HC275 - ML-D5A Operator's Manual

Instruction Manual
ML-D5A Moment Limiter
IHI Construction Machinery Limited
PUB. No. 1
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CONTENT
Moment Limiter Outline (Overload Protection Device ML-D5A) ...........................................1
Configuration and Wiring System of Major Moment Limiter Components...........................2
Operating Environment of the Moment Limiter .....................................................................3
Precautions in Handling the Moment Limiter ........................................................................4
Load Handling with the Moment Limiter ...............................................................................5
Functions of the Panel Keys ..................................................................................................6
Moment Limiter Operation and Display Screen ....................................................................7
1) Moment Limiter Operation ............................................................................7
2) Changing the Configuration of an Operational Machine ..............................8
3) Content of the [main MENU of FUNCTION] Screen .....................................9
Operating Procedure for the Main Menu
1) Setting the Crane Configuration ...................................................................................10
1-1) Selecting the [WORK NO.] ..........................................................................10
1-2) Selecting the [CRAWLER] Width.................................................................11
1-3) Selecting [BOOM LENGTH] and [JIB LENGTH]..........................................12
1-4) Selecting the Capacity of the Main and Auxiliary Hooks............................12
1-5) Selecting the Parts of Line for the Main and Auxiliary Hooks ....................13
1-6) Selecting the Hoist Drum Configuration .....................................................14
1-7) Selecting the Jib Offset Angle.....................................................................14
1-8) Selecting Special 2-Hooks..........................................................................14
1-9) Selection Completion ..................................................................................15
2) Checking Operator Aids .................................................................................................17
2-1) Overload Protection Device (Output Check) ....................................................18
3) Setting Work Limits (Automated Stop at Optional Angle and Working Radius)............20
3-1) Setting High Boom Angle Limits .................................................................22
3-1-1) High Boom Angle Determined ....................................................................22

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CONTENT
3-1-2) High Boom Angle Undetermined ................................................................23
3-2) Setting Low Boom Angle Limits..................................................................24
3-2-1) Low Boom Angle Determined .....................................................................24
3-2-2) Low Boom Angle Undetermined.................................................................25
3-3) Setting Work Limit Slow Down Angles .......................................................26
3-3-1) Setting the High Limit Boom Angle Slow Down Margin .............................26
3-3-2) Setting the Low Limit Boom Angle Slow Down Margin..............................27
3-3-3) Confirm Work Limit Temporary Setting ......................................................28
3-4) Setting Maximum Radius and Boom Tip Height Limits..............................29
3-4-1) Setting Maximum Radius Limits .................................................................30
3-4-2) Maximum Radius Determined.....................................................................30
3-4-3) Maximum Radius Undetermined ................................................................31
3-5-1) Setting Maximum Tip Height Limits............................................................32
3-5-2) Maximum Tip Height Determined ...............................................................32
3-5-3) Maximum Tip Height Undetermined ...........................................................33
3-6) Setting Work Limit Slow Down Margins .....................................................34
3-6-1) Setting Maximum Radius Slow Down Margins ..........................................34
3-6-2) Setting Maximum Tip Height Slow Down Margins .....................................35
3-6-3) Confirm Work Limit Temporary Settings ....................................................36
4) Selecting Monitor Functions (Hook Data Table, Monitoring Errors)..............................37
4-1) Table of Hook Data .....................................................................................37
4-2) Error Monitor (Error Display E***) ................................................................39
5) Test Mode ......................................................................................................................42
6) Adjustment-1 Mode........................................................................................................42
7) Adjustment-2 Mode........................................................................................................43
8) Property ..........................................................................................................................43
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CONTENT
9) WxR Table ......................................................................................................................44
10) Hook Data....................................................................................................................46
10-1) Manufacturer Supplied Hook Data .............................................................47
10-2) User Defined Hook Data .............................................................................48
11) Setting Slew Work Limits ............................................................................................50
11-1) Zero Adjustment..........................................................................................52
11-2) Setting Slew Work Limits ............................................................................53
11-2-1) Setting the Left Slew Limit ..........................................................................54
11-2-2) Rotation Angle Determined .........................................................................55
11-2-3) Rotation Angle Undetermined.....................................................................55
11-2-4) Setting the Right Slew Angle ......................................................................57
11-2-7) Setting the Margin Angle.............................................................................59
11-2-8) Confirm Slew Limit Temporary Setting .......................................................61
11-3-1) Setting Wall 1 Limits....................................................................................62
11-3-2) Setting Point 1.............................................................................................63
11-3-5) Setting the Radius of Point 1 ......................................................................66
11-3-6) Radius Determined......................................................................................66
11-3-7) Radius Undetermined .................................................................................67
11-3-8) Setting Point 2.............................................................................................68

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CONTENT
11-3-14) Setting the Margin .......................................................................................72
11-3-15) Establishing the Safety Region on the Inner Side of the Wall ....................73
11-3-16) Establishing the Safety Region on the Outer Side of the Wall ...................74
11-3-17) Confirm Wall 1 Temporary Settings ............................................................76
11-4-1) Setting Wall 2 Limits....................................................................................77
11-4-2) Setting Point 1.............................................................................................78
11-4-8) Setting Point 2.............................................................................................83
11-4-14) Setting the Margin .......................................................................................87
11-4-15) Establishing the Safety Region on the Inner Side of the Wall ....................88
11-4-16) Establishing the Safety Region on the Outer Side of the Wall ...................89
11-4-17) Confirm Wall 2 Temporary Settings ............................................................91
11-5-1) Crawler Width Limit.....................................................................................92
11-5-2) Confirm Crawler Width Limit Temporary Settings ......................................94
12) Glossary of Technical Terminology .............................................................................96

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ML-D5A MOMENT LIMITER
Moment Limiter Outline (Overload Protection Device ML-D5A)
The Moment Limiter (overload protection and range warning device) is an operator aid for
conducting safe crane operation. Be sure to read and fully understand the operating
instructions for the Moment Limiter to ensure safe crane operation.
Outline of Function
The Moment Limiter consists of an operational display, boom angle sensor, load sensor,
alarm, automatic stop circuit, etc.
When the actual load reaches 90% of the allowable load, an alarm will sound intermittently.
When the actual load reaches 100% of the allowable load, the alarm will sound
continuously and the Moment Limiter will automatically stop “Load Hoisting” and “Boom
Lowering” functions.
To release the automated stop, lower the suspended load to the ground, or hoist the boom.
Lowering of the load and hoisting of the boom can be performed even during an
automated stop.
Operational Display
Once the Moment Limiter is configured, the operational status will be displayed as [Actual
load], [Rated gross load], [Load ratio], [Working radius], [Boom angle], and [Slew angle].
• Reaching the rated gross load or the maximum working radius will cause an alarm to
sound and the Moment Limiter will automatically stop “Load Hoisting” and “Boom
Lowering” functions.
• When the main boom and auxiliary jib reaches the high limit angle or the low limit angle
an alarm will sound and the Moment Limiter will automatically stop “Boom Hoisting” or
“Boom Lowering” functions.
• By setting the slow down angle, the working speed will be reduced as it nears the
limiting angle. This prevents an abrupt automatic stopping action upon reaching the
limiting angle.
Angle Sensor
Detects the angle of the main boom and luffing jib, and then displays the angles on the
operational screen of the Moment Limiter.
Load Sensor
Detects the tension of the boom suspension in order to determine the total load weight and
then displays the weight on the operational screen of the Moment Limiter.
HC275.MLD5A.2007.1.01 SECTION 1 PAGE 1

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Configuration and Wiring System of Major Moment Limiter Components
Operation/Display Part
Load Sensor (1) Limit Switch
Crane Actual Load

Allowable Load Angle Sensor
Working Radius Tower Boom
Boom Angle Crane Boom
Jib Angle
Load Ratio
Angle
Load Sensor (2) Sensor
Tower
Power Source 24 Jib
(19~35 V)
Stopping Output
Alarm (90% intermittent sound,

Luffing Jib Crane Load Hoisting 100% continuous sound)
Boom Lowering
Luffing Tower Crane
Boom Hoisting
Configuration of Major Equipment
Load Sensor (2)
Angle Sensor (2)
Load
Sensor (1)
Load
Sensor (1)
Angle Sensor (1) Angle Sensor (1)
Operation/Display
Operation/Display
Alarm
Buzzer
Crane Luffing Jib Crane

Luffing Tower Crane

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Operating Environment of the Moment Limiter
The Moment Limiter is a precision electronic component. Therefore, its operational

environment is limited. Operate or store it within the allowable environment ranges
indicated below.
Range of Operating Environment
Operating temperature: 30°F to 120°F

Storage temperature: –5°F to 185°F
Storage ambient humidity: 95% RH or less
Exposing the display to direct sunlight for long periods increases the component’s
temperature and leads to various problems such as the display color changing to black. In
order to prevent this, provide a sunshade for the Moment Limiter to ensure that the
temperature does not exceed the allowable operating temperatures.
Upon finishing work, when nighttime temperatures are expected to be lower than 30°F,
when the machine is left unused for a long period of time or when it is in a location
exposed to direct sunlight, provide an insulation cover for the Moment Limiter to ensure
that the temperature does not exceed the allowable storage temperatures.
Sunshade cover
Moment Limiter
Prevention of Water Entry, Lightning Strikes, Etc.
• Water entry leads to various problems with the Moment Limiter. To ensure that the
Moment Limiter is not exposed to water, place a waterproof cap on the wire harness
and Moment Limiter.
• Lightning strikes also lead to various problems with the Moment Limiter. During
thunderstorms, take measures to avoid lightning strikes such as lowering the boom to
the ground.
• Contact with solvents leads to various problems with the Moment Limiter as well. Do
not expose the Moment Limiter to solvents such as gasoline or alcohol and do not
allow solvents to splash onto the Moment Limiter.

