Post on 20-Dec-2015
description
WORK SHOP MANUAL
FURUKAWA UNIC CORPORATION
URW376C1AMRURW546C1AMR
1. General view 1-1
2. Major Specifications (URW376C1A) 2-1~6
3. Major specifications (URW546C1A) 3-1~6
4. Outrigger operationHow to extend outriggers 4-1
How to store outriggers 4-2
5. How to store outriggers when in an emergency5-1
5-2
6. Mode indicator lamp (control box) Mode indication when crane is in normal operation 6-1~2
Mode indication when crane is mistakenly operated 6-3
Indication of each operation 6-4
Error indication 6-5~6
7. List of voice messages 7-1
8. How to switch operation mode Switching of mode (Manual mode ⇔ Radio control mode) 8-1
How to operate outriggers by manual lever 8-2
How to operate outriggers by radio control transmitter 8-3
Switching of mode indicator(State ⇔ Operation) 8-4
Restting of interlocking balance control
Switching of "Shockless"function(Carry it out when it is not over-wound) 8-5
Switching of low-temperature operation mode
Method of engine start and stop that radio controller 8-6
9. Radio control cannot be operated 9-1
10. 10-1
11. 11-1
Control valve for carrier 11-2~5
Manifold 11-6~11
Pump 11-12
Crawling motor 11-13~15
12. Hydraulic circuit diagram (control valve for crane) 12-1
13. Swivel joint 13-1~6
14. Column 14-1~3
15. Hoist winch 15-1~3
Hydraulic circuit diagram (carrier)
Contents
When failed storage by normal operation
When failed extension by normal operation
Emergency measures
16. Hook 16-1
17. Turntable mounting procedures 17-1
18. Slewing deviceSlewing reduction gear 18-1~5
Piping 18-6~7
19. OutriggerHydraulic circuit diagram 19-1
Outrigger 19-2
Vertical outrigger cylinder 19-3
Horizontal outrigger cylinder 19-4
20. Derricking cylinder 20-1~3
21. Telescoping cylinderURW376C 21-1~4
URW546C 21-5~15
22. BoomURW376C 22-1~8
URW546C 22-9~15
Installation procedures for slide plate and guide 22-16
23. How to punch 23-1
24. Telescoping/derrick cylinder ass'y, 24-1~2
Measures toprevent piston from being loosened
25. Earth positionEarth for engine start relay and engine stop relay 25-1
Earth of the main harness 25-2
26. 26-1-1~2
Electric wiring in control seat part turnover prevention divice (degital type) 26-2
Power supply fuse 26-3
Solenoid valves for operating outrigger 26-4
Connector of Emergency stop 26-5
Wiring for operation switch panel 26-6~8
Switch panel(key switch type) (turnover prevention device) 26-9~10
Interlock for crane-crawl lever 26-11~12
The other side of accelerator pedal 26-13~14
Accelerator cable 26-15
26-16~19
Reay box 26-20~21
Buzzer 26-22
Eleectric Wiring Diagram
Electric wiring in control valve part turnover prevention device(degital type)
27. Position of hose 27-1
28. EngineAll view of engine 28-1
Wiring for warning lamp 28-2
Water separator、oil fillter element 28-3
Air cleaner element/Alternator 28-4
Electric Wiring diagram (engine part) 28-5
29. Power unit (Option)Electric Wiring diagram 29-1
Control box for power unit 29-2~3
Converter 29-4
Power unit (~37W0117) 29-5
Power unit (37W0120~) 29-6
30. 30-1
Inspection of derrick cylinder 30-2
Inspection of telescoping cylinder 30-3
30-4
31. Replacement of wire rope (for winding-up) 31-1~4
32. Replacement of expendable parts 32-1
33. List of recommended lubricantLubrication to carrier 33-1~2Lubrication to crane 33-3
34. Filling water and lubrication chartURW376C 34-1URW546C 34-2
35. Lubrication chartURW376C 35-1URW506C 35-2
36. Lubrication 36-1
37. Inspection recordsBefore starting crane operation 37-1Monthly self-inspection records 37-2Annual self-inspection records 37-3
38. Periodically replacing components and expedable parts 38-1
Inspection for sinking of cylinder
Inspection of outrigger cylinder
Digital Load Meter (DL-100)Initial setting up DL-1~5
Error code DL-5
Momet Lemitter (KM-100) Initial setting up KM-1~11
Control box modulation mode list KM-12
Error code KM-13~14
U-AOL system ( Anti overloading system ) KM-15~19
ご
4870
1750
3970220
2035
1215
1750
1800
1190
3530
4340
1300
300
300
1300
1.GENERAL VIEW
URW376C
URW546C
1-1
2-1
URW376C1A(6-section boom)
Crane capacity (Net rated load)
3.0t × 2.5m(With outriggers, extended fully)
Maximum lift above ground (Hook) 14.9mBoom to be extended to: 3.63m~5.85m~8.04m~10.23m~12.42m~14.61mMaximum working radius 14.45mSpeed of winding-up (Rope speed) 68m/min (At 4th layer on the drum)
Hoisting speed of hook 17m/min(At 4th layer on the drum, with 4-part line hooking)
Extending speed of boom 10.98m/23secRaising speed of boom 0° ~ 80°/10sec
mpr5.2deeps gniwelS)suounitnoc(°063egnar gniwelS
Hoisting ropeConstruction IWRC6 × WS(26) calss B[Breaking load:42.4kN
(4320kgf)]Diameter×length 8mm × 85m
Outrigger
HorizontalDirect pushing by double acting hydraulic cylinder (directly connected to hydraulic automatic locking device)
VerticalDirect pushing by double acting hydraulic cylinder (directly connected to hydraulic automatic locking device)
Hydraulic pumpRated pressure Crane: 20.6MPa(210kgf/cm2)
Crawl: 21.6MPa(220kgf/cm2)Rated discharge Approx. 60 ℓ/minRated rotation Approx. 2100rpm
Hydraulic oil tank Capacity 70 liters
(Speed indicated in the table below is at oil temperature range of 45~55°C, operating with no-load, and at rated pump discharge.)
Major specifications
MAJOR SPECIFICATIONS
2-2
Boom telescoping
Boom:6-section, Hexagonal box beam
Telescoped by direct pushing of double acting hydraulic cylinder together with by wire rope(With hydraulic automatic locking device)(2nd section : sequential actuation, 3rd, 4th, 5th & 6th sections: simul-taneous actuation)
Boom derricking Direct pushing by hydraulic cylinder(With hydraulic automatic locking device)
HoistingHydraulic motor: Axial plunger typeReduction gears: Spur-gear reductionBrake: Automatic mechanical brake
Slewing
Hydraulic motor: Axial plunger type noitcuder raeg-rupS+raeg-mroW :sraeg noitcudeR
(Supported by ball bearings)Brake: Worm self-lock
Hydraulic pump Variable delivery piston pumpHooking capacity 3.0t Number of slinging rope: 4
Safety devices
Safety valve for hydraulic circuitHydraulic automatic lockAutomatic stop for overwindingOverwinding alarmSlewing automatic lockAutomatic stop for leaving minimum wire ropeLoad indicator (With angle meter)Alarm buzzerRetaining mechanism to prevent wire rope from disengagementInterlock for crane-crawl operationCrane/outrigger interlocking deviceChecker for outrigger rotary set pin insertionDigital load meterEmergency stop buttonU-AOL systemLevel
Weight Approx. 3860kg
MAJOR SPECIFICATIONS
Equipment and construction
2-3
Crawling Endless rubber crawler
Crawler 300×52.5×88
Length of ground contact 1750mm
Pressure of ground contact 36.3kPa (0.37kgf/cm2)
Crawling speed Forward/Backward: 0~3km/h
Hill-climbing ability 23°
Engine Rated output15.17kW/2500rpm (20.6PS/2500rpm)
Crawling Independently driven by hydraulic power
Parking brake Disc brake with hydraulic motor built-in
Starting engine Electric starter
Fuel tank Capacity: 40 liters
MAJOR SPECIFICATIONS
Crawling device
2-4
MAJOR SPECIFICATIONS
1+2+3+4+5+6
1+2+3+4+5
1+2+3+4
1+2+3
1+21WORKING RADIUS(m)
WORKING RADIUS(m)
3.03.03.0
WORKING RADIUS(m)
WORKING RADIUS(m)
WORKING RADIUS(m)
2.0 2.5
3.0
3.0 3.52.35
4.0
2.171.951.5
1.671.12
4.5 5.0 5.69
2.7 3.0
1.450.9
1.30.72
1.070.47
10.071.041.03
3.5
0.930.82
0.840.64
0.730.47
0.620.31
0.520.22
0.470.13
4.0
0.380.09
2.242.24
2.09
OUTRIGGERSMAX EXTOUTRIGGERSNOT MAX EXT
OUTRIGGERSMAX EXTOUTRIGGERSNOT MAX EXT
OUTRIGGERSMAX EXTOUTRIGGERSNOT MAX EXT
OUTRIGGERSMAX EXTOUTRIGGERSNOT MAX EXT
OUTRIGGERSMAX EXTOUTRIGGERSNOT MAX EXT
2.06
4.5 5.01.651.57
1.45.5 6.0 7.0 7.88
4.0 4.5 5.0 6.0 7.0 8.0 9.0
4.5 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.26
4.9 5.5 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0
1.221.221.02
1.070.83
0.950.65
0.840.51
0.690.3
0.590.19
0.750.75
0.620.62
0.480.4
0.390.25
0.230.01
0.240.06
0.270.09
0.30.13
0.340.18
0.10.01
0.110.02
0.130.03
0.140.05
0.160.08
0.180.11
0.20.17
0.220.22
0.250.25
0.270.27
0.30.3
14.45
Net rated loads chart
NET RATEDLOAD(t)
NET RATEDLOAD(t)
NET RATEDLOAD(t)
NET RATEDLOAD(t)
NET RATEDLOAD(t)
BOOM SECTION
BOOM SECTION
BOOM SECTION
BOOM SECTION
BOOM SECTION
Chart of net rated load
2-5
MAJOR SPECIFICATIONS
Points to notice, Rated loadThe net rated load is performance when the crane is placed level and is based on •actual working radius including boom deflection under loaded. The net rated load is also based on strength and stability of the crane.‘Outriggers max ext’ means the state that the inner box is extended to the position •where the 2nd mark is visible.‘Outriggers not max ext’ means the state that the inner box is extended to the position •where the 2nd mark is invisible.When each of 4 outriggers has been set to different extension,operate the crane by •using the worst extended capacity.When each of boom sections being extended is exceeded even slightly,operate it by •application of the capacity for the next boom section.Boom• 1+2+3+4 means that the boom is extended to the position where the 1st mark on the 4th boom-section is visible.Boom• 1+2+3+4+5 means that the boom is extended to the position where the 2nd
mark on the 4th boom-section is visible.Operate the crane using the rated load capacity data under the boom extension of: •1+2+3+4 when the mark on the 3rd boom-section goes beyond the 2nd boom section, regardless of the displacement, 1+2+3+4+5 when the 1st mark on the side plate of the 4th boom-section goes beyond the 3rd boom-section, regardless of the displacement, 1+2+3+4+5+6 when the 2nd mark on the side plate of the 4th boom-section goes beyond the 3rd boom-section, regardless of the displacement.
MAJOR SPECIFICATIONS
Boom
Boom
Boom
Boom Boom
Boom
Boom
Boom
Boom
Boom Boom Boom
Boom
Boom
Boom
Boom Boom Boom Boom or :
Boom is extended to the mark on
the side plate of Boom .3
31+2+3
Boom or :
Boom is extended to where 2nd mark on the side plate of Boom is visible.3
41+2+3+4
Boom or :
Boom is extended to where 3rd mark on the side plate of Boom is visible.3
51+2+3+4+5
Boom
Boom BoomBoom
Boom
Boom
Boom
Boom BoomBoom
Boom
Boom
Boom
Boom BoomBoom
Boom
Boom
Boom or :
Boom , , , and are all extended to their extremes.65432
61+2+3+4+5+6
Boom or :
Boom is extended. 2
21+2
Boom :All booms are completely retracted.
11
1
1
1
1
2
3
2
2
2
2
4
4
4
4
4
4
5
5
5
5
5
5
6
6
6
6
6
6
3
3
3
3
1 2 3
● Operating condition of booms;
2-6
MAJOR SPECIFICATIONS
(Speed indicated in the table below is at oil temperature range of 45~55°C, operating with no-load, and at rated pump discharge.)
Major specificationsMajor specifications
Direct pushing by double acting hydraulic cylinder(directly connected to hydraulic automatic lockingdevice)
Crane capacity (Net rated load)
Hydraulicpump
3.0t×3.4m(With outriggers, extended fully)
Maximum lift above ground (Hook)
Horizontal
16.0m
Boom to be extended to:
Vertical
3.93m~6.33m~8.72m~11.05m~13.38m~15.71m
Maximum working radius 15.52m
Hoisting speed of hook17m/min(At 4th layer on the drum, with 4-part line hooking)
Extending speed of boom 11.78m/35sec
Raising speed of boom 0°~80°/18sec
Slewing speed
Speed of winding-up (Rope speed)
2.5r.p.m.
Slewing range
68m/min (At 4th layer on the drum)
360° (Continuous)
Hoisting rope Construction IWRC6×WS (26) class B [Breaking load: 42.4kN (4320 kgf)]
Diameter × length 8mm×91.5m
Outrigger
Direct pushing by double acting hydraulic cylinder(directly connected to hydraulic automatic lockingdevice)
Rated pressureCrane:20.6MPa(210kgf/cm )2
Crawl:21.6MPa(220kgf/cm )2
Rated discharge Approx. 60ℓ/min
Rated rotation Approx. 2100rpm
Hydraulic oil tank capacity 70 liters
URW506C (6-section boom)W506C (6-section boom)1
3-1
MAJOR SPECIFICATIONS
Equipment and constructionEquipment and construction
Boom telescoping
Boom: 6-section, Hexagonal box beam
Telescoped by direct pushing of double acting hydraulic cylindertogether with by wire rope(With hydraulic automatic locking device)(2nd section: sequential actuation, 3rd, 4th, 5th & 6th sections: simul-taneous actuation)
Boom derrickingDirect pushing by hydraulic cylinder(With hydraulic automatic locking device)
Hoisting
Hydraulic motor: Axial plunger type
Reduction gears: Spur-gear reduction
Brake: Automatic mechanical brake
Hydraulic motor: Axial plunger type
Reduction gears: Worm-gear+Spur-gear reduction(Supported by ball bearings)
Brake: Worm self-lock
Hydraulic pump Variable delivery piston pump
3.0 t Number of slinging rope: 4
Safety valve for hydraulic circuit
Slewing
Safety device
Hooking capacity
Weight Approx. 4880kg
Level
Checker for outrigger rotary set pin insertion
Crane/outrigger interlocking device
Interlock for crane-crawl operation
Retaining mechanism to prevent wire rope from disengagement
Alarm buzzer
Load indicator (With angle meter)
Automatic stop for leaving minimum wire rope
Slewing automatic lock
Overwinding alarm
Automatic stop for overwinding
Hydraulic automatic lock
3-2
MAJOR SPECIFICATIONS
Crawling deviceCrawling device
Crawling Endless rubber crawler
45.1kPa (0.46kgf/cm )2
Crawling speed
Crawler 300×52.5×88
Length of ground contact 1750mm
Rated output18.0kW/2100r.p.m (24.5PS/2100r.p.m)
Forward/Backward: 0~3km/h
Crawling Independently driven by hydraulic power
23°
Pressure of ground contact
Parking brake Disc brake with hydraulic motor built-in
Fuel tank Capacity: 40 liters
Engine
Hill-climbing ability
Starting engine Electric starter
3-3
2-4
MAJOR SPECIFICATIONS
1+2+3+4+5+6
1+2+3+4+5
1+2+3+4
1+2+3
1+21WORKING RADIUS(m)
WORKING RADIUS(m)
3.03.03.0
WORKING RADIUS(m)
WORKING RADIUS(m)
WORKING RADIUS(m)
2.0 2.5
3.0
3.0 3.52.35
4.0
2.171.951.5
1.671.12
4.5 5.0 5.69
2.7 3.0
1.450.9
1.30.72
1.070.47
10.071.041.03
3.5
0.930.82
0.840.64
0.730.47
0.620.31
0.520.22
0.470.13
4.0
0.380.09
2.242.24
2.09
OUTRIGGERSMAX EXTOUTRIGGERSNOT MAX EXT
OUTRIGGERSMAX EXTOUTRIGGERSNOT MAX EXT
OUTRIGGERSMAX EXTOUTRIGGERSNOT MAX EXT
OUTRIGGERSMAX EXTOUTRIGGERS
URW376C1A
NOT MAX EXT
OUTRIGGERSMAX EXTOUTRIGGERSNOT MAX EXT
2.06
4.5 5.01.651.57
1.45.5 6.0 7.0 7.88
4.0 4.5 5.0 6.0 7.0 8.0 9.0
4.5 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.26
4.9 5.5 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0
1.221.221.02
1.070.83
0.950.65
0.840.51
0.690.3
0.590.19
0.750.75
0.620.62
0.480.4
0.390.25
0.230.01
0.240.06
0.270.09
0.30.13
0.340.18
0.10.01
0.110.02
0.130.03
0.140.05
0.160.08
0.180.11
0.20.17
0.220.22
0.250.25
0.270.27
0.30.3
14.45
Net rated loads chart
NET RATEDLOAD(t)
NET RATEDLOAD(t)
NET RATEDLOAD(t)
NET RATEDLOAD(t)
NET RATEDLOAD(t)
BOOM SECTION
BOOM SECTION
BOOM SECTION
BOOM SECTION
BOOM SECTION
Chart of net rated load
MAJOR SPECIFICATIONS
• The net rated load is performance when the crane is placed level and is based onactual working radius including boom deflection under loaded. The net rated load isalso based on strength and stability of the crane.
• ‘Outriggers extended to maximum’ means the state that the inner box is extendedto the position where the 2nd ● mark is visible.
• ‘Outriggers extended to halfway’ means the state that the inner box is extended tothe position where the 1st ● mark is visible.
• ‘Outriggers extended to minimum’ means the state that the inner box is extended tothe position where the 1st ● mark is invisible.
• When each of 4 outriggers has been set to different extension, operate the craneby using the worst extended capacity.
• When each of boom sections being extended is exceeded even slightly, operate itby application of the capacity for the next boom section.
• Boom means that the boom is extended to the position where the 1st
mark on the 4th boom-section is visible.
• Boom means that the boom is extended to the position where the
2nd mark on the 4th boom-section is visible. • Operate the crane using the rated load capacity data under the boom extension
of: when the mark on the 3rd boom-section goes beyond the 2nd
boom section, regardless of the displacement, when the 1st mark
on the side plate of the 4th boom-section goes beyond the 3rd boom-section,
regardless of the displacement, when the 2nd mark on the
side plate of the 4th boom-section goes beyond the 3rd boom-section, regard lessof the displacement.
1 + 2 + 3 + 4 + 5 + 6
1 + 2 + 3 + 4 + 5
1 + 2 + 3 + 4
1 + 2 + 3 + 4 + 5
1 + 2 + 3 + 4
Points to notice, Rated loadPoints to notice, Rated load
3-5
MAJOR SPECIFICATIONS
Boom : or
Boom sections are extended to a position where 1st mark on the boom section (4) is visible.
41+2+3+4
Boom
Boom : or
Boom section(2) only is extended.
1+2
Boom :
All boom sections are retracted.
1
● How boom-sections aHow boom-sections are extendede extended
Boom : or
Boom sections(2), (3), (4), (5), and (6) are fully extended.
6
4
Boom 4
Boom 4
Boom 4
Boom 4
Boom 4
Boom 3
Boom 3
1+2+3+4+5+6
Boom : or
Boom sections(2) and (3) extended to
a position where the mark on theboom section (3) is visible.
3
2
1+2+3
Boom : or
Boom sections are extended to a position where 2rd mark on the boom section(4) is visible.
51+2+3+4+5
3-6
Boom 5
Boom 5
Boom 5
Boom 5
Boom 5
Boom 5
Boom 6
Boom 6
Boom 6
Boom 6
Boom 6
Boom 6
1Boom
1Boom
2Boom
2Boom
Boom 31Boom 2Boom
Boom 3
Boom 3
Boom 3
1Boom
1Boom
1Boom
2Boom
2Boom
2Boom
4 - 1
HOW TO EXTEND OUTRIGGERS
Traveling Crane
Extract the pins to rotate outriggers, then insert the pins.
Outrigger extension detector
Detector for ground contact of outrigger
Extension
Touching ground
Boom storage detector
5. Unwind the hook until it is off the weight for over-winding alarm, then raise the boom. Crane can now be operated when the storage lamps have gone out.
1. Throw the interlock of crane・traveling lever to crane side.2. Rotate the outriggers and insert the set pins securely to light up the extension lamp. Outriggers cannot be operated unless all 4 pieces of set pin have been inserted.3. As a general rule, extend the lateral members of outrigger to their full extents.4. Touch the vertical members of outrigger to the ground and raise the crawler by approximately 50mm to
4.OUTRIGGER OPERATION
4 - 2
HOW TO STORE OUTRIGGERS
Extract the pins to rotate outriggers, then insert the pins.
