Unic 376c1am R546c1amr Work Shop Manual x334x

ＷＯＲＫ　ＳＨＯＰ　ＭＡＮＵＡＬ

URW376C1AMR URW546C1AMR

ＦＵＲＵＫＡＷＡ　ＵＮＩＣ　ＣＯＲＰＯＲＡＴＩＯＮ

Contents １．

General view

１−１

２．

Major Specifications (URW376C1A)

２−１∼６

３．

Major specifications (URW546C1A)

３−１∼６

４．

Outrigger operation How to extend outriggers How to store outriggers

５．

How to store outriggers when in an emergency When failed storage by normal operation When failed extension by normal operation

６．

４−１ ４−２

５−１ ５−２

Mode indicator lamp (control box)            

Mode indication when crane is in normal operation Mode indication when crane is mistakenly operated Indication of each operation Error indication

７．

List of voice messages

８．

How to switch operation mode

６−１∼２ ６−３ ６−４ ６−５∼６ ７−１

Switching of mode (Manual mode ⇔ Radio control mode) How to operate outriggers by manual lever How to operate outriggers by radio control transmitter Switching of mode indicator(State ⇔ Operation) Restting of interlocking balance control    Switching of "Shockless"function(Carry it out when it is not over-wound)    Switching of low-temperature operation mode Method of engine start and stop that radio controller

８−１ ８−２ ８−３ ８−４

Radio control cannot be operated

９−１

１０．

Emergency measures

１０−１

１１．

Hydraulic circuit diagram (carrier）

１１−１ １１−２∼５ １１−６∼１１ １１−１２ １１−１３∼１５

           

９．

Control valve for carrier Manifold Pump Crawling motor

８−５ ８−６

１２．

Hydraulic circuit diagram (control valve for crane)

１２−１

１３．

Swivel t

１３−１∼６

１４．

Column

１4−１∼３

１５．

Ｈｏｉｓｔ winch

１５−１∼３

１６．

Hｏｏｋ

１６−１

１７．

Ｔｕｒｎｔａｂｌｅ ｍｏｕｎｔｉｎｇ ｐｒｏｃｅｄｕｒｅｓ

１７−１

１８．

Ｓｌｅｗｉｎｇ ｄｅｖｉｃｅ Ｓｌｅｗｉｎｇ ｒｅｄｕｃｔｉｏｎ ｇｅａｒ Ｐｉｐｉｎｇ

１９．

Outrigger Hydraulic circuit diagram Outrigger Vertical outrigger ｃｙｌｉｎｄｅｒ Ｈｏｒｉｚｏｎｔａｌ outrigger ｃｙｌｉｎｄｅｒ

２０．

Ｄerricking cylinder

２１．

Ｔelescoping cylinder ＵＲＷ３７６Ｃ ＵＲＷ５４６Ｃ

２２．

１８−１∼５ １８−６∼７

１９−１ １９−２ １９−３ １９−４ ２０−１∼３

２１−１∼４ ２１−５∼１５

Boom ＵＲＷ３７６Ｃ ＵＲＷ５４６Ｃ Installation procedures for slide plate and guide

２２−１∼８ ２２−９∼１５ ２２−１６

２３．

How to punch

２３−１

２４．

Telescoping/derrick cylinder ass'y, Measures toprevent piston from being loosened

２４−１∼２

２５．

Earth position Earth for engine start relay and engine stop relay Earth of the main harness

２６．

Eleectric Wiring Diagram Electric wiring in control seat part turnover prevention divice (degital type) Power supply fuse Solenoid valves for operating outrigger Connector of Emergency stop Wiring for operation switch Switch (key switch type) (turnover prevention device) Interlock for crane-crawl lever The other side of accelerator pedal Accelerator cable Electric wiring in control valve part turnover prevention device(degital type) Reay box Buzzer

２５−１ ２５−２ ２６−１−１∼２ ２６−２ ２６−３ ２６−４ ２６−５ ２６−６∼８ ２６−９∼１０ ２６−１１∼１２ ２６−１３∼１４ ２６−１５ ２６−１６∼１９ ２６−２０∼２１ ２６−２２

２７．

Position of hose

２８．

Engine All view of engine Wiring for warning lamp Water separator、oil fillter element Air cleaner element／Alternator Electric Wiring diagram (engine part)

２９．

２８－１ ２８－２ ２８－３ ２８－４ ２８－５

Ｐｏｗｅｒ　ｕｎｉｔ　（Ｏｐｔｉｏｎ） Electric Wiring diagram Control box for power unit Converter Power unit　（～37W0117） Power unit　（37W0120～）

３０．

２７－１

Inspection for sinking of cylinder Inspection of derrick cylinder Inspection of telescoping cylinder Inspection of outrigger cylinder

２９－１ ２９－２～３ ２９－４ ２９－５ ２９－６ ３０－１ ３０－２ 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 lubricant Lubrication to carrier Lubrication to crane

３４．

Filling water and lubrication chart ＵＲＷ３７６Ｃ ＵＲＷ５４６Ｃ

３５．

３４－１ ３４－２

Lubrication chart ＵＲＷ３７６Ｃ ＵＲＷ５０６Ｃ

３６．

Lubrication

３７．

Inspection records Before starting crane operation Monthly self-inspection records Annual self-inspection records

３８．

３３－１～２ ３３－３

Periodically replacing components and expedable parts

３５－１ ３５－２ ３６－１

３７－１ ３７－２ ３７－３ ３８－１

Digital Load Meter　（DL-100) Initial setting up Error code

DL－１～５ DL－５

Momet Lemitter　（KM-100) Initial setting up Control box modulation mode list Error code U-AOL system ( Anti overloading system )

KM－１～１１ KM－１２ KM－１３～１４ KM－１５～１９

1.GENERAL VIEW

1190

1800

URW376C

ご

1750 3530

300 1300

4340

1215

2035

URW546C

1750 220

3970 4870

1-1

300 1300

MAJOR SPECIFICATIONS URW376C1A(6-section boom) (Speed indicated in the table below is at oil temperature range of 45~55°C, operating with noload, and at rated pump discharge.)

Major specifications Crane capacity (Net rated load)

3.0t × 2.5m (With outriggers, extended fully)

Maximum lift above ground (Hook)

14.9m

Boom to be extended to:

3.63m~5.85m~8.04m~10.23m~12.42m~14.61m

Maximum working radius

14.45m

Speed of winding-up (Rope speed)

Extending speed of boom

68m/min (At 4th layer on the drum) 17m/min (At 4th layer on the drum, with 4-part line hooking) 10.98m/23sec

Raising speed of boom

0° ~ 80°/10sec

Slewing speed

2.5rpm

Slewing range

360°(continuous) IWRC6 × WS(26) calss B[Breaking load:42.4kN (4320kgf)] 8mm × 85m

Hoisting speed of hook

Hoisting rope

Construction Diameter×length Horizontal

Outrigger

Rated discharge

Direct pushing by double acting hydraulic cylinder (directly connected to hydraulic automatic locking device) Crane: 20.6MPa(210kgf/cm2) Crawl: 21.6MPa(220kgf/cm2) Approx. 60 ℓ/min

Rated rotation

Approx. 2100rpm

Vertical Rated pressure Hydraulic pump

Direct pushing by double acting hydraulic cylinder (directly connected to hydraulic automatic locking device)

Hydraulic oil tank Capacity

70 liters

2-1

MAJOR SPECIFICATIONS Equipment and construction Boom:6-section, Hexagonal box beam Boom telescoping

Boom derricking

Hoisting

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: simultaneous actuation) Direct pushing by hydraulic cylinder (With hydraulic automatic locking device) Hydraulic motor: Axial plunger type Reduction gears: Spur-gear reduction Brake: Automatic mechanical brake

Slewing

Hydraulic motor: Axial plunger type Reduction gears: Worm-gear+Spur-gear reduction (ed by ball bearings) Brake: Worm self-lock

Hydraulic pump

Variable delivery piston pump

Hooking capacity

3.0t Number of slinging rope: 4 Safety valve for hydraulic circuit Hydraulic automatic lock Automatic stop for overwinding Overwinding alarm Slewing automatic lock Automatic stop for leaving minimum wire rope Load indicator (With angle meter)

Safety devices

Alarm buzzer Retaining mechanism to prevent wire rope from disengagement Interlock for crane-crawl operation Crane/outrigger interlocking device Checker for outrigger rotary set pin insertion Digital load meter Emergency stop button U-AOL system Level

Weight

Approx. 3860kg

2-2

MAJOR SPECIFICATIONS Crawling device Crawling

Endless rubber crawler

Crawler

300×52.5×88

Length of ground

1750mm

Pressure of ground

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

2-3

MAJOR SPECIFICATIONS Chart of net rated load

Net rated loads chart BOOM SECTION WORKING RADIUS(m) OUTRIGGERS NET RATED MAX EXT OUTRIGGERS LOAD(t) NOT MAX EXT

BOOM SECTION WORKING RADIUS(m) OUTRIGGERS NET RATED MAX EXT OUTRIGGERS LOAD(t) NOT MAX EXT

BOOM SECTION WORKING RADIUS(m) OUTRIGGERS NET RATED MAX EXT OUTRIGGERS LOAD(t) NOT MAX EXT

BOOM SECTION WORKING RADIUS(m) NET RATED LOAD(t)

OUTRIGGERS MAX EXT OUTRIGGERS NOT MAX EXT

BOOM SECTION WORKING RADIUS(m) NET RATED LOAD(t)

OUTRIGGERS MAX EXT OUTRIGGERS NOT MAX EXT

1 1+2 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.69 3.0 3.0 2.35 1.95 1.67 1.45 1.3 1.07 3.0 3.0 2.17 1.5 1.12 0.9 0.72 0.47 1+2+3 2.7 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 7.88 2.24 2.09 1.65 1.4 1.22 1.07 0.95 0.84 0.69 0.59 2.24 2.06 1.57 1.22 1.02 0.83 0.65 0.51 0.3 0.19 1+2+3+4 4.0 4.5 5.0 6.0 7.0 8.0 9.0 10.07 1.04 0.93 0.84 0.73 0.62 0.52 0.47 0.38 1.03 0.82 0.64 0.47 0.31 0.22 0.13 0.09 1+2+3+4+5 4.5 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.26 0.75 0.62 0.48 0.39 0.34 0.3 0.27 0.24 0.23 0.75 0.62 0.4 0.25 0.18 0.13 0.09 0.06 0.01 1+2+3+4+5+6 4.9 5.5 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.45 0.3 0.27 0.25 0.22 0.2 0.18 0.16 0.14 0.13 0.11 0.1 0.3 0.27 0.25 0.22 0.17 0.11 0.08 0.05 0.03 0.02 0.01

2-4

MAJOR SPECIFICATIONS Points to notice, Rated load • The 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.

2-5

MAJOR SPECIFICATIONS ● Operating condition of booms; Boom 2

Boom 1

Boom 1 : All booms are completely retracted.

Boom 4 Boom 5 Boom 6

Boom 3 Boom 1

Boom 2

Boom 4

Boom 4

Boom 2

Boom 2

Boom 6

Boom 3

Boom 5

Boom 4

Boom

or

1+2+3+4

4

Boom 6

:

Boom is extended to where 2nd mark Boom 1

Boom 2

on the side plate of Boom

Boom 3

Boom 1+2+3+4+5 or 5 : Boom is extended to where 3rd mark Boom 2

Boom

1+2+3+4+5+6 2

,

3

,

4

,

or 5

6

and

on the side plate of Boom

3

is visible.

Boom 5

Boom 3

Boom 6

: 6

is visible.

Boom 6

Boom 4

Boom

3

Boom 5

Boom 4

Boom 1

2

or 2 : is extended.

Boom 1+2+3 or 3 : Boom is extended to the mark the side plate of Boom 3 .

Boom 5

Boom 3 Boom 1

1+2

Boom 6

Boom 3 Boom 1

Boom Boom

Boom 5

are all extended to their extremes.

2-6

on

MAJOR SPECIFICATIONS

1 URW506C W506C (6-section boom) (Speed indicated in the table below is at oil temperature range of 45~55°C, operating with noload, and at rated pump discharge.)

Major specifications Crane capacity (Net rated load)

3.0t×3.4m (With outriggers, extended fully)

Maximum lift above ground (Hook)

16.0m

Boom to be extended to:

3.93m～6.33m～8.72m～11.05m～13.38m～15.71m

Maximum working radius

15.52m

Speed 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

11.78m/35sec

Raising speed of boom

0°～80°/18sec

Slewing speed

2.5r.p.m.

Slewing range

360° (Continuous)

Hoisting rope Construction Diameter × length

IWRC6×WS (26) class B [Breaking load: 42.4kN (4320 kgf)]

Horizontal

Direct pushing by double acting hydraulic cylinder (directly connected to hydraulic automatic locking device)

V ertical

Direct pushing by double acting hydraulic cylinder (directly connected to hydraulic automatic locking device)

Rated pressure

Crane:20.6MPa(210kgf/cm2 ) Crawl:21.6MPa(220kgf/cm 2)

Rated discharge

Approx. 60ℓ/min

Rated rotation

Approx. 2100rpm

Outrigger

Hydraulic pump

8mm×91.5m

Hydraulic oil tank capacity

70 liters

3-1

MAJOR SPECIFICATIONS Equipment and construction Boom: 6-section, Hexagonal box beam

T elescoped by direct pushing of double acting hydraulic cylinder Boom telescoping

Boom derricking

together with by wire rope (With hydraulic automatic locking device) (2nd section: sequential actuation, 3rd, 4th, 5th & 6th sections: simultaneous actuation) Direct pushing by hydraulic cylinder (With hydraulic automatic locking device) Hydraulic motor: Axial plunger type

Hoisting

Reduction gears: Spur-gear reduction Brake: Automatic mechanical brake Hydraulic motor: Axial plunger type

Slewing

Reduction gears: Worm-gear+Spur-gear reduction (ed by ball bearings) Brake: Worm self-lock

Hydraulic pump

V ariable delivery piston pump

Hooking capacity

3.0 t Number of slinging rope: 4

Safety device

Safety valve for hydraulic circuit Hydraulic automatic lock Automatic stop for overwinding Overwinding alarm Slewing automatic lock Automatic stop for leaving minimum wire rope Load indicator (With angle meter) Alarm buzzer Retaining mechanism to prevent wire rope from disengagement Interlock for crane-crawl operation Crane/outrigger interlocking device Checker for outrigger rotary set pin insertion Level

Weight

Approx. 4880kg

3-2

MAJOR SPECIFICATIONS Crawling device Crawling

Endless rubber crawler

Crawler

300×52.5×88

Length of ground

1750mm

Pressure of ground

45.1kPa (0.46kgf/cm 2）

Crawling speed

Forward/Backward: 0～3km/h

Hill-climbing ability

23°

Engine

Rated output18.0kW/2100r.p.m (24.5PS/2100r.p.m)

Crawling

Independently driven by hydraulic power

Parking brake

Disc brake with hydraulic motor built-in

Starting engine

Electric starter

Fuel tank

Capacity: 40 liters

3-3

MAJOR SPECIFICATIONS Chart of net rated load

Net rated loads chart BOOM SECTION WORKING RADIUS(m) OUTRIGGERS NET RATED MAX EXT OUTRIGGERS LOAD(t) NOT MAX EXT

BOOM SECTION WORKING RADIUS(m) OUTRIGGERS NET RATED MAX EXT OUTRIGGERS LOAD(t) NOT MAX EXT

BOOM SECTION WORKING RADIUS(m) OUTRIGGERS NET RATED MAX EXT OUTRIGGERS LOAD(t) NOT MAX EXT

BOOM SECTION WORKING RADIUS(m) NET RATED LOAD(t)

OUTRIGGERS MAX EXT OUTRIGGERS NOT MAX EXT

BOOM SECTION WORKING RADIUS(m) NET RATED LOAD(t)

OUTRIGGERS MAX EXT OUTRIGGERS NOT MAX EXT

1 1+2 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.69 3.0 3.0 2.35 1.95 1.67 1.45 1.3 1.07 3.0 3.0 2.17 1.5 1.12 0.9 0.72 0.47 1+2+3 2.7 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 7.88 2.24 2.09 1.65 1.4 1.22 1.07 0.95 0.84 0.69 0.59 2.24 2.06 1.57 1.22 1.02 0.83 0.65 0.51 0.3 0.19 1+2+3+4 4.0 4.5 5.0 6.0 7.0 8.0 9.0 10.07 1.04 0.93 0.84 0.73 0.62 0.52 0.47 0.38 1.03 0.82 0.64 0.47 0.31 0.22 0.13 0.09 1+2+3+4+5 4.5 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.26 0.75 0.62 0.48 0.39 0.34 0.3 0.27 0.24 0.23 0.75 0.62 0.4 0.25 0.18 0.13 0.09 0.06 0.01 1+2+3+4+5+6 4.9 5.5 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.45 0.3 0.27 0.25 0.22 0.2 0.18 0.16 0.14 0.13 0.11 0.1 0.3 0.27 0.25 0.22 0.17 0.11 0.08 0.05 0.03 0.02 0.01 URW376C1A

2-4

MAJOR SPECIFICATIONS Points to notice, Rated load • The 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 extended to maximum’ means the state that the inner box is extended to the position where the 2nd ● mark is visible. • ‘Outriggers extended to halfway’ means the state that the inner box is extended to the position where the 1st ● mark is visible. • ‘Outriggers extended to minimum’ means the state that the inner box is extended to the position where the 1st ● 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, regard less of the displacement.

3-5

MAJOR SPECIFICATIONS ● How boom-sections a aree extended

Boom 1

Boom 2

Boom Boom 1

Boom

4

Boom

5

Boom

6

Boom : 1 All boom sections are retracted.

3

Boom 2

Boom

Boom

4

Boom : 1 + 2 or 2

5

Boom section(2) only is extended.

Boom Boom 1

Boom

3

Boom

Boom 2

6

Boom

4

Boom : 1 + 2 + 3 or 3

5

Boom sections(2) and (3) extended to a position where the mark on the boom section (3) is visible. Boom Boom 1

Boom 2

Boom

3

Boom

6

Boom

3

Boom

4

5

Boom

6

Boom : 1 + 2 + 3 + 4 or 4 Boom sections are extended to a position where 1st mark Boom 1

Boom 2

Boom

3

Boom

Boom

on the boom section (4) is visible.