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Precautions in Handling the Moment Limiter
Various issues may cause the Moment Limiter to malfunction. This may include faulty continuity
due to disconnection, water entry, faulty sensor functioning, deteriorated component parts,
power surges, loss of voltage, environmental temperature, and so forth.
Confirm the accuracy of the Moment Limiter by performing periodical inspections and
maintenance to ensure normal operation.
Leave the selector key switch of the Moment Limiter in the

[OPERATION] position at all times during machine operation. Note:
The key is removable while in the [OPERATION] position. With the
engine running the selector key switch may be rotated clockwise to the
[ERECTION] position. This should only be done at time of assembly,
disassembly, when changing the boom configuration or parts of line.
The selector key switch should never be turned counter clockwise to
the [TRANSPORT] position while the engine is running. Doing so may
interfere with the data exchange between the main card and the
Compact Flash® cards internal to the Moment Limiter. If it becomes
necessary to select the [TRANSPORT] position, first turn [OFF] the
ignition key. Once the Moment Limiter has powered off, after its timed
delay, you may select the [TRANSPORT] position and then [RESTART]
the engine.
• Perform inspections to confirm the load weight displayed. Suspend a load for which the
correct weight is known. Be sure to add the hook and rigging weights to the known weight of
the load. Then, compare that value to the load value displayed on the Moment Limiter.
• Perform inspections to confirm the working radius displayed. Measure the distance between
the slew center of rotation and the hook center. Then, confirm that the value is consistent
with the working radius displayed on the Moment Limiter.
• Faulty operation may occur due to close proximity of power sources. This may be reduced
by moving the machine further away from the power source.
• Ensure that environmental operating temperatures remain within the operational range by
using an engine block heater or cooler.
• The selection key for the main and auxiliary lifting points will return to default, (the main lifting
point), when the Moment Limiter is turned off. Be sure to reset the lifting point
correspondingly and confirm the current machine configuration when restarting the Moment
Limiter.
• Verify operation of the automated stopping device by checking the Moment Limiter operator
aids.
• Operating the Moment Limiter with a low voltage power source will cause erroneous readings.
• Be sure to change the Moment Limiter settings correspondingly when changing the
configuration of the crane.

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Load Handling with Moment Limiter
Even when Moment Limiter specifications have been set individually, the user defined set
values may be modified due to a change in boom configuration or hook block, to confirm
the current crane configuration, to inspect an operator aid, to detect erroneous settings,
etc.
Moment Limiter Key Functions
The Moment Limiter key functions are displayed at the bottom of the display screen. Be
sure to fully understand the on-screen instructions before operation, because applications
may differ.
Moment Limiter Screen
The Moment Limiter screen displays the machine load ratio, rated gross load, actual load,
boom angle, working radius and slew rotation angle.

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Functions of the Panel Keys
1 WxR - A selection key used to alternate between the operation screen and the load chart
screen.
2 i - When an error occurs during operation, the i symbol will appear with a message.
Press the i key to display error details and countermeasures. On certain set up screens,
it will allow you to view more information concerning the configuration of the crane.
3 О - A key used for execution, decision, main menu selection, and the like. Depending on
the screen, this key will also allow you to confirm information that you’ve entered. Be sure
to fully understand the on-screen instructions before operation, because applications may
differ.
4 X - A key used for canceling, suspending, screen selection, and the like. Be sure to fully
understand the on-screen instructions before operation, because applications may differ.
5 ▲ ▼ - Keys used for selecting items, changing screen contrast, and the like. Be sure to
fully understand the on-screen instructions before operation, because applications may
differ.
6 ◄ ► - Keys used for content selecting, display change, etc. Be sure to fully understand
the on-screen instructions before operation, because applications may differ.

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Moment Limiter Operation and Display Screen
Turning the engine key [ON] automatically turns on the power source of the Moment Limiter. The
“Operating status” screen (with present user defined set values) will then be displayed.
1) Moment Limiter Operation
When the machine is operational, turn the engine key

switch [ON]. The Moment Limiter will then display the
“Operating status” screen. This screen displays the
present user defined set values and is referred to as
[CHECKUP mode].
This screen is used to confirm that the user defined set
values are consistent with the current configuration of the
crane. When erroneous settings are not found and the
crane configuration is not being changed, operation may
begin once an operator aid check has been performed.
To perform an operator aid check press the X key. The

display will change to the “Operation” screen which has
a yellow background.
Press the O key and select the second item [02 CHECK
mode] on the “main Menu of Function”.

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For more information regarding the [02 CHECK mode]

procedure, refer to item “2) Checking Operator Aids.” in
the “Operating Procedure for the Main Menu” section of
this manual.
2) Changing the Configuration of an Operational

Machine
It may be necessary to change settings when verifying

the crane configuration on the “Working status” screen.
Press the X key to Display the “Moment Limiter” screen.

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Press the lOl key to display the [Main MENU of

FUNCTION] screen. Then select [01 ATT SET mode] from
the menu.
For more information regarding the [01 ATT SET mode]

procedure, refer to item “1) Setting the Crane
Configuration” in the “Operating Procedure for the Main
Menu” section of this manual.
3) Content of the [main MENU of FUNCTION] Screen
This menu is used to enter [01 ATT SET mode], [02

CHECK mode], [03 Work Limit mode], [04 MONITOR
mode], [05 TEST mode], [06 ADJUSTMENT-1 mode], [07
ADJUSTMENT-2 mode], [08 Property], [09 WxR Table],
[10 HOOK DATA mode], and [11 Slew Limit mode].
Select items, as instructed on the bottom of the screen,
using the ▲ ▼ keys.
To return to the “Moment Limiter screen,” press the Xl
key.

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Operating Procedure for the Main Menu
1) Setting the Crane Configuration
This function synchronizes the current crane

configuration with the Moment Limiter.
To set the current crane configuration, select [01 ATT
SET mode] from the [main MENU of FUNCTION] and
then press the O key. This screen allows setting of the
current crane configuration.
All operation will be stopped during the setting procedure.
1–1) Selecting the [WORK NO.]
Move the cursor to [WORK NO.] using the ▼ ▲ keys to

select the corresponding Work Number for the current
Operate the ◄ ► keys sequentially to display the Work
Numbers available for selection.
The display content differs, depending on the selected
Work No. The following example illustrates the use of
Work Number 11, a standard crane configuration.

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Work No. and Working Mode
The configuration of the Work No. and Working mode differ, specific to crane model and
serial number. For details, refer to the working mode table located on the left hand window
glass of the operating cab. (The following table is an example of the working mode table.)
1–2) Selecting [CRAWLER] Width
Move the cursor to [CRAWLER] using the ▼ ▲ keys.

Operate the ◄ ► keys sequentially to display the
available crawler width settings. Select [RET] if retracted
and [EXT] if extended.
Machines without an extension/retraction function, the
[RET] option will not be displayed for retraction.

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1–3) Selecting [BOOM LENGTH] and [JIB LENGTH]
Move the cursor to [BOOM LENGTH] or [JIB LENGTH]

using the ▼ ▲ keys.
corresponding boom length or auxiliary jib length that the
crane is currently configured with.
Select [0.0] when the crane is not equipped with an
auxiliary jib.
1–4) Selecting the Capacity of the Main and Auxiliary

Hooks
Move the cursor to [MAIN HK CAPA.] or [AUX. HK CAPA.]

using the ▼ ▲ keys.
corresponding hook capacity (nominal value) that the
crane is currently configured with.
Select [0.0] when the crane is not equipped with a main
or auxiliary hook.
The displayed [M] is designated for manufacturer

supplied standard main and auxiliary hooks.
When the crane is equipped with a user supplied main or
auxiliary hook, set the capacity of the hook to be used by
changing the display to [U].
To switch to user supplied hooks, move the cursor to [M]
using the ▼ ▲ keys then press the ◄ ► keys to
display the corresponding [U] before selecting the hook
capacity.

