WORKSHOP MANUAL HYDRAULIC CRANE _UR SERIES UR220, UR250, UR260, UR290, UR330, UR360, UR500 FURUKAWA UNC conronanen 1989-6INTRODUCTION This technical instruction manual describes the construction of the UR truck cranes and maintenance procedures for the servicemen engaged in their maintenance. Please carefully read the manual to acquire the proper maintenance skills and provide efficient, speedy, correct services that are essential to customer trust. In this way, UNIC truck cranes will be able to deliver their superb performance and be kept in satisfactory operat- ing condition. It is recommended that the separate parts list be referred to together with this manual. Technical Section, Service Department FURUKAWA UNIC CORPORATION84 & CONTENTS GENERAL VIEW Boom 1. Construction of Boom and Telescoping Cylinder Installation 2, Boom Disassembly Procedure (3-Section Boom) 3, Boom Disassembly Procedure (4-Section Boom) 4, Boom Disassembly Procedure (6-Section Boom) 5, Procedures for Housing into the Boom the Telescoping Cylinder for 4-Section, 5 Section, and Section 6. 6 Section Boom (Construction of Booms (4), (6) and (6) Simultaneous Extension/Retraction) Installation Procedures for Slide Plate and Wire Bracket . 8 How to Adjust Wire Ropes for Extension/Retraction (4Section Boom) 9. How to Adjust Wire Ropes for Extension/Retraction (Section Boom) . TELESCOPING CYLINDER : 1, Construction (2-Section ~ 6-Section) . 2, 3.Section Boom (Disassembly Procedures for Dual Telescoping Cylinders) : 3. 3.Seetion Boom (Explanation of Dual Cylinder Operation} 4, 4-Section Boom (Explanation of Dual Cylinder) 5. 5Section Boom, 6-Section Boom (Explanation of Triple Cylinders) 6. Explanation on Funetion and Working of Cushion Seal BASE 1. Construction of Base 2 3 4 5 6 Construction of the Base (Differential Type) Construction of the Base Construction of the Base (Differential Type) Construction of the Inner Box Extension Cable Installation Construction of the Inner Box Extension Cable Installation (Differential Type) 7 7. Construction ofthe Inner Box Extension Cable Instalation 8, Extension Cable Installation Procedure 9. Piping to Outrigger Cylinder 10. Piping to Outrigger Cylinder 11. Pulling out Order of Horizontal Inner Box . 12. High Outrigger OUTRIGGER CYLINDER 1. Construction of Vertical Outrigger Cylinder . Construction of the Part where Pilot Check Valve i Fitted Construction of Vertical Outrigger Cylinder. Construction of the Part where Pilot Check Valve is Fitted Construction of Vertical Outrigger Cylinder (High Outrigger) Construction of Horizontal Outrigger Cylinder 13 16 7 2 24 24 28 33 36 38 40 45 45, 46 47 48 49 50 51 52 54 55 56 57 59 59 59 60 61 62$6. 97. 38. gna, §13, gua. 915. SLEWING DEVICE . 1. Position of Soft Zone *S" onthe Turntable 2. Tightening Order of Turntable Bolts 3. Turntable Mounting Procedure 4, Tightening Torque for Bolts Fastening Turntable and Slewing Reduction Gear Numerical Tightening Order of Turntable Bolts Tightening Torque for Bolts Fastening Column LEWING REDUCTION GEAR Construction Reduction GeorDisasembly Procedure Precaution When Assembling Reduction Gear Bolt Tightening Torque for Bearing Housing Gear Oil for Reduction Gear HOIST WINCH (SILENT WINCH) Construction of Winch Construction of Brake Explanation of Operation Construction of Reduction Gear Bolt Fastening Reduction Gear Casing Gear Oil for Reduction Gear Brake Shoe Adjusting Procedure - Cause of Troubles and Remedy SWIVEL JOINT 1, Construction of Swivel Joint and Positions of Hoses 2, Swivel Joint Assembling Procedure SLIP RING ce 1. Canstruction of Slip Ring and Is Fitting Position DERRICK CYLINDER 1. Construction 2. Disassembling Procedure CONTROL, ‘ALARM SYSTEM 1, Push button Switch Installing Procedure 2, Wiring Diagram HYDRAULIC CIRCUIT 1, UR Series Standars 2. URH Series (High Outrigger). CONTROL VALVE (MODEL: MV.30A) 1, Composition of Valves and Inscribed Mark on Spoot 2, Relief Valve (RT-15C) 3. Explanation of Metern/Meterout S00! 6 63 63 cn 66 e 6B Cy 69 70 ” 78 5 76 76 76 D 78 80 8 ai 83 85, 86 86 a 87 87 88 90 9 on 92 92 93 95 95 96 97816. v7 gi, 319, 820. g21 COUNTERBALANCE VALVE . 5 1. Construction of Counterbalance Valve (or Derick) 2. Construction of Counterbalance Valve (for Telescoping Cylinder 3. Explanation of Counterbalance Valve Operation . DI-CO VALVE 1. Construction of DI-CO Valve 2, Explanation of DI-CO Valve Operation 3. DI-CO Valve Handling Precautions . 4. Failure in the Synchronized Opertion of Outrigger Gylingers CONSTRUCTION OF HOOK (FOR 6 SECTION BOOM) HOW TO HANDLE WIRE ROPES . 1. Passing Wire Rope into Wire Socket and Fastening It 2. Twisted Wire Rope Adjusting Procedure FILTERS LUBRICATION 100 100 100 101 103 103 104 105 106 107 108 108 108 109 10§1. GENERAL VIEW§2. BOOM 1, Construction of Boom and Telescoping Cylinder Installation 1, 2-Section Boom (Single Cylinder) 200M (1) BOOM (21 TELESCOPING CYLINDER COUNTERBALANCE VALVE 2. 3-Section Boom (Dual Cylinder) 00M i BOOM (2), 00M (3) TELESCOPING CYLINDER (2 \ TELESCOPING CYLINDER (1) COUNTERBALANCE VALVE 3. 4-Section Boom (Dual Cylinder + Wire Rope) WIRE ROPE FOR EXTENSION 800K (1) Boom (2) —_ 00m (3), 9) Sere a =} Wine ROPE FOR RETRACTION ° een > |COUNTERSALANCE VALVE 800M i)4. 5-Section Boom (Triple Cylinder + Wire Rope) 200% 11) 00m (2 800M (3) BOOM (4) \ BOOM (5) TELESCOPING CYLINDER (3) TELESCOPING CYLINDER @) TELESCOPING CYLINDER (1) COUNTERBALANCE VALVE 5. 6-Section Boom (Triple Cylinder + Wire Rope) BOOM (1) _800M(2)_ BOOMS] BOOM (@)_ BOOM IS! BOOM (6) TELESCOPING CYLINDER (3) TELESCOPING CYLINDER (2) TELESCOPING CYLINDER (1) es LOUNTERBALANCE VALVE2. Boom Disassembly Procedure (3-Section Boom) 1. Pull out the booms (2) and (3) from the boom (1). 800m (11 OUT FOR GUIDE ‘800M (2) BOLT FOR SLIDING PLATE 800M (3) 1) Remove the joint (for piping) of the telescope cylinder. 2) Remove the slide plates (side and lower plates), and guide, 3) Remove the pin (1) from the boom (1), and pull the booms (2) and (3) out of the boom (1). Pull out the boom (3) from the boom (2). 800M (2) BOLT FOR GUIDE iN 12) 800M (3) BOLT FOR SLIDE PLATE 1) Remove the slide plates (side and lower plates) and guide, 2) Remove the pin (2) from the boom (2), and pull out the boom (3).3. Pull out the telescoping cylinders (1) and (2) from the boom (3). TELESCOPING CYLINDER (1) {800M (3) PIN (3) TELESCOPING CYLINDER (2) 1) Pull out the telescoping cylinder (2) and the pin (3) from the boom (3). 2) From the boom (3) pull out the telescoping cylinder ass'y (1) and the telescoping cylinder ass'y (2) in the direction towards the rear. TELESCOPING CYLINDER (1) ASS'Y SELECTOR VALVE TELESCOPING CYLINOER (2) ASS'Y x Reassembling shall be made in reverse order of the disassembly procedures. Notes: 1. When assembling the pin, apply grease to the inside of its base for rust- proof purpose. Apply grease (Chassis Grease No.1) to the inner surface of the bush. Apply “THREE BOND #1102" to the slide plate for the purpose to pre- vent it from falling, To the slide plate surface apply the disulfide molyb- div grease, 4. To the slide sheave pin do not apply grease.3. Boom Disassembly Procedure (4-Section Boom) 1. Pull out the booms (2), (3), and (4) from the boom (1). BOLT FOR GUIDE pm BOOM IH! \ 000 OXecom /soou BOLT FOR SLIDE PLATE 1) Remove the telescoping cylinder joint (for piping). 2) Remove the slide plate and the guide. 3) Remove the pin (1) Irom the boom (1), and then pull out the booms (2) (3). and (4) 2. Pull out the booms (3) and (4) from the boom (2). ADJUST NUT BOLT FOR GUIDE 800m 12) FOR EXTENDING WIRE ROPE 800M i) BOLT FOR SLIDE PLATE 800M 13 [on 1). Remove the slide plates (side plate and lower plate) and the guide. 2) Remove the adjust nut for the extending wire rope 3) Remove the pin (2) from the boom (2), and then pull out the booms (3). and (42. Pull out the telescoping cylinders (1) and (2) from the booms (3) and (4). ADWUST BOLT TELESCOPING CYLINDER (2) TELESCOPING CYLINDER (1) ROR tee Gwen ea oom (3) | som iat 1) Remove the adjust bolt for the retracting wire rope. 2} Pull out the left and the right pins (3) from the rear end of the boom (3), 3) From the bonis (3) and (4) pull out the telescoping cylinder ass'ys (1) and (2) rearward Boom (3) |_soom ia 14. Pull out the boom (4) from the boom (3). BOLT FOR GUIDE, 800% (3) 800M (4) BOLT FOR SLIDE PLATE 1) Remove the slide plate (lower plate) and the guide. 