, chassis, main circuit board Slewing angle input error :Wiring of slewing angle signal of rotary brush, connector : “Slewing angle adjustment” : Rotary brush, analog circuit board < Adjust > checking) —32-E90 Check and adjustment Slewing angle input error (only for checking) :Confirm that crane is facing forward correctly (can vary depending on model) See E80 :See E80 < Replace > : See E80 Front jack extension detection switch error (only for (§} checking) :Confirm that crane is facing forward correctly (can vary depending on model) Switch wiring, connector < Replace > : Switch, main circuit board Top terminal communication error :Check optical fiber light emission between top terminal and optical cord reel, Wiring between optical cord reel, L 6 —detector and main unit; power source voltage of connector and top terminal : Top terminal circuit board, optical cord reel, analog circuit board of main unit Top terminal communication data defect :Luminance of optical fiber See E90 : See E90 ae@) Check and adjustment Description of display table ‘The items of Table 1 or Table 2 are displayed according to the combination of the work condition switch, ADJUST 1 switch and the load indication selector switch. Table 1 shows when the ADJUST switch is OFF and Table 2 shows when the ADJUST switch is ON. How to look at the table < : Same as left Blank space : Nothing will be displayed The adjustment switch is to be used when reading the value of lower numeral by truncating the numeral displayed. Example |When boom length is 12.35m : ADJUST2 = OFF ADJUST2 = ADJUST —34-Check and adjustment Display Table 1 Adjust/switch (OFF) Boom operation Main rooster Jib set switen | Load display 7 - coastal OFF oN ON eh [Desree of safety) < - Jib angle | 1 jib offset 7 indicator angle LCD Boom length [Boom tength (m)/¥aximum Tift lpoom tength (m)|* 2 Maximum display Reference | | Load indicator Joverall load _jffoisting_ overall (on) Boom angle ° ~ a omen Boom angle (°) radius indicator [Working radius - Boom work ___ [ee my a we? Load. display selector fou ay Safety I < indicator pce Come on < Jib angle Llib offset angle < ass indicator ce) lor no display ao 18.8.8. or boom Lop Boom length {Boom length (m)/aximum lift engin or no [Crane code display ecterence ‘sting « — Reference Hoisting overall |8.8.. 'Performance Load indicator |oyerall load(ton)|load (ton) jor no display |code lana. Boom angle y j- - lor boom angle |ACS type indicator lor_no display leas. ae Work radius (m)| < lor error number|Software code indicator lor_no display * 1: Displays only when luffing jib is set. %2: Indicates maximum hoist of main boom. Note : When an error occurs, the error number is displayed at a time other than for code display (maximum right column) and other display will disappear. =35-Check and adjustment Display Table 2 Adjust/switch (ADJUST) ‘Boom operation’ status Main rooster Jib set Switch — Load display oF - selector OFF | ON OFF ON Safety | 7 Z . Paice \Safety indication! | Come on | < = - Jib angle Boom top angle | : % 1 Jibto-ground| _ indicator jangle or jib e) | loffset_angle (°) Boom length Maximum lift Maximum lift Tepe eee [Boom length (m)| M3 {Boom Jength (m)| 3% display peers Hoisting overall |* 2. a Load indicator Joverall toad —_Ploisting © Reference Hoisting overall ton) loverall load(ton)|load (ton) | Boom angle ° . S ee Boom angie () | Radius i | < «2 ~ indicator |Work radius (m) Work radius (m) Boom operation switch Jus i Load display 7 selector ay ca Safety = | = indicator < | - - « = LL — | i bt. i rr [#2 Luffing AV Hibvangle | HB to, ground - communication pressure lerror count —_|(kg/cnt) No, display or Boom length Maximum tift i Boom length(m) 3.00 voltage (V)|*3 memory LeD |indicator (m) lerror No. display — —— IDerrick cyiiaa 0 Reference ‘Hoisting overall |Slewing angle [Poryick cylinder Load indicator |Referene® on) lod Cron) ra} holding. pressure| Sf _ _ [kee Boom angle < < stewing angle |P, pressure indicator signal 1 (V) (kg/cm) radius indicator |Work radius (m) - Stewing, angle |Ps Pressure signal 2.