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Setting is still required when there is not a main or

auxiliary hook with a corresponding capacity listed.
Press the X key to display the [Main MENU of
FUNCTION] screen. Then select [10 HOOK DATA mode]
from the menu.
For more information regarding the [10 HOOK DATA
mode] procedure, refer to item “10–2) Input of user
supplied hook data” in the “Operating Procedure for the
Main Menu” section of this manual.
1–5) Selecting Parts of Line for the Main and Auxiliary

Hooks
Move the cursor to [MAIN HK P-LINE] or [AUX. HK P-

LINE] using the ▼ ▲ keys.
corresponding parts of line that the crane is currently
configured with.
Select [0.0] when the crane is not equipped with a main
or auxiliary hook.
The displayed [A] is designated for manufacturer

supplied “STANDARD” rope.
When the crane is equipped with an “OPTIONAL” rope,
select the parts of line to be used by changing the
display to [B].
To switch to “OPTIONAL” rope, move the cursor to [A]
using the ▼ ▲ keys then press the ◄ ► keys to
display the corresponding [B] before selecting the parts
of line.

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1–6) Selecting the Hoist Drum Configuration
Move the cursor to [MAIN HK DRUM] or [AUX. HK

DRUM] using the ▼ ▲ keys.
Operate the ◄ ► keys sequentially to select the
corresponding hoist drum for the main and auxiliary
lifting points.
Hoist drum names such as [Front], [Rear], [Right], [Left],
[Third], etc., will be displayed.
The configuration of the hoist drums differ specific to
crane model and serial number. For details, refer to the
crane operator’s manual.
Note: Once a selection has been chosen for the main
hoist drum, the auxiliary hoist drum will not need an
option to be selected. The Moment Limiter will
automatically select the unselected drum.
1–7) Selecting the Jib Offset Angle
Move the cursor to [OFFSET ANGLE] using the ▼ ▲

keys.
corresponding jib offset angle that the crane is currently
configured with.
When the crane is equipped with a Single Sheave
Extension, the offset angle is automatically selected and
displayed.
The [0.0] offset angle will be displayed when the crane is
not equipped with an auxiliary jib. This setting cannot be
changed.
1–8) Selecting Special 2-hooks
Move the cursor to [SPECIAL 2-HOOKS] using the ▼ ▲

keys.
Operate the ◄ ► keys sequentially to display [YES] only
when both the main and auxiliary hoist lines are
configured over the main boom sheaves.
When the crane is in the standard configuration, [NO] will
be displayed.

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1–9) Selection Completion
When the selection process has been completed, press

the lO key once to confirm the selections.
The screen will then change to the “Guide screen”. The

[ATT SET has been changed. and also ‘Work Limit’ has
been changed to ‘DEFAULT’-value. Please DO SET
‘Work Limit’ again!!] message will be displayed.
If “Work Limits” have been set previously, they have

returned to their default values and must be reset. Move
the cursor to [03 Work Limit mode] using the ▼ ▲ keys.
For more information regarding the [03 Work Limit mode]
procedure, refer to item “3) Setting Work Limits” in the
“Operating Procedure for the Main Menu” section of this
manual.

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When the display changes to the [main MENU of

FUNCTION] screen, press the X key to return to the
“Operation” screen.
Press the X key at any time during the selection

procedure to suspend or cancel the settings. The display
for each setting item will return to the original set value.
The Moment Limiter will automatically return to the

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2) Checking Operator Aids
This function is used to confirm that each operator aid is operating normally (with the
automatic stop and audible alarm).
While conducting any operator aid check, operate the crane slowly by reducing the
engine’s RPM.
With the [main MENU of FUNCTION] displayed, move the

cursor to [02 CHECK mode] using the ▼ ▲ keys. Press
the O key to display the [MENU of CHECK-mode]
screen.
Press the O key again to open the [OutPut-CHECK of

LMI (ML) mode] screen. Press the lO key once more to
begin the [CHECK mode] procedure.
When an error is generated during checking, the error message [ i E***] appears. Press the
li key on the right side of the panel to display the error content and countermeasures.
Follow the displayed instructions to correct the error.
To suspend the checking procedure, press the X key. The screen will return to the
[MENU of CHECK-mode] screen.

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2–1) Overload Protection Device (Output Check)
Performing this check will confirm operation of the audible alarm and automated stop at a
load ratio of 90% to 100% output.
Beginning on the [MENU of CHECK-mode] screen, press

the O key once to change the display to the [OutPut-
CHECK of LMI (ML) mode] screen.
Press O key once more to initiate the check of [OutPut-

CHECK of LMI (ML) mode].
After a few seconds pass, an intermittent alarm will

sound. The [Alarm/output] is displayed and a load ratio of
90% is shown by the upper bar graph. The Moment
Limiter provides the output at a load ratio of 90% to the
load chart’s rated capacity.

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After a few more seconds pass, a continuous alarm will

sound. The display will change to reflect 100% load ratio,
shown by the upper bar graph. The Moment Limiter
provides the output at a load ratio of 100% to the load
chart’s rated capacity.
Confirm that the intermittent alarm has changed to a
continuous alarm.
To confirm [Hook Hoisting] and [Boom lowering] checks,

operate the crane to confirm that the hook cannot be
hoisted up and that the boom cannot be lowered.
After confirming this, press the X key twice to return to
the [Main MENU of FUNCTION] screen.

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3) Setting Work Limits
The “Work limit” function is used to set the high and low limit angles of the boom with a
slow down angle for both, or a maximum radius limit and boom tip height limit, with a slow
down angle for both.
Setting the slow down angle causes the machine to automatically slow down when the
boom closes to the set work limit angles. When the boom reaches the work limit angle, an
audible alarm will sound and the boom will stop automatically.

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The boom angle limits and working radius limits may be freely set on the work limit screen.
In normal operating conditions, only one set of values will need to be set, using either the
high and low limit angles or the maximum radius and boom tip height limits.
When both the boom angle limits and working radius limits are set, the automatic stop
operation will be initiated by the first attained limit value.
Work Limits will be reset to default values when changing

the [ATT SET mode] or crane configuration. The
following message will be displayed upon confirmation of
changes, [ATT SET has been changed. and also ‘Work
Limit’ has been changed to ‘DEFAULT’-value. Please DO
SET ‘Work Limit’ again!!]. At this time, work limits will
need to be reestablished.
With the [main MENU of FUNCTION] displayed, move the

cursor to [03 Work Limit mode] using the ▼ ▲ keys.
Then, press O key to display the [WORK LIMIT (USER’S

SET)] screen to begin setting work limits.

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3–1) Setting High Boom Angle Limits
The numerical value on the screen represents the

present setting. Move the cursor to [Hi-LiMiT Boom-
Angle] using the ▼ ▲ keys. The display on the right
side of the screen will indicate [DEAD] when
inactivated or [LIVE] when activated. To change the
setting, press the ◄ ► keys to activate [Hi-LMT B-
Angle]. The high limit angle column will change to the
active or [LIVE] setting.
Press the O key and the display will change to the

[Hi-LiMiT Boom-Angle] setting screen. The numerical
value on the screen shows the crane’s current boom
angle. As the boom is hoisted, the numerical value in
the [NOW] column will adjust to reflect the crane’s
changing boom angle. The numerical value in the
[SPEC] column represents the maximum boom angle
allowed, which cannot be changed. The [Hi-LMT B-
Angle] may be set up to the maximum boom angle.
3–1–1) High Boom Angle Determined
When the high limit boom angle has previously been

determined, setting may be performed by selecting a
numerical value for the column of [SET Value] directly.
Press the ◄ ► keys sequentially to scroll through the

numerical values located at [SET Value] at the bottom
of the screen until the desired high limit boom angle is
displayed. Then, press the O key to accept this value
as the new high limit boom angle. Press the lO key
once more to confirm the new value. The new value
will now be displayed on the [WORK LIMIT (USER’S
SET)] screen.

