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Unic URW295CR, Maintenance Manual

The "Unic URW295CR" Maintenance Manual is a comprehensive user guide designed to assist you with the proper care and upkeep of your Unic URW295CR product. This essential manual is available for free download at manualshive.com, ensuring convenient access whenever you need it.

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Summary of Contents for URW295CR

Page 1: ...ＭＡＩＮＴＥＮＡＮＣＥ ＭＡＮＵＡＬ ＦＵＲＵＫＡＷＡ ＵＮＩＣ ＣＯＲＰＯＲＡＴＩＯＮ URW295CR ...

Page 2: ...io contorol mode ８ Method of engine start and stop that uses radio controller ７ ４ ８ Control box １ Internal view of control box ８ １ ２ Mode indicator lighting when it is in normal operation ８ ２ ３ Mode indicator blinking when it is in wrong operation ８ ３ ４ Mode indication of each operation ５ Error indication ８ ４ ５ ６ Zero point adjustment ８ ６ ８ ７ ８ ８ ９ ８ １０ ８ １１ 11 How to correct store of hook ８ １２ 12...

Page 3: ...c System １１ １ ２ Hydraulic Circuit Diagram control valve １１ ２ ３ Hydraulic circuit diagram １１ ３ １２ Piping １ Piping of control valve for running １２ １ ２ Control valve piping for crane １２ ２ ３ Outoriga change valve piping １２ ３ ４ Construction of swivel joint and position of houses １２ ４ ５ ５ Piping of Column １２ ６ １３ Boom 5 section boom 1 Simultaneous telescoping of boom4 and boom5 １３ １ 2 Boom 4 5 front sid...

Page 4: ...Hoist winch １７ １ ２ Caution to be taken when reass embling hoist winch １７ ２ ３ Cause of Troubles and Measures to be Taken Hoist winch １７ ３ １８ Hook １８ １ １９ Slewing １ Construction of slewing reduction gear １９ １ １９ ２ ３ Slewing reduction gear disassembly procedures １９ ３ ５ ２０ Turntable １ Turntable Mounting Procedures ２０ １ ２０ ２ ２１ Column ２１ １ ２２ Slip ring １ Construction of slip ring and its fitting positi...

Page 5: ...not function at all ２６ １ ２ How to control outriggers when in an emergency ２６ ２ ２６ ３ ４ ４ Inspection of derrick cylinder ２６ ５ ５ Insupection procedures when cylinder sinke ２６ ６ ６ Procedures for checking outriggers for sinking ２６ ７ ２７ Boom length detector １ How to install and detach boom length detector ２７ １ ２７ ２ ４ ２８ Mentenance And Inspection Of Carrier ２８ １ ３ ２９ Maintenance And Inspection Of Crane ２...

Page 6: ...１ Dimensions and weight of crane body The total length 2690ｍｍ Tread length 1050ｍｍ The total height 1375ｍｍ All width 600ｍｍ １ １ Total weight approx 1850kg ...

Page 7: ...ment 1 8 2 9 3 10 4 11 5 12 6 13 7 14 Accelerator lever Lock lever Crawling motor Hour meter Crawling lever Choke knob Idle roller Hydraulic oil tank Truck roller Stater switch Rubber crawler Horn switch Wheel sprocket Fuel tank ２ １ ...

Page 8: ...0 Boom Column Frame Hoist winch Crane operating levers Outrigger control levers Hook Slewing device Derrick cylinder Telescoping cylinder Outrigger Outrigger selection switch Over winding alarm Load meter Warning horn Wire rope Level Automatic stop for leaving minimum wire rope Load indicator With wire rope retaining roller Option Option ３ １ ...

Page 9: ...ulic automatic locking device Reduction gears Worm gear Spur gear reduction Supported by ball bearings Brake Worm self lock Hydraulic pump Variable delivery piston pump Hooking capacity ２ ９t Number of slinging rope 4 Safety device Hydraulic automatic lock Automatic stop for overwinding Overwinding alarm Load indicator Load indicator With angle meter Level Alarm buzzer Hook safety latch Interlock f...

Page 10: ...ed to the mark Boom 1 2 3 4 5 or 5 Boom section 2 3 4 and 5 are fully extended Outrigger Max EXT Outrigger Not Max EXT Outrigger Max EXT Outrigger Not Max EXT Outrigger Max EXT Outrigger Not Max EXT Outrigger Max EXT Outrigger Not Max EXT The rated load is performance when the crane is placed level and is based on an actual operating radius including boom deflection under load The rated load is al...

Page 11: ...rgency stop switch has not been depressed Depress emergency stop switch when the crane makes an uncontrolled movement All the crane functions stop to be operated Emergency stop switch Depression of switch means the emergency stop is activated If the emergency stop switch has been depressed depress it again for reset Mode indicator lamp blinks 59 when the emergency stop switch has been depressed Mo...

Page 12: ...listed below are not a fault When controlled through radio remote control device the movement of lever differs each time of operation or the control lever will not be shifted to its maximum When operation is switched from interlocking to independent control speed may become slower than that of the independent operation in itself Stop the radio remote control operation once and go back to independe...

Page 13: ...ights the radio controller can be operated 7 3 Switching of mode indicator State Operation State indication Operation indication normal case Depress both winding up and radio controller selector switches at the same time or turn OFF power to crane and turn it ON again Depress both winding up and radio controller selector switches simultaneously Mode indicator lamp is turned off Mode indicator lamp...

Page 14: ...re Low temperature operation mode operation mode ON OFF normal case Mode indicator shows 06 Voice message change control mode is issued Depress the switch for storing hook with the switch for slewing C W turned ON Depress the switch for storing hook with the switch for slewing C C W turned ON Turn ON winding down switch with para hook switch depressed Turn ON winding up switch with para hook switc...

Page 15: ...boom down turned ON Voice message change control mode is issued 7 7 Switching of outrigger radio contorol mode Turn ON mode operation switch to outrigger side Crane operation mode Outrigger operation mode normal case Mode indicator shows 04 Turn ON mode operation switch to crane side Voice message change control mode is issued Depress the switch for storing hook with the switch for boom up turned ...

Page 16: ...ondition １ Starter switch must be on ２ The power supply of the transmitter must be on ３ The operation mode must be a radio controll mode Engine stop Engine start Depress the switch for mode select with the switch for slewing C C W turned ON Depress the switch for mode select with the switch for slewing C W turned ON 7 4 ...

Page 17: ... back through ground circuit which in turn may damage the control box Be sure to observe the following 1 Turn OFF the starter switch 2 Disconnect the cable from the negative pole terminal of battery 3 Be sure to connect the ground cable of welder securely to the nearest position from the point to be welded Modo indicator Fuse Package Packing Radio remote control selector switch ８ １ ...