5

Boom

4

6

Boom : 1 + 2 + 3 + 4 + 5 or 5 Boom sections are extended to a position where 2rd mark Boom 1

Boom 2

Boom

Boom

3

Boom

on the boom section(4) is visible.

5

Boom

4

Boom : 1 + 2 + 3 + 4 + 5 + 6 or 6 Boom sections(2), (3), (4), (5), and (6) are fully extended.

3-6

6

4.OUTRIGGER OPERATION HOW TO EXTEND OUTRIGGERS

Traveling

Crane

Outrigger extension detector Extract the pins to rotate outriggers, then insert the pins.

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 of outrigger to their full extents. 4. Touch the vertical of outrigger to the ground and raise the crawler by approximately 50mm to

Extension Touching ground

Detector for ground of outrigger

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.

4-1

HOW TO STORE OUTRIGGERS 1. Store the hook and lower the boom until the storage 2. Retract vertical of outrigger to make outriggers horizontal. Check that all 4 lamps indicating the outriggers touched

Boom storage detector

3. Retract the lateral 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.

Storage Storage

Outrigger extension detector

Detector for ground of outrigger

Extract the pins to rotate outriggers, then insert the pins.

Traveling

4-2

Crane

5.HOW TO STORE OUTRIGGERS WHEN IN AN EMERGENCY HOW TO STORE OUTRIGGERS WHEN FAILED STORAGE BY NORMAL OPERATION 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 .

Outrigger①

Outrigger②

Outrigger③

Outrigger④

Vertical

5

Operation Depressing 1 to operate lever

Horizontal

Depressing 2 to operate lever

Vertical

Depressing 5 to operate lever

Horizontal

Depressing 6 to operate lever

Vertical

Depressing 7 to operate lever

Horizontal

Depressing 8 to operate lever

Vertical

Depressing 3 to operate lever

Horizontal

Depressing 4 to operate lever

7 3 1

Vertical

②

Horizontal

Vertical

③

Horizontal

Vertical

④

Horizontal

Vertical

①

Horizontal

6 8 4 2

Operator’s seat side

Outrigger to be actuated

Outrigger valve for vertical/Horizontal

Throw outrigger lever to your side.

5 6 7 8 3 4

Depress retraction button to turn it to secure it.

1 2

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.

5-1

Push the button at the center of solenoid valve with a screwdriver.

HOW TO EXTEND OUTRIGGERS WHEN FAILED EXTENSION BY NORMAL OPERATION 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 .

Outrigger①

Outrigger②

Outrigger③

Outrigger④

Vertical

5

Operation Depressing 1 to operate lever

Horizontal

Depressing 2 to operate lever

Vertical

Depressing 5 to operate lever

Horizontal

Depressing 6 to operate lever

Vertical

Depressing 7 to operate lever

Horizontal

Depressing 8 to operate lever

Vertical

Depressing 3 to operate lever

Horizontal

Depressing 4 to operate lever

7 3 1

Vertical

②

Horizontal

Vertical

③

Horizontal

Vertical

④

Horizontal

Vertical

①

Horizontal

6 8 4 2

Operator’s seat side

Outrigger to be actuated

Outrigger valve for vertical/Horizontal

Throw outrigger lever to your side.

5 6 7 8 3

Remove cover on arrow mark side and depress extension button to turn it to secure it.

4 1 2

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.

5-2

Push the button at the center of solenoid valve with a screwdriver.

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 operation and troubles in detail. When the “mode indicator lamp” lights, the crane system is working normally. When the ”mode indicator lamp” blinks, the crane system is in a trouble or prohibited operation is being carried out. Mode indicator lamp

◆1.Mode indication when crane is in normal operation It 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

Radio Manual control operation operation mode Priority mode

Current control is on traveling mode. No operation other than traveling is possible either by manual control or by radio remote control.

×

×

1

Current control is on normal crane operation mode. Operation is possible either by manual control or by radio remote control.

◯

×

9

Current control is on normal crane operation mode. Operation can only be carried out manually but not through radio remote control device.

×

◯

9

◯

×

Current operation is in outrigger radio control mode. Extension and retraction of outriggers can only be possible by manual control when in manual control mode or by radio remote control when in radio remote control mode. Operation other than the above is impossible either by manual or by radio remote control. Current control is on low temperature operation mode. Operation can be carried either by manual control or by radio remote control device. ６－１

5 ×

◯

(◯)

(◯)

8

MODE INDICATOR LAMP (Control Box)

Mode

Mode description

Radio Manual control operation Priority operation mode mode

Current control is on low temperature operation mode. Operation can be carried by manual control but not through 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 being controlled

―

―

4

Boom store or Automatic stop for overloading is actuated .

―

―

2

―

―

3

Automatic stop for overloading alarm is actuated .

●Remarks Since priority is assigned for each mode description, it is to be indicated in the order of higher priority. If the [.] (dot) is indicated on the bottom right of “mode indicator lamp”, it means the “radio control OFF” mode. Crane cannot be operated through radio control transmitter. When operated on outrigger radio control mode, crane operation other than extension/retraction of outriggers cannot be carried out. When the shock-less function has been cancelled, the letter on the left indicated in the mode indicator changes to [ ].

６－２

MODE INDICATOR LAMP (Control Box) ◆2.Mode indication when crane is mistakenly operated When prohibited operation or combination of operation which may invites dangerous situations has been carried out, the “mode indicator lamp” will blink corresponding numbers (operation error indication). When the operation error is indicated, the ”mode indicator lamp” blinks showing corresponding numbers accordingly. Confirm and follow the mode description concerned on the table illustrated below:

●Remarks The 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 is carried out in manual control mode.

Radio remote control cannot be carried out in manual control mode. When operating with radio remote controller, turn the selector switch located on the top of cover to radio remote control mode.

●Mode indicator lamp located in front of crane control levers will not be lit when in manual control mode.

●Mode indicator lamp located in front of crane control levers will be lit when in radio remote control mode.

Crane is being operated when in outrigger mode.

Crane cannot be operated when in outrigger control mode. When operating crane, turn the mode selector switch to “crane” to select crane mode.

Crane and outriggers are operated simultaneously.

When crane and outriggers are operated simultaneously, both operating functions are stopped automatically to avoid a risk. Stop the simultaneous operation once and carry out either one of operation.

“Low temperature operation mode” is being switched during crane operation.

In order to avoid a risk, “low temperature operation mode” cannot be switched during crane operation. Stop crane operation once to switch it to “low temperature operation mode”. For switching “low temperature operation mode”, refer to section 6u.“How to correct when operation becomes unstable due to low temperature” (on page 6-22).

６－３

MODE INDICATOR LAMP (Control Box) Mode

Description of wrong operation

Measures to be taken

Either one of operation such as “boom Up”, ”hook Up”, or ”boom Extend” (when operated on para-hook mode) is being carried out while hook has hit against weight for over-winding alarm.

Detach hook from weight for over-winding alarm. ●When raising boom through radio control device with hook hit against the weight for over-winding alarm, boom is to be “Up” while hook is winding “Down” as this operation allows hook to be released. Do not lift up a cargo while this is being indicated.

Emergency stop switch on the remote control device is pressed.

Release the Emergency stop switch when operating crane.

Operating one of boom lowering, wind-up, boom extending or slewing while the boom is at stowed position and fully lowered.

Operate boom raising to release the automatic stop system then operate others.

Operation of winding down hook is carried out while the sensor detecting minimum wire rope is being activated.

Stop winding down hook and wind it up so that the sensor detecting minimum wire rope will not be activated.

In the boom/outrigger interlocking device, outrigger operation is being carried out without boom being stored.

Stop outrigger operation without boom being stored. Operate outriggers after boom has been stored.

６． ．３ Mode indication of each operation Mode indication

２０ ２１ ２２ ２３ ２４ ２５ ２６ ２７ ２８

Operation Fastest speed mode Medium speed mode Slow speed mode ２ interlocking operation ３ interlocking operation ４ interlocking operation ５ interlocking operation ６ interlocking operation ７ interlocking operation

Mode indication

Operation

Mode indication

Operation

３０

Raising boom

３８

Storing hook

３１

Lowering boom

３９

Mode select

３２

Hoisting-up

４０

Horn

３３

Hoisting-down

３４

Retracting boom

３５

Extending boom

３６

Slewing C.W.

３７

Slewing C.C.W

００∼０.０

Speed: 0∼ 100%

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.

6-4

６．４

Error indication

When an error is detected, the mode indicator goes off or blinks and the voice message “Service remote control” sounds. Mode Available Measures Trouble indication operation Check all load cell wirings on outrigger and Digital No operation Amplipier wirings. Turnover prevention error １７ is possible. Zero-Point Adjust Digital Amplipier. Replace Digital Amplipier.

None

System error

No operation is possible.

４２

Replace fuse in control box. Turn power ON again. In case where it happens again, replace control box.

４３ ４４ ４５

No operation Readjust zero point. is possible. Operation is possible. Turn power ON again.

４６ ４７ ４８

In case where it happens again, replace control box.

４９ ５０ ５１ ５２ ５３

５５

Failure in radio controller receiver Transmitter lever has been pulled before indication on indicator “8.8” goes off. Transmitter switch has be depressed before indication on indicator "8.8" goes off.Signal from receiver failed to be received

“Hook storing/releasing switch”on crane side has been controlled before indicator "8.8" goes off. “Radio controller selector switch”in control box has been controlled before indicator "8.8" goes off.

Radio controller Check transmitter and receiver. cannot be operated. After turning power ON again, wait until　mode on "8.8" indicator goes off to operate　radio controller. Check connection of cable to receiver.

Operation is After turning power ON again, possible. wait until mode on "8.8" indicator goes off to operate radio controller. Turn power ON again. In case where it happens again, replace control box.

５６

No operation Turn power ON again. is possible. In case where it happens again, replace control box.

System error

５７ ５８ ６０ ６１ ６２ ６３ ６４ ６５

Unloading error

Radio controller　cannot be operated. Replace control box. No operation After turning power ON again, is possible. wait until “8.8”on mode indicator goes off to operate radio controller.

Spool neutral error Derrick Manual lever (spool) fails to be returned to neutral Hoisting within 2 seconds after power has been turned Telescoping ON.

Check that manual lever has not been caught.

Slewing

If lever has no problem, replace proportional solenoid valve.

Outrigger Acceleration （６－５）

When an error is detected, the mode indicator goes off or blinks and the voice message “Service remote control” sounds. Mode Available Measures Trouble indication operation

６６

Outrigger selection switch Front right RET/EXT

６７

Front left RET/EXT

６８

Rear left

７０

Derrick

７１

Hoisting

７３

Spool deviation error. Manual lever (spool) fails to be controlled as intended while radio controller is operated.

ET/EXT

７５

Acceleration

Hoisting

７８

Telescoping

７９

Slewing

８０

Derrick

８２

Slewing

８４

Outrigger

８５

Acceleration

９９

Operation is possible. Replace broken transmitter switch. Radio controller cannot be operated.

No operation is possible. Check connector of differential transformer　for connection.

Feed-back signal wire is broken. Hoisting Differential transformer is not functioning normally. Telescoping

８３

９８

If lever has no problem, replace proportional solenoid valve.

Derrick

７７

８１

Check that manual lever has not been caught.

Slewing High outrigger

Transmitter switch is broken.

No operation Check if oil pressure is applied. is possible.

Telescoping

７４

７６

It is possible to operate it excluding the damaged switch.

Rear right RET/EXT

６９

７２

Damaged switch exchange

If there is no problem, replace differential　transformer.

The voltage of the battery is nine volts or less.

No operation Battery exchange is possible. 98 blinking when the engine starts is not abnormal.

Transmitter batteries are dead.When batteries have Replace batteries of transmitter to turn it ON Operation is run out, voice message requesting replacement of again.Radio controller is wrong unless power indi possible. batteries is to be issued. cator lamp on transmitter lights or blinks　quickly.

（６－６）

7.LIST OF VOICE MESSAGES 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 not depressed. Emergency stop is released

Stop winch up. Scure lifting hook.

When switch is depressed. Emergency stop is functioning.

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.

When battery in the transmitter has run down.

Outrigger operation switch Operation mode switch

Outrigger monitor

Outrigger selector switch

Voice switch

Switches in detail

7-1

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㪙㫆㫆㫄㩷㪜㫏㫋㪼㫅㪻㫀㫅㪾㪆㪩㪼㫋㫉㪸㪺㫋㫀㫅㪾㩷㩿㪧㩷㪦㪥㪆㪦㪝㪝㪀 㩿㪜㫏㫋㪼㫅㫊㫀㫆㫅㪆㪩㪼㫋㫉㪸㪺㫋㫀㫆㫅㩷㫆㪽㩷㫆㫌㫋㫉㫀㪾㪾㪼㫉㩷 ԙ 㪪㫃㪼㫎㫀㫅㪾㩷㪚㪅㪚㪅㪮㪅㪆㪚㪅㪮㪅 㪜㫅㪾㫀㫅㪼㩷㪪㫋㪸㫉㫋㪆㪪㫋㫆㫇 㩿㪜㫏㫋㪼㫅㫊㫀㫆㫅㪆㪩㪼㫋㫉㪸㪺㫋㫀㫆㫅 㫆㪽㩷㫆㫌㫋㫉㫀㪾㪾㪼㫉㩷㽲㪀

䇭䇭䇭䇭䋵䋩䇭#NNVJGOQPKVQTNCORUCTGNKV ‫ޓޓޓޓ‬㪙㫆㫆㫄㩷㫊㫋㫆㫉㪸㪾㪼㩷㫄㫆㫅㫀㫋㫆㫉㩷㫃㪸㫄㫇 㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪫㪿㪼㩷㫄㫆㫅㫀㫋㫆㫉㩷㫃㪸㫄㫇㩷㫃㫀㪾㪿㫋㫊㩷㫎㪿㪼㫅㩷㫋㪿㪼㩷㪹㫆㫆㫄㩷㪿㪸㫊㩷 㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪹㪼㪼㫅㩷㫊㫋㫆㫉㪼㪻㪅 㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪦㫌㫋㫉㫀㪾㪾㪼㫉㫊㩷㪺㪸㫅㩷㪹㪼㩷㫆㫇㪼㫉㪸㫋㪼㪻㩷㫆㫅㫃㫐㩷㫎㪿㪼㫅㩷㫋㪿㪼㩷 㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㫄㫆㫅㫀㫋㫆㫉㩷㫃㪸㫄㫇㩷㫃㫀㪾㪿㫋㫊㪅

㪪㫋㫆㫉㫀㫅㪾㩷㪿㫆㫆㫂

㪪㫇㪼㪼㪻㩷㫃㪼㫍㪼㫉

㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪦㫌㫋㫉㫀㪾㪾㪼㫉㩷㫄㫆㫅㫀㫋㫆㫉㩷㫃㪸㫄㫇㩷㩿㪼㫏㫋㪼㫅㫊㫀㫆㫅㪀 㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪮㪿㪼㫅㩷㫋㫌㫉㫅㫀㫅㪾㩷㫆㫌㫋㫉㫀㪾㪾㪼㫉㫊㩷㫄㪸㫅㫌㪸㫃㫃㫐㩷㪽㫉㫆㫄㩷㫋㪿㪼㫀㫉㩷㫊㫋㫆㫉㪼㪻㩷 㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㫇㫆㫊㫀㫋㫀㫆㫅㫊㩷㪸㫅㪻㩷㫊㪼㫋㩷㫇㫀㫅㫊㩷㪿㪸㫍㪼㩷㪽㫌㫃㫃㫐㩷㪹㪼㪼㫅㩷㫀㫅㫊㪼㫉㫋㪼㪻㪃㩷 㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㫋㪿㪼㩷㫃㪸㫄㫇㩷㫀㫅㪻㫀㪺㪸㫋㫀㫅㪾㩷㪼㫏㫋㪼㫅㫊㫀㫆㫅㩷㫆㪽㫆㫌㫋㫉㫀㪾㪾㪼㫉㩷㫃㫀㪾㪿㫋㫊㪅 㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪦㫌㫋㫉㫀㪾㪾㪼㫉㫊㩷㪺㪸㫅㫅㫆㫋㩷㪹㪼㩷㫆㫇㪼㫉㪸㫋㪼㪻㩷㫌㫅㫃㪼㫊㫊㩷㪸㫃㫃㩷㫋㪿㪼㩷㪽㫆㫌㫉㩷㩿㪋㪀㩷㫇㫀㫅㫊㩷㪿㪸㫍㪼㩷㪹㪼㪼㫅㩷㫀㫅㫊㪼㫉㫋㪼㪻㪅

䇭䇭䇭䇭䋶䋩䇭6JGMG[UYKVEJQHVJGVTUOKVVGTKUVWTPGFQP 䇭䇭䇭䇭䋷䋩䇭2QYGTNCORKUNKVRWUJKPIUVCTVUYKVEJQHVJGVTUOKVVGT 䇭䇭䇭䇭䋸䋩㩷㩷6JGUGNGEVKQPUYKVEJKUEJIGFFVJGURGGFNGXGTKURWNNGF 䋨䋸䋭䋳䋩

5GNGEVQT UYKVEJGU

8.4 Switching of mode indicator (State ⇔ Operation) Depress both winding-up and mode selector switch simultaneously. Operation indication

State indication (normal case） Depress both winding-up and mode selector switches at the same time or turn OFF power to crane and turn it ON again.

＋ Radio control operation

8.5 Resetting of interlocking balance control

Depress the switch for storing hook with the switch for boom-up turned ON. Retaining function of dividing operation ON (normal case） Depress the switch for storing hook with the switch for boom-down turned ON.

(8-4)

Retaining function of dividing operation OFF Mode indicator shows [oF]. Voice message, “change control mode”is issued

8.6 Switching of "shockless"function　(Carry it out when it is not over-wound）

Turn ON winding-down switch with para-hook switch depressed. "shockless" (normal case）

No"shockless" “[-]” appears on the left side of mode indicator. Turn ON winding-up switch with para-hook switch depressed.

8.7 Switching of　low-temperature operation mode

Depress the switch for storing hook with the switch for slewing C.C.W.turned ON. Low-temperature operation mode OFF(normal case）

Low-temperature operation mode ON Depress the switch for storing hook with the switch for Mode indicator shows [06]. slewing C.W.turned ON. Voice message, “change control mode”is issued.