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3–1–2) High Boom Angle Undetermined
When the high limit boom angle has not previously

been determined, the setting value may be
determined by physically operating the machine.
To set the high limit boom angle begin hoisting the
boom. Located midway on the current screen the
[BEFORE] and [NOW] boom angle, radii and height
will be displayed. Continue hoisting the boom until
the desired high limit boom angle is displayed in the
[NOW] column.
Press the X key to close the setting screen. Then,

press the O key to open it once more. The value is
now displayed in the [BEFORE] column. Press the Ol
key to accept this value as the new high limit boom
angle.
Press the O key once more to confirm the new value.

The new value will now be displayed on the [WORK
LIMIT (USER’S SET)] screen.

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3–2) Setting Low Boom Angle Limits

present setting. Move the cursor to [Lo-LiMiT Boom-
Angle] using the ▼ ▲ keys. The display on the right
setting, press the ◄ ► keys to activate [Lo-LMT B-
Angle]. The low limit angle column will change to the
active or [LIVE] setting.

[Lo-LiMiT Boom-Angle] setting screen. The numerical
value on the screen shows the crane’s current boom
angle. As the boom is lowered, the numerical value in
the [NOW] column will adjust to reflect the crane’s
allowed, which cannot be changed. The [Lo-LMT B-
Angle] may be set up to the maximum boom angle.
3–2–1) Low Boom Angle Determined
When the low limit boom angle has previously been

of the screen until the desired low limit boom angle is
as the new low limit boom angle. Press the O key
once more to confirm the new value. The new value
will now be displayed on the [WORK LIMIT (USER’S
SET)] screen.

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3–2–2) Low Boom Angle Undetermined
When the high limit boom angle has not previously

been determined, the setting value may be determined
by physically operating the machine.
To set the low limit boom angle, begin lowering the
[BEFORE] and [NOW] boom angle, radii and height will
be displayed. Continue lowering the boom until the
desired low limit boom angle is displayed in the [NOW]
column.

key to accept this value as the new low limit boom
angle.


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3–3) Setting Work Limit Slow Down Angles
By establishing work limit slow down angles the machine will automatically slow down
when the boom closes to the set work limit angles. When the boom reaches the work
limit angle, an audible alarm will sound and the boom will stop automatically.
Regardless of the work limit angle setting, be sure to set a slow down angle of 2.0 –
3.0° minimum in order to prevent shock loading of the crane. The default value is 2.0°.
3–3–1) Setting the High Limit Boom Angle Slow Down

Margin
Move the cursor to the [SLOW-DN angle] under [Hi-

LMT B-Angle] using the ▼ ▲ keys. (It is not
necessary to activate this setting by changing it from
[DEAD] to [LIVE]).
Press the lOl key to open the [‘SLOW-DowN Angle’

(Hi)] setting screen. The numerical values on the screen
indicate the current boom angle, working radius and
boom tip height. To set the slow down angle, press the
◄ ► keys sequentially to scroll through the numerical
values located at [SET Value] on the bottom of the
screen until the desired slow down angle is displayed.
Press the lO key to accept the new slow down angle.
Press the lO key again, to confirm the new value. The

new value will now be displayed on the [WORK LIMIT
(USER’S SET)] screen.

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3–3–2) Setting Low Limit Boom Angle Slow Down Margin
Move the cursor to the [SLOW-DN angle] under [Lo-

LMT B-Angle] using the ▼ ▲ keys. (It is not
necessary to activate this setting by changing it from
[DEAD] to [LIVE]).
Press the lOl key to open the [SLOW-DN angle] setting

screen. The numerical values on the screen indicate
the current boom angle, working radius and boom tip
height
To set the slow down angle, press the ◄ ► keys
sequentially to scroll through the numerical values
located at [SET Value] on the bottom of the screen until
the desired slow down angle is displayed. Press the
lO key to accept the new slow down angle.
Press the lO key again, to confirm the new value. The


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3–3–3) Confirm Work Limit Temporary Settings
Now the work limit setting procedure is complete.
Locate the cursor to the [End of whole SET by O] at the

bottom of the screen and press the lOl key to confirm
the temporary setting of the work limits.
The new values will not be registered unless this step

is completed. The work limits are now set and the
display will return to the [Main MENU of FUNCTION]
screen.

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3–4) Setting Maximum Radius and Boom Tip Height Limits
Work Limits for [MAX RADI-LMT], and [MAX Height-LMT] may also be set.

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3–4–1) Setting Maximum Radius Limits

present setting. Move the cursor to [MAX RADI-LMT]
using the ▼ ▲ keys. The display on the right side of
the screen will indicate [DEAD] when inactivated or
[LIVE] when activated. To change the setting, press the
◄ ► keys to activate [MAX RADI-LMT]. The maximum
radius limit column will change to the active or [LIVE]
setting.

[MAX RADI-LMT] setting screen. The numerical value
on the screen shows the crane’s current radius. As the
boom is lowered or raised, the numerical value in the
[NOW] column will adjust to reflect the crane’s
allowed, which cannot be changed. The [MAX RADI-
LMT] may be set up to the maximum allowable radius
for the current configuration of the crane.
3–4–2) Maximum Radius Determined
When the maximum radius limit has previously been


of the screen until the desired maximum radius is
as the new maximum radius limit. Press the O key
once more to confirm the new value. The new value will
now be displayed on the [WORK LIMIT (USER’S SET)]
screen.

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3–4–3) Maximum Radius Undetermined
When the maximum radius limit has not previously

been determined, the setting value may be determined
by physically operating the machine.
To set the maximum radius limit, begin lowering the
[BEFORE] and [NOW] boom angle, radii and height will
be displayed. Continue hoisting the boom until the
desired maximum radius limit is displayed in the [NOW]
column.

key to accept this value as the new maximum radius
limit.


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3–5–1) Setting Maximum Tip Height Limits

present setting. Move the cursor to [MAX Height-
LMT] using the ▼ ▲ keys. The display on the right
setting, press the ◄ ► keys to activate [MAX
Height-LMT]. The maximum height limit column will
change to the active or [LIVE] setting.

[MAX Height-LMT] setting screen. The numerical
value on the screen shows the crane’s current
radius. As the boom is lowered or raised, the
numerical value in the [NOW] column will adjust to
reflect the crane’s changing boom angle. The
numerical value in the [SPEC] column represents the
maximum height limit, which cannot be changed.
The [MAX Height-LMT] may be set up to the
maximum allowable tip height for the current
3–5–2) Maximum Tip Height Determined
When the maximum height limit has previously been

Press the ◄ ► keys sequentially to scroll through
the numerical values located at [SET Value] at the
bottom of the screen until the desired maximum
height limit is displayed. Then, press the O key to
accept this value as the new maximum height limit.
Press the lOl key once more to confirm the new value.

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3–5–3) Maximum Tip Height Undetermined
When the maximum height limit has not previously

been determined, the setting value may be
determined by physically operating the machine.
To set the maximum height limit, begin raising the
[BEFORE] and [NOW] boom angle, radii and height
will be displayed. Continue raising the boom until the
desired maximum height limit is displayed in the
[NOW] column.

key to accept this value as the maximum height limit.


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3–6) Setting Work Limit Slow Down Margins
By establishing work limit slow down margins the machine will automatically slow down
when the boom closes to the set work limit angles. When the boom reaches the work
limit, an audible alarm will sound and the boom will stop automatically. Regardless of
the work limit setting, be sure to set a slow down angle of 2.0 – 3.0 feet minimum in
order to prevent shock loading of the crane. The default value is 0.3 feet.
3–6–1) Setting Maximum Radius Slow Down Margins
Move the cursor to the [SLOW-DN RADI] under [MAX

RADI-LMT] using the ▼ ▲ keys. (It is not necessary
to activate this setting by changing it from [DEAD] to
[LIVE]).
Press the lOl key to open the [SLOW-DN RADI] setting

screen. The numerical values on the screen indicate
the current boom angle, working radius and boom tip
height.
To set the slow down margin, press the ◄ ► keys
the desired slow down setting is displayed. Press the
lO key to accept the new slow down margin.
Press the O key again, to confirm the new value. The


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3–6–2) Setting Maximum Tip Height Slow Down Margins
Move the cursor to the [SLOW-DN Height] under [MAX

Height-LMT] using the ▼ ▲ keys. (It is not necessary
to activate this setting by changing it from [DEAD] to
[LIVE]).
Press the lO key to open the [SLOW-DN Height]

setting screen. The numerical values on the screen
indicate the current boom angle, working radius and
boom tip height
To set the slow down margin, press the ◄ ► keys
the desired slow down setting is displayed. Press the
lO key to accept the new slow down margin.
Press the O key again, to confirm the new value. The


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3–6–3) Confirm Work Limit Temporary Settings
Now the work limit setting procedure is complete.
Locate the cursor to the [End of whole SET by O] at the

bottom of the screen and press the O key to confirm
the temporary setting of the work limits.
The new values will not be registered unless this step

is completed. The work limits are now set and the
display will return to the [Main MENU of FUNCTION]
screen.