Page 18: ...about 2 seconds after the starter switch has been turned ON The crane is carrying out system diagnosis while the mode indicator is fully lit up What is to be checked during system diagnosis is if Electronic circuit in the control box is functioning correctly Manual control lever is at its neutral position and Remote controller is connected to the crane and the controller functions normally Current...

Page 19: ...rgency stop switch of the radio controller device is pushed The crane with the radio controller is operating it while checking the spool neutrality The winding up hook is operated in automatic stop for leaving minimam wire rope LED display ３５ ２６ ３６ ２１ ２２ ２３ ２５ Mode indication Mode indication ２８ ３０ ３１ ２４ ２７ ２０ ３７ ３２ ３３ ３４ Operation It is operated to selector switch of shock less function while oper...

Page 20: ...the damaged switch ６８ Rear right RET EXT ６９ Rear left ET EXT ８ ４ Radio controller selector switch in control box has been controlled before indicator 8 8 goes off Radio controller cannot be operated In case where it happens again replace control box wait until mode on 8 8 indicator goes off to operate radio controller Manual lever spool fails to be returned to neutral within 2 seconds after power ...

Page 21: ...ential transformer ８４ Outrigger ８５ Acceleration ９８ The voltage of the battery is nine volts or less Battery exchange ９９ ８ ５ Spool deviation error Manual lever spool fails to be controlled as intended while radio controller is operated Transmitter switch is broken Replace batteries of transmitter to turn it ON again Radio controller is wrong unless power indi cator lamp on transmitter lights or bli...

Page 22: ...inima wire rope 0 Depress radio remote control selector switch and slewing C W switch simultaneously until beep sound is heard then depress slewing C C W switch within 1 second with radio remote control selector switch depressed Shift lever in both directions to their full strokes 1 Check each lever and the accelerator is at its neutral position to depress hook storing switch Para hook ８ ６ Zero po...

Page 23: ... stays at its neutral position ８ Depress hook storing switch CF blinks again until beep sound is heard ９ Shift manual levers for controlling boom derrick hook Up Down telescoping slewing and outrigger in both directions to their full strokes Depress radio remote control selector switch and slewing C W switch simultaneously until beep sound is heard then depress slewing C C W switch within 1 second...

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Page 25: ...as not been set correctly following modes blink Where in error Where in error ｄ Derrick down o r Outrigger right Retract ｄ Derrick up o r Outrigger right Extend H Hoisting down o L Outrigger left Retract H Hoisting up o L Outrigger left Extend T Telescoping extend o d Outrigger right left Extend T Telescoping retract o d Outrigger right left Retract S Slewing C C W A Acceleration S Slewing C W Con...

Page 26: ...U QEEWTU CFLWUV KV CU HQNNQYU QY VQ EQTTGEV ETCPG QRGTCVKQP URGGF YJGP KV YKNN PQV DG TKIJV GXGP CHVGT RWOR JCU DGGP UGV CV VJG TCVGF URGGF 5VGR 5VGR 5VGR 5VGR 5VGR 5VGR 4GVWTP VQ UVGR VQ TG CFLWUV VJG CEEGNGTCVQT TCVG HQT UNGYKPI GGR FGRTGUUKPI VJG UYKVEJ HQT TGNGCUKPI CWVQOCVKE UVQR HQT QXGT YKPFKPI 6JKU CNNQYU VQ IKXG QHH C UQWPF CPF VVWTP KPVQ PQTOCN OQFG VQ UGVVNG VJG CEEGNGTCVQT TCVG HQT UNG...

Page 27: ...㫎㫊㪑㩷 㪜㫅㪾㫀㫅㪼㩷㫊㫇㪼㪼㪻㩷㫆㫅㩷㫋㪿㪼㩷㫄㪼㪻㫀㫌㫄㩷㫊㫇㪼㪼㪻㩷㫄㫆㪻㪼㩷㫀㫊㩷㪸㪹㫆㫌㫋㩷㪿㪸㫃㪽㩷㫋㪿㪼㩷㫊㫇㪼㪼㪻㩷㫆㫅㩷㫋㪿㪼㩷㫄㪸㫏㫀㫄㫌㫄㩷㫊㫇㪼㪼㪻㩷㫄㫆㪻㪼㪅 㩷㩷㩷㩷㩷㩷㩷㩷㩷㪜㫅㪾㫀㫅㪼㩷㫊㫇㪼㪼㪻㩷㫆㫅㩷㫋㪿㪼㩷㫊㫃㫆㫎㩷㫊㫇㪼㪼㪻㩷㫄㫆㪻㪼㩷㫀㫊㩷㫊㫆㫄㪼㫎㪿㪸㫋㩷㪿㫀㪾㪿㪼㫉㩷㫋㪿㪸㫅㩷㫋㪿㪼㩷㫀㪻㫃㪼㩷㫊㫇㪼㪼㪻㪅 㪧㫉㪼㫉㪼㫈㫌㫀㫊㫀㫋㪼㪑㩷㪪㫃㪼㫎㫀㫅㪾㩷㫊㫇㪼㪼㪻㩷㫆㫅㩷㫄㪸㫏㫀㫄㫌㫄㩷㫊㫇㪼㪼㪻㩷㫄㫌㫊㫋㩷㪹㪼㩷㫊㫆㫄㪼㫎㪿㪼㫉㪼㩷㪹㪼㫋㫎㪼㪼㫅㩷㪊㪌㩷㪸㫅㪻㩷㪋㪇㩷㫊㪼㪺㫆㫅㪻㫊㩷㫇㪼㫉㩷㫉㪼㫍㫆㫃㫌㫋㫀㫆㫅㪅 㪠㫅㩷㫋㪿㫀㫊㩷㪺㪸㫊㪼㪃㩷㪸㪻㫁㫌㫊㫋㩷㫀㫋㩷㫀㫅㩷㪸㪺㪺㫆㫉㪻㪸㫅㪺㪼㩷㫎㫀㫋㪿㩷㫇㫉㫆㪺㪼㪻㫌㫉㪼㫊㩷㪸㫊㩷㪽㫆㫃㫃㫆㫎㫊㪑㪟㫆㫎㪼㫍㪼㫉㪃㩷 㫋㪿㫀㫊㩷㪸㪻㫁㫌㫊㫋㫄㪼㫅㫋㩷㪸㫇㫇㫃㫀㪼㫊㩷㫋㫆㩷㫋㪿㪼㩷㪺㫉㪸㫅㪼㩷㫄㫆㫌㫅...