(V) | (keen) %1: Display varies according to crane model. #2: 3 This will not be displayed with some crane models. ‘he error numeral that occurred last is stored in the memory and displayed. This will be deleted when the power supply is interrupted. Note : implies “—" (minus sign) aaaCheck and adjustment 2-3 Adjustment (1) Before adjustment How to read sheet “Rajusting method Setting | ] No.| Tite Description colnet Boom Load | Display |Adiveing! Data operation ADIL | aepy | Weation | VRE) ate aa. \ ——} an + | | | | | | | | | | | QF NOT) < Adjusting procedure > D 2) 3) 4) Proceed to adjustment listed under “Title” in accordance with “Description”. Set the switches according to “Setting” and read the displayed value at “Display location” (shown below). Check if the value is within the allowable range. If the value is not within the allowable range, adjust with “Adjusting variable resistors” shown in “Layout of adjusting variable resistors”. If a satisfactory result is not obtained by the above procedure, carry out [IF NOT] procedure on the next line. —37-Check and adjustment (2) Adjustment of power supply (turn ON ADJ2 switch only when truncating display data; normally keep it OFF) ‘Adjusting method | Seating No) Tite Deserotion I po ' | gem ,| apse | ond, | eis AOS) Data operation} APJ! | display | Sans ne | Check if connector is inserted | Preparation : curly 1 aF Non) |eneck tue [Conemation | caution; Prosed to this step I +285 \stbisier ater efecting truncation ty” | (QQ) | oN | OFF |Note ’ a turning ON the ADJ2 switch Unit +305 » [rotase Recnfirm Nod by removing LO detector, pressure detector noes jand slewing angle detector in [seavence aeCheck and adjustment (3) Adjustment of boom angle (turn ON ADJ2 switch only when truncating display data; normally keep it OFF) ‘Adjusting method i Setting ] No. Description Display | Adjusting Beam, | ann | oud, |B |ACR| Doe mete” | ch | Spy | Make boom horizontal Zero using a level align angle 1 adiustment of [pointer of L@~ detector to fan ~ shaped |zero on fan ~ shaped plate plate Then tighten with serew and apply screw lock. Conformation |MOve fan —shaped plate | R0F otler | as" 2 [Conformation | ang fix at 10° by opr | orr | @ | 6 | t Jinserting thick paper | wo" Confirmation |§Move fan—shaped plate | FOF Mr | Ter" onfimation lang fix at 80" by orr | ofr | 9 | vR-A) 2 inserting thick paper 203° 3 | 1. Check wiring and connector OF NOT) Ja Replace analog circuit board or 1.8 ~ mechanism | | 44 |Reconfirmation|Reconirm No.2 if lof zero [adjustment is made at No. 3 —39-Check and adjustment (4) Adjustment of boom length (turn ON ADJ2 switch only when truncating display data; normally keep it OFF) ‘Adjusting method Setting ] Display | Adjusting| Boom | apn | Load yes! Data No} Title Description operation display | location ‘status | Switch | Selector Carry out one cycle of full Jextension and retraction of | boom, "Use “emergency 1 | Preparation | switch, for, sequential extension /retraction’ if provided, to fully extend | and retract. boom. | a — Fees to ce | retraction | fur adiusting VE, toa alors | adjusting | towards retraction ‘side to Note : Set.'Read-boom length > | Displayed with ADJ2 switch turned a ae ON to effect truncation. min. unit 0,05m | Extend boom length to Loosen gear lock screw of| potentiometer for setting Maximum | aximum boom length and extend boom eae completely. Turn’ setting adjustment | potentiometer 3 ‘counterclockwise until it hits against stopper (*). ‘Then tighten lock ‘screw’ and apply screw lock. Maximum, length +0.15m orr | OFF | L vr ‘Check wiring and ar Nor) _ | sonnector | 4 |Reconfirmation| If adjustment is made at No. 3) Check boom length at |Contimaton | which moniter lamp 2 ‘at lights up and length at of sequential | ith hostor is is control | Gxtinguished. by ‘extending 5 | and retracting boon Monitor es 05m lamp 2 lane 9: land 3 'etoetat OFF | OFF [Check wiring and GF NOT) —|connector. Replace analog circuit board. In the case of fixing on right side of boom. varsCheck and adjustment (5) Adjustment of