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4) Selecting Monitor Functions (Hook Data Table, Monitoring Errors)
These functions are mainly used to check the input/output status of each Moment Limiter
sensor. Normally used functions of [HOOK Data MONITOR] and [ERROR MONITOR] will
be introduced.
4–1) Table of Hook Data
Move the cursor to [04 MONITOR mode] using the ▼ ▲

keys and press the O key.
The [main of MONITOR] screen will be displayed.
Press the O key to view a table of hook data which

indicates the capacity (name), net weight, and limit
values of manufacturer supplied hooks applicable to this
machine.

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Refer to the hook weight when making a zero

adjustment of the Moment Limiter.
Press the ◄ ► keys, to view main and auxiliary hook
data.
For information on user defined hooks, refer to item [10

HOOK DATA mode] on the [Main MENU of FUNCTION]
screen.
Press the X key to return to the [main of MONITOR]

screen. Press the X key once more to return to the
[Main MENU of FUNCTION] screen.
All other functions located on the [main of MONITOR] including; [01 sensor
MONITOR], [02 Digital Input-MONITOR], [03 Digital Output-MONITOR], [05
ERROR MONITOR], [06 Analog Input-MONITOR] and [07 Over Load MONITOR]
are functions used by service technicians to assist with troubleshooting issues.
Unauthorized use of these functions could corrupt the Moment Limiter’s calibration
settings.

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4–2) Error monitor (Error display E***)
This function informs the user that an error has occurred relating to Moment Limiter
function.
When an error is generated during operation, an alarm

will sound and the error message [ il E***] will be
displayed at the bottom of the screen. Press the i key
to display error details and countermeasures.
Error Number
Display
Be sure to check the [ERROR monitor] screen after completing the countermeasure tasks,
because it may be possible for an error to occur in other functions not shown on the
Press the O key on the “Operation” screen to return to

the [Main MENU of FUNCTION] screen. Move the cursor
to [04 MONITOR mode] using the ▼ ▲ keys and press
the O key.

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Move the cursor to [05 ERROR MONITOR] using the ▼

▲ keys and press the O key.
When an error is found by opening [ERROR monitor]

screen, the number for which the error is generated will
be lit. Perform the corresponding countermeasures
listed in the following Error Number List.

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Error Number List
Error No. Major cause Check/Countermeasure
EEEE DSP [CPU] error Repair/replace by manufacturer
Angle meter sensor 1 error [Specified output

E100
value error] Wiring check
IN/OUT voltage check
Angle meter sensor 2 error [Specified output Replace angle meter
E101
value error]
Load cell 1 sensor error [Specified output value

E102
error] Wiring check
IN/OUT voltage check
Load cell 2 sensor error [Specified output value Replace load cell
E103
error]
Wiring check
Jib Angle 2 sensor error [Specified output value
E104 IN/OUT voltage check
error]
Replace sensor
Set content check

E114 Load chart missing
Roller width check, etc.
Communication error between operation and

E120 Repair/replace by manufacturer
display parts
E121 Operation part memory error Repair/replace by manufacturer
E122 Internal mode selection LS error Repair/replace by manufacturer
Writing error to EEPROM (Unable to write onto

EEPROM normally)
DSP computing error (Unable to calculate such

as dividing by zero)
Internal Dip-SW5 is turned off when

E125 Internal SW 5 setting and ATT setting not agreed setting Work Number 71.
Example: Turn Internal Dip-SW5 ON.
E127 Work record storage error Repair/replace by manufacturer
E128 Display part storage memory error Repair/replace by manufacturer
E129 Battery deteriorated—RTC error Replace battery
E130 Battery deteriorated–RTC transmission suspended Replace battery

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5) Test Mode
[05 TEST mode] is a function used by service technicians to assist with troubleshooting
issues. Unauthorized use of this function could corrupt the Moment Limiter’s calibration
settings. Should accidental entry occur; do not make any adjustments. Immediately press
the X key to return to the [Main MENU of FUNCTION] screen.
6) Adjustment-1
[06 Adjustment-1 mode] is a function used by the manufacturer to calibrate the Moment
Limiter. This function is for manufacturer use only. Unauthorized use of this function could
corrupt the Moment Limiter’s calibration settings.
Should accidental entry occur; do not make any adjustments. Immediately press the Xl
key to return to the [Main MENU of FUNCTION] screen.
Should the Moment Limiter calibrations settings become corrupt, please call the
manufacturer for more information.

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7) Adjustment-2
[07 Adjustment-2 mode] is a function used by the manufacturer to calibrate the Moment
Limiter. This function is for manufacturer use only. Unauthorized use of this function could
corrupt the Moment Limiter’s calibration settings.
Should accidental entry occur; do not make any adjustments. Immediately press the Xl
key to return to the [Main MENU of FUNCTION] screen.
Should the Moment Limiter calibrations settings become corrupt, please call the
manufacturer for more information.
8) Property
The [Property] screen is used to confirm the [Program No.] and [Data No.] entered in the
Moment Limiter. Confirm the program version and data number.
Located on the [Main MENU of FUNCTION], move the

cursor to [08 Property] and press the lO key.

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Press the X key to return to the [Main MENU of

FUNCTION] screen.
9) WxR Table
The [WxR Table] or rated gross load displays the actual

load weight, boom angle, working radius, load ratio and
the rated gross load.
Two methods are available to view the load chart, one
from [main MENU of FUNCTION] the other from
To view the load chart from the “Operation” screen press

the WxR key.

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To view the load chart from the [main MENU of

FUNCTION] screen, move the cursor to [09 WxR Table]
and press the O key.
Select the main or auxiliary lifting point using the ◄ ►

keys. When multiple load charts are available, select the
corresponding load chart using the ▲ ▼ keys.
To return to the “Operation” screen, press the WxR key.

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10) Hook Data
The hook data differs specific to crane model and serial number.
Hook data is classified into two categories; manufacturer supplied hooks and user defined
hooks.
When executing the zero adjustment of the Moment Limiter, refer to the hook weight.
Select [10 HOOK DATA mode] from [main MENU of

FUNCTION] and press the O key.
The [MENU of Hook Data] screen will appear.

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10–1) Manufacturer Supplied Hook Data
Select [MONITOR of Hook Data ‘M’] and press the Ol

key.
The [Hook Data table] for manufacturer supplied hooks

is displayed.
The hook capacity (name), weight, and limit value is set
for the hook data.
Use the ◄ ► keys to display [Main] or [AUX] hooks.

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10-2) User Defined Hook Data
Utilize this function to program user defined (customer supplied) hook data into the
Moment Limiter. User defined hook data may be entered for both the main and auxiliary
lifting points.
Select [10 HOOK DATA mode] from [main MENU of

FUNCTION] and press the O key.
The [MENU of Hook Data] screen will appear. Select

[USER’S HK Data ‘U’ INPUT mode] and press the Ol
key.
The [INPUT of USER’S HK Data ‘U’” screen will appear.

Move the cursor to the name column using the ▲ ▼
keys and then select the hook capacity (nominal name)
using the ◄ ► keys.

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Next, locate the cursor to the weight column using the

▲ ▼ keys, and then select the weight using the ◄ ►
keys.
Now, locate the cursor to the limit value using the ▲ ▼

keys, and then select the limit value using the ◄ ►
keys. Example: 50 Ton = 100.0 kips.
To program multiple hooks, repeat the above procedure. A maximum of three user
defined hooks may be registered to the [Main] and the [AUX].
Upon completion, move the cursor to [End of SET] at

the bottom of the screen using the ▲ ▼ keys. Then,
press the O key to confirm the new data. The new
values will not be registered unless this step is
completed. The display will return to the [MENU of
Hook Data] screen. Press the X key to return to the
[main MENU of FUNCTION] screen.

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11) Setting Slew Work Limits
The Slew limit function is used to set the [Slew limit angle], [Slew margin angle], [Slew
margin distance], etc. to the right and left in an operational environment. This function
allows the operator to set up a slew work limits. Use of the slew work limit function is
beneficial to maintain a user defined distance from specific work areas or objects.
Setting the slew limits will not automatically stop the movement of the
crane when entering into the user defined limited work area. Setting the
limits will initially cause the yellow margin band to appear on the lower
portion of the “Operational” screen. Continued slewing will cause the red
stop band to appear and a continuous alarm will sound. Upon hearing the
alarm, the operator should return the crane to a safe working area. It is the
responsibility of the operator to set limits that ensure that the crane, boom,
jib, load, rigging, etc. maintain a safe working distance.