Page 28: ... 㧟 㧠 㪚㫆㫅㪽㫀㫉㫄㩷㫋㪿㪼㩷㫀㫅㫀㫋㫀㪸㫃㩷㫍㪸㫃㫌㪼㩷㪹㫐㩷㪺㫆㫅㫋㫉㫆㫃㫃㫀㫅㪾㩷㫋㪿㪼㩷㫎㫀㫅㪻㫀㫅㪾㩷㪬㪧㪆㪛㫆㫎㫅㩷㫊㫎㫀㫋㪺㪿㩷㫆㫅 㫋㪿㪼㩷㫋㫉㪸㫅㫊㫄㫀㫋㫋㪼㫉㩷㫋㫆㩷㫎㫀㫅㪻㫀㫅㪾㩷㫌㫇㩷㫆㫅㪺㪼㪅 㧡 㧢 㪫㪿㫉㫆㫎㩷㫋㪿㪼㩹㪸㫌㫋㫆㫄㪸㫋㫀㪺㩷㫊㫋㫆㫇㩷㪽㫆㫉㩷㫆㫍㪼㫉㪄㫎㫀㫅㪻㫀㫅㪾㩷㫉㪼㫊㪼㫋㩹㫊㫎㫀㫋㪺㪿 㫋㫆㩹㫉㪼㫊㪼㫋㩷㫋㫆㩷㫄㪼㫄㫆㫉㫀㫑㪼㩷㫋㪿㪼㩷㫊㪼㫋㫋㫀㫅㪾㪅 6JG XQKEG UQWPFU CPF KV TGVWTPU VQ PQTOCN OQFG 㪮㪿㪼㫅㩷㪸㫃㫃㫆㫎㫀㫅㪾㩷㫋㪿㪼㩷㫊㫇㪼㪼㪻㩷㫆㪽㩷㫎㫀㫅㪻㫀㫅㪾㩷㫌㫇㩷㪿㫆㫆㫂㩷㫋㫆㩷㪹㪼㩷㪽㪸㫊㫋㪼㫉㪅 㪚㫆㫅㫋㫉㫆㫃㩷㫋㪿㪼㩷㫎㫀㫅㪻㫀㫅㪾㩷㪻㫆㫎㫅㩷㫊㫎㫀㫋㪺㪿㩷㫆㫅㩷㫋㪿㪼㩷㫋㫉㪸㫅㫊㫄㫀㫋㫋㪼㫉㩷㫋㫆 㫀㫅㪺㫉㪼㪸㫊㪼㩷㫄㫆㪻㪼㩷㫀㫅㪻㫀㪺㪸㫋㫀㫆㫅㩷㪹㫐㩷㪇㪅㪈㩷㪸㫋㩷㪸㩷...

Page 29: ...㵘 䋱䋰䋮 㧠 㪠㫅㩷㫊㫆㫄㪼㩷㪺㫆㫄㪹㫀㫅㪸㫋㫀㫆㫅㩷㫆㪽㩷㫋㪿㪼㩷㪺㪿㪸㫊㫊㫀㫊㩷㫆㪽㩷㫄㫆㫌㫅㫋㫀㫅㪾㩷㫋㫉㫌㪺㫂㩷㫎㫀㫋㪿㩷㫋㪿㪼㩷㪺㫉㪸㫅㪼㪃㩷㫋㪿㪼㩷㫎㫀㫉㪼㩷㫉㫆㫇㪼㩷㫄㪸㫐㩷㪺㫌㫋㩷㫀㫅㫋㫆㩷㫉㫆㫇㪼㫊㩷 㫆㫅㩷㫋㪿㪼㩷㪻㫉㫌㫄㩷㪹㪼㪺㪸㫌㫊㪼㩷㫋㪿㪼㩷㪿㫆㫆㫂㩷㫎㫀㫃㫃㩷㫅㫆㫋㩷㪹㪼㩷㫃㫆㫎㪼㫉㪼㪻㩷㪼㫍㪼㫅㩷㫎㪿㪼㫅㩷㫀㫋㩷㪿㪸㫊㩷㪹㪼㪼㫅㩷㫉㪼㫃㪼㪸㫊㪼㪻㪅 㪠㪽㩷㫋㪿㫀㫊㩷㪿㪸㫇㫇㪼㫅㫊㪃㩷㪸㪻㫁㫌㫊㫋㩷㫀㫋㩷㫀㫅㩷㪸㪺㪺㫆㫉㪻㪸㫅㪺㪼㩷㫎㫀㫋㪿㩷㫇㫉㫆㪺㪼㪻㫌㫉㪼㫊㩷㪸㫊㩷㪽㫆㫃㫃㫆㫎㫊㪑 㪟㫆㫎㪼㫍㪼㫉㪃㩷㫋㪿㫀㫊㩷㪸㪻㫁㫌㫊㫋㫄㪼㫅㫋㩷㪸㫇㫇㫃㫀㪼㫊㩷㪽㫆㫉㩷㫋㪿㪼㩷㪺㫉㪸㫅㪼㩷㫄㫆㫌㫅㫋㫀㫅㪾㩷㫋㪿㪼㩷㪺㫆㫅㫋㫉㫆㫃㩷㪹㫆㫏㩷㫆㪽㩷㫋㫐㫇㪼㩷㩹㪜㩹㩷㫆㫉㩷㪸㪽㫋㪼㫉㪅 㪛㪼㫇㫉㪼㫊㫊㩷㩹㪸㫌㫋㫆㫄㪸㫋㫀㪺㩷㫊㫋㫆㫇㩷㪽㫆㫉㩷㫆㫍㪼㫉㪄㫎㫀㫅㪻㫀㫅㪾㩷㫉㪼㫊㪼...