(8-5)

/GVJQFQHGPIKPGUVCTVFUVQRVJCVWUGUTCFKQEQPVTQNNGT 㪟㫆㫎㪼㫍㪼㫉㪃㩷㫋㪿㫀㫊㩷㫆㫇㪼㫉㪸㫋㫀㫆㫅㩷㫀㫊㩷㫇㫆㫊㫊㫀㪹㫃㪼㩷㫌㫅㪻㪼㫉㩷㫋㪿㪼㩷㪽㫆㫃㫃㫆㫎㫀㫅㪾㩷㪺㫆㫅㪻㫀㫋㫀㫆㫅㪅 㩷㩷㩷㩷㩷㩷㩷㩷䋱䋩䇭㪪㫋㪸㫉㫋㪼㫉㩷㫊㫎㫀㫋㪺㪿㩷㫆㫅㪅㩷㩷

㩷㩷㩷㩷㩷㩷㩷㩷 䇭䇭䇭䇭䋲䋩䇭㪪㪿㫀㪽㫋㩷㫋㪿㪼㩷㫃㪼㫍㪼㫉㩷㫋㫆㩷㵰㪚㫉㪸㫅㪼㵱㩷㫇㫆㫊㫀㫋㫀㫆㫅㪅

㩷㩷㩷㩷㩷㩷㩷㩷䋳䋩䇭2WUJVJGOQFGUGNGEVQTUYKVEJVQUYKVEJKVVQVJGTCFKQTGOQVGEQPVTQNOQFG 6JG/QFGKPFKECVQTNCORNKIJVUQP

䋴䋩䇭㪢㪼㫐㩷㫊㫎㫀㫋㪺㪿㩷㫆㫅㪅㩷

㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪛㪼㫇㫉㪼㫊㫊㩷㫋㪿㪼㩷㫊㫎㫀㫋㪺㪿㩷㪽㫆㫉㩷㫄㫆㪻㪼㩷㫊㪼㫃㪼㪺㫋㩷㫎㫀㫋㪿 㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㫋㪿㪼㩷㫊㫎㫀㫋㪺㪿㩷㪽㫆㫉㩷㫊㫃㪼㫎㫀㫅㪾㩷㪚㪅㪚㪅㪮㪅㫋㫌㫉㫅㪼㪻㩷㪦㪥㪅㩷 㪜㫅㪾㫀㫅㪼㩷㫊㫋㫆㫇 㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪛㪼㫇㫉㪼㫊㫊㩷㫋㪿㪼㩷㫊㫎㫀㫋㪺㪿㩷㪽㫆㫉㩷㫄㫆㪻㪼㩷㫊㪼㫃㪼㪺㫋㩷㫎㫀㫋㪿㩷 㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㫋㪿㪼㩷㫊㫎㫀㫋㪺㪿㩷㪽㫆㫉㩷㫊㫃㪼㫎㫀㫅㪾㩷㪚㪅㪮㪅㫋㫌㫉㫅㪼㪻㩷㪦㪥㪅㩷㩷

䋨䋸䋭䋶䋩

㪜㫅㪾㫀㫅㪼㩷㫊㫋㪸㫉㫋

9.RADIO CONTROL CANNOT BE OPERATED (In case where it is due to electrical failure) ◆ Turn "ON" the voice switch and start engine to check it. YES Power indicator lamp lights.

No

Radio control selector switch has been depressed. 「.」(dot) is shown at bottom-right side of mode

Depress radio control selector switch again.

"54" is shown on mode indicator.

Check receiver cable for connection.

"51" is shown on mode indicator.

Repair transmitter and receiver.

Moisture is stuck on inspection window of receiver.

Repair receiver.

Replace batteries. Battery life is approximately 20 hours when new 4 pieces of alkaline battery have been replaced.

Batteries have run down. ●"99" is blinking on mode indicator. ●Voice message requesting battery replacement is heard. ●Power indicator lamp blinks when batteries come close to be dead.

Repair transmitter and receiver. Power indicator lamp

Voice switch Receiver cable

Receiver Check lamps

Interference (Lights)

When receiving noise from outside, it lights in red.

Receiving (Blinks)

When receiving signal from transmitter, it blinks in green.

Error (Blinks)

When receiver is in trouble or batteries are running down, it blinks in red.

Power (Blinks)

When key switch turn on, it blinks in green.

9-1

10.EMERGENCY MEASURES TO BE TAKEN WHEN CRANE CANNOT BE OPERATED AT ALL

Procedure 1 Operate it while the safety device reset switch is being pushed up. 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.

Procedure 2 (In case where the crane cannot be operated even if the safety device reset switch is controlled.) Store the crane with the control box reset switch pushed up.

Procedure 3 (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.

Set bolt

Safety device reset switch

ML auto stop switch

Control box reset switch

10 - 1

Hexagon nut

Hydraulic Circuit Diagram (Carrier） Control valve for crane T

P

T2

It connects with drain pipe of Slewing motor and hoisting motor.

PB2 DR

DR2 DR1

P1

URW370CDE S/N 37W0062～ Manufacturing　2006/8～ URW506CDE S/N 50W0005～ Manufacturing　2006/8～

Manifold block

High pressure line

LP

Tank line

T0 RP

PB

T1

DR3 DR4 P2

GP

Crawlingmotor （left）

Dr

Dr

Crawlingmotor （right）

Reduction gear

Reduction gear

PP

PP

B A1

A

A

B1

B

A2

C

Forward

Forward

P1

P2

Backward

Backward

Control valve for carrier T

Return filter

B2

P1

P2

Engine Pump

１１－１

Control valve for carrier From the power unit

From the pump P2

To right B

To T1

To left A

From Manifold block P2

2 pump P e h t m Fro

To motor (right side) A To motor (right side) B

block PB d l o f i n To ma d block T1 To manifol To motor (left side) B To motor (left side) A

From manifold block P2

From the power unit P1

Control valve for carrier

it P2 n u r e he pow From t

Control valve for carrier

Left Right

Ground

Control valve for carrier

Sky

Left Right

The upper surface of manifold block

The upper surface of Manifold block

Ground

Side of manifold block

Sky

Ground

The front side of Manifold block

Sky

Ground

The front side of manifold block

Sky

Ground

The back side of Manifold block

Sky

Pump

Sky

Ground

Crawling motor

Sky

Ground

Sky

Ground

Crawling motor

Right

Crawling motor

Ground

Left Sky

Hydraulic Circuit Diagram (control valve for crane） High pressure line

Tank line

Pilot pressure line

Tank

Feed-back line Line filter

Gauge Port Solenoid valve for unloading

pump

Main relief valve Emergency screw

Pilot pressure Gauge Port

Solenoid valve for storing hook

Set bolt

Back pressure valve

Pressure reducing valve

Pressure regulator valve

Outrigger side

Accelerator

Hydraulic Circuit

Ext.

Outrigger

C.C.W

C.C.W

Hydraulic motor （Slewing）

C.W

C.W

Slewing

Telescope

Counter balance valve Ext.

Ret.

Telescope

Down

Up

Hydraulic motor （Hoist） Load metor Down

Up

Hoist

Counter balance valve

Lower

Raise

Derrick

Control valve (for crane) １２－１

Check valve

13.SWIVEL T Construction of swivel t and where hoses are attached

Front of crane （Column foot pin side）

2

6

5

1

Square ring 7

Seal ring

4 3

Rear of crane （Column derrick pin side）

Section A in detail,STK seal fitting

Inner t

Outer t

Fill up greese when mounting 6 DERRICK(RAISING)

4 DERRICK(LOWERING)

7

7

TELESCOPING(EXTENSION)

5

5

TELESCOPING(RETRACTION)

6

A

4 3

2 HOIST(DOWN)

3 HOIST(UP)

Fill up greese when mounting

2 1

1 HOIST(DRAIN)

１３－１

SWIVEL T PIPING

１３－２

⑥ Derrick(raising) ④ Derrick(lowering) ② Hoist(down)

⑦ Telescoping 　(extension) ⑤ Telescoping (retraction) ③ Hoist(up) ① Hoist(drain)

SWIVEL T PIPING

⑦ Telescoping 　(Extension)

⑥ Derrick 　(raising) ④ Derrick 　(Lowering)

⑤ Telescoping (Retraction) ③ Hoist(up)

② Hoist(Down)

① Hoist(Drain)

１３－３

SWIVEL T PIPING

⑦ Telescoping 　(Extension) ⑥ Derrick 　(raising) ④ Derrick 　(lowering)

⑤ Telescoping (retraction)

③ Hoist(up)

② Hoist(down)

① Hoist(drain)

１３－４

SWIVEL T PIPING

④ Derrick 　(lowering) ① HOIST(DRAIN) ⑥ Derrick 　(raising)

③ Hoist(up)

② Hoist(down)

⑦ Telescoping 　(Extension)

⑤ Telescoping (retraction)

１３－５

SWIVEL T PIPING

② Hoist(down)

③ Hoist(up)

⑦ Telescoping 　(Extension) ⑤ Telescoping (retraction) ① Hoist(drain)

⑥ Derrick 　(raising)

④ Derrick 　(lowering)

１３－６

14 COLUMN 14.1 Tightening torque for bolts fastening column and tightening order

Bolt for derrick pin Torque 78N-m（8kgf-m）

1

4

6

Bolt for column When assembling,apply ”LOCTITE #962T” Tighten the bolts in the numerical order as illustrated in the figure. Torque URW376CDE →　245N-m（25kgf-m） URW506CDE →　333N-m（34kgf-m） 5

7

11

10 9

8 2

3

１４－１

③ Hoist(up)

① Hoist(drain)

② Hoist(down)

１４－２

④ Derrick 　(lowering)

⑥ Derrick 　(raising)

⑤ Telescoping ⑦ Telescoping (retraction) 　(extension)

WIRE ROPE RETAINIG MECHANISM

Inside width of drum 154.8

１４－３ Limt switch (Electric wiring ass’y) 750306029 OMRON D4C1203

１５. HOIST WINCH 15. 1 Construction of Hoist Winch and brake shoe adjusting procedure Gear4 Drum Apply"LOCTITE #242"

Breather Gear2 Ratchet Wheel Brake Shoe

Split Pin

After assembling, apply grease to engaging tooth surfaces of the gear.

Castle Nut Rotate the gear shaft to check that the pawl makes a smooth movement.

Plain Washer Disk

Motor Bearing Pay attention to its direction. Gear1 Casing

Brake Shoe Ajusting procedures 1.Tighten the castle nut lightly with a spanner. 2.After tighning,loosen the castle nut for approx.1/6 turn and within this range align the castle nut with the hole in the gear shaft;and fix it with the split pin. 3.Replace the break shoe every 3years. １５－１

15. 2 Caution to be taken when reassembling hoist winch

Check that the spring is caught in the drill hole on the pawl.

Dimensions on both sides should beequally arranged when fitting the ratchet wheel.

Set bolt position 3

1

2

2

4

Ratchet Wheel

2

Tightening order of bolts for mounting reduction gear Tighten the hexagon socket head screws in diagonal order after the set bolt has been fastened first to align each screw hole. １５－２

15. 3 Cause of Troubles and Measures to be Taken (1) Hoist winch Problems

Possible cause

Measures to be taken

• Pump is faulty. (Pressure does not rise at idling speed.) (Total pressure required for operation is insufficient.)

• Replace.

• Relief set of control valve is faulty. (Pressure rises but not enough.)

• Adjust or replace.

• O-ring and other parts of relief valve of control valve are faulty. (Adjusting bolt of relief valve is tightened but unable to control pressure.)

• Replace parts or replace relief ass’y with new one.

• Hoist motor is faulty. (Quantity of drain is larger than the specified.)

• Replace.

Pressure rises but hoisting up impossible.

• Drum or internal mechanism of reduction gear is faulty.

• Overhaul reduction gear. • Inspect the drum

Pressure rises but lowering is impossible.

•Brake shoe is over-tightened..

• Adjust tightening of brake shoe. • Overhaul reduction gear. • Check drum.

Pressure does not rise.

•Drum or reduction gear is defective. Unable to maintain suspended load.

• Brake shoe is faulty. • Pawl is faulty.

• Replace brake shoe. • Replace pawl.

When lowering, hunting occurs.

• Brake shoe is faulty.

• Inspect brake shoe and check quantity of oil. • Adjust tightening of nut. • Disassemble reduction gear.

• Over-tightening of brake shoe. • Internal mechanism of reduction gear is faulty. When hoisting up, clattering sound is heard.

• Spring pressing the pawl against slide plate is faulty. • Bushing the part of fitting pawl is worn out.

１５－３

•Replace spring. • Replace bushing.

16. HOOK Apply"LOCTITE#242" Bearing-Thrust ball Aplly grease

Aplly grease

１６－１

If the gap of more than 2mm is confirmed, check the hook, the thrust bearings, and the nuts and replace a deformed (worn out) component.

Entire screw thread

Nut

Spring pins (both sides) Hook

Enlarged portion where sealing agent is to be applied.

W376C → 90 mm W546C →130 mm

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.　

10

18

3

15

7 11

14

Hydraulic motor

1

6

S

19 2

5 12

13 8

16

4

17

9

"S"Mark(Soft Zone) Turntable mounting bolts (19-M20)

Slewing reduction gear mounting bolt(4-M16)

Turntable After assembling ,apply grease to engaging tooth surfaces of the gears. 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. １７－１

18.SLEWING REDUCTION GEAR 1)Construction Gear shaft

Dust seal Taper roller bearing Breather

Filled with grease

Bearing housing

Nut

１８－１ Casing Warm wheel

Worm shaft Snap ring Taper roller bearing

Ball bearing Crown nut

(2) Construction to be taken when reassembling slewing reduction gear

Apply”ThreeBond #1401”to it.

Apply Grease to the inside of dust seal.

Dust Seal

Fill up with grease here. Use Lithium soap radical grease (such as Rizonix grease No.1 or Kyseki) Nut:Apply”LOCTITE #262”before tightening it. Note:Tighten the nut to the extent that the gear shaft can be rotated to either Direction with your both hands.

Bearing housing Assemble the worm wheel with the mark”V” directed upward.

Flange bolt Tightnig torque:

59N-m　(6kgf-m)

１８－２

(3) Slewing reduction gear disassembly procedures ①Remove 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 removing worm shaft is recommended.)

③Remove 8 pcs. of bolt (M10 X 25ℓ) which fasten the bearing housing and pull out the housing, utilizing 3 pcs. 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

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.

１８－５

１８－６

Ground

Pinping of Hydraulic Motor for Slewing

Sky

Ｃ.Ｃ.Ｗ

External pilot port

Ｃ.Ｗ

Pinping of Hydraulic Motor for Slewing

External pilot port

Ｃ.Ｃ.Ｗ

Ｃ.Ｗ

Drain port

１８－７

１９ Hydraulic Circuit Diagram (Outrigger） High pressure side

Tank side

Outrigger（Vertical） （Front, Right）

１９－１

Solenoid valve 740170008 to select Outrigger(Vertical) and Outrigger(Horizontal)

Outrigger（Horizontal） （Front, Right）

Outrigger（Vertical） （Front, Left）

Outrigger（Horizontal） （Front, Left）

Outrigger（Vertical） （Rear, Right）

Outrigger（Horizontal） （Rear, Right）

Outrigger（Vertical） （Rear, Left）

Outrigger（Horizontal） （Rear, Left）

Outrigger cylinder（Horizontal）

Outrigger cylinder（Vertical） Double pilot check valve 740197040

Solenoid valve 740170009 to extend Outrigger cylinder, and to withdraw Outrigger cylinder

Pilot check valve　601529000

19.HOW OUTRIGGERS ARE EXTENDED Vertically extending cylinder

Stroke:700(URW376C) Stroke:1020(URW546C) Horizontally extending cylinder

19-2

19.OUTRIGGER CYLINDER 1)Construction of vertically extending cylinder

Pilot check valve CD-02RA

In order to prevent moisture from entering the cylider from the threads, apply liquid gasket, solventless type #1101(fatty acid degenerated phenolic resin family),supplied by ThreeBond here (4 places on its circumference).

19-3 Apply grease here (IDEMITSU DUFNEET grease, model XCZ-1 or equivalent)

Split position of bushing

Split position of bushing

Construction of horizontally extending cylinder

Pilot check valve -02F

19-4

20.DERRICKING CYLINDER Split position of bushing Bend this toward the gland aftter the gland has been fightened. (1 place)

Counterbalance valve CB-03ED-W （Hydraulic driven）

Split position of bushing

20-1 In order to prevent moisture from entering the cylider from the threads, apply liquid gasket, solventless type #1101(fatty acid degenerated phenolic resin family),supplied by ThreeBond here (4 places on its circumference).

Apply grease here (IDEMITSU DUFNEET grease, model XCZ-1 or equivalent)

20.2　Flow of oil,when lowering

Rod Apply"LOCTITE"638"here Hexagon socket head screw For grand Bush omission stop 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. The check valve shuts and the amountof oil that returns to the tank is limited. Pressure oil Tank

The spool opens according to the reduction side pilot pressure

Counter-balance valve

Piston Hexagon socket head screw For piston turn stop 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. （２０－２）

20.3　Flow of oil,when raising Apply"LOCTITE"638"here

Rod Apply"LOCTITE"638"here

Hexagon socket head screw for gland-bush turn stop 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. Pressure oil Tank

Check Valve opens.

Counter-Balance Valve Check Valve opens. Spool opens

Piston

Hexagon socket head screw For piston turn stop 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. （２０－３）

When telescoping cylinder1 extends(URW376C) Selector valve ass’y Check valve2 Rod

Stopper

Check valve

２１－１

Tube/Rod

Check valve1 Tube

Piston１

Piston２ Spool Slide pipe

Pressure Oil

To Tank Counter-balance valve

How to extend the “tele1” section The 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 retraction side and so the “tele2” section does not operate.

When telescoping cylinder1 retructs(URW376C) Check valve 2

Rod

Seletor valve ass’y

Stopper

Check valve

Spool

２１－２

Tube/Rod

Tube

Piston１

Piston2

Check Valve1 Spool

Slide pipe

To Tank Counter-balance valve

Pressure Oil Pilot Pressure

How to retract the “tele1” section The 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 is returned 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 age 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.

When telescoping cylinder2 extends(URW376C) Check valve2 Rod

Selector valve ass’y

Stopper

Check valve

Tube/Rod

Piston1

Piston2

２１－３

Tube

Check valve1

Slide pipe

Pressure Oil To Tank Counter-balance valve

How to extend the “tele2” section The 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 the stopper 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 age 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.