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The following table illustrates the allowable slew work limit combinations.
Setting combinations for slew work limits

Left, Right Wall 1 Wall 2 Crawler width
Left, Right Yes Yes No
Wall 1 Yes Yes No
Wall 2 Yes Yes No
Crawler width Yes No No
To set the slew limit, move the cursor to [11 Slew Limit
mode] listed on the [main MENU of FUNCTION] screen.
Then, press the O key to display the [menu of SLEW

LiMiT] screen.
On the screen, [01 ZERO Adjust of SLEW Angle] and [02
LiMiT of SLEW] will be displayed.

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11–1) Zero Adjustment
This function is completed to register the 0° position of the crane superstructure. This
step must be completed prior to setting Slew Work Limits in order to calibrate the
Moment Limiter.
Select [01 ZERO Adjust of SLEW Angle] from the [menu

of SLEW LiMiT] and press the O key.
The [ZERO ADJUSTMENT of SLEW Angle] screen will

appear.
Follow the on-screen instruction; face the crane
superstructure forward (toward the front idler side), set
the slew lock pin and press the O key.
The numerical value of [Slew Angle] and [Count value]

will now be [0.0]. Press the O key again to complete
the zero adjustment setting. The screen will
automatically return to the [menu of SLEW LiMiT]
screen. Press the Xl key to return to the [main MENU
of FUNCTION] screen.

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11–2) Setting Slew Work Limits
Select [LiMiT of SLEW] from the menu and press the

lO key.
The [SLEW-WORK LiMiT (USER’S SET)] screen will be

displayed.
This menu is used to enter Slew Limits, Wall-1 Limits,
Wall-2 Limits and Crawler Width Limits.
Note: Rotation angles are registered by the Moment
Limiter in a clockwise rotation and expressed from 0° –
359°.

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11–2–1) Setting the Left Slew Limit

present setting. Move the cursor to [1 Left Slew
LMT], using the ▲ ▼ keys. The display on the right
side of the screen will indicate DEAD when inactive
or LIVE when active. Press the ◄ ► keys to
change the setting to LIVE and press the O key.
The display will change to “Present Setting Value”

Screen. Press the O key again to open the “Limit
Angle Setting Screen”.

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11-2-2) Rotation Angle Determined
When the rotation angle has previously been determined, setting may be performed
by selecting a numerical value for the column of [SETing VALUE] directly.
When setting a left limit angle of 60°, the 60° position to the left represents 300°
clockwise.
Locate the cursor in the [SETing VALUE] column on

the lower right side.
the numerical values until 300° is displayed. Press
the Ol key to accept this value.
Confirm that the upper display [Left Slew LMT] and
the left display [Limit] has changed to 300°, and
then press the O key to confirm this value as the
left slew limit.
The new value will now be displayed on the

“Present Set Value” screen.
11-2-3) Rotation Angle Undetermined
When the rotation angle has not previously been determined, the setting value may be
determined by physically operating the machine. Operating the machine changes the
numerical value in the [NOW] column to represent real time.
When setting a left limit angle of 60°, the 60° position to the left represents 300°
clockwise.

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Begin slewing the crane to the left until the display

reads 300° in the [NOW] column.

press the O key to open it again. The value is now
displayed in the [BEFORE] column. Press the O to
accept the new value. Confirm that the upper
display [Left Slew LMT] and the left display [Limit]
have changed to 300°, and then press the O key
to accept this value as the left slew limit.


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11–2–4) Setting the Right Slew Limit

present setting. Move the cursor to [1 Right Slew
LMT], using the ▲ ▼ keys. Press the O key to
open the “Limit Angle Setting” screen.
When the rotation angle has previously been

determined, setting may be performed by selecting
a numerical value for the column of [SETing VALUE]
directly.
When setting a right limit angle of 45°, locate the
cursor in the [SETing VALUE] column on the lower
right side.

the numerical values until 45° is displayed. Press the
lO key to accept this value.
Confirm that the upper display [Right Slew LMT] and
the left display [Limit] have changed to 45°, and then
press the O key to confirm this value as the left
slew limit.

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When setting a right limit angle of 45°, begin slewing

the crane to the right until the display reads 45° in
the [NOW] column.

displayed in the [BEFORE] column. Press the Ol
key to accept the new value. Confirm that the upper
display [Right Slew LMT] and the left display [Limit]
have changed to 45°, and then press the O key to
accept this value as the right slew limit.

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11–2–7) Setting the Margin Angle
Setting the [Margin Angle] is optional.

To set, move the cursor to [Margin Angle], using the
▲ ▼ keys. Press the O key to open the setting
screen.
When setting a [Margin angle] of 3°, locate the

cursor in the [SETing VALUE column on the lower
right side. Press the ◄ ► keys sequentially to
scroll through the numerical values until 3° is
displayed. Press the O key to accept this value.

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Confirm that the upper display [Margin Angle] has

changed to 3°, and then press the lO key to
confirm this value as the margin angle.

“Present set value screen”. The new value will now
be displayed on the “Present set value screen”.
Press the X key to return to [SLEW-WORK LiMiT


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11–2–8) Confirm Slew Limit Temporary Settings
Now the slew limit setting procedure is complete.
Locate the cursor to the [End of whole SET by O] at

the bottom of the screen and press the O key to
confirm the temporary setting of the slew limits
angles.
The new values will not be registered unless this

step is completed. The slew limit angles are now
set and the display will return to the [menu of SLEW
LiMiT] screen.
By setting the Left and Right Slew Limits with a Margin Angle for both, a safe working
range of 105° is established in the front of the machine. The safe working range is
positioned beginning at 60° to the left, and ending at 45° to the right, with a 3° margin
angle set before the limit angles to the left and right.

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11–3–1) Setting Wall 1 Limits
This function allows the operator to set up a Wall 1 limits. By establishing these limits
correctly, an audible alarm will sound before the machine enters the set boundaries.
Use of the slew work limit function is beneficial to maintain a user defined distance
from specific work areas or objects.
The wall may be set up for two separate locations within the operational radius (Wall 1
and/or Wall 2). It may also be set to establish the location of the work area inside or
outside the wall.
Each wall is represented as a straight line connecting Point 1 and Point 2, with the
slew angle and working area or distance set to each point. By setting Point 3, the
location of the work area is established inside or outside of the wall.

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11-3-2) Setting Point 1

present setting.
Move the cursor to [2 WALL-1 LMT P1] using the ▲
▼ keys. The display will indicate DEAD when
inactive or LIVE when active. Press the ◄ ► keys
to change the setting to LIVE , and then press the Ol
key.
The display will change to the “Present Set Value”

screen.
Press the O key again to open the “Wall 1 Setting”

screen.

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When the rotation angle has previously been determined, setting may be performed by
selecting a numerical value for the column of [SETing VALUE] directly.
When setting Point 1 of 60°, the 60° position to the left represents 300° clockwise.

the numerical values until 300° is displayed.
Press the O key to accept this value as the Point 1

limit. Confirm that the upper display [WALL-1 LMT P1]
and left [P1] limit has changed to 300°.
numerical value in the [NOW] column to represent real time. When setting Point 1 of
60°, the 60° position to the left represents 300° clockwise.

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displayed in the [BEFORE] column. Press the O key
to accept this value as the Point 1 limit.
Confirm that the upper display [WALL-1 LMT P1] and

the left [P1] limit has changed to 300°.

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11-3-5) Setting the Radius of Point 1
By setting the radius of Point 1, the distance is established from the machine’s center
of rotation to Point 1. The numerical value on the screen represents the present setting.
Press the ▲ ▼ keys to move the cursor to the radius

display column of [SETing VALUE], located on the
lower left side.
11-3-6) Radius Determined
When the radius has previously been determined,

setting may be performed by selecting a numerical
value for the column of [SET Value] directly.
When setting the radius to Point 1 of 32 feet, press
the ◄ ► keys sequentially to scroll through the
numerical values until 32 ft is displayed.
Then, press the O key to accept this value as the

radius to Point 1. Confirm that the upper display
[WALL-1 LMT P1] and left [P1] limit has changed to 32
ft. Press the O key once more to confirm the new
value.

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11-3-7) Radius Undetermined
When the radius has not previously been determined, the setting value may be
When setting a radius to Point 1 of 32 feet begin

hoisting or lowering the boom until the display reads
32 ft in the [NOW] column.

displayed in the [BEFORE] column. Press the ▲ ▼
keys to move the cursor to the radius display column
of [SETing VALUE], located on the lower left side.
Press the O key to accept this value as the radius to

Point 1. Confirm that the upper display [WALL-1 LMT
P1] and the left [P1] limit has changed to 32 ft. Press
the lO key once more to confirm the new value.