Page 30: ...EGFWTG 0QTOCN OQFG 4CFKQ EQPVTQN TGCF 㧜㧞 DNKPMU 29 XCNWG EQTTGEVKQP RTQEGFWTG 㪪㫋㪸㫅㪻㩷㫆㫅㩷㫋㪿㪼㩷㪻㫉㫀㫍㪼㫉㩾㫊㩷㫊㪼㪸㫋㩷㫊㫀㪻㪼㩷㪸㫅㪻㩷㫋㫌㫉㫅㩷㪦㪥㩷㫋㪿㪼㩷㫍㫆㫀㪺㪼㩷㫊㫎㫀㫋㪺㪿㩷 㫎㫀㫋㪿㩷㫋㪿㪼㩷㪺㫉㪸㫅㪼㩷㫇㫌㫋㩷㫌㫅㪻㪼㫉㩷㫆㫇㪼㫉㪸㫋㫀㫅㪾㩷㪺㫆㫅㪻㫀㫋㫀㫆㫅㪅 㧞 㪛㪼㫇㫉㪼㫊㫊㩷㫋㪿㪼㩷㩹㪸㫌㫋㫆㫄㪸㫋㫀㪺㩷㫊㫋㫆㫇㩷㪽㫆㫉㩷㫆㫍㪼㫉㪄㫎㫀㫅㪻㫀㫅㪾㩷㫉㪼㫊㪼㫋㩹㩷㫊㫎㫀㫋㪺㪿㩷㪸㫅㪻㩷㫋㪿㪼㩷㩹㫉㪸㪻㫀㫆 㫉㪼㫄㫆㫋㪼㩷㪺㫆㫅㫋㫉㫆㫃㩷㫊㪼㫃㪼㪺㫋㫆㫉㩹㩷㫊㫎㫀㫋㪺㪿㩷㪸㫋㩷㫋㪿㪼㩷㫊㪸㫄㪼㩷㫋㫀㫄㪼㩷㪽㫆㫉㩷㪸㩷㪺㪼㫉㫋㪸㫀㫅㩷㫇㪼㫉㫀㫆㪻㩷㫆㪽㩷㫋㫀㫄㪼㪅 㪮㪿㪼㫅㩷㫀㫋㩷㫀㫊㩷㫋㫌㫉㫅㪼㪻㩷㫀㫅㫋㫆㩷㪸㪺㪺㪼㫃㪼㫉㪸㫋㫀㫆㫅㩷㪸㪻㫁㫌㫊㫋㫄㪼㫅㫋㩷㫄㫆㪻㪼㪃 㩷㩹㪘㪚㩹㩷...

Page 31: ...y stop is released Emergency stop Secure lifting hook When the Hook store switch is operated Service remote control When the mode display blinks one of 42 58 and 60 87 Low transmitter battery When the battery of the transmitter has been run out Stop winch up When any of raising boom winding up hook and extending boom is operated during over wound condition When changeed to the low temperature oper...

Page 32: ...601239000 Proportional solenoid for accelerator cylinder 740192193 Needle valve for releasing automatic stop for over winding Pressure reducing valve Gauge port for pilot Main relief valve 606042000 Back pressure valve Pressure regulator valve 3 0MPa 30kgf cm 1 0MPa 10kgf cm Tank port Pressure difference1 2MPa 12kgf cm 9 1 MRV 500 control valve Flame side Piping port side Solenoid for storing hook...

Page 33: ...n out body Tank side ９ ２ 9 2 Main relief valve Ｏ ring 731191032 Ｏ ring 731191016 Backup ring 732121016 Ｏ ring 770170048 Backup ring 770180050 Ｏ ring 731191021 Backup ring 732121021 Ｏ ring 731171015 Backup ring 732121015 Ｏ ring 731191011 Ｏ ring 770170014 Backup ring 770180045 Gauge port PT1 4 Main relief valve 606042000 Ｏ ring 731191021 Gauge port for pilot pressure PF1 4 ...

Page 34: ...alve for storing hook Tank side ９ ３ In out body O ring 731171005 Relief valve for storing hook 606041000 Needle valve 605116040 9 3 Relief valve for storing hook Relief setting pressure for storing hook 3 9MPa 40kgf c at 17L min High pressure side High pressure side ...

Page 35: ...s sliding surface of spool may be damaged when trying to remove it Ｏ ring 731171512 Ｏ ring 731174009 Ｏ ring 731191014 Main relief Ｏ ring 731171005 Back up ring 732121005 Ｏ ring 731191512 Ｏ ring 731174008 Solenoid valve for unloading 740192192 Tank Pressure reducing valve To be connected to pilot section Pilot pressure Parts of regular replacement ...

Page 36: ... ９ ５ 9 5 Back pressure valve Ｏ ring 731191018 Back pressure valve Gauge port ...

Page 37: ...Extend Up Down Down UP Slew Telescope Hoist Derrick Outrigger ９ ６ High pressure side Tank side Control valves Pilot line Tank side 9 6 Pressure regulator valve Ｏ ring 731191022 Pressure regulator valve Choke plug with filter 605686360 ...

Page 38: ...enoid 740192193 Raise Up Retract C W Pressure regulator valves for each control element Lower Down Extend C C W Raise Up Retract C W Packing 770200059 Differential transformer 750211006 9 7 Valve body D H T S Ｏ ring 731171015 Badk up ring 732131015 Ｏ ring 731191014 ９ ７ Ｏ ring 731191006 Ｏ ring 731171015 Ｏ ring 731171011 Ｏ ring 731171011 Shuttle valve Raise Lower Up Down Retruct Exitend C W C C W ...

Page 39: ... Ｏ ring 731191512 Proportional solenoid 740192193 Pressure regulator valves for each control element Packing 770200059 Differential transformer 750211006 9 8 Valve body Outrigger Ｏ ring 731171015 Badk up ring 732131015 Ｏ ring 731191014 ９ ８ Ｏ ring 731171015 Ｏ ring 731171011 Ｏ ring 731191014 Ｏ ring 731171011 ...

Page 40: ...r High Pressure Tank Tank Ｏ ring 731171005 Ｏ ring 770170054 Ｏ ring 731191018 Ｏ ring 731194010 ９ ９ Tank High Pressure Tank Tank Ｏ ring 731194010 Ｏ ring 731171005 Ｏ ring 731191018 Ｏ ring 731191018 Ｏ ring 731191016 Ｏ ring 731171005 Ｏ ring 770170014 9 9 O ring fitted on jointing surface of valve body Accelerator cylinder Valve body Pressure regulator Valve body In out body High Pressure Ｏ ring 7701700...

Page 41: ...ng 731174009 Ｏ ring 731174008 Back up ring 732131015 Ｏ ring 731171015 Ｏ ring 770170053 Ｏ ring 731191512 Packing 770200059 9 10 Accelerator cylinder Accelerator Cylinder 601239000 Proportional solenoid 740192193 Differential transformer 750211008 ...

Page 42: ...WR V KU TGEQOOGPFGF VJCV VJG URQQN UJQWNF DG TGRNCEGF CU CP CUUGODN DGECWUG HQNNQYKPI CVVGPUKQP OWUV DG RCKF YJGP TGOQXKPI VJG ECR UETGY CPF VJG URQQN GPF VQ TG CUUGODNG P OCP ECUGU YJGTG QKN NGCMU QWV QH VJG URQQN KV OC DG FWG VQ FCOCIG KP VJG 1 TKPIU KP VJG INCPF CPF QT KP VJG XCNXG DQF YJKNG VJG URQQN KU DGKPI KPUGTVGF 6JGTGHQTG QDUGTXG VJG 1 TKPIU ECTGHWNN YJGP VJG URQQN JCU DGGP GZVTCEVGF 2CT...