Outrigger extension detectorDetector for ground contact of outrigger
Boom storage detector
1. Store the hook and lower the boom until the storage
3. Retract the lateral members of outrigger.
4. Extract the pins to rotate the outriggers then insert the pins.
5. Throw the interlock of crane・traveling lever to traveling side.
2. Retract vertical members of outrigger to make outriggers horizontal. Check that all 4 lamps indicating the outriggers touched
Storage
Storage
Traveling Crane
5 - 1
HOW TO STORE OUTRIGGERS WHEN FAILED STORAGE BY NORMAL OPERATION
1 2
3
7
5
4
8
6
1. Remove the label stuck cover located in the arrow direction.
2. Return the boom to the position where it is to be stored.3. Turn the retraction button on the valve for extension/retraction by 90゜with the button depressed to secure it. 4. Depress, with a screwdriver, button on the solenoid valve for which is intended to be actuated located on the outrigger valve for vertical/lateral members.
Outrigger to be actuated Operation
Outrigger① Vertical Depressing 1 to operate lever
Horizontal Depressing 2 to operate lever
Outrigger② Vertical Depressing 5 to operate lever
Horizontal Depressing 6 to operate lever
Outrigger③ Vertical Depressing 7 to operate lever
Horizontal Depressing 8 to operate lever
Outrigger④ Vertical Depressing 3 to operate lever
Horizontal Depressing 4 to operate lever
Vertical
Vertical
Vertical
Vertical
Horizontal
Horizontal
Horizontal
Horizontal①
④
③
②
Ope
rato
r’s s
eat s
ide
Outrigger valve for vertical/Horizontal members
66
8
4
2
5
7
3
1Depress retraction button to turn it to secure it.
Throw outrigger lever to your side.
5. Throw the outrigger lever to your side with the solenoid valve button depressed.
Sticker showing instructions on how to operate outriggers when in an emergency is stuck here.
Push the button at the center of solenoid valve with a screwdriver.
5.HOW TO STORE OUTRIGGERS WHEN IN AN EMERGENCY
5 - 2
HOW TO EXTEND OUTRIGGERS WHEN FAILED EXTENSION BY NORMAL OPERATION
1 2
3
7
5
4
8
6
1. Remove the label stuck cover located in the arrow direction.
2. Return the boom to the position where it is to be stored.3. Turn the retraction button on the valve for extension/retraction by 90゜with the button depressed to secure it. 4. Depress, with a screwdriver, button on the solenoid valve for which is intended to be actuated located on the outrigger valve for vertical/Horizontal members.
Outrigger to be actuated Operation
Outrigger① Vertical Depressing 1 to operate lever
Horizontal Depressing 2 to operate lever
Outrigger② Vertical Depressing 5 to operate lever
Horizontal Depressing 6 to operate lever
Outrigger③ Vertical Depressing 7 to operate lever
Horizontal Depressing 8 to operate lever
Outrigger④ Vertical Depressing 3 to operate lever
Horizontal Depressing 4 to operate lever
Vertical
Vertical
Vertical
Vertical
Horizontal
Horizontal
Horizontal
Horizontal①
④
③
②
Ope
rato
r’s s
eat s
ide
Outrigger valve for vertical/Horizontal members
66
8
4
2
5
7
3
1
Throw outrigger lever to your side.
5. Throw the outrigger lever to your side with the solenoid valve button depressed.
Sticker showing instructions on how to operate outriggers when in an emergency is stuck here.
Push the button at the center of solenoid valve with a screwdriver.
Remove cover on arrow mark side and depress extension button to turn it to secure it.
6. MODE INDICATOR LAMP (Control Box)
1 Mode indicator lamp (Control box)The “mode indicator lamp” is mounted in the control box indicating conditions of crane opera-tion and troubles in detail.
When the “mode indicator lamp” lights, thecrane system is working normally.
When the ”mode indicator lamp” blinks, thecrane system is in a trouble or prohibitedoperation is being carried out.
Mode indicator lamp
◆1.Mode indication when crane is in normal operationIt indicates each operation mode and condition of the crane when it is normal.Description of mode indication when it is in normal is as follows:
Mode indication when crane is in normal condition (lighting indication)
Mode Mode description
Radiocontrol
operationmode
Manualoperation
modePriority
Current control is on normal crane operation mode.Operation is possible either by manual control or byradio remote control.
◯ × 9
Current control is on normal crane operation mode.Operation can only be carried out manually but notthrough radio remote control device.
× ◯ 9
Current control is on traveling mode.No operation other than traveling is possible either bymanual control or by radio remote control.
× × 1
Current control is on low temperature operation mode.Operation can be carried either by manual control orby radio remote control device.
(◯) (◯) 8
Current operation is in outrigger radio control mode.Extension and retraction of outriggers can only be pos-sible by manual control when in manual control modeor by radio remote control when in radio remote con-trol mode.Operation other than the above is impossible either bymanual or by radio remote control.
◯ ×
5
× ◯
6-1
MODE INDICATOR LAMP (Control Box)
Mode Mode description
Radiocontrol
operationmode
Manualoperation
modePriority
Current control is on low temperature operation mode.Operation can be carried by manual control but notthrough radio remote control.
× ◯ 8
Hook hits against weight for over-winding alarm(over-wound condition).
― ― 7
During operation of storing hook. ― ― 6
Automatic stop for over-winding reset switch is beingcontrolled
― ― 4
Boom store or Automatic stop for overloadingis actuated .
― ― 2
Automatic stop for overloading alarmis actuated . ― ― 3
●RemarksSince priority is assigned for each mode description, it is to be indicated in the order of higherpriority.
If the [.] (dot) is indicated on the bottom right of “mode indicator lamp”, it means the “radiocontrol OFF” mode.Crane cannot be operated through radio control transmitter.
When operated on outrigger radio control mode, crane operation other than extension/retractionof outriggers cannot be carried out.
When the shock-less function has been cancelled, the letter on the left indicated in the modeindicator changes to [ ].
6-2
◆2.Mode indication when crane is mistakenly operatedWhen prohibited operation or combination of operation which may invites dangerous situationshas been carried out, the “mode indicator lamp” will blink corresponding numbers (operationerror indication).When the operation error is indicated, the ”mode indicator lamp” blinks showing correspondingnumbers accordingly.Confirm and follow the mode description concerned on the table illustrated below:
●RemarksThe operation error indication is not to indicate that the crane system is in trouble.The error indication is to be reset when stopping the operation concerned.
Mode description when crane is mistakenly operated (Blinking indication)
Mode Description of wrong operation Measures to be taken
Radio remote control operation iscarried out in manual controlmode.
●Mode indicator lamp located infront of crane control levers willnot be lit when in manual controlmode.
Radio remote control cannot be carried out inmanual control mode.When operating with radio remote controller,turn the selector switch located on the top ofcover to radio remote control mode.
●Mode indicator lamp located in front of cranecontrol levers will be lit when in radio remotecontrol mode.
Crane is being operated when inoutrigger mode.
Crane cannot be operated when in outriggercontrol mode.When operating crane, turn the mode selectorswitch to “crane” to select crane mode.
Crane and outriggers are operatedsimultaneously.
When crane and outriggers are operated simul-taneously, both operating functions are stoppedautomatically to avoid a risk.Stop the simultaneous operation once and carryout either one of operation.
MODE INDICATOR LAMP (Control Box)
“Low temperature operationmode” is being switched duringcrane operation.
In order to avoid a risk, “low temperature opera-tion mode” cannot be switched during craneoperation.Stop crane operation once to switch it to “lowtemperature operation mode”.For switching “low temperature operation
mode”, refer to section 6u.“How to correctwhen operation becomes unstable due to lowtemperature” (on page 6-22).
6-3
MODE INDICATOR LAMP (Control Box)
Mode Description of wrong operation Measures to be taken
Either one of operation such as“boom Up”, ”hook Up”, or”boom Extend” (when operatedon para-hook mode) is beingcarried out while hook has hitagainst weight for over-windingalarm.
Detach hook from weight for over-windingalarm.●When raising boom through radio controldevice with hook hit against the weight forover-winding alarm, boom is to be “Up”while hook is winding “Down” as this opera-tion allows hook to be released. Do not lift up a cargo while this is beingindicated.
Emergency stop switch on theremote control device is pressed.
Release the Emergency stop switch when oper-ating crane.
Operation of winding down hookis carried out while the sensordetecting minimum wire rope isbeing activated.
Stop winding down hook and wind it up so thatthe sensor detecting minimum wire rope willnot be activated.
In the boom/outrigger interlockingdevice, outrigger operation isbeing carried out without boombeing stored.
Stop outrigger operation without boom beingstored.Operate outriggers after boom has been stored.
6-4
6..3 Mode indication of each operation
OperationMode
indicationOperation
Fastest speedmode
Raising boom 38 Storing hook
Medium speedmode
Lowering boom 39 Mode select
Slow speedmode
Hoisting-up 40 Horn
2 interlockingoperation
Hoisting-down 000~0.0Speed: 0~100%
3 interlockingoperation
Retracting boom
4 interlockingoperation
Extending boom
5 interlockingoperation
Slewing C.W.
6 interlockingoperation
Slewing C.C.W
7 interlockingoperation
When wind-up switch of transmitter and radio control selector switch are pushed at the same time,it is change to the operation display.It returns to the state display when wind-up switch of transmitter and radio control selector switch are pushed at the same time again.
35
26 36
21
22
23
25
Modeindication
Modeindication
28
30
31
24
27
20
37
32
33
34
Operation
Operating one of boom lowering,wind-up, boom extending or slewingwhile the boom is at stowedposition and fully lowered.
Operate boom raising to release the automatic stop system then operate others.
6.4 Error indication
When an error is detected, the mode indicator goes off or blinks and the voice message “Service remote control” sounds.
Modeindication
TroubleAvailableoperation
None System error
42
43
44
45
46No operationis possible.
Readjust zero point.
47Operation is
possible. Turn power ON again.
48 In case where it happens again,
49replace control box.
50
51Check transmitter and receiver.
52After turning power ON again,
53
Check connection of cable to receiver.
After turning power ON again,
Turn power ON again.
56System error
No operationis possible.
Turn power ON again.
57
58 Unloading error Replace control box.
60Spool neutral error Derrick After turning power ON again,
61Hoisting
62Telescoping
63Slewing
Check that manual lever has not been caught.
64Outrigger
65 Acceleration
(6-5)
wait until mode on "8.8" indicator goes off tooperate radio controller.
“Hook storing/releasing switch”on crane side hasbeen controlled before indicator "8.8" goes off.
In case where it happens again,replace control box.
Measures
No operationis possible.
Failure in radio controller receiver Transmitter leverhas been pulled before indication on indicator“8.8” goes off.Transmitter switch has be depressed beforeindication on indicator "8.8" goes off.Signal fromreceiver failed to be received
Replace fuse in control box.Turn power ON again.In case where it happens again,replace control box.
No operationis possible.
Radiocontrollercannot beoperated.
Replace Digital Amplipier.
wait until mode on "8.8" indicator goes off tooperate radio controller.
17Zero-Point Adjust Digital Amplipier.
Check all load cell wirings on outrigger and DigitalAmplipier wirings.
Turnover prevention error
55“Radio controller selector switch”in control box hasbeen controlled before indicator "8.8" goes off.
wait until “8.8”on mode indicator goes off tooperate radio controller.
If lever has no problem, replace proportionalsolenoid valve.
Radio controller cannot be operated.
Manual lever (spool) failsto be returned to neutralwithin 2 seconds afterpower has been turnedON.
In case where it happens again,replace control box.
No operationis possible.
Operation ispossible.
When an error is detected, the mode indicator goes off or blinks and the voice message “Service remote control” sounds.
Modeindication
TroubleAvailableoperation
66Outrigger selection switch Front right RET/EXT Damaged switch exchange
67Front left RET/EXT It is possible to operate it excluding the damaged switch.
68Rear right RET/EXT
69Rear left ET/EXT
70 DerrickNo operationis possible.
Check if oil pressure is applied.
71 HoistingCheck that manual lever has not been caught.
72 Telescoping If lever has no problem,
73 Slewing
replace proportional solenoid valve.
74 High outrigger
75 AccelerationOperation is
possible.
76 Derrick Replace broken transmitter switch.
77 Hoisting
78 Telescoping
79 Slewing
80 DerrickNo operationis possible.
81 Hoisting
82 Telescoping If there is no problem,
83 Slewing
replace differential transformer.
84 Outrigger
85 Acceleration
98 The voltage of the battery is nine volts or less. Battery exchange
99
(6-6)
Spool deviation error.Manual lever (spool) failsto be controlled asintended while radiocontroller is operated.
Transmitter switch isbroken.
Replace batteries of transmitter to turn it ONagain.Radio controller is wrong unless power indicator lamp on transmitter lights or blinks quickly.
Feed-back signal wire isbroken.Differential transformer isnot functioning normally.
Transmitter batteries are dead.When batteries haverun out, voice message requesting replacement ofbatteries is to be issued.
98 blinking when the engine starts is notabnormal.
Check connector of differential transformer forconnection.
Operation ispossible.
No operationis possible.
Radiocontrollercannot beoperated.
Measures
7 - 1
7.LIST OF VOICE MESSAGES
When switch is not depressed.Emergency stop is released
Remote control ready. When power to the crane is supplied with key switch turn on.When it is turned to normal mode by depression of radio control selector switch.When emergency stop is released by depression of emergency stop switch.
When switch is depressed.Emergency stop is functioning.
When battery in the transmitter has run down.
Stop winch up.
Scure lifting hook.
When "raising boom","winding-up hook",or "extending boom" operation is carried out on over-wound condition.When hook storing switch is controlled.
Chenge control mode. When it has been selected to outrigger radio control mode.When outrigger radio control mode has been released.When it has been selected to low temperature operation mode.When low temperature operation mode has been released.
Service remote control. When mode indicator is blinking any of figures, [42~58] and [60~87].
Low transmitter battery.
Switches in detail
Voice switch
Outrigger monitor
Outrigger operation switchOperation mode switch
Outrigger selector switch
8.4 Switching of mode indicator (State ⇔ Operation)
State indication
(normal case)
8.5 Resetting of interlocking balance control
Retaining function of
dividing operation ON
(normal case) Depress the switch for storing hook with the switch
for boom-down turned ON.
Mode indicator shows [oF].
Voice message, “change control mode”is issued
Depress both winding-up and mode selector switchesat the same time or turn OFF power to crane and turnit ON again.
Depress both winding-up and mode selector switchsimultaneously.
Depress the switch for storing hook with the switchfor boom-up turned ON.
Retaining function of
dividing operation OFF
+
Radio control operation
Operation indication
( 8 - 4 )
8.6 Switching of "shockless"function (Carry it out when it is not over-wound)
"shockless" No"shockless"
(normal case) “[-]” appears on the left side of mode indicator.
8.7 Switching of low-temperature operation mode
Low-temperature Low-temperature
operation mode operation mode ONOFF(normal case)
Mode indicator shows [06].
Voice message, “change control mode”is issued.
Depress the switch for storing hook with the switch forslewing C.W.turned ON.
Depress the switch for storing hook with the switch forslewing C.C.W.turned ON.
Turn ON winding-down switch with para-hook switchdepressed.
Turn ON winding-up switch with para-hook switchdepressed.
( 8 - 5 )
9 - 1
◆ Turn "ON" the voice switch and start engine to check it.
Receiver cable
Interference (Lights)
Receiver
Check lamps
Power (Blinks)Error (Blinks)Receiving (Blinks)
9.RADIO CONTROL CANNOT BE OPERATED (In case where it is due to electrical failure)
Power indicator lamp lights.
Batteries have run down.
Radio control selector switch has been depressed.「.」(dot) is shown at bottom-right side of mode
Depress radio control selector switch again.
Check receiver cable for connection.
"54" is shown on mode indicator.
"51" is shown on mode indicator. Repair transmitter and receiver.
Moisture is stuck on inspection window of receiver.
Repair receiver.
●"99" is blinking on mode indicator.●Voice message requesting battery replacement is heard.●Power indicator lamp blinks when batteries come close to be dead.
Replace batteries.Battery life is approximately 20 hours when new 4 pieces of alkaline battery have been replaced.
Repair transmitter and receiver.
Power indicator lamp
YES No
When receiving noise from outside, it lights in red.
When receiving signal from transmitter, it blinks in green.
When receiver is in trouble or batteries are running down, it blinks in red.
When key switch turn on, it blinks in green.
Voice switch
10 - 1
Procedure 1
10.EMERGENCY MEASURES TO BE TAKEN WHEN CRANE CANNOT BE OPERATED AT ALL
When outriggers are raised before storing boom and hook, overturn prevention device is actuated so that crane cannot be operated.Store the crane while the reset switch of safety device is pushed up.If it is key switch type, operate it with the key turned to release side.
Operate it while the safety device reset switch is being pushed up.
Procedure 3
Procedure 2
Store the crane with the control box reset switch pushed up.
(In case where the crane cannot be operated even if the safety device reset switch is controlled.)
(In case where the crane cannot be operated even if control box reset switch is operated.)Unfasten the hexagon nut on the control valve to screw in the set bolt until it stops, then store the crane by using control lever.
Hexagon nutSet bolt
ML auto stop switch
Safety device reset switch
Control box reset switch
Manifold blockP1DR1PB2
PB
P1
A1 B1
A A
T
C
B
B1 B2A2
P2
P2P1
B
DR3
Dr Dr
DR4 P2 GP
PT
T2
T0
T1
DR DR2
LP
PPPP
RP
Reduction gear Reduction gear
Control valve for carrier
Engine
Return filter
Crawlingmotor (left) Crawlingmotor (right)
Pump
Forward
Backward
Forward
Backward
Hydraulic Circuit Diagram (Carrier)
Control valve for crane
High pressure line Tank line
It connects with drain pipe ofSlewing motor and hoisting motor.
11-1
URW370CDE S/N 37W0062~Manufacturing 2006/8~
URW506CDE S/N 50W0005~Manufacturing 2006/8~
Control valve for carrierFrom the power unit
From the pump P2
From Manifold block P2
To right B
To left A
To T1
Control valve for carrier
From the power unit P1
From manifold block P2
From the pow
er unit P2
From the pum
p P2
To manifold bloc
k PB
To manifold block T1
To motor (left side) A
To motor (left side) B
To motor (right side) A
To motor (right side) B
Control valve for carrier
Right
Left
Right Left
Ground
Sky
Control valve for carrier
The upper surface of manifold block
The upper surface of Manifold block
Side of manifold block
Ground
Sky
Ground
Sky
The front side of Manifold block
The front side of manifold block
Ground
Sky
The back side of Manifold block
Ground
Sky
Ground
Sky
Pump
Ground
Sky
Crawling motor
Ground
Sky
Crawling motor
Right
Ground
Sky
Crawling motor
Left
Gauge Port
Control valve (for crane)
Line filter
Check valve
Derrick
Hoist
Telescope
Slewing
Outrigger
Accelerator
Telescope
Load metor
C.W
C.C.W
UpDown
Counter balance valve
Counter balance valve
Hydraulic motor(Hoist)
Hydraulic motor(Slewing)
Outrigger side
Hydraulic Circuit
Pilot pressureGauge Port
Solenoid valvefor storing hook
Solenoid valvefor unloading Main relief valve
Pressure reducing valveSet bolt
Emergency screw
High pressure line Tank line Pilot pressure line Feed-back line
Pressure regulator valve
RaiseLower
UpDown
Ret.Ext.
C.WC.C.W
Ext.
Back pressure valve
Tank
Hydraulic Circuit Diagram (control valve for crane)
pump
12-1
Rear of crane(Column derrick pin side)
1
4
1
5
6
7
5
3
1
6
4
2
4
2
HOIST(UP)
HOIST(DRAIN)
HOIST(DOWN)
DERRICK(LOWERING)
DERRICK(RAISING)
3
TELESCOPING(RETRACTION)
TELESCOPING(EXTENSION)7
A
Outer joint
Fill up greesewhen mounting
Fill up greesewhen mounting
Inner joint
in detail,STK seal fittingSection A
Square ring Seal ring
6
3
7
5
2
Front of crane(Column foot pin side)
13.SWIVEL JOINT Construction of swivel joint and where hoses are attached
13-1
⑥ Derrick(raising)
③ Hoist(up)② Hoist(down)
SWIVEL JOINT PIPING
13-2
① Hoist(drain)
④ Derrick(lowering) ⑤ Telescoping (retraction)
⑦ Telescoping (extension)
⑦ Telescoping (Extension)
SWIVEL JOINT PIPING
13-3
① Hoist(Drain)② Hoist(Down)
③ Hoist(up)
⑤ Telescoping (Retraction)④ Derrick
(Lowering)
⑥ Derrick (raising)
② Hoist(down)
① Hoist(drain)
13-4
SWIVEL JOINT PIPING
③ Hoist(up)
⑤ Telescoping (retraction)
④ Derrick (lowering)
⑥ Derrick (raising)
⑦ Telescoping (Extension)
⑤ Telescoping (retraction)
② Hoist(down)
③ Hoist(up)
13-5
SWIVEL JOINT PIPING
① HOIST(DRAIN)
④ Derrick (lowering)
⑥ Derrick (raising)
⑦ Telescoping (Extension)
⑦ Telescoping (Extension)
13-6
SWIVEL JOINT PIPING
① Hoist(drain)
② Hoist(down)
③ Hoist(up)
④ Derrick (lowering)
⑥ Derrick (raising)
⑤ Telescoping (retraction)
1
6 4
5
10
8 9
11
7
2 3
Bolt for columnWhen assembling,apply ”LOCTITE #962T”Tighten the bolts in the numericalorder as illustrated in the figure.