pressure detector unit (turn ON ADJ2 switch only when truncating display data; normally keep it OFF) ] ] ‘Adjusting method Setting | | Display | Adjusting Boom | api | L024. | tocation | VR | Date loperation| ADVI, | display ‘status | Sieh | selector No] Tite | Description | | Retract and lower boom ee era ae | | completely | | Confirmation | Stop engine, Reduce ere ON | ON |R(@,) |P,2ERO |o~1 Note ke/eut of a0 | esindr PT and P2 ot sides to zero. | oo) : jae | ___het“ent Z Tcmece wing and | or nor) |somector este pressure detector unit or analog circuit board. Perform prescribed | | Confirmation |check before operating | lof span ACS and confirm that there is no error. Adjust with sensor tester | | F NOT) ~41-Check and adjustment (6) Adjustment of slewing angle (turn ON ADJ2 switch only when truncating display data; normally keep it OFF) Adjusting method T j | Setting No} Tite} Deseintion ita | Adit Boom Load justing |) Data | operation) ADJI | display | cation | VR | Biatus Selector 7 Front jon [Bring boom forward F 1 [Preparation OFF jack and sot slewing lock a ie i Caution | a Slowing to Cheek by tuming ON eae ADI2 switch to effect ON | oFF | w a i adjustment swt sel 2 1. If slewing angle is 180° , detach rotary OF NoT) | brush, tum rotary bar through 180° then reattach rotary brush. deviated by about 2. Remove other sensor connectors in sequence and reconfirm, 8, Replace rotary brush or analog circuit board. eesCheck and adjustment (7) Confirmation of load display selector switch and illumination changeover ‘using method Setting No| Tie Desrotion Boom | apy, | Load | Display | Adiusting | Data eeggtn| stich | dey | " | coniration fee tn of load other lift) f Yad press switch lod | RE oy EES ore | on ly sakctor a Toca ‘switch Toad) 1 1. Confim switch arin and compete OF NoT) 2. Replace main circuit Dood Tun ON working lamp Confirmation) witch and check that nation [pel urination tm iusinatin Fett up and LED Deihtoes reduced 2 1. Chee switch, wing sd connector 2. Replace main circuit OF NOT) board, display panel and panel creat fear! ~43-Check and adjustment (8) Confirmation of boom top angle Adjusting method Sekine i ou) poeipood) | | Display | Adjusting ae, | ann | ost, | Bowes | MURR] Dae ‘status | SWitch | selector [extend end of boom by 1 [Preparation abst 2m from minima Piao a eet at boom en (eet boom to horton | |zer ‘ign angle poitr te . 2 adjustment top terminal with 2er0 of ol Ca Ou |fan ~ shaped plate and | fons bac | | Jf | | | 7 Contomaon [Fi fen shaped pat a rar" Conimaton |B “Sy inning tick tein | ON | = | es ‘ pan | vost | As adjustment is to be | mode wit arable MOT | ter of Thee "27" on VR of main unit at the | omer : mor 3 2 ament (BE Sms Pla Atlin | oN | = | os iumror ar - Aajustment of Fix fon staoed oat atlasan | oy | | ag Wmv tt on oo | . Z _ ___| 803 Zero — reconfirmation | Reeonfirm 0 | | ee r connector Replace TT | NoT) circuit board or @T | watt -44Check and adjustment (9) Adjustment of jib ~ to ~ ground angle Adjusting method Setting 1 No.| Title Description Poon Display [Adiusting) peta ooo nl ADIL | (kO84, | location | Vit ‘aatus | SCH Selector Place @ level on ib to set to horizontal. Set jib angle indicator's black pointer at 0° 1 Preparation | (in black) of fan ~ shaped plate and red pointer at 90° (in black), and apply screw lock. Agaa* ? Zero ‘Align —40°in red on fan-shaped 7 Ada" 2 | adjustment [plate with red pointer selec 1 |otor OMe: A | rrinus Confirmation | Align 80° (in black) with black! 5, | gy | _ eae eevee of span {pointer I | ‘As adjustment is made with VR, Prencation (OF TT, set "OS" of main unit to center 5 339" Zero Set red 40" on fan—shaped | 5, - adjustment | plate with red pointer. ace ee ees 3 . 