Spool

6-Section Boom (Dual Cylinder) Operation(URW5４6C) (1) When Telescoping Cylinder1 extends

After the set-screw is tightened with LOCTITE #2701 applied hit with a punch at 2 places on the circumference and leave it as it is for 1 hour.

Rod

Check valve 1 Spool

Check valve

Bolt Tele2 Piston Apply"LOCTITE#638".

Seletor valve ass’y Check valve 2 Slide pipe

２１−５

Pressure Oil To Tank Counter-balance valve

How oil flows when tele1 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 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.

Tele1 Tele2 Counter-balance valve

Tele3

6-Section Boom (Dual Cylinder) Operation(URW５４6C) (2) When Telescoping Cylinder1 retracts

After the set-screw is tightened with LOCTITE #2701 applied hit with a punch at 2 places on the circumference and leave it as it is for 1 hour.

Check valve 1 Spool

Rod

Check valve Spool

Bolt Tele2 Piston Apply"LOCTITE #638".

Selector valve ass’y Check valve 2 Slide pipe

２１−６

Pressure Oil

To tank Counter balance Valve

Pilot Pressure

How oil flows when tele1 is retracted

Pressure 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 ass via 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 age 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.

Tele1 Tele2 counterbalance valve

Tele3

6-Section Boom (Dual Cylinder) Operation（URW5４6C) (3) When Telescoping Cylinder2 extends Slide pipe

Rod

Check valve 1

Selector valve ass’y

Check valve

Check valve 2

Piston

２１−７

Pressure Oil

After the set-screw is tightened with LOCTITE #2701 hit with a punch at 2 places on the circumference and leave it asit is for 1 hour.

To tank

Bolt Tele2

Check valve 1 Spool

Counter balance valve

Bolt Tele3

How oil flows when tele2 is extended

Rod 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 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 ass stage, the age 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 ass to extension side of tele3. Tele1 Tele2 Tele3

Piston Apply "LOCTITE #638".

Selector valve ass’y Check valve 2 Slide pipe

6-Section Boom (Dual Cylinder) Operation(URW5４6C) (4) When Telescoping Cylinder2 retracts Slide pipe

Rod

Check valve 1

Selector valve ass’y

Check valve Spool

Piston

２１−８

To tank

Check valve 2 Tele3

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.

Pressure Oil

Bolt Tele2

Check valve 1 Spool

Counter balance valve Pilot Pressure

Bolt Tele3

How oil flows when tele2 is retracted

Rod

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 ass via spool which leads the oil in the extension side of tele2 to the counterbalance 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 age 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.

Piston Apply"LOCTITE #638". Slide pipe

Tele1 Tele2 Tele3

Selector valve ass’y Check valve 2

６-Section Boom (Dual Cylinder) Operation(URW5４6C) (5) When Telescoping Cylinder3 extends Slide pipe

Rod

Check valve 1

Bolt Tele3

Check valve

Selector valve ass’y

Piston

Check valve 2

Slide pipe Pressure Oil

２１−９

Counter balance valve

To tank

Check valve 1 Spool

Rod

Bolt Tele3

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 reach the 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 ages 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.

Selector valve ass’y

Piston

Check valve 2 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.

Piston Apply "LOCTITE#638".

Tele1 Rod

Tele2 Tele3

6-Section Boom (Dual Cylinder) Operation(URW5４6C) (6) When Telescoping Cylinder3 retracts Slide pipe

Rod

Check valve 1

Check valve Spool

Bolt Tele3 Selector Valve

Piston

Check valve 2

Slide pipe To tank

２１−１０

Counterbalance valve

Pressure Oil

Check valve 1 Spool

Rod

Pilot Pressure

Bolt Tele3 Piston

How oil flows when tele3 is retracted

Pressure 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 pipe in 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 age 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.

Selector Valve Check valve 2 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.

Tele1

Rod Tele2 Tele3

Piston Apply"LOCTITE #638".

(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  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 flows through the central part of the piston as shown in the illustration and returns to the tank without being squeezed.

CUSHION SEAL

TUBE

PISTON

CHAMBER A

PLUNGER

② At the same time when the piston gets in the plunger, the chamber A is closed with the cushion seal. As a result, the pressure oil in the chamber A is forced to return only through a drilled hole in the state of being squeezed. Thus the piston shock at the stroke end is absorbed.

CUSHION SEAL

２１−１２

２. Cushion mechanism of the telescoping cylinder (2) for 6-section boom. SQUEEZING PART

PISTON

CUSHION SEAL

PLUNGER

(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. CUSHION SEAL

CHAMBER A

PLUNGER

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 GLAND

ROD

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 just before 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

A

NUT

B

SPOOL(1) C ADJUSTING BOLT

STICK

２１−１４

URW546C 6-section boom (Triple cylinders) Troubles

Possible cause

Measures to be taken

Retraction is normal, but when extending, booms (2) and (3) extend at the same time, in other words disorderly.

Some foreign substances are clogging the part? of selector valve of telescoping cylinder (1).

Disassemble selector valve for cleaning, or replace it with a new one.

Extension is normal, but when retracting, booms (3) (4) and (5) retract at the same time, in other words disorderly.

Some foreign substances are clogging the part? of selector valve of telescoping cylinder (2).

Extension is normal, but when retracting, booms (3), (4) and (5) retract at the same time, in other words disorderly.

Some foreign substances are clogging the part of selector valve of telescoping cylinder (2). Snap ring at the part? of selector valve of telescoping cylinder (2) got out of place.

Extension is normal, but when retracting, booms (2) and (3) retract at the same time, in other words disorderly.

Some foreign substances are clogging the part of selector valve of telescoping cylinder (1). Snap ring at the part? of selector valve of telescoping cylinder (2) got out of place.

Boom (2) extends but boom (3) does not extend.

Nut at slide pipe of telescoping cylinder (1) was loosened.

Disassemble telescoping cylinder (1) and tighten the nut.

Boom (2) and (3) extend, but boom (4) and (5) does not extend.

Nut at slide pipe of telescoping cylinder (2) loosened.

Disassemble telescoping cylinder (2) and tighten the nut.

After full extension, booms (5) retracts but boom (3) does not retract.

Adjusting bolt pushing the spool of selector valve of telescoping cylinder (2) was loosened. Selector valve spool of telescoping cylinder (2) was bent.

Adjust the bolt.

Boom (3), (4) and (5) retracts but boom (2) does not retract.

Adjusting bolt pushing the spool of selector valve of telescoping cylinder (1) was loosened. Selector valve spool of telescoping cylinder (1) was bent.

Disassemble selector valve for cleaning, or replace it with a new one. Rearrange snap ring.

Replace selector valve ass'y with a new one.

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 for extension were crossed when reassembling. ２１−１５

２２ ＵＲＷ３７６Ｃ

２２－１

６-section boom Boom 4 front side section in detail How sheave2 is mounted

Wire rope with role to extend boom 5 and role to retract boom 4

Boom 5 front side section in detail How sheave3 is mounted

Wire rope with role to extend boom 6 and role to retract boom 5

Sheave２ ２２−２

Boom４ Boom５ Boom５ Sheave３

Boom６

６-section boom Boom 3 rear side section in detail How sheave4 is mounted

Boom 4 rear side section in detail How sheave5 is mounted

Boom４ ２２−３

Wire rope of role to retract boom 6

Sheave４ Sheave５ Boom３ Wire rope of role to retract boom 4

Wire rope of role to extend boom 4

２２-４

２２-５

２２-６

２２-７

２２−８

２２ ＵＲＷ５４６Ｃ

Telescoping cylinder1 Boom5

Telescoping cylinder2 Boom1 Telescoping cylinder3

２２−９ Boom2 Boom3 Boom4

Boom6

２２－１０

２２-１１

２２-１２

２２-１３

２２-１４

２２-１５

Installation procedures for slide plate and guide It has similar construction irrespective of number of boom section

Bolt

Clearance 2mm

Clearance 1mm

When assembling, apply"LOKTITE #242".

Slide plate

２２－１６

２３　 HOW TO PUNCH (1) Purpose Troubles injuring the inside surface of cylinder tube due to screws mounting piston being loosened have been happened. Therefore, we not only upgraded the screw lock agent “LOCTITE #262” to “#2701” to strengthen adhesion but also 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 1.5mm 4. Punch 2 places around the screw thread in diagonal position.

Hexagon socket head screw Tighten each hexagon socket screw with "LOCTITE #2701" applied to the threads to punch specified places close to screw threads.

Fig.1 Piston

Points to 1. 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.)

（２３－１）

TELESCOPING/DERRICK CYLINDER ASS’Y, MEASURES TO PREVENT PISTON FROM BEING LOOSENED (Description) In order to ensure preventing the pistons of telescoping and derrick cylinders from becoming loose, fix the screw threads on the rods and the pistons with the adhesive “LOCTITE #638” (excepting for W376C telescopic cylinders). Besides, securing piston with screws and punching after application of “LOCTITE #2701” are also to be carried out　as before (Rods and pistons are to be fixed perfectly by application of adhesive “LOCTITE #638”.) (Main points) Rods and pistons are fixed by tightening after application of “LOCTITE” to the threads on the rods and on the pistons. 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 more effective as the target adhesion is to be at between metal components.) Note : Pay special attention to observing the points to notice illustrated below while working as curing itself and curing time of “LOCTITE” depends largely on how the adhesion procedures　have been carried out. Points to notice on procedures to apply “LOCTITE” Procedures 1. 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, 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 stuck before use. • When “LOCTITE” is applied to a component and it is shut off air, curing will start after 5 minutes from application 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 component without 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.

（２４－１）

TELESCOPING/DERRICK CYLINDER ASS’Y, MEASURES TO PREVENT PISTON FROM BEING LOOSENED (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 is in 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” to the 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. Chart of breakdown torque vs. curing Bolt:M10×P1.5- L2S 　　 timeWhen using "Lock Tight #638with primer #7471 (primer T)

Nut: M10×P1.5 Material:Soft steel (raw)

Breakdown torque (kgf/cm)

Ambient temperature 35℃

(5) Curing

• This is a period while an adhesive is being ed. 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.

15℃

0℃

Curing time (Hr)

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 “L OCTITE #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).

（２４－２）

25℃

Ground

Earth for engine start relay and engine stop relay

２５－１

Sky

Earth of the main harness

２５－２

Sky

Ground

Slip ring

26.1 ELECTRIC WIRING DIAGRAM ( CRANE )

SLOW DOWN(0V) ML STOP(12V) SUB BATTERY

BL Or

BL/Wh Or

G ML POWER(12V) Re

Ye Gr to Degital load display device

B SPEAKER Wh

MODE SELECTOR(TRAVEL/CRANE)

CONTOROL BOX

MRV-500 CONTROL VALVES Ye Wh BL B Gr Ye Wh BL B Gr Ye Wh BL B Gr Ye Wh BL B Gr Ye Wh BL B Gr Ye Wh BL B Gr

LVDT (DERRICK) LVDT (WINCH) LVDT (TELESCOPIC) LVDT (SLEWING) LVDT (OUTRIGGER) LVDT (ACCELERATOR)

２６－１－１

RAISE LOWER

UP DOWN

RETRACT EXTEND

RIGHT LEFT

B/Pi

Gr/BL Br/Wh

B/Pi

UNLOAD ACCELERATOR

Gr/Ye G/B

B/Pi

OUTRIGGER

INTER LOCK

LVDT 2 WINCH 1 LVDT 2 WINCH 2

LEAVING MINIMAM WIRE ROPE DETECTOR

LVDT 2 TELESCOPIC 1 LVDT 2 TELESCOPIC 2

Re/BL Wh/Vi

B/Re Ye/B

B/Pi Re/BL Wh/Vi

Gr/Re Vi/B

B/Pi Re/BL Wh/Vi

Gr/Vi Pi/Wh

B/Pi

Pi

Re/B Re/B

BL

B Pi

Re/B

B Pi

Re/B

Re/B

B Pi

Re/B

B Pi

Re/B

B Pi

B Gr/Pi

B Pi

B Re/B

LVDT 2 SLEWING 1 LVDT 2 SLEWING 2 OUTRRIGER MODE CRANE MODE LVDT 2 OUTRRIGER RIGHT SIDE 1 LVDT 2 OUTRRIGER RIGHT SIDE 2 OUTRRIGER MODE

OUTRRIGER(2)RETRACT

Ye

WINCH UP

OUTRRIGER(3)EXTEND

Br

WINCH DOWN

OUTRRIGER(3)RETRACT

Or

BOOM RETRACT

OUTRRIGER(4)EXTEND

Pi

BOOM EXTEND

OUTRRIGER(4)RETRACT

Sk

SLEWING C.W

ENGINE START

SLEWING C.C.W

Wh/B

HOOK RELIEF

Gr/Pi

UNLOADING

ENGINE STOP POWER SUPPLY(RSERVE) STOP SINAL 2

B/Re

ACCELERATOR

Wh/Re

OUTRRIGER

Re/B

Gr G/Re

OUTRRIGER(2)EXTEND OUTRRIGER(2)RETRACT

Ye/BL Br/Re

OUTRRIGER(3)EXTEND OUTRRIGER(3)RETRACT OUTRRIGER(4)EXTEND OUTRRIGER(4)RETRACT

MAIN RELAY N.O. B Re

Or/Gr Re/B

STORE HOOK AUTOMATIC STOP RESET

BL/Wh Vi/Or

Re/Gr

Vi/Gr Re

G

Vi/Ye

BL

Vi/Re

Br

BL/Pi

Ye

B/Or

Gr

Vi/BL

B

Ye

Wh Re

B Wh

B Vi/Re Gr/Or B B Br/Gr B

BZ

RADIO CONTROL SWITCH

Or Re Br

OUTRRIGER(HORIZONTAL) SELECT SWITCH OUTRRIGER(VERTICAL)

Or Re Br

CRANE OPERATION MODE SW OUTRRIGER

Re

Or Re Br

EXTEND OUTRRIGER(1)SW RETRACT

Re

Or Re Br

EXTEND OUTRRIGER(2)SW RETRACT

Re

Or Re Br

EXTEND OUTRRIGER(3)SW RETRACT

Re

Or Re Br

Br/B Ye/Gr Re Wh

Gr/Or

Wh/Or Ye/Re Pi/BL Ye/Wh Wh/Br

B/BL

B/BL

Wh/Ye

Sk

Gr/Or

Wh/Ye Re Gr/Wh

Wh/Ye B/Ye

BL/Vi Ye/Vi BL/Vi B/Br

HORN Pin1 VOICE AUTOMATIC STOP RESET

Re

SPARE POWER SUPPLLY

Pin2 Re Wh B Re Wh Pin3 B Pin4

Wh/B

Gr B

B Pi/Gr Re/Gr Vi/Gr

B Ye/B Gr/B Re

BL/Pi Vi/Or Or/Wh Wh

BL/Pi Vi/Or Or Wh

Sk G/B Or/B Wh

BL/Vi

BL/Vi

BL/B

Pi/B

Pi/B

Lg

Head light Head light

Or

Re

Re Re/Wh Re/Wh B B Wh/Gr

Re Wh B

Pi/Gr Or/Re

Wh/Gr Or/Gr Re Wh/Gr Br/Gr Re

Pi/Gr Or/BL

Re Wh B

Re

B

Re

B

Re

B

Re

B

Re

Re

Re

B

B

Gr B

B

Gr B

B

Gr B

Pi/Gr Gr/Br Re

Re B B Or/Ye

Gr B

Pi/Gr G/Gr

LED1 (1)HORIZONTAL (1)VERTICAL LED2

LED3

LED4

(2)HORIZONTAL (2)VERTICAL

(3)HORIZONTAL (3)VERTICAL

(4)HORIZONTAL (4)VERTICAL

Stored boom detection B Wh

Pi/B B

Re

EXTEND RETRUCT Br Re

HORN Release switch for safety device

(EARTH) (EARTH)

B Or/Ye

Wh B B

Ye B Wh B

Br/B

Br/BL

Gr G

Gr G/Re

BL Or

BL/Gr Or/Gr

Ye Br

Ye/BL Br/Re

Pi Wh/B

Pi/Ye Wh/BL

Re/B

Vi/Re

STOP

Re/B

Re G Wh B Gr G Ye B Or G Pi B BL G BL B

Wh/B Gr/B Ye/B Or/B Pi BL/B Br/B

B

Gr/Wh

B B

Wh B Wh B Wh B Wh B Wh B Wh B Wh B Wh B

Re B G Lg

G Re

HORN RELAY(N.O.)

BL Sk Or

BOOM STORAGE

Br

Re

HORN

Re/Wh

HOOK STORING

B Re

Re Pi/B

BL/Vi Ye/Br

Re

EMAGENCY STOP

CONTROL BOX RESET SW Re Or

POWER SUPPLY(MAIN) POWER SUPPLY(RADIO CONTROL)

Valve for carrier

BL/Vi G/BL

Br Re G B Br Or Or Re

B B Br/Ye B B/Ye Re/B Gr/Pi

Or/Gr

C.O.

Outrigger monitor Limit Switch

Gr/B

Pi

B

EXTEND OUTRRIGER(4)SW RETRACT ENGINE

Gr/B

Vi

Wh Re

N.O.