Torque URW376CDE → 245N-m(25kgf-m)URW506CDE → 333N-m(34kgf-m)
14 COLUMN14.1 Tightening torque for bolts fastening column and tightening order
Bolt for derrick pinTorque 78N-m(8kgf-m)
14-1
③ Hoist(up)
14-2
① Hoist(drain) ② Hoist(down)
④ Derrick (lowering)
⑤ Telescoping (retraction)
⑥ Derrick (raising)
⑦ Telescoping (extension)
Limt switch (Electric wiring ass’y)750306029 OMRON D4C1203
WIRE ROPE RETAINIG MECHANISM
14-3
Inside width of drum154.8
15. HOIST WINCH15. 1 Construction of Hoist Winch and brake shoe adjusting procedure
15-1
Brake Shoe Ajusting procedures1.Tighten the castle nut lightly with a spanner.2.After tighning,loosen the castle nut for approx.1/6 turnand within this range align the castle nut with the hole in thegear shaft;and fix it with the split pin.3.Replace the break shoe every 3years.
After assembling,apply grease toengaging toothsurfaces of the gear.
Rotate the gear shaft tocheck that the pawl makesa smooth movement.
Gear4
Drum
Apply"LOCTITE #242"
Breather
Gear2
Ratchet Wheel
Brake Shoe
SplitPin
CastleNut
PlainWasher
Disk
Bearing
Gear1
Casing
Motor
Pay attentionto its direction.
15-2
15. 2 Caution to be taken when reassembling hoist winch
Tightening order of bolts for mounting reduction gearTighten the hexagon socket head screws in diagonal orderafter the set bolt has been fastened first to align each screw hole.
Dimensions on both sidesshould beequally arrangedwhen fitting the ratchet wheel.
Set bolt position
Check that the spring is caughtin the drill hole on the pawl.
Ratchet Wheel
1 2 2
4
3
2
15. 3 Cause of Troubles and Measures to be Taken(1) Hoist winch
Problems Possible cause Measures to be taken
Pressure does not rise. • Pump is faulty.(Pressure does not rise at idling speed.)(Total pressure required for operation isinsufficient.)
• Replace.
• Relief set of control valve is faulty.(Pressure rises but not enough.)
• Adjust or replace.
• O-ring and other parts of relief valve ofcontrol valve are faulty.(Adjusting bolt of relief valve is tight-ened but unable to control pressure.)
• Replace parts or replace reliefass’y with new one.
• Hoist motor is faulty.(Quantity of drain is larger than the spec-ified.)
• Replace.
Pressure rises but hoistingup impossible.
• Drum or internal mechanism of reductiongear is faulty.
• Overhaul reduction gear.• Inspect the drum
Pressure rises but loweringis impossible.
•Brake shoe is over-tightened..
•Drum or reduction gear is defective.
• Adjust tightening of brakeshoe.
• Overhaul reduction gear.• Check drum.
Unable to maintain suspend-ed load.
• Brake shoe is faulty.• Pawl is faulty.
• Replace brake shoe.• Replace pawl.
When lowering, huntingoccurs.
• Brake shoe is faulty.
• Over-tightening of brake shoe.• Internal mechanism of reduction gear is
faulty.
• Inspect brake shoe and checkquantity of oil.
• Adjust tightening of nut.• Disassemble reduction gear.
When hoisting up, clatteringsound is heard.
• Spring pressing the pawl against slideplate is faulty.
• Bushing the part of fitting pawl is wornout.
•Replace spring.
• Replace bushing.
15-3
W376C → 90 mmW546C →130 mm
Enlarged portionwhere sealing agentis to be applied.
Apply"LOCTITE#242"
Bearing-Thrust ball
Aplly grease
If the gap of more than 2mm is confirmed,check the hook, the thrust bearings,and the nuts and replacea deformed (worn out) component.
Aplly grease
16. HOOK
16-1
NutHook
Spring pins
Entire screw thread
(both sides)
S
Slewing reduction gearmounting bolt(4-M16)
Turntable mounting bolts (19-M20)
Note:1. Tightening torque of bolts (4-M16) mounting slewing reduction gear is 255±29N-m(26±3Kgf-m) Tighten the mounting bolts in diagonal order.2.Position the mark “S”on the inner part of turntable directed toward the truck front when mounting turntable.3.Tightnen the bolts in the numerical order as illustrated inthe figure above.4.Tighten the turntable mounting bolts (19-M20) equally with a torque of 471±39N-m(48±4Kgf-m) Before mounting bolts are tightened,degrease the bolts and the tapped holes to apply "LOCTITE #962T" to the bolts and tighten them with an equal torque.5.The bolts for fastening the turntable(tempered bolts)must be UNIC genuine bolts, on which mark "UNIC12" is inscribed on the head.
Hydraulic motor
"S"Mark(Soft Zone)
17. Turntable Mounting Procedures (1) Turntable mounting procedures 1.Install the slewing reduction gear to the base. 2.Set the turntable on the base to screw-in the bolts for mounting turntable lightly. 3. Insert the thickness gauge(0.1~0.2mm)into the space between the turntable gear and the pinion gear,and press strongly the turntable to the pinion gear.
17-1
3
6
14
1018
2
19
4168
12
5
13
917
157
11
1
TurntableAfter assembling,apply grease toengaging toothsurfaces of the gears.
Warm wheel
Casing
Crown nut
Ball bearing
Filled with grease
Dust seal
Gear shaft
Nut
Bearing housing
Taper roller bearing
Snap ring
Taper roller bearing
Worm shaft
Breather
18.SLEWING REDUCTION GEAR1)Construction
18-1
(2) Construction to be taken when reassembling slewing reduction gear
Apply”ThreeBondApply Grease to
dust seal.
Dust Seal
Fill up with grease here.
Use Lithium soap radical grease
Nut:Apply”LOCTITE #262”before tightening it.
Note:Tighten the nut to the extent thatthe gear shaft can be rotated to eitherDirection with your both hands.
directed upward.wheel with the mark”V”
Assemble the wormBearing housing
Flange boltTightnig torque:
(such as Rizonix grease No.1 or Kyseki)
the inside of#1401”to it.
59N-m (6kgf-m)
18-2
(3) Slewing reduction gear disassembly procedures①Remove a snap ring (H-80) retaining the taper roller bearing which sustains the worm shaft.
②Turn the gear shaft counterclockwise, and pull out the worm shaft from the casing. (Use of special tool for
③Remove 8 pcs. of bolt (M10 X 25ℓ) which fasten the bearing housing and pull out the housing, utilizing 3 pcs.
removing worm shaft is recommended.)
of bolt for 3 through holes in the housing.
18-3
④This figure shows the pulled out housing with gear shaft and worm wheel.
⑤Grip the housing with a vice and pull out the worm wheel with a gear puller.
⑥Pull out the collar which is assembled in the nut.
18-4
18-5
⑦ Pull out the O-ring which is assembled in the nut.
⑧ With a pin spanner, remove the nut which retains the taper roller bearing.
Note: To the threaded part of the nut, “LOCTITE” was applied. Therefore, when loosening, warm up lightly the threaded part with gas flame, and then loosen. When reassembling, be sure to apply “LOCTITE #262” to the threaded part.
Pinping of Hydraulic Motor for Slewing
C.C.WSky
Ground
C.W External pilot port
18-6
External pilot port
C.C.W
Drain port
C.W
Pinping of Hydraulic Motor for Slewing
18-7
Double pilot check valve740197040
Solenoid valve 740170009 to extend Outrigger cylinder, and to withdraw Outrigger cylinder
Solenoid valve 740170008 to select Outrigger(Vertical) and Outrigger(Horizontal)
Pilot check valve 601529000
Outrigger cylinder(Horizontal)
Outrigger cylinder(Vertical)
19
-1
19Hydraulic Circuit Diagram(Outrigger)
Outrigger(Horizontal) (Front, Right)
Outrigger(Horizontal) (Front, Left)
Outrigger(Horizontal) (Rear, Left)
Outrigger(Horizontal) (Rear, Right)
Outrigger(Vertical) (Rear, Right)
Outrigger(Vertical) (Front, Left)
Outrigger(Vertical) (Front, Right)
Outrigger(Vertical) (Rear, Left)
High pressure side Tank side
Stroke:700(URW376C)Stroke:1020(URW546C)
19-2
Horizontally extending cylinder
Vertically extending cylinder
19.HOW OUTRIGGERS ARE EXTENDED
Pilot check valveCD-02RA
Split position of bushing
Split position of bushing
In order to prevent moisture from entering thecylider from the threads, apply liquid gasket,solventless type #1101(fatty acid degeneratedphenolic resin family),supplied by ThreeBondhere (4 places on its circumference).
Apply grease here(IDEMITSU DUFNEET grease,model XCZ-1 or equivalent)
19.OUTRIGGER CYLINDER1)Construction of vertically extending cylinder
19-3
Pilot check valveCP-02F
Construction of horizontally extending cylinder
19-4
Bend this toward the gland aftterthe gland has been fightened.
(1 place)
Split position of bushing
Split position of bushing
Counterbalance valveCB-03ED-W
(Hydraulic driven)
Apply grease here(IDEMITSU DUFNEET grease,model XCZ-1 or equivalent)
In order to prevent moisture from entering thecylider from the threads, apply liquid gasket,solventless type #1101(fatty acid degeneratedphenolic resin family),supplied by ThreeBondhere (4 places on its circumference).
20.DERRICKING CYLINDER
20-1
20.2 Flow of oil,when lowering
Hexagon socket head screw
For grand Bush omission stop
RodApply"LOCTITE"638"here
Pressure oil
The spool opens according to thereduction side pilot pressure
Hexagon socket head screw
For piston turn stop
Piston
Apply"LOCTITE #2701" With"Curing accelerator
#7649"If the addelerater is not used,
do not flow of the agent.After the screw is
tightened,hit with a pinch at 2 places on
its circumference.
Tank
The check valve shuts and theamountof oil that returns to thetank is limited.
(20-2)
Apply"LOCTITE #2701" With"Curing accelerator #7649"If the addelerater is not used,do not flow of the agent.After the screw is tightened,hit with a pinch at 2 places on its circumference.
Counter-balance valve
20.3 Flow of oil,when raising
Piston
RodApply"LOCTITE"638"here
Pressure oil
Tank
Check Valve opens.
Hexagon socket head screwFor piston turn stop
Hexagon socket head screwfor gland-bush turn stop
(20-3)
Counter-Balance ValveCheck Valve opens.Spool opens
Apply"LOCTITE #2701" With"Curing accelerator #7649"If the addelerater is not used,do not flow of the agent.After the screw is tightened,hit with a pinch at 2 places on its circumference.
Apply"LOCTITE #2701" With"Curing accelerator #7649"If the addelerater is not used,do not flow of the agent.After the screw is tightened,hit with a pinch at 2 places on its circumference.
Apply"LOCTITE"638"here
When telescoping cylinder1 extends(URW376C)
Rod
Check valve
Pressure Oil To Tank
Counter-balance valve
Tube/Rod
Stopper
TubeCheck valve1
SpoolPiston1 Piston2
Slide pipe
Check valve2Selector valve ass’y
How to extend the “tele1” sectionThe pressure oil opens the check valve in the counterbalance valve, enters the rod, goes through the slide pipe and reaches the check valve 1 of the selector valve ass’y.The “tele2” section is fully retracted at this time. The tube end opens the check valve 1 of the selector valve ass’y via the spool to lead the pressure oil to the extension side.Simultaneously, the oil at the retraction side of the “tele1” section flows through the rod and returns to the tank to extend the “tele1” section.Since the check valve 2 of the selector valve ass’y is closed,the pressure oil does not flow into the “tele2” section.Since the “tele2” section is fully retracted, the oil does not remain at the retractionside and so the “tele2” section does not operate.
21-1
When telescoping cylinder1 retructs(URW376C)
Rod
Check valve
Tube/Rod Tube
Stopper
Spool
Pilot Pressure
Check Valve1
Spool
Check valve 2
Piston1 Piston2
Slide pipe
Seletor valve ass’y
How to retract the “tele1” sectionThe pressure oil goes through the rod and enters the retraction side of the “tele1” section.The tube end opens the check valve 1 of the selector valve ass’y via the spool and leads the oil at the extension side of the “tele1” section to the counterbalance valve via the slide pipe.Although the check valve in the counterbalance valve is closed at this time, the spool is opened by the pilot pressure supplied from the retraction side. Therefore, the oil at the extension side isreturned to the tank and the “tele1” section is retracted.Although pressure is applied to the retraction side of the “tele2” section at the same time, the check valve 2 of the selector valve ass’y is closed and the passage at the extension side of the “tele2” section is interrupted. So, the oil does not remain at the extension side of the “tele2” section and the “tele2” section does not operate.
Pressure OilTo TankCounter-balance valve
21-2
When telescoping cylinder2 extends(URW376C)
Rod
Check valve
Pressure Oil To TankCounter-balance valve
Tube/Rod
Tube
Stopper
Piston1
Slide pipe
Piston2 Check valve1 Spool
Check valve2 Selector valve ass’y
How to extend the “tele2” sectionThe pressure oil opens the check valve in the counterbalance valve, enters the rod, goes through the slide pipe and reaches the check valve 2 of the selector valve ass’y.Right before the “tele1” section is fully extended, the slide pipe is pushed up by thestopper to open the check valve 2 of the selector valve ass’y. Then, the pressure oil is led to the extension side of the “tele2” section.Simultaneously, the oil at the retraction side of the “tele2” section goes through the rod and returns to the tank. Then, the “tele2” section is extended.At this time, the check valve 1 of the selector valve ass’y is closed and the passage at the extension side of the “tele1” section is interrupted.Since the “tele1” section is fully extended, the oil does not remain at the extension side and so the “tele1” section does not operate.
21-3
6-Section Boom (Dual Cylinder) Operation(URW546C)(1) When Telescoping Cylinder1 extends
How oil flows when tele1 is extendedPressure oil opens the check valve in the counter-balance valve to
enter the cylinder rod of tele1 and flows through the slide pipe to reach
the check valve 1 of selector valve ass’y.
The tele2 has been fully retracted at the time and the bolt opens the
check valve 1 of selector valve ass’y the extension side.
Simultaneously, oil in the retraction side of tele1 flows through the
dual cylinder in the rod to return to the tank.
This allows the tele1 to extend.
Since the check valve 2 of selector valve ass’y
pressure oil will not flows in the tele2.
Also, oil in the retraction side of tele2 will not flows in the tele1 as
the tele2 has been fully retracted so that the tele2 will not be actuated.
And the tele3 also will not be actuated according to the same reasons as in the tele2.
Rod
Check valve
After the set-screw is tightened with LOCTITE #2701 appliedhit with a punch at 2 places on the circumference and leave it as it is for 1 hour.
Spool
BoltTele2
Slide pipe
Seletor valve ass’y
Check valve 2
Tele1
Tele2
Tele3Counter-balancevalve
Check valve 1
PistonApply"LOCTITE#638".
Pressure Oil To TankCounter-balance valve
21-5
How oil flows when tele1 is retractedPressure oil flows through the dual cylinder of cylinder rod of tele1
to enter the retraction side of tele1. At this stage, the bolt opens the check valve 1 of selector valve assvia spool which leads the oil in the extension side to the counter-balance valve by way of slide pipe. Although the check valve in the counter-balance valve is closed at this time, the spool is opened by pilot pressure from the retraction side allowing the oil in the extension side to return to the tank. This allows the tele1 to retract. Although pressure is also applied to the retraction side of tele2 at this stage, the tele2 will not be actuated because the check valve 1 of selector valve ass’y for tele1 is closed and the passage to the extension side of tele2 is shut off so that no oil is to be remained in the extension side of tele2. And the tele3 also will not be actuated according to the same reasons as in the tele2.
counterbalancevalve
Tele2
Tele3
Tele1
PressureOilTo tank
PilotPressure
Counter balance Valve
SpoolCheck valve
Rod
Check valve 1
Spool
BoltTele2
Selector valve ass’y
Check valve 2
Slide pipe
PistonApply"LOCTITE #638".
6-Section Boom (Dual Cylinder) Operation(URW546C)(2) When Telescoping Cylinder1 retracts After the set-screw is tightened
with LOCTITE #2701 appliedhit with a punch at 2 places on the circumference and leave it as it is for 1 hour.
21-6
BoltTele2Selector
valve ass’y
BoltTele3
Selectorvalve ass’y
Check valve 2Slide pipe
Apply "LOCTITE #638".Piston
Rod
To tankPressure Oil
After the set-screw is tightened with LOCTITE #2701hit with a punch at 2 places on the circumference and leave it asit is for 1 hour.
Piston
Slide pipe Check valve 1
Check valve 2
Check valve 1Spool
Tele3
Tele2
Tele1
Counter balancevalve
How oil flows when tele2 is extendedPressure oil opens the check valve in the counter-balance valve to
enter the cylinder rod of tele1 and flows through the slide pipe to reach the check valve 2 of selector valve ass Since the slide pipe of tele1 is pulled by piston immediately before the tele1 is fully extended which in turn opens the check valve 2 of selector valve ass’y to lead the pressure oil to the extension side of tele2. Simultaneously, oil in the retraction side of tele2 flows through the dual cylinder in the cylinder rod of tele2 and through the dual cylinder in the cylinder rod of the tele1 to return to the tank. This allows the tele2 to extend. Since the check valve 1 of selector valve assstage, the passage on extension side for tele1 is shut off. The tele1 will not be actuated because no oil is remained in the retraction side of tele1 as the tele1 is fully extended. In addition, the tele3 will not be actuated because the check valve 2 of selector valve assto extension side of tele3.
6-Section Boom (Dual Cylinder) Operation(URW546C)(3) When Telescoping Cylinder2 extends
Check valve
Rod
21-7
Rod
Rod
Check valveSpool
To tank PressureOil
PilotPressure
Counter balance valve
PistonApply"LOCTITE #638".
Check valve 1
Check valve 1
Check valve 2
Bolt
Tele3
Tele2
Selectorvalve ass’y
Tele3
Slide pipeCheck valve 2
Selector valveass’y
applied,hit with a punch at 2 places on the circumference and leave it asit is for 1 hour.
After the set-screw is tightened with LOCTITE #2701
Piston
Tele2
Tele1
Tele3
How oil flows when tele2 is retracted Pressure oil flows through the dual cylinder of cylinder rod of tele1
to enter the retraction side of tele2. Also, the bolt for tele3 opens the check valve 1 of selector valve assvia spool which leads the oil in the extension side of tele2 to the counter-balance valve by way of the slide pipe of tele2, the check valve 2 of selector valve ass’y for tele1, and the slide pipe of tele1. Although the check valve in the counter-balance valve is closed at this time, the spool is opened by pilot pressure from the retraction side allowing the oil in the extension side to return to the tank. This allows the tele2 to retract. Although pressure is applied to the retraction side of tele1 at the time, the tele1 will not be actuated because the check valve 1 of selector valve ass’y is closed and the passage to the extension side of tele1 is shut off. And the tele3 also will not be actuated according to the same reasons as in the tele1.
6-Section Boom (Dual Cylinder) Operation(URW546C)
21-8
(4) When Telescoping Cylinder2 retracts
Slide pipe
Bolt
Spool
BoltTele3
BoltTele3
Selector valve ass’y
Check valve 1
Check valve 2
Check valve 1Slide pipe Spool
Slide pipe
Piston
Pressure Oil
Check valve
To tank
Rod
Rod
How oil flows when tele3 is extended Pressure oil opens the check valve in the counter-balance valve to enter the cylinder rod of tele1 and flows through the slide pipe to reachthe check valve 2 of selector valve ass’y. Since the slide pipe of tele1 is pulled by piston immediately before the tele1 is fully extended which in turn opens the check valve 2 of selector valve ass’y to lead the pressure oil to the extension side of tele2. Pressure oil entered the extension side of tele2 flows through the slide pipe to reach the check valve 2 of selector valve ass’y Since the slide pipe of tele2 is pulled by piston immediately before the tele2 is fully extended which in turn opens the check valve 2 of selector valve ass’y to lead the pressure oil to the extension side of tele3. Simultaneously, oil in the retraction side of tele3 flows through the dual cylinder in the cylinder rod of tele3 to enter the extension side of tele2, then it flows through the dual cylinder and further through the dual cylinder in the cylinder rod of the tele1 to return to the tank. This allows the tele3 to extend. Since the check valves 1 of selector valve ass’y of tele1 and tele2 are closed at this stage, the passages of extension side for tele1 and tele2 are shut off. Both tele1 and 2 will not be actuated because no oil is remained in the retraction side of tele1 and 2 as the tele1 and 2 are fully extended.
balanceCounter
valve
Rod
Tele3
Tele2
Tele1PistonApply "LOCTITE#638".