Page 43: ...ve for storing hook Primary pressure Secondary pressure Solenoid valve for unlading pressure reducing valve Pump Tank 2 Main relief valve 2 Relief valve for storing hook 2 Back pressure valve Pressure regulator valve 2 Emergency screw stop valve 3 0MPa 30kgf cm 20 6MPa 210kgf cm Set bolt stop valve 3 9MPa 40kgf cm Working pressure G P Pailot pressurer G P 1 0MPa 1 0MPa 10kgf cm Feedback 10kgf cm 2...

Page 44: ...k Solenoid valve for unlading pressure reducing valve Pump Tank 2 Main relief valve 2 Relief valve for storing hook 2 Back pressure valve 2 Pressure regulator valve 2 Emergency screw Stop valve 3 0MPa 30kgf cm 20 6MPa 210kgf cm Set bolt Stop valve 3 9MPa 40kgf cm G P Pailot pressurer G P 1 0MPa 10kgf cm 1 0MPa 10kgf cm Feedback Primary pressure Secondary pressure Working pressure Port relief for s...

Page 45: ...ndary pressure will not be returned to the tank to allow the crane to be operated Main valve Pressure reducing valve Set bolt Solenoid valve for unloading Relief valve for storing hook Solenoid valve for storing hook Pressure regulator valve Back pressure valve Tank Solenoid valve for storing hook Primary pressure Secondary pressure Solenoid valve for unlading pressure reducing valve Pump Tank 2 M...

Page 46: ...ing hook Solenoid valve for storing hook Pressure regulator valve Back pressure valve Tank Set bolt 10 4 Oil flow in the in out body when hook is being wound up by hook storing operation P1 Solenoid valve for storing hook Solenoid valve for unlading pressure reducing valve Pump Tank Main relief valve Relief valve for storing hook Back pressure valve Pressure regulator valve Emergency screw stop va...

Page 47: ...for unloading Relief valve for storing hook Solenoid valve for storing hook Pressure regulator valve Back pressure valve Tank Set bolt Core P1 Solenoid valve for storing hook Relief valve for storing hook 3 9MPa 40kgf cm 2 Solenoid valve for unlading pressure reducing valve Pump Tank Main relief valve Back pressure valve Pressure regulator valve Emergency screw stop valve 3 0MPa 30kgf cm 20 6MPa 2...

Page 48: ... to the circuit actuating boom up hook up boom retraction and slewing C W Raise Up Retract C W Detects spool position to apply signal input to control box Pilot pressure 10 6 Oil flow in the valve body when boom up hook up boom retraction and slewing C W are functioning Piston Spool Spool Core Pressure regulator valves for each control element Shuttle valve Differential transformer 1 Tank Tank Pro...

Page 49: ...e circuit actuating boom down hook down boom extension and slewing C C W 10 7 Oil flow in the valve body when boom down hook down boom extension and slewing C C W are functioning Shuttle valve Ｐ1 Actuator port Raise Up Retract C W Actuator port Lower Down Extend C C W Differential transformer Pilot pressure Spool Tank Tank Proportional solenoid ＯＮ Raise Up Retract C W Proportional solenoid ＯＦＦ Low...

Page 50: ...ylinder coil so that the iron core is gradually magnetized accordingly The iron core and the spool facing each other with the spring 1 placed them move downward to lead the pilot pressure to the piston for extension The cylinder extends to the position where the working force of cylinder for extension controlled by movement of spool and the force of spring 3 are balanced The position being balance...

Page 51: ...m Up SOL Down SOL Retracting SOL Extending SOL C W SOL Ext SOL C C W SOL Tank Shuttle valve Regulator valve for each control element Shuttle valve Regulator valve for each control element Shuttle valve Regulator valve for each control element Shuttle valve Regulator valve for each control element Regulator valve for each control element 11 1 Hydraulic System 2 1 0MPa 10kgf cm Working pressure Gaug...

Page 52: ...re line Tank line Pilot pressure line Feed back line Hydraulic motor type Internal pilot type Slewing Telescope Hoist Derrick Outrigger Raise Lower Up Down Retract Extend C W C C W Solenoid valve for storing hook Solenoid valve for unloading Main relief valve Back pressure valve Pressure regulator valve From pump Tank Pressure reducing valve Set bolt Emergency screw ...

Page 53: ... 770290150 Hydraulic motor 740360027 Ｗ Ｐ check valve 601463000 Filter 770290149 Left Right Front Right Front Left Rear Left Rear Right Slewing Geuge Port Hoist Derrick Telescoping Outrigger 21 6MPa 220Kgf c Rated revolution 1800rpm Pressure relief 11 3 Hydraulic Circuit Diagram Rated delivery 36L min Check valve 740197149 Counter balance valve 606004000 Filter770290147 １１ ３ return filter740580044 ...

Page 54: ...EGOGPV FXCPEGOGPV 4GVTGCV 4GVTGCV 2QOR㧞 6CPM㧝 6CPM㧞 KIJ RTGUUWTG NKPG HKNVGT V EQPPGEVU KV YKVJ VJG EQPVTQN XCNXG HQT VJG ETCPG GHV 4KIJV 2QOR QPVTQN XCNXG HQT TWPPKPI QVQT HQT TWPPKPI QVQT HQT TWPPKPI 2KRKPI QH EQPVTQN XCNXG HQT TWPPKPI 㧔㧝㧞㧙㧝㧕 2QOR ...

Page 55: ...QP GTTKEM QYGTKPI 4CKUKPI GHV 4KIJV 6GNGUEQRKPI QKUV 2NWI 1WVTKIIGT V EQPPGEVU KV HTQO 1WVQTKICUJKTKPFC VQ VJG VCPM 6Q VCPM QPPGEVKQP HTQO EQPVTQN XCNXG HQT TWPPKPI QPVTQN XCNXG HQT ETCPG 8KGY 8KGY QPVTQN XCNXG RKRKPI HQT ETCPG 㧔㧝㧞㧙㧞㧕 ...

Page 56: ... V EQPPGEVU KV YKVJ VJG ETCPG UKFG EQPVTQN XCNXG 4GCT NGHV GZVGPF 1WVTKIIGT 4GCT 4KIJV GZVGPF TQPV NGHV GZVGPF TQPV 4KIJV GZVGPF 4GCT NGHV TGVTCEV 4GCT 4KIJV TGVTCEV TQPV NGHV TGVTCEV TQPV 4KIJV TGVTCEV 1WVQTKIC EJCPIG XCNXG RKRKPI 㧔㧝㧞㧙㧟㧕 ...

Page 57: ...sing デリック 起 To hexagon socket head plug apply Lock Tight 202 before tightening Don t use a sealing tape When assembling fill up with chassis grease When assembling fill up with chassis grease Inner Joint Inner Joint Outer Joint Outer Joint A Square Ring Seal Ring Section A in detail STK seal fitting Hoist Up Telescoping Retraction Hoist Down Derrick Raising Derrick Lowering Telescoping Extention H...