B

OUTRRIGER MODE BUZZER OUTRRIGER MODE LAMP

Or Re Re

Or

B Re Gr B

Br/Gr

B

Wh

MODE LAMP

Re

Wh Gr

B Re/Wh

Gr

B Re

GND GND POWER SUPPLY(SOLENOID)

Re G

Or/Ye B

Or/Wh

OUTRRIGER(1)EXTEND OUTRRIGER(1)RETRACT

BL/Gr Or/Gr

Pi/Ye Wh/BL

MAIN

Speare power supplly Re B

BL/Wh

BL/Or

OUTRRIGER(2)EXTEND

BOOM LOWER

Re Re B

BL/Wh

G/Ye

MODE LAMP

B

Lg

LVDT 2 ACCELERATOR 1 OUTRRIGER(1)EXTEND LVDT 2 ACCELERATOR 2 OUTRRIGER(1)RETRACT BOOM RAISE

Vi

Pi

RADIO CONTROL MODE

G

Re/B

B Pi

B Pi

1+ 122 DERRICK 1 2 DERRICK 2

Re/BL Wh/Vi

B

HOOK RELIEF

LVDT LVDT LVDT LVDT LVDT

Re/BL Wh/Vi

B Pi

B Pi

Re/BL Wh/Vi B/Pi Vi/Wh G/Wh

Re/BL Wh/Vi

B

Or/Wh

BL/B

Re Re/Wh

Re

DIGITAL SIGNAL(-) SPEAKER(+) DIGITAL SIGNAL(+) OVERWINDING DETECTOR POWER SUPPLY (TRANSMITTER) SAFTY DEVICE RESET SW GND OPERATION SIGNAL

Re B

a b

Wh/Pi BL/Ye Re/Ye B/Gr Or/Gr

REMOTE CONTROL (TRANSMITTER)

Br/Ye

Re B

G/B Br

Ye

B

Wh Gr

RELAY BOX

ＭＬ control box

ＭＬSTOP ＭＬALARM OVERWINDING SIGNAL

Re

BZ

Or

Or

ＭＬALARM

+5V BOOM LENGTH

BL/Re

0V

BL/Re B

B

B B

Re

Re

Re

Re

Re

Re

Re

Ye

Gr

Gr

Ye

Ye

Gr

Gr/B

Wh

B/Wh

B/Wh

Gr

Gr

B/Wh

Ye/B

Ye

Wh

Wh

Re

BL

B

B

G Wh/Ye

Wh/Ye

Gr

Wh/Gr

Lg

Lg

LOAD DISPLAY UNIT

SLIP RING

Lg

（OVER FRONT HOISTING）

OVER FRONT HOISTING

B

BL/Wh

（LEAVING MINIMUM WIRE ROPE）

POWER SUPPLY

(+)DEGITAL SIGNAL (-)DEGITAL SIGNAL

B

Re/Wh

（OVERWINDING SIGNAL） （ＭＬALARM） （ＭＬSTOP）

+5V D-IN CLK LOAD GND

BL

BL

Re/B

Gr Pi

Re/B

Re/B

Re

Wh/B

Wh/B

Wh

G

G

B

BOOM LENGTH SENSOR

Gr

GND

Re

POWER SUPPLY RS485(+)

BOOM ANGLE

Br

Br

B

OVER FRONT HOISTING ＭＬSTOP OVERWINDING SIGNAL

(+) Ye DEGITAL SIGNAL

Ye

Ye

(-) Wh DEGITAL SIGNAL

Wh

Wh

CORD REEL

Ye

Ye

(+) DEGITAL SIGNAL

Wh

Wh

(-) DEGITAL SIGNAL

B

GND

B

THREE COLOURED LAMP

Re

Re

Ye

Ye

BL

BL

Br

Br

Wh

Wh

B

B

２６－1－2

B Wh Re/Wh Ye/B

Wh Gr

（ＭＬSTOP） （ＭＬALARM）

To relay box BL

Re/Wh Wh/Ye

Or BL/Wh

Power supply

B/Ye

Relay for alarm signal BL/Wh

B/Gr

Wh/Gr

B/Gr

Rest switch for safety device

B

Re

Or/Ye

Or/Ye

Re

B

G

B Or/Ye B Or/Ye

Rest switch for ML device

BL

Wh B

Ye Re

Ye Re

Br

Or

Or

Gr

Wh/Ye

Wh/Ye

Wh

Gr/Re

Gr

Br

B

B

B

BL/Wh

Sky Pi G Or

Re B

Outrigger１ Horizontal Length max.

Pi Wh Or Br

Re B

Outrigger4 Horizontal Length max.

Wh Pi Br Or

Re B

Outrigger2 Horizontal Length max.

Pi B Or B

Re B

B

Outrigger3 Horizontal Length max.

(EARTH)

Limit switch

B

Wh/Ye

Power supply for ML

Re

Re

Re

Re/Wh

B

B

B

B

Relay for stop signal Br

Or

Re

B

ＭＬ stop

B

Wh/Gr

Re

Re

N.C.

B/BL

Sky G

B/Ye

Relay for stop signal

B

Re

Wh

B Re Re/Wh BL/Wh

Re

Re/Wh

OVERWINDING　DETECTOR OVERWINDING DETECTOR

Limit switch for leaving minimum wire rope

To relay box

LOAD CELL

+5V SIGNAL（－） 0V SIGNAL（＋）

B

G

POWER SUPPLY

BOOM ANGLE SENSOR

Wh

RS485(-)

LOAD CELL AMP Re

B

B

Re B

Power supply

To stored boom detection

Or/Ye

To relay box

B

26.1 ELECTRIC WIRING DIAGRAM ( CRANE )

Electric wiring in control seat part

Operation switch （left side）

Operation switch （under side）

Operation switch （left side） Operation switch （right side）

２６－２

Crane Vertical Horizontal Retruct

パラ 切換

アウト 1

Outrigger２ Outrigger３

AUTOSTOP RELEASE 2

On

Head light

安全装置 　解除 リセット

格納

Radio contoller selector switch （Radio control／ Manual）

非常停止

To earth To earth To outrigger buzzer or to radio control To control valve

ラジコン スイッチ

（Horizontal）　Outrigger３　（Vertical） 電源

（Horizontal）　Outrigger２　（Vertical）

電源

（Horizontal）　Outrigger４　（Vertical）

スタート ストップ

（Horizontal）　Outrigger１　（Vertical） Solenoid selector valve

To Relay ＭＬ停止

ＭＬ停止

停止

予備電源

予備電源

転倒防止 　異常

ＭＬ電源 ON

転倒防止 ON

転倒防止

To relay or to diode

Hook

To outrigger mode indicator lamp To slip ring To Relay box

Rest switch for control box

水準器 ライト

ホ－ン

Store

SAFTY DEVICE RELEASE 1

SAFTY DEVICE RELEASE 2

reset

前照灯

Horn

前照灯１

前照灯２

Off

reset

ML STOP RELEASE

Rest switch for safety device

音声停止

Relay アウト 4

AUTO STOP INTERLOCK

AUTOSTOP RELEASE 1

Voice switch

Off

Outrigger４

Extend

On

アウト 2 アウト 3

　接地 LED

Automatic stop for over windiding reset switch

Outrigger１

Extend Retruct

reset

ML STOP RELEASE

AUTO STOP INTERLOCK

Control box

Stored boom

Outrigger operation

ＭＬ自動停止解除

　ピン LED

停止解除

Extend Retruct

reset

Outrigger pin 1 Outrigger pin 2 Outrigger pin 3 Outrigger pin 4

クレ－ン アウト

Extend Retruct

アウト V/H ランプ

台車側 電源

Outrigger（Vertical）ＬＥＤ Operation mode switch Outrigger

Operation switch （under side）

Relay

スタート ストップ

Outrigger（Horizontal）ＬＥＤ

Operation switch （right side）

　ブーム 格納検出

To outrigger monitor limit switch

スピーカ 　走行／ クレーン 予備電源

Power supply ( Carrier side )

To Key switch box ( Carrier side )

To limit switch to detect boom not being stored To speaker TO interlock Relay for crane-crawl opration 走行 クレーン 1 予備電源 1

走行 クレーン 2 C/O ソレノイド

アウト３（縦）

アウト （３）縦

アウト２（縦）

アウト （２）縦

アウト４（縦）

アウト （４）縦

アウト１（縦）

アウト （１）縦

アウト３（横）

アウト （３）横

アウト２（横）

アウト （２）横

アウト４（横）

アウト （４）横

アウト１（横）

アウト （１）横

TO solenoid of carrier side

予備電源 2 非常停止

Emergency stop Emergency stop(Head light side)

To earth

アース

アース

To relay box

Power supply fuse Control box

２６－３

２６－４

Ground

Solenoid valves for operating outrigger

Sky

Connector of Emergency stop

２６－５

Wiring for operation switch

２６－６

Wiring for operation switch

２６－７

Wiring for operation switch

２６－８

Switch

２６－９

Switch ( Key switch type ) ( Turnover prevention device)

２６－１０

Interlock for crane-crawl lever

２６－１１

Interlock for crane-crawl lever Crawl position

Crane position

２６－１２

２６－１３

Ground

The other side of accelerator pedal

Sky

The other side of accelerator pedal

Sky

Ground

２６－１４

Sky

It connects with the accelerator cylinder of the control valve.

２６－１５

Ground

It connects with the accelerator pedal.

Electric wiring in control valve part

Relay

ハ゜ラフック ランプ ハ゜ラフック ランプ

旋回 右

Ｓ左

旋回 左

RB バルブ４

RB 3COLOR LAMP

RB バルブ１

RB 電源

To slipring

OD

アウトリガ

D

H

T

S

　リレー ボックス

テレ 伸

Ｓ右

ＭＬ電源

POWER SUPPLY

ＭＬ停止

ML STOP 1

OD

EARTH EARTH

To degital load metor デリック

ホイスト

旋回

テレ

To 3 Color lamp

アウトリガ

POWER SUPPLY

To アウト 接地・ピン１ To アウト 接地・ピン４

AC

POWER SUPPLY

To アウト 張出４ AC

アクセル アクセル

UL

アン ロ－ド

HR

フック リリ－フ

ML STOP 2

To アウト 張出１

アウト 接地２

テレ 縮

Ｔ伸

アウト ピン２

ホイスト 下

Ｔ縮

アウト ピン３

ホイスト 上

Ｈ下

アウト 接地３

デリック 伏

Ｈ上

3COLOR LAMP

デリック 起

Ｄ伏

DL INDICATOR

Ｄ起

　ＲＢ走行 クレーン

RB アウト

　リレー ボックス

アウト 張出１

アウト ピン１

アウト 接地１

２６－１６

　リレー ボックス

モード ランプ

アウト ランプ１

アウト 接地４

アウト ピン４

アウト 張出４

アウト ランプ

アウト ランプ２

Diode

アウト 張出

OUT EXT DETECTION

予備電源 ML STOP 2

Sky

２６－１７

Ground

２６－１８

Sky

２６－１９

Ground

Relay box Sky

２６－２０

Ground

２６－２１

Sky

２６－２２

Ground Horn

Buzzer for Outrigger

Position of hose Telescoping Slewing

２７－１

Derrick Hoist

Engine

Air cleaner element

Fuse box

Solenoid to stop engine

Sky

Muffler ２８－１

Filling port

Ground

Oil fillter element

Water separator

Warning lamp and Fuse box Warning lamp Hour meter Starter switch

FUSE BOX

Wiring for warning lamp

ヒューズ BOX

EARTH

　台車 ハーネス

4 5

２８－２

7 8

FUSE BOX リレー

6

10

20 20 15 10 20

3

10

1 2

15

　キー スイッチ

3 10 30

It connects with the accelerator pedal.

Water separator ２８－３

Oil fillter element Drain plug

Air cleaner element

Alternator

２８－４

b b

Re a a

b

Re

Re/Wh

TERMINAL B PREHEAT

ELECTRIC WIRING DIAGRAM ( Engine part ) b

Re

Re a a

Re/Wh

W370CD

Carrier side

a

Re b b

Re

B/BL

Gr/B B/BL

a

Crane sideGr/B

B R Acc

R1 R2 C

OFF ON START

Engine start relay N.O. N.C.

Wh/Re

Wh/Re

Re/Wh

A CC

B

Or

BR R2

1 2 3 4

3 4 5 6

S R L P E

Wh/BL Wh/Gr Ye Wh/Ye B

B Re/Gr Gr/Wh BL/B

Wh

Re

R1 BL

Re

Ye/Gr

Warning lamp for air cleaner clogging

Re

Oil pressure switch

c BL/Wh d

Re

b

Re/Ye

a

Warning lamp for alternator(for charging) Pilot lamp indicating preheating engine

Glow lamp

BL/Re

a

b

Ye/Gr

c Wh d

Fuse e G f B

Re/BL

B B Battery

Air cleaner switch

Wh/Ye

Ye/Gr

L

P

Oil temperature switch （１０５℃） Oil tank

c

Water temperature switch （１０５℃）

Br/Wh B/BL

Re a BL/Re b

B/Ye

Switch

R

Engine

Fuse

Warning lamp for hydraulinc oil temperature

B

B

Alternator

Solenid to stop engine

e Re/BL f

Starter

BL/Re

S

Re

M

BL/Wh

Warning lamp for circulating water temperature

Re

a BL b

Re

Br B/Wh B

BL

Warning lamp for engine lubricating oil pressure

Wh

Fuse

B Hour meter

b B

1 2 3 4

Fuel pump

Re/Ye

Solnoid

Safety relay

B

Or

BL BL

a

Glow timer

Starter switch

BL L

Re/B

Glow relay

Power supply on crane side　　 Glow

20A Wh/Ye

15A Or/Gr

Re/BL

15A

Wh

Br Wh

Wh/BL Re

Wh Wh

Gr/Wh

BL

Gr/Wh

20A

Re B/Ye・G BL/B Re/Gr

Re

B/Wh Gr

20A

B

２８－５

b a b a

C

B/Wh Ye

30A

B/Wh B/Wh Gr Wh/BL

Gr/Wh

Emagency stop switch

Wh/Re

10A

B/Ye

B/Wh

3A Br/Wh

Wh/Re

Gr

Wh/Re

Re

Re

Re

Wh/B

Engine stop relay

Wh/Re Wh/B

b

b

Re

Re/Wh

a

Carrier side a

Or

Re b b

Re/Ye

Re

a a

a a

Re/Wh

Re Re

Gr/B B/BL

a a

Re b b

Gr/Re b b

Re

Gr/B B/BL

Ｗ３７０ＣＤＥ ELECTRIC WIRING DIAGRAM （Power unit option）

Engine start relay N.O. N.C. Wh/Re

b a b a

BL L

Re

3 4 5 6

S R L P E

Wh/BL Wh/Gr

Ye Wh/Ye B

1 2 3 4

B Re/Gr Gr/Wh BL/B

B Fuel pump

Or

Safety relay

Glow timer

Wh

Re/BL Wh

Re

Br

Glow relay

1 2 3 4

Wh/B

B

Starter switch R 2 R1

Glow

Wh/Ye

Wh/BL

Wh

Gr/Wh

Re

Gr/Wh

20A 15A 15A 20A

Wh

Gr

Gr/Wh

20A

Wh

B/Wh

Ye

10A 30A BL

B/Wh

Gr

3A Br/Wh

Wh/Re

Re B/Ye・G BL/B Re/Gr

ACC C

Wh/Re

B/Wh B/Wh Ｇｒ Wh/BL

Emagency stop switch

Re/Wh

B/Wh

Re

Re

Re

Power supply on crane side　　　

Or

B/Ye

Engine stop relay

Wh/B

Or/Gr

Wh/Re

BR

BL BL

BL

c d

TERMINAL B PREHEAT

B R Acc

R1 R2 C

e f

Starter Oil pressure switch

BL/Wh Re

B

Re/BL

Ye/Gr Wh

Engine

b

Fuse

BL/Re

Re/BL Switch

b

Re/Ye

b

Re/B B

Power unit

Air cleaner Switch

R

3φ3W S ＡＣ２００／２００、２２０Ｖ T 50/60Hz

X Y Z

X Y Z

（５．５Gr）

E

BL

B

Gr BL

B

a

B

Wh/Ye

Water tempernature switch(105℃）

c

G B

Oil temperature switch（１０５℃） Oil tank

Glow lamp a

a

Solenid

Solenid to stop engine BATTERY

BL/Re

ON START

P

Alternator

Re

Pilot lamp indicating preheating engine

OFF

L

B

BL/Wh

Warning lamp for alternator(for charging)

R B

B

a b

Re

Br B/Wh B Re

BL

Warning lamp for hydraulinc oil temperature

S

Re

BL/Re

e f

M

Br/Wh B/BL

c d

Fuse

BL

BL/Re

Warning lamp for circulating water temperature

Re

Re/Ye

a b

Re

Warning lamp for engine lubricating oil pressure

Warning lamp for air cleaner clogging

Wh

Fuse B

Hour meter

Ye/Gr

Ye/Gr

B/Ye

２９－１

Re Re/Ye

Gr BL

B

BL

B (2.0)

Wh

EM

P

E

U （５．５Re）

U

V （５．５Wh） W （５．５B）

V W

M

P

Power unit (7.5kw 15/14A)

Controlbox for Power unit ＡＣ４００Ｖ 50/60Hz

R S T E

X Y Z

Electric diagram of control box

E U

B

V W

M

R1

R S T

X Y Z

T1

P

ELB

Power unit

E

EM

THP(Set15A)

Converter

F1

F2

Earth

U V W B

6 QER 4 3

S1

M

RC

400 R0 SC 0 Converter

P + N -

E

SC

Earth

PBL

00

RC

PBS

QER

01 (1)

M

04

FUSE

BREAKER

２９－２

THP

03

M GL

EM Ry

Wh

(5)

02

FUSE

Electric diagram of control box Converter

R1

R S T

X Y Z

T1 ELB

E

THP(Set15A)

F2

M

RC

400 R0 SC 0 Converter

P + N -

E

SC

Earth

PBL

00

RC

PBS

QER

01 (1)

M Wh

F1

Earth

U V W B

6 QER 4 3

S1

04 EM Ry

２９－３

(5)

02

THP

03

M GL

Electric diagram of control box Converter

R1

R S T

X Y Z

T1 ELB

E

THP(Set15A)

F2

M

RC

400 R0 SC 0 Converter

P + N -

E

SC

Earth

PBL

00

RC

PBS

QER

01 (1)

M Wh

F1

Earth

U V W B

6 QER 4 3

S1

04 EM Ry

Converter

２９－４

(5)

02

THP

03

M GL

Power Unit (400V type ) S/N ～37W0117

Earth

Ｕ Ｕ１ Ｖ２

Ｖ１

Ｖ

Ｗ２ Ｖ２

Ｗ

Harness (Carrier side) ２９－５

Harness

Harness (Carrier side)

Emergency stop button

Re/B Re/Ye

Re/Ye

Switch for speed select Relay･Diode

Power Supply for Crane

W

V1 W2

Relay

W1 V2

Motor P EM

DC12V EMARGENCY

TH

U1

DC12V

DC12V

Emergency stop button

リレー

リレー

Harness

非常停止

V

V2

KEYSW

U

Harness

非常停止 （パネル）

非常停止

Earth

E

EARTH EARTH

Contorol box for power unit

非常停止 （前）

KEYSW

EARTH

EAR

FUSE

2NDSW

予備電源

EARTH

Diode

予備電源

Ｗ１

Harness

Power Unit (400V type ) S/N 37W0120～

Ｖ２

Harness (Carrier side)

Emergency stop button

Re/B Re/Ye

２９－６

Re/Ye

Switch for speed select Relay･Diode

Power Supply for Crane

非常停止 （パネル）

非常停止

Harness

TH

EARTH EARTH

Contorol box for power unit

非常停止 （前）

DC12V

EM

DC12V EMARGENCY

DC12V

非常停止

Relay

リレー

リレー

Harness KEYSW

Tag block of Motor

Emergency stop button

KEYSW

EARTH

EAR

FUSE

2NDSW

EARTH

Diode

P

Ｗ１

Harness

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.