After the set-screw is tightened with LOCTITE #2701 applied hit with a punch at 2 places on the circumference and leave it asit is for 1 hour.
Selector valve ass’y
Check valve 2Piston
6-Section Boom (Dual Cylinder) Operation(URW546C)(5) When Telescoping Cylinder3 extends
21-9
Check valve 1Slide pipe
Piston
Bolt
Bolt
Tele3
Check valve 2
Selector Valve
Slide pipeCheck valve 1
Spool
Check valve 2
Selector ValvePiston
PistonRod Apply"LOCTITE #638".
After the set-screw is tightened with LOCTITE #2701applied,hit with a punch at 2 places on the
circumference and leave it asit is for 1 hour.
Rod
Tele3
Tele2
Tele1
How oil flows when tele3 is retractedPressure oil flows through the dual cylinder of cylinder rod of tele1
and through the dual cylinder of tele2 to enter the retraction side of tele3. Also, oil in the extension side of tele3 flows by way of the selector valve of tele2, the slide pipe, the selector valve of tele1, and the slide pipein that order to reach the counter-balance valve. Although the check valve in the counter-balance valve is closed at this time, the spool is opened by pilot pressure from the retraction side allowing the oil to return to the tank. This allows the tele3 to retract. Although pressure is applied to the retraction side of tele1 at the time, the tele1 will not be actuated because the check valve 1 of selector valve ass’y of tele1 is closed and the passage to the extension side of tele1 is shut off. And the tele2 also will not be actuated according to the same reasons as in the tele1.
PressurePilot
To tank PressureOil
SpoolCheck valve
Rod
Counterbalancevalve
Tele3
6-Section Boom (Dual Cylinder) Operation(URW546C)
21-10
(6) When Telescoping Cylinder3 retracts
(7) Adjusting Procedures for Selector Valve with Adjusting Bolt
Adjusting Procedures with Adjusting Bolt
① Retract telescoping cylinders (1) and (2) to their minimum.
② Apply LOCTITE #242 to the threads of the adjusting bolt.
③ Put a board with a thickness of 3mm to the part marked with*.and tighten the adjusting bolt.
④ After adjusting, lock with the lock nut.
21-11
Function and Working of Cushion Seal
21-12
For the purpose of absorbing a piston shock to the stroke end, the 6-section boom have the cushion seal in the part of piston of the telescoping cylinder (2) and (3).
(1) Flow of Pressure Oil When Retracting
1. Cushion mechanism of the telescoping cylinder (3) for 6-section booms.
① In the retracting process, before the piston gets in the plunger, the pressure oil in the chamber A flowsthrough the central part of the piston as shown in the illustration and returns to the tank without beingsqueezed.
PLUNGERPISTONTUBE
② At the same time when the piston gets in the plunger, the chamber A is closed with the cushion seal.
state of being squeezed. Thus the piston shock at the stroke end is absorbed.
As a result, the pressure oil in the chamber A is forced to return only through a drilled hole in the
CHAMBER ACUSHION SEAL
CUSHION SEAL
2. Cushion mechanism of the telescoping cylinder (2) for 6-section boom.
② Cushion mechanism of the telescoping cylinder for 6-section booms is to squeeze the return pressure oil at the position just before the end of extension and absorb the piston shock to the stroke end.
SQUEEZING PART
PLUNGERPISTON CUSHION SEAL
SQUEEZING PARTGLAND ROD
(2) Flow of Pressure Oil When Extending
① When extending, the pressure oil flows into the chamber A as shown in the illustration. In this way, the telescoping cylinder extends.
PLUNGER
CHAMBER ACUSHION SEAL
21-13
Cause of Troubles and Measures to be Taken
(1) 6-section boom
①When retraction of the boom (3) becomes impossible at the position just before full retraction of the booms (4), (5)and (6), inspect the plunger which is assembled in the telescoping cylinder (3).
②When the boom (3) does not change over to the boom (2), and retraction becomes impossible at the position justbefore full retraction, inspect the drilled hole at the position of the plungerof the telescoping cylinder (2).
of the plunger of the telescoping cylinder (2).
(2) Cause of Troubles and Remedy
SPOOL(1)
NUTA
B
C
ADJUSTING BOLT
STICK
21-14
URW546C 6-section boom (Triple cylinders)
Troubles Possible cause Measures to be taken
Retraction is normal, but whenextending, booms (2) and (3)extend at the same time, inother words disorderly.
Some foreign substances are
clogging the part ? of selec-tor valve of telescoping cylin-der (1).
Disassemble selector valve forcleaning, or replace it with anew one.
Extension is normal, but whenretracting, booms (3) (4) and(5) retract at the same time, inother words disorderly.
Some foreign substances are
clogging the part ? of selec-tor valve of telescoping cylin-der (2).
Extension is normal, butwhen retracting, booms (3),(4) and (5) retract at thesame time, in other wordsdisorderly.
Some foreign substances are
clogging the part of selec-tor valve of telescoping cylin-der (2).
Snap ring at the part ? ofselector valve of telescopingcylinder (2) got out of place.
Disassemble selector valve forcleaning, or replace it with anew one.Rearrange snap ring.
Extension is normal, butwhen retracting, booms (2)and (3) retract at the sametime, in other words disor- derly.
Some foreign substances are
clogging the part of selec-tor valve of telescoping cylin-der (1).
Snap ring at the part ? ofselector valve of telescopingcylinder (2) got out of place.
Boom (2) extends but boom(3) does not extend.
Nut at slide pipe of telescop-ing cylinder (1) was loosened.
Disassemble telescopingcylinder (1) and tighten thenut.
Boom (2) and (3) extend,but boom (4) and (5) doesnot extend.
Nut at slide pipe of telescop-ing cylinder (2) loosened.
Disassemble telescopingcylinder (2) and tighten thenut.
After full extension, booms(5) retracts but boom (3)does not retract.
Adjusting bolt pushing thespool of selector valve oftelescoping cylinder (2) wasloosened.Selector valve spool of tele-scoping cylinder (2) was bent.
Adjust the bolt.
Replace selector valve ass'ywith a new one.
Boom (3), (4) and (5)retracts but boom (2) doesnot retract.
Adjusting bolt pushing thespool of selector valve oftelescoping cylinder (1) wasloosened.Selector valve spool of tele-scoping cylinder (1) was bent.
Note: During operation test after disassembling and repairing, the reason why the booms (4), (5)and (6) stop extending halfway is presumed that the left and the right wire ropes forextension were crossed when reassembling.
21-15
22-1
22 URW376C
Boom6
Boom5
Sheave3
Boom4
Boom5
Sheave2
Boom 4 front side section in detailHow sheave2 is mounted
Boom 5 front side section in detailHow sheave3 is mounted
Wire rope with role to extend boom 5
and role to retract boom 4
Wire rope with role to extend boom 6
and role to retract boom 5
6-section boom
22-2
Wire rope of role
to retract boom 6
Sheave5
Wire rope of role
to extend boom 4
Boom4
Sheave4
Wire rope of role to
retract boom 4
Boom3
Boom 3 rear side section in detailHow sheave4 is mounted
Boom 4 rear side section in detailHow sheave5 is mounted
6-section boom
22-3
22-4
22-5
22-6
22-7
22-8
Boom5
Boom1
Boom2
Boom3
Boom4 Boom6
Telescoping cylinder1
Telescoping cylinder2
Telescoping cylinder3
22-9
22 URW546C
22-10
22-11
22-12
22-13
22-14
22-15
Clearance 1mm
Clearance 2mm
When assembling,
apply"LOKTITE #242".
Slide plate
Bolt
22-16
Installation procedures for slide plate and guide
It has similar construction irrespective of number of boom section
23 HOW TO PUNCH
(1) PurposeTroubles injuring the inside surface of cylinder tube due to screws mounting piston being loosened have beenhappened.Therefore, we not only upgraded the screw lock agent “LOCTITE #262” to “#2701” to strengthen adhesion butalso added punching process (partly carried out for derrick cylinder). The section defines how to punch.
(2) Punching procedures
1. Use a punch whose tip is hard and sharp enough. Closeup
2. Hit the punch head hard enough with a hammer with the punch put at a distance of 1 1.5mm from the screw end.3. Hit the punch head so hard that the diameter of punch mark will be more than 1.5mm4. Punch 2 places around the screw thread in diagonal position.
Fig.1 Piston
Points to remember1. Take care not to break the target piston while punching.2. Make the clear punch mark as illustrated in Fig. 1.3. Punch within 5 minutes after “LOCTITE” has been applied.(Try not to give shock to the area where “LOCTITE” has been applied as it starts curing.)
punch specified places closeto screw threads.
Hexagon socket head screwTighten each hexagon socketscrew with "LOCTITE #2701"applied to the threads to
(23-1)
(Description)In order to ensure preventing the pistons of telescoping and derrick cylinders from becoming loose, fix the screw
(Rods and pistons are to be fixed perfectly by application of adhesive “LOCTITE #638”.)
(Main points)
Apply “LOCTITE” to the entire circumference of 2nd to 3rd threads from the thread end.Apply the primer as the gap in the effective diameter of threads exceeds 0.1mm.Use type #7474 (primer T) for the primer.(Although type #7469 is being used currently, type #7474 is moreeffective as the target adhesion is to be at between metal components.)Note : Pay special attention to observing the points to notice illustrated below while workingas curing itself and curing time of “LOCTITE” depends largely on how the adhesionprocedures have been carried out.
Points to notice on procedures to apply “LOCTITE”
Procedures1. Degreasing and cleaning →2. Priming coating →3. Application of “LOCTITE” →4. Assembly 5. Curing
(1) Degreasing and cleaning• Separate the oil well enough which has been applied to the threads (of rod/piston) to wipe it off with a rag or blow it off with compressed air.When blowing it off with air, remember that the unclean oil will not be blown off but will just escape along the threads.• In case of spray cleaning as well, target oil will not be removed but return if doing nothing but just spraying.• After carrying out degreasing and cleaning, wait until cleaning fluid is dried up completely.
(2) Priming coating• After primer #7471 has been applied, do not wipe it off but allow as it is for 5 10 minutes to dry naturally.(Application of “LOCTITE” without complete drying may result in reduction of adhesive strength by half.)• Although a component primed is effective for 7 days, store it by preventing dust and/or oil from being stuckbefore use.• When “LOCTITE” is applied to a component and it is shut off air, curing will start after 5 minutes fromapplication and will reach approx. 70% of curing in about 2 hours.(Curing time will be shortened by priming, but theoretical adhesive strength will be 85% against a componentwithout priming.)• Do not dip a primed component in “LOCTITE” agent directly.• Carry out priming at a place where well ventilated because priming agent escapes into air as vapor.
TELESCOPING/DERRICK CYLINDER ASS’Y, MEASURES TOPREVENT PISTON FROM BEING LOOSENED
Rods and pistons are fixed by tightening after application of “LOCTITE” to the threads on therods and on the pistons.
Besides, securing piston with screws and punching after application of “LOCTITE #2701” are alsoto be carried out as before
threads on the rods and the pistons with the adhesive “LOCTITE #638” (excepting for W376C telescopic cylinders).
(24-1)
(3) Application of “LOCTITE” • Apply “LOCTITE” sufficiently to the threads to fill them.Apply “LOCTITE” to the component mounting o-ring (piston) at the 2nd to 3rd threads from the thread end. (Refer to “Estimated adhesive consumption” illustrated below.) • “LOCTITE #638” is an anaerobic adhesive so that the part forced out will not cure because it isin contact with air.In addition, sticking of “#638” to o-rings and packings may cause the rubber to be
(When it is possible to be stuck on the rubber such as o-rings and packing, apply “ LOCTITE” tothe threads on piston side to avoid sticking to them.) • Try shortening the working period from the time when application of the “ LOCTITE” to a primed component to completion of fitting the component.
(4) Assembly • Tighten the component after application so that applied “LOCTITE” may spread entirely to the threads of the component. • Since “LOCTITE” forced out of the threads will not be cured, take care not the “LOCTITE” to be out during application as hydraulic oil is to be contaminated with it. • Work quickly as the “LOCTITET” in the treads starts curing. • Curing speed differs according to temperature(ambient temperature included) of target component.Since curing time becomes excessively longer at a temperature below 10°C, work with the component temperature raised to 15°C or over.
(5) Curing • This is a period while an adhesive is being joined.
Store the components still during the period.
(Recommended conditions is at an component
temperature of 15°C min. for more than 1 hour.)
Reference:
Estimated adhesive consumption when it is applied to 3 spirals of thread entirely.
Threading diameter Amount to be applied M40 0.46cc M60 0.69cc M80 0.92cc M100 1.15cc M120 1.38cc
Which primer of #7649 and #7471 should be used together with “LOCTITE #638”.
Curing speed of #7469 is faster than that of #7471 but adhesion strength is lower.
If adhesion is to be carried out between metal articles, #7471 gives better result.
Type #7471 is to be used in normal case (refer to manufacturer’s comment and catalog specifications).
TELESCOPING/DERRICK CYLINDER ASS’Y, MEASURES TOPREVENT PISTON FROM BEING LOOSENED
Chart of breakdown torque vs. curingtimeWhen using "Lock Tight #638withprimer #7471 (primer T)
(24-2)
Ambient temperature 35℃
Curing time (Hr)
25℃
15℃
0℃
Bolt:M10×P1.5- L2SNut: M10×P1.5Material:Soft steel (raw)
Bre
akdow
n t
orq
ue (
kgf/
cm
)
Ground
Sky
Earth for engine start relay and engine stop relay
25-1
Earth of the main harness
Ground
Sky
25-2
26.1 ELECTRIC WIRING DIAGRAM ( CRANE )
Wh/Ye
Re
BBrOr/Ye
(4)VERTICAL(4)HORIZONTAL
(3)HORIZONTAL(3)VERTICAL
(2)VERTICAL(2)HORIZONTAL
(1)HORIZONTAL(1)VERTICAL
Wh
Wh
Wh
Wh
Wh
Wh
Wh
WhB
B
B
B
B
B
B
B
B
B
Re
PiBBL
BLB
Wh
G
GrGYe
OrG
G
Wh/B
Re/B
B B
BB B
Wh
Wh
Ye
EXTENDRETRUCT
B
Pi
Wh
Ye
Gr
GBr
Gr/B
Ye/B
Or/B
BL/B
Br/B
G/BRe/B
RELAY BOX
Vi/Re
Wh/BPi Pi/Ye
Wh/BL
OrBL
YeBr
STOP
G
Br/B Br/BL
Gr GrG/Re
BL/GrOr/Gr
Ye/BLBr/Re
ReB
BB
Re
LgG
Or/Ye
Lg
BL/B
Pi/B
BL/Vi
OrSkBLB
Wh
Sk
Re
B
Wh
Ye/BPi/GrGr/BRe/Gr
Vi/Gr
G/BOr/B
BL/PiVi/OrOr
Release switch for safety device
Re
BL/ViYe/Br
BL/ViYe/Vi
BL/ViB/Br
B
B
B
B
Re
BL/ViG/BL
Re GrBPi/B
BOOM STORAGE
Re
Re
Re
Re
Re
Re
Re
Re
Re
B
BWh
Wh
Wh
B
Re
Pi/Gr
Pi/Gr
Or/GrWh/Gr
Wh/Gr
Or/Re
Or/BL
Br/GrPi/Gr
B
ReWh
Pin3
Pin4
Pin2
Pin1
Re
Re Re
BWh B
B
B
B B
B B
B
BGr
Gr
Gr
Gr
G/Gr
Pi/GrGr/Br
Pi/B
Stored boom detection
LED1
LED2
LED3
LED4
Pi/B
BL/Vi
Wh
BL/PiVi/OrOr/Wh
Outrigger monitorLimit Switch
26-1-1
C.O.
N.O.B
B
B
ReWh
Re/Wh
Valve for carrier
Re Gr
WhVi/Gr
ML POWER(12V)
Re Re
Re Re
B
Re
B
BL/WhVi/Or
Re/Wh
Speare power supplly
REMOTE CONTROL(TRANSMITTER)
G
HORN
Re
Gr/Wh
(EARTH)(EARTH)
BB
HORN RELAY(N.O.)
Re Or
Br
Head light
Head light
Re
ab
ReBr
B/BL
HOOK STORING
HORN
Wh/B
BRe
EMAGENCY STOP
Re AUTOMATIC STOP RESETOr
BBrOr
G
SPARE POWER SUPPLLY
VOICE
ReB
B
Re/B
B/Ye
Gr/Pi
B
BGr/Wh
Re
Br/Ye
Br
Re
ReOr
Or
Or
Re
ReRe
ReRe
Re
Re
Br
Br
Br
Br
Br
Or
Re
Re
Or
Re/Wh
Gr/BENGINE
OUTRRIGER(4)SW
OUTRRIGER(3)SW
OUTRRIGER(2)SW
OUTRRIGER(1)SW
EXTEND
EXTEND
EXTEND
EXTEND
RETRACT
RETRACT
RETRACT
RETRACT
Wh
Re
OrRe
CONTROL BOXRESET SW
B
Wh/Gr
Re/WhRe/Wh
Re
BGND
GND
HORN
POWER SUPPLY(MAIN)
POWER SUPPLY(RADIO CONTROL)
B Or/GrRe/BRe POWER SUPPLY(SOLENOID)
MAIN CONTACTRELAY N.O.