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The same setting method can be applied to Point 2 as set to Point 1. The numerical
value on the screen represents the present setting.
Move the cursor to [P2] using the ▲ ▼ keys and

press the O key. The display will change to the
“Wall 1 Setting” screen.

numerical value for the column of [SETing VALUE]
directly.
When setting Point 1 of 45°, locate the cursor in the
[SETing VALUE] column on the lower right side.

limit. Confirm that the upper display [WALL-1 LMT P2]
and right [P2] limit has changed to 45°.

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Begin slewing the crane to the right until the display

displayed in the [BEFORE] column.

limit. Confirm that the upper display [WALL-1 LMT
P2] and the right [P2] limit has changed to 45°.

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of rotation to Point 2. The numerical value on the screen represents the present
setting.
Press the ▲ ▼ keys to move the cursor to the

radius display column of [SETing VALUE], located
on the lower left side.

numerical values until 67 ft is displayed.

[WALL-1 LMT P2] and right [P2] limit has changed to
67 ft. Press the O key once more to confirm the
new value.

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67 ft in the [NOW] column.

keys to move the cursor to the radius display column
of [SETing VALUE], located on the lower left side.
Press the O key to accept this value as the radius to

Point 2. Confirm that the upper display [WALL-1 LMT
P2] and the right [P2] limit has changed to 67 ft. Press
the O key once more to confirm the new value.

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11-3-14) Setting the Margin
By setting Point 3, the location of the safety region is established inside or outside of
the wall. Therefore, before setting the margin distance, establish the safety region.
Locate the cursor to [Margin (P3] using the ▼ ▲

keys.
Press the O key to open the “Wall 1 Setting”

screen. The setting value is determined by
physically operating the machine. Operating the
machine changes the numerical value in the [NOW]
column to represent real time.

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11-3-15) Establishing the Safety Region on the Inner Side of the Wall
When establishing the safety region on the inner

side of the wall, begin hoisting or lowering the boom.
Continue hoisting or lowering the boom until the
display reads 25 feet in the [NOW] column.

press the lO key to open it again. The value is now
Press the lO key once to accept this value as the

margin distance for the safety region. Confirm that
the upper display has changed to 25 feet.

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The slow down margin must now be established.

When setting a slow down margin of 2 feet, press
numerical values until 2 feet is displayed. Press the
lO key once to accept this value as the slow down
margin.
Confirm that the upper display has changed to 2

feet. Press the O key once more to confirm the
new value.
11-3-16) Establishing the Safety Region on the Outer Side of the Wall
When establishing the safety region on the outer


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margin distance for the safety region. Confirm that the
upper display has changed to 75 feet.

When setting a slow down margin of 2 feet, press the
◄ ► keys sequentially to scroll through the
numerical values until 2 feet is displayed.

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Press the O key once to accept this value as the

slow down margin. Confirm that the upper display
has changed to 2 feet. Press the O key once more
to confirm the new value. Press the X key to return
to the [SLEW-WORK LiMiT (USER’S SET)] screen.
11–3–17) Confirm Wall 1 Temporary Settings
Now the Wall 1 setting procedure is complete.

confirm the temporary setting of the Wall 1 limits.

step is completed. The Wall 1 limits are now set and
the display will return to the [menu of SLEW LiMiT]
screen.

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11–4–1) Setting Wall 2 Limits
This function allows the operator to set up a Wall 1 limits. By establishing these limits
correctly, an audible alarm will sound before the machine enters the set boundaries.
Use of the slew work limit function is beneficial to maintain a user defined distance
from specific work areas or objects.
The wall may be set up for two separate locations within the operational radius (Wall 1
and/or Wall 2). It may also be set to establish the location of the work area inside or
outside the wall.
Each wall is represented as a straight line connecting Point 1 and Point 2, with the
slew angle and working area or distance set to each point. By setting Point 3, the
location of the work area is established inside or outside of the wall.

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present setting.
Move the cursor to [3 WALL-2 LMT P1] using the ▲
▼ keys. The display will indicate DEAD when
inactive or LIVE when active. Press the ◄ ► keys
to change the setting to LIVE , and then press the
lO key.

screen.
Press the O key again to open the “Wall 2 Setting”

screen.

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When the rotation angle has previously been determined, setting may be performed
by selecting a numerical value for the column of [SETing VALUE] directly.


limit. Confirm that the upper display [WALL-2-LMT
P1] and left [P1] limit has changed to 45°.

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displayed in the [BEFORE] column. Press the Ol
key to accept this value as the Point 1 limit.
Confirm that the upper display [WALL-2 LMT P1]

and the left [P1] limit has changed to 45°.

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setting.



[WALL-2 LMT P1] and left [P1] limit has changed to
67 feet. Press the O key once more to confirm the
new value.

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67 feet in the [NOW] column.

keys to move the cursor to the radius display
column of [SETing VALUE], located on the lower left
side.
Press the O key to accept this value as the radius

to Point 1. Confirm that the upper display [WALL-2
LMT P1] and the left [P1] limit has changed to 67 ft.
Press the O key once more to confirm the new
value.

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The same setting method can be applied to Point 2 as set to Point 1. The numerical
value on the screen represents the present setting.
Move the cursor to [P2] using the ▲ ▼ keys and

press the O key. The display will change to the
“Wall 2 Setting” screen.

determined, setting may be performed by selecting
a numerical value for the column of [SETing VALUE]
directly.
When setting Point 1 of 135°, locate the cursor in
the [SETing VALUE] column on the lower right side.
Press the O key to accept this value as the Point

2 limit. Confirm that the upper display [WALL-2
LMT P2] and right [P2] limit has changed to 135°.

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When setting Point 2 of 135°, locate the cursor in

the [SETing VALUE] column on the lower right side.
Begin slewing the crane to the right until the display

Press the O key to accept this value as the Point

2 limit. Confirm that the upper display [WALL-2
LMT P2] and the right [P2] limit has changed to
135°.

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setting.


Then, press the O key to accept this value as

the radius to Point 2. Confirm that the upper
display [WALL-2 LMT P2] and right [P2] limit has
changed to 67 feet. Press the O key once more
to confirm the new value.

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67 feet in the [NOW] column.

keys to move the cursor to the radius display
column of [SETing VALUE], located on the lower left
side.
Press the O key to accept this value as the radius

to Point 2. Confirm that the upper display [WALL-2
LMT P2] and the right [P2] limit has changed to 67
new value.

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11-4-14) Setting the Margin
By setting Point 3, the location of the safety region is established inside or outside of
the wall. Therefore, before setting the margin distance, establish the safety region.
Locate the cursor to [Margin (P3] using the ▼ ▲

keys.
Press the O key to open the “Wall 2 Setting”

screen. The setting value is determined by
physically operating the machine. Operating the
machine changes the numerical value in the [NOW]
column to represent real time.

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11-4-15) Establishing the Safety Region on the Inner Side of the Wall
When establishing the safety region on the inner




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numerical values until 2 feet is displayed. Press the
lO key once to accept this value as the slow down
margin.
Confirm that the upper display has changed to 2

new value.
11-4-16) Establishing the Safety Region on the Outer Side of the Wall
When establishing the safety region on the outer


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Press the O key once to accept this value as the

slow down margin. Confirm that the upper display
has changed to 2 feet. Press the O key once
more to confirm the new value. Press the X key
to return to the [SLEW-WORK LiMiT (USER’S
SET)] screen.
11–4–17) Confirm Wall 2 Temporary Settings
Now the Wall 2 limit setting procedure is complete.

confirm the temporary setting of the Wall 2 limits.

step is completed. The Wall 2 limits are now set
and the display will return to the [menu of SLEW
LiMiT] screen.

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11–5–1) Crawler Width Limit

The crawler width limit is a function to set the slew working limit within the center of
the carbody.
By setting the center of the left and right tracks as the slew limit angle, a margin
distance is set inside of them.
Locate the cursor to [4 CRAWLER Width LMT] using

the ▲ ▼ keys. The display on the right side of the
screen will indicate DEAD when inactive or LIVE
when active. Press the ◄ ► keys to change the
setting to LIVE , and then press the O key.

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screen.
Press the O key again to open the “Crawler Width

Limit Setting” screen.
To set the margin distance, locate the cursor to the

[SETing VALUE] on the lower left side of the screen.
When setting a margin distance of 1.5 feet, press the
◄ ► keys until 1.5 is displayed in the [SETing
VALUE] column.