Does the oil come out when removing the pipe at retracting side?

YES

Inside leakage occurs. The packing is damaged. The tube is scratched.

NO The derrick cylinder sinks.

Does the oil come out when removing the hose at lowering side?

YES

３０－１

Does the oil come out when removing the hose at retracting side?

YES

Does the oil come out when removing the hose at raising side?

The counterbalance YES valve malfunctions. The seat surface is damaged. Foreign matter is caught by the seat surface.

Does the oil come out when removing the hose at extending side?

The counterbalance YES valve malfunctions. The seat surface is damaged. Foreign matter is caught by the seat surface.

Inside leakage occurs. The packing is damaged. The tube is scratched.

NO

YES Check the pilot. The seat surface is damaged. Foreign matter is caught by the seat surface.

Inside leakage occurs. The packing is damaged. The tube is scratched.

NO The telescoping cylinder sinks.

Does the oil come out when removing the pipe at extending side?

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). ③In order to release pressure remained in the derrick system, stop the engine and shift the manual lever for raising/lowering of booms.

(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

Lowerring hose

Risinghose

Fig2 Counterbalancevalve Fault in seat surface Fig1 Load

Fig3

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 a mark 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 telescoping booms.

Put a mark on each boom

(2) Starting inspection ④Remove the retraction hose to check if oil overflows continuously out of the cylinder port of retraction side. At he same time, also check that which boom section sinks how far to grasp condition of booms as a whole. If no oil flows out of the port of retraction side, the cylinder is normal. ⑤Next, remove the extension hose, and if oil overflows continuously out of counter-balance valve port of extension side, there may be faulty on the seat surface of counter-balance valve (refer to Fig. 3). In 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 the retraction hose has been removed (refer to Fig. 2). Since overflowing oil out of the port on retraction side means internal leakage in the cylinder, check tele1 and tele2 separately. Be sure to measure the how far each boom sinks as it is an important point for judging that it is normal or abnormal.

Fig1 Counterbalancevalve Fault in seat surface

Fig2

(3) Inspection of tele1 ⑥Extend booms to a position where it is a little bit shorter than 2-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 telescoping booms. ⑨Remove the retraction hose. If oil overflows out of cylinder port of retraction side and boom2 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 a mark 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 telescoping booms. ⑬Remove the retraction hose. If oil overflows out of cylinder port of retraction side and boom3 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 for 5-section boom Be sure to check the boom sections one by one reliably.

30 - 3

Fig3

30.4　Procedures for checking outriggers for sinking

Raise vehicle by 50mm.

In case where outrigger sinks during crane operation Test 1 Putting the crane on a solid level ground, extend the outriggers to their extremes and raise the crane mounted vehicle by 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.

Retract Mark here .

Extend

Test 2 Exchange the W.P. check valve measuring maximum sinking and the one measuring minimum sinking to repeat the same procedures of “Test 1” above.

W.P. check valve

Starter key

Judgment by comparison When 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.

Outrigger mode indicator lump

Caution When a cylinder has been replaced of, re-adjustment of the load cell amplifier is needed.

How to release pressure out of outrigger cylinder circuit Be sure to operate by using the switch and the lever illustrated in the picture. Even if outriggers are controlled via radio controller, pressure in the circuit will not be released as the engine has been shut off so that oil pressure will not be generated and as a result the lever controlling 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.

30 - 4

Outrigger lever

Operation mode switch

Outrigger control switch

MAINTENANCE AND INSPECTION OF CRANE

31 Replacement of wire rope (for winding-up) Wire rope is an expendable article and it will be damaged and its strand wires are broken to allow it to be thinner through a long period of operation. Replace the rope according to following criteria.

1

♦1. Replacement criteria

1.

A rope in which amount of broken strand wires (except filler wires) comes to more than 10% within a pitch of twist. Replace the wire ropes intended for use with this crane if 13 pieces of strand wire have been broken within a pitch of twist.

2

2.

A rope being kinked.

3.

A rope from which its diameter has decreased by more than 7% of the nominal

3 Wire rope diameter

ロープ径

diameter. For example, if wire rope with a nominal diameter of 8mm is used, replace it when the diameter becomes 7.5mm. Refer to the section 17. MAJOR SPECIFICATIONS, for length and construction of the wire rope for winding-up.

4. A rope which has been deformed and/or corroded excessively.

4 ★Be sure to replace a wire rope when it comes under the criteria, item 1 through 4, illustrated above.

CAUTION ★ Wear leather gloves when

replacing wire ropes.

３１－１

MAINTENANCE AND INSPECTION OF CRANE ♦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 for where the weight for overwinding alarm is to be mounted.

Wire clip

Overwinding alarm detector Ring Wedge

Wire rope for overwinding alarm

Weight for overwinding alarm

Refer to the figure in the left for how to attach the hook.

Boom top Front of boom Guide

Higher side is to be in front

３１－２

MAINTENANCE AND INSPECTION OF CRANE 2. How to fix wire rope end Wire rope end 40mm a

Notch

Wire clip (Pay attention to mounting direction) 50mm

① When ing the wire rope end through the wire socket, be sure to it as indicated by the arrow mark on the socket. If it is ed from the opposite direction, service life of wire rope shortens as the wire rope is kept bent all the time. ② Do not forget to mount the wedge and the wire clip as illustrated in the figure in the left. Leave the wire rope end to allow a distance from the notch to the rope end by more than 40mm as illustrated in the figure as “a”.

Arrow mark Wedge (Wire rope diameter: 8mm)

③ the pin through with the wire socket Projection on upper part of wire socket

held with your hand and tighten it with the bolt securely.

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. the pin through and tighten it with bolt securely.

３１－３

MAINTENANCE AND INSPECTION OF CRANE ♦3. How to correct twisted wire ropes Wire ropes tend to turn in untwisting direction when they are under tension. If two or more wire ropes are hooked together, they tend to be twisted particularly while they are new. The twist will decreases as the ropes are getting fit to the crane. If wire ropes are twisted, correct them as follows:

1.

Unload the hook.

2.

Extend the boom fully.

3.

Raise the boom to an angle of approximately 65°.

4.

Unwind the hook until it comes close to the ground.

4-rope hooking

Wire socket

5. Check how many turns the wire rope has been twisted.

6. Direction that rope is untwisted

Direction that rope is twisted

Wind up the hook and retract the boom to be on a stored condition.

7.

Remove the wire socket and turn the socket in the untwisting direction by as many turns as the wire ropes have been twisted multiplied by the number of wire ropes being hooked. However, that the wire socket may be turned up to 4 turns at a time.

8. (Note) Rotate wire socket to the direction opposite to wire ropes have been twisted.

Attach the wire socket and repeat winding up and down the rope 2 or 3 times between both extremes. Then, check if twist of the wire ropes is corrected. If they remain twisted, repeat the procedures shown above.

３１－４

MAINTENANCE AND INSPECTION OF CRANE

32 Replacement of expendable parts ♦1. Replacement of gaskets and seals for each cylinder Although timing of replacement of a part varies according to how frequently the crane has been operated, replace gaskets and seals used in each cylinder after every 3 years of operation (period during which crane has not been operated is included) in order to operate the crane safely. Ask a local UNIC authorized service shop for replacement of gaskets and/or seals.

Sliding plate

♦2. Replacement of sliding plate of boom Replace it every 3 years.

♦3. Replacement of brake shoe of hoisting winch Replace it every 3 years.

Brake shoe

♦4. Cleaning and replacement of filter in the control valve If the filter built in the control valve is clogged up, radio remote control operation and acceleration interlocking operation cannot be carried out. Clean it by blowing air once after one year of use and replace it if it has been clogged up remarkably 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: Classification

Depending on atmospheric temperature

Rating to be applied

-30

-20

Engine oil Diesel engine oil of CD class

SAE5W

0

-10

10

20

30

SAE30 SAE10W SAE10W -30

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 a shorter engine life. Use oils that meet API Engine Service Classification CD.

♦2. Use the recommended grease for lubrication as below. Chassis grease Use 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.

♦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 should be mixed with water.)

CAUTION ★Use the softened water with less impurity such as tap water for cooling water. Do not use well water and river water as cooling water.

★Use of coolant which too much of antifreezing solution mixed with water allows the engine to be overheated earlier.

３３－１

WATER SUPPLY AND LUBRICATION TO CARRIER ♦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. Brand

Petroleum Maker

ISO VG 32

ISO VG 46

ESSO

Spinesso 32

T eresso 46

MOBIL

Mobil DTE 32

Mobil DTE Oil Medium

CALTEX

Spindura oil 32

Rando Oil 46

SHELL

Shell Tellus Oil 32

Shell Tellus Oil 46

★ Use the recommended lubricants listed below as gear oil for lubrication. Aplication Reducer for winch

Petroleum Maker Shell

Brand Shell Spirax EP 90

Use API service GL-4 gear oils. (Refer to the followings) Reducer for slewing gear

ESSO MOBIL CALTEX SHELL

Standard gear oil 90 Mobilube GX 90 Universal Thuban SEA 90 Shell Spirax EP 90

★ 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 grease Use NLGI No. 2 grade. Petroleum Maker

Brand

ESSO

Beacon G2

MOBIL

Mobilplex Special

CALTEX

Molytex Grease EP2

SHELL

Retinax AM ３３－３

WATER SUPPLY AND LUBRICATION TO CARRIER

34 Filling water and lubrication chart(URW376C) ④

⑤

Fuel

②

ご

③

Service interval

①

Where to lubricate

No. of part

Lubricant

Initial: Replace after 100 hours ① Engine (4.0 liters) After : Replace every 250 hours

1

Engine oil

Initial : 30 hours, Whenever nec- ② Tension adjustment of essary rubber crawler

2

Chassis grease

Replace antifreezing solution (LLC) every 2 years

1

Antifreezing solution

1

Hydraulic oil

Initial: Replace after 3 months After : Replace 2 years Replace every 1000 hours

③ Radiator (5.5iters) ④ Hydraulic oil tank

(70 liters)

Tool

Grease pump

⑤ Reduction gears of crawl- 2 (Right/ Diesel engine oil

ing motor (0.7 liters)

Left)

or Gear oil

Refer to “MAINTENANCE AND INSPECTION OF CARRIER” for replacement procedures. Fuel

Light oil

Fuel tank capacity

40 liters ３４−１

WATER SUPPLY AND LUBRICATION TO CARRIER

34 Filling water and lubrication chart (URW546C) 4

Fuel

5

2

OUTRIGGER

t

NOT MAX EXT.

SELECT

SET

ì²

3

1

Service interval

Where to lubricate

Initial: Replace after 100 hours After : Replace every 250 hours

①Engine 4.0 liters

No. of part

Lubricant

Tool

1

Engine oil

Initial : 30 hours, Whenever neces- ②Tension adjustment of sary rubber crawler

2

Chassis grease Grease pump

Replace antifreezing solution (LLC) ③Radiator 5.5liters every 2 years

1

Antifreezing solution

1

Hydraulic oil

Initial: Replace after 3 months After : Replace 2 years

④Hydraulic oil tank 70 liters

Replace every 1000 hours

⑤Reduction gears of crawl- 2 (Right/ Gear oil Left) ing motor 0.7 liters

Refer to "MAINTENANCE AND INSPECTION OF CARRIER" for replacement procedures. Fuel

light oil

Fuel tank capacity

40 liters

34-2

LUBRICATION TO CRANE

35 1 Lubrication chart(URW376C) ⑧

⑪

④

⑤

⑨

⑩

② ⑦ ③

⑫

6-section boom ⑬ ⑯ ⑭

⑥

①

ご

⑰

Service interval

Daily

Weekly

⑮

No. of Lubricant Tool part 5 Molybdenum grease Manual appli① Boom slide plate (Underside & side face of boom cation sections②, ③, ④, ⑤ and ⑥)For 6-section boom Grease pump Molybdenum grease Boom slide plate (Upper side of boom section ) 2 ② ① Grease pump 1 Chassis grease ③ Boom foot pin Grease pump 1 Chassis grease ④ Upper pin of derrick cylinder 1 Chassis grease ⑤ Lower pin of derrick cylinder Grease pump 1 Hydraulic oil(up to mid⑥ Oil tank (70 liters) dle of level gauge) Where to lubricate

⑦ Winch drum gears ⑧ Slewing gears

⑨ Winch reduction gears (Approx. 1.0 liter) ⑩ Slewing reduction gears (Approx. 0.7 liters) ⑪ Wire rope ⑫ Slewing bearings Monthly ⑬ Wire rope for boom extension ⑭ Outrigger fulcrum pin ⑮ Outer box ⑯ Outrigger vertical cylinder (Bracket side) ⑰ Outrigger vertical cylinder (Outer box side)

３５−１

1 1

Chassis grease Chassis grease

1 1 1 2 1 4 4 4 4

Gear oil Gear oil Rope grease Chassis grease Rope grease Chassis grease Chassis grease Chassis grease Chassis grease

Grease pump Manual application

Spray gun Grease pump Spray gun Grease pump Grease pump Grease pump Grease pump

LUBRICATION TO CRANE

35 Lubrication chart (URW546C) 8

9

10

6-section boom 13

1 11

4

5

2

7 3

12

16 14 OUTRIGGER

t

NOT MAX EXT.

SELECT

SET

ì²

6

17 Service interval

No. of Lubricant part Molybdenum grease 6 ① Boom slide plate (Underside & side face of boom sections ②, ③, ④, ⑤, ⑥ and ⑦) For 7-section boom Molybdenum grease 2 ② Boom slide plate (Upper side of boom section ①) Chassis grease 1 ③ Boom foot pin Daily Chassis grease 1 ④ Upper pin of derrick cylinder Chassis grease 1 ⑤ Lower pin of derrick cylinder 1 Hydraulic oil (up to mid⑥ Oil tank (70 liters) dle of level gauge) 1 Chassis grease ⑦ Winch drum gears 1 Chassis grease Weekly ⑧ Slewing gears Where to lubricate

⑨ Winch reduction gears (Approx. 1.0 liter) ⑩ Slewing reduction gears (Approx. 0.7 liters) ⑪ Wire rope ⑫ Slewing bearings Monthly ⑬ Wire rope for boom extension ⑭ Outrigger fulcrum pin ⑮ Outer box ⑯ Outrigger vertical cylinder (Bracket side) ⑰ Outrigger vertical cylinder (Outer box side)

35-2

1 1 1 2 1 4 4 4 4

Gear oil Gear oil Rope grease Chassis grease Rope grease Chassis grease Chassis grease Chassis grease Chassis grease

15

Tool Manual application Grease pump Grease pump Grease pump Grease pump

Grease pump Manual application

Spray gun Grease pump Spray gun Grease pump Grease pump Grease pump Grease pump

LUBRICATION TO CRANE

36 Lubrication ♦1. Replacement of gear oil (Winch reduction gears and Slewing reduction gears)

Winch reduction gears

★Air enters in and out of the gear case so that dirt and moisture are brought in the gear case. In addition, since hydraulic equipment gradually wears to produce worn particles, replace gear oil 6 months after the start of operation.

(Draining oil)

★After that, replace gear oil: • Once a year for winch reduction gears, and • Once every 2 years for slewing reduction gears. Drain plug

CAUTION

(Filling oil) Gear oil filling port

★Replace gear oil after oil temperature has dropped.

Oil level gauge

★Fill the gear oil for winch reduction gear to a middle of oil level gauge (approx. 1.0 liter).

Slewing reduction gears Oil level plug

Gear oil filling port Standard level range Approx. 0.7 liters

(Draining oil)

Drain plug

(Filling oil)

３６－１

When carrying out inspection before crane operation, use photocopy of this sheet.

CHART FOR INSPECTION BEFORE STARTING CRANE OPERATION Date:

,

,

Weather: (Fine, Cloudy, Rain, Snow)

Place

Device

Operator

Inspect for:

Check

Device

Inspect for:

Hydraulic pump

Tightness of fitting,Oil leak, unusual noise

Frame

Crack, tightness of bolts and missing

Hydraulic oil tank

Oil level, oil leak

Automatic stop for leaving minimum wire rope

It should make an automatic stop for unwinding when remaining wire rope on the drum come to 3 turns.

Outrigger

Gravity-descent, operating condition, Deformation, damage, oil leak, crack

Radio controller

Operating condition,

Hoist winch

Operating condition, braking performance, irregular winding

Overturn prevention device

Alarm, automatic stop, damage in wiring, tightness of detector

Swinging device

Operating condition, oil leak

Digital load meter

Load indication on no-load, damage in wiring

Derricking boom

Operating condition, oil leak, fitting of foot-pin

Overload prevention Power lamp should light, error lamp device should go off, damage in wiring

Telescoping boom

Operating condition, oil leak, deformation, crack, fitting of mounting pin

Hook

Rotation of hook, operating condition of retainer

Wire rope

Damage, Fastening at rope end

Rubber crawler

Tension, damage, crack

Over-winding alarm

Operating condition, alarm sound

Wheel sprocket

Tightness of bolts

Load meter

Oil leak, operating condition

Track roller

Tightness of nuts, oil leak

Alarm device

Operating condition, alarm sound

Piping High-pressure hose

Oil leak at each connection, damage

Engine

Automatic storing hook device

Automatic stop and storing operation

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

Interlocking device for crane・traveling lever

３７ - １

Crane will not function when selected on traveling side. Traveling will not function when selected on crane side.