OUTRRIGER(HORIZONTAL)
OUTRRIGER(VERTICAL)
SELECT SWITCH
CRANE
OUTRRIGEROPERATION MODE SW
RADIO CONTROL SWITCH
BZ
B
BGr
MODE LAMP
ReB
Gr
OUTRRIGER MODELAMP
OUTRRIGER MODEBUZZER
BB
BVi/ReGr/Or
Br/Gr
Re
B
Or
ReRe
Re
Or
Br/Gr
STORE HOOK
AUTOMATIC STOP RESETB/Ye
Or/Gr
Wh/Ye
Or
Wh/YePi
Vi
Sk
B/BL
Gr/B
Wh/Br
Gr/Or
MAINCONTACT
MODE LAMP
STOP SINAL 2
POWER SUPPLY(RSERVE)
ENGINE START
ENGINE STOP
OUTRRIGER(4)RETRACT
OUTRRIGER(3)RETRACT
OUTRRIGER(4)EXTEND Ye/Wh
Pi/BL
Ye/Re
Wh/Or
BL/Or
G/Ye
Br/B
Ye/Gr
Wh
Gr/Or
B
Re Wh
Ye
BL/Pi
Vi/BL
B/OrYe
Br
Gr
B
Wh
G
BL
Vi/Ye
Vi/Re
BL/Wh
Or/Wh
Re/Gr
BL/B
LgOVERWINDING DETECTOR
SPEAKER(+)
INTER LOCK
OPERATION SIGNAL
CRANE MODE
OUTRRIGER MODE
RADIO CONTROL MODE
LEAVING MINIMAMWIRE ROPE DETECTOR
OUTRRIGER(3)EXTEND
OUTRRIGER(1)RETRACT
OUTRRIGER(2)RETRACT
OUTRRIGER(1)EXTEND
OUTRRIGER(2)EXTEND
OUTRRIGER MODE
DIGITAL SIGNAL(-)DIGITAL SIGNAL(+)
POWER SUPPLY (TRANSMITTER)GND SAFTY DEVICE RESET SW
MODE SELECTOR(TRAVEL/CRANE)
CONTOROL BOX
LVDT 1+
LVDT 1-
LVDT 2-
LVDT 2 DERRICK 1LVDT 2 DERRICK 2
LVDT 2 WINCH 1LVDT 2 WINCH 2
LVDT 2 SLEWING 1LVDT 2 SLEWING 2
LVDT 2 TELESCOPIC 2LVDT 2 TELESCOPIC 1
BL
G BOOM LOWER
BOOM RAISE
LVDT 2 ACCELERATOR 1LVDT 2 ACCELERATOR 2
LVDT 2 OUTRRIGER RIGHT SIDE 1LVDT 2 OUTRRIGER RIGHT SIDE 2
Ye
Br
Or
Pi
Sk SLEWING C.W
BOOM EXTEND
BOOM RETRACT
WINCH DOWN
WINCH UP
Gr/Pi
Vi
Wh/B
B/Re
Wh/Re OUTRRIGER
ACCELERATOR
UNLOADING
HOOK RELIEF
SLEWING C.C.W
Gr
G/Re
BL/Gr
Or/Gr
Ye/BLBr/Re
Pi/YeWh/BL
OUTRRIGER(4)EXTENDOUTRRIGER(4)RETRACT
OUTRRIGER(3)EXTENDOUTRRIGER(3)RETRACT
OUTRRIGER(2)EXTEND
OUTRRIGER(1)EXTEND
OUTRRIGER(2)RETRACT
OUTRRIGER(1)RETRACT
BOUTRIGGER
B
B
B
B
B
B
B
ACCELERATOR
UNLOAD
HOOK RELIEF
Pi
Pi
Pi
Re/B
Re/B
Re/B
Pi
Pi
Gr/Pi
LEFTRIGHT
Re/B
Re/BB
B
B
B
B
B
Pi
Pi
Pi
Pi
Pi
Pi
Re/B
Re/B
Re/B
Re/B
EXTENDRETRACT
UPDOWN
B/ReYe/B
Gr/ReVi/B
Gr/Vi
Pi/Wh
B/Pi
Wh/Vi
Re/B
B/Pi
Pi
Re/BL
Re/BLWh/Vi
B/Pi
Wh/Vi
Wh/ViRe/BL
B/Pi
Re/BL
B Br/Ye
WhSPEAKEROr/Wh
BL/Wh
Or/Ye Re
B
Re Re
B B B
SLOW DOWN(0V)ML STOP(12V)
SUB BATTERY
BL BL/WhOr Or G
Ye
Gr
Slip ring
Wh/PiBL/YeRe/Ye
B/GrOr/Gr
Gr/YeG/B
Gr/BLBr/Wh
Wh/ViB/PiVi/WhG/Wh
Re/BL
Re/BLWh/Vi
B/Pi
Re/BLWh/Vi
B/PiB
YeWh
BL
Gr
BGr
Wh
BL
Ye
MRV-500CONTROL VALVES
LVDT
(DERRICK)
YeWh
BLBGr
Ye
Ye
Ye
Wh
Wh
Wh
BL
BL
BL
B
B
Gr
Gr
Gr
(WINCH)
LVDT
(TELESCOPIC)
LVDT
LVDT
(SLEWING)
(OUTRIGGER)
LVDT
LVDT
(ACCELERATOR)
RAISE
B
LOWER
to Degital load display device
Wh
Wh
BB
WhWh
BrBr
BL GrBL
Ye Ye
ReRe
B
Ye/BRe/Wh
BWh
THREE COLOURED LAMP
Re
ML stop
Ye/B
Gr/B
ML control box
BZB B Or
Re
Gr
Pi
BL
Or
B
RS485(-)
RS485(+)
MLALARM
MLSTOP
OVERWINDING SIGNAL
POWER SUPPLY
GND
(-)DEGITAL SIGNAL
(+)DEGITAL SIGNAL
BOOM ANGLE
0V
BOOM LENGTH
+5VRe/B
Wh/B
G
Br
Ye
Wh
Br
Ye
Wh
Wh/B
G
Re/B
Gr
Wh
Re
Wh
B
B
Re
Ye
Wh CORD REEL Wh
POWER SUPPLY
GND
OVERWINDINGDETECTOR
SIGNAL(-)
SIGNAL(+)
+5V
0V
LOAD CELL AMP
OVERWINDING DETECTORB
Ye
Wh
Re
Br B B
(+)DEGITAL SIGNAL
(-)DEGITAL SIGNAL
Re/Wh
B/BL
Wh/Gr
Gr/Re
Re
B
Wh
Gr
LOAD CELL
B
B
Sky
Outrigger4Horizontal Length max.
Outrigger2Horizontal Length max.
Outrigger3Horizontal Length max.
Outrigger1Horizontal Length max.
Wh
Br
Wh
Br
BOr
PiB
Or
Pi
Or
Pi
OrGPi
ReB
BRe
ReB
BRe
(EARTH)
B
G
Re
B
Power supplyB
Re
B
Re
OVER FRONT HOISTING
B
Re Re
SkyBL
Relay for alarm signal
Relay for stop signal
B
BOOMANGLE SENSOR
BOOMLENGTHSENSOR
Rest switch for safety device
Br
Rest switch for ML device
Wh/Gr
Wh/Ye
B/Gr
B/GrB/Ye
B/YeRe/Wh
BL/Wh
B
Re
G
N.C.
B
Or/Ye
Relay for stop signal
Re
Re/Wh
Re
B
B
BL/Wh
Or Or
BL
G
Re
Re
Power supply for ML
Wh
B
Ye
Gr
Re
B/Wh Gr
Re
Ye
Wh
B
Gr
B/Wh
Re
B
Limit switch for leaving minimum wire rope
B
Re
Re
Gr
Ye
BL
SLIP RING
Ye
B
(MLSTOP)(MLALARM)
ReRe/Wh
BL
Re/B
BL/Wh
BL/Wh
B
Or/Ye
OVERWINDING SIGNAL
MLALARM
MLSTOP
POWER SUPPLY
GND
LOAD
D-IN
CLK
+5V
B/Wh
Gr
Re
Wh/Gr
Wh/Ye
LgLg
Gr
Wh/Ye
G
Wh
Re
Ye
B
BL/Wh
BL/Re
BL/Re
Re/Wh
(+)DEGITAL SIGNAL
(-)DEGITAL SIGNAL
LOAD DISPLAY UNIT
(ML
STO
P)
(ML
ALA
RM)
(O
VER
WIN
DIN
G S
IGN
AL)
Lg
OVER FRONT HOISTING
B
(LE
AVIN
G MI
NIMU
M WI
RE R
OPE)
(OV
ER F
RO
NT
HO
ISTI
NG
)
Re
Ye
B
Wh
Gr
Br
Re
Ye
BB
Or/YeOr/Ye
B
BOr/Ye
Wh/Ye
Wh/Ye
Or
Wh/Ye
Or
Limit switch
Power supply
To relay box
To relay box
To relay box
To stored boom detection
26.1 ELECTRIC WIRING DIAGRAM ( CRANE )
26-1-
2
予備電源1
予備電源2
C/Oソレノイド
台車
側電
源
走行クレーン
1
走行クレーン
2
SAFTY DEVICERELEASE 2
AUTO STOPINTERLOCK
AUTO STOPINTERLOCK
ML STOPRELEASE
ML STOPRELEASE
SAFTY DEVICERELEASE 1
AUTOSTOPRELEASE
1
安全装置 解除
Operation switch panel(under side)Operation switch panel(right side)Operation switch panel(left side)
Operation mode switch
Outrigger operation
Outrigger1
Outrigger2
Outrigger3
Outrigger4
Horn
Hook
ML自動停止解除
Rest switch for safety device
Rest switch for control box
reset
reset
(4)横アウト
(2)横アウト
(3)横アウト
アウト
アウト
(2)縦アウト
アウト
アウトV/Hランプ
非常停止
非常停止
水準器ライト
LED ピン
音声停止
前照灯2
前照
灯前
照灯
1
接地LED
AUTOSTOPRELEASE
2
停止
解除
電源
ML電源ON
ML停止
予備電源
ML停止
リセット
電源
予備電源
予備電源
停止
異常転倒防止
転倒防止
スピーカ
アース アース
アウト(1)横
(3)縦
(4)縦
(1)縦
reset
On
Off
On
Off
Store
(Radio control/ Manual)
Extend
Retruct
Extend
RetructExtend
Retruct
Extend
Retruct
Horizontal
Vertical
Outrigger
Craneクレ-ンアウト
パラ切換
アウト1
アウト2
3アウト
アウト4
ホ-ン
格納
ラジコンスイッチ
Emergency stop
Emergency stop(Head light side)
Radio contoller selector switch
Outrigger(Vertical)LED
Outrigger(Horizontal)LED
Outrigger pin 1Outrigger pin 2Outrigger pin 3Outrigger pin 4
Stored boom
Voice switch
Automatic stop for over windiding reset switch
Head light
Solenoid selector valve
TO interlock for crane-crawl opration
TO solenoid of carrier side
To earth
To limit switch to detectboom not being storedTo speaker
Relay
reset
Relay
転倒防止ON
スタートストップ
スター
トス
トップ
ブーム格納検出
走行/ クレーン
(Horizontal) Outrigger3 (Vertical)
(Horizontal) Outrigger2 (Vertical)
(Horizontal) Outrigger4 (Vertical)
(Horizontal) Outrigger1 (Vertical)
アウト3(縦)
アウト2(縦)
アウト4(縦)
アウト1(縦)
アウト3(横)
アウト2(横)
アウト4(横)
アウト1(横)
Relay
To relay or to diode
To Relay
To Relay box
Power supply ( Carrier side )
To relay box
To slip ring
To outriggermode indicatorlamp
To earthTo earth
To outrigger buzzer or to radio controlTo control valve
To outrigger monitorlimit switch
To Key switch box( Carrier side )
Control box
Electric wiring in control seat part Operation switch panel(left side)
Operation switch panel(right side)
Operation switch panel(under side)
26
-2
Power supply fuse
Control box
26-3
Solenoid valves for operating outrigger
Ground
Sky
26-4
Connector of Emergency stop
26-5
Wiring for operation switch panel
26-6
Wiring for operation switch panel
26-7
Wiring for operation switch panel
26-8
Switch panel
26-9
Switch panel( Key switch type ) ( Turnover prevention device)
26-10
Interlock for crane-crawl lever
26-11
Interlock for crane-crawl leverCrawl position
Crane position
26-12
The other side of accelerator pedal
Ground
Sky
26-13
Ground
Sky
The other side of accelerator pedal
26-14
Ground
Sky
It connects with the accelerator pedal.
It connects with the accelerator cylinder of the control valve.
26-15
DLIN
DICA
TOR
To slipring
AC
D伏 H上 H下 T縮 T伸 S右 S左 ODD起
AC
UL HR
H T S ODD
デリック ホイスト テレ 旋回 アウトリガ
モー
ド
ボッ
クス
リレ
ー
アウ
トRB
RB
走行
クレ
ーン
電源
RB RB RB
EARTH
ボッ
クス
リレ
ーボ
ック
ス リ
レー
ピン
1ア
ウト
アウ
ト接
地1
接地
2ア
ウト
ピン
2ア
ウト
ロ-ドアン
リリ-フフック
左旋回旋回
右伸テレ
縮テレ
下ホイストホイスト
上伏デリック
起デリック
接地
4
アウ
トピ
ン4
アウ
ト
アウ
ト張
出1
アウ
ト
ラン
プ
接地
3ア
ウト
ピン
3ア
ウト
RB 3
COLO
RLA
MP
ML STOP2
ML STOP1
POWERSUPPLY
OUT EXTDETECTION
ML STOP2
POWERSUPPLY
POWERSUPPLY
予備電源
アウ
トラ
ンプ
ハ゜ラ
フッ
クラ
ンプ
アウ
トア
ウト
ハ゜ラ
フッ
クラ
ンプ
ランプ2
ラン
プ1
バル
ブ1
バル
ブ4
EARTH
ML電源
ML停止
アウト張出
張出
4
アウトリガ
アクセル アクセル
To アウト 張出1
To アウト 接地・ピン1
DiodeRelay
To アウト 張出4
To アウト 接地・ピン4
To degital load metor To 3 Color lamp3C
OLO
RLA
MP
Electric wiring in control valve part
26-16
Ground
Sky
26-17
26-18
26-19
Ground
Sky
Ground
Sky
Relay box
26-20
26-21
Horn
Ground
Sky
Buzzer for Outrigger
26-22
Position of hose
DerrickHoist
TelescopingSlewing
27-1
Ground
Sky
Water separatorOil fillter element
Muffler
Air cleaner element Fuse boxSolenoid to stop engine
Fillingport
Engine
28-1
10
1510 10
15
20
20
20
30
10
3
87
65
43
21
ハー
ネス
台車
リレー
スイッチ キー
BOX
ヒュ
ーズ
FUSE BOX
EARTH
Warning lamp and Fuse box
28-2
Starter switch
Hour meterWarning lamp
Wiring for warning lamp
FUSE BOX
It connects with the accelerator pedal.
Water separator
Oil fillter element
Drain plug
28-3
28-4
Alternator
Air cleaner element
N.O.
ab
ab
ReRe
CB
RRB
A
LR
12
CC
10A3A 30A 20A 20A 15A 15A 20A
OFF
ON
START
B B R R CTERMINAL
PREHEAT
Acc
BS
M
BR L
P
a b c
R 21
Engine stop relay
Engine start relay
Battery
Switch
a
b
a b
ab
cd
ef
ab
cd
ef
Oil pressureswitch
Glow lamp Water temperatureswitch (105℃)
Starter
Alternator
1 2 43
Engine
Fuse
Oil tank
Fuse
Starter switch
Glow relay Safety relay
Solnoid
Glow
1 2 3 4
Glow timer
6543 S R L P E
Fusea
b
ab
N.C.
Emagency stop switch
Gr/BB/BL
ab
ab
Gr/BB/BL
Re
Re
Re
Re/Wh
Carrier sideCrane side
Hour meter
Fuel pump
W370CD
ELECTRIC WIRING DIAGRAM ( Engine part )
Power supply on crane side
Re
Br
Re/Wh
B/Wh
B Re ReWh
Ye/G
r
Wh/Y
e
BL
B/Wh
Re
B/Wh Gr
Wh/BL
Re
Re
B/Ye
・G
BL/B
Re/Gr
BRe
/Gr
Gr/Wh
BL/B
Wh/BL
Wh/Gr
Ye Wh/Ye
B
WhRe
BL/R
e
Br/W
h
B/BL
B/Ye B
BL/Wh
Re/BL
BB
BL/R
e
Re/Y
e
B
Re/B
BG
WhYe/Gr
BL/ReRe
Re/BLRe
BL/WhRe
BLRe
B
B
Ye/Gr
BLBLBL
Or
Gr/Wh
YeGr
Gr/Wh
Re
Wh/Re Wh/Re
B/WhB/WhB/Wh
Gr
Gr/Wh
Wh/R
e
Wh/Re
Wh/Re
Br/Wh
Wh/BL
Re/BL
Or/Gr
BLB/Ye
ReWh/B
WhWh
Re WhBr
Wh
Wh/Y
e
Or
BL
Re/Wh
baa
b
ReRe/Ye
Wh/B
Wh/Re
28-5
Oil temperatureswitch (105℃)
Air cleaner switch
Solenid to stop engine
Warning lamp for engine lubricating oil pressure
Warning lamp for circulating water temperature
Warning lamp for air cleaner clogging
Warning lampfor hydraulinc oil temperature
Warning lamp for alternator(for charging)
Pilot lamp indicating preheating engine
N.O.
ab
ab
ReRe
CB
RRB
A
LR
12
CC
10A3A 30A 20A 20A 15A 15A 20A
OFF
ON
START
B B R R CTERMINAL
PREHEAT
Acc
B
SM
BR L
P
a b c
3φ3W
50/60HzAC200/200、220V
(7.5kw 15/14A)Power unit
X
Y
Z
RSTE
M P
E
U
V
W
R 21
Engine stop relay
Engine start relay
BATTERY
Switch
a
b
a b
ab
cd
ef
ab
cd
ef
Hour meter
Air cleanerSwitch
Oil pressure switch
Glow lamp
Water tempernatureswitch(105℃)
Starter
Alternator
1 2 43
Solenid to stop engine Engine
Fuse
Oil temperatureswitch(105℃)
Oil tank
Fuse
Starter switch
Glow relay Safety relay
Solenid
Gr
BL
GrBLB
Glow
1 2 3 4
Glow timer
6543 S R L P E
Fuse
ab
ab
N.C.
Emagencystop switch
Gr/B
B/BL
ab
ab
ab
ab
Gr/Re
Re/Ye
Gr/B
B/BL
Re
Or
Re
Re
Re
Re/Wh
Carrier side
BLB B
Fuel pump
Power supply on crane side
Re
Br
Re/Wh
B/Wh
B Re ReWh
Ye/G
r
Wh/Y
e
BL/R
e
BL
B/Wh
Re
B/Wh G
rWh
/BL Re
Re
B/Ye・
GBL
/BRe
/Gr B
Re/G
rGr
/Wh
BL/B
Wh/B
LWh
/Gr Ye
Wh/Y
eB
WhRe
BL/Re
Br/W
h
B/BL
B/Ye B
BL/W
h
Re/BL
B
Re/Ye
Re/Ye Re
B
Re/B
B
G
Wh
Ye/Gr
BL/Re
Re
Re/BL
Re
BL/Wh
Re
BL
Re
B
Ye/Gr
BLBLBL
Or
Gr/Wh
Ye
B/Wh
Gr
Gr/Wh
Re
B/Wh
Wh/Re Wh/Re
B/Wh
Gr
Gr/Wh
Wh/Re
Wh/Re
Br/Wh
BLB/YeRe
Wh/B
WhWh Wh/B
LRe Wh
Br Re/BL
Wh
Or/Gr
Wh/Ye
Or
Power unit
(5.5Gr)
(5.5Re)
(5.5Wh)
(5.5B)
(2.0)
U
V
W
X
Y
Z
EM
PB
Wh
BL
B
BL
Re/Wh
baa
b
Re
Re/Ye
B
Wh/B
29-1
W370CDEELECTRIC WIRING DIAGRAM (Power unit option)
BL/R
e
Warning lamp for engine lubricating oil pressure
Warning lamp for circulating water temperature
Warning lamp for air cleaner clogging
Warning lampfor hydraulinc oil temperature
Warning lamp for alternator(for charging)
Pilot lamp indicating preheating engine
FUSE FUSE
BREAKER
Converter
(1)
E
N -
+P 400
0SC
R0
RC
U
V
W
E
R
S
T
X
Z
Y
R1
S1
T13
4
6QER
F2F1
MCP
RC
SC
PBL
MCP 04
EM
00 PBS 01 QER 02
(5)
THP 03MCP
GL
Ry
Electric diagram of control box
B
Wh
THP(Set15A)
ELB
Earth
Earth
50/60HzAC400V
Power unit
X
Y
Z
RSTE
M P
E
U
V
W
Controlbox for Power unit
EM
B
29-2
Converter
Converter
(1)
E
N -
+P 400
0SC
R0
RC
U
V
W
E
R
S
T
X
Z
Y
R1
S1
T13
4
6QER
F2F1
MCP
RC
SC
PBL
MCP 04
EM
00 PBS 01 QER 02
(5)
THP 03MCP
GL
Ry
Electric diagram of control box
B
Wh
THP(Set15A)
ELB
Earth
Earth
29-3
Converter
Converter
Converter
(1)
E
N -
+P 400
0SC
R0
RC
U
V
W
E
R
S
T
X
Z
Y
R1
S1
T13
4
6QER
F2F1
MCP
RC
SC
PBL
MCP 04
EM
00 PBS 01 QER 02
(5)
THP 03MCP
GL
Ry
Electric diagram of control box
B
Wh
THP(Set15A)
ELB
Earth
Earth
29-4
Converter
29-5
Earth
U
V
W
V2
U1
W2
V1
W1V2
U1
V2
V1
W2
W1
V2
V
W
U
E Earth
DC12VMotor
Harness
DC12V
KEYS
W
リレー
Harness
リレー非常停止
非常停止
KEYSWRelay
Harness
Power Supplyfor Crane
EARTH
EARTH
EARTH
EARTH
EARTHEmergencystop button
非常停止(パネル)
Relay・Diode
非常停止(前)
Emergencystop button
Harness(Carrier side)
Switch for speed selectRe/Ye
Re/B
Re/Ye
2NDSW
FUSE
Diode
Harness Harness(Carrier side)
予備電源予備電源
P
EMEMARGENCY
DC12V
Contorol boxfor power unit
Power Unit (400V type ) S/N ~37W0117
29-6
W1V2
DC12V
Tag block of Motor
Harness
DC12V
KEYS
W
リレー
Harness
リレー非常停止
非常停止
KEYSWRelay
Harness
Power Supplyfor Crane
EARTH
EARTH
EARTH
EARTH
EARTHEmergencystop button
非常停止(パネル)
Relay・Diode
非常停止(前)
Emergencystop button
Harness(Carrier side)
Switch for speed selectRe/Ye
Re/B
Re/Ye
2NDSW
FUSE
Diode
P
EMEMARGENCY
DC12V
Contorol boxfor power unit
Power Unit (400V type )S/N 37W0120~
30-1
YES
YES
YES
YES
YES
YES
NO
NO
NO
30.1 Inspection for sinking of cylinder
The load is lowered.
Set the conditions for sinking in the crane. Stop the engine, change the lever and remove the pressure. Then, start the test.
The outrigger cylinder sinks.
The derrick cylinder sinks.
The telescoping cylinder sinks.
Does the oil come out when removing the pipe at retracting side?
Does the oil come out when removing the hose at lowering side?
Does the oil come out when removing the hose at retracting side?
Inside leakage occurs.The packing is damaged.The tube is scratched.
Does the oil come out when removing the pipe at extending side?
Does the oil come out when removing the hose at raising side?
Does the oil come out when removing the hose at extending side?
Check the pilot.The seat surface is damaged.
Foreign matter is caught by the seat surface.
Foreign matter is caught by the seat surface.
Foreign matter is caught by the seat surface.
The counterbalance valve malfunctions.The seat surface is damaged.