5 707" Adjustment | Align red 80° on fan ~ shaped - of span [plate with red pointer, eles eed laeae Zero : Zero emation|Reeontirm — 40 (Check wiring and connector. GF NOT) | Replace 6.5 or mechanical unit TT circuit board. For range within 0° — 80° , read numeral (in black) on fan~shaped plate For range within ~ 40° ~0°, read the numeral indicated by (Reference) |the red pointer on fan ~ shaped How to read | pate ‘The value read, minus 90° , is fan~ shaped |the sib angle. plate /Ex.: When the black numeral indicated on fan ~ shaped plate is| ‘800, jib angle is ~ 10° When the black numeral indicated on fan ~ shaped plate is -45-Check and adjustment (10) Confirmation of offset angle of power jib ] ‘Adjusting method Sting No) Tie Deserption Display | Adjust Boom Load lay | Adjusting} Data oneralon| ABE. | dpiy | sxation | "°VR mar ope. Mount jib to adjust 1 [Preparation |beom tap angle and ib anal t Retaet shit eninge [36 Lor | ope |_| gy a offset angle bes contemation oo of enim Extend ib tt evtinder ib Lor | gmp | ea offset angle ae ba 3 Adjust boom top angle GF NOT) Jand jib ~to~ ground angle —46-Check and adjustment (11) Adjustment of luffing jib AV detector ‘Adjusting method Setting ] | No.| Title Description lees Tesa | Display | Adjusting | Boom | aps | (best. | foven | “URI Date operation| ADIL | display Riatus | Switch | Se 1 Check oll leakage, gap | between cylinder and. | holder (A), and fit of | | [cylinder (B) Cootimation A 1 lorentinger | 8 Holder ioe and holder ‘mm Cylinder 8 A Set cylinder pressure of TT Zero | : o~1 Biaamene [ing 30 AV deter! BJ ] ox | on | os | ot Cet | i 2 | check wiring and UF NOT} | Replace pressure detector and TT circuit board | 1 Perform prescribed Confirmation |check before operating fof span | ACS and confirm that there is no error Check wiring and connector GF NOT) | Replace pressure detector or TT circuit | board 47Check and adjustment (12) Adjustment of ACC sensor 1) ACC pressure is displayed on COR digital display by the following operation : Starter switch “ON” Confirm oon of COR P.T.O. oo “ON Turn COR digital display oe switch to “TRIP//ACC" 4 es « ° eTRIPZacc . © *TACH Pressure is displayed on COR digital display 2 (unit: kee m!) a5}+t f / Ex: Pressure is 35kg/cni —48-Check and adjustment 2) Attach pressure gauge at accumulator pressure take off point and conduct zero and span adjustment while monitoring standard pressure. Release ACC sensor into atmosphere to bring it to Okg/cmf. Then bring digital display to Okg/cnf with ACC zero variable resistor. Note : When setting with VR, stop VR at a numeral ending with a clear 0, ie. 3.0, 2.0, 1.0 or 0. Even when you set at any numeral below these the display shows zero, but caution is required as the internal voltage would decline. Change pressure to accumulator of crane, read the standard pressure with a pressure gauge and set the value to the ACC SPAN variable resistor. -49-3. REPLACEMENTReplacement 3-1 Replacement of ROM (1) Before adjustment 1) Pay special attention to static electricity. Prevent any part of your body from directly touching the glass window of the ROM or rubbing it with plastic or a dry cloth, as this may cause the ROM to malfunction due to generation of static electricity on the window. 2) Use only the specified tool for connecting and disconnecting the ROM to prevent damage to the pins. 3) Connect the ROM in the correct alignment. The ROM can be damaged if connected in reverse and electricity conducted. 4) Confirm that a label has been correctly attached to the glass window. Be sure to attach a light~shield label to the glass window at the time of shipment from the factory, for prevention of entry of ultraviolet rays. If a gap exists between the glass window and label, ultraviolet rays will penetrate the inside and change the data in the ROM, which can cause malfunction. 