21 Pull out the boom (4) from the boom (3). EXTENDING WIRE ROPE 800M (4 x Reassenbling shall be made in reverse order of the disassembly procedures, Notes 1, When assembling the pin, apply grease to the insde of its base for rust proof purpose 2. Apply grease 9Chassis Grease No.1) to the inner surface of the bush. 3. Apply “THREE BOND #1102” to the slide plate for the purpose to pre- vent it from falling. To the slide plate surface apply the disulfide molyb- dic grease 4. To the slide sheave pin do not apply grease. x Disassembly and assembly of S-section booms, refer to the above proce- dures.4, Boom Disassembly Procedure (6-Section Boom) 1. Pull out the booms (2), (3), (4), (5), and (6) from the boom (1). PIN iit 00M It) BOLT FOR GUIDE BOLT FOR SLIDE PLATE 1) Remove the joint (for piping) from the telescoping cylinder. 2), Remove the slide plates (side plate and lower plate) and guide. 3) From the boom (1) remove the pin (1) and then pull out the booms (2), (3).(4). (5) and (6) 2. From the boom (2) pull out the booms (3), (4), (5), and (6) Boow (2) BOLT FOR GUIDE an iN (2 BOLT FOR SLIDE PLATE 1) Remove the slide plates (side plate and lower plate) and guide, 2) From the boom (2) remove the pin (2) and then pull out the booms (3), (4), (5), and (6).3. From the boom (3) pull out the boom (4), (5), and (6) BOOM (9) ADJUST NUT FOR EXTENDING WIRE ROPE BOLT FOR GUIDE Pin (3) BOLT FOR SLIDE PLATE 1) Remove the slide plates (side plate and lower plate) and guide. 2) Remove the adjust bolt for extending wire rope and pull out the tip of extending wire rope from the boom (3). 3) From the boom (3) pull out the pin (3) and then the booms (4), (5). and (6) 4. From the booms (4), (5), and (6) pull out the telescoping cylinders (1), (2), and (3), @) pin) 800M (a) Se Oe AUST BOLT SNAP RING. FOR RETRACTING WIRE ROPE Pints) SNAP RING RETRACTING WIRE ROPE ® 15 ® Loosen the adjust bolt at the top end of the boom and remove the wire rope. 2)® From the rear end of the boom remove the left and right pins (4) which fasten the retracting wire rope 3) ® From the rear end of the boom remove the left and right pins (5) which fasten the telescroping cylinder (3) -10-4) From the booms (4), (5), and (6) pull out the telescoping cylinder ass'ys (1), (2) and (3) rearward ‘oom 6) aoom a) \_ soon 18) ya RETRACT TELESCOPING CYLINDER (2) TELESCOPING CYLINDER (2) TELESCOPING CYLINDER (1) 5. From the boom (4) pull out the booms (5) and (6). WiRE ROPE ADJUST 8OLT FOR EXTENDING WIRE ROPE BOLT FOR GUIDE 00M a) 890M (6) 800K (6) BOLT FOR SLIDE PLATE 1) Remove the slide plates (side plate and lower plate) and guide. 2) Remove the adjust bolt for the extending wire rope and pull out the booms (5) and (6) from the boom (4), <=6, Pull out the boom (6) from the boom (5). BOLT FOR GUIDE soos) / 800m (6) / BOLT FOR SLIDE PLATE M10 x18.(7T) 1) Remove the slide plates (side plate and lower plate) and the guide. 2) Pull out the boom (6) from the boom (5). EXTENDING WIRE ROPE 800m (6) x Reassembling shall be made in reverse order of the disassembly procedures. Notes: 1, When assembling the pin, apply grease to the inside of its base for rust- proof purpose. Apply grease (Chassis Grease No. |) to the inner surface of the bush, Apply “THREE BOND #1102" to the slide plate for the purpose to pre- vent it from falling, To the slide plate surface apply the disulfide molyb- die grease 4. To the slide sheave pin do not apply grease. ae5. Procedures for Housing into the Boom the Telescoping Cylinders for 4-Section, 5-Section, and 6-Section 1, 4-Section and 5-Section RETRACTING WIRE ROPE Before housing the telescoping eylinder fit a special too! 10 the tip of the retracting wire rope to prevent it from slackening and house into the boom in the form of the telescoping eylinder assy 2. 6-Seetion For easier housing it is recommended to fit the following tools to the —- ool for(@) Tool fo Tool for © Caution Be sure to check if the left and right retracting wire ropes are crossing each other, and then assemble.3. Detailed drawing of the special tools Special tool tor mstall p the part @ of the retracting wite rope on the sale of counterbian Nut ¥ MATERIAL $881,184 CONTINUOUS THREAD STUD31 Special tool for installing the part C_ of the retracting wire rope (on the side of cha (4-Seetion and 5 ge-over valve) Section boom) Es} Aca DARL? =|) (rHAOUGH HOLE! c SQUARE PIPE (11 2 16» 16) 7 es (-Seenon boom? DRILL 13 fey ea EQUAL ANGLE STEEL (ox 50%45 nur MATERIAL 95411326. 6-Section Boom (Construction of Booms (4), (5) and (6) Simultaneous Extension/Retraction) 1) Booms (4), (3) and (6) are in the retracted state. TELESCOPING CYLINDER 121 ya WIC A soou ) Booms 4). (8) and (6) are in the hall-extended state, 00M «a 800m 15) 800% 6) \_TELESCOPING CY LINGER (3) TELESCOPING CYLINDER (2) 3) Booms (4), (5) and (6) are in the fully extended state, 200% (6) 200M 4) 800M 15) TELESCOPING CYLINDER (31 TELESCOPING CYLINDER 2) ~16-7. Installation Procedures for Slide Plate and Guide 1) Side slide plate and guide 10 suIDE PLATE VV ‘Adjur 0 1.8 ~ 2mm\ iia \ Agist 101.5 suis Notes 1. If the slide plate touches to tight to the boom, adjust with the shim 2. When taking out sitint of the guide a plain washer under che conical spring washer SLIDE PLATE e Of BOLT 12 os. [stun DE PLATE ouIDe Fit wire bracket to this place2) Installing the lower slide plate Py ry \stibe puare SLIDE BASE SOUS EASEE SLIDE BASE 3) Installing the slide plate at the rear end of the boom lupper part) SLIDE PLATE Nowe: Apply “THRE BOND #1120" to the slide plate for preventing ott Inspection of slide plate Measure the thickness of the slide plate and when it reaches se limit, replace He with a new one, Slide plate (thickness in mm) Before use Use limit pe 0 Pa aan i= 9075 t= 708, How to Adjust Wire Ropes for Extension/Retraction (4-Section Boom) WIRE ROPE FOR ExT oe ADUUSTING NUT A apwst Bout \ ADWUsT 801 1. Adjusting wire rope for retraction Ly Retract the boom (3) until it touches the tip of the boom (2) 2) Tighten the adjust bolt oF the wire rope For retraction until the hoom 4p touches the boom (3) Ror RETRACTION [aouust sour Note: When fitting the wire rope for retraction, the WIRE TOYOLOCK (ulloy caulking! shall be fitted so that it will be located at the position as showe in the sbove illustration (100 ~ 130 mm). 92. Adjusting the wire rope for extension 1) Adjust by oxhteni he adjust nut of the wire rope For extension to an eNtent that a gap will not be made between the boom (4) and the sip of the boom (34 (After tightening the adjust nut, be sure to tighten the lock nut firmly. 2) IV the wire rope Hor extension is stretehed 100 tight, te rope Jor retraction would become larger. Therefore, adjust the tension of the wire rope for extension a little slack, x After checking the extension/retraction movement, retract fully and check to see if there is any gap between the tip of the boom (3) and the boom (4), Ifa gap is found, readjust Alter completion of the above adjusting and checking work. lit the plate which prevents the adjust bolt of wire rope for retration from loosening.Adjustment of the wire rope for extension/retraction of 5-setion boom shall be made in accordance with the same procedures as those for 4- section boom. Inspection of the wire ropes for extension and retraction Cheek 10 see if the element wires are broken, If negative is the case. place the wire rope with a new one. Cheek to see if the wire rope is deformed remarkably, kinked, corroded When abnormality is found, replace it with a new one. Cheek the diameter. If decreased amount of the diameter is more than 7+ of the nominal diameter, replace it with a new one. Check to see if the oil and grease applied are proper both in quality and quantity I improper and insufficient, apply enough quantity of proper9. How to Adjust Wire Ropes for Extension/Retraction (6-Section Boom) 1, Adjusting wire rope for retraction » Retract 2) Highton adjust bolts so that the boom (6) touches to the boom ¢5) ane the boonty 4). 