Inside leakage occurs.The packing is damaged.The tube is scratched.
Inside leakage occurs.The packing is damaged.The tube is scratched.
The counterbalance valve malfunctions.The seat surface is damaged.
30. 2 Inspection of derrick cylinder
(1) Preparation before inspection
①Raise booms to an angle of approx. 30°.②Put a mark on the rod with a felt pen (refer to Fig. 1).
(2) Starting inspection
④Remove the lowering hose to check if oil overflows continuously out of the cylinder port of lowering side. At he same time, check also that how far the rod shifts. If no oil flows out of the port of lowering side, the cylinder is normal.⑤Next, remove the raising hose, and if oil overflows continuously out of counter-balance valve port of raising side, there may be faulty on the seat surface of counter-balance valve (refer to Fig. 3). In addition, check how far the cylinder sinks simultaneously.
Caution:In order to release pilot pressure in the lowering side, be sure to remove the raising hose after the lowering hose has been removed (refer to Fig. 2).If oil overflows out of the port on lowering side, it suggests internal leakage in the cylinder.Be sure to measure the how far each boom sinks as it is an important point for judging that it is
Put a mark on the rod with felt pen hose
Fig2
Fig3
Fig1
③In order to release pressure remained in the derrick system, stop the engine and shift the manual leverfor raising/lowering of booms.
Load
Lowerringhose
Risinghose
CounterbalancevalveFault in seat surface
30-2
30.3 INSUPECTION PROCEDURES WHEN CYLINDER SINKE Inspection of telescoping cylinder
(1) Preparation before inspection
①Allow booms to be horizontal and extend them fully to put amark on each boom section (refer to Fig. 1).②Raise booms to their maximum to sling a load.③In order to release pressure remained in the telescoping system,stop the engine and shift the manual lever for telescopingbooms.
(2) Starting inspection
④Remove the retraction hose to check if oil overflowscontinuously out of the cylinder port of retraction side.At he same time, also check that which boom section sinkshow far to grasp condition of booms as a whole.If no oil flows out of the port of retraction side, the cylinder isnormal.⑤Next, remove the extension hose, and if oil overflowscontinuously out of counter-balance valve port of extensionside, there may be faulty on the seat surface of counter-balancevalve (refer to Fig. 3). Fig1In addition, check how far boom3 sinks simultaneously.
Caution:In order to release pilot pressure in the retraction side,be sure to remove the extension hose after theretraction hose has been removed (refer to Fig. 2).Since overflowing oil out of the port on retraction sidemeans internal leakage in the cylinder, check tele1 andtele2 separately.Be sure to measure the how far each boom sinks as it isan important point for judging that it is normal orabnormal. Fig2
(3) Inspection of tele1
⑥Extend booms to a position where it is a little bit shorter than2-section boom to put a mark on the boom (refer to Fig. 4).⑦Raise booms to their maximum to sling a load.⑧In order to release pressure remained in the telescoping system,stop the engine and shift the manual lever for telescopingbooms.⑨Remove the retraction hose.If oil overflows out of cylinder port of retraction side andboom2 sinks, there may be internal oil leakage in tele1.In addition, check how far boom2 sinks simultaneously.
(4) Inspection of tele2
⑩Allow booms to be horizontal and extend them fully to put amark on each boom section (refer to Fig. 1).⑪Raise booms to their maximum to sling a load.⑫In order to release pressure remained in the telescoping system,stop the engine and shift the manual lever for telescopingbooms.⑬Remove the retraction hose.If oil overflows out of cylinder port of retraction side andboom3 sinks, there may be internal oil leakage in tele2.In addition, check how far boom3 sinks simultaneously.
The same procedures in checking boom sinkage are applied for5-section boomBe sure to check the boom sections one by one reliably. Fig3
Put a markon each boom
CounterbalancevalveFault in seat surface
30 - 3
30.4 Procedures for checking outriggers for sinking
In case where outrigger sinks during crane operation
Test 1Putting the crane on a solid level ground, extend the outriggers to their extremes and raise the crane mounted vehicleby 50mm from the ground to check the sinking condition.1. Stop the engine to release pressure remaining in the outrigger circuit.2. Disconnect all 8 hoses connecting to the W.P. check valve.3. Mark each rod of 4 outrigger cylinders.4. Measure the movement of each rod.
Test 2Exchange the W.P. check valve measuring maximum sinking and the one measuring minimum sinking to repeat the same procedures of “Test 1” above.
Judgment by comparisonWhen position of sinking is reversed in “Test 1” and ”Test 2”;W.P. check valve is faulty.If in failure, oil continuously comes out of the cylinder for extension.When position of sinking has not changed; Cylinder is faulty.
CautionWhen a cylinder has been replaced of, re-adjustment of the load cell amplifier is needed.
How to release pressure out of outrigger cylinder circuitBe sure to operate by using the switch and the lever illustrated in the picture.Even if outriggers are controlled via radio controller, pressure inthe circuit will not be released as the engine has been shut off sothat oil pressure will not be generated and as a result the levercontrolling outrigger will not move. 1. Shift the lever to CRANE position to start the engine. 2. Put the control mode switch at OUTRIGGER position. 3. Extend outriggers to allow each cylinder to extend to its stroke end and relief it. 4. Stop the engine. 5. Turn ON the starter key again to light the outrigger mode indicator lamp.At this time, do not start the engine. 6. Turn outrigger control switches ① through ④ to STORAGE side to throw the outrigger control lever. Release of hydraulic pressure can be felt . by holding the hose on extension side 7. Turn outrigger control switches ① through ④ to EXTENSION side to throw the outrigger control lever. Release of hydraulic pressure can be felt by holding the hose on retraction side. Outrigger control switch
Operation mode switch
Outrigger lever
Outrigger mode indicator lump
Raise vehicle by 50mm.
Retract
Extend
W.P. check valve
Mark here.
Starter key
30 - 4
MAINTENANCE AND INSPECTION OF CRANE
Wire rope is an expendable article and it willbe damaged and its strand wires are broken toallow it to be thinner through a long period ofoperation.Replace the rope according to following cri-teria.
♦1. Replacement criteria1. A rope in which amount of broken strand
wires (except filler wires) comes to morethan 10% within a pitch of twist.Replace the wire ropes intended for use withthis crane if 13 pieces of strand wire havebeen broken within a pitch of twist.
2. A rope being kinked.
3. A rope from which its diameter has
decreased by more than 7% of the nominaldiameter.For example, if wire rope with a nominaldiameter of 8mm is used, replace it when thediameter becomes 7.5mm.Refer to the section 17. MAJOR SPECIFI-CATIONS, for length and construction of thewire rope for winding-up.
4. A rope which has been deformed and/or
corroded excessively.
★Be sure to replace a wire rope when itcomes under the criteria, item 1 through 4,illustrated above.
31 Replacement of wirerope (for winding-up)
★Wear leather gloves whenreplacing wire ropes.
4
ロープ径
1
2
3Wire ropediameter
CAUTION
31-1
Boom top
Front of boom
Guide
Higher side is to be in front
♦2. How to replace wire ropes
1. Refer to the figure in the left for how to
hook the wire ropes for winding -up and forwhere the weight for overwinding alarm is tobe mounted.
Refer to the figure in the left for how toattach the hook.
MAINTENANCE AND INSPECTION OF CRANE
Wire clip
Wedge
Overwindingalarm detector
Ring
Wire rope foroverwinding alarm
Weight foroverwindingalarm
31-2
MAINTENANCE AND INSPECTION OF CRANE
50mm
40mma
Wire rope end
Notch
Wire clip
(Pay attention to mounting direction)
Arrow mark
Wedge(Wire rope diameter: 8mm)
Projection on upper part of wire socket
Stopper
If rope end is left by more than 40mm (as “a” illustrated above), rope end is visible through this hole. If not, adjust the distance of rope end.
Pass the pin through and tighten it with bolt securely.
2. How to fix wire rope end① When passing the wire rope end throughthe wire socket, be sure to pass it as indicatedby the arrow mark on the socket.If it is passed from the opposite direction,service life of wire rope shortens as the wirerope is kept bent all the time.
② Do not forget to mount the wedge and thewire clip as illustrated in the figure in the left.Leave the wire rope end to allow a distancefrom the notch to the rope end by more than40mm as illustrated in the figure as “a”.
③ Pass the pin through with the wire socketheld with your hand and tighten it with thebolt securely.
31-3
4-rope hookingWire socket
Direction that rope is untwisted
Direction that rope is twisted
(Note) Rotate wire socket to the direc-tion opposite to wire ropes have been twisted.
♦3. How to correct twisted wire ropesWire ropes tend to turn in untwisting direc-tion when they are under tension.If two or more wire ropes are hooked togeth-er, they tend to be twisted particularly whilethey are new.The twist will decreases as the ropes are get-ting fit to the crane.
If wire ropes are twisted, correct them as fol-lows:
1. Unload the hook.
2. Extend the boom fully.
3. Raise the boom to an angle of approxi-
mately 65°.
4. Unwind the hook until it comes close to
the ground.
5. Check how many turns the wire rope hasbeen twisted.
6. Wind up the hook and retract the boom to
be on a stored condition.
7. Remove the wire socket and turn the sock-
et in the untwisting direction by as manyturns as the wire ropes have been twistedmultiplied by the number of wire ropes beinghooked.However, remember that the wire socket maybe turned up to 4 turns at a time.
8. Attach the wire socket and repeat winding
up and down the rope 2 or 3 times betweenboth extremes.Then, check if twist of the wire ropes is cor-rected.If they remain twisted, repeat the proceduresshown above.
MAINTENANCE AND INSPECTION OF CRANE
31-4
♦1. Replacement of gaskets and seals
for each cylinderAlthough timing of replacement of a partvaries according to how frequently the cranehas been operated, replace gaskets and sealsused in each cylinder after every 3 years ofoperation (period during which crane has notbeen operated is included) in order to operatethe crane safely.Ask a local UNIC authorized service shop forreplacement of gaskets and/or seals.
32 Replacement ofexpendable parts
♦2. Replacement of sliding plate of
boomReplace it every 3 years.
♦3. Replacement of brake shoe of
hoisting winchReplace it every 3 years.
MAINTENANCE AND INSPECTION OF CRANE
Sliding plate
Brake shoe
♦4. Cleaning and replacement of filter
in the control valveIf the filter built in the control valve isclogged up, radio remote control operationand acceleration interlocking operation can-not be carried out.Clean it by blowing air once after one year ofuse and replace it if it has been clogged upremarkably or it has been damaged.
Filter
32-1
WATER SUPPLY AND LUBRICATION TO CARRIER
33 List of recommended lubricant
♦1. Use the engine oils as below:
♦2. Use the recommended grease for lubrication as below.Chassis greaseUse NLGI No. 2 grade for most temperatures.Use NLGI No. 1 grade for extremely low temperatures.
♦3. Use the fuel as specified below. (Diesel fuel oil)Use ONLY clean, high-quality fuel.Use Grade No. 2-D fuel above 4°C.Use Grade No. 1-D fuel below 4°C.
-30 -20 -10 3020100
SAE5W SAE30
SAE10W
SAE10W -30
Engine oil Diesel engine oil of CD class
Classification Depending on atmospheric temperature
Rating to be applied
The selection of engine oil is very important to a diesel engine.If an unsuitable oil is used, or oil change is neglected, it may result in damage, and ashorter engine life.Use oils that meet API Engine Service Classification CD.
♦4. Use an antifreezing solution for coolant• Antifreezing solution functions to prevent the water from freezing and the cooling system
from rusting. • Use an antifreezing solution if atmospheric temperature goes below the freezing point.• Use “Long Life Coolant (LLC)” as the antifreezing solution.
The “Long Life Coolant” can be used throughout the year.Replace the “Long Life Coolant” once every other year (in the season of autumn or fall).(Follow the instruction of the manufacturer on how much the antifreezing solution shouldbe mixed with water.)
★Use the softened water with less impurity such as tap water for cool-ing water.Do not use well water and river water as cooling water.
★Use of coolant which too much of antifreezing solution mixed withwater allows the engine to be overheated earlier.
CAUTION
33-1
♦5. Hydraulic oil is the same as the oil used in the crane.
♦6. Use the gear oils for the reduction gears of crawling motor .
WATER SUPPLY AND LUBRICATION TO CARRIER
33-2
LUBRICATION TO CRANE
♦1. List of recommended lubricants
★Use the UNIC genuine hydraulic oils listed below as hydraulic oil for the crane. Use industrial-type hydraulic oil
ISO VG 46 for temperatures above 32F.ISO VG 32 for temperatures below 32F.
★ Use the recommended lubricants listed below as gear oil for lubrication.
★ Use the recommended greases listed below as grease for lubrication.(a) Chassis grease
Use NLGI No. 2 grade for most temperatures.Use NLGI No. 1 grade for extremely low temperatures.
(b)Molybdenum greaseUse NLGI No. 2 grade.
Petroleum Maker Brand
ESSO Beacon G2
MOBIL Mobilplex Special
CALTEX Molytex Grease EP2
SHELL Retinax AM
Petroleum MakerBrand
ESSO Spinesso 32
MOBIL Mobil DTE 32
CALTEX Spindura oil 32
SHELL Shell Tellus Oil 32 Shell Tellus Oil 46
Rando Oil 46
Mobil DTE Oil Medium
Teresso 46
ISO VG 32 ISO VG 46
Aplication Petroleum Maker Brand
Reducer for winch Shell Shell Spirax EP 90
Reducer for slewinggear
Use API service GL-4 gear oils.(Refer to the followings)
ESSOMOBILCALTEXSHELL
Standard gear oil 90Mobilube GX 90Universal Thuban SEA 90Shell Spirax EP 90
33-3
Filling water and lubrication chart(URW376C)
Service interval Where to lubricateNo. ofpart Lubricant Tool
Initial: Replace after 100 hours After : Replace every 250 hours
① Engine (4.0 liters) 1 Engine oil
Initial : 30 hours, Whenever nec-essary
② Tension adjustment ofrubber crawler
2 Chassis grease Grease pump
Fuel Light oil
Fuel tank capacity 40 liters
④ ⑤ ②Fuel
ご
Replace antifreezing solution(LLC) every 2 years
③ Radiator (5.5iters) 1Antifreezingsolution
Initial: Replace after 3 months After : Replace 2 years
④ Hydraulic oil tank
(70 liters)1 Hydraulic oil
Replace every 1000 hours⑤ Reduction gears of crawl-
ing motor (0.7 liters)2 (Right/
Left) or Gear oilDiesel engine oil
Refer to “MAINTENANCE AND INSPECTION OF CARRIER” for replacement procedures.
WATER SUPPLY AND LUBRICATION TO CARRIER
①③
34-1
34
34-2
WATER SUPPLY AND LUBRICATION TO CARRIER
Filling water and lubrication chart (URW546C)4 5 2Fuel
SELECT SET
OUTRIGGER
tNOT MAX EXT.
ì²
3
1
Refer to "MAINTENANCE AND INSPECTION OF CARRIER" for replacement procedures.
Service interval Where to lubricate No. of part Lubricant Tool
Initial: Replace after 100 hours After : Replace every 250 hours ①Engine 4.0 liters 1 Engine oil
-secen revenehW ,sruoh 03 : laitinIsary
② Tension adjustment of rubber crawler 2 Chassis grease Grease pump
Replace antifreezing solution (LLC) every 2 years ③Radiator 5.5liters 1 Antifreezing
solution
Initial: Replace after 3 months After : Replace 2 years
④ Hydraulic oil tank 70 liters 1 Hydraulic oil
Replace every 1000 hours ⑤ Reduction gears of crawl-ing motor 0.7 liters
2 (Right/Left) Gear oil
Fuel light oil
Fuel tank capacity 40 liters
34
② ③④ ⑤ ⑦
⑧ ⑨ ⑩
⑪ ⑫
⑮⑰
⑯ ⑭
① ⑥
⑬
6-section boom
ご
Serviceinterval
Where to lubricateNo. ofpart
Lubricant
Daily
① Boom slide plate (Underside & side face of boom
sections②, ③, ④, ⑤ and ⑥)For 6-section boom
② Boom slide plate (Upper side of boom section ① )③ Boom foot pin
④ Upper support pin of derrick cylinder
⑤ Lower support pin of derrick cylinder
⑥ Oil tank (70 liters)
5
21111
Molybdenum grease
Molybdenum grease
Chassis grease
Chassis grease
Chassis grease
Hydraulic oil(up to mid-dle of level gauge)
Weekly⑦ Winch drum gears
⑧ Slewing gears
11
Chassis grease
Chassis grease
Monthly
⑨ Winch reduction gears (Approx. 1.0 liter)⑩ Slewing reduction gears (Approx. 0.7 liters)⑪ Wire rope⑫ Slewing bearings⑬ Wire rope for boom extension⑭ Outrigger fulcrum pin⑮ Outer box support⑯ Outrigger vertical cylinder (Bracket side)⑰ Outrigger vertical cylinder (Outer box side)
1
1
1
2
1
4
4
4
4
Gear oil
Gear oil
Rope greaseChassis grease
Rope greaseChassis grease
Chassis grease
Chassis grease
Chassis grease
Spray gun
Grease pump
Spray gun
Grease pump
Grease pump
Grease pump
Grease pump
Grease pump
Manual appli-
cation
Manual appli-cation
Grease pump
Grease pump
Grease pump
Grease pump
Tool
1 Lubrication chart(URW376C)
LUBRICATION TO CRANE
35-1
35
35-2
LUBRICATION TO CRANE
8 9 10
123
1416
1517
725
6
411
SELECT SET
OUTRIGGER
tNOT MAX EXT.
ì²
6-section boom13
1
Lubrication chart (URW546C)
Serviceinterval Where to lubricate No. of
part Lubricant Tool
Daily
① -ces moob fo ecaf edis & edisrednU( etalp edils mooB tions ②, ③, ④, ⑤, ⑥ and ⑦) For 7-section boom
② Boom slide plate (Upper side of boom section ①)③ Boom foot pin④ Upper support pin of derrick cylinder⑤ Lower support pin of derrick cylinder⑥ Oil tank (70 liters)
6
21111
Molybdenum grease
Molybdenum greaseChassis greaseChassis greaseChassis greaseHydraulic oil (up to mid-dle of level gauge)
Manual appli-cationGrease pumpGrease pumpGrease pumpGrease pump
Weekly⑦ Winch drum gears⑧ Slewing gears
11
Chassis greaseChassis grease
Grease pumpManual appli-cation
Monthly
⑨ Winch reduction gears (Approx. 1.0 liter)⑩ Slewing reduction gears (Approx. 0.7 liters)⑪ Wire rope⑫ Slewing bearings⑬ Wire rope for boom extension⑭ Outrigger fulcrum pin⑮ Outer box support⑯ Outrigger vertical cylinder (Bracket side)⑰ Outrigger vertical cylinder (Outer box side)
111214444
Gear oilGear oilRope greaseChassis greaseRope greaseChassis greaseChassis greaseChassis greaseChassis grease
Spray gunGrease pumpSpray gunGrease pumpGrease pumpGrease pumpGrease pump
35
LUBRICATION TO CRANE
Lubrication
(Draining oil)
Drain plug
(Filling oil)
Oil level gauge
Gear oil filling port
♦1. Replacement of gear oil(Winch reduction gears and Slewingreduction gears)
★Air enters in and out of the gear case so
that dirt and moisture are brought in thegear case.In addition, since hydraulic equipmentgradually wears to produce worn particles,replace gear oil 6 months after the start ofoperation.
★After that, replace gear oil:
• Once a year for winch reduction gears,and
• Once every 2 years for slewing reduc-tion gears.
★Replace gear oil after oil tem-perature has dropped.
Winch reduction gears
Slewing reduction gears
Drain plug(Draining oil)
Oil level plug Gear oilfilling port
StandardlevelrangeApprox.0.7 liters
CAUTION
(Filling oil)
★Fill the gear oil for winch reduction gear
to a middle of oil level gauge (approx. 1.0liter).
36-1
36
37 - 1
CHART FOR INSPECTION BEFORE STARTING CRANE OPERATIONWhen carrying out inspection before crane operation, use photocopy of this sheet.
Date: , ,Place
Weather: (Fine, Cloudy, Rain, Snow)Operator
Device Inspect for: Check
Hydraulic pump Tightness of fitting,Oil leak, unusual noise
Hydraulic oil tank Oil level, oil leak
Outrigger Gravity-descent, operating condition,
Hoist winch Operating condition, braking performance, irregular winding
Swinging device Operating condition, oil leak
Derricking boom Operating condition, oil leak, fitting of foot-pin
Telescoping boom Operating condition, oil leak, deforma-tion, crack, fitting of mounting pin
Hook Rotation of hook, operating condition of retainer
Wire rope Damage, Fastening at rope end
Over-winding alarm Operating condition, alarm sound
Load meter Oil leak, operating condition
Alarm device Operating condition, alarm sound
PipingHigh-pressure hose Oil leak at each connection, damage
Automatic storing hook device Automatic stop and storing operation
Deformation, damage, oil leak, crack
Device Inspect for: Check
Frame Crack, tightness of bolts and missing
Automatic stop for leaving minimum wire rope
Radio controller Operating condition,
Overturn prevention device
Digital load meter
Overload prevention device
Interlocking device for crane・traveling lever
Rubber crawler Tension, damage, crack
Wheel sprocket Tightness of bolts
Track roller Tightness of nuts, oil leak
Engine
Remaining fuel level, draining water, engine oil level, cooling water level, fan belt tension and adjustment, battery liquid level, unusual vibration, unusual noise, tightness and damage in each bolt
Traveling will not function when selected on crane side.