Page 58: ...KEM 4CKUKPI GTTKEM QYGTKPI 6GNGUEQRKPI ZVGPVKQP 6GNGUEQRKPI 4GVTCEVKQP QKUV 7R QKUV QYP QKUV TCKP GTTKEM 4CKUKPI GTTKEM QYGTKPI 6GNGUEQRKPI ZVGPVKQP 6GNGUEQRKPI 4GVTCEVKQP QKUV 7R QKUV QYP QKUV TCKP 㧔㧝㧞㧙㧡㧕 ...

Page 59: ... RTGRCTG VJG JQUG CPF VJG UCOG RCTV YJGP QW GZEJCPIG VJG JQUGU 2NGCUG EQPPGEV VJG GZEJCPIGF JQUGU YKVJ C PGY JQUG FTCI QWV VJG GZEJCPIGF JQUGU CPF EJCPIG C PGY JQUG CPF VJG KPUGTVKQP 2KRKPI QH QNWOP 㧔㧝㧞㧙㧢㧕 QKUV FTCKP QKUV WR QKUV FQYP ...

Page 60: ...lows boom3 to extend E xtension of tele3 allows boom4 to extend E xtension of tele3 allows sheave 1 to shift and boom5 is to be extended as it is pulled by extending wire R etracting wire follows accordingly R etraction of tele1 allows boom2 to retract R etraction of tele2 allows boom3 to retract R etraction of tele3 allows boom4 to retract R etraction of tele3 allows sheave 2 to shift and boom5 i...

Page 61: ... in detail R etracting wire rope E xtending wire rope Adjusting bolt for extending wire rope Boom5 Boom4 Guide Pipe Connect the cord which came out of the pipe to the overwinding detector by passing it through inside of the guide １３ ２ ...

Page 62: ... in detail Tele1 Tele2 Tele3 Tere3 Tube Boom4 Connecting Pin R etracting wire rope to the slide plate surface Apply the disulfide molybudenum grease Apply Three Bond 1102 to the slide plate to prevent it from falling Boom3 Boom4 １３ ３ ...

Page 63: ... tallation procedures for s lide plate and guide It has s imilar cons truction irres pective of number of boom s ection Clearance 1mm Clearance 2mm When assembling apply Lock tight 242 S lide plate Guide １３ ４ ...

Page 64: ...he bolt opens the check valve 1 of selector valve ass y via spool which leads the pressure oil to 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 is closed at the time pressure oil will not flows in the tele2 Also oil in the retracti...

Page 65: ...age the bolt opens the check valve 1 of selector valve ass y 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 Alt...

Page 66: ... ass y S ince 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 S imultaneously 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 t...

Page 67: ...raction side of tele2 Also the bolt for tele3 opens the check valve 1 of selector valve ass y via spool which leads the oil in the extension side of tele2 to the counter balance valve by way of the slide pipe of tele2 the check valve 2 of selector valve ass y for tele1 and the slide pipe of tele1 Although the check valve in the counter balance valve is closed at this time the spool is opened by pi...

Page 68: ...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 S ince 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...

Page 69: ...ele1 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...

Page 70: ...rocedures with Adjus ting B olt Retract telescoping cylinders 1 and 2 to their minimum ApplyÒ LOCK TIGHT 242Óto the threads of the adjusting bolt Put a board with a thickness of 3mm to the part marked with and tighten the adjusting bolt After adjusting lock with the lock nut １４ ７ ...

Page 71: ...r 4 section boom and that of the telescoping cylinder 3 for 5 section and 6 section booms 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 At the same time when the piston gets in the plunger the chamber A is closed with the cushi...

Page 72: ...d the snap ring and the pressure oil flows into the chamber A without being shut as shown in the illustration In this way the telescoping cylinder extends Cushion mechanism of the telescoping cylinder for 5 section and 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 １４ ９ ...

Page 73: ... and 6 inspect the plunger which is assembled in the telescoping cylinder 3 When 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 plunger of the telescoping cylinder 2 2 Cause of Troubles and Remedy SPOOL 1 NUT A B C ADJUSTING BOLT STICK 14 3 １４ １０ ...

Page 74: ... Ò disor derlyÓ Some foreign substances are clogging the part of selec tor valve of telescoping cylin der 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 telescop ing cylinder 1 was loosened Disassemble telescoping cylinder 1 and tighten the nut B oom 2 and 3 extend but boom 4 and 5 does not extend ...

Page 75: ...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 Tunk The check valve shuts and the amountof oil that returns to the tank is limited １５ １ Apply Lock tight 2701 With Curing accelerator 7649 If the addelerater is not used do not flow of the agent After the screw is tightened hit wi...

Page 76: ...Balance Valve Check Valve opens Spool opens Apply Lock tight 2701 With Curing accelerator 7649 If the addelerater is not used do not flow of the agent After the screw is tightened hit with a pinch at 2 places on its circumference Apply Lock tight 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 it...

Page 77: ...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 Fig 1 Piston Points to remember 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 LOCK TIG...

Page 78: ...air remember that the unclean oil will not be blown off but will just escape along the threads In case of spray cleaning as well target oil will not be removed but return if doing nothing but just spraying After carrying out degreasing and cleaning wait until cleaning fluid is dried up completely 2 Priming coating After primer 7471 has been applied do not wipe it off but allow as it is for 5 10 mi...

Page 79: ...he treads starts curing Curing speed differs according to temperature ambient temperature included of target component Since curing time becomes excessively longer at a temperature below 10 C work with the component temperature raised to 15 C or over 5 Curing This is a period while an adhesive is being joined Store the components still during the period Recommended conditions is at an component te...

Page 80: ...r Disk Apply Lock Tight 242 Bearing Pay attention to its direction Gear1 Casing Motor Rotate the gear shaft to check that the pawl makes a smooth movement 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 ...

Page 81: ...the pawl Ratchet Wheel Set bolt position Dimensions on both sides should beequally arranged when fitting the ratchet wheel 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 2 2 2 1 2 3 4 ...

Page 82: ...re 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 Drum or reduction gear is defective Adjust tightening of brake shoe Overhaul reduction gear Check drum Unable to maintain suspend ed load Brake shoe is faulty Pawl is faulty Replace brake shoe Repl...

Page 83: ...ring Thrust ball 9 0 Aplly grease 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 Spring pins both sides Enlarged portion where sealing agent is to be applied ...

Page 84: ...eduction gear 1 Construction of slewing reduction gear Casing Worm wheel Breather Gear shaft Bearing housing Crown nut Snap ring Teper roller bearing Worm shaft Taper roller bearing Ball bearing Crown nut Dust seal Flange bolt Nut ...