43), and (1 }© the tip of the boom (4). \aouusr HOLT 2 Adjust 1) Adiust by tightening the adjust aut of the wire rope for extension to an extent that a gap will not be made between the boom (0) and the tip of the boom «31 and alse the boom (5) and the tip of the boom (4). Utter ti 2) IF the wire rope for extension is stretched 100 tight, tension of the wire cing the adjust nut, be sure 10 tighten the lock nut firmly.) rope for retraction would become larger. Theretare, adjust the tension of the wire rope For extension a little slack AUST NUT ADJUST NUT B00M 16x After checking the exte n/retraction movement, retract fully and check to see if there is any gap between the boom (6) and the tip of the boom (5) and also between the boom (5) and the tip of the boom (4). When a gap is found, readjust GAP BETWEEN 800M {6} AND 600% (5 \ SAP BETWEEN BOOM (5) AND BOOM IA) Alter completion of the gdove adjusting and checking work, fit the plate (Just similar to tie cise of 4-seetion boom) witich prevents the adjust holt of the wire rope for retraction from loosening|. TELESCOPING CYLINDER. Construction {2-Section ~ 6-Section) aa 1. 2-Seetion Boom Telescuping Cylinder 2. 3-Seetion Bow Hh Construction oft Thuescort TELESCOPING.3. 4-Section Boom Dual Telescoping Cylinders 1) Construction of teteseoping eylinder (1) COUNTERVALANGE VALVE 2) Construction of telescoping cylinder (2) TELESCOPING CYLINDER 11) | " Vr i, ee &) TELESCOPING CYLINDER (3) 25 -45S ction Boom Triple Telescoping Cylinders Combinational construction of triple cylinders ® Ol ® \ == U Oo COUNTERDALANCE VALVE 11 Telescoping cylinder (1), Sectional view of Part ® of Selector Valve SELECTOR VALVE 21 Telescoping cylinder (2), Sectional view of Purt ® of Selector Valve 3) Telescoping cylinder (3), Sectional view of Part ©) PLUNGER 265. 6-Section Boom Triple Telescoping Cylinders Comhinatonal construction of COPING CYLINDER 11 \coun SCOPING CYLINDER (2 TELESCOPING CLI WIRE ROPE FOR RETR part ® pant @ x Construction of the selector valve and that of the plunger for 6-section boom (triple telescoping eylinders) are same as those of S-section boom2, 3-Section Boom (Disassembly Procedures for Dual Telescoping Cylinders) 1. Remove the bolt which connects the telescoping cylinder (1) with the telescoping cylinder (2) and separate the one from the other TELESCOPING CYLINDER (11 ) Remove 3 pes. of hexagon socket head bolt from the part 2) Next, remove 4 pes. of hexagon socket head bolt trom the part @ 282. Disassembly Procedures for Telescoping Cylinder (1) 11 Remove 3 pes. of hexagon socket head bolt which fusten the selector SELECTOR VAL HexAGo! THeao aort £4 Remove i lock serew For nut of the slile pipe 4EKAGON SOCKET HEAD SCREW x When assembling, apply LOCK TIGHT Jom the slide pipe remove the nut, check valve, and spring nur SPRING 94) Compensite the revolution stopper of the remove the gland from the tube witht a hook-spanner, and pull out the rod ass'y from the tubs a a. Compensate revolution stopper. Pall out the rod ass'y from the tube (1. $1 Loven the screw which stops revolution of the piston, and take out the IStON From thy Foe ass"y HEXAGON SOCKET HEAD seni When assembling, apply “LOCK TIGHT #242" tothe serew 64 brom the rod ass’y pull out the piston and the slide pipe at the same = =ali ——— —: Piston | supe pie 303. Disassembly Procedures for Telescoping Cylinder (2 HEXAGON SOCKET HEAD SCREW Ly Remove hexagon socket heal lock 2), Loosen the eylinder gover wath a crew for the eylinder cover. hook-spanner x When assembling, apply “LOCK. TIGHT #242" > screw 31 Pull out the rod ass’y from the 4) Remove the lock serew of the piv lube (2 ton, When assembling, apply “LOCK. TIGHT #242 ot GEE nen the piston with the hook4. Inspection 1) Cheek all the parts that they are free of harmful defects for operation such as flaw, crack, deformation, rust, burr, ete 2) Cheek that every part is free of attachments of metal powder. foreign substances. ete 3) Check to see if the piston rod sliding surface is free of damages harmful for operation. 4) In principle, packings and seals shall be replaced with new ones when dis- assembled. However, if these parts are forced to be reused. check very carefully and confirm that they are free of damage and tore stanees, x Assembly procedure is in the reverse order of disassembly. © Check that every part is free of metal powder attachment and then soak the parts in hydraulic oil 5. Adjusting Procedure for Selector Valve with Adjust Bolt | w Pu 4St board to th place 7 3 (Range for tightening) a oro A He" Lock NUT = Adjusting Procedure with Adjust Bolt Ly Put the telescoping cylinders (1) and (2) in the most retracted state. 2) Apply “LOCK TIGHT #262” to the threaded part of the adjust bolt 3) Pat 4 St board to the part marked x and tighten the adjust bolt 4) After adjusting, lock with the lock nut3. 3-Section Boom (Explanation of Dual Cylinder Operation) 1. Just before Extending Telescoping Cylinder Pressure oil enters into the chamber A, and passes through the slide pipe, Then it goes through the check valve (2) of te selector valve and the chamber B too, Finally it reaches the chamber C ChAMBER JAMBER 8 cHame 2. Extending Telescoping Cylinder (1) Pressure oil entered chamber C pushes up the piston (1): and the rod assy (1) extends.3. Estending Telescoping Cylinder (2) Just before the rod ass'y (1) of the telesvoping cylinder (1) reaches its n extension, the stopper of the slide pipe hits the piston (1), and vek valve (1) of Just at the sume time, the both of them are pushed « the selector valve opens. The pressure Dot the oil passes through the passige A sul Band reaches the chambe telescoping eylinder (2), where IDE PIPE PASSAGE A CHECK v esters gisrowaa \ 7 TELESCORING \EYLINDER 12 PASSAGE 8, Chamaen > / PISTON (2) 4. Retracting Telescoping Cylind Through the passage C ef the telescoping eylinder C1) the pressure oil and it enters into the chamb As a result, the telescoping eylinder (2) starts rv ows 2. rf via the passage D and pushes, down the piston (2) acting, TELESCOPING CYLINDER piston (21/ cHamBen €) 34Cylinder (1) Starts Retracti a Telescopi By means of the flow of pressure oll from the passage C the telescoping pidly, Just before revehing the minimum retruc cylinder (2) retracts tion, the spool is pushed by the selector stick locating at the tip of the ck valve (2) opens, when the piston starts to be rod assy CD. und the eb pushed up. The pressure oil in the chamber D flows through the cheek valve (2) and the slide pipe, and reaches the chamber A. Then, it returns to she tank via thy counterbalance ally OER C PISTON) CH PASSAGE C RETRACTION Tew 6. Retraction of Telescoping Cylinder (1) SCOPING CYLINDER 12) _ piston (1) is By means of the flow of pressure oil froni the pass pushed up. and the rod ass’y (1) retracts. When the rod ass’y (1) retracts, the slide pipe returns to ils original position from the position to which passages A and E are shut by il sn the chamber © passes through thy passage band the slide pipe and re- it way pushed up by the piston (1): and ty the cheek valve (1), When the rod ass'y C1 retracts, all of the pressure turas to the tank via the chamber A. In this Way, the telescoping cylinder (1) Finishes ity retracting operation. SLIDEPIPE PASSAGEA CHECK VALVE II cuanpen a FISTON PASSAGE € ia PASSAGE c4, 4-Section Boom (Explanation of Dual Cylinder) 1. Eatension of Telescoping Cylinder (1) coping cylinder (1) is sume as that of The extending provess of the tele into the chamber C pushes up the 3-seetion boom. Pressure oil ente piston (1) and the rod ass'y (1) extends, OD ASS 11 PISTON () cHameen c 2. Extension of Telescoping Cylinder |2) Just belore the rod assy (11 of the telescoping cylinder (1) reaches its Maxime ny estension, the slide pipe is pushed up by the pston (D. and the check valve (LP of the change-over vals opens. The pressure oil enters Into the chamber D of the telescoping cylinder (2), and then the tele scoping cylinder estends PISTON _SLIDE PIPE TELESCOPING CYLINDER 121 enero x63. Retraction of Telescoping Cylinder (2) Through the passage C of the telescoping cylinder (1) the pressure oil Flows in. and after passing through the passage D, it enters into the cham- of the telescoping eylinder (2), and it pushes down the tube (2) ber Thon telescoping cylinder (2) starts retracting operation. Tees “Tose 12 / 4. Retraction of Telescoping Cylinder (1) Telescoping cylinder (2) retracts following the flow of pressure oil from F stick locating at the the passage C. Just before the retraction, the selec Lip of the tube ass'y (2) pushes the spool to open check valve (2 The pressure oil in the chamber C goes through the ehek valve (2), stide pire. chamber A and returns to tank, In this way. the telescoping cylin der (1) retracts CHECK VAL —\— a] | LIOEPIPE CHamoen TELESCOPING CYLINDER \ PASSAGE a Lh 8 Oo f r|| = TUBE ASS'Y (2)5. 