Power lamp should light, error lamp should go off, damage in wiring
Crane will not function when selected on traveling side.
Load indication on no-load, damage in wiring
Alarm, automatic stop, damage in wiring, tightness of detector
It should make an automatic stop for unwinding when remaining wire rope on the drum come to 3 turns.
37-2
A CT L
Condition of air cleaner element
Contamination of fuel strainer and ignition plug
Fuel leak
Battery liquid level
Engine oil level and deterioration
Unusual vibration and noise
Tightness of fitting bolts, nuts, and missing
Crack, wear, damage in rubber crawler
Tightness of take-up bolts, nuts, and missing
Forward・backward operation of traveling lever
Operation of accelerator lever
Braking performance
Damage in stand lever and lock lever
Oil leak from reduction gear in traveling motor
Crack in welded section
Tightness of fitting bolts, nuts, pins, and missing
Oil leak, crack
Quantity, contamination, and deterioration of hydraulic oil
Contamination of air breather, return filter, suction filter
Operation, unusual noise, oil leak
Tightness of fitting bolts, nuts, and missing
Operation, deformation, crack in each lever
Missing knob, peeled off and deteriorated sticker
Oil leak
Tightness of fitting bolts, nuts, pins, and missing
Operation of cylinder, lamp, buzzerEffect of stopper pin when outriggers are stored and extended, deformation of pinsDeformation of outer box, inner box, suspending bracket of outrigger bodyOil leak from outrigger cylinder, gravity-descent
Tightness of fitting bolts, nuts, pins, and missing
Oil leak
Tightness of stopper mounting bolts, deformation of plate
Tightness of fitting bolts, nuts, and missing
Continuity of slip ring, damage in wiring, mounting
Operation, unusual noise, oil leak
Damage in air breather
Gear oil quantity, deterioration
Crack in drum, lubrication to gears
Tightness of fitting bolts, nuts, and missing
Operation, unusual noise, oil leak
Damage in air breather
Gear oil quantity, deterioration
Operation of turn-table, unusual noise, lubrication
Tightness of fitting bolts, nuts, and missing
Operation
Looseness in upper and lower pins of derrick cylinder
Oil leak from derrick cylinder, gravity-descent
Tightness of fitting bolts, nuts, and missing
Operation
Oil leak from telescoping cylinder, gravity-descent
Fitting of support pins, missing snap ring
Tightness of fitting bolts, nuts, and missing
1
2
3
4
5
6
7
8
9
10
11
12
Engine
Traveling devices
Frame
Hydraulic oil tank
Hydraulic pump
Control valve
Outriggers
Swivel joint
Hoist winch
Swing device
Derrick cylinder
Telescoping cylinder
MONTHLY SELF-INSPECTION RECORDS When carrying out inspection, use photocopy of this sheet. Keep the inspected results for 3 years.
Check Replacement Adjustment CleaningOverhaul Repair Tightening Oil supply
Check point What to check for: Checked resultNG
Measures takenOK
Crack, deformation
Tightness of bolts mounting turntable
Telescoping operation, lubrication
Deformation, crack, wear of sliding plate
Tightness of bolts mounting turntable, missing bolts
Damage, wear, rotaition sliding plate, missing bolts
Fitting of support pin, sheave pin
Tightness of fitting bolts, nuts, pins, and missing
Tightness of telescoping wire, wear, broken strand wire, corrosion
Specifications: length, thickness
Wear, broken strand wire, distortion, kink, corrosion, lubrication
Tight connection to wire socket, fastening clip at rope end
Deformation, crack of wire socket
Tight connection to drum, irregular winding, twist
Fitting of support pin, tightness of bolts and missing
Oil leak
Support of piping
Damage, aging, crack, twist, dent
Wear, deformation, rotation of hook and lubrication
Gauge mark distance of hook
Damage, wear, rotation of sheave and lubrication
Function, deformation, damage in retainer
Tightness of hook screws and looseness of thrust bearing (worn condition)
Tightness of fitting bolts, nuts, pins and missing
Function, oil leak, damage
Missing pointer, damage in indication plate, functionFunction, condition of over-wound detection switch and alarm soundWinding-up condition of cord reel, damage in cord, broken cordDamage in weight and sling wire
Setting condition
Function, alarm spund
Fitting, damage, deterioration
Operation
Condition of transmitter enclosure
Cable connections: tightness, contamination, corrosion
Damage, deterioration, twist of wiring and cables
Corrosion, deterioration, tightness of contact terminals
Oil leak from accelerator cylinder
Function of each solenoid valve, oil leakAlarm function when reaction force against outrigger drops
Crane operation when reaction force against outrigger drops
Cable connections: tightness, contamination, corrosion
Damage, deterioration, twist of wiring and cables
Corrosion, deterioration, tightness of contact terminals
Deformation, wear, damage in load cell
Function
Function
Mounting of detector switch
13
14
15
16
17
18
19
20
21
22
23
24
25
27
26
Boom
Wire rope
Piping
Hook
Automatic stop for over-wound alarm
Level
Alarm
Name plate
Radio remote control
Overturn prevention
Automatic stop for leaving minimum wire rope
Check point What to check for: Checked resultNG
Measures takenOK
Column
Load meter
Load indicator
3-color light
OperatorCrane modelDelivered dateInspected date
Remarks to be recorded
Inspected by Signature
Company in charge of inspection
37-3
A CT LANNUAL SELF-INSPECTION RECORDS When carrying out inspection, use photocopy of this sheet.
Keep the inspected results for 3 years.Check Replacement Adjustment CleaningOverhaul Repair Tightening Oil supply
Check point What to check for: Checked resultNG
Measures takenOK
Telescoping operation, lubrication
Deformation, crack, wear of sliding plate
Tightness of bolts mounting turntable, missing bolts
Damage, wear, rotaition sliding plate, missing bolts
Fitting of support pin, sheave pin
Tightness of fitting bolts, nuts, pins, and missing
Tightness of telescoping wire, wear, broken strand wire, corrosion
Specifications: length, thickness
Wear, broken strand wire, distortion, kink, corrosion, lubrication
Tight connection to wire socket, fastening clip at rope end
Deformation, crack of wire socket
Tight connection to drum, irregular winding, twist
Fitting of support pin, tightness of bolts and missing
Oil leak
Support of piping
Damage, aging, crack, twist, dent
Wear, deformation, rotation of hook and lubrication
Gauge mark distance of hook
Damage, wear, rotation of sheave and lubrication
Function, deformation, damage in retainer
Tightness of hook screws and looseness of thrust bearing (worn condition)
Tightness of fitting bolts, nuts, pins and missing
Function, oil leak, damage
Missing pointer, damage in indication plate, functionFunction, condition of over-wound detection switch and alarm soundWinding-up condition of cord reel, damage in cord, broken cordDamage in weight and sling wire
Setting condition
Function, alarm spund
Fitting, damage, deterioration
Operation
Condition of transmitter enclosure
Cable connections: tightness, contamination, corrosion
Damage, deterioration, twist of wiring and cables
Corrosion, deterioration, tightness of contact terminals
Oil leak from accelerator cylinder
Function of each solenoid valve, oil leakAlarm function when reaction force against outrigger drops
Crane operation when reaction force against outrigger drops
Cable connections: tightness, contamination, corrosion
Damage, deterioration, twist of wiring and cables
Corrosion, deterioration, tightness of contact terminals
Deformation, wear, damage in load cell
Zero-point adjustment and check for load cell Function
Function
Mounting of detector switch
14
15
16
17
18
19
20
21
22
23
24
25
27
28
26
Boom
Wire rope
Piping
Hook
Automatic stop for over-wound alarm
Level
Alarm
Name plate
Radio remote control
Overturn prevention
Automatic stop for leaving minimum wire rope
Check point What to check for: Checked resultNG
Measures takenOK
Load meter
Load indicator
3-color light
Load testTest load( ton)
OperatorCrane modelDelivered dateInspected date
Remarks to be recorded
Inspected by Signature
Company in charge of inspection
Condition of air cleaner element
Contamination of fuel strainer and ignition plug
Fuel leak
Battery liquid level
Engine oil level and deterioration
Unusual vibration and noise
Tightness of fitting bolts, nuts, and missing
Crack, wear, damage in rubber crawler
Tightness of take-up bolts, nuts, and missing
Forward・backward operation of traveling lever
Operation of accelerator lever
Braking performance
Damage in stand lever and lock lever
Oil leak from reduction gear in traveling motor
Crack in welded section
Tightness of fitting bolts, nuts, pins, and missing
Oil leak, crack
Quantity, contamination, and deterioration of hydraulic oil
Contamination of air breather, return filter, suction filter
Operation, unusual noise, oil leak
Tightness of fitting bolts, nuts, and missing
Operation, deformation, crack in each lever
Missing knob, peeled off and deteriorated sticker
Oil leak
Set pressure of relief valve
Tightness of fitting bolts, nuts, pins, and missing
Operation of cylinder, lamp, buzzerEffect of stopper pin when outriggers are stored and extended, deformation of pinsDeformation of outer box, inner box, suspending bracket of outrigger bodyOil leak from outrigger cylinder, gravity-descent
Tightness of fitting bolts, nuts, pins, and missing
Oil leak
Tightness of stopper mounting bolts, deformation of plate
Tightness of fitting bolts, nuts, and missing
Continuity of slip ring, damage in wiring, mounting
Operation, unusual noise, oil leak
Damage in air breather
Gear oil quantity, deterioration
Crack in drum, lubrication to gears
Tightness of fitting bolts, nuts, and missing
Operation, unusual noise, oil leak
Damage in air breather
Gear oil quantity, deterioration
Operation of turn-table, unusual noise, lubrication
Tightness of fitting bolts, nuts, and missing
Operation
Looseness in upper and lower pins of derrick cylinder
Oil leak from derrick cylinder, gravity-descent
Tightness of fitting bolts, nuts, and missing
Operation
Oil leak from telescoping cylinder, gravity-descent
Fitting of support pins, missing snap ring
Tightness of fitting bolts, nuts, and missing
1
2
3
4
5
6
7
8
9
10
11
12
Engine
Traveling devices
Frame
Hydraulic oil tank
Hydraulic pump
Control valve
Outriggers
Swivel joint
Hoist winch
Swing device
Derrick cylinder
Telescoping cylinder
Crack, deformation
Tightness of bolts mounting turntable13 Column
Winding-up capacity, braking with rated load lifted up
Gravity descent of derrick cylinder with rated load lifted up
Gravity descent of outrigger cylinder with rated load lifted
Gravity descent with rated load lifted up when boom extended to its extreme
Swing capacity with rated load lifted up
38-1
38. PERIODICALLY REPLACING COMPONENTS AND EXPEDABLE PARTS
Note: It is to be charged for replacement of expendable components.
In order to ensure safe operation of UNIC mini-crawler crane while maintaining its functions and performance, replace components specified as periodical replacement regularly.In addition, you are requested to replace the expendable components when you have noticed wear and damage as there may be exhausted and/or deteriorated components due to frequency of use and aging deterioration.In order to use the crane in good condition, we recommend regular replacement of the components as specified in the table below.
Item ReplacementComponents
Crane
Expendable parts
Replace according to damage and wear
Line filter Once a year
Packing and seal for each cylinder Every 3 years
Sliding plate of boom Every 3 years
Brake shoe of hoist winch Every 3 years
Wire rope Replace according to damage and wear
Rubber components, wiring, cables Replace according to damage
Batteries, bulbs, switches, fuses Replace according to damage and/or consumption
Enclosure, switch, lever of transmitter
Hydraulic oil
Gear oil (hoist winch)
Gear oil (swinging reduction gear)
Other greases
Lubrication
Every 2 years
Once a year
Every 2 years
Lubricate according to consumption
Traveling Expendable parts
Expendable parts
Diesel engine oil (traveling motor reduction gear)
Rubber crawler
Every 1,000 hours according to hour meter
Replace according to crack/elongation
Engine
Engine oil Every 100 hours according to hour meter
Battery Replace according to consumption and deterioration
Rubber components, wiring, cables Replace according to damage
REPLACEMENT OF HYDRAULIC OILAir entering in oil tank brings dust and moisture.Since contaminated and deteriorated hydraulic oil in pump and motor accelerates wear and seizure, replace hydraulic oil periodically in 3 months after start of machine operation and once every 2 years thereafter.If the periodical replacement has failed to be carried out, warranty repair will not be applied even if it is within warranty period
ONE-YEAR WARRANTY COMPONENTSIn case where it will not impair quality remarkably, rust in sliding part, in fitting part, and that resulted from operation and insufficient lubrication, warranty repair will not be applied.
DL-100Initial Setting Up of Digital Load Meter Appearance of Digital Load Meter
We explain below calling each three switches "L","C","R" on load indicator panel.
In normal mode load is indicated in unit of 0.02 t ("*.**"t).
L C R
t
DL-1
1
2
3 「H2」:2 lines
4 「H4」:4 lines
* 「H6」:6 lines
1
2
3
4
5
Note:
1
2
3
4
2
1
"0.00" t is indicated and memorized.
1
1
Setting lines of wire 2
Confirm lines of wire
Cranes remains without load and swinging load
Press "R" for 1 second.
3
Decide pressing "C"
After lines of wire set indicated lighting for
3seconds, digital load meter returns to normal
"KM-100" is installed with digital load meter,
2
Press "C" once
Indicated lighting for 3 seconds
If anti-overload system (below "AOL" )
Indicated brinking lines of wire
Press "L" and select lines of wire.
Confirming lines of wire
Press "C" long (3 seconds)
Load detector 0.0t/Setting line value
Indication brinks once.
Initial setting up is 4 lines.
Normal Mode
do the initial setting up of AOL.
mode.
DL-2
1
* 1)
* 2)
* 3)
* 4)
* 5)
1
2 Press "L" and adjust value to actual
weight value.
* 1) In case weight value is less than 10kg,
round up to the nearest whole number.
* 2) 2 lines:Possible range to set is 0.5t ~ 1.6t
* 3) 4 lines:Possible range to set is 1.0t ~ 3.2t
* 4) 6 lines:Possible range to set is 1.5t ~ 4.8t
* 5) Press "L" and load value is changed 0.01t lbs by
0.01t and Press "L" long and load value is
changed in the units of 0.1t.
* 6) Go once through value and get value to indicate
again in case of exceeding load value to set.
3 After adjusting to actual weight, press "R"
In normal mode load is indicated in unit of 0.02 t ("*.**"t).
Indication brinks once and value is memorized.
4 Press "C" and go to next item.
Load detector 0.5t / Setting line value
(2 lines:1t )
(4 lines:2t )
(6 lines:3t )
Lift the weight of clear weight as standard of
0.5t per one wire.
(Standard)
4-2 2
Changing modulation mode and
load detector 0.5t/Setting line value
selecting value with "L" doesn't lead to
Press "R" and get value to memorize.
indication.
memorization.
go to the next item pressing "C".
4-1
In case of not getting value to memorize,
Press "C"and "R" long at a time (5 seconds)
indication for 1 second, it is replaced by norma
changing modulation mode to normal mode,
In items that need setting up
go once through items or put the power off.
In each item of modulation mode, after initial
1
*4 *5
4
3
5・4・3・2・1
DL-3
5 Intial Setting up Completes
1 Press "C" repeatedly and go once through
items of modulation mode.
2 After going once through them and indicating
"8.8.8." for 1 second, detector finishes
modulation mode and returns to normal mode.
* 1) Detector has 2 item after this, but they has no
relation to initial setting, so skip them all.
* 2) Last item of modulation is indicated "o o o ".
* 3)
1
2
3
4
* 1)
* 2)
* 3)
* 4)
* 5)
of over 10t, it indicates "**.*"t (in unit of 0.1t)
for 0.5 second, memorized load meter is
indicated for one second.
In each item, during initial indication, switch
operation doesn't function. After changing
item and waiting for over one second, go to
Digital Loadmeter's Additional Indication
next item.
for 0.5 second, memorized load meter is
3, 4 4
Loadmeter can add and memorize Lifting load
value, and summon and indicate memorized
Function
Then after indication disappears, loadmeter
indicated for one second
Loadmeter adds current load value to load valu
1 2
returns to indication of lifting load value.
value.
In normal mode press "L". Then normal mode
is replaced by add mode.
Add mode lamp lights red in add mode.
Press "R" once and the detector memorizes
lifting load value. After indication disappears
load value is digital-indicated by three digit "*.
**"t (in unit of 0.02t).
"8.8.8." indicates on overwinding.
"OL" indicates on overloading.
6
Then after indication disappears, loadmeter
memorized whenever pressing "R" and
returns to indication of lifting load value.
re-memorizes. After disappearing indication
On pressing "C", it resets memorized load
value and returns to normal mode.
1
is digital-indicated by three digit. Then it is
replaced back by current lifting load value.
When loadmeter indicates memorized load
During pressing "C" and for 3 seconds after
releasing finger from "C", memorized load valu
In add mode and on pressing no switch, lifting
Impossible to add during brinking.
DL-4
According to overwinding signal from load detector or "KM-100" control box,
put on/off "Overwinding Signal Output".
And loadmeter brinks " O L " as load indication during overwinding.
When load signal from load detector or "KM-100" control box exceeds rated load of load cell,
put off "Overwinding Signal Output" and brink " O L " as load indication.
1
* 1) When "8.8.8."(overwinding) or " O L "(overloading)
brinks, it is impossible to reset zero.
In normal mode load is indicated in unit of 0.02 t ("*.**"t).
E06 Fault in digital loadmeter indicator
amplifier and digital load meter If wiring is normal, exchange digital
The snapping between load cell amplifier Confirm if wiring of digital loadmeter and
and digital load detector or fault in load cell load cell amplifier is snapped.
Exchange of load cell and load cell amplifier
E01 Fault in load cell amplifier Exchange of load cell and load cell amplifier
Fault in load cell Exchange of load cell and load cell amplifier
Fault in load cell
1
Error Code
Error Code
loadmeter assembly.
Measures
Fault in load cell Exchange of load cell and load cell amplifier
Exchange of digital loadmeter indicator
Fault in digital loadmeter indicator Exchange of digital loadmeter indicator
10
E07
"0.00"t is indicated after indication disappears
for 0.5 second.
What Goes Wrong
E05
E02
E03
E04
7 Overwinding Signal Output
8
When loadmeter puts zero reset into practice,
When you press "R" long (for one second) ,
you can reset zero of load value.
Function of Detecting Overload
9 Zero Reset
1 second
DL-5
KM-100Setting Up Of ML Control BoxAppearance Of ML Control Box
We explain below calling each three switches "L","C","R" on ML control box panel.
In normal mode load is indicated in unit of 0.1t ("*.*").
L C R
t
KM-1
1
2
3 「H2」:2 lines
4 「H4」:4 lines
* 「H6」:6 lines
Setting lines of wire
(In case of changing lines of wire)
1 Press "C" long (3 seconds)
2
3
1 2
1
2
3
4
5
1 Confirming lines of wire
2-1
"Pe" sounds
Normal Mode
Press "C" once
Indicated lighting for 3 seconds
Confirm lines of wire
Initial setting up is 4 lines.
Indicated brinking lines of wire
2-2 Setting lines of wire
Press "C" and decide
"Pe" sounds
(In case of changing lines of wire)
Press "L" and change indication
Decision ("H2" or "H4" or "H6" )is indicated
for 3 seconds.
Back to normal mode
t
MOMENT
H 4
t
MOMENT
H 4
t
MOMENT
H2orH4orH6
t
MOMENT
H2orH4orH6
Pe
Pe
KM-2
1
* 1)
* 2)
* 3)
* 4)
1 1 2
2
3
* 1)
* 2)
* 3)
1
2
3
Press "C" and go to next item.
Press "C" and go to next item.
detector.
Retract boom at minimum.
Press "R".
"Pe" sounds and set up boom length is
indicated and memorized.
5 Setting up minimum value in boom length
through model codes and indicate model code
to select again.
Take care that model code with "." right
under it is different from model code without it.
Sure to set up each detector when changing
model code.
(Each detector is reset up.)
model.
If model code to select goes over, go once
item.
Check if installing detector and detector itself
is abnormal.
Select model with "L".
(Go in turn by pressing "L" long)
Press "R".
Detector sounds "Pe", brinks, and memorize
4 Setting up model
Go once through items or put the power off.
"L": Mainly cord selection switch
"C": Go next item.
"R": Memory switch
When "---" indicates brinking, it shows except
range possible to set up the detector in the
up initially
3 Changing modulation mode and setting
Returning modulation mode to normal mode,
mode
Press "C"and "R" long at a time (5 seconds)
Wait for 1 second after changing item.