Page 85: ... m 17 2kgf m Nut Apply Lock Tight 262 before tightening it Fill up with grease here Use Lithium soap radical grease such as Rizonix grease No 1 or Kyseki Note Tighten the nut to the extent that the gear shaft can be rotated to either direction with your both hands Apply Grease to the inside of dust seal Reference Tightening torque 20N m 2kgf m Apply ThreeBond 1401 to it Dust Seal ...

Page 86: ...sustains the worm shaft Turn the gear shaft counterclockwise and pull out the worm shaft from the casing Use of special tool for removing worm shaft is recommended Remove 8 pcs of bolt M10 X 25 which fasten the bearing housing and pull out the housing utilizing 3 pcs of bolt for 3 through holes in the housing 19 3 ...

Page 87: ...This figure shows the pulled out housing with gear shaft and worm wheel Grip the housing with a vice and pull out the worm wheel with a gear puller Pull out the collar which is assembled in the nut 19 4 ...

Page 88: ... the nut which retains the taper roller bearing Note To the threaded part of the nut ÒLOCK TIGHTÓ was applied Therefore when loosening warm up lightly the threaded part with gas flame and then loosen When reassembling be sure to apply ÒLOCK TIGHT 262Ó to the threaded part 19 5 ...

Page 89: ...from the turntable and the pinion gear it tightens with the specified torque in the order of tightening the installation bolt ５ After it assembles it grease is painted on the gear tooth combination side S Back Front Ｓ Mark Soft zone Position Tempered bolt Slewing reduction gear ass y Bolt Pinion gear Turn table After assembling apply grease to engaging tooth surfaces of the gears ２０ １ Tighting seq...

Page 90: ...the figure above Tighting torque for bolts fastening slewing reduction gear ass y Tightning torque for bolts fastening turntable Parts Name Torque Bolt M14 40L 716114D40 167 20Ｎ ｍ 17 2 f m Tempered Bolt M18 75L 12 9 018542020 353 29Ｎ ｍ 36 3 f m Tighten the mounting bolts in diagonal order Before mounting bolts are tightened degrease the bolts and the tapped holes to apply Lock Tight 262 to the bol...

Page 91: ...n and tightening order Column Turntable Stopper Inspection Hole for bolts mounting turntable Bolts for Column ＭＪ６ ５０ １２Ｔ ０８Ｈ６５１０６０ When assembling apply Lock Tight ９６２Ｔ Tightning Torque ２５ ２Ｋｇｆ ｍ Tighten the bolts in the numerical order as illusted in the figure ２１ １ ...

Page 92: ...aling agent Cemedine SuperX White to the mounting surface over entire circumference Degrease sealing surface thoroughly Green Yellow Apply sealing agent Cemedine SuperX White to the mounting surface over entire circumference Degrease sealing surface thoroughly Yellow Green 22 1 ...

Page 93: ...wound condition with the overwinding alarm switch turned OFF Be sure to turn the switch ON before starting crane work and check that the alarm sounds every time when the weight for overwinding alarm is lifted up Since the length of wire rope hanging the weight is specified by laws and regulations con cerned do not make it short at random The alarm will not sound if the wires cords connected to the...

Page 94: ... QQO VQR KP FGVCKN ...

Page 95: ...h panel front Overwinding alarm switch Battery 12V Brown Yellow White Black Speaker Cord reel Black To detector leaving minimum wire rope Black Red Black Overwinding detector Yellow Green Slip ring Light Green Red Key switch ST IG B E BAT OFF STOP 1 RUN 2 START Black Red B E IG BAT ST Yellow Green ...

Page 96: ...erential transformer Differential transformer Differential transformer Differential transformer Differential transformer Differential transformer ON OFF SOL Switching to low pressure Unloading ON OFF SOL Proportional SOL Proportional SOL Proportional SOL Proportional SOL Proportional SOL Proportional SOL Proportional SOL Proportional SOL Proportional SOL Proportional SOL Retract Extend Retract Ret...

Page 97: ...ED LAMP RED YELLOW GREEN REMOTE CONTROL ON OFF RD BK WH GN 0V 5V LENGTH OVERHOIST SWITCH DC 12V LINEAR VARIABLE DIFFERENTIAL TRANSFORMER LVDT 2 DERRICK 2 LVDT 2 WINCH 2 LVDT 2 TELESCOPIC 2 LVDT 2 SLEWING 2 BK WH DETECTOR FOR FULLY RAISED BOOM ON WHEN FULLY RAISED OUTRIGGERS LIMIT SWITCH RD WH GN BK YE STORE HOOK OR WH GN LVDT WINCH EMERGENCY WH YE LG BU BK HORN 54 OUTRIGGER 1 EXT IN GY YE GN OR PO...

Page 98: ...Green Brown Sky Blue Red Red Red To detector for leaving minimum wire rope Red Red Red VIN Black Black Black GND White White White VOUT Green Green Green Green Black Black CLOSED ON SAFE Black BOOM LENGTH SENSOR 74M652300 OVERWINDING DETECTOR 603218000 SPARK PLUG Black GENERATOR Black Black Yellow Yellow REGULATOR Red Black OIL SENSOR STARTER MOTOR SOLENOID ENGINE GM401LE MITSUBISHI To Emergency s...

Page 99: ...winding alarm switch To be connected to slip ring Green Yellow Overwinding Light Yellow Green 24 3 General view To connected to BATTERY MAIN To connected to BATTERY RR Earth Black Red white Red Black Green Yellow ...

Page 100: ... 9 4 412 4 6 0 0 0 5 KOKV UYKVEJ ...

Page 101: ...QUKVKQP QH GCTVJ QPVTQN DQZ TGUGV UYKVEJ COR VJCV FKURNC U UVCVG QH NQCF QH ETCPG YQTM 1WVTKIIGT OQFG KPFKECVQT NCOR 6JG 1WVTKIIGT OQFG KPFKECVQT NCOR NKIJVU YJGP VJG QRGTCVKQP OQFG KU EJCPIGF VQ 1WVTKIIGT CPF QWVTKIIGT DW GT TKPIU 4GNC VJCV DNKPMU NQCF UVCVG KPFKECVQT NCOR 1WVTKIIGT DW GT ...

Page 102: ...J FGVGEVQT QQO CPING FGVGEVQT KOKV UYKVEJ HQT DQQO CPING OCZKOWO FGVGEVKQP KOKV UYKVEJ HQT DQQO CPING JQTK QPVCN FGVGEVKQP GTTKEM E NKPFGT NQYGT UKFG RTGUUWTG FGVGEVQT GTTKEM E NKPFGT TCKUG UKFG RTGUUWTG FGVGEVQT ...