5-Section Boom, 6-Section Boom (Explanation of Triple Cylinders) Py tend eylinder is Sune ay that of 4-section cess of the telescopi boom. 4 x. thei chang over operation is conducted by the seleetor valves and they extend in the order of telescoping eytinders (1), (2), and (3). 1, When Extending Telescoping Cylinder (11 TELESCOPING CYLINDER (1! SELECTOR VALVE oe 2, When Extending Telescoping Cylinder (2)3. When Extending Telescoping Cylinder (3) TELESCOPING CYLINDER @) x Retracting operation is in the reverse order of extending, and the telescoping. cylinders retract in the order of (3), 2), and (1). 396. Explanation on Function and Working of Cushion Seal bor the purpose of absorbing a piston shock to the stroke end. the 4-seetion boom hay cushion seal in the part of piston of the telescoping cylinder (2). while the S-section boom and 6-section boom have the cushion seal in their ylinders of (2) and (3) eleseopi 1. Flow of Pressure Oil When Retracting Cush.on mechanism of the telescoping cylinder (2) for 4-section boom and that of the telescoping cylinder (3) for 5-section and 6-section booms 1) In the retracting process, before the piston gets in the plunger. the pres sure vil 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 CHAMBER'A SUSHION SEAL CHAMBER A. \ pLuNcen 2) At the same time when the piston gets in the plunger. the ehamber Ais cloved with the cushion seal @. As a result, the pressure il in the cham ber A is forved to return only through a drilled 61 hole in the state of being squeezed. Thus the piston shock at the stroke end is absorbed CUSHION SEAL SNAP RING oETAN@ INSTALLATION DETAIL OF 403) Cushion mechanism of the telescoping cylinder (2) for 5-section and 6. section booms SQUEEZING PART 2. Flow of Pressure Oil When Extending 1) When extending. the cushion seal @ is pushed to the snap ring side, and the pressure oil flows into the chamber A without being shut as shown in the illustration. In this way, the telescoping cylinder extends, (@ —cusmion sear SNAP RING petal @ 2) Cushion mechanism of the telescoping eylinder for S-seetion and 6 section boom is to squeeze the return pressure oi at the position just be- fore the end of extension and absorb the piston shock to the stroke end, / ctano / 4-Cause of Troubles and Remedy |4-section boom) Just hefore the full getraction of the booms (3) and (4), and before He over {0 Ihe boom (2), i ¢, 30 ~ 40 sim betore changing over to the boon (2), reteueting operation has suddenly stopped. In such a case, itis presumed that some Foreign substance clogged a drill hole at the posi- tion @ of jhe plunger of the telescoping cylinder (2). PLUNGER \\ TELESCOPING CYLINDER (2) (S-section, 6-section boo s} When retraction of the boom (3) becomes impossible at the position just belore full retraction of the booms (4), (5) and (6), inspect the plunger astuchh is assembled in the telescoping cylinder (3), When thy own (3) doey nol change over to the boom (2), and retraction becomes umpossible at the position just before Full retraction, inspect the Uriled tole at the pesition ® of the plunger of the telescoping cylinder PLUNGER4. Cause of Troubies and Remedy Aust BOLT es 1) 3-section boom (Dual eylinders) Abnormal phenomenon Presumed cause Remedy 1. Retraction i normal. |) The part @ ofthe selector | « Disasemble selector valve but extending operation | vale is clogged with forego] "and clean i, or relace and sequence are not in | substances with anew one ‘good order, 2, Extension is onal, | a) The part @) ofthe selector | » Disassemble selector valve barre opeaion |“! ue ged wa eg) “anemone ain sequence are net in| Substances wiht now One a good order, bb) Snap ring af the part @ __j « Rearrange snap ving. ot out of place. 5. Hoom (2yextends but | 4) Nut at the slide pipe of | # Disassemble telescoping Thou (3) does not telescoping eylinder (1) |” eylinder (1) and tighten extend loosened. the nut 4, Alter fullextension of | 8) Adjust bolt pushing the | Adjust the bolt. twvoms, boom (3) e- spool of selector valve | «Straighten bended stick (eaets but boo (2) does| loosened or the stick was wot retract bended by Selector valve spool (1) | Replace selector valve was bended as'y with a new one 432) S-seetion boom and 6-section boom (Triple eylinders) Abnormal phenomenon Presumed cause Remedy T Reva aonb) 3) Song pregn stasis | «Diasenible sector he sthenextending booms |” clogged the pant gy ot" | “amielean itor replace THGnectgarthe] Skoreheareee | amhaatatane te? Smee, nanother "| seoping cylinder (1 word “disorderly.” 2, Extension normal: but | @) Some foreign substances ‘sen retracting, booms | clogged the pat @ of (SIcCA.C3)and(@)re- | selestor valve of fee tractat samme, | Scoping cylinder 2) snlanatver word "dis tdery 3. Extension isnonnal: but | a) Some foreign substances | » Disassemble selector vale ‘shemetracting booms: |" logged the pars @) of | and clean itor replace (rah (Sanhce? | kona ee sith enew one tractatthe same time. | Scoping cylinder invanotheewordds- | b) Sip neat the part © | Reurange snap rng orders selector valve of tes scoping cylinder (2) Bot out of place. 4, Extension is normal: bat [ a) Some foreign substances: when retracting, booms |” clogged the part @) of (2yand (3) rettact atthe | selector valve of tele sme tne, in another scoping cylinder (1) wor “isorderly by Snap ing atthe part fof selector valve of tele scoping cylinder (1) got out of place, 5 Boom (2) extends, but | ay Nut at slide pipe of tele. | « Disassemble telscoping oon (3}dves noi ex- | scoping cylinder (1) splinder (1) and tighren tend Toosened. the nat 6 Booms(2)and (3)ex-_ | a) Nut at slide pipe of tele- | « Disassemble telescoping rend, but booms (4), (5) | "scoping eylinder (2) cylinder (2) and tighten and (6} do not extend loosened. the nut, 7 Alter full exiension, — | a} Adjust bole pushing the | «adjust the bol. bnooms id). t3}und (6) |" spookof selector valve of | ¢Replece selector valve retract but boom (3) telescopmg eylinder (2) | “ass4ywich a new one, toes not retract. loosened, by) Selector valve. spool of ielescoping cylinder 2) ‘was bended S. Booms (31,14), (5) nd] ay Adjust bolt pushing the (6) retract but boom (2) |” spout of selector vaive of oes not retract. telescoping cylinder (1) loosene y SEI ae spool of telescoping cylinder wosbended.” Caution; During operation test after disassembling and reparing, the phenomenon that the booms (4), (3) and (6) stop extending halfway is presumed that the left and right wire ropes for extension were crossed when reassembling. As to the 4-section boom check the cause of troubles following the procedures for Sec: tion and 6-section booms. 4484. BASE 1. Construction of Base HALF-TONE AREA IS | HyORAULIC O1L TANK SUCTION FILTER INNER BOx Uren checking oil quasi, cap Dur hot sere gauge in Gauce vote UPPER LIMaiT LOWER LiMarT enor Standard oil quantity isthe midale a between upper and lower litits of oil ene i When checking quantiy, just put the cap on the oil inlet but not screw the gauge in. 45-2. Construction of the Base (Differential Type) HALE-TONE AREA 1S HYORAULC OIL TANK on weer HON FLL TER \ inner 80x Pr — (if \ UmPER LIM LOWER Lint fren / DETAIL OF @ FILTER FITTING pera. or © Standard oi! quantity is the middle between upper and lower limits of oil gauge When checking quantiy, just put the cap on the oil inlet but not serew the gauge in. ~ 463. Construction of the Base4, Construction of the Base (Differential Type] HALETONE AREA IS HYDRAULIC OIL TANK | CYLINDER FOR HORIZONTAL OUTRIGGER | \ nen Box5. Construction of the Inner Box Extension Cable Installation / an ‘ONe-ToucH Leven @) \ INNER 80x CONSTRUCTION OF INSTALLATION one-rouce LEVER - 49 -6. Construction of the Inner Box Extension Cable Installation (Differential Type) SY ONE-TOUCH LEVER @) (CONSTRUCTION OF INSTALLATION \ \ caste so7. Construction of the Inner Box Extension Cable Installation NNER BOX ONE-TOUCH LevER @) ® one-rou8, Extension Cable Installation Procedure 8) NER BOX ) Stopper Pin ® Inner Her cables are connected to the stapner pi OUTER CABLE INNER CABLE STOPPER PIN 2) Onestouch lever side ® Conneet outer cable COLLAR Ax shown im the above illustration, fit 2 pes. of collar and tix the outer cable by tightening the nuts. 3) Fit.a boot to prevent entrance of water, dust, ete INSULATION Lock TIE10 the one-touch lever. cable to the lever, pull the inner cable with a thin nose plier to tie position where the stopper pin starts to move. At this 4) Fit the inner cable For fixing the ini position fix the vable with an MS x 88 bolt STOPPER