Check

MONTHLY SELF-INSPECTION RECORDS Check point

What to check for: Condition of air cleaner element Contamination of fuel strainer and ignition plug

1 Engine

When carrying out inspection, use photocopy of this sheet. Check Keep the inspected results for 3 years. Overhaul

Checked result Measures Check point taken OK NG

13 Column

3 Frame

Deformation, crack, wear of sliding plate

Hydraulic oil tank

4

Hydraulic 5 pump

6 Control valve

8 Swivel t

Fitting of pin, sheave pin Tightness of fitting bolts, nuts, pins, and missing

Tightness of take-up bolts, nuts, and missing

Tightness of telescoping wire, wear, broken strand wire, corrosion

Forward・backward operation of traveling lever

Specifications: length, thickness

Operation of accelerator lever

Wear, broken strand wire, distortion, kink, corrosion, lubrication 15 Wire rope

Deformation, crack of wire socket

Oil leak from reduction gear in traveling motor

Tight connection to drum, irregular winding, twist

Crack in welded section

Fitting of pin, tightness of bolts and missing

Tightness of fitting bolts, nuts, pins, and missing

Oil leak 16 Piping

Damage, aging, crack, twist, dent

Contamination of air breather, return filter, suction filter

Wear, deformation, rotation of hook and lubrication

Operation, unusual noise, oil leak

Gauge mark distance of hook

Tightness of fitting bolts, nuts, and missing

17 Hook

Function, deformation, damage in retainer

Missing knob, peeled off and deteriorated sticker

Tightness of hook screws and looseness of thrust bearing (worn condition)

Oil leak

Tightness of fitting bolts, nuts, pins and missing

Tightness of fitting bolts, nuts, pins, and missing

18 Load meter

Operation of cylinder, lamp, buzzer

19 Load indicator Missing pointer, damage in indication plate, function

Function, oil leak, damage

Automatic stop for 20 over-wound alarm

Function, condition of over-wound detection switch and alarm sound Winding-up condition of cord reel, damage in cord, broken cord Damage in weight and sling wire

Tightness of fitting bolts, nuts, pins, and missing

21 Level

Setting condition

Oil leak

22 Alarm

Function, alarm spund

Tightness of stopper mounting bolts, deformation of plate

23 Name plate

Fitting, damage, deterioration

Deformation of outer box, inner box, suspending bracket of outrigger body Oil leak from outrigger cylinder, gravity-descent

Tightness of fitting bolts, nuts, and missing

Operation

Continuity of slip ring, damage in wiring, mounting

Condition of transmitter enclosure

Gear oil quantity, deterioration

Cable connections: tightness, contamination, corrosion Radio remote Damage, deterioration, twist of wiring and cables 24 control Corrosion, deterioration, tightness of terminals

Crack in drum, lubrication to gears

Oil leak from accelerator cylinder

Tightness of fitting bolts, nuts, and missing

Function of each solenoid valve, oil leak

Operation, unusual noise, oil leak

Alarm function when reaction force against outrigger drops

Damage in air breather

Crane operation when reaction force against outrigger drops

Operation of turn-table, unusual noise, lubrication

25

Overturn prevention

Cable connections: tightness, contamination, corrosion Damage, deterioration, twist of wiring and cables Corrosion, deterioration, tightness of terminals

Tightness of fitting bolts, nuts, and missing

Deformation, wear, damage in load cell

Operation

Telescoping cylinder

Damage, wear, rotation of sheave and lubrication

Operation, deformation, crack in each lever

10 Swing device Gear oil quantity, deterioration

12

of piping

Quantity, contamination, and deterioration of hydraulic oil

Damage in air breather

11 Derrick cylinder

Tight connection to wire socket, fastening clip at rope end

Damage in stand lever and lock lever

Operation, unusual noise, oil leak 9 Hoist winch

Damage, wear, rotaition sliding plate, missing bolts

Crack, wear, damage in rubber crawler

Effect of stopper pin when outriggers are stored and extended, deformation of pins

7 Outriggers

Tightness of bolts mounting turntable, missing bolts 14 Boom

Tightness of fitting bolts, nuts, and missing

Oil leak, crack

Checked result Measures taken OK NG

Tightness of bolts mounting turntable Telescoping operation, lubrication

Braking performance

Adjustment A Cleaning C Tightening T Oil supply L

Crack, deformation

Battery liquid level

Unusual vibration and noise

devices

What to check for:

Fuel leak

Engine oil level and deterioration

2 Traveling

Replacement Repair

Function

Looseness in upper and lower pins of derrick cylinder

26 3-color light

Oil leak from derrick cylinder, gravity-descent Tightness of fitting bolts, nuts, and missing

Automatic stop for Function 27 leaving minimum wire rope Mounting of detector switch

Operation

Remarks to be recorded

Oil leak from telescoping cylinder, gravity-descent Fitting of pins, missing snap ring Tightness of fitting bolts, nuts, and missing

Operator Crane model Delivered date Inspected date

Company in charge of inspection Inspected by Signature

３７－２

ANNUAL SELF-INSPECTION RECORDS Check point

When carrying out inspection, use photocopy of this sheet. Check Keep the inspected results for 3 years. Overhaul

Checked result Measures Check point taken OK NG

What to check for:

Telescoping operation, lubrication

Contamination of fuel strainer and ignition plug

Deformation, crack, wear of sliding plate

devices

4

Hydraulic oil tank

Fitting of pin, sheave pin

Unusual vibration and noise

Tightness of fitting bolts, nuts, pins, and missing

Tightness of fitting bolts, nuts, and missing

Tightness of telescoping wire, wear, broken strand wire, corrosion

Crack, wear, damage in rubber crawler

Specifications: length, thickness

Tightness of take-up bolts, nuts, and missing

Wear, broken strand wire, distortion, kink, corrosion, lubrication 15 Wire rope

Deformation, crack of wire socket

Braking performance

Tight connection to drum, irregular winding, twist

Damage in stand lever and lock lever

Fitting of pin, tightness of bolts and missing Oil leak 16 Piping

Crack in welded section

Damage, aging, crack, twist, dent

Oil leak, crack

Wear, deformation, rotation of hook and lubrication

Quantity, contamination, and deterioration of hydraulic oil

Gauge mark distance of hook 17 Hook

Function, deformation, damage in retainer

Tightness of fitting bolts, nuts, and missing

Tightness of hook screws and looseness of thrust bearing (worn condition)

Tightness of fitting bolts, nuts, pins and missing 18 Load meter

Operation of cylinder, lamp, buzzer

Automatic stop for 20 over-wound alarm

Effect of stopper pin when outriggers are stored and extended, deformation of pins

Function, condition of over-wound detection switch and alarm sound Winding-up condition of cord reel, damage in cord, broken cord Damage in weight and sling wire

21 Level

Setting condition

22 Alarm

Function, alarm spund

23 Name plate

Fitting, damage, deterioration

Tightness of fitting bolts, nuts, pins, and missing Set pressure of relief valve

Deformation of outer box, inner box, suspending bracket of outrigger body Oil leak from outrigger cylinder, gravity-descent Tightness of fitting bolts, nuts, pins, and missing

Operation

Oil leak

Condition of transmitter enclosure

Tightness of stopper mounting bolts, deformation of plate Tightness of fitting bolts, nuts, and missing Continuity of slip ring, damage in wiring, mounting

Cable connections: tightness, contamination, corrosion Radio remote Damage, deterioration, twist of wiring and cables 24 control Corrosion, deterioration, tightness of terminals

Operation, unusual noise, oil leak

Oil leak from accelerator cylinder

Damage in air breather

Function of each solenoid valve, oil leak

Gear oil quantity, deterioration

Alarm function when reaction force against outrigger drops

Crack in drum, lubrication to gears

Crane operation when reaction force against outrigger drops

Tightness of fitting bolts, nuts, and missing Operation, unusual noise, oil leak

25

Overturn prevention

10 Swing device Gear oil quantity, deterioration

Function

26 3-color light

Operation

Automatic stop for Function 27 leaving minimum wire rope Mounting of detector switch

Looseness in upper and lower pins of derrick cylinder

Winding-up capacity, braking with rated load lifted up

Oil leak from derrick cylinder, gravity-descent

Operation Oil leak from telescoping cylinder, gravity-descent

Load test 28 Test load ( ton)

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

Fitting of pins, missing snap ring Tightness of fitting bolts, nuts, and missing

13 Column

Zero-point adjustment and check for load cell

Tightness of fitting bolts, nuts, and missing

Tightness of fitting bolts, nuts, and missing

Telescoping cylinder

Damage, deterioration, twist of wiring and cables

Deformation, wear, damage in load cell

Operation of turn-table, unusual noise, lubrication

12

Cable connections: tightness, contamination, corrosion

Corrosion, deterioration, tightness of terminals

Damage in air breather

11 Derrick cylinder

Function, oil leak, damage

19 Load indicator Missing pointer, damage in indication plate, function

6 Control valve Oil leak

9 Hoist winch

Damage, wear, rotation of sheave and lubrication

Operation, unusual noise, oil leak

Missing knob, peeled off and deteriorated sticker

8 Swivel t

of piping

Tightness of fitting bolts, nuts, pins, and missing

Operation, deformation, crack in each lever

7 Outriggers

Tight connection to wire socket, fastening clip at rope end

Operation of accelerator lever

Contamination of air breather, return filter, suction filter Hydraulic 5 pump

Checked result Measures taken OK NG

Damage, wear, rotaition sliding plate, missing bolts

Engine oil level and deterioration

Oil leak from reduction gear in traveling motor 3 Frame

Adjustment A Cleaning C Tightening T Oil supply L

Tightness of bolts mounting turntable, missing bolts 14 Boom

Battery liquid level

Forward・backward operation of traveling lever 2 Traveling

What to check for:

Condition of air cleaner element

Fuel leak 1 Engine

Replacement Repair

Remarks to be recorded

Crack, deformation Tightness of bolts mounting turntable

Operator Crane model Delivered date Inspected date

Company in charge of inspection Inspected by Signature

３７－３

38. PERIODICALLY REPLACING COMPONENTS AND EXPEDABLE PARTS 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

Components 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

Expendable parts Wire rope

Crane

Replacement

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 Replace according to damage and wear

Lubrication

Traveling Expendable parts

Engine

Hydraulic oil

Every 2 years

Gear oil (hoist winch)

Once a year

Gear oil (swinging reduction gear)

Every 2 years

Other greases

Lubricate according to consumption

Diesel engine oil (traveling motor reduction gear)

Every 1,000 hours according to hour meter

Rubber crawler

Replace according to crack/elongation

Engine oil

Every 100 hours according to hour meter Replace according to consumption and deterioration

Expendable parts Battery Rubber components, wiring, cables

Replace according to damage

Note: It is to be charged for replacement of expendable components.

REPLACEMENT OF HYDRAULIC OIL Air 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 COMPONENTS In 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.

３８－１

DL-100 Initial Setting Up of Digital Load Meter Appearance of Digital Load Meter

t

Ｌ Ｃ Ｒ We explain below calling each three switches "L","C","R" on load indicator . In normal mode load is indicated in unit of 0.02 t ("*.**"t). DL-1

1 1 2 3 4 *

2

2

Confirming lines of wire Normal Mode Press "C" once Indicated lighting for 3 seconds Confirm lines of wire Initial setting up is 4 lines.

「H2」：2 lines 「H4」：4 lines 「H6」：6 lines

Setting lines of wire

1

2

Press "C" long (3 seconds) Indicated brinking lines of wire Press "L" and select lines of wire. Decide pressing "C" After lines of wire set indicated lighting for 3seconds, digital load meter returns to normal mode. Note: If anti-overload system (below "AOL" ) "KM-100" is installed with digital load meter, do the initial setting up of AOL. 1 2 3 4 5

3 1 2 3 4

Load detector　0.0ｔ/Setting line value

1

Cranes remains without load and swinging load Press "R" for 1 second. Indication brinks once. "0.00" t is indicated and memorized.

DL-2

4-1 Changing modulation mode and

1

load detector　0.5ｔ/Setting line value 1 Press "C"and "R" long at a time (5 seconds) * 1) In each item of modulation mode, after initial indication for 1 second, it is replaced by norma indication. * 2) changing modulation mode to normal mode, go once through items or put the power off. * 3) In items that need setting up selecting value with "L" doesn't lead to memorization. * 4) Press "R" and get value to memorize. * 5) In case of not getting value to memorize, go to the next item pressing "C".

*4

*5

4-2 Load detector　0.5t　/　Setting line value

2

3

* * * * *

*

1 Lift the weight of clear weight as standard of 0.5t per one wire. （Standard） （2 lines：1t ） （4 lines：2t ） （6 lines：3t ） 2 Press "L" and adjust value to actual weight value. 1) In case weight value is less than 10kg, round up to the nearest whole number. 2) 2 lines：Possible range to set is 0.5t ～ 1.6t 3) 4 lines：Possible range to set is 1.0t ～ 3.2t 4) 6 lines：Possible range to set is 1.5t ～ 4.8t 5) Press "L" and load value is changed 0.01t lbs by 0.01t and Press "L" long and load value is changed in the units of 0.1t. 6) Go once through value and get value to indicate again in case of exceeding load value to set. 3 After adjusting to actual weight, press "R" In normal mode load is indicated in unit of 0.02 t ("*.**"t). Indication brinks once and value is memorized. 4 Press "C" and go to next item. DL-3

5･4･3･2･1

4

5 1 2

* 1) * 2) * 3)

6

1 2 3

4

* 1)

* 2)

* 3)

* 4) * 5)

1

Intial Setting up Completes Press "C" repeatedly and go once through items of modulation mode. After going once through them and indicating "8.8.8." for 1 second, detector finishes modulation mode and returns to normal mode. Detector has 2 item after this, but they has no relation to initial setting, so skip them all. Last item of modulation is indicated "o o o ". In each item, during initial indication, switch operation doesn't function. After changing item and waiting for over one second, go to next item.

Digital Loeter's Additional Indication Function Loeter can add and memorize Lifting load value, and summon and indicate memorized 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 for 0.5 second, memorized load meter is indicated for one second Then after indication disappears, loeter returns to indication of lifting load value. Loeter adds current load value to load valu memorized whenever pressing "R" and re-memorizes. After disappearing indication for 0.5 second, memorized load meter is indicated for one second. Then after indication disappears, loeter returns to indication of lifting load value. In add mode and on pressing no switch, lifting load value is digital-indicated by three digit "*. **"t (in unit of 0.02t). "8.8.8." indicates on overwinding. "OL" indicates on overloading. Impossible to add during brinking. During pressing "C" and for 3 seconds after releasing finger from "C", memorized load valu is digital-indicated by three digit. Then it is replaced back by current lifting load value. When loeter indicates memorized load of over 10t, it indicates "**.*"t (in unit of 0.1t) On pressing "C", it resets memorized load value and returns to normal mode. DL-4

1

2

3, 4

4

7

8

Overwinding Signal Output According to overwinding signal from load detector or "KM-100" control box, put on/off "Overwinding Signal Output". And loeter brinks " O L " as load indication during overwinding. Function of Detecting Overload 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

9 Zero Reset 1 When you press "R" long (for one second) , you can reset zero of load value. When loeter puts zero reset into practice, "0.00"t is indicated after indication disappears for 0.5 second. * 1) When "8.8.8."(overwinding) or " O L "(overloading) brinks, it is impossible to reset zero.

1 second

10 Error Code Error Code E01 E02 E03 E04 E05 E06 E07

What Goes Wrong Fault in load cell amplifier Fault in load cell Fault in load cell Fault in load cell Fault in digital loeter indicator Fault in digital loeter indicator The snapping between load cell amplifier and digital load detector or fault in load cell amplifier and digital load meter

In normal mode load is indicated in unit of 0.02 t ("*.**"t).

DL-5

Measures Exchange Exchange Exchange Exchange

of of of of

load load load load

cell cell cell cell

and and and and

load load load load

cell cell cell cell

amplifier amplifier amplifier amplifier

Exchange of digital loeter indicator Exchange of digital loeter indicator Confirm if wiring of digital loeter and load cell amplifier is snapped. If wiring is normal, exchange digital loeter assembly.

KM-100 Setting Up Of ML Control Box Appearance Of ML Control Box

t

Ｌ Ｃ Ｒ We explain below calling each three switches "L","C","R" on ML control box . In normal mode load is indicated in unit of 0.1t ("*.*"). KM-1

1 1 2 3 4 *

Confirming lines of wire Normal Mode Press "C" once Indicated lighting for 3 seconds Confirm lines of wire Initial setting up is 4 lines.

「H2」：2 lines 「H4」：4 lines 「H6」：6 lines

H 4

t

MOMENT

2-1 Setting lines of wire (In case of changing lines of wire) 1 Press "C" long (3 seconds) 2 "Pe" sounds 3 Indicated brinking lines of wire

H 4

t

Pe MOMENT

2-2 Setting lines of wire (In case of changing lines of wire) 1 Press "L" and change indication 2 Press "C" and decide 3 "Pe" sounds 4 Decision ("H2" or "H4" or "H6" )is indicated for 3 seconds. 5 Back to normal mode

1

2

H2orH4orH6

H2orH4orH6

t

MOMENT

KM-2

t

Pe MOMENT

３ 1 * 1)

* 2)

* 3)

* 4)

Changing modulation mode and setting up initially 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.) Returning modulation mode to normal mode, mode 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 item. Check if installing detector and detector itself is abnormal.

4 Setting up model 1 Select model with "L". (Go in turn by pressing "L" long) 2 Press "R". 3 Detector sounds "Pe", brinks, and memorize model. * 1) If model code to select goes over, go once through model codes and indicate model code to select again. * 2) Take care that model code with "．" right under it is different from model code without it. * 3) Sure to set up each detector when changing model code. （Each detector is reset up.)

Pe t

MOMENT

1

2

c o d

t

Pe

Model

t

MOMENT

MOMENT

Press "C" and go to next item. 5

Setting up minimum value in boom length detector. 1 Retract boom at minimum. 2 Press "R". 3 "Pe" sounds and set up boom length is indicated and memorized.

Ｌ　＿　１

Pe

MOMENT

Press "C" and go to next item.

KM-3

t

6 1 2 3 * 1)

Setting up middle value in boom length (Except 2 section boom) Move boom by indicated section. Press "R". "Pe" sounds and boom section set up is indicated and memorized. 3 to 4 section boom is set up with boom ① and ②. 5 to 6 section boom is set up with boom ①, ②, and ③.

Pe

(S

L＿ ti ）

t

MOMENT

Press "C" and go to next item. 7 1 2 3 4

Setting up maximum value in boom length Indicate maximum boom section. Extend boom at maximum. Press "R". "Pe" sounds and boom section set up is indicated and memorized.