Page 103: ...T OCZKOWO NGPIVJ FGVGEVKQP KOKV UYKVEJ HQT 5NGYKPI UVQTCIG FGVGEVKQP KOKV UYKVEJ HQT EJCPIG FGVGEVKQP QH TWPPKPI CPF ETCPG QRGTCVKQP KOKV UYKVEJ HQT 1WVTTKIIGT UVQTCIG FGVGEVKQP KOKV UYKVEJ HQT 1WVTTKIIGT OCZKOWO CPING FGVGEVKQP ...

Page 104: ...l the emergency stop switch unit insert the protrusion into the groove of the thread section If the nut is tightened excessively the switch does not return correctly Locked condition Unlocked condition Fit the metal fixture s direction to the groove and insert the unit 25 1 ...

Page 105: ...lly while paying attention that the hexagon nut will not be turned together with the set bolt Lock the set bolt with the hexagon nut to prevent it from being loosened This allows the crane to be operated by manual control but the automatic stop for over winding will not function ７ Extract the lock pin with your hand to screw in the emergency screw and disconnect the power connector BATTERY MAIN Al...

Page 106: ...th button 1 depressed Retract Operate lever with button 2 depressed Extend Operate lever with button 5 depressed Retract Operate lever with button 6 depressed Extend Operate lever with button 7 depressed Retract Operate lever with button 8 depressed Extend Operate lever with button 3 depressed Retract Operate lever with button 4 depressed The button at the center of the electro magnetic valve is p...

Page 107: ...l sounds Mode indicator lamp on the control box blinks to show where in trouble Mode indication Area in trouble ８０ Derrick ８１ Hoist ８２ Telescoping ８３ Slewing ８４ Outrigger ８５ Accelerator How to check differential transformer Measure resistance between each combination of terminals If any of measured resistance shows a big difference replace the transformer Terminals between Resistance １ ２ ２４Ω ３ ４ ６...

Page 108: ...terminal of Terminals between Resistance １ ３ Insulateｄ １ ４ Insulateｄ １ ５ Insulateｄ Blk Grn Yel Not used Blu Wht Measure resistance of terminal from each terminal of Terminals between Resistance ２ ３ Insulateｄ ２ ４ Insulateｄ Blk Grn Yel ２ ５ Insulateｄ Not used Blu Wht If correct resistance is measured at both steps and above replace the wire harness Insulateｄ Insulateｄ Terminal arrangement of connecto...

Page 109: ...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 ...

Page 110: ... 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 Fig2 3 Inspection of tele1 Extend 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 Raise booms to their maximum to sling a load In order to release pressure remained in the te...

Page 111: ...e 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 Ext...

Page 112: ...of boom length detector to the connectors of over winding detector and of load cell amplifier for load detection In order to facilitate next maintenance move the stopper for preventing over wound located at the window in the boom length detector to the boom top When the boom length detector is installed and detached follow the steps illustrated below by paying Move the stopper for preventing over ...

Page 113: ...use as a guide when reassembling put marks on the cover the case and the base plate 3 Unfasten the bushing and the screw to remove the cover 4 Unfasten the screw to remove the bracket out of the case 5 Remove the stopper for preventing over wound to wind up the cord on the drum until no force of spiral spring is felt 6 Loosen the countersunk screw to separate the case from the base plate 7 Remove ...

Page 114: ...d on the boom top out of the window 16 In order to prevent the cord wound up on the drum from being loose hold it with your hand to fit it into the case while taking off the gummed tape 17 Put the base plate onto the cord wound up on the drum while holding the cord so that it will not be loose to fasten the plain washer and the bolt temporarily on the rotating shaft Next fasten the countersunk scr...

Page 115: ...entiometer with new one 21 Rotate the gear with your hand to engage the gear with the drum shaft at the position where resistance measures 300Ω between terminals 2 white and 3 black to fix the bracket to the case Use a digital circuit tester for resistance measurement Pull out the cord to a certain extent out of the drum to check that the resistance between terminals 2 white and 3 black makes a sm...

Page 116: ...gauge and wipe it off with a piece of clean rag Insert the gauge fully again th Check the oil for contamination and viscosity at the same time where it is wetted with oil Oil quantity to be filled up 1 2 litters Frame Truck roller Function Hydraulic oil tank Engine Fuel leakage Remaining fuel quantity Engine oil quantity Filling up Battery electrolytic solution Unusual vibration Noise Loose bolt B...

Page 117: ...illing up Clean up the suction strainer and the return filter once a year Park the crawler on a flat ground to stop the engine Capacity of hydraulic oil tank 27 liters Check the oil quantity at the oil level gauge located in front of oil tank A proper quantity of hydraulic oil is somewhere between UPPER and LOWER limits as illustrated in the figure Check oil quantity in the reduction gears of craw...

Page 118: ...of bolts Missing bolt Function Oil leakage Deformation Cracks Mounting of fixing pin Rotation of hook Function of retaining mechanism Hool Wire rope Overwinding alarm Irregular winding Function Oil leakage Hoisting winch Derricking boom Moment limiter Telescoping boom Mounting of foot pin Oil leakage Damage Function Oil leakage Function Braking function Pump Hydraulic oil tank Oil level Oil leakag...

Page 119: ...item 1 through 4 illustrated above １ Refer to the figure in the left for how to hook the wire ropes for winding up and for whiere the weight for over winding alarm is to be mounted 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 1 A rope in which amount of ...

Page 120: ...ind the hook until it comes close to the ground 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 3 Pass the pin through with the wire socket held with your hand and tighten it with the bolt securely ４ How to correct twisted wire...

Page 121: ...Replacement of gaskets and seals for each cylinder Replace it every 3 years Replacement of sliding plate of boom Replace it every 3 years Replacement of brake shoe of hoisting winch Replace it every 3 years Sliding plate Brake shoe 29 4 ...

Page 122: ...ON OF CARRIER for replacement procedures 30 hours Whenever necessary Service interval Where to lubricate Lubricant Tool Engine １ ２liters 1 Engine oil ３２mm spanner Hydraulic oil tank ２７liters 1 Hydraulic oil Tension adjustment of rubber crawler It exchanges it every 1 year or 500 hours Replace every 1000 hours Fuel Fuel tank capacity Gasoline ７liters Reduction gears of crawling motor ０ ３３liters ret...

Page 123: ...utirigger fulcrum pin 4 Grease pump Grease pump Rope grease Manual application Spray gun Grease pump Grease pump Grease pump Grease pump Grease pump Weekly Monthly Chassis grease Chassis grease Gear oil Gear oil Chassis grease Chassis grease Molybdenum grease Chassis grease Chassis grease Daily Chassis grease Boom slide plate Upperside of boom section Boom slide plate Underside side face of boom s...

Page 124: ... 㧟㧞 ...

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