PIN, Note: Tighten firmly the bolt so that the cable will not come off After connecting, pull the lever and check to see if the Lip of the stoppe pin is in the state as shown in the below illustration. Lt x Caution: When the lever is pulled, the tip of the stopper pin must not be protruded or retracted (o0 much from the bottom face of the inner box. \ storren pin Lever isin the state of 9 pulled 39. Piping to Outrigger Cylinder SB) out in ® @ Pring a joint biock ~ ] isPeciri (SPECIFI Arion CATION! _ s 4 Caution: When connecting high pressure nylon hose, take special care not to twist the hose. Also when stretching or retracting outriggers, the hose Should not be rubbed with the inside wall of the box x Tightening torque for the nut to fasten the band Tightening torque: 3.6 ko-m10, Piping to Outrigger Cylinder PILOT CHECK VALVE out Caution: When connectin; high pressure nylon hose, take special care not to vist the hose. Also when stretching or retracting outriggers, the hose should not be rubbed with the inside wall of the box.11. Pulling out Order of Horizontal Inner Box CONNECTOR BOLT Ina10 x 20) sont suoex 3) Remeve 2 pes. of ear © 4) Pull out the inner box and put the bolt position of the stopper upon the part @ hy 5) Remove 2 pes. of hexagon socket head bolt (MIO x 25) which fasten the stopper 6) Take out the stopper throu the window of the side plate. 7) Carefully pull out the inner box so as not fo damage the hose — STOPPER12. High Outrigger 1. Horizontal Type Inner Box Hydraulic Pressure Stretching Construction BASE MAIN BODY. SOMZUNTACOUTmicoeR cvuiNoeR/ —_onizonTat nen sox/ ‘uling Out Order of Horizontal Inner Box bs Ly Remove 4 pipe connectors @ 2) Pull out the pin which fixes the horizontal cylinder © 3) Pull out the horizontal inner box. {nstallation of pilot check valve3 Olinder OUTRIGGER CYLINDER IVERTICAL! OUT —— aN 7 eae LINDEA [HORIZONTAL! OUT OUTRIGGER CYLINDER VERTICAL! N. Tins photo shows that the horizontal ylides asgembied in the inne box.§5. OUTRIGGER CYLINDER 1. Construction of Vertical Outrigger Cylinder Before fitting the dust seal apply grease. | Geease: Mdemitsu Daphne XC2-1 or its equivalent \ \,\\Mexacon socxer 3uAND / TUBE Assy \ Roo assy (EM HEAD SCREW \ piston Note: Belore fastening hexagon socket head screw for piston, epply “LOCK TIGHT #2427 (After applying, do not flow hydraslic oil for about | hours 2. Construction of the Part where Pilot Check Valve is Fitted TUBE ASS PILOT CHECK VALVE jut [EXTENSION (RETRACTION! PILOT CHECK VALVE ASS'Y ImoDeL: oP. 03F) ”3. Construction of Vertical Outrigger Cylinder »HEXAGON SOCKET HEAD SCREW _GLAND CYLINDER cov HEXAGON SOCKET use assy HEAD SCREW PuLoT vaLve., ROD Ass" Note: Before fastening hexagon socket head serews for the eylinder cover and piston, apply “LOCK TIGHT #242." 4. Construction of the Part where Pilot Check Valve is Fitted PILOT CHECK VALVE IEXTENSION) (RETRACTION Tuee ASSY 7) PILOT CHECK VALVE ASS'¥ MODEL: cP-02F1 605. Construction of Vertical Outrigger Cylinder (High Outrigger) MHEXAGON SOCKET HEXAGON SOCKET DOUBLE FILOT HEAD SCREW HEAD SCREW CHECK VALVE Note: Betor piston, apply “LOCKTIGHT #242." fastening hexagon socket head screws for the eylinder cover snd Deal of leat spring fitting LEAF SPRING Before fosening apy “LOCKTIGHT” 7 Costruction of Pilot Check Valve (CP-036) (EXTENSION! RETRACTION! po seue PLOT HECK VA / gousce eicot (EXTENSION) (RETRACTION! 616. Construction of Horizontal Outrigger Cylinder CYLINDER COVER Revolution stopper of gland: Alter tightening the gland, fold # part of the cylinder cover flange to the side of the gland, cuano_/ vera ot @ -62§6. SLEWING DEVICE 1. Position of Soft Zone “S” on the Turntable FRONT SIDE © When mounting the turntable, the inner soft zone marked “S* on the turntable must be positioned on the rear side (cargo deck side 2. Tightening Order of Turntable Bolts © Tighten the bolts in the numerical order as shown in the above illustra 633. Turntable Mounting Procedure suanTapLe FEVOLUTIGN STO} tuate! ae pinion GEAR TURKIABLE 3011,/ ase wain 8007 TF sin neue GEAR ASS'Y Ly Install the slewing reduction gear ass'y to the buse main body. 21 Mount the tumtable on the base and screw lightly the turntable bolts in the base main body ~ 64ance gauge (0.1 ~ 02 mm) into the space between the strongly the turntable to the 3) Insert the turntable gear and the pinion gear, and pre CLEARANCE GAUGE PINION GEAR TABLE 4) Fusten turntable bolts following the specified tightening torque and the nuinerical order so that it will not part from the pinion gear } After tightening tuntable bolts, fold the inside square corner of the re- to follow one flat side of the hexagon bolt head. velution stopper pla 6) Alter assembling, apply grease 10 engaging tooth surfaces of the gears.nthe ) Insert the clearance gauge (0.1 ~ 0.2 mm) into the space betw: turntable 1d press strongly the turntable to the pinion geal arand the pinion CLEARANCE GAUGE, 4) Fasten turntable bolts following the specified tightening torque and the numerical order so that it will not part from the pinion gear. bolts, fold the inside square corner of the re volution stopper plate to follow one flat side of the hexagon bolt head 5) After tightening turntabl 6) After assembling, apply grease to engaging tooth surfuces of the gears.4. Tightening Torque for Bolts Fastening Turntable and Slewing Reduction Gear cumin WET sours o FOR TURNTABLE ~ BOLTS FOR SLEWING. SLEWING ReoUCTION GEAR ASS Place of use Tightening torque viog | Slowing reduc. | Tempered nolt 15~ 19kgm UR220Seres "Non year | M14x400 (107) | (Desired value: 17 kom! Turntable ~ 39kgm UR250 Series, (Turntable eee eraY Seer 1B x75C(12T} | (Desived value: 36 ka-m) __ inna) 7 oo | Siewing reduc: |” Tempered bol 16~ 19kgm tion gear | MI4'x 88 (HOT) | (esived value: 17 kon) R200 Series — * on | Turrets | Tempered bol 45~51 kom (Tunable yd 75€ (HOT) | (Desired valve 48ka-m) 7 Slewing reduc- | Tempered bolt 29kom | Rh es D MIS x50€ (10T) | (Desired value: 26 kgm Turntable fanape Temperes bolt 45~ 51k a M20 x 920 (12T) | (Desired value: 48 kg-m) Siew eauc | Tempered bolt 33 29k50 tion gear M16 x 50(10T) | (Desired value: 26 kg-m} aso0 sanes == ——— Hoe 28 kant | Tucble | tempered bok 45~S1kom (Tarmable | zon 95127) | (Desired value: 4Bko mi Note: The bolts for the turntable (tempered bolts} must be UNIC genuine bol, on the head of which “UNIC 10” or "UNIC 12" is inscribed. = 665. Numerical Tightening Order of Turntable Bolts When tightening. follow the below illustrated numerical tightening order. Model URSOO Series 69 ~6. Tightening Torque for Bolts Fastening Column COLUMN main BODY Bouts FOR COLUMN \ quantas.e Part Na Mods! | Pee of we unaa0series ) C20" | Tempered bor | 23~27 kgm R250 Series | (Tuma | igiesoe i2ty | (Desved value: 29 kom) | Gouna | Temosred bot 23~ 27 kgm Urano sim | an | TOMES 9 eS I Column 7 Lr _ | Mlurmable | ign S08 G27) | (Oesied value 23 kgm) Came Temoered bot 52~ 364g (rurmisble MJHE x SSCITOT) (Desired value: 34 kom) Note: Betore tightening the bolts for column, apply "LOCKTIGHT #262.” Numerical Tightening Order UR5OO Series§7. SLEWING SPEED REDUCER 1. Construction GEAR SHAFT TAPER Ai DUST SEAL, )- BEARING HOUSING CASING WORM WHEEL BREATHER SNAP RING CROWN NUT 092. Speed Reducer Disassembly Procedure 1 Remose a snap ring (IEKO) which retains the taper roller bearing whieh urn the Shalt counterclockwise, pull out the worm shaft from the caning. 