Ｌ＿(Section）

t

Pe

MOMENT

Press "C" and go to next item. 1 8 Setting up boom angle detector at 5° 1 Move boom angle at 5° 2 Press "L" and adjust indication value to actual value. 3 Press "R" 4 "Pe" sounds and indication blinks once and "5°"is memorized. * 1) Possible range to modulate is 5゜±2゜. (0, 1゜unit) * 2) Go in order with pressing "L" long. (Next 7°, back to 3°. 5,6,7,3,4,5…)

2

A　_　5

A _ 5

t

t

Pe

MOMENT

MOMENT

Press "C" and go to next item. 9 Setting up boom angle detector at 70° 1 Move boom angle at 5° 2 Press "L" and adjust indication value to actual value. 3 Press "R" 4 "Pe" sounds and indication blinks once and is memorized. * 1) Possible range to modulate is 70゜±2゜. (0, 1゜unit) * 2) Go in order with pressing "L" long. (Next 72°, back to 68°. 70,71,72,68,69,70…)

1

2

A　7 0

MOMENT

Press "C" and go to next item.

KM-4

t

A 7 0

Pe

MOMENT

t

10 Load detector　0.0t/Setting line value 1 Press "R" with hook only keeping 2 "Pe" sounds and indication blinks once and is memorized. * 1) Wire line is displayed on initial indication.

1

2

０．０　０

Ｈ2orＨ4orＨ6

t

Pe

MOMENT

t

MOMENT

Press "C" and go to next item. 11 Load detector　0.5t/Setting line value 1 Lift the weight of clear weight. （2 lines：1t ） （4 lines：2t ） （6 lines：3t ） 2 Press "L" and indicate same weight value as weight. 3 Press "R" without load swinging. 4 "Pe" sounds and indication blinks once and is memorized. * 1) Range set on load detector 2 lines：0.5t ～ 1.6t （1t is best condition） 4 lines：1t ～ 3.2t （2t is best condition） 6 lines：1.5t～ 4.8t （3t is best condition） * 2) Press "L" and load value is changed 0.01t by 0.01t. * 3) Press "L" long and load value is changed in the units of 0.1t.

1

2

Pe Load Value

Ｈ２orＨ４orＨ６

t

MOMENT

t

MOMENT

Press "C" and go to next item.

12 Initial Setting up Completes 1 Press "C" repeatedly and go once through items of modulation cord. 2 When items of modulation go once through, "Pe" sounds. And after "8.8.8." is indicated for 1 second, detector returns to normal mode. * 1) This operation has no relation to initial setting up, so after this skip 11th item.

KM-5

８．８．８．

t

MOMENT

Pe

t

13 Indication of Boom Length 1 Indicate current boom length ( ｢**.*｣ m ). 2 While only pressing "R", output voltage (｢**.*｣V) from the detector is indicated.

Initial Indication

－　L　－

1

＊＊.＊m

t

t

2

＊.＊＊Ｖ

t

Press "C" and go next item. 14 Indication of Boom Angle 1 Indicate current boom angle ("**.*"degrees). 2 While only pressing "R", output voltage ("**.*"V) from the detector is indicated.

Initial Indication

－　A　－

1

t

2

＊.＊V

t

Press "C" and go next item.

KM-6

＊＊.＊°

t

Initial Indication

"Angle for detecting boom angle" - "Angle of boom warping" * 2) Range of revisable boom warping angle is from 0.0 degree to 3.0 degree and 3.0 degree is back to 0.00 degree. While pressing "L", revised boom warping angle * 3) is indicated. On releasing finger from "L", working radius after boom warping angle is revised is indicated.

1

－　ｒ　－

＊＊.＊m

t

＝

15 Indication of Working Radius 1 Indicate current working radius ("**.*"m ). 2 Whenever pressing "L", revise angles of boom warping. 3 Initial value of warping boom angle is "1.0" degree and revise value +0.1 by +0.1 degree. 4 On pressing "R", "Pe" sounds and indication brinks once and is memorized. * 1) Boom angle used to calculate working radius is "Boom angle for calculating working radius"

t

MOMENT

MOMENT

2,3

4

＊.＊°

＊＊.＊m

t

t

Pe

MOMENT

MOMENT

Press "C" and go to next item.

16 Three Digit Indication of Lifting Load 1 Indicate current lifting load ("*.**"t ). 2 While only pressing "R", indicate output voltage of differential motion("*.**"V) from detector.

Initial Indication

－　Ｆ　－

1

t

2

＊＊.＊Ｖ

Press "C" and go to next item.

KM-7

t

＊.＊＊t

t

17 Rated Load Indication 1 Indicate current rated load ("*.**"t). 2 While only pressing "R", indicate current load rate ("***"%).

Initial Indication

Ξ　Ｆ　Ξ

1

＊.＊＊t

t

t

2

＊＊＊％

t

Press "C" and go to next item.

18 Setting up Intermission Alarm Output Factor_K0 ① Set up factor ("*.**") for decision formula of ML intermission alarm output. ② Whenever pressing "L", revise value +0.05 by +0.05. ③ When pressing "R", "Pe" sounds and indication brinks once and is memorized. * １ Refer to "Model code list" about initial value of ML alarm output factor_K1. * ２ Range of revisable factor is from 0.50 to 1.50. When factor is over 1.50, it is back to 0.50.

Initial Indication

ｃ　0

2

Factor

t

MOMENT

MOMENT

3 ※ Mode only for Japan. Set to the same value as K1. Factor

Press "C" and go to next item.

KM-8

t

Pe

t

19 Setting up Continuous Alarm Output Factor_K1 ① Set up factor ("*.**") for decision formula of ML continuous alarm output. ② Whenever pressing "L", revise value +0.05 by +0.05. ③ When pressing "R", "Pe" sounds and indication brinks once and is memorized. * １ Refer to "Model code list" about initial value of ML alarm output factor_K1. * ２ Range of revisable factor is from 0.50 to 1.50. When factor is over 1.50, it is back to 0.50.

Initial Indication

2

ｃ　1

Factor

t

t

MOMENT

MOMENT

3

Factor

t

Pe

Press "C" and go to next item.

20 Setting up Stop Output Factor _K2 1 Set up factor ("*.**") for decision formula of ML stop output. 2 Whenever pressing "L", revise value +0.05 by +0.05. 3 When pressing "R", "Pe" sounds and indication brinks once and is memorized. * 1) Refer to "Model code list" about initial value of ML stop output factor_K2. * 2) Range of revisable factor is from 0.50 to 1.50. When factor is over 1.50, it is back to 0.50. Note: Factor for Taiwan is "1.00". Factor for Australia and Europe is "1.10".

Initial Indication

ｃ　2

KM-9

Factor

t

t

3

Factor

Press "C" and go to next item.

2

t

Pe

21 Setting up Stop Return Factor _ K3 1 Return ML stop output "ON" to "OFF". Set up factor ("*.**") for decision formula. 2 Whenever pressing "L", revise value +0.05 by +0.05. 3 When pressing "R", "Pe" sounds and indication brinks once and is memorized. * 1) Refer to "Model code list" about initial value of ML stop return output factor_K3. * 2) Range of revisable factor is from 0.50 to 1.50. When factor is over 1.50, it is back to 0.50. Note: Factor for Taiwan is "0.95". Factor for Australia and Europe is "1.05".

ｃ　3

Factor

t

MOMENT

Factor

t

MOMENT

t

Pe

Press "C" and go to next item.

22 Setting up Front Performance Mode 1 Set up if controling with front rated load chart or with performance calculated from rear performance. 2 Whenever pressing "L", change modes as "F_ _⇀r_ _⇀r00⇀r05⇀r10...⇀r95⇀F_ _⇀... "

* *

*

*

3 Pressing "R", "Pe" sounds and indication brinks once and is memorized. 1) In front zone when selecting "F__", control with front rated load chart. 2) In front zone when selecting "r__", control with 100% performance of rear performance. 3) In front zone when selecting "r**", control with **% performance of rear performance. 4) It is possible to set up within percentage 0% to 100% in units of 5%.

Initial Indication

KM-10

Mode Value

t

3

Mode Value

t Pe MOMENT

Press "C" and go to next item.

2

t

23 Setting up ML Stop Output Mode 1 Setting up if output of KM-100 is alarm type or autostop type. 2 Whenever pressing "L", alarm type changes "off", autostop type changes "on". 3 Pressing "R", "Pe " sounds and indication brinks once and is memorized.

Initial Indication

2

Mode Value

t

t

3

Mode Value

t

Pe

Press "C" and go to next item. 24 Resetting set-up value 1 Reset set-up value and return the detector to initial condition. 2 Pressing "L" and "R" long at a time (3 seconds), all set-up value is reset. And "Pe" sounds and "000" is indicated. 3 Pressing "C", "Pe" sounds and "8.8.8." is indicated for 1 second. Then modulation mode is finished and returned to normal mode.

Initial Indication

2

t

3

８．８．８．

Pe

KM-11

t

０　０　０

Pe

t

KM-100 ML Control Box Modulation Mode List №

1 2 3 4

heading

first indication（1sec）

usual indication

left SW

Changing modulation mode

－

－

－

Setting up model

「ｃｏｄ」

「（Model code）」

Select Model

Setting up minimum value 「Ｌ＿１」 「Ｌ＿１」 in boom length detector Setting up middle value in 「Ｌ＿（Section）」 「Ｌ＿（Section）」 boom length detector Setting up maximum value 「Ｌ＿（Section）」 「Ｌ＿（Section）」 in boom length detector

－ － － Adjust indication value to actual value Adjust indication value to actual value

5

Setting up boom angle detector at 5°

「Ａ＿５」

「（Indication value）」

6

Setting up boom angle detector at 70°

「Ａ７０」

「（Indication value）」

「（Wire line）」

「０．００」

－

「（Wire line）」

「（Load value）」

Adjust load value

7 8

Load detector 0lbs／setting line value Load detector 1100lbs／setting line

9

Indication of boom length

「－Ｌ－」

「（Boom length）」

－

10

Indication of boom angle

「－Ａ－」

「（Boom angle）」

－

「－ｒ－」

「（Working radius）」

Warping boom angle

「－Ｆ－」

「（Lifting load）」

－

「≡Ｆ≡」

「（Rated load）」

－

「（Factor）」

Revise factor

「（Factor）」

Revise factor

「（Factor）」

Revise factor

「（Factor）」

Revise factor

「（Mode value）」

Select Mode

「（Mode value）」

Select Mode

「ｏｏｏ」

Press long at once（3sec）

Indication of working radius Three digital indication of 12 lifting load

11

13 14 15 16 17 18 19 20

Rated load indication

Setting up Intermission 「　ｃ０」 alarm output factor K0 Setting up continuous 「　ｃ１」 alarm output factor K1 Setting up stop output 「　ｃ２」 factor K2 Setting up stop return 「　ｃ３」 output factor K3 Setting up "Outrugger 「（Mode value）」 not max mode" Setting up ML stop output 「（Mode value）」 mode Resetting set-up value

「ｏｏｏ」

KM－12

center SW right SW Press long at Press long at once once （5sec） （5sec） Go to next memorized item Go to next memorized item Go to next memorized item Go to next memorized item

remarks Returning modulation mode to normal mode,go once through items or put the power off. Refer to Model code list（№0628） Set up boom length at minimum is indicated and memorized （「＊．＊＊」ft） Set up boom length at 2or 3-section is indicated and memorized （「＊．＊＊」ft）、Except 2 section boom Set up boom length at maximum is indicated and memorized （「＊．＊＊」ｍ）

Go to next item

memorized

Possible range to modulate is 3.0°～7.0°（Initial value is 5.0°）

Go to next item

memorized

Possible range to modulate is 68°～72°（Initial value is 70°）

memorized

「Ｈ２」（2 lines）,「Ｈ４」（4 lines）,「Ｈ６」（6 lines）

Go to next item Go to next item Go to next item Go to next item Go to next item Go to next item Go to next item Go to next item Go to next item Go to next item Go to next item Go to next item Go to next item Conpleted

memorized indicate voltage indicate voltage memorized indicate voltage Rated load indication memorized

「Ｈ２」（2 lines）,「Ｈ４」（4 lines）,「Ｈ６」（6 lines） Possible range to modurate500lbs～1800lbs／wire lines Indication of boom length（「＊＊．＊」ft） Indication of voltage（「＊．＊＊」Ｖ） Indication of boom angle（「＊＊．＊」°） Indication of voltage（「＊．＊＊」Ｖ） Indication of working radius（「＊＊．＊」ft） Possible range to modulate is 0.0°～3.0°（initial value 1.0°） Indication of lifting load（「＊．＊＊」X1000lbs） indicate voltage（「＊．＊＊」Ｖ） Indication of rated load（「＊．＊＊」X1000lbs） Indication of rated load ratio（「＊＊＊」％） Possible range to modulate is 0.50～1.50（per 0.05） Mode only for Japan. Set to the same value as K1.

memorized

Possible range to modulate is 0.50～1.50（per 0.05）

memorized

Possible range to modulate is 0.50～1.50（per 0.05）

memorized

Possible range to modulate is 0.50～1.50（per 0.05）

memorized

「Ｆ‗ ‗」Outrigger not max ext. 、「ｒ‗ ‗」Outrigger max ext.100％ 「ｒ＊＊」＊＊％ of Outrigger max ext.（per 5％）

memorized

「　ｏｎ」Autostop type、「ｏＦＦ」Alarm type

Press long at once(3 seconds),all set-up value is reset and 「000」 Press long at is indicated.When modulation mode is finished,「888」 is indicated once（3sec） for 1 second.

Mode(Error code) list of Moment limiter Error code Ｅ０１ Ｅ０２ Ｅ０３ Ｅ０４ Ｅ０５ Ｅ０６ Ｅ０７ Ｅ０８ Ｅ０９

Trouble Defection of Load cell Amplifier Load Signal(A) from Load cell to Amplifier of Load cell is disconnected.. Load Signal(B) from Load cell to Amplifier of Load cell is disconnected.. Load Signal(A),(B) from Load cell to Amplifier of Load cell is disconnected.. Moment limiter control box is broken. Moment limiter control box is broken. Signals from Amplifier of Load cell to Moment limiter control box is disconnected.. Signals from Boom Angle detector are disconnected. Signals from Boom Length detector are detected.

KM-13

Reset (Try to turn on power.) Check wiring and connector. Check wiring and connector. Check wiring and connector. Reset (Try to turn on power.) The setting change was done 100,000 times or more. Check wiring and connector. Check wiring and connector. Check wiring and connector.

Model code list

KM-100-CA

Model code Model 295 URW295C

Loading capacity 2.9ｔ

Division for Japan

K1 1.00

K2 1.25

K3 1.15

Type Alarm

375 376

URW375CD URW376CD

2.9ｔ 2.9ｔ

for Japan for Japan

1.00 1.00

1.25 1.25

1.15 1.15

Alarm Alarm

506 305

URW506CD URW295C

2.9ｔ 2.9ｔ

for Japan for Japan

1.00 0.90

1.25 2.00

1.15 1.80

Alarm Alarm

385 386

URW375CD URW376CD

2.9ｔ 2.9ｔ

for Japan for Japan

0.90 0.90

2.00 2.00

1.80 1.80

Alarm Alarm

516 285

URW506CD URW295CMR-A

2.9ｔ 2.9ｔ

for Japan for Japan

0.90 0.90

2.00 1.00

1.80 0.95

Alarm Auto stop

365 366 496 295. 375. 376. 546.

URW375CD-A URW376CD-A URW506CD-A URW295C URW375CDA URW376CDA URW546CDA

2.9ｔ 2.9ｔ 2.9ｔ 2.9ｔ 3.0ｔ 3.0ｔ 4.0t

for Japan for Japan for Japan for Russia for AUS for AUS for AUS

0.90 0.90 0.90 0.90 0.90 0.90 0.90

1.00 1.00 1.00 1.10 1.10 1.10 1.10

0.95 0.95 0.95 1.05 1.05 1.05 1.05

Auto Auto Auto Auto Auto Auto Auto

KM-14

stop stop stop stop stop stop stop

DESCRIPTION OF EACH CONTROL DEVICE

U-AOL system (Anti overloading system) ◆1. Function of U-AOL 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 load Rated 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.

WARNING ★ The 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 lifted 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 container during lifting operation. This may cause the crane to be damaged or overturned.

KM-15

DESCRIPTION OF EACH CONTROL DEVICE ◆2. Construction of U-AOL system

Boom length detector

Boom angle detector

3-color indictor lamp

Over-load alarm control box Capacity limit alarm buzzer

Load detector

◆3. Operation of U-AOL system 1.Over-load alarm ◆ Capacity limit alarm

WARNING ★ If the capacity limit alarm is actuated, stop the crane operation immediately 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, Pingpong”) to issue an alarm. When the load applied to the crane reaches the capacity limit, crane functions listed below stop automatically: ong, Ping-p Ping-pong

・Extending boom ・Lowering boom ・Winding-up hook ・Swinging CW.&C.C.W.

KM-16

DESCRIPTION OF EACH CONTROL DEVICE ◆4.

M e a s u re s t o b e t a k e n w h e n U-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.

Step 1 Throwing 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. OFF

Step 2 If 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.

ML auto stop switch

CAUTION ★ Boom cannot be extended even when the safety device is being cancelled. ★ 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. ◆5. Function of load indication In normal operation, the load is to be indicated in the weight of 0.1t on the digital indicator in the over-load alarm control box. OUTRIGGERS

t

NOT MAX EXT

SELECT

SET

MOMENT LIMITER

URW376C1A, URW540C1A

KM-17

DESCRIPTION OF EACH CONTROL DEVICE ◆ Designation of each part of

Lamp indicating Outriggers not max EXT

Capacity limit alarm

Indicator:

Indicator

It indicates weight of lifted cargo (t).

Lamp indicating outriggers not max ext: It indicates in “green” when outriggers are not in maximum extension.

OUTRIGGERS

t

NOT MAX EXT

“Check” switch: It is to confirm operation of each indication and alarm. SELECT

SET

MOMENT LIMITER

“Check” switch

◆

Error indication of overload alarm device

When an error is detected, corresponding error code appears on the control box.

Error code

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.

KM-18

DESCRIPTION OF EACH CONTROL DEVICE Digital indicator

◆6. Checking U-AOL system before starting crane operation Before starting the crane operation, checks follows:

●Remarks

OUTRIGGERS

t

NOT MAX EXT

SELECT

SET

MOMENT LIMITER

The power to U-AOL system is supplied through ON/OFF control of crane-crawl lever. ◆Checking over-load alarm system 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.

Switch for setting number of slinging wire rope

Checking switch

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.

KM-19