Unic 376c1am r546c1amr Work Shop Manual

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． Hｏｏｋ１６－１

１７．Ｔｕｒｎｔａｂｌｅ　ｍｏｕｎｔｉｎｇ　ｐｒｏｃｅｄｕｒｅｓ１７－１

１８．Ｓｌｅｗｉｎｇ　ｄｅｖｉｃｅＳｌｅｗｉｎｇ　ｒｅｄｕｃｔｉｏｎ　ｇｅａｒ１８－１～５

Ｐｉｐｉｎｇ１８－６～７

１９． OutriggerHydraulic circuit diagram １９－１

Outrigger １９－２

Vertical　outrigger　ｃｙｌｉｎｄｅｒ１９－３

Ｈｏｒｉｚｏｎｔａｌ　outrigger　ｃｙｌｉｎｄｅｒ１９－４

２０．Ｄerricking　cylinder ２０－１～３

２１．Ｔelescoping　cylinderＵＲＷ３７６Ｃ２１－１～４

ＵＲＷ５４６Ｃ２１－５～１５

２２． BoomＵＲＷ３７６Ｃ２２－１～８

ＵＲＷ５４６Ｃ２２－９～１５

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 chartＵＲＷ３７６Ｃ３４－１ＵＲＷ５４６Ｃ３４－２

３５． Lubrication chartＵＲＷ３７６Ｃ３５－１ＵＲＷ５０６Ｃ３５－２

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


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


Crawling device

2-4


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





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


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.


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


(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


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


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


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 EXTOUTRIGGERS

URW376C1A

NOT 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


• 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


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


Outrigger③ Vertical Depressing 7 to operate lever


Outrigger④ Vertical Depressing 3 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


Outrigger② Vertical Depressing 5 to operate lever


Outrigger③ Vertical Depressing 7 to operate lever


Outrigger④ Vertical Depressing 3 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.


“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 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

２６３６

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


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.


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.


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.


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


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


Right

Left

Right Left

Ground

Sky


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


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)




② Hoist(down)

③ Hoist(up)

１３－５

SWIVEL JOINT PIPING

① HOIST(DRAIN)





１３－６

SWIVEL JOINT PIPING

① Hoist(drain)

② Hoist(down)

③ Hoist(up)




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)




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


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)



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"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


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


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.


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.


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.


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 disorderly.


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

２２ＵＲＷ３７６Ｃ

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



２２－９

２２ＵＲＷ５４６Ｃ

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.



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


２６－７


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


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


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.



The counterbalance valve malfunctions.The seat surface is damaged.



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.


Wire clip

Wedge

Overwindingalarm detector

Ring

Wire rope foroverwinding alarm

Weight foroverwindingalarm

３１－２


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.


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.


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 .


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.


①③

３４－１

34

34-2


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)


３５－１

35

35-2


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

(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


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


Operation, deformation, crack in each lever

Missing knob, peeled off and deteriorated sticker

Oil leak


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


Oil leak

Tightness of stopper mounting bolts, deformation of plate


Continuity of slip ring, damage in wiring, mounting


Damage in air breather

Gear oil quantity, deterioration

Crack in drum, lubrication to gears





Operation of turn-table, unusual noise, lubrication


Operation

Looseness in upper and lower pins of derrick cylinder

Oil leak from derrick cylinder, gravity-descent


Operation

Oil leak from telescoping cylinder, gravity-descent

Fitting of support pins, missing snap ring


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 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




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



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


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 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




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




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



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


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


Oil leak, crack

Quantity, contamination, and deterioration of hydraulic oil

Contamination of air breather, return filter, suction filter



Operation, deformation, crack in each lever

Missing knob, peeled off and deteriorated sticker

Oil leak

Set pressure of relief valve


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


Oil leak

Tightness of stopper mounting bolts, deformation of plate


Continuity of slip ring, damage in wiring, mounting




Crack in drum, lubrication to gears





Operation of turn-table, unusual noise, lubrication


Operation

Looseness in upper and lower pins of derrick cylinder

Oil leak from derrick cylinder, gravity-descent


Operation

Oil leak from telescoping cylinder, gravity-descent

Fitting of support pins, missing snap ring


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).

ＬＣＲ

t

DL-1

1

2

3 「H2」：2 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



* 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"


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.


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 ("*.*").

ＬＣＲ

t

KM-1

1

2



* 「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.


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


3 to 4 section boom is set up with boom ①

and ②.



5 to 6 section boom is set up with boom ①,

②, and ③.


"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


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°



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


6 lines：1.5t～ 4.8t


* 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.


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


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


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


2

Indicate current lifting load ("*.**"t ).

While only pressing "R", indicate output voltage

of differential motion("*.**"V) from detector.

Initial Indication 1


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 ("***"%).


Indicate current rated load ("*.**"t).

While only pressing "R", indicate current load


2


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.


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.


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)



1.50.

3

Note: Factor for Taiwan is "1.00".


Factor for Australia and

Europe is "1.10".

2

_K2


of ML stop output.



3


of ML stop output factor_K2.


+0.05.


20 Setting up Stop Output Factor Initial Indication

+0.05.




of ML alarm output factor_K1.


1.50.



of ML continuous alarm output.


Factor_K1


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".


Set up factor ("*.**") for decision formula.

Europe is "1.05".

+0.05.




of ML stop return output factor_K3.


1.50.



22 Setting up Front Performance Mode Initial Indication 2

Pressing "R", "Pe" sounds and indication


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**",


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.


3


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



305 URW295C 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



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


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


◆ 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


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


●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:

Unic 376c1am r546c1amr Work Shop Manual

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Transcript of Unic 376c1am r546c1amr Work Shop Manual