1Use af special tool for removing worm shaft is recommended.) page 73, Remove 8 pes at bolt (MIO x 25@) which fasten the bearing housing tnd pull out the housing, utilizing 3 pes. of bolt for 3 through holes in4. This photo shows the pulled out housing with gear shaft and worm wheelPull owt the O-ring which is assembled in the nut S. With a pin spanner remove the nut which retains the laper roller bearing. Note: Io the threaded part of the nut “LOCKTIGHT™ was applied. There for. when loosing, warm up lightly the threaded part with gas Mame, and then loosen. When reassembling, be sure to apply "LOCKTIGHT #262" to the threaded partSpecial 1o0! for removing the worm shaft from the slewing reduction gear (Sectional view of worm shaft in assembly) CASING 8 ous PLAIN WASHER, NUT ANG se_ KEY MATERIAL, B3, Precautions When Assembling Slewing Redui DUST SEAL: Apply "THREEBOND #1401 vz BOND S10 eee Flt up with grease, GEAR SHAFT x Grease, Lithium soap radical (Example: Kyoseki Rizonix Grease No.1) NUT: Before tightening, apply “LOCKTIGHT #262." Note: Tightening force of the nut shall be equal to the extent that the gear shaft can be rotated clockwise as well as counterclockwise with both hands, Reference tightening torque: 1.7 ~ 2.4 kgm (Desired value: 2kg:) 2 Apply grease 10 the inside of lip of the dust seal GREASE ~ oe D 3. When sssembling, be re (0 have the side with the “V" face up. ®V" MARK ON THE UPPER SURFACE —_WoRM WHEEL4, Bolt Tightening Torque for Bearing Housing BEARING HOUSING BOLT FOR HOUSING Model "Place of use Part name Tightening torque R220 geigg grmatatonet | temperevor | 2~4 kgm Unaso Sees Slewnavese | eee TION) | Oesied vale kgm inwatatonct | yempeagon | baawm UR290 Series Slewing reduc- empered bol 7 ies Sepenees,. | melaot ior | bestest ko R990 geieg | 4malaton ot | remmpeadt vote 5 Tham URI60 Se sea nousne | MIOx25@(7T) | Desired value: 6 o-m reco sees | Qategel | ramoweason | = 7hom | | | Seammyemue | gOe280(71) | Desves value kgm Note: Betore tightening tempered bolts, remove ail or grease {rom the bolts, and then apoly “LOCKTIGHT #262" Gear Oil for Speed Reducer ‘od API SeiceGsiiction vanity of Gear GI UR220 i: - ~| URE eres | GLA x00 KyowtiP Ger Yo0 | Apex 09 es R290 Sens | GLot #00 Kyowki Gear YOO [Approx 0.3 iw "EIRP seues_| GL #50 Kyosho YOD por. 07 Wer UR5OO Series __GL-f #90 KyowtkiP Gear Y90 ‘Approx, 1.05 iter a5)§8. HOIST WINCH (SILENT WINCH) 1. Construction of Winch EAR (a) SEAR ean (2 2. Construction of Brake Brake shoe iy pat in the space between the gear (2) and ratchet wheel. and also in the space between the disk and ratchet wheel, Ratchet wheel can free hy be rotated as long as the direction of rotation is winding up. However. when lowering, rotation is stopped by a pawl, and the gear (2) is pressed against the ratchet wheel through the brake shoe. Thus, the brake is applied nn the lowering direction RATCHET WHEEL BEARING a RATCHET BRAKE SHOE OW sea mel HOISTING UP DIRECTION SeLiT PIN ~. castue NuT PLAIN WASHER | seaming — PAWL \ isk RATCHET WHEEL EAB 2, 16Explanation of Operation (When hoisting up) When hoisting up, the gear (2) is rotated clockwise. As the gear (2) and gear shaft are enguged each other by left-handed serew, gear (2) moves toward arrow (+) direction and is pressed against the ratchet wheel Ratchet wheel is free during clockwise rotation, and accordingly both the ratehet wheel and the gear (2) are incorporated in one solid body. (When lowering) When lowering. the gear (2) is rotated counterclockwise, and it moves arrow (=) direction against the gear shaft. With the ratchet wheel being locked on, the gear (2) is lowered in the state that it is parted from the ratchet When lowering speed of suspended load is faster (han that of motor. the gear shalt sy forced 10 turn counterclockwise and as a result the gear (2) is moved towards arrow (+) direction, and is pressed against the ratchet wheel. Be- cause of this reason, suspended load will not fall Only when the gear (2)is rotated by the gear (1), the gear (2) parts from the ratchet whee! and lowering can be conducted. SEAR (2) separates hom RATCHET WHEEL -1-4. Construction of Reduction Gear AATCHET WHEEL PAM Geant) _voist woroa Paw! and bush at @ are one solid body, and with the force of spring itis ah ways pressed against the side face of the gear (1). Accordingly. the pawl ro- tates following the rotating direction of the gear (1), (When hoisting up) A ° RATCHET WHEEL” When borsting up. the pawl i moved towards parting directing from the ratchet wheel, Theretore. ratchet wheel d ot Hit the pawl: andl weeordling(When lowering) ET WHEEL When lowermg, the pawl is pushed towards the teeth of the ratchet wheel and engages. Lowering rotation of the ratchet wheel is stopped by the pawl, and lowering speed is braked to a fixed and constant one with a brake shoe5. Bolt Fastening Reduction Gear Casing Bolt locating at the upper right of the reduction geur casing is a set bolt for Other 3 pes. are heagou socket head bolts. Oecd Set bott eo = Hexagon socket head bolt 3 pcs positioning the casi Note: Tightening order of bolt: Set bolt for positioning is the first, and then n socket head bolts diagonally. 6. Gear Oil for Reduction Gear The air gous in and out treely the inside of the gear case, and accordingly, water and dust are mixed in the gear oil. Also the gears themselves produce abrasion powder during operition, Therefore, make initial gear oil change at the Lime 6 months after the first use, and thereafter, make gear oil change one every 2 years, Classification of API Service Quantity of oi GL-4 =90 Aporox. 0.8 liter \When shipping fram the factory, the gear ease (0.9 liter for new rane} 's filled with Kyoseki EP Gear Y90 807. Brake Shoe Adjusting Procedure RATCHET WHEEL, BRAKE SHOE aust SPLIT PIN \ CASTLE NUT \ BEARING isk Assemble in the order of gear (2), brake shoe, ratchet wheel, disk, and plain washer: and tighten castle nut with a spanner, Then loosen the castle nut for 1/6 turn and within this range mateh the hole for split pin in the gear shaft to the groove of the castle nut; and fix with the split pin. 1f tightened too mach, it may ewuse hunting -81-8. Cause of Troubles and Remedy Hoist Winch Abnormal phenomenon Presumed cause Remedy [1 Pressuce dues nov rise,| 3) Pumps faulty, | + Replace a (Pressure does not rise at ‘ling cpm.) (Total pressure requited for operation is insufficient) “Gy Rell set oF conte valve is faulty (Peessute ses but not wou) 4) O-ring and other parts of Tphdjuat oF replace replace Replace parts: relief valve of control valve | relief ass'y with 2 new are faulty ones, (Adjust bolt of relief valve is tightened but unable to oReqiase. (Quantity of drain is small- _“eethun specified one.) Disassemibie redu hoisting up is impossi-| nism of speed reducer is | « Inspect the drum, aa fauy Pressure rises but low- a) Drum or internal mecha- | » Too much tightening of fering is impossible. | nism of speed reducer is |” brake shoe fauky. + Disassemble reduction gear. Inspect the drum. 4 Unable te maintain Ya) Brake shoe faulty * Replace brake shoe suspended load bb) Pavel is Faulty, # Replace paw oc is faulty. |e Inspect brake shoe and check quaatity of cil ‘© Agjust tightening of nut brake shoe «Internal mechanism of | «Disassemble reduction gear. sed eeducer ful % Ting wp.) Spring to press the pawl «Replace spine chiterngsound is against sie plate i faulty heard | by Bush atthe part oF fiting | « Replace bush paw! worn out§9. SWIVEL JOINT 1. Construction of Swivel Joint and Positions of Hoses (LOWEPING): i if Ng oh —— al, 2@Os Qo \ noisr cou) Photo shows Swilvel Joint is installed 2) Photo shows Outer Joint is taken out INNER JOINT ouTER JOINT SNEED proms 842. Swivel Joint Assembling Procedure © Alter fitting the sqstore ring, cheek to . see if it is Owisted, then Tit the seal x When fitting seal ring, itis recommend: ed to use the jig as shown below Iilustration of STK See! fitting 2 ROUND BAR] LBPIPE CLINCHED, @ The upper most @ and the lower most @) of the inner joine must be filed ap with erease © To the part where STK seal i to be se thinly fitted apply chassis er © Put the outer joint over the inner joint taking are that the STK seal fitted to the inner joint will not be bit 85$10. SLIP RING 1. Construction of Slip Ring and Its Fitting Position, FEMALE SLIP RING Beloresghtening cross-recessed panhead sere, sooty "LOCK TG #272 SWIVEL JOINT v0.82 21900 ¢ (neo$11, DERRICK CYLINDER 1. Construction HEXAGON SOCKET HEAD SCREW ‘Apply geste tothe groove Grease shal be “Ideitea Daphne XCZ-1 sHEXAGON SOCKET STUBEE \asrou ween Note: Before tightening hexagon socket head screws to the piston and gland, apply “LOCK TIGHT 2242." (After applying, do not flow hydraulic oil) 2. Disassembling Procedure 1) Remove the counterbalance valve 2) Compensate rotation stopper of the gland and then loosen and remove it from the eylinder tube, Puil out the piston rod. 2) Remove hexagon socket head serew which stops rotasion of the piston Pull out the piston trom the rod ass'y. piston —\GLANO$12, CONTROL, ROLLER CONTROL VALVE on pecninarvALLEy Photo shows the side the roller sinstalled. Photo shaws the side the contro! valve is installed Both the left and the right outriggers shall be installed to the control rod. Fit the plates (o the where the roller is touching. Within the range of spool stroke. the engine revolution can be accelerated.REFERENCE ROLLER DETAIL OF @ When ssemuling et she ciearance betwee PLAIN WASHER coven \ ou ock wurs LEVER ASS'Y When nealing DETAIL OF © Installation Procedure ) When installing the lever ass’y. tighten the double lock nut so that the plain washer is pushed into the place 3.5 mm inside trom the ead face of the cover. 