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Press the O key to accept this value as the margin

distance. Ensure that the new value is displayed in the
margin column on the upper right side of the screen.
Press the O key to confirm the margin distance. The

screen will return to “Present Set Value” screen.
Press the X key to return to the [SLEW-WORK LiMiT
11–5–2) Confirm Crawler Width Limit Temporary Settings
Now the Crawler Width limit setting procedure is complete.
Locate the cursor to the [End of whole SET by O]

at the bottom of the screen and press the O key
to confirm the temporary setting of the Crawler
Width limits.

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step is completed. The Crawler Width limits are
now set and the display will return to the [menu of
SLEW LiMiT] screen.
Press the X key to return to the [main MENU of

FUNCTION] screen.
Press the X key again to return to the “Moment

Limiter” screen.

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Glossary of Technical Terminology
Actual Load The weight of the object being lifted or lowered, including load
block, ropes, slings, shackles, and any other rigging attachment.
Anti-Two Block Device A device which, when activated, disengages all crane functions
whose movement can cause two-blocking.
Auxiliary Hook The assembly of a secondary hook used either in conjunction with
or independently of the main hook or block.
Auxiliary Jib A supplemental extension attached to the boom to provide added

boom length for lifting specified loads.
Boom Angle The angle above or below the horizontal of the longitudinal axis of
the base boom section.
Boom Head The outer extremity of the crane boom, which contains the hoist
sheave assembly.
Boom Tip Extension An extension attached to the boom point to provide added boom
length.
B-Top ML-D5A specification meaning that the boom point sheave

assembly is installed in the main boom head.
Carrier (Carbody) The structural part of the crane located below the superstructure,
usually the portion responsible for transporting the crane.
Center of Rotation The vertical axis around which the crane superstructure rotates
before a load is applied to the crane hook.
Continuous Alarm A constant audible signal used to warn the operator the rated
capacity, work limits, slew limits, etc… have been met.
Fixed Jib (#2 Jib) An extension attached to the boom point to provide added boom
length for lifting specified loads. The jib may be in line with the
boom or offset to various angles in the vertical plane of the boom.
Hook/Block Capacity The lifting capacity of the hook block or ball, as determined by the
manufacturer’s published load chart.
Hook Center The vertical center of the hook block or ball.
Hoist Drum The spool or cylindrical member around which the cable is wound
for lifting and lowering the load or boom.
Intermittent Alarm A rhythmic audible signal used to warn the operator of encroaching
upon the rated capacity, work limits, slew limits, etc…
J-Top ML-D5A specification for the fixed jib.
Lifting Point The location of the hoist rope for the current lift e.g. auxiliary jib,
boom tip extension, fixed jib, luffing jib, luffing tower or main boom.

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Load Ratio The percentage of the rated capacity of the crane, as determined by
the manufacturer’s published capacity chart.
Load Chart The lifting capacity of the crane, as determined by the

manufacturer’s published capacity chart.
Luffing Tower The main boom is assembled without the boom point sheave
assembly installed, enabling the installation of the luffing tower
configuration.
Luffing Jib An auxiliary jib that is able to boom up and down independently of
the main boom.
Main Block The assembly of a primary hook used either in conjunction with or
independently of the auxiliary hook or block.
Main Boom A structural member attached to the revolving superstructure used

for guiding and acting as a support for the load.
Margin A spare amount, measure or degree established for contingencies or

special situations as they relate to the safe operation of the crane.
Overload The point at which the actual load exceeds the rated capacity of the
crane.
Parts of Line The number of parts of hoist rope between the boom head and
lower auxiliary hook or main block.
Radius The horizontal distance from the centerline of rotation to the center
of the hook or to the center of gravity when a load is applied to the
crane hook.
Rated Capacity The lifting capacity of the crane as determined by the

manufacturer’s published capacity charts.
Rated Gross Load The total allowable sum of the load, hook block and/or ball, rigging
and all attachment weights as determined by the manufacturer’s
published load chart.
Rating A factor determined by legislation that limits the proportion of the

capability of the cranes that may be utilized in a lifting operation.
Usually expressed as a percentage of strength or stability.
Reeving A rope system in which the rope travels around drums and sheaves.
Rope Limit The maximum permitted single line pull determined by the
construction and diameter of wire rope.
Safety Region The area of the safe operating perimeters of the crane, established
by jobsite supervision or the crane operator.
Sensor A device that responds to physical stimulus and transmits a

resulting impulse.

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Sheave A grooved wheel or pulley.
Slew Rotation Angle The horizontal angle measured from the zero degree center of
rotation, over the front or rear as specified by the manufacturer, to
the centerline of the boom.
Superstructure The structural part of the crane above the carrier, usually rotating.
Total Load Weight The total sum of the load, hook block and/or ball, rigging and all
attachment weights. Refer to the manufacturer’s published load
chart for more information, specific to the make and model of crane.
Two-Blocking The condition in which the hook block or ball comes into contact
with boom point sheave assembly.

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Notes

HC275 - ML-D5A Operator's Manual

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Instruction Manual

ML-D5A Moment Limiter

IHI Construction Machinery Limited

Moment Limiter Outline (Overload Protection Device ML-D5A) ...........................................1

Configuration and Wiring System of Major Moment Limiter Components...........................2

Operating Environment of the Moment Limiter .....................................................................3

Precautions in Handling the Moment Limiter ........................................................................4

Load Handling with the Moment Limiter ...............................................................................5

Functions of the Panel Keys ..................................................................................................6

Moment Limiter Operation and Display Screen ....................................................................7

1) Moment Limiter Operation ............................................................................7

2) Changing the Configuration of an Operational Machine ..............................8

3) Content of the [main MENU of FUNCTION] Screen .....................................9

Operating Procedure for the Main Menu

1) Setting the Crane Configuration ...................................................................................10

1-1) Selecting the [WORK NO.] ..........................................................................10

1-2) Selecting the [CRAWLER] Width.................................................................11

1-3) Selecting [BOOM LENGTH] and [JIB LENGTH]..........................................12

1-4) Selecting the Capacity of the Main and Auxiliary Hooks............................12

1-6) Selecting the Hoist Drum Configuration .....................................................14

1-7) Selecting the Jib Offset Angle.....................................................................14

1-8) Selecting Special 2-Hooks..........................................................................14

1-9) Selection Completion ..................................................................................15

2) Checking Operator Aids .................................................................................................17

2-1) Overload Protection Device (Output Check) ....................................................18

3-1) Setting High Boom Angle Limits .................................................................22

3-1-1) High Boom Angle Determined ....................................................................22

3-1-2) High Boom Angle Undetermined ................................................................23

3-2) Setting Low Boom Angle Limits..................................................................24

3-2-1) Low Boom Angle Determined .....................................................................24

3-2-2) Low Boom Angle Undetermined.................................................................25

3-3) Setting Work Limit Slow Down Angles .......................................................26

3-3-3) Confirm Work Limit Temporary Setting ......................................................28

3-4) Setting Maximum Radius and Boom Tip Height Limits..............................29

3-4-1) Setting Maximum Radius Limits .................................................................30

3-4-2) Maximum Radius Determined.....................................................................30

3-4-3) Maximum Radius Undetermined ................................................................31

3-5-1) Setting Maximum Tip Height Limits............................................................32

3-5-2) Maximum Tip Height Determined ...............................................................32

3-5-3) Maximum Tip Height Undetermined ...........................................................33

3-6) Setting Work Limit Slow Down Margins .....................................................34

3-6-1) Setting Maximum Radius Slow Down Margins ..........................................34

3-6-2) Setting Maximum Tip Height Slow Down Margins .....................................35

3-6-3) Confirm Work Limit Temporary Settings ....................................................36

4) Selecting Monitor Functions (Hook Data Table, Monitoring Errors)..............................37

4-1) Table of Hook Data .....................................................................................37

4-2) Error Monitor (Error Display E***) ................................................................39

5) Test Mode ......................................................................................................................42

9) WxR Table ......................................................................................................................44

10) Hook Data....................................................................................................................46

10-1) Manufacturer Supplied Hook Data .............................................................47

10-2) User Defined Hook Data .............................................................................48

11) Setting Slew Work Limits ............................................................................................50

11-1) Zero Adjustment..........................................................................................52

11-2) Setting Slew Work Limits ............................................................................53

11-2-1) Setting the Left Slew Limit ..........................................................................54

11-2-2) Rotation Angle Determined .........................................................................55

11-2-3) Rotation Angle Undetermined.....................................................................55

11-2-4) Setting the Right Slew Angle ......................................................................57

11-2-5) Rotation Angle Determined .........................................................................57

11-2-6) Rotation Angle Undetermined.....................................................................58

11-2-7) Setting the Margin Angle.............................................................................59

11-2-8) Confirm Slew Limit Temporary Setting .......................................................61