5) Whenever replacing the program ROM, perform the following in order to confirm that the newly installed ROM is functioning correctly. a) Set the boom operation status switch for )} checking. b) Turn OFF the ADJ1 switch and the ADJ2-switch. ©) Turn ON the load display selector switch. Upon completion of the above settings, crane code is indicated on boom length indicator, performance code on the load indicator, ACS mode on the boom angle indicator and software code on the radius indicator. These indications must be read as follows ample (L) 243 : Crane code : (W) 1.0: Performance code : Compatibility is retained for a change in the numeral below the decimal point. However, the ROM is unusable when the numeral above the decimal point is different from data before replacing the ROM, as performance differs before and after replacement. (6) 10.3 : ACS model “10” indicates MS-10 and “3” indicates C (“I" denotes A). (R) 0.1: Software code : Whenever the ROM is replaced, confirm the crane code and performance codes. At this time, the 4th digit must be read using adjust switch 2. Also the seal on the ROM indicates the following : Example. 103001 |-> ACS type software code si > Indicates inserting locatin. See diagram belowReplacement Analog circuit board S1_: Program ROM VO : Voice ROMReplacement 3-2 Replacement of optical cable reel and optical fiber cable Refer to 1—8 optical cable reel structural diagram. Disassembly procedure Remove hexagon nuts (four M6, which secure the cover). JRemove power supply cable and remove cover from cable reel a) Remove hexagon nut fixed with a nylon clip on bearing. b) Disconnect power supply connector of amplifier circuit board. Remove plate in bearing held by fixing screws (two M4). Fix cable reel base plate, hold by hand near optical fiber end connector, and remove screws (four M5) fixing cable reel case. In this condition, turn cable reel case to the jieft until there is no spring force remaining in cable reel (about nine turns). Remove E-ring (E~15) attached to shaft using a straight ~ blade screwdriver. At this time the cover should be protected so that it does not touch the optical connector. Slowly lift cable reel while shaking it sideways. At this time, take care so that relay rod will not lift together with case. Using a wrench or pair of pliers, remove optical connector nut at optical fiber connecting area, and separate optical fiber from cable reel. Remove cable reel from the plate held with one M5 screw. GorReplacement No. Assembly procedure Wind optical fiber to cable reel a) Attach optical fiber to optical fiber connecting area by putting it through hole of cord reel, Caution: Check that there is no dirt or marks on optical connector end, b) Put cable reel vertically (at this time fix relay rod with a tape to prevent it from coming off) and wind optical fiber evenly while turning cable reel. Fix cable reel to base plate with one MS bolt. Fix so that the collar attached to cable| reel aligns to stopper of base plate and apply screw lock to screws. Setting of cable reel Fix base plate, hold by hand connector area of optical fiber end and turn cablereel nine times to the right. In this condition, cover with cable reel case. At this time, water extraction part of base plate and cable guide part of cable reel case should be in the normal condition. Fix cable reel case. Three M5 x 12 Put on M5 x20 in correct position and attach grounding wire. Dix end of optical fiber at an M5 x 20, using a rope Fix E~ring firmy to the shaft using a pair of pliers after lifting shaft (an air breather} Jshould be screwed into relay rod. Ensure that optical connectors are not bent or marked.) Also, E~ring should be fixed with the turning side up. Fixing of optical sensor Confirm that there is no dirt on optical connector and cover with optical sensor. At this time, confirm that bush is installed. Then attach plate to bearing, and fix shielding line to one end (two M4). After fixing, hold light receptor by hand and confirm that there is no play. Be sure| to apply screw lock. Fix power supply cable a) Fix lead cable with hexagon nut to screw of bearing with nylon clip. b) Firmly insert power supply connector to amplifier circuit board. Fix cover with a hexagon nut (four M6) Reference diagram Grounding wire fixing “(MB x 20) “water extraction orifice Cable guide —54-KATO WORKS CO.,LTD. HEAD OFFICE 9.37, Higashi-ohi 1-chome, (OVERSEAS MARKETING DEPT.) Shinagawa-ku, Tokyo, 140-0011 Japan Telephone Tokyo (03) 3458-1111 Telex Number 222-4519 (CRKATO J) Cable Address CRANEKATO TOKYO o4101TI 7. 1991-205 (71) 1 4, 2005-10 (TT) 1-8-1330458