2) Then tighten the lever ass'ys until it reaches the double lock mut Caution: If the direction of the lever is not proper, loosen within one revo- lution and tighten the double lock nuts with the tightening torque of 10 kg-m and up. 891a, 01 1990U09 t (al ich | , / fe : ; ele eft WA1SAS WEvIV “ELS| Nuon roman voave L may ave, $2409 2) NIU ars QW TONDHOM "A108 fo moa = 2 oP) 7330 a409 | NYO JTOIHIA o. Oe ginleia eatwousrvounsanrownon — TP Ga | Lg. = - -—— Ei iL fit cae | | aoe EDD owe tet | Iyo19a13a) wawTy ONIONIM3A0 LQ | Ya3u quod | 4oxoaasns i HOLIMS H¥39 asuange (A008 SwioNnos) ven iy ONIONIARYS AO wes6erg BULIM °Z ava \ aaa iz g Zz eb e toawissz TROD Waa FKISaWTE aivia sve aanpasoig Bumpers youMg uoung-ysng “L 91 -30IAag ONIMSTS. 3ONITAD ONIdODSITaL 089 AIA SONVIVEHSINNOS YOLOW LSIOH t ¥30NITA9 NaD9IHLNO. — FR, es NIWA SONVIVEUBINNOD BN WA wORHD LOE Puepurig sug YN *L LINDUID SFINVYGAH “PLS$15. CONTROL VALVE (MODEL: MV-30A) 1. Composition of Valves and Inscribed Mark on Spool rpont weaie) Pe | ITeLescoring evunoen I s.ewine oevice 3 ric ourriccer {<= LEFT OUTRIGGER TAT is \ ne.n0o a eto ughening ore: 280 :25.49em M0 pe Midler x Control valves control working of every actuator of crane. The spools assembled in the control valves are different each other uecording to respective actusitor 942. Relief Valve (RT-15C) The reliel valve isa preventive valve to control the pressure in the hydraulic circuit would not become higher than specified pressure. 1. Construction of Valve PRESSURE CIRCUIT ADJUST BOLT cap MAIN SPRING ii Tony —— —_— sci ~_Pnessune cincuIT PILOT SPRING _/ | /nestRictinc| HOLE IRESTRICTING HOLE euotvacve _/ _vomrice) | /mainvacve \_tonirice) 2. Adjusting Procedure The hydraulic pressure in the relief valve is decided by the movable al lowance of its adjust serew. For adjusting the pressure, loosen the cap and mut, and turn the screw clockwise with a (~) driver to increase the pressure. while on the contrary turn the screw counterclockwise for reducing the pressure. @ When setting up. Be sure 1o wateh the pressure m: © Alter setting up Be sure to tighten the nut and the cap securely $0 us not to be loosened, When lightening the nut and the cap, hold the screw with the (~) driver 4s it is feared that loosening of screw is apt to happen while tightening, er. Caution Engine rpm at the time of setting up the hydraulic pressure should con- form to the rated revolution of the pump, which is 1600 rpm. Never set up the hydraulic pressure when the engine is running at idling speed or high speed. 95 —3. Explanation of Meter-in/Meter-out Spool ) Meterin AAs shown n the aboxe illistration, the hydraulic oil sent from the pump Hlows through the high pressure Feeder passage P and is restricted at the spool notch @ and sent to the cylinder. Returning oil in the eylinder will be sent back (0 the tank without being restricted at 8 In this way the hydrali oil is restricted at the *IN* side of the actuator. Meter in Spool The meterin spool is fitted to the cylinder circuit. IV the inflow oil speed is higher than that of return oil, the internal pressure in the tube would become hivher and there is a fear That the internal pressure may expand the tube. Therefore, start time of return oil from the cylinder is set faster than that of inflow x Thus. the meterin circuit spool is assembled in the control valves of the telescoping cylin- ler, derrick cylinder and outrigger cylinder. 96Meterout Circuit a =] a i“ won) \ yx @ “‘Vvawvecon, 8) As shown in the above illustration. the hydraulic oil sent from the pump is sent 10 the motor via the high pressure feeder passage P without being restricted at @ . Return oil in the motor is restricted by the spool noteh at B and Hows back to the tank, Thus, the fydraulie oil is re stricted at the “OUT™ side of the actuator, # Meter-out Spool cs The meter-out spool is fitted 10 the motor eit- ai Wipeout ee Stn tol od st sel caim iensor tc ota al nyse ere - rtcintaeareamartenemers — (SKEEER] setstower than that of inflow oil, Tt x Thus the meter-out circuit spool is assembled in the motors of the hoist and slewi device. uu Be _97H Series x The construction of the spool for High Outrigger (H) Crane specifica: tion (outrigger cylinder, telescoping cylinder, and Di-Co valve} is shown in the below illustration cap SCREW SPOOL END Nostawe } Note: Before assembling, apply “LOCK TIGHT #242" to the th part of the cup serew and spool end. + How to remove the plug from the inside of the spool soo. eno / [ewe — \ onine 153) 570 1) Remove the cup serew and spool end Belore removing soak the spool in the 80°C of up hot water for about 10 minutes because “LOCK TIGHT was applied 10 the various parts 24 Pull out the plu Plug is thresleal with M3, so use a screw driver for removing 98§16. COUNTERBALANCE VALVE 1. Construction of Counterbalance Valve (for Derrick) \ coUNTERBALANCE VALVE MARK D / \eTscrew MODEL (CB-03€0) 2. Construction of Counterbalance Valve (for Telescoping Cylinder) ve The counterbalance valve For telescoping cylinder has a wire in the part @) shown below (10 prevent hunting when the telescoping cylinders retracted) ne oni 0s) DETANL OF PART@ MODEL (C8-03ET) 99 —3. Explanation of Counterbalance Valve Operation 1 Extend vylinder CHECK VALVE | eee In extending the cylinder, the oil Nowiny out of the control valve pushes the cheek valve in the of the cylinder, The oil in the retracting side of the eylinder ows lircetly through the subplate to return fo the tank: ounterbalaney valve to ler the extending side The oil in the exteniling side of the eylinder Hows pushing the check valve that is pressed by a spring, so it will not Now back even though thy loud should apply a eylinder retracting force. Ww clivek valve was not used here, the oil in the extending side of the cylinder would Mow buck due to the load applied to the cylinder the homent the cylinder started to extend (when the spool of the control valve hewn to open), thus retracting the cylinder instead of extending it 100 -Retracting Cylinder L onirice [oHAMBER A TE In retracting the cylinder, the control valve changes the direction of oil flow to the retracting side of the cylinder through the subplate At the same time, the oil flows into chamber A through the orifice in the valve IF the spool does not move, the oil in the extending side of the tel ing cylinder is blocked because the circuit is closed by the check valve und the check part of the spool But, because ail flows from the control valve to the retracting side of the cylinder, the pressure on the retracting side increases, and the oil in hack of the spool {in chamber A) combines to generate a pressure high- cr than the spring pressure to move the spool to the right. Thiy results in a clearance between the valve body and the check part of the spool. through which the oil in the extending side of the cylinder flows through port P back into the control valve. der is so designed that the oil in the extending side will not sscop- Now unless the pressuire of the oil flowing into the retracting side of the cylinder reaches a specific level. So the cylinder will not suddenly retract in the event of damage, through the load remains suspended lor$17, DI-CO VALVE (DIVIDER-COLLECTOR VALVE) DI-CO VALVE, 1, Construction of DI-CO Valve The DCO valve isa hydraulic mechanism combining the functions of a di: vidler valve aud collector valve, and i used in simultaneously extending or elructing the fight and left high-outriggers. TOCONTROL VALVE MAIN SPOOL SUBSPOOL SPRING i U © LI \cover [OUTRIGGER cvLiNDER (OUTRIGGER eYLINDER, 1022. Explanation of DI-CO Valve Operation 1. Extending The DE-CO valve operates as a divider valve as described below fers chamber a through port 1. flows from the center of the subspools to the right and left, and via orifices b and ¢ to passages Pressure oil ¢ A and ¢. from which the oil flows through passages f and g to ports and 3. Chambers and B are connected 10 chambers b and ¢ through sinall holes hand i If the resistance of port 2 increases to be greater than the resistance of port 1. the pressure on part 2 increases to reduce the pressure difference between chambers a and b so that the flow of oil to port 2 decreases. Thus. the pressure oil passing orifice b reaches chamber A. and the pres: sure inside chamber A in creases. When a pressure difference arises be- tween chambers A and B, the pressure oil in chamber A pushes piston H up {© move the main spool to the right. AS a tween passages # and © narrows to reduce the flow of oil to port 3 until there is no pressure difference between ports 2 and 3. AL this point the ruin spo! stops. and oil is supplied to ports 2 und 3 at the same rate. esull, the clearance be- _——— CONTROL VALVE MAIN SPOOL 1GEC ‘CHAMBER C ORIFICE » CHAMBER » PISTON H ae OUTRIGGER CYLINDER: OUTRIGGER CYLINDER Passat 103 — CHAMBER @1 b a 4) 2 Retracting The DI-CO valve operates as a collector valve as described below. Pressure oil Mows from ports 2 and 3. to passages Uo and © via passiges fund g 0 move the right and left subspools to the center The oil then flows from passages f and g into chambers b and ¢ via passages d and ©. und to port 1 via orifices b and ©. When there is 1 resistance difference between ports 2 and 3, the valve operates in the same way as the divider valve to supply the oil from port I at the sunie rate CONTROL VALV: suBsPooL SUBSPOOL ‘OUTRIGGER GYLINOEA (OUTRIGGER CYLINDER, CO Valve Handling Precautions When mounting the valve, make sure that the spools inside are level Ir gither port 2 or port 3 is closed, the other port is also closed to block oil flow Completely vent air trom the piping, ete Belure correcting errors in the synchronized operation of the outr r cylinders. apply pressure to retract the outrigger vylinders all the brrory a the synchronized operition of the outrigger eylinders will increase if oil flow is reversed halfway in their stroke tosFailure in the Synchronized Operation of Outrigger Cylinders * Lack of oil Mow @ Insufficient pressure Air trapped inside @ Resistance difference between right © Oil leakuge and left in inner box Check the above and if nothing wrong is found, disassemble and check the decompression valve Disassembling Procedure 11 Remove the cover on one side, 2) Push the main spool with your finger and see if it returns to the original position by the Force of the spring. Also check the subspools for opera- tion 3) It any spool fails to return to its original position, or does not move properly, remove it and clean it of foreign matter. 4) Make sure to install the spools in the correct direction after cleaning, = 105 —$18, CONSTRUCTION OF HOOK (FOR 6-SECTION BOOM) 1, Procedure for Changing Wire Rope Sling from 4 to 3 Ropes _| 44) Mount hook cover back, making sure that bolts are tightened firm: ch wire sacket back 10 Rook, 6) Check that bolis for wire socket 5I making sure that bolt is tightened and cover are tightened securely securely Precaut * The m nuim hoisting load for 3-rope sling is 2.2 tons. * If the hook touches the ground when changing the number of wire ropes. the ropes on the drum will loosen, Before starting work after re- moving or adding wire ropes, be sure to wind the wire ropes tense and tight 106819, HOW TO HANDLE WIRE ROPES 1b Passing Wire Rope into Wire Socket and Fastening It Pass the socket long the arrow mark on the sock- et. If the wire rope is inserted in the op- posite direction, it will be kept bent und end of a wire rope into the wire last short. Do not forget to attach the wedge and WIRE SOCKET wire clip. \weoce ‘WIRE CLIP When attaching the wire socket to the Be caveat ot asembing} oom, make sure that the arrow mark Pome ae nar ‘on the face of the wire socket faces out- aes ward as shown at lett Twisted Wire Rope Adjusting Procedure Ware rope tends to turn in the untwisting direction under tension. When the hook carries two or more wire ropes, they can easily turn, especially when they are still new. Wire ropes becomes steady with use Observe the wire rope adjustment procedure below in such a case. 1) katend the boom fully 2) Set the boom to an angle of about 65° 3) Hoist a load so that the wire ropes will be tense 41 Check the wire ropes for the number of turns 51 Remove the wire socket, and turn i€ in the wire rope untwisting dire tion by the number of wire rope tums multiplied by the number of wire ropes. However, the wire socket may be turned only up to 4 times. 6) Atter attuching the wire socket back (o position. wind up and down the sire ropes all the way and repeat it a few times to check that they are back to normal, If there is still a twist remaining, repeat the above pro- y LUnewsting direction Wire ope twisting rope sing 3:r0pe slog 214-1008 sing Note: Turn the wire socket opposite to the wire rope twisting direction except int the case of 3-rope sling in which case the wire socket Should he turned in the same direetion = 107§20. FILTERS 1, Suction Filter and Line Filter (for UR330, 360) SUCTION FILTER LINE FILTER, Part No.740582023 Part No.740880204 2. Suction Filter The suetion filter is attached to the end of the pump suction pipe in the oil lank It is a notch-wire type. When changing hydraulic oil, cheek the filter that 1 is not clogged up. Hit is, elean it Care must be taken against a clogged-up filter because it will adversely at Feet pump suction, possibly causing cavitation, abnormal noise, and pump Failure 3. Line Filter The line filter is installed halfway between the control valve and oil tank. It as u filter paper type with a bypass valve, Filter replacing intervals vary nerully, however, replace it for the first tine three monthy after initial use of the crane, and once a year there depending on the requeney of use. Ger \LINE FILTER lox§21. LUBRICATION Apart Srom the liydraulic oil that is necessary for hydraulically driving the crane Lubrication (oiling aad greasing) is required to ensure smooth opera- Lion of the crane parts, reduce their weur, and extend life, 1. Selection of Hydraulic Oil Use the genuine hydraulic oils specified below for UNIC truck crane. Goneral UNIC HYDRO 56 a | For areas with sub-20r0 For cold season UNIC HYDRO 32 | 2. Changing Hydraulic Oil Aarcarries foreign matter and moisture into the oil tank. The hydraulic parts, produce metal dust little by little with use. Change the hydraulic oil three mouths after the new erane is first used. Thereafter. change it once a year in carly autumn, If ambient temperature falls below 0°C, water in the tank ond hydraulic circuit may freeze. Changing the hydraulic oil in early autunin sy erfective for preventing it To check oil level. insert the levet gauge into the oil filler without screwing it in, and check that oil fevel is halfway between the upper and lower limits oon the gauge Iegert it av gouge Ino oiler without car Seremingit in, and ‘heck ol lee LEVEL GAUGE UPPER LiMniT Lower Lin Y 109 ~3. Greasing 1) Use the grease specified below for UNIC truck erates Chassis grease No.1 (Wiseosity 310 ~ 340) Molybdenum disvitide "No.2 (Viscosity 265 ~ 295) 2 Grewsing Swivel Be Be sure t beari tse the swivel ball bearing. Hit is nol well lubricated. the may make abnormal noise. Grease it once a month, oF if the rane 1s fequently used, once at week, while turning the swivel Ho3) Greasing Chart Py “ Note: Do not grease slide sheave pin,=a Labreation ae No.0 | abrcant | aetho eee Lubrsating point Woof | Lubricant | Method Buy [1 Boum ste las tbawom | 1] Molvadenam anal and sides of section 2) grease | 2section boom 2) Boom slide plate (bottom 2 Molybdenum | Manual and sides of sections 2, 3] ‘sreate | -BSeetion boom | 3) Boom stide plate {bottom 3 Molybdenum | Manual and sides of sections 2,3, 4) srease 4' Section boom ! 4) Boom slide plate (bottom 4 | Molybdenum | Manual | and sides of sections 2,3, 4, 5) Grease | S'Section boom 51 Boom slide plate (bottom and | § | Molybdenum | Manual sides of sections 2,3, 4,5, 6) Grease 6 Selection boom 8) Boom foot in a Chassis | Greate gene gun 1) Derrick evlinder upper jt Chasis | Grease support pin ease gun 8) Derrick evlinder lower 1 Chassis supsort pin ease 9} Oit ram. 1 | Hydraulic oi (3255 Iters(32 liters) (Mid point i between upper and lower iimits of tevel ee uel a Weekly 10) Wineh deum ge ia Chan | Grease ‘ease oun 11) Smivel gear (ed Chassis | Manual orease wu" 112) Propeller shaft 3 Chassis | Grease je | __geae gun Ioninly 13) Winch reduction gear 5 Gear or {about 0.8 Iter) 14) Swivel reduction gear 1 Gea {sbout 07 iter) 18) Wire rope 1 Chassis | Manual ovease 16), Swivel bearing 2 Chassis | Grease grease | gunes Een Ep ee) ele Sea) HEAD OFFICE : No.28 Mori bidg., 16- 13, Nislazabu 4- chome Minato- ku Tokyo 106, Japan