(Item is not changed without waiting over
1 second.)t
MOMENT
Pe
t
MOMENT
Model
t
MOMENT
c o d Pe
t
MOMENT
L _ 1
Pe
KM-3
Setting up middle value in boom length
1
2
3
* 1)
1
2
3
4
1 2
1
2
actual value.
3
4
* 1)
(0, 1゜unit)
* 2)
1 2
1
2
actual value.
3
4
* 1)
(0, 1゜unit)
* 2)
6
7 Setting up maximum value in boom length
(Except 2 section boom)
Move boom by indicated section.
Press "R".
"Pe" sounds and boom section set up is
indicated and memorized.
3 to 4 section boom is set up with boom ①
and ②.
Press "C" and go to next item.
Press "C" and go to next item.
5 to 6 section boom is set up with boom ①,
②, and ③.
Press "C" and go to next item.
"5°"is memorized.
Possible range to modulate is 5゜±2゜.
Go in order with pressing "L" long.
(Next 7°, back to 3°. 5,6,7,3,4,5…)
Move boom angle at 5°
Press "L" and adjust indication value to
8 Setting up boom angle detector at 5°
Indicate maximum boom section.
Extend boom at maximum.
Press "R".
"Pe" sounds and boom section set up is
indicated and memorized.
Press "R"
"Pe" sounds and indication blinks once and
9 Setting up boom angle detector at 70°
Press "L" and adjust indication value to
Press "R"
Move boom angle at 5°
"Pe" sounds and indication blinks once and
Press "C" and go to next item.
is memorized.
Possible range to modulate is 70゜±2゜.
Go in order with pressing "L" long.
(Next 72°, back to 68°. 70,71,72,68,69,70…)
t
MOMENT
L_(S ti )
Pe
t
MOMENT
L_(Section)
Pe
t
MOMENT
A _ 5
t
MOMENT
A _ 5
Pe
t
MOMENT
A 7 0
t
MOMENT
A 7 0
Pe
KM-4
1 2
1
2
* 1)
1 1 2
2
3 Press "R" without load swinging.
4 "Pe" sounds and indication blinks once and
is memorized.
* 1) Range set on load detector
2 lines:0.5t ~ 1.6t
(1t is best condition)
4 lines:1t ~ 3.2t
(2t is best condition)
6 lines:1.5t~ 4.8t
(3t is best condition)
* 2) Press "L" and load value is changed 0.01t by
0.01t.
* 3) Press "L" long and load value is changed in the
units of 0.1t.
Press "C" and go to next item.
1
2
* 1)
Press "C" repeatedly and go once through
items of modulation cord.
When items of modulation go once through,
"Pe" sounds. And after "8.8.8." is indicated for
1 second, detector returns to normal mode.
12 Initial Setting up Completes
This operation has no relation to initial setting
up, so after this skip 11th item.
as weight.
10 Load detector 0.0t/Setting line value
11
Press "R" with hook only keeping
"Pe" sounds and indication blinks once and
is memorized.
Wire line is displayed on initial indication.
Load detector 0.5t/Setting line value
(4 lines:2t )
(6 lines:3t )
Press "L" and indicate same weight value
Press "C" and go to next item.
Lift the weight of clear weight.
(2 lines:1t )
t
MOMENT
0.0 0
Pet
MOMENT
H2orH4orH6
t
MOMENT
Load Value
Pe
t
MOMENT
H2orH4orH6
t8.8.8.
t
MOMENT
Pe
KM-5
1
2
1
2
13 Indication of Boom Length 1
Indicate current boom length ( 「**.*」 m ).
While only pressing "R", output voltage
Initial Indication
(「**.*」V) from the detector is indicated.
2
Indicate current boom angle ("**.*"degrees).
Press "C" and go next item.
14 Indication of Boom Angle Initial Indication 1
While only pressing "R", output voltage
("**.*"V) from the detector is indicated.
2
Press "C" and go next item.
t- L -
t**.*m
t- A -
t**.*°
t*.**V
t*.*V
KM-6
1
2
3
4
* 1)
* 2)
* 3)
1
2
16 Three Digit Indication of Lifting Load
Press "C" and go to next item.
2
Indicate current lifting load ("*.**"t ).
While only pressing "R", indicate output voltage
of differential motion("*.**"V) from detector.
Initial Indication 1
Press "C" and go to next item.
is back to 0.00 degree.
While pressing "L", revised boom warping angle
is indicated. On releasing finger from "L",
working radius after boom warping angle is
revised is indicated.
degree and revise value +0.1 by +0.1 degree.
On pressing "R", "Pe" sounds and indication
"Boom angle for calculating working radius"
=
4
from 0.0 degree to 3.0 degree and 3.0 degree
Range of revisable boom warping angle is 2,3
"Angle for detecting boom angle"
- "Angle of boom warping"
brinks once and is memorized.
Boom angle used to calculate working radius is
15 Indication of Working Radius Initial Indication 1
Indicate current working radius ("**.*"m ).
Whenever pressing "L", revise angles of boom
warping.
Initial value of warping boom angle is "1.0"
t
MOMENT
- r -
t
MOMENT
**.*m
t
MOMENT
*.*°
t- F -
t*.**t
t**.*V
t
MOMENT
**.*m
Pe
KM-7
1
2
①
②
③
* 1
* 2
※
17 Rated Load Indication
rate ("***"%).
Initial Indication 1
Indicate current rated load ("*.**"t).
While only pressing "R", indicate current load
Press "C" and go to next item.
2
brinks once and is memorized.
Factor_K0
Set up factor ("*.**") for decision formula
18 Setting up Intermission Alarm Output
Range of revisable factor is from 0.50 to
1.50.
When factor is over 1.50, it is back to 0.50.
Initial Indication 2
3
of ML intermission alarm output.
Whenever pressing "L", revise value +0.05 by
+0.05.
When pressing "R", "Pe" sounds and indication
Refer to "Model code list" about initial value
of ML alarm output factor_K1.
Mode only for Japan.
Press "C" and go to next item.
Set to the same value as K1.
tΞ F Ξ
t*.**t
t***%
t
MOMENT
c 0
t
MOMENT
Factor
tFactor
Pe
KM-8
①
②
③
* 1
* 2
1
2
3
* 1)
* 2)
Press "C" and go to next item.
Range of revisable factor is from 0.50 to
1.50.
3
Note: Factor for Taiwan is "1.00".
When factor is over 1.50, it is back to 0.50.
Factor for Australia and
Europe is "1.10".
2
_K2
Set up factor ("*.**") for decision formula
of ML stop output.
When pressing "R", "Pe" sounds and indication
brinks once and is memorized.
3
Refer to "Model code list" about initial value
of ML stop output factor_K2.
Whenever pressing "L", revise value +0.05 by
+0.05.
Press "C" and go to next item.
20 Setting up Stop Output Factor Initial Indication
+0.05.
When pressing "R", "Pe" sounds and indication
brinks once and is memorized.
Refer to "Model code list" about initial value
of ML alarm output factor_K1.
Range of revisable factor is from 0.50 to
1.50.
When factor is over 1.50, it is back to 0.50.
Initial Indication 2
of ML continuous alarm output.
Whenever pressing "L", revise value +0.05 by
Factor_K1
Set up factor ("*.**") for decision formula
19 Setting up Continuous Alarm Output
t
MOMENT
c 1
t
MOMENT
Factor
tFactor
tc 2
tFactor
tFactor
Pe
Pe
KM-9
1
2
3
* 1)
* 2)
1
2
3
* 1)
* 2)
performance.
* 3)
performance.
* 4)
21 Setting up Stop Return Factor _ K3
Return ML stop output "ON" to "OFF".
Factor for Australia and
Note: Factor for Taiwan is "0.95".
Whenever pressing "L", revise value +0.05 by
Set up factor ("*.**") for decision formula.
Europe is "1.05".
+0.05.
When pressing "R", "Pe" sounds and indication
brinks once and is memorized.
Refer to "Model code list" about initial value
of ML stop return output factor_K3.
Range of revisable factor is from 0.50 to
1.50.
When factor is over 1.50, it is back to 0.50.
Press "C" and go to next item.
22 Setting up Front Performance Mode Initial Indication 2
Pressing "R", "Pe" sounds and indication
brinks once and is memorized.
Set up if controling with front rated load chart
or with performance calculated from rear
In front zone when selecting "F__",
control with front rated load chart.
performance.
Whenever pressing "L", change modes as
"F_ _⇀r_ _⇀r00⇀r05⇀r10...⇀r95⇀F_ _⇀... "
In front zone when selecting "r__", 3
control with **% performance of rear
It is possible to set up within percentage 0%
control with 100% performance of rear
In front zone when selecting "r**",
Press "C" and go to next item.
to 100% in units of 5%.
t
MOMENT
c 3
t
MOMENT
Factor
tFactor
Pe
t tMode Value
t
MOMENT
Mode Value
Pe
KM-10
1
2
3
1
2
3
3
Pressing "L" and "R" long at a time (3
seconds), all set-up value is reset. And "Pe"
sounds and "000" is indicated.
Pressing "C", "Pe" sounds and "8.8.8." is
indicated for 1 second. Then modulation mode
is finished and returned to normal mode.
24 Resetting set-up value Initial Indication 2
Reset set-up value and return the detector
to initial condition.
Press "C" and go to next item.
3
brinks once and is memorized.
Pressing "R", "Pe " sounds and indication
23 Setting up ML Stop Output Mode 2
Setting up if output of KM-100 is alarm type
or autostop type.
Whenever pressing "L", alarm type changes
Initial Indication
"off", autostop type changes "on".t t
Mode Value
tMode Value
Pe
t t0 0 0
t8.8.8.
Pe
Pe
KM-11
KM-100 ML Control Box Modulation Mode List
№ heading first indication(1sec) usual indication left SW center SW right SW remarks
Changing modulation mode - - -Press long at
once(5sec)
Press long atonce
(5sec)
Returning modulation mode to normal mode,go once throughitems or put the power off.
1 Setting up model 「cod」 「(Model code)」 Select ModelGo to next
itemmemorized Refer to Model code list(№0628)
2Setting up minimum valuein boom length detector
「L_1」 「L_1」 -Go to next
itemmemorized
Set up boom length at minimum is indicated and memorized(「*.**」ft)
3Setting up middle value in
boom length detector「L_(Section)」 「L_(Section)」 -
Go to nextitem
memorizedSet up boom length at 2or 3-section is indicated and memorized(「*.**」ft)、Except 2 section boom
4Setting up maximum valuein boom length detector
「L_(Section)」 「L_(Section)」 -Go to next
itemmemorized
Set up boom length at maximum is indicated and memorized(「*.**」m)
5Setting up boom angle
detector at 5°「A_5」 「(Indication value)」
Adjust indicationvalue to actual
value
Go to nextitem
memorized Possible range to modulate is 3.0°~7.0°(Initial value is 5.0°)
6Setting up boom angle
detector at 70°「A70」 「(Indication value)」
Adjust indicationvalue to actual
value
Go to nextitem
memorized Possible range to modulate is 68°~72°(Initial value is 70°)
7Load detector
0lbs/setting line value「(Wire line)」 「0.00」 -
Go to nextitem
memorized 「H2」(2 lines),「H4」(4 lines),「H6」(6 lines)
8Load detector
1100lbs/setting line「(Wire line)」 「(Load value)」 Adjust load value
Go to nextitem
memorized「H2」(2 lines),「H4」(4 lines),「H6」(6 lines)Possible range to modurate500lbs~1800lbs/wire lines
9 Indication of boom length 「-L-」 「(Boom length)」 -Go to next
itemindicatevoltage
Indication of boom length(「**.*」ft)Indication of voltage(「*.**」V)
10 Indication of boom angle 「-A-」 「(Boom angle)」 -Go to next
itemindicatevoltage
Indication of boom angle(「**.*」°)Indication of voltage(「*.**」V)
11Indication of working
radius「-r-」 「(Working radius)」
Warping boomangle
Go to nextitem
memorizedIndication of working radius(「**.*」ft)Possible range to modulate is 0.0°~3.0°(initial value 1.0°)
12Three digital indication of
lifting load「-F-」 「(Lifting load)」 -
Go to nextitem
indicatevoltage
Indication of lifting load(「*.**」X1000lbs)indicate voltage(「*.**」V)
13 Rated load indication 「≡F≡」 「(Rated load)」 -Go to next
itemRated loadindication
Indication of rated load(「*.**」X1000lbs)Indication of rated load ratio(「***」%)
14Setting up Intermissionalarm output factor K0
「 c0」 「(Factor)」 Revise factorGo to next
itemmemorized
Possible range to modulate is 0.50~1.50(per 0.05)Mode only for Japan. Set to the same value as K1.
15Setting up continuousalarm output factor K1
「 c1」 「(Factor)」 Revise factorGo to next
itemmemorized Possible range to modulate is 0.50~1.50(per 0.05)
16Setting up stop output
factor K2「 c2」 「(Factor)」 Revise factor
Go to nextitem
memorized Possible range to modulate is 0.50~1.50(per 0.05)
17Setting up stop return
output factor K3「 c3」 「(Factor)」 Revise factor
Go to nextitem
memorized Possible range to modulate is 0.50~1.50(per 0.05)
18Setting up "Outrugger
not max mode"「(Mode value)」 「(Mode value)」 Select Mode
Go to nextitem
memorized「F‗ ‗」Outrigger not max ext. 、「r‗ ‗」Outrigger max ext.100%「r**」**% of Outrigger max ext.(per 5%)
19Setting up ML stop output
mode「(Mode value)」 「(Mode value)」 Select Mode
Go to nextitem
memorized 「 on」Autostop type、「oFF」Alarm type
20 Resetting set-up value 「ooo」 「ooo」Press long atonce(3sec)
ConpletedPress long atonce(3sec)
Press long at once(3 seconds),all set-up value is reset and 「000」is indicated.When modulation mode is finished,「888」 is indicatedfor 1 second.
KM-12
Mode(Error code) list of Moment limiterError code Trouble
E01 Defection of Load cell Amplifier Reset (Try to turn on power.)
E02 Load Signal(A) from Load cell to Amplifier of Load cell is disconnected.. Check wiring and connector.
E03 Load Signal(B) from Load cell to Amplifier of Load cell is disconnected.. Check wiring and connector.
E04 Load Signal(A),(B) from Load cell to Amplifier of Load cell is disconnected.. Check wiring and connector.
E05 Moment limiter control box is broken. Reset (Try to turn on power.)
E06 Moment limiter control box is broken. The setting change was done 100,000 times or more.
E07 Signals from Amplifier of Load cell to Moment limiter control box is disconnected.. Check wiring and connector.
E08 Signals from Boom Angle detector are disconnected. Check wiring and connector.
E09 Signals from Boom Length detector are detected. Check wiring and connector.
KM-13
Model code Model Loading capacity Division K1 K2 K3 Type
295 URW295C 2.9t for Japan 1.00 1.25 1.15 Alarm
375 URW375CD 2.9t for Japan 1.00 1.25 1.15 Alarm
376 URW376CD 2.9t for Japan 1.00 1.25 1.15 Alarm
506 URW506CD 2.9t for Japan 1.00 1.25 1.15 Alarm
305 URW295C 2.9t for Japan 0.90 2.00 1.80 Alarm
385 URW375CD 2.9t for Japan 0.90 2.00 1.80 Alarm
386 URW376CD 2.9t for Japan 0.90 2.00 1.80 Alarm
516 URW506CD 2.9t for Japan 0.90 2.00 1.80 Alarm
285 URW295CMR-A 2.9t for Japan 0.90 1.00 0.95 Auto stop
365 URW375CD-A 2.9t for Japan 0.90 1.00 0.95 Auto stop
366 URW376CD-A 2.9t for Japan 0.90 1.00 0.95 Auto stop
496 URW506CD-A 2.9t for Japan 0.90 1.00 0.95 Auto stop
295. URW295C 2.9t for Russia 0.90 1.10 1.05 Auto stop
375. URW375CDA 3.0t for AUS 0.90 1.10 1.05 Auto stop
376. URW376CDA 3.0t for AUS 0.90 1.10 1.05 Auto stop
546. URW546CDA 4.0t for AUS 0.90 1.10 1.05 Auto stop
KM-100-CA Model code list
KM-14
KM-15
DESCRIPTION OF EACH CONTROL DEVICE
U-AOL system (Anti overloading system)
U-AOL system is a safety device that detects load applied to the crane to issue an alarm automatically when the load reaches the rated total load.
* Rated total loadRated total load is maximum load based on hoisting capacity of the crane as against raised angle and/or extended length of the boom and this includes weight of hooking implement.
Function of U-AOL system1.◆
WARNINGThe system is not for preventing the crane from overturning. ★
Operate the crane by paying full attention to its stability.Even if the system actuates, load applied to the crane may increase ★
due to inertia so that the crane might be damaged when a lift-ed cargo is swinging or working speed is too fast. Do not put too much dependence on the system but try to operate it carefully at all times for securing safety.
Do not carry out operation which increases lifting load, such as piling ★up a cargo on the lifted pallet or pouring a liquid into the lifted contain-er during lifting operation. This may cause the crane to be damaged or overturned.
KM-16
DESCRIPTION OF EACH CONTROL DEVICE
Boom angle detector
Over-load alarmcontrol box
Boom length detector
3-color indictor lamp
Load detector
Capacity limit alarm buzzer
Construction of U-AOL system2.◆
Capacity limit alarm ◆
1.Over-load alarmOperation of U-AOL system3.◆
WARNING
★ If the capacity limit alarm is actuated, stop the crane operation imme-diately to move the lifted cargo toward safer side.
When the load applied to the crane comes close to the rated total load (capacity limit), the alarm buzzer sounds (“Ping-pong, Ping-pong”) to issue an alarm.
Ping-pong,
Ping-p
ong
When the load applied to the crane reaches the capacity limit, crane functions listed below stop automatically:
・Extending boom ・Lowering boom・Winding-up hook ・Swinging CW.&C.C.W.
KM-17
DESCRIPTION OF EACH CONTROL DEVICE
◆ nehw nekat eb ot serusaeM .4U-AOL system is in trouble.
In case where the crane becomes impossible to be operated due to system trouble, cancel the U-AOL system to store the crane.
ML auto stop switch
OFF
Step 1Throwing the ML auto stop switch to “OFF”position allows the ML device is to be cancelled (for 5 seconds maximum).Carry out winding-up hook, lowering boom, and slewing operation with each control lever.
Step 2If the crane cannot be operated by the step 1 above, operate the crane by following
◆2.“ How to reset when automatic stop for overwinding is found to be out of order” section.
CAUTION★ Boom cannot be extended even when the safety device is being can-celled.★ In case where the crane is operated with the safety device has been cancelled once, it will take 30 seconds until it can be cancelled next time.
MOMENT LIMITER
tOUTRIGGERS
NOT MAX EXT
SELECT SET
URW376C1A, URW540C1A
◆ noitacidni daol fo noitcnuF .5In normal operation, the load is to be
latigid eht no t1.0 fo thgiew eht ni de tacidniindicator in the over-load alarm control box.
KM-18
DESCRIPTION OF EACH CONTROL DEVICE
MOMENT LIMITER
tOUTRIGGERS
NOT MAX EXT
SELECT SET
Lamp indicating Outriggers not max EXT
Indicator
“Check” switch
fo trap hcae fo noitangiseD ◆
Capacity limit alarmIndicator:It indicates weight of lifted cargo (t).Lamp indicating outriggers not max ext:It indicates in “green” when outriggers are not in maximum extension.“Check” switch:It is to confirm operation of each indication and alarm.
Errorcode
Trouble
Trouble may be in load indicator.
Trouble may be in overload alarm control box.
Trouble may be in connection between load detector
Trouble may be in boom length detector.
Trouble may be in boom angle detector.
◆ ecived mrala daolrevo fo noitacidni rorrE When an error is detected, corresponding error code appears on the control box.
KM-19
DESCRIPTION OF EACH CONTROL DEVICE
●RemarksThe power to U-AOL system is supplied through ON/OFF control of crane-crawl lever.
MOMENT LIMITER
tOUTRIGGERS
NOT MAX EXT
SELECT SET
Digital indicator
Checking switch Switch for setting number of slinging wire rope
◆ metsys mrala daol-revo gnikcehC Check that [0.0] t is indicatetd on the digital indicator when no-load is applied.
Depress the checking switch to confirm that [8.8.8.] appears on the digital indicator.
Confirm that crane functions listed below cannot be operated while the checking switch is being depressed.
・Extending boom ・Lowering boom・Winding-up hook ・Swinging C.W.&C.C.W.
Depress the switch for setting number of slinging wire rope to confirm that [H4] appears on the digital indicator.Indicator returns to wait indication in 3 seconds after the switch has been released.
In case where anything unusual is found while inspection before starting work is being carried out or the crane is being operated, ask a UNIC authorized service shop for inspection immediately.
metsys LOA-U gnikcehC 6.◆before starting crane operation
Before starting the crane operation, checks follows: